Airtrek Workshop Manual

GROUP INDEX

OUTLANDER WORKSHOP MANUAL

FOREWORD

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

00

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

11

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

12

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

13

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

14

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

15

This Workshop manual contains procedures for service mechanics, including removal, disassembly, in- Engine Electrical. . . . . . . . . . . . . . . . spection, adjustment, reassembly and installation. Use the following manuals in combination with this Engine and Emission Control . . . . . manual as required.

16 17

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

21

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

22

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

25

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

26

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

27

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

31

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

32

All information, illustrations and product descriptions Front Suspension . . . . . . . . . . . . . . . contained in this manual are current as at the time of publication. We, however, reserve the right to make Rear Suspension . . . . . . . . . . . . . . . changes at any time without prior notice or obligation.

33

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

35

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

36

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

37

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

42

Exterior . . . . . . . . . . . . . . . . . . . . . . . Interior and Supplemental .......... Restraint System (SRS) Chassis Electrical . . . . . . . . . . . . . . . Heater, Air Conditioner and Ventilation . . . . . . . . . . . . . . . . . . . .

51

TECHNICAL INFORMATION MANUAL INZE03E1 WORKSHOP MANUAL BODY REPAIR MANUAL BNZE03E1 PARTS CATALOGUE B606R503A_

ÈMitsubishi Motors Europe B.V.

May 2003

34

52 54 55

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES (1)

Improper service or maintenance of any component of the SRS or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative). (2) The SRS components and seat belt with pretensioner should not be subjected to heat, so remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting. • SRS-ECU, air bag module and clock spring 93C or more • Seat belt with pre-tensioner: 90C or more (3) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this Manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

11B-1

GROUP 11B

00 11

ENGINE OVERHAUL

12 13 14

CONTENTS HOW TO USE THIS MANUAL. . . . . .

11B

GENERAL INFORMATION . . . . . . . .

11B

GENERAL SPECIFICATIONS . . . . . .

11B

SERVICE SPECIFICATIONS. . . . . . .

11B

EXHAUST MANIFOLD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . .

15 11B

WATER PUMP AND WATER HOSE . 11B WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION . . . . . . . .

16 17 21

11B

ROCKER ARMS AND CAMSHAFT . . 11B

22 25

11B

ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION . . . . . . . .

11B

26

TORQUE SPECIFICATIONS . . . . . . .

11B

ROCKER ARMS AND CAMSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11B

27

SEALANTS . . . . . . . . . . . . . . . . . . . .

11B

CYLINDER HEAD AND VALVES. . . . 11B

31

SPECIAL TOOLS. . . . . . . . . . . . . . . .

11B

REWORK DIMENSIONS . . . . . . . . . .

ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION . . . . . . . .

TIMING BELT. . . . . . . . . . . . . . . . . . .

11B

11B

TIMING BELT INSPECTION. . . . . . . . . . . .

11B

FUEL AND EMISSION PARTS . . . . . 11B

INTAKE MANIFOLD REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . .

EXHAUST MANIFOLD. . . . . . . . . . . .

32

CYLINDER HEAD AND VALVES INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11B

33

OIL PAN AND OIL PUMP. . . . . . . . . . 11B

11B

INTAKE MANIFOLD . . . . . . . . . . . . .

11B

11B

TIMING BELT REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . .

FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . .

CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION . . . . . . . .

35

OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . .

11B

OIL PAN AND OIL PUMP INSPECTION. . .

11B

36

PISTON AND CONNECTING ROD . . 11B

37

PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION . . . . . . . .

11B

PISTON AND CONNECTING ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11B

42 51 52

11B

11B

34

CRANKSHAFT AND CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

11B

CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION . . . . . . . .

11B

11B

CRANKSHAFT AND CYLINDER BLOCK INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11B

54 55

ENGINE OVERHAUL

11B-2

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL M1113025100155

HOW TO USE THIS MANUAL Scope of Service Explanations This manual describes service procedures performed after removal of the engine from the vehicle. For removal of the engine from the vehicle, installation of the engine in the vehicle, and on-vehicle inspection and service of the engine, please use the separate Workshop Manuals prepared for the vehicle. How to Read Explanations Service steps (1) A component part drawing is shown at the beginning of each section to enable the technician to ascertain the installed condition of the component parts. (2) Service steps are indicated by means of numbers in the component part drawing. Non-reusable parts are indicated as such, and tightening torques are shown. ·Removal steps The numbers of the part names match the numbers in the component part drawing and indicate the removal sequence. ·Installation steps Installation steps are omitted wherever installation can be achieved simply by performing the removal steps in reverse. ·Disassembly steps The numbers of the part names match the numbers in the component part drawing and indicate the disassembly sequence. ·Reassembly steps Reassembly steps are omitted wherever reassembly can be achieved simply by performing the disassembly steps in reverse.

Classification of Service Points Key service points, service standards, and instructions for using special tools are collated as service points and explained in detail.

<>: Outward-pointing brackets denote removal service points or disassembly service points. >>A<<: Inward-pointing brackets denote installation service points or reassembly service points.

Lubricant and Sealant Symbols Every location where a lubricant or sealant must be applied or added is indicated using a relevant symbol in the component part drawing and/or on the page after the component part drawing.

. . . . . . . . . . Grease . . . . . . . . . . Sealant or form-in-place gasket (FIPG) . . . . . . . . . . Brake fluid . . . . . . . . . . Engine oil or gear oil

Inspection Only those inspection procedures which use special tools or measuring appliances are described. You must perform general visual inspection and part cleaning whenever necessary although their procedures are not described in this manual.

AK202851

ENGINE OVERHAUL

11B-3


Page number

Section title

ENGINE OVERHAUL CRANKSHAFT AND CYLINDER BLOCK

11-54

CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION 3 Apply engine oil to all moving parts before installtion.

2

Denotes non-reusable part. 1

11 ± 1 N·m

6

9

8

16

4

A

5

11 ± 1 N·m

15

132 ± 5 N·m

7

9.0 ± 1.0 N·m

Tightening torque 14

13

12 11 10

25 ± 2 N·m + 90º to 100º

AK204351AB

Removal steps 1. Drive plate bolt 2. Adapter plate 3. Drive plate 4. Crankshaft bushing 5. Rear plate 6. Bellhousing cover >>E<< 7. Oil seal case >>D<< 8. Oil seal >>C<< 9. Bearing cap bolt 10. Bearing cap >>B<< 11. Crankshaft bearing, lower >>A<< 12. Crankshaft

INSTALLATION SERVICE POINTS >>A<< THRUST BEARING INSTALLATION

Grooves AK100786AB

The alphabetical character in this category of heading matches that of the relevant removal steps, installation steps, disassembly steps, or reassembly steps.

Procedures and cautions for removal, installation, disassembly, and reassembly are explained under this category of heading.

AK300250

ENGINE OVERHAUL

11B-4

GENERAL INFORMATION

GENERAL INFORMATION M1113000100233

VEHICLE AND ENGINE MODELS Vehicle name

Vehicle model

Engine model

Displacement Specification mL

Outlander

CU2W

4G63-7

1,997

Double overhead camshaft, 16-valve

GENERAL SPECIFICATIONS M1113000200478

Items

Specification

Bore stroke mm

85 88

Displacement mL

1,997

Combustion chamber

Pentroof type

Number of cylinders

4

Valve mechanism

Type

Double overhead camshaft

Number of intake valves

2

Number of exhaust valves

2

Lash adjusters

Hydraulic

Rocker arms

Roller cam followers

Compresssion ratio

10.0

Fuel injection system

Electronically controlled multi-point injection (MPI) system

Ignition system

Electronically controlled two-coil system

Generator

Alternator (with built-in IC regulator)

Starter motor

Gear reduction drive type

SERVICE SPECIFICATIONS M1113000300419

Items

Standard value

Limit

Auto-tensioner rod extension length (with timing belt installed) mm

3.8 - 4.5

-

Auto-tensioner rod extension length (when free) mm

12.0

-

Auto-tensioner rod retraction length (when pressed with force of 98 to 196 N) mm

Less than 1

-

34.91

34.41

Less than 0.05

0.2

TIMING BELT

ROCKER ARMS AND CAMSHAFTS Cam height mm CYLINDER HEAD AND VALVES Cylinder head gasket surface warp mm

ENGINE OVERHAUL

11B-5

SERVICE SPECIFICATIONS

Items

Standard value

Limit

Cylinder head gasket surface grinding limit (including cylinder block grinding amount) mm

-

0.2

Cylinder head overall height mm

131.9 - 132.1

-

Cylinder head bolt nominal length mm

-

99.4

Valve margin mm

Intake valves

1.0

0.5

Exhaust valves

1.5

1.0

Valve stem diameter mm

6.6

-

Valve face angle

45.5

-

Intake valves

0.02 - 0.05

0.10

Exhaust valves

0.05 - 0.09

0.15

Intake valves

109.5

109.0

Exhaust valves

109.7

109.2

Intake valves

49.2

49.7

Exhaust valves

48.4

48.9

Valve spring free height mm

48.3

47.3

Valve spring load/height N/mm

294/40

-

Valve spring squareness

1.5or less

4

Valve face-to-seat contact width mm

0.9 - 1.3

-

Valve guide inside diameter mm

6.6

-

Valve guide press-in height mm

19.2 - 19.8

-

Drive gear

0.08 - 0.14

-

Driven gear

0.06 - 0.12

-

85.0

-

Valve stem-to-guide clearance mm Valve height mm Valve stem projection mm

OIL PAN AND OIL PUMP Oil pump gear side clearance mm

PISTONS AND CONNECTING RODS Piston outside diameter mm Piston ring side clearance in ring groove mm

No. 1

0.02 - 0.06

0.1

No. 2

0.02 - 0.06

0.1

Piston ring end gap mm

No. 1

0.20 - 0.30

0.8

No. 2

0.30 - 0.45

0.8

Oil ring

0.10 - 0.40

1.0

Piston pin outside diameter mm

22.0

-

Piston pin press-in load (at ambient temperature) N

7,350 - 17,100

-

Oil clearance at crankshaft pins mm

0.03 - 0.05

0.1

Connecting rod big end thrust clearance mm

0.10 - 0.25

0.4

Crankshaft end play mm

0.05 - 0.25

0.4

Crankshaft journal diameter mm

57.0

-

Crankshaft pin diameter mm

45.0

-

Oil clearance at crankshaft journals mm

0.03 - 0.04

0.1

Cylinder block gasket surface warp mm

0.05

0.1

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL

11B-6

REWOK DIMENSIONS

Items

Standard value

Limit

Cylinder block gasket surface grinding limit (including cylinder head grinding amount) mm

-

0.2

Cylinder block overall height mm

284

-

Cylinder bore diameter mm

85

-

Taper of cylinder mm

0.01 or less

-

Cylinder-to-piston clearance mm

0.02 - 0.04

-

Crankshaft bearing cap bolt nominal length mm

-

71.1

REWOK DIMENSIONS M1113024300178

Items

Standard value

CYLINDER HEAD AND VALVES Diameter of oversize valve seat ring hole in cylinder head mm

Intake Exhaust

Diameter of oversize valve guide hole in cylinder head mm

0.03 oversize

35.30 - 35.33

0.06 oversize

35.60 - 35.63

0.03 oversize

33.30 - 33.33

0.06 oversize

33.60 - 33.63

0.05 oversize

12.05 - 12.07

0.25 oversize

12.25 - 12.27

0.50 oversize

12.50 - 12.52

TORQUE SPECIFICATIONS M1113023400503

Items

Tightening torque N¼m

ALTERNATOR AND IGNITION COIL Oil level gauge guide bolts

13 1

Idler pulley bolt

79 5

Auto-tensioner assembly bolts (M8)

22 4

Auto-tensioner assembly bolts (M10)

44 10

Water pump pulley bolt

8.8 1.0

Alternator brace bolt (flange bolt)

23 3

Alternator brace bolt (washer assembled bolt)

22 4

Alternator nuts

44 10

Crankshaft pulley bolt

25 4

Center cover bolts

3.0 0.5

Ignition coil bolts

10 2

Spark plugs

25 5

TIMING BELT Timing belt cover bolts (flange bolts)

11 1

Timing belt cover bolts (washer-assembled bolts)

9.0 1.0

ENGINE OVERHAUL

11B-7

TORQUE SPECIFICATIONS

Items


Power steering pump bracket bolts

49 9

Tensioner pulley bolt

48 5

Tensioner arm bolt

21 4

Auto-tensioner bolts

23 3

Idler pulley bolt

35 6

Crank angle sensor bolts

8.8 1.0

Oil pump sprocket nut

54 4

Crankshaft bolt

167

Tensioner B bolt

19 3

Counterbalance shaft sprocket bolt

45 3

Rocker cover bolts

3.5 0.5

Engine support bracket bolts

49 5

Camshaft sprocket bolt

88 10

FUEL SYSTEM Vacuum hose and pipe clamp bolt

11 1

Throttle body bolts

19 3

EGR valve bolts

20 2

Fuel pressure regulator bolts

9.0 2.0

Delivery pipe and injector assembly bolts

11 1

Solenoid valve assembly bolts

9.0 1.0

INTAKE MANIFOLD Intake manifold stay bolts

31 3

Intake manifold bolts (M8)

20 2

Intake manifold bolts and nuts (M10)

36 6

Engine hanger bolt

19 3

EXHAUST MANIFOLD Oxygen sensor

44 5

Exhaust manifold cover bolts

14 1

Exhaust manifold bracket bolt (Cylinder block side)

35 6

Exhaust manifold bracket bolt (Exhaust manifold side)

44 5

Exhaust manifold nuts (M8)

29 3

Exhaust manifold nuts (M10)

49 5

WATER PUMP AND WATER HOSE Coolant temperature sensor

29 10

Coolant temperature gauge unit

10.8 1.0

Water inlet fitting bolts

13 2

Water outlet fitting bolts

13 2

Thermostat housing bolts

23 4

Water inlet pipe bolts

13 2

Water pump bolts

14 1

11B-8

ENGINE OVERHAUL TORQUE SPECIFICATIONS

Items


Knock sensor

23 2

ROCKER ARMS AND CAMSHAFTS Camshaft position sensor bolts

8.8 1.0

Cover bolts

10 2

Camshaft position sensing cylinder bolt

22 4

Camshaft position sensor support bolts

14 1

Bearing cap bolts

20 1

Oil delivery body bolts

11 1

CYLINDER HEAD AND VALVES Cylinder head bolts

78 2 loosen completely 20 2 90 + 90

OIL PUMP CASE AND OIL PAN Drain plug

39 5

Transmission stay bolts

22 4

Oil pan upper section bolts

9.0 3.0

Oil pan lower section bolts

9.0 3.0

Oil screen bolts

19 3

Oil pressure switch

19 3

Relief plug

44 5

Oil filter bracket bolts

19 3

Plug cap

23 3

Flange bolts

36 3

Oil pump case bolts

23 3

Oil pump cover bolts

17 1

Oil pump cover screws

10 2

PISTONS AND CONNECTING RODS Connecting rod cap nuts

20 2 90 to 94

CRANKSHAFT AND CYLINDER BLOCK Flywheel bolts

132 5

Rear plate bolts

11 1

Bell housing cover bolts

9.0 1.0

Rear oil seal case bolts

11 1

Beam bearing cap bolts

25 2 90 to 100

ENGINE OVERHAUL

11B-9

SEALANTS

SEALANTS M1113000500402

Items

Specified sealants

Engine support bracket bolts

Mitsubishi Genuine Part No.MD970389 or equivalent

Semicircular packing

3M ATD No.8660 or equivalent

Rocker cover

Mitsubishi Genuine Part No. MD970389 or equivalent

Engine coolant temperature sensor

3M Nut Locking Part No.4171 or equivalent

Engine coolant temperature e gauge unit


Water outlet fitting* Thermostat housing*


Cylinder head (camshaft bearing cap fitting section)


Camshaft position sensor support*


Oil pressure switch


Oil pan*


Rear oil seal case* NOTE: *: Part to be sealed with a form-in-place gasket (FIPG) FORM-IN-PLACE GASKET (FIPG) This engine has several areas where the form-inplace gasket (FIPG) is used for sealing. To ensure that the FIPG fully serves its purpose, it is necessary to observe some precautions when applying it. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of fluid passages. To prevent leaks or blocking of passages, therefore, it is absolutely necessary to apply the FIPG evenly without a break, while observing the correct bead size. FIPG hardens as it reacts with the moisture in the atmospheric air, and it is usually used for sealing metallic flange areas. REMOVAL OF FIPG SEALED PARTS Parts sealed with a FIPG can be easily removed without need for the use of a special method. In some cases, however, the FIPG in joints may have to be broken by tapping parts with a mallet or similar tool. You can also tap a flat, thin gasket scraper into the joint to break the FIPG, taking extreme care not to damage the mating surfaces.The oil pan remover (MD998727) is available as a special tool for removing the oil pan. The tool, however, must not be

CLEANING FIPG APPLICATION SURFACE Thoroughly remove all substances deposited on the FIPG application surface, using a gasket scraper or wire brush. Make sure that the FIPG application surface is flat and smooth. Also make sure that the surface is free from oils, greases and foreign substances. Do not fail to remove old FIPG that may remain in the fastener fitting holes. APPLICATION OF FIPG Applied FIPG bead should be of the specified size and free of any break. FIPG can be wiped away unless it has completely hardened. Install the mating parts in position while the FIPG is still wet (in less than 15 minutes after application). Do not allow FIPG to spread beyond the sealing areas during installation. Avoid operating the engine or letting oils or water come in contact with the sealed area before a time sufficient for FIPG to harden (approximately one hour) has passed. FIPG application method may vary from location to location. Follow the instruction for each particular case described later in this manual.

ENGINE OVERHAUL

11B-10

SPECIAL TOOLS

SPECIAL TOOLS M1113000600465

Tool

Number

Name

Use

MD998781

Flywheel stopper

Retention of flywheel

MD998778

Crankshaft sprocket puller

Removal of crankshaft sprocket and crankshaft sprocket B

MD998785

Sprocket stopper

Retention of counterbalancer shaft sprocket

MD998767

Tension pulley socket Manipulation of tensioner pulley wrench during adjustment of timing belt tension

MD998738

Set screw

Retention of tentioner arm and auto-tensioner during timing belt installation

MD998713

Camshaft oil seal installer

Installation of camshaft oil seal

MD998442

Air bleed wire

Air bleeding of lash adjuster

D998781

D998767

D998738

D998713

ENGINE OVERHAUL

11B-11

SPECIAL TOOLS

Tool

Number

Name

Use

MB991654

Cylinder head bolt wrench

Removal and installation of cylinder head bolts

MD998772

Valve spring compressor

Compression of valve spring

MD998735


Compression of valve spring

MD998737

Valve stem seal installer

Installation of valve stem seal

MD998162

Plug wrench

Removal and installation of front case plug cap (Use with MD998783.)

MD998783

Plug wrench retainer

Removal and installation of front case plug cap (Use with MD998162.)

MD998371

Silent shaft bearing puller

Removal of counterbalancer shaft front bearing

MD998372

Silent shaft bearing puller

Removal of counterbalancer shaft front and rear bearings

B991654

ENGINE OVERHAUL

11B-12

SPECIAL TOOLS

Tool

Number

Name

Use

MB991603

Silent shaft bearing installer stopper

Guide and stopper for removal and press-fitting of counterbalancer shaft rear bearing

MD998705

Silent shaft bearing installer

Press-fitting of counterbalancer shaft front and rear bearings

MD998375

Crankshaft front oil seal installer

Installation of crankshaft front oil seal

MD998285

Crankshaft front oil seal guide

Guide for installation of crankshaft front oil seal

MD998780

Piston pin setting tool Removal and press-fitting of piston pin

MD998776

Crankshaft rear oil seal installer

Installation of crankshaft rear oil seal

MB990938

Handle

Installation of crankshaft rear oil seal (Use with MD998776.)

D998285

D998776

B990938

ENGINE OVERHAUL

11B-13

ALTERNATOR AND IGNITION SYSTEM

ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION M1113001000392

12

3.0 ± 0.5 N·m

1

N2

10 ± 2 N·m

13 14

15

13 ± 1 N·m

25 ± 5 N·m

3 10

44 ± 10 N·m

N4

9 22 ± 4 N·m

8 7 44 ± 10 N·m

23 ± 3 N·m

8.8 ± 1.0 N·m

25 ± 4 N·m

11

79 ± 5 N·m

6N 22 ± 4 N·m

1. 2. 3. 4. 5. 6. 7. 8.

Removal steps Oil level gauge O-ring Oil level gauge guide O-ring Idler pulley Cap Auto-tensioner assembly Water pump pulley

5

AK204441AB

Removal steps&RQWLQXHG 9. Alternator brace 10. Alternator 11. Crankshaft pulley 12. Center cover 13. Spark plug cable 14. Ignition coil 15. Spark plug

ENGINE OVERHAUL

11B-14

TIMING BELT

TIMING BELT REMOVAL AND INSTALLATION M1113001900500

21

1

11 ± 1 N·m

5

3.5 ± 0.5 N·m

24

25

22

28 20

6

48 ± 5 N·m

N 23

21 ± 4 N·m

12

11 ± 1 N·m

26 N

7 23 ± 3 N·m

27 N 32 11 ± 1 N·m

11 ± 1 N·m

11 167 N·m

2

33

29

49 ± 5 N·m 9.0 ± 1.0 N·m

4

31

45 ± 3 N·m

16 17

19 ± 3 N·m

14

3

30

34 19

88 ± 10 N·m

18 13 8

9

8.8 ± 1.0 N·m

49 ± 9 N·m

15

10

35 ± 6 N·m

AK204445 AB

54 ± 5 N·m

<>

<> <>

Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 3. Power steering pump bracket >>M<< 4. Timing belt >>L<< 5. Tensioner pulley 6. Tensioner arm >>K<< 7. Auto-tensioner 8. Idler pulley 9. Crank angle sensor >>J<< 10. Oil pump sprocket >>I<< 11. Crankshaft bolt

Removal steps&RQWLQXHG 12. Crankshaft sprocket 13. Crankshaft sensing blade 14. Tensioner B <> >>H<< 15. Timing belt B <> >>G<< 16. Counterbalancer shaft sprocket >>F<< 17. Spacer <> >>E<< 18. Crankshaft sprocket B 19. Crankshaft key 20. Breather hose 21. Positive crankcase ventilation (PCV) hose

<> >>I<< >>I<<

ENGINE OVERHAUL TIMING BELT

>>D<< >>D<< >>C<< >>B<< <> >>A<<

Removal steps&RQWLQXHG 22. PCV valve 23. PCV valve gasket 24. Oil filler cap 25. Rocker cover 26. Rocker cover gasket A 27. Rocker cover gasket B 28. Semicircular packing 29. Engine support bracket 30. Camshaft sprocket bolt 31. Camshaft sprocket 32. Timing belt rear cover, right 33. Timing belt rear upper cover, left 34 Timing belt rear lower cover, left

REMOVAL SERVICE POINTS <> TIMING BELT REMOVAL

11B-15

CAUTION Never remove the timing belt with any piston at the top dead center (TDC). If a piston is at TDC, the exhaust valves of the cylinder are pushed by the exhaust cams, compressing the valve springs. If the belt is removed under this condition, the sprocket will be turned in the reverse direction by the force of the springs, incurring risk of injury. 2. Set the timing mark of the exhaust camshaft sprocket to a point about one tooth before the TDC of the No.1 cylinder piston on compression stroke. 3. Loosen the lock nut of the tensioner pulley, then remove the timing belt. <> OIL PUMP SPROCKET REMOVAL

Crosspoint screwdriver AK202756AB

1. If the timing belt is to be reused, make an arrow mark with something like chalk on the back of the belt indicating the direction of rotation so it may be reinstalled in the same direction. Timing mark

AK202825 AB

1. Remove the plug on the left side of cylinder block. 2. Insert a crosspoint screwdriver (shank diameter 8 mm) to prevent the counterbalancer shaft from rotating. 3. Remove the flange bolt. 4. Remove the oil pump sprocket. <> CRANKSHAFT BOLT REMOVAL

AK202757 AB

MD998781 AK202738 AB

1. Hold the drive plate with the special tool Fly wheel stopper(MD998781). 2. Remove the crankshaft bolt.

ENGINE OVERHAUL

11B-16

TIMING BELT

<> CRANKSHAFT SPROCKET REMOVAL

1. Use the special tool Sprocket stopper (MD998785) to prevent the counterbalancer shaft sprocket from rotating. 2. Remove the counterbalancer shaft mounting bolt.

MD998778

<> CRANKSHAFT SPROCKET B REMOVAL

MD998778 AK202741 AB

Use the special tool Crankshaft sprocket puller (MD998778) if the sprocket is stuck and hard to remove. AK202740AB

<> TIMING BELT B REMOVAL

Use the special tool Crankshaft sprocket puller (MD998778) if the sprocket is stuck and hard to remove. <> CAMSHAFT SPROCKET BOLT REMOVAL

AK202758AB

If the timing belt is to be reused, make an arrow mark with something like chalk on the back of the timing belt indicating the direction of rotation so it may be reinstalled in the same direction. AK202858AB

<> COUNTERBALANCER SHAFT SPROCKET REMOVAL

MD998785

AK202739AB

Remove the camshaft sprocket bolt while preventing the camshaft from rotation using a wrench fitted on the hexagonal portion of the camshaft.

ENGINE OVERHAUL

11B-17

TIMING BELT

INSTALLATION SERVICE POINTS >>A<< CAMSHAFT SPROCKET BOLT INSTALLATION

>>C<< SEMICIRCULAR PACKING INSTALLATION 1. Remove thoroughly the old sealant and FIPG remaining on the semicircular packing, cylinder head, and rocker cover.

AK202858AB AK202860AB

2. Apply sealant to the surface indicated in the drawing of the semicircular packing. Specified sealant: 3M ATD No.8660 or equivalent 3. Install the semicircular packing on the cylinder head. 10 mm AK202859

Tighten the camshaft sprocket bolt to 88 10 N¼m while preventing the camshaft from rotation using a wrench fitted on the hexagonal portion of the camshaft. >>B<< ENGINE SUPPORT BRACKET INSTALLATION

10 mm

Semicircular packing Cylinder head

AK202861 AB

4. Apply sealant to the area indicated in the drawing of the semicircular packing and cylinder head. Specified sealant: 3M ATD No.8660 or equivalent >>D<< ROCKER COVER/ROCKER COVER GASKET A INSTALLATION Timing belt side AK202743AB

1. Remove thoroughly the old sealant remaining on the indicated bolt and in its hole. 2. Coat the bolt with sealant, then install and tighten it. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent

AK202862 AB

1. Apply beads of FIPG on the surfaces of the rocker cover indicated in the drawing.

ENGINE OVERHAUL

11B-18

TIMING BELT

Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent 2. Install the rocker cover gasket A on the rocker cover before the FIPG hardens.

>>F<< SPACER INSTALLATION Spacer

Oil seal

Timing belt side

Chamfer

Counterbalancer shaft AK202820 AB

CAUTION AK202863 AB

3. Apply beads of FIPG to the surfaces of the rocker cover indicated in the drawing. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent 4. Install the rocker cover on the cylinder head before the FIPG hardens.

If the spacer is opposite in direction to that shown in the drawing when installed, it will damage the oil seal lip. 1. Smear slightly oil on the outer surface of the spacer that comes into contact with the oil seal. 2. Install the spacer with the chamfered end toward the oil seal. >>G<< COUNTERBALANCER SHAFT SPROCKET INSTALLATION

>>E<< CRANKSHAFT SPROCKET B INSTALLATION MD998785

Sprocket "B" Crankshaft

AK202739AB

Degrease Front case

AK101651AC

Clean and then degrease the crankshaft sprocket B and the sprocket fitting surface of the crankshaft. NOTE: Degreasing is necessary to prevent lack of frictional coefficient between the mating surfaces.

1. Use the special tool Sprocket stopper (MD998785) as shown in the drawing to prevent the counterbalancer shaft sprocket from rotating. 2. Tighten the sprocket mounting bolt to 45 3 N¼m.

ENGINE OVERHAUL

11B-19

TIMING BELT

>>H<< TIMING BELT B INSTALLATION

Timing marks

5. Make sure that the timing marks on the oil pump case and those of the sprockets are all aligned with each other. 5 – 7 mm

Timing marks

AK202920 AB

1. Align the timing marks on the crankshaft sprocket B and counterbalancer shaft sprocket with the corresponding timing marks on the oil pump case. 2. Install the timing belt B on the crankshaft sprocket B and counterbalancer shaft sprocket. There should be no slack in the tension section of the belt. Tensioner B

Tension section of belt Timing belt B

AK202919 AB

6. Push a central point of the timing belt B tension section lightly with an index to see if it deflects 5 7 mm. >>I<< CRANKSHAFT BOLT/CRANKSHAFT SPROCKET/CRANKSHAFT SENSING BLADE INSTALLATION Crankshaft sensing blade Crankshaft bolt Crankshaft Clean

Tensioner B center Mounting bolt center

AK202921 AB

3. Make sure that the tensioner B center is positioned as shown in the drawing relative to the mounting bolt center.

Washer Chamfer Degrease Crankshaft sprocket AK202838 AB

1. Clean and then degrease the crankshaft sprocket, sprocket fitting surface of the crankshaft, and crankshaft sensing blade. Install the crankshaft sprocket and crankshaft sensing blade on the crankshaft. 2. Clean the bolt hole in the crankshaft, and then washer. 3. Apply a necessary minimum amount of oil to the threads and seating surface of the crankshaft bolt.

AK202922AB

4. Lift the tensioner B with fingers to move it in the direction of the arrow until the tension section of the timing belt becomes taut. While keeping the tensioner B in this position, tighten its bolt. NOTE: When the bolt is tightened, prevent the tensioner B shaft from turning. If the shaft turns, the belt will be overtightened.

MD998781 AK202738 AB

ENGINE OVERHAUL

11B-20

TIMING BELT

4. Hold the drive plate using the special tool Fly wheel stopper(MD998781). 5. Tighten the crankshaft bolt to a torque of 167 N¼m. >>J<< OIL PUMP SPROCKET INSTALLATION

AK202767

2. Install the auto-tensioner in position. Leave the wire installed until the auto-tensioner is completely installed. Crosspoint screwdriver AK202732 AB

>>L<< TENSIONER PULLEY INSTALLATION

1. Prevent the counterbalancer shaft from rotating in the same method as in the removal procedure. 2. Install the oil pump sprocket. 3. Install the oil pump sprocket. 4. Tighten the flange nut to 54 5 N¼m. >>K<< AUTO-TENSIONER INSTALLATION Tensioner pulley holes A

AK202759AB

B

Install the tensioner pulley with its holes aligned as shown in the drawing. >>M<< TIMING BELT INSTALLATION Timing marks AK202768 AB

1. If the auto-tensioner rod remains in its fully extended position, reset it to the retracted position as follows: (1) Clamp the auto-tensioner in a vise at right angles to the jaws. (2) Push in the rod little by little with the vise until the set hole A in the rod is aligned with the set hole B in the cylinder. (3) Insert a piece of wire (1.4 mm diameter) into the set holes. (4) Remove the auto-tensioner from the vise.

AK202903 AB

1. Bring the timing mark on the exhaust camshaft sprocket to a point one sprocket tooth away from the timing mark on the rocker cover in the counterclockwise direction. NOTE: If the timing marks were aligned, the exhaust camshaft would be turned counterclockwise by one sprocket tooth and stay there by the force of the valve springs.

ENGINE OVERHAUL TIMING BELT

Timing marks

AK202904 AB

2. Align the timing mark on the intake camshaft sprocket with that on the rocker cover. NOTE: The intake camshaft will be turned slightly clockwise from where the timing marks are aligned by the force of the valve springs and stay there.

11B-21

(2) Insert a crosspoint screwdriver with a shank diameter of 8 mm through the plug hole. If it can be inserted 60 mm or more, the sprocket is in the correct phase. If the insertion depth is up to 20 - 25 mm, the screwdriver is blocked by the counterbalancer shaft. Then turn the oil pump sprocket one turn and realign the timing marks. Then check that the screwdriver can be inserted 60 mm or more. Keep the screwdriver inserted until installation of timing belt is finished.

Timing marks

AK202761 AB

(3) Turn the oil pump sprocket counterclockwise by one sprocket tooth.

AK202760

3. Bring the timing mark on the crankshaft sprocket to a point one sprocket tooth away from the mating timing mark in the counterclockwise direction like in the operation with the exhaust camshaft sprocket. AK202771

5. Install the timing belt on the exhaust camshaft sprocket, and hold it in place with a paper clip at the point indicated in the drawing.

Plug

Crosspoint screwdriver AK202752 AB

4. Align the timing mark on the oil pump sprocket with that on the cylinder block. (1) Remove the plug from the cylinder block. AK202772

ENGINE OVERHAUL

11B-22

TIMING BELT

6. Turn the intake camshaft sprocket counterclockwise to bring the timing mark on it one sprocket tooth away from the mating timing mark in the counterclockwise direction. Then install the timing belt on the sprocket and hold it in place with a paper clip. NOTE: The timing marks will be aligned when the belt is installed since the intake camshaft is turned slightly clockwise by the force of the valve springs.

9. Install the timing belt on the tensioner pulley. NOTE: Turning slightly the intake camshaft sprocket counterclockwise will facilitate installation of the belt on the tensioner pulley. Crankshaft sprocket

Timing marks

AK202763AB

AK202847 AB

7. Turn the exhaust camshaft sprocket clockwise to align the timing marks, and make sure that the intake camshaft sprocket timing marks are also aligned.

10.Turn slightly the crankshaft sprocket clockwise to take up the slack in the idler pulley portion of the timing belt. 11.Check that each of the timing marks on the crankshaft, oil pump, and exhaust camshaft sprockets is one sprocket tooth away from its mating timing mark in the counterclockwise direction.

MD998767

Crankshaft sprocket

Oil pump sprocket AK202762AB

8. Install the timing belt on the idler pulley, oil pump sprocket, and crankshaft sprocket, in this order. NOTE: There should be no slack in the installed portion of the belt.

Camshaft sprocket Tensioner pulley

AK202773 AB

AK202764 AB

12.Turn the tensioner pulley counterclockwise using the special tool Tension pulley socket wrench (MD998767) to give tension to the belt and hold the tensioner in position by temporarily tightening the tensioner lock bolt. NOTE: Take up the slack in the belt portion between the intake and exhaust camshaft sprockets. 13.Turn the crankshaft clockwise to make the timing mark align with the No.1 cylinder top dead center mark.

ENGINE OVERHAUL

11B-23

TIMING BELT

20.Check that the wire (inserted in the auto-tensioner when it was installed) can be moved freely. If the wire can be pulled freely, the belt tensioner is adjusted properly. Remove the wire. At that time, check that the auto-tensioner rod extends by the specified amount. Standard value: 3.8 - 4.5 mm

MD998738

CAUTION AK202774 AB

14.Install the special tool Set screw (MD998738) and turn down the tool until the wire (inserted in the auto-tensioner when it was installed) can be moved freely.

Be sure to check the tightening torque of the crankshaft bolt anytime the crankshaft has been turned counterclockwise. If the torque lower than specification, tighten the bolt to the specified torque. 21.If the wire cannot be pulled out freely, perform the steps 14. through 18. again to make the belt tension proper.

INSPECTION M1113002000362

TIMING BELT Check closely the entire timing belt. Replace it if any of the following conditions is found.

MD998767

AK202775 AB

CAUTION Prevent the timing belt from slipping as it becomes loose following rotation of the intake and exhaust camshafts. 15.Loosen the tensioner pulley lock bolt. 16.Turn the torque wrench attached to the special tool Tension pulley socket wrench (MD998767) counterclockwise until the slack in the timing belt is taken up. 17.Turn the torque wrench clockwise from the position of step 16. until the torque wrench reading becomes 3.5 N¼m, then tighten the tensioner pulley lock bolt.

AK202794

1. Hardened back side rubber Back side surface is glossy, lacking in elasticity, and so hard that no impression is left when pressed with fingernail. Cracks

Peeling of canvas

Cracks

Cracks in sides

Extension amount

Cracks in tooth roots AK202829 AB

18.Remove the special tool that was installed in step 14. 19.Turn the crankshaft clockwise two turns, then let it alone for approx. 15 minutes.

2. 3. 4. 5.

Cracks in back rubber surface Cracks in canvas Cracks in tooth roots Cracks in belt sides

AK202793 AB

ENGINE OVERHAUL

11B-24

TIMING BELT

AUTO-TENSIONER

Rounded edge

12 mm

Abnormal wear (Fluffy strand)

AK202795 AB

6. Abnormally worn belt sides; NOTE: belt sides are normal if they have “knifecut” surfaces. Canvas lost and rubber exposed Missing Tooth

AK202796 AB

7. Badly worn teeth Initial stage: Canvas is worn (canvas fiber is fluffy; teeth look whitish due to worn-out rubber; canvas texture is unclear) Second stage: Canvas is lost and rubber is exposed (tooth width narrows down) 8. Missing tooth

AK202765 AB

1. Check the auto-tensioner for leaks from the sealed sections. Replace it if leaky. 2. Check the rod end for wear and other damage. Replace the auto-tensioner if the rod is badly worn or damaged. 3. Measure the extension length of the rod. If it is not within the standard value range, replace the auto-tensioner. Standard value: 12 mm 98 to 196 N

Movement

AK202766 AB

4. Press the rod with a force of 98 to 196 N and measure the amount of retraction. If the measurement exceeds the standard value, replace the auto-tensioner. Standard value: 1 mm maximum

ENGINE OVERHAUL

11B-25

FUEL AND EMISSION PARTS

FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION M1113002200355

9

7 8

11 ± 1 N·m 9.0 ± 1.0 N·m

18 10 N

9.0 ± 2.0 N·m

17 2

11 ± 1 N·m

15 N 16

19 ± 3 N·m

3

14

13 N 5

11 12

4 20 ± 2 N·m

6 11 ± 1 N·m

1

11 ± 1 N·m

AK204439AB

>>C<<

>>B<<

1. 2. 3. 4. 5. 6. 7. 8. 9.

Removal steps Vacuum hose and pipe Vacuum pipe Throttle body assembly Throttle body gasket EGR valve EGR gasket Vacuum hose Fuel hose Fuel pressure regulator

>>A<<

Removal steps&RQWLQXHG 10. O-ring 11. Delivery pipe and injector 12. Insulator 13. Insulator 14. Injector 15. O-ring 16. Grommet 17. Delivery pipe 18. Solenoid valve assembly

11B-26

ENGINE OVERHAUL FUEL AND EMISSION PARTS

INSTALLATION SERVICE POINTS >>A<< INJECTOR INSTALLATION 1. Apply a thin coat of engine oil to a new O-ring.

CAUTION Prevent engine oil from getting into the delivery pipe. 2. Insert the injector into the delivery pipe while turning it in both directions carefully not to damage the O-ring. 3. Check that the injector turns smoothly. If it does not, the O-ring may be jamming, so remove the injector and check the O-ring for damage. If the Oring is intact, insert the injector into the delivery pipe and check it for smooth rotation again. >>B<< FUEL PRESSURE REGULATOR INSTALLATION 1. Apply a thin coat of engine oil to a new O-ring.

CAUTION Prevent engine oil from getting into the delivery pipe. 2. Insert the fuel pressure regulator into the delivery pipe while turning it in both directions carefully not to damage the O-ring.

3. Check that the fuel pressure regulator turns smoothly. If it does not, the O-ring may be jamming, so remove the fuel pressure regulator and check the O-ring for damage. If the O-ring is intact, insert it into the delivery pipe and check it for smooth rotation again. >>C<< THROTTLE BODY GASKET INSTALLATION Tab

AK202905 AB

Install the throttle body gasket with its tab located as shown in the drawing.

ENGINE OVERHAUL

11B-27

INTAKE MANIFOLD

INTAKE MANIFOLD REMOVAL AND INSTALLATION M1113002700286

36 ± 6 N·m

19 ± 3 N·m

2

4 3

36 ± 6 N·m 20 ± 2 N·m

31 ± 3 N·m

1

AK204438 AB

Removal steps

>>A<< 1. Intake manifold stay 2. Intake manifold 3. Intake manifold gasket 4. Engine hanger

INSTALLATION SERVICE POINTS >>A<< INTAKE MANIFOLD STAY INSTALLATION

Intake manifold stay AK202865 AB

Tighten the bolts to the specified torque 31 3 N¼m on both ends after making sure that the stay is in close contact with the bosses on the intake manifold and cylinder block.

ENGINE OVERHAUL

11B-28

EXHAUST MANIFOLD

EXHAUST MANIFOLD REMOVAL AND INSTALLATION M1113004900383

14 ± 1 N·m 44 ± 5 N·m 29 ± 3 N·m

1

14 ± 1 N·m

2

6 4

5

49 ± 5 N·m

3

35 ± 6 N·m

44 ± 5 N·m AK204437 AB

Removal steps 1. Oxygen sensor 2. Exhaust manifold cover 3. Exhaust manifold bracket

Removal steps&RQWLQXHG 4. Engine hanger 5. Exhaust manifold 6. Exhaust manifold gasket

ENGINE OVERHAUL

11B-29

WATER PUMP AND WATER HOSE

WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION M1113017900220

13 ± 2 N·m

7

9 13 ± 2 N·m

13 ± 2 N·m

6 1 23 ± 4 N·m

2

11 10

5 4

8

10.8 ± 1.0 N·m

3 29 ± 10 N·m

14 23 ± 2 N·m

13 12 14 ± 1 N·m AK204436AB

>>E<< >>D<< >>C<< >>B<< >>A<< >>A<< >>A<<

Removal sequence 1. Water hose 2. Water hose 3. Coolant temperature sensor 4. Coolant temperature gauge unit 5. Water inlet fitting 6. Thermostat 7. Water outlet fitting 8. Thermostat housing 9. O-ring 10. Water inlet pipe 11. O-ring 12. Water pump 13. Water pump gasket 14. Knock sensor

INSTALLATION SERVICE POINTS >>A<< O-RING/WATER INLET PIPE INSTALLATION

CAUTION Never allow any oil or grease to touch the Orings. Clamp the water inlet pipe only after installation of the thermostat case. Replace the O-rings at both ends of the water inlet pipe with new ones. Insert the O-rings into the water pump and thermostat housing after wetting their peripheries with water.

11B-30

ENGINE OVERHAUL WATER PUMP AND WATER HOSE

>>B<< THERMOSTAT HOUSING INSTALLATION

>>D<< COOLANT TEMPERATURE GAUGE UNIT INSTALLATION

AK202918AB

1. Remove all old FIPG remaining on the thermostat housing and cylinder head. 2. Apply a 2.7 0.3 mm diameter bead of FIPG on the indicated surface of the thermostat housing. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent >>C<< WATER OUTLET FITTING INSTALLATION

AK202800AB

1. Remove all old sealant remaining on the threaded hole in the coolant temperature gauge unit and the thermostat housing. NOTE: A new coolant temperature gauge unit is coated with sealant. It does not require coating with sealant before installation. 2. Apply sealant to the indicated threads of the coolant temperature gauge unit. Specified sealant: 3M Nut Locking Part No.4171 or equivalent >>E<< COOLANT TEMPERATURE SENSOR INSTALLATION

AK202755AB

1. Remove all old FIPG remaining on the water outlet fitting and thermostat housing. 2. Apply a 2.7 0.3 mm diameter bead of FIPG to the indicated surface of the water outlet fitting. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent

AK202799AB

CAUTION When using a tool, avoid letting it touch the connector portion which is made of plastic. 1. Remove all old sealant remaining on the threads of the coolant temperature sensor and in the threaded hole in the thermostat housing. 2. Apply sealant to the coolant temperature sensor’s threads indicated in the drawing. Specified sealant: 3M ATD Part No.8660 or equivalent

ENGINE OVERHAUL

11B-31

ROCKER ARMS AND CAMSHAFT

ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION M1113005400455

10 ± 2 N·m

3

8

N4

11 14 13 20 ± 1 N·m

6 9

12

14 ± 1 N·m

2N 1

10 22 ± 4 N·m

5

15

8.8 ± 1.0 N·m 11 ± 1 N·m

18

N7

16 17

Apply engine oil to all moving parts before installation.

AK202894 AB

>>F<< >>E<< >>D<< >>C<< >>C<<

1. 2. 3. 4. 5. 6. 7. 8. 9.

Removal steps Camshaft position sensor O-ring Cover Gasket Camshaft position sensing cylinder Camshaft position sensor support Camshaft oil seal Bearing cap, rear right Bearing cap, rear left

>>C<< >>C<< >>C<< >>C<< >>C<< >>B<< <> >>A<<

Removal steps&RQWLQXHG 10. Bearing cap, front 11. Bearing cap No.5 12. Bearing cap No.2 13. Bearing cap No.3 14. Bearing cap No.4 15. Camshaft 16. Rocker arm 17. Lash adjuster 18. Oil delivery body

ENGINE OVERHAUL

11B-32


SERVICE POINTS FOR REMOVAL

1. Set each camshaft with its dowel pin at the top.

<> LASH ADJUSTER REMOVAL

CAUTION When reusing a lash adjuster, it must be washed and inspected before installation. (Refer to 311B, the instruction under LASH ADJUSTER in the INSPECTION section.)

INSTALLATION SERVICE POINTS >>A<< LASH ADJUSTER INSTALLATION

CAUTION When reusing a lash adjuster, it must be washed and inspected before installation. (Refer to 311B, the instruction under LASH ADJUSTER in the INSPECTION section.) Install the lash adjuster into the rocker arm, being careful not to spill the diesel fuel it contains. >>B<< CAMSHAFT INSTALLATION Timing belt side

Cap number Intake/exhaust identification letter

AK202870 AB

2. The bearing caps No. 2 to 5 are identical in shape for both intake and exhaust camshafts. Check the identification mark on each cap before installation. Identification mark (stamped on front and Nos. 2 - 5 bearing caps) I: intake camshaft E: exhaust camshaft 3. Remove completely sealant remaining on the bearing caps and cylinder head.

Slit

Exhaust camshaft AK202869 AB AK202871AB

CAUTION Do not confuse the intake camshaft with the exhaust camshaft. The exhaust camshaft has a 4 mm wide slit at the rear end. >>C<< BEARING CAP INSTALLATION Dowel pin

AK203979 AC

4. Apply sealant to the surfaces indicated in the drawing. Specified sealant: 3M ATD No.8660 or equivalent 5. Install each bearing cap and tighten its bolts in two or three passes. 6. Finally tighten the bolts to 20 1 N¼m. 7. Check that the rocker arms are correctly installed. NOTE: Wipe off any squeezed out sealant completely.

ENGINE OVERHAUL

11B-33


>>D<< CAMSHAFT OIL SEAL INSTALLATION MD998713

1. Turn the exhaust camshaft to the No.1 cylinder top dead center position. NOTE: The camshaft will slightly turn counterclockwise by the force of the exhaust valve spring. 2. Install the camshaft position sensing cylinder with the smaller vane located as shown in the drawing.


CAMSHAFT AK202872 AB

Use the special tool Camshaft oil seal installer (MD998713) to drive each oil seal into position in the cylinder head. >>E<< CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION AK202797AB

Measure the cam height (nose-to-heel diameter). If any cam is worn beyond the limit, replace the camshaft. Standard value: 34.91 mm Limit: 34.41 mm AK202754AB

1. Remove completely the FIPG remaining on the camshaft position sensor support and cylinder head. 2. Apply a 3 1 mm diameter bead of FIPG to the indicated surface of the camshaft position sensor support. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent

LASH ADJUSTERS

CAUTION The lash adjuster is a precision-engineered component. Do not allow dust or other foreign matter to enter it. Do not disassemble lash adjusters. Use only non-contaminated diesel fuel to clean the lash adjuster. For rough cleaning

For finish cleaning

For diesel fuel filling

B

C

>>F<< CAMSHAFT POSITION SENSING CYLINDER INSTALLATION Smaller vane A

AK202836 AB

Cam position sensor AK202844 AB

1. Prepare three containers and approximately five liters of diesel fuel. Pour into each container the diesel fuel in an amount enough for a lash adjuster placed in the container in its upright position to completely submerge.

ENGINE OVERHAUL

11B-34


CAUTION The hole in the side of the lash adjuster must be directed toward the inside of container A. Never direct it against any person. 4. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure chamber. AK202837

2. Place the lash adjuster in container A and wash its outside surface. NOTE: Use a nylon brush if there are hard-toremove deposits. Diesel fuel MD998442 AK202839 AB

CAUTION

Diesel fuel MD998442 AK202839 AB

CAUTION The steel ball spring of the lash adjuster is extremely weak. The lash adjuster’s functionality may be badly affected if the special tool is inserted too strongly. 3. While gently pushing the internal steel ball using the special tool Air bleed wire (MD998442), move the plunger in and out 5 - 10 times to eliminate stiffness in the plunger and expel contaminated oil. NOTE: The plunger must be free from jamming and any other abnormalities. If a defect is found in plunger operation, replace the lash adjuster.

The steel ball spring of the lash adjuster is extremely weak. The lash adjuster’s functionality may be badly affected if the special tool is inserted too strongly. 5. Soak the lash adjuster in the diesel fuel in container B. Move the plunger in and out 5 - 10 times by gently pushing the internal steel ball using the special tool Air bleed wire (MD998442) until the plunger moves smoothly to wash the lash adjuster’s pressure chamber.

MD998442 Diesel fuel AK202840 AB

CAUTION

MD998442 Diesel fuel AK202840 AB

The hole in the side of the lash adjuster must be directed toward the inside of container B. Never direct it against any person. 6. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure chamber.

ENGINE OVERHAUL ROCKER ARMS AND CAMSHAFT

11B-35

8. Place the lash adjuster upright with the plunger at the top. Push the plunger firmly until it makes a full stroke, then return the plunger slowly and release the hold of the steel ball to allow the pressure chamber to be filled with diesel fuel.

MD998442

Diesel fuel AK202841 AB

CAUTION Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel fuel. 7. Soak the lash adjuster in the diesel fuel in container C. Gently push the internal steel ball using the special tool Air bleed wire (MD998442).

MD998442

Diesel fuel AK202842 AB

AK202843

9. Take the lash adjuster out of the container, place it upright with the plunger at the top, and push the plunger firmly. The plunger must not move at all. NOTE: If the lash adjuster contracts, perform the operations 7. through 9. again. Replace the lash adjuster if it still contracts even after the pressure chamber has completely been filled with diesel fuel (air has been bled). 10.Keep the serviced lash adjusters in their upright positions to prevent diesel fuel from spilling out. Protect them from dust or other foreign matter. Install the lash adjusters onto the engine as soon as possible.

ENGINE OVERHAUL

11B-36

CYLINDER HEAD AND VALVES

CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION M1113006900389

78 ± 2 N·m → loosen completely → 20 ± 2 N·m → 90˚ + 90˚

1 2

4 5 6 12 N 13 16 N

8 9 10 14 N 15 17 N

20

19 N 11

18 N 7

3N


AK202895 AB

Removal steps

<> >>D<< 1. Cylinder head bolt <> >>C<< >>B<<

2. 3. 4. 5. 6.

Cylinder head assembly Cylinder head gasket Retainer lock Valve spring retainer Valve spring

<> >>C<< >>B<< >>A<<

Removal steps&RQWLQXHG 7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring 11. Exhaust valve 12. Valve stem seal 13. Valve spring seat

ENGINE OVERHAUL

11B-37

CYLINDER HEAD AND VALVES Removal steps&RQWLQXHG

>>A<< 14. Valve stem seal 15. Valve spring seat 16. Intake valve guide 17. Exhaust valve guide 18. Intake valve seat 19. Exhaust valve seat 20. Cylinder head

INSTALLATION SERVICE POINTS >>A<< VALVE STEM SEAL INSTALLATION

MD998737

REMOVAL SERVICE POINTS <> CYLINDER HEAD BOLT REMOVAL AK202874 AB

CAUTION MB991654

AK202723 AB

Use the special tool Cylinder head bolt wrench (MB991654) to loosen the cylinder head bolts. <> RETAINER LOCK REMOVAL MD998772

The special tool must always be used when installing the valve stem seal. Improper installation could result in oil leaks past the valve guide. 1. Install the valve spring seat. 2. Install the valve. 3. Apply a thin coat of engine oil to a new valve stem seal. 4. Use the special tool Valve stem seal installer (MD998737) to install the stem seal on the valve guide. Use the stem of the valve to guide the stem seal. Intake valve stem seal Colour: Gray

AK202742 AB

Exhaust valve stem seal Colour: Grayish green

AK202875 AB

NOTE: Do not confuse the stem seals for intake valves with those for exhaust valves.

MD998735

>>B<< VALVE SPRING INSTALLATION

Painted end AK202873 AB

Compress the valve spring using the special tool Valve spring compressor (MD998772), then remove the retainer lock. NOTE: Store removed valves, springs and other parts, after putting to each of them a tag that identifies its cylinder No. or installation location.

Spring retainer

Stem seal Spring seat AK202551AB

Install each valve spring with the painted end toward the rocker arm.

ENGINE OVERHAUL

11B-38


>>C<< RETAINER LOCK INSTALLATION MD998772

2. Apply engine oil to the threads and washer of the bolt. NOTE: Use the special tool Cylinder head bolt wrench (MB991654) to tighten the bolts. Timing belt side

8

6

1

3

10

4

2

5

9

AK202742 AB

MD998735

7 AK202806 AB

3. Tighten the bolts to 78 2 N¼m in the indicated sequence. 4. Loosen all the bolts completely. 5. Tighten the bolts again to a torque of 20 2 N¼m in the indicated sequence. AK202873 AB

Compress the valve spring using the special tool Valve spring compressor (MD998772), then install the retainer lock.

90˚

>>D<< CYLINDER HEAD BOLT INSTALLATION 90˚

Paint marks AK202720 AB

CAUTION Nominal length

AK202750 AB

MB991654

If the tightening angle is smaller than 90, proper fastening performance could not be assured. Be sure to respect that angle. If the bolt is tightened to an angle greater than the specified angle, loosen the bolt completely and then retighten it beginning with the first step. 6. Make paint marks on each bolt’s head and on the cylinder head. 7. Turn the bolts 90 in the tightening direction and in the indicated sequence. 8. Give another 90 turn in the tightening direction to each bolt, making sure that the paint mark on the bolt head and that on the cylinder head are on the same line.

AK202723 AB

1. When reusing a cylinder head bolt, check that its nominal length (shank length) is not greater than the limit. If the limit is exceeded, replace the bolt. Limit: 99.4 mm


CYLINDER HEAD 1. Before cleaning the cylinder head, check it for traces of water and gas leakage and for cracks and any other damage.

ENGINE OVERHAUL

11B-39


2. Thoroughly remove oils, scale, sealants, carbon and other contamination. Clean the oil passages, then check using compressed air that they are not blocked.

Standard values: Intake 1.0 mm Exhaust 1.5 mm Limits: Intake 0.5 mm Exhaust 1.0 mm

AK202724

Total length

CAUTION The thickness of the metal that can be removed by grinding from both the cylinder head and the mating cylinder block is limited to 0.2 mm in total. 3. Check the cylinder head gasket surface for warp using a straightedge and thickness gauge. If the surface is warped beyond the limit, grind the surface for rectification. Gasket surface warp Standard value: Less than 0.05 mm Limit: 0.2 mm Grinding limit: 0.2 mm Cylinder head height (standard value for new part): 131.9 - 132.1 mm VALVES 1. Check the valve face for correct contact with the seat. Reface the valve if the contact is partial or one sided.

AK202876 AB

3. Measure the total length of the valve. Replace the valve if the length is less than the limit. Standard values: Intake 109.50 mm Exhaust 109.70 mm Limits: Intake 109.00 mm Exhaust 109.20 mm VALVE SPRINGS Out of square

Free height

AK202706 AB

Contact (Should be at center of face) Margin

AK202729 AB

2. Measure the margin. Replace the valve if its margin is smaller than the limit.

1. Measure the free height of the spring. Replace the spring if its height is smaller than the limit. Standard value: 47.0 mm Limit: 46.0 mm 2. Measure the squareness of the spring. Replace the spring if it is out of square beyond the limit. Standard value: 1.5 or smaller Limit: 4

ENGINE OVERHAUL

11B-40


VALVE GUIDE

With the valve installed in position and its face pressed against the valve seat, measure the valve stem projection (distance between the the valve stem end and spring seating surface). If the measurement exceeds the limit, replace the valve seat. Standard values: Intake 49.20 mm Exhaust 48.40 mm

valve guide

Stem diameter Guide inside diameter

AK202709 AB

Measure the valve guide inside diameter and valve stem diameter to calculate the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both. Standard values: Intake 0.02 - 0.05 mm Exhaust 0.05 - 0.09 mm

Limits: Intake 49.70 mm Exhaust 48.90 mm

VALVE SEAT RECONDITIONING 1. Before reconditioning the valve seat, check the clearance between the valve guide and valve stem and, if necessary, replace the valve guide. 0.9 – 1.3 mm

0.9 – 1.3mm

65˚

65˚

Limits: Intake 0.10 mm Exhaust 0.15 mm

25˚

15˚

VALVE SEATS

44˚ Valve stem end Valve stem projection Spring seating surface AK202814 AB

AK202850 AB

2. Resurface the valve seat to the indicated width and angles. 3. After resurfacing, lap the valve and valve seat using lapping compound.

ENGINE OVERHAUL

11B-41


VALVE SEAT REPLACEMENT

4. Resurface the valve seat. See the VALVE SEAT RECONDITIONING section.

0.5 – 1 mm

VALVE GUIDE REPLACEMENT 1. Force out the valve guide toward the cylinder block using a press. Cut

CAUTION 0.5 – 1 mm

AK202707 AB

1. Cut inside of the valve seat to be replaced until its wall becomes thin enough for removal, then remove the valve seat.

Do not use a replacement valve guide of the same size as the removed one. 2. Machine the valve guide hole in the cylinder head to the size matched to the selected oversize valve guide. Valve guide hole diameters 0.05 oversize: 12.05 - 12.07 mm 0.25 oversize: 12.25 - 12.27 mm 0.50 oversize: 12.50 - 12.52 mm

Valve seat height

Oversize hole diameter AK202708 AB

2. Rebore the valve seat hole in the cylinder head to a diameter matched to the diameter of the selected oversize valve seat. Intake valve seat hole diameters: 0.3 oversize: 35.30 - 35.33 mm 0.6 oversize: 35.60 - 35.63 mm Exhaust valve seat hole diameters: 0.3 oversize: 33.30 - 33.33 mm 0.6 oversize: 33.60 - 33.63 mm 3. Before fitting the valve seat, cool it in liquid nitrogen to prevent damage to its hole in the cylinder head due to interference.

19.2 – 19.8 mm AK202877 AB

3. Press-fit the valve guide until it remains protruded above the cylinder head by the amount indicated in the drawing. NOTE: . 1. Press the valve guide from above the cylinder head. 2. The valve guides for the intake valves are different in length from those for the exhaust valves (45.5 mm for intake valves; 50.5 mm for exhaust valves) 4. After installing the valve guide, insert a new valve in it to check for smooth movement.

ENGINE OVERHAUL

11B-42

OIL PAN AND OIL PUMP

OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION M1113008100301

19 ± 3 N·m

10

Apply engine oil to all moving parts before installtion.

32 31

28

30

21 23 ± 3 N·m 10 ± 2 N·m

23 ± 3 N·m

29

22

20

23 24

8

16

19 ± 3 N·m

7

19 ± 3 N·m

26

15

9

17 ± 1 N·m

25 19

14 13

27

17 18

9.0 ± 3.0 N·m

36 ± 3 N·m

11 3

4

23 ± 3 N·m

23 ± 3 N·m

12

1

39 ± 5 N·m

2 44 ± 5 N·m

5

6

9.0 ± 3.0 N·m 39 ± 5 N·m

9.0 ± 3.0 N·m

22 ± 4 N·m

2

1 9.0 ± 3.0 N·m

AK202676 AB

9.0 ± 3.0 N·m

>>O<< >>N<< <> <> <>

>>M<< >>L<< >>L<<

Removal steps 1. Drain plug 2. Drain plug gasket 3. Oil filter 4. Transmission stay <4WD> 5. Oil pan <2WD> 6. Oil pan lower section <4WD> 7. Oil pan upper section <4WD> 8. Oil screen 9. Gasket 10.Oil pressure switch

>>K<<

<>

>>J<<

<>

>>I<< >>H<<

Removal steps&RQWLQXHG 11.Relief plug 12.Gasket 13.Relief spring 14.Relief plunger 15.Oil filter bracket 16.Gasket 17.Plug 18.O-ring 19.Flange bolt 20.Front case

ENGINE OVERHAUL

11B-43


>>G<< >>G<< >>F<< >>E<< >>D<< <> >>C<< <> >>B<< <> >>A<<

Removal steps&RQWLQXHG 21.Gasket 22.Oil pump cover 23.Oil pump driven gear 24.Oil pump drive gear 25.Crankshaft front oil seal 26.Counterbalancer shaft oil seal 27.Oil pump oil seal 28.Counterbalancer shaft, right 29.Counterbalancer shaft, left 30.Counterbalancer shaft front bearing 31.Counterbalancer shaft rear bearing, right 32.Counterbalancer shaft rear bearing, left

REMOVAL SERVICE POINTS <> OIL PAN REMOVAL <2WD>

<> OIL PAN UPPER SECTION REMOVAL <4WD> A

A

AK202692 AB

Screw bolts into the bolt holes A shown in the drawing (holes at both ends) to remove the oil pan.

CAUTION Do not use a scraper or the special tool to remove the oil pan.

MD998727

<> PLUG REMOVAL MD998162

AK202574 AB

1. Remove the oil pan bolts. 2. Insert the special tool Oil pen remover (MD998727) into the joint between the cylinder block and oil pan by tapping the tool with a hammer. 3. Remove the oil pan by tapping an edge of the special tool Oil pen remover (MD998727) with a hammer to move it sideways. <> OIL PAN LOWER SECTION REMOVAL <4WD> Remove the oil pan by tapping it through a piece of wood applied to a side with a plastic hammer.

MD998783 AK202585 AB

Fit the teeth of the special tool in notches of the plug as shown in the drawing and support the tool with the special tool to loosen the plug. Plug wrench (MD998162) Plug wrench retainer (MD998783) <> FLANGE BOLT REMOVAL

CAUTION Do not use a scraper or the special tool to remove the oil pan. Plug

Crosspoint screwdriver AK202586 AB

1. Remove the plug on the left side of the cylinder block. Insert a cross point screwdriver (shank diameter 8 mm) into the plug hole more than 60 mm to prevent the left counterbalancer shaft from rotating.

ENGINE OVERHAUL

11B-44


2. When removing the rear bearing of the left counterbalancer shaft, install the special tool Silent shaft bearing installer stopper (MB991603) on the front of the cylinder block and use a special tool Silent shaft bearing puller (MD998372) to pull out the bearing.

INSTALLATION SERVICE POINTS AK202642

2. Loosen and remove the flange bolt.

>>A<< LEFT COUNTERBALANCER SHAFT REAR BEARING INSTALLATION MB991603

<> COUNTERBALANCER SHAFT FRONT BEARING REMOVAL

MD998705 AK202548 AB

Front bearing

1. Install the special tool Silent shaft bearing installer stopper (MB991603) on the cylinder block.

MD998371 AK202633 AB

CAUTION Remove the front bearing first. Otherwise, the special tool cannot be used. Use the special tool Silent shaft bearing puller (MD998371) to remove the counterbalancer shaft front bearing from the cylinder block. <> COUNTERBALANCER SHAFT REAR BEARING REMOVAL 1. Use the special tool Silent shaft bearing puller (MD998371) to remove the counterbalancer shaft rear bearings from the cylinder block. MB991603

MD998372

AK202634 AB

MB991603 MD998705

Rear bearing AK202635 AB

2. Set the rear bearing on the special tool Silent shaft bearing installer (MD998705). NOTE: The left counterbalancer shaft rear bearing has no oil hole. 3. Force the rear bearing into the cylinder block by sticking the special tool.

ENGINE OVERHAUL

11B-45


>>B<< RIGHT COUNTERBALANCER SHAFT REAR BEARING INSTALLATION

MD998705

Guide pin AK202581 AB

AK202579 AB

1. Install the guide pin on the cylinder block.

>>C<< COUNTERBALANCER SHAFT FRONT BEARING INSTALLATION

Rear bearing (Right) Ratchet ball

Oil hole

Tool element for rear bearing installation AK202582 AB

AK202549 AB

2. Set the bearing on the special tool Silent shaft bearing installer (MD998705) with its oil hole on the ratchet ball.

1. Detach from the special tool Silent shaft bearing installer (MD998705) its element for rear bearing installation.

MD998705

Guide pin Guide pin AK202579 AB

AK202580 AB

3. Insert the special tool Silent shaft bearing installer (MD998705) while passing the guide pin through its hole and force the bearing into position by striking the tool.

2. Install the guide pin on the cylinder block. Front bearing Ratchet ball

Oil hole

AK202549 AC

3. Set the bearing on the special tool Silent shaft bearing installer (MD998705) with its oil hole on the ratchet ball.

ENGINE OVERHAUL

11B-46


>>E<< COUNTERBALANCER SHAFT OIL SEAL INSTALLATION MD998705 Socket wrench

Oil seal

Front case

Guide pin AK202580 AB

4. Insert the special tool Silent shaft bearing installer (MD998705) into the cylinder block while passing the guide pin through its hole and force the bearing into position by striking the tool.

AK202646 AB

Use an appropriate socket wrench to install the counterbalancer shaft oil seal. >>F<< CRANKSHAFT OIL SEAL INSTALLATION

MD998375 Oil seal Front case AK202583AB

>>D<< OIL PUMP OIL SEAL INSTALLATION

Oil seal

Socket wrench

AK202645 AB

Use the special tool Crankshaft front oil seal installer (MD998375) to install the crankshaft oil seal. >>G<< OIL PUMP DRIVEN GEAR/OIL PUMP DRIVE GEAR INSTALLATION

Front case Alignment marks AK202639 AB

Use an appropriate socket wrench to install the oil pump oil seal. AK202660 AB

Apply engine oil generously to the gears and line up the alignment marks.

ENGINE OVERHAUL

11B-47


>>H<< FRONT CASE INSTALLATION Counterbalancer shaft, left

MD998285

1. Insert a correspond screwdriver (shank diameter 8 mm) into the hole in the left side of the cylinder block to prevent the counterbalancer shaft from rotating.

Counterbalancer shaft, right

AK202577 AB

1. Install the special tool crankshaft front oil seal guide (MD998258) on the front end of crankshaft and apply a thin coat of engine oil to the outer surface of the special tool. Be sure to use the special tool when the front case is fitted with an oil seal. 2. Install the front case on the cylinder block with a new front case gasket in between and temporarily tighten all the flange bolts except those that are used for tightening the filter bracket. 3. Install the oil filter bracket on the front case with the oil filter bracket gasket in between and temporarily tighten the washer-assembled bolts.

AK202642

2. Tighten the flange bolts. >>J<< PLUG INSTALLATION 1. Install a new O-ring on the front case. MD998162

MD998783 AK202585 AB

2. Use the special tool to tighten the plug to the specified torque. Plug wrench (MD998162) Plug wrench retainer (MD998783)

MD998285

AK202656 AB

4. Tighten all the bolts to the specified torques.

>>K<< OIL PRESSURE SWITCH INSTALLATION

>>I<< FLANGE BOLT INSTALLATION

AK202625AB

Crosspoint screwdriver

CAUTION AK202641 AB

Be careful not to block the oil passage with sealant. 1. Apply sealant to the threaded portion. Specified Sealant: 3M ATD Part No.8660 or equivalent

ENGINE OVERHAUL

11B-48


Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.

MD998054

M6 × 16 AK204037AD

2. Tighten the oil pressure switch together with the cylinder block by the specified torque using of the special tool Oil pressure switch wrench MD998054. Tightening torque: 19 3 N¼m >>L<< OIL PAN UPPER SECTION/OIL PAN LOWER SECTION INSTALLATION <4WD>

CAUTION Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage. 1. Clean the gasket surfaces of the cylinder block and oil pan. Timing belt side

AK202685 AB

3. Install the shorter bolts in the locations indicated in the drawing.

CAUTION Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage. 4. Thoroughly remove old FIPG from the gasket surfaces of the oil pan upper and lower sections. Timing belt side

Bolt hole area

Grooved area

Bolt hole area

Grooved area AK202688 AB

CAUTION Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage. 2. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan.

AK202686 AB

CAUTION Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage.

ENGINE OVERHAUL

11B-49


5. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.

Timing belt side M6 × 8

Timing belt side 9

Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent NOTE: In the grooved areas on the oil pan flange, apply FIPG bead along the center of the groove.

8

5

4

12

1 11

3 2

6

7

AK202693 AB

10 AK202687 AB

6. Install the oil pan lower section by tightening the bolts in the indicated sequence. >>M<< OIL PAN INSTALLATION <2WD>

3. Install the shorter bolts in the locations indicated in the drawing. >>N<< OIL FILTER INSTALLATION Bracket side

CAUTION Do not apply FIPG over remaining old FIPG. Doing so could result in oil leakage. 1. Thoroughly remove old FIPG from the gasket surfaces of the cylinder block and oil pan.

Engine oil

Timing belt side AK202556 AB

Bolt hole area

Grooved area

AK202694 AB

CAUTION Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could result in leakage. 2. Apply a 4 mm diameter bead of FIPG to the flange surface all around the oil pan.

1. Clean the installation surface of the filter bracket. 2. Apply engine oil to the o-ring of the oil filter. 3. Install the oil filter to the bracket and tighten it to the specified torque. Tightening torque: 14 2 N¼m 4. If no torque wrench can be used for tightening, use the following procedure: (1) Screw in the oil filter until its o-ring contacts the oil filter bracket. (2) Tighten the oil filter 3/4 turn.

ENGINE OVERHAUL

11B-50


>>O<< DRAIN PLUG GASKET INSTALLATION Drain plug

AK202835AB

Oil pan Gasket

Oil pan side

2. Check the journals for seizure, damage and defective contact with bearings. If any of these faults is found, replace the counterbalance shaft, bearings and/or oil pump case assembly. OIL PUMP

AK202603AB

CAUTION Installing the gasket with the wrong side facing the oil pan will result in oil leakage. Replace the drain plug gasket with a new one. Install it with the side indicated in the drawing toward the oil pan.


COUNTERBALANCE SHAFTS 1. Check that the oil holes are not blocked. Clean if necessary.

AK202831

1. Install the drive and driven gears in the oil pump case. 2. Measure the gear side clearance using a straight edge and thickness gauge. Standard values: Drive gear 0.08 - 0.14 mm Driven gear 0.06 - 0.12 mm

ENGINE OVERHAUL

11B-51

PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION M1113008400528

6 7 8


10 4

9 12 11

5

3 2 1

20 ± 2 N·m + 90˚ to 94˚

AK202896 AB

>>G<< <> >>F<< >>E<< >>D<< >>C<<

1. 2. 3. 4. 5. 6.

Removal steps Connecting rod cap nut Connecting rod cap Connecting rod bearing Piston and connecting rod assembly Connecting rod bearing Piston ring No. 1

Removal steps&RQWLQXHG

>>C<< 7. Piston ring No. 2 >>B<< 8. Oil ring <> >>A<< 9. Piston pin 10. Piston 11. Connecting rod 12. Bolt

ENGINE OVERHAUL

11B-52


REMOVAL SERVICE POINTS <> CONNECTING ROD CAP REMOVAL Push rod

Cylinder number

Front mark Front mark

Guide C

AK202812 AB

Mark the cylinder number on the side of the connecting rod big end as a guide for reassembly.

Base

<> PISTON PIN REMOVAL Push rod

Guide A: 17.9 mm Guide B AK202781 AB

Guide A: 18.9 mm

GuidE C Guide A: 20.9 mm Base

1. Insert the tool element, Push rod, into the piston from the front mark side, then attach the element, Guide C, to the push rod. 2. Place the piston and connecting rod assembly on the element, Base, with the front mark facing up. 3. Use a press to remove the piston pin. NOTE: Keep the disassembled pistons, piston pins and connecting rods cylinder by cylinder.

INSTALLATION SERVICE POINTS Guide A: 21.9 mm

>>A<< PISTON PIN INSTALLATION Timing belt side

Crankshaft bore size mark

AK202783 AB

No.4 No.3 No.2 No.1

The special tool Piston pin setting tool (MD998780), consists of the elements shown in the drawing.

AK202923 AB

1. When replacing a piston, check the cylinder bore size mark stamped at the indicated location on the cylinder block and select an appropriate replacement piston using the following table. Cylinder bore size mark

Piston size mark

I

A

II

No mark

III

C

ENGINE OVERHAUL

11B-53


NOTE: The piston size mark is located on the piston top surface.

D

C

3 mm + L

Guide B

Guide A AK202789 AB

Connecting rod Piston

B

8. Screw the tool element, Guide B, into the tool element, Guide A until the gap between both the elements is equal to the dimension L (obtained in step 3.) plus 3 mm.

Piston pin

A

Push rod Piston pin

AK202784 AB

2. Measure the following dimensions: A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod small end width 3. Obtain dimension L from the measurements using the following formula. L = [(A-C) - (B-D)] 2 4. Insert the tool element, Push rod, into the piston pin and attach the element, Guide A, to the push rod end. 5. Assemble the connecting rod with the piston with their front marks facing in the same direction. 6. Apply engine oil to the outside surface of the piston pin. 7. Insert the assembly of piston pin, Push rod, and Guide A (put together in step 4.) into the piston holes from the front mark side.

Front mark

Front mark

Guide A Base

Guide B

AK202782 AB

9. Place the piston and connecting rod assembly onto the element, Piston setting base, with the front marks facing up. 10.Install the piston pin using a press. If the required press force is less than the standard value, replace the piston and piston pin assembly or the connecting rod, or both. Standard value: 7,350 - 17,100 N

ENGINE OVERHAUL

11B-54


>>B<< OIL RING INSTALLATION

>>C<< PISTON RING NO. 2/PISTON RING NO. 1 INSTALLATION

Lower side rail end gap

Upper side rail end gap

Piston ring expander Spacer end gap

AK202879 AB AK202786 AB

1. Fit the oil ring spacer into the piston ring groove. Install the upper side rail, then the lower side rail. NOTE: . 1. Locate the side rail and spacer end gaps as shown in the drawing. 2. New spacers and side rails are an identified by color marks as follows: Size

Color mark

Standard

Non mark

0.50 mm oversize

Blue

1.00 mm oversize

Yellow

Identification mark Size marks

No. 1 No. 2

AK202807 AB

CAUTION Use of ring expander to expand the side rail end gap can break the side rail, unlike other piston rings. Side rail end

Using a piston ring expander, install the piston rings with their identification marks facing up (toward the piston crown). Identification marks: No. 1 ring 1R No. 2 ring 2R NOTE: Each of the available piston rings has a size mark as follows: Size

Size mark

Standard No. 1 ring No mark (blue paint on periphery) No. 2 ring No mark (green paint on periphery) AK202785 AB

2. To install each side rail, first fit one end of the rail into the piston groove, then press the remaining portion progressively into position by finger as shown in the drawing. 3. Make sure that the installed side rails move smoothly in either direction.

0.50 mm oversize

50

1.00 mm oversize

100

>>D<< PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION 1. Apply engine oil generously to the piston’s outside surface, piston rings, and oil ring.

ENGINE OVERHAUL

11B-55

PISTON AND CONNECTING ROD Side rail No. 1

No. 2

2. Crankshaft pin diameter marks are stamped in the indicated locations.

Side rail AK202730 AB

2. Align the end gaps of the piston rings and oil ring (side rails and spacer) as shown in the drawing. 3. Insert the piston and connecting rod assembly from the top of cylinder with the front mark on the crown toward the camshaft sprocket.

AK202719AB

3. Connecting rod bearing identification mark is stamped in the indicated location on each bearing. Crankshaft pin

Connecting rod bearing

Identification Diameter mm mark

Identification mark

I

44.995 - 45.000 1

II

44.985 - 44.995 2

III

AK202798

CAUTION Do not strike the assembly with a large force. Doing so could break the piston rings. When striking the assembly into cylinder, do not allow it to interfere with the oil jet. 4. Use a piston ring band to hold the piston rings compressed when inserting the piston and connecting rod assembly into the cylinder.

44.980 - 44.985 3 If the crankshaft pin diameter mark is “I”, select a bearing marked “1”. If the crankshaft pin diameter mark is illegible, measure the pin diameter and select a bearing with the mark corresponding to the measurement. 4. Install the upper and lower halves of the selected bearing on the connecting rod big end and cap, respectively. >>F<< CONNECTING ROD CAP INSTALLATION

>>E<< CONNECTING ROD BEARING INSTALLATION 1. When replacing the connecting rod bearing, select a bearing of the size appropriate for the crankshaft pin diameter in accordance with the crankshaft pin and connecting rod bearing matching table shown below. Locations of crankshaft pin diameter marks

No. 1

No. 4

Cylinder number

Bearing locating notches

No. 2 No. 3

AK202909 AB

AK202813 AB

1. Install the bearing cap on the connecting rod while aligning the marks made during disassembly. If the connecting rod is new and has no alignment mark, assemble it with the cap such that the both bearing locating notches are on the same side as shown in the drawing.

ENGINE OVERHAUL

11B-56


CAUTION If the tightening angle is less than 90, adequate tightness could not be assured. If the tightening angle exceeds 94, loosen the nut completely and then perform the tightening procedure again beginning with the first step. 7. Turn the nut 90 to 94 to bring the mark on the nut into alignment with that on the bolt. AK202821

2. Make sure that the thrust clearance of the connecting rod big end is proper. Standard value: 0.10 - 0.25 mm Limit: 0.4 mm >>G<< CONNECTING ROD CAP NUT INSTALLATION 1. The connecting rod cap bolts and nuts are tightened using the torque-to-yield method. For this reason, each bolt to be reused must be checked for elongation before installation. Whether or not the bolt has been elongated can be determined by running a nut with fingers through all the threads of the bolt. If the nut does not turn smoothly over all the threads, the bolt has been elongated and must be replaced. 2. Apply engine oil to the threads and bearing surface of each nut before installation. 3. Finger-tighten the nuts on the bolts, then tighten the nuts alternately and repeatedly to install the cap properly. 4. Tighten the nuts to a torque of 20 2 N¼m. 90˚ to 94˚


PISTON RING

AK202787

1. Measure the clearance between each piston ring and its groove. If the limit is exceeded, replace the ring or piston, or both. Standard values: No. 1 ring: 0.03 - 0.07 mm No. 2 ring: 0.02 - 0.06 mm Limits: 0.1 mm Force ring down with piston

Paint marks

Paint marks

Piston ring Nut

Bolt AK202721 AB

5. Make a paint mark on the head of each nut. 6. Make a paint mark on the bolt at a point 90to 94 away from the paint mark made on the nut in the tightening direction.

End gap

AK202788 AB

2. Install a piston ring or oil ring side rail into the cylinder bore and force it down with the head of a piston until the ring is at right angles to the cylinder wall. Measure the end gap with a thickness gauge. NOTE: If the end gap is excessive, replace the piston ring. Standard values: No. 1 ring: 0.25 - 0.35 mm No. 2 ring: 0.40 - 0.55 mm Oil ring: 0.10 - 0.40 mm

ENGINE OVERHAUL PISTON AND CONNECTING ROD

11B-57

Limits: No. 1 ring: 0.8 mm No. 2 ring: 0.8 mm Oil ring: 1.0 mm CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) 1. Wipe off oil from the crankshaft pin and connecting rod bearing. 2. Cut a piece of plastic gauge whose length is equivalent to the width of the bearing and place it on the crankshaft pin in parallel with its axis. 3. Install the connecting rod cap carefully and tighten the nuts to the specified torque20 2 N¼m + 90 to 94. 4. Remove the nuts, then remove the connecting rod cap carefully.

AK202848

5. Measure the largest width of the crushed plastic gauge using the ruler printed on the bag of the plastic gauge. Standard value: 0.03 - 0.05 mm Limit: 0.1 mm

ENGINE OVERHAUL

11B-58


CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION M1113008700507

CAUTION On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in damage.

3 Apply engine oil to all moving parts before installtion.

2 1

11 ± 1 N·m

6

9

8

16

4

A

5

11 ± 1 N·m

15

132 ± 5 N·m

7

9.0 ± 1.0 N·m

14

13

12 11 10

25 ± 2 N·m + 90º to 100º

AK204351AB

>>E<< >>D<<

1. 2. 3. 4. 5. 6. 7. 8.

Removal steps Flywheel bolt Adapter plate Flywheel Adapter plate Crankshaft bushing Rear plate Bell housing cover Oil seal case


>>C<< 9. Oil seal >>C<< 10. Bearing cap bolt >>B<< 11. Beam bearing cap 12. Crankshaft bearing, lower

>>B<< 13. Crankshaft >>A<< 14. Crankshaft bearing, upper 15. Thrust bearing 16. Cylinder block

ENGINE OVERHAUL

11B-59


INSTALLATION SERVICE POINTS >>A<< THRUST BEARING INSTALLATION

If the crankshaft journal diameter mark is “0” and the cylinder block bearing bore mark is “1”, then select a bearing with a “2” mark as the No. 1, 2, 4 or 5 bearing and a bearing with a “1” mark as the No. 3 bearing. If the crankshaft journal diameter mark is illegible, measure the journal diameter and select a bearing with the mark corresponding to the measurement.

Groove Timing belt side AK202769 AB

Diameter identification marks of bearing bores in cylinder block

Install the two thrust bearings in the No. 3 bearing bore in the cylinder block. Each thrust bearing must be installed with the grooved end toward the crankshaft web. NOTE: Applying engine oil to the bearings will help facilitate holding them in position.

No. 4 No. 5

No. 3 No. 1 No. 2

>>B<< CRANKSHAFT BEARING INSTALLATION

Cylinder bore size mark

Location of crankshaft journal diameter marks

No. 2 No. 1

No. 3 AK202777 AB

No. 4

No. 5

AK202908 AB

1. Location of crankshaft journal diameter marks Crankshaft journal diameter Identification mark Journal diameter measurement mm 0

1

2

56.994 - 57.000

56.988 - 56.994

56.982 - 56.988

2. The diameter identification marks of the bearing bores in the cylinder block are stamped in the location shown in the drawing.

Cylinder block bearing bore marking

No. 1, 2, 4 and 5 bearing

No. 3 bearing

0

1

0

1

2

1

2

3

2

0

2

1

1

3

2

2

4

3

0

3

2

1

4

3

2

5

4

Crankshaft bearing marking

ENGINE OVERHAUL

11B-60


Crankshaft bearing size mark location size mark

8

4

1

5

9

7

3

2

6

10

Size mark AK202753 AB

3. The size mark of each crankshaft bearing is indicated by ink in the location shown in the drawing.

Groove

Arrow

AK202737 AB

4. Tighten the bolts to 25 2 N¼m in the indicated sequence. 5. Make a paint mark on the head of the bolt. 6. Make a paint mark on the bearing cap at a point 90 to 100 away from the paint mark made on the bolt head in the tightening direction.

Paint mark

Paint mark

Upper bearing half Lower bearing half 90˚ to 100˚

AK202770 AB

4. Install bearing halves with oil grooves in the cylinder block bearing bores. 5. Install bearing halves with no oil grooves in the beam bearing cap. >>C<< BEAM BEARING CAP/BEARING CAP BOLT INSTALLATION 1. Install the beam bearing cap on the cylinder block with the arrow pointing to the timing belt.

AK202722 AB

CAUTION If the tightening angle is less than 90, adequate tightness could not be assured. If the tightening angle exceeds 100, loosen the bolt completely and then perform the tightening again beginning with the first step. 7. Turn clockwise the bolts 90 to 100 in the indicated tightening sequence to bring the mark on each bolt head into alignment with that on the bearing cap.

Nominal length AK202805 AB

2. Measure the nominal length of each bearing cap bolt before installation. If the measurement exceeds the limit, replace the bolt. Limit: 71.1 mm 3. Apply engine oil to the threads and bearing surface of the bolt.

AK202823

8. After installing the beam bearing cap, measure the end play of the crankshaft. If the end play exceeds the limit, replace the crankshaft bearings. Standard value: 0.05 - 0.25 mm

ENGINE OVERHAUL

11B-61


Limit: 0.4 mm >>D<< REAR OIL SEAL INSTALLATION

MB990938

Measure the crankshaft oil clearance using a plastic gauge as follows: 1. Wipe off oil from the crankshaft journal surface and the crankshaft bearing inner surface. 2. Install the crankshaft. Plastic gauge

MD998776

AK202827 AB

Use the special tools to press-fit the rear oil seal in the rear oil seal case. Handle (MB990938) Crankshaft rear oil seal installer (MD998776) >>E<< REAR OIL SEAL CASE INSTALLATION 1. Remove completely old FIPG remaining on the rear oil seal case and cylinder block.

AK202826 AB

3. Cut a piece of plastic gauge whose length is equivalent to the width of the bearing and place it on the crankshaft journal in parallel with its axis. 4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque of 25 2 N¼m + 90 to 100. 5. Remove the bolts, then remove the crankshaft bearing cap carefully.

AK202824AB

2. Apply a bead of FIPG to the surface of the rear oil seal case as shown in the drawing. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent 3. Install the oil seal into the cylinder block after applying an appropriate amount of engine oil to the entire circumference of its lip portion. 4. Install the rear oil seal case by tightening its bolts to 11 1 N¼m.


CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) This plastic gauge method is recommended as a simplest way of measuring the crankshaft oil clearance.

Plastic gauge AK202822 AB

6. Measure the largest width of the crushed plastic gauge using the ruler printed on the bag of the plastic gauge. Standard value: 0.02 - 0.04 mm Limit: 0.1 mm CYLINDER BLOCK 1. Visually check the cylinder block for scratches, rust, and any other corrosion. Also check it for cracks using a flaw detecting penetrant. If any defect is evident, replace the cylinder block.

11B-62

ENGINE OVERHAUL CRANKSHAFT AND CYLINDER BLOCK

BORING CYLINDERS 1. Select an oversize of the pistons to be used based on the largest of the cylinder bores.

AK202833

2. Use a straightedge and thickness gauge to check the cylinder block top surface for warp. Make sure that the surface is free from remaining gasket material and other foreign matter. Standard value: 0.05 mm Limit: 0.1 mm 3. Check cylinder walls for scratches and seizure. If defects are evident, rebore to oversize or replace the cylinder block.

11.65 mm Piston diameter AK202880 AB

2. Oversize pistons are available in two oversizes: 0.50 mm and 1.00 mm. Bore each cylinder to a size that provides the standard clearance when combined with the selected piston. The reference position for piston diameter measurement is as shown in the drawing. 3. Based on the piston diameter measurement, calculate the boring finish dimension. Boring finish dimension = [Piston diameter] + [0.02 - 0.04 mm (clearance between piston and cylinder)] - [0.02 mm (honing margin)]

CAUTION 12 mm

AK202731 AB

4. Use a cylinder gauge to measure the cylinder bore diameter and taper. If the cylinder is worn badly, rebore it to an oversize and replace the piston and piston rings with ones matched with the new bore size. Standard value: 85.00 mm Taper: 0.01 mm

To prevent deformation of cylinder block that would result from the heat generated by boring, bore the cylinders in the following sequence: No. 2 No. 4 No. 1 No. 3. 4. Bore all the cylinders to the calculated boring finish dimension. 5. Hone the bored cylinders to the final finish dimension (piston diameter + clearance between piston and cylinder). 6. Check the clearance between the piston and cylinder. Standard value: 0.02 - 0.04 mm

16-1

GROUP 16

00 11

ENGINE ELECTRICAL

12 13 14 15 16

CONTENTS

17 CHARGING SYSTEM . . . . . . . .

16

GENERAL INFORMATION . . . . . .

16


16

22

SERVICE SPECIFICATIONS. . . . .

16

SERVICE SPECIFICATIONS . . . . .

16

25

SPECIAL TOOL . . . . . . . . . . . . . . .

16

SPECIAL TOOL . . . . . . . . . . . . . . .

16

26

ON-VEHICLE SERVICE. . . . . . . . .

16

ON-VEHICLE SERVICE . . . . . . . . .

16

IGNITION SYSTEM . . . . . . . . .

16

21

27 31

ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . .

16

IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK . . . . . . . . . . . . .

16

OUTPUT CURRENT TEST . . . . . . . . . .

16

RESISTIVE CORD CHECK . . . . . . . . . .

16

REGULATED VOLTAGE TEST. . . . . . .

16

SPARK PLUG CHECK AND CLEANING

16

CAMSHAFT POSITION SENSOR CHECK

16

CRANK ANGLE SENSOR CHECK . . . .

16

DETONATION SENSOR CHECK . . . . .

16

IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN OSCILLOSCOPE . . . . . . . . . . . . . . . . . .

16

36

IGNITION COIL. . . . . . . . . . . . . . . .

16

37

REMOVAL AND INSTALLATION. . . . . .

16

42

CAMSHAFT POSITION SENSOR .

16

51


16

52

16

54

WAVEFORM CHECK USING AN OSCILLOSCOPE. . . . . . . . . . . . . . . . . .

ALTERNATOR ASSEMBLY . . . . .

16 16

REMOVAL AND INSTALLATION . . . . .

16

DISASSEMBLY AND REASSEMBLY . .

16

INSPECTION . . . . . . . . . . . . . . . . . . . . .

16

STARTING SYSTEM . . . . . . . . .

16


16


16

STARTER MOTOR ASSEMBLY . .

16


16

INSPECTION . . . . . . . . . . . . . . . . . . . . .

16

DISASSEMBLY AND REASSEMBLY . .

16

INSPECTION . . . . . . . . . . . . . . . . . . . . .

16

CRANKSHAFT POSITION SENSOR REMOVAL AND INSTALLATION. . . . . .

16

DETONATION SENSOR . . . . . . . .

16


16

32 33 34 35

55

ENGINE ELECTRICAL

16-2

CHARGING SYSTEM

CHARGING SYSTEM GENERAL INFORMATION M1161000100287

The charging system uses the alternator output to keep the battery charged at a constant level under various electrical loads. OPERATION

The average output voltage fluctuates slightly with the alternator load condition. When the ignition switch is turned on, current flows in the field coil and initial excitation of the field coil occurs. When the stator coil begins to generate power after the engine is started, the field coil is excited by the output current of the stator coil. The alternator output voltage rises as the field current increases and it falls as the field current decreases. When the battery voltage (alternator "S" terminal voltage) reaches a regulated voltage of approximately 14.4 V, the field current is cut off. When the battery voltage drops below the regulated voltage, the voltage regulator regulates the output voltage to a constant level by controlling the field current. In addition, when the field current is constant, the alternator output voltage rises as the engine speed increases.

Voltage

Approximately 14.4 V

Time

AKX00183 AC

Rotation of the excited field coil generates AC voltage in the stator. This alternating current is rectified through diodes to DC voltage having a waveform shown in the illustration. SYSTEM DIAGRAM

Alternator

B Stator coil Engine-ECU or Engine-A/T-ECU

G S L

Field coil

+ FR Voltage regulator

Ignition switch Charge warning light

Battery –

AK100054 AF

ALTERNATOR SPECIFICATIONS Item

Specification

Type

Battery voltage sensing

Rated output V/A

12/90

Voltage regulator

Electronic built-in type

ENGINE ELECTRICAL

16-3

CHARGING SYSTEM


Item

Standard value

Limit

Alternator output line voltage drop (at 30 A) V

-

maximum 0.3

Regulated voltage ambient -20C temperature at voltage regulator V 20C

14.2 - 15.4

-

13.9 - 14.9

-

60C

13.4 - 14.6

-

80C

13.1 - 14.5

-

-

70 % of normal output current

Output current

SPECIAL TOOL M1161000600163

Tool

Number

Name

Use

MB991519

Alternator test harness

Checking the alternator ("S" terminal voltage)

ON-VEHICLE SERVICE ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST M1161000900249

Ammeter (clamp-type) Alternator

Voltmeter (digital-type)

"B" terninal

Battery

AK203361AD

This test determines whether the wiring from the alternator "B" terminal to the battery (+) terminal (including the fusible line) is in a good condition or not. 1. Always be sure to check the following before the test. Alternator installation Drive belt tension

(Refer to 311A, GROUP 11A - On-Vehicle Service.) Fusible link Abnormal noise from the alternator while the engine is running 2. Turn the ignition switch to the "LOCK" (OFF) position. 3. Disconnect the negative battery cable.

16-4

ENGINE ELECTRICAL CHARGING SYSTEM

4. Connect a clamp-type DC test ammeter with a range of 0 - 100 A to the alternator "B" terminal output wire. NOTE: The way of disconnecting the alternator output wire and of connecting the ammeter is possibly not found the problem that the output current is dropping due to the insufficient connection between terminal "B" and the output wire. 5. Connect a digital-type voltmeter between the alternator "B" terminal and the battery (+) terminal. [Connect the (+) lead of the voltmeter to the "B" terminal and the connect the (-) lead of the voltmeter to the battery (+) cable]. 6. Reconnect the negative battery cable. 7. Connect a tachometer or the MUT-II (Refer to 311A, GROUP 11A - On-Vehicle Service - Idle speed check). 8. Leave the hood open. 9. Start the engine. 10.With the engine running at 2,500 r/min, turn the headlamps and other lamps on and off to adjust the alternator load so that the value displayed on the ammeter is slightly above 30 A.

Adjust the engine speed by gradually decreasing it until the value displayed on the ammeter is 30 A. Take a reading of the value displayed on the voltmeter at this time. Limit: maximum 0.3 V NOTE: When the alternator output is high and the value displayed on the ammeter does not decrease until 30 A, set the value to 40 A. Read the value displayed on the voltmeter at this time. When the value range is 40 A, the limit is maximum 0.4 V. 11.If the value displayed on the voltmeter is above the limit value, there is probably a malfunction in the alternator output wire, so check the wiring between the alternator "B" terminal and the battery (+) terminal (including fusible link). If a terminal is not sufficiently tight or if the harness has become discolored due to overheating, repair and then test again. 12.After the test, run the engine at idle. 13.Turn off all lamps and the ignition switch. 14.Remove the tachometer or the MUT-II. 15.Disconnect the negative battery cable. 16.Disconnect the ammeter and voltmeter. 17.Connect the negative battery cable.

ENGINE ELECTRICAL

16-5

CHARGING SYSTEM

OUTPUT CURRENT TEST M1161001000238

Load Ammeter (clamp-type)

Voltmeter

+

–

Inition switch

Charging indicator B FR L

Brake warning light

S G

Battery

Alternator

Engine-ECU or Engine-A/T-ECU

AK203362 AH

This test determines whether the alternator output current is normal. 1. Before the test, always be sure to check the following. Alternator installation Battery (Refer to 354A, GROUP 54A - Battery - On-Vehicle Service.) NOTE: The battery should be slightly discharged. The load needed by a fully-charged battery is insufficient for an accurate test. Drive belt tension (Refer to 311A, GROUP 11A - On-Vehicle Service.) Fusible link Abnormal noise from the alternator while the engine is running. 2. Turn the ignition switch to the "LOCK" (OFF) position. 3. Disconnect the negative battery cable.

CAUTION Never use clips but tighten bolts and nuts to connect the line. Otherwise loose connections (e.g. using clips) will lead to a serious accident because of high current. 4. Connect a clamp-type DC test ammeter with a range of 0 - 100 A to the alternator "B" terminal output wire. NOTE: The way of disconnecting the alternator output wire and of connecting the ammeter is possibly not found the problem that the output current is dropping due to the insufficient connection between terminal "B" and the output wire. 5. Connect a voltmeter with a range of 0 - 20 V between the alternator "B" terminal and the earth [Connect the (+) lead of the voltmeter to the "B" terminal, and then connect the (-) lead of the voltmeter to the earth]. 6. Connect the negative battery cable. 7. Connect a tachometer or the MUT-II (Refer to 311A, GROUP 11A - On-Vehicle Service - Idle speed check).

16-6


8. Leave the hood open. 9. Check that the reading on the voltmeter is equal to the battery voltage. NOTE: If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the alternator "B" terminal and the battery (+) terminal. 10.Turn the light switch on to turn on headlamps and then start the engine. 11.Immediately after setting the headlamps to high beam and turning the heater blower switch to the high revolution position, increase the engine speed to 2,500 r/min and read the maximum current output value displayed on the ammeter. Limit: 70 % of normal current output

NOTE: . For the nominal current output, refer to the Alternator Specifications. Because the current from the battery will soon drop after the engine is started, the above step should be carried out as quickly as possible in order to obtain the maximum current output value. The current output value will depend on the electrical load and the temperature of the alternator body. If the electrical load is small while testing, the specified level of current may not be output even though the alternator is normal. In such cases, increase the electrical load by leaving the headlamps turned on for some time to discharge the battery or by using the lighting system in another vehicle, and then test again. The specified level of current also may not be output if the temperature of the alternator body or the ambient temperature is too high. In such cases, cool the alternator and then test again. 12.The reading on the ammeter should be above the limit value. If the reading is below the limit value and the alternator output wire is normal, remove the alternator from the engine and check the alternator. 13.Run the engine at idle after the test. 14.Turn the ignition switch to the "LOCK" (OFF) position. 15.Remove the tachometer or the MUT-II. 16.Disconnect the negative battery cable. 17.Disconnect the ammeter and voltmeter. 18.Connect the negative battery cable.

ENGINE ELECTRICAL

16-7

CHARGING SYSTEM

REGULATED VOLTAGE TEST M1161001100246

Load

Ammeter (clamp-type) Ignition switch

MB991519 Black B

FR L S G

Alternator

Blue Battery

Engine-ECU or Engine-A/TECU

Red

Yellow

Voltmeter (digital-type)

AK202360AH

This test determines whether the voltage regulator correctly controlling the alternator output voltage. 1. Always be sure to check the following before the test. Alternator installation Check that the battery installed in the vehicle is fully charged. (Refer to 354A, GROUP 54A - Battery - OnVehicle Service.) Drive belt tension (Refer to 311A, GROUP 11A - On-Vehicle Service.) Fusible link Abnormal noise from the alternator while the engine is running 2. Turn the ignition switch to the "LOCK" (OFF) position. 3. Disconnect the negative battery cable. 4. Use the special tool Alternator test harness (MB991519) to connect a digital voltmeter between the alternator "S" terminal and earth [Connect the (+) lead of the voltmeter to the "S" terminal, and then connect the (-) lead of the voltmeter to a secure earth or to the battery (-) terminal]. 5. Connect a clamp-type DC test ammeter with a range of 0 - 100 A to the alternator "B" terminal output wire.

NOTE: The way of disconnecting the alternator output wire and of connecting the ammeter is possibly not found the problem that the output current is dropping due to the insufficient connection between terminal "B" and the output wire. 6. Reconnect the negative battery cable. 7. Connect a tachometer or the MUT-II (Refer to 311A, GROUP 11A - On-Vehicle Service - Idle speed check). 8. Turn the ignition switch to the "ON" position and check that the reading on the voltmeter is equal to the battery voltage. NOTE: If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the alternator "S" terminal and the battery (+) terminal. 9. Turn all lamps and accessories off. 10.Start the engine. 11.Increase the engine speed to 2,500 r/min. 12.Read the value displayed on the voltmeter when the alternator output current alternator becomes 10 A or less. 13.If the voltage reading conforms to the value in the voltage regulation, then the voltage regulator is operating normally. If the voltage is not within the standard value, there is a malfunction of the voltage regulator or of the alternator.

ENGINE ELECTRICAL

16-8

CHARGING SYSTEM

14.After the test, lower the engine speed to the idle speed. 15.Turn the ignition switch to the "LOCK" (OFF) position. 16.Remove the tachometer or the MUT-II. 17.Disconnect the negative battery cable.

18.Disconnect the ammeter and voltmeter. 19.Connect the alternator output wire to the alternator "B" terminal. 20.Remove the special tool, and return the connector to the original condition. 21.Connect the negative battery cable.

Voltage Regulation Table Standard value: Inspection terminal Terminal "S"

Voltage regulator ambient temperature C

Voltage V

-20

14.2 - 15.4

20

13.9 - 14.9

60

13.4 - 14.6

80

13.1 - 14.5

WAVEFORM CHECK USING AN OSCILLOSCOPE M1161001200124

MEASUREMENT METHOD Alternator CH1

"B" terminal

AK100002 AC

Connect the oscilloscope special patterns pick-up to the alternator "B" terminal.

STANDARD WAVEFORM Observation Conditions Function

Special pattern

Pattern height

Variable

Variable knob

Adjust while viewing the waveform.

Pattern selector

Raster

Engine speed

Curb idle speed

ENGINE ELECTRICAL

16-9

CHARGING SYSTEM

(V) 0.4 0.2 Voltage at alternator "B" terminal

0 –0.2 –0.4 Time AKX00189AG

NOTE:

when the voltage waveform reaches an excessively high value (approximately 2 V or higher at idle), it often indicates an open circuit due to a brown fuse between alternator "B" terminal and battery, but not a defective alternator.

AKX00190

The voltage waveform of the alternator "B" terminal can undulate as shown in the illustration. This waveform is produced when the regulator operates according to fluctuations in the alternator load (current), and is normal for the alternator. In addition,

EXAMPLE OF ABNORMAL WAVEFORMS NOTE: . 1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the oscilloscope. 2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not operating). (Waveforms can be observed when the headlamps are illuminated.) 3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging system totally.

16-10


Abnormal waveform

Problem cause

Example 1

Open diode

AKX00191

Example 2

Short in diode

AKX00192

Example 3

Broken wire in stator coil

AKX00193

Example 4

Short in stator coil

AKX00194

Example 5

Open supplementary diode

AKX00195

At this time, the charging warning lamp is illuminated.

ENGINE ELECTRICAL

16-11

CHARGING SYSTEM

ALTERNATOR ASSEMBLY REMOVAL AND INSTALLATION M1161001400504

Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Under Cover 351). Drive Belt Removal (Refer to GROUP 11A, Crankshaft Pulley 311A).

Post-installation Operation Drive Belt Installation (Refer to GROUP 11A, Crankshaft Pulley 311A). Drive Belt Tension Adjustment (Refer to GROUP 11A, Onvehicle Service 311A). Under Cover Installation (Refer to GROUP 51, Under Cover 351).

3 5 1

7 11 ± 1 N·m

13 ± 1 N·m

44 ± 10 N·m

9

12 ± 2 N·m

8

N2

4

22 ± 4 N·m (Engine oil)

23 ± 3 N·m

6 8.8 ± 1.0 N·m AC301643 AB

1. 2. 3. 4.

Removal steps Oil level gauge and guide O-ring Detonation sensor harness connector and clamp Power steering oil pressure hose clamp

<>

<>

5. 6. 7. 8. 9.

Removal steps&RQWLQXHG Harness connector Water pump pulley Alternator connector Alternator brace Alternator assembly

ENGINE ELECTRICAL

16-12

CHARGING SYSTEM

REMOVAL SERVICE POINT <> HARNESS CONNECTOR DISCONNECTION

<> ALTERNATOR ASSEMBLY REMOVAL Remove the alternator assembly from above the vehicle.

Lock lever

AC200022AE

Move the lock lever of the ABS-ECU connector as shown in the illustration, and then disconnect the harness connector.

ENGINE ELECTRICAL

16-13

CHARGING SYSTEM

DISASSEMBLY AND REASSEMBLY M1161001600155

1 4

3

5 7

6

2

10

12

9 8

14 13 11

AK202845 AB

<> <> >>B<<

1. 2. 3. 4. 5. 6. 7.

Disassembly steps Front bracket assembly Alternator pulley Rotor Rear bearing Bearing retainer Front bearing Front bracket

<> <> >>A<<

Disassembly steps&RQWLQXHG 8. Stator 9. Plate 10. Regulator assembly 11. Brush 12. Rubber packing 13. Rectifier 14. Rear bracket

ENGINE ELECTRICAL

16-14

CHARGING SYSTEM

DISASSEMBLY SERVICE POINTS <> FRONT BRACKET ASSEMBLY REMOVAL

<> STATOR / REGULATOR ASSEMBLY REMOVAL Rectifier assembly

Solder

Solder AK202778 AB

AK202718

CAUTION

CAUTION Do not insert the screwdriver blades too deep. Doing so could damage the stator coil. Insert the blades of screwdrivers between the front bracket assembly and stator core, and pry and separate them with the screwdrivers. <> ALTERNATOR PULLEY REMOVAL

Use a 180 - 250 W soldering iron, and finish unsoldering within four seconds. Diodes will be damaged by heat if unsoldering time is too long. Avoid applying undue force to the diode leads. 1. Unsolder the stator leads from the main diode of the rectifier assembly when the stator is removed. 2. When removing the rectifier assembly from the regulator assembly, undo the soldered points on the rectifier assembly.

REASSEMBLY SERVICE POINTS >>A<< REGULATOR ASSEMBLY INSTALLATION

AK202714

Wire

CAUTION Perform operation carefully not to damage the rotor. Clamp the rotor in a vise with the pulley facing up to remove the pulley.

AK202779 AB

Rear bracket Brush

Wire

AK202830 AB

After installing the regulator assembly, insert a piece of wire through the hole in the rear bracket while pressing the brush to keep the brush against movement.

ENGINE ELECTRICAL

16-15

CHARGING SYSTEM

NOTE: Holding the brush with the wire facilities installation of the rotor.

STATOR

>>B<< ROTOR INSTALLATION

Wire

AK202716

AK202779 AB

Remove the brush holding wire after the rotor has been installed.

1. Check the continuity between coil leads. If there is no continuity, replace the stator.


ROTOR

AK202717

2. Check the continuity between coil and core. If there is no continuity, replace the stator. AK202735

RECTIFIER ASSEBMLY

1. Measure the resistance between the two slip rings of the rotor coil to check the continuity between them. Replace the rotor if the resistance is not within the standard value range. Standard value: 3 - 5 W 2. Check the continuity between the slip rings and core. AK202803

1. Check the condition of the (+) heat sink by checking continuity between the (+) heat sink and each of the stator coil lead connecting terminals. If continuity is present for both terminals, the diode is shorted. Replace the rectifier assembly.

AK202736

3. If continuity is present, replace the rotor.

ENGINE ELECTRICAL

16-16

STARTING SYSTEM

BRUSH

Protrusion length

AK202802

2. Check the condition of the (-) heat sink by checking continuity between the (-) heat sink and each of the stator coil lead connecting terminals. If continuity is present in both directions, the diode is shorted. Replace the rectifier assembly.

AK202808 AB

1. Measure the length of the protrusion of the brush. Replace the brush if the protrusion length is shorter than the limit. Limit: 2 mm minimum 2. Unsolder the lead of the brush. The brush will come out, becoming ready for removal. Solder

AK202804

3. Check the condition of the diode trio by testing continuity of each of the three diodes using a circuit tester connected to both sides of the diode. Connect in a polarity and then reverse the polarity for each test. If continuity exists or no continuity exists for both polarities, the diode is defective. Replace the rectifier assembly if any of the diodes is defective.

AK202834 AB

3. Install a new brush by pushing it into the holder as shown in the drawing and soldering the lead.

STARTING SYSTEM GENERAL INFORMATION M1162000100183

If the ignition switch is turned to the "START" position, current flows in the pull-in and holding coils provided inside magnetic switch, attracting the plunger, When the plunger is attracted, the lever connected to the plunger is actuated to engage the starter clutch. On the other hand, attracting the plunger will turn on the magnetic switch, allowing the "B" terminal and "M" terminal to conduct. Thus, current flows to engage the starter motor.

When the ignition switch is returned to the "ON" position after starting the engine, the starter clutch is disengaged from the ring gear. An overrunning clutch is provided between the pinion and the armature shaft, to prevent damage to the starter.

ENGINE ELECTRICAL

16-17

STARTING SYSTEM

SYSTEM DIAGRAM

Holding coil

Plunger

Pull-in coil

Lever

B Ignition switch

Overrunning clutch

M S

+

Pinion gear

Armature

Battery

– Brush Yoke

AK202970 AB

STARTER MOTOR SPECIFICATIONS Item

Specification

Type

Reduction drive with planetary gear

Rated output kW/V

1.4/12

Number of pinion teeth

8


Item

Standard value

Limit

Pinion gap mm

0.5 - 2.0

-

Commutator run-out mm

0.05

0.1

Commutator diameter mm

29.4

28.8

Undercut depth mm

0.5

0.2

ENGINE ELECTRICAL

16-18

STARTING SYSTEM

STARTER MOTOR ASSEMBLY REMOVAL AND INSTALLATION M1162001000587

Pre-removal and Post-installation Operation Resonator and Air Intake Duct Removal and Installation (Refer to GROUP 15, Air Cleaner 314). Under Cover Removal and Installation (Refer to GROUP 51, Under Cover 311A).

18 ± 3 N·m

4

9.0 ± 2.0 N·m

3 30 ± 3 N·m

1 49 ± 9 N·m

6

2 5 AC301550 AB

1. 2. 3.

Removal steps Starter cover Starter connector Clutch release cylinder connecting bolts

REMOVAL SERVICE POINT <> STARTER ASSEMBLY REMOVAL Remove the starter assembly from above the vehicle.

<>

4. 5. 6.

Removal steps&RQWLQXHG Clutch hose clamp Starter assembly Starter cover bracket

ENGINE ELECTRICAL

16-19

STARTING SYSTEM

STARTER MOTOR ASSEMBLY INSPECTION M1162001100186

PINION GAP ADJUSTMENT

MAGNETIC SWITCH PULL-IN TEST

Switch S

S M

M

B

battery

Starter motor

B

Battery

Starter motor

Wire

AKX01242 AE

AKX01238 AF

1. Disconnect the field coil wire from the M-terminal of the magnetic switch. 2. Connect a 12-volt battery between the S-terminal and M-terminal.

CAUTION This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 3. Set the switch to "ON", and the pinion will move out.

Wire

1. Disconnect the field coil wire from the M-terminal of the magnetic switch.

CAUTION This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the S-terminal and M-terminal. 3. If the pinion moves out, the pull-in coil is good. If it doesn’t, replace the magnetic switch. MAGNETIC SWITCH HOLD-IN TEST

Stopper

S M

B

Battery Pinion Pinion gap

Starter motor

AKX00198 AC

4. Check the pinion-to-stopper clearance (pinion gap) with a feeler gauge. Standard value: 0.5 - 2.0 mm

Wire AKX01244AE


CAUTION

AKX00199

5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket.

This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the S-terminal and body. 3. Manually pull out the pinion as far as the pinion stopper position. 4. If the pinion remains out, everything is in order. If the pinion moves in, the hold-in circuit is open. Replace the magnetic switch.

ENGINE ELECTRICAL

16-20

STARTING SYSTEM

FREE RUNNING TEST Ammeter A

S M

MAGNETIC SWITCH RETURN TEST

Carbon-pile rheostat

B

S M

B

Battery Starter motor

Battery

V Voltmeter

Starter motor AKX01246 AE

1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to the starter motor as follows: 2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series between the positive battery terminal and starter motor terminal. 3. Connect a voltmeter (15-volt scale) across the starter motor. 4. Rotate the rheostat to full-resistance position. 5. Connect the battery cable from the negative battery terminal to the starter motor body. 6. Adjust the rheostat until the battery positive voltage shown on the voltmeter is 11 V. 7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Current: maximum 90 Amps

Wire

AKX01248 AE


CAUTION This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the M-terminal and body.

WARNING Be careful not to get your fingers caught when pulling out the pinion. 3. Pull the pinion out and release. If the pinion quickly returns to its original position, everything is operating properly. If it doesn’t, replace the magnetic switch.

ENGINE ELECTRICAL

16-21

STARTING SYSTEM


3

12 16 14

13

11 15 21 2 20 19 17 18

5

22

4 8

1

6

7 9

10

<>

Disassembly steps 1. Cover 2. Screw 3. Magnetic switch 4. Screw 5. Bolt 6. Rear bracket 7. Brush holder 8. Rear bearing 9. Armature 10. Yoke assembly 11. Ball

AK202910 AB

<> >>A<< <> >>A<<

Disassembly steps&RQWLQXHG 12. Packing A 13. Packing B 14. Plate 15. Planetary gear 16. Lever 17. Snap ring 18. Stop ring 19. Overrunning clutch 20. Internal gear 21. Planetary gear shaft 22. Front bracket

ENGINE ELECTRICAL

16-22

STARTING SYSTEM

DISASSEMBLY SERVICE POINTS

STARTER MOTOR PARTS CLEANING

<> MAGNETIC SWITCH REMOVAL

Never clean in a solvent such starter motor parts as the magnetic switch, brush holder, and armature. If they are soaked in a solvent, their insulation could be impaired. When these parts require cleaning, wipe off contamination with cloth. 1. Never soak the drive unit in a solvent. If it is washed in a solvent, the grease having been packed in the overrunning clutch at the factory will be washed out. Wipe the drive unit with cloth if it requires cleaning.

B terminal

M terminal

S terminal

Field coil lead

AK202890 AB

REASSEMBLY SERVICE POINTS

CAUTION Do not clamp the yoke assembly with a vise. Disconnect the lead from the M terminal of the magnetic switch.

>>A<< STOP RING/SNAP RING INSTALLATION

<> SNAP RING/STOP RING REMOVAL Socket wrench Stop ring Stop ring

Overrunning clutch

Stop ring

Pinion Gear Overrunning clutch

Snap ring

AK202911 AB

Use a suitable puller to pull the stop ring until it gets over the snap ring. AK202790 AB

1. Apply a long socket wrench of an appropriate size to the stop ring and strike the wrench to drive out the stop ring toward the pinion gear side. Snap ring pliers


COMMUTATOR

Snap ring Pinion gear Overrunnning clutch

AK202712 AK202791 AB

2. Remove the snap ring with snap ring pliers, then remove the stop ring and overrunning clutch.

1. Support the armature with a pair of V block and turn it to measure the runout of the surface not rubbed by the brushes using a dial gauge. Standard value: 0.05 mm or less Limit: 0.1 mm

ENGINE ELECTRICAL

16-23

STARTING SYSTEM

Push the brush into the brush holder to make sure that the spring is working on the brush. If the spring is not working, replace the brush holder. OVERRUNNING CLUTCH

Free

AK202715

2. Measure the diameter of the commutator. Standard value: 29.4 mm Limit: 28.8 mm

Lock AK202710 AB

Segment

1. Make sure that the pinion cannot be turned counterclockwise and can be turned clockwise freely. 2. Check the pinion for abnormal ware and damage.

Undercut Mica

BRUSHES

AK202711 AB

3. Measure the depth of the undercut between segments. Standard value: 0.5 mm Limit: 0.2 mm BRUSH HOLDER

Brush height

AK202846 AB

AK202897

1. Check the commutator contacting surface of each brush for abnormal roughness. Also check the height of the brush. Replace the brush holder if the height is lower than the limit. Limit: 7.0 mm 2. When the contact surface of the brush is rectified or the brush holder is replaced, recondition the contact surface with sandpaper wrapped around the commutator.

ENGINE ELECTRICAL

16-24

STARTING SYSTEM

ARMATURE COIL 1. Check the armature coil for short circuit as follows:

MAGNETIC SWITCH

A Growler

M terminal AK202891 AB

AK202733 AB

2. Set the armature in a growler.

CAUTION Clean the surface of the armature thoroughly before performing the test. 3. While holding a thin strip of iron against the armature in parallel with its axis, turn the armature slowly. The armature is normal if the iron strip is not attracted to the armature or it does not vibrate.

1. Coil open circuit test Check that there is continuity between the M terminal and body A. If there is no continuity, replace the magnetic switch.

B terminal


AK202734

4. Check the insulation between commutator segments and armature coils. The armature coils are properly insulated if no continuity is present.

2. Contact fusion check Check that there is no continuity between the B terminal and M terminal. If there is continuity, replace the magnetic switch.

B terminal


AK202713

5. Check continuity between a segment and another. There is no open circuit in the tested coil if there is continuity.

3. Switch contact check Push the indicated end of the magnetic switch with a strong force to close the internal contacts. Without releasing the switch end, check that there is continuity between the B terminal and M terminal. If there is no continuity, replace the magnetic switch.

ENGINE ELECTRICAL

16-25

IGNITION SYSTEM

IGNITION SYSTEM GENERAL INFORMATION M1163000100249

This system is equipped with two ignition coils (A and B) with built-in power transistors for the No. 1 and No. 4 cylinders and the No. 2 and No. 3 cylinders respectively. Interruption of the primary current flowing in the primary side of ignition coil A generates a high voltage in the secondary side of ignition coil A. The high voltage thus generated is applied to the spark plugs of No. 1 and No. 4 cylinders to generate sparks. At the time that the sparks are generated at both spark plugs, if one cylinder is at the compression stroke, the other cylinder is at the exhaust stroke, so that ignition of the compressed air/fuel mixture occurs only for the cylinder which is at the compression stroke. In the same way, when the primary current flowing in ignition coil B is interrupted, the high voltage thus generated is applied to the spark plugs of No. 2 and No. 3 cylinders.

The engine-ECU or engine-A/T-ECU turns the two power transistors inside the ignition coils alternately on and off. This causes the primary currents in the ignition coils to be alternately interrupted and allowed to flow to fire the cylinders in the order 1-3-4-2. The engine-ECU or engine-A/T-ECU determines which ignition coil should be controlled by means of the signals from the camshaft position sensor which is incorporated in the camshaft and from the crank angle sensor which is incorporated in the crankshaft. It also detects the crankshaft position in order to provide ignition at the most appropriate timing in response to the engine operation conditions. It also detects the crankshaft position in order to provide ignition at the most appropriate timing in response to the engine operation conditions. When the engine is cold or operated at high altitudes, the ignition timing is slightly advanced to provide optimum performance. When the automatic transmission shifts gears, the ignition timing is also retarded in order to reduce output torque, thereby alleviating shifting shocks.

SYSTEM DIAGRAM

Air flow sensor Intake air temperatur sensor Ignition switch

Engine coolant temperature sensor Camshaft position sensor Crank angle sensor Barometric pressure sonsor

Ignition coil B

Ignition coil A

Engine-ECU or Engine-A/TECU Battery Spark plug

Detonatoin sensor Cylinder No.

2

3

4

1

Ignition switch-ST AK101074 AF

ENGINE ELECTRICAL

16-26

IGNITION SYSTEM

IGNITION COIL SPECIFICATION Item

Specification

Type

Molded 2-coil

SPARK PLUG SPECIFICATIONS Item

Specification

NGK

IGR6A11


IGNITION COIL Item

Standard value

Secondary coil resistance kW

8.5 - 11.5

SPARK PLUG Item

Standard value

Limit

Spark plug gap mm

1.0 - 1.1

1.3

Item

Standard value

Limit

Resistance kW

-

Maximum 19

RESISTIVE CORD


Tool

Number

Name

Use

MD998773

Detonation sensor wrench

Detonation sensor removal and installation

ON-VEHICLE SERVICE IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK M1163001200272

Check by the following procedure, and replace if there is a malfunction.

ENGINE ELECTRICAL

16-27

IGNITION SYSTEM

SECONDARY COIL RESISTANCE CHECK

RESISTIVE CORD CHECK M1163001400113

AKX01264

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

Measure the resistance of the all spark plug cables. 1. Check cap and coating for cracks. 2. Measure resistance. Limit: Maximum 19 kW

SPARK PLUG CHECK AND CLEANING M1163004300290

NOTE: .

CAUTION

1.5 V

–

AKX00382

+

When pulling off the spark plug cable from the plug always hold the cable cap, not the cable. 1. Remove the spark plug cables. 2. Remove the spark plugs.

CAUTION

1 2 3

AKX01265AD

An analogue-type circuit tester should be used. Connect the negative (-) prove of the circuit tester to terminal No. 1.

Do not attempt to adjust the gap of the iridium plug. Always use a plug cleaner and finish cleaning within 20 seconds. Do not use wire brushes. Otherwise, the iridium and platinum tip may be damaged.

CAUTION This test must be performed quickly (in less than 10 seconds) to prevent coil from burning and power transistor from breakage. 1.5 V power supply between 2 - 3

Continuity between 1 2

When current is flowing

Continuity

When current is not flowing

No continuity

Iridium tip

Platinum tip AKX01327AD

3. Check the plug gap and replace if the limit is exceeded. Standard value: 1.0 - 1.1 mm Limit: 1.3 mm

CAUTION Be careful not to allow foreign matter in cylinders. 4. Clean the engine plug holes. 5. Install the spark plugs.

ENGINE ELECTRICAL

16-28

IGNITION SYSTEM

CAMSHAFT POSITION SENSOR CHECK M1163004400167

Check the camshaft position sensor circuit if selfdiagnosis code, No. P340 is shown. (Refer to 313A, GROUP 13A - Troubleshooting - Inspection procedure for diagnosis code.)

CRANK ANGLE SENSOR CHECK M1163004500205

Check the crank angle sensor circuit if self-diagnosis code, No. P335 is shown. (Refer to 313A GROUP 13A - Troubleshooting - Inspection procedure for diagnosis code.)

DETONATION SENSOR CHECK M1163002900036

Check the detonation sensor circuit if self-diagnosis code, No. P0325 is shown. (Refer to 313A, GROUP 13A - Troubleshooting - Inspection procedure for diagnosis code.)

IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN OSCILLOSCOPE M1163001700170

MEASUREMENT METHOD 1. Clamp the secondary pickup around the spark plug cable.

NOTE: . The peak ignition voltage will be reversed when the spark plug cables No. 2 and No. 4, or No. 1 and No. 3 cylinders are clamped. Because of the two-cylinder simultaneous ignition system, the waveforms for two cylinders in each group appear during waveform observation (No. 1 cylinder - No. 4 cylinder, No. 2 cylinder - No. 3 cylinder). However, waveform observation is only applicable for the cylinder with the spark plug cable clamped by the secondary pickup. Identifying which cylinder waveform is displayed can be difficult. For reference, remember that the waveform of the cylinder attached to the secondary pickup will be displayed as stable. 2. Clamp the spark plug cable with the trigger pickup. NOTE: Clamp the trigger pickup to the same spark plug cable clamped by the secondary pickup.

STANDARD WAVEFORM Observation Conditions Function Secondary Pattern height

High (or Low)

Pattern selector

Raster

Engine revolutions

Curb idle speed

ENGINE ELECTRICAL

16-29

IGNITION SYSTEM

Spark line (point A)

kV

Ignition voltage (point D)

Secondary ignition voltage wave pattern Wave dampling reduction section (point B)

Dwell section

0 Point C Time

AKX00278AD

Observation Conditions (The only change from above condition is the pattern selector.) Pattern selector Display

kV

NO. 1 cylinder

NO. 3 cylinder ignition noise

Secondary ignition voltage wave pattern

NO. 2 cylinder ignition noise

Time

0 2

NO. 4 cylinder

Newtral section

AKX01275 AC

ENGINE ELECTRICAL

16-30

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 force electrode

Concentration Ignition of air mixture timing

Spark plug cable

Length

Long

Small

Normal

Low

Rich

Advanced

Leak

Short

Large

Large wear

High

Lean

Retarded

High resistance

High

Large

Large wear

High

Lean

Retarded

High resistance

Low

Small

Normal

Low

Rich

Advanced

Leak

Large

Plug is fouled -

-

-

-

Height

Slope

Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5) Number of vibrations

Coil and condenser

3 or more

Normal

Except above

Abnormal

Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5) Number of vibrations

Coil

5 - 6 or higher

Normal

Except above

Abnormal

Point D: Ignition voltage height (distribution per each cylinder) shows the following trends. Ignition voltage

Plug gap

Condition of Compression electrode force

Concentration Ignition of air mixture timing

Spark plug cable

High

Large

Large wear

High

Lean

Retarded

High resistance

Low

Small

Normal

Low

Rich

Advanced

Leak

EXAMPLES OF ABNORMAL WAVEFORMS

AKX00280

Example 1 Wave characteristics Spark line is high and short. Cause of problem Spark plug gap is too large.

AKX00281

Example 2 Wave characteristics Spark line is low and long, and is sloping. Also, the second half of the spark line is distorted. This could be a result of misfiring. Cause of problem Spark plug gap is too small.

ENGINE ELECTRICAL

16-31

IGNITION SYSTEM

AKX00282

Example 3 Wave characteristics Spark line is low and long, and is sloping. However, there is almost no spark line distortion. Cause of problem Spark plug gap is fouled.

AKX00283

Example 4 Wave characteristics Spark line is high and short. Difficult to distinguish between this and abnormal waveform example 1. Cause of problem Spark plug cable is nearly falling off (Causing a dual ignition).

AKX00284

Example 5 Wave characteristics No waves in wave damping section. Cause of problem Layer short in ignition coil.

ENGINE ELECTRICAL

16-32

IGNITION SYSTEM

IGNITION COIL REMOVAL AND INSTALLATION M1163004000374

10 ± 2 N·m 3.0 ± 0.5 N·m

2

1 4

4 3 2

3

5 25 ± 4 N·m

AC301786 AB

1. 2. 3.

Removal steps Rocker cover centre cover Ignition coil connector Spark plug cable

4. 5.

Removal steps&RQWLQXHG Ignition coil Spark plug

ENGINE ELECTRICAL

16-33

IGNITION SYSTEM

CAMSHAFT POSITION SENSOR REMOVAL AND INSTALLATION M1163003400410

2

3N

1

8.8 ± 1.0 N·m

AC301556 AB

1.

Removal steps Camshaft position sensor connector connection

2. 3.

Removal steps&RQWLQXHG Camshaft position sensor O-ring

ENGINE ELECTRICAL

16-34

IGNITION SYSTEM

CRANKSHAFT POSITION SENSOR REMOVAL AND INSTALLATION M1163003500398

3.0 ± 0.5 N·m

22 ± 4 N·m

6 1 8.8 ± 1.0 N·m

2

8

22 ± 4 N·m

4 3

7 8.8 ± 1.0 N·m 49 ± 9 N·m

5

49 ± 9 N·m

AC301612

1.

<>

2. 3. 4.

Removal steps Power steering pressure switch connector A/C compressor connector A/C compressor connector clamp Power steering oil pump assembly

REMOVAL SERVICE POINT <> POWER STEERING OIL PUMP ASSEMBLY REMOVAL Remove the power steering oil pump assembly from the bracket with the hose attached. NOTE: Place the removed power steering oil pump assembly in a place where it will not be a hindrance when removing and installing and secure it with a cord or wire.

5. 6. 7. 8.

Removal steps&RQWLQXHG Power steering oil pump bracket Rocker cover centre cover Crankshaft position sensor Crankshaft position sensor connector bracket

ENGINE ELECTRICAL

16-35

IGNITION SYSTEM

DETONATION SENSOR REMOVAL AND INSTALLATION M1163002800493

CAUTION Do not drop or hit the detonation sensor against other components. Internal damage may result, and the detonation sensor will need to be replaced.

1

2 23 ± 2 N·m

1.

<>

>>A<<

2.

AC301657AB

Removal steps Detonation sensor connector connection Detonation sensor

REMOVAL SERVICE POINT

INSTALLATION SERVICE POINT

<> DETONATION SENSOR REMOVAL

>>A<< DETONATION SENSOR INSTALLATION

Detonation sensor

MD998773

Detonation sensor

MD998773 AC100807 AC

Use special tool detonation sensor wrench (MD998773) to remove the detonation sensor.

AC100807 AC

Use special tool detonation sensor wrench (MD998773) to tighten the detonation sensor to the specified torque.

127(6

21B-1

GROUP 21B

00 11

CLUTCH OVERHAUL

12 13 14 15 16

CONTENTS

17 HOW TO USE THIS MANUAL. . . . . .

21B

CLUTCH . . . . . . . . . . . . . . . . . . . . . . .

21B

CLUTCH REMOVAL AND INSTALLATION

21B

21

GENERAL SPECIFICATIONS . . . . . .

21B

CLUTCH INSPECTION . . . . . . . . . . . . . . . .

21B

22


21B

CLUTCH RELEASE CYLINDER . . . .

21B

25

TORQUE SPECIFICATIONS . . . . . . .

21B

CLUTCH RELEASE CYLINDER DISASSEMBLY AND REASSEMBLY . . . . .

21B

26

21B

CLUTCH RELEASE CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

21B

27

LUBRICANTS . . . . . . . . . . . . . . . . . .

31 32 33 34 35 36 37 42 51 52 54 55

CLUTCH OVERHAUL

21B-2



HOW TO USE THIS MANUAL Scope of Service Explanations This manual describes service procedures performed after removal of the transmission from the vehicle. For removal of the transmission from the vehicle, installation of the transmission in the vehicle, and on-vehicle inspection and service of the transmission, please use the separate Workshop Manuals prepared for the vehicle. How to Read Explanations Service steps (1) A component part drawing is shown at the beginning of each section to enable the technician to ascertain the installed condition of the component parts. (2) Service steps are indicated by means of numbers in the component part drawing. Non-reusable parts are indicated as such, and tightening torques are shown. ·Removal steps: The numbers of the part names match the numbers in the component part drawing and indicate the removal sequence. ·Installation steps: Installation steps are omitted wherever installation can be achieved simply by performing the removal steps in reverse. ·Disassembly steps: The numbers of the part names match the numbers in the component part drawing and indicate the disassembly sequence. ·Reassembly steps: Reassembly steps are omitted wherever reassembly can be achieved simply by performing the disassembly steps in reverse.

Classification of Service Points Key service points, service standards, and instructions for using special tools are collated as service points and explained in detail.

<>: Outward-pointing brackets denote removal service points or disassembly service points. >>A<<: Inward-pointing brackets denote installation service points or reassembly service points.

Lubricant and Sealant Symbols Every location where a lubricant or sealant must be applied or added is indicated using a relevant symbol in the component part drawing and/or on the page after the component part drawing.

. . . . . . . . . . Grease . . . . . . . . . . Sealant or form-in-place gasket (FIPG) . . . . . . . . . . Brake fluid . . . . . . . . . . Gear oil

Inspection If an inspection reveals a defect or fault, effect a repair and, if necessary, replace relevant parts.

AK300001

CLUTCH OVERHAUL

21B-3


Group title

Section title

Page number

MANUAL TRANSMISSION OVERHAUL CONTROL HOUSING

22-43

CONTROL HOUSING DISASSEMBLY AND REASSEMBLY

Denotes non-reusable part.

6

10

3

7

12

13 14

5 4 9 8

11

15

Tightening torque 2

1 22.3 ±0.3 N·m

Disassembly steps 1. Spring washer 2. Stopper bracket <> >>E<< 3. Lock pin 4. Interlock plate 5. Control finger

Procedures and cautions for removal, installation, disassembly, and reassembly are explained under this category of heading.

AK204399AB

Disassembly steps >>D<< 6. Spring pin 7. Stopper body 8. Spring 9. Spacer 10. Control shaft DISASSEMBLY SERVICE POINTS <> LOCK PIN REMOVAL Drive out the lock pin from the direction shown.

Lock pin

Control finger AK204273 AB

The alphabetical character in this category of heading matches that of the relevant removal steps, installation steps, disassembly steps, or installation steps. AK300002

CLUTCH OVERHAUL

21B-4

GENERAL SPECIFICATIONS


Item

Specification

Clutch operating method

Hydraulic type

Clutch disc type

Single dry disc type

Clutch disc size OD ID mm

230 155

Clutch cover type

Diaphragm spring type

Clutch cover setting load N

4,320


Item

Limit

Diaphragm spring end height difference

0.5 mm

Clutch disc facing rivet sink

Minimum 0.3 mm


Part

N¼m

Clutch fluid line bracket bolt

18 3

Clutch tube flare nut

15 1

Union bolt

22 2

Clutch release cylinder mounting bolt

18 3

Clutch cover mounting bolt

18 3

Fulcrum

35 6

Air bleeder

17 1

LUBRICANTS M1212000400120

Item

Specified lubricant

Release fork and release bearing contact surface

MITSUBISHI genuine grease Part Number 0101011 or equivalent

Release fork and fulcrum contact surface Release fork and release cylinder pushrod contact surface Clutch disc splines Piston and piston cup Release cylinder inner surface

Brake fluid DOT3 or DOT4

CLUTCH OVERHAUL

21B-5

CLUTCH

CLUTCH DISASSEMBLY AND REASSEMBLY M1212001000125

18 ± 3 N·m

1

2 3

35 ± 6 N·m

17 11

16

14

12

4 15

5

13

22 ± 2 N·m

7 6 9

8

15 ± 1 N·m

18 ± 3 N·m 18 ± 3 N·m

10 AK204191AB

1. 2. 3. 4. 5. 6. 7. 8. 9.

Removal steps Clutch fluid line bracket Insulator Washer Clutch tube Union bolt Union Gasket Valve plate Compression spring

>>B<< >>B<< <>

>>A<<

10. 11. 12. 13. 14. 15. 16. 17.

Removal steps&RQWLQXHG Clutch release cylinder Clutch cover Clutch disc Return clip Clutch release bearing Release fork Release fork boot Fulcrum

CLUTCH OVERHAUL

21B-6

CLUTCH

REMOVAL SERVICE POINT <> RELEASE FORK REMOVAL

1. Apply Mitsubishi genuine grease part number 0101011 or equivalent to the illustrated positions of the release fork. 2. Install the release fork to the fulcrum. >>B<< CLUTCH DISC AND CLUTCH COVER INSTALLATION

Fulcrum

Flywheel

Clutch disc

Clip Clutch disc guide

Release fork

AK204409AB

Move the release fork in the direction shown to remove the clip from the fulcrum.

Clutch cover

INSTALLATION SERVICE POINTS >>A<< RELEASE FORK INSTALLATION

Apply grease

AK204214 AB

1. Apply Mitsubishi genuine grease part number 0101011 or equivalent to the clutch disc splines and rub it in the splines with a brush. 2. Using the clutch disc guide to position the clutch disc on the flywheel. 3. Install the clutch cover onto the flywheel.


Apply grease

Apply grease AK204410AB

CLUTCH COVER 1. Check the diaphragm spring end for wear and uneven height. Replace if wear is evident or height difference exceeds the limit. Limit: 0.5 mm 2. Check the pressure plate surface for wear, cracks and discoloration. 3. Check the rivets of the strap plate for looseness. If loose, replace the clutch cover.

CLUTCH OVERHAUL CLUTCH

CLUTCH DISC

CAUTION Don’t clean the clutch disc in a cleaning solvent. 1. Check the facing for loose rivets, uneven contact, evidence of seizure, or deposited oils and greases. If defective, replace the clutch disc. NOTE: If contaminated with grease or oil, determine the source of the contaminant and repair it.

21B-7

3. Check the torsion spring for play and damage. If defective, replace the clutch disc. 4. Place the clutch disc on the input shaft and check for sliding condition and play in the rotating direction. If poor sliding condition is evident, clean, reassemble, and recheck. If excessive play is evident, replace the clutch disc and/or input shaft. CLUTCH RELEASE BEARING

Rivet sink

Torsion spring

AK300248AB

2. Measure the rivet sink. Replace the clutch disc if it is below the limit. Minimum limit: 0.3 mm

CAUTION Release bearing is packed with grease. Therefore, do not wash it in a cleaning solvent. 1. Check for seizure, damage, noise or binding/ rough rotation. 2. Check for wear on the surface which contacts with the diaphragm spring. 3. Check for wear on the surface which contacts with the release fork. If abnormally worn, replace. RELEASE FORK If the surface which contacts with the bearing is abnormally worn, replace.

CLUTCH OVERHAUL

21B-8

CLUTCH RELEASE CYLINDER

CLUTCH RELEASE CYLINDER DISASSEMBLY AND REASSEMBLY M1212001500119

3

2

5

4

1

6 9 17 ± 1 N·m

7

8

AK204216AB

<>

>>A<<

1. 2. 3. 4. 5.

Disassembly steps Push rod Boot Piston assembly Piston cup Piston

6. 7. 8. 9.

Disassembly steps&RQWLQXHG Conical spring Cap Air bleeder Release cylinder

CLUTCH OVERHAUL

21B-9

CLUTCH RELEASE CYLINDER

DISASSEMBLY SERVICE POINT

REASSEMBLY SERVICE POINT

<> PISTON ASSEMBLY REMOVAL

>>A<< PISTON ASSEMBLY INSTALLATION

AKX00765

AK204411AB

1. Cover with a shop towel to prevent the piston from popping out.

CAUTION Apply compressed air slowly to prevent brake fluid from splashing. 2. Apply the compressed air into the tube mounting hole to remove the piston assembly.

AK204412AB

1. Apply brake fluid DOT3 or DOT4 to the piston cup and inner surface of the release cylinder. 2. Insert the piston assembly into the release cylinder.


PISTON CUP Check the lip of piston cup for scratch. If it is scratched, check the inner surface of the release cylinder for scratches. RELEASE CYLINDER Check the inner surface of the release cylinder for scratches or abnormal wear, replace if necessary.

127(6

22B-1

GROUP 22B

00 11

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL

12 13 14 15 16 17 21 22

CONTENTS GENERAL INFORMATION . . . . . . . . GENERAL SPECIFICATIONS . . . . . . SERVICE SPECIFICATIONS. . . . . . .

22B 22B

25

OUTPUT SHAFT. . . . . . . . . . . . . . . . . 22B OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

22B

OUTPUT SHAFT INSPECTION . . . . . . . . .

22B

31

REVERSE IDLER GEAR . . . . . . . . . . 22B

32

22B

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT . . . . . . .

22B

TORQUE SPECIFICATION . . . . . . . .

22B

SPEEDOMETER GEAR . . . . . . . . . . . 22B

22B

SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B

22B

SELECT LEVER . . . . . . . . . . . . . . . . . 22B

SEALANTS . . . . . . . . . . . . . . . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . .

22B

TRANSMISSION . . . . . . . . . . . . . . . .

22B

TRANSMISSION DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

22B

TRANSMISSION INSPECTION . . . . . . . . .

22B

INPUT SHAFT . . . . . . . . . . . . . . . . . .

22B

INPUT SHAFT DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

22B

INPUT SHAFT INSPECTION . . . . . . . . . . .

22B

26

REVERSE IDLER GEAR DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . .

22B

27

33 34 35 36

SELECT LEVER DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

37

22B

42

CONTROL HOUSING . . . . . . . . . . . . . 22B

51

CONTROL HOUSING DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

22B

52

CLUTCH HOUSING . . . . . . . . . . . . . . 22B

54

CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

22B

Continued on next page

55

22B-2 TRANSMISSION CASE. . . . . . . . . . . TRANSMISSION CASE DISASSEMBLY AND REASSEMBLY. . . . . . . . . . . . . . . . . . .

DIFFERENTIAL . . . . . . . . . . . . . . . . . DIFFERENTIAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .

22B 22B

22B 22B

CENTER DIFFERENTIAL . . . . . . . . . 22B CENTER DIFFERENTIAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . .

22B

TRANSFER . . . . . . . . . . . . . . . . . . . . 22B TRANSFER DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

22B

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL GENERAL INFORMATION

22B-3


MANUAL TRANSMISSION MODELS Transmission model

Combined engine

Vehicle model

F5M42-2-Y4B2

4G63-D4-MPI

CU2W

W5M42-1-Z4B2

4G63-D4-MPI

CU2W

22B-4


SECTIONAL VIEW

AK204419


22B-5

AK204420


22B-6

GENERAL SPECIFICATIONS


TRANSMISSION MODEL TABLE Transmission Speedomerter model gear ratio

Final gear ratio

Vehicle model

Engine model

Transfer gear ratio

F5M42-2-Y4B2

36/27

4.625

CU2W

4G63-D4-MPI

-

W5M42-1-Z4B2

36/27

4.687

CU2W

4G63-D4-MPI

0.3018

GEAR RATIO TABLE F5M42 1st

3.583

2nd

1.947

3rd

1.379

4th

1.030

5th

0.820

Reverse

3.363

W5M42


Item

Standard value

Minimum limit

Differential case preload

0.05 - 0.11 mm

-

Input shaft front bearing end play

0 - 0.12 mm

-

Input shaft 5th speed gear end play

0 - 0.09 mm

-

Input shaft rear bearing end play

0 - 0.12 mm

-

Synchronizer ring back surface to gear clearance

-

0.5 mm

Output shaft roller bearing inner race end play

0 - 0.12 mm

-

Output shaft 3rd speed gear end play

0 - 0.09 mm

-

Output shaft ball bearing end play

0 - 0.09 mm

-

Differential pinion backlash

0 - 0.15 mm

-

Center differential pinion backlash

0.025 - 0.150 mm

-

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT M1222012000120

SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING END PLAY) Thickness mm

Identification symbol

Thickness mm


2.24

None

2.38

Brown

2.31

Blue

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT

22B-7

SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY AND OUTPUT SHAFT FRONT BEARING END PLAY) Thickness mm


Thickness mm


1.43

Green (2)

1.59

Yellow (2)

1.51

White (2)

THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY) Thickness mm


Thickness mm


2.82

0

2.98

6

2.86

2

3.02

7

2.90

3

3.06

8

2.94

5

3.10

9

SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR END PLAY) Thickness mm


Thickness mm


2.81

Green

2.97

Orange

2.85

White

3.01

Red

2.89

Yellow

3.05

Pink

2.93

Black

3.09

Blue

SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY) Thickness mm


Thickness mm


2.31

Black (2)

2.55

Yellow

2.35

None

2.59

Black

2.39

Blue

2.63

Orange

2.43

Brown

2.67

Blue

2.47

Green

2.71

Brown

2.51

White

SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) Thickness mm


Thickness mm


0.71

71

1.01

01

0.74

74

1.04

04

0.77

77

1.07

07

0.80

80

1.10

J

0.83

83

1.13

D

0.86

86

1.16

K

0.89

89

1.19

L

0.92

92

1.22

G

0.95

95

1.25

M

0.98

98


22B-8

TORQUE SPECIFICATIONS

SPACER (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PRELOAD) Thickness mm


Thickness mm


0.74

74

1.04

04

0.77

77

1.07

07

0.80

80

1.10

J

0.83

83

1.13

D

0.86

86

1.16

K

0.89

89

1.19

L

0.92

92

1.22

G

0.95

95

1.25

M

0.98

98

1.28

N

1.01

01

1.31

E

SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE BACKLASH) Thickness mm


Thickness mm


0.72 - 0.79

-

0.98 - 1.02

-

0.80 - 0.84

-

1.02 - 1.06

-

0.85 - 0.90

-

1.07 - 1.11

-

0.90 - 0.94

-

1.12 - 1.16

-

0.94 - 0.98

-

1.16 - 1.20

-

SPACER (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE BACKLASH) Thickness mm


Thickness mm


0.75 - 0.82

-

1.05 - 1.12

-

0.83 - 0.92

-

1.09 - 1.16

-

0.93 - 1.00

-

1.15 - 1.22

-

1.01 - 1.08

-


Part

N¼m

Roll stopper bracket mounting bolt

70 10

Shift cable bracket mounting bolt

18 3

Select lever mounting bolt

18 3

Speedometer gear mounting bolt

3.9 1.0

Backup light switch

32 2

Poppet spring

32 2

Harness bracket bolt

18 3

Harness bracket bolt

3.9 1.0

Interlock plate bolt

30 3

Control housing mounting bolt

18 3

Under cover mounting bolt

6.9 0.9

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL SEALANTS AND ADHESIVES

Part

N¼m

Reverse idler gear shaft mounting bolt

48 6

Clutch housing-transaxle case mounting bolt

44 5

Front bearing retainer mounting bolt

18 3

Transfer - clutch housing mounting bolt

69 10

Select lever mounting nut

11 1

Stopper bracket mounting bolt

22.3 0.3

Clutch release bearing retainer mounting bolt

9.8 0.2

Differential drive gear mounting bolt

132 5

22B-9

SEALANTS AND ADHESIVES M1222000500106

Item

Specified sealant

Clutch housing-transaxle case mating surface

MITSUBISHI Genuine sealant part No. MD997740 or equivalent

Under cover-transaxle case mating surface Control housing-transaxle case mating surface Air breather

3M SUPER WEATHERSTRIP No.8001 or equivalent

Differential drive gear bolt

3M STUD Locking No.4170 or equivalent

FORM-IN-PLACE GASKET (FIPG) This transmission has several areas where the formin-place gasket (FIPG) is used for sealing. To ensure that the FIPG fully serves its purpose, it is necessary to observe some precautions when applying it. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of fluid passages. To prevent leaks or blocking of passages, therefore, it is absolutely necessary to apply the FIPG evenly without a break, while observing the correct bead size. FIPG hardens as it reacts with the moisture in the atmospheric air, and it is usually used for sealing metallic flange areas. Disassembly Parts sealed with a FIPG can be easily removed without need for the use of a special method. In some cases, however, the FIPG in joints may have to be broken by tapping parts with a mallet or similar tool.

Surface Preparation Thoroughly remove all substances deposited on the FIPG application surface, using a gasket scraper. Make sure that the FIPG application surface is flat and smooth. Also make sure that the surface is free from oils, greases and foreign substances. Do not fail to remove old FIPG that may remain in the fastener fitting holes. FIPG Application Applied FIPG bead should be of the specified size and free of any break. FIPG can be wiped away unless it has completely hardened. Install the mating parts in position while the FIPG is still wet (in less than 10 minutes after application). Do not allow FIPG to spread beyond the sealing areas during installation. Avoid operating the transmission or letting oils or water come in contact with the sealed area before a time sufficient for FIPG to harden (approximately one hour) has passed. FIPG application method may vary from location to location. Follow the instruction for each particular case described later in this manual.


22B-10

LUBRICANTS


TRANSMISSION Item

Specified lubricant

Each O-ring

Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4

Each oil seal Select lever shoe

MITSUBISHI genuine grease part No.0101011 or equivalent

TRANSFER Item

Specified lubricant

Each O-ring

Hypoid gear oil API classification GL-5 SAE 90

Each oil seal


Tool

Number

Name

Application

MB990935

Installer adapter

Installation of differential case taper roller bearing outer race and center differential case rear taper roller bearing outer race

MB990938

Handle

Use with Installer adapter

MB990927

Installer adapter

Installation of sealing cap

MD998801

Bearing remover

Installation and removal of gears, bearings and sleeves

MD998812

Installer cap

Use with Installer and Installer adapter

B990938

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL SPECIAL TOOLS

Tool

22B-11

Number

Name

Application

MD998813

Installer-100

Use with Installer cap and Installer adapter

MD998816

Installer adapter (30) Installation of input shaft front bearing

MD998825

Installer adapter (52) Installation of 1st-2nd speed synchronizer hub, 3rd-4th speed synchronizer hub and 1st speed gear sleeve

MD998824

Installer adapter (50) Installation of 4th speed gear sleeve, 5th speed gear and thrust plate stopper

MD998818

Installer adapter (38) Installation of input shaft rear bearing, roller bearing inner race, reverse gear sleeve and output shaft rear ball bearing

MD998917

Bearing remover

Installation and removal of gears, bearing and sleeves

MD998814

Installer-200

Use with Installer cap and Installer adapter

MD998822

Installer adapter (46) Installation of 2nd speed gear sleeve and 3rd speed gear

22B-12 Tool


Number

Name

Application

MD998819

Installer adapter (40) Installation of 5th-reverse speed synchronizer hub, 4th speed gear and 5th speed gear sleeve

MD999566

Claw

Removal of taper roller bearing outer race

MD998772


Removal of output shaft front roller bearing outer race

MD998346

Bearing outer race remover

Removal of output shaft front roller bearing outer race

MB990934

Installer adapter

Installation of output shaft front roller bearing outer race

MB991550

Bearing outer race installer

Installation of center differential case front taper roller bearing outer race

MB990926

Installer adapter

Installation of clutch housing input shaft oil seal

MD998325

Differential oil seal installer

Installation of differential oil seal


Tool

22B-13

Number

Name

Application

MD998823

Installer adapter (48) Installation of differential case taper roller bearing and center differential case rear taper roller bearing

MB990930

Installer adapter

MD998830

Installer adapter (66) Installation of center differential case front taper roller

MB990937

Installer adapter

Installation of transfer oil seal

MD998800

Oil seal adapter


MB990887

Ring


MB990891

Bushing remover installer base

Using with ring

MB990936

Installer adapter


Removal of center differential case front taper roller bearing bearing


22B-14

TRANSMISSION

TRANSMISSION DISASSEMBLY AND REASSEMBLY M1222001000126

3

4

18 ± 3 N·m

32 ± 2 N·m

6

3.9 ± 1.0 N·m

8

3.9 ± 1.0 N·m

7 11

5

70 ± 10 N·m

18 ± 3 N·m

9

10

2

1 70 ± 10 N·m

AK203151AC

>>J<< >>I<<

1. 2. 3. 4. 5. 6. 7.

Disassembly steps Roll stopper bracket, front Roll stopper bracket, rear Shift cable bracket Select lever Speedometer gear Backup light switch Gasket

8. 9. 10. 11.

Disassembly steps&RQWLQXHG Poppet spring Gasket Harness bracket Harness bracket


22B-15

TRANSMISSION

14 Apply gear oil to all moving parts before installation.

18 ± 3 N·m 30 ± 3 N·m

15

12

44 ± 5 N·m

22

20

13

21

23

18 17

19

24

48 ± 6 N·m

25

16 6.9 ± 0.9 N·m

AK204218AB

>>H<< >>G<<

12. 13. 14. 15. 16. 17. 18. 19.

Disassembly steps Interlock plate bolt Gasket Control housing Neutral return spring Under cover Reverse idler gear shaft bolt Gasket Reverse idler gear assembly

<> <>

>>F<< >>E<< >>D<< >>D<<

20. 21. 22. 23. 24. 25.

Disassembly steps&RQWLQXHG Sealing cap Transaxle case Outer race Spacer Magnet holder Magnet


22B-16

TRANSMISSION Apply gear oil to all moving parts before installation.

30 29

27 28

26 32

38

31

34

33

39

36 37

18 ± 3 N·m

35

AK204219AB

>>C<<

<> <> <>

>>C<< >>C<< >>B<< >>B<< >>B<<

26. 27. 28. 29. 30. 31. 32. 33.

Disassembly steps Spring pin 1st-2nd speed shift rail 1st-2nd speed shift fork Spring pin Spring pin 3rd-4th speed shift rail 3rd-4th speed shift fork 5th speed-reverse shift rail

<>

>>B<<

<> <>

>>A<< >>A<<

34. 35. 36. 37. 38. 39.

Disassembly steps&RQWLQXHG 5th speed-reverse shift fork Front bearing retainer Input shaft Output shaft Differential Clutch housing


22B-17

TRANSMISSION

18 ± 3 N·m

7

6

32 ± 2 N·m

3.9 ± 1.0 N·m

4

9 11

3.9 ± 1.0 N·m

14

10 18 ± 3 N·m

5

13

8 70 ± 10 N·m

12

2 70 ± 10 N·m

1

3 69 ± 10 N·m AK204184AB

>>J<< >>I<<

1. 2. 3. 4. 5. 6. 7. 8.

Disassembly steps Transfer O-ring Roll stopper bracket, front Roll stopper bracket, rear Roll stopper bracket, adaptor Shift cable bracket Select lever Speedometer gear

9. 10. 11. 12. 13. 14.

Disassembly steps&RQWLQXHG Backup light switch Gasket Poppet spring Gasket Harness bracket Harness bracket


22B-18

TRANSMISSION

17 18 ± 3 N·m Apply gear oil to all moving parts before installation.

30 ± 3 N·m

18

15

25

23

16

44 ± 5 N·m

24

26

21 20

22

27

48 ± 6 N·m

28

19 6.9 ± 0.9 N·m

AK204187AB

>>H<< >>G<<

15. 16. 17. 18. 19. 20. 21. 22.

Disassembly steps Interlock plate bolt Gasket Control housing Neutral return spring Under cover Reverse idler gear shaft bolt Gasket Reverse idler gear assembly

<> <>

>>F<< >>E<< >>D<< >>D<<

23. 24. 25. 26. 27. 28.

Disassembly steps&RQWLQXHG Sealing cap Transaxle case Outer race Spacer Magnet holder Magnet


22B-19

TRANSMISSION

33

Apply gear oil to all moving parts before installation.

32

30 31

29 35

41

34

37

36

42

39 40

18 ± 3 N·m

38

AK204189AB

>>C<<

<> <>

>>C<< >>C<< >>B<< >>B<<

29. 30. 31. 32. 33. 34. 35.

Disassembly steps Spring pin 1st-2nd speed shift rail 1st-2nd speed shift fork Spring pin Spring pin 3rd-4th speed shift rail 3rd-4th speed shift fork

<> <>

>>B<< >>B<<

<> <>

>>A<< >>A<<

36. 37. 38. 39. 40. 41. 42.

Disassembly steps&RQWLQXHG 5th speed-reverse shift rail 5th speed-reverse shift fork Front bearing retainer Input shaft Output shaft Differential Clutch housing


22B-20

TRANSMISSION

DISASSEMBLY SERVICE POINTS <> SEALING CAP REMOVAL

Sealing cap

<> 3RD-4TH SPEED SHIFT RAIL/3RD-4TH SPEED SHIFT FORK/5TH SPEED-REVERSE SHIFT RAIL/5TH SPEED-REVERSE SHIFT FORK REMOVAL 1. Shift the 3rd-4th speed shift fork and 5th speedreverse shift fork in the direction shown. 3rd-4th speed shift fork

AK204301 AB

1. Drive a screwdriver into the center of the sealing cap. 2. Bend the screwdriver back to remove the sealing cap. <> TRANSAXLE CASE REMOVAL 1. Remove all sixteen bolts securing the transaxle case to the clutch housing.

5th speed reverse shift fork

AK204222 AB

2. Pull up on the 3rd-4th speed shift rail and 5th speed-reverse shift rail and take them out of the hole in the clutch housing.

3rd-4th speed shift rail

Snap ring

5th speedreverse shift rail

AK204223 AB AK204226 AB

2. Use snap ring pliers to expand the indicated snap ring. The snap ring will release the grooved ball bearing, and the output shaft assembly will fall under its own weight.

CAUTION Do not use a scraper or chisel to remove the transaxle case. 3. Remove the transaxle case from the clutch housing by gently prying on opposite sides at the same time.

3. Slide the 3rd-4th speed shift rail and 5th speedreverse shift rail in the direction shown and remove them together with the shift forks. <> INPUT SHAFT AND OUTPUT SHAFT REMOVAL Input shaft

Output shaft

AK204224 AB

Remove the input and output shafts together.

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL TRANSMISSION

22B-21

ADJUSTMENT BEFORE REASSEMBLY


SPACER SELECTION FOR DIFFERENTIAL CASE PRELOAD ADJUSTMENT

>>A<< OUTPUT SHAFT/INPUT SHAFT INSTALLATION Input shaft

Solders

Output shaft

AK204224 AB

AK204227 AB

1. Put solders (1.6 mm diameter, about 10 mm long) in the illustrated positions of the transaxle case. 2. Install the taper bearing outer race and differential assembly into the transaxle case. NOTE: If necessary, replace the differential case and taper bearing before carrying out these adjustments. 3. Install the clutch housing and tighten the bolts to the specified torque. Tightening torque: 44 5 N¼m 4. Remove the clutch housing, and then remove the differential assembly. 5. Remove the outer race and take out crushed solders.

Install the input and output shafts together. >>B<< 5TH SPEED-REVERSE SHIFT FORK/5TH SPEED-REVERSE SHIFT RAIL/3RD-4TH SPEED SHIFT FORK/3RD-4TH SPEED SHIFT RAIL INSTALLATION 3rd-4th speed synchronizer sleeve 5th speedreverse synchronizer sleeve

AK204229AB

1. Shift the 3rd-4th speed synchronizer sleeve and 5th speed-reverse synchronizer sleeve in the direction shown. 3rd-4th speed shift rail

AKX00953

6. Measure the thickness of the crushed solder with a micrometer and select a spacer that will provide the standard preload value. Standard value: 0.05 - 0.11 mm preload

5th speedreverse shift fork

3rd-4th speed shift fork 5th speedreverse shift rail

AK204230 AB

2. Assemble the 3rd-4th speed shift rail and fork, and the 5th speed-reverse shift rail and fork.


22B-22

TRANSMISSION

Installer adapter (MB990935) Handle (MB990938) 5th speedreverse shift rail 3rd-4th speed shift rail

>>E<< TRANSAXLE CASE INSTALLATION

CAUTION Squeeze sealant evenly onto the transaxle housing. Do not leave gaps or excess amounts, otherwise oil leaks are likely. AK204223 AC

3. While fitting each shift fork in the groove of synchronizer sleeve, slide the shift rails in the direction shown and install. 4. Insert the 3rd-4th speed shift rail and 5th speedreverse shift rail into the rail hole in the clutch housing. >>C<< SPRING PIN INSTALLATION 1. Align the pin holes in the shift rail and shift fork. Shift fork Shift rail

2.5 mm

AK204232AB

1. Apply a 2 mm diameter bead of sealant (Mitsubishi Genuine Part number MD997740 or equivalent) as illustrated onto the transaxle case. NOTE: Be sure to install the transaxle case onto the transaxle housing while the sealant is still wet (within 15 minutes).

Spring pin

AK204302 AC

2. Insert the new spring pin. Push it in as shown so that the slit and center axis of the rail are aligned. Snap ring

>>D<< SPACER AND OUTER RACE INSTALLATION 1. Install the spacer selected in the section "ADJUSTMENT BEFORE REASSEMBLY."

MB990938

MB990935 AK204231 AB

2. Using special tools, press the outer race into the transaxle case.

AK204226 AB

2. Align the transaxle case and expand the snap ring. After the case is on far enough for the snap ring to ride on the bearing, release the snap ring. Push down on the transaxle case, twisting it from side to side until the case contacts the housing. 3. Tighten the transaxle case mounting bolts to the specified torque. Tightening torque: 44 5 N¼m 4. Place the transaxle upside down and let the snap ring fit in the groove by the output shaft’s own weight. NOTE: After installation, keep the sealed area away from oil for approximately one hour.


>>F<< SEALING CAP INSTALLATION MB990938

22B-23

2. Install the under cover to the transaxle case and tighten the bolts to specified torque. Tightening torque: 6.9 0.9 N¼m NOTE: After installation, keep the sealed area away from oil for approximately one hour.

MB990927

>>H<< CONTROL HOUSING INSTALLATION

CAUTION AK204234 AB

Squeeze sealant onto the case. Do not leave gaps or excess amounts, otherwise oil leaks are likely.

1. Using special tools, press install the sealing cap onto the case. Installer adapter (MB990927) Handle (MB990938) Sealing cap

AK204236AB

AK204233 AB

2. Evenly press the sealing cap so it is fully seated and not at an angle. >>G<< UNDER COVER INSTALLATION

CAUTION Squeeze sealant onto the case. Do not leave gaps or excess amounts, otherwise oil leaks are likely.

1. Apply a 0.2 mm diameter bead of sealant (Mitsubishi Genuine Part number MD997740 or equivalent) as llustrated onto the control housing. NOTE: Be sure to install the housig to the case quickly while the sealant is still wet (within 15 minutes). 2. Install the control housing to the transaxle case and tighten the bolts to specified torque. Tightening torque: 18 3 N¼m NOTE: After installation, keep the sealed area away from the oil for approximately one hour. >>I<< SPEEDOMETER GEAR INSTALLATION O-ring

AK204235AB

1. Apply a 2 mm diameter bead of sealant (Mitsubishi Genuine Part number MD997740 or equivalent) as illustrated onto the under cover. NOTE: Be sure to install the under cover to the case quickly while the sealant is still wet (within 15 minutes).

AK204237 AB

1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4) to the O-ring of the speedometer gear. Install into the transaxle housing. 2. Tighten the bolt to specified torque. Tightening torque: 3.9 1.0 N¼m

22B-24


>>J<< SELECT LEVER INSTALLATION


Control shaft

BACKUP LIGHT SWITCH

Select lever shoe

AK204238 AB

1. Apply grease (Mitsubishi Genuine Part number 0101011 or equivalent) to the control shaft sliding portion of the select lever shoe. 2. Install the select lever and tighten the bolts to specified torque. Tightening torque: 18 3 N¼m

AKX00952

Check for continuity between terminals. SWITCH CONDITION

CONTINUITY

Pressed

Open

Released

Conductive


22B-25

INPUT SHAFT

INPUT SHAFT DISASSEMBLY AND REASSEMBLY M1222001600117


11

10

12 14 15

13

16

19

18

2

20

4 6 7

1

8

3

16

17

5

AK204391AB

<> <> <> <>

>>M<< >>L<< >>K<< >>J<< >>I<< >>H<< >>E<< >>D<<

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Disassembly steps Snap ring Ball bearing Thrust plate stopper Thrust plate 5th speed gear 4th speed gear Needle roller bearing 4th speed gear sleeve Synchronizer ring Synchronizer spring

>>G<< >>F<< >>E<< >>D<<

<>

>>C<< >>B<< >>A<<

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Disassembly steps&RQWLQXHG Synchronizer sleeve 3rd-4th speed synchronizer hub Synchronizer ring Synchronizer spring 3rd speed gear Needle roller bearing Snap ring Ball bearing Oil seal Input shaft


22B-26

INPUT SHAFT


<>4TH SPEED GEAR SLEEVE REMOVAL

<> BALL BEARING REMOVAL

MD998801

MD998801

AK204241 AB AK204239 AB

1. Using special tool Bearing remover (MD998801), support the ball bearing, and then set them on the press. 2. Push down on the input shaft with the press and remove the ball bearing.

1. Using special tool Bearing remover (MD998801), support the 3rd speed gear, and then set them on the press. 2. Push down on the input shaft with the press and remove the 4th speed gear sleeve. <> BALL BEARING REMOVAL

<> THRUST PLATE STOPPER REMOVAL MD998801

AK204242 AB AK204293AB

Using a screwdriver, pry up at the position shown in the illustration and remove the thrust plate stopper. <>5TH SPEED GEAR REMOVAL

1. Using special tool Bearing remover (MD998801), support the ball bearing, and then set them on the press. 2. Push down on the input shaft with the press and remove the ball bearing.


MD998801

>>A<< OIL SEAL INSTALLATION

Oil seal

3.5 mm

AK204240 AB

1. Using special tool Bearing remover (MD998801), support the 5th speed gear, and then set them on the press. 2. Push down on the input shaft with the press and remove the 5th speed gear.

AK204243 AC

Install the oil seal into the end of the input shaft as shown.


22B-27

INPUT SHAFT

>>B<< BALL BEARING INSTALLATION MD998812 MD998813 MD998801

MD998816

Install the synchronizer spring onto the synchronizer ring as shown. >>E<< SYNCHRONIZER RING INSTALLATION

CAUTION There are 3rd speed and 4th speed synchronizer rings, if the wrong one is installed it will effect the shift feeling. Notch

AK204244AC

1. Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press. 2. Using special tools, press install the ball bearing with the press. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (30) (MD998816) >>C<< SNAP RING INSTALLATION

AK204312 AB

1. Ascertain whether or not there are identification notches on the synchronizer ring. Two notches: 3rd speed synchronizer ring No notches: 4th speed synchronizer ring 2. Install the synchronizer ring so that it completely fits over the machined cone of the gear. >>F<< 3RD-4TH SPEED SYNCHRONIZER HUB INSTALLATION Installation direction

Snap ring AK204245 AB

1. Install the thickest snap ring that can be fitted in the snap ring groove of input shaft. 2. Make sure that the ball bearing end play meets the standard value. Standard value: 0 - 0.12 mm Groove

>>D<< SYNCHRONIZER SPRING INSTALLATION

SYNCHRONIZER Synchrnizer SPRING spring

AK204263AB

AK204295 AB

1. Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press. 2. Make sure that the synchronizer ring has been perfectly matched to the 3rd speed gear cone. 3. Check the installation direction of the 3rd-4th speed synchronizer hub, and put it on the input shaft.


22B-28

INPUT SHAFT

MD998812 MD998813 MD998801

MD998825

2. Install the synchronizer sleeve so that the areas with teeth that have raised tips (three areas total) are aligned with the areas on the synchronizer hub that have deep grooves between the teeth (three areas total). >>H<< 4TH SPEED GEAR SLEEVE INSTALLATION

AK204246 AC

4. Using special tools, press install the 3rd-4th speed synchronizer hub with the press. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (52) (MD998825) 5. Make sure that the synchronizer ring can rotate freely. >>G<< SYNCHRONIZER SLEEVE INSTALLATION Identification groove

Installation direction

MD998812 MD998813 MD998801

MD998824

AK204247 AC

1. Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press. 2. Using special tools, install the 4th speed gear sleeve with the press. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (50) (MD998824) >>I<< 5TH SPEED GEAR INSTALLATION

AK204296AC

1. Check the installation direction of the synchronizer sleeve, and install it onto the 3rd-4th speed synchronizer hub.

MD998812 MD998813 MD998801

MD998824

Projecting portion

AK204248 AB

Deep grooves

AK204199AB

1. Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press. 2. Using special tools, install the 5th speed gear onto the input shaft with the press. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (50) (MD998824)


22B-29

INPUT SHAFT

>>J<< THRUST PLATE INSTALLATION Surface stamped with identification mark

2. Using special tools, install the ball bearing onto the input shaft with the press. Installer cap (MD998812) Installer adapter (38) (MD998818) >>M<< SNAP RING INSTALLATION

Thrust plate AK204249AB

1. Install the thickest thrust plates that can be fitted in the groove of the input shaft. Install the thrust plate so the surface stamped with the identification mark is facing up. 2. Make sure that the 5th speed gear end play meets the standard value. Standard value: 0 - 0.09 mm >>K<< THRUST PLATE STOPPER INSTALLATION

Snap ring

AK204251 AB

1. Install the thickest snap ring that can be fitted in the groove of the input shaft. 2. Make sure that the ball bearing end play meets the standard value. Standard value: 0 - 0.12 mm

MD998812

INSPECTION

MD998813

INPUT SHAFT

M1222001700095

MD998824

AK204294 AB

Install the thrust plate stopper by pressing special tools, by hand. Make sure that it is not tilted. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (50) (MD998824) >>L<< BALL BEARING INSTALLATION MD998812 MD998818

AK204201AB

1. Check the outside diameter of the needle bearing mounting portion for damage, abnormal wear and seizure. 2. Check the splines for damage and wear. 3. Check that the helical gear teeth surfaces are not damaged or worn.

MD998801

AK204250 AC

1. Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press.

NEEDLE ROLLER BEARING 1. Combine the needle roller bearing with the input shaft or bearing sleeve and gear, and check that it rotates smoothly without noise or play. 2. Check the needle roller bearing cage for deformation.


22B-30

INPUT SHAFT

SYNCHRONIZER RING

SYNCHRONIZER SLEEVE AND HUB Sleeve

Hub AK204298AB

1. Check the clutch gear teeth for damage and broken. 2. Check internal surface for damage, wear and broken threads. Gear

A Synchronizer ring

AK204217 AB

1. Combine the synchronizer sleeve and hub, and check that they slide smoothly. 2. Check that the sleeve is free from damage at its inside splines ends. SYNCHRONIZER SPRING Check that the spring is not sagging, deformed or broken. SPEED GEARS

AK204307 AB

3. Force the synchronizer ring toward the clutch gear and check clearance "A". If "A" is less than the limit, replace the synchronizer ring. Minimum limit: 0.5 mm AK204299AB

1. Check that the helical and clutch gear tooth surfaces are not damaged or worn. 2. Check that the synchronizer cone surfaces are not roughened, damaged or worn. 3. Check that the gear inside diameter and front and rear surfaces are not damaged and worn.


22B-31

OUTPUT SHAFT

OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY M1222002200112

20 22 24


26

19

27 29

18

21 23

4

25 1

28

5

30 32 33

31

13 3 2

36 12 34

15

35

7

17 14 10 11 16

9

8

6 4

13 AK204392AB

<> <>

>>Q<< >>P<< >>O<<

<>

>>M<< >>L<< >>F<< >>N<< >>M<< >>L<<

<>

>>K<< >>J<< >>I<< >>H<<

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Disassembly steps Snap ring Ball bearing Reverse gear sleeve Needle roller bearing Reverse gear Synchronizer ring Synchronizer spring Synchronizer sleeve 5th speed-reverse synchronizer hub Synchronizer ring Synchronizer spring 5th speed gear Needle roller bearing 5th speed gear sleeve 4th speed gear Snap ring 3rd speed gear

<>

>>G<<

>>D<< >>F<< >>E<< >>D<<

<>

>>C<< >>B<<

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Disassembly steps&RQWLQXHG 2nd speed gear Needle roller bearing 2nd speed gear sleeve Inner synchronizer ring Synchronizer cone Outer synchronizer ring Synchronizer spring Synchronizer sleeve 1st-2nd speed synchronizer hub Outer synchronizer ring Synchronizer spring Inner synchronizer ring Synchronizer cone 1st speed gear Needle roller bearing 1st speed gear sleeve Snap ring


22B-32 <>

>>A<<

OUTPUT SHAFT Disassembly steps&RQWLQXHG 35. Roller bearing inner race 36. Output shaft

DISASSEMBLY SERVICE POINTS <> BALL BEARING REMOVAL MD998917

<> 5TH SPEED-REVERSE SYNCHRONIZER HUB REMOVAL Synchronizer hub MD998801

Ball bearing

AK204254 AB

AK204252 AC

1. Using special tool Bearing remover (MD998917), support the ball bearing, and then set them on the press. 2. Push down on the output shaft with the press, and remove the ball bearing. <> REVERSE GEAR BEARING SLEEVE REMOVAL

MD998801

1. Using special tool Bearing remover (MD998801), support the 4th speed gear, and then set them on the press. 2. Push down on the output shaft with the press and remove the 5th speed-reverse synchronizer hub. <> 3RD SPEED GEAR REMOVAL

MD998917

3rd speed gear

Reverse gear bearing sleeve

AK204255 AB

AK204253 AB

1. Using special tool Bearing remover (MD998801), support the reverse gear, and then set them on the press. 2. Push down on the output shaft with the press and remove the reverse gear bearing sleeve.

1. Using special tool Bearing remover (MD998917), support the 2nd speed gear, and then set them on the press. 2. Push down on the output shaft with the press and remove the 3rd speed gear. <> 2ND SPEED GEAR SLEEVE REMOVAL

2nd speed gear sleeve MD998917

AK204256 AC

1. Using special tool Bearing remover (MD998917), support the 1st speed gear, and then set them on the press.


22B-33

OUTPUT SHAFT

2. Push down on the output shaft with the press and remove the 2nd speed gear sleeve. <> 1ST SPEED GEAR SLEEVE REMOVAL

REASSEMBLY SERVICE POINTS >>A<< ROLLER BEARING INNER RACE INSTALLATION

MD998801 1st speed gear sleeve

MD998812 MD998818 Roller bearing inner race

MD998801

AK204260 AB AK204257 AC

1. Using special tool Bearing remover (MD998801), support the 1st speed gear sleeve, and then set them on the press. 2. Push down on the output shaft with the press and remove the 1st speed gear sleeve. <> ROLLER BEARING INNER RACE REMOVAL

MD998917

1. Using special tool Bearing remover (MD998801), support the output shaft gear, and then set them on the press. 2. Using special tools, install the roller bearing inner race with the press. Installer cap (MD998812) Installer adapter (38) (MD998818) >>B<< SNAP RING INSTALLATION

Roller bearing inner race

Snap ring

AK204258 AB

1. Using special tool Bearing remover (MD998917), support the roller bearing inner race, and then set them on the press. 2. Push down on the output shaft with the press and remove the roller bearing inner race.

AK204261 AB

1. Install the thickest snap ring that can be fitted in the groove of output shaft. 2. Make sure that the roller bearing inner race end play meets the standard value. Standard value: 0 - 0.12 mm >>C<<1ST SPEED GEAR SLEEVE INSTALLATION 1. Set the output shaft on the press support stand.

22B-34

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL OUTPUT SHAFT

MD998812

MD998812 MD998814 1st speed gear sleeve MD998825

MD998814 1st-2nd speed synchronizer hub

AK204265 AC

AK204262 AC

2. Using special tools, install the 1st speed gear sleeve with the press. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (52) (MD998825) >>D<< SYNCHRONIZER SPRING INSTALLATION

MD998825

3. Using special tools, install the 1st-2nd speed synchronizer hub with the press. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (52) (MD998825) 4. Make sure that the outer synchronizer ring on the 1st speed gear side can rotate freely. >>F<< SYNCHRONIZER SLEEVE INSTALLATION Identification groove

Installation direction

Synchronizer spring AK204316AB

Install the synchronizer spring onto the outer synchronizer ring as shown. >>E<< 1ST-2ND SPEED SYNCHRONIZER HUB INSTALLATION 1. Set the output shaft on the press support stand.

AK204296AC

1. Check that the synchronizer sleeve is in the correct direction for installation, and install it on the 1st-2nd speed synchronizer hub. Projecting portion

Installation direction Deep grooves AK204305 AC

2. Check that the 1st-2nd speed synchronizer hub is in the correct installation direction, and put it on the output shaft.

AK204199AB

2. Install the synchronizer sleeve so that the areas with teeth that have raised tips (three areas total) are aligned with the areas on the synchronizer hub that have deep grooves between the teeth (three areas total).


22B-35

OUTPUT SHAFT

>>G<< 2ND SPEED GEAR SLEEVE INSTALLATION 1. Set the output shaft on the press support stand.

>>I<< SNAP RING INSTALLATION

MD998812 MD998813 MD998822

Snap ring AK204268AB

AK204266 AC

2. Using special tools, install the 2nd speed sleeve onto the output shaft with the press. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (46) (MD998822) >>H<< 3RD SPEED GEAR INSTALLATION 1. Check that the 2nd speed gear and the outer synchronizer ring have been properly installed. Also, make sure the claws on the synchronizer cone (four places) are correctly fitted into the holes in the 2nd speed gear (four places).

1. Install the thickest snap ring that can be fitted in the groove of output shaft. 2. Make sure that the 3rd speed gear end play meets the standard value. Standard value: 0 - 0.09 mm >>J<< 4TH SPEED GEAR INSTALLATION 1. Set the output shaft on the press support stand. MD998812 MD998813 4th speed gear

MD998819

MD998812 MD998814 3rd speed gear

MD998822

AK204267 AB

2. Using special tools, install the 3rd speed gear onto the output shaft with the press. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (46) (MD998822) 3. Make sure that the 2nd speed gear and the outer synchronizer ring can rotate freely.

AK204269 AB

2. Using special tools, install the 4th speed gear onto the output shaft with the press. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (40) (MD998819) >>K<< 5TH SPEED GEAR SLEEVE INSTALLATION MD998812 5th speed gear sleeve

MD998813 MD998819

AK204300 AB

Using special tools, install the 5th speed gear sleeve onto the output shaft with the press. Installer cap (MD998812)


22B-36

OUTPUT SHAFT

Installer-100 (MD998813) Installer adapter (40) (MD998819) >>L<< SYNCHRONIZER SPRING INSTALLATION Installation direction

AK204306 AB

SYNCHRONIZER Synchrnizer SPRING spring

AK204263AB

3. Check that the 5th speed-reverse synchronizer hub is oriented correctly for installation, and fit it on the output shaft.

Install the synchronizer spring onto the synchronizer ring as shown.

MD998812 MD998813 MD998819

>>M<< SYNCHRONIZER RING INSTALLATION Synchronizer hub

CAUTION There is a 5th speed synchronizer ring and a reverse synchronizer ring. Be careful not to confuse the two when installing, as a mistake can effect the shift feeling.

AK204228 AB

4. Using special tools, press install the 5th speedreverse synchronizer hub with the press. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (40) (MD998819) 5. Make sure that the synchronizer ring on the 5th speed gear side can rotate freely.

Notch

AK204393AB

1. Check for the presence of identification notches on the synchronizer ring. No notches: 5th speed synchronizer ring Three notches: Reverse synchronizer ring 2. Install the synchronizer ring so that it fits completely over the machined cone of the gear. >>N<< 5TH SPEED-REVERSE SYNCHRONIZER HUB INSTALLATION 1. Set the output shaft on the press support stand. 2. Make sure that the synchronizer ring is fitted correctly on the cone of the 5th speed gear.

>>O<< REVERSE GEAR SLEEVE INSTALLATION 1. Make sure the synchronizer ring, reverse gear and needle roller bearing have been correctly installed. MD998812 MD998818 Reverse gear

Reverse gear sleeve

AK204270 AB

2. Using special tools, press fit the reverse gear sleeve. Make sure that the reverse gear and the synchronizer ring can rotate freely during the pressing process. Installer cap (MD998812)


Installer adapter (38) (MD998818) >>P<< BALL BEARING INSTALLATION 1. Check the installation direction of the ball bearing.

22B-37

1. Check the splines for damage and wear. 2. Check that the helical gear teeth surfaces are not damaged or worn. NEEDLE ROLLER BEARING 1. Combine the needle roller bearing with the bearing sleeve and gear, and check that it rotates smoothly without noise or play. 2. Check the needle roller bearing cage for deformation.

MD998812 MD998818 Ball bearing

SYNCHRONIZER RING AK204271 AC

2. Using special tools, install the ball bearing with the press. Installer cap (MD998812) Installer adapter (38) (MD998818) >>Q<< SNAP RING INSTALLATION AK204298AB

1. Check if the clutch gear teeth are damaged or broken. 2. Check internal surface for damage, wear and broken threads. Snap ring Gear

A Synchronizer ring

AK204272 AC

1. Install the thickest snap ring that can be fitted in the groove of output shaft. 2. Make sure that the ball bearing end play meets the standard value. Standard value: 0 - 0.09 mm


OUTPUT SHAFT

AK204310AB

AK204307 AB

3. Force the synchronizer ring toward the clutch gear and check clearance "A". If "A" is less than the limit, replace the synchronizer ring. Minimum limit: 0.5 mm


22B-38

OUTPUT SHAFT

OUTER SYNCHRONIZER RING/INNER SYNCHRONIZER RING/SYNCHRONIZER CONE

CAUTION

1. Check that the clutch gear tooth surfaces and cone surfaces are not damaged or broken. A

Gear

When replacing, replace the outer ring, inner ring and cone as a set.

Outer ring Cone

Inner ring AK203130AD

AK204309AB

1. Check that the clutch gear tooth surfaces and cone surfaces are not damaged or broken.

2. Install the outer ring, inner ring and cone, force them toward the gear, and check clearance "A". If "A" is less than the limit, replace them as a set. Minimum limit: 0.5 mm SYNCHRONIZER SLEEVE AND HUB

Gear

Sleeve

A Outer ring Cone

Inner ring

Hub AK204259 AB

2. Install the outer ring, inner ring and cone, force them toward the gear, and check clearance "A". If "A" is less than the limit, replace them as a set. Minimum limit: 0.5 mm OUTER SYNCHRONIZER RING/INNER SYNCHRONIZER RING/SYNCHRONIZER CONE

AK204217 AB

1. Combine the synchronizer sleeve and hub, and check that they slide smoothly. 2. Check that the sleeve is free from damage at its inside splines ends. SYNCHRONIZER SPRING

CAUTION When replacing, replace the outer ring, inner ring and cone as a set.

AK204314AB

Check that the spring is not sagging, deformed or broken. AK204395AB


SPEED GEARS

22B-39

1. Check that the helical and clutch gear tooth surfaces are not damaged or worn. 2. Check that the synchronizer cone surfaces are not roughened, damaged or worn. 3. Check that the gear inside diameter and front and rear surfaces are not damaged and worn.

AK204299AB


22B-40

REVERSE IDLER GEAR

REVERSE IDLER GEAR DISASSEMBLY AND REASSEMBLY M1222012500084


1 7

2 3 5 6 4

AK204396AB

1. 2. 3. 4.

Disassembly steps Snap ring Cone spring Thrust washer Steel ball

5. 6. 7.

Disassembly steps&RQWLQXHG Reverse idler gear Needle roller bearing Reverse idler gear shaft


22B-41

SPEEDOMETER GEAR

SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY M1222003400089


4

2

3

1

AK204397AB

1. 2.

Disassembly steps E-clip Speedometer driven gear

3. 4.

Disassembly steps&RQWLQXHG O-ring Sleeve


22B-42

SELECT LEVER

SELECT LEVER DISASSEMBLY AND REASSEMBLY M1222012800074

6 5

7

1

8 2 9

11 ± 1 N·m

3 4

10

AK204398AB

>>A<< >>A<< >>A<<

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Disassembly steps Dust cover Nut Spring washer Washer Select lever bushing Select lever shoe Select lever Select lever bushing Dust cover Select lever shaft

REASSEMBLY SERVICE POINT >>A<< DUST COVER AND SELECT LEVER BUSHING INSTALLATION Select lever bushing

Dust cover AK204311 AB

Make sure the dust cover and select lever bushing installation direction is correct, and the distinguished parts are correctly assembled as shown.


22B-43

CONTROL HOUSING

CONTROL HOUSING DISASSEMBLY AND REASSEMBLY M1222013100090

6

10

3

7

12

13 14

5 4 9 8

11

15

2

1

22.3 ±0.3 N·m AK204399AB

<>

>>E<< >>D<<

>>C<< >>B<< >>A<<

1. 2. 3 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Disassembly steps Spring washer Stopper bracket Lock pin Interlock plate Control finger Spring pin Stopper body Spring Spacer Control shaft Air breather Control shaft boot Oil seal Needle bearing Control housing

DISASSEMBLY SERVICE POINT <> LOCK PIN REMOVAL

Lock pin

Control finger AK204273 AB

Drive out the lock pin from the direction shown.

22B-44

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL CONTROL HOUSING


>>C<< AIR BREATHER INSTALLATION

>>A<< NEEDLE BEARING INSTALLATION Control housing Needle bearing Model number stamped side

0 – 0.5 mm AK204274AB AK204176AC

Press fit the needle bearing into the control housing side as shown. Make sure that the side with the model number stamped on it faces the end of the control housing as shown.

1. Apply sealant (3M SUPER WEATHERSTRIP No. 8001 or equivalent) to the inserting portion of air breather.

Emboss mark

>>B<< OIL SEAL INSTALLATION

AK204220 AB

2. Install the air breather so that the embossed mark is in the direction shown in the figure. AK204303AB

Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W85W conforming to API classification GL-4) to the oil seal lip area.

>>D<< SPRING PIN INSTALLATION

Control shaft Stopper body Installation direction

Slit Spring pin AK204177AB

Drive in the spring pin so that the slit is in the direction shown in the figure.

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL CONTROL HOUSING

>>E<
22B-45

Drive the lock pin in from the direction shown in the figure.

AK204273 AC


22B-46

CLUTCH HOUSING

CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY M1222003700109

7

4

6

3

5

2 1 9.8 ± 2.0 N·m AK204400AB

<> <>

>>E<< >>D<< >>C<< >>B<< >>A<<

1. 2. 3 4. 5. 6. 7.

Disassembly steps Clutch release bearing retainer Oil seal Oil seal Outer race Outer race Bushing Clutch housing

DISASSEMBLY SERVICE POINTS <> OUTER RACE REMOVAL

MD999566

AK204276 AB

Using special tool Claw (MD999566), remove the outer race from the clutch housing.


22B-47

CLUTCH HOUSING

<> OUTER RACE REMOVAL MD998772

>>B<< OUTER RACE INSTALLATION

MD998346

Model number stamped side

AK204277AB

1. 2.

Set special tools as indicated in the figure. Valve spring compressor (MD998772) Bearing outer race remover (MD998346) Turn the nut on special tool Bearing outer race remover (MD998346) to pull up on the tool and take out the outer race.


AK204279 AB

1. Check the installation direction of the outer race. Install the outer race so the side with the model number stamping can be seen.

MB990938 MB990934

>>A<< BUSHING INSTALLATION

Seam of bushing

AK204280 AB

Air vent

2. Using special tools, press fit the outer race into the clutch housing. Handle (MB990938) Installer adapter (MB990934) AK204278 AB

>>C<< OUTER RACE INSTALLATION 1. Check the installation direction of the outer race.

1. Press fit the bushing so the seam is away from the air vent. MB990938

1 mm MB990935 MB991550 AK204281 AC

AK204291 AC

2. Be sure the bushing is fully seated as shown. It must be 1 mm below the housing surface.

2. Using special tools, press fit the outer race into the clutch housing. Handle (MB990938) Installer adapter (MB990935) Bearing outer race installer (MB991550)

22B-48

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL CLUTCH HOUSING

>>D<
>>E<< OIL SEAL INSTALLATION

AK204284AB

AK204282AB

1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4) to the oil seal lip.

1. Apply transmission oil (Hypoid gear oil SAE 75W90 or 75W-85W conforming to API classification GL-4) to the oil seal lip.

MB990938 MD998325

MB990926 AK204283 AB

2. Using special tool Differential oil seal installer (MD998325), press fit the oil seal into the clutch housing.

AK204285 AB

2. Using special tools, press fit the oil seal into the clutch housing. Handle (MB990938) Installer adapter (MB990926)


22B-49

TRANSMISSION CASE

TRANSMISSION CASE DISASSEMBLY AND REASSEMBLY M1222013400079

1 2

5

4

3

6 AK204407AB

>>C<< >>B<<

1. 2. 3.

Disassembly steps Oil seal Needle bearing Oil guide

>>A<<

4. 5. 6.

Disassembly steps&RQWLQXHG Snap ring Bushing Transaxle


22B-50

TRANSMISSION CASE

REASSEMBLY SERVICE POINTS >>A<< BUSHING INSTALLATION Model number stamped side Seam of bushing

AK204287 AB

Air vent AK204292 AB

1. Press fit the bushing so the seam is away from the air vent.

2. Press fit the needle bearing until it is flush with the case. >>C<
3 mm

AK204304 AC

2. Be sure the bushing is fully seated as shown. It must be 3 mm below the housing surface. >>B<< NEEDLE BEARING INSTALLATION 1. Check the installation direction of the needle bearing.

AK204286AB

1. Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4).

MD998325

AK204288 AB

2. Using special tool Differential oil seal installer (MD998325), press fit the oil seal into the transaxle case.

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL DIFFERENTIAL

22B-51

DIFFERENTIAL DISASSEMBLY AND REASSEMBLY M1222002500094

2


3 8

6 5 4

132 ± 5 N·m

8 1

7 5 2 6

9

AK204408AB

<>

>>D<< >>C<< >>B<< >>A<< >>A<<

1. 2. 3. 4. 5.

Disassembly steps Differential drive gear Taper roller bearing Lock pin Pinion shaft Pinion

>>A<< >>A<< >>A<<

6. 7. 8. 9.

Disassembly steps&RQWLQXHG Washer Side gear Spacer Differential case

22B-52

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL DIFFERENTIAL

DISASSEMBLY SERVICE POINT <> TAPER ROLLER BEARING REMOVAL MD998801

AKX00770

3. Insert the pinion shaft. AK204289 AB

1. Using special tool Bearing remover (MD998801), support the taper roller bearing, and then set them on the press. 2. Push down on the differential case with the press and remove the bearing.

REASSEMBLY SERVICE POINTS >>A<< SPACER/SIDE GEAR/WASHER/PINION/ PINION SHAFT INSTALLATION

AKX00768

1. After a spacer has been mounted on the back surface of the side gear, install the side gear in the differential case. NOTE: When a new side gear is to be installed, mount a medium thickness spacer. 2. Set the washer on the back of each pinion, and put both pinions simultaneously in mesh with the side gears. While rotating them, install them in position.

AKX00766

4. Measure the backlash between the side gear and pinion. Standard value: 0 - 0.15 mm 5. If the backlash is out of specification, select a spacer that should get the back lash with in the standard value and re-measure the backlash. NOTE: Repeat until the backlash on both sides are equal. >>B<
AK204290 AB

Install the lock pin so that it will be oriented in the direction shown.


22B-53

DIFFERENTIAL

>>C<< TAPER ROLLER BEARING INSTALLATION

MD998812 MD998823

1. Apply sealant (3MÉ AAD Part Number 8730 or 8731 or equivalent) to the entire threaded portion of the bolt.

Taper roller bearing

3

1

5

8

7 6 AK204319 AC

Using special tools, install the taper roller bearing with the press. Installer cap (MD998812) Installer adapter (48) (MD998823) >>D<< DIFFERENTIAL DRIVE GEAR INSTALLATION

AK204320AB

2

4 AK204221 AC

2. Tighten to the specified torque in the illustrated sequence. Tightening torque: 132 5 N¼m


22B-54

CENTER DIFFERENTIAL

CENTER DIFFERENTIAL DISASSEMBLY AND REASSEMBLY M1222002800040


3

2

11

5

12

6

7

12

132 ± 5 N·m

4

17 9 14

10

12 13

12

11

8

15

16

9 AK204225AB

<>

>>D<< >>C<< >>B<< >>C<< >>C<< >>C<< >>C<< >>C<< >>C<<

1. 2. 3. 4. 5. 6. 7. 8. 9.

Disassembly steps Center differential drive gear Center differential flange Taper roller bearing Snap ring Front output shaft Spacer Side gear Lock pin Pinion shaft

<>

>>C<< >>C<< >>C<< >>C<< >>C<< >>A<<

10. 11. 12. 13. 14. 15. 16. 17.

Disassembly steps&RQWLQXHG Pinion shaft holder Pinions Washers Side gear Spacer Taper roller bearing Speed meter drive gear Differential case

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL CENTER DIFFERENTIAL

DISASSEMBLY SERVICE POINTS <> TAPER ROLLER BEARING REMOVAL

22B-55

Using special tools, install the taper roller bearing with the press. Installer cap (MD998812) Installer adapter (66) (MD998830) >>B<< TAPER ROLLER BEARING INSTALLATION

MD998917

MD998823

MD998812

AK204264AB

1. Support the taper roller bearing with special tool bearing remover (MD998917), and then set them on the press. 2. Push down on the differential case with the press to remove the bearing. <> TAPER ROLLER BEARING REMOVAL

MD998917

MB990930

AK204308AB

Using special tools, install the taper roller bearing with the press. Installer cap (MD998812) Installer adapter (48) (MD998823) >>C<< SPACER, SIDE GEAR, WASHER, PINION AND PINION SHAFT, PINION SHAFT HOLDER, LOCK PIN, FRONT OUTPUT SHAFT, SNAP RING, CENTER DIFFERENTIAL FLANGE, INSTALLATION

AK204275AB

1. Support the taper roller bearing with special tools, and then set them on the press. Bearing remover (MD998917) Installer adapter (MB990930) 2. Push down on the differential case with the press to remove the bearing.

REASSEMBLY SERVICE POINTS >>A<< TAPER ROLLER BEARING INSTALLATION

MD998830

MD998812

AK204297AB

AK204315

1. Mount a spacer on the back surface of the side gear, and then install the side gear in the differential case. NOTE: When a new side gear is to be installed, use a medium thickness spacer (0.93 to 1.00 mm). 2. Place the washers on the back of the pinions, and simultaneously mesh the four pieces with the side gears. Place them into position while rotating them. Then, install the pinion shaft holder. 3. Insert the pinion shaft.

22B-56

MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL CENTER DIFFERENTIAL

Differential case Lock pin Pinion shaft

Standard value: 0.025 - 0.150 mm 9. If the backlash is out of the standard value, select a spacer and re-measure the backlash. NOTE: Adjust until the backlash on both sides are equal. >>D<< CENTER DIFFERENTIAL DRIVE GEAR INSTALLATION

AK204317AC

4. Install the lock pin so that it will be oriented in the direction shown. 5. Install the front output shaft on the side gear, and install the snap ring. 6. Mount a spacer on the back surface of the side gear, and then install the side gear in the differential case. NOTE: When a new side gear is to be installed, use a medium thickness spacer. 7. Install the center differential flange by aligning the matching marks, and temporarily tighten the four machine screws.

AK204320AB

1. Apply sealant (3M STUD Locking No.4170 or equivalent) to the entire threaded portion of the bolt. 1

3

10 8

5

6 7

4 9

2

AK204318AB AK204389

8. Measure the backlash between the side gear and pinion.

2. Tighten to the specified torque in the illustrated sequence. Tightening torque: 132 5 N¼m


22B-57

TRANSFER

TRANSFER DISASSEMBLY AND REASSEMBLY M1222004000062

4 1 2

5 6

3

7

11 8 9


10 23 ± 3 N·m

>>E<< >>D<< >>A<< >>A<< >>A<< >>C<< >>B<< >>A<<

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Disassembly steps Dust seal guide Oil seal Oil seal O-ring O-ring O-ring Oil seal Oil seal O-ring Transfer cover Transfer

REASSEMBLY SERVICE POINTS >>A<< O-RING INSTALLATION Install a O-ring to the transfer, and apply gear oil (Hypoid gear oil API classification GL-5 SAE 90) to the O-ring.

AK204413AB

>>B<< OIL SEAL INSTALLATION 1. Apply gear oil (Hypoid gear oil API classification GL-5 SAE 90). MB990938 MB990937

AK204414AB

2. Using special tools, press fit the oil seal into the transfer cover. Installer adapter (MB990937) Handle (MB990938)


22B-58

TRANSFER

>>C<< OIL SEAL INSTALLATION 1. Apply gear oil (Hypoid gear oil API classification GL-5 SAE 90). MD998800

2. Using special tools, press fit the oil seal into the transfer. Ring (MB990887) Bushing remover installer base (MB990891) >>E<< OIL SEAL INSTALLATION 1. Apply gear oil (Hypoid gear oil API classification GL-5 SAE 90).

MB990936 AK204415AB

2. Using special tool oil seal installer (MD998800), press fit the oil seal into the transfer cover. >>D<< OIL SEAL INSTALLATION 1. Apply gear oil (Hypoid gear oil API classification GL-5 SAE 90). MB990891 MB990887

AK204416 AB

AK204417AB

2. Using special tool installer adapter (MB990936), press fit the oil seal into the transfer.

12-1

GROUP 12

00 11

ENGINE LUBRICATION

12 13 14 15 16

CONTENTS

17 GENERAL INFORMATION . . . . . . . .

12

SPECIAL TOOLS . . . . . . . . . . . . . . . .

12

SERVICE SPECIFICATION . . . . . . . .

12

ON-VEHICLE SERVICE . . . . . . . . . . .

12

ENGINE OIL CHECK . . . . . . . . . . . . . . . . .

12

ENGINE OIL REPLACEMENT . . . . . . . . . .

12

ENGINE OIL FILTER REPLACEMENT. . . .

12

OIL PRESSURE CHECK . . . . . . . . . . . . . .

12

LUBRICANT. . . . . . . . . . . . . . . . . . . .

12

SEALANT. . . . . . . . . . . . . . . . . . . . . .

12

21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

ENGINE LUBRICATION

12-2

GENERAL INFORMATION


The lubrication method is a fully force-fed, full-flow filtration type. The oil pump is a gear type which is driven by the crankshaft via the timing belt.

ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided. Recommended Precautions The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them. 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. Do not wear heavily soiled clothing and oilimpregnated foot-wear. Overalls must be cleaned regularly and kept separate from personal clothing. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Obtain First Aid treatment immediately for open cuts and wounds. Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised. Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work. If skin disorders develop, obtain medical advice without delay.

SERVICE SPECIFICATION M1121000300135

Item Oil pressure kPa

Standard value at idle

29 or more

at 3,500 r/min

294 - 686

LUBRICANT M1121000400400

Item

Specification

Engine oil ACEA classification

A1, A2 or A3

Engine oil API classification

SG or higher

Engine oil quantity L

Oil filter

0.3

Total

4.3

ENGINE LUBRICATION

12-3

SEALANT

SEALANT M1121000500140

Item

Specified sealant

Remark

Oil pressure switch

3M ATD Part No. 1215, 3M ATD Part No. 1141E, 3M ATD Part No. 1212D or equivalent

-


Tool

Number

Name

Use

MB991610

Oil filter wrench

Removal and installation of engine oil filter (When using the oil filter of MD356000)

MD998054

Oil pressure switch wrench

Removal and installation of oil pressure switch

MB991610

ON-VEHICLE SERVICE ENGINE OIL CHECK M1121000900320

1. Pull out the level gauge slowly and check that the oil level is in the illustrated range. 2. Check that the oil is not excessively dirty, that there is no coolant or petrol mixed in, and that it has sufficient viscosity.

Drain plug

Drain plug gasket

Oil pan side

ENGINE OIL REPLACEMENT

Oil pan

M1121001000386

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C. 2. Remove the engine oil filler cap.

CAUTION Use care as oil could be hot. 3. Remove the drain plug to drain oil.

AC300837AB

4. Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque. Tightening torque: 39 5 N¼m NOTE: Install the drain plug gasket so it faces in the direction shown in the illustration.

ENGINE LUBRICATION

12-4

ON-VEHICLE SERVICE

MB991610 or commerciallyavailable tool

AC000093 AH

AC301513

5. Refill with specified quantity of oil. Specified Engine Oil (ACEA and API classification): ACEA A1, A2 or A3/API SG or higher Total quantity (Includes volume inside oil filter): 4.3 L 6. Install the engine oil filler cap. 7. Check oil level.

5. Use the respective tool in the following table to remove the engine oil filter. 6. Clean the filter bracket side mounting surface.

ENGINE OIL FILTER REPLACEMENT M1121001100350

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C. 2. Remove the engine oil filler cap.

CAUTION Use care as oil could be hot. 3. Remove the drain plug to drain oil. 4. Remove the under cover.

O-ring AC103250 AD

7. Apply a small amount of engine oil to the O-ring of the new oil filter. 8. Once the O-ring of the oil filter is touching the flange, use the respective tool in the following table to tighten to the specified torque. 9. Install the drain plug and refill the engine oil (Refer to 312). 10.Race the engine 2-3 times, and check to be sure that no engine oil leaks from installation section of the oil filter.

Number

Special tool

Tightening torque

MD356000

Oil filter wrench (MB991610) or equivalent

Approximately 3/4 turn (14 2 N¼m)

MD136466, MD322508

Commercially- available tool Approximately 3/4 turn (17 3 N¼m)

OIL PRESSURE CHECK M1121002300294

Cylinder block

Oil pressure switch

AK000197AF

ENGINE LUBRICATION

12-5

ON-VEHICLE SERVICE

1. Check engine oil quantity. 2. Remove the oil pressure switch terminal.

CAUTION MD998054

AKX00295AD

AKX00294 AD

Since sealant is applied to the thread of oil pressure switch, take care not to damage the oil pressure switch when removing it. 3. Use the special tool Oil pressure switch wrench (MD998054) to remove the oil pressure switch. 4. Install the oil pressure gauge. NOTE: Use an adapter of PT 1/8 thread. 5. Run the engine to warm it. 6. After the engine has been warmed up, check that oil pressure is within the standard value. Standard value: At idle: 29 kPa or more At 3,500 r/min: 294 - 686 kPa 7. Remove the oil pressure gauge.

8. Apply the specified sealant to the thread of oil pressure switch. Specified sealant: 3M ATD Part No. 1215 or equivalent

CAUTION MD998054

AKX00294 AD

Do not start the engine within one hour after the oil pressure switch has been installed. 9. Use the special tool to tighten the oil pressure switch to the specified torque. Tightening torque: 19 3 N¼m 10.Install the oil pressure switch terminal.

127(6

11A-1

GROUP 11A

00 11

ENGINE MECHANICAL

12 13 14 15 16

CONTENTS


11A


11A

SEALANTS . . . . . . . . . . . . . . . . . . . .

11A

SPECIAL TOOLS. . . . . . . . . . . . . . . .

11A

ON-VEHICLE SERVICE. . . . . . . . . . .

CAMSHAFT AND VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A REMOVAL AND INSTALLATION . . . . . . . .

11A

22

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A

25

REMOVAL AND INSTALLATION <2WD>. .

11A


11A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11A

27

CRANKSHAFT OIL SEAL . . . . . . . . . 11A

31

11A

DRIVE BELT TENSION CHECK. . . . . . . . .

11A

AUTO-TENSIONER CHECK . . . . . . . . . . .

11A

IGNITION TIMING CHECK . . . . . . . . . . . . .

11A

IDLE SPEED CHECK . . . . . . . . . . . . . . . . .

11A

IDLE MIXTURE CHECK . . . . . . . . . . . . . . .

11A

COMPRESSION PRESSURE CHECK. . . .

11A

MANIFOLD VACUUM CHECK . . . . . . . . . .

11A

LASH ADJUSTER CHECK . . . . . . . . . . . . .

11A

REMOVAL AND INSTALLATION . . . . . . . .

11A

CYLINDER HEAD GASKET . . . . . . . . 11A REMOVAL AND INSTALLATION . . . . . . . .

11A

TIMING BELT . . . . . . . . . . . . . . . . . . . 11A

11A

26

32 33 34 35


11A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11A

36

ENGINE ASSEMBLY . . . . . . . . . . . . . 11A

37

CRANKSHAFT PULLEY . . . . . . . . . . 11A REMOVAL AND INSTALLATION . . . . . . . .

21


11A

42 51 52 54 55

ENGINE MECHANICAL

11A-2

GENERAL INFORMATION


Item

4G63

Total displacement mL

1,997

Bore Stroke mm

85 88

Compression ratio

10.0

Compression chamber

Pentroof

Camshaft arrangement

DOHC

Number of valve Valve timing

Intake

8

Exhaust

8

Intake opening

BTDC 17

Intake closing

ABDC 51

Exhaust opening

BBDC 57

Exhaust closing

ATDC 13

Fuel system

Electronically controlled multipoint fuel injection

Rocker arm

Roller type

Auto-lash adjuster

Equipped


Item

Standard value

Limit

Vibration frequency Hz (Reference)

110 - 144

-

Tension N (Reference)

245 - 412

-

Basic ignition timing

5 BTDC 2

-

Ignition timing

Approximately 10 BTDC

-

Idle speed r/min

750 100

-

CO contents %

0.5 or less

-

HC contents ppm

100 or less

-

Compression pressure kPa-r/min

1,370 - 250

930 - 250

Compression pressure difference of all cylinders kPa

-

Maximum 98

Intake manifold vacuum kPa

-

Minimum 60

Cylinder head bolt nominal length mm

-

99.4

Drive belt tension

Balancer timing belt tension (When adjusted)

Deflection mm

5-7

-

Balancer timing belt tension (When replaced)

Deflection mm

5-7

-

ENGINE MECHANICAL

11A-3

SEALANTS

Item

Standard value

Limit

5 - 10

-

Timing belt tensioner adjuster rod protrusion amount mm

3.8 - 4.5

-

Timing belt tensioner adjuster rod movement mm

Within 1

-

Balancer timing belt tension (When checked)

Deflection mm

SEALANTS M1112000500238

Item

Specified Sealant

Remark

Cylinder head

MITSUBISHI GENUINE PART MD970389 or equivalent

Semi-drying sealant

Camshaft position sensor support Rocker cover Camshaft end seal

3M ATD Part No.8660 or equivalent

Rocker cover gasket

MITSUBISHI GENUINE PART MD970389 or equivalent

Engine oil pan <2WD> Engine upper oil pan <4WD> Engine lower oil pan <4WD>


Tool

Number

Name

Use

MB991502

MUT-II sub assembly

Drive belt tension check Checking the ignition timing Checking the idle speed

MB991668

Belt tension meter set

Drive belt tension check (used together with MUT-II)

MD998772


Compressing valve spring

MD998737

Valve stem seal installer

Valve stem seal installation

B991502

B991668

MD998772

ENGINE MECHANICAL

11A-4

SPECIAL TOOLS

Tool

Number

Name

Use

MD998713

Camshaft oil seal installer

Camshaft oil seal installation

MD998727

Oil pan remover

Oil pan removal <2WD>

MD998781

Flywheel stopper

Supporting the flywheel

MB990938

Installer bar

Crankshaft rear oil seal installation

MD998776

Crankshaft rear oil seal installer

MD998285

Crankshaft front oil seal guide

MD998375

Crankshaft front oil seal installer

MB991654

Cylinder head bolt wrench (12)

D998713

D998727

D998781

B990938

D998776

Crankshaft front oil seal installation

D998285

B991654

Removal and installation of cylinder head bolt

ENGINE MECHANICAL

11A-5

SPECIAL TOOLS

Tool

Number

Name

Use

MD998738

Adjusting bolt

Supporting the timing belt tensioner arm and timing belt tensioner adjuster

MB991367

Special spanner

Holding the crankshaft camshaft drive sprocket

MB991385

Pin

MD998767

Tensioner wrench

D998738

B991367

B991385

D998767

Valve timing belt tension adjustment

ENGINE MECHANICAL

11A-6

ON-VEHICLE SERVICE

Tool

Number

Name

Use

MB991454

Engine hanger balancer

MB991527

Hanger

When the engine hanger is used: Supporting the engine assembly during removal and installation of the transmission assembly NOTE: Special tool MB991454 is a part of engine hanger attachment set MB991453.

MB991895

Engine hanger

B991454

B991527

Z203830

MB991928 A: MB991929 B: MB991930 E C: MB991931 D: MB991932 E: MB991933 F: MB991934

Slide bracket (HI)

F A

D B

Engine hanger A: Joint (50) 2 B: Joint (90) 2 C: Joint (140) 2 D: Foot (standard) 4 E: Foot (short) 2 F: Chain and hook assembly

C B991928

ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK M1111003100399

CAUTION Check the drive belt tension after turning the crankshaft clockwise one turn or more.

Indicator mark

A

AC107639AB

1. Make sure that the indicator mark is within the area marked with A in the illustration.

2. If the mark is out of the area, replace the drive belt. (Refer to 311A.) NOTE: The drive belt tension check is not necessary as auto-tensioner is adopted.

ENGINE MECHANICAL

11A-7

ON-VEHICLE SERVICE

AUTO-TENSIONER CHECK M1111003000154

CAUTION

OPERATION CHECK 1. Turn OFF the engine from the idle state then check to see that the drive belt is not protruding from the pulley width of the auto-tensioner. 2. Remove the drive belt.(Refer to 311A.)

16-pin

MUT-II

AC107640AB

3. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto tensioner. Turn the auto-tensioner to the left and right to check and see that there is no threading. 4. If there are any problems in the procedure 1 or 3, replace the auto-tensioner.(Refer to 311A.) 5. Install the drive belt.(Refer to 311A.)

FUNCTION CHECK You can verify if the auto-tensioner is defective or not by checking the drive belt tension. When using MUT-II 1. Check the drive belt tension. (Refer to 311A.) 2. Measure the drive belt tension vibration frequency by the following procedures:

MB991668 AC211862 AB

To prevent damage to MUT-II, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting MUT-II. (1) Connect special tool belt tension meter set (MB991668) to the MUT-II. (2) Connect the MUT-II to the diagnosis connector. (3) Turn the ignition switch to ON position, and select "BELT TENSION" on the menu screen.

ENGINE MECHANICAL

11A-8

ON-VEHICLE SERVICE

CAUTION The temperature of the surface of the belt should be as close to normal temperature as possible. Do not allow any contaminants such as water or oil to get onto the microphone. If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. Do not take the measurement while the vehicle’s engine is running. Power steering oil pump pulley

Power steering oil pump pulley

Water pump pulley

AC102807AB

2. Use a belt tension gauge in the middle of the belt between the pulleys (at the place indicated by the arrow) to measure that the belt tension is within the standard value. Standard value: 245 - 412 N 3. If not within the standard value, replace the autotensioner.(Refer to 311A.)

IGNITION TIMING CHECK

15˚

MB991668 Water pump pulley

10 – 20 mm

Belt tension gauge

M1111001700425

15˚

AC102022 Y0195AU

MUT-II Gentry tap with your finger AC102806 AB

(4) Hold special tool belt tension meter set (MB991668) to the middle of the drive belt between the pulleys (at the place indicated by arrow), approximately 10 - 20 mm away from the rear surface of the belt so that it is perpendicular to the belt (within an angle of 15 degree). (5) Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and measure that the vibration frequency of the belt is within the standard value. Standard value: 110 - 144 Hz 3. If not within the standard value, replace the autotensioner. (Refer to 311A.) When using a tension gauge 1. Check the drive belt tension. (Refer to 311A.)

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition. 2. Turn the ignition switch to the "LOCK" (OFF) position and then connect the MUT-II to the diagnosis connector. 3. Connect a timing light. 4. Start the engine and let it run at idle. 5. Use the MUT-II to measure engine idle speed and check that it is within the standard value. Standard value: 750 100 r/min 6. Select No. 17 of the MUT-II Actuator test. 7. Check that basic ignition timing is within the standard value. Standard value: 5 BTDC 2 8. If the basic ignition timing is outside the standard value, inspect the MPI system (Refer to 313A, GROUP 13A - Troubleshooting - Inspection chart for diagnosis code).

ENGINE MECHANICAL

11A-9

ON-VEHICLE SERVICE

CAUTION If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine. 9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. 10.Check that ignition timing is at the standard value. Standard value: approximately 10 BTDC NOTE: . The ignition timing may fluctuate within 7 BTDC. This is normal. In higher altitude, the ignition timing is more advanced than the standard value by approximately 5. 11.Remove the timing light. 12.Turn off the ignition switch and then remove the MUT-II.

Standard value: 750 100 r/min NOTE: . The idle speed is controlled automatically by the idle speed control system. When using the MUT-II, select item No. 22 and take a reading of the idle speed. 8. If the idle speed is outside the standard value, inspect the MPI system (Refer to 313A, GROUP 13A - Troubleshooting - Inspection chart for diagnosis code).

IDLE MIXTURE CHECK M1111002100255

AC102022 Y0195AU

MUT-II

IDLE SPEED CHECK M1111003500472

AC102022 Y0195AU AK000871 AC

MUT-II

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition. 2. Turn the ignition switch to "LOCK" (OFF) position. 3. Connect the MUT-II to the diagnosis connector or connect a tachometer to the engine speed detection connector. 4. Connect a timing light.

1. Before inspection, set the vehicle to the preinspection condition. 2. Turn the ignition switch to "LOCK" (OFF) position. 3. Connect the MUT-II to the diagnosis connector or connect a tachometer to the engine speed detection connector. 4. Connect a timing light.

Engine speed ditection connector

AK000899 AC

Engine speed ditection connector

AK000899 AC

5. Start the engine and let it run at idle. 6. Check that ignition timing is at the standard value. Standard value: approximately 10 BTDC 7. Check the idle speed.

5. Start the engine and let it run at idle. 6. Check that ignition timing is at the standard value. Standard value: approximately 10 BTDC 7. Run the engine at 2,500 r/min for 2 minutes. 8. Set the CO, HC tester. 9. Check the CO contents and the HC contents at idle. Standard value CO contents: 0.5 % or less HC contents: 100 ppm or less 10.If there is a deviation from the standard value, check the following items:

ENGINE MECHANICAL

11A-10

ON-VEHICLE SERVICE

Diagnosis output Fuel pressure Injector Ignition coil, spark plug cable, 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.

COMPRESSION PRESSURE CHECK M1111002600465

Crank angle sensor connector

AK201364AC

1. Before inspection, set the vehicle to the preinspection condition. 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crank angle sensor connector. NOTE: Doing this will prevent the engine-ECU or engine-A/T-ECU from carrying out ignition and fuel injection.

8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Maximum 98 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 from (6) to (8). (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression dose 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.Install the spark plugs and spark plug cables. 12.Use the MUT-II to erase the diagnosis codes. NOTE: This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

MANIFOLD VACUUM CHECK M1111002700417

AC102022 Y0195AU

MUT-II

CAUTION Keep away from the spark plug hole when cranking. If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous. 5. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. 6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250 r/ min): 1,370 kPa Limit (at engine speed of 250 r/min): Minimum 930 kPa

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition. 2. Turn the ignition switch to "LOCK" (OFF) position. 3. Connect a tachometer or connect the MUT-II to the diagnosis connector. Vacuum gauge

Fuel pressure regulator

AK201369AB

ENGINE MECHANICAL

11A-11

ON-VEHICLE SERVICE

4. Attach a three-way joint to the vacuum hose between the fuel pressure regurator and the air intake plenum, and connect a vacuum gauge. 5. Start the engine and check that idle speed is within the standard valve. Standard value: 750 100 r/min 6. Check the intake manifold vacuum. Limit: Minimum 60 kPa 7. Turn off the ignition switch. 8. Remove the vacuum gauge and the three-way joint, and then connect the vacuum hose. 9. Remove the engine tachometer or the MUT-II.

LASH ADJUSTER CHECK M1111002900336

If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and dose not stop, carry out the following check. NOTE: . 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. However, this noise is not related to the actual engine load. Because of this, if the noise dose not occur immediately after the engine is started, if it dose not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters. If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick. 1. Start the engine. 2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise dose not occur immediately after the engine is started, or if it dose not change in accordance with the engine speed, the problem is not being caused by the lash adjusters, so check for some other cause of the problem. Moreover, if the noise dose not change in accordance with the engine speed, the cause of the problem is probably not with the engine (In these cases, the lash adjusters are normal).

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 to D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings (In such cases, the lash adjusters are normal). 4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or disappeared, oil sludge could make the lash adjusters stick. Clean the lash adjusters (Refer to GROUP 11D Rocker Arms and Camshaft - Rocker Arms and Camshaft Inspection 311B). If not improved, go to step 5. 5. Bleed air from the lash adjusters (Refer to 311A ). 6. If the noise has not disappeared even after the air bleeding, clean the lash adjusters (Refer to GROUP 11D - Rocker Arms and Camshaft Rocker Arms and Camshaft Inspection 311B).

NOTE: . If the vehicle is parked on a slope fir 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. After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high-pressure chamber. If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters.

Good Max Min. AKX00328 AE

1. Check the engine oil and replenish or replace the oil if necessary.

ENGINE MECHANICAL

11A-12

ON-VEHICLE SERVICE

NOTE: . If there is an only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage. If the amount of oil is greater than normal, then the oil will being mixed by the crankshaft and a large amount of air may get mixed into the oil. If the oil is degenerated, air and oil will not separate easily in oil, and the amount of air mixed into the oil will increase.

High-pressure chamber AK100001AC

If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve close. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal.

Drive pattern for air breeding Gradually open Close the throttle valve the throttle valve Approximately 3,000 r/min Idle speed

15 s

15 s

Once AKX00330AE

2. Run the engine at idle for 1 - 3 minutes to let it warm up. 3. With no load on the engine, repeat the drive pattern shown in the illustration above and check if the abnormal noise disappears (The noise should normally disappear after 10 - 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters). 4. After the noise has disappeared, repeat the drive pattern shown in the illustration above a further 5 times. 5. Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.

ENGINE MECHANICAL CRANKSHAFT PULLEY

11A-13

CRANKSHAFT PULLEY REMOVAL AND INSTALLATION M1112001600409

Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Under Cover 351).

Post-installation Operation Drive Belt Tension Check (Refer to 311A). Under Cover Installation (Refer to GROUP 51, Under Cover 351).

2 1

25 ± 4 N·m

AC300537AB

<>

1. 2.

Removal steps Drive belt Crank shaft damper pulley

ENGINE MECHANICAL

11A-14

CRANKSHAFT PULLEY


CAUTION

<> DRIVE BELT REMOVAL The following operations will be needed due to the serpentine drive system with the drive belt autotensioner.

To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk. Auto-tensioner

Auto-tensioner

Hole B

L-shaped hexagon wrench Hole A

AC107641AB

AC107640AC

1. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto-tensioner, and turn the autotensioner anti-clockwise until it hits the stopper.

2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt.

ENGINE MECHANICAL

11A-15

CAMSHAFT AND VALVE STEM SEAL

CAMSHAFT AND VALVE STEM SEAL REMOVAL AND INSTALLATION M1112006600211

CAUTION *Remove and assemble the marked parts in each cylinder unit. Pre-removal Operation Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner 315). Battery and Battery Tray Removal Valve Timing Belt Removal (Refer to 311A).

Post-installation Operation Valve Timing Belt Installation (Refer to 311A). Battery and Battery Tray Installation Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner 315). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Drive Belt Tension Check (Refer to 311A).

11 ± 1 N·m 3.0 ± 0.5 N·m

11 ± 1 N·m

2

4 6 3.5 ± 0.5 N·m

5 8 9.0 ± 2.0 N·m

1 8.8 ± 1.0 N·m

11 ± 1 N·m

9 N

11

12 11 ± 1 N·m

3

N 10

7

AC300538 AB

1. 2. 3. 4.

Removal steps Accelerator cable connection Rocker cover centre cover Crank angle sensor connector Control wiring harness connection Spark plug cables and ignition coils (Refer to GROUP 16, Ignition Coil 316).

>>N<< >>M<<

Removal steps&RQWLQXHG 5. Rocker cover PCV hose 6. Rocker cover breather hose 7. Control wiring harness connection 8. Rocker cover 9. Camshaft end seal 10. Spark plug hole gaskets

ENGINE MECHANICAL

11A-16 <>


>>L<< >>K<<

Removal steps&RQWLQXHG 11. Rocker cover gasket 12. Radiator upper hose connection

22

20

24

25

23

20 ± 1 N·m


21

26

19 17

N 18

11 ± 1 N·m

89 ± 9 N·m

13

30 29

25 ± 4 N·m

22 ± 4 N·m

15 31* 32* 33* N 34*

16

27 28

10 ± 2 N·m

14 N 14 ± 1 N·m

31* 32* 33* 35* N AC300539 AB

<>

>>J<< >>I<< >>H<< >>G<< >>F<< >>F<< >>F<< >>F<< >>F<<

Removal steps 13. Camshaft position sensor support cover 14. Camshaft position sensor support cover gasket 15. Camshaft position sensing cylinder 16. Camshaft position sensor support 17. Camshaft sprockets 18. Camshaft oil seals 19. Camshaft bearing caps, front 20. Camshaft bearing caps, rear 21. Camshaft bearing caps, No.2 22. Camshaft bearing caps, No.5 23. Camshaft bearing caps, No.3

>>F<< >>E<< >>E<< >>D<< <>

>>C<< >>B<< >>A<< >>A<<

24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

Removal steps&RQWLQXHG Camshaft bearing caps, No.4 Inlet camshaft Exhaust camshaft Rocker arms Rocker arm lash adjusters Oil delivery body Spark plugs Valve spring retainer locks Valve spring retainers Valve springs Inlet valve stem seals Exhaust valve stem seals

ENGINE MECHANICAL

11A-17


LUBRICATION AND SEALING POINTS

10 mm

10 mm

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent Rocker cover

10 mm

10 mm

Cylinder head

A 10 mm

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

Sealant: 3M ATD Part No.8660 or equivalent A A

φ 3 mm


(Lip section)

Engine oil

AC300541


ENGINE MECHANICAL

11A-18


REMOVAL SERVICE POINTS

<> VALVE SPRING RETAINER LOCKS REMOVAL

<> RADIATOR UPPER HOSE DISCONNECTION

CAUTION When removing valve spring retainer locks, leave the piston of each cylinder in the TDC (Top Dead Centre) position. The valve may fall into the cylinder if the piston is not properly in the TDC position.

Mating marks

MD998772

AC200641AC

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose. <> CAMSHAFT SPROCKETS REMOVAL

AC201799 AB

Use special tool valve spring compressor (MD998772) to compress the valve spring, remove the valve spring retainer locks.

INSTALLATION SERVICE POINTS >>A<< EXHAUST VALVE STEM SEALS/INLET VALVE STEM SEALS INSTALLATION Gray

Gray green

Inlet side

Exhaust side

AC201457AB

1. Hold the hexagon part of the camshaft with a wrench. 2. Loosen the camshaft sprocket mounting bolts and remove the camshaft sprocket.

AC201542AB

1. Check the valve stem seal colour to identify the inlet side or exhaust side. 2. Apply a small amount of engine oil to the valve stem seals.

ENGINE MECHANICAL

11A-19


CAUTION Valve stem seals cannot be reused. The special tool valve stem seal installer (MD998737) must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide. MD998737 Valve Valve stem seal Valve guide AC107414 AC

3. Use special tool to fill a new valve stem seal in the valve guide using the valve stem area as a guide.

>>D<< ROCKER ARM LASH ADJUSTERS INSTALLATION

CAUTION If the rocker arm lash adjuster is reused, always clean and check it before installation. (Refer to GROUP 11B, Rocker Arms and Camshaft Inspection). >>E<< EXHAUST CAMSHAFT/INLET CAMSHAFT INSTALLATION 1. Remove sealant remained on the cylinder head. 2. Apply engine oil to the cam and the journal of the camshaft.

CAUTION Engine front

>>B<< VALVE SPRINGS INSTALLATION

Slit

Rocker arm side Exhaust camshaft AC201458AB

Do not install wrong camshaft at the side of inlet or exhaust. The exhaust camshaft has a slit at the rear surface. 3. Install the camshaft to the cylinder head.

Identification colour AC201453AB

Install the valve springs with its identification colour painted end facing the locker arm. >>C<< VALVE SPRING RETAINER LOCKS INSTALLATION

>>F<< CAMSHAFT BEARING CAPS, NO. 4/ CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT BEARING CAPS, NO. 5/CAMSHAFT BEARING CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/ CAMSHAFT BEARING CAPS, FRONT INSTALLATION Approximately 3˚

MD998772

Dowel pin

AC201799 AB

Use special tool valve spring compressor (MD998772) to compress the valve spring in the same manner as removal.

Inlet side

Exhaust side AC201459AB

1. Set the dowel pin of the camshaft to the position as shown in the illustration.

ENGINE MECHANICAL

11A-20

E4

Engine front


Bearing cap No. Identification of inlet side and exhaust side AC201460AB

2. Since the shape of camshaft bearing caps No.2 5 is identical, check the identification marks so that the bearing cap No., inlet side, or exhaust side cannot be mistaken to install to the direction as shown in the illustration. Identification mark (engraved on the front and bearing caps No.2 - 5) I: Inlet side E: Exhaust side

5. Check the identification marks on the camshaft bearing caps, front so that inlet side and exhaust side cannot be mistaken in the same way as that of bearing caps No.2 - 5.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time. 6. Tighten the bearing cap mounting bolts increasing the pressure in 2 to 3 times and finally tighten to the specified torque. Tightening torque: 20 1 N¼m 7. Ensure that the rocker arms are installed properly. NOTE: Remove an excess of sealant completely. >>G<< CAMSHAFT OIL SEALS INSTALLATION

Engine front

MD998713

AC201461AB

3. Apply sealant to the positions (6 areas) of the upper side of the cylinder head as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the camshaft bearing caps, rear and camshaft bearing caps, front within 15 minutes after applying liquid gasket.

Engine front

Front marking

AC201462AB

4. Position the camshaft bearing caps, rear in the direction as shown in the illustration for installation.

AC102323 AB

1. Apply engine oil to the entire inner diameter of the oil seal lip. 2. Use special tool camshaft oil seal installer (MD998713) to press-fit the oil seals. >>H<< CAMSHAFT SPROCKETS INSTALLATION

AC201457AB

1. Hold the hexagon part of the camshaft with a wrench in the same manner as removal. 2. Tighten the camshaft sprocket mounting bolts to the specified torque. Tightening torque: 89 9 N¼m

ENGINE MECHANICAL CAMSHAFT AND VALVE STEM SEAL

>>I<< CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION 1. Remove sealant from the camshaft position sensor support and cylinder head surfaces.

11A-21

2. Install the vane (small) of the camshaft position sensing cylinder at an angle of approximately 45 degrees to the position of the dowel pin of the exhaust camshaft. 3. Tighten the camshaft position sensing cylinder mounting bolts to the specified torque. Tightening torque: 22 4 N¼m >>K<< RADIATOR UPPER HOSE CONNECTION Projection

φ 3 mm

AC201463 AB

2. Apply the sealant to the camshaft position sensor support flange in a continuous bead as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the camshaft position sensor support within 15 minutes after applying liquid gasket. 3. Install the camshaft position sensor support to the cylinder head.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time. 4. Tighten the camshaft position sensor support mounting bolts to the specified torque. Tightening torque: 14 1 N¼m

Water outlet fitting

Mating marks AC200642 AE

1. Insert each hose as far as the projection of the water outlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose. >>L<< ROCKER COVER GASKET INSTALLATION 1. Remove sealant remained on the rocker cover.

>>J<< CAMSHAFT POSITION SENSING CYLINDER INSTALLATION Approximately 45˚

Dowel pin

Vane (small)

Vane (large) AC201464AB

1. Set the dowel pin of the exhaust camshaft to the position (No.1 cylinder at compression TDC) as shown in the illustration. NOTE: Use the force of the exhaust valve spring to rotate anti-clockwise.

AC201465AB

2. Apply sealant to the positions (4 areas) of the lower side of the rocker cover as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the rocker cover gasket within 15 minutes after applying liquid gasket. 3. Install the rocker cover gasket to the rocker cover.

ENGINE MECHANICAL

11A-22


>>M<< CAMSHAFT END SEAL INSTALLATION >>N<< ROCKER COVER INSTALLATION Engine front

AC201469AB

1. Apply sealant to the positions of the rocker cover gasket (6 areas) as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the rocker cover within 15 minutes after applying liquid gasket. 2. Install the rocker cover to the cylinder head.

10 mm 10 mm

Cylinder head AC201468 AB

Apply sealant to the positions of the camshaft end seal as shown in the illustration and install to the cylinder head. Specified sealant: 3M ATD Part No.8660 or equivalent NOTE: Install the camshaft end seal within 15 minutes after applying liquid gasket.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time. 3. Tighten the rocker cover mounting bolts to the specified torque. Tightening torque: 3.5 0.5 N¼m

ENGINE MECHANICAL

11A-23

OIL PAN

OIL PAN REMOVAL AND INSTALLATION <2WD> M1112002800592

Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Under Cover 351). Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315).

Post-installation Operation Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Under Cover Installation (Refer to GROUP 51, Under Cover 351).

1

5 N

4

35 ± 6 N·m

3

39 ± 5 N·m

9.0 ± 3.0 N·m

2 26 ± 5 N·m 9.0 ± 1.0 N·m

9.0 ± 3.0 N·m

1. 2. 3.

Removal steps Exhaust manifold bracket Flywheel housing front lower cover Engine oil pan drain plug

AC300542 AB

>>B<< 4. <> >>A<< 5.

Removal steps&RQWLQXHG Engine oil pan drain plug gasket Engine oil pan

ENGINE MECHANICAL

11A-24

OIL PAN


3. Assemble the engine oil pan to the cylinder block.

<> ENGINE OIL PAN REMOVAL 1. Remove the engine oil pan mounting bolts.

CAUTION Perform this slowly to avoid deformation of the engine oil pan flange.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during that time.

MD998727

MD998727

M6 × 8 mm AC102698 AB

INSTALLATION SERVICE POINTS

4. Tighten the engine oil pan mounting bolts to the specified torque. Be careful when installing, as the oil pan mounting bolts (indicated in the illustration) have different lengths from the other bolts. Tightening torque: 9.0 3.0 N¼m

>>A<< ENGINE OIL PAN INSTALLATION 1. Remove sealant from the engine oil pan and cylinder block surfaces.

>>B<< ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION

AC102324 AB

2. Remove the engine oil pan using special tool oil pan remover (MD998727).

Engine oil pan side

φ 4 mm Groove portion Bolt hole portion

AC102133AB

2. Apply a bead of the sealant to the cylinder block mating surface of the engine oil pan as shown. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the engine oil pan within 15 minutes after applying sealant.

AC102325 AE

Replace the gasket with a new gasket. Install the new gasket in the direction shown in the illustration.

ENGINE MECHANICAL

11A-25

OIL PAN

REMOVAL AND INSTALLATION <4WD> M1112002800600

Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Under Cover 351). Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Centre Member Removal (Refer to GROUP 32, Engine Roll Stopper and Centre Member 332).

Post-installation Operation Centre Member Installation (Refer to GROUP 32, Engine Roll Stopper and Centre Member 332). Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Under Cover Installation (Refer to GROUP 51, Under Cover 351).

6

9.0 ± 3.0 N·m

N

2

4

3

9.0 ± 3.0 N·m

39 ± 5 N·m

44 ± 10 N·m

9.0 ± 1.0 N·m

22 ± 4 N·m

5 9.0 ± 3.0 N·m

1

9.0 ± 3.0 N·m AC300543 AB

>>D<<

1.

>>C<<

2. 3. 4.

Removal steps Transmission housing front lower cover stay Flywheel housing front lower cover Engine oil pan drain plug Engine oil pan drain plug gasket

<> <>

>>B<< >>A<<

5. 6.

Removal steps&RQWLQXHG Engine lower oil pan Engine upper oil pan

ENGINE MECHANICAL

11A-26

OIL PAN



<> ENGINE LOWER OIL PAN REMOVAL 1. Remove the engine lower oil pan mounting bolts.

>>A<< ENGINE UPPER OIL PAN INSTALLATION 1. Remove sealant from the engine upper oil pan and cylinder block surfaces.

CAUTION Do not use special tool oil pan remover (MD998727). The engine upper oil pan is made of aluminium and this tool will damage it.

φ 4 mm Bolt hole portion

Groove portion

Engine lower oil pan AC102931AB

2. Apply a piece of wood to the lower oil pan and strike it with a hammer to remove the engine lower oil pan. <> ENGINE UPPER OIL PAN REMOVAL 1. Remove the engine upper oil pan mounting bolts.

CAUTION Do not use special tool oil pan remover (MD998727). The engine upper oil pan is made of aluminium and this tool will damage it.

AC102242AB

2. Apply a bead of the sealant to the mating surface of the engine upper oil pan as shown. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the engine upper oil pan within 15 minutes after applying sealant. 3. Assemble the engine upper oil pan to the cylinder block.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during that time. B

B

B

B

B A

B

A B

B

B

B

AC102946AB

2. Screw in the bolt into bolt hole A in the location shown. Then lift the upper oil pan and remove it.

B

B

B

B

B B A

A AC102929AB

4. Insert the bolts to the engine upper oil pan as shown, and tighten them to the specified torque.

ENGINE MECHANICAL

11A-27

OIL PAN

Name

Symbol

Flange bolt A B

Quantity

Size mm (D L)

Name

2

M6 16

Flange bolt A

16

M6 18

B

NOTE: D: Nominal diameter, L: Nominal length Tightening torque: 9.0 3.0 N¼m >>B<< ENGINE LOWER OIL PAN INSTALLATION 1. Remove sealant from the engine lower oil pan and engine upper oil pan.

Symbol

Quantity

Size mm (D L)

1

M6 75

11

M6 10

NOTE: D: Nominal diameter, L: Nominal length Tightening torque: 9.0 3.0 N¼m >>C<< ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION

Engine lower oil pan side

φ 4 mm AC102325 AF

Bolt hole portion

Groove portion

AC102243AB

2. Apply a bead of the sealant to the mating surface of the engine lower oil pan as shown. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the engine lower oil pan within 15 minutes after applying sealant. 3. Assemble the engine lower oil pan to the engine upper oil pan.

CAUTION Then wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during that time. B-1

B-11

M1112002900210

B-7 B-6 A-3

B-8 B-9

B-12

B-2

>>D<< TRANSMISSION HOUSING FRONT LOWER COVER STAY INSTALLATION Install the transmission housing front lower cover stay in the following order. 1. Tighten the engine side four mounting bolts to the specified torque. Tightening torque: 22 4 N¼m 2. Tighten the transmission side two mounting bolts to the specified torque. Tightening torque: 44 10 N¼m

INSPECTION

B-10

B-4 B-5

Replace the gasket with a new one. Install the new gasket in the direction shown in the illustration.

AC102930AB

4. Insert the bolts to the engine lower oil pan as shown, and tighten them to the specified torque in the order shown.

Check the oil pan for cracks. Check the oil pan sealant-coated surface for damage and deformation.

ENGINE MECHANICAL

11A-28

CRANKSHAFT OIL SEAL

CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION M1112003100273

132 ± 5 N·m

4 5 7

8 9

6

N

3 N

9

3

2

Lip section

Lip section

Engine oil

1

AC300544 AB

>>D<<

1.

>>C<<

2. 3.

Crankshaft front oil seal removal steps Valve timing belt, balancer timing belt (Refer to 311A). Crankshaft balancer shaft drive sprocket Crankshaft key Crankshaft front oil seal

<> <>

>>B<<

>>A<<

4. 5. 6. 7. 8. 9.

Crankshaft rear oil seal removal steps Transmission assembly Flywheel bolts Flywheel adapter plate Flywheel assembly Flywheel adapter plate Crankshaft bush Crankshaft rear oil seal

ENGINE MECHANICAL

11A-29

CRANKSHAFT OIL SEAL

REMOVAL SERVICE POINTS <> TRANSMISSION ASSEMBLY REMOVAL

CAUTION

2. Use the following special tools to press-fit the oil seal. Installer bar (MB990938) Crankshaft rear oil seal installer (MD998776) >>B<< FLYWHEEL BOLTS INSTALLATION

Engine front

MD998781

Flywheel assembly Flywheel bolt AC300897 AB

Do not remove the flywheel bolt shown by the arrow. If this bolt is removed, the flywheel assembly will become out of balance and damaged. Refer to GROUP 22A, Transmission Assembly 322A. <> FLYWHEEL BOLTS REMOVAL

AC211914AC

1. Use special tool flywheel stopper (MD998781) to secure the flywheel in the same manner as removal. 2. Tighten the flywheel bolts to the specified torque. Tightening torque: 132 5 N¼m >>C<< CRANKSHAFT FRONT OIL SEAL INSTALLATION

MD998781

Crankshaft

MD998375

(Engine oil) AC211914AC

1. Use special tool flywheel stopper (MD998781) to secure the flywheel. 2. Remove the flywheel bolts.

INSTALLATION SERVICE POINTS >>A<< CRANKSHAFT REAR OIL SEAL INSTALLATION Oil seal

MB990938 (Engine oil)

MD998776

Crankshaft AC102328 AB

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.

MD998285 (Oil applied to the circumference)

Oil seal AC102329 AC

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip. 2. Apply a small amount of engine oil to the outer diameter of special tool crankshaft front oil seal guide (MD998285) and install it to the crankshaft. 3. Use special tool crankshaft front oil seal installer (MD998375) to press-fit the oil seal.

ENGINE MECHANICAL

11A-30

CYLINDER HEAD GASKET

>>D<< CRANKSHAFT BALANCER SHAFT DRIVE SPROCKET INSTALLATION : Clean : Clean and degrease

Crankshaft

Front case Crankshaft balancershaft drive sprocket

Engine front

AC211222 AB

1. Clean or degrease the front case, the crankshaft and the crankshaft balancer shaft drive sprocket as shown. NOTE: Also clean the degreased surfaces. 2. Install the crankshaft balancer shaft drive sprocket in the direction shown in the illustration.

CYLINDER HEAD GASKET REMOVAL AND INSTALLATION M1112004000655

Pre-removal Operation Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) 313A.] Under Cover Removal (Refer to GROUP 51, Under Cover 351). Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner 315). Battery Removal Rocker Cover Centre Cover Removal (Refer to 311A ). Valve Timing Belt Removal (Refer to 311A).

Post-installation Operation Valve Timing Belt Installation (Refer to 311A). Rocker Cover Centre Cover Installation (Refer to 311A ). Battery Installation Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner 315). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Check and Adjustment 317). Drive Belt Tension Check (Refer to 311A). Under Cover Installation (Refer to GROUP 51, Under Cover 351). Fuel Leak Check

ENGINE MECHANICAL

11A-31


9 10

5.0 ± 1.0 N·m

16

12

7 17

5

6 14

8

5.0 ± 1.0 N·m

4 18

15 9.0 ± 2.0 N·m

13 11

3

20 2

13 ± 1 N·m

1

(Engine oil)

N

19

AC300545 AB

Removal steps A/C compressor connector Power steering fluid pressure switch connector 3. Crank angle sensor connector 4. Ignition coil connectors 5. Detonation sensor connector 6. Purge control solenoid valve connector 7. EGR control solenoid valve connector 8. Injector connectors 9. Throttle position sensor connector 10. Idle speed control servo connector 11. Camshaft position sensor connector 1. 2.

Removal steps&RQWLQXHG 12. Oxygen sensor connector 13. Engine coolant temperature sensor connector 14. Engine coolant temperature gauge unit connector 15. Capacitor connector 16. Accelerator cable connection 17. Brake booster vacuum hose connection 18. Engine oil level gauge and guide assembly 19. O-ring 20. Canister vacuum hose connection

ENGINE MECHANICAL

11A-32


24 25

26

78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚

5.0 ± 1.0 N·m

27 N

(Engine oil)

28

(Engine oil)

29

22 11 ± 1 N·m

21 30 N 31 ± 3 N·m

23

AC300546 AB

21. 22. 23.

24.

Removal steps Detonation sensor connection Battery wiring harness connection Inlet manifold stay Exhaust manifold (Refer to GROUP 15, Exhaust Manifold 315). Water outlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe 314). Rocker cover (Refer to 311A). Heater water hose connection

>>C<< <>

>>C<< >>B<< >>A<<

25. 26. 27. 28. 29. 30.

Removal steps&RQWLQXHG Fuel return line hose connection Fuel high-pressure hose connection O-ring Cylinder head bolts Cylinder head assembly Cylinder head gasket

ENGINE MECHANICAL

11A-33


REMOVAL SERVICE POINT <> CYLINDER HEAD BOLTS REMOVAL

Identification mark "63" MB991654

Exhaust side AC107217AC

2. Assemble to the cylinder block so the cylinder head gasket identification mark "63" is at the top surface and on the exhaust side.

Engine front

>>B<< CYLINDER HEAD BOLTS INSTALLATION 3

5

10

8

2 (Engine oil)

1

7

9

6

4

AC201623 AB

Using special tool cylinder head bolt wrench (MB991654), loosen the cylinder head bolts in two or three steps in the order of the numbers shown in the illustration. NOTE: If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it by using a magnet.

INSTALLATION SERVICE POINTS >>A<< CYLINDER HEAD GASKET INSTALLATION

CAUTION Do not allow any foreign materials to get into the coolant passages, oil passages and cylinder. 1. Remove the gasket from the cylinder head and cylinder block.

A AC102537AB

1. Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace the bolt with a new one. Limit (A): 99.4 mm 2. Apply a small amount of engine oil to the thread of the bolts and to the washers.

ENGINE MECHANICAL

11A-34


CAUTION The bolt is not tightened sufficiently if the bolt is tightened less than 90 degree angle. (5) Tighten the bolt an additional 90 degree angle as shown. Then check to see that the paint mark on the head of the cylinder head bolts and the paint mark on the cylinder head are aligned. (6) If tightening the bolt 90 degree angle results in moving the paint mark on the bolt past the paint mark on the cylinder head, remove the bolt and start over from step 1.

MB991654

Engine front

8

6

1

3

9

>>C<< O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION

10

4

2

5

7

Do not let any engine oil get into the delivery pipe. 1. Apply a small amount of new engine oil to the Oring. 2. Turning the fuel high-pressure hose to the right and left, install it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage. After this, re-insert it to the delivery pipe and check that the hose turns smoothly. 4. Tighten the fuel high-pressure hose mounting bolts to the specified torque. Tightening torque: 5.0 1.0 N¼m

AC201625 AB

3. Use special tool cylinder head bolt wrench (MB991654) to tighten the cylinder head bolts as follows: (1) Tighten the cylinder head bolts to 78 2 N¼m in the order shown. (2) Loosen the bolts fully in the reverse order of that shown. (3) Tighten the cylinder head bolts to 20 2 N¼m in the order shown. Step (4) 90˚

Paint marking

Step (5) 90˚

Paint marking AC102331AB

(4) Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degree angle as shown.

CAUTION

ENGINE MECHANICAL

11A-35

TIMING BELT

TIMING BELT REMOVAL AND INSTALLATION M1112004300656

Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Under Cover 351). Crankshaft Shaft Damper Pulley Removal (Refer to 311A).

Post-installation Operation Crankshaft Shaft Damper Pulley Installation (Refer to 311A). Drive Belt Tension Check (Refer to 311A). Under Cover Installation (Refer to GROUP 51, Under Cover 351).

10 9 2

8

48 ± 5 N·m

11 ± 1 N·m 21 ± 4 N·m

3 8.8 ± 1.0 N·m

23 ± 3 N·m

11

1 6 44 ± 10 N·m

N

5 4 22 ± 4 N·m

>>H<<

1. 2. 3. 4. 5. 6. 7.

7 11 ± 1 N·m

79 ± 5 N·m

9.0 ± 1.0 N·m

Removal steps Control wiring harness connection Timing belt upper cover Water pump pulley Idler pulley End cap Auto-tensioner Timing belt lower cover

AC300547 AB

Removal steps&RQWLQXHG Engine front mounting bracket (Refer to GROUP 32, Engine Mount 332). Valve timing belt tension adjustment 8. Valve timing belt 9. Timing belt tensioner pulley 10. Timing belt tensioner arm 11. Timing belt tensioner adjuster

>>G<< <>

>>F<< >>E<< >>D<<

ENGINE MECHANICAL

11A-36

TIMING BELT

12

22 ± 4 N·m

16 35 ± 6 N·m

21 20

22 ± 4 N·m

13

19 ± 3 N·m

14 (Engine oil) 49 ± 9 N·m

15 18

19

49 ± 9 N·m

17 8.8 ± 1.0 N·m

167 N·m AC300548 AB

<>

Removal steps 12. Power steering fluid pressure switch connector 13. Power steering oil pump assembly 14. A/C compressor connector 15. Power steering oil pump bracket 16. Timing belt idler pulley 17. Crank angle sensor

<>

<>

>>C<< >>C<< >>B<<

18. 19.

>>A<< >>A<<

20. 21.

Removal steps&RQWLQXHG Crankshaft camshaft drive sprocket Crankshaft angle sensing blade Balancer timing belt tension adjustment Balancer timing belt tensioner Balancer timing belt

REMOVAL SERVICE POINTS <> VALVE TIMING BELT REMOVAL

CAUTION Never turn the crankshaft anti-clockwise.

MD998738

Timing mark

Timing belt under cover AC102492 AB

AC102487

1. Turn the crankshaft clockwise, align each timing mark to set No.1 cylinder to TDC of its compression stroke.

2. Remove the timing belt under cover rubber plug and then set the special tool adjusting bolt (MD998738).

ENGINE MECHANICAL

11A-37

TIMING BELT

CAUTION The special tool can be gradually installed at a rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the special tool may bend. Timing belt tensioner arm

MD998738

AC107289 AB

<> POWER STEERING OIL PUMP ASSEMBLY REMOVAL With the hose installed, remove the power steering oil pump assembly from the bracket. NOTE: Secure the removed power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the balancer timing belt. <> CRANKSHAFT CAMSHAFT DRIVE SPROCKET REMOVAL Crankshaft camshaft drive sprocket

MB991385

3. Screw in the special tool until it comes in contact with the timing belt tensioner arm. MB991367

B

A

AC102332 AB

AC102775AB

4. Gradually screw in the special tool. Then align the timing belt tensioner adjuster rod set hole A with the timing belt tensioner adjustor cylinder set hole B. Timing belt tensioner pulley mounting bolt

1. Use the following special tools to support the crankshaft camshaft drive sprocket. Special spanner (MB991367) Pin (MB991385) 2. Loosen the crankshaft pulley centre bolt and remove the crankshaft camshaft drive sprocket. <> BALANCER TIMING BELT REMOVAL

CAUTION To reuse the balancer timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.

INSTALLATION SERVICE POINTS >>A<< BALANCER TIMING BELT/BALANCER TIMING BELT TENSIONER INSTALLATION

Wire

Balancershaft sprocket Belt tension side AC107185 AB

Timing mark

Timing mark

5. Insert a wire, etc.in the set hole.

CAUTION To reuse the valve timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk. 6. After removal of adjusting bolt special tool, loosen the timing belt tensioner pulley mounting bolt and remove the valve timing belt.

Crankshaft balancershaft drive sprocket

AC102689 AB

1. Ensure that the crankshaft balancershaft drive sprocket timing marks and balancershaft sprocket timing marks are aligned.

ENGINE MECHANICAL

11A-38

TIMING BELT

2. Install the balancer timing belt on the crankshaft balancershaft drive sprocket and balancershaft sprocket. There should be no slack on the tension side. Centre of the mounting bolt

1. With your fingers, lift the balancer timing belt tensioner in the direction of the arrow. Apply pressure of 3.0 0.4 N¼m to the balancer timing belt. Tighten the assembling bolt to the specified torque. Then, fix the balancer timing belt tensioner. Tightening torque: 19 3 N¼m Balancershaft sprocket

Timing mark

Centre of the pulley

Timing mark

AC102690 AB

3. Assemble and temporarily fix the centre of the pulley of the balancer timing belt tensioner so that it is at the top left from the centre of the mounting bolt, and the pulley flange is at the front-side of the engine. 4. Adjust the balancer timing belt tension. >>B<< BALANCER TIMING BELT TENSION ADJUSTMENT

CAUTION When tightening the mounting bolt, ensure that the tensioner does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension of the belt.

AC102691

Crankshaft balancershaft drive sprocket

AC102689AC

2. Turn the crankshaft clockwise two turns to set No.1 cylinder to TDC of its compression stroke and check that the sprocket timing marks are aligned.

ENGINE MECHANICAL

11A-39

TIMING BELT

Approximately 100 N

Deflection

AC102693 AB

3. Apply a pressure of approximately 100N at the centre (arrow area) between the sprocket as shown, then inspect whether the belt deflection is within the standard value. Standard value: At adjustment: 5 - 7 mm At replacement: 5 - 7 mm 4. If not within the standard value, adjust the belt tension again. >>C<< CRANKSHAFT ANGLE SENSING BLADE/ CRANKSHAFT CAMSHAFT DRIVE SPROCKET INSTALLATION : Clean : Clean and degrease : Apply engine oil

2. Install the crankshaft angle sensing blade and crankshaft camshaft drive sprocket in the direction shown. 3. Place the larger chamfer side of the crank shaft pulley washer in the direction shown and then assemble on the crankshaft pulley centre bolt. 4. Apply some engine oil to the crankshaft pulley centre bolt bearing surface and screw. Crankshaft camshaft drive sprocket

MB991367

AC102332 AB

5. Use the following special tool as during removal to support the crankshaft camshaft drive sprocket. Special spanner (MB991367) Pin (MB991385) 6. Tighten the crankshaft pulley centre bolts to the specified torque. Tightening torque: 167 N¼m >>D<< TIMING BELT TENSIONER ADJUSTER INSTALLATION 1. Install according to the following procedures when the timing belt tensioner adjuster rod is fully extended.

Crankshaft pulley center bolt Crankshaft camshaft drive sprocket

CAUTION Crankshaft

If the compression is too fast, the procedure may damage the rod. A

Crankshaft pulley washer Engine front

MB991385

B

Crankshaft angle sensing blade AC211535AB

1. Clean or degrease the crankshaft, the crankshaft angle sensing blade, the crankshaft camshaft drive sprocket and crankshaft pulley washer as shown. NOTE: Also clean the degreased surfaces.

AC102334 AB

(1) Slowly compress the timing belt tensioner adjuster rod using a press or vice, then align the set hole A of the rod with set hole B of the timing belt tensioner adjuster cylinder.

ENGINE MECHANICAL

11A-40

TIMING BELT

>>F<< VALVE TIMING BELT INSTALLATION Wire Timing mark

AC102335 AB

(2) Insert a wire or pin into the aligned set hole. NOTE: When replacing the timing belt tensioner adjuster with new parts, the timing belt tensioner adjuster is set with a pin. 2. Assemble the timing belt tensioner adjuster to the engine, then tighten the assembling bolt to the specified torque. Do not remove the wire or pin until the tension of the valve timing belt is adjusted. Tightening torque: 23 3 N¼m

Camshaft sprocket

Crankshaft camshaft drive sprocket

Timing mark Timing mark

>>E<< TIMING BELT TENSIONER PULLEY INSTALLATION

Engine oil pump sprocket

AC102486 AC

1. Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket. Bolt Balancershaft

Timing belt tensioner pulley hole

Plug AC102336AB

Temporarily tighten the timing belt tensioner pulley as shown.

Cylinder block AC102337 AE

2. Adjust the timing mark of the engine oil pump sprocket. Unplug the cylinder block plug. Insert a bolt (M6 sectional width 10 mm, minor diameter 45 mm) from the plug hole and then check. If the bolt comes in contact with the balancer shaft turn the sprocket one rotation. Re-adjust the timing mark and then check to see that the bolt fits. Do not remove the bolt until the valve timing belt is assembled.

ENGINE MECHANICAL TIMING BELT

3. Install the valve timing belt as follows: Inlet side camshaft sprocket

11A-41


Exhaust side camshaft sprocket

AC201802 AB

Timing belt tensioner pulley


Timing belt idler pulley

(3) Use two wrenches to align the timing mark on the rocker cover with that on the camshaft sprocket. Pass the valve timing belt around the inlet-side camshaft sprocket.


AC102488 AC

(1) Pass the valve timing belt around the crankshaft camshaft drive sprocket, the engine oil pump sprocket and the timing belt idler pulley in that order.

Paper clip

AC201803AB

(4) Hold the valve timing belt with paper clips. (5) Pass the valve timing belt around the timing belt tensioner pulley.

CAUTION Paper clip

Incorporate the valve timing belt. Then apply reverse rotation (anti-clockwise rotation) pressure to the cam shaft sprocket. Re-check to see that each timing mark is aligned while the tension side of the belt is tight. (6) Remove the two paper clips.

AC201801AB

(2) Pass the valve timing belt around the exhaustside camshaft sprocket, and hold the valve timing belt with paper clip. MD998767

AC102694 AB

4. Turn the timing belt tensioner in the direction shown using special tool tensioner wrench (MD998767) to apply tension to the valve timing belt. Then pre-tighten the timing belt tensioner pulley. 5. Check that the timing marks are aligned.

ENGINE MECHANICAL

11A-42

TIMING BELT Bolt Balancershaft

CAUTION When tightening the mounting bolt, ensure that the timing belt tensioner pulley does not rotate with the bolt. Allowing it to rotate with the bolt can cause deficient tension of the belt.

Plug Cylinder block AC102337 AE

6. Remove the bolt inserted in Step 2 above, then assemble the cylinder block plug. 7. Tighten the cylinder block plug to the specified torque. Tightening torque: 30 3 N¼m 8. Adjust the valve timing belt tension. >>G<< VALVE TIMING BELT TENSION ADJUSTMENT

MD998767

AC102695AB

6. With special tool tensioner wrench (MD998767) and torque wrench, apply tension torque 3.5 N¼m, and tighten the timing belt tensioner pulley mounting bolt to the specified torque. Tightening torque: 48 5 N¼m

MD998738

Wire


1. Set special tool adjusting bolt (MD998738) when removing the valve timing belt.

CAUTION Always screw in special tool by hand, since use of a spanner or other tools may damage the wire or pin inserted in the timing belt tensioner adjuster. 2. Gradually screw in special tool until the wire or pin inserted in the timing belt tensioner adjuster lightly moves. 3. Turn the crankshaft 1/4 turn anti-clockwise. 4. Turn the crankshaft in the clockwise direction until you align each timing mark to set No.1 cylinder to TDC of its compression stroke. 5. Loosen the timing belt tensioner pulley mounting bolt.

AC102776 AB

7. Remove wire or pin inserted to timing belt tensioner.

MD998738


8. Remove the special tool adjusting bolt (MD998738), and install the rubber plug to the timing belt under cover. 9. Rotate the crankshaft clockwise two turns, and leave it for about 15 minutes.

ENGINE MECHANICAL

11A-43

TIMING BELT

CAUTION Always check the tightening torque of the crank shaft pulley centre bolt when turning the crack shaft pulley centre bolt anti-clockwise. Retighten if it is loose.

Wire

Timing mark

AC102776 AB

10.Insert wire or pin removed in Step 7 again, and ensure that it can be pulled out easily. When wire or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or pin.

Camshaft sprocket


A

Timing belt tensioner adjuster


AC102338AB

If the projection of timing belt tensioner adjuster rod is within the standard value, appropriate tension is applied. Standard value (A): 3.8 - 4.5 mm 11.If wire or pin cannot be easily pulled out, repeat Step 1 through Step 9 to reach proper valve timing belt tension.


AC201411AB

12.Check again that the timing marks on sprockets are aligned. >>H<< END CAP INSTALLATION

CAUTION Always replace the end cap with new parts since there may be fall-off or sealing defect if the end cap is re-used.


TIMING BELT TENSIONER ADJUSTER CHECK 1. Check for oil leak from seal, and replace it if leak is detected. 2. Check for wear or damage at the top of the rod. Replace it, if required.

ENGINE MECHANICAL

11A-44

TIMING BELT

98 – 196 N

Movement

BALANCER TIMING BELT TENSION CHECK Check the balancer timing belt tension as follows:

A

B Approximately 100 N

Rod

Timing belt tensioner adjuster AC102339 AB

3. Hold the timing belt tensioner adjuster by hand, and press the top end of the rod onto the metal (e.g. cylinder block) under a pressure of 98 - 196 N to measure the movement of the rod. Standard value: Within 1 mm A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement 4. If the measured value is out of the standard value, replace the timing belt tensioner adjuster.

Deflection

AC102693 AB

1. Apply a pressure of approximately 100 N at the centre (arrow area) between the sprocket as shown then inspect whether the deflection is within the standard value. Standard value: 5 - 10 mm 2. If not within the standard value, adjust the belt tension. (Refer to 311A).

ENGINE MECHANICAL ENGINE ASSEMBLY

11A-45

ENGINE ASSEMBLY REMOVAL AND INSTALLATION M1112001000720

CAUTION *: indicates parts which should be temporarily tightened, and then fully tightened with the engine weight applied on the vehicle body. Pre-removal Operation Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) 313A.] Hood Removal (Refer to GROUP 42, Hood 342). Under Cover Removal (Refer to GROUP 51, Under Cover 351). Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner 315). Battery and Battery Tray Removal Rocker Cover Centre Cover Removal (Refer to 311A ). Radiator Assembly Removal (Refer to GROUP 14, Radiator 314). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Starter Assembly Removal (Refer to GROUP 16, Starter Motor Assembly 316).

Post-installation Operation Starter Assembly Installation (Refer to GROUP 16, Starter Motor Assembly 316). Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Radiator Assembly Installation (Refer to GROUP 14, Radiator 314). Battery and Battery Tray Installation Rocker Cover Centre Cover Installation (Refer to 311A ). Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner 315). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement 312). Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Check and Adjustment 317). Drive Belt Tension Check (Refer to 311A). Under Cover Installation (Refer to GROUP 51, Under Cover 351). Hood Installation (Refer to GROUP 42, Hood 342). Fuel Leak Check

ENGINE MECHANICAL

11A-46

ENGINE ASSEMBLY

9 5.0 ± 1.0 N·m

10

17

12

7 5

6 14

8

5.0 ± 1.0 N·m

4

15 11

9.0 ± 2.0 N·m

13

3

2 1

9.0 ± 2.0 N·m

18 5.0 ± 1.0 N·m

16

9.0 ± 2.0 N·m 5.0 ± 1.0 N·m

1. 2. 3. 4. 5. 6. 7. 8. 9.

Removal steps A/C compressor connector Power steering fluid pressure switch connector Crank angle sensor connector Ignition coil connectors Detonation sensor connector Purge control solenoid valve connector EGR control solenoid valve connector Injector connectors Throttle position sensor connector

10. 11. 12. 13. 14.

<>

15. 16. 17. 18.

AC300549 AB

Removal steps&RQWLQXHG Idle speed control servo connector Camshaft position sensor connector Oxygen sensor connector Engine coolant temperature sensor connector Engine coolant temperature gauge unit connector Capacitor connector Battery wiring harness connection Accelerator cable connection Drive belt

ENGINE MECHANICAL

11A-47

ENGINE ASSEMBLY

23 24 19

25 5.0 ± 1.0 N·m

26 N

(Engine oil)

12 ± 2 N·m

20 44 ± 10 N·m*

22 ± 4 N·m

27

N

22 22 ± 4 N·m

45 ± 5 N·m*

29 28 21 AC300550 AB

<> <>

Removal steps 19. Brake booster vacuum hose connection 20. Canister vacuum hose connection 21. A/C compressor and clutch assembly 22. Power steering oil pump assembly 23. Heater water hoses connection 24. Fuel return line hose connection

>>E<< <> <> <>

>>E<< >>D<< >>C<< >>B<< >>A<<

Removal steps&RQWLQXHG 25. Fuel high-pressure hose connection 26. O-ring Transmission assembly 27. Self-locking nuts 28. Engine front mounting bracket 29. Engine assembly

ENGINE MECHANICAL

11A-48

ENGINE ASSEMBLY


<> TRANSMISSION ASSEMBLY REMOVAL

<> DRIVE BELT REMOVAL The following operations will be needed due to the serpentine drive system with the drive belt autotensioner. Auto-tensioner

AC300950AB

Hole B

Hole A

AC107640AC


CAUTION To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.

1. Pre-tighten the 2 bolts on the car to assemble the radiator support upper insulator to set the special tools engine hanger MB991895 or engine hanger MB991928. 2. Remove the transmission assembly (Refer to GROUP 22A, Transmission Assembly 322A). <> ENGINE FRONT MOUNTING BRACKET REMOVAL 1. Support the engine with a garage jack. 2. Remove the following special tool. MB991895 MB991527

Auto-tensioner

L-shaped hexagon wrench

MB991454 AC107631AB AC107641AB

2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt. <> A/C COMPRESSOR AND CLUTCH ASSEMBLY/POWER STEERING OIL PUMP ASSEMBLY REMOVAL With the hose installed, remove the A/C compressor and clutch assembly, and power steering oil pump assembly from the bracket. NOTE: Secure the removed A/C compressor and clutch assembly, and power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the engine assembly.

(1) Remove special tool MB991895. MB991928

MB991527 MB991454 AC211405 AB

(2) Remove special tool MB991928.

ENGINE MECHANICAL

11A-49

ENGINE ASSEMBLY

2. Support the engine assembly with a garage jack. 3. Remove the chain block. 4. Use the following special tool as during removal to support the engine.

MB991454 MB991527

MB991895 MB991527

AC107632 AB

3. Hold the engine assembly with a chain block, etc. 4. Place a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine assembly is no longer being applied to the engine front mounting bracket. 5. Loosen the engine front mounting bracket mounting nuts and bolt, and remove the engine front mounting bracket.

MB991454 AC107631AB

(1) Set special tool MB991895. (Refer to GROUP 22A, Transmission Assembly 322A).

<> ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.

MB991928

MB991527

INSTALLATION SERVICE POINTS >>A<< ENGINE ASSEMBLY INSTALLATION

MB991454 AC211405 AB

(2) Set special tool MB991928 (Refer to GROUP 22A, Transmission Assembly 322A).

MB991454 MB991527

>>C<< SELF-LOCKING NUTS INSTALLATION

CAUTION Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.

Do not tighten the self-locking nuts while the engine is hot. Tighten the self-locking nuts to the specified torque while the engine is cold. Tightening torque: 45 5 N¼m

>>B<< ENGINE FRONT MOUNTING BRACKET INSTALLATION 1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine front mounting bracket while adjusting the position of the engine.

>>D<< TRANSMISSION ASSEMBLY INSTALLATION 1. Install the transmission assembly (Refer to GROUP 22A, Transmission Assembly 322A).

AC107632 AB

ENGINE MECHANICAL

11A-50

ENGINE ASSEMBLY

>>E<< O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION

AC300950AB

2. Remove from the car the 2 bolts, to assemble the radiator support upper insulator.

Do not let any engine oil get into the delivery pipe. 1. Apply a small amount of new engine oil to the Oring. 2. Turning the fuel high-pressure hose to the right and left, install it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage. After this, re-insert it to the delivery pipe and check that the hose turns smoothly. 4. Tighten the fuel high-pressure hose mounting bolts to the specified torque. Tightening torque: 5.0 1.0 N¼m

11-1

GROUP 11

ENGINE

00 11 12 13

CONTENTS

14 15 16

ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A

17

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

127(6

22A-1

GROUP 22A

00 11

MANUAL TRANSMISSION

12 13 14 15 16

CONTENTS

17 GENERAL INFORMATION . . . . . . . . LUBRICANT. . . . . . . . . . . . . . . . . . . .

22A 22A

SPECIAL TOOLS. . . . . . . . . . . . . . . .

22A


22A

TRANSMISSION OIL LEVEL CHECK . . . .

22A

TRANSMISSION OIL REPLACEMENT . . .

22A

TRANSFER OIL CHECK . . . . . . . . . . . . . .

22A

TRANSFER OIL REPLACEMENT . . . . . . .

22A

TRANSMISSION CONTROL . . . . . . .

22A


22A

SHIFT LEVER ASSEMBLY . . . . . . . . . . . . .

22A

DISASSEMBLY AND REASSEMBLY . . . . .

22A

TRANSFER ASSEMBLY . . . . . . . . . .

22A


22A

TRANSMISSION ASSEMBLY . . . . . . 22A REMOVAL AND INSTALLATION . . . . . . . .

22A

21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

MANUAL TRANSMISSION

22A-2

GENERAL INFORMATION


The manual transmission come in two models, namely, F5M42 and W5M42. Item

Specification

Transmission model

F5M42 (2WD)

Engine model

4G63-DOHC-MPI

Transmission type

5-speed forward, 1-speed reverse constant mesh

Transmission gear ratio

W5M42 (4WD)

1st

3.583

3.583

2nd

1.947

1.947

3rd

1.379

1.379

4th

1.030

1.030

5th

0.820

0.820

Reverse

3.363

3.363

Final reduction ration (Differential gear ratio)

4.625

4.687

Speedometer gear ratio

31/36

31/36


Item

Specified lubricant

Quantity L

Transmission oil

Gear oil SAE 75W-90 or 75W-85W conforming to API GL-4

2.2 <2WD> 2.3 <4WD>

Transfer oil

Hypoid gear oil API classification GL-5 SAE90

0.53

MANUAL TRANSMISSION

22A-3

SPECIAL TOOLS


Tool

Number

Name

Use

MB991453

Engine hanger assembly

MB991454

Engine hanger balancer

When the engine hanger is used: Supporting the engine assembly during removal and installation of the transmission assembly NOTE: Special tool MB991454 is a part of engine hanger attachment set MB991453.

MB991527

Engine hanger

MB991895

Engine hanger

B991453

B991454

B991527

MB991895

MB991928 A: MB991929 B: MB991930 E C: MB991931 D: MB991932 E: MB991933 F: MB991934

Slide bracket (HI)

F A

D B C

B991928

Engine hanger A: Joint (50) 2 B: Joint (90) 2 C: Joint (140) 2 D: Foot (standard) 4 E: Foot (short) 2 F: Chain and hook assembly

MANUAL TRANSMISSION

22A-4

ON-VEHICLE SERVICE

ON-VEHICLE SERVICE TRANSMISSION OIL LEVEL CHECK

TRANSFER OIL CHECK

M1221000900446

M1221001100089

Filler plug hole

Filler plug hole

Transmission oil

Filler plug

Filler plug

Transfer oil

AC210553 AB

AC210553AC

1. Remove the filler plug. 2. Check that the oil level is up to the lower edge of the filler plug hole. 3. Check that the oil is not noticeably dirty. 4. Tighten the filler plug to the specified torque. Tightening torque: 32 2 N¼m

1. Remove the filler plug. 2. Check that the oil level is up to the lower edge of the filler plug hole. 3. Check that the oil is not noticeably dirty. 4. Tighten the filler plug to the specified torque. Tightening torque: 32 2 N¼m

TRANSMISSION OIL REPLACEMENT

TRANSFER OIL REPLACEMENT

M1221001000350

M1221001200064

Filler plug Filler plug

Drain plug AC210554 AB

1. Remove the filler plug. 2. Remove the drain plug and drain the oil. 3. Tighten the drain plug to the specified torque. Tightening torque: 32 2 N¼m 4. Fill with gear oil API classification GL-4 SAE 75W85W or 75W-90 until the level comes to the lower portion of filler plug hole. Quantity: 2.2 L <2WD> Quantity: 2.3 L <4WD> 5. Tighten the filler plug to the specified torque. Tightening torque: 32 2 N¼m

Drain plug AC210555 AB

1. Remove the filler plug. 2. Remove the drain plug and drain the oil. 3. Tighten the drain plug to the specified torque. Tightening torque: 32 2 N¼m 4. Fill with hypoid gear oil API classification GL-5 SAE90 until the level comes to the lower portion of filler plug hole. Quantity: 0.53 L 5. Tighten the filler plug to the specified torque. Tightening torque: 32 2 N¼m

MANUAL TRANSMISSION

22A-5

TRANSMISSION CONTROL

TRANSMISSION CONTROL REMOVAL AND INSTALLATION M1221003800523

WARNING Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift cable and select cable assembly. Pre-removal and Post-installation Operation Air Cleaner Assembly Removal and Installation (Refer to GROUP 15, Air Cleaner 315). Battery and Battery Tray Removal and Installation.

7

11 9

12 ± 2 N·m

10 N

8

3

4

7

5

6.0 ± 1.5 N·m

1

2 6

12 ± 2 N·m

12 AC210284AB

1. 2. 3.

>>B<<

4. 5.

<> >>A<< <> >>A<<

6. 7. 8. 9.

Gearshift cable and select cable assembly removal steps Gearshift lever knob Front floor console (Refer to GROUP 52A 352A). Snap pin Select cable connection (Gearshift lever side) Gearshift cable clip Gearshift cable connection (Gearshift lever side) SRS-ECU (Refer to GROUP 52B 352B). Console side cover bracket Snap pin Gearshift link clip Select cable connection (Transmission side)

<> >>A<< >>A<<

>>B<<

Gearshift cable and select cable assembly removal steps 10. Gearshift cable connection (Transmission side) 11. Gearshift cable and select cable assembly Gearshift lever assembly removal steps 1. Gearshift lever knob Front floor console (Refer to GROUP 52A 352A). 2. Snap pin 3. Select cable connection (Gearshift lever side) 4. Gearshift cable clip 5. Gearshift cable connection (Gearshift lever side) 12. Gearshift lever assembly

MANUAL TRANSMISSION

22A-6



CAUTION

<> GEARSHIFT LINK CLIP/SELECT CABLE CONNECTION (TRANSMISSION SIDE)/GEAR SHIFT CABLE CONNECTION (TRANSMISSION SIDE) REMOVAL

New gearshift link clip

Gearshift cable, Select cable

Claws

Cable bracket

Shift cable, Select cable Gearshift link clip AC210556 AB

Push up the claws of the gearshift link clip using a screwdriver, etc., and then remove the gearshift link clip from the bracket together with the cables.

INSTALLATION SERVICE POINTS >>A<< GEARSHIFT CABLE AND SELECT CABLE ASSEMBLY/GEARSHIFT CABLE CONNECTION (TRANSMISSION SIDE)/SELECT CABLE CONECTION (TRANSMISSION SIDE)/GEARSHIFT LINK CLIP INSTALLATION Select lever

AC210558 AB

Insert thoroughly the gearshift link clip, shift cable and select cable until they click in place. 3. After installing the new gearshift link clip to the cable bracket of the transmission, install the shift cable and select cable to the cable bracket. NOTE: The clip is reversible. 4. Move the shift lever to all positions and check that the operation is smooth. >>B<< GEAR SHIFT CABLE CLIP INSTALLATION

Neutral position

AC210557AB

1. Set the transmission side shift lever and the passenger compartment side shift lever to the neutral position. 2. Install the painted part of the shift cable end (transmission side) and painted part of the select cable (transmission side) facing the snap pin.

9.5 mm

5 - 8 mm AC210559AB

1. Make sure that there is no excessive play at the shift cable end gearshift cable clip. If there is excessive play or the gearshift cable clip is disengaged from the shift cable end, check the clip opening gap. If the gap is more than 9.5 mm, squeeze the gearshift cable clip until the relaxed gap reaches 5 to 8 mm.

MANUAL TRANSMISSION

22A-7


3. Install the shift cable to the shift lever.

AC210560 AB

2. Engage the gearshift cable clip with the shift cable hook securely, and push the gearshift cable clip with your thumbs until it clicks in place.

SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY M1221004000177

7

8

9 14 ± 2 N·m

1

3

9

4 3 2

6 5 10 ± 1 N·m

12

11 10 AC210285 AB

1. 2. 3. 4. 5. 6. 7.

Disassembly steps Gearshift link bolt Gearshift select lever Gearshift link bushing Gearshift lever spring Gearshift link collar Bolt Gearshift lever retainer

Disassembly steps&RQWLQXHG 8. Gearshift lever 9. Gearshift link bushing 10. Gearshift lever bracket distance piece 11. Gearshift link bushing 12. Gearshift lever bracket

MANUAL TRANSMISSION

22A-8

TRANSFER ASSEMBLY

TRANSFER ASSEMBLY REMOVAL AND INSTALLATION M1221003200037

CAUTION *: Indicates parts which should be temporarily tightened, and then fully tightened after installing the engine into the vehicle. Pre-removal and Post-installation Operation Front Under Cover Removal and Installation (Refer to GROUP 51, Front Bumper 351). Side Under Cover Removal and Installation (Refer to GROUP 51, Front Bumper 351). Engine Coolant Draining and Supplying (Refer to GROUP 14, On-vehicle Service 314). Transfer Oil Draining and Supplying (Refer to 322A). Drive Shaft, Output Shaft Removal and Installation (Refer to GROUP 26 326). Front Exhaust Pipe Removal and Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Propeller Shaft Removal and Installation (Refer to GROUP 25 325).

10 3 69 ± 10 N·m

9.0 ± 2.0 N·m

7

8N

9

N

4

30 ± 3 N·m

69 ± 10 N·m 52 ± 7 N·m

5 N

9.0 ± 2.0 N·m

2 1

52 ± 7 N·m

30 ± 3 N·m

6 69 ± 10 N·m 69 ± 10 N·m

1. 2. 3. 4. 5.

Removal steps Water feed tube assembly Gasket Water return tube assembly Gasket Rear roll stopper connection bolt

<>

AC210286 AB

Removal steps&RQWLQXHG 6. Centre member assembly 7. Transfer assembly 8. O-ring 9. Water feed hose 10. Water return hose

MANUAL TRANSMISSION TRANSFER ASSEMBLY

REMOVAL SERVICE POINTS <> TRANSFER ASSEMBLY REMOVAL

Engine and Transmission assembly Transfer assembly

AC207772 AC

With the engine mount and transmission assembly towards the front of the vehicle, and remove the transfer assembly from between the engine block and crossmember.

22A-9

MANUAL TRANSMISSION

22A-10

TRANSMISSION ASSEMBLY

TRANSMISSION ASSEMBLY REMOVAL AND INSTALLATION M1221002700222

CAUTION *: Indicates parts which should be temporarily tightened, and then fully tightened after installing the engine into the vehicle. Pre-removal and Post-installation Operation Air Cleaner assembly, Air Cleaner Bracket Removal and Installation (Refer to GROUP 15, Air Cleaner 315). Battery and Battery Tray Removal and Installation. Front Under Cover Removal and Installation (Refer to GROUP 51, Front Bumper 351). Side Under Cover Removal and Installation (Refer to GROUP 51, Front Bumper 351). Transfer Oil Draining and Supplying <4WD> (Refer to 322A). Drive Shaft Removal and Installation (Refer to GROUP 26 326). Output Shaft Removal and Installation <4WD> (Refer to GROUP 26 326). Front Exhaust Pipe Removal and Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Propeller Shaft Removal and Installation <4WD> (Refer to GROUP 25 325). 18 ± 3 N·m

18 ± 3 N·m

6

5

5 18 ± 3 N·m

4

1 2

3 7 70 ± 10 N·m <2WD> 70 ± 10 N·m

8

<4WD>

7 70 ± 10 N·m AC210287AB

1. 2. 3. 4. 5.

Removal steps Transmission harness clamp Back-up lamp switch connector Vehicle speed sensor connector Clutch release cylinder and clutch oil pipe Snap pin

6.

7.

Removal steps&RQWLQXHG Cable bracket and cable assembly Transfer assembly (Refer to 322A). Rear roll mount bracket

MANUAL TRANSMISSION

22A-11

TRANSMISSION ASSEMBLY 8.

<>

Removal steps&RQWLQXHG Rear roll mount adapter bracket <4WD> Engine and transmission assembly supporting

47 ± 7 N·m*

48 ± 5 N·m 48 ± 5 N·m

82 ± 7 N·m*

9 48 ± 5 N·m

9 48 ± 5 N·m

9

11 12 10

11

48 ± 5 N·m

15 13

<4WD>

16

44 ± 10 N·m

14 <2WD>

22 ± 4 N·m 9.0 ± 1.0 N·m

14

26 ± 5 N·m 9.0 ± 1.0 N·m AC210288 AB

Removal steps Transmission assembly upper part coupling bolts Starter coupling bolts (Refer to GROUP 16 316.) 10. Transmission mount assembly 11. Transmission mount stopper 12. Transmission mount bracket 9.

<> >>B<<

<> <> >>A<<

Removal steps&RQWLQXHG Engine assembly supporting Clutch release bearing connection Transmission stay <4WD> Bell housing cover Transmission assembly lower part coupling bolts 16. Transmission assembly

13. 14. 15.

MANUAL TRANSMISSION

22A-12


REMOVAL SERVICE POINTS <> ENGINE AND TRANSMISSION ASSEMBLY SUPPORTING/TRANSMISSION MOUNT ASSEMBLY REMOVAL

Front Side Slide Bracket (HI)

Joint (90) (MB991930)

Engine and transmission assembly

Foot (Standard) Joint (50) (MB991932) (MB991929) Foot (Standard) (MB991932) AC212277AB

Garage jack

AC210384 AB

While supporting the engine and transmission assembly with a garage jack, remove the transmission mount assembly.

2. (1) Assemble the engine hanger (special tool MB991928). Set following parts to the base hanger. Slide bracket (HI) Foot (standard) (MB991932) Joint (90) (MB991930) Joint (50) (MB991929)

<> ENGINE ASSEMBLY SUPPORT

AC210400 AB AC210400 AB

MB991895

MB991928

Slide Bracket (HI)

MB991929

MB991527 MB991934 MB991932 MB991454 MB991454 AC210388 AB

1. (1) Set special tool MB991895 to the strut mounting nuts and the radiator support upper insulator mounting bolts, which are located in the engine compartment, as shown. (2) Set special tools MB991454 to hold the engine/transmission assembly.

MB991930 MB991932 MB991527

AC210392 AB

(2) Set the engine hanger (special tool MB991928) to the strut mounting nuts and the radiator support upper insulator mounting bolts, which are located in the engine compartment, as shown. NOTE: Adjust the engine hanger balance by sliding the slide bracket (HI). (3) Set special tools MB991454 to hold the engine/transmission assembly.

MANUAL TRANSMISSION

22A-13


<> CLUTCH RELEASE BEARING SEPARATION

CAUTION B

A Release Fork

CAUTION Be sure to push the release fork in the direction A before inserting a screwdriver. 3. Separate the release bearing from the wedge collar by prying with the screwdriver (turning the screwdriver grip 90). NOTE: The release fork is forced to move fully in the direction B by the return spring as soon as it is separated from the wedge collar.


Service Hole

Wedge Collar

Release Bearing

AC210561AB

If it is hard to turn the screwdriver (to pry off the release bearing), remove the screwdriver once and repeat the below procedure after pushing the release fork fully in the direction a two or three times. Forcibly prying can cause the release bearing to be damaged. 1. Remove the cover from the service hole in the clutch housing. 2. While pushing the release fork by hand in the direction A, insert a flap-tip screwdriver between the release bearing and the wedge collar.

>>A<< TRANSMISSION STAY INSTALLATION Install the transmission stay as below. 1. Tighten the engine-side bolts to the specified torque. Tightening torque: 22 4 N¼m 2. Tighten the transmission-side bolts to the specified torque. Tightening torque: 44 10 N¼m >>B<< TRANSMISSION MOUNT STOPPER INSTALLATION Engine side Arrow

Transmission mount stopper

Transmission mount bracket

AC210408 AB

Install the transmission mount stopper so that the arrow points as shown in the illustration.

127(6

54A-1

GROUP 54A

00 11

CHASSIS ELECTRICAL

12 13 14 15

CONTENTS BATTERY. . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS. . . . . ON-VEHICLE SERVICE. . . . . . . . . FLUID LEVEL AND SPECIFIC GRAVITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING . . . . . . . . . . . . . . . . . . . . . . BATTERY TEST . . . . . . . . . . . . . . . . . .

54A 54A 54A 54A 54A 54A

IGNITION SWITCH* . . . . . . . . . .

54A

SPECIAL TOOLS. . . . . . . . . . . . . .

54A

INTRODUCTION . . . . . . . . . . . . . .

54A

TROUBLESHOOTING . . . . . . . . . .

54A


54A

HOW TO REGISTER ENCRYPTED CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSPONDER LOCK CHECK . . . . . .

54A 54A

16

IGNITION SWITCH . . . . . . . . . . . . . REMOVAL AND INSTALLATION. . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .

COMBINATION METER ASSEMBLY . . . . . . . . . . . . . . .

54A 54A 54A

17 21 22

54A

25 26


54A

SEALANT . . . . . . . . . . . . . . . . . . . .

54A

SPECIAL TOOLS . . . . . . . . . . . . . .

54A

32


54A

33


54A 54A 54A 54A 54A

27

SPEEDOMETER CHECK . . . . . . . . . . . TACHOMETER CHECK. . . . . . . . . . . . . FUEL GAUGE UNIT CHECK <2WD> . . FUEL GAUGE UNIT CHECK <4WD> . . ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK . . . . . . . . . . . . . .

54A


31

34 35 36 37 42 51

:$51,1*65(*$5',1*6(59,&,1*2)6833/(0(17$/5(675$,176<67(0656 (48,33('9(+,&/(6

WARNING (1)

Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from rendering the SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRSrelated component. NOTE The SRS includes the following components: front impact sensors, SRS-ECU, SRS warning lamp, air bag module, clock spring and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

52 54 55

54A-2 COMBINATION METER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . DISASSEMBLY AND ASSEMBLY . . . . .

REAR FOG LAMP . . . . . . . . . . . . . 54A 54A 54A

REMOVAL AND INSTALLATION. . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .

54A 54A 54A

SIDE TURN SIGNAL LAMP . . .

54A

SPECIAL TOOL . . . . . . . . . . . . . . .

54A

SIDE TURN SIGNAL LAMP. . . . . .

54A 54A

HEADLAMP . . . . . . . . . . . . . . .

54A

SERVICE SPECIFICATIONS . . . .

54A

TROUBLESHOOTING . . . . . . . . .

54A

ON-VEHICLE SERVICE . . . . . . . .

54A 54A

ROOM LAMP . . . . . . . . . . . . . .

54A

54A 54A


54A

REAR COMBINATION LAMP .

54A

REAR COMBINATION LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . .

54A

SPECIAL TOOL . . . . . . . . . . . . . . .

54A

REAR COMBINATION LAMP . . . .

54A 54A

HEADLAMP AIMING . . . . . . . . . . . . . . . . LUMINOUS INTENSITY MEASUREMENT. . . . . . . . . . . . . . . . . . . BULB REPLACEMENT . . . . . . . . . . . . . .

HEADLAMP. . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . .

HEADLAMP LEVELING SWITCH REMOVAL AND INSTALLATION . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . .

54A 54A 54A 54A 54A

FOG LAMP . . . . . . . . . . . . . . . .

54A


54A

SPECIAL TOOL . . . . . . . . . . . . . .

54A


54A

ON-VEHICLE SERVICE . . . . . . . .

54A 54A

FOG LAMP AIMING . . . . . . . . . . . . . . . .



HIGH MOUNTED STOP LAMP HIGH MOUNTED STOP LAMP . . . REMOVAL AND INSTALLATION. . . . . .

LICENCE PLATE LAMP. . . . . . LICENCE PLATE LAMP . . . . . . . .

FOG LAMP . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . .

FOG LAMP SWITCH. . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . .

REAR FOG LAMP . . . . . . . . . .

54A 54A 54A 54A 54A

54A


54A

SPECIAL TOOL . . . . . . . . . . . . . .

54A


54A 54A 54A

54A 54A 54A

HAZARD WARNING LAMP SWITCH . . . . . . . . . . . . . . . . . .

54A


54A

SPECIAL TOOL . . . . . . . . . . . . . . .

54A

HAZARD WARNING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION. . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .

54A 54A 54A


54A-3 COLUMN SWITCH. . . . . . . . . . . . . . . 54A SPECIAL TOOL . . . . . . . . . . . . . . . COLUMN SWITCH. . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .

54A 54A 54A 54A

HORN . . . . . . . . . . . . . . . . . . . . . 54A

RHEOSTAT . . . . . . . . . . . . . . . RHEOSTAT. . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION. . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .

SPEAKER. . . . . . . . . . . . . . . . . SPEAKER . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION. . . . . .

HORN . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .

54A 54A 54A

CLOCK. . . . . . . . . . . . . . . . . . . . 54A SPECIAL TOOL . . . . . . . . . . . . . . .

54A

CLOCK. . . . . . . . . . . . . . . . . . . . . .

54A 54A


CIGARETTE LIGHTER . . . . . . . 54A INSPECTION . . . . . . . . . . . . . . . . .

54A

ACCESSORY SOCKET. . . . . . . 54A SPECIAL TOOL . . . . . . . . . . . . . . .

54A

ACCESSORY SOCKET. . . . . . . . .

54A 54A 54A

REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .

ANTENNA . . . . . . . . . . . . . . . . ANTENNA. . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION. . . . . .

REAR WINDOW DEFOGGER .

54A 54A 54A 54A

54A 54A 54A

54A 54A 54A

54A


54A


54A


54A 54A

PRINTED HEATER LINES CHECK . . . .

REAR WINDOW DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION. . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .

54A 54A 54A

CHASSIS ELECTRICAL

54A-4

BATTERY

BATTERY SERVICE SPECIFICATIONS M1541000300179

Items

Specification

Specific gravity of the battery fluid

1.220 - 1.290 (20C)

ON-VEHICLE SERVICE

CHARGING M1541001100468

FLUID LEVEL AND SPECIFIC GRAVITY CHECK M1541001000416

Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks.

CAUTION If the battery fluid is below the LOWER LEVEL, the battery could explode in using. If the battery fluid is over the UPPER LEVEL, leakage could result. Therometer

Hydrometer

Battery fluid

AC211242AB

1. Use a hydrometer and thermometer to check the specific gravity of the battery fluid. Standard value: 1.220 - 1.290 (20C) 2. The specific gravity of the battery fluid varies with the temperature, so use the following formula to calculate the specific gravity for 20C. Use the calculated value to determine whether or not the specific gravity is satisfactory. D20 = (t-20) X 0.0007 + Dt D20: Specific gravity of the battery fluid calculated for 20C Dt: Actually measured specific gravity t: Actually measured temperature Battery type Capacity (5-hour rate) 75D23L

53 A

3. Determine when charging is finished. When the specific gravity of the battery electrolyte is constantly within 1.250 - 1.290 for a continuous period of one hour or more.

CAUTION The battery plus should be removed during charging. The battery electrolyte level may rise and overflow from the battery during charging. Explosions may occur if the battery is brought close to naked flames during charging. After charging is complete, replace the battery plus, pour water over the battery to rinse away any sulphuric acid, and let the battery stand to dry. Do not let the battery electrolyte temperature rise above approximately 45C (approximately 55C during rapid charging). 1. Remove the battery from the vehicle. 2. The normal charging current is a value in amperes which is 1/10th of the battery capacity. If the battery needs to be charged rapidly because of reasons such as time limitations, the maximum charging current for rapid charging is the battery capacity expressed as an ampere value.

Normal charging current Rapid charging current 5.3 A

53 A

When the voltage per cell during charging is 2.5 V constantly for a continuous period of one hour more.

CHASSIS ELECTRICAL

54A-5

BATTERY

BATTERY TEST

STEP 4. Check the open circuit voltage. (1) Turn headlamps on for 15 seconds. (2) Turn headlamps off for two minutes to allow battery positive voltage to stabilize. (3) Disconnect the battery cables. (4) Read open circuit voltage.

M1541001200465

BATTERY TESTING PROCEDURE STEP 1. Check the battery cables. Remove the negative cable, then the positive cable. Check for dirty or corroded connections.

Q: Is open circuit voltage 12.4 volts or more? YES : Go to Step 6. NO : Go to Step 5.

Q: Are the battery cables dirty or have corroded connections? YES : Clean the battery cables. Then go to Step 2. NO : Go to Step 2.

STEP 5. Charge battery. Q: Charging the battery? YES : Go to Step 6. NO : Charge the battery at 5 amps for 15 hours.

STEP 2. Check the battery post. Check for loose battery post. Q: Are the battery post faulty? YES : Replace the battery. Then go to Step 4. NO : Go to Step 3.

Then re-test, go to Step 4. STEP 6. Check the load test. (1) Connect a load tester to the battery. (2) Load the battery at the recommended discharge rate (See LOAD TEST RATE CHART) for 15 seconds. (3) Read voltage after 15 seconds, then remove load. (4) Compare the measured value with the minimum voltage. (See LOAD TEST CHART.)

STEP 3. Check the battery case and cover. (1) Remove the hold-downs and shields. (2) Check for broken/cracked case or cover. Q: Is the battery case or cover faulty? YES : Replace the battery. Then go to Step 4. NO : Go to Step 4.

Q: Is the voltage higher than minimum voltage? NO : Replace the battery. Then go to Step 4. YES : The battery is normal.

LOAD TEST CHART Temperature C 21 and above

16

10

4

-1

-7

-12

-18

Minimum voltage

9.5

9.4

9.3

9.1

8.9

8.7

8.5

9.6

LOAD TEST RATE CHART Battery type

75D23L

Charging time when fully discharged h (5amp. rated current charging)

11

Load test (Amps)

275

CHASSIS ELECTRICAL

54A-6

IGNITION SWITCH

IGNITION SWITCH SPECIAL TOOLS M1543000601492

Tool

Number

Name

Use

MB991502

MUT-II sub assembly

Immobilizer system check Encrypted code registration

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe

Making voltage and resistance measurements during troubleshooting A: Connect pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection

B991502

A

B

C

D MB991223 AC

INTRODUCTION

IMMOBILIZER SYSTEM M1543009901230

IGNITION KEY REMINDER BUZZER The ignition key reminder buzzer will sound under the following condition, and warn the driver to remove the ignition key. The driver’s door is opened when the ignition switch is at "LOCK" (OFF) or "ACC" position without removing the ignition key. However, the lamp reminder buzzer will take precedence over this function.

DOOR LOCK PREVENTION FUNCTION If the key is left in the ignition switch while the driver’s door opened or the assistant door opened, all door are automatically unlock to prevent locking the ignition key in the vehicle after door is locked.

The immobilizer system consists of the ignition key, the immobilizer-ECU with key ring antenna, and the engine-ECU. The ignition key has a built-in transponder. Only the registered ignition key permits the engine to start, therefore, the engine can never be started by means of a forged key or by connecting the ignition wiring directly. The system is significantly safe and reliable against theft. In addition, the driver has only to turn the ignition switch to the "ON" position to activate the immobilizer system. If the requirements for starting the engine are not satisfied, the engine will be immobilized. If a registered ignition key is lost, all your ignition keys need to be registered again using MUT-II to ensure security (Refer to 354A). An additional ignition key can be registered as follows (only if no ignition keys are lost): Using MUT-II (Refer to 354A).

CHASSIS ELECTRICAL

54A-7

IGNITION SWITCH

OPERATION 1. When the ignition switch is turned to "ON" position, the engine-ECU sends a requirement for the encrypted code to the immobilizer-ECU (at this time, the engine is remobilized). 2. When the immobilizer-ECU receives the requirement from the engine-ECU, the immobilizer-ECU supplies power to the transponder inside the ignition key via the antenna. The energized transponder sends the encrypted code back to the immobilizer-ECU via the antenna.

3. The immobilizer-ECU judges the encrypted code with its code logic in itself. If they are identical, the immobilizer-ECU sends the encrypted code to the engine-ECU. 4. If the engine-ECU can not receive the encrypted code, the engine will be immobilized.

Immobilizer-ECU with an antenna Ignition key

Power (Wireress)

Control signal

Engine-ECU Injector

CPU

CPU

Encrypted code

Ignition Memory

Transponder

Encrypted code (Wireless)

MUT-II

Steering lock

AC206892 AD

TROUBLESHOOTING

IMMOBILIZER SYSTEM DIAGNOSIS

IGNITION KEY REMINDER BUZZER AND DOOR LOCK PREVENTION FUNCTION DIAGNOSIS

DIAGNOSIS CODE CHART

M1543000700935

The ignition key reminder buzzers are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Diagnosis 354B. Using SWS monitor: GROUP 54C, SWS Diagnosis 354C. Diagnosis code No. Diagnosis item

M1543007100376

CAUTION During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) disconnected. On completion, confirm all systems for diagnosis code code(s). If diagnosis code code(s) are set, erase them all. Use the following chart to develop proper diagnostic strategy. Reference page

11

Transponder communication system or radio interference of encrypted code

354A.

12

Encrypted codes are not the same or are not registered

354A.

CHASSIS ELECTRICAL

54A-8

IGNITION SWITCH

DIAGNOSTIC TROUBLE CODE PROCEDURES

Code No.11: Transponder Communication System or Radio Interference of Encrypted Code

Ignition Key Ring and Immobilizer-ECU Circuit IMMOBILIZER-ECU

HIGH FREQUENCY CIRCUIT

C-304-1

IGNITION KEY RING ANTENNA

TRANSPONDER

IGNITION KEY

AC300911AB

DIAGNOSIS CODE SET CONDITION Diagnosis code No.11 may be output if other ignition keys are in the vicinity of the vehicle as it is being started. The transponder’s encrypted code is not sent to the immobilizer-ECU immediately after the ignition switch is turned to "ON" position. NOTE: Diagnosis code No.11 is always output together with MPI system diagnosis code No.P1610. TROUBLESHOOTING HINTS Radio interference of the encrypted code Malfunction of the transponder Malfunction of the immobilizer-ECU.

DIAGNOSIS PROCEDURE STEP 1. Check for presence of other key near the key in the ignition. Q: Is there any other key near the key in the ignition? YES : Move the other key well away from key

being used. Retest the system. NO : Go to Step 2.

STEP 2. Check that the engine start using the spare ignition key which encrypted code has been registered. Q: Does the engine start using the spare ignition key for which the encrypted code has been registered? YES : Replace the ignition key that does not work.

Then register the password (secret code) and encrypted code 354A. Retest the system. NO : Go to Step 3. STEP 3. Check the diagnosis code. Q: Which diagnosis code is set, code No.11 or 12? the encrypted code has been registered? Code No.12 is set : Refer to354A. Code No.11 is set : Go to Step 4.

CHASSIS ELECTRICAL

54A-9

IGNITION SWITCH

STEP 4. Connector check: Immobilizer-ECU connector C-304-1. Connector: C-304-1 C-304-1

Harness side AC211664AB

Q: Are immobilizer-ECU connector C-304-1 in good condition? YES : Replace immobilizer-ECU and Then

register the password (secret cod) and encrypted code. Retest the system. NO : Repair or replace the damage component(s).

Code No.12: Encrypted Codes are Not identical or not Registered DIAGNOSIS CODE SET CONDITION The encrypted code sent by the transponder is not the same encrypted code which is registered in the immobilizer-ECU. NOTE: Diagnosis code No.12 is always output together with MPI system diagnosis code No.P1610. TROUBLESHOOTING HINTS The encrypted code in the ignition key has not been properly registered Malfunction of immobilizer-ECU.

DIAGNOSIS PROCEDURE Was the encrypted code registered? YES : Replace the immobilizer-ECU and then re-

register the encrypted code (Refer to 354A ). NO : Register the encrypted code (Refer to 354A).

SYMPTOM CHART M1543007200986

Symptom

Inspection procedure No.

Reference page

Communication with MUT-II is impossible

1

354A

The ignition key cannot be registered

2

354A

Engine cranks but does not start

3

354A

CHASSIS ELECTRICAL

54A-10

IGNITION SWITCH

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Communication with MUT-II is Impossible.

ENGINE CONTROL RELAY

POWER SOURCE

IMMOBILIZERECU

ENGINE-ECU

Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

SB : Sky blue AC301596AB

TECHNICAL DESCRIPTION (COMMENT) This malfunction may be caused by a defective immobilizer-ECU, engine-ECU, or a defect in the communication line between the immobilizerECU and engine-ECU. If this malfunction appears when the MPI system and MUT-II can communicate each other, MPI system diagnosis code No.P1610 will reset. If the MPI system is normal, the engine control relay can be determined as normal. In addition, if the MPI system and MUT-II can communicate each other, the circuits between the diagnosis connector and the engine-ECU can determined as normal.

NOTE: If this malfunction appears, MPI system diagnosis code No.P1610 will be output. TROUBLESHOOTING HINTS Malfunction of the immobilizer-ECU Malfunction of the engine-ECU The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector

CHASSIS ELECTRICAL

54A-11

IGNITION SWITCH

DIAGNOSIS PROCEDURE STEP 1. Check if MUT-II can communicate with the MPI system and if an MPI system diagnosis code other than P1610 is set. Q: Can MUT-II communicate with the MPI system? Is an MPI system diagnosis code other than P1610 set? YES : Go to Step 2. NO : Refer to GROUP 13A, MPI Diagnosis

STEP 3. Connector check: Immobilizer-ECU connector C-304-1 and engine control relay connector B-17X Connector: B-17X

Relay box side

313A. STEP 2. Measure the voltage at immobilizer-ECU connector C-304-1.

AC211667AB

Connector: C-304-1

Connector: C-304-1 C-304-1 C-304-1

Harness side Harness side AC211664AB AC211664AB

(1) Disconnect immobilizer-ECU connector C-304-1. (2) Turn the ignition switch to the "ON" position. C-304-1 Harness connector: Component side

component(s). Confirm that MUT-II communicates normally.

AC212142 AB

(3) Measure the voltage between terminal 1 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 3.

Q: Are immobilizer-ECU connector C-304-1 and engine control relay connector B-17X in good condition? YES : Go to Step 4. NO : Repair or replace the damaged

CHASSIS ELECTRICAL

54A-12

IGNITION SWITCH

STEP 4. Check the harness wires between immobilizer-ECU connector C-304-1 (terminal 1) and engine control relay connector B-17X (terminal 1).

NOTE: Connectors: C-17, C-106

Connector: B-17X

C-106(GR)

Relay box side

C-17(GR) C-17

AC211667AB

Connector: C-304-1

C-106

C-304-1

Harness side

AC212135AB

AC211664AB

Connector: C-304

Harness side

C-304 AC212136AB

Prior to the wiring harness inspection, check intermediate connector C-106, joint connector C-17 and key reminder switch connector C-304, and repair if necessary. Q: Are the harness wires between immobilizer-ECU connector C-304-1 (terminal 1) and engine control relay connector B-17X (terminal 1) in good condition? YES : There is no action to be taken. NO : Replace damaged component(s). Confirm

that MUT-II communicates normally.

CHASSIS ELECTRICAL

54A-13

IGNITION SWITCH

STEP 5. Measure the resistance at immobilizerECU connector C-304-1. Connector: C-304-1

STEP 7. Check the harness wire between immobilizer-ECU connector C-304-1 (terminal 4) and earth. Connector: C-304-1

C-304-1 C-304-1

Harness side Harness side AC211664AB AC211664AB

(1) Disconnect immobilizer-ECU connector C-304-1. NOTE: C-304-1 Harness connector: Component side

Connector: C-304

Harness side

C-304 AC212143AB

AC212136AB

(2) Measure the resistance between terminal 4 and earth. OK: 2 ohms or less

Prior to the wiring harness inspection, check key reminder switch connector C-304, and repair if necessary.

Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 6.

Q: Is the harness wire between immobilizer-ECU connector C-304-1 (terminal 4) and earth in good condition? YES : There is no action to be taken. NO : Repair or replace the damaged

STEP 6. Connector check: immobilizer-ECU connector C-304-1 Connector: C-304-1 C-304-1


Q: Is immobilizer-ECU connector C-304-1 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged



CHASSIS ELECTRICAL

54A-14

IGNITION SWITCH

STEP 8. Connector check: immobilizer-ECU connector C-304-1 and engine-ECU connector C136 Connector: C-136

STEP 9. Check the harness wires between immobilizer-ECU connector C-304-1 (terminal 3) and engine-ECU connector C-136 (terminal 51). Connector: C-136

Harness side

C-136

Harness side

C-136

AC300688AB

Connector: C-304-1

AC300688AB

Connector: C-304-1 C-304-1

C-304-1

Harness side


Q: Are immobilizer-ECU connector C-304-1 and engine-ECU connector C-136 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged

AC211664AB

NOTE: Connector: C-104


C-104 AC300232 AB

Connector: C-304

Harness side

C-304 AC212136AB

Prior to the wiring harness inspection, check key reminder switch connector C-304, intermediate connector C-104, and repair if necessary.

CHASSIS ELECTRICAL IGNITION SWITCH Q: Are the harness wires between immobilizer-ECU connector C-304-1 (terminal 3) and engine-ECU connector C-136 (terminal 51) in good condition? YES : Go to Step 10. NO : Repair or replace the damaged

component(s). Confirm that MUT-II communicates normally. STEP 10. Replace the immobilizer-ECU or engine-ECU. Replace the immobilizer-ECU.

54A-15

STEP 11. Recheck for malfunction. Q: Is a malfunction eliminated? YES : The procedure is complete. (If no

malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope with Intermittent Malfunction 300). NO : Replace the engine-ECU.

Q: Did the communication with MUT-II become possible after replacing the immobilizer-ECU? YES : Register the password (secret code) and

encrypted code 354A. Confirm that MUT-II communicates normally NO : Go to Step 11.

INSPECTION PROCEDURE 2: The Ignition Key cannot be Registered. TECHNICAL DESCRIPTION (COMMENT) The ignition key transponder or the immobilizer-ECU is suspected to be defective. TROUBLESHOOTING HINTS Malfunction of the ignition key Malfunction of immobilizer-ECU DIAGNOSIS PROCEDURE STEP 1. Check for diagnosis code.

STEP 2. Retest the system. Q: Does registered ignition key function properly? YES : The procedure is complete. (If no

malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope with Intermittent Malfunction 300). NO : Replace the immobilizer-ECU.

Q: Does diagnosis code No.11 reset? YES : Refer to 354A. NO : Replace the ignition key that cannot be

registered. Then re-register the encrypted code. (Refer to 354A). Verify that the ignition key can be registered, then Go to Step 2.

INSPECTION PROCEDURE 3: Engine does not Start (Cranking but no Initial Combustion). TECHNICAL DESCRIPTION (COMMENT) If the fuel injectors are not operating, there might be a problem with the MPI system in addition to a malfunction of the immobilizer system. It is normal for this to occur if an attempt is made to start the engine using a key that has not been properly registered. TROUBLESHOOTING HINTS Malfunction of MPI system Malfunction of immobilizer-ECU

DIAGNOSIS PROCEDURE STEP 1. Check the system voltage. Measure the system voltage during cranking. Q: Is the voltage 8 volts or more? YES : Go to Step 2. NO : Check the battery. Refer to 354A. The

engine should start.

CHASSIS ELECTRICAL

54A-16

IGNITION SWITCH

STEP 2. Check the immobilizer system diagnosis code and MPI system diagnosis code. Q: Which diagnosis code resets, the immobilizer system diagnosis code or the MPI system diagnosis code? Immobilizer system diagnosis code is set : Refer

STEP 3. Check the starting system. Q: Does the engine start? YES : Go to Step 4. NO : Refer to GROUP 13A, Diagnosis -

Symptom Chart 313A. If the malfunction is not resolved, replace the immobilizer-ECU. Then register the password (secret code) and encrypted code. (Refer to 354A.) The engine should start.

to 354A. MPI system diagnosis code is set : Refer to

GROUP 13A, Diagnosis 313A. No diagnosis code is set : Go to Step 3.

STEP 4. Retest the system Q: Is the malfunction eliminated? YES : The procedure is complete. (If no

malfunction are not found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points-How to Cope with Intermittent Malfunction 300.) NO : Replace the immobilizer-ECU.

DATA LIST REFERENCE TABLE M1543007300295

Item No.

Inspection item

Inspection requirement

Normal condition

01

Key has been registered

-

Number of registered ignition keys

CHECK AT IMMOBILIZER-ECU M1543007600434

TERMINAL VOLTAGE CHECK

AC212297AB

Terminal No.

Signal

Inspection condition

Terminal voltage

1

Immobilizer-ECU power supply

Ignition switch: "LOCK" (OFF)

0V

Ignition switch: "ON"

System voltage

2

-

-

-

3

Engine-ECU

-

-

4

Immobilizer-ECU earth

Always

0V

CHASSIS ELECTRICAL

54A-17

IGNITION SWITCH

ON-VEHICLE SERVICE

Registration with the MUT-II

HOW TO REGISTER ENCRYPTED CODE

To prevent damage to MUT-II, always turn the ignition switch to "LOCK" (OFF) position before connecting or disconnecting MUT-II. NOTE: . Using the key ID register function will cause all key IDs that have been previously registered in the immobilizer-ECU to be erased. All keys need to be registered. Those which have been registered before should be on hand before using this function. If registering more than one key, do not disconnect MUT-II halfway through the registration process. After registering key IDs, check that the engine can be started using all of the keys that have been registered. If the engine will not start, refer to Immobilizer System Diagnosis 354A.

M1543008100391

CAUTION Because registering the encrypted codes is done after all previously-registered codes have been erased, you should keep all of the ignition keys that have already been registered accessible. If the ignition key, Immobilizer-ECU, engine-ECU is replaced or an ignition key is added, encrypted codes of all the ignition keys must be registered. (A maximum of eight different ignition key can be registered.) Moreover, when the immobilizer-ECU has been replaced, you will need to use MUT-II to register the immobilizer-ECU and input the vehicle secret code and to register the password (secret code) that the owner specifies into the immobilizerECU. If an attempt is made to start the engine with an unregistered ignition key, cranking occurs, but fuel supply is cut off to disable the engine. In approximately. NOTE: Engine-ECU has an encrypted code for immobilizer-ECU, and the encrypted code is registered in the immobilizer-ECU and ignition key.

CAUTION

16-PIN

POINTS TO NOTE DURING OPERATION If none of the functions can be used, check the diagnosis codes, and after carrying out any necessary repairs, repeat the operation. If an incorrect password is input ten times in a row, the immobilizer-ECU judges that an unauthorized operation is being attempted. Start-prevention mode will be set, and engine operation will stop and all special functions will be disabled. If the ignition switch is turned to "ON" position, "Unauthorized operation, startprevention mode" will be cancelled.

MB991502 AC300380 AB

1. Connect MUT-II to diagnosis connector (16- pin). 2. Turn the ignition switch to "ON" position.

KEY ID (ENCRYPTED CODE) REGISTRATION All ignition keys can be registered with MUT-II. Additional ignition keys can be registered with MUTII.

AC000522AD

3. At "System Select," press "YES"

CHASSIS ELECTRICAL

54A-18

IGNITION SWITCH

AC000523AC

4. Select "Immobilizer," press "YES".

AC000530AC

ACX01626 AC

7. Input the password. Use the "UP" and "DOWN" keys to change the current password digit to a value between 0 and 9. Use the "LEFT" and "RIGHT" keys to move to a different password digit. Press the "YES" key to accept the password. If an incorrect password is input five times in a row, this screen is displayed and the immobilizerECU switches to unauthorized operation, startprevention mode. NOTE: Four separate digits must be input to make up the password.

5. Select "Special Func", press "YES". If diagnosis code No.11 exists, "Can’t execute" will be displayed. Check for diagnosis code No.11(Refer to 354A.)

ACX01561 AD

8. Press the "YES" key to start key ID registration.

AC000518 AC

ACX01562 AC

ACX01558 AG

6. Select "key ID register", press "YES".

9. This will be displayed when the key ID registration is successful. If an error occurs during key ID registration, the message "Can’t execute" will be displayed. If the key has already been registered, "Key ID has been registered" will be displayed.

CHASSIS ELECTRICAL

54A-19

IGNITION SWITCH

16-PIN

MB991502 ACX01563 AC

AC300380 AB

10.The number of keys currently registered will be displayed. To register an additional key, replace the ignition key with the next key to be registered within five seconds and then press the "YES" key. Key ID registration screen will be displayed, then register another key. If key ID registration is complete, press the "NO" key. NOTE: A maximum of eight different keys can be registered. 11.This completes the registration operation. Turn the ignition switch "LOCK" (OFF) and leave it off for approximately ten seconds. 12.Check that the engine can be started with each of the ignition keys. 13.Check that the immobilizer system diagnosis code and MPI system diagnosis code did not set. 14.Turn the ignition switch to "LOCK" (OFF) position. 15.Disconnect MUT-II.

1. Connect MUT-II (MB991502) to the 16-pin diagnosis connector. 2. Turn the ignition switch to "ON" position.

AC000522AD

3. At "System Select," press "YES"

Registration of additional keys with the MUT-II Additional key(s) can be registered with the MUT-II while keeping all existing key data.

CAUTION To prevent damage to MUT-II, always turn the ignition switch to "LOCK" (OFF) position before connecting or disconnecting MUT-II. NOTE: To register additional keys with the MUT-II, no registered keys must be lost.

AC000523AC


AC000530AC

5. Select "Special Func", press "YES". If diagnosis code No.11 exists, "Can’t execute" will be displayed. Check for diagnosis code No.11(Refer to 354A.)

CHASSIS ELECTRICAL

54A-20

IGNITION SWITCH

AC101476 AB

AC000518 AC

AC101478 AB

6. Select "Add key ID reg", press "YES".

9. The number of keys currently registered will be displayed. To register an additional key, replace the ignition key with the next key to be registered within five seconds and then press the "YES" key. Key ID registration screen will be displayed, then register another key. NOTE: A maximum of eight different keys can be registered. If key ID registration is complete, press the "NO" key. 10.This completes the registration operation. Turn the ignition switch "LOCK" (OFF) and leave it off for approximately ten seconds. 11.Check that the engine can be started with each of the ignition keys. 12.Check that the immobilizer system diagnosis code and MPI system diagnosis code did not set. 13.Turn the ignition switch to "LOCK" (OFF) position. 14.Disconnect MUT-II.

TRANSPONDER LOCK CHECK M1543024100090 AC101477 AB

7. Press the "YES" key to start key ID registration. 8. This will be displayed when the add key ID registration is successful. If an error occurs during key ID registration, the message "Can’t execute" will be displayed. If the key has already been registered, "Key ID has been registered" will be displayed.

Follow the procedure below to judge if the ignition key can be overwritten (i.e. the ignition key is correct) or not.

16-PIN

MB991502 AC300380 AB

1. Connect MUT-II to the 16-pin diagnosis connector. 2. Turn the ignition switch to "ON" position.

CHASSIS ELECTRICAL

54A-21

IGNITION SWITCH

AC000522AD

3. At "System Select," press "YES."

AC106459 AD

5. Select "Data list" press "YES".

AC000523AC


AC106460 AB

6. Confirm "TP LOCK CHECK." TP Lock Check Ignition Key:

Judgment Of Ignition Key

UNLOCK

Can be overwritten

Correct

LOCK

Can not be overwritten

Incorrect

CHASSIS ELECTRICAL

54A-22

IGNITION SWITCH

IGNITION SWITCH REMOVAL AND INSTALLATION M1543002100401

WARNING

Before removal of the air bag module, refer to GROUP 52B, SRS Service Precautions and

Air Bag Module and Clock Spring 352B. When removing and installing the steering wheel, do not let it bump against the air bag module. Section A – A

3

Claw

4 3

2.5 ± 0.5 N·m

A A

2 5 1 7 6

1.5 ± 0.5 N·m

NOTE : Claw position

2.5 ± 0.5 N·m

8 9 4

AC300001 AB AC300451

Removal steps 1. Instrument lower panel (Refer to GROUP 52A, Instrument panel 352A ) 2. Steering wheel (Refer to GROUP 37A, Steering wheel 337)

Removal steps&RQWLQXHG 3. Column cover upper 4. Column cover lower

CHASSIS ELECTRICAL

54A-23

IGNITION SWITCH Removal steps&RQWLQXHG 5. Clock spring and column switch assembly (Refer to GROUP 52B, Air bag modules and clock spring 352B ) 6. Steering lock cylinder Ignition switch connector 7. Ignition switch Key reminder switch connector

<>

REMOVAL SERVICE POINT <> STEERING LOCK CYLINDER REMOVAL

Removal steps&RQWLQXHG 8. Key reminder switch and bulb assembly 9. Immobilizer-ECU

Switch position

Tester connection

Specified condition

"LOCK" (OFF)

1 - 2, 1 - 3, 1 - 4, 1- 5, 1 - 6, 2 - 3, 2 - 4, 2- 5, 2 - 6, 3 - 4, 3- 5, 3 - 6, 4- 5, 4 - 6, 5-6

Open circuit

"ACC"

1-6

Less than 2 ohms

"ON"

1 - 2, 1 - 4, 1 - 6, 2 - 4, 2 - 6, 4 - 6

Less than 2 ohms

"START"

1 - 2, 1 - 5, 2-5

Less than 2 ohms

Lock pin AC200314 AB

1. Insert the key in the steering lock cylinder and turn it to the "ACC" position. 2. Using a small Phillips head screwdriver, pull the steering lock cylinder toward you.


IGNITION SWITCH CONTINUITY CHECK

KEY REMINDER SWITCH CONTINUITY CHECK

1 2 3 4 5 6 1 2 3 4 5 6 7

AC200316 AB

Disconnect ignition switch connector C-303 without removing the ignition switch. Then check the continuity.

AC200315 AB

Disconnect key reminder switch connector C-304 without removing the ignition switch and key reminder switch. Then check the continuity. Status of ignition key

Tester connection

Specified condition

Removed

4-6

Less than 2 ohms

Inserted

4-6

Open circuit

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COMBINATION METER ASSEMBLY

COMBINATION METER ASSEMBLY SERVICE SPECIFICATIONS M1543000300294

Item

Standard value

Speedometer indication error km/h

Tachometer indication error r/min

Fuel gauge unit resistance W

2WD

20

20 - 24

40

40 - 44

80

80 - 86

120

122 - 128

160

163 - 170

200

204 - 212

700

700 100

2,000

2,000 100

3,000

3,000 150

4,000

4,000 200

5,000

5,000 250

6,250

6,250 150

Float position F (highest) 3.0 0.6 Float position E (lowest) 110 2.5

4WD

Fuel pump and gauge unit

Float position F (highest) 1.5 0.5

Fuel gauge unit

Float position F (highest) 1.5 0.5

Float position E (lowest) 55 1.5 Float position E (lowest) 55 1.5

Fuel gauge unit float height mm

2WD 4WD

Float position F (A)

35.4 2

Float position E (B)

186.7 2

Fuel pump and gauge unit

Float position F (At)

36.7 2


149.6 2

Fuel gauge unit

Float position F (A)

23.4 2


194.2 2

Engine coolant temperature gauge unit resistance W

SEALANT M1543024600017

Item

Specified sealant

Engine coolant temperature gauge unit

3M 1215 or equivalent

104 + 13.5 (at 70C)

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Tool

Number

Name

Use

MB990784

Ornament remover

Removal of instrument panel driver’s side garnish and meter bezel.

MB991502

MUT-II sub assembly

Reading MPI system diagnosis code

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222


Making voltage and resistance measurements during troubleshooting A: Connect pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection

MB990784

B991502

A

B

C

D MB991223 AC

TROUBLESHOOTING SYMPTOM CHART M1543007200997

Symptom


Reference page

Speedometer does not work (the other meters work).

1

354A

Tachometer does not work (the other meters work).

2

354A

Fuel gauge does not work (the other meters work).

3

354A

Engine coolant temperature gauge does not work (the other meters work).

4

354A

Combination meters does not work (the instruments do not work).

5

354A

CHASSIS ELECTRICAL

54A-26


SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Speedometer does not work (the other meters work.)

IGNITION SWITCH (IG1)

COMBINATION METER

CONTROL CIRCUIT

VEHICLE SPEED SENSOR

DIAGNOSIS CONNECTOR FRONT SIDE

ENGINE-ECU


SB : Sky blue

AC301597AB

TECHNICAL DESCRIPTION (COMMENT) The engine-ECU and its associated components, the combination meter assembly, the wiring harness, or the connector(s) may be defective.

TROUBLESHOOTING HINTS Malfunction of the engine-ECU Malfunction of the combination meter assembly The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector.

CHASSIS ELECTRICAL

54A-27


DIAGNOSIS PROCEDURE

STEP 3. Check the wiring harness between combination meter connector C-04 (terminal 46) and diagnosis connector C-24 (terminal 14). NOTE:

STEP 1. Check the speedometer.

Connectors: C-02, C-04, C-24 C-04

C-02 16-PIN

MB991502 AC300380 AB

C-24(B)

(1) Connect the MUT-II to the diagnosis connector. (2) Use the MUT-II to enter simulated vehicle speed. Q: Does the speedometer show that simulated vehicle speed? YES : Go to Step 5 NO : Go to Step 2

C-02

C-04 harness side

C-24

STEP 2. Connector check: Combination meter connector C-04 and diagnosis connector C-24 Connectors: C-04, C-24

AC210823 AB

Prior to the wiring harness inspection, joint connector C-02, and repair if necessary.

C-04

Q: Is the wiring harness between combination meter connector C-04 (terminal 46) and diagnosis connector C-24 (terminal 14) in good condition? YES : Go to Step 4 NO : Repair or replace the damage

component(s).

C-24(B)

STEP 4. Retest the system.

C-04 harness side

Q: Is the speedometer normal? YES : The procedure is complete. (If no

malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points-How to Cope with Intermittent Malfunction 300). NO : Replace the combination meter assembly.

C-24

AC210822 AB

Q: Is combination meter connector C-04 and diagnosis connector C-24 in good condition? YES : Go to Step 3 NO : Repair or replace the damage

component(s).

STEP 5. Read diagnosis code by using the MUTII. Q: Is the MPI-related diagnosis code set? YES : Refer to GROUP 13A - Troubleshooting

313A. NO : Go to Step 6

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STEP6. Connector check: Joint connector C-02 and engine-ECU connector C-137 Connector: C-02

STEP 7. Check the wiring harness between joint connector C-02 (terminal 25) and engine-ECU connector C-137 (terminal 86). Connector: C-02

C-02 C-02

AC210824 AB AC210824 AB

Connector: C-137

C-137

Harness side

Connector: C-137

Harness side

AC300691AB

C-137

Q: Is joint connector C-02 and engine-ECU connector C-137 in good condition? YES : Go to Step 7 NO : Repair or replace the damage

AC300691AB


component(s).

C-105 C-16 (L) C-16

C-105

AC300692 AB

Prior to the wiring harness inspection, check intermediate connectors C-105, joint connectors C16 and repair if necessary.

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COMBINATION METER ASSEMBLY Q: Is the wiring harness between joint connector C-02 (terminal 25) and engine-ECU connector C-137 (terminal 86) in good condition? YES : Go to Step 8 NO : Repair or replace the damage

component(s).

STEP 9. Pulse check Use the MUT-II or a voltmeter to check that the vehicle speed signal is received. System switch

Check conditions

Vehicle speed signal

When the vehicle speed has reached 10 km/h or more


OK: The MUT-II sounds or the voltmeter needle fluctuates.

Q: Is the speedometer normal? YES : The procedure is complete. (If no

malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points-How to Cope with Intermittent Malfunction 300). NO : Go to Step 9.

Q: Is the check result normal? YES : Replace the combination meter assembly. NO : Replace the engine-ECU.

INSPECTION PROCEDURE 2: Tachometer does not work (the other meters work.)

COMBINATION METER

CONTROL CIRCUIT

ENGINE-ECU


SB : Sky blue

AC301769AB

TECHNICAL DESCRIPTION (COMMENT) Ignition signal may not be received from the engineECU, or the combination meter assembly, the wiring harness, or the connector(s) may be defective.

TROUBLESHOOTING HINTS Malfunction of the combination meter assembly The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector.

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DIAGNOSIS PROCEDURE STEP 1. Using MUT-Il, read MPI diagnosis code. Q: Is the MPI-related diagnosis code set? Code No.P0300 is set : Refer to GROUP 13A -

STEP 4. Check the wiring harness between combination meter connector C-04 (terminal 47) and engine-ECU connector C-136 (terminal 58) Connector: C-04 C-04

Troubleshooting 313A. NO : Go to Step 2

Harness side

STEP 2. Connector check: Combination meter connector C-04 and engine-ECU connector C-136 Connector: C-04 AC210827AB

C-04 Harness side

Connector: C-136 Harness side

AC210827AB


C-136

AC300688AB


C-136

AC300688AB

Q: Is combination meter connector C-04 and engineECU connector C-136 in good condition? YES : Go to Step 3 NO : Repair or replace the damage

component(s). STEP 3. Retest the system. Q: Is the tachometer normal? YES : Intermittent Malfunction. Refer to GROUP

00, How to Use Troubleshooting/Inspection Service Points-How to Cope with Intermittent Malfunction 300). NO : Go to Step 4

C-105 AC210826 AB

Prior to the wiring harness inspection, check intermediate connector C-105, and repair if necessary. Q: Is the wiring harness between combination meter connector C-04 (terminal 47) and engine-ECU connector C-136 (terminal 58) in good condition? YES : Replace the combination meter assembly. NO : Repair or replace the damage

component(s).

CHASSIS ELECTRICAL COMBINATION METER ASSEMBLY

54A-31

INSPECTION PROCEDURE 3: Fuel gauge does not work (the other meters work.)

Fuel Gauge Circuit COMBINATION METER

CONTROL CIRCUIT

FUEL GAUGE UNIT (SUB) FUEL GAUGE UNIT FUEL PUMP AND GAUGE UNIT (MAIN)

Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet AC301770 AB

TECHNICAL DESCRIPTION (COMMENT) If only the fuel gauge does not operate, fuel gauge unit <2WD>, the fuel pump and gauge unit <4WD>, the combination meter, wiring harness or connector(s) may be defective.

TROUBLESHOOTING HINTS Malfunction of the fuel gauge unit. The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector. Malfunction of the combination meter.

54A-32


DIAGNOSIS PROCEDURE STEP 1. Check the fuel gauge circuit. (1) Disconnect D-15 <2WD> fuel gauge unit connector or D-16 <4WD> fuel pump and gauge unit (main) connector.

STEP 2. Connector check: Combination meter connector C-04, fuel gauge unit connector D-15 <2WD> or fuel pump and gauge unit (main) connector D-16 <4WD> Connector: C-04 C-04 Harness side

MB991219 Test lamp (12 V - 3.4 W) Harness side D-15 <2WD> 3 2 1

Harness side D-16 <4WD>

AC103414 AC AC211647

(2) Connect a test lamp (12 V - 3.4 W) via test harness (MB991219) between the wiring harness connector terminals 1 and 2. (3) Turn the ignition switch to the "ON" position. Q: Does the test lamp illuminate? YES : Go to Step 8. NO : Go to Step 2.

AC210827AB

3 2 1 5 4

Connectors: D-15<2WD>, D-16<4WD> D-15<2WD> harness side 3 2 1

D-15 (B) D-16 (GR)

D-16<4WD> harness side 3 2 1 5 4

AC211648 AB

Q: Is combination meter connector C-04, fuel gauge unit connector D-15 <2WD> or fuel pump and gauge unit (main) connector D-16 <4WD> in good condition? YES : Go to Step 3. NO : Repair or replace the damaged

component(s).

CHASSIS ELECTRICAL

54A-33


STEP 3. Check the wiring harness between combination meter connector C-04 (terminal 43) and fuel gauge unit connector D-15 (terminal 1) <2WD> or fuel pump and gauge unit (main) connector D-16 (terminal 2) <4WD>.

NOTE: Connectors: D-12, D-24

Connectors: C-04, C-117 C-04 D-12

D-24

C-117 D-12 harness side

C-04 harness side

D-24

C-117 AC301594 AB

AC211650AB

Connectors: D-15<2WD>, D-16<4WD> D-15<2WD> harness side 3 2 1

D-15 (B) D-16 (GR)

D-16<4WD> harness side

Prior to the wiring harness inspection, check fuel gauge unit (sub) connector D-12, intermediate connector C-117, D-24, and repair if necessary. Q: Is the wiring harness between combination meter connector C-04 (terminal 43) and fuel gauge unit connector D-15 (terminal 1) <2WD> or fuel pump and gauge unit (main) connector D-16 (terminal 2) <4WD> in good condition? YES : Go to Step 4. NO : Repair or replace the damaged

component(s). Then go to Step 4.

3 2 1 5 4

STEP 4. Retest the system. AC211648 AB

Q: Is the fuel gauge normal? YES : The procedure is complete. (If no


CHASSIS ELECTRICAL

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STEP 5. Connector check: Fuel gauge unit connector D-15 <2WD> or fuel pump and gauge unit (main) D-16 <4WD> Connectors: D-15<2WD>, D-16<4WD> D-15<2WD> harness side 3 2 1

D-15 (B) D-16 (GR)


AC211648 AB

Q: Is fuel gauge unit connector D-15 <2WD> or fuel pump and gauge unit (main) D-16 <4WD> in good condition? YES : Go to Step 6. NO : Repair or replace the damaged

component(s). STEP 6. Check the wiring harness between fuel gauge unit connector D-15 (terminal 2) <2WD> and fuel pump and gauge unit connector D-16 (terminal 1) <4WD> and earth. Connectors: D-15<2WD>, D-16<4WD> D-15<2WD> harness side 3 2 1

D-15 (B) D-16 (GR)


AC211648 AB

NOTE:

Q: Is the wiring harness between fuel gauge unit connector D-15 (terminal 2) <2WD> and fuel pump and gauge unit connector D-16 (terminal 1) <4WD> and earth in good condition? YES : Go to Step 7. NO : Repair or replace the damaged

component(s). STEP 7. Retest the system. Q: Is the fuel gauge normal? YES : The procedure is complete. (If no

malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points-How to Cope with Intermittent Malfunction 300). NO : Carry out the troubleshooting again. STEP 8. Check the fuel gauge circuit. (1) Disconnect D-15 <2WD> fuel gauge unit connector or D-16 <4WD> fuel pump and gauge unit (main) connector.

MB991219 Test lamp (12 V - 3.4 W) Component side D-15 <2WD> 3 2 1

Component side D-16 <4WD> 3 2 1 5 4 AC103414 AC211647 AB

(2) Connect a test lamp (12 V - 3.4 W) via special tool test harness (MB991219) between the wiring harness connector terminals 1 and 2. (3) Turn the ignition switch to the "ON" position. Q: Does the fuel gauge in the combination meter fluctuate about half of it full scale? YES : Replace the fuel gauge unit. NO : Go to Step 9.

Connector: D-24

STEP 9. Retest the system. Q: Is the fuel gauge normal? YES : The procedure is complete. (If no D-24 AC301595 AB

Prior to the wiring harness inspection, check intermediate connectors D-24, and repair if necessary.

malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points-How to Cope with Intermittent Malfunction 300). NO : Replace combination meter.

CHASSIS ELECTRICAL

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INSPECTION PROCEDURE 4: Engine Coolant Temperature Gauge does not Work. (the other meters work.)

COMBINATION METER

CONTROL CIRCUIT

ENGINE COOLANT TEMPERATURE GAUGE UNIT


SB : Sky blue

AC301771AB

TECHNICAL DESCRIPTION (COMMENT) If only the engine coolant temperature gauge does not operate, the combination meter, the wiring harness or its connector may be defective. TROUBLESHOOTING HINTS Malfunction of the engine coolant temperature gauge unit The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector. Malfunction of the combination meter.

DIAGNOSIS PROCEDURE STEP 1. Check the engine coolant temperature gauge circuit. (1) Disconnect the B-109 engine coolant temperature gauge unit connector. Test lamp (12 V 3.4 W - 7.0 W)

Connector

Earth AC102026AD

(2) Connect a test lamp (12 V - 3.4 W to 12 V - 7.0 W) to the wiring harness side connector. (3) Ignition switch: ON Q: Does the test lamp illuminate? YES : Go to Step 5. NO : Go to Step 2.

CHASSIS ELECTRICAL

54A-36


STEP 2. Connector check: Combination meter connector C-04 and engine coolant temperature gauge unit connector B-109 Connector: C-04

STEP 4. Check the wiring harness between combination meter connector C-04 (terminal 44) and engine coolant temperature gauge unit connector B-109 (terminal 1). Connector: C-04

C-04

C-04 Harness side Harness side

AC210827AB AC210827AB

Connector: B-109 Connector: B-109 Harness side Harness side B-109(B) B-109(B) AC211653AC AC211653AC

Q: Is combination meter connector C-04 and engine coolant temperature gauge unit connector B-109 in good condition? YES : Go to Step 3. NO : Repair or replace the damage


component(s). STEP 3. Retest the system. Q: Is the engine coolant temperature gauge normal? YES : The procedure is complete. (If no


C-104(B) AC211655 AB

Prior to the wiring harness inspection, check intermediate connectors C-104, and repair if necessary. Q: Is the wiring harness between combination meter connector C-04 (terminal 44) and engine coolant temperature gauge unit connector B-109 (terminal 1) in good condition? YES : Go to Step 6. NO : Repair or replace the damage

component(s).


STEP 5. Check the engine coolant temperature gauge circuit. (1) Disconnect the B-109 engine coolant temperature gauge unit connector. Test lamp (12 V 3.4 W - 7.0 W)

Connector

Earth AC102026AD

(2) Connect a test lamp (12 V - 3.4 W to 12 V - 7.0 W) to the wiring harness side connector. (3) Ignition switch: ON Q: Does the engine coolant temperature gauge in the combination meter fluctuate about half of it full scale? YES : Replace the engine coolant temperature

gauge unit. NO : Go to Step 6.

54A-37

STEP 6. Retest the system Q: Is the engine coolant temperature gauge normal? YES : The procedure is complete. (If no

malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points-How to Cope with Intermittent Malfunction 300). NO : Replace the combination meter.

CHASSIS ELECTRICAL

54A-38


INSPECTION PROCEDURE 5: Combination meter does not work. (the instruments do not work)

FUSIBLE LINK 1


COMBINATION METER CONTROL CIRCUIT


SB : Sky blue

AC301772 AB

TECHNICAL DESCRIPTION (COMMENT) The cause is thought to be malfunction of the power, earth circuitry or combination meter.

TROUBLESHOOTING HINTS Malfunction of the combination meter Damaged wiring harness or connectors

CHASSIS ELECTRICAL

54A-39


DIAGNOSIS PROCEDURE

STEP 2. Connector check: Combination meter connector C-04 for damage.

STEP 1. Measure the voltage at combination meter connector C-04 in order to check the battery circuit of power supply system to the combination meter.

Connector: C-04 C-04 Harness side

Connector: C-04 C-04 Harness side AC210827AB

AC210827AB

(1) Disconnect the combination meter connector C04 and measure the voltage at combination meter connector C-04 harness side. C-04 Harness side

AC211656AC

(2) Measure the voltage between terminal 34 and earth. OK: System voltage Q: IS the check result normal? YES : Go to Step 4. NO : Go to Step 2.

Q: Is combination meter connector C-04 in good condition? YES : Go to Step 3. NO : Repair or replace the connector. Check to

see that all meters operate.

CHASSIS ELECTRICAL

54A-40


STEP 3. Check the wiring harness between combination meter connector C-04 (terminal 34) and fusible link (1).

NOTE: . Connectors: C-02, C-116

Fusible link (1)

C-02

Fusible link (1)

C-116 AC200715 AE

C-02

Connector: C-04 C-04

C-116 Harness side

AC211668AB AC210827AB

Connectors: C-202, C-204 C-202

C-204(B)

C-202 harness side

C-204 harness side

AC211670 AB

Prior to the wiring harness inspection, check intermediate connectors C-116, junction block connectors C-202 and C-204 and joint connector C02, and repair if necessary. .

CHASSIS ELECTRICAL

54A-41

COMBINATION METER ASSEMBLY Q: Are the wiring harness between combination meter connector C-04 (terminal 34) and fusible link (1) in good condition? YES : There is no action to be taken. NO : Repair or replace the wiring harness. Check

to see that all meters operate. STEP 4. Measure the voltage at combination meter connector C-04 to check the battery circuit of power supply system to the combination meter. Connector: C-04

STEP 5. Connector check: combination meter connector C-04 Connector: C-04 C-04 Harness side

AC210827AB

C-04 Harness side

Q: Is combination meter connector C-04 in good condition? YES : Go to Step 6. NO : Repair or replace the connector. Check to

see that all meters operate.

AC210827AB

(1) Measure at combination meter connector C-04 without disconnecting the connector. (2) Turn the ignition switch to “ON” position. C-04 Harness connector: Component side

AC211674AB


CHASSIS ELECTRICAL

54A-42


STEP 6. Check the wiring harness between combination meter connector C-04 (terminal 42) and ignition switch (IG1). Connector: C-04

STEP 7. Measure the resistance at combination meter connector C-04 to check the earth circuit to the combination meter. Connector: C-04

C-04

C-04 Harness side

Harness side

AC210827AB

AC210827AB

(1) Disconnect the combination meter connector C04 and measure the resistance at combination meter connector C-04.

NOTE: Connectors: C-203, C-205 C-203

C-04 Harness connector

C-205

C-203 harness side AC211676AB

C-205 harness side

AC211675AB

Prior to the wiring harness inspection, check Junction block connectors C-203 and C-205, and repair if necessary. Q: Are the wiring harness between combination meter connector C-04 (terminal 42) and ignition switch (IG1) in good condition? YES : There is no action to be taken. NO : Repair or replace the wiring harness. Check

to see that all meters operate.

(2) Measure the resistance between terminal 40 and earth. OK: 2 ohms or less (3) Measure the resistance between terminal 41 and earth. OK: 2 ohms or less Q: Is the check result normal? YES : Repair or replace the connector. NO : Go to Step 8.

CHASSIS ELECTRICAL

54A-43


STEP 8. Connector check: Combination meter connector C-04 for damage.

ON-VEHICLE SERVICE SPEEDOMETER CHECK

Connector: C-04

M1543000900393

Adjust the pressure of tyres to the specified level. (Refer to GROUP 31, On-vehicle Service 331.)

C-04 Harness side

CAUTION Do not operate the clutch suddenly. Do not increase/decrease speed rapidly while testing.

CAUTION <4WD> AC210827AB

Q: Is combination meter connector C-04 in good condition? YES : Go to Step 9. NO : Repair or replace the wiring harness. Check

to see that all meters operate. Free roler

STEP 9. Check the wiring harness between combination meter connector C-04 (terminal 40 and 41) and earth.

AC107077AC

Set a free-roller on the rear tyre for 4WD. <2WD>

Connector: C-04 C-04 Harness side

Wheel chocks AC107078 AC

AC210827AB

Q: Are the wiring harness between combination meter connector C-04 (terminal 40 and 41) and earth in good condition? YES : This procedure is complete. NO : Repair or replace the wiring harness. Check

to see that all meters operate.

1. Set the vehicle onto a speedometer tester and use wheel chocks to hold the rear wheels. Tension bar

Front

Anchor plate

AC001288 AB

2. To prevent the front wheel from moving from side to side, attach tension bars to the tie-down hook, and secure both ends to anchor plates. 3. To prevent the vehicle from moving, attach a chain or wire to the rear retraction hook, and make sure the end of the chain or wire is secured.

CHASSIS ELECTRICAL

54A-44


4. Check if the speedometer indicator range is within the standard values. Standard value:

4,000 r/min: 200 r/min 5,000 r/min: 250 r/min 6,250 r/min: 150 r/min

FUEL GAUGE UNIT CHECK <2WD>

Standard indicator km/h

Allowance range km/h

20

20 - 24

40

40 - 44

Remove the fuel pump module and the remove the fuel gauge unit. (Refer to GROUP 13B, Fuel Tank 313B.)

80

80 - 86

FUEL GAUGE UNIT RESISTANCE

120

122 - 128

160

163 - 170

200

204 - 212

M1543001200427

Fuel gauge

Earth

5. If not to the standard value, inspect for proper tyre size. If not correct, replace the tyres with original size tyres and retest. If correct, replace the speedometer. If still not to standard value, replace the vehicle speed sensor.

TACHOMETER CHECK

Position F M1543001000401

Tachometer

Engine speed detection connector

Position E

Paper clip

AC210843 AB

1

AC203782 AC

1. Attach an external high quality tachometer to the engine speed detection connector on the harness side (such as with a paper clip). NOTE: For tachometer check, use an external high quality inductive tachometer. 2. Compare the readings of the vehicle tachometer and the external tachometer at every engine speed, and check if the variations are within the standard values. Standard values: 700 r/min: 100 r/min 2,000 r/min: 100 r/min 3,000 r/min: 150 r/min

1. Check that resistance value between the fuel gauge terminal and earth terminal is at the standard value when the fuel gauge unit float is between position "F" (highest) and position "E" (lowest). Standard value: Float position "F": 3 0.6 W Float position "E": 110 2.5 W 2. Check that resistance value changes smoothly when the float moves slowly between position "F" (highest) and position "E" (lowest). 3. If all checks are correct, go to fuel gauge unit float height check. If any check is not correct, replace the fuel gauge unit.

CHASSIS ELECTRICAL

54A-45


FUEL GAUGE UNIT FLOAT HEIGHT

A

Position F B

Position E

AC210842AB

1. Move the float and measure height A at position "F" (highest) and B at position "E" (lowest) with the float arm touching stopper. Standard value: Position F (A): 35.4 mm 2 mm Position E (B): 186.7 mm 2 mm 2. If all checks are correct, go to fuel gauge unit float height check. If any check is not correct, replace the fuel gauge unit.

1. Check that resistance value between the fuel gauge terminal and earth terminal is at the standard value when the fuel gauge unit float is between position "F" (highest) and position "E" (lowest). Standard value: Float position "F": 1.5 0.5 W Float position "E": 55 1.5 W 2. Check that resistance value changes smoothly when the float moves slowly between position "F" (highest) and position "E" (lowest). 3. If all checks are correct, go to fuel gauge unit float height check. If any check is not correct, replace the fuel gauge unit.

FUEL GAUGE UNIT FLOAT HEIGHT A B Position F

FUEL GAUGE UNIT CHECK <4WD> M1543001200438

Remove the fuel pump module and the remove the fuel gauge unit. (Refer to GROUP 13B, Fuel Tank 313B.)

FUEL GAUGE UNIT RESISTANCE

Position E Position F

Earth

Fuel gauge Earth

A

B

Fuel gauge Position E

AC211661 AC

Position F

Position F

Position E Position E AC211660 AC

1. Move the float and measure height A at position "F" (highest) and B at position "E" (lowest) with the float arm touching stopper. Standard value : Float position A: 36.7 mm Float position B: 149.6 2 mm Standard value : Float position A: 23.4 2 mm Float position B: 194.2 2mm 2. If all checks are correct, go to fuel gauge unit float height check. If any check is not correct, replace the fuel gauge unit.

CHASSIS ELECTRICAL

54A-46


ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK M1543001500376

1. Drain the engine coolant. (Refer to GROUP 14On-vehicle Service 314.) 2. Remove the engine coolant temperature gauge unit. 11 ± 1 N·m

Circuit tester

ACX00780AH

4. After inspection, apply specified sealant at threads of engine coolant temperature gauge unit, and tighten to the specified torque. Semi-drying sealant: 3M 1215 or equivalent 5. Add engine coolant. (Refer to GROUP 14 - Onvehicle Service 314.)

Thermometer

ACX00779 AI

3. Put engine coolant temperature gauge unit into the hot water in specified temperature, and ensure that basic resistance is within standard value. Standard value: 104 13.5 W (at 70C) Reference value Temperature (C) Resistance W 50

230

60

155

80

73

COMBINATION METER ASSEMBLY REMOVAL AND INSTALLATION M1543021300017

1.5 ± 0.5 N·m

1

2 3

1.5 ± 0.5 N·m

AC211662 AB

CHASSIS ELECTRICAL

54A-47

COMBINATION METER ASSEMBLY Removal steps 1. Instrument panel driver’s side garnish (Refer to GROUP 52A - Instrument panel 352A.) 2. Meter bezel (Refer to GROUP 52A Instrument panel 352A.) 3. Combination meter assembly

DISASSEMBLY AND ASSEMBLY M1543003100329

4

1.5 ± 0.5 N·m

3

5

2

1 AC211663 AB

Disassembly steps 1. Meter glass 2. Meter panel 3. Circuit board cover

Disassembly steps&RQWLQXHG 4. Bulb 5. Combination meter assembly

CHASSIS ELECTRICAL

54A-48

HEADLAMP

HEADLAMP SERVICE SPECIFICATIONS M1542000300280

Item Headlamp aiming

Standard value

Limit

Vertical direction

42 mm (0.24) below horizontal (H)

51 mm ( 0.29) from the standard value

Horizontal direction

Position at which the stat up point of 15 is crossed with vertical line (V)

87 mm ( 0.5) from the standard value

TROUBLESHOOTING M1542000701203

Features the headlamp automatic shutdown function to avoid battery drain when the headlamps are left on. The main features are as follows: Extinguishes automatically in three minutes if the ignition switch is turned off with the lighting switch on. Extinguishes in one second if the driver’s door is opened within that 3-minute period. If the headlamps are turned on with the ignition switch off, the headlamps and tail lamps will extinguish in three minutes after the driver’s door is opened or closed. The headlamps are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Diagnosis 354B. Using SWS monitor: GROUP 54C, SWS Diagnosis 354C.

7. Place the vehicle on a level floor, perpendicular to a flat screen 10 m away from the bulb centremarks on the headlamp lens. 8. Rock vehicle sideways to allow vehicle to assume its normal position. 9. Bounce the front suspension through three (3) oscillations by applying the body weight to hood or bumper. (1) Headlamp centre

Screen

(3)

(2)

Vehicle centre line (3) 10 m

ON-VEHICLE SERVICE HEADLAMP AIMING M1542000900497

PRE-AIMING INSTRUCTIONS 1. Inspect for badly rusted or faulty headlamp assemblies. 2. These conditions must be corrected before a satisfactory adjustment can be made. 3. Inspect tyre inflation, and adjust if it is necessary. 4. If the fuel tank is not full, place a weight in luggage room of the vehicle to simulate weight of a full tank (0.8 kg per litre). 5. There should be no other load in the vehicle other than driver or substituted weight of approximately 75 kg placed in driver’s position. 6. Thoroughly clean the headlamp lenses.

Headlamp centre

AC300909AB

10.Four lines of adhesive tape (or equivalent markings) are required on screen or wall: (1) Position a vertical tape or mark so that it is aligned with the vehicle centre line. (2) Measure the distance from the centre-marks on the headlamp lens to the floor. Transfer the measurement to the screen. Horizontal tape or mark on the screen is for reference of vertical adjustment. NOTE: Height from the floor to the centre of the headlamps (Reference value): 840 mm

CHASSIS ELECTRICAL

54A-49

HEADLAMP

(3) Measure the distance from the centre line of the vehicle to the centre of each headlamp. Transfer the measurement to the screen. Vertical tape or mark on the screen with reference to the centre line of each headlamp bulb.

(V) Distance of vertical direction Headlamp centre [42 mm (0.24˚)] (H) 15˚

HEADLAMP ADJUSTMENT High intensity zone

CAUTION Do not cover a headlamp for more than three minutes to prevent the plastic headlamp lens deformation. When adjusting one headlamp beam, make sure that another headlamp is off by disconnecting the connector from it. When reconnecting the connector, make sure that the headlamp beam is not disturbed accidentally. 1. The low-beam headlamp should project on the screen upper edge of the beam (cut-off).

ACX01800AD

Standard value: (Vertical direction) 42 mm (0.24) below horizontal (H) (Horizontal direction) Position at which the stat up point of 15 is crossed with vertical line (V) Limit: Vertical direction; 51 mm ( 0.29) from the standard value Horizontal direction; 87 mm ( 0.5) from the standard value

LUMINOUS INTENSITY MEASUREMENT M1542001000419

Vertical direction

Vertical direction AC300115 AB

2. If not the case, turn the adjusting screws to achieve the specified low-beam cut-off location on the aiming screen.

1. Set the headlamps to high-beam 2. Using a photometer, and following its manufacturer’s instruction manual, measure the headlamp centre intensity and check to be sure that the limit value is satisfied. Limit: 30,000 cd or more {When a screen is set 25m ahead of the vehicle} NOTE: When measuring the intensity, maintain an engine speed of 2,000 r/min., with the battery fully charged. There may be special local regulations pertaining to headlamp intensity. Be sure to make any adjustments necessary to satisfy such regulations. If an illuminometer is used to make the measurements, convert its values to photometer values by using the following formula. I =E x r2: I = intensity (cd) E = illumination (lux) r = distance (m) from headlamps to illuminometer

CHASSIS ELECTRICAL

54A-50

HEADLAMP

BULB REPLACEMENT

Position Lamp Bulb M1542001300595

Headlamp Bulb CAUTION Do not touch the surface of the bulb with hands or dirty gloves as the bulb may pop after a short time. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing. 1. Disconnect the headlamp connector. Socket cover

CAUTION As a principal, the position lamps can be removed as individual part. If not, remove the position lamp from the headlamp and position lamp assembly, and then remove the position lamp from the headlamp. Then replace the bulb. Do not touch the bulb surface bare-handed or with dirty gloves. If dirt is attached on surface of the bulb, immediately use alcohol or thinner to remove dirt, and install the bulb after well dried.

AC300097 AB

2. Remove the socket cover, and then remove the bulb. Position lamp socket

AC300089 AB

1. Screw out the position lamp socket. 2. Disconnect the connector.

Front Turn-Signal Lamp bulb CAUTION Do not touch the bulb surface bare-handed or with dirty gloves. If dirt is attached on surface of the bulb, immediately use alcohol or thinner to remove dirt, and install the bulb after well dried.

Front turn-signal lamp socket AC300098 AB

Disconnect the connector, and screw out the front turn-signal lamp socket.

CHASSIS ELECTRICAL HEADLAMP

54A-51

HEADLAMP REMOVAL AND INSTALLATION M1542001800211

Post-installation Operation Headlamp Aiming Adjustment (Refer to 354A.)

1 4.9 ± 0.7 N·m

2

<>

1. 2.

AC300070 AB

Removal steps Radiator grill Headlamp assembly

REMOVAL SERVICE POINT <> HEADLAMP ASSEMBLY REMOVAL

AC201812 AD

1. Remove half of the front bumper assembling clips and bolts. NOTE: The Figure illustrates the procedures to remove the headlamp assembly (LH).

2. Slide the front bumper down to remove the headlamp assembly.

CHASSIS ELECTRICAL

54A-52

HEADLAMP

HEADLAMP LEVELING SWITCH REMOVAL AND INSTALLATION M1542013700039

2

1

AC210845AE

Removal steps 1. Instrument lower panel (Refer to GROUP 52A-Instrument panel assembly 352A .) 2. Headlamp leveling switch


HEAD LAMP LEVELING SWITCH RESISTANCE CHECK

AC212497AB

Terminal No.

Switch position

Resistance

4-6

0

750 ohms

1

1050 ohms

2

1410 ohms

3

1710 ohms

4

2010 ohms

0, 1, 2, 3, 4

2830 ohms

5-6

CHASSIS ELECTRICAL

54A-53

FOG LAMP

FOG LAMP SERVICE SPECIFICATIONS M1542000300291

Item

Standard value

Fog lamp aiming (vertical direction)

Within 45 mm (0.86) to 75 mm (1.44) below the vertical centre line ahead of fog lamp.


Tool

Number

Name

Use

MB990784

Ornament remover Removal of instrument panel driver’s side garnish, meter bezel and fog lamp switch

MB990784


When the front fog lamp switch is turned to ON with the tail lamp or the headlamp on (the tail lamp switch or the headlamp switch is ON), the fog lamp relay turns on, and the fog lamps will illuminate. If the tail lamps or the headlamps are turned off with the lighting switch OFF while the fog lamps are on, the front fog lamps turn off at the same time to prevent unattended operation. If the tail lamps are turned off by the headlamp automatic shutdown function, the fog lamps turn off at the same time. However, if the tail lamps illuminate again, the fog lamps do not. The front fog lamps are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Diagnosis 354B. Using SWS monitor: GROUP 54C, SWS Diagnosis 354C.

3. Inspect tyre inflation, and adjust if necessary. 4. If fuel tank is not full, place a weight in the trunk of the vehicle to simulate weight of a full tank (0.8 kg per litre). 5. There should be no other load in the vehicle other than driver or substituted weight of approximately 75 kilograms placed in driver’s position. 6. Thoroughly clean the fog lamp lenses. 7. Place the vehicle on a level floor, perpendicular to a flat screen 3 meters away from the bulb centremarks on the fog lamp lens. 8. Rock the vehicle sideways to allow the vehicle to assume its normal position. 9. Bounce the front suspension through three (3) oscillations by applying the body weight to the hood or bumper.

55 mm

55 mm

33 mm

ON-VEHICLE SERVICE Fog lamp centre

FOG LAMP AIMING

33 mm

M1542001100416

PRE-AIMING INSTRUCTIONS 1. Inspect for badly rusted or faulty fog lamp assemblies. 2. These conditions must be corrected before a satisfactory adjustment can be made.

AC300907AB

10.Measure the centre of the fog lamps as shown in the illustration.

CHASSIS ELECTRICAL

54A-54

FOG LAMP

FOG LAMP ADJUSTMENT

(1) Screen

Fog lamp centre (3)

(2)

Vehicle centre line

Vertical centre line ahead of fog lamp H Cut off line

V

45 mm

(3)

A

75 mm

3m B AC212529 AB

11.Four lines of adhesive tape (or equivalent markings) are required on screen or wall: (1) Position a vertical tape or mark so that it is aligned with the vehicle centre line. (2) Measure the distance from the centre of the fog lamp lens to the floor. Transfer the measurement to the screen. Horizontal tape or mark on the screen is for reference of vertical adjustment. (3) Measure the distance from the centre line of the vehicle to the centre of each fog lamp. Transfer the measurement to the screen. Vertical tape or mark on the screen is for reference to the centre line of each fog lamp.

A: Upper most level of cut off line B: Lower most level of cut off line

AC212531AC

1. Check if the beam shining onto the screen is at the standard value. Standard value: Fog lamp cut off line (Vertical direction): Within 45 mm (0.86) to 75 mm (1.44) below the vertical centre line ahead of fog lamp.

Vertical adjustment

AC300910 AB

2. If it is not within the standard value range, adjust by turning the adjusting screw. NOTE: The horizontal direction is non-adjustable. If deviation of the lamp beam axis exceeds the standard value, check that the mounting location or some other points are not faulty.

CHASSIS ELECTRICAL

54A-55

FOG LAMP

FOG LAMP REMOVAL AND INSTALLATION M1542001500447

4.9 ± 0.7 N·m

3 2 1 1.

Removal steps Fog lamp assembly

REMOVAL SERVICE POINT <> FOG LAMP BULB REMOVAL

CAUTION Use the specified genuine part when replacing the bulb. Do not touch the glass portion of bulb with bare hand or dirty gloves. Should the glass portion be spoiled, remove the soil as soon as possible using alcohol or thinner and let it dry before mounting.

AC201732 AC

Turn the fog lamp bulb left to remove it.

<>

AC212438 AB

2. 3.

Removal steps&RQWLQXHG Fog lamp Fog lamp bulb

CHASSIS ELECTRICAL

54A-56

FOG LAMP

FOG LAMP SWITCH REMOVAL AND INSTALLATION M1542013900022

1.5 ± 0.5 N·m

2

1

Vehicles with front fog lamp

Vehicles without front fog lamp

4

5 3

AC212463 AC

Removal steps&RQWLQXHG 3. Fog lamp switch bracket 4. Fog lamp switch (front and rear fog lamp switch) 5. Fog lamp switch (rear fog lamp switch)

Removal steps 1. Instrument panel driver’s side garnish (Refer to GROUP 52A, Instrument panel 352A.) 2. Meter bezel (Refer to GROUP 52A, Instrument panel 352A.)


FRONT FOG LAMP SWITCH CONTINUITY CHECK Switch position Tester connection Pressed

Specified condition

1 - 2 (without Less than 2 rear fog lamp) ohms 5 - 6 (with rear fog lamp)

Released AC201409 AB

1-2

Open circuit

CHASSIS ELECTRICAL

54A-57

REAR FOG LAMP

FRONT FOG LAMP RELAY CHECK

Front fog lamp relay

Battery voltage

Tester connection

Specified condition

Not supplied

1-4

Open circuit

Connect 1-4 terminal 3 to the positive battery terminal Connect terminal 2 to the negative battery terminal

Less than 2 ohms

1 4 2

3

AC212478 AB

REAR FOG LAMP TROUBLESHOOTING M1542000701225

If the rear fog lamp switch is turned ON when the headlamp or the front fog lamp is turned ON, the rear fog lamp is switched ON and OFF alternatively. If the headlamp and the front fog lamp, the rear fog lamp is turned OFF at the same time.

The fog lamps are controlled by the Smart Wiring System (SWS). For Troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Diagnosis 354B. Using SWS monitor: GROUP 54C, SWS Diagnosis 354C.


Tool

MB990784

Number

Name

Use

MB990784

Ornament remover Removal of instrument panel driver’s side garnish, meter bezel and fog lamp switch

CHASSIS ELECTRICAL

54A-58

REAR FOG LAMP

REAR FOG LAMP REMOVAL AND INSTALLATION M1542009800066

1

1.5 ± 0.5 N m

2

Vehicles with front fog lamp Vehicles without front fog lamp

4

5 3

6 9

8

7

AC300487AB

1.

2. 3. 4. 5.

Rear fog lamp switch removal steps Instrument panel driver’s side garnish (Refer to GROUP 52A, Instrument panel 352A.) Meter bezel (Refer to GROUP 52A, Instrument panel 352A.) Fog lamp switch bracket Fog lamp switch (front fog lamp switch and rear fog lamp switch) Fog lamp switch (rear fog lamp switch)

6. 7. 8. 9.

Rear fog lamp removal steps Rear bumper (Refer to GROUP 51, Rear bumper 351.) Rear fog lamp assembly Rear fog lamp body and lens Socket Bulb


REAR FOG LAMP SWITCH CONTINUITY CHECK

AC201409 AB

Switch position Tester connection

Specified condition

Pressed

1-2

Less than 2 ohms

Released

1-2

Open circuit

CHASSIS ELECTRICAL

54A-59

SIDE TURN SIGNAL LAMP

REAR FOG LAMP RELAY CHECK

Battery voltage

Tester connection

Specified condition

Not supplied

1-4

Open circuit


Less than 2 ohms

Junction block Rear fog lamp relay

1

1 2 3 4

4 2

3

AC210598 AB

SIDE TURN SIGNAL LAMP SPECIAL TOOL M1542000600720

Tool

MB990784

Number

Name

Use

MB990784

Ornament remover Removal of side turn-signal lamp

CHASSIS ELECTRICAL

54A-60

SIDE TURN SIGNAL LAMP

SIDE TURN SIGNAL LAMP REMOVAL AND INSTALLATION M1542003300137

1

4 3

2

AC203309 AD

<> >>A<< 1. 2. 3. 4.

Removal steps Side turn-signal lamp assembly Side turn-signal lamp Bulb Socket



<> SIDE TURN-SIGNAL LAMP REMOVAL

>>A<< SIDE TURN-SIGNAL LAMP INSTALLATION Hook Fender panel

Side turn-signal lamp

Claw

MB990784 Vehicle front

AC200034 AC

Use a special tool ornament remover (MB990784), etc. to remove the side turning-signal lamp by pushing the fender forward, bending the hook, and then unclamping the thumb.

Vehicle front

AC200035AC

Clamp the thumb on the fender panel the assemble the side turn signal lamp.

CHASSIS ELECTRICAL ROOM LAMP

54A-61

ROOM LAMP TROUBLESHOOTING M1542000701236

Room lamp delay shutdown function The room lamp off is delayed by ETACS-ECU. The lamps off delay time vary according to the conditions. The control details are as follows. The lamp delay off Yes/NO and delay time can be set with the settings (adjustment function). for adjustment methods and adjustment details (post-adjustment operations). ADJUSTMENT PROCEDURE Not using SWS monitor: GROUP 54B, 354B . Using SWS monitor: GROUP 54C, 354B . The room lamp lights up if the ignition switch is at the "LOCK" (OFF) position and either of the doors are opened (either of the door switches: ON). At this time, if all doors are closed (all door switches: OFF) then the lamp will gradually dim down to lamps off in about 15 seconds. NOTE: When the lamps are dimmed and the ignition switch is turned ON or if the door is locked, then the dimming operations stop and the lamps are turned OFF. When the ignition switch is at the ON position and one of the doors are opened (one of the door switches: ON) then the room lamp will light up. At this time, if all doors are closed (all door switches: OFF) then the lamps will dim out. When the ignition key is pulled out the room lamp lights up and then will dim out in 15 seconds. The lamp will dim out if the ignition key is inserted again and the door is locked while the timer is activated.

The room lamp is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Diagnosis 354B. Using SWS monitor: GROUP 54C, SWS Diagnosis 354C. Interior lamp automatic cut function The interior lamp automatic cut function, dims out the room lamp and other interior lamps by activating the keep relay built-in the ETACS-ECU when the ignition switch is OFF and the multi-purpose fuse loaded signals built-in the ETACS-ECU is ON and 30 minutes passes. The lamps lights back up if the ignition switch is turned to the ON position or either of the doors is opened (either of the door switches: ON). The function Yes/No feature can be changed with the settings (adjustment function). for adjustment methods and adjustment details (postadjustment operations). ADJUSTMENT PROCEDURE Not using SWS monitor: GROUP 54B, 354B . Using SWS monitor: GROUP 54C, 354B . The head lamp are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Diagnosis 354B. Using SWS monitor: GROUP 54C, SWS Diagnosis 354C.

CHASSIS ELECTRICAL

54A-62

REAR COMBINATION LAMP

REAR COMBINATION LAMP REAR COMBINATION LAMP DIAGNOSIS M1542000701247

The lamps setup on the rear combination lamp is controlled in the same manner as the lamps of the headlamp assembly. For details go to the reference. For troubleshooting, refer to respective Groups below.

Not using SWS monitor: GROUP 54B, SWS Diagnosis 354B. Using SWS monitor: GROUP 54C, SWS Diagnosis 354C.


Tool

Number

Name

Use

MB990784

Ornament remover Removal of ventilation cap and rear combination lamp assembly

MB990784

REAR COMBINATION LAMP REMOVAL AND INSTALLATION M1542003900418

Section A - A

2

Clip

1 A 4.9 ± 0.7 N·m

3 A

AC210600 AE

Removal steps Ventilation cap (Refer to GROUP 52A, Trims 352A.) Rear combination lamp connector connection

Removal steps&RQWLQXHG 1. Rear combination lamp 2. Harness assembly 3. Bulb

CHASSIS ELECTRICAL

54A-63

HIGH MOUNTED STOP LAMP

HIGH MOUNTED STOP LAMP HIGH MOUNTED STOP LAMP REMOVAL AND INSTALLATION M1542005100429

2.5± 0.3 N·m

2

1

5.1 ± 0.2 N·m

5.1 ± 0.2 N·m

AC100674 AF

Removal steps Tailgate upper trim (Refer to GROUP 52A, Tailgate trim 352A .) High-mounted stop lamp connector connection

1. 2.

Removal steps&RQWLQXHG Spoiler High-mounted stop lamp

CHASSIS ELECTRICAL

54A-64

LICENCE PLATE LAMP

LICENCE PLATE LAMP LICENCE PLATE LAMP REMOVAL AND INSTALLATION M1542004200166

5

5

4

4

3

3

2

2

1

1 (L.H.side)

(R.H.side) AC300488AB

1. 2. 3.

Removal steps Licence plate lamp lens Packing Licence plate lamp body

4. 5.

Removal steps&RQWLQXHG Licence plate lamp bulb Socket assembly

CHASSIS ELECTRICAL

54A-65

HAZARD WARNING LAMP SWITCH

HAZARD WARNING LAMP SWITCH TROUBLESHOOTING M1542000701258

FLASHER TIMER FUNCTION The hazard warning lamps (flasher timer function) are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below.



Tool

Number

Name

Use

MB990784

Ornament remover Removal of centre lower panel assembly

MB990784

HAZARD WARNING LAMP SWITCH REMOVAL AND INSTALLATION M1542006600416 AC300490

1

1.5 ± 0.5 N·m

2 Removal steps 1. Centre lower panel assembly (Refer to GROUP 52A, Instrument panel 352A.) 2. Hazard warning lamp switch

AC301773AB

CHASSIS ELECTRICAL

54A-66

COLUMN SWITCH


HAZARD WARNING LAMP SWITCH CONTINUITY CHECK

Switch position Tester connection

Specified condition

Released

1-2

Open circuit

Pressed

1-2

Less than 2 ohms

AC102590 AB

COLUMN SWITCH SPECIAL TOOL M1542000600753

Tool

MB990784

Number

Name

Use

MB990784

Ornament remover Removal of column cover

CHASSIS ELECTRICAL

54A-67

COLUMN SWITCH

COLUMN SWITCH REMOVAL AND INSTALLATION M1543009100413

Section A - A

2 Claw

Column cover A A

5

4

Note : Claw position

3 1

Removal steps 1. Instrument panel (Refer to GROUP 52A, Instrument panel 352A.) 2. Column cover upper

AC100538 AC

Removal steps&RQWLQXHG 3. Column cover lower 4. Turn-signal and lighting switch 5. Windshield wiper and washer switch

CHASSIS ELECTRICAL

54A-68

COLUMN SWITCH


TURN-SIGNAL AND LIGHTING SWITCH CHECK Turn-signal and lighting switch

AC103138 AC

Switch position Tester condition

Specified condition

OFF

3 - 4, 3 - 6, 3 - 7, 3 - 8, 3 - 9, 3 - 10, 3 - 11

Open circuit

Headlamp washer switch

3-4

Less than 2 ohms

Headlamp switch

3-6

Less than 2 ohms

Switch position Tester condition

Specified condition

Tail lamp switch

3-7

Less than 2 ohms

Passing switch

3-8

Less than 2 ohms

Dimmer switch

3-9

Less than 2 ohms

Turn-signal lamp 3 - 10 switch (RH)

Less than 2 ohms

Turn-signal lamp 3 - 11 switch (LH)

Less than 2 ohms

NOTE: Integrated column ECU does not allow windshield wiper switch continuity test. For inspection and diagnosis, refer to the respective Group below. .


CHASSIS ELECTRICAL HORN

54A-69

HORN HORN REMOVAL AND INSTALLATION M1543007900394

21 ± 4 N·m

1 21 ± 4 N·m

2 Removal Steps 1. Horn 2. Horn

AC203808 AC

CHASSIS ELECTRICAL

54A-70

CLOCK


HORN RELAY CONTINUITY CHECK

Battery voltage

Tester connection

Specified condition

Not applied

1-4

Open circuit

Connect terminal 1 - 4 2 to the positive battery terminal Connect terminal 3 to the negative battery terminal

Less than 2 ohms

Horn relay

4

1

3

2

AC210599 AF

CLOCK SPECIAL TOOL M1543000601511

Tool

MB990784

Number

Name

Use

MB990784

Ornament remover Removal of instrument panel garnish, meter bezel and instrumental panel centre clock panel

CHASSIS ELECTRICAL

54A-71

CIGARETTE LIGHTER

CLOCK REMOVAL AND INSTALLATION M1543005900183

1.5± 0.5 N·m

2

1

4 3

1.5± 0.5 N·m

AC100537 AC

Removal steps 1. Instrument panel driver’s side garnish (Refer to GROUP 52A, Instrument panel 352A.) 2. Meter bezel (Refer to GROUP 52A, Instrument panel 352A.)

Removal steps&RQWLQXHG 3. Instrument panel clock garnish (Refer to GROUP 52A, Instrument panel 352A.) 4. Clock

CIGARETTE LIGHTER INSPECTION M1543005700231

CIGARETTE LAMPER CHECK Element Spot

ACX01832 AD

Take out the plug, and check for a worn edge on the element spot connection, and for shreds of tobacco or other material on the element. Using an ohmmeter, check that the element resistance value is 1.7 ohms.

CHASSIS ELECTRICAL

54A-72

ACCESSORY SOCKET

ACCESSORY SOCKET SPECIAL TOOL M1543000601522

Tool

Number

Name

Use

MB990784

Ornament remover Removal of quarter trim lower

MB990784

ACCESSORY SOCKET REMOVAL AND INSTALLATION M1543008900223

1 2

Removal Steps Quarter trim lower (LH) (Refer to GROUP 52A, Trim352A.)

AC300489 AC

Removal Steps&RQWLQXHG 1. Socket case 2. Accessory socket

CHASSIS ELECTRICAL

54A-73

ACCESSORY SOCKET


ACCESSORY SOCKET RELAY CONTINUITY CHECK

Accessory socket relay

4

1

3

2

AC210599 AB

Battery voltage

Tester Specified connection condition

Not applied

1-4

Open circuit

Connect terminal 2 to the positive battery terminal Connect terminal 3 to the negative battery terminal

1-4

Less than 2 ohms

CHASSIS ELECTRICAL

54A-74

RHEOSTAT

RHEOSTAT RHEOSTAT REMOVAL AND INSTALLATION M1542006000287

2

1

AC210844AB

Removal steps 1. Instrument lower panel (Refer to GROUP 52A-Instrument panel assembly 352A .) 2. Rheostat


RHEOSTAT RESISTANCE CHECK

40W

AC212513AB

1. Connect the battery and the test bulb (40 W) as shown in the illumination.

2. Operate the rheostat, and if brightness changes smoothly without switching off, rheostat function is normal.

CHASSIS ELECTRICAL

54A-75

SPEAKER

SPEAKER SPEAKER REMOVAL AND INSTALLATION M1544002600421

5 6

1.5 ± 0.5 N·m

4 3 2

1.5 ± 0.5 N·m

1

AC102825 AD

1. 2.

Front door speaker removal steps Front door speaker garnish Front door speaker

3. 4. 5. 6.

Rear door speaker removal steps Rear door speaker garnish Rear door speaker Tweeter removal steps Delta cover (Refer to GROUP 51, Door Mirror 351.) Tweeter

CHASSIS ELECTRICAL

54A-76

ANTENNA

ANTENNA ANTENNA REMOVAL AND INSTALLATION M1544002900499

Pre-removal and Post-installation Operation Front pillar trim, Quarter trim upper, Quarter trim lower, Centre pillar trim lower, Centre pillar trim upper (Refer to GROUP 52A - Trim 352A.) Assist Grip, Headlining (Refer to GROUP 52A Headlining 352A.) Instrument Panel Removal and Installation (Refer to GROUP 52A, Instrument Panel 352A).

1 3

4

2

3.0 ± 1.0 N·m

AC300925 AB

Removal steps 1. Rod assembly 2. Antenna nut

Removal steps&RQWLQXHG 3. Base 4. Antenna feeder assembly

CHASSIS ELECTRICAL

54A-77

REAR WINDOW DEFOGGER

REAR WINDOW DEFOGGER GENERAL INFORMATION M1543000100290

Rear Defogger operation The defogger relay turns ON if the defogger switch built-in the A/C-ECU is turned ON when the ignition switch is in the "ON" position. When the defogger relay turns ON, power is supplied to the defogger and the defogger is activated. The defogger comes with a timer function that causes the defogger switch to automatically turn OFF in about 11 minutes (manual A/C) or about 20 minutes (automatic A/C) after the defogger switch is turned ON.

3. If 12 volts is indicated at A, there is a break in the negative terminals from A. Move test bar slowly to negative terminal to detect where voltage changes suddenly (0volts). 4. If 0 volts is indicated at A, there is a break in the positive terminals from A. Defect where the voltage changes suddenly (12 volts) in the same method described above.

REAR WINDOW DEFOGGER SWITCH REMOVAL AND INSTALLATION M1543006200295


The rear window defogger is controlled by the A/CECU. For troubleshooting, refer to GROUP 55ATroubleshooting 355A or GROUP 55BTroubleshooting 355B.

Refer to GROUP 55A, Heater Control Assembly and Blower Switch Assembly 355A.


DEFOGGER RELAY CHECK

ON-VEHICLE SERVICE PRINTED HEATER LINES CHECK M1543001800292

Normal characterstic curve Voltage

A (Center point) Approximately 6 V

Positive terminal

Junction block

Defogger relay

Negative terminal

Print heater line

OFF

5

ON

4

Abnormal characterstic curve 1 Voltage

3

Open circuit point AC212486 AB

Positive terminal

Print heater line

Battery voltage

Tester connection

Specified condition

Not supplied

4-5

Open circuit


4-5

Less than 2 ohms

Negative terminal ACX00813 AC

1. Run engine at 2,000 r/min. Check heater element with battery at full. 2. Turn "ON" rear window defogger switch. Measure heater element voltage with circuit tester at rear window glass centre A. Condition is good if it indicates about six volts.

127(6

13A-1

GROUP 13A

MULTIPORT FUEL INJECTION (MFI)

00 11 12 13 14 15

CONTENTS

16 17


13A

ENGINE CONTROL RELAY CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A


13A

FUEL PUMP RELAY CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A

22

SEALANT. . . . . . . . . . . . . . . . . . . . . .

13A

INTAKE AIR TEMPERATURE SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A

25

SPECIAL TOOLS. . . . . . . . . . . . . . . .

13A

ENGINE COOLANT TEMPERATURE SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13A

26

TROUBLESHOOTING . . . . . . . . . . . .

13A

THROTTLE POSITION SENSOR CHECK . 13A

27

ON-VEHICLE SERVICE. . . . . . . . . . . 13A THROTTLE BODY (THROTTLE VALVE AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13A THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13A BASIC IDLE SPEED ADJUSTMENT . . . . . 13A FUEL PRESSURE TEST . . . . . . . . . . . . . . 13A FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) . . . . . . . . . . 13A FUEL PUMP OPERATION CHECK . . . . . . 13A COMPONENT LOCATION . . . . . . . . . . . . . 13A

OXYGEN SENSOR CHECK . . . . . . . . . . . . 13A

21

INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A

31

IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) CHECK . . . . . . . . . . . 13A

32

INJECTOR . . . . . . . . . . . . . . . . . . . . . 13A

33

REMOVAL AND INSTALLATION . . . . . . . . 13A

34

THROTTLE BODY ASSEMBLY . . . . . 13A

35

REMOVAL AND INSTALLATION . . . . . . . . 13A

36

THROTTLE BODY ASSEMBLY DISASSEMBLY AND REASSEMBLY . . . . . 13A

ENGINE ECU . . . . . . . . . . . . . . . . . . . 13A REMOVAL AND INSTALLATION . . . . . . . . 13A

37 42 51 52 54 55


13A-2

GENERAL INFORMATION


The Multipoint Fuel Injection System consists of sensors which detect the engine conditions, the engineECU which controls the system based on signals from these sensors, and actuators which operate under the control of the engine-ECU. The engineFUEL INJECTION CONTROL The injector drive times and injection timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continuallychanging engine operation conditions. A single injector is mounted at the intake port of each cylinder. Fuel is sent under pressure from the fuel tank by the fuel pump, with the pressure being regulated by the fuel pressure regulator. The fuel thus regulated is distributed to each of the injectors. Fuel injection is normally carried out once for each cylinder for every two rotations of the crankshaft. The firing order is 1-3-4-2. This is called sequential fuel injection. The engine-ECU provides a richer air/fuel mixture by carrying out "open-loop" control when the IDLE AIR CONTROL The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in accordance with changes in idling conditions and engine load during idling. The engine-ECU drives the idle speed control motor to keep the engine running at the pre-set idle target speed in accordance with the engine coolant temperature and

ECU carries out activities such as fuel injection control, idle speed control and ignition timing control. In addition, the engine-ECU is equipped with several diagnosis modes which simplify troubleshooting when a problem develops. engine is cold or operating under high load conditions in order to maintain engine performance. In addition, when the engine is warm or operating under normal conditions, the engine-ECU controls the air/fuel mixture by using the oxygen sensor signal to carry out "closed-loop" control in order to obtain the theoretical air/fuel mixture ratio that provides the maximum cleaning performance from the three way catalyst.

air conditioner load. In addition, when the air conditioner switch is turned off and on while the engine is idling, the idle speed control motor operates to adjust the throttle valve bypass air amount in accordance with the engine load conditions in order to avoid fluctuations in the engine speed.

IGNITION TIMING CONTROL The power transistor located in the ignition primary circuit turns ON and OFF to control the primary current flow to the ignition coil. This controls the ignition timing in order to provide the optimum ignition timing with respect to the engine operating conditions. The ignition timing is determined by the engine-ECU from the engine speed, intake air volume, engine coolant temperature and atmospheric pressure. SELF-DIAGNOSIS FUNCTION When an abnormality is detected in one of the sensors or actuators related to emission control, the engine warning lamp (check engine lamp) illuminates as a warning to the driver. When an abnormality is detected in one of the sensors or actuators, a diagnosis code corresponding to the abnormality is output. OTHER CONTROL FUNCTIONS 1. Fuel Pump Control

The RAM data inside the engine-ECU that is related to the sensors and actuators can be read by means of the MUT-II. In addition, the actuators can be force-driven under certain circumstances.

Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running.

MULTIPORT FUEL INJECTION (MFI) GENERAL INFORMATION

2. A/C Relay Control Turns the compressor clutch of the A/C ON and OFF. 3. Fan Motor Control The revolutions of the radiator fan and condenser fan are controlled in response to the engine coolant temperature and vehicle speed. 4. Purge Control Solenoid Valve Control

(Refer to 317, GROUP 17 - Engine And Emission Control - Evaporative Emission Control System). 5. EGR Control Solenoid Valve Control [Refer to 317, GROUP 17 - Engine And Emission Control - Exhaust Gas Recirculation (EGR) System].

GENERAL SPECIFICATIONS Items Throttle body

Specifications Throttle bore mm

60

Throttle position sensor

Variable resistor type

Idle speed control servo

Stepper motor type

Engine-ECU

Identification No.

E6T38971

Sensors

Air flow sensor

Karman vortex type

Barometric pressure Sensor

Semiconductor type

Intake air temperature sensor

Thermistor type

Engine coolant temperature

Thermistor type

Oxygen sensor

Zirconia type

Inhibitor switch

Contact switch type

Camshaft position sensor

Hall element type

Crank angle sensor

Hall element type

Detonation sensor

Piezoelectric type

Power steering fluid pressure switch

Contact switch type

Engine control relay type

Contact switch type

Fuel pump relay type

Contact switch type

Injector type and number

Electromagnetic type, 4

Injector identification mark

HDA 250E

EGR control solenoid valve

Duty cycle type solenoid valve

Purge control solenoid valve

Duty cycle type solenoid valve

Actuators

Fuel pressure Regulator pressure kPa regulator

13A-3

329


13A-4

GENERAL INFORMATION

MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM 1 2 3 4

Oxygen sensor (front) Oxygen sensor (rear) Air flow sensor Intake air temperature sensor 5 Throttle position sensor 6 Camshaft position sensor 7 Crank angle sensor 8 Barometric pressure sensor 9 Engine coolant temperature sensor 10 Detonation sensor

Power supply Ignition switch-IG Ignition switch-ST A/C switch A/C load signal A/C pressure sensor Power steering fluid pressure switch Alternator FR terminal Vehicle speed sensor

Engine control relay Fuel pump relay A/C compressor relay Ignition coil Fan controller Engine warning lamp Diagnosis output Alternator G terminal Oxygen sensor heater Tachometer

4 Intake air temperature sensor 2 Idle speed control servo 3 Air flow sensor (Stepper motor) 8 Barometric 5 Throttle position pressure sensor sensor

6 Camshaft position sensor

Air

Fuel pressure regulator

To fuel tank

1 Injector 2 Idle speed control servo (Stepper motor) 3 EGR control solenoid valve 4 Purge control solenoid valve

Engine-ECU

M

M

A

From fuel pump EGR valve Canister

1 Oxygen sensor (front) 1 Injector Catalytic converter

9 Engine coolant temperature sensor

3 EGR control solenoid valve

10 Detonation sensor 7 Crank angle sensor 2 Oxygen sensor (rear) Catalytic converter

4 Purge control solenoid valve

AK204338 AB


13A-5



Items

Specifications

Basic idle speed r/min

700 50

Throttle position sensor adjusting voltage mV

535 - 735

Throttle position sensor resistance kW

3.5 - 6.5

Idle speed control servo coil resistance (at 20C) W

28 - 33

Intake air temperature sensor -20C resistance kW 0C

13 - 17

Engine coolant temperature sensor resistance kW

5.3 - 6.7

20C

2.3 - 3.0

40C

1.0 - 1.5

60C

0.56 - 0.76

80C

0.30 - 0.42

-20C

14 - 17

0C

5.1 - 6.5

20C

2.1 - 2.7

40C

0.9 - 1.3

60C

0.48 - 0.68

80C

0.26 - 0.36

Oxygen sensor output voltage (at racing) V

0.6 - 1.0

Oxygen sensor heater resistance (at 20C) W

front

4.5 - 8.0

rear

11 - 18

Fuel pressure kPa

Vacuum hose disconnection

330 - 350 at curb idle

Vacuum hose connection

Approximately. 270 at curb idle

Injector coil resistance (at 20C) W

10.5 - 13.5

SEALANT M1131000500237

Item

Specified sealant

Remark

Engine coolant temperature sensor Threaded portion

3M Nut Locking Part No. 4171 or equivalent

Drying sealant


13A-6

SPECIAL TOOLS


Tool

Number

Name

Use

MB991502

MUT-II sub assembly

Reading diagnosis code MPI system inspection

MB991348

Test harness set

Measurement of voltage during troubleshooting Inspection using an oscilloscope

MB991709

Test harness

Measurement of voltage during troubleshooting Inspection using an oscilloscope Adjusting of idle speed control servo

MD998478

Test harness (3pin, triangle)

Measurement of voltage during Troubleshooting Inspection using an oscilloscope

MB991536

Check harness for throttle position sensor adjustment

Measurement of voltage during Troubleshooting Adjusting of throttle position sensor

MD998464

Test harness (4pin, square)

Measurement of voltage during Troubleshooting Inspection of oxygen sensor (front)

MB991658

Test harness

Measurement of voltage during Troubleshooting Inspection of oxygen sensor (rear)

B991502

MB991348

MB991536

MB991658

MULTIPORT FUEL INJECTION (MFI) SPECIAL TOOLS

Tool

13A-7

Number

Name

Use

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222


Check at the ECU terminals A: Connector pin contact inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection

MD998709

Adaptor hose

Measurement of fuel pressure

MD998742

Hose adaptor

MB991637

Fuel pressure gauge set

MB991223

MB991637


13A-8

TROUBLESHOOTING

Tool

Number

Name

Use

MD998706

Injector test set

Checking the spray condition of injectors

MB991607

Injector test harness

MD998741

Injector test adaptor

MB991608

Clip

MD998706

MB991607

MD998741

MB991608

TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW M1131150000342

Refer to 300, GROUP 00 - How to Use Troubleshooting/Inspection Service Points. NOTE: If the engine-ECU is replaced, the steering lock cylinder and ignition key should be replaced together with it.

DIAGNOSIS FUNCTION M1131155500074

ENGINE WARNING LAMP (CHECK ENGINE LAMP)

Engine warning lamp (check engine lamp)

AK300251AB

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.

MULTIPORT FUEL INJECTION (MFI) TROUBLESHOOTING

ENGINE WARNING LAMP INSPECTION ITEMS Code No. Diagnosis item

-

Engine-ECU

P0100

Air flow sensor system

P0105

Barometric pressure sensor system

P0110

Intake air temperature sensor system

P0115

Engine coolant temperature sensor system

P0120

Throttle position sensor system

P0125*

Feedback system monitor

P0130

Oxygen sensor (front) system

P0135

Oxygen sensor heater (front) system

P0136

Oxygen sensor (rear) system

P0141

Oxygen sensor heater (rear) system

P0170

Abnormal fuel system

P0201

No. 1 injector system

P0202


P0203


P0204


P0300

Random cylinder mis-fire detection system

P0301*

No. 1 cylinder mis-fire detection system

P0302*


P0303*


P0304*


P0325

Detonation sensor system

P0335

Crank angle sensor system

P0340

Camshaft position sensor system

P0403

EGR control solenoid valve system

P0420

Catalyst deterioration system

P0443

Purge control solenoid valve system

P0500

Vehicle speed sensor system

P0505

Idle speed control system

P0551*

Power steering fluid pressure switch system

P1603*

Battery back-up line system

P1610

Immobilizer system

13A-9


13A-10

TROUBLESHOOTING

NOTE: . If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication between MUT-II and the engine-ECU is impossible. In this case, the diagnosis code cannot be read. After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is next turned on and the same malfunction is re-detected.However, for items marked with a "*" in the diagnosis code number column, the engine warning lamp illuminates only on the first detection of the malfunction. After the engine warning lamp illuminates, it will be switched off under the following conditions. When the engine-ECU monitored the power train malfunction three times* met set condition requirements, it detected no malfunction. *: In this case, "one time" indicates from engine start to stop. For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.) are similar to those when the malfunction was first recorded. Sensor 1 indicates, the sensor mounted at a position closest to the engine, and sensor 2 indicates the sensor mounted at the position second closest to the engine.

METHOD OF READING AND ERASING DIAGNOSIS CODES

INSPECTION USING MUT-II DATA LIST AND ACTUATOR TESTING

Refer to 300, GROUP 00 - How to Use Troubleshooting/Inspection Service Points.

1. Carry out inspection by means of the data list and the actuator test function, if there is an abnormality, check and repair the chassis harness and components. 2. After repairing, re-check using the MUT-II and check that the abnormal input and output have returned to normal as a result of the repairs. 3. Erase the diagnosis code memory. 4. Remove the MUT-II, and then start the engine again and carry out a road test to confirm that the problem has disappeared.

DIAGNOSIS USING DIAGNOSIS 2 CODES 1. Switch the diagnosis mode of the engine control unit to DIAGNOSIS 2 mode using the MUT-II. 2. Carry out a road test. 3. Take a reading of the diagnosis code and repair the problem location. 4. Turn the ignition switch to OFF and then back to ON again. NOTE: By turning the ignition switch to OFF, the ENGINE-ECU will switch the diagnosis mode from DIAGNOSIS 2 mode to DIAGNOSIS 1 mode. 5. Erase the diagnosis codes.

FREEZE FRAME DATA When the engine-ECU detects a malfunction and stores a diagnosis code, it also stores a current status of the engine. This function is called "Freeze frame data". By analysing this "Freeze frame" data with the MUT-II, an effective troubleshooting can be performed. The display items of freeze frame data are shown below.

DISPLAY ITEM LIST Item No. Data

Unit

21


C

22

Engine speed

r/min

24

Vehicle speed

km/h

80

Long-term fuel compensation (long-term fuel trim)

%

82

Short-term fuel compensation (short-term fuel trim)

%


13A-11

TROUBLESHOOTING

Item No.

Data

88

Fuel control condition

87

Unit Open loop

OL

Closed loop

CL

Open loop owing to drive condition

OL-DRV.

Open loop owing to system malfunction

OL-SYS.

Closed loop based on one oxygen sensor

CL- H02S

Calculation load value

%

Diagnosis code during data recording

-

NOTE: If malfunctions have been detected in multiple systems, store one malfunction only, which has been detected first.

READINESS TEST STATUS The engine-ECU monitors the following main diagnosis items, judges if these items are in good condition or not, and the stores its history. this history can be read out by using MUT-II. (If the ECU has judged a item before, the MUT-II displays "Complete").

In addition, if diagnosis codes are erased or the battery cable is disconnected, this history will also be erased (the memory will be reset). Catalyst: P0420 Oxygen sensor: P0130 Oxygen sensor heater: P0135, P0141

FAIL-SAFE FUNCTION REFERENCE TABLE When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning item

Control contents during malfunction

Air flow sensor

1. 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 the pre-set mapping. 2. Fixes the idle speed control servo in the appointed position so idle control is not performed.


Controls as if the intake air temperature is 25C.

Barometric pressure sensor

Controls as if the barometric pressure is 101 kPa.

Throttle position sensor No increase in fuel injection amount during acceleration due to the throttle position sensor signal. Engine coolant temperature sensor

Controls as if the engine coolant temperature is 80C.


Injectors fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the ignition switch is turned to the "ON" position, the No. 1 cylinder top dead centre is not detected at all)

Oxygen sensor (front)

Air/fuel ratio feedback control (closed loop control) is not performed.

Oxygen sensor (rear)

Performs the feedback control (closed loop control) of the air/fuel ratio by using only the signal of the oxygen (front) installed on the front of the catalytic converter.

Detonation sensor

Fixes the ignition timing as that for regular gasoline.


13A-12

TROUBLESHOOTING

Malfunctioning item

Control contents during malfunction

Ignition coil (incorporating power transistor)

Cuts off the fuel supply to cylinders with an abnormal ignition.

Alternator FR terminal

Does not control the output of the alternator according to an electrical load. (works as a normal alternator)

Misfiring

If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be shut down.

INSPECTION CHART FOR DIAGNOSIS CODE M1131151000624

Code No.

Diagnosis item

Reference page

P0100

Air flow sensor system

313A

P0105

Barometric pressure sensor system

313A

P0110

Intake air temperature sensor system

313A

P0115

Engine coolant temperature sensor system

313A

P0120

Throttle position sensor system

313A

P0125*

Feedback system monitor

313A

P0130

Oxygen sensor (front) system

313A

P0135

Oxygen sensor heater (front) system

313A

P0136

Oxygen sensor (rear) system

313A

P0141

Oxygen sensor heater (rear) system

313A

P0170

Abnormal fuel system

313A

P0201

No.1 Injector system

313A

P0202


313A

P0203


313A

P0204


313A

P0300

Random cylinder mis-fire detection system

313A

P0301*

No.1 cylinder mis-fire detection system

313A

P0302*


313A

P0303*


313A

P0304*


313A

P0325

Detonation sensor system

313A

P0335

Crank angle sensor system

313A

P0340

Camshaft position sensor system

313A

P0403

EGR control solenoid valve system

313A

P0420

Catalyst deterioration system

313A

P0443

Purge control solenoid valve system

313A

P0500

Vehicle speed sensor system

313A

P0505

Idle speed control system

313A

P0551*

Power steering fluid pressure switch system

313A


13A-13

Code No.

Diagnosis item

Reference page

P0622

Alternator FR terminal system

313A

P1603*

Battery back-up line system

313A

P1610

Immobilizer system

313A

NOTE: . Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit. Check that the engine-ECU earth circuit is normal before checking for the cause of the problem. After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the engine is started and the same malfunction is re-detected. However, for items marked with "*", the diagnosis code is recorded on the first detection of the malfunction. Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates the sensor mounted at the position second closest to the engine.


13A-14

TROUBLESHOOTING

INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No. P0100 Air Flow Sensor System

Air flow sensor circuit

Battery

W-B W-B 3

4 B-17X

1

2

3

4

Engine control relay

1

2

R

4 B-08 Air flow sensor

1 2 3 4 5 6 7

5

7

3

G-W 20 J/C (1) C-16

G-B

W-R

C-135

17

G-W 19

40

90

C-137

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

C-134

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

5V

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU

Wire colour code B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray R: Red P: Pink V:Violet AK300252 AB


OPERATION Power is supplied to the air flow sensor (terminal No. 4) from the engine control relay (terminal No. 1) and earthed to the engine-ECU (terminal No. 40) from the air flow sensor (terminal No. 5). A power voltage of 5 V is applied to the air flow sensor output terminal (terminal No. 3) from the engine-ECU (terminal No. 90). An air flow sensor filter reset signal is inputted to the air flow sensor (terminal No. 7) from the engine-ECU (terminal No. 19). FUNCTION Air flow sensor outputs a pulse signal proportional to the intake air flow rate. The engine-ECU determines the basic injection timing of the injector using the pulse signal output from the air flow sensor and the engine speed signal. When the throttle position sensor output is low, the engine-ECU causes the power transistor in the unit to be ON to send an air flow sensor filter reset signal to the air flow sensor. In response to the reset signal, the air flow sensor resets the filter circuit to improve the ability of the air flow sensor to measure the air flow rate in the area where the intake air flow rate is low. TROUBLE JUDGMENT Check Condition Engine speed is 500 r/min or more. Judgment Criterion Sensor output frequency of 3.3 Hz or less for 2 seconds. PROBABLE CAUSE Failed air flow sensor Open/short circuit in air flow sensor circuit or loose connector contact Failed engine-ECU

13A-15

DIAGNOSIS PROCEDURE STEP 1. MUT-II data list Refer to Data list reference table 313A. a. Item 12: Air flow sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-08 air flow sensor connector Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Q: Is the check result normal? YES : Go to Step 3 . NO : Repair.

STEP 3. Measure voltage at B-08 air flow sensor connector. Connector: B-08

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB

Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 3 and earth. OK: 4.9 - 5.1 V Q: Is the check result normal? YES : Go to Step 9 . NO : Go to Step 4 .


13A-16

TROUBLESHOOTING

STEP 4. Measure voltage at C-137 engine-ECU connector. CONNECTOR: C-137

STEP 5. Connector check: C-137 engine-ECU connector CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Harness side connector AK300254 AB

Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 90 and earth. OK: 4.9 - 5.1 V Q: Is the check result normal? YES : Go to Step 5 . NO : Go to Step 6 .

AK300254 AB

Connector: B-08

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB

Q: Is the check result normal? YES : Check and repair harness between B-08

(terminal No. 3) air flow sensor connector and C-137 (terminal No. 90) engine-ECU connector. Check output line for open circuit. NO : Repair.


13A-17

TROUBLESHOOTING

STEP 6. Connector check: C-137 engine-ECU connector. CONNECTOR: C-137

STEP 7. Check harness between B-08 (terminal No. 3) air flow sensor connector and C-137 (terminal No. 90) engine-ECU connector. Connector: B-08

B-08 (B) C-137 7 6 5 4 3 2 1


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

AK300253 AB

CONNECTOR: C-137


Q: Is the check result normal? YES : Go to Step 7 . NO : Repair. C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Check output line for short circuit. Q: Is the check result normal? YES : Go to Step 8 . NO : Repair.

STEP 8. MUT-II data list Refer to Data list reference table 313A. a. Item 12: Air flow sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Replace engine-ECU.


13A-18

TROUBLESHOOTING

STEP 9. Measure voltage at B-08 air flow sensor connector.

STEP 10. Connector check: B-17X engine control relay connector CONNECTOR: B-17X

Connector: B-08

Relay box’s triangle marks

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB

Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 4 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 11 . NO : Go to Step 10 .

2

1

4

3

B-17X


AK300255 AB

Connector: B-08

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB


(terminal No. 4) air flow sensor connector and B-17X (terminal No.1) engine control relay connector. Check power supply line for open/short circuit. NO : Repair. STEP 11. Check at B-08 air flow sensor connector. Connector: B-08

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB

Disconnect and measure at harness side. Resistance between terminal No. 5 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 14 . NO : Go to Step 12 .


13A-19

TROUBLESHOOTING



C-135

B-08 (B)

7 6 5 4 3 2 1


38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

AK300253 AB

CONNECTOR: C-135



38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


NOTE: Before checking harness, check intermediate connector C-16, and repair if necessary. Check earthing line for open circuit and damage. Q: Is the check result normal? YES : Go to Step 8 . NO : Repair.


13A-20

TROUBLESHOOTING



B-08 (B) B-08 (B) 7 6 5 4 3 2 1


AK300253 AB

Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 7 and earth. OK: 7 - 8 V

7 6 5 4 3 2 1


AK300253 AB

CONNECTOR: C-134

Q: Is the check result normal? YES : Go to Step 17 . NO : Go to Step 15 .

C-134

STEP 15. Connector check: C-134 engine-ECU connector 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

CONNECTOR: C-134


Check reset signal line for short circuit. C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



Q: Is the check result normal? YES : Replace air flow sensor. NO : Repair.


13A-21

TROUBLESHOOTING



B-08 (B) B-08 (B) 7 6 5 4 3 2 1


AK300253 AB

Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness. Transmission: Neutral Voltage between terminal No. 7 and earth. OK: 0 - 1 V (Engine: Idling) 6 - 9 V (Engine: 3,000 r/min)

7 6 5 4 3 2 1


AK300253 AB

CONNECTOR: C-134


C-134

STEP 18. Connector check: C-134 engine-ECU connector

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector CONNECTOR: C-134 AK300257 AB

Check reset signal line for open circuit and damage.

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14





13A-22

TROUBLESHOOTING

STEP 20. Measure output waveform at B-08 air flow sensor connector (Use oscilloscope). Connector: B-08

STEP 23. Check harness between B-08 (terminal No. 4) air flow sensor connector and B-17X (terminal No. 1) engine control relay connector. Connector: B-08

B-08 (B) B-08 (B) 7 6 5 4 3 2 1


AK300253 AB

Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness. Engine: Idling Transmission: Neutral Voltage between terminal No. 3 and earth. OK: Waveforms should be displayed on inspection procedure using an oscilloscope (Refer to 313A) and noise should not be displayed in the waveform.

7 6 5 4 3 2 1


AK300253 AB

CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

B-17X



AK300255 AB

Check power supply line for damage.

STEP 21. Replace air flow sensor. After replacing the air flow sensor, re-check the trouble symptoms. Q: Is the check result normal? YES : Go to Step 22 . NO : Check end.



STEP 22. Connector check: B-17X engine control relay connector CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

B-17X


C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


AK300257 AB




13A-23

TROUBLESHOOTING

STEP 25. Check harness between B-08 (terminal No. 3) air flow sensor connector and C-137 (terminal No. 90) engine-ECU connector.

STEP 26.Connector check: C-135 engine-ECU connector CONNECTOR: C-135

Connector: B-08

B-08 (B)

C-135

7 6 5 4 3 2 1


AK300253 AB

CONNECTOR: C-137

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


Connector: B-08

C-137 B-08 (B) 8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

7 6 5 4 3 2 1



AK300253 AB

AK300254 AB

Check output line for damage. Q: Is the check result normal? YES : Go to Step 26 . NO : Repair.

Q: Is the check result normal? YES : Check intermediate connector C-16, and

repair if necessary. If intermediate connector is normal, check and repair harness between B-08 (terminal No. 5) air flow sensor connector and C-135 (terminal No. 40) engine-ECU connector. Check earthing line for damage. No : Repair.


13A-24

TROUBLESHOOTING

Code No. P0105: Barometric Pressure Sensor System

Barometric pressure sensor circuit

B-08 Barometric pressure sensor (Incorporated in air flow sensor)

1 2 3 4 5 6 7

1

5

2 B-W

20

Y-B

J/C (1) C-16

G-W 17

B-W 81

85

40

C-135

C-137

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

5V Engine-ECU


OPERATION A power voltage of 5 V is applied to the barometric pressure sensor power terminal (terminal No. 1) of the air flow sensor connector from the engine-ECU (terminal No. 81) and earthed to the engine-ECU (terminal No. 40) from the air flow sensor (terminal No. 5). The sensor signal is inputted to the engine-ECU (terminal No. 85) from the barometric pressure sensor output terminal (terminal No. 2) of the air flow sensor connector. FUNCTION The barometric pressure sensor converts the barometric pressure into a voltage signal and inputs the signal to the engine-ECU.

In response to the signal, the engine-ECU corrects the fuel injection amount, etc. TROUBLE JUDGMENT Check Condition 2 seconds later after the ignition switch has been in "ON" position or the engine has started up. The battery voltage is 8 V or more. Judgment Criterion The sensor output voltage is 4.5 V or more (Barometric pressure of above 114 kPa or equivalent) for 2 seconds. Or The sensor output voltage is 0.2 V or less (Barometric pressure of below 53kpa or equivalent) for 2 seconds.


13A-25

TROUBLESHOOTING

PROBABLE CAUSE Failed barometric pressure sensor Open/short circuit in barometric pressure sensor circuit or loose connector contact Failed engine-ECU


DIAGNOSIS PROCEDURE STEP 1. MUT-II data list Refer to Data list reference table 313A. a. Item 25: Barometric pressure sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-08 air flow sensor connector

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB


Connector: B-08

STEP 4. Measure voltage at C-137 engine-ECU connector. CONNECTOR: C-137 B-08 (B)

7 6 5 4 3 2 1


AK300253 AB


C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-26

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




Connector: B-08

B-08 (B)

7 6 5 4 3 2 1


AK300254 AB

AK300253 AB


(terminal No. 1) air flow sensor connector and C-137 (terminal No. 81) engine-ECU connector. Check power supply line for open circuit. NO : Repair.


13A-27

TROUBLESHOOTING



Connector: B-08

B-08 (B) B-08 (B) 7 6 5 4 3 2 1


7 6 5 4 3 2 1


AK300253 AB

CONNECTOR: C-137

AK300253 AB

Disconnect connector, and measure at harness side. Voltage between terminal No. 5 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 12 . NO : Go to Step 10 .

C-137


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Check power supply line for short circuit. Q: Is the check result normal? YES : Go to Step 8 . NO : Repair.

STEP 8. MUT-II data list Refer to Data list reference table 313A. a. Item No. 25: Barometric pressure sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




13A-28

TROUBLESHOOTING



Connector: B-08

B-08 (B) B-08 (B) 7 6 5 4 3 2 1


7 6 5 4 3 2 1


AK300253 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


NOTE: Before checking harness, check intermediate connector C-16, and repair if necessary. Check earthing line for open circuit or damage. Q: Is the check result normal? YES : Go to Step 8 . NO : Repair.

AK300253 AB

Use special tool test harness (MB991709) to connect only terminal No. 1, No. 2 and No. 5, and then measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: 4.9 - 5.1 V Q: Is the check result normal? YES : Go to Step 14 . NO : Go to Step 13 .



13A-29


B-08 (B) C-137 7 6 5 4 3 2 1

Harness side connector 8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Connector: B-08

Use special tool test harness (MB991709) to connect only terminal No. 1, No. 2 and No. 5, and then measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 5 and earth. OK: 0.5 V or less Q: Is the check result normal? YES : Go to Step 16 . NO : Go to Step 15 .

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB


(terminal No. 1) air flow sensor connector and C-137 (terminal No. 81) engine-ECU connector. Check power supply line for damage. NO : Repair.

AK300253 AB


13A-30

TROUBLESHOOTING



B-08 (B) C-135 7 6 5 4 3 2 1

Harness side connector 38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


Connector: B-08

AK300253 AB

Use special tool test harness (MB991709) to connect only terminal No. 1, No. 2 and No. 5, and then measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 2 and earth. OK: Altitude 0m: 3.8 - 4.2 V Altitude 600m: 3.5 - 3.9 V Altitude 1,200m: 3.3 - 3.7 V Altitude 1,800m: 3.0 - 3.4 V Q: Is the check result normal? YES : Go to Step 19 . NO : Go to Step 17 .

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB


repair if necessary. If intermediate connector is normal, check and repair harness between B-08 (terminal No. 5) air flow sensor connector and C-135 (terminal No. 40) engine-ECU connector. Check earthing line for damage. NO : Repair.


C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-31

TROUBLESHOOTING



Connector: B-08

B-08 (B) C-137 7 6 5 4 3 2 1


AK300253 AB

CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 85 and earth. OK: Altitude 0m: 3.8 - 4.2 V Altitude 600m: 3.5 - 3.9 V Altitude 1,200m: 3.3 - 3.7 V Altitude 1,800m: 3.0 - 3.4 V

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Check output line for short circuit and damage. Q: Is the check result normal? YES : Replace air flow sensor. NO : Repair.



13A-32

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




Connector: B-08

B-08 (B)

7 6 5 4 3 2 1


AK300254 AB

AK300253 AB


(terminal No. 2) air flow sensor connector and C-137 (terminal No. 85) engine-ECU connector. Check output line for open circuit and damage. NO : Repair.


13A-33

TROUBLESHOOTING

Code No. P0110: Intake Air Temperature Sensor System

Intake air temperature sensor circuit

B-08 Intake air temperature sensor (Incorporated in air flow sensor)

1 2 3 4 5 6 7

5

6

B-W

20 J/C (1) C-16

Y-L

17 B-W

72

40 C-137

C-135

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

5V Engine-ECU


OPERATION A power voltage of 5 V is applied to the intake air temperature sensor output terminal (terminal No. 6) of the air flow sensor connector from the engine-ECU (terminal No. 72) The power voltage is earthed to the engine-ECU (terminal No. 40) from the air flow sensor (terminal No. 5). FUNCTION The intake air temperature sensor converts the intake air temperature into a voltage and inputs the voltage signal to the engine-ECU. In response to the signal, the engine-ECU corrects the fuel injection amount, etc. The intake air temperature sensor is a kind of resistor, which has characteristics to reduce its resistance as the intake air temperature rises. Therefore, the sensor output voltage varies with the intake air temperature, and becomes lower as the intake air temperature rises.

TROUBLE JUDGMENT Check Condition 2 seconds later after the ignition switch has been in "ON" position or the engine has started up. Judgment Criterion The sensor output voltage is 4.6 V or more (intake air temperature of below -45C or equivalent) for 2 seconds. Or The sensor output voltage is 0.2 V or loss (intake air temperature above 125C or equivalent) for 2 seconds. PROBABLE CAUSE Failed intake air temperature sensor Open/short circuit in intake air temperature sensor circuit or loose connector contact Failed engine-ECU


13A-34

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 4. Measure voltage at B-08 air flow sensor connector.

STEP 1. MUT-II data list Refer to Data list reference table 313A. a. Item 13: Intake air temperature sensor OK: At ambient temperature (atmospheric temperature) or equivalent. Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-08 air flow sensor connector

Connector: B-08

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB

Disconnect connector, and measure at harness side. Voltage between terminal No. 5 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 8 . NO : Go to Step 5 .

Connector: B-08


B-08 (B)

CONNECTOR: C-135 7 6 5 4 3 2 1


AK300253 AB


STEP 3. Check intake air temperature sensor itself. Check intake air temperature sensor itself (Refer to 313A). Q: Is the check result normal? YES : Go to Step 4 . NO : Replace air flow sensor.

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39





13A-35

STEP 7. MUT-II data list Refer to Data list reference table 313A. a. Item 13: Intake air temperature sensor OK: At ambient temperature (atmospheric temperature) or equivalent. Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


B-08 (B)

7 6 5 4 3 2 1


AK300253 AB

CONNECTOR: C-135


C-135

B-08 (B)

7 6 5 4 3 2 1


38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



AK300253 AB



13A-36

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



Connector: B-08

Connector: B-08

B-08 (B)

B-08 (B)

7 6 5 4 3 2 1


7 6 5 4 3 2 1 AK300253 AB

Measure engine-ECU terminal voltage. Disconnect B-08 air flow sensor connector. Ignition switch: ON Voltage between terminal No. 72 and earth. OK: 4.5 - 4.9 V


AK300254 AB


AK300253 AB


(terminal No. 6) air flow sensor connector and C-137 (terminal No. 72) engine-ECU connector. Check output line for open circuit. NO : Repair.


13A-37

TROUBLESHOOTING



B-08 (B) C-137 7 6 5 4 3 2 1


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

AK300253 AB

CONNECTOR: C-137



8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-38

TROUBLESHOOTING



B-08 (B) B-08 (B) 7 6 5 4 3 2 1


AK300253 AB

Use special tool test harness (MB991709) to connect only terminal No. 5 and No. 6, and then measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 6 and earth. OK: Ambient temperature at -20C: 3.8 - 4.4 V Ambient temperature at 0C: 3.2 - 3.8 V Ambient temperature at 20C: 2.3 - 2.9 V Ambient temperature at 40C: 1.5 - 2.1 V Ambient temperature at 60C: 0.8 - 1.4 V Ambient temperature at 80C: 0.4 - 1.0 V Q: Is the check result normal? YES : Go to Step 7 . NO : Go to Step 14 .

7 6 5 4 3 2 1


AK300253 AB

CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82






C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


Connector: B-08

B-08 (B)

7 6 5 4 3 2 1


AK300253 AB

Q: Is the check result normal? YES : Check intermediate connector C-16 and

repair if necessary. If intermediate connector is normal, check and repair harness between B-08 (terminal No. 5) air flow sensor connector and C-135 (terminal No. 40) engine-ECU connector. Check earthing line for damage. NO : Repair.

13A-39


13A-40

TROUBLESHOOTING

Code No. P0115: Engine Coolant Temperature Sensor System

Engine coolant temperature sensor circuit

B-108 (MU802406) Engine coolant temperature sensor

1 2

2

BR

1

Y-G

92

83

C-137 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

Engine-ECU 5V


OPERATION A power voltage of 5 V is applied to the engine coolant temperature sensor output terminal (terminal No. 1) from the engine-ECU (terminal No. 83). The power voltage is earthed to the engine-ECU (terminal No. 92) from the engine coolant temperature sensor (terminal No. 2). FUNCTION The engine coolant temperature sensor converts the engine coolant temperature into a voltage signal, and inputs the voltage to the engine-ECU. In response to the signal, the engine-ECU controls the fuel infection amount and the fast idle speed when the engine is cold state.

The engine coolant temperature sensor is a kind of resistor, which has characteristics to reduce its resistance as the engine coolant temperature rises. Therefore, the sensor output voltage varies with the engine coolant temperature, and becomes lower as the engine coolant temperature rises. TROUBLE JUDGMENT Check Condition 2 seconds later after the ignition switch has been in "ON" position or just after the engine has started up. Judgment Criterion The sensor output voltage is 4.6 V or more (water temperature of below -45C or equivalent) for 2 seconds. Or The sensor output voltage of 0.1 V or less (water temperature of above 140C or equivalent) for 2 seconds.


13A-41

TROUBLESHOOTING

Check Condition After the engine has started up.

STEP 3. Measure resistance at B-108 engine coolant temperature sensor connector.

Judging Conditions The sensor output voltage rises 1.6 V or more (engine coolant temperature below 40C or equivalent) from 1.6 V or less (engine coolant temperature above 40C or equivalent).

Connector: B-108 2 1 Harness side connector

PROBABLE CAUSE Failed engine coolant temperature sensor Open/short circuit in engine coolant temperature sensor circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. MUT-II data list Refer to Data list reference table 313A. a. Item 21: Engine coolant temperature sensor OK: Engine cold state: At ambient temperature (atmospheric temperature) or equivalent. Engine hot state: At 80 - 120C Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-108 engine coolant temperature sensor connector Connector: B-108 2 1 Harness side connector

B-108 (B) AK300261 AB


B-108 (B) AK300261 AB

Disconnect connector, and measure at sensor side. Resistance between terminal No. 1 and No. 2. OK: Engine coolant temperature at -20C: 14 - 17 kW Engine coolant temperature at 0C: 5.1 - 6.5 kW Engine coolant temperature at 20C: 2.1 - 2.7 kW Engine coolant temperature at 40C: 0.9 - 1.3 kW Engine coolant temperature at 60C: 0.48 0.68 kW Engine coolant temperature at 80C: 0.26 0.36 kW Q: Is the check result normal? YES : Go to Step 4 . NO : Replace engine coolant temperature

sensor.


13A-42

TROUBLESHOOTING

STEP 4. Measure voltage at B-108 engine coolant temperature sensor connector. Connector: B-108


2 1 Harness side connector

B-108 (B)

C-137

AK300261 AB


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



B-108 (B) AK300261 AB

Measure engine-ECU terminal voltage. Disconnect B-108 engine coolant temperature sensor. Ignition switch: ON Voltage between terminal No. 83 and earth. OK: 4.5 - 4.9 V Q: Is the check result normal? YES : Go to Step 6 . NO : Go to Step 7 .


13A-43

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




B-108 (B) AK300261 AB


(terminal No. 1) engine coolant temperature sensor connector and C-137 (terminal No. 83) engine-ECU connector. Check output line for open circuit. NO : Repair.

AK300254 AB



13A-44

TROUBLESHOOTING

STEP 8. Check harness between B-108 (terminal No. 1) engine coolant temperature sensor connector and C-137 (terminal No. 83) engineECU connector.

STEP 10. Measure voltage at B-108 engine coolant temperature sensor connector. Connector: B-108 2 1

Connector: B-108



B-108 (B) AK300261 AB

B-108 (B) AK300261 AB

CONNECTOR: C-137

Disconnect connector and measure at harness side. Voltage between terminal No. 2 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 13 . NO : Go to Step 11 .


C-137

Q: Is the check result normal? CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



STEP 9. MUT-II data list Refer to Data list reference table 313A. a. Item 21: Engine coolant temperature sensor OK: Engine cold state: At ambient temperature (atmospheric temperature) or equivalent. Engine hot state: At 80 - 120 C Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


YES : Go to Step 12 . NO : Repair.


13A-45

TROUBLESHOOTING

STEP 12. Check harness between B-108 (terminal No. 2) engine coolant temperature sensor connector and C-137 (terminal No. 92) engineECU connector.

STEP 13. Measure voltage at B-108 engine coolant temperature sensor connector. Connector: B-108 2 1

Connector: B-108



B-108 (B) AK300261 AB

B-108 (B) AK300261 AB

CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Check earthing line for open circuit and damage. Q: Is the check result normal? YES : Go to Step 9 . NO : Repair.

Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: Engine coolant temperature at -20C: 3.9 - 4.5 V Engine coolant temperature at 0C: 3.2 - 3.8 V Engine coolant temperature at 20C: 2.3 - 2.9 V Engine coolant temperature at 40C: 1.3 - 1.9 V Engine coolant temperature at 60C: 0.7 - 1.3 V Engine coolant temperature at 80C: 0.3 - 0.9 V Q: Is the check result normal? YES : Go to Step 9 . NO : Go to Step 14 .


13A-46

TROUBLESHOOTING


STEP 15. Check harness between B-108 (terminal No. 1) engine coolant temperature sensor connector and C-137 (terminal No. 83) engineECU connector. Connector: B-108 2 1 Harness side connector

C-137 B-108 (B) 8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

AK300261 AB


CONNECTOR: C-137 AK300254 AB


C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82





C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



B-108 (B) AK300261 AB

Q: Is the check result normal? YES : Check harness between B-108 (terminal

No. 2) engine coolant temperature sensor connector and C-137 (terminal No. 92) engine-ECU connector. Check earthing line for damage. NO : Repair.

13A-47


13A-48

TROUBLESHOOTING

Code No. P0120: Throttle Position Sensor System Throttle position sensor circuit

B-06 (MU802724) Throttle position sensor

1 2 3 4

1

Y-B

O

81

4

2

BR

84

92

C-137 Engine-ECU

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

5V


OPERATION A power voltage of 5 V is applied to the throttle position sensor (terminal No. 1) from the engineECU (terminal No. 81). The power voltage is earthed to the engine-ECU (terminal No. 92) from the throttle position sensor (terminal No. 4). The sensor signal is inputted to the engine-ECU (terminal No. 84) from the throttle position sensor output terminal (terminal No. 2). FUNCTION The throttle position sensor converts the opening of the throttle valve into a voltage and inputs the voltage signal to the engine-ECU. In response to the signal, the engine-ECU checks the opening of the throttle valve.

TROUBLE JUDGMENT Check Condition Ignition switch: ON Or Excluding 2 seconds after the ignition switch has been in "ON" position or just after the engine has started up. Judgment Criteria The sensor output voltage is 0.2 V or less for 2 seconds. Or When the engine speed is 1,000 r/min or less and the charging efficiency is 40% or less, the throttle position sensor output voltage is 4.4 V or more for 2 seconds.


13A-49

TROUBLESHOOTING

PROBABLE CAUSE Failed throttle position sensor Open/short circuit in throttle position sensor circuit or loose connector contact Failed engine-ECU

STEP 4. Measure voltage at B-06 throttle position sensor connector. Connector: B-06 B-06 (B)

DIAGNOSIS PROCEDURE STEP 1. MUT-II data list Refer to Data list reference table 313A. a. Item 14: Throttle position sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-06 throttle position sensor connector

4 3 2 1 Harness side connector

AK300263 AB


Connector: B-06 B-06 (B)



AK300263 AB


STEP 3. Check throttle position sensor itself. Check throttle position sensor itself (Refer to 313A). Q: Is the check result normal? YES : Go to Step 4 . NO : Replace throttle position sensor.

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-50

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82






AK300254 AB

AK300263 AB


(terminal No. 1) throttle position sensor connector and C-137 (terminal No. 81) engine-ECU connector. Check power supply line for open circuit. NO : Repair.


13A-51

TROUBLESHOOTING

STEP 8. Check harness between B-06 (terminal No. 1) throttle position sensor connector and C137 (terminal No. 81) engine-ECU connector.

STEP 10. Measure resistance at B-06 throttle position sensor connector. Connector: B-06

Connector: B-06

B-06 (B) B-06 (B)



AK300263 AB

CONNECTOR: C-137

AK300263 AB

Disconnect connector, and measure at harness side. Resistance between terminal No. 4 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 13 . NO : Go to Step 11 .

C-137


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Check power supply line for short circuit. Q: Is the check result normal? YES : Go to Step 9 . NO : Repair.

STEP 9. MUT-II data list Refer to Data list reference table 313A. a. Item 14: Throttle position sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-52

TROUBLESHOOTING

STEP 12. Check harness between B-06 (terminal No. 4) throttle position sensor connector and C137 (terminal No. 92) engine-ECU connector.

STEP 13. Measure voltage at B-06 throttle position sensor connector. Connector: B-06

Connector: B-06

B-06 (B) B-06 (B)



AK300263 AB

CONNECTOR: C-137

Use special tool test harness (MB991536) to connect connector, and measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: 4.9 - 5.1 V Q: Is the check result normal? YES : Go to Step 15 . NO : Go to Step 14 .

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



AK300263 AB


13A-53

TROUBLESHOOTING



C-137


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Connector: B-06


Use special tool test harness (MB991536) to connect connector, and measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 4 and earth. OK: 0.5 V or less Q: Is the check result normal? YES : Go to Step 17 . NO : Go to Step 16 .

B-06 (B)

AK300263 AB


(terminal No. 1) throttle position sensor connector and C-137 (terminal No. 81) engine-ECU connector. Check power supply line for damage. NO : Repair.

AK300263 AB


13A-54

TROUBLESHOOTING



C-137


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



AK300263 AB

Use special tool test harness (MB991536) to connect connector, and measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 2 and earth. OK: Accelerator pedal fully released: 0.535 - 0.735 V Accelerator pedal fully depressed: 4.5 - 5.0 V Q: Is the check result normal? YES : Go to Step 20 . NO : Go to Step 18 .


AK300263 AB


(terminal No. 4) throttle position sensor connector and C-137 (terminal No. 92) engine-ECU connector. Check earthing line for damage. NO : Repair.

STEP 18. Adjust throttle position sensor Adjust throttle position sensor (Refer to 313A ). Q: Is the adjusted value normal? YES : Go to Step 19 . NO : Adjust throttle position sensor.


13A-55

TROUBLESHOOTING


STEP 20. Measure voltage at C-137 engine-ECU connector CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 84 and earth. OK: Accelerator pedal fully released: 0.535 - 0.735 V Accelerator pedal fully depressed: 4.5 - 5.0 V



AK300254 AB

AK300263 AB


(terminal No. 2) throttle position sensor connector and C-137 (terminal No. 84) engine-ECU connector. Check output line for short circuit and damage. NO : Repair.



13A-56

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82






AK300254 AB

AK300263 AB


(terminal No. 2) throttle position sensor connector and C-137 (terminal No. 84) engine-ECU connector. Check output line for open circuit and damage. NO : Repair.

Code No. P0125: Feedback system monitor OPERATION Refer to P0201 injector circuit 313A. Refer to P0202 injector circuit 313A. Refer to P0203 injector circuit 313A. Refer to P0204 injector circuit 313A. Refer to P0130 Oxygen sensor (front) circuit 313A. FUNCTION The engine-ECU effects air-fuel ratio feedback control in accordance with the signals from the heater oxygen sensor (front).

If the heated oxygen sensor (front) has deteriorated, corrections will be made by the heated oxygen sensor (rear). diagnosis code P0125 becomes stored in memory if a failure is detected in the above air/fuel ratio feedback control system. TROUBLE JUDGMENT Check Conditions The engine coolant temperature approximately. 82C or more.


13A-57

TROUBLESHOOTING

Within the range of air-fuel ratio feedback operation. Not in low speed operation. Judgment Criteria The oxygen sensor output voltage is not deviated from 0.5 V for 30 seconds. PROBABLE CAUSE Failed oxygen sensor (front) Harness damage in oxygen sensor (front) circuit or loose connector contact Failed oxygen sensor (rear) NOTE: When the oxygen sensor (front) begins to deteriorate, the oxygen sensor output voltage will deviate from the voltage when the sensor was new (normally 0.5 volt at stoichiometric ratio). This deviation will be corrected by the oxygen sensor (rear).If the oxygen sensor (rear) responds poorly because it has deteriorated, it will improperly correct the oxygen sensor (front). Thus, even when closed loop control is being effected, the fluctuation of the oxygen sensor (front) output voltage decreases, without intersecting with 0.5 volt. As a result, there is a possibility of diagnosis code P0125 becoming registered. Failed fuel system Failed exhaust system Failed engine-ECU

STEP 3.Check for intake of air from intake hose and inlet manifold. Q: Is the check result normal? YES : Go to Step 4 . NO : Repair.

STEP 4.Check for leakage of exhaust emission from exhaust manifold. Q: Is the check result normal? YES : Go to Step 5 . NO : Repair.

STEP 5.Check throttle body (throttle valve portion) for contamination. Q: Is the check result normal? YES : Go to Step 6 . NO : Clean throttle body (throttle valve portion)

(Refer to 313A). STEP 6. Connector check: B-112 oxygen sensor (front) connector, C-137 engine-ECU connector Connector: B-112 Oxygen sensor (front) B-112 (B)

DIAGNOSIS PROCEDURE STEP 1. MUT-II self-diag code Q: Is any other diagnosis code than P0170 output? YES : Inspection chart for diagnosis code (Refer

to 313A). NO : Go to Step 2 .

2 1 4 3 Harness side connector CONNECTOR: C-137

STEP 2.MUT-II data list Refer to Data list reference table 313A. a. Item 12: Air flow sensor b. Item 21: Engine coolant temperature sensor c. Item 25: Barometric pressure sensor d. Item 69: Oxygen sensor (rear) Q: Are the check results normal? YES : Go to Step 3 . NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an abnormal data valve (Refer to Inspection Chart for Diagnosis Codes 313A).

AK300264 AB

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-58

TROUBLESHOOTING

STEP 7. Check oxygen sensor (front) itself. Check oxygen sensor (front) itself (Refer to 313A).

STEP 9. Connector check: Injector connector Connector: B-01, B-02, B-04, B-05

Q: Is the check result normal? YES : Go to Step 8 . NO : Replace oxygen sensor (front).

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

STEP 8. Check harness between B-112 oxygen sensor (front) connector and C-137 engine-ECU connector. Connector: B-112 Oxygen sensor (front) B-112 (B)

M


a. b. c. d.

AK300265 AB

B-01 (No.1 injector connector) B-02 (No.2 injector connector) B-04 (No.3 injector connector) B-05 (No.4 injector connector)



AK300264 AB

CONNECTOR: C-137

STEP 10. Check injector itself. Check Injector itself (Refer to 313A). Q: Is the check result normal? YES : Go to Step 11 . NO : Replace injector.

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-59

TROUBLESHOOTING

STEP 11. Connector check: B-17X engine control relay connector and B-134 engine-ECU connector. CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

STEP 12. Check harness between B-17X engine control relay connector and injector connector. CONNECTOR: B-17X Relay box’s triangle marks

B-17X

2

1

4

3

B-17X



AK300255 AB

AK300255 AB

Connector: B-01, B-02, B-04, B-05 CONNECTOR: C-134 B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



M


AK300265 AB

a. Check harness between B-17X (terminal No. 1) engine control relay connector and B-01 (terminal No. 1) No. 1 injector connector. b. Check harness between B-17X (terminal No. 1) engine control relay connector and B-02 (terminal No. 1) No. 2 injector connector. c. Check harness between B-17X (terminal No. 1) engine control relay connector and B-04 (terminal No. 1) No. 3 injector connector. d. Check harness between B-17X (terminal No. 1) engine control relay connector and B-05 (terminal No. 1) No. 4 injector connector. Check power supply line for damage. Q: Are the check results normal? YES : Go to Step 13 . NO : Repair


13A-60

TROUBLESHOOTING

STEP 13. Check harness between injector connector and C-134 engine-ECU connector.

Q: Is the check result normal? YES : Repair. NO : Replace engine-ECU

Connector: B-01, B-02, B-04, B-05

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

M


AK300265 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


a. Check harness between B-01 (terminal No. 2) No. 1injector connector and C-134 (terminal No. 1) engine-ECU connector. b. Check harness between B-02 (terminal No. 2) No. 2 injector connector and C-134 (terminal No. 14) engine-ECU connector. c. Check harness between B-04 (terminal No. 2) No. 3 injector connector and C-134 (terminal No. 2) engine-ECU connector. d. Check harness between B-05 (terminal No. 2) No. 4 injector connector and C-134 (terminal No. 15) engine-ECU connector. Q: Are the check results normal? YES : Go to Step 14 . NO : Repair

STEP 14. Measure fuel pressure. Measure fuel pressure (Refer to 313A).


13A-61

TROUBLESHOOTING

Code No. P0130: Oxygen Sensor (Front) System

Oxygen sensor (front) circuit

B-112 (MU802605) Oxygen sensor (front)

1 2 3 4

From Engine control relay

1

3

2

4

To engine-ECU B

2 B

W 92

J/C (2) C-17

1

76 B

C-137 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

Engine-ECU


OPERATION The sensor signal is inputted to the engine-ECU (terminal No. 76) from the oxygen sensor output terminal (terminal No. 4). The oxygen sensor (terminal No. 2) is earthed with engine-ECU (terminal No. 92). FUNCTION The oxygen sensor converts the concentration of oxygen in the exhaust emission into a voltage and inputs the signal to the engine-ECU. When the air-fuel ratio is richer than the theoretical air-fuel ratio, the oxygen sensor outputs a voltage of about 1 V. When it is leaner than the theoretical air-fuel ratio, it outputs a voltage of about 0 V. In response to the signal, the engine-ECU controls the fuel infection amount so that the air-fuel ratio can be equivalent to the theoretical air-fuel ratio.

TROUBLE JUDGMENT Check Condition Above 3 minutes later after the engine has started up. The engine coolant temperature approximately 82C or more. The engine speed is 1,200 r/min or more. The volumetric efficiency 25% or more. The monitoring time is 5 seconds. Judgment Criteria When the oxygen sensor (front) output voltage is 0.2 V or less and a power voltage of 5 V is applied to the oxygen sensor (front) in the engine-ECU, the sensor output voltage is 4.5 V or more. Check Condition The engine speed is 3,000 r/min or less. During the air-fuel ratio feedback control


13A-62

TROUBLESHOOTING

Judgment Criteria When the oxygen sensor (front) output frequency is 6 or less for 10 seconds on the average.

STEP 3. Measure voltage at B-112 oxygen sensor (front) connector. Connector: B-112

PROBABLE CAUSE Failed oxygen sensor Open/short circuit in oxygen sensor (front) circuit or loose connector contact Failed engine-ECU

Oxygen sensor (front) B-112 (B)

2 1 4 3

DIAGNOSIS PROCEDURE STEP 1. MUT-II data list Refer to Data list reference table 313A. a. Item 11: Oxygen sensor (front) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-112 oxygen sensor (front) connector


AK300264 AB



Connector: B-112 Oxygen sensor (front) B-112 (B)

C-137



AK300264 AB

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-63

TROUBLESHOOTING

STEP 5. Check harness between B-112 (terminal No. 2) oxygen sensor (front) connector and C-137 (terminal No. 92) engine-ECU connector. Connector: B-112 Oxygen sensor (front) B-112 (B)

2 1 4 3

STEP 6. MUT-II data list Refer to Data list reference table 313A. a. Item 11: Oxygen sensor (front) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Replace engine-ECU. STEP 7. Measure at B-112 oxygen sensor (front) connector.


AK300264 AB

Connector: B-112 CONNECTOR: C-137

Oxygen sensor (front) B-112 (B)

2 1 4 3

C-137


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



AK300264 AB

Use special tool test harness (MD998464) to connect connector, and measure at pick-up harness. Engine: After warm-up Ignition switch: ON Voltage between terminal No. 2 and earth. OK: 0.5 V or less Q: Is the check result normal? YES : Go to Step 9 . NO : Go to Step 8 .


13A-64

TROUBLESHOOTING


STEP 9. Measure voltage at B-112 oxygen sensor (front) connector. Connector: B-112 Oxygen sensor (front) B-112 (B)

2 1 4 3

C-137

Harness side connector 8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




AK300264 AB


(terminal No. 2) oxygen sensor (front) connector and C-137 (terminal No. 92) engine-ECU connector. Check earthing line for damage. NO : Repair.

AK300264 AB

Use special tool test harness (MD998464) to connect connector, and measure at pick-up harness. Engine: After warm-up Voltage between terminal No. 4 and earth. OK: 600 - 1,000 mV when 200 mV or lower abrupt racing is done a few seconds after abrupt deceleration from 4,000 r/min. Q: Is the check result normal? YES : Go to Step 12 . NO : Go to Step 10 .

STEP 10. Check oxygen sensor itself Check oxygen sensor (front) itself (Refer to 313A). Q: Is the check result normal? YES : Go to Step 11 . NO : Replace oxygen (front) sensor.


13A-65

TROUBLESHOOTING


STEP 12. Measure voltage at C-137 engine-ECU connector.

CONNECTOR: C-137

CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82





AK300264 AB


(terminal No. 4) oxygen sensor (front) connector and C-137 (terminal No. 76) engine-ECU connector. Check output line for damage. NO : Repair.

AK300254 AB

Measure engine-ECU terminal voltage. Transmission: Neutral Engine: After warm-up Voltage between terminal No. 76 and earth. OK: 600 - 1,000 mV when 200 mV or lower abrupt racing is done a few seconds after abrupt deceleration from 4,000 r/min.



13A-66

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82





AK300264 AB


(terminal No. 4) oxygen sensor (front) connector and C-137 (terminal No. 76) engine-ECU connector. Check output line for open circuit. NO : Repair.

AK300254 AB



13A-67

TROUBLESHOOTING

Code No. P0135: Oxygen Sensor Heater (Front) System

Oxygen sensor (front) heater circuit

Battery

W-B W-B

1

2

3

4

3

4

B-17X

Oxygen sensor (front) B-112 (MU8026053)

Engine control relay 1

1 2 3 4

2 1

3

2

4

To engine-ECU

R

Y-R 60 C-136 51 52 53 54 55 56 57 58 59 60 61 62

Engine-ECU


OPERATION Power is supplied to the heater power terminal (terminal No. 1) of the oxygen sensor (front) connector from the engine control relay (terminal No. 1). The heater (terminal No. 3) of the oxygen sensor (front) connector is controlled by the power transistor in the engine-ECU (terminal No. 60).

FUNCTION The power supply to the oxygen sensor heater (front) is controlled by the ON/OFF control of the power transistor in the engine-ECU. Heating the oxygen sensor heater (front) enables the oxygen sensor to provide good response even when the exhaust emission temperature is low.


13A-68

TROUBLESHOOTING

TROUBLE JUDGMENT Check Conditions The engine coolant temperature is approximately. 20C or higher. The oxygen sensor heater (front) is in "ON" position. The engine speed is 50 r/min or more. The battery voltage is 11 - 16 V. Judgment Criteria The heater current of oxygen sensor heater (front) is below 0.2 A or above 3.5 A for 1 second. PROBABLE CAUSE Failed oxygen sensor heater Open/short circuit in oxygen sensor (front) circuit or loose connector contact Failed engine-ECU

STEP 2. Measure resistance at B-112 oxygen sensor (front) connector. Connector: B-112 Oxygen sensor (front) B-112 (B)


AK300264 AB

Disconnect connector, and measure at sensor side. Resistance between terminal No. 1 and No. 3. OK: 4.5 - 8.0 W Q: Is the check result normal? YES : Go to Step 3 . NO : Replace oxygen sensor (front).

DIAGNOSIS PROCEDURE STEP 1. Connector check: B-112 oxygen sensor (front) connector

STEP 3. Measure voltage at B-112 oxygen sensor (front) connector.

Connector: B-112 Oxygen sensor (front)


B-112 (B) B-112 (B)



AK300264 AB


AK300264 AB



13A-69

TROUBLESHOOTING


1

4

3

CONNECTOR: C-136

B-17X


2


C-136


AK300255 AB

56 55 54 53 52 51 62 61 60 59 58 57



B-112 (B)

Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 60 and earth. OK: System voltage


AK300268 AB

AK300264 AB


(terminal No. 1) oxygen sensor connector and B-17X (terminal No. 1) engine control relay connector. Check power supply line for open/short circuit. NO : Repair.



C-136

56 55 54 53 52 51 62 61 60 59 58 57




13A-70

TROUBLESHOOTING

STEP 7. Check harness between B-112 (terminal No. 3) oxygen sensor (front) connector and C-136 (terminal No. 60) engine-ECU connector.



C-136


AK300264 AB

56 55 54 53 52 51 62 61 60 59 58 57

CONNECTOR: C-136



STEP 9. Check harness between B-112 (terminal No. 1) oxygen sensor (front) connector and B17X (terminal No. 1) engine control relay connector.

56 55 54 53 52 51 62 61 60 59 58 57



AK300268 AB

Check earthing line for open/short circuit.

B-112 (B)

Q: Is the check result normal? YES : Replace engine-ECU. NO : Repair. 2 1 4 3 Harness side connector

AK300264 AB


2

1

4

3

B-17X


AK300255 AB

Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 10 . NO : Repair.


STEP 10. Check harness between B-112 (terminal No. 3) oxygen sensor (front) connector and C-136 (terminal No. 60) engine-ECU connector. Connector: B-112 Oxygen sensor (front) B-112 (B)


AK300264 AB

CONNECTOR: C-136

C-136

56 55 54 53 52 51 62 61 60 59 58 57


Check earthing line for damage. Q: Is the check result normal? YES : Go to Step 11 . NO : Repair.

13A-71

STEP 11. Check the trouble symptoms. Q: Does trouble symptom persist? YES : Replace engine-ECU. NO : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300).


13A-72

TROUBLESHOOTING

Code No. P0136: Oxygen Sensor (Rear) System

Oxygen sensor (rear) circuit

C-18 (MU801688)

1 2 3 4


From engine control relay

2

1

3

4

To engine-ECU

B

P

3

L

J/C (2) C-17 92

1

75

B C-137 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

Engine-ECU


OPERATION The sensor signal is inputted to the engine-ECU (terminal No. 75) from the oxygen sensor (rear) output terminal (terminal No. 4). The oxygen sensor (rear) (terminal No. 3) is earthed with engine-ECU (terminal No. 92). FUNCTION The oxygen sensor (rear) converts the concentration of oxygen in the exhaust emission into a voltage signal and inputs the voltage signal to the engine-ECU. When the air-fuel ratio is richer than the theoretical air-fuel ratio, the oxygen sensor (rear) outputs a voltage of about 1 V. When it is leaner than the theoretical air-fuel ratio, it outputs a voltage of about 0 V. In response to the signal, the engine-ECU controls the fuel infection amount so that the air-fuel ratio can be equivalent to the theoretical air-fuel ratio.

TROUBLE JUDGMENT Check Conditions Above 3 minutes later after the engine has started up. The engine coolant temperature is approximately. 82C or higher. The engine speed is 1,200 r/min or more. The volumetric efficiency is 25% or more. The monitoring time is 5 seconds. Judgment Criteria When the oxygen sensor (rear) output voltage is 0.2 V or less and a power voltage of 5 V is applied to the oxygen sensor (rear) in the engineECU, the sensor output voltage is 4.5 V or more. PROBABLE CAUSE Failed oxygen sensor Open/short circuit in oxygen sensor (rear) circuit or loose connector contact Failed engine-ECU


13A-73

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3. Measure voltage at C-18 oxygen sensor (rear) connector.

STEP 1. MUT-II data list Refer to Data list reference table 313A. a. Item 59: Oxygen sensor (rear)

Connector: C-18 1 2 3 4

Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 .

Harness side connector C-18


STEP 2. Connector check: C-18 oxygen sensor (rear) connector Connector: C-18 1 2 3 4 Harness side connector C-18


AK300270 AB


STEP 4. Connector check: C-137 engine-ECU connector AK300270 AB

CONNECTOR: C-137


C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-74

TROUBLESHOOTING

STEP 5. Check harness between C-18 (terminal No. 3) oxygen sensor (rear) connector and C-137 (terminal No. 92) engine-ECU connector.

STEP 6. MUT-II data list Refer to Data list reference table 313A. a. Item 59: Oxygen sensor (rear) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

Connector: C-18 1 2 3 4 Harness side connector


C-18


STEP 7. Measure voltage at C-18 oxygen sensor (rear) connector. Connector: C-18 1 2 3 4 Harness side connector

AK300270 AB

C-18

CONNECTOR: C-137


C-137 AK300270 AB

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness. Engine: After warm-up Ignition switch: ON Voltage between terminal No. 3 and earth. OK: 0.5 V or less Q: Is the check result normal? YES : Go to Step 9 . NO : Go to Step 8 .


13A-75

TROUBLESHOOTING


STEP 9. Measure voltage at C-18 oxygen sensor (rear) connector. Connector: C-18 1 2 3 4 Harness side connector C-18

C-137 Oxygen sensor (rear) 8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Connector: C-18 1 2 3 4 Harness side connector C-18


AK300270 AB

Q: Is the check result normal? YES : Check and repair harness between C-18

(terminal No. 3) oxygen sensor connector and C-137 (terminal No. 92) engine-ECU connector. Check earthing line for damage. NO : Repair.

AK300270 AB

Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness. Engine: After warm-up Voltage between terminal No. 4 and earth. OK: 600 - 1,000 mV when 200 mV or lower abrupt racing is done a few seconds after abrupt deceleration from 4,000 r/min. Q: Is the check result normal? YES : Go to Step 12 . NO : Go to Step 10 .

STEP 10. Check oxygen sensor (rear) itself. Check oxygen sensor (rear) itself (Refer to 313A). Q: Is the check result normal? YES : Go to Step 11 . NO : Replace oxygen (rear) sensor.


13A-76

TROUBLESHOOTING



CONNECTOR: C-137

CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82





AK300270 AB


(terminal No. 4) oxygen sensor connector and C-137 (terminal No. 75) engine-ECU connector. Check output line for damage. NO : Repair.

AK300254 AB

Measure engine-ECU terminal voltage. Transmission: Neutral Engine: After warm-up Voltage between terminal No. 75 and earth. OK: 600 - 1,000 mV when 200 mV or lower abrupt racing is done a few seconds after abrupt deceleration from 4,000 r/min.



13A-77

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82





AK300270 AB


(terminal No. 4) oxygen sensor (rear) connector and C-137 (terminal No. 75) engine-ECU connector. Check output line for open circuit. NO : Repair.

AK300254 AB



13A-78

TROUBLESHOOTING

Code No. P0141: Oxygen Sensor Heater (Rear) System

Oxygen sensor (rear) heater circuit

Battery

W-B W-B

1

2

3

4

3

4

B-17X

Oxygen sensor (rear) C-18 (MU801688)

Engine control relay 1

1 2 3 4

2 2

1

3

4

R To engine-ECU

R

2 J/C (2) C-17

1

Y-R

54 C-136 51 52 53 54 55 56 57 58 59 60 61 62

Engine-ECU Wire colour code B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray R: Red P: Pink V:Violet AK300271 AB

OPERATION Power is supplied to the heater power terminal (terminal No. 2) of the oxygen sensor (rear) connector from the engine control relay (terminal No. 1). The heater (terminal No. 1) of the oxygen sensor (rear) connector is controlled by the power transistor in the engine-ECU (terminal No. 54).

FUNCTION The power supply to the oxygen sensor heater (rear) is controlled by the ON/OFF control of the power transistor in the engine-ECU. Heating the oxygen sensor heater (rear) enables the oxygen sensor to provide good response even when the exhaust emission temperature is low.


13A-79

TROUBLESHOOTING

TROUBLE JUDGMENT Judgment Criteria The engine coolant temperature is approximately. 20 C or higher. The oxygen sensor heater (rear) is in "ON" position. The engine speed is 50 r/min or more. The battery voltage is 11 - 16 V. Judgment Criteria The heater current of front oxygen sensor heater (rear) is below 0.2 A or above 3.5 A for 1 second.

STEP 2. Measure resistance at C-18 oxygen sensor (rear) connector. Connector: C-18 1 2 3 4 Harness side connector C-18


PROBABLE CAUSE Failed oxygen sensor heater (rear) Open/short circuit in oxygen sensor (rear) circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. Connector check: C-18 oxygen sensor (rear) connector Connector: C-18 1 2 3 4 Harness side connector

AK300270 AB

Disconnect connector, and measure at sensor side. Resistance between terminal No. 1 and No. 2. OK: 11 - 18 W Q: Is the check result normal? YES : Go to Step 3 . NO : Replace oxygen (rear) sensor.

STEP 3. Measure voltage at C-18 oxygen sensor (rear) connector. Connector: C-18

C-18

1 2 3 4


Harness side connector C-18 AK300270 AB


Q: Is the check result normal? YES : Go to Step 2 . NO : Repair. AK300270 AB



13A-80

TROUBLESHOOTING

STEP 4. Connector check: B-17X engine control relay connector CONNECTOR: C-137


C-136

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

56 55 54 53 52 51 62 61 60 59 58 57





AK300268 AB

Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 54 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 8 . NO : Go to Step 6 .


AK300270 AB


repair if necessary. If intermediate connector is normal, check and repair harness between C-18 (terminal No. 2) oxygen sensor (rear) connector and B-17X (terminal No. 1) engine control relay connector. Check power supply line for open/short circuit. NO : Repair.

C-136

56 55 54 53 52 51 62 61 60 59 58 57




13A-81

TROUBLESHOOTING

STEP 7. Check harness between C-18 (terminal No. 1) oxygen sensor connector and C-136 (terminal No. 54) engine-ECU connector.



C-18

Oxygen sensor (rear) 56 55 54 53 52 51 62 61 60 59 58 57

Harness side connector AK300268 AB AK300270 AB

CONNECTOR: C-136

C-136

56 55 54 53 52 51 62 61 60 59 58 57


Check earthing line for open/short circuit. Q: Is the check result normal? YES : Replace engine-ECU. NO : Repair.



13A-82

TROUBLESHOOTING

STEP 9. Check harness between C-18 (terminal No. 2) oxygen sensor connector and B-17X (terminal No. 1) engine control relay connector. Connector: C-18

STEP 10. Check harness between C-18 (terminal No. 1) oxygen sensor connector and C-136 (terminal No. 54) engine-ECU connector. Connector: C-18

1 2 3 4

1 2 3 4





AK300270 AB


2

1

4

3

AK300270 AB

CONNECTOR: C-136

B-17X


C-136 AK300255 AB

NOTE: Before checking harness, check intermediate connector C-17, and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 10 . NO : Repair.

56 55 54 53 52 51 62 61 60 59 58 57






13A-83

Code No. P0170: Abnormal Fuel System OPERATION Refer to P0201 injector circuit 313A. Refer to P0202 injector circuit 313A. Refer to P0203 injector circuit 313A. Refer to P0204 injector circuit 313A. FUNCTION If the fuel system goes out of order, the fuel correction value will become larger. The engine-ECU checks whether the fuel correction value is within the standard limits. TROUBLE JUDGMENT Check Conditions In learning air-fuel ratio Judgment Criteria The compensation value of fuel injection amount is too low for 2 seconds or more. Or The compensation value of fuel injection amount is too high for 2 seconds or more. PROBABLE CAUSE Failed fuel supply system Failed oxygen sensor (front) Failed intake air temperature sensor Failed air flow sensor Failed purge control solenoid valve Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. MUT-II self-diag code Q: Is any other diagnosis code than P0170 output? YES : Inspection chart for diagnosis code (Refer


STEP 2. MUT-II data list Refer to Data list reference table 313A. a. Item 12: Air flow sensor b. Item 13: Intake air temperature sensor c. Item 21: Engine coolant temperature sensor d. Item 22: Barometric pressure sensor Q: Are the check results normal? YES : Go to Step 3 . NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes 313A). STEP 3. Check for intake of air from intake hose and inlet manifold. Q: Is the check result normal? YES : Go to Step 4 . NO : Repair.

STEP 4. Check for leakage of exhaust emission from exhaust manifold. Q: Is the check result normal? YES : Go to Step 5 . NO : Repair.

STEP 5. Check throttle body (throttle valve portion) for contamination. Q: Is the check result normal? YES : Go to Step 6 . NO : Clean throttle body (throttle valve portion)

(Refer to 313A). STEP 6. MUT-II data list Refer to Data list reference table 313A. a. Item 11: Oxygen sensor (front). Q: Is the check result normal? YES : Go to Step 7 . NO : Check oxygen sensor (front) system (Refer

to313A, Code No. P0130).


13A-84

TROUBLESHOOTING

STEP 7. Connector Check: Injector connector Connector: B-01, B-02, B-04, B-05

STEP 9. Connector check: B-17X engine control relay connector and B-134 engine-ECU connector CONNECTOR: B-17X

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

M


a. b. c. d.

AK300265 AB

B-01 (No.1 injector connector). B-02 (No.2 injector connector). B-04 (No.3 injector connector). B-05 (No.4 injector connector).


2

1

4

3

B-17X


AK300255 AB

CONNECTOR: C-134

Q: Are the check results normal? YES : Go to Step 8 . NO : Replace.

STEP 8. Check injector itself. Check Injector itself (Refer to 313A). Q: Is the check result normal? YES : Go to Step 9 . NO : Replace injector.

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Q: Is the check result normal? YES : Go to Step 10 . NO : Replace.


13A-85

TROUBLESHOOTING

STEP 10. Check harness between B-17X engine control relay connector and injector connector. Connector: B-01, B-02, B-04, B-05

Connector: B-01, B-02, B-04, B-05

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

M

AK300265 AB

CONNECTOR: B-17X

2

1

4

3

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

M



STEP 11. Check harness between injector connector and C-134 engine-ECU connector.


AK300265 AB

CONNECTOR: C-134

B-17X


C-134 AK300255 AB

a. Check harness between B-17X (terminal No. 1) engine control relay connector and B-01 (terminal No. 1) No. 1 injector connector. b. Check harness between B-17X (terminal No. 1) engine control relay connector and B-02 (terminal No. 1) No. 2 injector connector. c. Check harness between B-17X (terminal No. 1) engine control relay connector and B-04 (terminal No. 1) No. 3 injector connector. d. Check harness between B-17X (terminal No. 1) engine control relay connector and B-05 (terminal No. 1) No. 4 injector connector. Check power supply line for damage. Q: Are the check results normal? YES : Go to Step 11 . NO : Replace.

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


a. Check harness between B-01 (terminal No. 2) No. 1injector connector and C-134 (terminal No. 1) engine-ECU connector. b. Check harness between B-02 (terminal No. 2) No. 2 injector connector and C-134 (terminal No. 14) engine-ECU connector. c. Check harness between B-04 (terminal No. 2) No. 3 injector connector and C-134 (terminal No. 2) engine-ECU connector. d. Check harness between B-05 (terminal No. 2) No. 4 injector connector and C-134 (terminal No. 15) engine-ECU connector. Q: Are the check results normal? YES : Go to Step 12 . NO : Replace.

STEP 12. Check purge control solenoid valve itself. Check purge control solenoid valve itself (Refer to GROUP 17 - Emission Control System - Evaporative Emission Control System 317). Q: Is the check result normal? YES : Go to Step 13 . NO : Replace purge control solenoid valve.

13A-86


STEP 13. Measure fuel pressure. Measure fuel pressure (Refer to 313A). Q: Is the check result normal? YES : Replace engine-ECU. NO : Repair.


13A-87

TROUBLESHOOTING

Code No. P0201: No. 1 Injector System

Injector circuit Battery

W-B W-B 3

4 B-17X

1

2

3

4


2

1 R

R Injector No. 1 B-01

R 1

1 2

Injector No. 2

1

1

Injector No. 4

B-04

B-05

1 2

1 2

1 2

2

Y-R

1

Injector No. 3

R

B-02

2

Y

R

1

2

Y-G

14

2

L

2

15

Engine-ECU

C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26


13A-88


OPERATION Power is supplied to the injector (terminal No. 1) from the engine control relay (terminal No. 1). The engine-ECU (terminal No. 1) makes the power transistor in the unit be in "ON" position, and that makes currents go on the injector (terminal No. 2). FUNCTION The engine-ECU controls the power supply interval of the injector. The fuel injection amount of the injector depends on the power supply interval. TROUBLE JUDGMENT Check Conditions The engine speed is 50 - 1,000 r/min. The throttle position sensor output voltage is 1.15 V or less. Injector not in forced drive (actuator test) mode Judgment Criterion No surge voltage of the injector coil is detected for 2 seconds. PROBABLE CAUSE Failed No. 1 injector Open/short circuit in injector circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. MUT-II actuator test Refer to Actuator test reference table list 313A . a. Item 01: No. 1 injector OK: Idling state varies. Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


STEP 2. Connector check: B-01 No. 1 injector connector Connector: B-01

B-01 (GR)

M


AK300265 AC


STEP 3. Measure resistance at B-01 No. 1 injector connector. Connector: B-01

B-01 (GR)

M


AK300265 AC

Disconnect connector, and measure at injector side. Resistance between terminal No. 1 and No. 2. OK: 10.5 - 13.5 W Q: Is the check result normal? YES : Go to Step 4 . NO : Replace No. 1 injector.


13A-89

TROUBLESHOOTING

STEP 4. Measure voltage at B-01 No. 1 injector connector.


Connector: B-01


B-17X

B-01 (GR) 2

1

4

3

M


AK300265 AC

Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: System voltage


AK300255 AB

Connector: B-01

B-01 (GR)


M


AK300265 AC

Q: Is the check result normal? YES : Check and repair harness between B-17X

(terminal No. 1) engine control relay connector and B-01 (terminal No. 1) No. 1 injector connector. Check power supply line for open/short circuit. NO : Repair. STEP 6. Connector check: B-17X engine control relay connector CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

B-17X



AK300255 AB


13A-90

TROUBLESHOOTING

STEP 7. Check harness between B-17X (terminal No. 1) engine control relay connector and B-01 (terminal No. 1) No. 1 injector connector. CONNECTOR: B-17X Relay box’s triangle marks

STEP 9. Check harness between B-01 (terminal No. 2) No.1 injector connector and C-134 (terminal No. 1) engine-ECU connector. Connector: B-01

B-17X B-01 (GR)

2

1

4

3 M


AK300255 AB


AK300265 AC

CONNECTOR: C-134

Connector: B-01

B-01 (GR)

C-134

M


AK300265 AC




C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

Check output line for open/short circuit and damage. Q: Is the check result normal? YES : Go to Step 10 . NO : Repair.


STEP 10. Measure signal waveform at C-134 engine-ECU connector (Use oscilloscope). CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Engine: Idling Transmission: Neutral Voltage between terminal No. 1 and earth. OK: Waveforms should be display on Inspection procedure using an oscilloscope (Refer to 313A). Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


13A-91


13A-92

TROUBLESHOOTING



W-B W-B 3

4 B-17X

1

2

3

4


2

1 R


R 1

1 2

Injector No. 2

1

1

Injector No. 4

B-04

B-05

1 2

1 2

1 2

2

Y-R

1

Injector No. 3

R

B-02

2

Y

R

1

2

Y-G

14

2

L

2

15

Engine-ECU

C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26



13A-93

TROUBLESHOOTING

OPERATION Power is supplied to the injector (terminal No. 1) from the engine control relay (terminal No. 1). The engine-ECU (terminal No. 14) makes the power transistor in the unit be in "ON" position, and that makes currents go on the injector (terminal No. 2). FUNCTION The engine-ECU controls the power supply interval of the injector. The fuel injection amount of the injector depends on the power supply interval. TROUBLE JUDGMENT Check Conditions The engine speed is 50 - 1,000 r/mim. The throttle position sensor output voltage 1.15 V or less. Injector not in forced drive (actuator test) mode Judgment Criteria No surge voltage of the injector coil is detected for 2 seconds. PROBABLE CAUSE Failed No. 2 injector Open/short circuit in No. 2 injector circuit or loose connector contact Failed engine-ECU




B-02 (GR)

M


AK300265 AD


STEP 3. Measure at resistance B-02 No. 2 injector connector. Connector: B-02

B-02 (GR)

M


AK300265 AD



13A-94

TROUBLESHOOTING



Connector: B-02


B-17X

B-02 (GR) 2

1

4

3

M


AK300265 AD



AK300255 AB

Connector: B-02

B-02 (GR)


M


AK300265 AD


(terminal No. 1) engine control relay connector and B-02 (terminal No. 1) No. 2 injector connector. Check power supply line for open/short circuit and damage. NO : Repair. STEP 6. Connector check: B-17X engine control relay connector CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

B-17X



AK300255 AB


13A-95

TROUBLESHOOTING


STEP 9. Check harness between B-02 (terminal No. 2) No. 2 injector connector and C-134 (terminal No. 14) engine-ECU connector. Connector: B-02

B-17X B-02 (GR)

2

1

4

3 M


AK300255 AB


AK300265 AD

CONNECTOR: C-134

Connector: B-02

B-02 (GR)

C-134

M


AK300265 AD




C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



13A-96

TROUBLESHOOTING


C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Engine: Idling Transmission: Neutral Voltage between terminal No. 9 and earth. OK: Waveform should be display on Inspection procedure using an oscilloscope (Refer to 313A). Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP



13A-97

TROUBLESHOOTING



W-B W-B 3

4 B-17X

1

2

3

4


2

1 R


R 1

1 2

Injector No. 2

1

1

Injector No. 4

B-04

B-05

1 2

1 2

1 2

2

Y-R

1

Injector No. 3

R

B-02

2

Y

R

1

2

Y-G

14

2

L

2

15

Engine-ECU

C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26


13A-98


OPERATION Power is supplied to the injector (terminal No. 1) from the engine control relay (terminal No. 1). The engine-ECU (terminal No. 2) makes the power transistor in the unit be in "ON" position, and that makes currents go on the injector (terminal No. 2). FUNCTION The engine-ECU controls the power supply interval of the injector. The fuel injection amount of the injector depends on the power supply interval. TROUBLE JUDGMENT Check Conditions The engine speed is 50 - 1,000 r/mim. The throttle position sensor output voltage is 1.15 V or less. Injector not in forced drive (actuator test) mode Judgment Criteria No surge voltage of the injector coil is detected for 2 seconds. PROBABLE CAUSE Failed No. 3 injector Open/short circuit in No. 3 injector circuit or loose connector contact Failed engine-ECU




B-04 (GR)

M


AK300265 AE



B-04 (GR)

M


AK300265 AE



13A-99

TROUBLESHOOTING



Connector: B-04


B-17X

B-04 (GR) 2

1

4

3

M


AK300265 AE



AK300255 AB

Connector: B-04

B-04 (GR)


M


AK300265 AE


(terminal No. 1) engine control relay connector and B-04 (terminal No. 1) No. 3 injector connector. Check power supply line for open/short circuit. NO : Repair. STEP 6. Connector check: B-17X engine control relay connector CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

B-17X



AK300255 AB


13A-100

TROUBLESHOOTING



B-17X B-04 (GR)

2

1

4

3 M


AK300255 AB


AK300265 AE

CONNECTOR: C-134

Connector: B-04

B-04 (GR)

C-134

M


AK300265 AE




C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




13A-101


13A-102

TROUBLESHOOTING



W-B W-B 3

4 B-17X

1

2

3

4


2

1 R


R 1

1 2

Injector No. 2

1

1

Injector No. 4

B-04

B-05

1 2

1 2

1 2

2

Y-R

1

Injector No. 3

R

B-02

2

Y

R

1

2

Y-G

14

2

L

2

15

Engine-ECU

C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26



13A-103

TROUBLESHOOTING

OPERATION Power is supplied to the injector (terminal No. 1) from the engine control relay (terminal No. 1). The engine-ECU (terminal No. 15) makes the power transistor in the unit be in "ON" position, and that makes currents go on the injector (terminal No. 2). FUNCTION The engine-ECU controls the power supply interval of the injector. The fuel injection amount of the injector depends on the power supply interval. TROUBLE JUDGMENT Check Conditions The engine speed is 50 - 1,000 r/mim. The throttle position sensor output 1.15 V or less. Injector not in forced drive (actuator test) mode Judgment Criterion No surge voltage of the injector coil is detected for 2 seconds PROBABLE CAUSE Failed No. 4 injector Open/short circuit in No. 4 injector circuit or loose connector contact Failed engine-ECU




B-05 (GR)

M


AK300265 AF



B-05 (GR)

M


AK300265 AF



13A-104

TROUBLESHOOTING



Connector: B-05


B-17X

B-05 (GR) 2

1

4

3

M


AK300265 AF



AK300255 AB

Connector: B-05

B-05 (GR)


M


AK300265 AF


(terminal No. 1) engine control relay connector and B-05 (terminal No. 1) No. 4 injector connector. Check power supply line for open/short circuit and damage. NO : Repair. STEP 6. Connector check: B-17X engine control relay connector CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

B-17X


Q: Is the check result normal? YES : Go to Step 7. NO : Repair.

AK300255 AB


13A-105

TROUBLESHOOTING



B-17X B-05 (GR)

2

1

4

3 M


AK300255 AB


AK300265 AF

CONNECTOR: C-134

Connector: B-05

B-05 (GR)

C-134

M


AK300265 AF




C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



13A-106

TROUBLESHOOTING


C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




Code No. P0300: Random cylinder mis-fire detected OPERATION Refer to P0201 injector circuit 313A. Refer to P0202 injector circuit 313A. Refer to P0203 injector circuit 313A. Refer to P0204 injector circuit 313A. FUNCTION If a misfire occurs while the engine is running, the engine speed changes for an instant. The engine-ECU checks for such changes in engine speed. TROUBLE JUDGMENT Check Conditions 5 seconds later after the engine has started up. The engine speed is 500 - 4,500 r/min. The engine coolant temperature is -10C or higher. The intake air temperature is -10C or higher.

The barometric pressure is 72 kPa or more. The volumetric efficiency is 30 - 60%. The adaptive learning has been completed with the vane that generates the crankshaft position signals. During the engine operation except the shift change or low speed driving and rapid acceleration and deceleration, also intermittent operation of air compressor (A/C: within the 3 seconds after changing to ON from OFF or to OFF from ON). The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms. Judgment Criteria The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified number (of 7.3 % on more than the two cylinders) with the engine speed of 200 r/min. Or


13A-107

TROUBLESHOOTING

The number of misfiring (that is 1.5 times the emission standard limit) is beyond the specified number (of 2 % on more than the two cylinders) with the engine speed of 1000 r/min. PROBABLE CAUSE Ignition system related part(s) failed Failed crank angle sensor Incorrect air-fuel ratio Low compression pressure Failed coolant temperature sensor Skipping of timing belt teeth. EGR system and EGR valve failed Failed engine-ECU

STEP 3.Check ignition coil spark. Q: Is the check resuit normal? YES : Go to Step 4 . NO : Check ignition circuit system (Refer to

Inspection procedure 29 313A). STEP 4.Connector check: Injector connector Connector: B-01, B-02, B-04, B-05

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

DIAGNOSIS PROCEDURE M

STEP 1.MUT-II data list Item 22: Crank angle sensor OK: Keep the engine speed constant to make the pulse width of output waveform constant. Q: Is the check result normal? YES : Go to Step 2 . NO : Check crank angle sensor system (Refer to

Code No. P0335 313A). STEP 2.MUT-II data list Refer to Data list reference table 313A. a. Item 21: Engine coolant temperature sensor b. Item 81: Long-term fuel compensation c. Item 82: Short-term fuel compensation Q: Are the check results normal? YES : Go to Step 3 . NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an abnormal data valve (Refer to, Inspection Chart for Diagnosis Codes 313A).


a. b. c. d.

AK300265 AB

B-01 (No.1 injector connector) B-02 (No.2 injector connector) B-04 (No.3 injector connector) B-05 (No.4 injector connector)

Q: Are the check results normal? YES : Go to Step 5 . NO : Repair.

STEP 5.Check injector itself. Check Injector itself (Refer to 313A). Q: Is the check result normal? YES : Go to Step 6 . NO : Replace injector.


13A-108

TROUBLESHOOTING

STEP 6.Connector check: B-17X engine control relay connector and B-134 engine-ECU connector CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

STEP 7. Check harness between B-17X engine control relay connector and injector connector. CONNECTOR: B-17X Relay box’s triangle marks

B-17X

2

1

4

3

B-17X



AK300255 AB

AK300255 AB

Connector: B-01, B-02, B-04, B-05 CONNECTOR: C-134 B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



M


AK300265 AB

a. Check harness between B-17X (terminal No. 1) engine control relay connector and B-01 (terminal No. 1) No. 1 injector connector. b. Check harness between B-17X (terminal No. 1) engine control relay connector and B-02 (terminal No. 1) No. 2 injector connector. c. Check harness between B-17X (terminal No. 1) engine control relay connector and B-04 (terminal No. 1) No. 3 injector connector. d. Check harness between B-17X (terminal No. 1) engine control relay connector and B-05 (terminal No. 1) No. 4 injector connector. Check power supply line for damage. Q: Are the check results normal? YES : Go to Step 8 . NO : Repair.


STEP 8. Check harness between injector connector and C-134 engine-ECU connector. Connector: B-01, B-02, B-04, B-05

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

13A-109

STEP 9. Measure fuel pressure. Measure fuel pressure (Refer to fuel pressure test 313A) Q: Is the check result normal? YES : Go to Step 10 . NO : Repair.

STEP 10. Check for intake of air from intake hose and inlet manifold. M


AK300265 AB


CONNECTOR: C-134

STEP 11. Check for skipped timing belt teeth. Q: Is the check result normal? YES : Go to Step 12 . NO : Repair. C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


a. Check harness between B-01 (terminal No. 2) No. 1injector connector and C-134 (terminal No. 1) engine-ECU connector. b. Check harness between B-02 (terminal No. 2) No. 2 injector connector and C-134 (terminal No. 14) engine-ECU connector. c. Check harness between B-04 (terminal No. 2) No. 3 injector connector and C-134 (terminal No. 2) engine-ECU connector. d. Check harness between B-05 (terminal No. 2) No. 4 injector connector and C-134 (terminal No. 15) engine-ECU connector. Check output line for damage. Q: Are the check results normal? YES : Go to Step 9 . NO : Repair.

STEP 12. Exhaust gas recirculation system check. Exhaust gas recirculation system check [Refer to GROUP 17 - Exhaust gas recirculation (EGR) system 317]. Q: Is the check result normal? YES : Replace engine-ECU NO : Repair.

13A-110


Code No. P0301: No. 1 cylinder mis-fire detection system OPERATION Refer to P0201 injector circuit 313A. FUNCTION If a misfire occurs while the engine is running, the engine speed changes for an instant. The engine-ECU checks for such changes in engine speed. TROUBLE JUDGMENT Check Conditions 5 seconds later after the engine has started up. The engine speed is 500 - 4,500 r/min. The engine coolant temperature is -10C or higher. The intake air temperature is -10C or higher. The barometric pressure is 72 kPa or more. The volumetric efficiency is 30 - 60 %. The adaptive learning has been completed with the vane that generates the crankshaft position signals. During the engine operation except the shift change or low speed driving and rapid acceleration and deceleration, also intermittent operation of air compressor (A/C: within the 3 seconds after changing to ON from OFF or to OFF from ON). The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms. Judgment Criterion The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified number (of 7.3 % on more than the two cylinders) with the engine speed of 200 r/min. Or The number of misfiring (that is 1.5 times the emission standard limit) is beyond the specified number (of 2 % on more than the two cylinders) with the engine speed of 1,000 r/min.

PROBABLE CAUSE Ignition system related part(s) failed Low compression pressure Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1.Check ignition coil spark. Q: Is the check result normal? YES : Go to Step 2 . NO : Check ignition Circuit System (Refer to

Inspection procedure 29 313A) STEP 2.Connector check: B-01 No.1 injector connector Connector: B-01

B-01 (GR)

M


AK300265 AC


STEP 3.Check No.1 injector itself. Check Injector itself (Refer to 313A). Q: Is the check result normal? YES : Go to Step 4 . NO : Replace No.1 injector.


13A-111

TROUBLESHOOTING


STEP 5.Check harness between B-17X (terminal No. 1) engine control relay connector and B-01 (terminal No. 1) No.1 injector connector. CONNECTOR: B-17X

B-17X


2

1

2

1

4

3

4

3


AK300255 AB

CONNECTOR: C-134

B-17X


AK300255 AB

Connector: B-01

B-01 (GR)

C-134

M

2 1 Harness side connector 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



AK300265 AC



13A-112

TROUBLESHOOTING

STEP 6. Check harness between B-01(terminal No. 2) No.1 injector connector and C-134 (terminal No. 1) engine-ECU connector

STEP 7. Measure fuel pressure. Measure fuel pressure (Refer to fuel pressure test 313A). Q: Is the check result normal? YES : Replace engine-ECU. NO : Repair.

Connector: B-01

B-01 (GR)

M


AK300265 AC

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



Code No. P0302: No. 2 cylinder mis-fire detection system OPERATION Refer to P0202 injector circuit 313A. FUNCTION If a misfire occurs while the engine is running, the engine speed changes for an instant. The engine-ECU checks for such changes in engine speed. TROUBLE JUDGMENT Check Conditions 5 seconds later after the engine has started up. The engine speed is 500 - 4,500 r/min. The engine coolant temperature is -10C or higher.

The intake air temperature is -10C or higher. The barometric pressure is 72 kPa or more. The volumetric efficiency is 30 - 60 %. The adaptive learning has been completed with the vane that generates the crankshaft position signals. During the engine operation except the shift change or low speed driving and rapid acceleration and deceleration, also intermittent operation of air compressor (A/C: within the 3 seconds after changing to ON from OFF or to OFF from ON). The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms.


13A-113

TROUBLESHOOTING

Judgment Criterion The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified number (of 7.3 % on more than the two cylinders) with the engine speed of 200 r/min. Or The number of misfiring (that is 1.5 times the emission standard limit) is beyond the specified number (of 2 % on more than the two cylinders) with the engine speed of 1,000 r/min. PROBABLE CAUSE Ignition system related part(s) failed Low compression pressure Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1.Check ignition coil spark. Q: Is the check result normal? YES : Go to Step 2 . NO : Check ignition circuit system (Refer to



2

1

4

3

B-17X


AK300255 AB

CONNECTOR: C-134

Inspection procedure 29 313A). STEP 2.Check connector: B-02 No.2 injector connector Connector: B-02

C-134

B-02 (GR) 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector M



AK300257 AB AK300265 AD



13A-114

TROUBLESHOOTING

STEP 5.Check harness between B-17X (terminal No. 1) engine control relay connector and B02(terminal No. 1) No.2 injector connector.

STEP 6. Check harness between B-02 (terminal No. 2) No.2 injector connector and C-134 (terminal No. 14) engine-ECU connector


Connector: B-02

B-17X B-02 (GR)

2

1

4

3 M



AK300255 AB

AK300265 AD

CONNECTOR: C-134

Connector: B-02

B-02 (GR)

C-134

M


AK300265 AD


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




STEP 7. Measure fuel pressure. Measure fuel pressure (Refer to fuel pressure test 313A) Q: Is the check result normal? YES : Replace engine-ECU. NO : Repair.

Code No. P0303: No. 3 cylinder mis-fire detection system OPERATION Refer to P0203 injector circuit 313A. FUNCTION If a misfire occurs while the engine is running, the engine speed changes for an instant. The engine-ECU checks for such changes in engine speed.

TROUBLE JUDGMENT Check Conditions 5 seconds later after the engine has started up. The engine speed is 500 - 4,500 r/min. The engine coolant temperature is -10C or higher. The intake air temperature is -10C or higher. The barometric pressure is 72 kPa or more.


13A-115

TROUBLESHOOTING

The volumetric efficiency is 30 - 60%. The adaptive learning has been completed with the vane that generates the crankshaft position signals. During the engine operation except the shift change or low speed driving and rapid acceleration and deceleration, also intermittent operation of air compressor (A/C: within the 3 seconds after changing to ON from OFF or to OFF from ON). The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms. Judgment Criterion The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified number (of 7.3 % on more than the two cylinders) with the engine speed of 200 r/min. Or The number of misfiring (that is 1.5 times the emission standard limit) is beyond the specified number (of 2 % on more than the two cylinders) with the engine speed of 1,000 r/min.


STEP 4.Connector check: B-17X engine control relay connector, B-134 engine-ECU connector CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

B-17X


AK300255 AB

CONNECTOR: C-134


DIAGNOSIS PROCEDURE

C-134

STEP 1.Check ignition coil spark. Q: Is the check result normal? YES : Go to Step 2 . NO : Check ignition circuit system (Refer to

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Inspection procedure 29 313A). STEP 2.Connector check: B-04 No.3 injector connector Connector: B-04

B-04 (GR)

M



AK300265 AE

AK300257 AB



13A-116

TROUBLESHOOTING

STEP 5.Check harness between B-17X (terminal No. 1) engine control relay connector and B-04 (terminal No. 1) No.3 injector connector.

STEP 6. Check harness between B-04 (terminal No. 2) No.3 injector connector and C-134 (terminal No. 2) engine-ECU connector


Connector: B-04

B-17X B-04 (GR)

2

1

4

3 M



AK300255 AB

AK300265 AE

CONNECTOR: C-134

Connector: B-04

B-04 (GR)

C-134

M


AK300265 AE


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14





Code No. P0304: No. 4 cylinder mis-fire detection system OPERATION Refer to P0204 injector circuit 313A. FUNCTION If a misfire occurs while the engine is running, the engine speed changes for an instant. The engine-ECU checks for such changes in engine speed.

TROUBLE JUDGMENT Check Conditions 5 seconds later after the engine has started up. The engine speed is 500 - 4,500 r/min. The engine coolant temperature is -10C or higher. The intake air temperature is -10C or higher. The barometric pressure is 72 kPa or more.


13A-117

TROUBLESHOOTING

The volumetric efficiency is 30 - 60%. The adaptive learning has been completed with the vane that generates the crankshaft position signals. During the engine operation except the shift change or low speed driving and rapid acceleration and deceleration, also intermittent operation of air compressor (A/C: within the 3 seconds after changing to ON from OFF or to OFF from ON). The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms. Judgment Criterion The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified number (of 7.3 % on more than the two cylinders) with the engine speed of 200 r/min. Or The number of misfiring (that is 1.5 times the emission standard limit) is beyond the specified number (of 2 % on more than the two cylinders) with the engine speed of 1,000 r/min.



2

1

4

3

B-17X


AK300255 AB

CONNECTOR: C-134


DIAGNOSIS PROCEDURE C-134

STEP 1.Check the ignition coil spark. Q: Is the check result normal? YES : Go to Step 2 . NO : Check ignition Circuit System (Refer to

Inspection procedure 29 313A).

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


STEP 2.Connector check: B-05 No.4 injector connector Connector: B-05

B-05 (GR)

M



AK300265 AF



13A-118

TROUBLESHOOTING

STEP 5.Check harness between B-17X (terminal No. 1) engine control relay connector and B-05 (terminal No. 1) No.4 injector connector. CONNECTOR: B-17X Relay box’s triangle marks

STEP 6. Check harness between B-05 (terminal No. 2) No.4 injector connector and C-134 (terminal No. 15) engine-ECU connector. Connector: B-05

B-17X B-05 (GR)

2

1

4

3 M


AK300255 AB


AK300265 AF

CONNECTOR: C-134

Connector: B-05

B-05 (GR)

C-134

M


AK300265 AF


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14





13A-119

TROUBLESHOOTING

Code No. P0325: Detonation Sensor System

Detonation sensor circuit

C-137 Engine-ECU

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

78 W

B

B

B-103 (MU802661)

B 2

1

1 2

Detonation sensor

Wire colour code B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown R: Red P: Pink V: Violet

O: Orange GR: Gray

AK300273 AB

OPERATION The sensor signal is inputted to the engine-ECU (terminal No. 78) from the detonation sensor (terminal No. 1). FUNCTION The detonation sensor detects the vibration of the cylinder block caused by detonation waves, and inputs a signal to the engine-ECU. In response to the signal, the engine-ECU provides controls to retard the ignition timing when the detonation occurs.

TROUBLE JUDGMENT Check Condition 2 seconds later after the engine has started up. Judgment Criteria The change amount of the detonation sensor output voltage (the detonation sensor peak voltage in every one third a turn of the crankshaft) is below 0.08 V in 200 consecutive times.


13A-120

TROUBLESHOOTING

PROBABLE CAUSE Failed detonation sensor Open/short circuit in detonation sensor circuit or loose connector contact Failed engine-ECU

STEP 2. Measure resistance at B-103 detonation sensor connector. Connector: B-103 2 1

DIAGNOSIS PROCEDURE STEP 1. Connector check: B-103 detonation sensor connector

Harness side connector B-103 (GR)

Connector: B-103 2 1 Harness side connector B-103 (GR)

Detonation sensor Alternator AK300274 AB

Disconnect connector, and measure at harness side. Resistance between terminal No. 2 and earth. OK: 2 W or less



Q: Is the check result normal? YES : Go to Step 3 . NO : Check and repair harness between B-103

(terminal No. 2) detonation sensor connector and body earth. Check earthing line for open circuit and damage.


13A-121

TROUBLESHOOTING


STEP 4. Check harness between B-103 (terminal No. 1) detonation sensor connector and C-137 (terminal No.78) engine-ECU connector. Connector: B-103 2 1 Harness side connector B-103 (GR)

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



STEP 5. Check the trouble symptoms. Q: Does trouble symptom persist? YES : Go to Step 6 . NO : Intermittent malfunction (Refer to GROUP


13A-122


STEP 6. Replace detonation sensor. After replacing the detonation sensor, re-check the trouble symptoms. Q: Does trouble symptom persist? YES : Replace engine-ECU. NO : Check end.


13A-123

TROUBLESHOOTING

Code No. P0335: Crank Angle Sensor System Crank angle sensor circuit

Battery

W-B W-B 3

4 B-17X 1

2

3

4


1

2

R B-29 (MU802603)

3

1 2 3

Crank angle sensor

2

1 B-W 18 J/C(1) C-16

G-R 17

B-W 40

89 C-137

C-135 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

5V

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

Engine-ECU Wire colour code B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown R: Red P: Pink V: Violet

O: Orange GR: Gray

AK300275 AB

13A-124


OPERATION Power is supplied to the crank angle sensor (terminal No. 3) from the engine control relay (terminal No. 1) and is earthed to the engine-ECU (terminal No. 40) from the crank angle sensor (terminal No. 1). A power voltage of 5 V is applied to the crank angle sensor output terminal (terminal No. 2) from the engine-ECU (terminal No. 89). FUNCTION The crank angle sensor detects the crank angle (position) and inputs a pulse signal to the engineECU. In response to the signal, the engine-ECU controls the injector, etc.

DIAGNOSIS PROCEDURE STEP 1. MUT-II data list Refer to Data list reference table 313A. a. Item 22: Crank angle sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-29 crank angle sensor connector Connector: B-29

TROUBLE JUDGMENT Check Condition Engine in cranking state. Judgment Criterion The sensor output voltage remains unchanged (no pulse signal is inputted) for 2 seconds.

2 1 3 Harness side connector

B-29 (B)

PROBABLE CAUSE Failed crank angle sensor Open/short circuit in crank angle sensor circuit or loose connector contact Failed engine-ECU

Crank angle sensor AK300276 AB



13A-125

TROUBLESHOOTING

STEP 3. Measure voltage at B-29 crank angle sensor connector.


Connector: B-29

CONNECTOR: C-137


B-29 (B)

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Connector: B-29 2 1 3 Harness side connector


B-29 (B)



Measure engine-ECU terminal voltage. Disconnect B-29 crank angle sensor connector. Ignition switch: ON Voltage between terminal No. 89 and earth. OK: 4.9 - 5.1 V



13A-126

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82





AK300254 AB

B-29 (B)



(terminal No. 2) crank angle sensor connector and C-137 (terminal No. 89) engine-ECU connector. Check output line for open circuit. NO : Repair.


13A-127

TROUBLESHOOTING

STEP 7. Check harness between B-29 (terminal No. 2) crank angle sensor connector and C-137 (terminal No. 89) engine-ECU connector.

STEP 8. MUT-II data list Refer to Data list reference table 313A. a. Item 22: Crank angle sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


B-29 (B)

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Replace engine-ECU. STEP 9. Measure voltage at B-29 crank angle sensor connector. Connector: B-29 2 1 3 Harness side connector

B-29 (B)


CONNECTOR: C-137

Crank angle sensor C-137 AK300276 AB

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82





13A-128

TROUBLESHOOTING

STEP 10. Connector check: B-17X engine control relay connector

Connector: B-29


2

1

4

3


STEP 11. Measure resistance at B-29 crank angle sensor connector.

B-17X 2 1 3 Harness side connector

B-29 (B)

AK300255 AB


B-29 (B)


Disconnect connector, and measure at harness side. Resistance between terminal No. 1 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 14 . NO : Go to Step 12 . Crank angle sensor AK300276 AB



(terminal No. 3) crank angle sensor connector and B-17X (terminal No. 1) engine control relay connector. Check power supply line for open/short circuit. NO : Repair.

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




13A-129

TROUBLESHOOTING


STEP 14. Measure output waveform at B-29 crank angle sensor connector (Use oscilloscope). Connector: B-29


B-29 (B)


B-29 (B)

Crank angle sensor Crank angle sensor AK300276 AB AK300276 AB

CONNECTOR: C-135

C-135


38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



Use special tool test harness (MB998478) to connect connector, and measure at pick-up harness. Engine: Idling Transmission: Neutral Voltage between terminal No. 2 and earth. OK: Waveforms should be displayed on Inspection procedure using an oscilloscope (Refer to 313A), its maximum value should be 4.8 V or more, and its minimum value should be 0.6 V or less with no noise in waveform.


13A-130

TROUBLESHOOTING


2

1

4

3

Connector: B-29

B-17X


STEP 16. Check harness between B-29 (terminal No. 3) crank angle sensor connector and B-17X (terminal No. 1) engine control relay connector.


B-29 (B)

AK300255 AB




2

1

4

3

B-17X


AK300255 AB



13A-131

TROUBLESHOOTING

STEP 17. Connector check: C-135 and C-137 engine-ECU connectors CONNECTOR: C-135, C-137

STEP 18. Check harness between B-29 (terminal No. 2) crank angle sensor connector and C-137 (terminal No. 89) engine-ECU connector. Connector: B-29 2 1 3 Harness side connector

B-29 (B)

C-135 C-137

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

C-135 Harness side connector

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

C-137 Harness side connector AK300277 AB



CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-132

TROUBLESHOOTING


STEP 20. Check the crankshaft sensing blade.

Connector: B-29

Q: Is the check result normal? YES : Go to Step 21 . NO : Replace the crankshaft sensing blade.


STEP 21: MUT-II data list Refer to Data list reference table 313A. a. Item 22: Crank angle sensor

B-29 (B)


00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Replace crank angle sensor.


CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


NOTE: Before checking harness, check intermediate connector C-16, and repair if necessary. Check earthing line for damage. Q: Is the check result normal? YES : Go to Step 20 . NO : Repair.


13A-133

TROUBLESHOOTING

Code No. P0340: Camshaft Position Sensor System

Camshaft position sensor circuit

Battery

W-B W-B 3

4 B-17X

1

2

3

4


1

2

R 3

B-106 (MU802337)


1 2 3

2

1 B-W

19 J/C (1) C-16

L-Y

17 B-W

40

88

C-135

C-137

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

5V Engine-ECU


OPERATION Power is supplied to the camshaft position sensor (terminal No. 3) from the engine control relay (terminal No. 1) and is earthed to the engine-ECU (terminal No. 40) from the camshaft position sensor (terminal No. 1).

A power voltage of 5 V is applied to the camshaft position sensor output terminal (terminal No. 2) from the engine-ECU (terminal No. 88). FUNCTION The camshaft position sensor detects the top dead center on the compression stroke of the No. 1 cylinder and inputs a pulse signal to the engineECU.


13A-134

TROUBLESHOOTING

TROUBLE JUDGMENT

STEP 2. Measure voltage at B-106 camshaft position sensor connector.

Check Condition After the engine has started up.

Connector: B-106

Judgment Criterion The sensor output voltage remains unchanged (no pulse signal is inputted) for 2 seconds. PROBABLE CAUSE Failed camshaft position sensor Open/short circuit in camshaft position sensor circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. Connector check: B-106 camshaft position sensor connector Connector: B-106 3 2 1 Harness side connector

B-106 (B)

AK300279 AB



B-106 (B)

AK300279 AB



STEP 3. Connector check: B-17X engine control relay connector

STEP 4. Measure voltage at B-106 camshaft position sensor connector. Connector: B-106


13A-135

B-17X 3 2 1 Harness side connector

2

1

4

3

B-106 (B)


AK300255 AB


AK300279 AB


B-106 (B)

AK300279 AB


(terminal No. 3) camshaft position sensor connector and B-17X (terminal No. 1) engine control relay connector. Check power supply line for open/short circuit. NO : Repair.


13A-136

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



Connector: B-106

Connector: B-106 3 2 1

3 2 1



B-106 (B)

B-106 (B)

AK300279 AB

Measure engine-ECU terminal voltage. Disconnect B-106 camshaft position sensor connector. Ignition switch: ON Voltage between terminal No. 88 and earth. OK: 4.9 - 5.1 V Q: Is the check result normal? YES : Go to Step 6 . NO : Go to Step 7 .

AK300254 AB

AK300279 AB


(terminal No. 2) camshaft position sensor connector and C-137 (terminal No. 88) engine-ECU connector. Check output line for open circuit. NO : Repair.


13A-137

TROUBLESHOOTING


STEP 8. Check harness between B-106 (terminal No. 2) camshaft position sensor connector and C-135 (terminal No. 56) engine-ECU connector. Connector: B-106 3 2 1 Harness side connector

C-137

B-106 (B)

AK300279 AB

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

CONNECTOR: C-135



38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39






13A-138

TROUBLESHOOTING

STEP 10. Measure resistance at B-106 camshaft position sensor connector. Connector: B-106

STEP 12. Check harness between B-106 (terminal No. 1) camshaft position sensor connector and C-135 (terminal No. 40) engine-ECU connector. Connector: B-106

3 2 1 3 2 1



B-106 (B) B-106 (B) AK300279 AB

Disconnect connector, and measure at harness side. Resistance between terminal No. 1 and earth. OK: 2 W or less

AK300279 AB

CONNECTOR: C-135

Q: Is the check result normal? YES : Go to Step 13 . NO : Go to Step 11 . C-135


38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


C-135


38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



NOTE: Before checking harness, check intermediate connector C-16, and repair if necessary. Check earthing line for open circuit and damage.


13A-139

TROUBLESHOOTING

STEP 13. Measure output waveform at B-106 camshaft position sensor connector (Use oscilloscope). Connector: B-106

STEP 15. Check harness between B-106 (terminal No. 3) camshaft position sensor connector and B-17X (terminal No. 1) engine control relay connector. Connector: B-106

3 2 1 3 2 1



B-106 (B) B-106 (B) AK300279 AB

Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness. Engine: Idling Transmission: Neutral Voltage between terminal No. 2 and earth. OK: Waveforms should be displayed on Inspection procedure using an oscilloscope (Refer to 313A), its maximum value should be 4.8 V or more, and its minimum value should be 0.6 V or less with no noise in waveform. Q: Is the check result normal? YES : Go to Step 9 . NO : Go to Step 14 .

1

4

3

B-17X




2

1

4

3

B-17X



CONNECTOR: B-17X

2

CONNECTOR: B-17X

AK300255 AB


STEP 14. Connector check: B-17X engine control relay connector.


AK300279 AB

AK300255 AB


13A-140

TROUBLESHOOTING

STEP 16. Connector check: C-135 and C-137 engine-ECU connectors CONNECTOR: C-135, C-137

STEP 17. Check harness between B-106 (terminal No. 2) camshaft position sensor connector and C-137 (terminal No. 88) engine-ECU connector. Connector: B-106 3 2 1 Harness side connector

C-135 C-137

B-106 (B)

AK300279 AB

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

C-135 Harness side connector

CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

C-137 Harness side connector C-137

AK300277 AB


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




STEP 18. Check harness between B-106 (terminal No. 1) camshaft position sensor connector and C-135 (terminal No. 40) engine-ECU connector. Connector: B-106

13A-141

STEP 19. Check camshaft position sensing cylinder. Q: Is the check result normal? YES : Go to Step 20 . NO : Replace camshaft position sensing cylinder.


Q: Does trouble symptom persist? YES : Replace camshaft position sensor. NO : Intermittent malfunction (Refer to GROUP

B-106 (B)

AK300279 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


NOTE: Before checking harness, check intermediate connector C-16, and repair if necessary. Check earthing line for damage. Q: Is the check result normal? YES : Go to Step 19 . NO : Repair.

STEP 20. Check the trouble symptoms.



13A-142

TROUBLESHOOTING

Code No. P0403: EGR Control Solenoid Valve System

EGR control solenoid valve circuit

Battery

W-B W-B 4

3

B-17X 1

2

3

4


1

2

R

1 B-102 1 2

EGR control solenoid valve 2

L

76 C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU


O: Orange GR: Gray

AK300280 AB

OPERATION Power is supplied to the EGR control solenoid valve (terminal No. 1) from the engine control relay (terminal No. 1).

The engine-ECU (terminal No. 6) makes the power transistor in the unit be in "ON", and that makes currents go on the EGR control solenoid valve (terminal No. 2).


13A-143

TROUBLESHOOTING

FUNCTION In response to the signal from the engine-ECU, the EGR control solenoid valve controls the operation of the EGR valve.

STEP 3. Measure resistance at B-102 EGR control solenoid valve connector. Connector: B-102


TROUBLE JUDGMENT Check Conditions Except the engine stalling The battery voltage is 10 - 16 V.

B-102 (BR)

Judgment Criteria If the off surge voltage from the motor coil is not generated when the EGR valve control motor is driven. PROBABLE CAUSE Failed EGR control solenoid valve Open/short circuit in EGR control solenoid valve circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. MUT-II actuator test Refer to Actuator test reference table 313A. a. Item 10: EGR control solenoid valve OK: Operating sound can be heard and the valve vibrates. Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-102 EGR control solenoid valve connector Connector: B-102


B-102 (BR)

AK300281 AB


AK300281 AB

Disconnect connector, and measure at solenoid valve side. Resistance between terminal No. 1 and No. 2. OK: 29 - 35 W (at 20C) Q: Is the check result normal? YES : Go to Step 4 . NO : Replace EGR control solenoid valve.

STEP 4. Measure voltage at B-102 EGR control solenoid valve connector. Connector: B-102


B-102 (BR)

AK300281 AB



13A-144

TROUBLESHOOTING


2

1

4

3


B-17X

C-134


AK300255 AB

Connector: B-102


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


B-102 (BR)

AK300281 AB


(terminal No. 1) EGR control solenoid valve connector and B-17X (terminal No. 1) engine control relay connector. Check power supply line for open/short circuit. NO : Repair.



13A-145

TROUBLESHOOTING



CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



Connector: B-102


B-102 (BR)

AK300281 AB


(terminal No. 2) EGR control solenoid valve connector and C-134 (terminal No. 6) engine-ECU connector. Check output line for open/short circuit. NO : Repair.

AK300257 AB



13A-146

TROUBLESHOOTING

STEP 9. Check harness between B-102 (terminal No. 2) EGR control solenoid valve connector and C-134 (terminal No. 6) engine-ECU connector. Connector: B-102

2 1

STEP 10. Check harness between B-102 (terminal No. 1) EGR control solenoid valve connector and B-17X (terminal No. 1) engine control relay connector. Connector: B-102

2 1



B-102 (BR) B-102 (BR) AK300281 AB AK300281 AB

CONNECTOR: C-134 CONNECTOR: B-17X Relay box’s triangle marks

C-134

2

1

4

3

B-17X

Harness side connector 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



AK300255 AB


STEP 11. MUT-II actuator test Refer to actuator test reference table list 313A . Item 10: EGR control solenoid valve OK: Operating sound can be heard and the valve vibrates. Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP



13A-147

Code No. P0420: Catalyst malfunction FUNCTION The signal from the heated oxygen sensor (rear) differs from the heated oxygen sensor (front). That is because the catalytic converter purifies exhaust gas. When the catalytic converter has deteriorated, the signal from the heated oxygen sensor (front) becomes similar to the heated oxygen sensor (rear). The engine-ECU compares the output of the front and rear heated oxygen sensor signals.

STEP 2.MUT-II data list Refer to Data list reference table 313A. a. Item 11: Oxygen sensor (front) b. Item 59: Oxygen sensor (rear) Q: Is the check result normal? YES : Go to Step 3 . NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an abnormal data valve (Refer to Inspection Chart for Diagnosis Codes 313A).

TROUBLE JUDGMENT Check Conditions Engine speed: 3,000 r/min or less. During the driving. During the air-fuel ratio feedback control. Judgment Criterion When the output frequency ratio of the oxygen sensor (rear) vs. The oxygen sensor (front) is 0.8 or more on the average for 12 seconds. PROBABLE CAUSE Catalytic converter deteriorated Failed oxygen sensor (front) Failed oxygen sensor (rear) Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1.Check for leakage of exhaust emission from exhaust manifold. Q: Is the check result normal? YES : Go to Step 2 . NO : Repair.

STEP 3.MUT-II data list a. Item 11: Oxygen sensor (front) OK: 0 - 0.4 and 0.6 - 1.0 volt should alternate 15 times or more within 10 seconds (engine speed at 2,000 r/min). Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the oxygen sensor (front).

STEP 4.Replace the oxygen sensor (rear). After replacing the oxygen sensor (rear), recheck the trouble symptoms. Q: Is the check result normal? YES : Go to Step 5 . NO : Check end.

STEP 5.Replace the catalytic converter. After replacing the catalytic converter, re-check the trouble symptoms. Q: Is the check result normal? YES : Replacing engine-ECU. NO : Check end.


13A-148

TROUBLESHOOTING

Code No. P0443: Purge Control Solenoid Valve System Purge control solenoid valve circuit

Battery

W-B W-B 4

3

B-17X 1

2

3

4


1

2

R

2

B-101 (MU802779)


1 2 1

BR

9 C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU


O: Orange GR: Gray

AK300282 AB

OPERATION Power is supplied to the purge control solenoid valve (terminal No. 2) from the engine control relay (terminal No. 1).

The engine-ECU (terminal No. 9) makes the power transistor in the unit be in "ON" position, and that makes currents go on the purge control solenoid valve (terminal No. 1).


13A-149

TROUBLESHOOTING

FUNCTION In response to a signal from the engine-ECU, the purge control solenoid valve controls the flow rate of the purge air to be introduced into the surge tank.

STEP 3: Measure resistance at B-101 purge control solenoid valve connector. Connector: B-101 2 1 Harness side connector

TROUBLE JUDGMENT Check Conditions Ignition switch: ON The battery voltage is 10 V or more. Judgment Criteria The surge voltage (system voltage + 2 V) of solenoid coil is not detected when the purge control solenoid valve is turned in OFF position from ON. The battery voltage is 10 V or more.

B-101 (B)

AK300283AB

Disconnect connector, and measure at solenoid valve side. Resistance between terminal No. 1 and No. 2. OK: 30 - 34 W (at 20C)

PROBABLE CAUSE Failed purge control solenoid valve Open/short circuit in purge control solenoid value circuit or loose connector contact Failed engine-ECU

Q: Is the check result normal? YES : Go to Step 4 . NO : Replace purge control solenoid valve.

DIAGNOSIS PROCEDURE

STEP 4. Measure voltage at B-101 purge control solenoid valve connector.

STEP 1. MUT-II actuator test Item 08: Purge control solenoid valve OK: Operating sound can be heard and the valve vibrates Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-101 purge control solenoid valve connector Connector: B-101 2 1 Harness side connector

B-101 (B)

AK300283AB



B-101 (B)

AK300283AB



13A-150

TROUBLESHOOTING


2

1

4

3


B-17X

C-134


AK300255 AB


B-101 (B)

AK300283AB


(terminal No. 2) purge control solenoid valve connector and B-17X (terminal No. 1) engine control relay connector. Check power line for open/short circuit. NO : Repair.

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




13A-151

TROUBLESHOOTING



CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




B-101 (B)

AK300283AB


(terminal No. 1) purge control solenoid valve connector and C-134 (terminal No. 9) engine-ECU connector. Check output line for open and short circuit. NO : Repair.

AK300257 AB



13A-152

TROUBLESHOOTING

STEP 9. Check harness between B-101 (terminal No. 1) purge control solenoid valve connector and C-134 (terminal No. 9) engine-ECU connector. Connector: B-101

STEP 10. Check harness between B-101 (terminal No. 2) purge control solenoid valve connector and B-17X (terminal No. 1) engine control relay connector. Connector: B-101

2 1

2 1



B-101 (B)

B-101 (B)

AK300283AB

AK300283AB

CONNECTOR: B-17X

CONNECTOR: C-134


C-134

2

1

4

3

B-17X



AK300255 AB

Check power line for damage. Q: Is the check result normal? YES : Go to Step 11 . NO : Repair.


STEP 11. MUT-II actuator test Item 08: purge control solenoid valve OK: Operating sound can be heard and the valve vibrates Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP



13A-153

TROUBLESHOOTING

Code No. P0500: Vehicle speed sensor system

Vehicle speed sensor circuit

Ignition switch

Engine-ECU C-137

C-303 1 2 3 4 5 6

R

LOCK

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

ST ACC IG1 IG2

2 L-B

86

C-203 6 W-L 2 J/B 7.5A C-202 11

3 J/C (1) C-16

Meter and gauge

1

B-W

2 C-106 3 W-L

B-W 3

1 B-115 1 2 3

Vehicle speed sensor

2 B 8 J/C (2) C-17 B

1


O: Orange GR: Gray

AK300284 AB

OPERATION A power voltage of 5 V is applied to the vehicle speed sensor (terminal No. 3) from the engineECU (terminal No. 86).

FUNCTION The vehicle speed sensor converts the vehicle speed to the voltage, and then input it into the engine-ECU

13A-154


TROUBLE JUDGMENT Check Conditions 2 seconds later after the engine has started up. Engine speed: 2,000 r/min or more. Under the high load operation (The volumetric efficiency is 40 - 75 %). Judgment Criterion The sensor output voltage remains unchanged (no pulse signal is inputted) for 2 seconds. PROBABLE CAUSE Failed Vehicle speed sensor Open/short circuit in vehicle speed sensor circuit or loose connector contact Failed engine-ECU

STEP 2.MUT-II data list Refer to Data list reference table 313A. a. Item 24: Vehicle speed sensor Q: Is the check result normal? YES : Go to Step 3 . NO : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). STEP 3.Check connector: C-137 engine-ECU connector CONNECTOR: C-137

DIAGNOSIS PROCEDURE STEP 1.Check the speedometer Q: Is the check result normal? YES : Go to Step 2 . NO : Check the speedometer (Refer to GROUP

54A -Combination Meter Assembly and Vehicle speed sensor - On-vehicle Service 354A).

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




STEP 4.Check harness between C-137 (terminal No. 86) engine-ECU connector and B-115 (terminal No. 3) Vehicle speed sensor connector. CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


CONNECTOR: B-115 3 2 1 Harness side connector

AK300285AB

NOTE: Before checking harness, check intermediate connector C-16, and repair if necessary. Check output line for open circuit and damage. Q: Is the check result normal? YES : Go to Step 5 . NO : Repair.

STEP 5.Check the trouble symptoms. Q: Does trouble symptom persist? YES : Replacing engine-ECU. NO : Intermittent malfunction (Refer to GROUP


C-137

B-115 (B)

13A-155


13A-156

TROUBLESHOOTING

Code No. P0505: Idle Speed Control Servo System

Idle speed control servo circuit Battery

W-B W-B 3

4

B-17X 1

2

3

4


1

2

R

R

R 2

5

B-105 1 2 3 4 5 6


1

L-Y

Y-L

4

4

3

W

17

6

G-Y

5

18

C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU Wire colour code B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray R: Red P: Pink V:Violet AK300286 AB


13A-157

TROUBLESHOOTING

OPERATION The power is supplied to the idle speed control servo (terminal No. 2 and No. 5) from the engine control relay (terminal No. 1). The engine-ECU (terminal No. 4, No. 5, No. 17 and No. 18) makes power transistor in the unit be in "ON" position in order, and that makes currents go on the idle speed control servo (terminal No. 1, No. 3, No. 4 and No. 6).

Judgment Criteria The actual idle speed is higher than the target idle speed by 100 r/min or more for 10 seconds.

FUNCTION The idle speed control servo opens and closes the servo valve in response to a signal from the engine-ECU to control the intake air flow rate during idling.

DIAGNOSIS PROCEDURE

TROUBLE JUDGMENT Check conditions The vehicle speed has reached 1.5 km/h or more at least once. During the closed-loop idle speed control. Judgment Criteria The actual idle speed is higher than the target idle speed by 300 r/min or more for 10 seconds. Check conditions The vehicle speed has reached 1.5 km/h or more at least once. During the closed-loop idle speed control. The highest ambient temperature at the last drive is 45 C or less. The engine coolant temperature is approximately. 82C or higher. The battery voltage is 10 V or more. The intake air temperature is -10C or higher. Judgment Criteria The actual idle speed is higher than the target idle speed by 200 r/min or more for 10 seconds. Check conditions During the closed-loop idle speed control. The engine coolant temperature is approximately. 82C or higher. The battery voltage is 10 V or more. The power steering switch is in OFF position. The charging efficiency is 40 % or less. The intake air temperature is -10C or higher.

PROBABLE CAUSE Failed idle speed control servo Open/short circuit in idle speed control servo circuit or loose connector contact Failed engine-ECU

STEP 1. MUT-II Data List Refer to Data list reference table 313A. a. Item 45: Idle speed control position Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: B-105 idle speed control servo connector Connector: B-105 3

2 1


B-105 (B) AK300287 AB


STEP 3. Check idle speed control servo itself. Check idle speed control servo itself (Refer to 313A). Q: Is the check result normal? YES : Go to Step 4 . NO : Replace idle speed control servo.


13A-158

TROUBLESHOOTING

STEP 4. Measure voltage at B-105 idle speed control servo connector. Connector: B-105

STEP 5. Check connector: B-17X engine control relay connector CONNECTOR: B-17X

3

2 1


B-105 (B) AK300287 AB

Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 2 and earth, also between terminal No. 5 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 6 . NO : Go to Step 5 .


2

1

4

3

B-17X


AK300255 AB

Connector: B-105 3

2 1


B-105 (B) AK300287 AB


(terminal No. 2 or No. 5) idle speed control servo connector and B-17X (terminal No. 1) engine control relay connector. Check power supply line for open/short circuit. NO : Repair.


13A-159

TROUBLESHOOTING


Check power supply line for open/short circuit. STEP 7. Connector check: C-134 engine-ECU connector CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Connector: B-105

AK300257 AB

3

2 1


B-105 (B) AK300287 AB

Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 4 and earth, between terminal No. 5 and earth, between terminal No. 17 and earth, also voltage between terminal No. 18 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 7 . NO : Check and repair harness between B-105

idle speed control servo and C-134 engineECU. 1. Harness between idle speed control servo terminal No. 1 and engineECU connector terminal No. 4 2. Harness between idle speed control servo terminal No. 3 and engineECU connector terminal No. 17 3. Harness between idle speed control servo terminal No. 4 and engineECU connector terminal No. 5 4. Harness between idle speed control servo terminal No. 6 and engineECU connector terminal No. 18



13A-160

TROUBLESHOOTING

STEP 8. Check harness between B-105 idle speed control servo and C-134 engine-ECU. Connector: B-105 3

2 1

STEP 9. Check harness between B-105 (terminal No. 2 or No. 5) idle speed control servo connector and B-17X (terminal No. 1) engine control relay connector. Connector: B-105


3

2 1


B-105 (B) AK300287 AB

B-105 (B) CONNECTOR: C-134

AK300287 AB


C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

1

4

3


AK300255 AB



1. Harness between idle speed control servo terminal No. 1 and engine-ECU connector terminal No. 4 2. Harness between idle speed control servo terminal No. 3 and engine-ECU connector terminal No. 17 3. Harness between idle speed control servo terminal No. 4 and engine-ECU connector terminal No. 5 4. Harness between idle speed control servo terminal No. 6 and engine-ECU connector terminal No. 18 Check output line for damage. Q: Is the check result normal? YES : Go to Step 9 . NO : Repair.

2

B-17X


STEP 10. MUT-II Data List Refer to Data list reference table 313A. a. Item 45: Idle speed control position Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP



13A-161

Code No. P0551: Power Steering Fluid Pressure Switch System

Power steering pressure switch

C-135 Engine-ECU

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

37

Y

B-28 (MU801211)

1

1 Power steering pressure switch


CONDITION The battery voltage is applied to the power steering fluid pressure switch (terminal No. 1) from the engine-ECU (terminal No. 37). FUNCTION It is detected whether a load is applied on the power steering fluid pump by steering or not, and the signal is inputted to the engine-ECU. When the power steering fluid pressure switch "ON" signal (a large load on the power steering fluid pump) is inputted, the engine-ECU provides the idle-up control. TROUBLE JUDGMENT Check Conditions The intake air temperature is -10C or higher.

The engine coolant temperature is approximately 30C or higher. Repeat, 10 times or more, the *1 running and stop also *2 running. *1 running: engine speed of 2,500 r/min or more (Vehicle speed of 50 km/h or more). *2 running: Vehicle speed of 1.5 km/h or less. Judgment Criteria The power steering pressure switch remains in ON position. PROBABLE CAUSE Failed power steering fluid pressure switch Open/short circuit in power steering fluid pressure switch circuit or loose connector contact Failed engine-ECU


13A-162

TROUBLESHOOTING

DIAGNOSIS PROCEDURE


STEP 1. Connector check: B-28 power steering fluid pressure switch connector

CONNECTOR: C-135

CONNECTOR: B-28

C-135

B-28 (B) 1 Harness side connector

AK300289 AB

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



AK300256 AB

STEP 2. Measure voltage at B-28 power steering fluid pressure switch connector.


CONNECTOR: B-28


AK300289 AB


Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 37 and earth. OK: System voltage


13A-163

TROUBLESHOOTING



C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




CONNECTOR: B-28


AK300256 AB

AK300289 AB


(terminal No. 1) power steering fluid pressure switch connector and C-135 (terminal No. 37) engine-ECU connector. Check output line for open circuit. NO : Repair.


13A-164

TROUBLESHOOTING

STEP 6. Check harness between B-28 (terminal No. 1) power steering fluid pressure switch connector and C-135 (terminal No. 37) engineECU connector.


CONNECTOR: B-28

B-28 (B)

C-135

1 Harness side connector

AK300289 AB

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


C-135

Measure engine-ECU terminal voltage. Engine: Idling Voltage between terminal No. 37 and earth. OK: System voltage (Steering wheel: Stationary) 1 V or less (Steering wheel: Turned) Q: Is the check result normal? YES : Go to Step 11 . NO : Go to Step 9 .

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




STEP 7. MUT-II Data List Refer to Data list reference table 313A. a. Item 27: Power steering fluid pressure switch

C-135



38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




13A-165

TROUBLESHOOTING

STEP 10. Check harness between B-28 (terminal No. 1) power steering fluid pressure switch connector and C-135 (terminal No. 37) engineECU connector.


CONNECTOR: B-28

B-28 (B)

C-135


AK300289 AB

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


Check output line for damage. Q: Is the check result normal? YES : Replace power steering fluid pressure

switch. NO : Repair.


13A-166

TROUBLESHOOTING

Code No. P0622: Alternator FR Terminal System

Alternator circuit

C-135 Engine-ECU

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

41

Y-B

B-19 1

Y-B

B-30 (MU802046) 1 2 3 4

4

IC Voltage regulator

Alternator


O: Orange GR: Gray

AK300290 AB

OPERATION The energized state of the alternator field coil is inputted from the alternator (terminal No. 4) to the engine-ECU (terminal No. 41). FUNCTION A signal of the power supply duty ratio for the alternator field coil is inputted to the engine-ECU. In response to the signal, the engine-ECU detects the alternator output current and controls the idling speed according to the output current (electric load).

TROUBLE JUDGMENT Check Condition Engine speed is 50 r/min or more. Judgment Criterion Input voltage from alternator FR terminal is the system voltage or more for 20 seconds. PROBABLE CAUSE Alternator FR terminal circuit open circuited Failed engine-ECU


13A-167

TROUBLESHOOTING

DIAGNOSIS PROCEDURE


STEP 1. Connector check: B-19 intermediate connector

CONNECTOR: B-19

CONNECTOR: B-19 B-19 (B) B-19 (B)

Female side connector

3 2 1 6 5 4 Female side connector

3 2 1 6 5 4

AK300294 AB


STEP 2. Measure voltage at B-19 intermediate connector.

AK300294 AB


STEP 4. Check harness between B-19 (terminal No. 1) intermediate connector and C-135 (terminal No. 41) engine-ECU connector. CONNECTOR: B-19

CONNECTOR: B-19 B-19 (B) B-19 (B) 1 2 3 4 5 6

1 2 3 4 5 6 Male side connector

Male side connector AK300295 AB

Disconnect connector, and measure at male connector side. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: System voltage

AK300295 AB

CONNECTOR: C-135


C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



13A-168



00 - How to Use Troubleshooting/Inspection Service Points 300). STEP 6. Measure voltage at B-19 intermediate connector.

B-19 (B)

3 2 1 6 5 4

B-30 (GR)

4 3 2 1 AK300296 AB


STEP 8. Check harness between B-30 (terminal No. 4) alternator connector and B-19 (terminal No. 1) intermediate connector. AK300294 AB

Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 9 . NO : Go to Step 7 .

CONNECTOR: B-30


CONNECTOR: B-19


STEP 7. Connector check: B-30 alternator connector

CONNECTOR: B-30

B-30 (GR)


AK300296 AB

CONNECTOR: B-19

B-19 (B)


AK300294 AB

Check output line for short circuit. Q: Is the check result normal? YES : Replace alternator. NO : Repair.


STEP 9. Measure voltage at B-19 intermediate connector. CONNECTOR: B-19

13A-169

STEP 11. Check harness between B-30 (terminal No. 4) alternator connector and B-19 (terminal No. 1) intermediate connector pin No. 1. CONNECTOR: B-30

B-19 (B) B-30 (GR) 3 2 1 6 5 4 Female side connector

4 3 2 1 AK300294 AB

Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness. Engine: Idle after warm-up Transmission: Neutral Radiator fan: Inactive Voltage between terminal No. 1 and earth. OK: Switching the headlamps to ON from OFF causes the voltage to fall. Q: Is the check result normal? YES : Go to Step 5 . NO : Go to Step 10 .

Harness side connector CONNECTOR: B-19

B-19 (B)


Check output line for damage. STEP 10. Connector check: B-30 alternator connector CONNECTOR: B-30

B-30 (GR)



AK300296 AB

AK300296 AB


AK300294 AB


13A-170

TROUBLESHOOTING

STEP 12. Check harness between B-19 (terminal No. 1) intermediate connector and C-135 (terminal No. 41) engine-ECU connector. CONNECTOR: B-19

Q: Same symptoms regenerated? YES : Replace alternator. NO : Intermittent malfunction (Refer to Group 00

- How to Use troubleshooting/Inspection Service Points 300). B-19 (B)


AK300295 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



STEP 13. Check trouble symptom.


13A-171

Code No. P1603: Battery Backup Line System

Battery backup circuit Battey

W

9 20A

Relay box

W-B

A-14 5

W-B

80 C-137 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

Battery backup

Engine-ECU


O: Orange GR: Gray

AK300297 AB

OPERATION Power is directly supplied to the engine-ECU (terminal No. 80) from the battery.

TROUBLE JUDGMENT

FUNCTION The engine-ECU is check the open circuit of battery backup line.

Judgment Criterion The battery backup line voltage 6 V or less.

Check Condition Ignition switch: ON

PROBABLE CAUSE Open/short circuit in battery backup line circuit or loose connector contact Failed engine-ECU


13A-172

TROUBLESHOOTING

DIAGNOSIS PROCEDURE


STEP 1 MUT-II self-diag code Temporarily place the ignition switch in "LOCK" (OFF) position, and 10 seconds after that, place it in "ON" position again.

CONNECTOR: C-137

Q: Is the diagnosis code P1603 set? YES : Go to Step 2 . NO : Intermittent malfunction (Refer to GROUP

00 - How to use Troubleshooting/Inspection Service Points 300). STEP 2. Measure voltage at C-137 engine-ECU connector.

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


CONNECTOR: C-137 AK300254 AB



C-137

Q: Does trouble symptom persist? YES : Replace engine-ECU. NO : Intermittent malfunction (Refer to GROUP

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

00 - How to Use Troubleshooting/Inspection Service Points300).


Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 80 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 3 . NO : Check intermediate connector A-14, and

repair if necessary. If intermediate connector is normal, check and repair harness between battery and C-137 (terminal No. 80) engine-ECU connector. Check power supply line for open/short circuit.


13A-173

Code No. P1610: Immobilizer System

Immobilizer-ECU circuit

Signal transmission circuit

C-304-1

Immobilizer-ECU

3

7

1 2 3 4 5 6 7

C-304 (MU801547)

V 11

C-104

V 51 C-136 51 52 53 54 55 56 57 58 59 60 61 62

Engine-ECU


OPERATION The signals are sent and received between engine-ECU (terminal No. 51) and immobilizerECU (terminal No. 7). FUNCTION Engine-ECU sends or receives the control signals to or from immobilizer-ECU to certify the ignition key. NOTE: . If the registered ignition keys are close each other when starting the engine, radio interference may cause this code to be displayed. This code may be displayed when registering the key encrypted code.

TROUBLE JUDGMENT Check Condition Ignition switch: ON Judgment Criterion Improper communication problems between the engine-ECU and the immobilizer-ECU are detected. PROBABLE CAUSE Open/short circuit in immobilizer system circuit or loose connector contact Failed immobilizer-ECU Failed engine-ECU


13A-174

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP 1. Connector check: C-304 immobilizerECU connector and C-136 engine-ECU connector

STEP 2. Check harness between C-304 (terminal No. 3) immobilizer-ECU connector and C-136 (terminal No. 51) engine-ECU connector. Connector: C-304 Harness side connector

Connector: C-304 Harness side connector

1 2 76543

1 2 76543

C-304 C-304 AK203418 AC AK203418 AC

CONNECTOR: C-136

CONNECTOR: C-136

C-136 C-136 56 55 54 53 52 51 62 61 60 59 58 57

56 55 54 53 52 51 62 61 60 59 58 57



AK300268 AB AK300268 AB


NOTE: Before checking harness, check intermediate connector C-104, and repair if necessary. Check output line for open/short circuit and damage. Q: Is the check result normal? YES : Go to Step 3 . NO : Repair.

STEP 3. Check the trouble symptoms. Q: Is the check result normal? YES : Go to Step 4 . NO : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). STEP 4. After replacing the immobilizer-ECU, recheck the trouble symptoms. Q: Is the check result normal? YES : Replace engine-ECU. NO : Check end.


13A-175

INSPECTION CHART FOR TROUBLE SYMPTOMS M1131151500522

Items

Trouble symptom


Communication with MUT-II is impossible

Communication with all system is not possible

1

Communication with engine-ECU only is not possible

2

Engine warning lamp

The engine warning lamp does not illuminate right after the ignition switch 3 is turned the "ON" position The engine warning lamp remains illuminating and never goes out

Starting

Starting impossible (No initial combustion)

The starter is impossible to operate. 5

Starting impossible (Starter operative but no initial combustion)

The starter is operative and cranks the engine, but none of initial combustion is in the cylinders and the engine is not started.

Starting impossible The initial combustion occurs, but (Initial combustion but no complete the engine stalls soon due to the combustion) incomplete combustion.

Improper idling

Engine stalls

4

6

7

Improper starting (Long time to start)

It is long cranking to start the engine.

Unstable idling (Rough idling, hunting)

The engine speed is not constant 8 and changeable during the idling. Usually, the judgment can be based on the movement of the tachometer pointer, also on the vibration transmitted to the steering wheel, sift lever, vehicle body and so on.

Improper idling speed

The proper idling speed is not satisfied.

Engine stalled during idling (Die out)

The engine stalls during the idling in no relation to the vehicle movement.

The engine stalls when starting the The engine stalls during the car operation, or when the accelerator (Pass out) pedal is depressed from the idling. The engine stalls when decelerating

9

The engine stalls at the deceleration. 10


13A-176

TROUBLESHOOTING

Items

Trouble symptom


Driving

Engine does not revolve up

The engine speed is not higher when 11 the accelerator pedal is depressed.

Hesitation, sag

The response of vehicle speed 12 (engine speed) is delayed when the accelerator pedal is depressed, or the vehicle speed (engine speed) is temporarily dropped during the acceleration. These phenomena are called "hesitation" and the serious hesitation is called "sag".

Poor acceleration

The engine cannot obtain the acceleration corresponding to the degree of throttle opening although the engine is smooth at the constant speed.

Stumble

The engine speed increase is delayed when the accelerator pedal is initially depressed at the starting.

Surge

The vehicle body is repeated to vibrate jollity in the forward and backward directions at the constant speed or acceleration.

The feeling of impact or vibration when accelerating

The large impact feeling occurs at the acceleration.

13

The feeling of impact or vibration when decelerating

The large impact feeling occurs at the deceleration.

14

Knocking

Sharp sound like a hammer striking on the cylinder walls during the driving can be heard and wrongly affects the driving.

15

Ignition timing offset

The basic ignition timing is deviated from the datum value.

16

Stopping

Run on (Dieseling)

The engine continues to run after the 17 ignition switch is in "LOCK (OFF)" position.

Exhaust gas

Odor, white smoke, black smoke, high-concentration CO/HC during idling

The exhaust gas is extremely rank odor, white smoke or black smoke. The concentration of CO & HC is high during the idling.

18

Charging performance

Battery rundown

The battery is soon rundown or the charging ability of battery is small.

19


13A-177

Items

Trouble symptom

Cooling performance

Overheating

The temperature of engine cooling water is extremely high.

20

Abnormal rotation of fan Motor

The fan motor is abnormally rotated when the ignition switch is in "ON" position in no relation to the engine cooling water temperature.

21

Poor A/C Performance

The temperature of air cooling from A/C is not efficient or very far from the target temperature.

22

A/C performance


PROBLEM SYMPTOMS TABLE Inspection Trouble symptom procedure No.

Reference page

1

Communication with all system is not possible

313A

2

Communication with engine-ECU only is not possible

313A

3

The engine warning lamp does not illuminate right after the ignition switch is turned the "ON" position

313A

4

The engine warning lamp remains illuminating and never goes out

313A

5

Starting impossible (No initial combustion)

313A

6

Starting impossible (Starter operative but no initial combustion)

313A

7

Starting impossible (Initial combustion but no complete combustion)

313A

Starting impossible (Long time to start) 8

Unstable idling (Rough idling, hunting)

313A

Improper idling speed (Too high or too low) Engine stalls during idling (Die out) 9

The engine stalls when starting the car (pass out)

313A

10

The engine stalls when decelerating

313A

11

Engine does not revolve up

313A

12

Hesitation, sag

313A

Poor acceleration Stumble Surge 13

The feeling of impact or vibration when accelerating

313A

14

The feeling of impact or vibration when decelerating

313A

15

Knocking

313A

16

Ignition timing offset

313A

17

Run on (Dieseling)

313A

18

Odor, white smoke, black smoke, high-concentration CO/HC during idling

313A

19

Battery rundown

313A

20

Overheating

313A


13A-178

TROUBLESHOOTING

Inspection Trouble symptom procedure No.

Reference page

21

Abnormal rotation of fan motor

313A

22

Poor A/C performance

313A

23

Engine-ECU power supply, engine control relay, ignition switch-IG1 system

313A

24

Fuel pump system

313A

25

Fan control relay system

313A

26

A/C switch system

313A

27

A/C compressor relay system

313A

28

A/C load signal system

313A

29

A/C pressure sensor system

313A

30

Ignition circuit system

313A


13A-179

TROUBLESHOOTING

SYMPTOM PROCEDURES

Inspection Procedure 1: Communication with All System is not Possible Data link connector circuit

Fusible link (1)

R

C-116 15 R C-204 1

15 15A

J/B

12 C-205

W-B

C-24

16

1 2 3 4 5 6 7 8 9 10 1112 13 14 1516

Data link connector 5

4 B

B


OPERATION Battery voltage is applied to diagnosis connector (terminal No.16). Diagnosis connector (terminals No. 4 and 5) are earthed to the vehicle body.

COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed power supply circuit or failed earthing circuit of diagnosis connector. PROBABLE CAUSE Failed diagnosis connector Open/short circuit in diagnosis connector circuit Failed MUT-II


13A-180

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3: Measure voltage at C-24 diagnosis connector.

STEP 1: Check connector: C-24 diagnosis connector

Connector: C-24

Connector: C-24

1 2 3 4 5 6 7 8 9 10 1112 13 14 1516 1 2 3 4 5 6 7 8 9 10 1112 13 14 1516

C-24 (B)

Harness side connector AK203424 AE



STEP 2: Measure resistance at C-24 diagnosis connector. Connector: C-24

1 2 3 4 5 6 7 8 9 10 1112 13 14 1516

C-24 (B)

Disconnect connector, and measure at the harness side. Voltage between terminal No. 16 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 4 . NO : Check intermediate connectors C-116, C-204

and C-205, and repair if necessary. If connectors are normal, check and repair harness between C-24 (terminal No. 16) diagnosis connector and battery. Check power supply line for open/short circuit. STEP 4: Replace MUT-II After replacing the MUT-II, re-check the trouble symptoms.

C-24 (B)


Disconnect connector, and measure at harness side. Resistance between terminal No. 4 and earth, also between terminal No. 5 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 3 . NO : Check and repair harness between C-24

(terminal No. 4) diagnosis connector and body earth, also between C-24 (terminal No. 5) diagnosis connector and body earth. Check earthing line for open circuit and damage.

Q: Does trouble symptom persist? YES : Go to Step 5 . NO : Check end


STEP 5: Check harness between C-24 (terminal No. 6) diagnosis connector and battery. Connector: C-24

1 2 3 4 5 6 7 8 9 10 1112 13 14 1516

C-24 (B)


NOTE: Before checking harness, check intermediate connectors C116, C-204 and C-205, and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Check and repair harness between C-24

(terminal No. 4 and No. 5) diagnosis connector and body earth. Check earthing line for damage. NO : Repair.

13A-181


13A-182

TROUBLESHOOTING

Inspection Procedure 2: Communication with Engine-ECU only is not Possible.

Data link connector circuit

C-136 Engine-ECU

51 52 53 54 55 56 57 58 59 60 61 62

62 O-W

C-105 5

O-W

32

J/C (3) C-02 29

O-L C-24 1 2 3 4 5 6 7 8 9 10 1112 13 14 1516

7

Data link connector


OPERATION There is data communication between diagnosis connector output terminal (terminal No. 7) and engine-ECU (terminal No. 62).

DIAGNOSIS PROCEDURE

COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed power supply circuit or failed earthing circuit of engine-ECU.

Q: Is lamp illuminating for few seconds? YES : Go to Step 2 . NO : Check engine-ECU power supply, engine

PROBABLE CAUSE Open/short circuit in engine-ECU power circuit Between engine-ECU and diagnosis connector for short circuit Failed engine-ECU

STEP 1: Check engine warning lamp. Ignition switch: OFF ON

control relay and ignition switch IG1 system (Refer to Inspection Procedure 23 313A ).


13A-183

TROUBLESHOOTING

STEP 2: Connector check: C-136 engine-ECU connector CONNECTOR: C-136

STEP 3: Check harness between C-24 (terminal No. 7) diagnosis connector and C-136 (terminal No. 62) engine-ECU connector. Connector: C-24

C-136

1 2 3 4 5 6 7 8 9 10 1112 13 14 1516

C-24 (B)


56 55 54 53 52 51 62 61 60 59 58 57

CONNECTOR: C-136



56 55 54 53 52 51 62 61 60 59 58 57


NOTE: Before Checking harness, check intermediate connectors C-105 and C-02, and repair if necessary. Check communication line for open/short circuit and damage. Q: Is the check result normal? YES : Go to Step 4 . NO : Repair.

STEP 4: Check the trouble symptom. Q: Does trouble symptom persist? YES : Replace engine-ECU. NO : Intermittent malfunction (Refer to GROUP



13A-184

TROUBLESHOOTING

Inspection Procedure 3: The Engine Warning Lamp Does not Illuminate Right after the Ignition Switch is Turned The "ON" Position

Malfunction indicator lamp (Engine warning lamp) circuit

Ignition switch C-303 LOCK

R

1 2 3 4 5 6

ST

ACC IG1

IG2

2 L-B

C-203 6 2 7.5A

J/B

25 C-205

C-04

B-W

42

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 G

Malfunction indicator lamp (Engine warning lamp)

C-05

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 2122 G

G

G

14 R-W

7 C-105 R-W 36 C-135 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

Engine-ECU


OPERATION Battery voltage is applied to engine warning lamp of combination meter connector (terminal No. 42) from ignition switch.

Engine-ECU (terminal No. 36) makes power transistor in unit be in "ON" position, and that makes currents go on engine warning lamp of combination meter connector (terminal No. 14).


13A-185

TROUBLESHOOTING

COMMENTS ON TROUBLE SYMPTOM Engine-ECU turns on engine warning lamp for 5 seconds to check for burnt-out bulb immediately after ignition switch is turned to ON. If engine warning lamp is not lit just after turning ignition switch to "ON" position, failure is possibly caused by burn-out bulb, open/short circuit or other faults.

STEP 3: Connector check: C-04 combination meter connector CONNECTOR: C-04 C-04

PROBABLE CAUSE Engine warming lamp bulb burnt out Failed ignition switch Open/short circuit in engine warning lamp circuit for or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE

41 40 39 38 37 36 35 34 33 32 31 52 51 50 49 48 47 46 45 44 43 42 G

G


STEP 1: Check engine start-up. Q: Is engine started? YES : Go to Step 2 . NO : Check engine-ECU power supply, engine

control relay and ignition switch IG1 system (Refer to Inspection Procedure 23 313A ). STEP 2: Check engine warning lamp for burntout bulb.

AK300303AB

Q: Is the check result normal? YES : Go to Step 4 . NO : Repair

STEP 4: Measure voltage at C-04 combination meter connector. CONNECTOR: C-04 C-04

Q: Is the check result normal? YES : Go to Step 3 . NO : Replace engine warning lamp.

41 40 39 38 37 36 35 34 33 32 31 52 51 50 49 48 47 46 45 44 43 42 G

G

Harness side connector AK300303AB

Disconnect connector, and measure at the harness side. Ignition switch: ON Voltage between terminal No. 42 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 6 . NO : Go to Step 5 .


13A-186

TROUBLESHOOTING

STEP 5: Connector check: C-303 ignition switch connector CONNECTOR: C-303


C-303 3 2 1 6 5 4 C-135


38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

CONNECTOR: C-04


C-04

AK300256 AB


STEP 7: Measure voltage at C-135 engine-ECU connector. CONNECTOR: C-135

41 40 39 38 37 36 35 34 33 32 31 52 51 50 49 48 47 46 45 44 43 42 G

G


Q: Is the check result normal? YES : Check intermediate connectors C-203 and

C-205, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-04 (terminal No. 42) combination meter connector and C-303 (terminal No. 2) ignition switch connector. Check power supply line for open/short circuit. NO : Repair

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




13A-187

TROUBLESHOOTING

STEP 8: Check connector: C-05 combination meter connector


CONNECTOR: C-05 C-05 (L)

C-303 3 2 1 6 5 4 Harness side connector AK300304 AB


11 10 9 8 7 6 5 4 3 2 1 22 2120 19 18 17 16 15 14 1312 G

G


CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



repair if necessary. If intermediate connector is normal, check and repair harness between C-05 (terminal No. 14) combination meter connector and C-135 (terminal No. 36) engine-ECU connector. Check output line for open/short circuit. NO : Repair


13A-188

TROUBLESHOOTING

STEP 10: Check harness between C-04 (terminal No. 42) combination connector and C-303 (terminal No. 2) ignition switch connector.



C-04

11 10 9 8 7 6 5 4 3 2 1 22 2120 19 18 17 16 15 14 1312

41 40 39 38 37 36 35 34 33 32 31 52 51 50 49 48 47 46 45 44 43 42 G

G

AK300305 AB


CONNECTOR: C-303


NOTE: Before checking harness, check intermediate connectors C-203 and C-205, and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 11 . NO : Repair.

G


G



STEP 12: Check harness between C-05 (terminal No. 14) combination connector and C-135 (terminal No. 36) engine-ECU connector. CONNECTOR: C-05 C-05 (L)

11 10 9 8 7 6 5 4 3 2 1 22 2120 19 18 17 16 15 14 1312 G

G


CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


NOTE: Before checking harness, check intermediate connector C-105, and repair if necessary. Check output line for damage. Q: Is the check result normal? YES : Go to Step 13 . NO : Repair.

13A-189

STEP 13: Check the trouble symptoms. Q: Does trouble symptom persist? YES : Replace engine-ECU. NO : Intermittent malfunction (Refer to GROUP



13A-190

TROUBLESHOOTING

Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and never goes out

Malfunction indicator lamp (Engine warning lamp) circuit

Ignition switch C-303 LOCK

R

1 2 3 4 5 6

ST

ACC IG1

IG2

2 L-B

C-203 6 2 7.5A

J/B

25 C-205

C-04

B-W

42

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 G

Malfunction indicator lamp (Engine warning lamp)

C-05

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 2122 G

G

G

14 R-W

7 C-105 R-W 36 C-135 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

Engine-ECU


OPERATION Battery voltage is applied to engine warning lamp (terminal No. 42) from ignition switch.

Engine-ECU (terminal No. 36) makes power transistor in unit be in "ON" position, and that makes currents go on engine warning lamp (terminal No. 14).


13A-191

TROUBLESHOOTING

COMMENT ON TROUBLE SYMPTOM Engine-ECU has detected failed sensor or failed actuator. Or failure is possibly caused by short circuit or other faults.


PROBABLE CAUSE Short circuit in between engine warning lamp and engine-ECU circuit. Failed engine-ECU

DIAGNOSIS PROCEDURE

C-135

STEP 1: MUT-II self-diag code Q: Diagnosis code set? YES : Inspection chart for diagnosis code (Refer

to 313A.) NO : Go to Step 2 .

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


STEP 2: Connector check: C-135 engine-ECU connector


CONNECTOR: C-135

C-135 11 10 9 8 7 6 5 4 3 2 1 22 2120 19 18 17 16 15 14 1312

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

G

AK300305 AB



G


Disconnect connector, and measure at the harness side. Ignition switch: ON Voltage between terminal No. 36 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 4 . NO : Check intermediate connector C-105, and

repair if necessary. If intermediate connector is normal, check and repair harness between C-05 (terminal No. 14) combination meter connector and C-135 (terminal No. 22) engine-ECU connector. Check output line for short circuit.

13A-192


STEP 4: Check the trouble symptoms. Q: Does trouble symptom persist? YES : Replace engine-ECU. NO : Intermittent malfunction (Refer to GROUP


Inspection Procedure 5: Starting impossible (No Initial Combustion) COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed starter itself or failed related circuit.


PROBABLE CAUSE Failed battery Failed starter motor Open/short circuit in starter associated circuit or loose connector contact

DIAGNOSIS PROCEDURE STEP 1: Check battery voltage. Measure battery voltage at cranking. OK: 8 V or higher Q: Is the check result normal? YES : Go to Step 2 . NO : Check battery (Refer to GROUP 54A -

Battery - On-vehicle Service - Battery Test 354A). STEP 2: MUT-II data list Item 18: Cranking signal OK: ON (Ignition switch: ST) OFF (Ignition switch: ON) Q: Is the check result normal? YES : Go to Step 8 . NO : Go to Step 3 .

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-193

TROUBLESHOOTING

STEP 4: Measure voltage at C-137 engine-ECU connector.

STEP 6: Check ignition switch. CONNECTOR: C-137

CONNECTOR: C-137

C-137 C-137 8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



AK300254 AB

Disconnect connector, and measure at the harness side. Ignition switch: ST Voltage between terminal No. 71 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 7 . NO : Go to Step 5 .

CONNECTOR: C-303


STEP 5: Connector check: C-303 ignition switch connector


CONNECTOR: C-303



Check ignition switch (Refer to GROUP 54A Ignition Switch - Ignition Switch 354A).

B-19, and repair if necessary. If intermediate connector are normal, check and repair harness between C-137 (terminal No. 71) inhibitor switch connector and C-303 (terminal No. 5) ignition switch connector. Check power supply line for open/short circuit. NO : Replace ignition switch.


13A-194

TROUBLESHOOTING

STEP 7: Connector check: C-303 ignition switch connector and B-26 starter connector

STEP 8: Check connector: B-26 starter connector CONNECTOR: B-26

CONNECTOR: C-303

B-26 (B)

C-303 3 2 1 6 5 4



AK300306 AB

AK300304 AB


CONNECTOR: B-26

STEP 9: Measure voltage at B-26 starter connector. B-26 (B)

CONNECTOR: B-26


AK300306 AB


B-19, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-303 (terminal No. 5) ignition switch connector and B-26 (terminal No. 1) starter connector. Check output line for short circuit. NO : Repair.


AK300306 AB

Disconnect connector, and measure at the harness side. Ignition switch: ST Voltage between terminal No. 1 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 11 . NO : Go to Step 10 .


13A-195

TROUBLESHOOTING


STEP 11: Connector check: B-25 starter connector CONNECTOR: B-25

C-303 3 2 1 6 5 4

B-25 1


AK300307 AB


CONNECTOR: B-26

STEP 12: Measure voltage at B-25 starter connector.

B-26 (B)

CONNECTOR: B-25



AK300306 AB

Q: Is the check result normal? YES : Check intermediate connectors B-19 and C-

106, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-303 (terminal No. 5) ignition switch connector and B-26 (terminal No. 1) starter connector. Check output line for open circuit and damage. NO : Repair.

B-25 1 Harness side connector

AK300307 AB

Disconnect connector, and measure at the harness side. Voltage between terminal No. 1 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 13 . NO : Check and repair harness between B-25

(terminal No. 1) starter connector and battery. Check power supply line for open/short circuit.


13A-196

TROUBLESHOOTING

STEP 13: Check harness between C-303 (terminal No. 5) ignition switch connector and B-26 (terminal No. 1) starter connector.

STEP 14: Check harness between B-25 (terminal No. 1) starter connector and battery. CONNECTOR: B-25

CONNECTOR: C-303

C-303 3 2 1 6 5 4

B-25 1 Harness side connector


AK300307 AB

Check power supply line for damage. Q: Is the check result normal? YES : Replace starter. NO : Repair.

CONNECTOR: B-26


AK300306 AB

NOTE: Before checking harness, check intermediate connectors B-19 and C-106, and repair if necessary. Check output line for damage. Q: Is the check result normal? YES : Go to Step 14 . NO : Repair.

Inspection Procedure 6: Starting impossible (Starter Operative but No Initial Combustion) COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed ignition circuit, failed fuel feed or other faults. PROBABLE CAUSE Failed battery Timing belt broken Failed idle speed control Throttle valve fouled around Failed ignition system Failed fuel system Failed immobilizer system Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1: Check battery voltage. Measure battery voltage at cranking. OK: 8 V or higher Q: Is the check result normal? YES : Go to STEP 2 . NO : Check battery (Refer to GROUP 54 -

Battery - On-vehicle Service - Battery test 354A).


13A-197

TROUBLESHOOTING

STEP 2: Check engine warning lamp for burnt out bulb. Q: Is the check result normal? YES : Go to Step 3 . NO : Check engine-ECU power supply, engine

control relay and ignition switch IG1 system (Refer to Inspection Procedure 23 313A ). STEP 3: MUT-II self-diag code Q: Diagnosis code set? YES : Inspection chart for diagnosis codes (Refer

to 313A) NO : Go to Step 4 .

STEP 8: MUT-II DATA LIST Item 18: Cranking signal OK: ON (Ignition switch: ST) OFF (Ignition switch: ON) Q: Is the check result normal? YES : Go to Step 10 . NO : Go to Step 9 .


STEP 4: MUT-II actuator test Item 07: Fuel pump OK: Operating sound of fuel pump can be heard.

C-137

Q: Is the check result normal? YES : Go to Step 5 . NO : Check fuel pump system (Refer to

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

Inspection Procedure 24 313A) STEP 5. Check timing belt for breakage. Engine: Cranking OK: Camshaft rotates.


CONNECTOR: C-303

Q: Is the check result normal? YES : Go to Step 6 . NO : Replace timing belt.

STEP 6. Check the engine start ability. With depressing the accelerator pedal slightly, and start the engine. Q: Is the start ability good? YES : Go to Step 7 . NO : Go to Step 8 .

STEP 7: Check idling speed control for operating sound. Check idle speed control servo for operating sound (Refer to 313A). Q: Is the check result normal? YES : Clean throttle body (throttle valve portion)

(Refer to 313A). NO : Check idle speed control servo system

(Refer to code No. P0505 313A).


Q: Is the check result normal? YES : Check intermediate connectors B-19 and C-

106, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-303 (terminal No. 5) ignition switch connector and C-137 (terminal No. 71) engine-ECU connector. Check output line for open/short circuit. NO : Repair.

13A-198


STEP 10: MUT-II DATA LIST Refer to Data list reference table 313A. a. Item 22: Crank angle sensor

STEP 12: Connector check: B-110 and B-111 ignition coil connectors Connector: B-110, B-111

Q: Is the check result normal? YES : Go to Step 11 . NO : Check crank angle sensor system (Refer to

Code No. P0335 313A).

B-111 (GR)


STEP 11: Check injector for operating sound. Check injector for operating sound (Refer to 313A). Q: Can operating sound be heard? YES : Go to Step 12 . NO : Check the injector system of the defective

cylinder. (Refer to Code No. P0201: No. 1 injector system 313A.) (Refer to Code No. P0202: No. 2 injector system 313A.) (Refer to Code No. P0203: No. 3 injector system 313A.) (Refer to Code No. P0204: No. 4 injector system 313A.)

B-110 (GR) AK300308 AB


STEP 13: Measure voltage at each of B-110 and B-111 ignition coil connectors. Connector: B-110, B-111

B-111 (GR)


B-110 (GR) AK300308 AB



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TROUBLESHOOTING

STEP 14: Connector check: C-303 ignition switch connector

STEP 15: Check ignition coil spark. CONNECTOR: C-303

CONNECTOR: C-303

C-303 3 2 1 6 5 4

C-303 3 2 1 6 5 4



AK300304 AB AK300304 AB

Connector: B-110, B-111 Connector: B-110, B-111

B-111 (GR)


B-111 (GR)


B-110 (GR) B-110 (GR)

AK300308 AB

AK300308 AB

Q: Is the check result normal? YES : Check intermediate connectors A-14, C-

116, C-203 and C-205, and repair if necessary. Check and repair harness between C-303 (terminal No. 2) ignition switch connector and (terminal No. 1) affected cylinders ignition coil connector. Check power supply line for open/short circuit. NO : Repair.

Q: Is the check result normal? YES : Go to Step 16 . NO : Check intermediate connectors A-14, C-116,

C-203 and C-205, and repair if necessary. Check and repair harness between C-303 (terminal No. 2) ignition switch connector and (terminal No. 1) affected cylinder’s ignition coil connector. Check power supply line for damage. STEP 16: Replace engine-ECU After replacing the engine-ECU, re-check the trouble symptoms. Q: Does trouble symptom persist? YES : Check for foreign matters (water, kerosene,

etc.) in fuel and replace if necessary. NO : Check end.

Inspection Procedure 7: Starting Impossible (Initial Combustion But no Complete Combustion), Improper Starting (Long time to Start) COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by poor ignition, incorrect air-fuel ratio at cranking, improper fuel pressure or other faults. PROBABLE CAUSE Failed battery Failed ignition system Failed fuel system

Air-fuel ratio control Failed idle speed control system Failed intake system Failed exhaust gas cleaning system Throttle valve fouled around Timing belt not in place Compression pressure improper Failed engine-ECU

13A-200


DIAGNOSIS PROCEDURE STEP 1: Check battery condition. Q: Have the battery terminal been disconnected? YES : After warm-up engine, idle for about 10

minutes. NO : Go to Step 2 .

STEP 2: Check battery voltage. Measure battery voltage at cranking. OK: 8 V or higher Q: Is the check result normal? YES : Go to Step 3 . NO : Check battery (Refer to GROUP 54 -

Battery - On-vehicle Service - Battery Test 354A). STEP 3: MUT-II self-diag code Q: Diagnosis code set? YES : Inspection chart for diagnosis codes (Refer

to 313A) NO : Go to Step 4 .

STEP 4: MUT-II data list Refer to Data list reference table 313A. a. Item 13: Intake air temperature sensor b. Item 21: Engine coolant temperature sensor c. Item 25: Barometric pressure sensor Q: Are the check results normal? YES : Go to Step 5 . NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes 313A). STEP 5: Check start ability. With depressing the accelerator pedal slightly, and start the engine. Q: Is the start ability good? YES : Go to Step 6 . NO : Go to Step 7 .

STEP 6: Check idle speed control servo for operating sound. Check idle speed control servo for operating sound (Refer to 313A). Q: Is the check result normal? YES : Clean throttle body (throttle valve portion)

(Refer to 313A). NO : Check idle speed control servo system

(Refer to Code No. P0505 313A). STEP 7: MUT-II actuator test Item 07: Fuel pump OK: Operating sound of fuel pump can be heard. Q: Is the check result normal? YES : Go to Step 8 . NO : Check fuel pump system (Refer to

Inspection Procedure 24 313A). STEP 8: Check air intake from intake hose and inlet manifold. Q: Is the check result normal? YES : Go to Step 9 . NO : Repair.

STEP 9: Check injector for operating sound. Check injector for operating sound at engine cranking (Refer to 313A). Q: Can operating sound be heard? YES : Go to Step 10 . NO : Check the injector system of the defective

cylinder. (Refer to Code No. P0201: No.1 injector system 313A.) (Refer to Code No. P0202: No.2 injector system 313A.) (Refer to Code No. P0203: No.3 injector system 313A.) (Refer to Code No. P0204: No.4 injector system 313A.) STEP 10. Check timing marks of timing belt. Q: Is the check result normal? YES : Go to Step 11 . NO : Align timing marks.


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TROUBLESHOOTING


STEP 13: Connector check: B110 and B-111 ignition coil connectors Connector: B-110, B-111

B-111 (GR)


C-134 B-110 (GR) AK300308 AB

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



AK300257 AB

Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 13 and earth, also between terminal No. 26 and earth. OK: 0.5 V or less

STEP 14: Check ignition coil spark. Q: Is the check result normal? YES : Go to Step 19 . NO : Go to Step 15 .

STEP 15: Check spark plug.


Q: Is the check result normal? YES : Go to Step 16 . NO : Replace spark plug.


STEP 16: Check spark plug cable itself. Check spark plug cable itself (Refer to GROUP 16 - Ignition System - On-vehicle Service 316 ). Q: Is the check result normal? YES : Go to Step 17 . NO : Replace spark plug cable.

C-134

STEP 17: Check ignition coil itself. Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316). 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



(terminal No. 13 and No. 26) engine-ECU connector and body earth. Check earthing line for open circuit and damage. NO : Repair.

Q: Is the check result normal? YES : Go to Step 18 . NO : Replace ignition coil.


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TROUBLESHOOTING

STEP 18: Check harness between terminal No. 2 of each cylinder’s ignition coil connector and vehicle body earth. Connector: B-110, B-111

B-111 (GR)


STEP 19: Check spray condition of injector. Check each injector for spray condition (Refer to 313A). Q: Is the check result normal? YES : Go to Step 20 . NO : Replace injector.

STEP 20: Check compression pressure. Check compression pressure (Refer to GROUP 11A - On-vehicle Service 311A). B-110 (GR) AK300308 AB


CONNECTOR: C-134

C-134

STEP 21: Check EGR control solenoid valve itself. Check EGR control solenoid valve itself [Refer to GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317 ]. Q: Is the check result normal? YES : Go to Step 22 . NO : Replace EGR control solenoid valve.

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Check earthing line for open circuit and damage. Q: Is the check result normal? YES : Check and repair harness between terminal

No. 3 of each cylinder’s ignition coil connector and C-134 engine-ECU connector. Check signal line for open/short circuit and damage. NO : Repair.

STEP 22: Check EGR valve itself. Check EGR valve itself [Refer to GROUP 17 Emission Control System - Exhaust Gas Recirculation (EGR) System 317]. Q: Is the check result normal? YES : Go to Step 23 . NO : Replace EGR valve.

STEP 23: Replace engine-ECU. After replacing the engine-ECU, re-check the trouble symptoms. Q: Does trouble symptom persist? YES : Check for foreign matters (water, kerosene,


Inspection Procedure 8: Unstable idling (Rough idling, hunting), Improper idling speed (Too high or too low), Engine stalls during idling (Die out) COMMENT ON TROUBLE SYMPTOM Probable causes can be widely found in ignition system, air-fuel ratio control system, idle speed control system, fuel system, etc. A sudden engine stall is possibly caused by poor connector contact.

PROBABLE CAUSE Failed ignition system Failed fuel system Failed air-fuel ratio control system Failed idle speed control system Failed intake/exhaust system


Failed emission gas cleaning system Throttle valve body fouled Timing belt out of place Compression pressure improper Failed engine-ECU

DIAGNOSIS PROCEDURE

13A-203

STEP 5: Check idle speed control servo for operating sound. Check idle speed control servo for operating sound (Refer to 313A). Q: Is the check result normal? YES : Go to Step 6 . NO : Check idle speed control servo system

(Refer to Code No. P505 313A). STEP 1: Check battery condition. Q: Has the battery terminal been disconnected? YES : After warm-up engine, idle for about 10

minutes. NO : Go to Step 2 .

STEP 2: MUT-II self-diag code Q: Diagnosis code set? YES : Inspection chart for diagnosis code (Refer

to 313A). NO : Go to Step 3 . STEP 3: MUT-II data list Refer to Data list reference table 313A. a. Item 12: Air flow sensor b. Item 13: Intake air temperature sensor c. Item 14: Throttle position sensor d. Item 21: Engine coolant temperature sensor e. Item 25: Barometric pressure sensor Q: Are the check results normal? YES : Go to Step 4 . NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes 313A). STEP 4: MUT-II data list Refer to Data list reference table 313A. a. Item 27: Power steering fluid pressure switch Q: Is the check result normal? YES : Go to Step 5 . NO : Check power steering fluid pressure switch

system (Refer to Code No. P0551 313A ).

STEP 6: Check throttle body (throttle valve portion) for contamination. Q: Is the check result normal? YES : Go to Step 7 . NO : Clean throttle body (throttle valve portion)

(Refer to 313A). STEP 7: Check air intake from intake hose and inlet manifold. Q: Is the check result normal? YES : Go to Step 8 . NO : Repair.

STEP 8: Check injector for operating sound. Check injector for operating sound (Refer to 313A). Q: Can operating sound be heard? YES : Go to Step 9 . NO : Check the injector system of the defective

cylinder. (Refer to Code No. P0201: No. 1 injector system 313A.) (Refer to Code No. P0202: No. 2 injector system 313A.) (Refer to Code No. P0203: No. 3 injector system 313A.) (Refer to Code No. P0204: No. 4 injector system 313A.) STEP 9: Check timing marks of timing belt. Q: Is the check result normal? YES : Go to Step 10 . NO : Align timing marks.

STEP 10. MUT-II data list Refer to Data list reference table 313A. a. Item 11: Oxygen sensor (front) Q: Is the check result normal? YES : Go to Step 11 . NO : Check oxygen sensor (front) system (Refer

to Code No. P0130 313A).


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TROUBLESHOOTING

STEP 11: Measure voltage at C-134 engine-ECU connector.


CONNECTOR: C-134

CONNECTOR: C-135

C-134

C-135

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 13 and earth, also between terminal No. 26 and earth. OK: 0.5 V or less Q: Is the check result normal? YES : Go to Step 13 . NO : Go to Step 12 .


C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



(terminal No. 13 and No. 26) engine-ECU connector and body earth. Check earthing line for open circuit and damage. NO : Repair.

AK300256 AB

Measure engine-ECU terminal voltage. Engine: Idling after warm-up Transmission: Neutral Radiator fan: Not operating Voltage between terminal No. 33 and earth. OK: Switching the headlamps to ON from OFF causes the voltage to increase by 0.2 3.5 V.



13A-205

TROUBLESHOOTING

STEP 14. Connector check: C-135 engine-ECU connector and B-30 alternator connector CONNECTOR: C-135

STEP 15. Check harness between C-135 (terminal No. 33) engine-ECU connector and B-30 (terminal No. 1) alternator connector. CONNECTOR: C-135

C-135 C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



CONNECTOR: B-30 CONNECTOR: B-30

B-30 (GR) B-30 (GR) 4 3 2 1 Harness side connector


4 3 2 1 AK300296 AB


AK300296 AB

NOTE: Before checking harness, check intermediate connector B-19, and repair if necessary. Check output line for open/short circuit and damage. Q: Is the check result normal? YES : Go to Step 16 . NO : Repair.


13A-206

TROUBLESHOOTING


STEP 17. Connector check: C-135 engine-ECU connector and B-30 alternator connector CONNECTOR: C-135

C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



Measure engine-ECU terminal voltage. Engine: Idling after warm-up Transmission: Neutral Radiator fan: Not operating Voltage between terminal No. 33 and earth. OK: Switching the headlamps to ON from OFF causes the voltage to fall.


AK300256 AB

CONNECTOR: B-30

B-30 (GR)



AK300296 AB


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TROUBLESHOOTING

STEP 18. Check harness between C-135 (terminal No. 54) engine-ECU connector and B-30 (terminal No. 4) alternator connector.


CONNECTOR: C-135

C-134 C-135

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



CONNECTOR: B-30

B-30 (GR)


AK300296 AB

NOTE: Before checking harness, check intermediate connector B-19, and repair if necessary. Check output line for open/short circuit and damage. Q: Is the check result normal? YES : Go to Step 19 . NO : Repair.

Measure engine-ECU terminal voltage. Engine: Idling A/C switch: ON (A/C compressor ON) Voltage between terminal No. 24 and earth. OK: 1 V or less (with outside air temperature sensor ambient temperature at 18C or higher and A/C set for maximum air flow at minimum temperature) System voltage (with A/C set for minimum air flow at room temperature)

Q: Is the check result normal? YES : Go to Step 21 . NO : Check A/C load signal system (Refer to

Inspection Procedure 28 313A). STEP 21. Connector check: B-110 and B-111 ignition coil connectors Connector: B-110, B-111

STEP 19. Check the trouble symptoms. Q: Does trouble symptom persist? YES : Replace alternator. NO : Intermittent malfunction (Refer to GROUP

B-111 (GR)



B-110 (GR) AK300308 AB


13A-208


STEP 22. Check ignition coil spark. Q: Is the check result normal? YES : Go to Step 27 . NO : Go to Step 23 .

STEP 26. Check harness between terminal No. 2 of ignition coil connector of each cylinder and body earth. Connector: B-110, B-111

STEP 23. Check spark plug. Q: Is the check result normal? YES : Go to Step 24 . NO : Replace spark plug.

STEP 24. Check individual spark plug cable Check spark plug cable itself (Refer to GROUP 16 - Ignition System - On-vehicle Service 316 ).

B-111 (GR)


B-110 (GR) AK300308 AB

CONNECTOR: C-134

Q: Q: Is the check result normal? YES : Go to Step 25 . NO : Replace spark plug cable.

STEP 25. Check ignition coil itself. Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316). Q: Is the check result normal? YES : Go to Step 26 . NO : Replace ignition coil.

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Check earthing line for open/short circuit and damage. Q: Is the check result normal? YES : Check and repair harness between terminal

No. 3 of ignition coil connector of each cylinder and C-134 engine-ECU Check signal line for open/short and damage. NO : Repair. STEP 27. Check injector for spray condition. Check each injector for spray condition (Refer to 313A). Q: Is the check result normal? YES : Go to Step 28 . NO : Replace injector.

STEP 28. Check compression pressure. Check compression pressure (Refer to GROUP 11A - On-vehicle Service 311A). Q: Is the check result normal? YES : Go to Step 29 . NO : Repair.


STEP 29. Check purge control solenoid valve itself. Check purge control solenoid valve itself (Refer to GROUP 17 - Emission Control System - Evaporative Emission Control System 317) Q: Is the check result normal? YES : Go to Step 30 . NO : Replace purge control solenoid valve.

STEP 30. Check EGR control solenoid valve itself. Check EGR control solenoid valve itself [Refer to GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317 ]. Q: Is the check result normal? YES : Go to Step 31 . NO : Replace EGR control solenoid valve.

13A-209

STEP 31. Check EGR control solenoid valve itself. Check EGR control solenoid valve itself [Refer to GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317 ]. Q: Is the check result normal? YES : Go to Step 32 . NO : Replace EGR valve.

STEP 32. MUT-II actuator test Item 07: Fuel pump OK: Operating sounds of fuel pump can be heard. Q: Is the check result normal? YES : Go to Step 33 . NO : Check fuel pump system (Refer to

inspection Procedure 24 313A). STEP 33. Replace engine-ECU. After engine-ECU is replaced, re-check for trouble symptom. Q: Does trouble system persist? YES : Check for foreign matters (water, kerosene,


Inspection Procedure 9: The Engine Stalls when Starting the Car (Pass Out) COMMENT ON TROUBLE SYMPTOM Engine stall on starting is possibly caused by misfire due to failed spark plug, improper air-fuel ratio at accelerator pedal depression or other faults. PROBABLE CAUSE Failed ignition system Failed intake system Failed emission gas cleaning system Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. MUT-II self-diag code Q: Diagnosis code set? YES : Inspection chart for diagnosis code (Refer



STEP 3. Check EGR valve itself. Check EGR valve itself [Refer to GROUP 17 Emission Control System - Exhaust Gas Recirculation (EGR) System 317]. Q: Is the check result normal? YES : Go to Step 4 . NO : Replace EGR valve.


13A-210

TROUBLESHOOTING

STEP 4. Check air intake from intake hose and inlet manifold. Q: Is the check result normal? YES : Go to Step 5 . NO : Repair.


STEP 5. Connector check: B-110 and B-111 ignition connectors. Connector: B-110, B-111

B-111 (GR)

STEP 9. Check ignition coil itself. Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).



B-111 (GR)


B-110 (GR) AK300308 AB

B-110 (GR)


AK300308 AB

CONNECTOR: C-134

STEP 6. Check ignition coil spark. Q: Is the check result normal? YES : Replace engine-ECU. NO : Go to Step 7 . C-134


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


STEP 8.Check spark plug cable itself. Check spark plug cable itself (Refer to GROUP 16 - Ignition System - On-vehicle Service 316 ). Q: Is the check result normal? YES : Go to Step 9 . NO : Replace spark plug cable.

AK300257 AB


No. 3 of ignition coil connector of each cylinder and C-134 engine-ECU. Check signal line for open/short circuit and damage. NO : Repair.


13A-211

TROUBLESHOOTING

Inspection Procedure 10. The Engine Stalls when Decelerating COMMENT ON TROUBLE SYMPTOM Engine stall on deceleration is possibly caused by insufficient air intake, improper air-fuel ratio due to failed exhaust gas recirculation system or other faults. PROBABLE CAUSE Failed idle speed control system Failed ignition system Failed emission control system Throttle valve fouled Failed engine-ECU

DIAGNOSIS PROCEDURE



(Refer to 313A). STEP 1. MUT-II self-diag code Q: Diagnosis code set? YES : Inspection chart for diagnosis code (Refer


STEP 2. MUT-II data list Refer to Data list reference table 313A. a. Item 14: Throttle position sensor

STEP 7. Connector check: B-110 and B-111 ignition coil connectors Connector: B-110, B-111

B-111 (GR)


Q: Is the check result normal? YES : Go to Step 3 . NO : Check throttle position sensor system

B-110 (GR)

(Refer to Code No. P0120 313A). STEP 3. MUT-II data list Item 45: Idle speed control servo position OK: Idle speed control servo drops to 0 - 2 Steps at deceleration (engine at 1,000 r/min or higher). Q: Is the check result normal? YES : Go to Step 4 . NO : Check idle speed control servo system

(Refer to Code No. P0505 313A). STEP 4. Check EGR control solenoid valve itself. Check EGR control solenoid valve itself [Refer to GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317 ]. Q: Is the check result normal? YES : Go to Step 5 . NO : Replace EGR control solenoid valve.

AK300308 AB


STEP 8. Check ignition coil spark. Q: Is the check result normal? YES : Replace engine-ECU. NO : Go to Step 9 .


13A-212


STEP 10. Check spark plug cable itself. Check spark plug cable itself (Refer to GROUP 16 - Ignition System - On-vehicle Service 316 ).


Q: Is the check result normal? YES : Go to Step 11 . NO : Replace spark plug cable. B-111 (GR)



B-110 (GR)


AK300308 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



No. 3 of ignition coil connector of each cylinder and C-134 engine-ECU. Check signal line for open/short circuit and damage. NO : Repair.

Inspection Procedure 11: Engine does not Revole Up COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed fuel system, ignition system or other faults.

DIAGNOSIS PROCEDURE

PROBABLE CAUSE Failed ignition system Failed fuel system Timing belt out of place Failed engine-ECU

Q: Diagnosis code set? YES : Inspection chart for diagnosis code (Refer

STEP 1. MUT-II self-diag code



13A-213

TROUBLESHOOTING

STEP 2. Check timing marks of timing belt. Q: Is the check result normal? YES : Go to Step 3 . NO : Align match marks.


STEP 3. Connector check: B-110 and B-111 ignition coil connectors B-111 (GR)


Connector: B-110, B-111

B-111 (GR)


B-110 (GR) AK300308 AB

CONNECTOR: C-134 B-110 (GR) AK300308 AB


C-134


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



STEP 6. Check spark plug cable itself. Check spark plug cable itself (Refer to GROUP 16 - Ignition System - On-vehicle Service 316 ). Q: Is the check result normal? YES : Go to Step 7 . NO : Replace spark plug cable.



No. 3 of ignition coil connector of each cylinder and C-134 engine-ECU. Check signal line for open/short circuit and damage. NO : Repair STEP 9. Measure fuel pressure. Measure fuel pressure (Refer to 313A). Q: Is the check result normal? YES : Replace engine-ECU. NO : Repair

13A-214


Inspection Procedure 12: Hesitation, sag,poor acceleration, stumble, surge COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed ignition system, improper air-fuel ratio, improper compression pressure or other faults. PROBABLE CAUSE Failed air-fuel ratio control system Failed ignition system Failed fuel system Failed intake and exhaust system Failed emission control system Throttle valve fouled Improper compression pressure Failed engine-ECU


to 313A). NO : Go to Step 2 . STEP 2. Check injector for operating sound. Check injector for operating sound (Refer to 313A). Q: Can operating sound be heard? YES : Go to Step 3 . NO : Check the injector system of the defective

cylinder. (Refer to code No. P0201: No. 1 injector system 313A). (Refer to code No. P0202: No. 2 injector system 313A). (Refer to code No. P0203: No. 3 injector system 313A). (Refer to code No. P0204: No. 4 injector system 313A).

STEP 3. MUT-II data list Refer to Data list reference table 313A. a. Idem 13: Intake air temperature sensor b. Item 14: Throttle position sensor c. Item 21: Engine coolant temperature sensor d. Item 25: Barometric pressure sensor Q: Are the check results normal? YES : Go to Step 4 . NO : Perform the diagnosis code classified check

Procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes 313A). STEP 4. Check purge control solenoid valve itself. Check purge control solenoid valve itself (Refer to GROUP 17 - Emission Control System Evaporative Emission Control System 317). Q: Is the check result normal? YES : Go to Step 5 . NO : Replace purge control solenoid valve.


STEP 6. Check EGR valve itself. Check EGR itself [Refer to GROUP 17 - Emission Control System - Exhaust Gas Recirculation (EGR) System 317]. Q: Is the check result normal? YES : Go to Step 7 . NO : Replace EGR valve.

STEP 7. MUT-II data list Refer to Data list reference table 313A. a. Item 11: Oxygen sensor (front) Q: Is the check result normal? YES : Go to Step 8 . NO : Check oxygen sensor system (Refer to

Code No. P0130 313A).


13A-215

TROUBLESHOOTING


B-111 (GR)



B-111 (GR)


B-110 (GR) B-110 (GR)

AK300308 AB

AK300308 AB


CONNECTOR: C-134


C-134


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14





No. 3 of ignition coil connector of each cylinder and C-134 engine-ECU Check signal line for open/short circuit and damage. NO : Repair. STEP 14. Check throttle body (throttle valve portion) for contamination. Q: Is the check result normal? YES : Go to Step 15 . NO : Clean throttle body (throttle valve portion)

(Refer to 313A). STEP 15. Measure fuel pressure. Measure fuel pressure (Refer to 313A). Q: Is the check result normal? YES : Go to Step 16 . NO : Repair.


13A-216

TROUBLESHOOTING

STEP 16. Check compression pressure. Check compression pressure (Refer to GROUP 11A - On-vehicle Service 311A). Q: Is the check result normal? YES : Replace engine-ECU. NO : Repair.

Inspection Procedure 13. The Feeling of Impact or Vibration when Accelerating COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed ignition leak with rise in spark plug-required voltage at acceleration. PROBABLE CAUSE Failed ignition system Failed engine-ECU

Q: Is the check result normal? YES : Replace engine-ECU. NO : Go to Step 4 .




STEP 2. Check connector: B-110 and B-111 ignition coil connectors Connector: B-110, B-111

B-111 (GR)

STEP 3. Check ignition coil spark.


B-110 (GR) AK300308 AB





13A-217


B-111 (GR)


B-110 (GR) AK300308 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



3 of ignition coil connector of each cylinder and C-134 engine-ECU Check signal line for open/short circuit and damage. NO : Repair.

Inspection Procedure 14: The feeling of impact or vibration when decelerating COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by insufficient air intake due to failed idle speed control system. PROBABLE CAUSE Failed idle speed control system Throttle valve body fouled Failed engine-ECU



13A-218


STEP 2. Check idle speed control servo for operating sound. Check idle speed control servo for operating sound (Refer to 313A). Q: Is the check result normal? YES : Go to Step 3 . NO : Check idle speed control servo system

STEP 3. MUT-II data list Refer to Data list reference table 313A. a. Item 14: Throttle position sensor Q: Is the check result normal? YES : Go to Step 4 . NO : Check throttle position sensor system

(Refer to Code No. P0120 313A).

(Refer to Code No. P0505 313A). STEP 4. Check throttle body (throttle valve) contamination. Q: Is the check result normal? YES : Replace engine-ECU. NO : Clean throttle body (throttle valve portion)

(Refer to 313A).

Inspection Procedure 15: Knocking COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed detonation control, improper thermal value of spark plug or other faults. PROBABLE CAUSE Defective detonation sensor Failed detonation control system Failed ignition system Defective spark plug Failed engine-ECU


B-111 (GR)


B-110 (GR)



AK300308 AB


STEP 3. Check ignition coil spark. Q: Is the check result normal? YES : Check detonation sensor (Refer to Code

No. P0325 313A). NO : Go to Step 4 .



13A-219

TROUBLESHOOTING

STEP 5. Check spark plug cable itself. Check spark plug cable itself (Refer to GROUP 16 -Ignition System - On-vehicle Service 316 ).

STEP 7. Check harness between ignition coil connector terminal No. 2 of each cylinder and body earth. Connector: B-110, B-111

Q: Is the check result normal? YES : Go to Step 6 . NO : Replace spark plug cable. B-111 (GR)



B-110 (GR) AK300308 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Check earthing line for open circuit and damage. Q: Is the check result normal? YES : Check and repair harness between ignition

coil connector terminal No. 3 of each cylinder and C-134 engine-ECU connector. Check signal line for open circuit, short circuit and damage. NO : Repair.

Inspection Procedure 16: Ignition Timing Offset COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed crank angle sensor, failed camshaft position sensor, improper installed timing belt or other faults. PROBABLE CAUSE Failed crank angle sensor Failed camshaft position sensor Improperly installed timing belt Failed engine-ECU




13A-220

TROUBLESHOOTING

STEP 2. Measure output waveforms of crank angle sensor and camshaft position sensor (Use oscilloscope). Connector: B-29




B-29 (B)


00 - How to Use Troubleshooting/Inspection Service Points 300). STEP 4. Check crank angle sensor and camshaft position sensor mounted conditions. Q: Is the check result normal? YES : Go to Step 5 . NO : Repair.

STEP 5. Check timing marks of timing belt. Crank angle sensor

Q: Is the check result normal? YES : Go to Step 6 . NO : Align timing marks.

AK300276 AB

STEP 6. Check crank angle sensor vane.


Q: Is the check result normal? YES : Go to Step 7 . NO : Replace crank angle sensor vane.

STEP 7. Check camshaft position sensing cylinder.

B-106 (B)

AK300279 AB

Crank Angle Sensor Use special tool test harness (MB998478) to connect B-29 crank angle sensor connector, and measure at pick-up harness. Engine: Idling Transmission: Neutral Voltage between terminal No. 2 and earth. Camshaft Position Sensor Use special tool test harness (MD991709) to connect B-106 camshaft position sensor connector, and measure at pick-up harness. Engine: Idling Transmission: Neutral Voltage between terminal No. 2 and earth. OK: Output waveform timings of both sensors are the same as the check procedure (Refer to 313A) using an oscilloscope.

Q: Is the check result normal? YES : Go to Step 8 . NO : Replace camshaft position sensing cylinder.

STEP 8. Replace crank angle sensor. After replacing the crank angle sensor, re-check the trouble symptoms. Q: Does trouble symptom persist? YES : Go to Step 9 . NO : Check end.


13A-221

STEP 9. Replace camshaft position sensor. After replacing the camshaft position sensor, recheck the trouble symptoms. Q: Does trouble symptom persist? YES : Replace engine-ECU. NO : Intermittent malfunction (Refer to GROUP


Inspection Procedure 17: Run on (Dieseling) COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by leakage from injector. PROBABLE CAUSE Failed injector Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. Check injector for spray condition. Check each injector for spray condition (Refer to 313A). Q: Does trouble symptom persist? YES : Replace engine-ECU. NO : Replace injector.

Inspection Procedure 18: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC during Idling COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by improper air-fuel ratio, deteriorated catalyst, failed ignition system, failed fuel system, failed compression pressure or other faults. PROBABLE CAUSE Incorrect air/fuel ratio Failed ignition system Failed fuel system Failed intake and exhaust system Failed emission control system Failed compression pressure Failed catalytic converter Failed engine-ECU

STEP 2. Check injector for operating sound. Check injector for operating sound (Refer to 313A). Q: Can operating sound be heard? YES : Go to Step 3 . NO : Check the injector system of the defective

cylinder. (Refer to 313A, Code P0201: No. 1 injector System) (Refer to 313A, Code P0202: No. 2 injector System) (Refer to 313A, Code P0203: No. 3 injector System) (Refer to 313A, Code P0204: No. 4 injector System)



STEP 3. Check ignition timing. Check ignition timing. (Refer to GROUP 11A On-vehicle Service 311A). Q: Is the check result normal? YES : Go to Step 4 . NO : Check for offset ignition timing (Refer to

Inspection Procedure 16 313A).

13A-222


STEP 4. MUT-II Data List Refer to Data list reference table 313A. a. Item 12: Air flow sensor b. Item 13: Intake air temperature sensor c. Item 21: Engine coolant temperature sensor d. Item 25: Barometric pressure sensor

STEP 10. Check EGR control solenoid valve itself. Check EGR control solenoid valve itself [Refer to GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317 ].

Q: Are the check results normal? YES : Go to Step 5 . NO : Perform the diagnosis code classified check

Q: Is the check result normal? YES : Go to Step 11 . NO : Replace EGR control solenoid valve.

Procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes 313A). STEP 5. Check air intake from intake hose and inlet manifold. Q: Is the check result normal? YES : Go to Step 6 . NO : Repair.

STEP 6. Check for emission leakage from exhaust manifold. Q: Is the check result normal? YES : Go to Step 7 . NO : Repair.


(Refer to 313A).


STEP 12. Measure fuel pressure. Measure fuel pressure (Refer to 313A). Q: Is the check result normal? YES : Go to Step 13 . NO : Repair.

STEP 13. Check positive crankcase ventilation valve itself. Check positive crankcase ventilation valve itself (Refer to GROUP 17 - Emission Control System - crankcase Emission Control System 317). Q: Is the check result normal? YES : Go to Step 14 . NO : Replace positive crankcase ventilation

valve.

STEP 8. MUT-II data list Refer to Data list reference table 313A. a. Item 11: Oxygen sensor (front)

STEP 14. Check spark plug.

Q: Is the check result normal? YES : Go to Step 9 . NO : Check oxygen sensor (front) system (Refer

Q: Is the check result normal? YES : Go to Step 15 . NO : Replace spark plug.

to Code No. P0130 313A). STEP 9. Check Purge control solenoid valve itself. Check purge control solenoid valve itself (Refer to GROUP 17 - Emission Control System Evaporative Emission Control System 317). Q: Is the check result normal? YES : Go to Step 10 . NO : Replace purge control solenoid valve.



13A-223


STEP 18. Check injector for spraying condition. Check each injector for spray condition (Refer to 313A).


Q: Does trouble symptom persist? YES : Go to Step 19 . NO : Replace injector.

STEP 17. Check compression pressure. Check compression pressure (Refer to GROUP 11A - On-vehicle Service 311A).

STEP 19. Replace catalytic converter. After replacing the catalytic converter, re-check the trouble symptoms.


Q: Does trouble symptom persist? YES : Replace engine-ECU. NO : Check end

Inspection Procedure 19: Battery Rundown COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed alternator, failed generation control circuit or other faults.

STEP 2. Connector check: B-19 intermediate connector CONNECTOR: B-19

PROBABLE CAUSE Failed battery Alternator G terminal short-circuited Failed alternator Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. Check battery voltage. Measure battery voltage during cranking. OK: 8 V or more Q: Is the check result normal? YES : Go to Step 2 . NO : Check battery (Refer to GROUP 54 -


B-19 (B)



AK300294 AB

13A-224


STEP 3. Measure voltage at B-19 intermediate connector.

STEP 4. Connector check: C-303 ignition switch connector CONNECTOR: C-303

CONNECTOR: B-19

B-19 (B) C-303 3 2 1 6 5 4



Disconnect connector, and measure at male connector side. Ignition switch: ON Voltage between terminal No. 5 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 5 . NO : Go to Step 4 .

AK300304 AB

AK300295 AB

CONNECTOR: B-19

B-19 (B)


AK300295 AB

Q: Is the check result normal? YES : Check intermediate connectors C-04, C-05,

C-105, C-203 and C-205, and repair if necessary. If intermediate connectors are normal, check and repair harness between B-19 (terminal No. 5) intermediate connector and C-303 (terminal No. 2) ignition switch connector. Check power supply line for open/short circuit. NO : Repair.


13A-225

TROUBLESHOOTING

STEP 5. Measure voltage at B-19 intermediate connector. CONNECTOR: B-19

STEP 7. Check harness between B-19 (terminal No. 4) intermediate connector and B-30 (terminal No. 1) alternator connector. CONNECTOR: B-19

B-19 (B) B-19 (B) 3 2 1 6 5 4 Female side connector

3 2 1 6 5 4 AK300294 AB

Disconnect connector, and measure at female connector side. Ignition switch: ON Voltage between terminal No. 4 and earth. OK: System voltage


AK300294 AB

CONNECTOR: B-30


B-30 (GR)

STEP 6. Connector check: B-30 alternator connector


4 3 2 1

CONNECTOR: B-30




B-30 (GR)

AK300296 AB

AK300296 AB

13A-226


STEP 8. Check harness between B-19 (terminal No. 5) intermediate connector and B-30 (terminal No. 3) alternator connector. CONNECTOR: B-19

STEP 9. Check harness between B-30 (terminal No. 3) alternator connector and C-303 (terminal No. 2) ignition switch connector. CONNECTOR: B-30

B-19 (B) B-30 (GR) 3 2 1 6 5 4 Female side connector

4 3 2 1 AK300294 AB


AK300296 AB

CONNECTOR: C-303

CONNECTOR: B-30

B-30 (GR)

C-303 3 2 1 6 5 4



Check power supply line for open/short circuit. Q: Is the check result normal? YES : Go to Step 9 . NO : Repair.

AK300304 AB

AK300296 AB

NOTE: Before checking harness, check intermediate connectors C-04, C-05, C-105, C-203 and C-205 and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Replace alternator. NO : Repair.


C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




13A-227

TROUBLESHOOTING



CONNECTOR: C-135

CONNECTOR: C-135

C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



CONNECTOR: B-19

B-19 (B)


AK300295 AB

Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 33 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 12 . NO : Check and repair harness between B-19

(terminal No. 4) intermediate connector and C-135 (terminal No. 33) engine-ECU connector. Check output line for short circuit.

AK300256 AB

Measure engine-ECU terminal voltage. Engine: Idling after warm-up Transmission: Neutral Radiator fan: Inactive Voltage between terminal No. 8 and earth. OK: Switching the headlamps to ON from OFF causes the voltage to increase by 0.2 3.5 V.

Q: Is the check result normal? YES : Go to Step 13 . NO : Check alternator.



13A-228


Inspection Procedure 20: Overheating COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by failed engine cooling system, failed fan controller, failed engine coolant temperature sensor or other faults. PROBABLE CAUSE Insufficient or deteriorated engine coolant Failed fan controller Failed engine coolant temperature sensor Failed thermostat Failed water pump Failed radiator core Failed engine-ECU


to 313A). NO : Go to Step 2 . STEP 2. Check engine coolant NOTE: If engine coolant level falls too early, check for leaky spots, and repair if necessary. Check engine coolant (Refer to GROUP 14 - Onvehicle Service 314). Q: Is the check result normal? YES : Go to Step 3 . NO : Replace or add engine coolant.

STEP 3. MUT-II actuator test Item 21: Fan controller OK: Fan motor rotating Q: Is the check result normal? YES : Go to Step 4 . NO : Check fan control relay system (Refer to

Inspection Procedure 25 313A). STEP 4. MUT-II Data List Item 21: Engine coolant temperature sensor OK: Engine cold state: At ambient temperature (atmospheric temperature) or equivalent. Engine hot state: At 80 - 120C Q: Is the check result normal? YES : Go to Step 5 . NO : Check engine coolant temperature sensor

system (Refer to Code No. P0115 313A ). STEP 5. Check thermostat. Check thermostat (Refer to GROUP 14 - Thermostat 314). Q: Is the check result normal? YES : Go to Step 6 . NO : Replace thermostat.

STEP 6. Check water pump. Check water pump. Q: Is the check result normal? YES : Replace radiator. NO : Replace water pump.


13A-229

Inspection Procedure 21: Abnormal Rotation of Fan Motor

Fan controller (Radiator fan, A/C condensor fan) Circuit

5V

A-20 (MU802322) 1 2 3

Fan controller

2 L-W

7 A-14

L-W

21 C-134 Engine-ECU 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26


OPERATION The control (duty) signal is inputted to the fan controller (terminal No. 2) from the engine-ECU (terminal No. 21). FUNCTION The engine-ECU inputs a duty signal suitable for the engine coolant temperature, vehicle speed and A/C switch position to the fan controller. In response to the signal, the fan controller controls the rotating speeds of the radiator fan and A/C condenser fan (The fan speed becomes higher as the average voltage of the terminal comes nearer to 5V).

PROBABLE CAUSE Failed fan controller Open/short circuit in fan controller circuit or loose connector contact Failed engine-ECU


13A-230

TROUBLESHOOTING

DIAGNOSIS PROCEDURE





CONNECTOR: C-134

STEP 4. Measure voltage at C-134 engine-ECU connector. C-134

CONNECTOR: C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


AK300257 AB


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


STEP 2. Check at C-134 engine-ECU connector. CONNECTOR: C-134

AK300257 AB

Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 21 and earth. OK: 4.9 - 5.1 V C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Q: Is the check result normal? YES : Replace fan controller. NO : Go to Step 5 .

STEP 5. Connector check: A-20 fan controller connector Connector: A-20

AK300257 AB

Disconnect connector, and measure at harness side. Ignition switch: ON Short-circuit terminal No. 21 to earth. OK: Fan motor stops rotating. Q: Is the check result normal? YES : Go to Step 3 . NO : Go to Step 4 .

A-20 (GR)



AK203423 AC


13A-231

STEP 6. Check harness between A-20 (terminal No. 2) fan controller connector and C-134 (terminal No. 21) engine-ECU connector. Connector: A-20

A-20 (GR)


AK203423 AC

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


NOTE: Before checking harness, check intermediate connector A-14, and repair if necessary. Check output line for open circuit. Q: Is the check result normal? YES : Replace fan controller. NO : Repair.

Inspection Procedure 22: Poor A/C Performance COMMENT ON TROUBLE SYMPTOM Failure is possibly caused by short /overcharged A/C refrigerant, failed A/C control system, failed fan control system or other faults. PROBABLE CAUSE Short or overcharged A/C refrigerant Failed A/C compressor relay Failed fan controller Failed A/C-ECU

Failed engine-ECU



13A-232


STEP 2. A/C compressor magnet clutch operation check. Engine: Idling A/C set temperature: Maximum Cool when temperature in cabin is 25C or more Maximum Hot when temperature in cabin is 25C or less OK: Magnet clutch active (when A/C is ON) Magnet clutch inactive (when A/C is OFF)

STEP 4. MUT-II data list Item 49: A/C relay a. Engine: Running at idle b. A/C set temperature: Maximum Cool when temperature in cabin is 25C or more. Maximum Hot when temperature in cabin is 25C or less. OK: ON (when A/C is ON) OFF (when A/C is OFF)


Q: Is the check result normal? YES : Check A/C system (Refer to GROUP 55A -

Troubleshooting 355A). NO : Check A/C compressor relay (Refer to

STEP 3. MUT-II data list Item 28: A/C switch a. Engine: Idling b. A/C set temperature: Maximum Cool when temperature in cabin is 25C or more Maximum Hot when temperature in cabin is 25C or less OK: ON (when A/C is ON) OFF (when A/C is OFF) Q: Is the check result normal? YES : Go to Step 4 . NO : Check A/C switch (Refer to Inspection

Procedure 26 313A).

inspection procedure 27 313A). STEP 5. Check charged amount of A/C refrigerant. Check charged amount of A/C refrigerant (Refer to GROUP 55A - On-vehicle Service 355A). Q: Is the check result normal? YES : Go to Step 6 . NO : Adjust charged amount of A/C refrigerant.

STEP 6. MUT-II actuator test Item 21: Fan controller OK: Fan motor rotates. Q: Is the check result normal? YES : Check A/C load signal system (Refer to

Inspection Procedure 28 313A). NO : Check fan control relay system (Refer to

Inspection Procedure 25313A).


13A-233

TROUBLESHOOTING

Inspection Procedure 23: Engine-ECU Power Supply, Engine Control Relay, Ignition Switch-IG1 System Power supply and ignition switch-IG circuit

Battery

W

9 20A

Relay box

Ignition switch

123 456

ACC

ST

W-B

C-303

LOCK

R IG1

A-14 5

IG2

2

W-B

L-B 6

W-B

W-B 4

B-17X

1

2

3

4

8 7.5A

J/B

3 1 C-202


L-B

2

1

R C-106 10

4

J/C (2) C-17

W-B

Y-G 9

L-B

10

R

R 12

25

38

80

82

Battery backup

Power source

C-134

C-135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

Engine-ECU

C-137 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

Wire colour code B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray R: Red P: Pink V:Violet AK300310

AB

13A-234


OPERATION The battery voltage is applied to the engine control relay (terminal No. 3 and 4). The engine-ECU (terminal No. 38) makes the power transistor in the unit be in "ON" position and makes currents go on the engine control relay coil, and that makes the relay be in "ON" position. When the engine control relay is in "ON" position, the battery voltage is supplied to the engineECU, the sensor and the actuator from the engine control relay (terminal No. 1). FUNCTION When the ignition switch ON signal is input to the engine-ECU, the engine-ECU places the engine control relay in the ON position. Accordingly, the battery voltage is supplied to the engine-ECU, sensor and actuator. PROBABLE CAUSE Failed engine control relay Open/short circuit in engine control relay circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE


2

1

4

3

B-17X


AK300255 AB


STEP 3. Check engine control relay. Check engine control relay (Refer to 313A). Q: Is the check result normal? YES : Go to Step 4 . NO : Replace engine control relay.

STEP 4. Measure voltage at B-17X engine control relay connector. CONNECTOR: B-17X

STEP 1. Check battery voltage. Measure battery voltage during cranking. OK: 8 V or more Q: Is the check result normal? YES : Go to Step 2 . NO : Check battery (Refer to GROUP 54 -



2

1

4

3


B-17X

AK300255 AB

Remove relay, and measure at relay box side. Voltage between terminal No. 3 and earth, also between terminal No. 4 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 5 . NO : Check intermediate connector A-14, and

repair if necessary. If intermediate connector is normal, check and repair harness between B-17X (terminal No. 4) engine control relay connector and battery. Check power supply line for open/short circuit.


13A-235

TROUBLESHOOTING



CONNECTOR: C-134

C-134

C-137

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 12 and earth, also between terminal No. 25 and earth. OK: System voltage Q: Is the check result normal? YES : Check and repair C-134 engine-ECU

AK300254 AB

Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 82 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 12 . NO : Go to Step 8 .

connector. NO : Go to Step 6 .



CONNECTOR: C-137

CONNECTOR: C-137

C-137 C-137 8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

AK300254 AB





13A-236

TROUBLESHOOTING

STEP 9. Check ignition switch. Check ignition switch (Refer to GROUP 54A Ignition Switch - Ignition Switch 354A). Q: Is the check result normal? YES : Go to Step 10 . NO : Replace ignition switch.

STEP 11. Check harness between C-303 (terminal No. 2) ignition switch connector and C-137 (terminal No. 82) engine-ECU connector. CONNECTOR: C-303



C-303

CONNECTOR: C-137

3 2 1 6 5 4 Harness side connector AK300304 AB


C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


NOTE: Before checking harness, check intermediate connectors C-106, C-202 and C-203, and repair if necessary. Check output line for open/short circuit. Q: Is the check result normal? YES : Check and repair ignition switch IG1 power

supply line harness and connector. Check power supply line for short circuit. NO : Repair.


13A-237

TROUBLESHOOTING



C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 38 and earth. OK: 1 V or less


2

1

4

3


AK300256 AB

B-17X


AK300255 AB

Measure engine-ECU terminal voltage. Ignition switch: OFF Voltage between terminal No. 38 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 13 . NO : Check and repair harness between B-17X

(terminal No. 2) engine control relay connector and C-135 (terminal No. 38) engine-ECU connector. Check earthing line for open/short circuit.


13A-238

TROUBLESHOOTING

STEP 14. Connector check: C-135 engine-ECU connector, C-303 ignition switch connector CONNECTOR: C-135

STEP 15. Check harness between C-303 (terminal No. 2) ignition switch connector and C-137 (terminal No. 82) engine-ECU connector. CONNECTOR: C-303

C-303 C-135


38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

CONNECTOR: C-137


CONNECTOR: C-303

C-137 C-303 3 2 1 6 5 4

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




NOTE: Before checking harness, check intermediate connectors C-106, C-202 and C-203 and repair if necessary. Check output line for open/short circuit. Q: Is the check result normal? YES : Go to Step 16 . NO : Repair.




13A-239

TROUBLESHOOTING

STEP 17. Check harness between B-17X (terminal No. 1) engine control relay connector and C-134 (terminal No. 12 and No. 25) engineECU connector. CONNECTOR: B-17X Relay box’s triangle marks

2

1

4

3

B-17X

STEP 18. Check engine control relay output power supply harness and connector for short circuit. Q: Is the check result normal? YES : Go to Step 19 . NO : Repair.

STEP 19. Check harness between B-17X (terminal No. 3 and No. 4) engine control relay connector and battery. CONNECTOR: B-17X


AK300255 AB


B-17X

CONNECTOR: C-134 2

1

4

3


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


NOTE: Before checking harness, check intermediate connector C-17, and repair if necessary. Check output line for open/short circuit and damage. Q: Is the check result normal? YES : Go to Step 18 . NO : Repair.

AK300255 AB

NOTE: Before checking harness, check intermediate connector A-14, and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 20 . NO : Repair.


13A-240

TROUBLESHOOTING

STEP 20. Check harness between B-17X (terminal No. 2) engine control relay connector and C-135 (terminal No. 38) engine-ECU connector. CONNECTOR: B-17X B-17X


2

1

4

3


AK300255 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




13A-241

TROUBLESHOOTING

Inspection Procedure 24: Fuel Pump System

Fuel pump circuit Battery C-303

W

123 456

24 15A

L-B

C-202 2

4 C-213

1 2 3 4

1 2 3 4

OFF

Fuel pump relay (1) C-215

C-203 6

3

1

ON

1

Ignition switch

ACC IG2

2

C-116 41

C-215

ST IG1

Reray box

W

W

LOCK

R

ON

OFF

2

Fuel pump relay (2) C-213

4

C-209 1

C-205 11

3

8 7.5A J/B

2

C-205 14

B-L D-24 6

B

G B-L 5 Fuel pump D-16 (MU802058)

M

1 2 3 4 5

4

8

B D-24 4 G B 22

C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU



13A-242

TROUBLESHOOTING

OPERATION The battery voltage is applied to the fuel pump relay (1) (terminal No. 3) form the ignition switch and is earthed to the vehicle body from the fuel pump relay (1) (terminal No. 2). The battery voltage is applied to the fuel pump relay (1) (terminal No. 4) and to the fuel pump relay (2) (terminal No. 1) from the fuel pump relay (1) (terminal No. 1). The battery voltage is applied to the fuel pump relay (2) (terminal No. 3) from the ignition switch. The engine-ECU (terminal No. 22) makes the power transistor in the unit be in "ON" position and makes currents go on the fuel pump relay (2) coil, and that makes the relay be in "ON" position. When the fuel pump relay (2) is in "ON" position, the battery voltage is supplied to the fuel pump (low pressure) from the fuel pump relay (2) (terminal No. 4). FUNCTION When the ignition switch ON signal is input to the engine-ECU, the engine-ECU places the fuel pump relay in the "ON" position. Accordingly, the battery voltage is supplied to the fuel pump. PROBABLE CAUSE Failed fuel pump relay Failed fuel pump Open/short circuit in fuel pump drive circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. Connector check: C-215 fuel pump relay (1) connector and C-213 fuel pump relay (2) connector CONNECTOR: C-213, C-215

Junction block’s triangle marks

C-215 C-213


AK300312 AB


STEP 2. Check fuel pump relay. Fuel pump relay, continuity check (Refer to 313A). Q: Is the check result normal? YES : Go to Step 3 . NO : Replace fuel pump relay.

STEP 3. Measure resistance at C-215 fuel pump relay (1) connector. CONNECTOR: C-215


C-215 2 1 4 3 Harness side connector

AK300313 AB

Remove relay, and measure at junction block side. Resistance between terminal No. 2 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 4 . NO : Check intermediate connector C-205, and

repair if necessary. If intermediate connector is normal, check and repair harness between C-215 (terminal No. 2) fuel pump relay (1) connector and body earth. Check earthing line for open circuit and damage.


13A-243

TROUBLESHOOTING

STEP 4. Measure voltage at C-215 fuel pump relay (1) connector. CONNECTOR: C-215





AK300313 AB

Remove relay, and measure at junction block side. Ignition switch: ON Voltage between terminal No. 3 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 6 . NO : Go to Step 5 .

CONNECTOR: C-215



AK300313 AB


repair if necessary. If intermediate connector is normal, check and repair harness between C-215 (terminal No. 3) fuel pump relay (1) connector and C-303 (terminal No. 2) ignition switch connector. Check power supply line for open circuit and damage. NO : Repair.

13A-244


STEP 6. Measure voltage at C-215 fuel pump relay (1) connector. CONNECTOR: C-215





AK300313 AB

Remove relay, and measure at junction block side. Voltage between terminal No. 4 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 7 . NO : Check intermediate connectors C-116 and

C-202, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-215 (terminal No. 4) fuel pump relay (1) connector and battery. Check power supply line for open/short circuit. STEP 7. Measure voltage at C-213 fuel pump relay (2) connector. CONNECTOR: C-213

C-213



AK300321 AB

Remove relay, and measure at junction block side. Ignition switch: ON Voltage between terminal No. 3 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 9 . NO : Go to Step 8 .

CONNECTOR: C-213

C-213



AK300321 AB


repair if necessary. If intermediate connector is normal, check and repair harness between C-303 (terminal No. 2) ignition switch connector and C-213 (terminal No. 3) fuel pump relay (2) connector. Check power supply line for open/short circuit. NO : Repair.


13A-245

TROUBLESHOOTING



CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




AK300257 AB

CONNECTOR: C-213

C-213



AK300321 AB

Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 22 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 11 . NO : Check intermediate connectors C-106 and

C-205, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-213 (terminal No. 2) fuel pump relay (2) connector and C134 (terminal No. 22) engine-ECU connector. Check earthing line for open/short circuit.

13A-246


STEP 11. Connector check: D-16 fuel pump connector Connector: D-16

STEP 13. Check harness between C-213 (terminal No. 4) fuel pump relay (2) connector and D-16 (terminal No. 5) fuel pump connector. CONNECTOR: C-213

D-16 (GR) 3 2 1 5 4 Harness side connector



C-213

AK203431AC AK300321 AB


Connector: D-16

STEP 12. Measure voltage at D-16 fuel pump connector. D-16 (GR)

Connector: D-16

3 2 1 5 4 Harness side connector D-16 (GR)

3 2 1 5 4 Harness side connector

AK203431AC

Disconnect connector, and measure at harness side. Ignition switch: ON Using a jumper wire, connect C-134 (terminal No. 22) engine-ECU connector and earth. Voltage between terminal No. 5 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 14 . NO : Go to Step 13 .

AK203431AC

NOTE: Before checking harness, check intermediate connectors D-209 and D-24, and repair if necessary. Check output line for open/short circuit and damage. Q: Is the check result normal? YES : Replace engine-ECU. NO : Repair.


13A-247

TROUBLESHOOTING

STEP 14. Measure resistance at D-16 fuel pump connector. Connector: D-16

STEP 16. Check harness between C-303 (terminal No. 2) ignition switch connector and C-215 (terminal No. 3) fuel pump relay (1) connector. CONNECTOR: C-303

D-16 (GR) 3 2 1 5 4 Harness side connector

C-303 3 2 1 6 5 4

AK203431AC

Disconnect connector, and measure at harness side. Resistance between terminal No. 4 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 15 . NO : Check intermediate connector D-24, and

repair if necessary. If intermediate connector is normal, check and repair harness between D-16 (terminal No. 4) fuel pump connector and body earth. Check earthing line for open circuit and damage. STEP 15. Connector check: C-303 ignition switch connector CONNECTOR: C-303

C-303 3 2 1 6 5 4


CONNECTOR: C-215


AK300313 AB

NOTE: Before checking harness,check intermediate connector C-203, and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 17. NO : Repair.

STEP 17. Check harness between battery and C215 (terminal No. 4) fuel pump relay (1) connector. CONNECTOR: C-215






AK300313 AB

NOTE: Before checking harness, check intermediate connector C-202, and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 18 . NO : Repair.


13A-248

TROUBLESHOOTING

STEP 18. Check harness between C-215 (terminal No. 1) fuel pump relay (1) connector and C-213 (terminal No. 1) fuel pump relay (2) connector. CONNECTOR: C-213, C-215


STEP 20. Check harness between C-213 (terminal No. 3) fuel pump relay (2) connector and C-134 (terminal No. 22) engine-ECU connector. CONNECTOR: C-213


C-215 C-213



C-213

AK300312 AB


AK300321 AB

CONNECTOR: C-134


STEP 19. Check harness between C-303 (terminal No. 2) ignition switch connector and C-213 (terminal No. 3) fuel pump relay (2) connector.

C-134

CONNECTOR: C-303 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



CONNECTOR: C-213

C-213



AK300321 AB


NOTE: Before checking harness, check intermediate connectors C-106 and C-205, and repair if necessary. Check earthing line for open/short circuit. Q: Is the check result normal? YES : Go to Step 21. NO : Repair.


STEP 21. Check harness between C-213 (terminal No. 3) fuel pump relay (2) connector and D-16 (terminal No.5) fuel pump connector. CONNECTOR: C-213



C-213

AK300321 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


NOTE: Before checking harness, check intermediate connectors D-24 and C-205, and repair if necessary. Check output line for open/short circuit. Q: Is the check result normal? YES : Replace fuel pump. NO : Repair.

13A-249


13A-250

TROUBLESHOOTING

Inspection Procedure 25: Fan Control Relay System

Fan control relay Circuit Battery W

9 20A W-B A-14 5 W-B

W-B 3

4 B-17X

1

2

3

4


1 Engine control system

2

R To engine-ECU

4

Fusible link (2)

J/C (2) C-17

5

R A-14 11

L-W R

1

4 A-10X

1

2

Fan control relay

3

4 2

3 B

L 3

A-20 (MU802322) 1 2 3

Smoothing circuit

Fan controller


O: Orange GR: Gray AK300323 AB


OPERATION The battery voltage is applied to the fan control relay (terminal No. 1) from the engine control relay (terminal No. 1) and is earthed to the vehicle body from the fan control relay (terminal No. 3). The battery voltage is applied to the fan control relay (terminal No. 4). When the fan control relay is in "ON" position, the battery voltage is supplied to the fan controller (terminal No. 3) from the fan control relay (terminal No. 2). FUNCTION When the engine control relay is in "ON" position, the fan control relay is also simultaneously placed in "ON" position. Accordingly, the battery voltage is supplied to the fan controller. PROBABLE CAUSE Failed fan control relay Failed fan controller Failed radiator fan motor Failed condenser fan motor Open/short circuit in fan control relay circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. Connector check: A-10X fan control relay connector CONNECTOR: A-10X

2

STEP 2. Check fan control relay. Check fan control relay (Refer to GROUP 14 On-vehicle Service 314). Q: Is the check result normal? YES : Go to Step 3 . NO : Replace fan control relay.

STEP 3. Measure resistance at A-10X fan control relay connector. CONNECTOR: A-10X

A-10X

3

2


Remove relay and measure at relay box side. Resistance between terminal No. 3 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 4 . NO : Check and repair harness between A-10X

(terminal No. 3) fan control relay connector and body earth. Check earthing line for open circuit and damage.

CONNECTOR: A-10X

A-10X

1



AK300324 AB

STEP 4. Measure voltage at A-10X fan control relay connector. A-10X

3

13A-251

AK300324 AB

3

2


AK300324 AB

Remove relay and measure at relay box side. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 6 . NO : Go to Step 5 .


13A-252

TROUBLESHOOTING


STEP 6. Measure voltage at A-10X fan control relay connector. CONNECTOR: A-10X

B-17X A-10X

2

1

4

3

3


AK300255 AB

A-10X

2

1



AK300324 AB

Remove relay, and measure at relay box side. Voltage between terminal No. 4 and earth OK: System voltage

CONNECTOR: A-10X

3

2

AK300324 AB

Q: Is the check result normal? YES : Check intermediate connectors A-14 and C-

17, and repair if necessary. If intermediate connectors are normal, check and repair harness between B-17X (terminal No. 1) engine control relay connector and A-10X (terminal No. 1) fan control relay connector. Check power supply line for open/short circuit. NO : Repair.

Q: Is the check result normal? YES : Go to Step 7 . NO : Check and repair harness between battery

and A-10X (terminal No. 4) fan control relay connector. Check power supply line for open/short circuit. STEP 7. Connector check: A-20 fan controller connector Connector: A-20

A-20 (GR)



AK203423 AC


13A-253

TROUBLESHOOTING

STEP 8. Measure voltage at A-20 fan controller connector.


Connector: A-20


B-17X

A-20 (GR)


AK203423 AC


STEP 9. Check harness between A-10X (terminal No. 2) fan control relay connector and A-20 (terminal No. 3) fan controller connector.

2

1

4

3


AK300255 AB


STEP 11. Check harness between B-17X (terminal No. 1) engine control relay connector and A-10X (terminal No. 1) fan control relay connector. CONNECTOR: B-17X Relay box’s triangle marks

B-17X

CONNECTOR: A-10X

A-10X

3

2


2

1

4

3


AK300255 AB

CONNECTOR: A-10X

AK300324 AB

A-10X Connector: A-20 3


A-20 (GR)


AK300324 AB

NOTE: Before checking harness, check intermediate connectors A-14 and C-17, and repair if necessary. Check power supply line for damage. AK203423 AC

Check output line for open/short circuit. Q: Is the check result normal? YES : Go to Step 10 . NO : Repair.

2

Q: Is the check result normal? YES : Check and repair harness between A-10X

(terminal No. 3) fan control relay connector and body earth. Check earthing line for damage. NO : Repair.


13A-254

TROUBLESHOOTING


STEP 14. MUT-II actuator test Item 21: Fan controller OK: Fan motor rotates. Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

C-134

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Replace engine-ECU. STEP 15. Measure voltage at C-134 engine-ECU connector.

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

CONNECTOR: C-134



C-134

STEP 13. Fan motor drive test. CONNECTOR: C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


Disconnect C-134 engine-ECU connector. Ignition switch: ON OK: Fan motor rotates. Q: Is the check result normal? YES : Go to Step 14 . NO : Go to Step 15 .



13A-255

TROUBLESHOOTING

STEP 16. Check harness between A-10X (terminal No. 4) fan control relay connector and battery. CONNECTOR: A-10X

STEP 18. Check harness between A-20 (terminal No. 2) fan controller connector and C-134 (terminal No. 21) engine-ECU connector. Connector: A-20

A-10X A-20 (GR) 3

2


AK300324 AB



AK203423 AC

CONNECTOR: C-134


STEP 17. Check harness between A-10X (terminal No. 2) fan control relay connector and A-20 (terminal No. 3) fan controller connector.

C-134

CONNECTOR: A-10X 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

A-10X


3

2


AK300324 AB

Q: Is the check result normal? YES : Replace fan motor and fan controller. NO : Repair.

Connector: A-20

A-20 (GR)


NOTE: Before checking harness, check intermediate connector A-14, and repair if necessary. Check output line for short circuit.

AK203423 AC

Check output line for damage. Q: Is the check result normal? YES : Replace fan motor and fan controller. NO : Repair.


13A-256

TROUBLESHOOTING

Inspection Procedure 26: A/C Switch System

A/C Switch circuit

C-06 A/C-ECU

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

4 34 G-B C-104 7 G-B 45 C-135 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

Engine-ECU


OPERATION The battery voltage is applied to the engine-ECU (terminal No. 45) from the A/C-ECU (terminal No. 4) or A/C-ECU (terminal No. 34) . FUNCTION When the A/C switch is in "ON" position, A/C switch ON signal is inputted to the engine-ECU from the A/C-ECU. In response to the signal, the engine-ECU controls the A/C compressor relay.

PROBABLE CAUSE Failed A/C Failed A/C system Open/short circuit in A/C circuit or loose connector contact Failed engine-ECU


13A-257

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP 1. Measure voltage at C-135 engine-ECU connector. CONNECTOR: C-135

STEP 2. Measure voltage at C-06 A/C-ECU connector or C-26 A/C-ECU connector . Connector: C-06

C-06 (B)

C-135

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9


AK300326 AB

Connector: C-26

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


Measure engine-ECU terminal voltage. Engine: Running at idle A/C set temperature: Maximum Cool when temperature in cabin is 25C or more Maximum Hot when temperature in cabin is 25C or less Voltage between terminal No. 45 and earth. OK: System voltage (when A/C is ON) 0.5 V or less (when A/C is OFF) Q: Is the check result normal? YES : Go to Step 6 . NO : Go to Step 2 .

28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29

C-26 (B)


AK300327AB

Measure engine-ECU terminal voltage. Engine: Idling A/C set temperature: Maximum Cool when temperature in cabin is 25C or more Maximum Hot when temperature in cabin is 25C or less Voltage between terminal No. 4 and earth Voltage between terminal No. 34 and earth OK: System voltage Q: Is the check result normal? YES : Go to Step 5 . NO : Go to Step 3 .


13A-258

TROUBLESHOOTING

STEP 3. Connector check: C-06 A/C-ECU connector or C-26 A/C-ECU connector C-135 engine-ECU connector Connector: C-06

STEP 4. Check harness between C-06 A/C-ECU connector or C-26 A/C-ECU connector and C-135 (terminal No. 45) engine-ECU connector. Connector: C-06

C-06 (B)

C-06 (B)

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9


AK300326 AB

Connector: C-26

28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29


AK300326 AB

Connector: C-26

28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29

C-26 (B)


AK300327AB

CONNECTOR: C-135

C-26 (B)


AK300327AB

CONNECTOR: C-135

C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




AK300256 AB

NOTE: Before checking harness, check intermediate connector C-104, and repair if necessary. Check output line for short circuit. Q: Is the check result normal? YES : Check A/C system (Refer to GROUP 55A -

Troubleshooting 355A). NO : Repair.


13A-259

TROUBLESHOOTING

STEP 5. Connector check: C-06 A/C-ECU connector or C-26 A/C-ECU connector and C-135 engine-ECU connector


Connector: C-06

C-06 (B) C-135 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9


AK300326 AB

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39


Connector: C-26

AK300256 AB

Q: Is the check result normal? YES : Go to Step 7 . NO : Repair. 28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29

C-26 (B)


AK300327AB

CONNECTOR: C-135

C-135

STEP 7. MUT-II data list Item 28: A/C switch a. Engine: Idling b. A/C set temperature: Maximum Cool when temperature in cabin is 25C or more. Maximum Hot when temperature in cabin is 25C or less. OK: ON (when A/C is ON) OFF (when A/C is OFF) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



repair if necessary. If intermediate connector is normal, check and repair harness between C-06 (terminal No. 4) or C-26 (terminal No. 34) A/C-ECU connector and C-135 (terminal No. 45) engine-ECU connector. Check output line for open circuit. NO : Repair.


13A-260

TROUBLESHOOTING

Inspection Procedure 27: A/C Compressor Relay System

A/C compressor relay Circuit Ignition switch C-303 1 2 3 4 5 6

R

LOCK

ST IG1

ACC IG2

4 L-R Battery

C-203 2 5 J/B 7.5A

W

10 10A

C-205 16

Relay box

L-R B-R

C-106 11

A-14 9

B-R

L-R 3

4 B-18X

1

2

3

4

A/C compressor relay

1

2

A/C-ECU

G

B-W 1

8 Engine-ECU

A/C compressor assembly B-27 (MU802653)

1

A/C refrigerant temperature switch

Magnetic clutch

C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26


O: Orange GR: Gray AK300328 AB


13A-261

TROUBLESHOOTING

OPERATION The battery voltage is applied to the A/C compressor relay (terminal No. 4). The battery voltage is applied to the A/C compressor relay (terminal No. 3) from the ignition switch. The engine-ECU (terminal No. 8) makes the power transistor in the unit be in "ON" position and makes currents go on the A/C compressor relay coil, and that makes the relay be in "ON" position. When the A/C compressor is in "ON" position, the battery voltage is supplied to the A/C compressor (terminal No. 1) from the A/C compressor relay (terminal No. 1). FUNCTION When the A/C switch "ON" signal is input to the engine-ECU, the engine-ECU places the A/C compressor relay in the "ON" position. Accordingly, the battery voltage supplied to the A/C compressor operates the magnet clutch. PROBABLE CAUSE Failed A/C compressor relay Failed A/C compressor magnet clutch Open/short circuit in A/C compressor relay circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. Connector check: B-18X A/C compressor relay connector CONNECTOR: B-18X Relay box’s triangle marks

2

1

4

3

B-18X



AK300329 AB

STEP 2. A/C compressor relay check. Check A/C compressor relay (Refer to GROUP 55A - On-vehicle Service 355A). Q: Is the check result normal? YES : Go to Step 3 . NO : Replace A/C compressor relay.

STEP 3. Measure voltage at B-18X A/C compressor relay connector. CONNECTOR: B-18X Relay box’s triangle marks

2

1

4

3

B-18X


AK300329 AB

Remove relay, and measure at relay box side. Ignition switch: ON Voltage between terminal No. 3 and earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 5 . NO : Go to Step 4 .


13A-262

TROUBLESHOOTING

STEP 4. Connector check: C-303 ignition switch connector

STEP 5. Measure voltage at B-18X A/C compressor relay connector. CONNECTOR: B-18X

CONNECTOR: C-303


B-18X


2

1

4

3


1

4

3


AK300329 AB

Remove relay, and measure at relay box side. Voltage between terminal No. 4 and earth. OK: System voltage


2

B-18X

Q: Is the check result normal? YES : Go to Step 6 . NO : Check intermediate connector A-14, and

AK300329 AB

Q: Is the check result normal? YES : Check intermediate connectors C-106, C-

202 , C-203 and C-205 , and repair if necessary. If intermediate connectors are normal, check and repair harness between B-18X (terminal No. 3) A/C compressor relay connector and C-303 (terminal No. 4) ignition switch connector. Check power supply line for open/short circuit. NO : Repair.

repair if necessary. If intermediate connector is normal, check and repair harness between B-18X (terminal No. 4) A/C compressor relay connector and battery. Check power supply line for open/short circuit. STEP 6. Connector check: B-27 A/C compressor connector CONNECTOR: B-27



AK300330 AB


13A-263

TROUBLESHOOTING

STEP 7. Measure voltage at B-27 A/C compressor connector.


CONNECTOR: B-27

B-27 (B) C-134


AK300330 AB

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


B-18X


2

1

4

3


Measure engine-ECU terminal voltage. Ignition switch: ON Voltage between terminal No. 8 and earth. OK: System voltage AK300329 AB

Disconnect connector, and measure at harness side. Remove B-18X (terminal No. 1 and No. 4) A/C compressor relay and short-circuit of harness side connector. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: System voltage



Q: Is the check result normal? YES : Go to Step 8 . NO : Check and repair harness between B-27

(terminal No. 1) A/C compressor connector and B-18X (terminal No. 1) A/C compressor relay connector. Check output line for open/short circuit.

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




13A-264

TROUBLESHOOTING

STEP 10. Check harness between B-18X (terminal No. 2) A/C compressor relay connector and C-134 (terminal No. 8) engine-ECU connector. CONNECTOR: B-18X Relay box’s triangle marks

2

1

4

3

B-18X

STEP 11. MUT-II Data List Item 49: A/C relay a. Engine: Idling b. A/C set temperature: Maximum Cool when temperature in cabin is 25C or more Maximum Hot when temperature in cabin is 25C or less OK: ON (when A/C is ON) OFF (when A/C is OFF) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


AK300329 AB

CONNECTOR: C-134

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Replace engine-ECU. STEP 12. Connector check: C-134 engine-ECU connector

C-134

CONNECTOR: C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




13A-265

TROUBLESHOOTING

STEP 13. Check harness between B-18X (terminal No. 2) A/C compressor relay connector and C-134 (terminal No. 8) engine-ECU connector.

STEP 15. Check harness between C-303 (terminal No. 4) ignition switch connector and B-18X (terminal No. 3) A/C compressor relay connector. CONNECTOR: C-303


B-18X

C-303 2

1

4

3



AK300329 AB

CONNECTOR: B-18X CONNECTOR: C-134


C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




1

4

3


3 2 1 6 5 4

AK300329 AB

NOTE: Before checking harness, check intermediate connectors C-106, C-202 , C-203 and C205 , and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 16 . NO : Repair.

STEP 16. Check harness between battery and B18X (terminal No. 4) A/C compressor relay connector. CONNECTOR: B-18X Relay box’s triangle marks

C-303

2

1

4

3

B-18X




2

B-18X

AK300329 AB

NOTE: Before checking harness, check intermediate connector A-14, and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 17 . NO : Repair.


13A-266

TROUBLESHOOTING

STEP 17. Check harness between B-18X (terminal No. 1) A/C compressor relay connector and B-27 (terminal No. 1) A/C compressor relay connector. CONNECTOR: B-18X Relay box’s triangle marks

2

1

4

3

B-18X


AK300329 AB

CONNECTOR: B-27


AK300330 AB

Check output line for damage. Q: Is the check result normal? YES : Replace A/C compressor magnet clutch. NO : Repair.


13A-267

Inspection Procedure 28: A/C Load Signal System

A/C load signal circuit

C-06 A/C-ECU

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5 32 L-W C-106 6 L-W 24 C-134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU


OPERATION The A/C load signal is inputted to the engineECU (terminal No. 24) from the A/C-ECU (terminal No. 5). or (terminal No. 32) FUNCTION The magnitude of the A/C compressor load is detected and input to the engine-ECU. The engine-ECU provides A/C idle up control according to the A/C compressor load condition.

PROBABLE CAUSE Failed A/C-ECU Open/short circuit in A/C load signal circuit or loose connector contact Failed engine-ECU


13A-268

TROUBLESHOOTING

DIAGNOSIS PROCEDURE



CONNECTOR: C-134

CONNECTOR: C-134

C-134 C-134 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



Measure engine-ECU terminal voltage. Engine: Idling A/C switch: ON (A/C compressor in driven state) Voltage between terminal No. 24 and earth OK: 1 V or less (when the temperate around the atmospheric air temperature sensor is 18C or more, and the A/C is set to the lowest temperature and the maximum air flow rate) System voltage (when the A/C is set to the temperature in the cabin and the minimum air flow rate)




00 - How to Use Troubleshooting/Inspection Service Points 300). STEP 4. Connector check: C-134 engine-ECU connector CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




13A-269

TROUBLESHOOTING

STEP 5. Measure voltage at C-06 A/C-ECU connector or C-26 A/C-ECU connector . Connector: C-06

STEP 6. Connector Check: C-06 A/C-ECU connector or C-26 A/C-ECU connector Connector: C-06

C-06 (B)

C-06 (B)

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9


AK300326 AB

Connector: C-26

28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29


AK300326 AB

Connector: C-26

28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29

C-26 (B)


AK300327AB

Measure A/C-ECU terminal voltage. Engine: Idling A/C set temperature: Maximum Cool when temperature in cabin is 25C or more Maximum Hot when temperature in cabin is 25C or less Voltage between terminal No. 5 and earth Voltage between terminal No. 32 and earth OK: System voltage Q: Is the check result normal? YES : Go to Step 8 . NO : Go to Step 6 .

C-26 (B)



AK300327AB


13A-270

TROUBLESHOOTING

STEP 7. Check harness between C-06 (terminal No. 5) or C-26 (terminal No. 32) A/C-ECU connector and C-134 (terminal No. 24) engineECU connector. Connector: C-06

STEP 8. Check connector: C-06 A/C-ECU connector or C-26 A/C-ECU connector Connector: C-06

C-06 (B) C-06 (B)

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9



AK300326 AB

Connector: C-26

28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29

Connector: C-26

28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29

C-26 (B)


C-26 (B)


AK300326 AB

AK300327AB

AK300327AB

CONNECTOR: C-134 CONNECTOR: C-134

C-134 C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14


AK300257 AB

NOTE: Before checking harness, check intermediate connector C-104, and repair if necessary. Check output line for short circuit. Q: Is the check result normal? YES : Check A/C system (Refer to GROUP 55A -

Troubleshooting 355A). NO : Repair.


repair if necessary. If intermediate connector is normal, check and repair harness between C-06 (terminal No. 5) or C-26 (terminal No. 32) A/C-ECU connector and C-134 (terminal No. 24) engine-ECU connector. Check output line for open circuit. NO : Repair.


13A-271

TROUBLESHOOTING

Inspection Procedure 29: A/C Pressure Sensor System

A/C Pressure sensor circuit

A-02 (MU802509)

A/C Pressure sensor

1 2 3 3

2

1 BR

G-Y

G-R C-116 5

17

A-14 17

BR

G-R C-105 21

C-104 4

G-Y

81

A/C-ECU

G-R

BR 92

42

C-135

C-137

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 9192

5V

Engine-ECU


OPERATION A power voltage of 5 V is applied to the A/C pressure sensor power terminal (terminal No. 3) from the engine-ECU (terminal No. 81) and is earthed to the engine-ECU (terminal No. 92) from the A/C pressure sensor (terminal No. 1). The sensor signal is inputted to the engine-ECU (terminal No. 42) from the A/C pressure sensor output terminal (terminal No. 2).

FUNCTION The A/C pressure sensor detects the A/C refrigerant pressure and inputs the pressure signal to the engine-ECU. The engine-ECU uses the signal for ON/OFF control of the magnet clutch of the A/C compressor. PROBABLE CAUSE Failed A/C pressure sensor Open/short circuit in A/C pressure sensor circuit or loose connector contact Failed engine-ECU


13A-272

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3. Measure voltage at A-02 A/C pressure sensor connector.

STEP 1. MUT-II Data List

Connector: A-02

Connector: A-02

A-02 (B) A-02 (B) 3 2 1 Harness side connector

3 2 1 Harness side connector AK300340AB

Refer to Data list reference table 313A. a. Item 3A: A/C pressure sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection Service Points 300). NO : Go to Step 2 . STEP 2. Connector check: A-02 A/C pressure sensor connector

AK300340AB



Connector: A-02

A-02 (B) C-137



8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82




13A-273

TROUBLESHOOTING



C-137

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82



AK300254 AB


Connector: A-02

A-02 (B)


Q: Is the check result normal? YES : Check intermediate connector A-14, and

repair if necessary. If intermediate connector is normal, check and repair harness between A-02 (terminal No. 3) A/C pressure sensor connector and C-137 (terminal No. 81) engine-ECU connector. Check power line for open circuit. NO : Repair.


13A-274

TROUBLESHOOTING

STEP 7. Check harness between A-02 (terminal No. 3) A/C pressure sensor connector and C-137 (terminal No. 81) engine-ECU connector.

STEP 9. Measure resistance at A-02 A/C pressure sensor connector. Connector: A-02

Connector: A-02



CONNECTOR: C-137

AK300340AB

Disconnect connector, and measure at harness side. Resistance between terminal No. 1 and earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 12 . NO : Go to Step 10 .

C-137


8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


NOTE: Before checking harness, check intermediate connector A-14, and repair if necessary. Check power line for short circuit. Q: Is the check result normal? YES : Go to Step 8 . NO : Repair.

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


STEP 8. MUT-II Data List Refer to Data list reference table 313A. a. Item 3A: A/C pressure sensor Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


AK300254 AB



13A-275

TROUBLESHOOTING

STEP 11. Check harness between A-02 (terminal No. 1) A/C pressure sensor connector and C-137 (terminal No. 92) engine-ECU connector.

STEP 12. Measure voltage at A-02 A/C pressure sensor connector. Connector: A-02

Connector: A-02



CONNECTOR: C-137

AK300340AB

Use special tool test harness (MB991348) to connect connector, and measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 3 and earth. OK: 4.9 - 5.1 V Q: Is the check result normal? YES : Go to Step 14 . NO : Go to Step 13 .

C-137

8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


NOTE: Before checking harness, check intermediate connectors C-105 and C-116, and repair if necessary. Check earthing line for open circuit or damage. Q: Is the check result normal? YES : Go to Step 8 . NO : Repair.


13A-276

TROUBLESHOOTING



CONNECTOR: C-137

A-02 (B)


C-137

AK300340AB 8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Connector: A-02

Use special tool test harness (MB991348) to connect connector, and measure at pick-up harness. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: 0.5 or less Q: Is the check result normal? YES : Go to Step 16 . NO : Go to Step 15 .

A-02 (B)


Q: Is the check result normal? YES : Check intermediate connector A-14, and

repair if necessary. If intermediate connector is normal, check and repair harness between A-02 (terminal No. 3) A/C pressure sensor connector and C-137 (terminal No. 81) engine-ECU connector. Check power line for damage. NO : Repair.


13A-277

TROUBLESHOOTING



CONNECTOR: C-137

A-02 (B)


C-137

AK300340AB 8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82


Connector: A-02

Use special tool test harness (MB991348) to connect connector, and measure at pick-up harness. Engine: Running at idle A/C switch: ON Voltage between terminal No. 2 and earth. OK: 1.8 - 2.0 V (A/C refrigerant pressure: 1 kPa) 3.23 - 3.57 V (A/C refrigerant pressure: 2 kPa) Q: Is the check result normal? YES : Go to Step 19 . NO : Go to Step 17 .

A-02 (B)




C-116, and repair if necessary. If intermediate connectors are normal, check and repair harness between A-02 (terminal No. 1) A/C pressure sensor connector and C-137 (terminal No. 92) engine-ECU connector. Check earthing line for damage. NO : Repair.

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39




13A-278

TROUBLESHOOTING

STEP 18. Check harness between A-02 (terminal No. 2) A/C pressure sensor connector and C-135 (terminal No. 42) engine-A/T-ECU connector.


Connector: A-02

A-02 (B) C-135


38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

CONNECTOR: C-135


C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

Measure engine-ECU terminal voltage. Engine: Running at idle A/C switch: ON Voltage between terminal No. 42 and earth. OK: 1.8 - 2.0 V (A/C refrigerant pressure: 1 kPa) 3.23 - 3.57 V (A/C refrigerant pressure: 2 kPa)



NOTE: Before checking harness, check intermediate connectors C-105 and C-116, and repair if necessary. Check output line for short circuit and damage. Q: Is the check result normal? YES : Replace A/C pressure sensor. NO : Repair.


13A-279

TROUBLESHOOTING



C-135

C-135

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39



AK300256 AB


Connector: A-02

A-02 (B)



C-116, and repair if necessary. If intermediate connectors are normal, check and repair harness between A-02 (terminal No. 2) A/C pressure sensor connector and C-135 (terminal No. 42) engine-ECU connector. Check power line for open circuit and damage. NO : Repair.


13A-280

TROUBLESHOOTING

Inspection Procedure 30: Ignition Circuit System

Ignition circuit Ignition switch C-303 1 2 3 4 5 6

R

LOCK

ST IG1

ACC IG2

2

L-B

C-203 6 1 10A

J/B

W

10 C-205 C-116 26

W

W

A-14 16 W

W

1

1

Ignition coil 1 B-110

Ignition coil 2 B-111

1 2 3

1 2 3 3

2

Spark plug

B

2

1

B-107 Capacitor

3

B W-L

B-L

B 10

23

C-134 Engine-ECU

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26



13A-281

TROUBLESHOOTING

OPERATION The battery voltage is applied to the ignition coil (terminal No. 1) from the ignition switch and is earthed to the vehicle body from the ignition coil (terminal No. 2). A power voltage of 12 V is applied to the ignition coil output terminal (terminal No. 3) from the engine-ECU (terminal No. 10 and No. 23). FUNCTION When the engine-ECU makes the power transistor in the unit be in "OFF" position, the battery voltage in the unit is applied to the power transistor unit, and that makes the power transistor unit be in "ON" position. The engine-ECU makes the power transistor in the unit be in "ON", and that makes the power transistor unit be in "OFF" position. In response to the signal from the engine-ECU, the power transistor unit is in "ON" position. The primary current is going to the ignition coil. When the power transistor unit is in "OFF" position, the primary current is interrupted and high voltage is generated in the secondary coil. PROBABLE CAUSE Failed ignition coil Failed spark plug Failed spark plug cable Open/short circuit in ignition primary circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE STEP 1. Check spark plug cable itself. Check spark plug cable itself (Refer to GROUP 16 - Ignition System - On-vehicle Service 316 ). Q: Is the check result normal? YES : Go to Step 2 . NO : Replace spark plug cable.



B-111 (GR)


B-110 (GR) AK300308 AB



STEP 5. Measure voltage at B-111 and B-110 ignition coil connectors. Connector: B-110, B-111

B-111 (GR)


B-110 (GR) AK300308 AB



13A-282

TROUBLESHOOTING


STEP 7. Measure voltage at B-111 and B-110 ignition coil connectors. Connector: B-110, B-111

C-303

B-111 (GR)


3 2 1 6 5 4 Harness side connector

B-110 (GR) AK300304 AB


B-111 (GR)


B-110 (GR) AK300308 AB

Q: Is the check result normal? YES : Check intermediate connectors A-14, C-

203, C-205 and C-116, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-303 (terminal No. 2) ignition switch connector and B-111 (terminal No. 1) ignition coil connector, also between C-303 (terminal No. 2) ignition switch connector and B-110 (terminal No. 1) ignition coil connector. Check power supply line for open/short circuit. NO : Repair.

AK300308 AB

Disconnect connector, and measure at harness side. Engine: Cranking Voltage between terminal No. 3 and earth. OK: 0.5 - 4.0 V Q: Is the check result normal? YES : Go to Step 13 . NO : Go to Step 8 .


13A-283

TROUBLESHOOTING



CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




B-111 (GR)

AK300257 AB

Connector: B-110, B-111 3 2 1 Harness side connector

B-110 (GR)

B-110 (GR)

AK300308 AB

AK300308 AB

Measure engine-ECU terminal voltage. Disconnect B-111 and B-110 ignition coil connectors. Engine: Cranking Voltage between terminal No. 10 and earth, also between terminal No. 23 and earth. OK: 0.5 - 4.0 V Q: Is the check result normal? YES : Go to Step 9 . NO : Go to Step 10 .

B-111 (GR)



(terminal No. 3) ignition coil connector and C-134 (terminal No. 23) engine-ECU connector, also between B-110 (terminal No. 3) ignition coil connector and C-134 (terminal No. 10) engine-ECU connector. Check output line for open circuit. NO : Repair.


13A-284

TROUBLESHOOTING


STEP 11. Check harness between B-111 (terminal No. 3) ignition coil connector and C-134 (terminal No. 23) engine-ECU connector, also between B110 (terminal No. 3) ignition coil connector and C-134 (terminal No. 10) engine-ECU connector. CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14



B-111 (GR)


B-110 (GR) AK300308 AB





13A-285

TROUBLESHOOTING

STEP 13. Measure resistance at B-111 and B-110 ignition coil connectors. Connector: B-110, B-111

B-111 (GR)


STEP 14. Check harness between C-303 (terminal No. 2) ignition switch connector and B-111 (terminal No. 1) ignition coil connector, also between C-303 (terminal No. 2) ignition switch connector and B-110 (terminal No. 1) ignition coil connector. CONNECTOR: C-303

B-110 (GR) AK300308 AB

Disconnect connector, and measure at harness side. Resistance between terminal No. 2 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 14 . NO : Check and repair harness between B-111

(terminal No. 2) ignition coil connector and body earth, also between B-110 (terminal No. 2) ignition coil connector and body earth. Check earthing line for open circuit and damage.



B-111 (GR)


B-110 (GR) AK300308 AB

NOTE: Before checking harness, check intermediate connectors A-14, C-116, C-203 and C-205, and repair if necessary. Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 15 . NO : Repair.


13A-286

TROUBLESHOOTING

STEP 15. Check harness between B-111 (terminal No. 3) ignition coil connector and C-134 (terminal No. 23) engine-ECU connector, also between B110 (terminal No. 3) ignition coil connector and C134 (terminal No. 10) engine-ECU connector. Connector: B-110, B-111

B-111 (GR)


B-110 (GR) AK300308 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14




13A-287

TROUBLESHOOTING

Data List Reference Table M1131152000735

Item Inspection No. item 11


Oxygen Engine: After sensor (front) warm-up (leaner by deceleration, richer by acceleration) Engine: After warm-up (using oxygen sensor, check air-fuel ratio as well as control status by engine-ECU.

12

13

14

16

Air flow sensor *1



Normal condition


Reference page

Excessive deceleration from 4,000 r/min

200 mV or less

Code No. P0130

313A

At excessive acceleration

600 - 1,000 mV

Idle operation

400 mV or less À 600 - 1,000 mV (altered)

-

-

Code No. P0110

313A

Code No. P0120

313A

Procedure No. 23

313A

2,500 r/min

Engine coolant Idle operation temperature: 2,500 r/min 80 - 95C Lamps, electric Acceleration cooling fan and all accessories: OFF Transmission: Neutral Ignition switch: “ON” or engine running

Ignition switch: “ON”

16 - 24 Hz 72 - 112 Hz According to acceleration, frequency is amplified.

Intake air temperature: -20C

-20C

Intake air temperature: 0C

0 C


20C


40C


80 C

Set to Idle position

535 - 735 mV

Release accelerator pedal gradually

Increased according to accelerator pedal stroke

Release accelerator pedal fully

4,500 - 5,000 mV

Power supply Ignition switch: “ON” voltage

System voltage


13A-288

TROUBLESHOOTING

Item Inspection No. item


Normal condition


Reference page

18

Cranking signal (ignition switch-ST)


Engine: Stopped

OFF

313A

Engine: Cranking

ON

Procedure No. 23


Ignition switch: “ON” or engine running

Coolant temperature: -20C -20C

Code No. P0115

313A

Code No. P0335

313A

Code No. P0105

313A

Code No. P0551

313A

Procedure No. 26

313A

21

Coolant temperature: 0C 0 C Coolant temperature: 20C 20C Coolant temperature: 40C 40C Coolant temperature: 80C 80C

22

Crank angle sensor

Engine: Cranking Tachometer: Connected

Compare engine Matched speed on tachometer with the value displayed on MUT-II

Engine: Idle operation

Coolant temperature: 1,100 - 1,300 -20C r/min Coolant temperature: 1,100 - 1,300 0 C r/min Coolant temperature: 1,100 - 1,300 20C r/min Coolant temperature: 940 - 1,140 r/min 40C Coolant temperature: 650 - 850 r/min 80C

25

27

28



Altitude: 0m

101 kPa

Altitude: 600m

95 kPa

Altitude: 1,200m

88 kPa

Altitude: 1,800m

81 kPa

Power Engine: Idle steering fluid operation pressure switch

Steering wheel: Not operated

OFF

Steering wheel: Operated

ON

A/C switch

AC switch: OFF

OFF

AC A/C switch: compressor ON is not driven

OFF

Engine: Idle

A/C compressor is driven

ON


13A-289

TROUBLESHOOTING



Normal condition


Reference page

37

Engine coolant temperature: 80 - 95C Lamps, electric cooling fan and all accessories: OFF

Idel operation

13 - 33 %

-

-

2,500 r/min

12 - 32 %

Excessive acceleration

According to acceleration, volumetric efficiency is increased.

A/C in MAX COOL state (under high load)

2,200 mV or more

Procedure No. 29

313A

-

-

Procedure No. 30

313A

3A

41

Volumetric efficiency

A/C pressure sensor

Injectors *2

After engine warm-up, idle operation A/C switch: ON

A/C in MAX HOT 1,800 mV or less state (under low load)

Engine: Cranking Coolant temperature: 5.6 - 8.4 ms 0C (all cylinders in simultaneous injecting operation) Coolant temperature: 5.6 - 8.4 ms 20C Coolant temperature: 5.6 - 8.4 ms 80C

Injectors*3

44

Ignition advance

Engine coolant temperature: 80 - 95C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral

Idle operation

2.0 - 3.2 ms

2,500 r/min

2.2 - 3.4 ms

Excessive acceleration

Increased

Engine: After Idle operation warm-up 2,500 r/m Install timing light (for use to measure actual ignition timing)

2 - 18BTDC 18 - 38BTDC


13A-290

TROUBLESHOOTING



Normal condition


Reference page

45

ISC (stepper motor) servo position*4

Engine coolant A/C switch: OFF temperature: A/C switch: OFF 80 - 95C ON Lighting, electric cooling fan and accessories: OFF Transmission: Neutral Engine: Idle operation (When A/C switch is ON, A/C compressor must be ON)

2 - 25 steps

-

-

A/C relay

Engine: After warm-up, idle operation after warm-up

Procedure No. 27

313A

0 mV or less À 600 - 1,000 mV (altered)

Code No. P0136

313A

0.9 - 4.9 gm/s

-

-

49

A/C switch: OFF

OFF

A/C A/C switch: compressor ON is not driven

OFF

A/C compressor is driven 59

Oxygen Engine: After sensor (rear) warm-up

12 *5

Air flow sensor

Increased 10 70 steps


Engine coolant Idle operation temperature: 2,500 r/min 80 - 95C Lamps, electric Acceleration cooling fan and all accessories: OFF Transmission: Neutral

ON

7.2 - 13.2 gm/s According to acceleration, frequency is amplified.


13A-291

TROUBLESHOOTING



Normal condition


Reference page

13 *5


Intake air temperature: -20C

-20C

Code No. P0110

313A


0 C


20C


40C


80 C Code No. P0115

313A

-

-

21 *5




Coolant temperature: -20C -20C Coolant temperature: 0C 0C Coolant temperature: 20C 20C Coolant temperature: 40C 40C Coolant temperature: 80C 80C

22 *5

Crank angle sensor

Engine: Cranking Tachometer: Connected

Compare engine Matched speed on tachometer with the value displayed on MUT-II

Engine: Idle operation

Coolant temperature: 1,100 - 1,300 -20C r/min Coolant temperature: 1,100 - 1,300 r/min 0C Coolant temperature: 1,100 - 1,300 r/min 20C Coolant temperature: 940 - 1,140 r/min 40C Coolant temperature: 650 - 850 r/min 80C

24 *5

Vehicle Drive 40 km/h speed sensor

Approximately 40 Code No. km/h P0500

313A

44 *5

Ignition advance

2 - 18 deg

-

Engine: After Idle operation warm-up 2,500 r/m Install timing light (for use to measure actual ignition timing)

18 - 38 deg

-


13A-292 Item Inspection No. item

TROUBLESHOOTING


Normal condition


Reference page

81 *5

Long-term Engine: After warm-up, 2,500 r/min fuel without any load (during closed loop) compensatio n

-12.5 - 12.5 %

Code No. P0170

313A

82 *5

Shot-term Engine: After warm-up, 2,500 r/min fuel without any load (during closed loop) compensatio n

-25 - 25 %

Code No. P0170

313A

87 *5

Calculation losd value

Engine: After warm-up

Idle operation

13 - 33 %

-

-

2,500 r/m

12 - 32 %

88 *5

Fuel control condition

Engine: After warm-up

2,500 r/m

Closed loop

-

-

Acceleration

Open loop-drive condition

8A *5

Throttle position sensor (Throttle opening angle)


Set to Idle position

0 - 10 %

313A

Release accelerator pedal gradually

Increased according to accelerator pedal stroke

Code No. P0120

Release accelerator pedal fully

80 - 100 %

Excessive deceleration from 4,000 r/min

0.2 V or less À 0.6 - 1 V (altered)

Code No. P0130

313A

Idle operation 2,500 r/min

0.4 V or less À 0.6 - 1 V (altered)


0 V or less À 0.6 Code No. - 1 V (altered) P0136

313A

A1 *5

Oxygen Engine: After sensor (front) warm-up (leaner by deceleration, richer by acceleration) Engine: After warm-up (using oxygen sensor, check air-fuel ratio as well as control status by engine-A/ECU.

A1 *5

Oxygen Engine: After sensor (rear) warm-up

CAUTION When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward NOTE: *1: On the new vehicle (mileage: 500 km or less), air flow sensor output frequency may be higher by approx. 10%. NOTE: *2: Injector drive time ranges shown are when power voltage is 11 V and the cranking speed is 250 r/min. or less. NOTE: *3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approx. 10%. NOTE: *4: On the new vehicle (mileage: 500 km or less), the number of steps of stepper motor may be larger by approx. 30 steps. NOTE: *5: When service data in check mode is selected, the data is not displayed.


13A-293

TROUBLESHOOTING

Actuator Test Reference Table M1131152500439


Drive content

Inspection conditions

Normal condition

Code No. /Inspection procedure No.

Reference page

01

Cut off No. 1 injector

Engine: After warm-up, idle operation (Cut off injectors sequentially to check for a cylinder that does not change engine in idle status.

Engine is changed (becomes unstable or stalled)

Code No. P0201

313A

Code No. P0202

313A

Code No. P0203

313A

Code No. P0204

313A

Procedure No. 24

313A

Injector

02


03


04


07

Fuel pump

Drive fuel pump to circulate fuel

Ignition Hold return Pulse is felt switch: "ON" hose with fingers to feel pulse of fuel flowing Check for pump operating noise near fuel tank

Operating noise audible

08


Switch solenoid Ignition switch: "OFF" valve from OFF to ON

When the valve Code No. is actuated, P0443 operating noise is audible

313A

10


Switch solenoid Ignition switch: "ON" valve from OFF to ON

When the valve Code No. is actuated, P0403 operating noise is audible.

313A

17

Basic ignition Switch engine- Engine: Idle operation timing ECU to ignition Install timing light timing adjusting mode

5 BTDC

-

-

21

Fan controller

Fan motor is rotated

Procedure No. 21

313A

Actuate fan motor

Ignition switch: "ON" A/C switch: ON


13A-294

TROUBLESHOOTING

CHECK AT THE ECU TERMINALS

NOTE: . 1. Make the voltage measurement with the engine-ECU connector connected. 2. You may find it convenient to pull out the engine-ECU to make it easier to reach the connector terminals. 3. The checks can be carried out off the order given in the chart.

M1131153500175

TERMINAL VOLTAGE CHECK CHART Needle-nosed wire probe

CAUTION Short-circuiting the positive (+) probe between a connector terminal and earth could damage the vehicle wiring, the sensor, engine-ECU or all of them. Be careful to prevent this! 3. If voltmeter shows any division from standard value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. 4. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem.

AK201749AB

1. Connect a needle-nosed wire probe to a voltmeter probe. 2. Insert the needle-nosed wire probe into each of the engine-ECU connector terminals from the wire side, and measure the voltage while referring to the check chart.

Engine-ECU Connector Terminal Arrangement Engine-ECU Connector C-134

C-135

C-136

C-137

1 2 3 4 5 6 7 8 9 10 11 12 13 31 32 33 34 35 36 37 38 51 52 53 54 55 56 71 72 73 74 75 76 77 78 79 80 81 14 15 16 17 18 19 20 21 22 23 24 25 26 39 40 41 42 43 44 45 46 57 58 59 60 61 62 82 83 84 85 86 87 88 89 90 9192

AK300342 AB

Terminal No.

Check item

Check condition (Engine condition)

Normal condition

1

No. 1 injector

14

No. 2 injector

While engine is idling after having warmed up, suddenly depress the accelerator pedal.

From 11 - 14 V, momentarily drops slightly

2

No. 3 injector

15

No. 4 injector

4

Stepper motor coil

17

Stepper motor coil

5

Stepper motor coil

18

Stepper motor coil

6

EGR control solenoid Valve

Engine: Soon after the warmed up engine System voltage À 1 V or is star less (Changes repeatedly) A/C switch: OFF ON (A/C compressor is operating)


System Voltage

While engine is idling, suddenly depress the accelerator pedal.

From system voltage, momentarily drops


13A-295

TROUBLESHOOTING

Terminal No.

Check item


Normal condition

8

A/C relay

Engine: Idle speed A/C switch: OFF ON (A/C compressor is operating)

System voltage or Momentarily 6V or more 1 V or less

9



System voltage

Running at 3,500 r/min while engine is warming up after having been started.

1 V or less

10

Ignition coil - No. 1, No. 4

Engine r/min: 3,000 r/min

0.3 - 3.0 V

23

Ignition coil - No. 2, No. 3

12

Power supply


System voltage

25 19 21 22

Air flow sensor reset Engine: Idle speed Signal Engine r/min: 3,000 r/min

6-9V

Fan controller

Radiator and condenser fan is not operating

0 - 0.3 V

Radiator and condenser fan is operating

0.7 V or more

Ignition switch: ON

System voltage

Engine: Idle speed

1 V or less

Fuel pump relay

24

A/C load signal

33

Alternator G terminal

36

Engine warming lamp

Ignition switch: "LOCK" (OFF) "ON"

37


Engine: Idling after warming up

0-1V

Refer to GROUP 55 - Troubleshooting (Inspection at the Automatic compressor - ECU Terminal) Engine: Warm, idle (radiator fan: OFF) Headlamp: OFF ON Stop lamp: OFF ON Rear defogger switch: OFF ON

Voltage increases by 0.2 3.5 V

1 V or less System voltage (After several seconds have elapsed)

When steering wheel System voltage is Stationary When steering wheel 1 V or less is turned

38

Control relay (Power Ignition switch: "LOCK" (OFF) supply) Ignition switch: "ON" Engine: Warm, idle (radiator fan: OFF) Headlamp: OFF ON Stop lamp: OFF ON Rear defogger switch: OFF ON

41

Alternator FR terminal

42

A/C pressure sensor Engine: Idling A/C switch: ON

When A/C is "MAX, COOL" condition (when the load by A/C is high)

System voltage 1 V or less Voltage decreases

2.2 V or more

When A/C is "MAX, 1.8 V or less HOT" condition (when the load by A/C is low)

13A-296


Terminal No.

Check item


Normal condition

45

A/C switch

Engine: Idle speed

0.5 V or less

Turn the A/C switch OFF

Turn the A/C switch System voltage ON (A/C compressor is operating) 54

Oxygen sensor heater (rear)


1 V or less

Engine r/min:Racing

System voltage

58

Tachometer signal


0.3 - 3.0 V

60

Oxygen sensor heater (front)


1 V or less

Engine r/min:5,000 r/min

System voltage

71

Ignition switch - ST

Engine: Cranking

8 V or more

72



When intake air 3.8 - 4.4 V temperature is -20C When intake air temperature is 0C

3.2 - 3.8 V

When intake air temperature is 20C

2.3 - 2.9 V


1.5 - 2.1 V


0.8 - 1.4 V


0.4 - 1.0 V

75


Engine: Idling after warmed up (Check using 0 À 0.6 V (Changes a digital type voltmeter) repeatedly)

76


Engine: Running at 2,500 r/min after warmed 0 À 0.8 V (Changes up (Check using a digital type voltmeter) repeatedly)

80

Backup power supply

Ignition switch: "LOCK" (OFF)

System voltage

81

Sensor impressed voltage


4.9 - 5.1 V

82

Ignition switch - IG


System voltage

83



When engine coolant 3.9 - 4.5 V temperature is -20C When engine coolant 3.2 - 3.8 V temperature is 0C When engine coolant 2.3 - 2.9 V temperature is 20C When engine coolant 1.3 - 1.9 V temperature is 40C When engine coolant 0.7 - 1.3 V temperature is 60C When engine coolant 0.3 - 0.9 V temperature is 80C


13A-297

TROUBLESHOOTING

Terminal No.

Check item


Normal condition

84



Set throttle valve to idle Position

0.535 - 0.735 V

Fully open throttle valve

4.4 - 5.3 V

Altitude: 0 m

3.8 - 4.2 V

Altitude: 600 m

3.5 - 3.9 V

Altitude: 1,200 m

3.3 - 3.7 V

Altitude: 1,800 m

3.0 - 3.4 V

85

Barometric pressure Ignition switch: "ON" sensor

86


Ignition switch: "ON" Move the vehicle forword slowly

0 À 5 V Changes repeatedly

88


Engine: Cranking

0.4 - 3.0 V

Engine: Idling

1.5 - 3.0 V

Crank angle sensor

Engine: Cranking

0.4 - 4.0 V

Engine: Idling speed

1.5 - 2.5 V

Engine: Idle speed

2.2 - 3.2 V

89 90

Air flow sensor


CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to "LOCK" (OFF) position. 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. NOTE: . 1. When measuring resistance and checking continuity, a harness for checking contact pin pressure should be used instead of inserting a test probe. 2. Checking need not be carried out in the order given in the chart.

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 and/or ohmmeter. Be careful to prevent this! 4. If the ohmmeter shows any deviation from the standard value, check the corresponding sensor, actuator and related electrical wiring, and the repair or replace. 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement has corrected the problem.


13A-298

TROUBLESHOOTING

Engine-ECU Harness Side Connector Terminal Arrangement Engine-ECU Harness Side Connector C-137

C-136

C-135

C-134

8180 79 78 77 76 75 74 73 72 71 56 55 54 53 52 51 38 37 36 35 34 33 32 31 13 12 11 10 9 8 7 6 5 4 3 2 1 92 91 90 89 88 87 86 85 84 83 82 62 61 60 59 58 57 46 45 44 43 42 41 40 39 26 25 24 23 22 21 20 19 18 17 16 15 14 AK300343 AB

Terminal No.

Inspection item

Normal condition (Check condition)

1 - 12

No. 1 injector

13 - 16 W (At 20C)

12 - 14

No. 2 injector

2 - 12

No. 3 injector

12 - 15

No. 4 injector

4 - 12

Stepper motor coil (A1)

12 - 17

Stepper motor coil (A2)

5 - 12

Stepper motor coil (B1)

12 - 18

Stepper motor coil (B2)

6 - 12


29 - 35 W (At 20C)

9 - 12


29 - 35 W (At 20C)

12 - 54

Oxygen sensor heater(rear)

11 - 18 W (At 20C)

12 - 60

Oxygen sensor heater(front)

4.5 - 8.0 W (At 20C)

26 - 33 W (At 20C)

13 - Body ECU earth earth

Continuity (0 W)

26 - Body earth 81 - 83


14 - 17 kW (When coolant temperature is -20C) 5.1 - 6.5 kW (When coolant temperature is 0C) 2.1 - 2.7 kW (When coolant temperature is 20C) 0.9 - 1.3 kW (When coolant temperature is 40C) 0.48 - 0.68 kW (When coolant temperature is 60C) 0.26 - 0.36 kW (When coolant temperature is 80C)

72 - 81


13 - 17 kW (When intake air temperature is -20C) 5.3 - 6.7 kW (When intake air temperature is 0C) 2.3 - 3.0 kW (When intake air temperature is 20C) 1.0 - 1.5 kW (When intake air temperature is 40C) 0.56 - 0.76 kW (When intake air temperature is 60C) 0.30 - 0.42 kW (When intake air temperature is 80C)

INSPECTION PROCEDURE USING OSCILLOSCOPE M1131154500479

The output signals of the sensors and the conditions of the actuation signals of the actuators can be inspected visually by observing the waveforms on

the oscilloscope.


13A-299

TROUBLESHOOTING

AIR FLOW SENSOR

2. Connect the oscilloscope special patterns pickup to air flow sensor connector terminal No. 3.

Measurement Method Oscilloscope 1 2 3 4 5 6 7 Special patterns pickup

Alternate Method (Test harness not available) 1. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 90. Standard Wave Pattern Observation conditions Function Special patterns

AK000786 AE

1. Disconnect the air flow sensor connector, and connect the special tool Test harness (MB991709) in between (All terminals should be connected).

Pattern height

Low

Pattern selector

Display

Engine speed

Idle

Standard wave pattern (V) 10

The time (cycle time) T is reduced when the amount of intake air inereases.

T T1

T2

Times T1 and T2 are equal.

0

Time AK202334 AB

Observation conditions (from conditions above engine is increased by racing.) (V) 10

T

0

Time

AK202335 AB

Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.

13A-300


Examples of Abnormal Wave Patterns

CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR Measurement Method Camshaft position Oscilloscope sensor connector 1 2 3

Special patterns pick-up

AKX01597

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. However, when an ignition leak occurs during acceleration, the wave pattern will be distorted temporarily, even if the air flow sensor is normal.

1 2 3

Crank angle sensor connector AK000840AC

1. Disconnect the camshaft position sensor connector and connect the special tool Test harness (MB991709) in between (All terminals should be connected). 2. Connect the oscilloscope special pattern pickup to camshaft position sensor terminal No. 2. 3. Disconnect the crank angle sensor connector and connect the special tool Test harness (MD998478) in between. 4. Connect the oscilloscope special patterns pickup to crank angle sensor terminal No. 2. Alternate Method (Test harness not available) 1. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 88 (When checking the camshaft position sensor signal wave pattern). 2. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 89 (When checking the crank angle sensor signal wave pattern).


13A-301

TROUBLESHOOTING

Standard Wave Pattern Observation condition Function

Special patterns

Pattern height

Low

Pattern selector

Display

Engine speed

Idle 2 engine revolutions (1 camshaft revolution)

Standard Wave Pattern (V)

The time (cycle time) T is reduced when the engine speed increases

75˚ BTDC 5˚ BTDC

Crank angle sensor output wave pattern

0 Camshaft position sensor output wave pattern

Time

0 TDC: Top dead centre

No.1 TDC

Wave Pattern Observation Points Check that cycle time T becomes shorter when the engine speed increases.

No.3 TDC

No.4 TDC

No.2 TDC

AK202336 AB

Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started.


AKX01602 AKX01597

Example 1 Cause of problem Sensor interface malfunction

Example 2 Cause of problem Loose timing belt Abnormality in sensor disk Wave pattern characteristics Wave pattern is displaced to the left or right.


13A-302

TROUBLESHOOTING

INJECTOR Measurement Method Oscilloscope

1 2 Special patterns pickup

AK101807AC

1. Disconnect the injector connector, and then connect the special tool Test harness set (MB991348) in between (All terminals should be connected). 2. Connect the oscilloscope special patterns pickup to terminal No. 2 of the injector connector.

Alternate Method (Test harness not available) 1. Connect the oscilloscope special patterns pickup to engine- ECU terminal No. 1 (When checking the No. 1 cylinder). 2. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 14 (When checking the No. 2 cylinder). 3. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 2 (When checking the No. 3 cylinder). 4. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 15 (When checking the No. 4 cylinder). Standard Wave Pattern Observation conditions Function Special patterns Pattern height

Variable

Variable knob

Adjust while viewing the wave pattern

Pattern selector

Display

Engine speed

Idle

Standard wave pattern Point A.

(V)

Solenoid back electromotive force (Approx.7×10V)

50

Point B Injector drive time Time

Power voltage 0 Drive signal: ON

Drive signal: OFF AK202347AB


13A-303

TROUBLESHOOTING

Wave Pattern Observation Points Point A: Height of solenoid back electromotive force Contrast with standard wave pattern

Probable cause

Solenoid coil back electromotive force is low or doesn’t appear at all.

Short in the injector solenoid

1. Disconnect the ISC servo connector, and connect the special tool Test harness (MB991709) in between. 2. Connect the oscilloscope special patterns pickup to the ISC servo-side connector terminal No. 1, No. 3, No. 4 and No. 6 respectively. Alternate Method (Test harness not available) 1. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 4, connection terminal No. 5, connection terminal No. 17, and connection terminal No. 18 respectively.

Point B: Injector drive time

Standard Wave Pattern Observation conditions Function Special patterns When idling When racing

AKX01605AE

The injector drive time will be synchronized with the MUT-II tester display. When the engine is suddenly raced, the drive time will be greatly extended at first, but the drive time will soon match the engine speed.

Pattern height

High

Pattern selector

Display

Engine condition

When the engine coolant temperature is 20C or below, turn the ignition switch from LOCK (OFF) position to ON (without starting the engine).

IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR)

While the engine is idling, turn the A/C switch to ON.

Measurement Method

Immediately after starting the warm engine.

Oscilloscope 1 2 3 4 5 6 Special patterns pickup

AK300344AB


13A-304

TROUBLESHOOTING

Standard wave pattern

(V)

30 Stepper motor control signal wave pattern

The wave pattern appears for an instant, but soon disappears.

Point B Coilreverse electromotive force (Approx.3x10V)

Point A Induced electromotive force from the motor turning

20

10

Time

AK201857 AB

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.

Motor is malfunctioning

Example 1 Cause of problem Motor is malfunctioning. (Motor is not operating.) Wave pattern characteristics Induced electromotive force from the motor turning does not appear.

Open circuit side

Point B: Height of coil reverse electromotive force Contrast with standard wave pattern

Probable cause

Coil reverse electromotive force does not appear or is extremely small.

Short in the coil

Examples of Abnormal Wave Pattern

AKX01608AE

Normal side

AKX01609AF

Example 2 Cause of problem Open circuit in the line between the stepper motor and the engine-ECU. Wave pattern characteristics Current is not supplied to the motor coil on the open circuit side (Voltage does not drop to 0 V). Furthermore, the induced electromotive force waveform at the normal side is slightly different from the normal waveform.


13A-305

TROUBLESHOOTING

IGNITION COIL AND POWER TRANSISTOR Measurement Method Oscilloscope

1 2 3 Special patterns pickup

1. Disconnect the ignition coil connector, and connect the special tool Test harness set (MB991348) in between (All terminals should be connected).

Crank angle sensor output wave pattern

Alternate Method (Test harness not available) 1. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 10 (No. 1 - No. 4), connection terminal No. 23 (No. 2 - No.3) respectively. Standard Wave Pattern

AK300345 AB

Standard wave pattern

2. Connect the oscilloscope special patterns pickup to terminal No. 3 of each ignition coil connector in turn.

Observation condition Function

Special patterns

Pattern height

Low

Pattern selector

Display

Engine r/min

Approximately. 1,200 r/min

(V) 6 4

T 5˚ BTDC Compression top dead center

75˚ BTDC

2 0 4

Power transistor control signal wave pattern

T1

Ignition period

2 0

OFF

ON Dwell section

T : Revolution time corresponding to a crank angle of 180˚ T1 : Time computed by the engine-ECU : Spark advance angle

Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2).

AK204435 AC

Condition of wave pattern build-up section and maximum voltage

Probable cause

Rises from approximately. 2 V to approximately 4.5 V at the top-right

Normal

2 V rectangular wave

Open-circuit in ignition primary circuit

Rectangular wave at power voltage

Power transistor malfunction


13A-306

ON-VEHICLE SERVICE


Normal wave pattern VB

Normal wave pattern

2V AKX01613AD

AKX01612AD

Example 1 Wave pattern during engine cranking Cause of problem Open-circuit in ignition primary circuit Wave pattern characteristics Top-right part of the build-up section cannot be seen, and voltage value is approximately 2 V too low.

Example 2 Wave pattern during engine cranking Cause of problem Malfunction in power transistor Wave pattern characteristics Power voltage results when the power transistor is ON.

ON-VEHICLE SERVICE THROTTLE BODY (THROTTLE VALVE AREA) CLEANING M1131001000332

1. Remove the air intake hose from the throttle body. 2. Spray cleaning fluid on a clean cloth.

5. Adjust the basic idle speed (Refer to 313A).

THROTTLE POSITION SENSOR ADJUSTMENT M1131001100414

CAUTION Do not spray the cleaning fluid directly to the throttle valve. Make sure the cleaning fluid does not enter the motor from the bypass line. Also make sure it does not enter the sensor through the shaft. Be careful not to rub off the molybden applied around the throttle valve shaft.


1

2 3 4

Equipment side connector

AK300346 AB

1. Connect the MUT-II to the diagnosis connector. When not using the MUT-II, proceed as follows. 15 mm 15 mm Throttle position sensor Areas on throttle valve to apply molybdenum disulfide

AK000833AD

3. Wipe off the dirt around the throttle valve with the cloth sprayed with cleaning fluid. 4. Attach the air intake hose.

MB991536

AK201752AB

MULTIPORT FUEL INJECTION (MFI) ON-VEHICLE SERVICE

(1) Disconnect the throttle position sensor connector and connect the special tool Test harness (MB991536) between the disconnected connector taking care not to confuse the terminal to be connected. (2) Connect digital voltmeter between the terminal No. 2 (special tool’s yellow clip on the sensor output) and the terminal No. 4 (special tool’s red clip on the sensor earth) of the throttle position sensor connector. 2. Turn the ignition switch to "ON" position (but do not start the engine). 3. Check the output voltage of the throttle position sensor. Standard value: 535 - 735 mV

AK300347AB

4. If not within the standard value, loosen the throttle position sensor mounting bolts. Then rotate the sensor body to adjust. 5. Turn the ignition switch to "LOCK" (OFF) position. 6. Remove the MUT-II. If the MUT-II is not used, remove the special tool, and then connect the throttle position sensor connector. 7. If a diagnosis code is displayed, erase the diagnosis code by using the MUT-II or disconnect the negative battery cable from the battery terminal and then leave it for at least 10 seconds. After that, reconnect the battery cable, and then let the engine run at idle for approximately 10 minutes.

13A-307

BASIC IDLE SPEED ADJUSTMENT M1131001800468

CAUTION 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. 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. If this occurs, adjust by the following procedure. The adjustment, if made, should be made after first confirming that the spark plugs, the injectors, the idle speed control servo, the compression pressure, etc., are all normal. 1. Before inspection and adjustment, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector (16-pin). NOTE: When the MUT-II is connected, the diagnosis control terminal should be earthed. 3. Start the engine and run at idle. 4. Select the item No. 30 of the MUT-II Actuator test. NOTE: This holds the ISC servo at the basic step to adjust the basic idle speed. 5. Check the idle speed. Standard value: 700 50 r/min NOTE: . The engine speed may be 20 to 100 r/min lower than indicated above for a new vehicle [driven approximately 500 km or less], but no adjustment is necessary. If the engine stalls or the engine speed is low even though the vehicle has been driven approximately 500 km or more, it is probable that deposits are adhered to the throttle valve, so clean it (Refer to 313A).

AK300348

6. If not within the standard value range, turn the speed adjusting screw (SAS) to make the necessary adjustment.


13A-308

ON-VEHICLE SERVICE

NOTE: If the idling speed is higher than the standard value range even when the SAS is fully closed, check whether or not there is any indication that the fixed SAS has been moved. If there is an indication that it has been moved, adjust the fixed SAS. 7. Press the MUT-II clear key, and release the ISC servo from the Actuator test mode. NOTE: Unless the ISC servo is released, the Actuator test mode will continue 27 minutes. 8. Turn the ignition switch to "LOCK" (OFF) position. 9. Disconnect the MUT-II. 10.Start the engine again and let it run at idle speed for about 10 minutes; check that the idling condition is normal.

FUEL PRESSURE TEST M1131001900368

1. Release residual pressure from the fuel pipe line to prevent fuel gush out (Refer to 313A).

a. Remove the union joint and bolt from the special tool Adaptor hose (MD998709) and attach the special tool Hose adaptor (MD998742) to the adaptor hose. b. Via a gasket, install the special tool Fuel pressure gauge set (MB991637) into the special tool that has already assembled as described in (a) above. a. Remove the union joint and bolt from special tool Adaptor hose (MD998709) and attach the special tool Hose adaptor (MD998742) to the adaptor hose. b. Via a suitable O-ring or gasket, install the fuel pressure gauge to the special tool that has already assembled as described in (a) above. Fuel pressure gauge set

CAUTION Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.

O-ring or gasket MD 998709 Delivery pipe

MD 998742 High-pressure fuel hose AKX01457AF

4. Install the assembled fuel pressure measurement tools between the fuel rail and fuel high-pressure hose.

CAUTION AK300349AB

2. Disconnect the high-pressure fuel hose at the delivery pipe side. MB 991637 Gasket MD 998709 Delivery pipe

MD 998742 High-pressure fuel hose AKX01458AG

3. Assemble the fuel pressure measurement tools as follows.

To prevent damage to the MUT-ll, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the MUT-ll. 5. Connect the MUT-II to the diagnosis connector. 6. Turn the ignition switch to "ON" position (But do not start the engine). 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. 9. Start the engine and run at idle. 10.Measure fuel pressure while the engine is running at idle. Standard value: Approximately. 270 kPa at cerb idle


AK300349AB

11.Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed by a finger. Symptom Probable cause

Fuel pressure too low Fuel pressure drops after racing No fuel pressure in fuel return hose Fuel pressure too high

13A-309

Standard value: 330 - 350 kPa at cerb idle 12.Check to see that fuel pressure at idle does not drop even after the engine has been raced several times. 13.Racing the engine repeatedly, hold the fuel return hose lightly with fingers to feel that fuel pressure is present in the return hose. NOTE: If the fuel flow rate is low, there will be no fuel pressure in the return hose. 14.If any of fuel pressure measured in steps 10 to 13 is out of specification, troubleshoot and repair according to the table below. Remedy

Clogged fuel filter

Replace fuel filter

Fuel leaking to return side due to Replace fuel pressure regulator poor fuel regulator valve seating or settled spring Low fuel pump delivery pressure

Replace fuel pump

Binding valve in fuel pressure regulator

Replace fuel pressure regulator

Clogged fuel return hose or pipe

Clean or replace hose or pipe

Same fuel pressure when vacuum Damaged vacuum hose or hose is connected and when Clogged nipple disconnected 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

Replace vacuum hose or clean nipple

Remedy

Fuel pressure drops gradually after Leaky injector engine is stopped Leaky fuel regulator valve seat

Replace injector

Fuel pressure drops sharply immediately after engine is stopped

Replace fuel pump

Check valve in fuel pump is held open

16.Release residual pressure from the fuel pipe line (Refer to 313A).

CAUTION Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. 17.Remove the fuel pressure gauge and special tool from the delivery pipe.

Replace fuel pressure regulator

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 toque. Tightening torque: 8.8 1.9 N¼m 20.Check for any fuel leaks by following the procedure in step 7. 21.Disconnect the MUT-II.


13A-310

ON-VEHICLE SERVICE

FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) M1131000900558

(2) Remove the rear seat assembly (Refer to GROUP 52A,Rear Seat Assembly Removal and Installation 352A). Service hole cover

WARNING When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray. 1. Remove the rear seat assembly (Refer to GROUP 52A - Rear Seat Assembly 352A). Service hole cover AC102784 AB

(3) Remove the service hole cover.

AC102784 AB

2. Remove the service hole cover. Fuel pump assembly <2WD> or fuel tank pump and gauge assembly <4WD> AC101011AE connector

(4) Disconnect the fuel pump assembly <2WD> or the fuel tank pump and gauge assembly <4WD> connector. Fuel pump assembly <2WD> or fuel tank pump and gauge assembly <4WD> connector

1

AC101011AD

3. Disconnect the fuel pump assembly connector <2WD> or fuel tank pump and gauge assembly connector <4WD>. 4. After starting the engine and letting it run until it stops naturally, turn the ignition switch to the "LOCK" (OFF) position. 5. Connect the fuel pump assembly connector <2WD> or fuel tank pump and gauge assembly connector <4WD>. 6. Install the service hole cover and rear seat assembly (Refer to GROUP 52A - Rear Seat Assembly 352A).

FUEL PUMP OPERATION CHECK M1131002000584

1. Check the operating of the fuel pump by MUT-II to force-drive the fuel pump. 2. If the fuel pump will not operate, check by using the following procedure. If normal, check the fuel pump drive circuit. (1) Turn the ignition switch to the "LOCK" (OFF) position.

2 4

3 5

AC101012 AD

(5) When the fuel pump drive connector is attached directly to the battery, check if the sound of the fuel pump operation can be heard. If no operating sound is heard, replace the fuel tank pump (Refer to GROUP 13A, Fuel Pump Module Disassembly and Assembly 352A). NOTE: As the fuel pump is an in-tank type, the fuel pump sound is hard to hear. Remove the fuel tank filler tube cap and check from the tank inlet. (6) Check for fuel pressure by pinching the fuel hose with fingertips.


(7) Connect the fuel pump assembly <2WD> or the fuel tank pump and gauge assembly <4WD> connector.

13A-311

(8) Install the service hole cover and rear seat assembly (Refer to GROUP 52A, Rear Seat Assembly Removal and Installation P.52A-25).

COMPONENT LOCATION M1131002100622

Name

Symbol

Name

Symbol

Air flow sensor (with intake air temperature sensor and barometric pressure sensor)

G

Engine-ECU

T

Engine warming lamp (check engine lamp)

Q

A/C relay

O

Fuel pump relay (1) and (2)

P

A/C switch

S


F

A/C pressure sensor

A

Ignition coil

I


L

Injector

D

Crank angle sensor

C


K

Detonation sensor

H


U

Diagnosis connector

R


B


J


J


O


E


M


N

A

B

C

H P

Q

R

S

T

D

I

J

E

K

F

L

G

M

N

O

U

AK300351AB


13A-312

ON-VEHICLE SERVICE

ENGINE CONTROL RELAY CONTINUITY CHECK

INTAKE AIR TEMPERATURE SENSOR CHECK

M1131050000185


1

2

3

4

M1131002800364




1 2 3 4 5 6 7

Equipment side connector AK300352 AB

Tester Battery Voltage Connectio n Terminal

Normal State

2-3

No Voltage

Continuity

1-4

No Voltage

No continuity

Voltage (Connect Continuity positive (+) terminal of battery to terminal No. 3 and negative (-) terminal of battery to terminal No. 2.)

AK300354 AB

1. Disconnect the air flow sensor connector. 2. Measure resistance between terminals No. 5 and No. 6. Standard value: 13 - 17 kW (at -20C) 5.3 - 6.7 kW (at 0C) 2.3 - 3.0 kW (at 20C) 1.0 - 1.5 kW (at 40C) 0.56 - 0.76 kW (at 60C) 0.30 - 0.42 kW (at 80C) 3. Remove the air flow sensor

FUEL PUMP RELAY CONTINUITY CHECK Intake air temperature sensor

M1131033000193

Junction block’s triangle marks Fuel pump relay (1) Fuel pump relay (2)

1 3

2 4 AKX01621AD

Equipment side connector AK300353 AB

Tester Battery Voltage Connectio n Terminal

Normal State

2-3

No Voltage

Continuity

1-4

No Voltage

No continuity

Voltage (Connect Continuity positive (+) terminal of battery to terminal No. 3 and negative (-) terminal of battery to terminal No. 2.)

4. Measure resistance while heating the sensor using a hair drier. Normal condition: Temperature (C) Resistance (kW) Higher

Smaller

5. If the value deviates from the standard value or the resistance remains unchanged, replace the air flow sensor assembly. 6. Install the air flow sensor and tighten it to the specified torque. Tightening torque: 8.8 1 N¼m


13A-313

ON-VEHICLE SERVICE

ENGINE COOLANT TEMPERATURE SENSOR CHECK M1131003100335

CAUTION Be careful not to touch the connector (resin section) with the tool when removing and installing.

1 2

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 10 N¼m

THROTTLE POSITION SENSOR CHECK M1131003200398


AK300355

1. Remove the engine coolant temperature sensor.

1

2 3 4


AKX01622

2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance. Standard value: 14 - 17 kW (at -20C) 5.1 - 6.5 kW (at 0C) 2.1 - 2.7 kW (at 20C) 0.9 - 1.3 kW (at 40C) 0.48 - 0.68 kW (at 60C) 0.26 - 0.36 kW (at 80C) 3. If the resistance deviates from the standard value greatly, replace the sensor.

AK300346 AB

1. Disconnect the throttle position sensor connector. 2. Measure the resistance between the throttle position sensor side connector terminal No. 1 and terminal No. 4. Standard value: 3.5 - 6.5 kW 3. Measure the resistance between the throttle position sensor side connector terminal No. 2 and terminal No. 4. Normal condition: Throttle valve slowly Changes smoothly in open until fully open from proportion to the opening the idle position angle of the throttle valve 4. If the resistance is outside the standard value, or if it doesn’t change smoothly, replace the throttle position sensor. NOTE: For the throttle position sensor adjustment procedure, refer to 313A.

OXYGEN SENSOR CHECK M1131005000497



AKX01623AD

1 2 3 4 Equipment side connector

AK300356 AB


13A-314

ON-VEHICLE SERVICE

1. Disconnect the oxygen sensor connector and connect the special tool Test harness (MD998464) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (4.5 - 8.0 W at 20C) between terminal No. 1 (red clip of special tool) and No. 3 (blue clip of special tool) on the oxygen sensor connector. 3. If there is no continuity, replace the oxygen sensor. 4. Warm up the engine until engine coolant is 80C or higher. 5. Perform a tracing for 5 minutes or more with the engine speed of 4,500 r/min.

Oxygen sensor equipment side connector

Black

White

MD998464

AKX01624 AF

6. Connect a digital voltage meter between terminal No. 2 (black clip of special tool) and No. 4 (white clip of special tool). 7. While repeatedly racing the engine, measure the oxygen sensor output voltage. Standard value: Engine Oxygen Remarks sensor output voltage When racing the engine

0.6 - 1.0 V

If you make the air-fuel ratio rich by racing the engine repeatedly, a normal oxygen sensor will output a voltage of 0.6 - 1.0 V.

CAUTION Be very careful when connecting the jumper wire; incorrect connection can damage the oxygen sensor. Be careful the heater is broken when voltage of beyond 8V is applied to the oxygen sensor heater. NOTE: If the sufficiently high temperature (of approximate 400C or more) is not reached although the oxygen sensor is normal, the output voltage would be possibly low although the rich air-fuel ratio. Therefore, if the output voltage is low, use a jumper wire to connect the terminal No.1 (red clip of special tool) and the terminal No. 3 (blue clip of special tool) of the oxygen sensor with a (+) terminal and (-) terminal of 8 V power supply respectively, then check again. 8. If the sensor is defective, replace the oxygen sensor. NOTE: For removal and installation of the oxygen sensor, refer to GROUP 15 - Exhaust Manifold. 315.


2 1 4 3 Equipment side connector

Oxygen sensor connector (rear) Oxygen sensor (rear)

AK300357 AB

1. Disconnect the oxygen sensor connector and connect the special tool Test harness (MB991658) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20C) between terminal No. 1 and No. 2 on the oxygen sensor connector. 3. If there is no continuity, replace the oxygen sensor. 4. Warm up the engine until engine coolant is 80C or higher. 5. Perform a tracing for 5 minutes or more with the engine speed of 4,500 r/min.


13A-315

ON-VEHICLE SERVICE

INJECTOR CHECK M1131005200327

Oxygen sensor

Check the Operation Sound Injector 1 2 Equipment side connector

MB991658 AK000121 AC

6. Connect a digital voltage meter between terminal No. 3 and No. 4. 7. While repeatedly racing the engine, measure the oxygen sensor output voltage. Standard value: Engine Oxygen Remarks sensor output voltage When racing the engine

0.6 - 1.0 V

If you make the air-fuel ratio rich by racing the engine repeatedly, a normal oxygen sensor will output a voltage of 0.6 - 1.0 V.

CAUTION Be very careful when connecting the jumper wire; incorrect connection can damage the oxygen sensor. Be careful the heater is broken when voltage of beyond 8V is applied to the oxygen sensor heater. NOTE: If the sufficiently high temperature (of approximate 400C or more) is not reached although the oxygen sensor is normal, the output voltage would be possibly low although the rich air-fuel ratio. Therefore, if the output voltage is low, use a jumper wire to connect the terminal No.2 and the terminal No. 1 of the oxygen sensor with a (+) terminal and (-) terminal of 8 V power supply respectively, then check again. 8. If the sensor is defective, replace the oxygen sensor. NOTE: For removal and installation of the oxygen sensor, refer to GROUP 15 - Exhaust Pipe and Main Muffler 315.

AK300358 AB

1. Use a stethoscope to listen to the operation sound (clicking) of the injectors while the engine is idling or cranking.

CAUTION Beware that the operation sounds of other injectors can be heard even if the injector that is being inspected might not be operating. 2. Verify that the operation sound increases with the engine speed. NOTE: If the operating sound cannot be heard, inspect the injector actuation circuit.

Measurement of Resistance between Terminals 1. Disconnect the injector connector. 2. Measure the resistance between terminals. Standard value: 10.5 - 13.5 W (at 20C) 3. Connect the injector connector.

Check the Injection Condition 1. Following the steps below, bleed out the residual pressure within the fuel pipe line to prevent flow of the fuel (Refer to 313A). 2. Remove the injector. 3. Assemble the following special tools as shown in Fig. Injector test set (MD998706) Injector test harness (MB991607) Injector test adaptor (MD998741) Clip (MB991608)


13A-316

ON-VEHICLE SERVICE

High-pressure fuel hose MD998741 Return hose

MB991607 Pressure regulator

Clip (MB991608) MD998706

Injector

Battery

AK101794 AD

4. Connect the MUT-II to the diagnosis connector. 5. Turn the ignition switch to "ON" position (But do not start the engine). 6. Select "Item No. 07" from the MUT-II Actuator test to drive the fuel pump.

IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) CHECK M1131005400417

Check the Operation Sound

Mainhose

1 2

3

4 5

6

Equipment side connector Return hose Injector

Idle speed control servo AK300359 AB

Battery

AK101795 AC

7. Activate the injector and check the atomized spray condition of the fuel. The condition can be considered satisfactory unless it is extremely poor. 8. Stop the actuation of the injector, and check for leakage from the injector’s nozzle. Standard value: 1 drop or less per minute 9. Activate the injector without activating the fuel pump; then, when the spray emission of fuel from the injector stops, disconnect the special tool and restore it to its original condition. 10.Disconnect the MUT-II.

1. Check that the engine coolant temperature is 20C 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 20C or below is also okay. 2. Check that the operation sound of the stepper motor can be heard after the ignition is turned to the "ON" position (but without starting the engine). 3. If the operation sound cannot be heard, check the stepper motor’s activation circuit. If the circuit is normal, it is probable that there is a malfunction of the stepper motor or of the engineECU.


Check the Coil Resistance

13A-317

Operation Check

1 2 3 4 5 6

AKX01626

1 2 3 4 5 6

AKX01561AE

1. Disconnect the idle speed control servo connector. 2. Measure the resistance between terminal No. 2 and either terminal No. 1 or terminal No. 3 of the connector at the idle speed control servo side. Standard value: 28 - 33 W (at 20C) 3. Measure the resistance between terminal No. 5 and either terminal No. 6 or terminal No. 4 of the connector at the idle speed control servo side. Standard value: 28 - 33 W (at 20C)

1. Remove the throttle body. 2. Remove the stepper motor. 3. Connect the special tool Test harness (MB991709) to the idle speed control servo connector. 4. Connect the positive (+) terminal of a power supply (approximately 6 V) to the terminals No. 2 and No. 5. 5. With the idle speed control servo as shown in the illustration, connect the negative (-) terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor. (1) Connect the negative (-) terminal of the power supply to the terminal No. 1 and terminal No. 4. (2) Connect the negative (-) terminal of the power supply to the terminal No. 3 and terminal No. 4. (3) Connect the negative (-) terminal of the power supply to the terminal No. 3 and terminal No. 6. (4) Connect the negative (-) terminal of the power supply to the terminal No. 1 and terminal No. 6. (5) Connect the negative (-) terminal of the power supply to the terminal No. 1 and terminal No. 4. (6) Repeat the tests in sequence from (5) to (1). 6. If vibration is detected during the test, the stepper motor can be considered to be normal.


13A-318

INJECTOR

INJECTOR REMOVAL AND INSTALLATION M1131007100649

Post-installation Operation Air Cleaner Installation (Refer to GROUP 15, Air Cleaner 315). Fuel Leakage Inspection.

Pre-removal Operation Fuel Discharge Prevention (Refer to 313A). Air Cleaner Removal (Refer to GROUP 15, Air Cleaner 315).

4

3

11 ± 1 N·m

8.9 ± 1.9 N·m

9 5

8 7N 6 5.0 ± 1.0 N·m

19 15 N 16 18 17

10 N

6,10 7,11

2

11

18

12

13 19

16

N 15

14

1

Engine Oil AC300484 AB

1. 2. 3. 4. 5.

>>A<<

>>A<< <> >>A<<

6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18 19.

Removal steps PCV hose connection Injector connector Idle speed control servo connector Throttle position sensor connector Emission control equipment hose connector Fuel high-pressure hose connection O-ring Fuel return hose connection Fuel hose Delivery pipe pressure regulator O-ring Fuel delivery pipe and fuel injector assembly Insulators Fuel injector assembly O-ring Fuel injector sheets Insulators Fuel injectors Fuel delivery pipe

REMOVAL SERVICE POINT <> FUEL DELIVERY PIPE AND FUEL INJECTOR ASSEMBLY REMOVAL

CAUTION Do not drop the injector. Remove the fuel delivery pipe with the fuel injector assembly attached to it.

INSTALLATION SERVICE POINT >>A<< FUEL INJECTOR ASSEMBLY/DELIVERY PIPE PRESSURE REGULATOR/FUEL HIGHPRESSURE HOSE INSTALLATION

CAUTION Do not let the engine oil get into the delivery pipe will be damaged. 1. Apply a drop of new engine oil to the O-ring.


13A-319

THROTTLE BODY ASSEMBLY

2. Turn the fuel injector assembly. To the right and left to install to the fuel delivery pipe. Repeat for delivery pipe pressure regulator and fuel highpressure hose. Be careful not to damage the Oring. After installing, check that the item turns smoothly. 3. If it dose not turn smoothly, the O-ring may be trapped, remove the item, re-install it into the fuel delivery pipe and check again.

4. Tighten the delivery pipe pressure regulator and fuel high-pressure hose to the specified torque. Tightening torque: 8.9 1.9 N¼m 5.0 1.0 N¼m

THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION M1131007700544

Pre-removal Operation Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Air Cleaner Removal (Refer to GROUP 15, Air Cleaner 315).

Post-installation Operation Air Cleaner Installation (Refer to GROUP 15, Air Cleaner 315). Engine Coolant Supplying (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314). Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Adjustment 317).

6

7 2 5.0 ± 1.0 N·m

1

19 ± 3 N·m

N8

3 4 5 1. 2. 3. 4. 5.

Removal steps Accelerator cable connection Throttle position sensor connector Idle speed control servo connector Water return hose connection Water feed hose connection

6.

>>A<<

7. 8.

AC300416AB

Removal steps&RQWLQXHG Emission vacuum hose connection Throttle body assembly Throttle body gasket


13A-320


INSTALLATION SERVICE POINT >>A<< THROTTLE BODY GASKET INSTALLATION

Install the throttle body gasket as shown in the illustration.

CAUTION Poor idling etc. may result if the throttle body gasket is installed incorrectly. Up

Towards front of vehicle

AC200313AB

THROTTLE BODY ASSEMBLY DISASSEMBLY AND REASSEMBLY M1131009700409

5 6 2.0 ± 0.5 N·m 2.0 ± 0.5 N·m

1 2 3 4 AK203824 AB

<> <>

>>A<<

1. 2. 3. 4.

Removal steps Throttle position sensor Idle speed control servo O-ring Throttle body

Removal steps&RQWLQXHG 5. Speed adjusting screw 6. O-ring


13A-321


NOTE: . The speed adjusting screw is correctly adjusted at the factory and should not be removed. If the speed adjusting screw should happen to have been removed, carry out speed adjusting screw adjutment.

DISASSEMBLY SERVICE POINTS <> THROTTLE POSITION SENSOR DISASSEBLY 1. Do not disassemble the sensor and motor. 2. Do not clean the sensor and motor by dipping them into cleaning solvent. Clean them with shop towel. <> THROTTLE BODY DISASSEMBLY 1. Do not disassemble the throttle body. 2. Check if the vacuum port or passage is clogged. Use compressed air to clean the vacuum passage.

REASSEMBLY SERVICE POINT >>A<< THROTTLE POSITION SENSOR (TPS) INSTALLATION

AK203835AB

1. Install the throttle position sensor to the throttle body as shown in the illustration. 2. Turn the throttle position sensor 90 degrees counterclockwise to set it, and tighten the screws.

Throttle position sensor power

Earth

Throttle position sensor output AK200203 AB

3. Connect an ohmmeter between terminals 2 (output) and 4 (earth), or between terminals 1 (power) and 2 (output). Then, make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position.


13A-322

ENGINE ECU

ENGINE ECU REMOVAL AND INSTALLATION M1131033800036

Pre-removal and Post-installation Operation Cowl Side Trim (RH) Removal and Installation (Refer to GROUP 52A, Instrument Panel Assembly 352A).

3 5.0 ± 1.0 N·m

2

1

5.0 ± 1.0 N·m

AC300630AB

1.

REMOVAL STEPS Engine-ECU connector

2. 3.

REMOVAL STEPS&RQWLQXHG Engine-ECU Engine-ECU bracket

13-1

GROUP 13

FUEL

00 11 12 13

CONTENTS

14 15 16

MULTIPORT FUEL INJECTION (MFI) . . . . . . . . . . . . . . . . . . . . 13A

17

FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B

21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

127(6

13B-1

GROUP 13B

00 11

FUEL SUPPLY

12 13 14

CONTENTS GENERAL INFORMATION . . . . . . . .

13B

SEALANT. . . . . . . . . . . . . . . . . . . . . .

13B


13B

FUEL PUMP OPERATION CHECK . . . . . .

13B

FUEL GAUGE UNIT CHECK . . . . . . . . . . .

13B

FUEL PUMP ASSEMBLY <2WD>, FUEL TANK PUMP AND GAUGE ASSEMBLY <4WD> REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 13B FUEL GAUGE UNIT REPLACEMENT . . . .

13B

15

FUEL TANK GAUGE UNIT REPLACEMENT <2WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13B

FUEL TANK GAUGE UNIT REPLACEMENT <4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13B

FUEL TANK . . . . . . . . . . . . . . . . . . . .

13B


13B

FUEL PUMP ASSEMBLY <2WD>, FUEL TANK PUMP AND GAUGE ASSEMBLY <4WD> DISASSEMBLY AND REASSEMBLY 13B FUEL TANK GAUGE UNIT DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . .

13B

16 17 21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

FUEL SUPPLY

13B-2

GENERAL INFORMATION


The fuel tank is located under the floor of the rear seats to provide increased protection and a more luggage space. A fuel tank safety valve assembly has been adopted to prevent fuel from leaking out in case of a collision.

A fuel pump assembly <2WD>, fuel pump and gauge assembly <4WD> including fuel pump, fuel filter, reservoir and fuel gauge unit, has been adopted to lighten weight and improve serviceability.

SEALANT M1135005200017

Item

Specified sealant

Service hole cover and floor pan <2WD>

3MÉ 8513 Grommets windshield sealer (Black)

ON-VEHICLE SERVICE FUEL PUMP OPERATION CHECK M1135001000118

Refer to GROUP 13A - On-vehicle Service, Fuel Pump Operation Check 313A.

FUEL GAUGE UNIT CHECK

2. Remove the service hole cover mounting screws and remove the service hole cover. Fuel pump assembly <2WD> or fuel tank pump and gauge assembly <4WD> connector

M1135003100296

Refer to GROUP 54A - Combination Meter, On-vehicle Service, Fuel Gauge Unit Check 354A <2WD>, 354A <4WD>.

Fuel suction tube <4WD>

FUEL PUMP ASSEMBLY <2WD>, FUEL TANK PUMP AND GAUGE ASSEMBLY <4WD> REPLACEMENT M1135004900240

1. Remove the rear seat cushion assembly (Refer to GROUP 52A - Rear seat assembly 352A). Service hole cover

Fuel return hose

Fuel high-pressure hose AC102778AB

AC102784 AB

3. Disconnect the fuel pump assembly <2WD> or fuel tank pump and gauge assembly <4WD> connector, fuel return hose, fuel high-pressure hose and fuel suction tube <4WD>.

FUEL SUPPLY

13B-3

ON-VEHICLE SERVICE

CAUTION

CAUTION

Fuel tank pump and gauge assembly

Corresponding side Fuel high-pressure hose or fuel pump suction tube <4WD>

Service hole Float

3 mm AC107193 AC

For 4WD: Pay attention not to damage the float when removing and installing fuel tank pump and gauge assembly through the service hole. 4. Remove the mounting nuts and fuel pump bracket plate, and remove the fuel pump assembly <2WD>, fuel tank pump and gauge assembly <4WD> from the service hole. 5. Install the fuel pump assembly <2WD>, fuel tank pump and gauge assembly <4WD> to the fuel tank through the service hole.

Quick connector AC300047AC

After connecting the fuel high-pressure hose or fuel pump suction tube <4WD>, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm. Fuel pump assembly <2WD> or fuel tank pump and gauge assembly <4WD> connector

Fuel suction tube <4WD>

Fuel pump braket plate

2.5 ± 0.4 N·m AC107194AC

6. Install the fuel pump bracket plate to the fuel tank and tighten the mounting nuts to the specified torque. Tightening torque: 2.5 0.4 N¼m

Fuel return hose

Fuel high-pressure hose AC102778AB

7. Connect the fuel pump assembly <2WD> or fuel tank pump and gauge assembly <4WD> connector, fuel return hose, fuel high-pressure hose and fuel suction tube <4WD>. Service hole cover

AC102784 AB

FUEL SUPPLY

13B-4

ON-VEHICLE SERVICE

8. Tighten the service hole cover mounting screws and install the service hole cover. 9. Install the rear seat cushion assembly. (Refer to GROUP 52A - Rear seat assembly 352A).

CAUTION Fuel tank gauge unit

FUEL GAUGE UNIT REPLACEMENT Gauge unit

FUEL TANK GAUGE UNIT REPLACEMENT <2WD> M1135001400279

1. Remove the rear seat cushion assembly (Refer to GROUP 52A - Rear Seat Assembly 352A). Flat-tipped screwdriver

Service hole

AC107188AD

Pay attention not to damage the gauge unit and the float of the fuel tank gauge unit when withdrawing it from the service hole. 4. Remove the fuel tank gauge unit mounting nuts and remove the fuel tank gauge unit from service hole.

CAUTION Fuel tank gauge unit Service hole cover

AC107600AC

2. Pry off the service hole cover using a flat-tipped screwdriver, etc.

Gauge unit

Fuel tank gauge unit

Service hole

AC107188AE

Pay attention not to damage the gauge unit and the float of the fuel tank gauge unit when inserting it from the service hole. Fuel tank gauge unit harness connector

AC107601AC

2.5 ± 0.4 N·m

3. Disconnect the fuel tank gauge unit harness connector.

AC107602 AC

5. Install the fuel tank gauge unit to the fuel tank through the service hole, and tighten the mounting nuts to the specified torque. Tightening torque: 2.5 0.4 N¼m

FUEL SUPPLY

13B-5

ON-VEHICLE SERVICE Fuel tank gauge unit

Fuel tank gauge unit harness connector

Service hole cover

AC107603AC

AC107601AC

6. Connect the fuel tank gauge unit harness connector.

2. Remove the service hole cover mounting screws and remove the service hole cover. Fuel pump suction tube

Service hole cover Fuel tank gauge unit

Fuel tank gauge unit harness connector

Floor pan AC100961AD

7. Apply the specified sealant to the contact surfaces of the service hole cover and the floor pan, and install the service hole cover. Specified sealant: 3MÉ 8513 Grommets Windshield Sealer (Black) 8. Install the rear seat cushion assembly (Refer to GROUP 52A - Rear Seat Assembly 352A).

AC107189AC

3. Disconnect the fuel tank gauge unit harness connector and fuel pump suction tube.

CAUTION

Gauge unit Fuel tank gauge unit

FUEL TANK GAUGE UNIT REPLACEMENT <4WD>

Service hole M1135001400280

1. Remove the rear seat cushion assembly (Refer to GROUP 52A - Rear Seat Assembly 352A).

Float

AC107190AD

Pay attention not to damage the gauge unit and the float of the fuel tank gauge unit when withdrawing it from the service hole. 4. Remove the fuel tank gauge unit mounting nuts and remove the fuel tank gauge unit from service hole.

FUEL SUPPLY

13B-6

ON-VEHICLE SERVICE

CAUTION

CAUTION Main pipe nozzle or fuel main pipe Gauge unit

Fuel high-pressure hose or fuel pump suction tube

Fuel tank gauge unit Service hole

Float

3 mm

Quick connector

AC107190 AE

Pay attention not to damage the gauge unit and the float of the fuel tank gauge unit when inserting it from the service hole. 2.5 ± 0.4 N·m

AC300047AB

After connecting the fuel high-pressure hose or fuel pump suction tube, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm. Fuel pump suction tube

Fuel tank gauge unit

AC107618AC

5. Install the fuel tank gauge unit to the fuel tank through the service hole, and tighten the mounting nuts to the specified torque. Tightening torque: 2.5 0.4 N¼m

Fuel tank gauge unit harness connector AC107189AC

6. Connect the fuel tank pump gauge unit harness connector and fuel suction tube. Service hole cover

AC107603AC

7. Tighten the service hole cover mounting screws and install the service hole cover. 8. Install the rear seat cushion assembly (Refer to GROUP 52A - Rear Seat Assembly 352A).

FUEL SUPPLY

13B-7

FUEL TANK

FUEL TANK REMOVAL AND INSTALLATION M1135001900401

Pre-removal Operation Draining Fuel Fuel Pump Connector Disconnection (How to Reduce Fuel Pressure) (Refer to GROUP 13A - On-vehicle Service 313A). Centre Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Propeller Shaft Removal <4WD> (Refer to GROUP 25, Propeller Shaft 325).

Post-installation Operation Propeller Shaft Installation <4WD> (Refer to GROUP 25, Propeller Shaft 325). Centre Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Refilling Fuel Checking for Fuel Leaks

<2WD>

8

2.5 ± 0.4 N·m

21 11 12

2.5 ± 0.4 N·m

8

15 17

13

5 13

15 13

22

18 N

4

2.5 ± 0.4 N·m

9

2.5 ± 0.4 N·m

20 N

19

20 N 13

14 13

3

19 24

2

25

23

1

6

26 ± 4 N·m

26 ± 4 N·m

7 AC212356 AB

FUEL SUPPLY

13B-8

FUEL TANK

<4WD>

8

2.5 ± 0.4 N·m

21

16

11 12

8 2.5 ± 0.4 N·m

13 17

2.5 ± 0.4 N·m

15

13

15

5

13

22

N 18

2.5 ± 0.4 N·m

20 N

19

14

13

13

20 N

4 19 24

3

2

10

25

23

1

6

26 ± 4 N·m

<>

<>

7

Fuel tank assembly removal steps 1. Fuel filler hose connection 2. Fuel filler neck breather hose connection 3. Main pipe connection 4. Return pipe 5. Fuel vapour pipe 6. Parking brake cable clamp connection 7. Wiring harness clamp connection 8. Fuel tank gauge unit assembly, fuel pump assembly <2WD>, fuel tank pomp and gauge assembly <4WD> connector connection Rear differential support member installation nuts and bolts <4WD> (Refer to GROUP 27B - Rear Differential Carrier Assembly 327B). 9. Fuel tank assembly <2WD> 10. Fuel tank assembly <4WD>

AC212516AB

>>A<<

>>A<< <>

<>

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

23. 24. 25.

Fuel tank assembly removal steps&RQWLQXHG Fuel high-pressure hose Fuel return hose Fuel tank hose Fuel tank vapour hose 2way valve Fuel vapour pipe Fuel pump suction tube <4WD> Fuel tank gauge unit Gasket Fuel tank safety valve Gasket Fuel pump bracket plate Fuel pump assembly <2WD>, fuel tank pump and gauge assembly <4WD> Fuel filler hose Fuel filler neck breather hose Fuel tank

FUEL SUPPLY

13B-9

FUEL TANK

30

27 28

2

29 1 26 AC300410AB

Fuel filler neck removal steps Fuel filler hose connection 2. Fuel filler neck breather hose connection 26. Fuel filler neck protector 1.

27. 28. 29. 30.

Fuel filler neck removal steps Fuel tank cap Fuel filler neck Fuel filler neck valve Gasket

FUEL SUPPLY

13B-10

FUEL TANK


CAUTION

<> REAR DIFFERENTIAL SUPPORT MEMBER INSTALLATION NUTS AND BOLTS <4WD>/ FUEL TANK ASSEMBLY <4WD> REMOVAL Fuel tank assembly

Rear differential carrier assembly

Support the fuel tank assembly securely so that it does not fall off from the transmission jack. 3. Tilt the fuel tank assembly to disconnect the connectors. Towards front of vehicle


Tilt Towards front of vehicle

AC300033AB

1. Remove the rear differential support member installation nuts and bolts, and then tilt the rear differential carrier assembly (Refer to GROUP 27A - Rear Differential Carrier Assembly 327B ).

Lower

Fuel tank assembly

AC300043AB

4. Remove the fuel tank assembly to the direction shown, being careful not to strike it against the rear differential carrier assembly. <> FUEL TANK GAUGE UNIT/FUEL PUMP ASSEMBLY <2WD>, FUEL TANK PUMP AND GAUGE ASSEMBLY <4WD> REMOVAL

CAUTION When withdrawing the fuel tank gauge unit, fuel tank pump and gauge assembly from the fuel tank, be careful not damage the module unit and the float. Fuel tank assembly Transaxle jack

AC107196 AD

2. Raise and support the fuel tank assembly with a transmission jack, and remove the mounting nuts and bolts. Towards front of vehicle Fuel tank assembly


INSTALLATION SERVICE POINTS >>A<< FUEL PUMP SUCTION TUBE <4WD>/FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION

Corresponding side Fuel high-pressure hose or fuel pump suction tube <4WD>

Tilt

3 mm AC300040 AB

Quick connector AC300047AC

After connecting the fuel high-pressure hose or fuel pump suction tube <4WD>, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm.

FUEL SUPPLY

13B-11

FUEL TANK

FUEL PUMP ASSEMBLY <2WD>, FUEL TANK PUMP AND GAUGE ASSEMBLY <4WD> DISASSEMBLY AND REASSEMBLY M1135004600294

<2WD>

3

2 10 1N

N5

8

6 N5

4 9

11

7

AC300077AB

1. 2.

>>A<<

3. 4. 5.

Disassembly steps Gasket Fuel tank pump connector connection Fuel pump bracket Fuel pump hose O-ring

>>A<<

6. 7. 8. 9. 10. 11.

Disassembly steps&RQWLQXHG Fuel pump tube Fuel pump bracket Fuel tank pump Fuel tank pump cushion Fuel tank grommet Fuel tank filter assembly

FUEL SUPPLY

13B-12

FUEL TANK

<4WD>

5

4 N 13

2 1N 3

N

8 11

9 N

8

6 12

7

10 14

AC300470AB

Disassembly steps Gasket Fuel tank gauge unit connector connection 3. Fuel tank gauge unit 4. Fuel tank pump connector connection 5. Fuel pump bracket 6. Fuel pump hose 7. Fuel tank assist pump 8. O-ring 9. Fuel tank tube 10. Fuel pump bracket 1. 2.

>>A<<

>>A<<

11. 12. 13. 14.

Disassembly steps&RQWLQXHG Fuel tank pump Fuel tank pump cushion Fuel tank grommet Fuel tank filter assembly

REASSEMBLY SERVICE POINT >>A<< FUEL TANK GROMMET/O-RING INSTALLATION Apply gasoline on the grommet and the O-ring before mounting them to prevent damage or twisting.

FUEL SUPPLY

13B-13

FUEL TANK

FUEL TANK GAUGE UNIT DISASSEMBLY AND REASSEMBLY M1135051100057

<2WD>

<4WD>

3 3

1

1

2

AC102461 AD

1.

Disassembly steps Gasket

2. 3.

Disassembly steps&RQWLQXHG Fuel in tank filter <4WD> Fuel tank gauge unit

127(6

54-1

GROUP 54

CHASSIS ELECTRICAL

00 11 12 13 14 15

CONTENTS

16 17

CHASSIS ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54A

21 22

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54B

25

SMART WIRING SYSTEM (SWS) USING SWS MONITOR . . . . 54C

27

26 31 32 33 34 35 36 37 42 51 52 54 55

127(6

54B-1

GROUP 54B

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

00 11 12 13 14 15 16 17 21 22


54B

CHECK AT ECU TERMINAL . . . . . . . 54B

SPECIAL TOOLS. . . . . . . . . . . . . . . .

54B

ON-VEHICLE SERVICE . . . . . . . . . . . 54B


54B

CONFIGURATION FUNCTION . . . . . 54B

25 26 27 31 32 33 34 35 36 37 42 51 52 54 55


54B-2

GENERAL INFORMATION


The exclusive signal lines for transmitting the multidistribution data are connected as follows between the ETACS-ECU, column switch (incorporated inside the column-ECU), front-ECU, power window main switch (incorporated inside the power window-ECU), and power window sub switches (incorporated inside the power window-ECU) for internal communication.

Power window sub switch (Rear RH)

ETACS-ECU

Power window main switch

Column switch

Power window sub switch (Front)

Power window sub switch (Rear LH)

Front-ECU : Bidirectional communication : Unidirectional communication

Buzzer

When the ignition key is removed and then the driver’s door is opened with turning ON the tail lamp or the head lamp, the buzzer sounds continuously to alert the driver that the lamp is still ON. However, if the tail lamp or the headlamp is turned off by the headlamp auto-turn off function, the buzzer does not sound.

Lamp reminder function ON

Tail lamp or headlamp Key reminder switch

OFF ON (Key removed) OFF (Key inserted)

Driver's door switch Buzzer output

AC212517AG

ON (Open) OFF (Closed) ON (Tone alarn sounds) OFF (Tone alarm does not sound) AC101512

Central door locking Central door locking control function t: 0.25 seconds Lock switch Unlock switch

ON OFF ON OFF ON

Lock relay output

OFF

Unlock relay output

ON OFF

t t AC101496 AD

When the front doors is locked (when the lock switch turns ON after turning OFF the unlock switch in the driver’s door lock actuator), ETACS-ECU turns ON the lock relay output for 0.25 second, and locks all doors (including the tailgate). When the front doors is unlocked (when the unlock switch turns ON after turning OFF the lock switch on the driver’s door lock actuator), ETACS-ECU turns ON the unlock relay output for 0.25 second, and unlocks all doors (including the tailgate).


54B-3

GENERAL INFORMATION

Key reminder function

Key reminder switch

(Key inserted)ON (Key removed)OFF

Driver's door switch Driver's door actuator switch

(Open)ON (Close)OFF LOCK UNLOCK t

Lock relay

t

t

t

t

ON OFF

T2

T2

T2

T2

ON

Unlock relay OFF T1

T1

T1

t: 0.3 seconds T1: 0.25 seconds T2: 1 second

When the driver’s door is opened with the ignition key inserted to the ignition cylinder and the door is locked (when the lock switch turns ON after turning OFF the unlock switch in the driver’s door lock actuator), after approximately 0.3 second, ETACS-ECU turns ON the unlock relay output for 0.25 second to discourage the door lock operation so that the ignition key left in the ignition cylinder is prevented. If the discouraging the door lock operation fails, the current supply will be retried. (The unlock relay output is turned ON for 0.25 second up to five times with one second interval.) NOTE: The broken line in the graph indicates the current supply retry state if the discouraging door lock operation fails.

T1

T1

T1

T1

T1 AC101499 AB

Door unlock function with the impact detection If the vehicle crashed with the ignition switch ON or 30 seconds after turning the ignition switch to LOCK (OFF), and the impact sensor detects an impact greater than the specified value, the impact sensor sends the signal to ETACS-ECU. Then, within the 0.1 second, ETACS-ECU energizes the unlock relay for one second for releasing the door lock to prevent passengers to kept inside the vehicle after the crash. NOTE: The fail safe disables the operation under the following conditions. (Diagnosis code No. 31 or 32 is output at this time.) Turn ON the ignition switch again after turning the ignition switch to LOCK (OFF) to return from the fail safe state. . No. 31: When the ignition switch is ON, and the sensor shows under the short circuit detect voltage for 2.5 second No. 32: When the ignition switch is ON, and the sensor shows over the closed circuit detect voltage for 0.4 second


54B-4

GENERAL INFORMATION

Keyless entry system Keyless entry hazard lamp answer back function (the initial condition: with function of lock/ unlock) LOCK

Keyless entry transmitter

OFF

Lock relay output

UNLOCK ON

Unlock relay output Hazard warning light

OFF ON OFF

Illuminate

Extinguish AC101500 AB

The hazard answer back function that allows checking the lock/unlock state of the door easily even in the daytime is installed. When the lock signal from the keyless entry transmitter is received into ETACSECU, all doors (including the tailgate) are locked, and the turn signal lamp blinks twice. When the unlock signal is received, all doors (including the tailgate) are unlocked, and the turn signal lamp blinks once. NOTE: The answer back blink time can be adjusted by the adjusting function. Timed locking mechanism After unlocking the doors with the keyless entry transmitter, if no doors are opened, if the ignition key is not inserted or if the locking function is not operated, the ETACS-ECU automatically locks the doors in 30 seconds.

Windshield wiper and washer Intermittent control (the initial condition: with function) 18

Intermittent wiper volume "FAST" position

18

Intermittent time: TI(sec.)

Intermittent time: TI(sec.) 0

Intermittent wiper volume "SLOW" position 100

0

FAST SLOW Intermittent wiper volume position

Vehicle speed (km/h) AC300134 AB

ETACS-ECU calculates the intermittent time TI from the vehicle speed calculated from the windshield intermittent wiper volume of the column switch and the vehicle speed signals (engine-ECU), and sends it to the front ECU as SWS data.

NOTE: The vehicle speed sensing function can be invalidated by the adjusting function.

TI: Intermittent time ON Windshield wiper auto stop signal OFF ON Windshield wiper drive signal OFF

TI

TI

TI

AC300135 AC

The front ECU determines the intermittent time TI from the input SWS data, and turns ON the windshield wiper drive signal. When the wiper comes to the stop position, the windshield wiper auto-stop signal is turned OFF, and the windshield wiper drive signal turns OFF.

When the intermittent time TI is elapsed after being turned ON the windshield wiper drive signal, the windshield wiper drive signal is turned ON again, and the above-mentioned operation is repeated.


54B-5

GENERAL INFORMATION

Mist wiper control ON

Windshield wiper "MIST" switch

OFF ON

Windshield wiper auto stop signal

OFF ON

Windshield wiper drive signal

OFF

Windshield wiper speed switching relay

(HI) ON

TI

TI

(LO) OFF

Windshield wiper switch "OFF" position

Windshield wiper intermittent operation

TI: Intermittent time

AC300283 AC

When the windshield wiper mist switch of the column switch is turned ON while the ignition switch is ACC or ON, the column switch turns ON the windshield wiper drive signal. At the same time, the wiper speed switch relay turns to ON (HI). When the windshield mist wiper switch is ON, the windshield wiper operates at the high speed. Low speed wiper and high speed wiper control ON Windshield wiper "LO" switch OFF ON Windshield wiper "HI" switch OFF Windshield wiper auto stop signal

ON

Windshield wiper drive signal

ON

OFF

OFF

Windshield wiper speed (HI) ON switching relay (LO) OFF

Windshield wiper low speed operation

Windshield wiper hight speed operation AC300284AC

When the windshield low speed wiper switch of the column switch is turned ON while the ignition switch is ACC or ON, the column switch turns ON the windshield wiper drive signal. Also, the wiper speed switching relay turns to OFF (LO), and the windshield wiper operates at the low speed.

When the windshield high speed wiper switch is turned ON, the windshield wiper drive signal turns ON. Also, the wiper speed switching relay turns ON (HI), and the windshield wiper operates at the high speed.

54B-6

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR GENERAL INFORMATION

Rear wiper and washer Rear wiper control [the initial condition: 8 seconds (without successive operations)] ON

Rear wiper switch

OFF

Transmission range switch "R" position

ON OFF t

T2

T1

T2

T2

T1

ON

Rear wiper drive signal

OFF T3

T4

T4

T3

T4

t: 1.0 second T1: 7.4 seconds T2: 8.0 seconds T3: 3.0 seconds T4: 0.6 second

T4

T4

AC301877AB

1. When the rear wiper switch on the column switch is turned ON with the ignition switch at the ACC or ON position, ETACS-ECU turns ON the rear wiper drive signal for 3 seconds (approximately 2 operations) and performs the intermittent action at 8-second intervals. When the transmission range is moved to R (reverse) position during the rear wiper operation, the inhibitor switch R (reverse) position turns ON one second after that, ETACS-ECU sends the rear wiper drive signal for 3 seconds (approximately 2 operations), and operates the intermittent action in 8 seconds interval.

2. By the special operation of the rear wiper switch on the column switch (successive 2-time operations), the rear wiper operates continuously regardless of the set intermittent time. NOTE: The rear wiper intermittent time can be adjusted or canceled for continuous operation by the adjusting function.

Headlamp Headlamp automatic-shutdown function (the initial condition: with function)

Ignition switch (IG)

ON OFF

Driver's seat door switch

(Opend) ON (Closed) OFF Headlamp

Lighting switch

Tail lamp OFF

Tail lamp output

Headlamp output

ON OFF ON OFF

3 minutes

1 second AC300449 AB

Even when the lighting switch (tail lamp switch or head lamp) is ON, the headlamp (including the tail lamps) turns off automatically with any of the following conditions to prevent the battery discharge

caused by unattended operation.


54B-7

GENERAL INFORMATION

If the ignition switch is turned OFF with the lighting switch ON, the lamp turns off automatically after 3 minutes. If the driver’s door is opened during the 3 minutes, the lamp turns off after one second. (One seconds before turning off, the lamp reminder buzzer sounds.) After the head lamp auto cut function, when the lighting switch is turned OFF and then ON or, the ignition switch is turned ON, the head lamp lights again. NOTE: For vehicles with the keyless entry system, this function can be invalidated by the adjusting function.

Flasher timer function

Hazard warning lamp

Hazard lamp switch Turn signal lamp output RH Turn signal lamp output LH

Turn signal lamp Ignition switch (IG)

When the turn signal lamp switch is ON (LH or RH) with the ignition switch is ON, the turn signal lamp output (flash signal) is turned ON. If the lamp bulb of the front or rear turn signal lamp has burned out, the flashing speed becomes faster to alert the driver that the lamp bulb has burned out.

ON

ON OFF ON OFF ON OFF

AC101509AC

OFF

Turn signal lamp ON switch RH OFF Turn signal lamp ON switch LH OFF Turn signal lamp ON output RH OFF Turn signal lamp ON output LH OFF AC101508 AC

When the hazard lamp switch input signal turning from OFF to ON is detected, the flashing states turns over by the signal. (When the hazard lamp is not blinking, it blinks. If it is blinking, it turns off.) NOTE: . 1. The push-return switch is adopted for the hazard lamp switch. 2. Even if the lamp bulb has burned out, the flashing speed of the hazard lamp is not changed.

Fog lamp Front Fog Lamp Control Function

Headlamp Lighting switch

Tail lamp OFF

Front fog lamp switch Headlamp automatic shutdown output

Fog lamp output

ON OFF (Switched off) ON (Illuminated) OFF (Illuminated) ON (Extinguished) OFF AC212278 AF

When the fog lamp switch is turned to ON with the tail lamp or the headlamp lit (the taillamp switch or the headlamp switch is ON), the fog lamp relay turns ON, and the fog lamps lamp. If the tail lamp or the headlamp is turned off with the lighting switch OFF while the fog lamps lit, the fog lamps turn off the same time to prevent unattended operation.

If the tail lamp is turned off by the headlamp autoturn off function, the fog lamps turn off at the same time. However, if the tail lamps lamp again, the fog lamps do not.


54B-8

GENERAL INFORMATION

Rear Fog Lamp Control Function Headlamp Lighting switch Tail lamp OFF Illuminated

Front fog lamps

Extinguished

ON

Rear fog lamp switch

OFF

ON Rear fog lamps OFF AC212279 AB

If the rear fog lamp switch is turned ON when the headlamp or the front fog lamp is turned ON, the rear fog lamp is switched ON and OFF alternatively.

If the headlamp and the front fog lamp are turned OFF, the rear fog lamp is turned OFF at the same time.

Interior lamp Dimmer interior lamp control function (the initial condition: 15 seconds) ON Ignition switch

ACC OFF Key removed (Any one open) ON

Door switch

Driver's door lock actuator switch (lock switch)

(All closed) OFF (Any one open) ON (All closed) OFF LOCK

Lock/unlock signal by keyless entry

OFF UNLOCK 100 % 65 %

Room lamp brightness 0%

15 seconds

15 seconds

15 seconds AC300453 AD


54B-9

GENERAL INFORMATION

When the interior lamp switch is on the door position, By removing the ignition key with all doors and the ETACS-ECU controls the interior lamp lights as tailgate closed, the lamp turns ON 100%, and follows. turns off after 15 seconds. 1. When the ignition switch is OFF: By inserting the ignition key again or operating the By opening any door or tailgate lamps, the lamp door lock with the lamp lit, the lamps turns off. turns ON (100%), and dims (65%) when the door 4. Keyless entry room lamp answer back : seconds. The room lamp blinks two times while locking the However, when the ignition switch is turned ON or door for easy checking the keyless entry function. the door lock is operated, the lamps turn off at When the door is unlocked, the lamp lights on for that time. 15 seconds (100%), and turns off. 2. When the ignition switch is ON: NOTE: For the vehicles with the keyless entry By opening any door or tailgate lamps, the lamp system, the delayed interior lamp turning off duration (100%) turns ON and OFF when the door or tail and the operation times of the keyless entry interior gate is closed. lamp answer back can be changed by the adjusting 3. When all doors and the tailgate are closed, and function. the ignition key is removed : Interior lamp automatic-shutdown function (the initial condition: with function) ON Ignition switch

ACC OFF

Door switch

(Any one open) ON (All closed) OFF

Interior lamp

(Illuminated) ON (Extinguished) OFF

T T: 30 minutes t: Within 30 minutes

When the interior lamp such as the room lamp [all interior lamps connecting to the room lamp fuse (the front room lamp, the map lamp, the rear room lamp, and the ignition key cylinder illumination lamps)] is lit, but either one of the conditions is met, the interior lamp is turned off automatically for preventing the battery discharge caused by the unattended operation or the door-ajar. After 30 minutes with the interior lamp lit while the ignition switch is OFF, the lamp turns off automatically. After 30 minutes with any door opened while the ignition switch is OFF, the lamp turns off automatically.

T

t

t

t AC212552 AB

After auto-turn off function, the interior lamp turns ON when any of the following condition is met. Open and close doors. Operate the keyless entry transmitter. Turn the ignition switch to ACC or ON. NOTE: . 1. The interior lamp automatic-shutdown function can be disabled or enabled by the adjusting function. 2. After relighting, the lamp turns off after 30 minutes, when the interior lamp automaticshutdown function is met.

54B-10

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR GENERAL INFORMATION

Ignition key cylinder illumination lamp control function Ignition switch (IG)

Key reminder switch

Driver's seat door switch

Ignition key cylinder illumination lamp output

ON OFF (Key removed) ON (Key inserted) OFF (Opened) ON (Closed) OFF (Illuminated) ON

T

(Extinguished) OFF

T: 30 seconds

T

The ignition key cylinder illumination lamp lights for 30 seconds when the driver’s door is opened/closed with the ignition switch OFF. Also when the ignition key is removed from the ignition key cylinder, the lamp lights for 30 seconds. In any cases, the ignition key cylinder illumination lamp turns ON when the ignition switch is turned to ON.

T

T

T

T

T AC212553AB

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR SPECIAL TOOLS

54B-11


Tool

Number

Name

Use

MB991502

MUT-II sub assembly

Check the SWS (The MUT-II displays diagnosis codes and input signals)

MB991529

Diagnosis code check Input signal check by using a harness voltmeter

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set A: Check harness B: LED harness C: LED harness adapter D: Probe

B991502

MB991529

A

B

C

D MB991223 AC

Continuity check and voltage measurement at harness wire or connector A: For checking connector pin contact pressure B: For checking power supply circuit C: For checking power supply circuit D: For connecting a locally sourced tester

54B-12

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR TROUBLESHOOTING

TROUBLESHOOTING PRIOR TO TROUBLESHOOTING M1549014700312

Before carrying out troubleshooting, check the following two items. Make sure that the ETACS-ECU, the junction block (J/B), the front-ECU and the engine compartment relay box are connected securely. Check that the system fuses and fusible links are not burned out.

STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING M1549000500478

Refer to GROUP 00 - How to Use Troubleshooting/ Inspection Service Points 300.

DIAGNOSTIC FUNCTION M1549028900063

How to read diagnosis code Use the MUT-II to read diagnosis code (Refer to GROUP 00 - How to Use Troubleshooting/ Inspection Service Points 300.)

NOTE: Connect the MUT-II to the 16-pin diagnosis connector (black). NOTE: A diagnosis code can not be read when the ETACS-ECU is defective or the power supply voltage has risen. In this case, refer to inspection procedure A-1 "Communication with the MUT-II is not possible 354B."

How to check input signals 1. Use the MUT-II or a voltmeter to check input signals (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points 300 .) 2. The input signals below can be checked by connecting the MUT-II or a voltmeter to the diagnosis connector. NOTE: If a fault is found at the input signal check, refer to trouble symptom chart 354B.

Switches which are applicable to input signal check, and their check conditions Input signals

Requirements for sounding buzzer

Ignition switch (ACC)

When turned from the LOCK (OFF) position to the ACC position

Ignition switch (IG1)

When turned from ACC to ON

Back-up lamp switch

When the ignition switch is turned ON and the shift lever is moved to the R position.

Key reminder switch

When the inserted ignition key is pulled out

Hazard warning lamp switch

When the switch is turned from off to on

Front fog lamp switch Rear fog lamp switch Driver’s door switch

When the driver’s door is opened

All of the door switches

A door is opened when all the doors are closed

Driver’s door lock actuator

When the driver’s key cylinder or inside lock knob is unlocked or locked

Passenger’s door lock key cylinder switch

Turn the key to the lock or unlock position




54B-13

DIAGNOSIS CODE CHART

Input signals Column switch

Requirements for sounding buzzer Tail lamp switch

When the lighting switch is moved from the automatic lamp position to the tail lamp position.

Headlamp switch

When the lighting switch is moved from the tail lamp position to the automatic lamp position.

Dimmer switch


Passing lamp switch Turn-signal lamp switch (LH) Turn-signal lamp switch (RH) Wind shield mist wiper switch Headlamp washer switch Windshield intermittent wiper switch Windshield low-speed wiper switch Windshield high-speed wiper switch Windshield intermittent wiper volume

When the windshield intermittent wiper volume is rotated from "FAST" to "SLOW" (a pulse is sent around the volume middle position)

Windshield washer switch


Rear wiper switch Rear washer switch Keyless entry transmitter

Switches

Interior lamp loaded signal

When the switch is turned from off to on When a load is applied through multi-purpose fuse No.18

DIAGNOSIS CODE CHART M1549000700234

Code No.

Diagnosis Details

Reference page

11

Trouble related to the ETACS-ECU

354B

12

Trouble related to the column switch or improper connection to the ETACS-ECU

354B

13

Trouble related to the front-ECU or improper connection to the ETACS- 354B ECU

21

Short circuit in SWS communication line

354B

31

Open circuit in the signal line between the SRS-ECU and the ETACSECU (impact detection signal)

354B

32

Short circuit in the signal line between the SRS-ECU and the ETACSECU (impact detection signal)

54B-14

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR DIAGNOSTIC TROUBLE CODE PROCEDURES


Diagnosis code 11: Trouble related to the ETACS-ECU DIAGNOSIS CODE SET CONDITIONS The ETACS-ECU monitors the data, which the ECU itself sends. If errors occur consecutively 15 times (for 0.6 seconds), a diagnosis code will be set. Then, if the data does not contain any errors consecutively 15 times (for 0.6 seconds), the ECU will stop sending the diagnosis code. Possible causes Malfunction of the ETACS-ECU

DIAGNOSTIC PROCEDURE Check whether the diagnosis code is reset. (1) Erase the diagnosis code. (2) Again check that diagnosis code No.11 is set. Q: Is diagnosis code No.11 set? YES : Replace the ETACS-ECU. NO : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300).


54B-15

Diagnosis code 12: Trouble related to the column switch or improper connection with the ETACS-ECU

CAUTION Whenever the ECU is replaced, ensure that the power supply circuit, the earthing circuit and the communication circuit are normal. Column Switch Power Supply and SWS Communication Circuit IGNITION SWITCH (IG1)

FUSIBLE LINK 1

COLUMN-ECU

ETACS-ECU

COLUMN SWITCH


DIAGNOSIS CODE SET CONDITIONS If the column switch ignores the data request signal sent by the ETACS-ECU (three times or more for one second), this diagnosis code will be set. Then, when the column switch observes the request signal for one second, the ECU will stop sending the diagnosis code. Possible causes Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

Wire colour code B : Black LG : Light green G : Green L: Blue W : White Y: Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

DIAGNOSTIC PROCEDURE Step 1. Use the MUT-II to confirm a diagnosis code. (1) Ignition switch: ON (2) On completion, check that diagnosis code No.12 is not reset. Q: Is diagnosis code No.12 set? YES : Go to Step 5. NO : Go to Step 2.

54B-16


Step 2. Connector check: C-310 column switch connector Connector: C-310

Step 3. Measure the voltage at C-310 column switch connector. Connector: C-310

Harness side

Harness side

5 4 3 2 1 10 9 8 7 6

5 4 3 2 1 10 9 8 7 6

AC301399 AC

Q: Is the check result normal? YES : Go to Step 3. NO : Repair the defective connector.

AC301399 AC

(1) Remove the column switch, and measure at the wiring harness side.

Connector C-310 (Harness side)

5 4 3 2 1 10 9 8 7 6 AC301541BD

(2) Voltage between C-310 column switch connector terminal No.1 and body earth OK: System voltage Q: Is the check result normal? YES : Replace the column switch. NO : Go to Step 4.

Step 4. Check the wiring harness between C-310 column switch connector terminal No.1 and the battery. Connector: C-310

Harness side 5 4 3 2 1 10 9 8 7 6

AC301399 AC


54B-17


Q: Is the check result normal? YES : The trouble can be an intermittent


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness.

C-02

Step 5. Measure the resistance at the C-310 column switch connector. Connector: C-310 C-116 C-02 Harness side

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 2324 25 2627 28 2930 3132 33

5 4 3 2 1 10 9 8 7 6

C-116 1 2

5 6 7

3 4

AC301399 AC

8 9

10 1112 1314

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

1617 18 19 20 21

(1) Remove the column switch, and measure at the wiring harness side.

AC301396 AM


Connectors: C-202, C-204 Junction block (Front view) C-204(B) C-202

5 4 3 2 1 10 9 8 7 6 AC301541BE

(2) Resistance between C-310 column switch connector terminal No.4 and body earth OK: 2 W or less

Harness side C-202 6 5 4 3 2 1 14 13 12 11 10 9 8 7

C-204 1

AC210475 AL

Prior to the wiring harness inspection, check junction block connectors C-202, C-204, intermediate connector C-116 and joint connector C-02, and repair if necessary. Check the power supply line for open circuit.



54B-18


Step 6. Check the wiring harness between C-310 column switch connector terminal No.4 and the body earth. Connector: C-310

Step 8. Check the wiring harness from C-219 ETACS-ECU connector terminal Nos. 59 and 68 to C-310 column switch connector terminal Nos. 3 and 2. Connector: C-219 Junction block (Rear view)

Harness side

Harness side

5 4 3 2 1 10 9 8 7 6

C-219(GR)

AC301399 AC

Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

Connector: C-310

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Harness side

Step 7. Connector check: C-219 ETACS-ECU connector

5 4 3 2 1 10 9 8 7 6

Connector: C-219 Junction block (Rear view)

AC301399 AC


Harness side C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

AC301395 AC

Prior to the wiring harness inspection, check joint connector C-02, and repair if necessary. Check the communication lines for open circuit. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.


Step 9. Check whether the diagnosis code is reset. Replace the column switch, and then check that the diagnosis code is not reset. (1) Replace the column switch. (2) Ignition switch: ON (3) On completion, check that diagnosis code No.12 is not reset. Q: Is diagnosis code No.12 set? YES : Replace the ETACS-ECU. NO : The procedure is complete.

54B-19


54B-20


Diagnosis code 13: Trouble related to the front-ECU or improper connection with the ETACS-ECU

CAUTION Whenever the ECU is replaced, ensure that the power supply circuit, the earthing circuit and the communication circuit are normal. Front-ECU Power Supply and SWS Communication Circuit IGNITION SWITCH (IG2)

RELAY BOX (FUSE 22 )

FRONT-ECU POWER SOURCE

DIAGNOSIS CONNECTOR

ETACS-ECU

FRONT SIDE


DIAGNOSIS CODE SET CONDITIONS If the front-ECU has sent abnormal signal to the ETACS-ECU for consecutively 15 communication cycles (0.6 second), the diagnosis code will be set. If the front-ECU has sent normal signal to the ETACS-

SB : Sky blue

ECU for consecutively 15 communication cycles (0.6 second), the ETACS-ECU will stop sending the diagnosis code.


54B-21


Possible causes Malfunction of the front-ECU Malfunction of the ETACS-ECU Damaged harness wires and connectors

Step 3. Measure the voltage at A-11X front-ECU connector. Connector: A-11X

DIAGNOSTIC PROCEDURE Step 1. Use the MUT-II to confirm a diagnosis code. (1) Ignition switch: ON (2) On completion, check that diagnosis code No.13 is not reset. Q: Is diagnosis code No.13 set? YES : Go to Step 5. NO : Go to Step 2. Relay box side

Step 2. Connector check: A-11X front-ECU connector

11 10 9 8 7 6 5 4 3 2 1

Connector: A-11X

AC301483 AD

(1) Remove the front-ECU, and measure at the relay box side.

Connector A-11X (Relay box side) 11 10 9 8 7 6 5 4 3 2 1

Relay box side 11 10 9 8 7 6 5 4 3 2 1

AC301541AF

AC301483 AD


(2) Voltage between A-11X front-ECU connector terminal No.5 and body earth OK: System voltage Q: Is the check result normal? YES : Replace the front-ECU. NO : Go to Step 4.


54B-22


Step 4. Check the wiring harness between A-11X front-ECU connector terminal No.5 and the battery.

Step 5. Connector check: A-12X front-ECU connector Connector: A-12X

Connector: A-11X

Relay box side Relay box side 3130 29 2827 26 25 24 2322 21 11 10 9 8 7 6 5 4 3 2 1

AC301483 AE AC301483 AD

Check the power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent




54B-23


Step 6. Measure the resistance at A-12X frontECU connector. Connector: A-12X

Step 7. Check the wiring harness between A-12X front-ECU connector terminal No.21 and the body earth. Connector: A-12X

Relay box side Relay box side 3130 29 2827 26 25 24 2322 21 3130 29 2827 26 25 24 2322 21

AC301483 AE


AC301483 AE



Connector A-12X (Relay box side) 31 30 29 2827 26 25 24 2322 21

Step 8. Connector check: C-219 ETACS-ECU connector AC301541AG


(2) Resistance between A-12X front-ECU connector terminal No.21 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 7.


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE



54B-24


Step 9. Check the wiring harness between C-219 ETACS-ECU connector terminal No.59 and A-12X front-ECU connector terminal No.30.


Connector: A-12X

C-02

C-116 C-02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 2324 25 2627 28 2930 3132 33

C-116 Relay box side

1 2

3130 29 2827 26 25 24 2322 21

5 6 7

3 4

8 9

10 1112 1314

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

1617 18 19 20 21

AC301396 AM

AC301483 AE


Q: Is the check result normal? YES : Go to Step 10. NO : Repair the wiring harness. Harness side

C-219(GR)

Prior to the wiring harness inspection, check joint connector C-02 and intermediate connector C-116, and repair if necessary. Check the communication lines for open circuit.

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE

Step 10. Check whether the diagnosis code is reset. Replace the column switch, and then check that the diagnosis code is not reset. (1) Replace the column switch. (2) Ignition switch: ON (3) On completion, check that diagnosis code No.13 is not reset. Q: Is diagnosis code No.13 set? YES : Replace the ETACS-ECU. NO : The procedure is complete.


54B-25

Diagnosis code 21: Short circuit in SWS communication line

CAUTION Whenever the ECU is replaced, ensure that the communication circuit is normal. SWS Communication Line FRONT-ECU

COLUMN-ECU

COLUMN SWITCH

ETACS-ECU

CPU

POWER WINDOW MAIN SWITCH


DIAGNOSIS CODE SET CONDITIONS If the SWS communication line voltage is kept at low level for 0.3 second, the diagnosis code will be set. If the ETACS-ECU data line voltage is kept at high level for 0.3 second, or the ETACS-ECU has received normal signal from the other ECUs or switches, the ETACS-ECU will stop sending the diagnosis code. While this code is set, the other codes will not be set.

SB : Sky blue

Possible causes Malfunction of the column switch Malfunction of the front-ECU Malfunction of the power window main switch Malfunction of the ETACS-ECU Damaged harness wires and connectors


54B-26


DIAGNOSTIC PROCEDURE

Connector: E-05

Step 1. Connector check: A-11X front-ECU connector, C-203 column switch connector, C219 ETACS-ECU connector and E-05 power window main switch connector

Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

Connector: A-11X

AC301418 AC


Relay box side 11 10 9 8 7 6 5 4 3 2 1

AC301483 AD

Connector: C-203 Junction block (Front view)

Harness side 2 1 6 5 4 3

AC210474 AC



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE


54B-27


Step 2. Check the wiring harness from each of A12X front-ECU connector terminal No.30, C-310 column switch connector terminal No.3 and E-05 power window main switch connector terminal No.4 to C-219 ETACS-ECU connector terminal No.59.

Connectors: C-218, C-219 Junction block (Rear view)

C-218

Connector: A-11X

C-219(GR)

Harness side C-218 1 2 3 4 5

C-219 59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

Relay box side AC210477AD 11 10 9 8 7 6 5 4 3 2 1

Connector: E-05

AC301483 AD

Harness side


6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC


AC210474 AC


54B-28


NOTE:

Step 3. Check the wiring harness between C-310 column switch connector terminal No.2 and C219 ETACS-ECU connector terminal No.68.

Connectors: C-02, C-116


C-02

Harness side C-116

C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

C-02

AC210476 AE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 2324 25 2627 28 2930 3132 33

Connector: C-310

C-116 1 2

5 6 7

3 4

8 9

10 1112 1314

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

1617 18 19 20 21

Harness side AC301396 AM

Prior to the wiring harness inspection, check joint connector C-02, intermediate connectors C-116 and C-218, and repair if necessary. Check the communication lines for open circuit. Q: Is the check result normal? YES : Go to Step 3. NO : Repair the wiring harness.

5 4 3 2 1 10 9 8 7 6

AC301399 AC

Check the communication lines for open circuit. Q: Is the check result normal? YES : Go to Step 4. NO : Repair the wiring harness.

Step 4. Check whether the diagnosis code is reset. When A-11X front-ECU connector is disconnected, check that diagnosis code No.21 is not reset. However, diagnosis code No.13 will be set at this time. Q: Is diagnosis code No.21 set? YES : Replace the front-ECU. NO : Go to Step 5.

Step 5. Check whether the diagnosis code is reset. When E-05 power window main switch connector is disconnected, check that diagnosis code No.21 is not reset. Q: Is diagnosis code No.21 set? YES : Replace the power window main switch. NO : Go to Step 6.


54B-29

Step 6. Check that the hazard warning lamps illuminate. When the ignition switch is turned to the LOCK (OFF) position, check if the hazard warning lamps illuminate. Q: Is the check result normal? YES : Refer to diagnosis code No.12 "Column

switch fault or improper connection 354B ." NO : Refer to inspection procedure A-2 "Check the ETACS-ECU battery power supply circuit 354B."

Diagnosis code 31: Open circuit in signal line between the SRS-ECU and the ETACS-ECU (impact detection signal) Diagnosis code 32: Short circuit in signal line between the SRS-ECU and the ETACS-ECU (impact detection signal)

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal.

ETACS-ECU

SRS-ECU IMPACT-DEPENDENT DOOR UNLOCK SIGNAL PROCESSING CIRCUIT

Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

DIAGNOSIS CODE SET CONDITIONS If the voltage in the signal line between the SRSECU and the ETACS-ECU has exceeded 4.6 V for 40 milliseconds or more, the ETACS-ECU will set diagnosis code No.31 as an open circuit. If the signal line voltage has reached 1.5 V or less for at least 2.5 seconds, the ETACS-ECU will set diagnosis code

No.32 as a short circuit. If the ignition switch is turned off, the ETACS-ECU will stop sending the diagnosis code. Possible causes Malfunction of the SRS-ECU Malfunction of the ETACS-ECU Damaged harness wires and connectors


54B-30



Step 3. Measure the resistance at the C-115 SRSECU connector.

Step 1. Use the MUT-II to confirm a diagnosis code. Check that the SRS-ECU sets a diagnosis code. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to GROUP 52B - Troubleshooting

313A. Step 2. Connector check: C-115 SRS-ECU connector and C-220 ETACS-ECU connector Connector: C-115

Connector: C-115 Harness side 2 1 4 3 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

C-115(Y)

AC301397AH

(1) Disconnect the connector, and measure at the wiring harness side.

Harness side


2 1 4 3 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

2 1 4 3 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

C-115(Y)

AC301397AH


AC301541 AQ

(2) Resistance between C-115 SRS-ECU connector terminal No.15 and body earth OK: 2 W or less Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

AC210476 AF



Step 4. Check the wiring harness between C-115 SRS-ECU connector terminal No.15 and body earth. Connector: C-115 Harness side 4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

C-115(Y)

AC301397AH




54B-31

TROUBLE SYMPTOM CHART

Step 5. Check the wiring harness between C-220 ETACS-ECU connector terminal No.29 and C-115 SRS-ECU connector terminal No.14. Connector C-115 (Harness side) 2 1 4 3 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

Step 6. Check whether the diagnosis code is reset. Replace the ETACS-ECU, and then check that the diagnosis code is not reset. (1) Replace the ETACS-ECU. (2) Ignition switch: ON (3) Check that diagnosis code No.31 or 32 is not reset. Q: Is diagnosis code No.31 or 32 set? YES : Replace the SRS-ECU. NO : The procedure is complete.

AC301541 AQ


Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

AC210476 AF


TROUBLE SYMPTOM CHART M1549000800576

Symptom

Inspection procedure number

Reference page

Communication with the MUT-II is not possible.

A-1

354B

When the ignition switch is at the LOCK (OFF) position, the functions do A-2 not work normally.

354B

Check the battery power supply circuit to the ETACS-ECU.

Symptom


Reference page

Alarm Function

Lamp reminder buzzer function does not work normally.

B-1

354B

Central door locking

Central door locking system does not work. C-1

354B

A door can not be locked or unlocked by the central door locking system.

354B

C-2

54B-32

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR TROUBLE SYMPTOM CHART

Symptom

Power window

Keyless entry system

Windshield wiper and washer


Reference page

Power windows do not work at all.

D-1

354B

Driver’s power window does not work by means of the power window main switch.

D-2

354B

Relevant power window(s) do not work by means of the front and rear passenger’s power window sub switches.

D-3

354B

Front and/or rear passenger’s power window(s) do not work by means of the power window main switch.

D-4

354B

Power window anti-trap function does not work normally.

D-5

354B

Power windows lowers automatically while D-6 it is rising.

354B

Keyless entry system does not work.

E-1

354B

Keyless entry hazard warning lamp answerback function or the room lamp answerback function does not work normally.

E-2

354B

Encrypted code cannot be registered.

E-3

354B

The timer lock function does not work after E-4 the doors have been unlocked by the keyless entry system.

354B

The windshield wipers do not work at all.

F-1

354B

The windshield wipers do not work when F-2 the wiper switch is at "INT", "Washer" or "Mist" position. However, the wipers work at low speed when the switch is at "Lo" and "Hi" position.

354B

The windshield wipers do not stop at the specified park position.

F-3

354B

The windshield wipers do not work normally.

F-4

354B

The intermittent wiper interval cannot be adjusted by operating the windshield intermittent wiper volume control.

F-5

354B

The intermittent wiper interval is not changed according to the vehicle speed.

F-6

354B

The windshield washer does not work.

F-7

354B

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR TROUBLE SYMPTOM CHART

Symptom

54B-33


Reference page

Rear wiper does no not work at all.

G-1

354B

The rear wiper does not stop at the specified park position.

G-2

354B

When the shift lever is moved to "R" position during the rear wiper operation, the rear wiper does not operate at the continuous mode.

G-3

354B

The rear washer does not work.

G-4

354B

Headlamp washer

The headlamp washer does not work.

H-1

354B

Ignition key cylinder illumination lamp

The ignition key cylinder illumination lamp does not illuminate/extinguish normally.

I-1

354B

Headlamp and tail lamp

The tail lamps do not illuminate normally.

J-1

354B

The low-beam headlamps do not illuminate J-2 normally.

354B

The high-beam headlamps do not illuminate normally.

J-3

354B

The high-beam and low-beam headlamps do not illuminate when the passing switch is operated.

J-4

354B

The headlamp automatic shutdown function does not work normally.

J-5

354B

Any of tail lamps, position lamps or licence J-6 plate lamp does not illuminate.

354B

The headlamp(s) do not illuminate.

J-7

354B

The turn-signal lamps do not illuminate.

K-1

354B

The hazard warning lamps do not illuminate.

K-2

354B

Any of the turn-signal lamps does not illuminate.

K-3

354B

The front fog lamps do not illuminate normally.

L-1

354B

The rear front fog lamps do not illuminate normally.

L-2

354B

Either of the front fog lamps does not illuminate normally.

L-3

354B

Any of the rear fog lamps does not illuminate.

L-4

354B

Rear wiper and washer

Flasher timer

Fog lamp

54B-34

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK

Symptom

Interior lamp


Reference page

The front or rear room lamp does not M-1 illuminate or extinguish normally.

354B


354B

Interior lamp automatic shutoff function does not work normally.

M-3

354B

The door-ajar warning lamp does not illuminate/extinguish normally.

M-4

354B

CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK M1549024200125

If a problem is found in the Service Data inspection, observe the table below. Symptom


Reference page

The ignition switch (ACC) signal is not received.

N-1

354B

The ignition switch (IG1) signal is not received.

N-2

354B

The back-up lamp switch signal is not received.

N-3

354B

The driver’s door switch signal is not received.

N-4

354B

Column switch (lighting and turnsignal lamp switch)

N-5

354B

The tail lamp switch signal is not received. The headlamp switch signal is not received. The dimmer switch signal is not received. The passing switch signal is not received. The turn-signal lamp switch (LH) signal is not received. The turn-signal lamp switch (RH) signal is not received. The headlamp washer switch signal is not received.

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK

Symptom

Column switch (windshield wiper/ washer and rear wiper washer switch)

54B-35


Reference page

N-6

354B

N-7

354B

When the power window main switch N-8 is operated, the switch signals are not received.

354B

The windshield mist wiper switch signal is not received. The windshield intermittent wiper switch signal is not received. The windshield low-speed wiper switch signal is not received. The windshield high-speed wiper switch signal is not received. The windshield washer switch signal is not received. The rear wiper switch signal is not received. The rear washer switch signal is not received. The windshield intermittent wiper volume signal is not received.


The key reminder switch signal is not received.

N-9

354B

The hazard warning lamp switch signal is not received.

N-10

354B

All the door switch signals are not received.

N-11

354B

The driver’s door lock actuator switch signal is not received.

N-12

354B

The vehicle speed signal is not received.

N-13

354B

Each switch signal of the keyless entry transmitter is not received.

N-14

354B

The front fog lamp switch signal is not received.

N-15

354B

The rear fog lamp switch signal is not received.

N-16

354B

The interior lamp loaded signal is not detected.

N-17

354B

The passenger’s door lock key cylinder switch signal is not detected.

N-18

354B

54B-36

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION

OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION PROCEDURES M1549020300175

If troubles have occurred in the functions which use the SWS simultaneously, observe the table below to check input signals. (This table shows only the input signals which will cause troubles in at least two functions simultaneously). Function

N-1

N-2

N-4

N-5

N-6

N-9

N-11

N-12

N-13

N-17

Lamp reminder function

-

-

-

-

-

-

-

Control of central door locking

-

-

-

-

-

-

-

-

-


-

-

-

-

-

-

-

Door locking released due to impact detection.

-

-

-

-

-

-

-

-

-


-

-

-

-

-

-

Keyless entry hazard warning lamp answerback

-

-

-

-

-

-

-

-

-

-

Power window control

-

-

-

-

-

-

-

-

-

Control of windshield wiper washer

-

-

-

-

-

-

-

Rear wiper washer control

-

-

-

-

-

-

-

-

Ignition key cylinder illumination lamp function

-

-

-

-

-

-

Headlamp control

-

-

-

-

-

-

-

-

Tail lamp control

-

-

-

-

-

-

-

-

Headlamp automatic shutdown function

-

-

-

-

-

-

-

Fog lamp control

-

-

-

-

-

-

-

-

-

Turn-signal lamp control

-

-

-

-

-

-

-

-

Dome lamp control

-

-

-

-

Interior lamp automatic shutdown function

-

-

-

-

-

-

-

-

Door-ajar indicator lamp

-

-

-

-

-

-

-

-

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR SYMPTOM PROCEDURES

54B-37

SYMPTOM PROCEDURES

INSPECTION PROCEDURE A-1: No communication with MUT-II

CAUTION Whenever the ECU is replaced, ensure that the power supply circuit, the earthing circuit and the communication circuit are normal. MUT-II Communication and ETACS-ECU Earth Circuit

ETACSECU

DIAGNOSIS CONNECTOR Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

COMMENTS ON TROUBLE SYMPTOM It is suspected that the power supply circuit to the ETACS-ECU is defective, or the wiring harness between the diagnosis connector and the ETACSECU or their connector(s) is damaged. NOTE: If the wiring harness between the ETACSECU and body earth is defective, also check C-217 ETACS-ECU connector terminal No.3, and repair if necessary. Possible causes Malfunction of the ETACS-ECU Damaged harness wires and connectors

FRONT SIDE


DIAGNOSTIC PROCEDURE Step 1. Check that the MUT-II communicates with the other systems. Use the MUT-II to confirm that it communicates with the engine-ECU. Q: Is the check result normal? YES : Go to Step 2. NO : Diagnose the engine control system by

referring to 313A.

54B-38


Step 2. Check that the MUT-II can communicate with the system. When the ignition switch is turned ON, check if the MUT-II can communicate with the system.

Step 4. Measure the resistance at the C-219 ETACS-ECU connector. Connector: C-219 Junction block (Rear view)

Q: Is the check result normal? YES : Refer to inspection procedure A-2 "Check

the ETACS-ECU battery power supply circuit" 354B. NO : Go to Step 3.



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE

(1) Disconnect the connector, and measure at the junction block side.



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

Connector C-219 (Harness side) AC301541AY

(2) Resistance between C-219 ETACS-ECU connector terminal No.56 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.

Step 5. Check the wiring harness between C-219 ETACS-ECU connector terminal No.56 and body earth. Connector: C-219 Junction block (Rear view)


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE




54B-39

SYMPTOM PROCEDURES

Step 6. Connector check: C-24 diagnosis connector Connector: C-24

Step 7. Check the wiring harness from C-219 ETACS-ECU connector terminal Nos. 51 and 67 to C-24 diagnosis connector terminal Nos. 9 and 1. Connector: C-24

Harness side 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Harness side C-24(B)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

AC301395 AF

C-24(B) AC301395 AF




59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


Step 8. Retest the system. Check whether the communication with the MUT-II is possible. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the ETACS-ECU.


54B-40

SYMPTOM PROCEDURES

INSPECTION PROCEDURE A-2: When the ignition switch is at the LOCK (OFF) position, the functions do not work normally. Check the battery power supply circuit to the ETACS-ECU.

CAUTION Whenever the ECU is replaced, ensure that the power supply circuit and the earthing circuit are normal.

FUSIBLE LINK 1

ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM If this circuit is defective and the ignition switch is at the LOCK (OFF) position, the ETACS-ECU does not work. In this case, the functions below will be suspended. Lamp reminder function Keyless entry system Ignition key cylinder illumination lamp Headlamp automatic shutdown function However, when the ignition switch is at the ON position, the functions below will work. Reading diagnosis code and checking input signal by MUT-II. Central door locking Headlamp and tail lamp Hazard warning lamp Room lamps Possible causes Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Connector check: C-217 ETACS-ECU connector Connector: C-217 Junction block (Rear view)

Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC



54B-41

SYMPTOM PROCEDURES

Step 2. Measure the voltage at the C-217 ETACSECU connector. Connector: C-217 Junction block (Rear view)

Step 3. Check the wiring harness between C-217 ETACS-ECU connector terminal No.20 and fusible link (1). Connector: C-217 Junction block (Rear view)

Junction block side Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

(1) Remove the ETACS-ECU, and measure at the junction block side.

AC210476 AC


Connector C-217 (Junction block side) 2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

AC301541AS

(2) Voltage between C-217 ETACS-ECU connector terminal No.20 and body earth. OK: System voltage

Connector: C-204 Junction block (Front view) C-204(B)

Q: Is the check result normal? YES : Go to Step 4. NO : Go to Step 3. Harness side 1 AC210474 AD

Prior to the wiring harness inspection, check intermediate connector C-116 and junction block connector C-204, and repair if necessary. Check the power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-42


Step 4. Measure the resistance at the C-217 ETACS-ECU connector. Connector: C-217 Junction block (Rear view)



20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC


AC210476 AC

NOTE: Connector: C-205 Junction block (Front view)

Connector C-217 (Junction block side) 2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC301541AT

(2) Continuity between C-217 ETACS-ECU connector terminal No.3 and body earth. OK: 2W or less Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.

AC210474 AE

Prior to the wiring harness inspection, check junction block connector C-205, and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 6. Retest the system. Check that the battery power supply circuit to the ETACS-ECU is normal. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-43

TONE ALARM

INSPECTION PROCEDURE B-1: Lamp reminder buzzer function does not work normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Lamp Reminder Tone Alarm Function

ETACS-ECU

INPUT SIGNAL · DRIVER'S DOOR SWITCH · HEADLAMP SWITCH · IGNITION SWITCH (IG1) · TAIL LAMP SWITCH

COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Driver’s door switch Tail lamp switch Headlamp switch If this function does not work normally, these input signal circuit(s) or the ETACS-ECU may be defective. Possible causes Malfunction of the driver’s door switch Malfunction of the column switch Malfunction of the ETACS-ECU

Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Check the power supply circuit. When the ignition switch is turned to the LOCK (OFF) position, check if the hazard warning lamps illuminate. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure A-2 "Check

the ETACS-ECU battery power supply circuit 354B."

54B-44


Step 2. Pulse check Check the input signals below, which are related to the lamp reminder buzzer function. System switch

Check conditions



Driver’s door switch


Tail lamp switch

When the lighting switch is turned to the TAIL position

Headlamp switch

When the lighting switch is turned to the HEADLAMP position

OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? All the signals are received normally. : Go to Step

3. The ignition switch (IG1) signal is not received. :

Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354B." The driver’s door switch signal is not received. :

Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354B." The tail lamp switch signal is not received. : Refer to inspection procedure N-5 "The column switch (lighting and turn-signal lamp switch) signal is not received 354B." The headlamp switch signal is not received. :

Refer to inspection procedure N-5 "The column switch (lighting and turn-signal lamp switch) signal is not received 354B."

Step 3. Retest the system. The lamp reminder buzzer function should work normally. Q: Is the check result normal? YES : The trouble can be an intermittent



CENTRAL DOOR LOCKING SYSTEM

INSPECTION PROCEDURE C-1: Central Door Locking System does not Work.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal.

Central Door Lock Power Supply Circuit FUSIBLE LINK 1

ETACS-ECU DOOR UNLOCK RELAY

DOOR LOCK RELAY

FRONT DOOR LOCK ACTUATOR (LH)


SB : Sky blue

54B-45

54B-46


COMMENT ON TROUBLE SYMPTOM If the central door locking system does not work at all, the front door lock actuator (LH) or the ETACSECU may be defective. POSSIBLE CAUSES Malfunction of the front door lock actuator (LH) Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the power supply circuit. When the ignition switch is turned to the LOCK (OFF) position, check if the hazard warning lamps illuminate. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure A-2 "Check

the ETACS-ECU battery power supply circuit" 354B. Step 2. Pulse check Check the input signal from the driver’s door lock actuator switch. System switch

Check conditions

Driver’s door lock actuator switch


Step 3. Connector check: E-11 front door lock actuator (LH) connector Connector: E-11

E-11(B) Harness side 3 2 1 6 5 4

AC301418 AD


Step 4. Check the front door lock actuator (LH) Check that the front door lock actuator (LH) works normally. Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 5. NO : Replace the front door lock actuator (LH).

Step 5. Connector check: C-217 ETACS-ECU connector Connector: C-217

OK: The MUT-II sound or the voltmeter needle fluctuate. Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure N-12 "The

Junction block (Rear view)

driver’s door lock actuator signal is not received 354B." C-217 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210477 AB



54B-47

SYMPTOM PROCEDURES

Step 6. Check the wiring harness between C-217 ETACS-ECU connector terminal No. 2 and fusible link (1).


Connector: C-217

Junction block (Rear view) C-116

1 2 C-217 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

5 6 7

3 4

8 9

10 11 12 13 14

15

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301396 AB

Connector: C-204 Junction block (Front view) AC210477 AB

C-204(B) Fusible link: No.1

Harness side 1 AC210474 AD

AC301515 AB

Prior to the wiring harness inspection, check intermediate connector C-116 and junction block connector C-204, and repair if necessary. Check the power supply line for open or short circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

Step 7. Retest the system. Check that the central door locking system works normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-48


INSPECTION PROCEDURE C-2: A Door or a Tailgate can not be Locked or Unlocked by the Central Door Locking System.

Central Door Lock Circuit

ETACS-ECU DOOR LOCK RELAY

DOOR UNLOCK RELAY


FRONT DOOR LOCK ACTUATOR (RH)

REAR DOOR LOCK ACTUATOR (LH)

REAR DOOR LOCK ACTUATOR (RH)


TAILGATE LOCK ACTUATOR

SB : Sky blue


54B-49

SYMPTOM PROCEDURES

COMMENT ON TROUBLE SYMPTOM If a door or the tailgate can not be locked or unlocked by the central door locking system, the door lock actuator or the tailgate lock actuator may be defective. POSSIBLE CAUSES Malfunction of the door lock actuator Malfunction of the tailgate lock actuator Damaged harness wires and connectors

Step 3. Check the front door lock actuator (LH) Check that the front door lock actuator (LH) works normally. Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 4. NO : Replace the front door lock actuator (LH).

Step 4. Connector check: C-217, C-220 ETACSECU connector

DIAGNOSIS PROCEDURE


Step 1. Confirm which door lock actuator is defective.

C-217

Q: Which door fails to lock correctly? Driver’s door : Go to Step 2. Front passenger’s door : Go to Step 6. Rear right door : Go to Step 10. Rear left door : Go to Step 14. Tailgate : Go to Step 18.


Junction block (rear view) C-220 C-217 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

C-220 Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

E-11(B) Harness side

AC210477 AF 3 2 1 6 5 4

AC301418 AD




54B-50

SYMPTOM PROCEDURES

Step 5. Check the wiring harness from C-217 ETACS-ECU connector terminal No. 12 and C-220 ETACS-ECU connector No. 22 to E-11 front door lock actuator (LH) connector terminal Nos. 6 and 4.



C-217

C-118

Junction block (rear view) C-220

1 2 3 4 5 6 7 8 9 10 11

C-217 Junction block side

12 13 14 15 16 17 18 19 20 21 22

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

23 24 25 26 27

28 29 30 31 32

C-220 Harness side

AC301396 AE


29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39 AC210477 AF

Connector: E-11

Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE

E-11(B)

Prior to the wiring harness inspection, check intermediate connector C-118 and junction block connector C-205, and repair if necessary. Check the input and output lines for open circuit.


AC301418 AD




54B-51

SYMPTOM PROCEDURES

Step 6. Connector check: E-25 front door lock actuator (RH) connector Connector: E-25

Step 9. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 12 and 13 to E-25 front door lock actuator (RH) connector terminal Nos. 4 and 6. Connector: C-217

E-25 Harness side

E-25(B)

3 2 1 6 5 4 AC301412 AF



Step 7. Check the front door lock actuator (RH). Check that the front door lock actuator (RH) works normally. Refer to GROUP 42 - Door 342.

C-217 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

Q: Is the check result normal? YES : Go to Step 8. NO : Replace the front door lock actuator (RH).


AC210477 AB

Connector: E-25

Connector: C-217

E-25 Harness side

E-25(B)

3 2 1 6 5 4 Junction block (Rear view)


AC210477 AB


AC301412 AF

54B-52


NOTE:

Step 11. Check the rear door lock actuator (RH). Check that the rear door lock actuator (RH) is in good condition. Refer to GROUP 42 - Door 342.

Connector: C-15

Q: Is the check result normal? YES : Go to Step 12. NO : Replace the rear door lock actuator (RH).

2 1 3 4 5 6 10 11 12 7 8 9 13 14 15 16 17 18 19


C-15(GR) AC301397AD

Connector: C-217 Connector: C-205 Junction block (Front view)

Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1


28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE




malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. AC210477 AB

Step 10. Connector check: E-28 rear door lock actuator (RH) connector Connector: E-28

E-28(B) E-28 Harness side

3 2 1 6 5 4 AC301414 AE




54B-53

SYMPTOM PROCEDURES

Step 13. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 12 and 13 to E-28 rear door lock actuator (RH) connector terminal Nos. 2 and 3.


Connector: C-217 Harness side 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210474 AG

Connectors: D-02, D-31


D-02


D-31

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

D-02

1 2 3 4 5 6 7 8 AC210477 AB

D-31

Connector: E-28


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301409 AD

3 2 1 6 5 4 AC301414 AE

Prior to the wiring harness inspection, check D-02, D-31 intermediate connectors and C-209 junction block connector, and repair if necessary. Check the input and output lines for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-54

SYMPTOM PROCEDURES

Step 14. Connector check: E-08 rear door lock actuator (LH) connector Connector: E-08

Step 17. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 12 and 13 to E-08 rear door lock actuator (LH) connector terminal Nos. 3 and 2. Connector: C-217


3 2 1 6 5 4 AC301416 AE



Step 15. Check the rear door lock actuator (LH). Check that the rear door lock actuator (LH) is in good condition. Refer to GROUP 42 - Door 342.


Q: Is the check result normal? YES : Go to Step 16. NO : Replace the rear door lock actuator (LH).


AC210477 AB

Connector: E-08

Connector: C-217




AC210477 AB


3 2 1 6 5 4 AC301416 AE


54B-55

SYMPTOM PROCEDURES

NOTE:

Step 19. Check the tailgate lock actuator. Check that the tailgate lock actuator is in good condition. Refer to GROUP 42 - Tailgate 342.


Q: Is the check result normal? YES : Go to Step 20. NO : Replace the tailgate lock actuator. Harness side 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210474 AG


Connector: D-26 D-26

1 2 3 4 5 6 7 8 Junction block (Rear view) AC301410 AB

Prior to the wiring harness inspection, check D-26 intermediate connectors and C-209 junction block connector, and repair if necessary. Check the input and output lines for open circuit.




Step 18. Connector check: F-06 tailgate lock actuator connector Connector: F-06

F-06 Harness side F-06(B)

3 2 1 6 5 4

AC301665 AE




54B-56

SYMPTOM PROCEDURES

Step 21. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 12 and 13 to F-06 tailgate lock actuator connector terminal Nos. 2 and 3.



12

4 3 2 1 11 10 9 8

AC210474 AG

Prior to the wiring harness inspection, check intermediate connector F-05 and junction block connector C-209, and repair if necessary. Check the input and output lines for open circuit.


Q: Is the check result normal? YES : The trouble can be an intermittent C-217 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210477 AB

Connectors: F-05, F-06

F-06(B) F-05

F-05

1 2 3 4 5 6 7 8 9 10 F-06 Harness side

3 2 1 6 5 4 AC301666 AG



54B-57

INSPECTION PROCEDURE C-3: The central door locking system can not be operated by means of the front passenger’s door lock key cylinder.


Central Door Lock (Front Passenger's Door Lock Key Cyilinder Switch) Circuit FUSIBLE LINK 1



DOOR LOCK RELAY

INPUT SIGNAL FRONT PASSENGER'S DOOR LOCK KEY CYLINDER SWITCH

DOOR LOCK ACTUATOR AND TAILGATE LOCK ACTUATOR

COMMENTS ON TROUBLE SYMPTOM If the central door locking system does not work by means of the front passenger’s door lock key cylinder, the front passenger’s door lock key cylinder or the ETACS-ECU may be defective. Possible causes Malfunction of the front passenger’s door lock key cylinder Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Check the operation of the central door locking system. Check that the central door locking system works normally by means of the driver’s door lock key cylinder and inside lock knob. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure C-1 "Central

door locking system does not work at all 354B."


54B-58

SYMPTOM PROCEDURES

Step 2. Pulse check Check the input signal from the front passenger’s door lock key cylinder switch. System switch

Check conditions

Front passenger’s door lock key cylinder switch



Step 3. Retest the system. Check that the central door locking system works normally by means of the front passenger's door lock key cylinder. Q: Is the check result normal? YES : The trouble can be an intermittent


Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure N-18 "The

front passenger's door lock key cylinder switch signal is not received 354B."

INSPECTION PROCEDURE C-4: The Ignition Key Reminder Function does not Work Normally.


Ignition Key Reminder Function Circuit FUSIBLE LINK 1

ETACS-ECU INPUT SIGNAL DOOR UNLOCK RELAY


DOOR LOCK RELAY

· DRIVER'S DOOR LOCK ACTUCTOR SWITCH · DRIVER'S DOOR SWITCH · KEY REMINDER SWITCH


COMMENTS ON TROUBLE SYMPTOM If the key reminder function does not work normally, the input signal circuits below or the ETACS-ECU may be defective. Key reminder switch Driver's door switch Driver's door lock actuator

POSSIBLE CAUSES Malfunction of the key reminder switch Malfunction of the driver's door switch Malfunction of the driver's door lock actuator Malfunction of the ETACS-ECU Damaged harness wires and connectors



the ETACS-ECU battery power supply circuit" 354B.

54B-59

Step 2. Pulse check Check the input signals below which are related to the key reminder function. System switch

Check conditions



Key reminder switch





3. The driver’s door switch signal is not received. :

Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354B." The key reminder switch signal is not received. :

Refer to inspection procedure N-9 "The key reminder switch signal is not received 354B." The driver’s door lock actuator switch signal is not received. : Refer to inspection procedure N-12

"The driver’s door lock actuator signal is not received 354B. Step 3. Retest the system. Q: Does the ignition key reminder function work normally? YES : The trouble can be an intermittent


INSPECTION PROCEDURE C-5: The impact detection door unlock function does not function.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. COMMENTS ON TROUBLE SYMPTOM If the impact detection door unlock function does not work normally, the input signal circuit from the impact detection sensor, the SRS-ECU or the ETACS-ECU may be defective.

Possible causes Malfunction of the SRS-ECU Malfunction of the ETACS-ECU Damaged harness wires and connectors

54B-60


DIAGNOSTIC PROCEDURE Use the MUT-II to confirm a diagnosis code. Check whether the ETACS-ECU sets diagnosis code No.31 or 32. Q: Is the diagnosis code set? YES : Refer to 354B. NO : Replace the ETACS-ECU.


54B-61

POWER WINDOWS

INSPECTION PROCEDURE D-1: Power windows do not work at all.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Power Window Relay Circuit FUSIBLE LINK 5

ETACS-ECU


POWER WINDOW RELAY

POWER WINDOW SUB SWITCH (FRONT: RH)

CPU

COMMENTS ON TROUBLE SYMPTOM If the power windows do not work at all, the power window relay, the power window main switch or the ETACS-ECU may be defective.

POWER WINDOW SUB SWITCH (REAR: LH)

POWER WINDOW SUB SWITCH (REAR: RH)


Possible causes Malfunction of the power window relay Malfunction of the power window main switch Malfunction of the ETACS-ECU Damaged harness wires and connectors


54B-62

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE Step 1. Pulse check Check the input signal from the ignition switch. System switch

Check conditions



OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure A-2 "When

the ignition switch is at the LOCK (OFF) position, the functions do not work normally. Check the battery power supply circuit to the ETACS-ECU 354B." Step 2. Connector check: C-208 power window relay connector

Q: Is the check result normal? YES : Go to Step 4. NO : Replace the power window relay.

Step 4. Connector check: E-05 power window main switch connector Connector: E-05

E-05 Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301418 AF

Q: Is the check result normal? YES : Go to Step 5. NO : Repair the connector.

Connector: C-208 Junction block (front view)


3 2 1 4 5

AC210475 AD


Step 3. Check the power window relay. Refer to GROUP 42 - Door - On-vehicle Service 342.


54B-63

SYMPTOM PROCEDURES

Step 5. Measure the voltage at the E-05 power window main switch connector. Connector: E-05

Step 6. Check the wiring harness between C-208 power window relay connector terminal No.4 and E-05 power window main switch connector terminal No.6. Connectors: C-203, C-208 Junction block (front view) C-203


C-208

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the ON position.

C-203 Harness side

2 1 6 5 4 3 C-208 Junction block side

6 5 4 3 2 1 14 13 12 11 10 9 8 7 Connector E-05 (Harness side)

3 2 1 4 5 AC210475 AB

AC301469 AB

(3) Voltage between terminal 6 and body earth OK: System voltage

Connectors: E-05, E-12


E-05

E-12

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC


54B-64

SYMPTOM PROCEDURES

NOTE:

Step 7. Measure the voltage at C-208 power window relay connector.

Connector: C-118

Connector: C-208 Junction block (front view)

C-118

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32


3 2 1 4 5

AC301396 AE

Prior to the wiring harness inspection, check intermediate connectors C-118, E-12 and junction block connector C-203, and repair if necessary. Check the power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the harness wire, and then go to Step 7.

AC210475 AD


3 2 1 4 5

Connector C-208 (Junction block side)

AC301459AB

(3) Voltage between terminal 5 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 9. NO : Go to Step 8.


54B-65

SYMPTOM PROCEDURES

Step 8. Check the wiring harness between C-208 power window relay connector terminal No.5 and fusible link (5).

Connector: C-116

Connectors: C-203, C-208 Junction block (front view) C-203

C-208 C-116

1 2

C-203 Harness side


5 6 7

3 4

8 9

10 11 12 13 14

15

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301396 AB

3 2 1 4 5

Check the power supply line for open circuit. AC210475 AB


malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness.

Fusible link: No.5

AC301515 AC

NOTE: Prior to the wiring harness inspection, check intermediate connector C-116 and junction block connector C-203, and repair if necessary.


54B-66

SYMPTOM PROCEDURES

Step 9. Measure the resistance at C-208 power window relay connector. Connector: C-208 Junction block (front view)

Step 10. Check the wiring harness between C-208 power window relay connector terminal No.3 and body earth. Connectors: C-205, C-208 Junction block (front view)

C-205

C-208

C-205 Harness side


14 13 12 11 10 9 8 7 6 5 4 3 2 1

3 2 1 4 5

28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-208 Junction block side AC210475 AD


NOTE: Prior to the wiring harness inspection, check junction block connector C-205, and repair if necessary. Check the earth wires for open circuit.

malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. AC301460AB

(2) Resistance between terminal 3 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 12. NO : Go to Step 10.

AC210475 AC


3 2 1 4 5 Connector C-208 (Junction block side)

3 2 1 4 5


54B-67

SYMPTOM PROCEDURES





C-219 Harness side


59 58 57 56 55 5453 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69

AC210477 AB


AC210477 AC



54B-68

SYMPTOM PROCEDURES

Step 13. Check the wiring harness between C-219 ETACS-ECU connector terminal No.59 and E-05 power window main switch connector terminal No.4.

NOTE: Connectors : C-02, C-118

C-02

Connector: C-219

C-118

Junction block (Rear view) C-02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

C-219 Harness side

C-118 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

59 58 57 56 55 5453 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69

AC210477 AC

28 29 30 31 32

AC301396 AG

Prior to the wiring harness inspection, check intermediate connectors C-118, E-12 and joint connector C-02, and repair if necessary. Check the communication lines for open circuit. Q: Is the check result normal? YES : Go to Step 14. NO : Repair the wiring harness.


E-05

Step 14. Retest the system. After the power window main switch is replaced, check that all the power windows work. (1) Replace the power window main switch. (2) Check that the all the power windows work.

E-12


E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC



54B-69

INSPECTION PROCEDURE D-2: Driver’s power window does not work by means of the power window main switch.

Power Window (front: LH) Circuit

FUSIBLE LINK 5

POWER WINDOW RELAY

ETACS-ECU


FRONT (LH)

POWER WINDOW MOTOR (FRONT: LH)


SB : Sky blue

54B-70


COMMENTS ON TROUBLE SYMPTOM If the driver’s power window does not work by means of the power window main switch, the power window main switch or the driver’s door power window motor may be defective. Possible causes Malfunction of the power window main switch Malfunction of the power window motor (front, LH) Damaged harness wires and connectors

DIAGNOSIS PROCEDURE

STEP 3. Measure the resistance at the E-05 power window main switch connector. Connector: E-05


STEP 1. Check the power window main switch. Check that all of the front passenger’s and rear door power windows can operate by means of the power window main switch. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure D-1 "Power

windows do not work at all 354B." STEP 2. Connector check: E-05 power window main switch connector


6 5 4 3 2 1 14 13 12 11 10 9 8 7 Connector E-05 (Harness Side) AC301468 AB

(2) Resistance between terminal 2 and body earth OK: 2W or less

Connector: E-05

Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4. E-05 Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301418 AF



STEP 4. Check the wiring harness between E-05 power window main switch connector terminal No.2 and body earth. Connectors: E-05, E-12

54B-71


malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 5. Measure the voltage at the E-05 power window main switch connector.

E-05

Connector: E-05 E-12

E-05 Harness side

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

AC301418 AF


AC301419 AC


6 5 4 3 2 1 14 13 12 11 10 9 8 7 Connector E-05 (Harness side)

AC301469 AB

(3) Voltage between terminal 6 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 6. C-118

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32 AC301396 AE

Prior to the wiring harness inspection, check intermediate connectors C-118 and E-12, and repair if necessary. Check the earth wires for open circuit.

54B-72


Step 6. Connector check: C-208 power window relay connector Connector: C-208 Junction block (front view)

Step 7. Check the wiring harness between C-208 power window relay connector terminal No.4 and E-05 power window main switch connector terminal No.6. Connectors: C-203, C-208 Junction block (front view) C-203

C-208


C-203 Harness side

2 1 6 5 4 3

3 2 1 4 5


3 2 1 4 5

AC210475 AD


AC210475 AB


E-05

E-12

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC


54B-73

SYMPTOM PROCEDURES

NOTE:

STEP 9. Check the wiring harness from E-13 power window motor (front LH) connector terminal Nos. 1 and 3 to E-05 power window main switch connector terminal Nos. 7 and 1.

Connector: C-118

Connectors: E-05, E-12, E-13

E-13(GR) E-05 E-12 C-118

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

28 29 30 31 32

E-13 Harness side E-12

AC301396 AE


malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the harness wire, and then go to Step 7. STEP 8. Connector check: E-13 power window motor (front LH) connector Connector: E-13

E-13(GR) E-13 Harness side

3 2 1 6 5 4

AC301419 AD

NOTE: Prior to the wiring harness inspection, check intermediate connector E-12, and repair if necessary. Check the input and output lines for open or short circuit. Q: Is the check result normal? YES : Go to Step 10. NO : Repair the wiring harness.

STEP 10. Retest the system. After the power window main switch is replaced, check that the driver’s door power window can be operated by the power window main switch. (1) Replace the power window main switch. (2) Check that the driver’s power window works by means of the power window main switch. Q: Is the check result normal? YES : The trouble can be an intermittent

3 2 1 6 5 4 AC301418 AB


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window motor assembly (front LH).

54B-74


INSPECTION PROCEDURE D-3:Relevant power window(s) do not work by means of the front and rear passenger’s power window sub switches.

Power Window (front: RH) Circuit FUSIBLE LINK 5

POWER WINDOW RELAY

ETACSECU

POWER WINDOW SUB SWITCH (FRONT: RH) CPU

POWER WINDOW MOTOR (FRONT: RH)


SB : Sky blue


54B-75

SYMPTOM PROCEDURES Power Window (rear) Circuit

FUSIBLE LINK 5

POWER WINDOW RELAY

ETACS-ECU


POWER WINDOW SUB SWITCH (REAR: LH) CPU

CPU

POWER WINDOW MOTOR (REAR: RH)

POWER WINDOW MOTOR (REAR: LH)


COMMENTS ON TROUBLE SYMPTOM If the front passenger’s or rear power window does not work by means of the respective power window sub switch, the power window sub switch or the power window motor may be defective.

SB : Sky blue

Possible causes Malfunction of the power window sub switch (front, RH), power window sub switch (rear, RH) or power window sub switch (rear, LH) Malfunction of the power window motor (front, RH), power window motor (rear, RH) or power window motor (rear, LH) Damaged harness wires and connectors

54B-76


DIAGNOSIS PROCEDURE

Step 4. Measure the resistance at E-17 power window sub switch (front RH) connector.

Step 1. Check the power window main switch. Check that the power window lock switch is turned off. Q: Is the check result normal? YES : Go to Step 2. NO : Turn off the power window lock switch.

Connector: E-17 E-17 Harness side

3 2 1 8 7 6 5 4

Step 2. Determine a trouble spot. Q: Which power window does not work? Front passenger’s door : Go to Step 3. Rear right door : Go to Step 12. Rear left door : Go to Step 21.

AC301412 AB


Step 3. Connector check: E-17 power window sub switch (front RH) connector Connector: E-17

3 2 1 8 7 6 5 4

E-17 Harness side

3 2 1 8 7 6 5 4

Connector E-17 (Harness side) AC301474 AB

(2) Resistance between terminal 1 and body earth OK: 2W or less AC301412 AB




Step 5. Check the wiring harness from E-17 power window sub switch (front RH) connector terminal No.1 to body earth. Connectors: E-17, E-24

54B-77


malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 6. Measure the voltage at E-17 power window sub switch (front RH) connector.

E-17 Connector: E-17 E-24

E-17 Harness side

3 2 1 8 7 6 5 4 E-17 Harness side

3 2 1 8 7 6 5 4

AC301412 AB


E-24

1 2 3 4 5 6 7 8 AC301413 AC

3 2 1 8 7 6 5 4


Connector E-17 (Harness Side)

AC301470 AB


C-15(GR)

C-15

2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

AC301398 AC

Prior to the wiring harness inspection, check intermediate connector C-15, E-24, and repair if necessary. Check the earth wires for open circuit.

54B-78



Step 8. Check the wiring harness from E-17 power window sub switch (front LH) connector terminal No.4 to C-208 power window relay connector terminal No.4. Connectors: E-17, E-24

E-17

E-24

E-17 Harness side


3 2 1 8 7 6 5 4

3 2 1 4 5

E-24

1 2 3 4 5 6 7 8 AC210475 AD


AC301413 AC


C-208

C-203 Harness side


3 2 1 4 5 AC210475 AB


54B-79

SYMPTOM PROCEDURES

NOTE:

Step 10. Check the wiring harness from E-23 power window motor (front RH) connector terminal Nos. 1 and 3 to E-17 power window sub switch (front LH) connector terminal Nos. 5 and 7.

Connector: C-15


E-23(GR) E-17

C-15(GR)

E-24

C-15

2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

E-17 Harness side

3 2 1 8 7 6 5 4 AC301398 AC


malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 9. Connector check: E-23 power window motor (front RH) connector Connector: E-23 E-23 Harness side

3 2 1 6 5 4

E-23(GR)

AC301412 AC


E-23 Harness side

E-24

1 2 3 4 5 6 7 8

3 2 1 6 5 4 AC301413 AB


Step 11. Retest the system. After the power window sub switch (front RH) is replaced, check that the front passenger’s door power window can be operated by the power window sub switch (front RH). (1) Replace the power window sub switch (front RH). (2) Check that the front passenger’s door power window can be operated by the power window sub switch (front RH). Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window motor assembly (front RH).


54B-80

SYMPTOM PROCEDURES

Step 12. Connector check: E-21 power window sub switch (rear RH) connector Connector: E-21

Step 14. Check the wiring harness from E-21 power window sub switch (rear RH) connector terminal No.1 to body earth. Connectors: E-21, E-27

E-21

E-21 Harness side

3 2 1 8 7 6 5 4

E-27 AC301414 AC


E-21 Harness side

3 2 1 8 7 6 5 4

Step 13. Measure the resistance at E-21 power window sub switch (rear RH) connector. E-27 Connector: E-21

1 2 3 4 5 6 7 8 AC301415 AC

E-21 Harness side

NOTE: Connector: D-02

3 2 1 8 7 6 5 4

D-02 AC301414 AC


1 2 3 4 5 6 7 8

AC301408 AH

Prior to the wiring harness inspection, check intermediate connectors E-27 and D-02, and repair if necessary. Check the earth wires for open circuit.

3 2 1 8 7 6 5 4 Connector E-21 (Harness side)

AC301472 AB





Step 15. Measure the voltage at E-21 power window sub switch (rear RH) connector. Connector: E-21

54B-81


E-21 Harness side

3 2 1 8 7 6 5 4 AC301414 AC



3 2 1 4 5

3 2 1 8 7 6 5 4

AC210475 AD


AC301462 AC




54B-82

SYMPTOM PROCEDURES

Step 17. Check the wiring harness from E-21 power window sub switch (rear RH) connector terminal No.4 to C-208 power window connector terminal No.4.



E-21

C-13(L)

E-27 C-13 E-21 Harness side

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

3 2 1 8 7 6 5 4

E-27

AC301398 AB

3 1 2 4 5 6 7 8

Connector: D-02 AC301415 AC

D-02 1 2 3 4 5 6 7 8


AC301408 AH

Prior to the wiring harness inspection, check intermediate connectors C-13, D-02, E-27 and junction block connector C-203, and repair if necessary. Check the power supply line for open circuit.

C-208

C-203 Harness side


2 1 6 5 4 3



3 2 1 4 5 AC210475 AB


Step 18. Connector check: E-20 power window motor (rear RH) connector Connector: E-20


54B-83

Step 20. Retest the system. After the power window sub switch (rear RH) is replaced, check that the rear right door power window can be operated by the power window sub switch (rear RH). (1) Replace the power window sub switch (rear RH). (2) Check that the rear right door power window can be operated by the power window sub switch (rear RH). Q: Is the check result normal? YES : The trouble can be an intermittent

3 2 1 6 5 4 AC301414 AB


Step 19. Check the wiring harness from E-20 power window motor (rear RH) connector terminal Nos. 1 and 3 to E-21 power window sub switch (rear RH) connector terminal Nos. 7 and 5.

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window motor assembly (rear RH). Step 21. Connector check: E-01 power window sub switch (rear LH) connector Connector: E-01


E-20(GR)

E-21

E-01 Harness side

3 2 1 8 7 6 5 4 AC301416 AB

E-27


E-20 Harness side

3 2 1 6 5 4 E-27 E-21 Harness side

1 2 3 4 5 6 7 8

3 2 1 8 7 6 5 4 AC301415 AB



54B-84

SYMPTOM PROCEDURES

Step 22. Measure the resistance at E-01 power window sub switch (rear LH) connector. Connector: E-01

Step 23. Check the wiring harness from E-01 power window sub switch (rear LH) connector terminal No.1 to body earth. Connectors: E-01, E-09

E-01 E-01 Harness side

3 2 1 8 7 6 5 4

E-09 AC301416 AB


E-01 Harness side

3 2 1 8 7 6 5 4

E-09

3 2 1 8 7 6 5 4 Connector E-01 (Harness Side)

3 1 2 4 5 6 7 8


AC301417 AC

AC301461AB

NOTE: Connector: D-26 D-26

1 2 3 4 5 6 7 8

AC301410 AB

Prior to the wiring harness inspection, check intermediate connectors E-09 and D-26, and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



Step 24. Measure the voltage at E-01 power window sub switch (rear LH) connector. Connector: E-01

54B-85

Step 25. C-208 power window relay connector Connector: C-208 Junction block (front view)

E-01 Harness side

3 2 1 8 7 6 5 4 AC301416 AB



3 2 1 4 5 3 2 1 8 7 6 5 4 AC210475 AD

Connector E-01 (Harness side)

AC301462 AB




54B-86

SYMPTOM PROCEDURES

Step 26. Check the wiring harness from E-01 power window sub switch (rear LH) connector terminal No.4 to C-208 power window relay connector terminal No.4.



E-01


1 2 3

111213

4 5 6 7 8 9 10

14 1516 17 1819 20 2122 2324 25

3 2 1 8 7 6 5 4

26 27 28 29 32 33 34

35

30 31 36 37

38

E-09 AC301396 AC

1 2 3 4 5 6 7 8


D-26

1 2 3 4 5 6 7 8


AC301410 AB


C-208

C-203 Harness side


2 1 6 5 4 3



3 2 1 4 5 AC210475 AB


54B-87

SYMPTOM PROCEDURES

Step 27. Connector check: E-03 power window motor (rear LH) connector Connector: E-03

Step 28. Check the wiring harness from E-03 power window motor (rear LH) connector terminal Nos. 1 and 3 to E-01 power window sub switch (rear LH) connector terminal Nos. 7 and 5. Connectors: E-01, E-03, E-09


E-01 E-03(GR)

3 2 1 6 5 4 E-09

AC301416 AC


E-01 Harness side

3 2 1 8 7 6 5 4

E-03 Harness side

E-09

3 1 2 4 5 6 7 8

3 2 1 6 5 4 AC301417 AB


Step 29. Retest the system. After the power window sub switch (rear LH) is replaced, check that the rear left door power window can be operated by the power window sub switch (rear LH). (1) Replace the power window sub switch (rear LH). (2) Check that the rear left door power window can be operated by the power window sub switch (rear LH). Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window motor assembly (rear LH).


54B-88

SYMPTOM PROCEDURES

INSPECTION PROCEDURE D-4: Front and/or rear passenger’s power window(s) do not work by means of the power window main switch.

Power Window Circuit

REAR (RH)

FRONT (RH)

LOCK SWITCH

CPU

REAR (LH)


CPU POWER WINDOW SUB SWITCH (FRONT: RH)

CPU POWER WINDOW SUB SWITCH (REAR: LH)

CPU POWER WINDOW SUB SWITCH (REAR: RH)


SB : Sky blue


54B-89

SYMPTOM PROCEDURES

COMMENTS ON TROUBLE SYMPTOM If the passenger’s and/or rear power window does not work by means of the power window main switch, the power window main switch or the respective power window sub switch(es) may be defective. Possible causes Malfunction of the power window main switch Malfunction of the power window sub switch (front, RH), power window sub switch (rear, RH) or power window sub switch (rear, LH) Damaged harness wires and connectors

Step 3. Determine a trouble spot. Q: Which power window does not work when the power window main switch is operated? Front passenger’s door : Go to Step 4. Rear right door : Go to Step 7. Rear left door : Go to Step 10.

Step 4. Connector check: E-05 power window main switch connector and E-17 power window sub switch (front RH) connector Connector: E-05

DIAGNOSIS PROCEDURE Step 1. Check the power window main switch. Check that the driver’s power window works by means of the power window main switch. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure D-2 "Driver’s

power window does not work by means of the power window main switch 354B." Step 2. Check the power window sub switch. Check that each power window works by means of the respective power window sub switch when the power window lock switch is turned off.



3 2 1 8 7 6 5 4

Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure D-3 "Relevant

power window(s) do not work by means of the front and rear passenger’s power window sub switches 354B."

AC301412 AB



54B-90

SYMPTOM PROCEDURES

Step 5. Check the wiring harness between E-05 power window main switch connector terminal No.11 and E-17 power window sub switch (front LH) connector terminal No.6.



E-05

C-15(GR) E-12 C-15

2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

AC301398 AC

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Connector: C-118

AC301419 AC


E-17

E-24

E-17 Harness side

C-118

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

3 2 1 8 7 6 5 4

23 24 25 26 27

28 29 30 31 32

E-24

AC301396 AE

1 2 3 4 5 6 7 8 AC301413 AC

Prior to the wiring harness inspection, check intermediate connectors C-15, C-118, E-12 and E24, and repair if necessary. Check the communication lines for open circuit. Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness.


54B-91

SYMPTOM PROCEDURES

Step 6. Retest the system. After the power window sub switch (front LH) is replaced, check that the front passenger’s door power window can be operated by the power window sub switch. (1) Replace the power window sub switch (front LH). (2) Check that the front passenger’s power window works by means of the power window main switch.

Step 8. Check the wiring harness between E-05 power window main switch connector terminal No.11 and E-21 power window sub switch (rear RH) connector terminal No.6. Connectors: E-05, E-12

E-05


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window main switch. Step 7. Connector check: E-05 power window main switch connector and E-21 power window sub switch (rear RH) connector

E-12

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E-05 Harness side

AC301419 AC


6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301418 AF

E-21

Connector: E-21


E-21 Harness side

3 2 1 8 7 6 5 4 AC301414 AC


3 2 1 8 7 6 5 4

E-27

3 1 2 4 5 6 7 8 AC301415 AC


54B-92

SYMPTOM PROCEDURES

NOTE:

Connector: D-02

Connector: C-13

D-02 1 2 3 4 5 6 7 8

AC301408 AH

C-13(L)

C-13

Prior to the wiring harness inspection, check intermediate connectors C-13, C-118, D-02, E-12 and E-27, and repair if necessary. Check the communication lines for open circuit. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

AC301398 AB

Connector: C-118

Step 9. Retest the system. After the power window sub switch (rear RH) is replaced, check that the rear right door power window can be operated by the power window sub switch. (1) Replace the power window sub switch (rear RH). (2) Check that the rear right power window works by means of the power window main switch. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window main switch.

C-118

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32 AC301396 AE


54B-93

SYMPTOM PROCEDURES

Step 10. Connector check: E-05 power window main switch connector and E-01 power window sub switch (rear LH) connector Connector: E-05

Step 11. Check the wiring harness between E-05 power window main switch connector terminal No.11 and E-01 power window sub switch (rear LH) connector terminal No.6. Connectors: E-05, E-12

E-05 E-05 Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12 AC301418 AF

Connector: E-01

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7 E-01 Harness side

E-12

3 2 1 8 7 6 5 4 AC301416 AB


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC


E-01

E-09

E-01 Harness side

3 2 1 8 7 6 5 4

E-09

1 2 3 4 5 6 7 8 AC301417 AC


54B-94

SYMPTOM PROCEDURES

NOTE:

Step 12. Retest the system. After the power window sub switch (rear LH) is replaced, check that the rear left door power window can be operated by the power window sub switch. (1) Replace the power window sub switch (rear LH). (2) Check that the rear left power window works by means of the power window main switch.


C-118


C-117


C-117 1 2 3

4 5 6 7 8 9 10

111213

14 1516 17 1819 20 2122 2324 25 26 27 28 29 32 33 34

35

30 31 36 37

38

C-118 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

AC301396 AD


1 2 3 4 5 6 7 8

AC301410 AB



54B-95

NSPECTION PROCEDURE D-5: The window glass lowers automatically while it is rising. COMMENTS ON TROUBLE SYMPTOM If the sliding resistance is too great when the window is being raised or the window glass encounters an object, the window glass will lower by approximately 150 mm. Possible causes Improper adjusted door window glass Incorrectly installed or warped glass slider Malfunction of the power window motor Malfunction of the window regulator

DIAGNOSIS PROCEDURE

Step 2. Check the power window operating current. Check that the power window operating current is normal (Refer to GROUP 42 - Door - On-vehicle Service 342). Q: Is the check result normal? YES : Adjust the door window glass (Refer to

GROUP 42 - Door - On-vehicle service 342), and then go to Step 3. NO : Replace the defective power window motor assembly which operating current are abnormal.

Step 1. Check the power window anti-trap function. Check that the power window anti-trap function works. Refer to GROUP 42 - Door - On-vehicle Service 342.

Step 3. Check that the door window glasses are installed correctly. Check that the door window glasses are installed correctly. Refer to GROUP 42 - Door - On-vehicle Service 342.

Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure D-6 "Power

Q: Is the check result normal? YES : Go to Step 4. NO : Adjust the door window glass (Refer to

window anti-trap function does not work normally 354B."

GROUP 42 - Door - On-vehicle service 342). Step 4. Retest the system. Check that the power window does not lower automatically while it is being raised. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window motor assembly of the defective window.


54B-96

SYMPTOM PROCEDURES

INSPECTION PROCEDURE D-6: Power window anti-trap function does not work normally.

Power Window (front) Circuit



CPU

HALL IC

HALL IC

CPU

HALL IC

POWER WINDOW MOTOR (FRONT: LH) Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

HALL IC POWER WINDOW MOTOR (FRONT: RH) SB : Sky blue


54B-97

Power Window (rear) Circuit



CPU

HALL IC

HALL IC

CPU

HALL IC


POWER WINDOW MOTOR (REAR: LH) Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

COMMENTS ON TROUBLE SYMPTOM The revolution detection sensor, which is incorporated in the power window motor, may be defective. Possible causes Malfunction of the power window motor

HALL IC

SB : Sky blue

DIAGNOSIS PROCEDURE Step 1. Check the power window operating current. Check that the power window operating current is normal (Refer to GROUP 42 - Door - On-vehicle Service 342). Q: Is the check result normal? YES : Adjust the door window glass (Refer to


54B-98


Step 2. Confirm the power window learning function. Check that the power window switch has learned the fully closed position of the windows (Refer to GROUP 42 - Door 342).

Step 5. Check the wiring harness from E-05 power window main switch connector terminal Nos. 8, 9, 10 and 12 to E-13 power window motor (front RH) connector terminal Nos. 5, 4, 6 and 2. Connectors: E-05, E-12, E-13

Q: Is the check result normal? YES : Go to Step 3. NO : Make the power window switch learn the

fully closed position of the windows (Refer to GROUP 42 - Door 342).

E-13(GR) E-05 E-12

Step 3. Determine a trouble spot. Q: Which door does the power window anti-trap function fail on? Driver’s door : Go to Step 4. Front passenger’s door : Go to Step 7. Rear right door : Go to Step 13. Rear left door : Go to Step 19.

Step 4. Connector check: E-05 power window main switch connector and E-13 power window motor (front LH) connector

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7 E-13 Harness side E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

3 2 1 6 5 4

Connectors: E-05, E-13 AC301419 AD

NOTE: Prior to the wiring harness inspection, check intermediate connector E-12, and repair if necessary. Check the input and output lines to the revolution detection sensor for open or short circuit.

E-13(GR) E-05

Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness. E-05 Harness side

Step 6. Retest the system. After the power window main switch is replaced, check that the driver’s power window anti-trap function works. (1) Replace the power window main switch. (2) Check that the driver’s power window anti-trap function works.

6 5 4 3 2 1 14 13 12 11 10 9 8 7 E-13 Harness side

3 2 1 6 5 4 AC301419 AE





54B-99

SYMPTOM PROCEDURES

Step 7. Connector check: E-23 power window motor (front RH) connector Connector: E-23

Step 9. Check the wiring harness from E-23 power window motor (front RH) connector terminal No.5 to body earth. Connector: E-23

E-23 Harness side

E-23 Harness side

E-23(GR)

3 2 1 6 5 4

E-23(GR)

3 2 1 6 5 4

AC301412 AC AC301412 AC



Step 8. Measure the resistance at E-23 power window motor (front RH) connector. Connector: E-23 E-23 Harness side E-23(GR)

3 2 1 6 5 4

C-15(GR)

C-15 AC301412 AC


AC301398 AC

3 2 1 6 5 4


Prior to the wiring harness inspection, check intermediate connector C-15, and repair if necessary. Check the input and output lines to the revolution detection sensor for open or short circuit. AC301471AC

(2) Resistance between E-23 power window motor (front RH) connector terminal No.5 and body earth. OK: 2W or less Q: Is the check result normal? YES : Go to Step 10. NO : Go to Step 9.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Q: Is the check result normal? YES : Go to Step 10. NO : Repair the wiring harness.

54B-100


Step 10. Connector check: E-17 power window sub switch (front RH) connector Connector: E-17 E-17 Harness side

3 2 1 8 7 6 5 4

Step 12. Retest the system. After the power window sub switch (front LH) is replaced, check that the front passenger’s anti-trap function can be operated by the power window sub switch. (1) Replace the power window sub switch (front LH). (2) Check that the front passenger’s power window anti-trap function works. Q: Is the check result normal? YES : The trouble can be an intermittent

AC301412 AB


Step 11. Check the wiring harness from E-17 power window sub switch (front RH) connector terminal Nos. 2, 8 and 3 to E-23 power window motor (front LH) connector terminal Nos. 6, 4 and 2. Connectors: E-17, E-23, E-24

E-24

E-17 Harness side

E-23 Harness side

Step 13. Connector check: E-20 power window motor (rear RH) connector Connector: E-20


E-23(GR) E-17

3 2 1 8 7 6 5 4


E-24

1 2 3 4 5 6 7 8

3 2 1 6 5 4 AC301413 AB

NOTE: Prior to the wiring harness inspection, check intermediate connector E-24, and repair if necessary. Check the input and output lines to the revolution detection sensor for open or short circuit. Q: Is the check result normal? YES : Go to Step 12. NO : Repair the wiring harness.

3 2 1 6 5 4 AC301414 AB



Step 14. Measure the resistance at E-20 power window motor (rear RH) connector. Connector: E-20

54B-101

Step 15. Check the wiring harness from E-20 power window motor (rear RH) connector terminal No.5 to body earth. Connector: E-20

E-20(GR) E-20(GR)

E-20 Harness side

E-20 Harness side

3 2 1 6 5 4

3 2 1 6 5 4

AC301414 AB


AC301414 AB


3 2 1 6 5 4


1 2 3 4 5 6 7 8

(2) Resistance between E-20 power window motor (rear RH) connector terminal No.5 and body earth. OK: 2W or less Q: Is the check result normal? YES : Go to Step 16. NO : Go to Step 15.

AC301408 AH

AC301471AB

Prior to the wiring harness inspection, check intermediate connector D-02, and repair if necessary. Check the input and output lines to the revolution detection sensor for open or short circuit. Q: Is the check result normal? YES : Go to Step 16. NO : Repair the wiring harness.

Step 16. Connector check: E-21 power window sub switch (rear RH) connector Connector: E-21

E-21 Harness side

3 2 1 8 7 6 5 4 AC301414 AC



54B-102

SYMPTOM PROCEDURES

Step 17. Check the wiring harness from E-21 power window sub switch (rear RH) connector terminal Nos. 2, 8 and 3 to E-20 power window motor (rear RH) connector terminal Nos. 6, 4 and 2.

Step 19. Connector check: E-03 power window motor (rear LH) connector Connector: E-03

Connectors: E-20, E-21, E-27 E-03(GR)

E-20(GR)

E-21

E-03 Harness side

3 2 1 6 5 4 AC301416 AC

E-27


E-20 Harness side

Step 20. Measure the resistance at E-03 power window motor (rear LH) connector.

3 2 1 6 5 4 E-27 E-21 Harness side

1 2 3 4 5 6 7 8

Connector: E-03

3 2 1 8 7 6 5 4

E-03(GR) AC301415 AB


Step 18. Retest the system. After the power window sub switch (rear RH) is replaced, check that the rear right door anti-trap function can be operated by the power window sub switch. (1) Replace the power window sub switch (rear RH). (2) Check that the rear right power window anti-trap function works. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window motor assembly (rear RH).

E-03 Harness side

3 2 1 6 5 4 AC301416 AC


3 2 1 6 5 4


AC301463 AB

(2) Resistance between E-03 power window motor (rear LH) connector terminal No.5 and body earth. OK: 2W or less Q: Is the check result normal? YES : Go to Step 22. NO : Go to Step 21.


54B-103

SYMPTOM PROCEDURES

Step 21. Check the wiring harness from E-03 power window motor (rear LH) connector terminal No.5 to body earth. Connector: E-03

Step 23. Check the wiring harness from E-01 power window sub switch (rear LH) connector terminal Nos. 8, 2 and 3 to E-03 power window motor (rear LH) connector terminal Nos. 6, 4 and 2. Connectors: E-01, E-03, E-09


E-01 E-03(GR)

3 2 1 6 5 4 E-09

AC301416 AC


E-01 Harness side

D-26

3 2 1 8 7 6 5 4

1 2 3 4 5 6 7 8

E-03 Harness side AC301410 AB


Step 22. Connector check: E-01 power window sub switch (rear LH) connector

E-09

1 2 3 4 5 6 7 8

3 2 1 6 5 4 AC301417 AB


Step 24. Retest the system. After the power window sub switch (rear LH) is replaced, check that the rear left door anti-trap function can be operated by the power window sub switch. (1) Replace the power window sub switch (rear LH). (2) Check that the rear left power window anti-trap function works.

Connector: E-01

E-01 Harness side

3 2 1 8 7 6 5 4 AC301416 AB




54B-104


KEYLESS ENTRY SYSTEM

INSPECTION PROCEDURE E-1: Keyless Entry System does not Work.


Keyless Entry System Function Circuit ETACS-ECU

KEYLESS ENTRY RECEIVER

INPUT SIGNAL · ALL OF THE DOOR SWITCHES · DRIVER'S DOOR LOCK ACTUATOR SWITCH · KEYLESS ENTRY TRANSMITTER SWITCH · KEY REMINDER SWITCH

COMMENTS ON TROUBLE SYMPTOM If the keyless entry system does not work normally, the input signal circuits to the components below or the ETACS-ECU may be defective. Key reminder switch All of the door switches Keyless entry transmitter Driver’s door lock actuator POSSIBLE CAUSES Malfunction of the key reminder switch Malfunction of the door switches Malfunction of the keyless entry transmitter Malfunction of the driver’s door lock actuator Malfunction of the ETACS-ECU





Step 2. Pulse check Check the input signals below which are related to the keyless entry system. System switch

Check conditions

Key reminder switch






54B-105

Step 3. Retest the system. Check the keyless entry system works normally. Q: Is the check result normal? YES : The trouble can be an intermittent


Keyless entry transmitter When the switch is switch turned from off to on OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? All the signals are received normally. : Go to Step

3. The key reminder switch signal is not received. :

Refer to inspection procedure N-9 "The key reminder switch signal is not received 354B." All the door switch signals are not received. :

Refer to inspection procedure N-11 "All the door switch signals are not received 354B ." The driver’s door lock actuator switch signal is not received. : Refer to inspection procedure N-12

"The driver’s door lock actuator signal is not received 354B. The keyless entry transmitter switch signal is not received. : Refer to inspection procedure N-14

"Each switch signal of the keyless entry transmitter is not received 354B."

INSPECTION PROCEDURE E-2: Keyless Entry Hazard Warning Lamp Answerback Function or the Room Lamp Answerback Function does not Work Normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. COMMENTS ON TROUBLE SYMPTOM If the hazard warning lamp and the room lamp work normally, the ETACS-ECU may be defective.

Alternatively, it is possible that the keyless entry hazard warning lamp answerback function was disabled by the adjustment function. POSSIBLE CAUSES Defective turn-signal lamp Malfunction of the room lamp Malfunction of the ETACS-ECU Damaged harness wires and connectors

54B-106


DIAGNOSIS PROCEDURE

Step 3. Check the operation of the room lamps. Check that the room lamps illuminate normally.

Step 1. Check the adjustment function. Check that the keyless entry hazard warning lamp answerback function has been enabled by using the adjustment function. Q: Is the check result normal? YES : Go to Step 2. NO : Enable the keyless entry hazard warning

lamp answerback function by using the adjustment function. (Refer to 354B.) Step 2. Check the operation of the hazard warning lamp. Check that the hazard warning lamps illuminate normally.

Q: Is the check result normal? YES : Go to Step 4. NO : Refer to inspection procedure M-2 "The

front or rear room lamp does not illuminate/ extinguish 354B." Step 4. Retest the system. Check that the keyless entry hazard warning lamp answerback function or the room lamp answerback function work normally. Q: Is the check result normal? YES : The trouble can be an intermittent


Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure K-2 "The

hazard warning lamps do not illuminate 354B".

INSPECTION PROCEDURE E-3: Encrypted Code cannot be Registered.


Encrypted Transmitter Code Register Mode ETACS-ECU

INPUT SIGNAL · HAZARD WARNING LAMP SWITCH · KEYLESS ENTRY TRANSMITTER SWITCH · KEY REMINDER SWITCH

COMMENTS ON TROUBLE SYMPTOM If the encrypted code registration mode is not entered, the key reminder switch, the hazard warning lamp switch or the ETACS-ECU may be defective.

If the registration is not possible although the registration mode is entered, the keyless entry transmitter or the ETACS-ECU may be defective.


54B-107

POSSIBLE CAUSES Malfunction of the keyless entry transmitter Malfunction of the ETACS-ECU Damaged harness wires and connectors

Step 2. Pulse check Check the input signals below which are related to the encrypted code of the keyless entry transmitter. System switch

Check conditions

DIAGNOSIS PROCEDURE

Key reminder switch


Step 1. Check the encrypted code registration mode. Check that the encrypted code registration mode is entered.






Refer to inspection procedure N-9 "The key reminder switch signal is not received 354B." The hazard warning lamp switch signal is not received. : Refer to inspection procedure N-10

"The hazard warning lamp switch signal is not received 354B." The keyless entry transmitter switch signal is not received. : Refer to inspection procedure N-14

"Each switch signal of the keyless entry transmitter is not received 354B." Step 3. Retest the system. Check that the encrypted code can be registered. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-108


INSPECTION PROCEDURE E-4: The Timer Lock Function does not Work after the Doors have been Unlocked by the Keyless Entry System.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. COMMENT ON TROUBLE SYMPTOM If the keyless entry timer lock does not work normally, the input signal circuit(s) to the keyless entry transmitter or the ETACS-ECU may be defective. POSSIBLE CAUSES Malfunction of the keyless entry transmitter Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the operation of the keyless entry system. Check that the keyless entry system works normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure E-1 "Keyless

entry system does not work 354B." Step 2. Retest the system. Check that the timer lock works normally. Q: Is the check result normal? YES : The trouble can be an intermittent



WINDSHIELD WIPER AND WASHER

INSPECTION PROCEDURE F-1: The windshield wipers does not work at all.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Windshield Wiper Power Supply Circuit IGNITION SWITCH (ACC)

FRONT-ECU WIPER SPEED SWITCHING RELAY

WINDSHIELD WIPER MOTOR

CIRCUIT BREAKER


SB : Sky blue

54B-109

54B-110


COMMENTS ON TROUBLE SYMPTOM The windshield wiper motor, the column switch or the front-ECU may be defective. Possible causes Malfunction of the windshield wiper motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

Step 3. Connector check: B-07 windshield wiper motor connector Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

DIAGNOSTIC PROCEDURE AC301521AD

Step 1. Check the diagnosis code. When the ignition switch is turned to the LOCK (OFF) position, check that the ETACS-ECU does not set the diagnosis code.


Q: Is the diagnosis code set? YES : Refer to diagnosis code chart 354B. NO : Go to Step 2.

Step 4. Check the windshield wiper motor assembly. Refer to GROUP 51 - Windshield wiper 351.

Step 2. Pulse check Check the input signals below which are related to the windshield wiper. System switch

Check conditions


When turned from the LOCK (OFF) position to the ACC position.

Windshield mist wiper switch

When the switch is turned from off to on.

OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? All the signals are received normally : Go to Step

3. The ignition switch (ACC) signal is not received. :

Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354B." Windshield mist wiper switch signal is not received. : Refer to inspection procedure N-6 "The

column switch (windshield wiper washer and rear wiper washer switch) signal is not received 354B."

Q: Is the check result normal? YES : Go to Step 5 NO : Replace the windshield wiper motor

assembly.


54B-111

SYMPTOM PROCEDURES

Step 5. Measure the resistance at the B-07 windshield wiper motor connector. Connector: B-07 B-07(GR)

B-07 Harness side

Step 6. Check the wiring harness between B-07 windshield wiper motor connector terminal No.5 and body earth. Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

3 2 1 5 4

AC301521AD


AC301521AD


3 2 1 5 4

Connector B-07 (Harness side) AC301635 AB

(2) Continuity between B-07 windshield wiper motor connector terminal No.5 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 6.

C-17(GR)

C-17 Harness side

5 4 3 2 1 13 12 11 10 9 8 7 6

AC301398 AE

Prior to the wiring harness inspection, check the junction connector C-17 and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-112

SYMPTOM PROCEDURES


Step 8. Measure the voltage at the A-12X frontECU connector. Connector: A-12X

Relay box side

Relay box side

3130 29 2827 26 25 24 2322 21

3130 29 2827 26 25 24 2322 21

AC301483 AE


AC301483 AE

(1) Remove the front-ECU, and measure at the relay box side. (2) Ignition switch: ACC

31 30 29 2827 26 25 24 2322 21

Connector A-12X (Relay box side) AC301473 AB

(3) Check the voltage between the A-12X front-ECU connector terminal No.28 and body earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 10. NO : Go to Step 9.


54B-113

SYMPTOM PROCEDURES

Step 9. Check the wiring harness between A-12X front-ECU connector terminal No.28 and the ignition switch (ACC).


Connector: A-12X

C-116

1 2

Relay box side 3130 29 2827 26 25 24 2322 21

5 6 7

3 4

8 9

10 11 12 13 14

15

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301396 AB

AC301483 AE

Connectors: C-202, C-203 Junction block (Front view) C-203 C-202

C-202 Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

C-203 Harness side 2 1 6 5 4 3

AC210475 AM

Prior to the wiring harness inspection, check the junction block connectors C-202, C-203 and intermediate connector C-116 and repair if necessary. Check the power supply line to the ignition switch (ACC) for open circuit.


54B-114

SYMPTOM PROCEDURES



Step 11. Check the wiring harness between C-310 column switch connector terminal No.8 and A12X front-ECU connector terminal No.26. Connector: C-310

Step 10. Connector check: C-310 column switch connector Connector: C-310

C-310 Harness side

5 4 3 2 1 10 9 8 7 6 C-310 Harness side

5 4 3 2 1 10 9 8 7 6

AC301400 AB

NOTE: Connector: C-116 AC301400 AB


C-116

1 2

5 6 7

3 4

8 9

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

1617 18 1920 21

AC301396 AB

Prior to the wiring harness inspection, check the intermediate connector C-116 and repair if necessary. Check the wiper backup circuit.

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR SYMPTOM PROCEDURES Q: Is the check result normal? YES : Go to Step 12. NO : Repair the wiring harness.

54B-115

Step 12. Retest the system. The windshield wiper should now work normally at all. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the front-ECU.

INSPECTION PROCEDURE F-2: The windshield wipers does not work when the wiper switch is at "INT", "WASHER" or "MIST" position. However, the wipers work at low speed when the switch is at "LO" and "HI" position.


Windshield Wiper Motor Drive Circuit FRONT-ECU WIPER SPEED SWITCHING RELAY

INPUT SIGNAL · WINDSHIELD WIPER HI SPEED SWITCH · WINDSHIELD WIPER INTERMIT SWITCH · WINDSHIELD WIPER LO SPEED SWITCH · WINDSHIELD WIPER MIST SWITCH


CIRCUIT BREAKER

COMMENTS ON TROUBLE SYMPTOM The system may be at fail-safe mode as the SWS communication line is defective. If the front-ECU does not receive the ignition switch (ACC) signal due to an open circuit in the SWS communication lines or other reasons when the ignition switch is at the ACC position, the system will enter the fail-safe mode.


Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

54B-116


DIAGNOSTIC PROCEDURE Step 1. Check the diagnosis code. When the ignition switch is turned to the LOCK (OFF) position, check that the ETACS-ECU does not set the diagnosis code. Q: Is the diagnosis code set? YES : Refer to diagnosis code chart 354B. NO : Go to Step 2.


Check conditions








column switch (windshield wiper washer and rear wiper washer switch) signal is not received 354B." Step 3. Retest the system. The windshield wiper should now work normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-117

SYMPTOM PROCEDURES

INSPECTION PROCEDURE F-3: The windshield wipers do not stop at the specified park position

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Windshield Wiper Automatic Stop Relay Circuit IGNITION SWITCH (ACC) FRONT-ECU WIPER AUTOMATIC STOP RELAY



COMMENTS ON TROUBLE SYMPTOM The windshield wiper motor or the front-ECU may be defective. Possible causes Malfunction of the windshield wiper motor Malfunction of the front-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSTIC PROCEDURE Step 1. Connector check: B-07 windshield wiper motor connector Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD



54B-118

SYMPTOM PROCEDURES

Step 2. Check the windshield wiper motor assembly. Refer to GROUP 51 - Windshield wiper 351. Q: Is the check result normal? YES : Go to Step 3 NO : Replace the windshield wiper motor

assembly. Step 3. Measure the voltage at the B-07 windshield wiper motor connector. Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD

(1) Disconnect the connector, and measure at the wiring harness side. (2) Ignition switch: ACC

3 2 1 5 4 Connector B-07 (Harness side) AC301636 AB

(3) Check the voltage between the B-07 windshield wiper motor connector terminal No.2 and body earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

Step 4. Check the wiring harness between B-07 windshield wiper motor connector terminal No.2 and ignition switch (ACC). Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD


54B-119

SYMPTOM PROCEDURES



malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 5. Connector check: A-12X front-ECU connector C-104(B)

Connector: A-12X

C-104

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

AC301398 AF

Relay box side

Connectors: C-202, C-203 Junction block (Front view)

3130 29 2827 26 25 24 2322 21

C-203 C-202 AC301483 AE

Q: Is the check result normal? YES : Go to Step 6. NO : Repair the connector. C-202 Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7


AC210475 AM

Prior to the wiring harness inspection, check the junction connectors C-202, C-203 and the intermediate connector C-104 and repair if necessary. Check the power supply line to ignition switch (ACC) for open circuit.


54B-120

SYMPTOM PROCEDURES

Step 6. Check the wiring harness between B-07 windshield wiper motor connector terminal No.3 and A-12X front-ECU connector terminal No.29.

NOTE: Connector: A-14

Connector: A-12X

A-14(GR)

A-14

1 2 3 4 5 6 7 8 9 10 11 15 14 12 13 16 17

Relay box side 3130 29 2827 26 25 24 2322 21

AC210456 AD

AC301483 AE

Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD

Prior to the wiring harness inspection, check the intermediate connector A-14 and repair if necessary. Check the input signal lines. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

Step 7. Retest the system. Check that the windshield wipers stop at the specified park position. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-121

INSPECTION PROCEDURE F-4: The windshield wipers does not work normally.





CIRCUIT BREAKER

COMMENTS ON TROUBLE SYMPTOM The windshield wiper motor, the column switch or the front-ECU may be defective.


Possible causes Malfunction of the windshield wiper motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

54B-122



Check conditions





Windshield intermittent wiper switch


Windshield low-speed wiper switch


Windshield high-speed wiper switch


Step 2. Check the operation of the windshield wipers. Check that the windshield wipers work at high speed and the mist mode. Q: Is the check result normal? YES : Go to Step 3. NO : Go to Step 9.


B-07 Harness side

3 2 1 5 4




column switch (windshield wiper washer and rear wiper washer switch) signal is not received 354B." Windshield intermittent wiper switch signal is not received. : Refer to inspection procedure N-6 "The

column switch (windshield wiper washer and rear wiper washer switch) signal is not received 354B." Windshield low-speed wiper switch signal is not received. : Refer to inspection procedure N-6 "The

column switch (windshield wiper washer and rear wiper washer switch) signal is not received 354B." Windshield high-speed wiper switch signal is not received. : Refer to inspection procedure N-6 "The


AC301521AD



54B-123

SYMPTOM PROCEDURES

Step 4. Measure the voltage at the B-07 windshield wiper motor connector. Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

Step 5. Retest the system. Check that the windshield wipers work normally by moving the switch to each position. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the windshield wiper motor. Step 6. Connector check: A-12X front-ECU connector

AC301521AD

(1) Disconnect the connector, and measure at the wiring harness side. (2) Ignition switch: ON (3) Windshield wiper switch: LO

Connector: A-12X

3 2 1 5 4



Relay box side 3130 29 2827 26 25 24 2322 21

AC301483 AE



54B-124

SYMPTOM PROCEDURES


B-07 Harness side


B-07 Harness side

3 2 1 5 4

3 2 1 5 4

AC301521AD AC301521AD



Step 10. Measure the voltage at the B-07 windshield wiper motor connector. Connector: B-07 B-07(GR)

A-14(GR)

B-07 Harness side

3 2 1 5 4

A-14 AC301521AD

1 2 3 4 5 6 7 8 9 10 11 14 15 12 13 16 17

(1) Disconnect the connector, and measure at the wiring harness side. (2) Ignition switch: ON (3) Windshield wiper switch: HI

AC210456 AD

Prior to the wiring harness inspection, check the intermediate connector A-14, and repair if necessary. Check the power supply line to front-ECU for open circuit. Q: Is the check result normal? YES : Go to Step 8. NO : Replace the front-ECU.


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the windshield wiper motor.




54B-125

SYMPTOM PROCEDURES




B-07 Harness side

3 2 1 5 4


AC301521AD


A-14(GR)

Relay box side 3130 29 2827 26 25 24 2322 21

AC301483 AE

A-14

1 2 3 4 5 6 7 8 9 10 11 14 15 12 13 16 17


AC210456 AD

Prior to the wiring harness inspection, check the intermediate connector A-14, and repair if necessary. Check the power supply line to front-ECU for open circuit. Q: Is the check result normal? YES : Go to Step 14. NO : Replace the front-ECU.



54B-126


INSPECTION PROCEDURE F-5: The intermittent wiper interval can not be adjusted by operating the windshield intermittent wiper volume control.


Windshield Wiper Intermittent Volume Input Signal ETACS-ECU

INPUT SIGNAL WINDSHIELD WIPER INTERMITTENT VOLUME

COMMENTS ON TROUBLE SYMPTOM The column switch or the front-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Pulse check Check the input signals below which are related to the windshield intermittent wiper function. System switch

Check conditions


When turned from LOCK (OFF) position to the ACC position

Windshield intermittent wiper volume

When the windshield intermittent wiper volume is rotated from "FAST" to "SLOW" (a pulse is sent around the volume middle position)



Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354B." The windshield wiper volume signal is not received. : Refer to inspection procedure N-7 "The

windshield wiper volume signal is not received 354B."


54B-127

Step 2. Retest the system. Check that the windshield intermittent wiper interval can be adjusted by operating the windshield intermittent wiper volume control. OK: The intermittent wiper interval is changed as the intermittent wiper volume is rotated. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the front-ECU

INSPECTION PROCEDURE F-6: The intermittent wiper interval is not changed according to the vehicle speed.


Vehicle Speed Input Signal ETACS-ECU

INPUT SIGNAL VEHICLE SPEED

W3Z04E06AA

COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU calculates the intermittent wiper interval according to the vehicle speed signal which is sent by the engine-ECU. If the intermittent wiper interval does not depend on the vehicle speed, the input circuit of the vehicle speed signal and the ETACS-ECU may be defective. Possible causes Malfunction of the vehicle speed signal (engineECU) Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Retest the system. Check that the windshield intermittent wiper interval can be adjusted by operating the windshield intermittent wiper volume control. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure F-5 "The

intermittent wiper interval can not be adjusted by operating the windshield intermittent wiper volume control 354B ."

54B-128


Step 2. Pulse check Check the input signals below which are related to the vehicle speed-dependent intermittent wiper. System switch

Check conditions


When turned from LOCK (OFF) position to the ACC position

Vehicle speed signal (engine-ECU)



Step 3. Check the SWS monitor customized function. Use the SWS monitor customize function to confirm that "SPEED SEN WIP" is set to "W.FUNCTION".

CAUTION The SWS monitor must be used in order to confirm and change that setting. Use the SWS monitor to confirm and/or change the customized function. Q: Is the check result normal? YES : Go to Step 4. NO : Use the SWS monitor customize function to

set the "SPEED SEN WIP" to "W.FUNCTION" (Refer to GROUP 54C Customize adjustment 354B).


Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354B." The vehicle speed signal (engine-ECU) is not received. : Refer to inspection procedure N-13

"The vehicle speed signal is not received 354B."

Step 4. Retest the system. Check that the intermittent wiper interval depends on the vehicle speed. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-129

INSPECTION PROCEDURE F-7: The windshield washer does not work.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Windshield Washer Motor Circuit IGNITION SWITCH (ACC)

FRONT-ECU WINDSHIELD WASHER RELAY

INPUT SIGNAL WINDSHIELD WASHER

WINDSHIELD WASHER MOTOR


COMMENTS ON TROUBLE SYMPTOM The windshield washer motor, the column switch or the front-ECU may be defective. Possible causes Malfunction of the windshield washer motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the operation of the windshield wipers. Check that the windshield wipers work normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure F-1 "The

windshield wipers does not work at all 354B."

54B-130



Check conditions





Step 5. Measure the resistance at the A-26 windshield washer motor connector. Connector: A-26

A-26 Harness side

1 2


3.

AC210453 AF


The ignition switch (ACC) signal is not received. :

Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354B." Windshield washer switch signal is not received. : 1 2

Refer to inspection procedure N-6 "The column switch (windshield wiper washer and rear wiper washer switch) signal is not received 354B."

Connector A-26 (Harness side) AC301475 AB

Step 3. Connector check: A-26 windshield washer motor connector Connector: A-26

(2) Continuity between A-26 windshield washer motor connector terminal No.1 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 6.

A-26 Harness side

Step 6. Check the wiring harness between A-26 windshield washer motor connector terminal No.1 and body earth.

1 2

AC210453 AF


Step 4. Check the windshield washer motor assembly. Refer to GROUP 51 - Windshield washer 351. Q: Is the check result normal? YES : Go to Step 5 NO : Replace the windshield washer motor.

Connector: A-26

A-26 Harness side

1 2

AC210453 AF




54B-131

SYMPTOM PROCEDURES


Step 8. Check the wiring harness between A-26 windshield washer motor connector terminal No.2 and A-12X front-ECU connector terminal No.31. Connector: A-12X

Relay box side 3130 29 2827 26 25 24 2322 21

Relay box side 3130 29 2827 26 25 24 2322 21

AC301483 AE


AC301483 AE

Connector: A-26

A-26 Harness side

1 2

AC210453 AF

Check the power supply line to the ignition switch (ACC) for open circuit. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.

Step 9. Retest the system. The windshield washer should now work normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-132


REAR WIPER AND WASHER

INSPECTION PROCEDURE G-1: The rear wiper does not work at all.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Rear Wiper Drive Circuit IGNITION SWITCH (ACC)

ETACS-ECU REAR WIPER RELAY

INPUT SIGNAL REAR WIPER SWITCH

REAR WIPER MOTOR


COMMENTS ON TROUBLE SYMPTOM If the rear wiper does not work normally, the input signal circuits to the components below, the rear wiper motor or the ETACS-ECU may be defective. Ignition switch (ACC) Rear wiper switch

SB : Sky blue

Possible causes Malfunction of the rear wiper motor Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors


54B-133

SYMPTOM PROCEDURES

DIAGNOSTIC PROCEDURE Step 1. Use the MUT-II to confirm a diagnosis code. Check that the ETACS-ECU sets a diagnosis code. Q: Is diagnosis code set? YES : Refer to diagnosis code chart 354B. NO : Go to Step 2.

Step 2. Pulse check Check the input signals below which are related to the rear wiper. System switch

Check conditions



Column switch (rear wiper switch)



Step 4. Check the rear wiper motor. Refer to GROUP 51 - Rear wiper and washer 351 . Q: Is the check result normal? YES : Go to Step 5. NO : Replace the rear wiper motor.

Step 5. Measure the resistance at the F-02 rear wiper motor connector. Connector: F-02 F-02 Harness side

4 3 2 1

AC301665 AB


Q: Is the check result normal? All the signals are received normally. : Go to Step


Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354B." The column switch (rear wiper switch) signal is not received. : Refer to inspection procedure N-6 "The

column switch (windshield wiper washer and rear wiper washer switch) signal is not received 354B." Step 3. Connector check: F-02 rear wiper motor connector Connector: F-02 F-02 Harness side

4 3 2 1

AC301665 AB


4 3 2 1

Connector F-02 (Harness side) AC301641AB

(2) Resistance between F-02 rear wiper motor connector terminal No.1 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 6.


54B-134

SYMPTOM PROCEDURES

Step 6. Check the wiring harness between F-02 rear wiper motor connector terminal No.1 and body earth. Connector: F-02

Step 8. Check the wiring harness between C-217 ETACS-ECU connector terminal No.16 and F-02 rear wiper motor connector terminal No.2. Connector: C-217

F-02 Harness side

4 3 2 1

Junction block (Rear view) AC301665 AB

Check the earth line for open or short circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



Step 7. Connector check: C-217 ETACS-ECU connector AC210477 AB

Connector: C-217 Connector: F-02

F-02 Harness side

4 3 2 1 Junction block (Rear view)

AC301665 AB


AC210477 AB



NOTE:

54B-135

Step 9. Retest the system. Check that the rear wiper works normally.




C-209 Harness side 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210475 AO

Connector: F-05

F-05

1 2 3 4 5 6 7 8 9 10

AC301666 AB

Prior to the wiring harness inspection, check intermediate connector F-05 and junction block connectors C-209 and repair if necessary. Check the output line. Q: 1Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.


54B-136

SYMPTOM PROCEDURES

INSPECTION PROCEDURE G-2: The rear wiper does not stop at the specified park position.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Rear Wiper Auto-stop Signal Input IGNITION SWITCH (ACC)

ETACSECU REAR WIPER RELAY

REAR WIPER MOTOR


COMMENTS ON TROUBLE SYMPTOM If the rear wiper does not stop normally within the predetermined range, the rear wiper motor or the ETACS-ECU may be defective.

SB : Sky blue

Possible causes Malfunction of the rear wiper motor Malfunction of the ETACS-ECU Damaged harness wires and connectors


Step 1. Connector check: F-02 rear wiper motor connector Connector: F-02

54B-137

Step 3. Measure the voltage at the F-02 rear wiper motor connector. Connector: F-02

F-02 Harness side

F-02 Harness side

4 3 2 1

4 3 2 1

AC301665 AB

AC301665 AB


Step 2. Check the rear wiper motor. Refer to GROUP 51 - Rear wiper and washer 351 .


4 3 2 1

Q: Is the check result normal? YES : Go to Step 3. NO : Replace the rear wiper motor. Connector F-02 (Harness side) AC301642 AB

(3) Check the voltage between F-02 rear wiper motor connector terminal No.4 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

Step 4. Check the wiring harness between ignition switch (ACC) and F-02 rear wiper motor connector terminal No.4. Connector: F-02 F-02 Harness side

4 3 2 1

AC301665 AB


54B-138

SYMPTOM PROCEDURES Q: Is the check result normal? YES : The trouble can be an intermittent

NOTE: Connectors: C-203, C-209 Junction block (Front view)


C-203

Step 5. Connector check: C-217 ETACS-ECU connector C-209

Connector: C-217



C-209 Harness side 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210475 AN

Connector: F-05


AC210477 AB


F-05

1 2 3 4 5 6 7 8 9 10

AC301666 AB

Prior to the wiring harness inspection, check intermediate connector F-05 and junction block connectors C-203, C-209 and repair if necessary. Check the power supply line for open or short circuit.


54B-139

SYMPTOM PROCEDURES

Step 6. Check the wiring harness between C-217 ETACS-ECU connector terminal No.17 and F-02 rear wiper motor connector terminal No.3.


Connector: C-217

Junction block (Rear view) C-209 Harness side 7 6 5 15 1413


12

4 3 2 1 11 10 9 8

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210475 AO

Connector: F-05 AC210477 AB

Connector: F-02 F-02 Harness side

4 3 2 1

AC301665 AB

F-05

1 2 3 4 5 6 7 8 9 10

AC301666 AB

Prior to the wiring harness inspection, check intermediate connector F-05 and junction block connectors C-209 and repair if necessary. Check the power supply line for open or short circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

54B-140


Step 7. Retest the system. Check that the rear wiper auto stop function works normally. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE G-3: When the shift lever is moved to "R" position during the rear wiper operation, the rear wiper does not operate at the continuous mode.


"R" Position During Rear Wiper Operation Circuit IGNITION SWITCH (ACC)


INPUT SIGNAL · BACK-UP LAMP SWITCH ("R" POSITION) · REAR WIPER SWITCH

REAR WIPER MOTOR

COMMENTS ON TROUBLE SYMPTOM If the rear wiper does not operate consecutively when the selector lever is moved to the R position during the rear wiper operation, the input signal circuit to the back-up lamp switch ("R" position) or the ETACS-ECU may be defective. Possible causes Malfunction of the back-up lamp switch Malfunction of the ETACS-ECU

Damaged harness wires and connectors Step 1. Confirm the operation of the rear wiper. Check that the rear wiper work normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure G-1 "The rear

wiper does not work at all 354B."


Step 2. Pulse check Check the input signal, which are related to the R (reverse) gear-linked rear wiper operation. System switch

Check conditions

Back-up lamp switch

When the ignition switch is turned ON and the shift lever is moved to the R position.

OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure N-3 "The

back-up lamp switch signal is not received 354B."

54B-141

Step 3. Retest the system. Check that the rear wiper operates consecutively when the shift lever is moved to the R position during the rear wiper operation. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-142


INSPECTION PROCEDURE G-4: The rear washer does not work.


Rear Washer Drive Circuit IGNITION SWITCH (ACC)

ETACS-ECU REAR WASHER RELAY

INPUT SIGNAL REAR WASH. SW

REAR WASHER MOTOR


COMMENTS ON TROUBLE SYMPTOM If the rear washer does not work normally, the input signal circuits to the rear washer switch, rear washer motor or the ETACS-ECU may be defective. Possible causes Malfunction of the rear washer motor Malfunction of the column switch Malfunction of the ETACS-ECU


wiper does not work at all 354B."


Step 2. Pulse check Check the input signals below which are related to the rear washer. Ignition switch: ACC System switch

Check conditions

Column switch (rear washer switch)




54B-143

Step 5. Measure the resistance at the A-27 rear washer motor connector. Connector: A-27

A-27 Harness side

1 2 A-27(G) AC210453 AG


Step 3. Connector check: A-27 rear washer motor connector 1 2

Connector: A-27

Connector A-27 (Harness side)

A-27 Harness side

AC301639 AB

1 2

(2) Resistance between A-27 rear washer motor connector terminal No.1 and body earth OK: 2 W or less A-27(G) AC210453 AG


Step 4. Check the rear washer motor. Refer to GROUP 51 - Rear wiper and washer 351 . Q: Is the check result normal? YES : Go to Step 5. NO : Replace the rear washer motor.


Step 6. Check the wiring harness between A-27 rear washer motor connector terminal No.1 and body earth. Connector: A-27

A-27 Harness side

1 2 A-27(G) AC210453 AG




54B-144

SYMPTOM PROCEDURES


Step 8. Check the wiring harness between C-220 ETACS-ECU connector terminal No.23 and A-27 rear washer motor connector terminal No.2. Connector: A-27

A-27 Harness side


1 2 A-27(G) AC210453 AG

Connector: C-220

C-220 Harness side

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210477 AE



C-220 Harness side

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210477 AE


NOTE:

54B-145

Step 9. Retest the system. Check that the rear washer works normally.

Connector: C-116



C-116

1 2

5 6 7

3 4

8 9

10 11 12 13 14

15

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301396 AB

Prior to the wiring harness inspection, check intermediate connector C-116 and repair if necessary. Check the output signal line. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.

54B-146


HEADLAMP WASHER

INSPECTION PROCEDURE H-1: The headlamp washer does not work.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamp Washer Motor Circuit FUSIBLE LINK 5

FRONT-ECU HEADLAMP WASHER

INPUT SIGNAL HEADLAMP WASHER

HEADLAMP WASHER MOTOR


COMMENTS ON TROUBLE SYMPTOM The headlamp washer motor, the column switch or the front-ECU may be defective. POSSIBLE CAUSES Malfunction of the headlamp washer motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the diagnosis code. When the ignition switch is turned to the LOCK (OFF) position, check that the ETACS-ECU does not set the diagnosis code. Q: Is the diagnosis code set? YES : Refer to diagnosis code chart 354B. NO : Go to Step 2.



Check conditions



Headlamp washer switch When the switch is turned from off to on.

Step 5. Measure the resistance at the A-25 headlamp washer motor connector. Connector : A-25

A-25 Harness side

2 1


3.

54B-147

A-25(B)

AC210453 AI


The ignition switch (ACC) signal is not received. :

Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354B." Headlamp washer switch signal is not received. :

Refer to inspection procedure N-5 "The column switch (headlamp washer switch) signal is not received 354B." Step 3. Connector check: A-25 headlamp washer motor connector Connector : A-25

2 1 Connector A-25 (harness side)

AC301725 AB

(2) Continuity between A-25 headlamp washer motor connector terminal No.2 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 6.

A-25 Harness side

Step 6. Check the wiring harness between A-25 headlamp washer motor connector terminal No.2 and body earth.

2 1

A-25(B)

AC210453 AI


Step 4. Check the headlamp washer motor assembly. Refer to GROUP 51 - Headlamp washer 351. Q: Is the check result normal? YES : Go to Step 5 NO : Replace the headlamp washer motor.

Connector : A-25

A-25 Harness side

2 1

A-25(B)

AC210453 AI




54B-148

SYMPTOM PROCEDURES



Relay box side

Relay box side

11 10 9 8 7 6 5 4 3 2 1

11 10 9 8 7 6 5 4 3 2 1

AC301483 AD


AC301483 AD

(1) Remove the front-ECU, and measure at the junction block side. (2) Ignition switch: ACC

11 10 9 8 7 6 5 4 3 2 1

Connector A-11X (Relay box side)

AC301726 AB



54B-149

SYMPTOM PROCEDURES

Step 9. Check the wiring harness between A-11X front-ECU connector terminal No.3 and the fusible link (5). Connector: A-11X

Step 10. Check the wiring harness between A-25 headlamp washer motor connector terminal No.1 and A-11X front-ECU connector terminal No.1. Connector: A-11X

Relay box side

Relay box side

11 10 9 8 7 6 5 4 3 2 1

11 10 9 8 7 6 5 4 3 2 1

AC301483 AD

Check the power supply line from the fusible link (5) for open circuit.

AC301483 AD

Connector : A-25



A-25 Harness side

2 1

A-25(B)

AC210453 AI

Check the output line to headlamp washer motor for open circuit. Q: Is the check result normal? YES : Go to Step 11. NO : Repair the wiring harness.

Step 11. Retest the system. The headlamp washer should now work normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-150


IGNITION KEY HOLE ILLUMINATION LAMP

INSPECTION PROCEDURE I-1: The ignition key cylinder illumination lamp does not illuminate/ extinguish normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Ignition Key Cylinder Illumination Lamp Circuit

ETACS-ECU FUSIBLE LINK 1

KEY REMINDER SWITCH KEY CYLINDER ILLUMINATION LAMP


COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Driver’s door switch Ignition switch (IG1) Key reminder switch Driver’s door switch Interior lamp loaded signal If this function does not work normally, these input signal circuit(s), the ignition key cylinder illumination lamp or the ETACS-ECU may be defective. Possible causes Malfunction of the key reminder switch Malfunction of the driver’s door switch

SB : Sky blue

Malfunction of the ignition key cylinder illumination lamp Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Check the operation of the room lamp. Check that the room lamps illuminate and extinguish normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure M-1 "The

front or rear room lamp does not illuminate/ extinguish 354B ." Or refer to inspection procedure M-2 "The front or rear room lamp does not illuminate/extinguish 354B ."


Step 2. Pulse check Check the input signals below, which are related to the ignition key cylinder illumination lamp. System switch

Check conditions



Key reminder switch*




NOTE: *: Vehicles with keyless entry system OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? All the signals are received normally. : Go to Step


Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354B." The key reminder switch signal is not received. :

Refer to inspection procedure N-9 "The key reminder switch signal is not received 354B."

54B-151

Step 3. Connector check: C-304 key reminder switch connector Connector: C-304

Harness side 2 1 7 6 5 4 3

AC301399 AB


Step 4. Check the bulb of the ignition key cylinder illumination lamp. Check the bulb of the ignition key cylinder illumination lamp. Q: Is the check result normal? YES : Go to Step 5. NO : Replace the bulb of the ignition key cylinder

illumination lamp.

The driver’s door switch signal is not received. :

Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354B."

Step 5. Connector check: C-219 ETACS-ECU connector Connector: C-219 Junction block (Rear view)


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE



54B-152

SYMPTOM PROCEDURES

Step 6. Check the wiring harness from C-219 ETACS-ECU connector terminal Nos. 69 and 71 to C-304 ignition key cylinder illumination lamp connector terminal Nos. 1 and 2. Connector: C-219 Junction block (Rear view)


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the ETACS-ECU. Harness side

C-219(GR)

Step 7. Retest the system. Check that the ignition key cylinder illumination lamp illuminates/extinguishes normally.

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

Connector: C-304


AC301399 AB

Check the input and output lines for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.


54B-153

HEADLAMP AND TAIL LAMP

INSPECTION PROCEDURE J-1: The tail lamps do not illuminate normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Tail Lamp Relay Circuit BATTERY

FRONT-ECU

INPUT SIGNAL TAIL LAMP RELAY

· HEADLAMP AUTOMATIC SHUTDOWN · TAIL LAMP SWITCH

RELAY BOX

· LICENSE PLATE LAMP · POSITION LAMP (LH) · REAR COMBINATION LAMP (LH)

· POSITION LAMP (RH) · REAR COMBINATION LAMP (RH)

COMMENTS ON TROUBLE SYMPTOM If all the tail lamps do not illuminate, the tail lamp switch input circuit or the front-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors




54B-154

SYMPTOM PROCEDURES

Step 2. Pulse check Check the input signal from the tail lamp switch. System switch

Check conditions



Tail lamp switch





Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354B." The tail lamp switch signal is not received. : Refer to inspection procedure N-5 "The column switch (lighting and turn-signal lamp switch) signal is not received 354B."

Relay box side 11 10 9 8 7 6 5 4 3 2 1

AC301483 AD



Connector: A-11X


AC301541 AD

(2) Voltage between A-11X front-ECU connector terminal No.7 and body earth OK: System voltage Relay box side


11 10 9 8 7 6 5 4 3 2 1

AC301483 AD


Step 5. Check the wiring harness between A-11X front-ECU connector terminal No.7 and the battery. Check the power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-155

Step 6. Retest the system. Check that the tail lamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE J-2: The low-beam headlamps do not illuminate normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamp Relay (Low-Beam) Circuit BATTERY

FRONT-ECU

INPUT SIGNAL HEADLAMP RELAY: LO

· HEADLAMP AUTOMATIC SHUTDOWN · HEADLAMP SWITCH

RELAY BOX

HEADLAMP (LH)

HEADLAMP (RH)

COMMENTS ON TROUBLE SYMPTOM If the low-beam headlamps do not illuminate, the headlamp switch input circuit or the front-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors




54B-156

SYMPTOM PROCEDURES

Step 2. Pulse check Check the input signal from the headlamp switch. System switch

Check conditions



Headlamp switch





Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354B." The headlamp switch signal is not received. :

Relay box side 11 10 9 8 7 6 5 4 3 2 1

Refer to inspection procedure N-5 "The column switch (lighting and turn-signal lamp switch) signal is not received 354B." AC301483 AD



Connector: A-11X


AC301541 AE

(2) Voltage between A-11X front-ECU connector terminal Nos. 8, 9 and body earth OK: System voltage Relay box side


11 10 9 8 7 6 5 4 3 2 1

AC301483 AD



Step 5. Check the wiring harness between A-11X front-ECU connector terminal Nos. 8, 9 and the battery.

54B-157

Step 6. Retest the system. Check that the low-beam headlamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent

Connector: A-11X


Relay box side 11 10 9 8 7 6 5 4 3 2 1

AC301483 AD




54B-158

SYMPTOM PROCEDURES

INSPECTION PROCEDURE J-3: The high-beam headlamps do not illuminate normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamp Relay (High-Beam) Circuit BATTERY

FRONT-ECU

INPUT SIGNAL HEADLAMP RELAY: HI


RELAY BOX

· COMBINATION METER · HEADLAMP (LH)

HEADLAMP (RH)

COMMENTS ON TROUBLE SYMPTOM If the high-beam headlamps do not illuminate, the dimmer switch input circuit or the front-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Check that the headlamps operate. Check that the low-beam headlamps illuminate and extinguish normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure J-2 "The low-

beam headlamps do not illuminate normally 354B."


Step 2. Pulse check Check the input signal from the dimmer switch. System switch

Check conditions

Dimmer switch

When the dimmer switch is turned from off to on


column switch (lighting and turn-signal lamp switch) signal is not received 354B." Step 3. Retest the system. Check that the high-beam headlamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-159

INSPECTION PROCEDURE J-4: The high-beam and low-beam headlamps do not illuminate when the passing switch is operated.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. COMMENTS ON TROUBLE SYMPTOM If the low-beam and high-beam headlamps are normal, the passing switch input signal circuit or the front-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

Step 2. Pulse check Check the input signal from the passing switch. System switch

Check conditions

Passing lamp switch

When the passing switch is turned from off to on


column switch (lighting and turn-signal lamp switch) signal is not received 354B."

DIAGNOSTIC PROCEDURE Step 1. Check that the headlamps operate. Check that the low-beam and high-beam headlamps work normally. Q: Is the check result normal? YES : Go to Step 2. NO : Repair the headlamps. Refer to trouble

symptom chart 354B.

Step 3. Retest the system. When the passing switch is turned on, check if the headlamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE J-5: The headlamp automatic shutdown function does not work normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamp Automatic Shutdown Function ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below.

Ignition switch (IG1) Driver’s door switch Tail lamp switch

54B-160


Headlamp switch If this function does not work normally, these input signal circuit(s), the front-ECU or the ETACS-ECU may be defective. Note that this function can be disabled/enabled by the adjustment function (default setting; enabled). Possible causes Malfunction of the driver’s door switch Malfunction of the front-ECU Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Check the adjustment function. Check that the headlamp automatic shutdown function has been enabled by using the adjustment function. Q: Is the check result normal? YES : Go to Step 2. NO : Enable the headlamp automatic shutdown

function by using the adjustment function. Refer to 354B. Step 2. Check that the headlamps operate. Check that the low-beam and high-beam headlamps work normally. Q: Is the check result normal? YES : Go to Step 3. NO : Repair the headlamps. Refer to trouble

symptom chart 354B.

Step 3. Pulse check Check the input signals below, which are related to the headlamp automatic shutdown function. System switch

Check conditions





Tail lamp switch





Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354B." The tail lamp switch signal is not received. : Refer to inspection procedure N-5 "The column switch (lighting and turn-signal lamp switch) signal is not received 354B." Step 4. Retest the system. Replace the ETACS-ECU, and then check that the headlamp automatic shutdown function works normally. (1) Replace the ETACS-ECU. (2) Check that the headlamp automatic shutdown function works normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-161

SYMPTOM PROCEDURES

INSPECTION PROCEDURE J-6: Any of tail lamps, position lamps or licence plate lamp does not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Tail Lamps, Position Lamps and License Plate Lamps Circuit

TAIL LAMP RELAY

FRONT-ECU

RELAY BOX

HEADLAMP ASSEMBLY (POSITION) (LH) (RH)

REAR COMBINATION LAMP (TAIL: LH)

LICENCE PLATE LAMP (LH) (RH)


COMMENTS ON TROUBLE SYMPTOM If the tail lamps, the position lamps or the licence plate lamps do not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.

REAR COMBINATION LAMP (TAIL: RH)

SB : Sky blue

Possible causes Burned-out bulb Damaged harness wires and connectors


54B-162

SYMPTOM PROCEDURES



Step 1. Connector check: D-14 or D-19 rear combination lamp connector, A-29 or A-16 headlamp assembly connector, F-08 or F10 licence plate lamp connector

F-10(GR)

F-08(GR)

Connector: A-16

Harness side F-08

F-10

2 1

2 1


A-16(B) AC210455 AD

AC301666 AD

Connector: A-29

Q: Is the check result normal? YES : Go to Step 2. NO : Repair the defective connector. Harness side 3 2 1 6 5 4

Step 2. Check the bulbs of the tail lamps, the position lamp or the licence plate lamp. Check the bulb of the lamp which does not illuminate.

A-29(B)

AC210453 AC


Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb of the lamp which does not

illuminate. D-14

D-19

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

AC301411AB


Step 3. Measure the resistance at the D-14 or D-19 rear combination lamp connector, the A-29 or A-16 headlamp assembly connector, the F-08 or F-10 licence plate lamp connector.

54B-163


F-10(GR)

Connector: A-16

F-08(GR)

Harness side

Harness side

3 2 1 6 5 4

A-16(B)

F-08

F-10

2 1

2 1

AC210455 AD

Connector: A-29 AC301666 AD

(1) Disconnect the connector, and measure at the wiring harness side. (2) Check the resistance between the lamp connector and body earth.


A-29(B)

AC210453 AC

Connector A-16, A-29 (Harness side)


D-14

D-19

3 2 1 6 5 4 AC301541AI

Resistance between A-16 headlamp assembly connector terminal No.1 and body earth Resistance between A-29 headlamp assembly connector terminal No.1 and body earth

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

Connector D-14, D-19 (Harness side) 1 2 6 5 4 3

AC301411AB

AC301541BG


54B-164

SYMPTOM PROCEDURES

Resistance between D-14 rear combination lamp connector terminal No.3 and body earth Resistance between D-19 rear combination lamp connector terminal No.3 and body earth

Connector F-08, F-10 (Harness side) 2 1

AC301541BM

Resistance between F-08 licence plate lamp connector terminal No.1 and body earth Resistance between F-10 licence plate lamp connector terminal No.1 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.


54B-165

SYMPTOM PROCEDURES

Step 4. Check the wiring harness from D-14 or D-19 rear combination lamp connector terminal No.3, A-29 or A-16 headlamp connector terminal No.1 or F-08 or F-10 licence plate lamp connector terminal No.1 to body earth.

Connectors: F-08, F-09, F-10

F-10(GR)

Connector: A-16

F-08(GR) F-09(GR)

F-09


A-16(B) AC210455 AD

1 2 3 4

Harness side F-08 2 1

F-10 2 1


NOTE: Prior to the wiring harness inspection, check intermediate connector F-09 , and repair if necessary. Check the earth wires for open circuit.


A-29(B)

AC210453 AC


D-14

D-19

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

AC301411AB



54B-166

SYMPTOM PROCEDURES


Relay box side 11 10 9 8 7 6 5 4 3 2 1

AC301483 AD



54B-167

SYMPTOM PROCEDURES

Step 6. Check the wiring harness from D-14 or D-19 rear combination lamp connector terminal No.2, A-29 or A-16 headlamp assembly connector terminal No.2, F-08 or F-10 licence plate lamp connector terminal No.2 to A-11X front-ECU connector terminal No.4.


D-14

D-19

Connector: A-11X

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

AC301411AB

Connectors: F-08, F-09, F-10 Relay box side 11 10 9 8 7 6 5 4 3 2 1

F-10(GR) AC301483 AD

F-08(GR)

Connector: A-16

F-09(GR)

F-09 Harness side 3 2 1 6 5 4

A-16(B)

1 2 3 4


F-10 AC210455 AD

Connector: A-29

2 1

AC301666 AD


A-29(B)

AC210453 AC


54B-168

SYMPTOM PROCEDURES

NOTE:

Connector: D-31 Connectors: C-01, C-116, C-117 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

C-01

C-117

AC301408 AE

C-116

C-01

C-116 1 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

5 6 7

3 4

10 11 12 13 14

15

8 9

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

C-117 1 2 3

4 5 6 7 8 9 10

111213

14 1516 17 18 19 20 2122 232425 26 2728 29 32 33 34

35

30 31 36 37

38

AC301396 AN


Prior to the wiring harness inspection, check joint connector C-01 , intermediate connector C-116 , C-117 , D-31 , F-09 , junction block connector C-202 and C-209 , and repair if necessary. Check the output lines for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

Step 7. Retest the system. Check that the tail lamps, the position lamps and the licence plate lamps illuminate normally. Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent

C-202

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). When the tail lamps do not illuminate : Replace the rear combination lamp socket assembly.

C-209

When the position lamps do not illuminate :

Replace the position lamp socket. When the licence plate lamps do not illuminate :

Harness side C-202 6 5 4 3 2 1 14 13 12 11 10 9 8 7

Replace the licence plate lamp socket. C-209

7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210475 AJ


54B-169

INSPECTION PROCEDURE J-7: The headlamp(s) do not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamps (High-Beam Indicator Lamp) Circuit FRONT-ECU HEADLAMP RELAY: LO

HEADLAMP RELAY: HI

RELAY BOX

HEADLAMP (LH) (RH)

COMBINATION METER


COMMENTS ON TROUBLE SYMPTOM If any of the headlamps or the high-beam indicator does not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.

SB : Sky blue

Possible causes Malfunction of the headlamp bulbs Malfunction of the high-beam indicator bulb Damaged harness wires and connectors


54B-170

SYMPTOM PROCEDURES

DIAGNOSTIC PROCEDURE Step 1. Connector check: A-30 , A-15 headlamp assembly connector or C-05 combination meter connector

Step 2. Check the bulb(s) of the headlamps or the high-beam indicator lamp. Check the bulb(s) of the defective lamp. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb(s) of the defective lamp.

Connector: A-15

A-15(B) Harness side

Step 3. Measure the resistance at A-30 , A-15 headlamp assembly connector or C-05 combination meter connector. Connector: A-15

1 3 Y 2

A-15(B) AC210455 AC

Harness side

Connector: A-30

1 3 Y 2

AC210455 AC

A-30(B) Connector: A-30

Harness side 1 3 Y 2

AC210453 AD

Connector: C-05

A-30(B)

C-05(L)


AC210453 AD

Harness side (front view) Connector: C-05

C-05(L)

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301395 AE


Harness side (front view) 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301395 AE



54B-171

SYMPTOM PROCEDURES

(2) Check the resistance between the lamp connector and body earth.


Step 4. Check the wiring harness from A-30 or A-15 headlamp connector terminal No.2, or C-05 combination meter connector terminal No.8 to body earth. Connector: A-15

1 3 Y 2

A-15(B) Harness side AC301541AH


1 3 Y 2

AC210455 AC

Connector: A-30


A-30(B) Harness side 1 3 Y 2

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

AC210453 AD

G

Connector: C-05 AC301541 AO

Resistance between C-05 combination meter connector terminal No.8 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

C-05(L)


G

G

AC301395 AE

Check the earth wires for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.


54B-172

SYMPTOM PROCEDURES


Relay box side 11 10 9 8 7 6 5 4 3 2 1

AC301483 AD



Step 6. Check the wiring harness from A-30 , A-15 headlamp connector terminal No.1 , No.3 , C-05 combination meter connector terminal No.9 to A-11X front-ECU connector terminal No.6 or No.10 .

54B-173

Connector: A-11X

Connector: A-15

A-15(B) Harness side Relay box side

1 3 Y 2

11 10 9 8 7 6 5 4 3 2 1

AC210455 AC


NOTE: Prior to the wiring harness inspection, check intermediate connector C-116 , and repair if necessary. Check the output lines for open circuit.


AC210453 AD

Connectors: C-05, C-116 C-05(L)


Step 7. Retest the system. Check that the headlamps and the high-beam indicator lamp illuminate/extinguish normally. Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent

C-116

When the high-beam indicator lamp does not illuminate : Replace the combination meter.

C-116 1 2

5 6 7

3 4

10 11 12 13 14

15

8 9

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

Harness side C-05 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). When the headlamps do not illuminate : Replace the headlamp socket.

AC301396 AJ


54B-174

SYMPTOM PROCEDURES

FLASHER TIMER

INSPECTION PROCEDURE K-1: The turn-signal lamps do not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Turn-Signal Lamp Power Supply Circuit BATTERY

RELAY BOX

ETACS-ECU TURN-SIGNAL LAMP RELAY: RH

TURN-SIGNAL LAMP RELAY: LH

· FRONT TURN SIGNAL LAMP (LH) · SIDE TURN SIGNAL LAMP (LH)


· FRONT TURN SIGNAL LAMP (RH) · SIDE TURN SIGNAL LAMP (RH)

COMBINATION METER


COMMENTS ON TROUBLE SYMPTOM If all the turn-signal lamps do not illuminate, the ignition switch (IG1), the turn-signal lamp switch input circuit or the ETACS-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSTIC PROCEDURE Step 1. Check that the hazard warning lamps operate. Check that the hazard warning lamps illuminate normally. Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 2.



54B-175

Step 4. Check the wiring harness between C-217 ETACS-ECU connector terminal No.11 and the battery. Connector: C-217 Junction block (Rear view)


20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

AC210476 AC




1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Junction block side


20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC


Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC210474 AB


Prior to the wiring harness inspection, check intermediate connector C-116 and junction block connector C-202, and repair if necessary. Check the power supply line for open circuit.

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AC301541AU

(2) Voltage between C-217 ETACS-ECU connector terminal No.11 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.



54B-176


Step 5. Retest the system. Check that the turn-signal lamps illuminate normally.

Step 7. Retest the system. Check that the turn-signal lamps illuminate.



malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the ETACS-ECU. Step 6. Pulse check Check the input signals below, which are related to the turn-signal lamp illumination. System switch

Check conditions

Turn-signal lamp switch (RH)

When the turn-signal lamp switch (RH) is turned from off to on

Turn-signal lamp switch (LH)

When the turn-signal lamp switch (LH) is turned from off to on


7. The turn-signal lamp switch (RH) signal is not received. : Refer to inspection procedure N-5 "The

column switch (lighting and turn-signal lamp switch) signal is not received 354B." The turn-signal lamp switch (LH) signal is not received. : Refer to inspection procedure N-5 "The

column switch (lighting and turn-signal lamp switch) signal is not received 354B."



54B-177

INSPECTION PROCEDURE K-2: The hazard warning lamps do not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Hazard Warning Lamp Circuit BATTERY

RELAY BOX

ETACS-ECU INPUT SIGNAL TURN-SIGNAL LAMP RELAY: RH


· COMBINATION METER · FRONT TURN SIGNAL LAMP (LH) · REAR COMBINATION LAMP (LH) · SIDE TURN SIGNAL LAMP (LH)


· COMBINATION METER · FRONT TURN SIGNAL LAMP (RH) · REAR COMBINATION LAMP (RH) · SIDE TURN SIGNAL LAMP (RH)


COMMENTS ON TROUBLE SYMPTOM If the hazard warning lamps do not illuminate, the hazard warning lamp input signal circuit or the ETACS-ECU may be defective. Possible causes Malfunction of the hazard warning lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSTIC PROCEDURE Step 1. Check that the turn-signal lamps operate. Check that the turn-signal lamps illuminate normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure K-1 "The turn

signal lamps do not illuminate 354B."

54B-178


Step 2. Check the power supply circuit. When the ignition switch is at the LOCK (OFF) position, check that the functions below work normally. Lamp reminder function Central door locking system Dome lamp (excluding interior lamp automatic shutdown function) Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure A-2 "Check


Step 3. Pulse check Check the input signal from the hazard warning lamp switch. System switch

Check conditions


When the hazard warning lamp switch is turned from off to on

OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? The signal is received normally. : Go to Step 4. The hazard warning lamp switch signal is not received. : Refer to inspection procedure N-10

"The hazard warning lamp switch signal is not received 354B." Step 4. Retest the system. Check that the hazard warning lamps illuminate. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-179

INSPECTION PROCEDURE K-3: Any of the turn-signal lamps does not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Turn-Signal Lamps Circuit

ETACS-ECU

SIDE TURN SIGNAL LAMP (LH)

HEADLAMP ASSEMBLY (FRONT TURN: LH)

REAR COMBINATION LAMP (LH)

COMBINATION METER (LH) (RH)


SB : Sky blue

54B-180

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR SYMPTOM PROCEDURES Turn-Signal Lamps Circuit

ETACS-ECU

REAR COMBINATION LAMP (RH)

COMMENTS ON TROUBLE SYMPTOM If any of the turn-signal lamp does not illuminate normally, wiring harness connector(s) or the bulb may be defective.

HEADLAMP ASSEMBLY (FRONT TURN: RH)

SIDE TURN SIGNAL LAMP (RH)

Possible causes Defective turn-signal lamp bulb Damaged harness wires and connectors


54B-181

SYMPTOM PROCEDURES


Connectors: A-04, A-16

A-04(GR)

Step 1. Connector check: A-29 or A-16 front turn-signal lamp connector, A-01 or A-04 side turn-signal lamp connector, D-14 or D-19 rear combination lamp connector, C-05 and C-04 combination meter connector

A-16(B)

Connectors: A-01, A-29 A-01(GR) Harness side A-04

A-16

2 1

3 2 1 6 5 4

A-29(B) AC210456 AB

Connectors: C-04, C-05 C-05(L) C-04

Harness side A-29 A-01 2 1

3 2 1 6 5 4

AC210454 AB

Harness side C-05

C-04 41 4039 38 3736 35 3433 32 31 52 51 50 49 48 47 46 4544 43 42

G

G

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301396 AH


54B-182

SYMPTOM PROCEDURES

Step 2. Check the bulb(s) of the turn-signal lamps or the turn-signal indicator lamps. Check the bulb(s) of the defective lamp.


D-14

D-19

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

AC301411AB


Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb(s) of the defective lamp.


54B-183

SYMPTOM PROCEDURES

Step 3. Measure the resistance at the A-29 or A-16 front turn-signal lamp connector, the A-01 or A-04 side turn-signal lamp connector, the D-14 or D-19 rear combination lamp connector, the C-05 and C-04 combination meter connector.


Connectors: A-01, A-29 A-01(GR)

Harness side C-05

C-04 41 4039 38 3736 35 3433 32 31 52 51 50 49 48 47 46 4544 43 42

A-29(B)

G

G

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301396 AH



D-14

3 2 1 6 5 4

D-19

AC210454 AB


A-04(GR)

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

A-16(B)

AC301411AB

(1) Disconnect the connector, and measure at the wiring harness side. (2) Measure the resistance between the defective lamp connector terminal and body earth.

Harness side A-04

A-16

2 1

3 2 1 6 5 4

AC210456 AB


54B-184

SYMPTOM PROCEDURES



11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

3 2 1 6 5 4 AC301541AI



2 1

AC301541AB

Resistance between A-01 side turn-signal lamp connector terminal No.1 and body earth Resistance between A-04 side turn-signal lamp connector terminal No.1 and body earth


AC301541BG


AC301541 AP

Resistance between C-05 combination meter terminal No.12 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.


54B-185

SYMPTOM PROCEDURES

Step 4. Check the wiring harness from A-29 or A-16 front turn-signal lamp connector terminal No.2, A-01 or A-04 side turn-signal lamp connector terminal No.1, D-14 or D-19 rear combination lamp connector terminal No.3, or C-05 combination meter connector terminal No.12 to body earth.



Harness side C-05

C-04 41 4039 38 3736 35 3433 32 31 52 51 50 49 48 47 46 4544 43 42

A-29(B)

G

G

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301396 AH



D-14

3 2 1 6 5 4

D-19

AC210454 AB


A-04(GR)

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

A-16(B)

AC301411AB

Harness side A-04

A-16

2 1

3 2 1 6 5 4

AC210456 AB

54B-186


NOTE:


Connector: C-14

Connector: C-217 Junction block (Rear view) 1 2 3 4 5 6 7 8 9 10

AC301397 AC

Prior to the wiring harness inspection, check intermediate connector C-14 , and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



AC210476 AC



54B-187

SYMPTOM PROCEDURES

Step 6. Check the wiring harness from the A-29 or A-16 front turn-signal lamp connector terminal No.3, the A-01 or A-04 side turn-signal lamp connector terminal No.2, the D-14 or D-19 rear combination lamp connector terminal No.6, the C-05 combination meter connector terminal No.10 or C-04 combination lamp connector terminal No.31 to C217 ETACS-ECU connector terminal No.9 or 14 .


A-04(GR)

A-16(B)


Harness side A-04

A-16

2 1

3 2 1 6 5 4

AC210456 AB

A-29(B) Connectors: C-04, C-05, C-116

C-05(L) C-04


3 2 1 6 5 4

C-116 C-116 AC210454 AB

Harness side C-04

C-05

41 4039 38 3736 35 3433 32 31 52 51 50 49 48 47 46 4544 43 42

G

G

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301396 AI


54B-188

SYMPTOM PROCEDURES

NOTE:


Connector: C-14

1 2 3 4 5 6 7 8 9 10


AC210476 AC


AC301397 AC

Connectors: C-202, C-205, C-209 Junction block (Front view) D-14

D-19

C-202 C-205

C-209

Harness side

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

C-205

C-202 6 5 4 3 2 1 14 13 12 11 10 9 8 7

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-209 AC301411AB

7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210475 AH

Connector: D-31 3 4 1 2 5 6 7 8 9 10 1112 13 14 15 16

AC301408 AE

Prior to the wiring harness inspection, check intermediate connector C-14 , C-116 or D-31 and junction block connector C-202 , C-209 or C-205 , and repair if necessary. Check the output lines for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.


Step 7. Retest the system. Check that the turn-signal lamps and the indicator lamps illuminate normally. Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). The front turn-signal lamps do not illuminate. :

Replace the socket. The side turn-signal lamps do not illuminate. :

Replace the socket. The rear turn-signal lamps do not illuminate. :

Replace the socket assembly. The turn-signal indicator lamps do not illuminate. :

Replace the combination meter.

54B-189

54B-190


FOG LAMP

INSPECTION PROCEDURE L-1: The front fog lamps do not illuminate normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Front Fog Lamp Circuit BATTERY

RELAY BOX

FRONT FOG LAMP RELAY

FRONT-ECU FRONT FOG LAMP (LH)

FRONT FOG LAMP (RH)

COMBINATION METER


OPERATION The ETACS-ECU operates this function in accordance with the input signals below. Tail lamp switch Headlamp switch Front fog lamp switch

SB : Sky blue

If the front fog lamps do not illuminate normally, these input signal circuit(s) or the ETACS-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front fog lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors


DIAGNOSTIC PROCEDURE Step 1. Check that the tail lamps and headlamps operate. Check that the tail lamps and headlamps illuminate normally.

54B-191

Step 3. Connector check: A-05X front fog lamp relay connector. Connector: A-05X

Q: Is the check result normal? YES : Go to Step 2. NO : Check the tail lamps and the headlamps

(Refer to trouble symptom chart 354B). Step 2. Pulse check Check the input signals below, which are related to the front fog lamps. System switch

Check conditions



Tail lamp switch


Headlamp switch


Front fog lamp switch

When the front fog lamp switch is turned from off to on



Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354B." The tail lamp switch signal is not received. : Refer to inspection procedure N-5 "The column switch (lighting and turn-signal lamp switch) signal is not received 354B." The headlamp switch signal is not received. :

Refer to inspection procedure N-5 "The column switch (lighting and turn-signal lamp switch) signal is not received 354B." The front fog lamp switch signal is not received. :

Refer to inspection procedure N-15 "The front fog lamp switch signal is not received 354B."

Relay box side 2

1

4

3

Front of vehicle

AC301483AC


Step 4. Check the front fog lamp relay. Refer to GROUP 54A - Front fog lamp 354A. Q: Is the check result normal? YES : Go to Step 5. NO : Replace the front fog lamp relay.


54B-192

SYMPTOM PROCEDURES

Step 5. Measure the voltage at the A-05X front fog lamp relay connector. Connector: A-05X

Step 6. Check the wiring harness between A-05X front fog lamp relay connector (terminal Nos. 1 and 2) and the battery. Connector: A-05X

Relay box side 2

1

4

3

Relay box side

Front of vehicle

2

1

4

3

Front of vehicle AC301483AC

(1) Remove the front fog lamp relay, and measure at the relay box side.

AC301483AC


2

1

4

3


Connector A-05X (Relay box side) AC301541AC

(2) Check the voltage between the front fog lamp relay connector and body earth. Voltage between A-05X front fog lamp relay connector terminal No.1 and body earth Voltage between A-05X front fog lamp relay connector terminal No.2 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 6.


54B-193

SYMPTOM PROCEDURES


Step 8. Check the wiring harness between A-05X front fog lamp relay connector terminal No.3 and A-11X front-ECU connector terminal No.11. Connectors: A-05X, A-11X A-11X

A-05X

-

Relay box side

Relay box side A-05X 11 10 9 8 7 6 5 4 3 2 1

2

1

4

3

A-11X 11 10 9 8 7 6 5 4 3 2 1

Front of vehicle AC301483 AD AC301483 AB


Check the output lines for open circuit. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.

Step 9. Retest the system. Check that the front fog lamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-194


INSPECTION PROCEDURE L-2: The rear fog lamps do not illuminate normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Rear Fog Lamp Circuit FUSIBLE LINK 1

REAR FOG LAMP RELAY

COMBINATION METER REAR FOG LAMP

ETACS-ECU


OPERATION The ETACS-ECU operates this function in accordance with the input signals below. Tail lamp switch Headlamp switch Rear fog lamp switch If the rear fog lamps do not illuminate normally, these input signal circuit(s) or the ETACS-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the fog lamp switch Malfunction of the ETACS-ECU

SB : Sky blue


DIAGNOSTIC PROCEDURE Step 1. Check that the tail lamps and headlamps operate. Check that the tail lamps and headlamps illuminate normally. Q: Is the check result normal? YES : Go to Step 2. NO : Check the tail lamps and the headlamps

(Refer to trouble symptom chart 354B).


54B-195

SYMPTOM PROCEDURES

Step 2. Pulse check Check the input signals below, which are related to the rear fog lamps. System switch

Check conditions



Tail lamp switch


Headlamp switch


When the lighting switch is turned to the HEADLAMP position When the rear fog lamp switch is turned from off to on



Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354B." The tail lamp switch signal is not received. : Refer to inspection procedure N-5 "The column switch (lighting and turn-signal lamp switch) signal is not received 354B." The headlamp switch signal is not received. :

Refer to inspection procedure N-5 "The column switch (lighting and turn-signal lamp switch) signal is not received 354B." The rear fog lamp switch signal is not received. :

Refer to inspection procedure N-16 "The rear fog lamp switch signal is not received 354B."

Step 2. Connector check: C-212 rear fog lamp relay connector Connector: C-212 Junction block (Front view)

Junction block side 2 1 4 3

AC210474 AI


Step 3. Check the rear fog lamp relay. Refer to GROUP 54A - Rear fog lamp 354A. Q: Is the check result normal? YES : Go to Step 4. NO : Replace the rear fog lamp relay.


54B-196

SYMPTOM PROCEDURES

Step 4. Measure the voltage at the C-212 rear fog lamp relay connector. Connector: C-212 Junction block (Front view)

Step 5. Check the wiring harness between C-212 rear fog lamp relay connector (terminal Nos. 3 and 4) and the battery. Connectors: C-201, C-204, C-205, C-212 Junction block (Front view) C-204


C-205

2 1 4 3

AC210474 AI

Junction block side C-212

C-212

(1) Remove the rear fog lamp relay, and measure at the relay box side.

2 1 4 3

Harness side C-201 C-204

Connector C-212 (Relay box side)

5 4 3 2 1 13121110 9 8 7 6

2 1 4 3

1

C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210475 AE AC301541 AR

(2) Check the voltage between the rear fog lamp relay connector and body earth. Voltage between C-212 rear fog lamp relay connector terminal No.3 and body earth Voltage between C-212 rear fog lamp relay connector terminal No.4 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

AC301395 AH

Prior to the wiring harness inspection, check intermediate connector C-116 and junction block connectors C-201, C-204 and C-205, and repair if necessary. Check the power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-197

SYMPTOM PROCEDURES


Step 7. Check the wiring harness between C-212 rear fog lamp relay connector terminal No.2 and C-219 ETACS-ECU connector terminal No.74. Connectors: C-201, C-212 Junction block (Front view) C-201


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


C-212

Harness side

Junction block side

C-201

C-212

5 4 3 2 1 13121110 9 8 7 6

2 1 4 3

AC210475 AF



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE

NOTE: Prior to the wiring harness inspection, check junction block connector C-201, and repair if necessary. Check the output lines for open circuit. Q: Is the check result normal? YES : Go to Step 8. NO : Repair the wiring harness.

Step 8. Retest the system. Check that the rear fog lamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-198


INSPECTION PROCEDURE L-3: The front fog lamp(s) do not illuminate.


RELAY BOX



FRONT FOG LAMP (RH)

COMBINATION METER


COMMENTS ON TROUBLE SYMPTOM If any of the front fog lamps do not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.

SB : Sky blue

Possible causes Burned-out front fog lamp bulb Damaged harness wires and connectors


DIAGNOSTIC PROCEDURE Step 1. Connector check: A-24 or A-19 front fog lamp connector, or C-05 combination meter connector Connector: A-19

Harness side A-19(B) 2 1

AC210455 AE

Connector: A-24

Harness side 2 1

A-24(B) AC210453 AB

Connector: C-05

C-05(L)


G

G

AC301395 AE


54B-199

Step 2. Check the bulbs of the front fog lamps or the front fog lamp indicator lamp. Check the bulb(s) of the defective lamp. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb(s) of the defective lamp.


54B-200

SYMPTOM PROCEDURES

Step 3. Measure the resistance at A-24 or A-19 front fog lamp connector, or C-05 combination meter connector.

Resistance between A-19 front fog lamp connector terminal No.2 and body earth


Connector: A-19 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

Harness side A-19(B)

AC301541 AP

2 1

AC210455 AE

Connector: A-24


Harness side 2 1

A-24(B) AC210453 AB

Connector: C-05

C-05(L)


G

G

AC301395 AE



2 1 AC301541 AJ



Step 4. Check the wiring harness from A-24 or A-19 front fog lamp connector terminal No.2 or C-05 combination meter connector terminal No.12 to body earth.

54B-201

Step 5. Connector check: A-05X fog lamp relay connector Connector: A-05X

Connector: A-19


AC210455 AE

Relay box side

Connector: A-24

2

1

4

3

Front of vehicle

Harness side

AC301483AC

2 1

A-24(B) AC210453 AB

Connector: C-05

C-05(L)


G

G

AC301395 AE





54B-202

SYMPTOM PROCEDURES

Step 6. Check the wiring harness from A-24 or A-19 front fog lamp connector terminal No.1 or C-05 combination meter connector terminal No.7 to A05X fog lamp relay connector terminal No.4.


Connector: A-05X

C-116 C-116 1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

Harness side C-05 Relay box side 2

1

4

3

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

Front of vehicle

AC301483AC

G

AC301396 AJ

NOTE: Prior to the wiring harness inspection, check intermediate connector C-116 , and repair if necessary. Check the output lines for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

Connector: A-19

Step 7. Retest the system. Check that the fog lamp and the front fog lamp indicator lamp illuminate normally.


AC210455 AE

Connector: A-24

Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). The fog lamps do not illuminate. : Replace the fog lamp(s). The front fog lamp indicator lamp does not illuminate. : Replace the combination meter.

Harness side 2 1

A-24(B) AC210453 AB


54B-203

INSPECTION PROCEDURE L-4: Any of the rear fog lamps does not illuminate.


REAR FOG LAMP RELAY


ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM If any of the rear fog lamps do not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.

SB : Sky blue

Possible causes Burned-out rear fog lamp bulb Damaged harness wires and connectors


54B-204

SYMPTOM PROCEDURES

DIAGNOSTIC PROCEDURE Step 1. Connector check: F-12 rear fog lamp connector or C-05 combination meter connector Connector: C-05

Step 3. Measure the resistance at the F-12 rear fog lamp connector or C-05 combination meter connector. Connector: C-05

C-05(L)

C-05(L) Harness side (front view)

Harness side (front view)

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301395 AE

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301395 AE

Connector: F-12 Harness side

Connector: F-12

2 1

Harness side 2 1

F-12(B) F-12(B)

AC301665 AD

AC301665 AD


Step 2. Check the bulbs of the rear fog lamps or the rear fog lamp indicator lamp. Check the bulb(s) of the defective lamp. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb(s) of the defective lamp.



54B-205

SYMPTOM PROCEDURES

(2) Check the resistance between the lamp connector and body earth.

Connector F-12 (Harness side)

Step 4. Check the wiring harness from F-12 rear fog lamp connector terminal No.1, C-05 combination meter connector terminal No.12 to body earth. Connector: C-05

C-05(L)

2 1

Harness side (front view) AC301541BN

Resistance between F-12 rear fog lamp relay connector terminal No.1 and body earth

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301395 AE



11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301541 AP


F-12(B)

F-09(GR)

Harness side F-09 1 2 3 4

F-12

2 1

AC301666 AF

NOTE: Prior to the wiring harness inspection, check intermediate connector F-09 , and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-206



Step 6. Check the wiring harness from F-12 rear fog lamp connector terminal No.2, C-05 combination meter connector terminal No.5 to C-212 rear fog lamp relay connector terminal No.1. Connector: C-05

C-05(L)

Junction block side Harness side (front view)

2 1 4 3

AC210474 AI 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12


G

G

AC301395 AE

Connectors: C-201, C-212 Junction block (Front view) C-201

C-212

Harness side

Junction block side

C-201

C-212

5 4 3 2 1 13121110 9 8 7 6

2 1 4 3

AC210475 AF

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR SYMPTOM PROCEDURES Connectors: C-05, C-117 C-05(L)

54B-207

Step 7. Retest the system. Check that the rear fog lamp and the rear fog lamp indicator lamp illuminate normally. Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). The rear fog lamps do not illuminate. : Replace the rear fog lamp(s).

C-117

The rear fog lamp indicator lamp does not illuminate. : Replace the combination meter.

C-117 1 2 3

4 5 6 7 8 9 10

111213

14 1516 17 18 19 20 2122 232425 26 2728 29 32 33 34

35

30 31 36 37

38

Harness side C-05 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301396 AK


F-12(B)

F-09(GR)

Harness side F-09 1 2 3 4

F-12

2 1

AC301666 AF

NOTE: Prior to the wiring harness inspection, check intermediate connector C-117 , F-09 and junction block connector C-201 , and repair if necessary. Check the output lines for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.


54B-208

SYMPTOM PROCEDURES

ROOM LAMP

INSPECTION PROCEDURE M-1: The front or rear room lamp does not illuminate or extinguish normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Room Lamp Circuit

ETACS-ECU

REAR ROOM LAMP

FRONT ROOM LAMP


COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) All of the door switches Driver’s door lock actuator

SB : Sky blue

If this function does not work normally, these input signal circuit(s) or the ETACS-ECU may be defective. Possible causes Malfunction of the door switches Malfunction of the driver’s door lock actuator Malfunction of the ETACS-ECU Damaged harness wires and connectors


DIAGNOSTIC PROCEDURE Step 1. Check the power supply circuit. When the ignition switch is turned to the LOCK (OFF) position, check if the hazard warning lamps illuminate.

54B-209

Step 3. Connector check: D-05 front room lamp connector, D-11 rear room lamp connector Connector: D-05

Harness side

Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure A-2 "Check

1 2

the ETACS-ECU battery power supply circuit 354B." AC301408 AB

Step 2. Pulse check Check the input signals below, which are related to the front and rear room lamps. System switch

Check conditions






When the driver’s door is unlocked or locked



Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354B." All the door switch signals are not received. :


"The driver’s door lock actuator switch signal is not received 354B."

Connector: D-11 D-11(GR) Harness side 2 1

AC301410 AD


Step 4. Check the bulbs of the front or rear room lamps. Check that the front or rear room lamp bulbs are not burned out. Q: Is the check result normal? YES : Go to Step 5. NO : Replace the front or rear room lamp bulb.



AC210476 AC


54B-210


Step 6. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 5 and 6 to D-05 front room lamp connector terminal Nos. 2 and 1. Connector: C-217 Junction block (Rear view)

Step 7. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 5 and 6 to D-11 rear room lamp connector terminal Nos. 2 and 1. Connector: C-217 Junction block (Rear view)

Junction block side

Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

Connector: D-05

AC210476 AC

Connector: D-11 D-11(GR) Harness side

Harness side

1 2

2 1

AC301408 AB

NOTE:

AC301410 AD

NOTE:



Harness side

Harness side

3 2 1

3 2 1

AC210474 AH

AC210474 AH

Prior to the wiring harness inspection, check junction block connector C-210, and repair if necessary.




Step 8. Retest the system. Check that the front or rear room lamp illuminates and extinguishes normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-211

SYMPTOM PROCEDURES

INSPECTION PROCEDURE M-2: The front and rear room lamp do not illuminate or extinguish normally.


ETACS-ECU

REAR ROOM LAMP

FRONT ROOM LAMP


COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Key reminder switch All of the door switches Driver’s door lock actuator Interior lamp loaded signal

SB : Sky blue

If this function does not work normally, these input signal circuit(s), the interior lamp automatic shutdown function or the ETACS-ECU may be defective. The delay-off setting of this function can be changed by the adjustment function (default setting; 15 seconds). Possible causes Malfunction of the key reminder switch Malfunction of the door switches Malfunction of the driver’s door lock actuator Malfunction of the ETACS-ECU Damaged harness wires and connectors

54B-212


DIAGNOSTIC PROCEDURE Step 1. Check the adjustment function. Check that the room lamp delay-off time has been set to other than "0 second" by the adjustment function. Q: Is the check result normal? YES : Go to Step 2. NO : Use the adjustment function to set the room

lamp delay-off time to other than "0 second." Refer to 354B. Step 2. Check the power supply circuit. When the ignition switch is turned to the LOCK (OFF) position, check if the hazard warning lamps illuminate. Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure A-2 "Check


Step 3. Pulse check Check the input signals below, which are related to the front and rear room lamps. System switch

Check conditions








When a load is applied through multi-purpose fuse No.18



Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354B." All the door switch signals are not received. :


"The driver’s door lock actuator switch signal is not received 354B." Interior lamp loaded signal is not detected. : Refer to inspection procedure N-17 "Interior lamp loaded signal is not detected 354B."


54B-213

SYMPTOM PROCEDURES


Harness side


1 2

Junction block side

AC301408 AB

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

Connector: D-11

AC210476 AC

D-11(GR)

Connector: D-05

Harness side 2 1

Harness side 1 2

AC301410 AD


Step 5. Check the bulbs of the front or rear room lamps. Check that the front or rear room lamp bulbs are not burned out. Q: Is the check result normal? YES : Go to Step 6. NO : Replace the front or rear room lamp bulb.

AC301408 AB


Harness side 3 2 1

AC210474 AH


Prior to the wiring harness inspection, check junction block connector C-210, and repair if necessary. Q: Is the check result normal? YES : Go to Step 8. NO : Repair the wiring harness.


AC210476 AC



54B-214

SYMPTOM PROCEDURES





AC210476 AC


AC301410 AD


Harness side 3 2 1

AC210474 AH




54B-215

INSPECTION PROCEDURE M-3: Interior lamp automatic shutoff function does not work normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Interior Lamp Automatic Shut-off Function Circuit FUSIBLE LINK 1

ETACS-ECU INPUT SIGNAL ·ALL DOOR SWITCH ·FRONT DOOR SWITCH ·IGNITION SWITCH (ACC) ·IGNITION SWITCH (IG1) ·INTERIOR LAMP LOADED SIGNAL

KEEP RELAY

LOAD DETERMINATION CIRCUIT

INTERIOR LAMP CUT BACK-UP CIRCUIT

COMBINATION METER

COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates the interior lamp automatic shutdown function in accordance with the input signals below. Ignition switch (ACC) Ignition switch (IG1) Driver’s door switch All of the door switches Interior lamp loaded signal If this function does not work normally, these input signal circuit(s) or the ETACS-ECU may be defective. Note that this function can be disabled/enabled by the adjustment function (default setting; enabled).

· FRONT ROOM LAMP · REAR ROOM LAMP

Possible causes Malfunction of the door switches Malfunction of the room lamp Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Check the adjustment function. Check that the interior lamp automatic shutdown function has been enabled by using the adjustment function. Q: Is the check result normal? YES : Go to Step 2. NO : Enable the interior lamp automatic

shutdown function by using the adjustment function. Refer to 354B.

54B-216


Step 2. Check the power supply circuit. When the ignition switch is turned to the LOCK (OFF) position, check if the hazard warning lamps illuminate. Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure A-2 "Check


Step 3. Pulse check Check the input signals below, which are related to the front and rear dome lamps. System switch

Check conditions






Driver’s door is opened while all the other doors are closed.







Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354B." The ignition switch (IG1) signal is not received. :


Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354B." All the door switch signals are not received. :

Refer to inspection procedure N-11 "All the door switch signals are not received 354B ." Interior lamp loaded signal is not detected : Refer to inspection procedure N-17 "Interior lamp loaded signal is not detected 354B." Step 4. Retest the system. Check that the interior lamp automatic shutdown function works normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-217

INSPECTION PROCEDURE M-4: The door-ajar warning lamp does not illuminate/extinguish normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Door Ajar Indicator Lamp Circuit ETACS-ECU

INPUT SIGNAL COMBINATION METER

· ALL DOOR SWITCH · FRONT DOOR SWITCH


SB : Sky blue

COMMENTS ON TROUBLE SYMPTOM If the door-ajar warning lamp does not work normally, the input signal circuits from all the door switches or the ETACS-ECU may be defective.

Step 2. Pulse check Check the input signals below, which are related to the door-ajar warning lamp. System switch

Check conditions

Possible causes All the door switches are defective. Malfunction of the ETACS-ECU Damaged harness wires and connectors


Driver’s door is opened while all the other doors are closed.



DIAGNOSTIC PROCEDURE Step 1. Check the operation of the room lamp. Q: Does the room lamp illuminate/extinguish? YES : Go to Step 2. NO : Refer to inspection procedure M-1 "The

front or rear room lamp does not illuminate/ extinguish 354B." Or refer to inspection procedure M-2 "The front or rear room lamp does not illuminate/extinguish 354B ."


3. The driver’s door switch signal is not received. :

Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354B." All the door switch signals are not received. :

Refer to inspection procedure N-11 "All the door switch signals are not received 354B ."


54B-218

SYMPTOM PROCEDURES

Step 3. Connector check: C-05 combination meter connector Connector: C-05

C-05(L)

Step 6. Check the wiring harness from C-219 ETACS-ECU connector terminal Nos. 53 and 71 to C-05 combination meter connector terminal Nos. 21 and 22. Connector: C-05

C-05(L)

Harness side (front view) Harness side (front view)

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301395 AE

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G


G

AC301395 AE


Step 4. Check the door-ajar warning lamp bulb. Check the door-ajar warning lamp bulb. Q: Is the check result normal? YES : Go to Step 5. NO : Replace the door-ajar warning lamp bulb.



AC210476 AE




59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE


Step 7. Retest the system. Replace the ETACS-ECU, and then check that the door-ajar warning lamp illuminates/extinguishes normally. (1) Replace the ETACS-ECU. (2) Check that the door-ajar warning lamp illuminates/extinguishes normally. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the combination meter.


54B-219

INPUT SIGNAL PROCEDURES


INSPECTION PROCEDURE N-1: The ignition switch (ACC) signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Ignition Switch (ACC) Input Circuit IGNITION SWITCH (ACC)

ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM Input signal from the ignition switch (ACC) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Windshield wiper and washer Rear wiper and washer Interior lamp automatic shutdown function

SB : Sky blue


Possible causes Malfunction of the ETACS-ECU Damaged harness wires and connectors Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC


54B-220

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR INPUT SIGNAL PROCEDURES


Step 3. Check the wiring harness between C-217 ETACS-ECU connector terminal No.18 and the ignition switch (ACC). Connector: C-217 Junction block (Rear view)


20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Ignition switch: ACC position

AC210476 AC




AC210474 AC AC301541AV


Prior to the wiring harness inspection, check junction block connector C-203, and repair if necessary. Check the power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 4. Retest the system. Check that the ignition switch (ACC) signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-221


INSPECTION PROCEDURE N-2: The ignition switch (IG1) signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Ignition Switch (IG1) Input Circuit IGNITION SWITCH (IG1)

ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM Input signal from the ignition switch (IG1) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Ignition key cylinder illumination lamp Headlamp automatic shutdown function Turn signal lamp Room lamps Possible causes Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue



AC210476 AC


54B-222



Step 3. Check the wiring harness between C-217 ETACS-ECU connector terminal No.8 and the ignition switch (IG1). Connector: C-217 Junction block (Rear view)


20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Ignition switch: ON position

AC210476 AC




AC210474 AC AC301541AW



malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 4. Retest the system. Check that the ignition switch (IG1) signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-223

INSPECTION PROCEDURE N-3: The back-up lamp switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Back-up Lamp Switch Input Circuit IGNITION SWITCH (IG1)

BACK-UP LAMP SWITCH

ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM Input signal from the back-up lamp switch is used to operate the rear wiper. If the signal is abnormal, the rear wiper will not work normally.

SB : Sky blue

Possible causes Malfunction of the back-up lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

54B-224



Step 3. Measure the voltage at the C-220 ETACSECU connector.

Step 1. Connector check: B-114 back-up lamp switch connector and C-220 ETACS-ECU connector


Connector: B-114

Harness side Harness side 2 1

:

B-114(B)

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

AC210476 AF

AC301521 AB


(1) Disconnect the connector, and measure at the wiring harness side. (2) Ignition switch: ON (3) Shift position: R position Connector C-220 (Harness side)

Harness side

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210476 AF AC301541BA


Step 2. Check the back-up lamp switch Check the back-up lamp switch (Refer to GROUP 22B - Transmission 322B). Q: Is the check result normal? YES : Go to Step 3. NO : Replace the inhibitor switch.

(4) Voltage between C-220 ETACS-ECU connector terminal No.39 and body earth OK: System voltage Q: Is the check result normal? YES : Replace the ETACS-ECU. NO : Go to Step 4.


54B-225


Step 4. Measure the voltage at the B-114 back-up lamp switch connector. Connector: B-114

Step 5. Check the wiring harness between B-114 back-up lamp switch connector terminal No.1 and C-220 ETACS-ECU connector terminal No.39. Connector: B-114

Harness side :

Harness side

2 1

2 1

: B-114(B)

AC301521 AB

(1) Disconnect the connector, and measure at the wiring harness side. (2) Ignition switch: ON

B-114(B)

AC301521 AB


Connector B-114 (Harness side)

Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

2 1

AC210476 AF

AC301541AK

(3) Voltage between B-114 back-up lamp switch connector terminal No.2 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 6.


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

AC301395 AC

Connector: C-105

1 2 3 4 5 6 7 8 9 10 11 12 13 1415 16 1718 19 20 21 22

AC301397AF

Prior to the wiring harness inspection, check joint connector C-02 and intermediate connector C-105, and repair if necessary. Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.


54B-226


Step 6. Check the wiring harness between B-114 back-up lamp switch connector terminal No.2 and the ignition switch (IG1). Connector: B-114

Harness side 2 1

:

AC301521 AB


C-106(GR)

AC301397AG


C-202

Harness side C-202 6 5 4 3 2 1 14 13 12 11 10 9 8 7

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 7. Retest the system. Check that the back-up lamp switch signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent

B-114(B)

2 1 3 4 5 6 10 11 12 7 8 9 13 14 15 16 17 18 19


C-203 2 1 6 5 4 3

AC210475 AG

Prior to the wiring harness inspection, check intermediate connector C-106, junction block connectors C-202 and C-203, and repair if necessary. Check the power supply line to the ignition switch (IG1) for open circuit.



54B-227


INSPECTION PROCEDURE N-4: The driver’s door switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Driver's Door Switch Input Circuit

ETACS-ECU

FRONT DOOR SWITCH (LH)


COMMENTS ON TROUBLE SYMPTOM Input signal from the driver’s door switch is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Key reminder function Ignition key cylinder illumination lamp Headlamp automatic shutdown function Room lamps Possible causes Malfunction of the driver’s door switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

Step 2. Connector check: D-28 front door switch (LH) connector Connector: D-28

Harness side 3 2 1

AC301410 AF



Step 1. Check the installation condition. Check that the front door switch (LH) is installed on the body correctly.

Step 3. Check the front door switch (LH). Refer to GROUP 42 - Door 342.

Q: Is the check result normal? YES : Go to Step 2. NO : Correct the installation condition.

Q: Is the check result normal? YES : Go to Step 4. NO : Replace the front door switch (LH).

54B-228



Step 5. Check the wiring harness between D-28 front door switch (LH) connector terminal No.3 and C-217 ETACS-ECU connector terminal No.10. Connector: C-217 Junction block (Rear view)


20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

AC210476 AC


Connector: D-28

Harness side 3 2 1

AC301410 AF


Harness side 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210474 AG

Prior to the wiring harness inspection, check joint connector C-209, and repair if necessary. Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness.

Step 6. Retest the system. Check that the driver’s door switch signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-229

INSPECTION PROCEDURE N-5: The column switch (lighting, turn-signal lamp and headlamp washer switch) signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Lighting Switch Input Circuit COLUMN SWITCH COLUMN-ECU

LO

HI PASS

LH

OFF

DIMMER· PASSING SWITCH

RH

TURN-SIGNAL LAMP SWITCH

COMMENTS ON TROUBLE SYMPTOM Input signal from the column switch (lighting, turnsignal lamp and headlamp washer switch) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Headlamp and tail lamp Fog lamp Turn signal lamp Headlamp washer Possible causes Malfunction of the column switch Damaged harness wires and connectors

OFF

HEAD HEAD OFF TAIL TAIL

LIGHTING SWITCH

Step 2. Check the column switch (lighting switch and switch body). Refer to GROUP 54A - Column switch 354A. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the column switch.

Step 3. Use the MUT-II to confirm a diagnosis code. Check that the ETACS-ECU sets a diagnosis code. Q: Is the diagnosis code set? YES : Refer to diagnosis code chart 300. NO : Go to Step 4.

DIAGNOSTIC PROCEDURE Step 1. Check the column switch connector. Check that the wiper and washer switch connector, the lighting switch connector and the switch body connector are in good condition. Q: Is the check result normal? YES : Go to Step 2. NO : Repair the defective connector.

Step 4. Retest the system. Replace the column switch, and check if the column switch (lighting, turn-signal lamp and headlamp washer switch) sends signal. (1) Replace the column switch. (2) Check if the column switch (lighting and turnsignal switch) sends signal. Q: Is the check result normal? YES : The procedure is complete. NO : Replace the ETACS-ECU.

54B-230


INSPECTION PROCEDURE N-6: The column switch (windshield wiper washer and rear wiper washer switch) signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Windshield Wiper and Washer Switch Input Circuit COLUMN SWITCH COLUMN-ECU

UPPER SIDE

WINDSHIELD WIPER SWITCH

WINDSHIELD WASHER SWITCH

COMMENTS ON TROUBLE SYMPTOM Input signal from the column switch (wiper switch) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Windshield wiper and washer Rear wiper and washer Possible causes Malfunction of the column switch Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Use the MUT-II to confirm a diagnosis code. Check that the ETACS-ECU sets a diagnosis code. Q: Is the diagnosis code set? YES : Refer to diagnosis code chart 300. NO : Go to Step 2.

REAR WIPER SWITCH

REAR WASHER SWITCH

Step 2. Retest the system. Replace the column switch, and check if the column switch (windshield wiper washer and rear wiper washer switch) sends signal. (1) Replace the column switch. (2) Check if the column switch (windshield wiper/ washer and rear wiper washer switch) sends signal. Q: Is the check result normal? YES : The procedure is complete. NO : Replace the ETACS-ECU.


54B-231


INSPECTION PROCEDURE N-7: The windshield intermittent wiper volume signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Windshield Intermittent Wiper Interval Adjusting Knob Input Circuit ETACSECU

COLUMN SWITCH

WINDSHIELD INTERMITTENT WIPER INTERVAL ADJUSTING KNOB

UPPER SIDE


COMMENTS ON TROUBLE SYMPTOM The intermittent wiper interval is calculated in accordance with the input signal from the windshield intermittent wiper volume. If this signal is abnormal, the wiper interval can not be adjusted. Possible causes Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSTIC PROCEDURE Step 1. Connector check: C-310 column switch connector Connector: C-310

Harness side 5 4 3 2 1 10 9 8 7 6

AC301399 AC



54B-232


Step 2. Measure the resistance at the C-310 column switch connector. Connector: C-310

Step 4. Check the wiring harness between C-310 column switch connector terminal No.6 and C219 ETACS-ECU connector terminal No.66. Connector: C-219 Junction block (Rear view)

Harness side

Harness side

5 4 3 2 1 10 9 8 7 6

AC301399 AC

(1) Disconnect the connector, and measure at the column switch side.

C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE

Connector: C-310

Connector C-310 (Harness side) 5 4 3 2 1 10 9 8 7 6

Harness side 5 4 3 2 1 10 9 8 7 6

AC301399 AC

AC301541BC

(2) Resistance between C-310 column switch connector terminal No.6 and body earth OK: The resistance should rise from 0 to 1 kW when the windshield intermittent wiper volume is rotated from "Fast" to "Slow". Q: Is the check result normal? YES : Go to Step 3. NO : Replace the column switch.



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE


Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 5. NO : Repair the wiring harness.

Step 5. Retest the system. Check that the windshield intermittent wiper volume is sending a correct signal. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-233

INSPECTION PROCEDURE N-8: When the power window main switch is operated, the switch signals are not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Power Window Main Switch Input Circuit

FUSIBLE LINK 5

ETACS-ECU

POWER WINDOW RELAY

FRONT SIDE

DIAGNOSIS CONNECTOR



SB : Sky blue


54B-234


COMMENTS ON TROUBLE SYMPTOM Input signal from the power window main switch is used in order to check the power window main switch and confirm how the system is communicating with the ETACS-ECU. If the communication line is defective, the power windows will not work normally.

Step 3. Check the wiring harness between C-219 ETACS-ECU connector terminal No.59 and E-05 power window main switch connector terminal No.4. Connector: C-219 Junction block (Rear view)

Possible causes Malfunction of the power window main switch Damaged harness wires and connectors Harness side

DIAGNOSTIC PROCEDURE C-219(GR)

Step 1. Check the operation by using the power window main switch. Check if each window can be operated by means of the power window main switch.

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE


Q: Can each power window be operated by means of the power window main switch? YES : Go to Step 2. NO : Go to Step 5.

E-05

Step 2. Connector check: C-219 ETACS-ECU connector and E-05 power window main switch connector

E-12

E-05 Harness side


6 5 4 3 2 1 14 13 12 11 10 9 8 7


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

Connector: E-05

Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC


E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC


NOTE:

54B-235

Step 5. Connector check: E-05 power window main switch connector

Connectors : C-02, C-118

Connector: E-05 C-02

C-118

Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC

C-02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

C-118


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32


AC301396 AG


Step 4. Replace the power window main switch, and then retest the system. Replace the power window main switch, and check that the power window main switch signal is received. (1) Replace the power window main switch. (2) Check that the power window main switch signal is received. Q: Is the check result normal? YES : The procedure is complete. NO : Replace the ETACS-ECU.

Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC

(1) Remove the power window main switch, and measure at the wiring harness side.


6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301541BH

(2) Voltage between E-05 power window main switch connector terminal No.6 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 9. NO : Go to Step 7.

54B-236


Step 7. Connector check: C-208 power window relay connector Connector: C-208 Junction block (Front view)

Step 8. Check the wiring harness between C-208 power window relay connector terminal No.4 and E-05 power window main switch connector terminal No.6. Connectors: C-203, C-208 Junction block (Front view) C-203

Junction block side 3 2 1 4 5

AC210474 AF

C-208

Q: Is the check result normal? YES : Go to Step 8. NO : Repair the defective connector. Harness side

Junction block side

C-203

C-208 3 2 1 4 5

2 1 6 5 4 3

AC210475 AI


E-05

E-12

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC


54B-237


NOTE:

Step 10. Check the wiring harness between E-05 power window main switch connector terminal No.2 and body earth.

Connector: C-118


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

E-05

AC301395 AH

E-12

Prior to the wiring harness inspection, check intermediate connectors C-118, E-12 and junction block connector C-203, and repair if necessary. Check the power supply line for open circuit.

E-05 Harness side


6 5 4 3 2 1 14 13 12 11 10 9 8 7


E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Step 9. Measure the resistance at the E-05 power window main switch connector.

AC301419 AC

Connector: E-05


Harness side

1 2 3 4 5 6 7 8 9 10 11

6 5 4 3 2 1 14 13 12 11 10 9 8 7

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

AC301418 AC


AC301395 AH





6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301541BI

(2) Resistance between E-05 power window main switch connector terminal No.2 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 11. NO : Go to Step 10.

54B-238


Step 11. Retest the system. Check that each switch signal is received by operating the power window main switch. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE N-9: The key reminder switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Key Reminder Switch Input Circuit ETACSECU

KEY REMINDER SWITCH WHEN REMOVING KEY: ON


COMMENTS ON TROUBLE SYMPTOM Input signal from the key reminder switch is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Key reminder function Keyless entry system Ignition key cylinder illumination lamp

SB : Sky blue

Room lamps Possible causes Malfunction of the key reminder switch Malfunction of the ETACS-ECU Damaged harness wires and connectors



54B-239

Step 3. Measure the resistance at the C-304 key reminder switch connector.

Step 1. Connector check: C-304 key reminder switch connector

Connector: C-304

Connector: C-304



AC301399 AB


Step 2. Check the key reminder switch. Refer to GROUP 54A - Ignition switch 354A.

AC301399 AB


Connector C-304 (Harness side) 2 1 7 6 5 4 3

Q: Is the check result normal? YES : Go to Step 3. NO : Replace the key reminder switch.

AC301541 BB

(2) Resistance between C-304 key reminder switch connector terminal No.4 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

Step 4. Check the wiring harness between C-304 key reminder switch connector terminal No.4 and the body earth. Connector: C-304


AC301399 AB



54B-240



Step 6. Check the wiring harness between C-304 key reminder switch connector terminal No.6 and C-220 ETACS-ECU connector terminal No.30. Connector: C-220 Junction block (Rear view)

Harness side Harness side

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

AC210476 AF

AC210476 AF


Connector: C-304


AC301399 AB


Step 7. Retest the system. Check that the key reminder switch signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-241


INSPECTION PROCEDURE N-10: The hazard warning lamp switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Hazard Warning Lamp Switch Input Circuit ETACSECU



COMMENTS ON TROUBLE SYMPTOM Input signal from the hazard warning lamp switch is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Keyless entry system (encrypted code registration) Hazard warning lamp Possible causes Malfunction of the hazard warning lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSTIC PROCEDURE Step 1. Connector check: C-22 hazard warning lamp switch connector Connector: C-22

Harness side 4 3 2 1

AC301395 AI


Step 2. Check the hazard warning lamp switch. Refer to GROUP 54A - Hazard warning lamp switch 354A. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the hazard warning lamp switch.


54B-242


Step 3. Measure the resistance at the C-22 hazard warning lamp switch connector.


Connector: C-22

Harness side

Harness side

4 3 2 1

C-219(GR) AC301395 AI



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


Step 6. Check the wiring harness between C-219 ETACS-ECU connector terminal No.55 and C-22 hazard warning lamp switch connector terminal No.1.

4 3 2 1

Connector: C-22 AC301541 AZ

(2) Resistance between C-22 hazard warning lamp switch connector terminal No.2 and body earth OK: 2 W or less



AC301395 AI

Step 4. Check the wiring harness between C-22 hazard warning lamp switch connector terminal No.2 and the body earth.


Connector: C-22

Harness side C-219(GR) Harness side

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

4 3 2 1

Check the input line for open circuit. AC301395 AI





54B-243

Step 7. Retest the system. Check that the hazard warning lamp switch signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE N-11: All the door switch signals are not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. All Door Switches Input Circuit

ETACS-ECU

FRONT DOOR SWITCH (RH)

REAR DOOR SWITCH (RH)

TAILGATE REAR DOOR SWITCH SWITCH (LH)


COMMENTS ON TROUBLE SYMPTOM Input signals from all the door switches are used to operate the functions below. If the signal(s) are abnormal, these functions will not work normally. Keyless entry system Room lamps


SB : Sky blue

Possible causes Malfunction of the door switches Malfunction of the ETACS-ECU Damaged harness wires and connectors

54B-244



Connectors: D-10, D-20, D-28

Step 1. Pulse check Check the input signal from the driver’s door switch. System switch

Check conditions




D-01 D-20 D-28

Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure N-4 "The

driver’s door switch signal is not received 354B." Step 2. Connector check: D-28 , D-42 , D-10 or D-20 door switch connectors or F-07 tailgate switch connector, and C-217 ETACS-ECU connector

Harness side D-01

D-20

D-28

3 2 1

3 2 1

3 2 1

AC301411AC

Connector: D-42


Harness side 3 2 1


AC301408 AF

AC210476 AC

Connector: F-07 Harness side 1

F-07(B)

AC301665 AC


Step 3. Check the installation condition. Check that the door switch is installed on the body correctly. Q: Is the check result normal? YES : Go to Step 4. NO : Correct the installation condition.


54B-245


Step 4. Check the door switch. Refer to GROUP 42 - Door 342.

Connector: D-42

Q: Is the check result normal? YES : Go to Step 5. NO : Replace the door switch.

Harness side 3 2 1

Step 5. Check the wiring harness from terminal No.2 of the D-28 , D-42 , D10 or D-20 door switch connector or terminal No.1 of the F-07 tailgate switch connector to terminal No.7 of the C-217 ETACS-ECU connector.

AC301408 AF



F-05

F-07(B)


AC210476 AC

Harness side Connectors: D-10, D-20, D-28

F-05

F-07

1 2 3 4 5 6 7 8 9 10

1

D-01 D-20

AC301666 AC

D-28

Harness side D-01

D-20

D-28

3 2 1

3 2 1

3 2 1

AC301411AC


54B-246


NOTE:

Step 6. Retest the system. Check that all the driver’s door switch signals are received normally.

Connector: C-13

Q: Is the check result normal? YES : The trouble can be an intermittent C-13(L)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

AC301397AB


C-205

C-209

Harness side C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-209 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210475 AK

Prior to the wiring harness inspection, check intermediate connector F-05 or C-13 and junction block connector C-205 or C-209 , and repair if necessary. Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness between each of

the door switches and the ETACS-ECU.



54B-247

INSPECTION PROCEDURE N-12: The driver’s door lock actuator switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Door Lock Actuator Input Circuit

ETACS-ECU

DOOR LOCK ACTUATOR (FRONT: LH)

COMMENTS ON TROUBLE SYMPTOM Input signal from the driver’s door lock actuator is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Key reminder function Central door locking Keyless entry system Room lamps Possible causes Malfunction of the front door lock actuator (LH) Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Connector check: E-11 front door lock actuator (LH) connector Connector: E-11


AC301418 AD



54B-248


Step 2. Check the front door lock actuator (LH). Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the front door lock actuator (RH).

Step 4. Check the wiring harness between E-11 front door lock actuator (LH) connector terminal No.1 and body earth Connector: E-11

Step 3. Measure the resistance at the E-11 front door lock actuator (LH) connector.


Connector: E-11

3 2 1 6 5 4

AC301418 AD

E-11(B)

NOTE:

Harness side

Connector: C-118 3 2 1 6 5 4

AC301418 AD



23 24 25 26 27

28 29 30 31 32

AC301395 AH

Prior to the wiring harness inspection, check intermediate connector C-118, and repair if necessary. Check the earth wires for open circuit.

3 2 1 6 5 4 AC301541BK

(2) Resistance between E-11 front door lock actuator (LH) connector terminal No.1 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 5. Connector check: C-220 ETACS-ECU connector Connector: C-220 Junction block (Rear view)

Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

AC210476 AF



Step 6. Check the wiring harness from E-11 front door lock actuator (LH) connector terminal Nos. 2 and 3 to C-220 ETACS-ECU connector terminal Nos. 36 and 35. Connector: C-220 Junction block (Rear view)

Step 7. Retest the system. Check that the driver’s door lock actuator switch signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the ETACS-ECU. Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210476 AF

Connector: E-11


AC301418 AD


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

54B-249

28 29 30 31 32

AC301395 AH

Prior to the wiring harness inspection, check intermediate connector C-118, and repair if necessary. Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

54B-250


INSPECTION PROCEDURE N-13: The vehicle speed signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Vehicle Speed Sensor Input Circuit ETACS-ECU



COMMENTS ON TROUBLE SYMPTOM Vehicle speed signal is used to operate the windshield wiper (vehicle speed-dependent wiper function). If this signal is abnormal, the windshield wipers do not work normally. Possible causes Malfunction of the vehicles speed sensor Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSTIC PROCEDURE Step 1. Check the speedometer. Check that the speedometer works normally. Q: Is the diagnosis code set? YES : Go to Step 2. NO : Diagnose the combination meter (Refer to

GROUP 54A - Combination meter 354A ).


54B-251


Step 2. Connector check: B-115 vehicles speed sensor connector Connector: B-115

Step 4. Check the wiring harness between B-115 vehicles speed sensor connector terminal No.2 and the body earth. Connector: B-115

Harness side B-115(B)

Harness side

3 2 1

B-115(B)

3 2 1

AC301521AC


Step 3. Measure the resistance at the B-115 vehicles speed sensor connector.

AC301521AC


4 5 1 2 3 6 7 8 9 10 1112 13

Connector: B-115


3 2 1

AC301521AC


C-17(GR) AC301397AE

Prior to the wiring harness inspection, check joint connector C-17, and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 5. Connector check: C-219 ETACS-ECU connector



3 2 1

AC301541 AL

(2) Resistance between B-115 vehicles speed sensor connector terminal No.2 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE



54B-252


Step 6. Check the wiring harness between B-115 vehicles speed sensor connector terminal No.3 and C-219 ETACS-ECU connector terminal No.63.


Connector: B-115


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

3 2 1 AC301395 AC

Connectors: C-16, C-105 AC301521AC



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

C-105 C-16(L)

AC210476 AE

C-16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

C-105 1 2 3 4 5 6 7 8 9 10 11 12 13 1415 16 1718 19 20 21 22

AC301398 AD

Prior to the wiring harness inspection, check joint connector C-02, C-16 and intermediate connector C105, and repair if necessary. Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

Step 7. Retest the system. Check that the vehicle speed signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-253

INSPECTION PROCEDURE N-14: Each switch signal of the keyless entry transmitter is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Transmitter Input Circuit ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM Input signal from the keyless entry transmitter is used to operate the keyless entry system. If the signal is abnormal, the keyless entry system will not work normally. Possible causes Malfunction of the keyless entry transmitter Defective battery of the keyless entry transmitter Malfunction of the ETACS-ECU

DIAGNOSTIC PROCEDURE Step 1. Pulse check Check whether the ETACS-ECU receives signal from a transmitter or not. For this check, you should use the 2-button-type transmitter (integrated with a key), which cover screw is silver and has already been registered. NOTE: For how to register the keyless entry transmitter encrypted code, refer to GROUP 42 On-vehicle Service 342. System switch

Check conditions

Keyless entry transmitter When the switch is "LOCK/UNLOCK" switch turned from off to on OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? YES : Go to Step 2. NO : Go to Step 4.

KEYLESS ENTRY TRANSMITTER

Step 2. Check the transmitter battery. Refer to GROUP 42 - Keyless entry system 342. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the keyless entry transmitter

battery. Step 3. Register the encrypted code, and then retest the system. (1) Register the keyless entry transmitter again. (2) Check that each signal is received from the keyless entry transmitter. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the keyless entry transmitter. Step 4. Retest the system. Check that each signal is received from the keyless entry transmitter. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-254


INSPECTION PROCEDURE N-15: The front fog lamp switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Front Fog Lamp Switch Input Circuit ETACSECU

FOG LAMP SWITCH

NOTE : WITHOUT REAR FOG LAMP : WITH REAR FOG LAMP


COMMENTS ON TROUBLE SYMPTOM Input signal from the front fog lamp switch is used to operate the front fog lamps. If the signal is abnormal, the front fog lamps will not illuminate and extinguish normally. Possible causes Malfunction of the fog lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSTIC PROCEDURE Step 1. Connector check: C-03 fog lamp switch connector Connector: C-03


AC301395 AD


Step 2. Check the front fog lamp switch. Refer to GROUP 54A - Front fog lamp 354A. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the fog lamp switch.


Step 3. Measure the resistance at the C-03 fog lamp switch connector. Connector: C-03

54B-255

Step 4. Check the wiring harness from C-03 fog lamp switch connector terminal No.2 or 6 to body earth. Connector: C-03


Harness side AC301395 AD

6 5 4 3 2 1

(1) Remove the fog lamp switch, and measure at the wiring harness side.

AC301395 AD

Check the earth wires for open circuit. Connector C-03 (Harness side)



6 5 4 3 2 1

*2

*1

Note *1: Without rear fog lamp *2: With rear fog lamp

Step 5. Connector check: C-219 ETACS-ECU connector AC301541 AM

(2) Resistance between C-03 fog lamp switch connector terminal No.2 or 6 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE



54B-256


Step 6. Check the wiring harness from C-219 ETACS-ECU connector No.54 to C-03 fog lamp switch connector terminal No.1 or 5 . Connector: C-03




AC301395 AD



Step 7. Retest the system. Check that the front fog lamp switch signal is received normally.

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE



54B-257


INSPECTION PROCEDURE N-16: The rear fog lamp switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Rear Fog Lamp Switch Input Circuit ETACSECU

FOG LAMP SWITCH


COMMENTS ON TROUBLE SYMPTOM Input signal from the rear fog lamp switch is used to operate the rear fog lamps. If the signal is abnormal, the rear fog lamps will not illuminate and extinguish normally. Possible causes Malfunction of the fog lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSTIC PROCEDURE Step 1. Connector check: C-03 fog lamp switch connector Connector: C-03


AC301395 AD


Step 2. Check the rear fog lamp switch. Refer to GROUP 54A - Rear fog lamp 354A. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the fog lamp switch.

54B-258


Step 3. Measure the resistance at the C-03 fog lamp switch connector.


Connector: C-03

Harness side

Harness side

6 5 4 3 2 1

C-219(GR) AC301395 AD

(1) Remove the fog lamp switch, and measure at the wiring harness side. Connector C-03 (Harness side)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


Step 6. Check the wiring harness between C-219 ETACS-ECU connector terminal No.21 and C-03 fog lamp switch connector terminal No.1.

6 5 4 3 2 1

Connector: C-03

AC301541 AN

(2) Continuity between C-03 fog lamp switch connector terminal No.2 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.


AC301395 AD


Step 4. Check the wiring harness between C-03 fog lamp switch connector terminal No.2 and body earth. Harness side

Connector: C-03

C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

Harness side

Check the input line for open circuit.

6 5 4 3 2 1

AC301395 AD





Step 7. Retest the system. Check that the rear fog lamp switch signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54B-259


54B-260


INSPECTION PROCEDURE N-17: Interior lamp loaded signal is not detected.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Interior Lamp Automatic Shut-off Function Circuit IGNITION SWITCH (ACC)

FUSIBLE LINK 1


RELAY BOX

ETACS-ECU

KEEP RELAY INTERIOR LAMP CUT BACK-UP CIRCUIT

POWER SOURCE


COMBINATION METER

· FRONT LAMP · REAR LAMP


COMMENTS ON TROUBLE SYMPTOM The interior lamp automatic shutdown function operates in accordance with the interior lamp loaded signal. If this signal is abnormal, the functions below will not work normally. Ignition key cylinder illumination lamp

SB : Sky blue

Room lamps Possible causes Malfunction of the ETACS-ECU Damaged wiring harness or connector(s)



54B-261


Step 1. Check the power supply circuit. When the ignition switch is turned to the LOCK (OFF) position, check if the hazard warning lamps illuminate.


Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure A-2 "Check



AC210476 AC


(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Turn the ignition switch to the ON position.



AC210476 AC AC301541AW



54B-262





20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC


AC210476 AC

(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Turn the ignition switch to the ACC position.

Connector C-217 (Junction block side) Harness side

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1

2 1 6 5 4 3

AC210474 AC

Prior to the wiring harness inspection, check junction block connector C-203, and repair if necessary. Check the power supply line to the ignition switch (IG1) for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


AC301541AX




54B-263

Step 7. Retest the system. Check that the interior lamp loaded signal is received normally. Q: Is the check result normal? YES : The trouble can be an intermittent



AC210476 AC


1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG


Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC210474 AB

Prior to the wiring harness inspection, check junction block connector C-202 or intermediate connector C116, and repair if necessary. Check the power supply line to the ignition switch (ACC) for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54B-264


INSPECTION PROCEDURE N-18: The passenger’s door lock key cylinder switch signal is not detected.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Door Lock Key Cylinder Switch Input Circuit ETACS-ECU

DOOR LOCK KEY CYLINDER SWITCH (RH)


COMMENTS ON TROUBLE SYMPTOM Input signal from the front passenger’s door lock key cylinder switch is used to operate the central door locking function. If the signal is abnormal, the central door locking function will not work normally. Possible causes Malfunction of the front passenger’s door lock key cylinder switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSTIC PROCEDURE Step 1. Connector check: E-18 door lock key cylinder switch (RH) connector Connector: E-18 Harness side E-18(B) 3 2 1

AC301412 AD



54B-265


Step 2. Check the door lock key cylinder switch (RH). Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the door lock key cylinder switch

Step 4. Check the wiring harness between E-18 door lock key cylinder switch (RH) connector terminal No. 2 and body earth. Connector: E-18 Harness side

(RH).

E-18(B) 3 2 1

Step 3. Measure the resistance at the E-18 door lock key cylinder switch (RH) connector. Connector: E-18 AC301412 AD

Harness side E-18(B)


3 2 1

AC301412 AD


2 1 3 4 5 6 10 11 12 7 8 9 13 14 15 16 17 18 19

C-15(GR) AC301397AD



Q: Is the check result normal? YES : Intermittent malfunction. (Refer to GROUP

3 2 1

AC301541BL

(2) Resistance between E-18 door lock key cylinder switch (RH) connector terminal No. 2 and body earth OK: 2 W or less

00 - How to Cope with Intermittent Malfunction 300).) NO : Repair the wiring harness. Step 5. Connector check: C-220 ETACS-ECU connector Connector: C-220 Junction block (Rear view)

Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4. Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210476 AF


54B-266


Step 6. Check the wiring harness from E-18 door lock key cylinder switch (RH) connector terminal Nos. 1 and 3 to C-220 ETACS-ECU connector terminal Nos. 28 and 27. Connector: C-220 Junction block (Rear view)

Step 7. Retest the system. Check that the passenger’s door lock key cylinder switch signal is received normally. Q: Is the check result normal? YES : Intermittent malfunction. (Refer to GROUP

00 - How to Cope with Intermittent Malfunction 300).) NO : Replace the ETACS-ECU. Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210476 AF

Connector: E-18 Harness side E-18(B) 3 2 1

AC301412 AD


2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

C-15(GR) AC301397AD


SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR CHECK AT ECU TERMINAL

54B-267

CHECK AT ECU TERMINAL M1549001200599

ETACS-ECU

AC005554AF

NOTE: Terminal numbers 1 to 20 can not be measured as the ETACS-ECU is mounted on the junction block directly. The values are for reference only. Terminal Check items No.

Check conditions

Normal conditions

1

Output to the power window relay

When the power windows are operative

System voltage

2

Power supply to the central door locking system (battery positive voltage)

Always

System voltage

3

Earth (for ECU)

Always

0V

4


Ignition switch: ACC

System voltage

5

Output to room lamp

When the room lamp is on

2 V or less

6

Power supply to interior lamp (battery positive voltage)

Always (when the interior lamp off function is off)

System voltage

7

Input from all the door switches

One of the door switches: ON (door 0 V open)

8

Power supply from ignition switch (IG1)

Ignition switch: ON

9

Output to right turn-signal lamps

When right turn-signal lamps are on System voltage

10

Input from driver’s door switch

Driver’s door switch: ON (door open)

0V

11

Power supply to hazard warning lamp (battery positive voltage)

Always

System voltage

12

Output to central door locking (for locking the doors)

When the door lock actuators lock the doors

System voltage

13

Output to central door locking (for unlocking the doors other than the driver’s door)

When the door lock actuators unlock the doors

System voltage

14

Output to left turn-signal lamps

When the left turn-signal lamps are System voltage on

15

-

-

-

16

Output to rear wiper

When rear wiper is operating

System voltage

17

Input of rear wiper automatic stop signal


System voltage

18

Power supply from ignition switch (ACC)


System voltage

System voltage

54B-268


Terminal Check items No.

Check conditions

Normal conditions

19

-

-

-

20

Battery power supply (for ECU)

Always

System voltage

21

Input from rear fog lamp switch

Rear fog lamp switch: ON

0V

22

Output to central door locking (for unlocking the driver’s door)


System voltage

23

Rear washer output

When rear washer is operating

System voltage

24 to 28 -

-

-

29

Input of collision signal

-

-

30

Input to key reminder switch

Key reminder switch: ON (ignition key removed)

0V

31 to 34 -

-

-

35

Input to driver’s door lock actuator (lock switch)

Driver’s door lock: Locked

0V

36

Input to driver’s door lock actuator (unlock switch)

Driver’s door lock: Unlocked

0V

37, 38

-

-

-

39

Input to inhibitor switch ("R" position)

Selector lever: R Ignition switch: ON

System voltage

40 to 44 -

-

-

51

When diagnosis code is set (the MUT-II is connected or the diagnosis connector No.1 is earthed)

0 to 12 V (pulse signal)

When input check signal is sent

0 V, 12 V (input signal is fluctuating)

-

Setting diagnosis code or sending input check signal

52

-

-

53

Output to door-ajar indicator lamp

When door-ajar indicator lamp is on 0 V

54

Input from front fog lamp switch

Front fog lamp switch: ON

0V

55

Input from hazard warning lamp switch

Hazard warning lamp switch: ON

0V

56

Earth (for sensor)

Always

0V

57, 58

-

-

-

59

SWS communication line

Always


60 to 62 -

-

-

63

Input of vehicle speed signal

When the vehicle is being driven


64, 65

-

-

-

66

Input from windshield intermittent wiper volume

Turn the ignition switch to the ACC position, and move the wiper volume from "Fast" to "Slow."

0 to 2.5 V

67

Input from diagnosis control

When MUT-II is connected

0V

68

Input of SWS request signal

Always


69

Output to ignition key cylinder illumination lamp

When ignition key cylinder illumination is on

2 V or less


54B-269


Check conditions

Normal conditions

70

-

-

-

71

Power supply to interior lamp


System voltage

72

-

-

-

73

Output to seat belt warning lamp

When seat belt warning lamp is on

0V

74

Output to rear fog lamp

When rear fog lamp is on

System voltage

Column switch

AC005555AB

Termin al No.

Check items

Check conditions

Normal conditions

1

System voltage

Always

System voltage

2


Always


3


Always


4

Earth

Always

0V

5

-

-

-

6

Output to windshield intermittent wiper volume

Ignition switch: ACC 0 to 2.5 V Move the wiper volume from "Fast" to "Slow."

7

-

-

8

Back-up output to windshield wiper Windshield low-speed wiper switch 0 V switch or windshield high-speed wiper switch: ON

9


10

Back-up output to headlamp switch Headlamp switch: ON

Ignition switch: ON

-

System voltage 0V

54B-270


Front-ECU

1 2 3 4 5 6 7 8 9 10 11

2122 23242526 272829 30 31 AC103263 AB

NOTE: Measurement is not possible as the front-ECU is mounted on the relay box directly. The values are for reference only. Terminal Check items No.

Check conditions

Normal conditions

1

Output to headlamp washer

When headlamp washer is operating

System voltage

2

-

-

-

3

Battery power supply (for headlamp Always washer)

System voltage

4

Output to tail lamps

When the tail lamps are on

System voltage

5


Always

System voltage

6

Output to low-beam headlamps

When low-beam headlamps are on System voltage

7

Battery power supply (for tail lamps) Always

System voltage

8, 9

Battery power supply (for headlamps)

Always

System voltage

10

Output to high-beam headlamps

When high-beam headlamps are on System voltage

11

Output to front fog lamps

When front fog lamps are on

System voltage

21

Earth

Always

0V

22

Power supply to the ignition switch (IG2)

Ignition switch: ON

System voltage

23

-

-

-

24

Output to windshield wiper (high speed operation)

When windshield wipers are operating at high speed

System voltage

25

Output to windshield wiper (low speed operation)

When windshield wipers are operating at low speed

System voltage

26

Back-up input from windshield wiper switch

Windshield low-speed wiper switch 0 V or windshield high-speed wiper switch: ON

27

Back-up input from headlamp switch

Headlamp switch: ON

0V

28



System voltage

29

Input of windshield wiper automatic When windshield wipers are stop signal operating

System voltage

30


Always


31

Output to windshield washer

When windshield washer is operating

System voltage


54B-271


1 2 3 4 5 6 7 8 9 10 11 12 13 14 AC103264 AE


Check conditions

Normal conditions

1

Output to power window motor

-

-

2

Earth

Always

0V

3

-

-

-

4

SWS communication line (to ETACS-ECU)

Always


5

-

-

-

6

Power supply

Power window relay: ON

System voltage

7


-

-

8

Input from power window motor (pulse sensor earth)

-

0V

9

Input from power window motor (pulse sensor signal)

When the power windows are operating


10




11

SWS communication line (power window sub switch)



12

Input from power window motor (power supply to pulse sensor)


5V

13, 14

-

-

-

54B-272


Power window sub switch

1 2 3 4 5 6 7 8

AC103265 AE


Check conditions

Normal conditions

1

Earth

Always

0V

2

Input from power window motor

-

-

3


-

-

4

Power supply


System voltage

5


-

-

6




7


-

-

8


-

-

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR ON-VEHICLE SERVICE

54B-273

ON-VEHICLE SERVICE CONFIGURATION FUNCTION M1549002500429

Ignition switch: "LOCK" (OFF) position Driver’s door switch: OFF (driver’s door closed) ii. When the windshield washer switch is ON for more than ten seconds, the buzzer in the ETACS-ECU sounds for three seconds, and the configuration mode will be set. 2. Conditions for exiting the configuration mode Diagnosis control: OFF (Disconnect the MUTII or the earth of No.1 pin of the 16-pin diagnosis connector disconnected.) Key reminder switch: ON (Remove the ignition key) Ignition switch: Turning to any position other than "LOCK" (OFF) position Driver’s door switch: ON (driver’s door opened) When three minutes pass without configurations performed When the other warning buzzer output is generated 3. Configurations of various functions

According to the configuration mode entry conditions of the input switch, the following functions can be adjusted. The data on configuration will be memorized even if the battery is removed. Keyless entry system hazard answerback function Vehicle speed-dependent wiper function Headlamp automatic-shutdown function Delayed lamp-off time of the room lamp Interior lamp automatic-shutdown function Initialization of all functions (Returns to initial settings) 1. Conditions for entering the configuration mode i. Set each switch to the following state. Hazard lamp switch: OFF Diagnosis control: ON (Connect the MUTII or earth No.1 pin of the 16-pin diagnosis connector.) Key reminder switch: OFF (Insert the ignition key) Function Configuration procedure Keyless entry system hazard answerback function

When the lock button of the transmitter is pressed twice continuously within two seconds, the hazard answerback function during the lock state will be switched between available or unavailable. Function available: Buzzer sounds once. (Initial state) Function not available: Buzzer sounds twice. When the unlock button of the transmitter is pressed twice continuously within two seconds, the hazard answerback function during the unlock state will be switched between available or unavailable. Function available: Buzzer sounds once. (Initial state) Function not available: Buzzer sounds twice.

Vehicle speed-dependent wiper function

When the windshield wiper mist switch is turned ON for more than two seconds, the vehicle speed-dependent wiper function is switched between available or unavailable. Function available: Buzzer sounds once. (Initial state) Function not available: Buzzer sounds twice.

Headlamp automaticshutdown function

When the passing switch is turned ON for more than two seconds with the head lamp switch ON and the turn signal lamp switch turned to RH, the headlamp automatic-shutdown function is switched between available or unavailable. Function not available: Buzzer sounds twice. Function available: (when the tail lamp illuminates with the ignition switch turned to the "LOCK" (OFF) position, it is not automatically turned off): Buzzer sounds three times. (Initial state)

54B-274

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR ON-VEHICLE SERVICE

Function

Configuration procedure

Delayed lamp-off time of the interior lamp

When the turn signal lamp switch is set in the order of RH to LH to RH to LH within three seconds from the LH position, the delayed lamp-off time switches (Returns to a after e, and repeats from a in order.) a. 30 seconds: Buzzer sounds once. b. 10 seconds: Buzzer sounds twice. c. 0 seconds (No delay time): Buzzer sounds three times. d. 15 seconds: Buzzer sounds four times. (Initial state) e. 7.5 seconds: Buzzer sounds five times.

Interior lamp automaticshutdown function

When the hazard lamp switch is turned ON for more than two seconds, the interior lamp automatic-shutdown function switches in the following order. (a and b switches alternately) a. Function available: Buzzer sounds once. (Initial state) b. Function not available: Buzzer sounds twice.

Initialization of all functions

When the windshield washer switch is ON for more than 20 seconds continuously, the buzzer sounds twice, and all functions will be initialized. (Settings are returned to their initial states.) The configuration mode entry buzzer sounds after 10 seconds, however to initialize all functions, the ON state should be continued for 20 seconds. When the windshield washer switch is ON for more than 20 seconds continuously without the configuration mode set, the configuration mode will be set after 10 seconds without the initialization of all functions.

54C-1

GROUP 54C

00 11

SMART WIRING SYSTEM (SWS) USING SWS MONITOR

12 13 14 15 16 17 21 22

CONTENTS

25


54C


SPECIAL TOOLS. . . . . . . . . . . . . . . .

54C

CHECK AT ECU TERMINAL . . . . . . . 54C

54C

26 27 31 32 33 34 35 36 37 42 51 52 54 55


54C-2

GENERAL INFORMATION


For the general information regarding the SWS, refer to GROUP 54B - General Information 354B.


Tool

Number

Name

Use

MB991502

MUT-II sub-assembly

Check the SWS (The MUT-II displays diagnosis codes and pulse check)

MB991862 A: MB991806 B: MB991812 C: MB991822

SWS monitor kit A: SWS monitor cartridge B: SWS monitor harness (for columnECU) C: Probe harness

SWS communication line check (ECU check and service data)

MB991529

Diagnosis code check Input signal check by using a harness voltmeter

B991502

A

B

C

B991813

MB991529

SMART WIRING SYSTEM (SWS) USING SWS MONITOR SPECIAL TOOLS

Tool A

B

54C-3

Number

Name

Use

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222



MB991854

SWS monitor harness SWS communication line check (for 13-pin connector) (ECU check and service data)

MB991896

Adapter harness for door communication

C

D MB991223AB

MB991854

MB991896

Door communication line check (service data)

54C-4

SMART WIRING SYSTEM (SWS) USING SWS MONITOR TROUBLESHOOTING

TROUBLESHOOTING PRIOR TO TROUBLESHOOTING M1549014700323

Before carrying out troubleshooting, check the following two items.

Make sure that the ETACS-ECU, the junction block (J/B), the front-ECU and the engine compartment relay box are connected securely. Check that the system fuses and fusible links are not burned out.

STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING M1549000500489

1. Gather information about the problem from the customer.

2. Verify that the condition described by the customer exists. Check that the ETACS-ECU is applicable for the 3. Confirming version number and destination

NG

If the ECU is not applicable for them, replace it with correct one.

OK

4. ECU check on the SWS monitor

vehicle specifications.

NG

Check the power supply circuit for the ECU communication lines and repair if necessary.

OK

5. Check the data list by using the SWS monitor.

NG

6. Check of input signal circuit system

OK

7. Check of output signal circuit system AC211883 AB

1. Gather information about the problem from the customer. 2. Verify that the condition described by the customer exists. NOTE: If an error occurs in the SWS communication line, the ECU isolated from the communication line performs a fail-safe or backup operation, so the problem may not match the one shown in the Trouble Symptom Chart. However, the cause of the failure can be tracked down by performing the following troubleshooting with the SWS monitor. 3. Confirming version number and destination Check whether the SWS version number (0) and destination (EU W/O DRL) meet the vehicle specifications. If they are different, replace the ETACS-ECU with a correct one.

4. ECU check on the SWS monitor Check whether the communication status of the input- or output-signal-side ECU associated with the defective function is normal. If "OK " is displayed for all related ECUs, they communicate with each other normally and the input or output signal circuit system may be defective. Therefore, check SWS monitor service data. If "NG" is displayed for any of the related ECUs, something may be wrong with the ECU for which "NG" appears, its power supply or earthing system, or a wiring harness or connector between the SWS monitor and the ECU. Check the wiring harness and connectors associated with the ECU and examine the ECU itself. 5. Check the data list by using the SWS monitor.


54C-5

TROUBLESHOOTING

6.

7.

Select the defective function from the functionspecific diagnostic menu, and check the service data that appears for each function item. This allows you to check whether the transmission data is normal or not. You can judge which circuit is the cause of the trouble, input circuit or output circuit. NOTE: In addition to the function-specific diagnostic menu, a service data menu is available for SWS monitor service data to check all items for each ECU. The switch condition does not meet the service data display: Input signal system related to defective functions The switch condition meets the service data display: Output signal system related to defective functions Check of input signal circuit system Check relevant switch, sensor, input signal-side ECU and their wiring harness and connector. Check of output signal circuit system Check an output signal-side ECU, electrical load components and their wiring harness and connector.

How to connect the SWS communication line Diagnosis connector (13-pin)

Diagnosis connector (16-pin) MB991502

MB991854 AC200084AG

Connect special tool SWS monitor harness (for 13pin connector) to the diagnosis connector (13-pin connector) MB991854.

How to establish communication between doors MB991822 MB991812

HOW TO CONNECT THE SWS MONITOR M1549014800342

MB991896

CAUTION Always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the SWS monitor and the MUT-II. How to connect the SWS communication line

Column switch connector

MB991812

Column switch connector at harness side AC103262AE

1. Remove the steering column cover. 2. Remove the steering column switch connector. 3. Connect special tool SWS monitor harness (for column-ECU) MB991812.

AC103783AC

1. Connect special tool SWS monitor harness (for column-ECU) MB991812 to special tool adapter harness for door communication MB991896. 2. Connect special tool Probe harness MB991822 to special tool adapter harness for door communication MB991896 assembled in step 1. 3. Confirm that all the harnesses are connected. Then insert the probe of special probe harness MB991822 to each female connector terminal on special tool adapter harness for door communication MB991896 by backprobing. NOTE: For the connectors and their terminal numbers on the door communication line for the probe to insert, refer to the reference table.

54C-6


Reference table of connectors and their terminal numbers on door communication line Insert the probe of the probe harness to each female connector terminal on the door communication line by backprobing. Connector name Connector number Intermediate connector

Instrument panel wiring harness and floor wiring harness (RH) combination

C-13 (Floor wiring harness (RH) side)

Instrument panel wiring C-15 (Front door wiring harness and front door wiring harness (RH) side) harness (RH) combination Instrument panel wiring harness and floor wiring harness (LH) combination

Terminal No. 4

17

C-117 (Instrument panel wiring 10 harness side)

Instrument panel wiring C-118 (Front door wiring harness and front door wiring harness (LH) side) harness (LH) combination

26

Floor wiring harness (RH) and D-02 (Floor wiring harness rear door wiring harness (RH) (RH) side) combination

7

Floor wiring harness (LH) and D-26 (Floor wiring harness rear door wiring harness (LH) (LH) side) combination

7

Rear door wiring harness (LH) E-09 (Rear door wiring and rear door sub wiring harness (LH) side) harness (LH) combination

6

Front door wiring harness E-12 (Front door wiring (LH) and front door sub wiring harness (LH) side) harness (LH) combination

1

Front door wiring harness E-24 (Front door wiring (RH) and front door sub wiring harness (RH) side) harness (RH) combination

6

Rear door wiring harness E-27 (Rear door wiring (RH) and rear door sub wiring harness (RH) side) harness (RH) combination

6


E-05

11

Power window sub switch (front, RH)

E-17

6

Power window sub switch (rear RH)

E-21

6

Power window sub switch (rear LH)

E-01

6


54C-7

TROUBLESHOOTING Connectors: C-13, C-15 Connector: D-02 D-02 1 2 3 4 5 6 7 8

C-13(L)

C-15(GR)

AC301408 AH

Connector: D-26 C-13

C-15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

D-26

1 2 3 4 5 6 7 8

AC301398 AZ

AC301410 AB

Connectors: C-117, C-118 Connectors: E-01, E-09 E-01 Harness side E-01

3 2 1 8 7 6 5 4

C-118

E-09

C-117

3 1 2 4 5 6 7 8

C-117 1 2 3

E-09 AC301416 AG

4 5 6 7 8 9 10

111213

14 1516 17 1819 20 2122 2324 25 26 27 28 29 32 33 34

35

30 31 36 37

38

C-118 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

AC301396 AD


54C-8

TROUBLESHOOTING Connectors: E-17, E-24


E-17 Harness side 3 2 1 8 7 6 5 4

E-05

E-17

E-24 E-24

3 1 2 4 5 6 7 8

E-12

AC301412 AH

E-05 Harness side

Connectors: E-21, E-27 E-21 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

3 2 1 8 7 6 5 4

E-21

E-12 E-27

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

E-27

3 1 2 4 5 6 7 8

AC301414 AI

AC301419 AC

ECU CHECK M1549014900305

Use the MUT-II and the SWS monitor to check ECUs (Refer to MUT-II reference manual). 1. The following ECUs can be checked by using the MUT-II and the SWS monitor. NOTE: If a malfunction is found by the "ECU CHECK", proceed "Symptom Procedure" (Refer to 354C).

SWS monitor-compatible ECUs and their conditions Item No.

ECUs to be checked

Display on MUT-II Normal conditions

ECU conditions

80

Column switch (columnECU)

COLUMN ECU

OK*1

All of the column switch, power supply, earth and interconnecting communication line are normal

83

ETACS-ECU

ETACS ECU

OK

All of the ETACS-ECU switch, power supply, earth and interconnecting communication line are normal

84

Front-ECU

FRONT ECU

OK*2

All of the front-ECU, power supply, earth and interconnecting communication line are normal

85

Power window main switch (power window module)

P/W MODULE

OK*2 (when All of the power window main switch, power supply, earth and the ignition switch is ON) interconnecting communication line are normal

-

Other SWS-related ECUs

Other ECUs

NG

ECUs are not used


54C-9

TROUBLESHOOTING

NOTE: .

*1: If "NG" is displayed beside the ETACS-ECU while the ignition switch is off, "NG" is also displayed beside the column-ECU. *2: If "NG" is displayed beside the ETACS-ECU, "NG" is also displayed beside the front-ECU and the power window main switch (power window module).

DATA LIST CHECK M1549015000327

1. Use the MUT-II and the SWS monitor to check "DATA LIST." This "DATA LIST" check is applicable for signals, which are transmitted and received through the SWS communication line and the communication lines routed from one door to another. For the input signals which are not applicable for the SWS monitor check, refer to pulse check procedure 354C.

NOTE: If a problem is found in the "DATA LIST" check, refer to the Problems during Input Signal Check (Refer to 354C). 2. The following input signals can be checked by using the MUT-II and the SWS monitor.

DATA LIST REFERENCE TABLE Column switch (column-ECU) Item No. Check items Display on MUT-II

Check conditions

Normal condition

00

lighting switch: HEAD

ON

lighting switch: Other than HEAD

OFF

01 02 03 05

06

07

08

09

10

Headlamp switch

HEADLAMP SW

Tail lamp switch

TAIL LAMP SW Lighting switch: TAIL

Dimmer switch

DIMMER SW

Passing lamp PASSING SW switch

ON

Lighting itch: OFF

OFF

Dimmer switch: ON

ON

Dimmer switch: OFF

OFF

Passing lamp which: ON

ON

Passing lamp which: OFF

OFF


INT WIPER SW Wiper switch: INT

Windshield low-speed wiper switch

LO WIPER SW Wiper switch: LO

Windshield high-speed wiper switch

HI WIPER SW

Wind shield mist wiper switch

MIST WIPER SW


FRONT WASH. Windshield washer switch: ON SW Windshield washer switch: OFF

ON


TURN SIG. RH Turn-signal lamp switch: RH

ON

Wiper switch: Other than INT

ON OFF ON

Wiper switch: Other than LO

OFF

Wiper switch: HI

ON

Wiper switch: Other than HI

OFF

Wiper switch: Mist

ON

Wiper switch: Other than mist

OFF

Turn-signal lamp switch: Other than RH

OFF

OFF


54C-10

TROUBLESHOOTING

Item No. Check items Display on MUT-II 11

13 14 15

Check conditions


TURN SIG. LH Turn-signal lamp switch: LH

Rear wiper switch

REAR WIPER SW

Rear washer REAR WASH. switch SW

Normal condition ON

Turn-signal lamp switch: Other than LH

OFF

Rear wiper switch: INT

ON

Rear wiper switch: Other than INT

OFF

Rear wiper switch: Washer

ON

Rear wiper switch: Other than washer

OFF

With or INT WIP KNOB Vehicles with intermittent wiper control without Vehicles without intermittent wiper control windshield intermittent wiper control

EQUIP


Headlamp washer switch: ON

ON

Headlamp washer switch: OFF

OFF

Item No. Check items Display on MUT-II

Check conditions

Normal conditions

30

Ignition switch: ON or START

ON

Ignition switch: LOCK (OFF) or ACC

OFF

Ignition switch: ACC or ON

ON

Ignition switch: LOCK (OFF) or START

OFF

16

HD WASHER SW

NONE

ETACS-ECU

31 32


IG SW(IG1)

Ignition IG SW(ACC) switch (ACC)

Driver’s door DR DOOR SW Driver's door switch ON (The driver’s door switch is open).

ON

Driver's door switch OFF (The driver's door OFF is closed). 33

35

36

Reception of P/W SW power ACCEPT window switch Headlamp automatic shutdown function

Request of fog lamp illumination


Ignition switch: from ON or START to LOCK from PERMIT to (OFF) or ACC PROHIBIT (after approximately 30 seconds)

HD AUTO-CUT 1. Lighting switch: Other than OFF 2. Ignition switch: from ON or START to LOCK (OFF) or ACC 3. Driver's door switch: ON (driver's door open)

F.FOG LAMP

PERMIT

OFF to ON (after approximately one second)

When requirements for the headlamp automatic shutdown are not satisfied

OFF

1. Lighting switch: "TAIL" or "HEAD" 2. Fog lamp switch: ON

ON

Other than the conditions above

OFF


54C-11

TROUBLESHOOTING


Check conditions

Normal conditions

37

Windshield INT WIPE intermittent TIME wiper interval

1. Ignition switch: ACC or ON 2. Operate the intermittent wiper control, and change the wiper interval

The MUT-II displays intermittent wiper interval in response to the intermittent wiper control positions

41

Back-up lamp switch

INHIBITOR SW Back-up lamp switch: ON

Buzzer

BUZZER

ON

Back-up lamp switch: OFF

OFF

1. Ignition switch: LOCK (OFF) 2. Tail lamp or headlamp switch: ON 3. Driver’s door switch: ON (driver’s door open)

ON

When requirements for sounding each warning buzzer are not satisfied

OFF


Check conditions

Normal conditions

70

lighting switch: Other than OFF (excluding when high-beam is on) or the wiper switch is at position other than OFF

Normal response

Ignition switch: ON or START Lighting switch: OFF lightingr switch: OFF

SLEEP RESPONSE

Lamping switch: HEAD Headlamps: at high beam

HI BEAM RESPONSE

-

No response

43

Front-ECU

Response by Front ECU the frontresponse ECU

NOTE: For item number 70, the MUT-II also displays "NG" under the "ECU Check" when it displays "No response" under the front-ECU check.


54C-12

TROUBLESHOOTING

Power window main switch (power window module) Item No. Check items Display on MUT-II 71

Response from power window module

Check conditions

P/W ECU ACK Ignition switch: ON or START

Normal conditions NORMAL ACK

1. Ignition switch: ON or START INPUT CHECK 2. Operate any switch of the power window (only momentarily main switch. when switch is operated)

-

NO ACK

NOTE: For item number 71, the MUT-II also displays "NG" under the "ECU CHECK" when it displays "NO ACK" under the "P/W ECU ACK" check. Communication between doors Item No. Check items Display on MUT-II C0

C1

C2

C4

C5

C6

C8

Check conditions

Front passenger’s power window UP switch

PASS DOR UP Front passenger’s power window switch: UP

Front passenger’s power window DOWN switch

PASS DOR DOWN

Front PASS DOR passenger’s AUTO power window AUTO switch Rear right power window UP switch

REAR RH UP

Rear right power window DOWN switch

REAR RH DOWN

Normal conditions ON

Front passenger’s power window switch: Other than "UP"

OFF

Front passenger’s power window switch: DOWN

ON

Front passenger’s power window switch: Other than "DOWN"

OFF

Front passenger’s power window switch: AUTO

ON

Front passenger’s power window switch: Other than "AUTO"

OFF

Rear right power window switch: UP

ON

Rear right power window switch: Other than OFF "UP" Rear right power window switch: DOWN

ON

Rear right power window switch: Other than OFF "DOWN"

Rear right REAR RH power AUTO window AUTO switch

Rear right power window switch: AUTO

Rear left power window UP switch

Rear left power window switch: UP

ON

Rear left power window switch: Other than "UP"

OFF

REAR LH UP

ON

Rear right power window switch: Other than OFF "AUTO"


54C-13

TROUBLESHOOTING


Check conditions

Normal conditions

C9

Rear left power window switch: DOWN

ON

Rear left power window switch: Other than "DOWN"

OFF

Rear left power window switch: AUTO

ON

Rear left power window switch: Other than "AUTO"

OFF

CA

CB

CD

CE

CF

Rear left power window DOWN switch

REAR LH DOWN

Rear left REAR LH power AUTO window AUTO switch Power window lock switch

P/W LOCK SW Power window lock switch: ON

Multi-stop

MLT-MODE STOP

ON

Power window lock switch: OFF

OFF

1. When multimode is working 2. Either function of keyless entry transmitter: ON

ON (only momentarily when switch is operated)

Other than the conditions above

OFF

Reception of P/W SW power RECEPT window switch


PERMIT



ON

Ignition switch: LOCK (OFF) or ACC

OFF

IG1

Ignition switch: from ON or START to LOCK from PERMIT to (OFF) or ACC PROHIBIT (after approximately 30 seconds)

NOTE: Service data of door communication will be sent from the power window main switch to the door communication line. Therefore, the display will remain "OFF" unless the probe is inserted.

54C-14


FUNCTION DIAGNOSIS The table below shows the service data and their normal condition, which are displayed during the "FUNCTION DIAG." The row "Normal conditions" shows values, which are shown when each operation is made. Wiper Item

Input signals

Item No. Display on MUT-II

Normal conditions

F.WIPER INT (intermittent)


05

INT WIPER SW

ON

06 Windshield lowspeed wiper switch

LO WIPER SW

OFF

Windshield high07 speed wiper switch

HI WIPER SW

OFF


MIST WIPER SW

OFF

Windshield washer 09 switch

FRONT WASH. SW

OFF


31

IG SW(ACC)

ON

Windshield intermittent wiper interval

37

WIPER INT TIME

The MUT-II displays intermittent wiper interval in response to the intermittent wiper control positions

Response by the front-ECU

70

FRONT ECU ACK

NORMAL ACK or HI-BEAM ACK


05

INT WIPER SW

OFF

Windshield low06 speed wiper switch

LO WIPER SW

ON

07 Windshield highspeed wiper switch

HI WIPER SW

OFF


MIST WIPER SW

OFF

FRONT WASH. SW

OFF

F.WIPER LO (low speed)

08

08

Windshield washer 09 switch Ignition switch (ACC)

31

IG SW(ACC)

ON


70

FRONT ECU ACK



54C-15

Item

Input signals


Normal conditions

F.WIPER HI (high speed)


05

INT WIPER SW

OFF


LO WIPER SW

OFF


HI WIPER SW

ON


MIST WIPER SW

OFF


FRONT WASH. SW

OFF


31

IG SW(ACC)

ON


70

FRONT ECU ACK


F.WIPER MIST Windshield intermittent wiper switch

05

INT WIPER SW

OFF


LO WIPER SW

OFF


HI WIPER SW

OFF


MIST WIPER SW

ON


FRONT WASH. SW

OFF


31

IG SW(ACC)

ON


70

FRONT ECU ACK



08

MIST WIPER SW

OFF


FRONT WASH. SW

ON


31

IG SW(ACC)

ON


70

FRONT ECU ACK



16

HD WASHER SW

ON


31

IG SW(ACC)

ON


70

FRONT ECU ACK


F.WIPER WASH

HD WASHER

08

08

54C-16


Rear wiper Item

Input signals


Normal conditions

REAR WIPER

Rear wiper switch

13

REAR WIPER SW

ON

Rear washer switch 14

REAR WASH. SW

OFF


31

IG SW(ACC)

ON

Rear wiper switch

13

REAR WIPER SW

ON


31

IG SW(ACC)

ON

Back-up lamp switch

41

INHIBITOR SW

ON

Rear washer switch 14

REAR WASH. SW

ON


31

IG SW(ACC)

ON

Item

Input signals


Normal conditions

OFF

Headlamp switch

00

HEADLAMP SW

OFF

Tail lamp switch

01

TAIL LAMP SW

OFF

Passing lamp switch

03

PASSING SW

OFF


30

IG SW(IG1)

ON


35

HD AUTO-CUT

OFF


70

FRONT ECU ACK


Headlamp switch

00

HEADLAMP SW

OFF

Tail lamp switch

01

TAIL LAMP SW

ON

Passing lamp switch

03

PASSING SW

OFF

Ignition switch (IG1)*

30

IG SW(IG1)

ON


35

HD AUTO-CUT

OFF


70

FRONT ECU ACK

NORMAL ACK

REV. INTERLOCK

REAR WASHER

Lighting

TAIL LAMP


Item

Input signals

54C-17


Normal conditions

00

HEADLAMP SW

ON

03

PASSING SW

OFF


30

IG SW(IG1)

ON


35

HD AUTO-CUT

OFF


70

FRONT ECU ACK

NORMAL ACK

HEADLAMP HI Headlamp switch (high-beam) Dimmer switch

00

HEADLAMP SW

ON

02

DIMMER SW

ON


30

IG SW(IG1)

ON


35

HD AUTO-CUT

OFF


70

FRONT ECU ACK

HI-BEAM ACK

Passing lamp switch

03

PASSING SW

ON


70

FRONT ECU ACK


Headlamp switch

00

HEADLAMP SW

Either of items is ON

Tail lamp switch

01

TAIL LAMP SW


30

IG SW(IG1)

ON


35

HD AUTO-CUT

OFF

Request of fog lamp illumination

36

F.FOG LAMP

ON


70

FRONT ECU ACK

NORMAL ACK

Headlamp switch

00

HEADLAMP SW

ON

Tail lamp switch

01

TAIL LAMP SW

ON


35

HD AUTO-CUT

OFF


70

FRONT ECU ACK


HEADLAMP Headlamp switch LO (low-beam) Passing lamp switch

PASSING LAMP

F.FOG LAMP

REAR FOG LAMP


54C-18 Item

TROUBLESHOOTING

Input signals


Normal conditions

00

HEADLAMP SW

Either is on

Tail lamp switch

01

TAIL LAMP SW


30

IG SW(IG1)

OFF

Driver’s door switch 32

DR DOOR SW

ON


35

HD AUTO-CUT

ON


70

FRONT ECU ACK


HD AUTO-CUT Headlamp switch

NOTE: . 1. When checking the input signals (off, tail, low-beam or high-beam), turn the ignition switch to the "ON" position in order to disable the headlamp automatic shutdown function. However, the titles on the MUT-II screen will not be highlamped as this has nothing to do with actual lamp operation. 2. For checking item "HEADLAMP HI", the MUT-II displays "OFF" on the item No.2 "DIMMER SW" when the headlamps are at high-beam. Therefore, the MUT-II should display "ON" momentarily when the dimmer switch is operated. Turn signal lamp Item

Input signals


Normal conditions

Turn-signal lamp (RH)


10

TURN SIGNAL RH SW

ON


11

TURN SIGNAL LH SW

OFF


30

IGNITION SW IG1

ON


10

TURN SIGNAL RH SW

OFF


11

TURN SIGNAL LH SW

ON


30

IGNITION SW IG1

ON

Turn-signal lamp (LH)


54C-19

Buzzer Item

Input signals


Normal conditions

00

HEADLAMP SW

Either is on

01

TAIL LAMP SW

30

IGNITION SW IG1

OFF

Driver’s door switch 32

DRIVER DOOR SW

ON


35

HD LAMP AUTOCUT

OFF

Buzzer

43

Buzzer

ON

Lamping Headlamp switch monitor buzzer Tail lamp switch Ignition switch (IG1)

NOTE: The headlamp automatic shutdown function works in approximately one second after the lamping monitor buzzer starts sounding, and then the buzzer ceases sounding.

PULSE CHECK M1549015100313

CAUTION

NOTE: If a problem is found in the "Pulse Check", refer to the Problems during Input Signal Check (Refer to 354C). 2. Use the MUT-II or voltmeter to check the following input signals.

Before connecting or disconnecting the MUT-II, turn the ignition switch to the "LOCK" (OFF) position. 1. The input signals (signals other than communication line signals), which are compatible with the SWS monitor by using the MUT-II or voltmeter, can be confirmed by the Pulse Check. Switches which are applicable to input signal check, and their check conditions Input signals

Requirements for sounding buzzer

Key reminder switch

When the inserted ignition key is pulled out.



Front fog lamp switch Rear fog lamp switch All of the door switches

A door is opened when all the doors are closed.

Driver’s door lock actuator

When the driver’s key cylinder or inside lock knob is unlocked or locked.


When the vehicle speed has reached 10 km/ h or more.

Keyless entry transmitter Interior lamp loaded signal

Switches

When the switch is turned from off to on. When a load is applied through multipurpose fuse No.18.

54C-20

SMART WIRING SYSTEM (SWS) USING SWS MONITOR TROUBLE SYMPTOM CHART

MUT-II drive recorder function M1549017800125

1. The SWS monitor cartridge memory can store the ECU check results, the service data, the communication data obtained by the function diagnosis. This communication data can be displayed as a chart or graphical form.

2. If data obtained by the drive recorder function has to be stored for long time, the data can be transferred to the SWS monitor cartridge. By doing this, you can disconnect the MUT-II to prevent excessive battery drain. NOTE: For the details about the MUT-II drive recorder function, refer to MUT-II reference manual.


Symptom


Reference page

Communication with the SWS monitor is impossible.

A-1

354C

Communication with the column switch (column-ECU) is impossible.

A-2

354C

Communication with the ETACS-ECU is Impossible.

A-3

354C

Communication with the front-ECU is Impossible.

A-4

354C

Communication with the power window main switch (power window module) is Impossible.

A-5

354C


Reference page

Symptom

Alarm Function

Lamp reminder buzzer function does not work normally.

B-1

354C

Central door locking


354C


354C

A door or a tailgate can not be locked or unlocked by the central door locking system.

C-2

354C

A door or a tailgate can not be locked or unlocked by the central door locking system.

C-2

354C

The Ignition Key Reminder Function does not Work Normally.

C-3

354C

The impact detection door unlock function does not function.

C-4

354C


Symptom

Power window


Windshield wiper and washer

54C-21


Reference page

Power windows do not work at all.

D-1

354C

Driver’s power window does not work by means of the power window main switch.

D-2

354C

Relevant power window(s) do not work by means of the front and rear passenger’s power window sub switches.

D-3

354C

Front and/or rear passenger’s power window(s) do not work by means of the power window main switch.

D-4

354C

The window glass lowers automatically while it is rising.

D-5

354C

Power window anti-trap function does not work normally.

D-6

354C

Keyless entry system does not work.

E-1

354C

Keyless entry hazard warning lamp answerback function or the room lamp answerback function does not work normally.

E-2

354C

Encrypted code cannot be registered.

E-3

354C

The timer lock function does not work after E-4 the doors have been unlocked by the keyless entry system.

354C

The windshield wipers do not work at all.

F-1

354C

The windshield wipers do not work when F-2 the wiper switch is at "INT", "Washer" or "Mist" position. However, the wipers work at low speed when the switch is at "Lo" and "Hi" position.

354C

The windshield wipers do not stop at the specified park position.

F-3

354C

The windshield wipers do not work normally.

F-4

354C

The intermittent wiper interval cannot be adjusted by operating the windshield intermittent wiper volume control.

F-5

354C

The intermittent wiper interval is not changed according to the vehicle speed.

F-6

354C

The windshield washer does not work.

F-7

354C

54C-22


Symptom


Reference page

Rear wiper does no not work at all.

G-1

354C

The rear wiper does not stop at the specified park position.

G-2

354C

When the shift lever is moved to "R" position during the rear wiper operation, the rear wiper does not operate at the continuous mode.

G-3

354C

The rear washer does not work.

G-4

354C

Headlamp washer

The headlamp washer does not work.

H-1

354C

Ignition key cylinder illumination lamp

The ignition key cylinder illumination lamp does not illuminate/extinguish normally.

I-1

354C

Headlamp and tail lamp

The headlamps do not illuminate when the J-1 lighting switch is at "TAIL" or "PASSING" position, but illuminate only at low beam when the switch is at "HEAD" position. However, the headlamps do not illuminate at high beam.

354C

The tail lamps do not illuminate normally.

J-2

354C

The low-beam headlamps do not illuminate J-3 normally.

354C

The high-beam headlamps do not illuminate normally.

J-4

354C

The high-beam and low-beam headlamps do not illuminate when the passing switch is operated.

J-5

354C

The headlamp automatic shutdown function does not work normally.

J-6

354C

Any of tail lamps, position lamps or licence J-7 plate lamp does not illuminate.

354C

Either of the headlamps or high-beam indicator lamps does not illuminate.

J-8

354C

The turn-signal lamps do not illuminate.

K-1

354C

The hazard warning lamps do not illuminate.

K-2

354C

Any of the turn-signal lamps does not illuminate.

K-3

354C

The front fog lamps do not illuminate normally.

L-1

354C

The rear front fog lamps do not illuminate normally.

L-2

354C

Either of the front fog lamps does not illuminate normally.

L-3

354C

Any of the rear fog lamps does not illuminate.

L-4

354C

Rear wiper and washer

Flasher timer

Fog lamp

SMART WIRING SYSTEM (SWS) USING SWS MONITOR CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK

Symptom

Interior lamp


54C-23 Reference page


354C


354C

Interior lamp automatic shutoff function does not work normally.

M-3

354C

The door-ajar warning lamp does not illuminate/extinguish normally.

M-4

354C

CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK M1549024200136

If a problem is found in the Service Data or Pulse Check inspection, observe the table below. Symptom


Reference page

The ignition switch (ACC) signal is not received.

N-1

354C

The ignition switch (IG1) signal is not received.

N-2

354C

The back-up lamp switch signal is not received.

N-3

354C

The driver’s door switch signal is not received.

N-4

354C

Column switch (lighting and turnsignal lamp switch)

N-5

354C

The tail lamp switch signal is not received. The headlamp switch signal is not received. The dimmer switch signal is not received. The passing switch signal is not received. The turn-signal lamp switch (LH) signal is not received. The turn-signal lamp switch (RH) signal is not received. The headlamp washer switch signal is not received.

54C-24

SMART WIRING SYSTEM (SWS) USING SWS MONITOR CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK

Symptom

Column switch (windshield wiper/ washer and rear wiper washer switch)


Reference page

N-6

354C

N-7

354C

When the power window main switch N-8 is operated, the switch signals are not received.

354C

The windshield mist wiper switch signal is not received. The windshield intermittent wiper switch signal is not received. The windshield low-speed wiper switch signal is not received. The windshield high-speed wiper switch signal is not received. The windshield washer switch signal is not received. The rear wiper switch signal is not received. The rear washer switch signal is not received. The windshield intermittent wiper volume signal is not received.


The front fog lamp switch signal is not received.

N-9

354C

The rear fog lamp switch signal is not received.

N-10

354C

The key reminder switch signal is not received.

N-11

354C

The hazard warning lamp switch signal is not received.

N-12

354C

All the door switch signals are not received.

N-13

354C

The driver’s door lock actuator switch signal is not received.

N-14

354C

The vehicle speed signal is not received.

N-15

354C

Each switch signal of the keyless entry transmitter is not received.

N-16

354C

The interior lamp loaded signal is not detected.

N-17

354C

The passenger’s door lock key cylinder switch signal is not detected.

N-18

354C


54C-25

OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION PROCEDURES

OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION PROCEDURES M1549020300186

If troubles have occurred in the functions which use the SWS simultaneously, observe the table below to check input signals.

(This table shows only the input signals which will cause troubles in at least two functions simultaneously).

Function

N-1

N-2

N-4

N-5

N-6

N-11

N-13

N-14

N-15

N-17

Lamp reminder function

-

-

-

-

-

-

-

Control of central door locking

-

-

-

-

-

-

-

-

-


-

-

-

-

-

-

-

Door locking released due to impact detection.

-

-

-

-

-

-

-

-

-


-

-

-

-

-

-

Keyless entry hazard warning lamp answerback

-

-

-

-

-

-

-

-

-

-

Power window control

-

-

-

-

-

-

-

-

-

Control of windshield wiper washer

-

-

-

-

-

-

-

Rear wiper washer control

-

-

-

-

-

-

-

-

Ignition key cylinder illumination lamp function

-

-

-

-

-

-

Headlamp control

-

-

-

-

-

-

-

-

Tail lamp control

-

-

-

-

-

-

-

-


-

-

-

-

-

-

-

Fog lamp control

-

-

-

-

-

-

-

-

-

Turn-signal lamp control

-

-

-

-

-

-

-

-

Dome lamp control

-

-

-

-

Interior lamp automatic shutdown function

-

-

-

-

-

-

-

-

Door-ajar indicator lamp

-

-

-

-

-

-

-

-

54C-26

SMART WIRING SYSTEM (SWS) USING SWS MONITOR SYMPTOM PROCEDURES

SYMPTOM PROCEDURES

INSPECTION PROCEDURE A-1: Communication with the SWS monitor is impossible.

CAUTION Whenever the ECU is replaced, ensure that the power supply circuit, the earthing circuit and the communication circuit are normal. MUT-II Communication and ETACS-ECU Earth Circuit

ETACSECU

DIAGNOSIS CONNECTOR Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

COMMENTS ON TROUBLE SYMPTOM The SWS monitor may be connected improperly. Possible causes Malfunction of the SWS monitor body (I/F cartridge)

FRONT SIDE


Malfunction of the SWS monitor harness Malfunction of the ETACS-ECU Damaged harness wires and connectors


DIAGNOSIS PROCEDURE

54C-27

Step 4. Measure the resistance at the C-219 ETACS-ECU connector.

Step 1. Check that the MUT-II communicates with the other systems. Use the MUT-II to confirm that it communicates with the engine-ECU.


Q: Is the check result normal? YES : Go to Step 2. NO : Diagnose the engine control system. Refer

to 313A.


Step 2. Check that the MUT-II can communicate with the system. When the ignition switch is turned ON, check if the MUT-II can communicate with the system.

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


Q: Is the check result normal? YES : Refer to Inspection Procedure A-3

"Communication with ETACS-ECU is impossible 354C." NO : Go to Step 3. Step 3. Connector check: C-219 ETACS-ECU connector

Connector C-219 (Harness side) AC301541AY


(2) Resistance between C-219 ETACS-ECU connector terminal No.56 and body earth OK: 2 W or less Harness side

C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE





59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

Check the earth wires for open circuit. Q: Are the check results normal? YES : The trouble can be an intermittent


54C-28


Step 6. Connector check: C-24 diagnosis connector Connector: C-24

Step 7. Check the wiring harness from C-219 ETACS-ECU connector terminal Nos. 51 and 67 to C-24 diagnosis connector terminal Nos. 9 and 1. Connector: C-24

Harness side 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Harness side C-24(B)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

AC301395 AF

C-24(B) AC301395 AF




59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE

Check the communication lines for open circuit. Q: Are the check results normal? YES : Replace the ETACS-ECU. NO : Repair the wiring harness.


54C-29

INSPECTION PROCEDURE A-2: Communication with the column switch (column-ECU) is not possible.

CAUTION Whenever the ECU is replaced, ensure that the power supply circuit, the earthing circuit and the communication circuit are normal. Column Switch Power Supply and SWS Communication Circuit FUSIBLE LINK 1


COLUMN-ECU

ETACS-ECU

COLUMN SWITCH


COMMENTS ON TROUBLE SYMPTOM The power supply circuit to the column switch (column-ECU) may be defective. If the wiring harness of the battery power supply circuit for the ECU (column switch terminal No.1) is defective, also check the power supply circuit to the ignition switch (IG1) (column switch terminal No.9) and repair if necessary.


TROUBLESHOOTING HINTS Malfunction of the ETACS-ECU Malfunction of the column switch Damaged harness wires and connectors

54C-30


DIAGNOSIS PROCEDURE Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF

Step 3. Measure the voltage at C-310 column switch connector. Connector: C-310

Harness side

ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure A-3

"Communication with ETACS-ECU is impossible 354C."

5 4 3 2 1 10 9 8 7 6

AC301399 AC



Step 2. Connector check: C-310 column switch connector Q: Is the check result normal? YES : Go to Step 3. NO : Repair the defective connector.

5 4 3 2 1 10 9 8 7 6 AC301541BD

(2) Voltage between C-310 column switch connector No.1 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.


54C-31

SYMPTOM PROCEDURES

Step 4. Check the wiring harness between C-310 column switch connector terminal No.1 and fusible link (1).


Fusible link: No.1

C-02

C-116 C-02

AC301515 AB

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 2324 25 2627 28 2930 3132 33

Connector: C-310

C-116 1 2

Harness side

5 6 7

3 4

8 9

10 1112 1314

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

1617 18 19 20 21

5 4 3 2 1 10 9 8 7 6

AC301399 AC

AC301396 AM

Connectors: C-202, C-204 Junction block (Front view) C-204(B) C-202

Harness side C-202 6 5 4 3 2 1 14 13 12 11 10 9 8 7

C-204 1

AC210475 AL

Prior to the wiring harness inspection, check intermediate connector C-116, joint connector C-02, junction block connectors C-202 and C204, and repair if necessary. Check the power supply line for open circuit.


54C-32

SYMPTOM PROCEDURES



Step 6. Check the wiring harness between C-310 column switch connector No.4 and body earth Connector: C-310

Step 5. Measure the resistance at C-310 column switch connector.

Harness side

Connector: C-310

5 4 3 2 1 10 9 8 7 6

AC301399 AC

Harness side 5 4 3 2 1 10 9 8 7 6

AC301399 AC






5 4 3 2 1 10 9 8 7 6

Harness side AC301541BE

(2) Continuity between C-310 column switch connector No.4 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 6.

C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE




54C-33

Step 9. ECU check on the SWS monitor Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU OK: "OK" is displayed on the "COLUMN ECU" menu. Q: Is the check result normal? YES : Go to Step 10. NO : Replace the column switch.


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

Step 10. Retest the system. Check that the ETACS-ECU communicates with the column switch. Q: Is the check result normal? YES : The trouble can be an intermittent

Connector: C-310

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the ETACS-ECU. Harness side 5 4 3 2 1 10 9 8 7 6

AC301399 AC


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

AC301395 AC

Prior to the wiring harness inspection, check joint connector C-02, and repair if necessary. Check the communication lines for open circuit. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.

54C-34


INSPECTION PROCEDURE A-3: Communication with the ETACS-ECU is not possible.

CAUTION Whenever the ECU is replaced, ensure that the power supply circuit, the earthing circuit and the communication circuit are normal. Etacs-ECU Power Supply and SWS Communication Circuit IGNITION SWITCH (IG1)

FUSIBLE LINK 1

ETACSECU POWER SOURCE


DIAGNOSIS CONNECTOR

COLUMN-ECU

COLUMN SWITCH

FRONT SIDE

COMMENTS ON TROUBLE SYMPTOM It is suspected that the power supply circuit to the ETACS-ECU is defective, or the wiring harness between the SWS monitor and the ETACS-ECU or their connector(s) is damaged. If the battery power supply circuit to the ECU (terminal No.20 of the ETACS-ECU) is damaged, also check the power supply circuit from the ignition switch (IG1) (terminal

No.8 of the ETACS-ECU), and repair if necessary. If the earth circuit to the ECU (terminal No.3 of the ETACS-ECU) is defective, also check the earth circuit to the sensor (terminal No.56 of the ETACSECU), and repair if necessary. TROUBLESHOOTING HINTS Malfunction of the ETACS-ECU Damaged harness wires and connectors


54C-35

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE Step 1. Connector check: C-217 ETACS-ECU connector

Step 3. Check the wiring harness between C-217 ETACS-ECU connector terminal No.20 and fusible link (1). Fusible link: No.1


Junction block side AC301515 AB

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC






AC210476 AC



AC210476 AC


1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG



C-204(B)

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Harness side AC301541AS


1 AC210474 AD


54C-36





Step 4. Measure the resistance at the C-217 ETACS-ECU connector. Connector: C-217 Junction block (Rear view) Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

NOTE: Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1


AC210476 AC

(1) Remove the ETACS-ECU, and measure at the junction block side. Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15


AC210474 AE

Prior to the wiring harness inspection, check junction block connector C-205, and repair if necessary. Check the earth wires for open circuit.

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AC301541AT

(2) Resistance between C-217 ETACS-ECU connector terminal No.3 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.




54C-37

SYMPTOM PROCEDURES

Step 6. Connector check: C-219 ETACS-ECU connector and C-310 column switch connector Connector: C-219 Junction block (Rear view)



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


Connector: C-310

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

Connector: C-310

Harness side 5 4 3 2 1 10 9 8 7 6

AC301399 AC


Harness side 5 4 3 2 1 10 9 8 7 6

AC301399 AC


Step 8. ECU check on the SWS monitor Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-38

SYMPTOM PROCEDURES

INSPECTION PROCEDURE A-4: Communication with the front-ECU is not possible.

CAUTION Whenever the ECU is replaced, ensure that the power supply circuit, the earthing circuit and the communication circuit are normal. Front-ECU Power Supply and SWS Communication Circuit IGNITION SWITCH (IG2)

RELAY BOX (FUSE 22 )

FRONT-ECU POWER SOURCE

DIAGNOSIS CONNECTOR

ETACS-ECU

FRONT SIDE


COMMENTS ON TROUBLE SYMPTOM It is suspected that the power supply circuit to the front-ECU is defective, or the wiring harness between the SWS monitor and the front-ECU or their connector(s) is damaged. If the battery power supply

SB : Sky blue

circuit to the ECU (terminal No.5 of the front-ECU) is damaged, also check the power supply circuit from the ignition switch (IG2) (terminal No.22 of the frontECU), and repair if necessary.


54C-39

SYMPTOM PROCEDURES

Possible causes Malfunction of the front-ECU Malfunction of the ETACS-ECU Damaged harness wires and connectors


DIAGNOSIS PROCEDURE Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure A-3

Relay box side 11 10 9 8 7 6 5 4 3 2 1

"Communication with ETACS-ECU is impossible 354C." AC301483 AD


(1) Disconnect the connector, and measure at the relay box side. (2) Ignition switch: ON


AC301541AF

(3) Voltage between A-11X front-ECU connector No.5 and body earth OK: System voltage

Relay box side


11 10 9 8 7 6 5 4 3 2 1

AC301483 AD



54C-40

SYMPTOM PROCEDURES

Step 4. Check the wiring harness between A-11X front-ECU connector terminal No.5 and the battery.


Connector: A-11X

Relay box side Relay box side 3130 29 2827 26 25 24 2322 21 11 10 9 8 7 6 5 4 3 2 1

AC301483 AE AC301483 AD





54C-41

SYMPTOM PROCEDURES

Step 6. Measure the resistance at A-12X frontECU connector. Connector: A-12X

Step 7. Check the wiring harness between A-12X front-ECU terminal connector No.21 and body earth. Connector: A-12X

Relay box side Relay box side 3130 29 2827 26 25 24 2322 21 3130 29 2827 26 25 24 2322 21

AC301483 AE

(1) Disconnect the connector, and measure at the relay box side.

AC301483 AE



Connector A-12X (Relay box side) 31 30 29 2827 26 25 24 2322 21

Step 8. Connector check: C-219 ETACS-ECU connector AC301541AG


(2) Resistance between A-12X front-ECU connector terminal No.21 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 7.


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE



54C-42

SYMPTOM PROCEDURES

Step 9. Check the wiring harness between A-12X front-ECU connector terminal No.30 and C-219 ETACS-ECU connector terminal No.59.


Connector: A-12X

C-02

C-116 C-02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 2324 25 2627 28 2930 3132 33

C-116 Relay box side

1 2

3130 29 2827 26 25 24 2322 21

5 6 7

3 4

8 9

10 1112 1314

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

1617 18 19 20 21

AC301396 AM

AC301483 AE


Q: Is the check result normal? YES : Go to Step 10. NO : Repair the wiring harness. Harness side

C-219(GR)

Prior to the wiring harness inspection, check joint connector C-02 and intermediate connector C-116, and repair if necessary. Check the communication lines for open circuit.

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE

Step 10. ECU check on the SWS monitor Check that the power supply and earth lines to the front-ECU and the SWS communication lines are normal. Ignition switch: ON ECUS TO BE CHECKED FRONT ECU OK: "OK" is displayed on the "FRONT ECU" menu. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-43

INSPECTION PROCEDURE A-5: Communication with the power window main switch (power window module) is Impossible.

CAUTION Whenever the ECU is replaced, ensure that the power supply circuit, the earthing circuit and the communication circuit are normal. Power Window Main Switch and SWS Communication Circuit FUSIBLE LINK 5

ETACS-ECU

POWER WINDOW RELAY

FRONT SIDE

DIAGNOSIS CONNECTOR



SB : Sky blue


54C-44

SYMPTOM PROCEDURES

COMMENTS ON TROUBLE SYMPTOM The power window main switch, the power supply circuit (power window relay driving circuit) or communication circuit for that switch may be defective. Possible causes Malfunction of the power window main switch Malfunction of the power window relay Malfunction of the ETACS-ECU Damaged harness wires and connectors


Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

DIAGNOSIS PROCEDURE

AC301418 AC

Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure A-3




Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC

Step 2. Check the data list by using the SWS monitor. ETACS ECU Ignition switch: ON Item No.

Item name

Normal conditions

Item 30

IG SW(IG1)

ON



OK: Normal condition is displayed. Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure N-2 "The

ignition switch (IG1) signal is not received 354C."

6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301541BH



54C-45

SYMPTOM PROCEDURES


Step 7. Measure the voltage at C-208 power window relay connector. Connector: C-208 Junction block (Front view)

Junction block side

Junction block side

3 2 1 4 5

3 2 1 4 5

AC210474 AF


Step 6. Check the power window relay. Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 7. NO : Replace the power window relay.

AC210474 AF

(1) Remove the power window relay, and measure at the junction block side. Connector C-208 (Junction block side) 3 2 1 4 5

AC301541BO

(2) Voltage between C-208 power window relay connector terminal No.5 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 9. NO : Go to Step 8.


54C-46

SYMPTOM PROCEDURES

Step 8. Check the wiring harness between C-208 power window relay connector terminal No.3 and fusible link (5). Fusible link: No.5


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 9. Measure the resistance at C-208 power window relay connector. Connector: C-208 Junction block (Front view)

AC301515 AC



C-203

AC210474 AF

(1) Remove the power window relay, and measure at the junction block side. C-208

3 2 1 4 5

Harness side

Junction block side

C-203

C-208 3 2 1 4 5

2 1 6 5 4 3

AC210475 AI


1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG


Connector C-208 (Junction block side) AC301541BP

(2) Resistance between C-208 power window relay connector terminal No.3 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 11. NO : Go to Step 10.


54C-47

SYMPTOM PROCEDURES

Step 10. Check the wiring harness between C-208 power window relay connector terminal No.3 and body earth. Connectors: C-205, C-208 Junction block (Front view)


C-205 C-208

C-208

Harness side

Junction block side

C-205

C-208 3 2 1 4 5

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

Harness side

Junction block side

C-203

C-208 3 2 1 4 5

2 1 6 5 4 3

AC210475 AP

NOTE: Prior to the wiring harness inspection, check junction block connector C-205, and repair if necessary. Check the earth wires for open circuit.

AC210475 AI



E-05


E-12

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC


AC301419 AC


54C-48

SYMPTOM PROCEDURES

NOTE:


Connector: C-118

Connector: E-05 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

Harness side AC301395 AH


6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC





6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301541BI

(2) Resistance between E-05 power window main switch connector terminal No.2 and body earth OK: 2 W or less


54C-49

SYMPTOM PROCEDURES

Step 14. Check the wiring harness between E-05 power window main switch connector terminal No.2 and body earth. Connectors: E-05, E-12


E-05

Harness side C-219(GR) E-12

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

AC301395 AH

Prior to the wiring harness inspection, check intermediate connectors C-118 and E-12, and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent




54C-50

SYMPTOM PROCEDURES

Step 16. Check the wiring harness between C-219 ETACS-ECU connector terminal No.59 and E-05 power window main switch connector terminal No.4.

NOTE: Connectors : C-02, C-118

C-02

Connector: C-219 Junction block (Rear view) C-118


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE


C-02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

C-118 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

E-05 AC301396 AG

Prior to the wiring harness inspection, check intermediate connectors C-118, E-12 and joint connector C-02, and repair if necessary. Check the communication lines for open circuit.

E-12

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC


Step 17. ECU check on the SWS monitor Check that the power supply and earth lines to the power window main switch (power window module) and the SWS communication lines are normal. Ignition switch: ON ECUS TO BE CHECKED P/W MODULE OK: "OK" is displayed on the "P/W MODULE" menu. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-51

TONE ALARM

INSPECTION PROCEDURE B-1: Lamp reminder buzzer function does not work normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Lamp Reminder Tone Alarm Function

ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Driver’s door switch Tail lamp switch Headlamp switch If this function does not work normally, these input signal circuit(s) or the ETACS-ECU may be defective. Possible causes Malfunction of the driver’s door switch Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the column switch (column-ECU) and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU COLUMN ECU OK: "OK" is displayed for all the items Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "ETACS ECU" menu. :

Refer to Inspection Procedure A-3 "Communication with ETACS-ECU is impossible 354C." "NG" is displayed on the "COLUMN ECU" menu. :

Refer to Inspection Procedure A-2 "Communication with column switch (column-ECU) is impossible 354C."


54C-52

SYMPTOM PROCEDURES

Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the lamp reminder function. BUZZER - LGT MONI. ALRM Ignition switch: OFF (key removed) lighting switch: HEAD Driver’s door: open Item No.

Item name

Normal conditions

Item 00

HEADLAMP SW ON when the lighting switch is at HEAD

Item 01

TAIL LAMP SW

ON when the lighting switch is at TAIL

Item 30

IG SW(IG1)

OFF

Item 32

DR DOOR SW

ON

Item 43

BUZZER

ON

OK: Normal conditions are displayed for all the items. Q: Is the check result normal? Normal conditions displayed for all the items : Go

to Step 3. Normal condition is not displayed for item No.00 or No.01 : Refer to inspection procedure N-5 "The

column switch (lighting and turn-signal lamp switch) signal is not received 354C." Normal condition is not displayed for item No.30 :

Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354C." Normal condition is not displayed for item No.32 :

Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354C." Normal condition is not displayed for item No.43 :

Replace the ETACS-ECU.

Step 3. Retest the system. The lamp reminder buzzer function should work normally. Q: Is the check result normal? YES : The trouble can be an intermittent



CENTRAL DOOR LOCKING SYSTEM

INSPECTION PROCEDURE C-1: Central Door Locking System does not Work.


Central Door Lock Power Supply Circuit FUSIBLE LINK 1


DOOR LOCK RELAY



SB : Sky blue

54C-53

54C-54


COMMENT ON TROUBLE SYMPTOM If the central door locking system does not work at all, the front door lock actuator (LH) or the ETACSECU may be defective. POSSIBLE CAUSES Malfunction of the front door lock actuator (LH) Malfunction of the ETACS-ECU Damaged harness wires and connectors


"Communication with ETACS-ECU is impossible 354C." Step 2. Pulse check Check the input signal from the driver’s door lock actuator switch. System switch

Check conditions





AC301418 AD


Step 4. Check the front door lock actuator (LH). Check that the front door lock actuator (LH) works normally. Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 5. NO : Replace the front door lock actuator (LH).




driver’s door lock actuator signal is not received 354C."


AC210477 AB



54C-55

SYMPTOM PROCEDURES

Step 6. Check the wiring harness between C-217 ETACS-ECU connector terminal No.2 and fusible link (1).


Connector: C-217

Junction block (Rear view) C-116

1 2 C-217 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

5 6 7

3 4

8 9

10 11 12 13 14

15

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301396 AB

Connector: C-204 Junction block (Front view) AC210477 AB

C-204(B) Fusible link: No.1

Harness side 1 AC210474 AD

AC301515 AB

Prior to the wiring harness inspection, check intermediate connector C-116 and junction block connector C-204, and repair if necessary. Check the power supply line for open or short circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

Step 7. Retest the system. Check that the central door locking system works normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54C-56


INSPECTION PROCEDURE C-2: A Door or a Tailgate can not be Locked or Unlocked by the Central Door Locking System.

Central Door Lock Circuit

ETACS-ECU DOOR LOCK RELAY

DOOR UNLOCK RELAY


FRONT DOOR LOCK ACTUATOR (RH)

REAR DOOR LOCK ACTUATOR (LH)

REAR DOOR LOCK ACTUATOR (RH)


TAILGATE LOCK ACTUATOR

SB : Sky blue


54C-57

SYMPTOM PROCEDURES

COMMENT ON TROUBLE SYMPTOM If a door or the tailgate can not be locked or unlocked by the central door locking system, the door lock actuator or the tailgate lock actuator may be defective. POSSIBLE CAUSES Malfunction of the door lock actuator Malfunction of the tailgate lock actuator Damaged harness wires and connectors

Step 3. Check the front door lock actuator (LH). Check that the front door lock actuator (LH) works normally. Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 4. NO : Replace the front door lock actuator (LH).

Step 4. Connector check: C-217, C-220 ETACSECU connector

DIAGNOSIS PROCEDURE


Step 1. Confirm which door lock actuator is defective.

C-217

Q: Which door fails to lock correctly? Driver’s door : Go to Step 2. Front passenger’s door : Go to Step 6. Rear right door : Go to Step 10. Rear left door : Go to Step 14. Tailgate : Go to Step 18.

Step 2. Connector check: E-11 front door lock actuator (LH) Connector: E-11

Junction block (rear view) C-220 C-217 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

C-220 Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42


AC210477 AF 3 2 1 6 5 4

AC301418 AD




54C-58

SYMPTOM PROCEDURES

Step 5. Check the wiring harness from C-217 ETACS-ECU connector terminal No.12 and C-220 ETACS-ECU connector No.22 to E-11 front door lock actuator (LH) terminal Nos. 6 and 4.



C-217

Junction block (rear view)

C-118

C-220

1 2 3 4 5 6 7 8 9 10 11


12 13 14 15 16 17 18 19 20 21 22

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

23 24 25 26 27

28 29 30 31 32

C-220 Harness side

AC301396 AE

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

Connector: C-205 Junction block (Front view) AC210477 AF

Connector: E-11

Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

E-11(B)

AC210474 AE


AC301418 AD

Prior to the wiring harness inspection, check intermediate connector C-118 and junction block connector C-205, and repair if necessary. Check the input and output lines for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-59

SYMPTOM PROCEDURES

Step 6. Connector check: E-25 front door lock actuator (RH) connector Connector: E-25

Step 9. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 12 and 13 to E-25 front door lock actuator (RH) connector terminal Nos. 4 and 6. Connector: C-217

E-25 Harness side

E-25(B)

3 2 1 6 5 4 AC301412 AF



Step 7. Check the front door lock actuator (RH). Check that the front door lock actuator (RH) works normally. Refer to GROUP 42 - Door 342.


Q: Is the check result normal? YES : Go to Step 8. NO : Replace the front door lock actuator (RH).


AC210477 AB

Connector: E-25

Connector: C-217

E-25 Harness side

E-25(B)

3 2 1 6 5 4 Junction block (Rear view)


AC210477 AB


AC301412 AF

54C-60


NOTE:

Step 11. Check the rear door lock actuator (RH). Check that the rear door lock actuator (RH) is in good condition. Refer to GROUP 42 - Door 342.

Connector: C-15

Q: Is the check result normal? YES : Go to Step 12. NO : Replace the rear door lock actuator (RH).

2 1 3 4 5 6 10 11 12 7 8 9 13 14 15 16 17 18 19


C-15(GR) AC301397AD

Connector: C-217 Connector: C-205 Junction block (Front view)

Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1


28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE





Step 10. Connector check: E-28 rear door lock actuator (RH) connector Connector: E-28


3 2 1 6 5 4 AC301414 AE




54C-61

SYMPTOM PROCEDURES

Step 13. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 12 and 13 to E-28 rear door lock actuator (RH) connector terminal Nos. 2 and 3.



12

4 3 2 1 11 10 9 8

AC210474 AG



D-02


D-31

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

D-02

1 2 3 4 5 6 7 8 AC210477 AB

D-31

Connector: E-28


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301409 AD

3 2 1 6 5 4 AC301414 AE

Prior to the wiring harness inspection, check D-02, D-31 intermediate connectors and C-209 junction block connector, and repair if necessary. Check the input and output lines for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-62

SYMPTOM PROCEDURES

Step 14. Connector check: E-08 rear door lock actuator (LH) connector Connector: E-08

Step 17. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 12 and 13 to E-08 rear door lock actuator (LH) connector terminal Nos. 3 and 2. Connector: C-217


3 2 1 6 5 4 AC301416 AE



Step 15. Check the rear door lock actuator (LH). Check that the rear door lock actuator (LH) is in good condition. Refer to GROUP 42 - Door 342.


Q: Is the check result normal? YES : Go to Step 16. NO : Replace the rear door lock actuator (LH).


AC210477 AB

Connector: E-08

Connector: C-217




AC210477 AB


3 2 1 6 5 4 AC301416 AE


54C-63

SYMPTOM PROCEDURES

NOTE:

Step 19. Check the tailgate lock actuator. Check that the tailgate lock actuator is in good condition. Refer to GROUP 42 - Tailgate 342.


Q: Is the check result normal? YES : Go to Step 20. NO : Replace the tailgate lock actuator. Harness side 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210474 AG



1 2 3 4 5 6 7 8 Junction block (Rear view) AC301410 AB

Prior to the wiring harness inspection, check D-26 intermediate connectors and C-209 junction block connector, and repair if necessary. Check the input and output lines for open circuit.




Step 18. Connector check: F-06 tailgate lock actuator connector Connector: F-06

F-06 Harness side F-06(B)

3 2 1 6 5 4

AC301665 AE




54C-64

SYMPTOM PROCEDURES

Step 21. Check the wiring harness from C-217 ETACS-ECU connector terminal Nos. 12 and 13 to F-06 tailgate lock actuator connector terminal Nos. 2 and 3.



12

4 3 2 1 11 10 9 8

AC210474 AG

Prior to the wiring harness inspection, check intermediate connector F-05 and junction block connector C-209, and repair if necessary. Check the input and output lines for open circuit.


Q: Is the check result normal? YES : The trouble can be an intermittent C-217 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210477 AB


F-06(B) F-05

F-05

1 2 3 4 5 6 7 8 9 10 F-06 Harness side

3 2 1 6 5 4 AC301666 AG



54C-65

SYMPTOM PROCEDURES

INSPECTION PROCEDURE C-3: The Central Door Locking System can not be Operated by Means of the Front Passenger’s Door Lock Key Cylinder.


Central Door Lock (Front Passenger's Door Lock Key Cyilinder Switch) Circuit FUSIBLE LINK 1



DOOR LOCK RELAY

INPUT SIGNAL FRONT PASSENGER'S DOOR LOCK KEY CYLINDER SWITCH


COMMENT ON TROUBLE SYMPTOM If the central door locking system does not work by means of the front passenger’s door lock key cylinder, the front passenger’s door lock key cylinder or the ETACS-ECU may be defective. POSSIBLE CAUSES Malfunction of the front passenger’s door lock key cylinder Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the operation of the central door locking system. Check that the central door locking system works normally by means of the driver’s door lock key cylinder and inside lock knob. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure C-1 "Central

door locking system does not work at all 354C."

54C-66




Step 3. Pulse check Check the input signal from the front passenger’s door lock key cylinder switch. System switch

Check conditions

Front passenger’s door lock key cylinder switch



front passenger's door lock key cylinder switch signal is not received 354C." Step 4. Retest the system. Check that the central door locking system works normally by means of the front passenger's door lock key cylinder. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-67

SYMPTOM PROCEDURES

INSPECTION PROCEDURE C-4: The Ignition Key Reminder Function does not Work Normally.


Ignition Key Reminder Function Circuit FUSIBLE LINK 1

ETACS-ECU INPUT SIGNAL DOOR UNLOCK RELAY


DOOR LOCK RELAY

· DRIVER'S DOOR LOCK ACTUCTOR SWITCH · DRIVER'S DOOR SWITCH · KEY REMINDER SWITCH


COMMENTS ON TROUBLE SYMPTOM If the key reminder function does not work normally, the input signal circuits below or the ETACS-ECU may be defective. Key reminder switch Driver’s door switch Front door lock actuator (LH) POSSIBLE CAUSES Malfunction of the key reminder switch Malfunction of the driver’s door switch Malfunction of the front door lock actuator (LH) Malfunction of the ETACS-ECU Damaged harness wires and connectors




54C-68

SYMPTOM PROCEDURES

Step 2. Confirm communication data by using the SWS monitor. Check the SWS communication signals, which are related to the key reminder function.

Step 3. Pulse check Check the input signals below which are related to the key reminder function. System switch

Check conditions

ETACS ECU Driver’s door: open

Key reminder switch




Item No.

Item name

Normal conditions

Item 32

DR DOOR SW

ON


driver’s door switch signal is not received 354C."



Refer to inspection procedure N-9 "The key reminder switch signal is not received 354C." The driver’s door lock actuator switch signal is not received. : Refer to inspection procedure N-14

"The driver’s door lock actuator signal is not received 354C. Step 4. Retest the system. Q: Does the ignition key reminder function work normally? YES : The trouble can be an intermittent



54C-69

INSPECTION PROCEDURE C-5: The Impact Detection Door Unlock Function does not Function.


Impact Detection Door Unlock Function Circuit ETACS-ECU

SRS-ECU IMPACT-DEPENDENT DOOR UNLOCK SIGNAL PROCESSING CIRCUIT


SB : Sky blue

COMMENTS ON TROUBLE SYMPTOM If the impact detection door unlock function does not work normally, the input signal circuit from the impact detection sensor, the SRS-ECU or the ETACS-ECU may be defective.

Step 2. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF

POSSIBLE CAUSES Malfunction of the SRS-ECU Malfunction of the ETACS-ECU Damaged harness wires and connectors

ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu.

DIAGNOSIS PROCEDURE

Q: Is the check result normal? YES : Go to Step 3. NO : Refer to Inspection Procedure A-3

Step 1. Use the MUT-II to confirm a diagnosis code. Check that the SRS-ECU sets a diagnosis code. Q: Is the diagnosis code set? YES : Refer to GROUP 52B - Troubleshooting

352B. NO : Go to Step 2.



54C-70

SYMPTOM PROCEDURES

Step 3. Connector check: C-115 SRS-ECU connector Connector: C-115

Step 6. Check the wiring harness between C-115 SRS-ECU connector terminal No.14 and C-220 ETACS-ECU connector terminal No.29. Connector: C-115

Harness side

Harness side

2 1 4 3 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

2 1 4 3 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

C-115(Y) C-115(Y) AC301397AH AC301397AH


Connector: C-220

Step 4. Check the SRS-ECU. Check that the SRS-ECU works normally. Refer to GROUP 52B - SRS Control Unit (SRS-ECU) 352B . Junction block (Rear view)

Q: Is the check result normal? YES : Go to Step 5. NO : Replace the SRS-ECU.


C-220 Harness side

Connector: C-220

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

AC210477 AE


Check the power supply line for open or short circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

C-220 Harness side

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210477 AE



Step 7. Measure the resistance at the C-115 SRSECU connector. Connector: C-115

54C-71

Step 8. Check the wiring harness between C-115 SRS-ECU connector terminal No.15 and body earth. Connector: C-115

Harness side

Harness side

2 1 4 3 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

2 1 4 3 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

C-115(Y) C-115(Y) AC301397AH

1. Disconnect the connector, and measure at the wiring harness side.

AC301397AH

Check the earth line for open or short circuit.

2.



4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

Connector C-115 (harness side)

Step 9. Retest the system. Check that the impact detection door unlock function works normally. AC301708 AB

Resistance between C-115 SRS-ECU connector terminal No.15 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 9. NO : Go to Step 8.




54C-72

SYMPTOM PROCEDURES

POWER WINDOWS

INSPECTION PROCEDURE D-1: Power windows do not work at all.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Power Window Relay Circuit FUSIBLE LINK 5

ETACS-ECU


POWER WINDOW RELAY


CPU

COMMENTS ON TROUBLE SYMPTOM If the power windows do not work at all, the power window relay, the power window main switch or the ETACS-ECU may be defective.




Possible causes Malfunction of the power window relay Malfunction of the power window main switch Malfunction of the ETACS-ECU Damaged harness wires and connectors


54C-73

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the power window main switch (power window module) and the SWS communication lines are normal. Turn the ignition switch to the ON position. ECUS TO BE CHECKED ETACS ECU P/W MODULE OK: "OK" are displayed for all the items Q: Is the check result normal? "OK" are displayed for all the items : Go to Step 2. "NG" is displayed on the "ETACS ECU" menu. :

Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the power windows. POWER WINDOW Turn the ignition switch to the ON position. Power window main switch: UP Item No.

Item name

Normal conditions

30

IG SW (IG1)

ON

33

P/W SW ACCEPT

PERMIT

71

P/W ECU ACK

INPUT CHECK (only momentarily when switch is operated)

Refer to Inspection Procedure A-3 "Communication with ETACS-ECU is impossible 354C."

OK: Normal conditions are displayed for all the items.

"NG" is displayed on the "P/W MODULE" menu. :

Refer to Inspection Procedure A-4 "Communication with power window main switch (power window module) is impossible 354C."

Q: Is the check result normal? Normal conditions displayed for all the items : Go

to Step 3. Normal condition is not displayed for item No.30 :

Refer to inspection procedure O-2 "The ignition switch (IG1) signal is not received 354C." Normal condition is not displayed for item No.33 :

Replace the ETACS-ECU. Normal condition is not displayed for item No.71 :

Replace the power window main switch. Step 3. Confirm communication data by using the SWS monitor. Check the SWS communication signal, which are related to the power windows. DOOR CNT. COM. Insert the probe (For the insertion point, refer to 354C). Turn the ignition switch to the ON position. Power window main switch: UP Item No.

Item name

Normal conditions

C0

PASS DOR UP

ON

OK: Normal condition is displayed. Q: Is the check result normal? YES : Go to Step 4. NO : Replace the power window main switch.

54C-74


Step 4. Retest the system. Check that the all the power windows work. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE D-2: Driver’s power window does not work by means of the power window main switch.

Power Window (front: LH) Circuit POWER WINDOW MAIN SWITCH

FRONT (LH)

POWER WINDOW MOTOR (FRONT: LH)


COMMENTS ON TROUBLE SYMPTOM If the driver’s power window does not work by means of the power window main switch, the power window main switch or the driver’s door power window motor may be defective.

SB : Sky blue

Possible causes Malfunction of the power window main switch Malfunction of the power window motor (front LH) Damaged harness wires and connectors


54C-75

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE STEP 1. Check the power window main switch. Check that all of the front passenger’s and rear door power windows can operate by means of the power window main switch.

STEP 3. Check the wiring harness from E-13 power window motor (front LH) connector terminal Nos. 1 and 3 to E-05 power window main switch connector terminal Nos. 7 and 1. Connectors: E-05, E-12, E-13


E-13(GR)

windows do not work at all 354C." STEP 2. Connector check: E-05 power window main switch connector and E-13 power window motor (front LH) connector Connectors: E-05, E-13

E-05 E-12

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7 E-13 Harness side

E-13(GR) E-05

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

3 2 1 6 5 4

AC301419 AD

E-05 Harness side

NOTE: Prior to the wiring harness inspection, check intermediate connector E-12, and repair if necessary. Check the input and output lines for open or short circuit.

6 5 4 3 2 1 14 13 12 11 10 9 8 7


E-13 Harness side

3 2 1 6 5 4 AC301419 AE


STEP 4. Retest the system. After the power window main switch is replaced, check that the driver’s door power window can be operated by the power window main switch. (1) Replace the power window main switch. (2) Check that the driver’s power window works by means of the power window main switch. Q: Is the check result normal? YES : The trouble can be an intermittent


54C-76


INSPECTION PROCEDURE D-3: Relevant power window(s) do not work by means of the front and rear passenger’s power window sub switches.

Power Window (front: RH) Circuit FUSIBLE LINK 5

POWER WINDOW RELAY

ETACSECU

POWER WINDOW SUB SWITCH (FRONT: RH) CPU

POWER WINDOW MOTOR (FRONT: RH)


SB : Sky blue


54C-77

SYMPTOM PROCEDURES Power Window (rear) Circuit

FUSIBLE LINK 5

POWER WINDOW RELAY

ETACS-ECU


POWER WINDOW SUB SWITCH (REAR: LH) CPU

CPU


POWER WINDOW MOTOR (REAR: LH)


COMMENTS ON TROUBLE SYMPTOM If the front passenger’s or rear power window does not work by means of the respective power window sub switch, the power window sub switch or the power window motor may be defective.

SB : Sky blue

Possible causes Malfunction of the power window sub switch (front RH), power window sub switch (rear RH) or power window sub switch (rear LH) Malfunction of the power window motor (front RH), power window motor (rear RH) or power window motor (rear LH) Damaged harness wires and connectors

54C-78


DIAGNOSIS PROCEDURE

STEP 4. Measure the resistance at E-17 power window sub switch (front RH) connector.

STEP 1. Check the power window main switch. Check that the power window lock switch is turned off. Q: Is the check result normal? YES : Go to Step 2. NO : Turn off the power window lock switch.


3 2 1 8 7 6 5 4

STEP 2. Determine a trouble spot. Q: Which power window does not work? Front passenger’s door : Go to Step 3. Rear right door : Go to Step 12. Rear left door : Go to Step 21.

AC301412 AB


STEP 3. Connector check: E-17 power window sub switch (front RH) connector Connector: E-17

3 2 1 8 7 6 5 4

E-17 Harness side

3 2 1 8 7 6 5 4

Connector E-17 (Harness side) AC301474 AB

(2) Resistance between terminal 1 and body earth OK: 2W or less AC301412 AB




STEP 5. Check the wiring harness from E-17 power window sub switch (front RH) connector terminal No.1 to body earth. Connectors: E-17, E-24

54C-79


malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. STEP 6. Measure the voltage at E-17 power window sub switch (front RH) connector.

E-17 Connector: E-17 E-24

E-17 Harness side

3 2 1 8 7 6 5 4 E-17 Harness side

3 2 1 8 7 6 5 4

AC301412 AB


E-24

1 2 3 4 5 6 7 8 AC301413 AC

3 2 1 8 7 6 5 4



AC301470 AB


C-15(GR)

C-15

2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

AC301398 AC

Prior to the wiring harness inspection, check intermediate connector C-15, E-24, and repair if necessary. Check the earth wires for open circuit.


54C-80

SYMPTOM PROCEDURES

STEP 7. Connector check: C-208 power window relay connector Connector: C-208 Junction block (front view)

STEP 8. Check the wiring harness from E-17 power window sub switch (front LH) connector terminal No.4 to C-208 power window connector terminal No.4. Connectors: E-17, E-24

E-17

E-24

E-17 Harness side


3 2 1 8 7 6 5 4

3 2 1 4 5

E-24

1 2 3 4 5 6 7 8 AC210475 AD


AC301413 AC


C-208

C-203 Harness side


3 2 1 4 5 AC210475 AB


54C-81

SYMPTOM PROCEDURES

NOTE:

STEP 10. Check the wiring harness from E-23 power window motor (front RH) connector terminal Nos. 1 and 3 to E-17 power window sub switch (front LH) connector terminal Nos. 5 and 7.

Connector: C-15


E-23(GR) E-17

C-15(GR)

E-24

C-15

2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

E-17 Harness side

3 2 1 8 7 6 5 4 AC301398 AC


malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. STEP 9. Connector check: E-23 power window motor (front RH) connector Connector: E-23 E-23 Harness side

3 2 1 6 5 4

E-23(GR)

AC301412 AC


E-23 Harness side

E-24

1 2 3 4 5 6 7 8

3 2 1 6 5 4 AC301413 AB


STEP 11. Retest the system. After the power window sub switch (front RH) is replaced, check that the front passenger’s door power window can be operated by the power window sub switch (front RH). (1) Replace the power window sub switch (front RH). (2) Check that the front passenger’s door power window can be operated by the power window sub switch (front RH). Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window motor assembly (front RH).


54C-82

SYMPTOM PROCEDURES

STEP 12. Connector check: E-21 power window sub switch (rear RH) connector Connector: E-21

STEP 14. Check the wiring harness from E-21 power window sub switch (rear RH) connector terminal No.1 to body earth. Connectors: E-21, E-27

E-21

E-21 Harness side

3 2 1 8 7 6 5 4

E-27 AC301414 AC


E-21 Harness side

3 2 1 8 7 6 5 4

STEP 13. Measure the resistance at E-21 power window sub switch (rear RH) connector. E-27 Connector: E-21

1 2 3 4 5 6 7 8 AC301415 AC

E-21 Harness side


3 2 1 8 7 6 5 4

D-02 AC301414 AC


1 2 3 4 5 6 7 8

AC301408 AH

Prior to the wiring harness inspection, check intermediate connectors E-27 and D-02, and repair if necessary. Check the earth wires for open circuit.

3 2 1 8 7 6 5 4 Connector E-21 (Harness side)

AC301472 AB





STEP 15. Measure the voltage at E-21 power window sub switch (rear RH) connector. Connector: E-21

54C-83

STEP 16. Connector check: C-208 power window relay connector Connector: C-208 Junction block (front view)

E-21 Harness side

3 2 1 8 7 6 5 4 AC301414 AC



3 2 1 4 5

3 2 1 8 7 6 5 4

AC210475 AD


AC301462 AC




54C-84

SYMPTOM PROCEDURES

STEP 17. Check the wiring harness from E-21 power window sub switch (rear RH) connector terminal No.4 to C-208 power window connector terminal No.4.



E-21

C-13(L)


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

3 2 1 8 7 6 5 4

E-27

AC301398 AB

3 1 2 4 5 6 7 8


D-02 1 2 3 4 5 6 7 8


AC301408 AH


C-208

C-203 Harness side


2 1 6 5 4 3



3 2 1 4 5 AC210475 AB


54C-85

SYMPTOM PROCEDURES

STEP 18. Connector check: E-20 power window motor (rear RH) connector Connector: E-20

STEP 19. Check the wiring harness from E-20 power window motor (rear RH) connector terminal Nos. 1 and 3 to E-21 power window sub switch (rear RH) connector terminal Nos. 7 and 5. Connectors: E-20, E-21, E-27


E-20(GR)

E-21

3 2 1 6 5 4

E-27

AC301414 AB


E-20 Harness side

3 2 1 6 5 4 E-27 E-21 Harness side

1 2 3 4 5 6 7 8

3 2 1 8 7 6 5 4 AC301415 AB

NOTE: Prior to the wiring harness inspection, check intermediate connector E-27, and repair if necessary. Check the input and output lines for open or short circuit.

54C-86


STEP 20. Retest the system. After the power window sub switch (rear RH) is replaced, check that the rear right door power window can be operated by the power window sub switch (rear RH). (1) Replace the power window sub switch (rear RH). (2) Check that the rear right door power window can be operated by the power window sub switch (rear RH). Q: Is the check result normal? YES : The trouble can be an intermittent


STEP 22. Measure the resistance at E-01 power window sub switch (rear LH) connector. Connector: E-01

E-01 Harness side

3 2 1 8 7 6 5 4 AC301416 AB


STEP 21. Connector check: E-01 power window sub switch (rear LH) connector Connector: E-01

3 2 1 8 7 6 5 4 Connector E-01 (Harness Side)

E-01 Harness side

(2) Resistance between terminal 1 and body earth OK: 2W or less

3 2 1 8 7 6 5 4 AC301416 AB


AC301461AB



STEP 23. Check the wiring harness from E-01 power window sub switch (rear LH) connector terminal No.1 to body earth.

54C-87

STEP 24. Measure the voltage at E-01 power window sub switch (rear LH) connector. Connector: E-01



3 2 1 8 7 6 5 4

E-09

AC301416 AB


E-01 Harness side

3 2 1 8 7 6 5 4

3 2 1 8 7 6 5 4

E-09

3 1 2 4 5 6 7 8 AC301417 AC



AC301462 AB

(3) Voltage between terminal 4 and body earth OK: System voltage

D-26


1 2 3 4 5 6 7 8

AC301410 AB

Prior to the wiring harness inspection, check intermediate connectors E-09 and D-26, and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-88

SYMPTOM PROCEDURES

STEP 25. C-208 power window relay connector Connector: C-208 Junction block (front view)

STEP 26. Check the wiring harness from E-01 power window sub switch (rear LH) connector terminal No.4 to C-208 power window connector terminal No.4. Connectors: E-01, E-09

E-01

E-09


E-01 Harness side

3 2 1 4 5

3 2 1 8 7 6 5 4

E-09

1 2 3 4 5 6 7 8

AC210475 AD


AC301417 AC


C-208

C-203 Harness side


3 2 1 4 5 AC210475 AB


54C-89

SYMPTOM PROCEDURES

NOTE:

STEP 27. Connector check: E-03 power window motor (rear LH) connector

Connector: C-117

Connector: E-03


3 2 1 6 5 4 AC301416 AC

C-117

1 2 3

111213

4 5 6 7 8 9 10

14 1516 17 1819 20 2122 2324 25 26 27 28 29 32 33 34

35

30 31 36 37

38

AC301396 AC


STEP 28. Check the wiring harness from E-03 power window motor (rear LH) connector terminal Nos. 1 and 3 to E-01 power window sub switch (rear LH) connector terminal Nos. 7 and 5. Connectors: E-01, E-03, E-09


E-01

1 2 3 4 5 6 7 8

E-03(GR)

E-09

AC301410 AB

Prior to the wiring harness inspection, check intermediate connectors C-117, D-26, E-09 and junction block connector C-203, and repair if necessary. Check the power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


E-01 Harness side

3 2 1 8 7 6 5 4

E-03 Harness side

E-09

3 1 2 4 5 6 7 8

3 2 1 6 5 4 AC301417 AB


54C-90


STEP 29. Retest the system. After the power window sub switch (rear LH) is replaced, check that the rear left door power window can be operated by the power window sub switch (rear LH). (1) Replace the power window sub switch (rear LH). (2) Check that the rear left door power window can be operated by the power window sub switch (rear LH). Q: Is the check result normal? YES : The trouble can be an intermittent



54C-91

SYMPTOM PROCEDURES

INSPECTION PROCEDURE D-4: Front and/or rear passenger’s power window(s) do not work by means of the power window main switch.

Power Window Circuit

REAR (RH)

FRONT (RH)

LOCK SWITCH

CPU

REAR (LH)


CPU POWER WINDOW SUB SWITCH (FRONT: RH)

CPU POWER WINDOW SUB SWITCH (REAR: LH)

CPU POWER WINDOW SUB SWITCH (REAR: RH)


SB : Sky blue


54C-92

SYMPTOM PROCEDURES

COMMENTS ON TROUBLE SYMPTOM If the passenger’s and/or rear power window does not work by means of the power window main switch, the power window main switch or the respective power window sub switch(es) may be defective. Possible causes Malfunction of the power window main switch Malfunction of the power window sub switch (front RH), power window sub switch (rear RH) or power window sub switch (rear LH) Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the power window main switch (power window module) and the SWS communication lines are normal. Turn the ignition switch to the ON position. ECUS TO BE CHECKED P/W MODULE OK: "OK" is displayed on the "P/W MODULE" menu. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure A-5

"Communication with power window main switch (power window module) is impossible 354C." Step 2. Confirm communication data by using the SWS monitor. Check the SWS communication signal from the power window lock switch to the ETACS-ECU. DOOR CNT. COM. Insert a probe between a power window sub switch of a door of which power window does not work and the power window main switch (For the insertion point, refer to 354C). Turn the ignition switch to the ON position. Power window lock switch: OFF Item No.

Item name

Normal conditions

Item CB

P/W LOCK SW

OFF

OK: Normal condition is displayed. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the power window main switch.

Step 3. Confirm communication data by using the SWS monitor. Check the SWS communication signals, which are used when the front and/or rear passenger’s door power windows are operated by the power window main switch. DOOR CNT. COM. Insert a probe between a power window sub switch of a door of which power window does not work and the power window main switch (For the insertion point, refer to 354C). Turn the ignition switch to the ON position. Are normal conditions displayed when each switch of the power window main switch is operated? Item No.

Item name

Normal conditions

C0

PASS DOR UP

ON

C1

PASS DOR DOWN ON

C2

PASS DOR AUTO

ON

C4

REAR RH UP

ON

C5

REAR RH DOWN

ON

C6

REAR RH AUTO

ON

C8

REAR LH UP

ON

C9

REAR LH DOWN

ON

CA

REAR LH AUTO

ON

OK: Normal conditions are displayed for all the items. Q: Is the check result normal? Normal conditions are displayed for all of items C0, C1 and C2 when the front passenger’s power window does not work. : Go to Step 6. Normal conditions are displayed for none of items C0, C1 and C2 when the front passenger’s power window does not work. : Go to Step 4. Normal conditions are displayed for all of items C4, C5 and C6 when the rear right power window does not work. : Go to Step 12. Normal conditions are displayed for none of items C4, C5 and C6 when the rear right power window does not work. : Go to Step 10. Normal conditions are displayed for all of items C8, C9 and CA when the rear left power window does not work. : Go to Step 18. Normal conditions are displayed for none of items C8, C9 and CA when the rear left power window does not work. : Go to Step 16. Normal condition is displayed for any of the items. : Replace the power window main switch.


54C-93

SYMPTOM PROCEDURES


Connector: C-118

Connector: E-05



C-118

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Step 5. Check the wiring harness from E-05 power window main switch connector terminal No.11 to the inserted probe.

23 24 25 26 27

28 29 30 31 32 AC301396 AE

Connector: E-05 Connector: E-12

E-05 Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12 AC301418 AF

NOTE: Connector: C-15 E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

C-15(GR)

AC301419 AF

C-15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

AC301398 AC

54C-94


NOTE:

Connector: E-24

Connector: C-15

E-24

1 2 3 4 5 6 7 8

AC301412 AG

Prior to the wiring harness inspection, check intermediate connectors C-15, C-118, E-12 and E24, and repair if necessary. Check the communication lines for open circuit.

C-15(GR)

C-15

2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19


Step 6. Connector check: E-17 power window sub switch (front LH) connector AC301398 AC

Connector: E-17 Connector: C-118

E-17 Harness side

3 2 1 8 7 6 5 4

AC301412 AB


C-118

Step 7. Check the wiring harness from E-17 power window sub switch (front LH) connector terminal No.6 to the inserted probe. Connector: E-17

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

E-17 Harness side

28 29 30 31 32 AC301396 AE

3 2 1 8 7 6 5 4

AC301412 AB


54C-95

Step 9. Retest the system. After the power window sub switch (front LH) is replaced, check that the front passenger’s door power window can be operated by the power window sub switch. (1) Replace the power window sub switch (front LH). (2) Check that the front passenger’s power window works by means of the power window main switch.

Connector: E-12

E-12

Q: Is the check result normal? YES : The trouble can be an intermittent E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window main switch. Step 10. Connector check: E-05 power window main switch connector Connector: E-05

AC301419 AF


E-24

3 1 2 4 5 6 7 8

6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301418 AF

AC301412 AG

Prior to the wiring harness inspection, check intermediate connectors C-15, C-118, E-12 and E24, and repair if necessary. Check the communication lines for open circuit. Q: Is the check result normal? YES : Go to Step 8. NO : Repair the wiring harness.

Step 8. Check the power window sub switch. Check that the front passenger’s power window works by means of the power window sub switch (front LH) when the power window lock switch is turned off. Q: Is the check result normal? YES : Go to Step 9. NO : Refer to inspection procedure D-3 "Relevant

power window(s) do not work by means of the front and rear passenger’s power window sub switches 354C."


Step 11. Check the wiring harness from E-05 power window main switch connector terminal No.11 to the inserted probe. Connector: E-05



54C-96

SYMPTOM PROCEDURES

NOTE:

Connector: D-02

Connector: C-13

D-02 1 2 3 4 5 6 7 8

AC301408 AH

C-13(L)

Connector: E-27

C-13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

E-27

3 1 2 4 5 6 7 8 AC301414 AH AC301398 AB

Connector: C-118


Step 12. Connector check: E-21 power window sub switch (rear RH) connector Connector: E-21 C-118

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

E-21 Harness side

3 2 1 8 7 6 5 4 AC301414 AC

AC301396 AE



54C-97

SYMPTOM PROCEDURES

Step 13. Check the wiring harness from E-21 power window sub switch (rear RH) connector terminal No.6 to the inserted probe.

Connector: C-118

Connector: E-21

E-21 Harness side

3 2 1 8 7 6 5 4

C-118

AC301414 AC

NOTE: 1 2 3 4 5 6 7 8 9 10 11

Connector: C-13

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32 AC301396 AE

Connector: D-02 D-02 C-13(L)

1 2 3 4 5 6 7 8

C-13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

AC301408 AH

Connector: E-27

AC301398 AB

E-27

1 2 3 4 5 6 7 8 AC301414 AH


54C-98


Step 14. Check the power window sub switch. Check that the rear right power window works by means of the power window sub switch (rear RH) when the power window lock switch is turned off.

Step 17. Check the wiring harness from E-05 power window main switch connector terminal No.11 to the inserted probe. Connector: E-05


power window(s) do not work by means of the front and rear passenger’s power window sub switches 354C." Step 15. Retest the system. After the power window sub switch (rear RH) is replaced, check that the rear right door power window can be operated by the power window sub switch. (1) Replace the power window sub switch (rear RH). (2) Check that the rear right power window works by means of the power window main switch.




C-118


C-117

C-117


1 2 3

4 5 6 7 8 9 10

111213

14 1516 17 1819 20 2122 2324 25 26 27 28 29 32 33 34

35

30 31 36 37

38

C-118 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

E-05 Harness side

23 24 25 26 27

28 29 30 31 32

AC301396 AD

6 5 4 3 2 1 14 13 12 11 10 9 8 7

Connector: D-26 AC301418 AF

D-26


1 2 3 4 5 6 7 8

AC301410 AB


54C-99

Step 18. Connector check: E-01 power window sub switch (rear LH) connector

Connector: E-09

Connector: E-01

E-09

3 1 2 4 5 6 7 8

E-09 AC301416 AD

E-01 Harness side

3 2 1 8 7 6 5 4

Connector: E-12

AC301416 AB


E-12

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

AC301419 AF



54C-100

SYMPTOM PROCEDURES

Step 19. Check the wiring harness from E-01 power window sub switch (rear LH) connector terminal No.6 to the inserted probe.

Connector: E-09


3 1 2 4 5 6 7 8

E-01 Harness side

E-09 AC301416 AD

3 2 1 8 7 6 5 4

Connector: E-12 AC301416 AB


E-12

C-118 C-117

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

C-117 1 2 3

4 5 6 7 8 9 10

111213

14 1516 17 1819 20 2122 2324 25 26 27 28 29 32 33 34

35

30 31 36 37

38

C-118 AC301419 AF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

AC301396 AD



1 2 3 4 5 6 7 8

Step 20. Check the power window sub switch. Check that the rear left power window works by means of the power window sub switch (rear LH) when the power window lock switch is turned off. AC301410 AB


power window(s) do not work by means of the front and rear passenger’s power window sub switches 354C."


54C-101

Step 21. Retest the system. After the power window sub switch (rear LH) is replaced, check that the rear left door power window can be operated by the power window sub switch. (1) Replace the power window sub switch (rear LH). (2) Check that the rear left power window works by means of the power window main switch. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE D-5: The window glass lowers automatically while it is rising. COMMENTS ON TROUBLE SYMPTOM If the sliding resistance is too great when the window is being raised or the window glass encounters an object, the window glass will lower by approximately 150 mm. Possible causes Improper adjusted door window glass Incorrectly installed or warped glass slider Malfunction of the power window motor Malfunction of the window regulator

DIAGNOSIS PROCEDURE

STEP 2. Check the power window operating current. Check that the power window operating current is normal (Refer to GROUP 42 - Door - On-vehicle service 342). Q: Is the check result normal? YES : Adjust the door window glass (Refer to


STEP 1. Check the power window anti-trap function. Check that the power window anti-trap function works. Refer to GROUP 42 - Door - On-vehicle Service 342.

STEP 3. Check that the door window glasses are installed correctly. Check that the door window glasses are installed correctly. Refer to GROUP 42 - Door - On-vehicle Service 342.


Q: Is the check result normal? YES : Go to Step 4. NO : Adjust the door window glass (Refer to

window anti-trap function does not work normally 354C."

GROUP 42 - Door - On-vehicle service 342). STEP 4. Retest the system. Check that the power window does not lower automatically while it is being raised. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the power window motor assembly of the defective window.


54C-102

SYMPTOM PROCEDURES

INSPECTION PROCEDURE D-6: Power window anti-trap function does not work normally.

Power Window (front) Circuit



CPU

HALL IC

HALL IC

CPU

HALL IC

POWER WINDOW MOTOR (FRONT: LH) Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

HALL IC POWER WINDOW MOTOR (FRONT: RH) SB : Sky blue


54C-103

Power Window (rear) Circuit



CPU

HALL IC

HALL IC

CPU

HALL IC


POWER WINDOW MOTOR (REAR: LH) Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

COMMENTS ON TROUBLE SYMPTOM The revolution detection sensor, which is incorporated in the power window motor, may be defective. Possible causes Malfunction of the power window motor

HALL IC

SB : Sky blue

DIAGNOSIS PROCEDURE STEP 1. Check the power window operating current. Check that the power window operating current is normal (Refer to GROUP 42 - Door - On-vehicle service 342). Q: Is the check result normal? YES : Adjust the door window glass (Refer to



54C-104

SYMPTOM PROCEDURES

STEP 2. Confirm the power window learning function. Check that the power window switch has learned the fully closed position of the windows (Refer to GROUP 42 - Door 342).

STEP 5. Check the wiring harness from E-05 power window main switch connector terminal Nos. 8, 9, 10 and 12 to E-13 power window motor (front RH) connector terminal Nos. 5, 4, 6 and 2. Connectors: E-05, E-13

Q: Is the check result normal? YES : Go to Step 3. NO : Make the power window switch learn the

fully closed position of the windows (Refer to GROUP 42 - Door 342).

E-13(GR) E-05

STEP 3. Determine a trouble spot. Q: Which door does the power window anti-trap function fail on? Driver’s door : Go to Step 4. Front passenger’s door : Go to Step 7. Rear right door : Go to Step 13. Rear left door : Go to Step 19.

STEP 4. Connector check: E-05 power window main switch connector and E-13 power window motor (front LH) connector Connectors: E-05, E-13

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7 E-13 Harness side

3 2 1 6 5 4 AC301419 AE

Check the input and output lines to the revolution detection sensor for open or short circuit.

E-13(GR) E-05


STEP 6. Retest the system. After the power window main switch is replaced, check that the driver’s power window anti-trap function works. (1) Replace the power window main switch. (2) Check that the driver’s power window anti-trap function works.

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7 E-13 Harness side


3 2 1 6 5 4 AC301419 AE




54C-105

SYMPTOM PROCEDURES

STEP 7. Connector check: E-23 power window motor (front RH) connector Connector: E-23

STEP 9. Check the wiring harness from E-23 power window motor (front RH) connector terminal No.5 to body earth. Connector: E-23

E-23 Harness side

E-23 Harness side

E-23(GR)

3 2 1 6 5 4

E-23(GR)

3 2 1 6 5 4

AC301412 AC AC301412 AC



STEP 8. Measure the resistance at E-23 power window motor (front RH) connector. Connector: E-23 E-23 Harness side E-23(GR)

3 2 1 6 5 4

C-15(GR)

C-15 AC301412 AC


AC301398 AC

3 2 1 6 5 4


Prior to the wiring harness inspection, check intermediate connector C-15, and repair if necessary. Check the input and output lines to the revolution detection sensor for open or short circuit. AC301471AC

(2) Resistance between E-23 power window motor (front RH) connector terminal No.5 and body earth. OK: 2W or less Q: Is the check result normal? YES : Go to Step 10. NO : Go to Step 9.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19


54C-106


STEP 10. Connector check: E-17 power window sub switch (front RH) connector Connector: E-17 E-17 Harness side

3 2 1 8 7 6 5 4

STEP 12. Retest the system. After the power window sub switch (front LH) is replaced, check that the front passenger’s anti-trap function can be operated by the power window sub switch. (1) Replace the power window sub switch (front LH). (2) Check that the front passenger’s power window anti-trap function works. Q: Is the check result normal? YES : The trouble can be an intermittent

AC301412 AB


STEP 11. Check the wiring harness from E-17 power window sub switch (front RH) connector terminal Nos. 2, 8 and 3 to E-23 power window motor (front LH) connector terminal Nos. 6, 4 and 2. Connectors: E-17, E-23, E-24

E-24

E-17 Harness side

E-23 Harness side

STEP 13. Connector check: E-20 power window motor (rear RH) connector Connector: E-20


E-23(GR) E-17

3 2 1 8 7 6 5 4


E-24

1 2 3 4 5 6 7 8

3 2 1 6 5 4 AC301413 AB


3 2 1 6 5 4 AC301414 AB



STEP 14. Measure the resistance at E-20 power window motor (rear RH) connector. Connector: E-20

54C-107

STEP 15. Check the wiring harness from E-20 power window motor (rear RH) connector terminal No.5 to body earth. Connector: E-20

E-20(GR) E-20(GR)

E-20 Harness side

E-20 Harness side

3 2 1 6 5 4

3 2 1 6 5 4

AC301414 AB


AC301414 AB


3 2 1 6 5 4


1 2 3 4 5 6 7 8

(2) Resistance between E-20 power window motor (rear RH) connector terminal No.5 and body earth. OK: 2W or less Q: Is the check result normal? YES : Go to Step 16. NO : Go to Step 15.

AC301408 AH

AC301471AB


STEP 16. Connector check: E-21 power window sub switch (rear RH) connector Connector: E-21

E-21 Harness side

3 2 1 8 7 6 5 4 AC301414 AC



54C-108

SYMPTOM PROCEDURES

STEP 17. Check the wiring harness from E-21 power window sub switch (rear RH) connector terminal Nos. 2, 8 and 3 to E-20 power window motor (rear RH) connector terminal Nos. 6, 4 and 2.

STEP 19. Connector check: E-03 power window motor (rear LH) connector Connector: E-03

Connectors: E-20, E-21, E-27 E-03(GR)

E-20(GR)

E-21

E-03 Harness side

3 2 1 6 5 4 AC301416 AC

E-27


E-20 Harness side

STEP 20. Measure the resistance at E-03 power window motor (rear LH) connector.

3 2 1 6 5 4 E-27 E-21 Harness side

1 2 3 4 5 6 7 8

Connector: E-03

3 2 1 8 7 6 5 4

E-03(GR) AC301415 AB


STEP 18. Retest the system. After the power window sub switch (rear RH) is replaced, check that the rear right door anti-trap function can be operated by the power window sub switch. (1) Replace the power window sub switch (rear RH). (2) Check that the rear right power window anti-trap function works. Q: Is the check result normal? YES : The trouble can be an intermittent


E-03 Harness side

3 2 1 6 5 4 AC301416 AC


3 2 1 6 5 4


AC301463 AB

(2) Resistance between E-03 power window motor (rear LH) connector terminal No.5 and body earth. OK: 2W or less Q: Is the check result normal? YES : Go to Step 22. NO : Go to Step 21.


54C-109

SYMPTOM PROCEDURES

STEP 21. Check the wiring harness from E-03 power window motor (rear LH) connector terminal No.5 to body earth. Connector: E-03

STEP 23. Check the wiring harness from E-01 power window sub switch (rear LH) connector terminal Nos. 8, 2 and 3 to E-03 power window motor (rear LH) connector terminal Nos. 6, 4 and 2. Connectors: E-01, E-03, E-09


E-01 E-03(GR)

3 2 1 6 5 4 E-09

AC301416 AC


E-01 Harness side

D-26

3 2 1 8 7 6 5 4

1 2 3 4 5 6 7 8

E-03 Harness side AC301410 AB


STEP 22. Connector check: E-01 power window sub switch (rear LH) connector

E-09

1 2 3 4 5 6 7 8

3 2 1 6 5 4 AC301417 AB


STEP 24. Retest the system. After the power window sub switch (rear LH) is replaced, check that the rear left door anti-trap function can be operated by the power window sub switch. (1) Replace the power window sub switch (rear LH). (2) Check that the rear left power window anti-trap function works.

Connector: E-01

E-01 Harness side

3 2 1 8 7 6 5 4 AC301416 AB




54C-110



INSPECTION PROCEDURE E-1: Keyless Entry System does not Work.


Keyless Entry System Function Circuit ETACS-ECU


INPUT SIGNAL · ALL OF THE DOOR SWITCHES · DRIVER'S DOOR LOCK ACTUATOR SWITCH · KEYLESS ENTRY TRANSMITTER SWITCH · KEY REMINDER SWITCH

COMMENTS ON TROUBLE SYMPTOM If the keyless entry system does not work normally, the input signal circuits to the components below or the ETACS-ECU may be defective. Key reminder switch All of the door switches Keyless entry transmitter Driver’s door lock actuator POSSIBLE CAUSES Malfunction of the key reminder switch Malfunction of the door switches Malfunction of the keyless entry transmitter Malfunction of the driver’s door lock actuator Malfunction of the ETACS-ECU Damaged harness wires and connectors




Step 2. Pulse check Check the input signals below which are related to the keyless entry system. System switch

Check conditions

Key reminder switch








Refer to inspection procedure N-11 "The key reminder switch signal is not received 354C." All the door switch signals are not received. :

Refer to inspection procedure N-13 "All the door switch signals are not received 354C ." The driver’s door lock actuator switch signal is not received. : Refer to inspection procedure N-14

"The driver’s door lock actuator signal is not received 354C. The keyless entry transmitter switch signal is not received. : Refer to inspection procedure N-16

"Each switch signal of the keyless entry transmitter is not received 354C."

54C-111

Step 3. Retest the system. Check the keyless entry system works normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54C-112


INSPECTION PROCEDURE E-2: Keyless Entry Hazard Warning Lamp Answerback Function or the Room Lamp Answerback Function does not Work Normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. COMMENTS ON TROUBLE SYMPTOM If the hazard warning lamp and the room lamp work normally, the ETACS-ECU may be defective. Alternatively, it is possible that the keyless entry hazard warning lamp answerback function was disabled by the adjustment function. POSSIBLE CAUSES Defective turn-signal lamp Malfunction of the room lamp Malfunction of the ETACS-ECU Damaged harness wires and connectors

Step 3. Check the operation of the room lamps. Check that the room lamps illuminate normally. Q: Is the check result normal? YES : Go to Step 4. NO : Refer to inspection procedure M-2 "The

front or rear room lamp does not illuminate/ extinguish 354C." Step 4. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF

DIAGNOSIS PROCEDURE

ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu.

Step 1. Check the adjustment function. Check that the keyless entry hazard warning lamp answerback function has been enabled by using the adjustment function.


Q: Is the check result normal? YES : Go to Step 2. NO : Enable the keyless entry hazard warning

lamp answerback function by using the adjustment function (Refer to GROUP 54B - Adjustment function 354B). Step 2. Check the operation of the hazard warning lamp. Check that the hazard warning lamps illuminate normally. Q: Is the check result normal? YES : Go to Step 3. NO : Refer to inspection procedure K-2 "The

hazard warning lamps do not illuminate 354C".

"Communication with ETACS-ECU is impossible 354C." Step 5. Retest the system. Check that the keyless entry hazard warning lamp answerback function or the room lamp answerback function work normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-113

INSPECTION PROCEDURE E-3: Encrypted Code cannot be Registered.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Encrypted Transmitter Code Register Mode ETACS-ECU

INPUT SIGNAL · HAZARD WARNING LAMP SWITCH · KEYLESS ENTRY TRANSMITTER SWITCH · KEY REMINDER SWITCH

COMMENTS ON TROUBLE SYMPTOM If the encrypted code registration mode is not entered, the key reminder switch, the hazard warning lamp switch or the ETACS-ECU may be defective. If the registration is not possible although the registration mode is entered, the keyless entry transmitter or the ETACS-ECU may be defective.

Step 2. Pulse check Check the input signals below which are related to the encrypted code of the keyless entry transmitter.

POSSIBLE CAUSES Malfunction of the keyless entry transmitter Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the encrypted code registration mode. Check that the encrypted code registration mode is entered. Q: Is the check result normal? YES : Go to Step 3. NO : Go to Step 2.

System switch

Check conditions

Key reminder switch




Keyless entry transmitter When the switch is turned from off to on switch OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? All the signals are received normally. : Go to Step


Refer to inspection procedure N-11 "The key reminder switch signal is not received 354C." The hazard warning lamp switch signal is not received. : Refer to inspection procedure N-12

"The hazard warning lamp switch signal is not received 354C." The keyless entry transmitter switch signal is not received. : Refer to inspection procedure N-16

"Each switch signal of the keyless entry transmitter is not received 354C."

54C-114


Step 3. Retest the system. Check that the encrypted code can be registered. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE E-4: The Timer Lock Function does not Work after the Doors have been Unlocked by the Keyless Entry System.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. COMMENT ON TROUBLE SYMPTOM If the keyless entry timer lock does not work normally, the input signal circuit(s) to the keyless entry transmitter or the ETACS-ECU may be defective. POSSIBLE CAUSES Malfunction of the keyless entry transmitter Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the operation of the keyless entry system. Check that the keyless entry system works normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure E-1 "Keyless

entry system does not work 354C." Step 2. Retest the system. Check that the timer lock works normally. Q: Is the check result normal? YES : The trouble can be an intermittent




INSPECTION PROCEDURE F-1: The windshield wipers does not work at all.


Windshield Wiper Power Supply Circuit IGNITION SWITCH (ACC)

FRONT-ECU WIPER SPEED SWITCHING RELAY


CIRCUIT BREAKER


SB : Sky blue

54C-115

54C-116


COMMENTS ON TROUBLE SYMPTOM The windshield wiper motor, the column switch or the front-ECU may be defective. If a problem is found in the ECU check by using the SWS monitor, also check the wiper backup circuit (between C-310 column switch connector terminal No.8 and A-12X front-ECU connector terminal No.26) and repair if necessary. POSSIBLE CAUSES Malfunction of the windshield wiper motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Turn the ignition switch to the ON position. ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "COLUMN ECU" menu. :

Refer to Inspection Procedure A-2 "Communication with column switch (column-ECU) is impossible 354C." "NG" is displayed on the "FRONT ECU" menu. :

Refer to Inspection Procedure A-4 "Communication with front-ECU is impossible 354C."

Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the windshield wiper function. F.WIPER INT Turn the ignition switch to the ACC position. Windshield wiper switch: INT Item No.

Item name

Normal conditions

Item 05

INT WIPER SW

ON

Item 31

IGNITION SW ACC

ON

Item 70

FRONT ECU ACK NORMAL ACK or HI-BEAM ACK



Replace the column switch. Normal condition is not displayed for item No.31 :

Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354C." Normal condition is not displayed for item No.70 :

Replace the front-ECU. Step 3. Connector check: B-07 windshield wiper motor connector Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD



54C-117

SYMPTOM PROCEDURES



B-07 Harness side

assembly.

3 2 1 5 4

Step 5. Measure the resistance at the B-07 windshield wiper motor connector. Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD


AC301521AD

(1) Disconnect the connector, and measure at the wiring harness side. C-17(GR)

3 2 1 5 4

C-17 Harness side

5 4 3 2 1 13 12 11 10 9 8 7 6


(2) Continuity between B-07 windshield wiper motor connector terminal No.5 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 6.

AC301398 AE

Prior to the wiring harness inspection, check the junction connector C-17 and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-118

SYMPTOM PROCEDURES



Relay box side

Relay box side

3130 29 2827 26 25 24 2322 21

3130 29 2827 26 25 24 2322 21

AC301483 AE


AC301483 AE

(1) Remove the front-ECU, and measure at the relay box side. (2) Ignition switch: ACC

31 30 29 2827 26 25 24 2322 21

Connector A-12X (Relay box side) AC301473 AB



54C-119

SYMPTOM PROCEDURES

Step 9. Check the wiring harness between A-12X front-ECU connector terminal No.28 and ignition switch (ACC).


Connector: A-12X

C-116

1 2

Relay box side 3130 29 2827 26 25 24 2322 21

5 6 7

3 4

8 9

10 11 12 13 14

15

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301396 AB

AC301483 AE

Connectors: C-202, C-203 Junction block (Front view) C-203 C-202

C-202 Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7


AC210475 AM

Prior to the wiring harness inspection, check the junction block connectors C-202, C-203 and intermediate connector C-116 and repair if necessary. Check the power supply line from ignition switch (ACC) for open circuit.


54C-120

SYMPTOM PROCEDURES



Step 10. Retest the system. The windshield wiper should now work normally at all. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE F-2: The windshield wipers does not work when the wiper switch is at "INT", "WASHER" or "MIST" position. However, the wipers work at low speed when the switch is at "LO" and "HI" position.





CIRCUIT BREAKER

COMMENTS ON TROUBLE SYMPTOM The system may be at fail-safe mode as the SWS communication line is defective. If the ETACS-ECU does not receive the ignition switch (ACC) signal due to an open circuit in the SWS communication lines or other reasons when the ignition switch is at the ACC position, the system will enter the fail-safe mode.


POSSIBLE CAUSES Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors


DIAGNOSIS PROCEDURE Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Turn the ignition switch to the ACC position. ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "COLUMN ECU" menu. :



54C-121

Step 2. Retest the system. The windshield wiper should now work normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-122

SYMPTOM PROCEDURES

INSPECTION PROCEDURE F-3: The windshield wipers do not stop at the specified park position

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Windshield Wiper Automatic Stop Relay Circuit IGNITION SWITCH (ACC) FRONT-ECU WIPER AUTOMATIC STOP RELAY



COMMENTS ON TROUBLE SYMPTOM The windshield wiper motor or the front-ECU may be defective. POSSIBLE CAUSES Malfunction of the windshield wiper motor Malfunction of the front-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSIS PROCEDURE Step 1. Connector check: B-07 windshield wiper motor connector Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD




assembly. Step 3. Measure the voltage at the B-07 windshield wiper motor connector. Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD




54C-123

Step 4. Check the wiring harness between B-07 windshield wiper motor connector terminal No.2 and ignition switch (ACC). Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD


54C-124

SYMPTOM PROCEDURES Q: Is the check result normal? YES : The trouble can be an intermittent


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 5. Connector check: A-12X front-ECU connector C-104(B)

Connector: A-12X

C-104

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

AC301398 AF

Relay box side


3130 29 2827 26 25 24 2322 21

C-203 C-202 AC301483 AE

Q: Is the check result normal? YES : Go to Step 6. NO : Repair the connector. C-202 Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7


AC210475 AM

Prior to the wiring harness inspection, check the junction connectors C-202, C-203 and the intermediate connector C-104 and repair if necessary. Check the power supply line from ignition switch (ACC) for open circuit.


54C-125

SYMPTOM PROCEDURES

Step 6. Check the wiring harness between B-07 windshield wiper motor connector terminal No.3 and A-12X front-ECU connector terminal No.29.


Connector: A-12X

A-14(GR)

A-14

1 2 3 4 5 6 7 8 9 10 11 15 14 12 13 16 17

Relay box side 3130 29 2827 26 25 24 2322 21

AC210456 AD

AC301483 AE

Connector: B-07 B-07(GR)

B-07 Harness side

3 2 1 5 4

AC301521AD

Prior to the wiring harness inspection, check the intermediate connector A-14 and repair if necessary. Check the input signal lines. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

Step 7. Retest the system. Check that the windshield wipers stop at the specified park position. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-126

SYMPTOM PROCEDURES

INSPECTION PROCEDURE F-4: The windshield wipers does not work normally.


Windshield Wiper Motor Drive Circuit FRONT-ECU


WIPER SPEED SWITCHING RELAY


CIRCUIT BREAKER

COMMENTS ON TROUBLE SYMPTOM The windshield wiper motor, the column switch or the front-ECU may be defective. POSSIBLE CAUSES Malfunction of the windshield wiper motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors


Step 1. Confirm communication data by using the SWS monitor. Check the SWS communication signal, which are related to the windshield wipers. Column switch (column-ECU) Ignition switch: ON Move the windshield wiper switch to each position. Item No.

Item name

Normal condition

Item 05

INT WIPER SW

ON

Item 06

LO WIPER SW

ON

Item 07

HI WIPER SW

ON

Item 08

MIST WIPER SW

ON

OK: Normal conditions are displayed for all the functions of the switch. Q: Is the check result normal? Normal conditions are displayed for all the items. :

Go to Step 2. NO : Replace the column switch



B-07 Harness side

3 2 1 5 4

54C-127


assembly. Step 4. Retest the system. Check that the windshield wipers work normally by moving the switch to each position.

AC301521AD




INSPECTION PROCEDURE F-5: The intermittent wiper interval can not be adjusted by operating the windshield intermittent wiper volume control.


Windshield Wiper Intermittent Volume Input Signal ETACS-ECU

INPUT SIGNAL WINDSHIELD WIPER INTERMITTENT VOLUME

COMMENTS ON TROUBLE SYMPTOM The column switch or the front-ECU may be defective.

POSSIBLE CAUSES Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors


54C-128

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE Step 1. Check the ETACS ANAL data by using the SWS monitor. Rotate the windshield intermittent wiper volume. Item No.

Item name

Normal conditions

Item 02

WPR VOL VOLT

Displays the voltage in the windshield wiper intermittent volume. Changes in accordance with the position of the windshield wiper intermittent volume.

Step 2. Retest the system. Check that the windshield intermittent wiper interval can be adjusted by operating the windshield intermittent wiper volume control. OK: The intermittent wiper interval is changed as the intermittent wiper volume is rotated. Q: Is the check result normal? YES : The trouble can be an intermittent


OK: Normal condition is displayed. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure N-7 "The

windshield intermittent wiper volume signal is not received 354C."

INSPECTION PROCEDURE F-6: The intermittent wiper interval is not changed according to the vehicle speed.


Vehicle Speed Input Signal ETACS-ECU

INPUT SIGNAL VEHICLE SPEED

W3Z04E06AA

COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU calculates the intermittent wiper interval according to the vehicle speed signal which is sent by the engine-ECU.

If the intermittent wiper interval does not depend on the vehicle speed, the input circuit of the vehicle speed signal and the ETACS-ECU may be defective.


54C-129

POSSIBLE CAUSES Malfunction of the vehicle speed signal (engineECU) Malfunction of the ETACS-ECU Damaged harness wires and connectors

Step 3. Check the ETACS ANAL data by using the SWS monitor. Enter a simulated vehicle speed. Item No.

Item name

Normal conditions

DIAGNOSIS PROCEDURE

Item 03

SPEED SENSOR

Displays the speed which fluctuates within 2 km/h from the entered vehicle speed.

Step 1. Retest the system. Check that the windshield intermittent wiper interval can be adjusted by operating the windshield intermittent wiper volume control. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure F-5 "The

intermittent wiper interval cannot be adjusted by operating the windshield intermittent wiper volume control 354C ."

OK: Normal condition is displayed. Q: Is the check result normal? YES : Go to Step 4. NO : Refer to Inspection Procedure N-13 "The

vehicle speed signal is not received 354C ."

Step 2. Check the adjustment function. Check that "SPEED SEN WIP" is set to "W.FUNCTION" by using the adjustment function.

Step 4. Retest the system. Check that the intermittent wiper interval depends on the vehicle speed.

Q: Is the check result normal? YES : Go to Step 3. NO : Set "SPEED SEN WIP" to "W.FUNCTION"


by using the adjustment function.(Refer to 354B).



54C-130

SYMPTOM PROCEDURES

INSPECTION PROCEDURE F-7: The windshield washer does not work.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Windshield Washer Motor Circuit IGNITION SWITCH (ACC)

FRONT-ECU WINDSHIELD WASHER RELAY

INPUT SIGNAL WINDSHIELD WASHER

WINDSHIELD WASHER MOTOR


COMMENTS ON TROUBLE SYMPTOM The windshield washer motor, the column switch or the front-ECU may be defective. POSSIBLE CAUSES Malfunction of the windshield washer motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the operation of the windshield wipers. Check that the windshield wipers work normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure F-1 "The

windshield wipers does not work at all 354C."


Step 2. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Turn the ignition switch to the ACC position. ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items

Step 4. Connector check: A-26 windshield washer motor connector Connector: A-26

A-26 Harness side

1 2

Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 3. "NG" is displayed on the "COLUMN ECU" menu. :


Refer to Inspection Procedure A-4 "Communication with front-ECU is impossible 354C." Step 3. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the windshield washer function. F.WIPER WASH Turn the ignition switch to the ACC position. Windshield washer switch: ON Item No.

Item name

Normal conditions

Item 09

FRONT WASH. SW

ON

Item 31

IG SW (ACC)

ON

Item 70


OK: Normal conditions are displayed for all the items. Q: Is the check result normal? Normal conditions are displayed for all the items :

Go to Step 4. Normal condition is not displayed for item No.09 :



Replace the front-ECU.

54C-131

AC210453 AF


Step 5. Check the windshield washer motor assembly. Refer to GROUP 51 - Windshield washer 351. Q: Is the check result normal? YES : Go to Step 6 NO : Replace the windshield washer motor.


54C-132

SYMPTOM PROCEDURES

Step 6. Measure the resistance at the A-26 windshield washer motor connector. Connector: A-26

Step 7. Check the wiring harness between A-26 windshield washer motor connector terminal No.1 and body earth. Connector: A-26

A-26 Harness side

A-26 Harness side

1 2

1 2 AC210453 AF


AC210453 AF


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. 1 2



Connector: A-12X

(2) Continuity between A-26 windshield washer motor connector terminal No.1 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 7.

Relay box side 3130 29 2827 26 25 24 2322 21

AC301483 AE



Step 9. Check the wiring harness between A-26 windshield washer motor connector terminal No.2 and A-12X front-ECU connector terminal No.31.

54C-133

Step 10. Retest the system. The windshield washer should now work normally. Q: Is the check result normal? YES : The trouble can be an intermittent


Connector: A-12X

Relay box side 3130 29 2827 26 25 24 2322 21

AC301483 AE

Connector: A-26

A-26 Harness side

1 2

AC210453 AF

Check the power supply line from the ignition switch (ACC) for open circuit. Q: Is the check result normal? YES : Go to Step 10. NO : Repair the wiring harness.

54C-134



INSPECTION PROCEDURE G-1: The rear wiper does not work at all.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Rear Wiper Drive Circuit IGNITION SWITCH (ACC)


INPUT SIGNAL REAR WIPER SWITCH

REAR WIPER MOTOR


COMMENTS ON TROUBLE SYMPTOM If the rear wiper does not work normally, the input signal circuits to the components below, the rear wiper motor or the ETACS-ECU may be defective. Ignition switch (ACC) Rear wiper switch

SB : Sky blue

Possible causes Malfunction of the rear wiper motor Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors


54C-135

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE

Step 3. Connector check: F-02 rear wiper motor connector

Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the ETACS-ECU and the SWS communication lines are normal. Ignition switch: ACC


4 3 2 1

ECUS TO BE CHECKED COLUMN ECU ETACS ECU OK: "OK" is displayed for all the items AC301665 AB

Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "COLUMN ECU" menu. :

Refer to Inspection Procedure A-2 "Communication with column switch (column-ECU) is impossible 354C." "NG" is displayed on the "ETACS ECU" menu. :

Refer to Inspection Procedure A-3 "Communication with ETACS-ECU is impossible 354C." Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the rear wiper function. REAR WIPER Ignition switch: ACC Rear wiper switch: ON Item No.

Item name

Normal conditions

Item 13

REAR WIPER SW

ON

Item 31

IG SW (ACC)

ON




Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354C."




54C-136

SYMPTOM PROCEDURES

Step 5. Measure the resistance at the F-02 rear wiper motor connector. Connector: F-02 F-02 Harness side

Step 6. Check the wiring harness between F-02 rear wiper motor connector terminal No.1 and body earth. Connector: F-02 F-02 Harness side

4 3 2 1 4 3 2 1

AC301665 AB


AC301665 AB



4 3 2 1


Connector F-02 (Harness side) AC301641AB

Connector: C-217

(2) Resistance between F-02 rear wiper motor connector terminal No.1 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 6.



AC210477 AB



54C-137

SYMPTOM PROCEDURES



Connector: C-217

Junction block (Rear view) C-209 Harness side 7 6 5 15 1413


12

4 3 2 1 11 10 9 8

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210475 AO

Connector: F-05 AC210477 AB


4 3 2 1

AC301665 AB

F-05

1 2 3 4 5 6 7 8 9 10

AC301666 AB

Prior to the wiring harness inspection, check intermediate connector F-05 and junction block connectors C-209 and repair if necessary. Check the output signal line for open or short circuit. Q: 1Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.


54C-138

SYMPTOM PROCEDURES

Step 9. Retest the system. Check that the rear wiper works normally. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE G-2: The rear wiper does not stop at the specified park position.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Rear Wiper Auto-stop Signal Input IGNITION SWITCH (ACC)

ETACSECU REAR WIPER RELAY

REAR WIPER MOTOR


SB : Sky blue


COMMENTS ON TROUBLE SYMPTOM If the rear wiper does not stop normally within the predetermined range, the rear wiper motor or the ETACS-ECU may be defective.

54C-139

Step 3. Measure the voltage at the F-02 rear wiper motor connector. Connector: F-02 F-02 Harness side

Possible causes Malfunction of the rear wiper motor Malfunction of the ETACS-ECU Damaged harness wires and connectors

4 3 2 1

Step 1. Connector check: F-02 rear wiper motor connector AC301665 AB



4 3 2 1

4 3 2 1 AC301665 AB



Connector F-02 (Harness side) AC301642 AB

(3) Check the voltage between F-02 rear wiper motor connector terminal No.4 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

Step 4. Check the wiring harness between ignition switch (ACC) and F-02 rear wiper motor connector terminal No.4. Connector: F-02 F-02 Harness side

4 3 2 1

AC301665 AB


54C-140

SYMPTOM PROCEDURES NO : Repair the wiring harness.

NOTE: Connector: F-05


Junction block (Rear view) F-05

1 2 3 4 5 6 7 8 9 10 C-217 Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1 AC301666 AB

Connectors: C-203, C-209 Junction block (Front view) AC210477 AB

C-203

Q: Is the check result normal? YES : Go to Step 6. NO : Repair the connector. C-209


C-209 Harness side 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210475 AN

Prior to the wiring harness inspection, check intermediate connector F-05 and junction block connectors C-203, C-209 and repair if necessary. Check the power supply line for open or short circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300).


54C-141

SYMPTOM PROCEDURES


NOTE: Connector: F-05

Connector: C-217

Junction block (Rear view) F-05

1 2 3 4 5 6 7 8 9 10


AC301666 AB

AC210477 AB



4 3 2 1

AC301665 AB

C-209 Harness side 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210475 AO

Prior to the wiring harness inspection, check intermediate connector F-05 and junction block connectors C-209 and repair if necessary. Check the output signal line for open or short circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

54C-142


Step 7. Retest the system. Check that the rear wiper auto stop function works normally. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE G-3: When the shift lever is moved to "R" position during the rear wiper operation, the rear wiper does not operate at the continuous mode.


"R" Position During Rear Wiper Operation Circuit IGNITION SWITCH (ACC)


INPUT SIGNAL · BACK-UP LAMP SWITCH ("R" POSITION) · REAR WIPER SWITCH

REAR WIPER MOTOR

COMMENTS ON TROUBLE SYMPTOM If the rear wiper does not operate consecutively when the shift lever is moved to the R position during the rear wiper operation, the input signal circuit to the back-up lamp switch ("R" position) or the ETACSECU may be defective.



Step 1. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the R (reverse) gear-linked rear wiper operation. REAR WIPER-REV. INTERLOCK Ignition switch: ON Rear wiper switch: ON Shift position: R position Item No.

Item name

Normal conditions

Item 41

INHIBITOR SW

ON


back-up lamp switch signal is not received 354C."

54C-143

Step 2. Retest the system. Check that the rear wiper operates consecutively when the shift lever is moved to the R position during the rear wiper operation. Q: Is the check result normal? YES : The trouble can be an intermittent


54C-144


INSPECTION PROCEDURE G-4: The rear washer does not work.


Rear Washer Drive Circuit IGNITION SWITCH (ACC)

ETACS-ECU REAR WASHER RELAY

INPUT SIGNAL REAR WASH. SW

REAR WASHER MOTOR


COMMENTS ON TROUBLE SYMPTOM If the rear washer does not work normally, the input signal circuits to the rear washer switch, rear washer motor or the ETACS-ECU may be defective. Possible causes Malfunction of the rear washer motor Malfunction of the column switch Malfunction of the ETACS-ECU


wiper does not work at all 354C."


Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the rear washer function. REAR WIPER-REAR WASHER Ignition switch: ACC Rear washer switch: ON Item No.

Item name

Normal conditions

Item 14

REAR WASH. SW

ON

Step 5. Measure the resistance at the A-27 rear washer motor connector. Connector: A-27

A-27 Harness side

1 2 A-27(G)


54C-145

AC210453 AG


column switch (windshield wiper washer and rear wiper washer switch) signal is not received 354C." Step 3. Connector check: A-27 rear washer motor connector

1 2

Connector: A-27


(2) Resistance between A-27 rear washer motor connector terminal No.1 and body earth OK: 2 W or less

A-27 Harness side

1 2


A-27(G) AC210453 AG


Step 4. Check the rear washer motor. Refer to GROUP 51 - Rear wiper and washer 351 . Q: Is the check result normal? YES : Go to Step 5. NO : Replace the rear washer motor.

Step 6. Check the wiring harness between A-27 rear washer motor connector terminal No.1 and body earth. Connector: A-27

A-27 Harness side

1 2 A-27(G) AC210453 AG




54C-146

SYMPTOM PROCEDURES


Step 8. Check the wiring harness between C-220 ETACS-ECU connector terminal No.23 and A-27 rear washer motor connector terminal No.2. Connector: A-27

A-27 Harness side


1 2 A-27(G) AC210453 AG

Connector: C-220

C-220 Harness side

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210477 AE



C-220 Harness side

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210477 AE


NOTE:

54C-147

Step 9. Retest the system. Check that the rear washer works normally.

Connector: C-116



C-116

1 2

5 6 7

3 4

8 9

10 11 12 13 14

15

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301396 AB

Prior to the wiring harness inspection, check intermediate connector C-116 and repair if necessary. Check the output signal line for open or short circuit. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.

54C-148


HEADLAMP WASHER

INSPECTION PROCEDURE H-1: The headlamp washer does not work.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamp Washer Motor Circuit FUSIBLE LINK 5

FRONT-ECU HEADLAMP WASHER

INPUT SIGNAL HEADLAMP WASHER

HEADLAMP WASHER MOTOR


COMMENTS ON TROUBLE SYMPTOM The headlamp washer motor, the column switch or the front-ECU may be defective.

Possible causes Malfunction of the headlamp washer motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors


DIAGNOSIS PROCEDURE

Step 3. Connector check: A-25 headlamp washer motor connector

Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Turn the ignition switch to the ON position. ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "COLUMN ECU" menu. :


Refer to Inspection Procedure A-4 "Communication with front-ECU is impossible 354C." Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the headlamp washer function. HD WASHER Turn the ignition switch to the ACC position. Headlamp washer switch: ON Item No.

Item name

Normal conditions

Item 16

HD WASHER SW

ON

Item 31

IG SW (ACC)

ON

Item 70







54C-149

Connector : A-25

A-25 Harness side

2 1

A-25(B)

AC210453 AI


Step 4. Check the headlamp washer motor assembly. Refer to GROUP 51 - Headlamp washer 351. Q: Is the check result normal? YES : Go to Step 5 NO : Replace the headlamp washer motor.


54C-150

SYMPTOM PROCEDURES

Step 5. Measure the resistance at the A-25 headlamp washer motor connector. Connector : A-25

Step 6. Check the wiring harness between A-25 windshield washer motor connector terminal No.2 and body earth. Connector : A-25

A-25 Harness side

A-25 Harness side

2 1

2 1 A-25(B)

AC210453 AI


A-25(B)

AC210453 AI


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. 2 1 Connector A-25 (harness side)

Step 7. Connector check: A-11X front-ECU connector AC301725 AB

Connector: A-11X

(2) Continuity between A-25 headlamp washer motor connector terminal No.2 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 6.

Relay box side 11 10 9 8 7 6 5 4 3 2 1

AC301483 AD




54C-151

Step 9. Check the wiring harness between A-11X front-ECU connector terminal No.3 and the fusible link (5). Connector: A-11X

Relay box side Relay box side 11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1

AC301483 AD

(1) Remove the front-ECU, and measure at the junction block side. (2) Ignition switch: ACC

AC301483 AD

Check the power supply line to the fusible link (5) for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. 11 10 9 8 7 6 5 4 3 2 1

Connector A-11X (Relay box side)

AC301726 AB



54C-152

SYMPTOM PROCEDURES

Step 10. Check the wiring harness between A-25 headlamp washer motor connector terminal No.1 and A-11X front-ECU connector terminal No.1. Connector: A-11X



Relay box side 11 10 9 8 7 6 5 4 3 2 1

AC301483 AD

Connector : A-25

A-25 Harness side

2 1

A-25(B)

Step 11. Retest the system. The headlamp washer should now work normally.

AC210453 AI

Check the power supply line from the fusible link (5) for open circuit. Q: Is the check result normal? YES : Go to Step 11. NO : Repair the wiring harness.


54C-153

IGNITION KEY HOLE ILLUMINATION LAMP

INSPECTION PROCEDURE I-1: The ignition key cylinder illumination lamp does not illuminate/ extinguish normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Ignition Key Cylinder Illumination Lamp Circuit

ETACS-ECU FUSIBLE LINK 1

KEY REMINDER SWITCH KEY CYLINDER ILLUMINATION LAMP


COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Driver’s door switch Ignition switch (IG1) Key reminder switch Driver’s door switch Interior lamp loaded signal If this function does not work normally, these input signal circuit(s), the ignition key cylinder illumination lamp or the ETACS-ECU may be defective. Possible causes Malfunction of the key reminder switch Malfunction of the driver’s door switch

SB : Sky blue

Malfunction of the ignition key cylinder illumination lamp Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the operation of the room lamp. Check that the dome lamps illuminate and extinguish normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure M-1 "The

front or rear room lamp does not illuminate/ extinguish 354C ." Or refer to inspection procedure M-2 "The room lamp does not illuminate/extinguish 354C ."

54C-154



"Communication with ETACS-ECU is impossible 354C." Step 3. Check the data list by using the SWS monitor. Check the SWS communication signal, which are related to the ignition key cylinder illumination lamp.

Step 4. Pulse check Check the input signals below, which are related to the ignition key cylinder illumination lamp. System switch

Check conditions

Key reminder switch



key reminder switch signal is not received 354C." Step 5. Connector check: C-304 key reminder switch connector Connector: C-304

ETACS ECU Ignition switch: OFF Driver’s door: open

Harness side

Item No.

Item name

Normal conditions

Item 30

IG SW(IG1)

OFF

Item 32

DR DOOR SW

ON

OK: Normal conditions displayed for all the items Q: Is the check result normal? Normal conditions are displayed for all the items. : Go to

Step 4. Normal conditions are displayed for all the items. : Go to Step

5. Normal condition is not displayed for item No.30. :

Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354C." Normal condition is not displayed for item No.32. :

Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354C."

2 1 7 6 5 4 3

AC301399 AB


Step 6. Check the bulb of the ignition key cylinder illumination lamp. Check the bulb of the ignition key cylinder illumination lamp. Q: Is the check result normal? YES : Go to Step 7. NO : Replace the bulb of the ignition key cylinder

illumination lamp.


54C-155

SYMPTOM PROCEDURES


Step 8. Check the wiring harness from C-219 ETACS-ECU connector terminal Nos. 69 and 71 to C-304 ignition key cylinder illumination lamp connector terminal Nos. 1 and 2. Connector: C-219 Junction block (Rear view)


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

Connector: C-304


AC301399 AB

Check the input and output lines for open circuit. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.

Step 9. Retest the system. Check that the ignition key cylinder illumination lamp illuminates/extinguishes normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54C-156


HEADLAMP AND TAIL LAMP

INSPECTION PROCEDURE J-1: The headlamps do not illuminate when the lamping switch is at "TAIL" or "PASSING" position, but illuminate only at low beam when the switch is at "HEAD" position. However, the headlamps do not illuminate at high beam.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. COMMENTS ON TROUBLE SYMPTOM If the headlamps illuminate only at low beam regardless of the lighting switch position, the headlamp fail-safe function may be activated. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "COLUMN ECU" menu. :


Refer to Inspection Procedure A-4 "Communication with front-ECU is impossible 354C." Step 2. Retest the system. Check that the headlamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the column switch.


54C-157

INSPECTION PROCEDURE J-2: The tail lamps do not illuminate normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Tail Lamp Relay Circuit BATTERY

FRONT-ECU

INPUT SIGNAL TAIL LAMP RELAY

· HEADLAMP AUTOMATIC SHUTDOWN · TAIL LAMP SWITCH

RELAY BOX

· LICENSE PLATE LAMP · POSITION LAMP (LH) · REAR COMBINATION LAMP (LH)

· POSITION LAMP (RH) · REAR COMBINATION LAMP (RH)

COMMENTS ON TROUBLE SYMPTOM If all the tail lamps do not illuminate, the tail lamp switch input circuit or the front-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors


DIAGNOSIS PROCEDURE Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "COLUMN ECU" menu. :



54C-158


Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the tail lamps.


LIGHTING - TAIL LAMP Ignition switch: ON Lighting switch: TAIL Item No. Item name

Normal conditions

Item 00

HEADLAMP SW

ON when the lighting switch is at HEAD

Item 01

TAIL LAMP SW


Item 03

PASSING SW

OFF

Item 30

IG SW(IG1)

ON

Item 35

HD AUTO-CUT

OFF

Item 70

FRONT ECU ACK

NORMAL ACK

OK: Normal conditions displayed for all the items Q: Is the check result normal? Normal conditions are displayed for all the items. :

Go to Step 3. Normal condition is not displayed for item 00, 01 or 03. : Refer to inspection procedure N-5 "The

column switch (lighting and turn-signal lamp switch) signal is not received 354C." Normal condition is not displayed for item No.30. :


Refer to Inspection Procedure J-5 "The headlamp automatic shutdown function does not work normally 354C." Normal condition is not displayed for item No.70. :


Relay box side 11 10 9 8 7 6 5 4 3 2 1

AC301483 AD




54C-159

Step 5. Check the wiring harness between A-11X front-ECU connector terminal No.7 and the battery. Connector: A-11X


AC301483 AD


AC301483 AD




Step 6. Retest the system. Check that the tail lamps illuminate normally. AC301541 AD

(2) Voltage between A-11X front-ECU connector terminal No.7 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.



54C-160


INSPECTION PROCEDURE J-3: The low-beam headlamps do not illuminate normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamp Relay (Low-Beam) Circuit BATTERY

FRONT-ECU

INPUT SIGNAL HEADLAMP RELAY: LO


RELAY BOX

HEADLAMP (LH)

HEADLAMP (RH)

COMMENTS ON TROUBLE SYMPTOM If the low-beam headlamps do not illuminate, the headlamp switch input circuit or the front-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors






Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the low-beam headlamps.

54C-161


LIGHTING - HEADLAMP LO Ignition switch: ON Lighting switch: HEAD Item No.

Item name

Normal conditions

Item 00

HEADLAMP SW

ON

Item 03

PASSING SW

OFF

Item 30

IG SW(IG1)

ON

Item 35

HD AUTO-CUT

OFF

Item 70

FRONT ECU ACK

NORMAL ACK

OK: Normal conditions displayed for all the items

Relay box side 11 10 9 8 7 6 5 4 3 2 1

Q: Is the check result normal? Normal conditions are displayed for all the items. :

Go to Step 3. Normal condition is not displayed for item 00 or 03. : Refer to inspection procedure N-5 "The





AC301483 AD



54C-162

SYMPTOM PROCEDURES


Step 5. Check the wiring harness between A-11X front-ECU connector terminal Nos. 8, 9 and the battery. Connector: A-11X


AC301483 AD


AC301483 AD




Step 6. Retest the system. Check that the low-beam headlamps illuminate normally. AC301541 AE

(2) Voltage between A-11X front-ECU connector terminal Nos. 8, 9 and body earth OK: System voltage Q: Are the check results normal? YES : Go to Step 6. NO : Go to Step 5.




54C-163

INSPECTION PROCEDURE J-4: The high-beam headlamps do not illuminate normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamp Relay (High-Beam) Circuit BATTERY

FRONT-ECU

INPUT SIGNAL HEADLAMP RELAY: HI


RELAY BOX

· COMBINATION METER · HEADLAMP (LH)

HEADLAMP (RH)

COMMENTS ON TROUBLE SYMPTOM If the high-beam headlamps do not illuminate, the dimmer switch input circuit or the front-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors





54C-164


Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the high-beam headlamps. LIGHTING - HEADLAMP HI Ignition switch: ON Lighting switch: HEAD Dimmer switch: from OFF to ON, and then to OFF again Item No. Item name

Normal conditions

Item 00

HEADLAMP SW

ON

Item 02

DIMMER SW

from OFF to ON, and then to OFF again ("ON" should be displayed when the dimmer switch is operated)

Item 03

PASSING SW OFF

Item 30

IG SW(IG1)

ON

Item 35

HD AUTOCUT

OFF

Item 70

FRONT ECU ACK

NORMAL ACK


Go to Step 3. Normal condition is not displayed for item 00, 02 or 03. : Refer to inspection procedure N-5 "The





Step 3. Retest the system. Check that the high-beam headlamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-165

SYMPTOM PROCEDURES

INSPECTION PROCEDURE J-5: The high-beam and low-beam headlamps do not illuminate when the passing switch is operated.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. COMMENTS ON TROUBLE SYMPTOM If the low-beam and high-beam headlamps are normal, the passing switch input signal circuit or the front-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

Step 2. Check the data list by using the SWS monitor. Check the ETACS-ECU signals which are related to the headlamps. COLUMN ECU Passing lamp switch: ON Item No.

Item name

Normal conditions

Item 03

PASSING SW

ON


DIAGNOSIS PROCEDURE

column switch (lighting and turn-signal lamp switch) signal is not received 354C."

Step 1. Check the operation of the headlamps. Check that the low-beam and high-beam headlamps illuminate normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure J-2 "The low-

beam headlamps do not illuminate normally 354C." And refer to inspection procedure J-3 "The high-beam headlamps do not illuminate normally 354C."

Step 3. Retest the system. When the passing switch is turned on, check if the headlamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE J-6: The headlamp automatic shutdown function does not work normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamp Automatic Shutdown Function ETACS-ECU


54C-166


COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Driver’s door switch Tail lamp switch Headlamp switch If this function does not work normally, these input signal circuit(s), the front-ECU or the ETACS-ECU may be defective. On vehicles with keyless entry system, note that this function can be disabled/ enabled by the customize function (default setting; enabled). Possible causes Malfunction of the driver’s door switch Malfunction of the front-ECU Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

Step 2. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU), the ETACS-ECU and the front-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU ETACS ECU FRONT ECU OK: "OK" is displayed for all the items Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 3. "NG" is displayed on the "COLUMN ECU" menu. :


Refer to Inspection Procedure A-3 "Communication with ETACS-ECU is impossible 354C."

DIAGNOSIS PROCEDURE

"NG" is displayed on the "FRONT ECU" menu. :


Step 1. Check the adjustment function. Check that the headlamp automatic shutdown function has been enabled by using the adjustment function. Q: Is the check result normal? YES : Go to Step 2. NO : Enable the headlamp automatic shutdown

function by using the adjustment function. Refer to GROUP 54B - Configuration Function 354B.

Step 3. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the headlamp automatic shutdown function. LIGHTING - HD AUTO-CUT Ignition switch: from ON to OFF Lighting switch: "TAIL" or "HEAD" Item No.

Item name

Normal conditions

Item 00


Item 01

TAIL LAMP SW


Item 30

IG SW(IG1)

from ON to OFF

Item 70

FRONT ECU ACK

SLEEP ACK or NORMAL ACK


Driver’s door: open Item No.

Item name

Normal conditions

Item 32

DR DOOR SW

ON

Item 35

HD AUTO-CUT

OFF

OK: Normal conditions displayed for all the items Q: Is the check result normal? Normal conditions displayed for all the items : Go

to Step 4. Normal condition is not displayed for item 00 or 01. : Refer to inspection procedure N-5 "The



Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354C." Normal condition is not displayed for item 35 or 70. : Replace the front-ECU.

54C-167

Step 4. Retest the system. Check that the headlamp automatic shutdown function works normally. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-168

SYMPTOM PROCEDURES

INSPECTION PROCEDURE J-7: Any of tail lamps, position lamps or licence plate lamp does not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Tail Lamps, Position Lamps and License Plate Lamps Circuit

TAIL LAMP RELAY

FRONT-ECU

RELAY BOX

HEADLAMP ASSEMBLY (POSITION) (LH) (RH)

REAR COMBINATION LAMP (TAIL: LH)

LICENCE PLATE LAMP (LH) (RH)


COMMENTS ON TROUBLE SYMPTOM If the tail lamps, the position lamps or the licence plate lamps do not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.

REAR COMBINATION LAMP (TAIL: RH)

SB : Sky blue

Possible causes Burned-out bulb Damaged harness wires and connectors


54C-169

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE


Step 1. Connector check: D-14 or D-19 rear combination lamp connector, A-29 or A-16 headlamp assembly connector, F-08 or F10 licence plate lamp connector

F-10(GR)

F-08(GR)

Connector: A-16

Harness side F-08

F-10

2 1

2 1


A-16(B) AC210455 AD

AC301666 AD

Connector: A-29

Q: Is the check result normal? YES : Go to Step 2. NO : Repair the defective connector. Harness side 3 2 1 6 5 4

A-29(B)

AC210453 AC

Step 2. Check the bulbs of the tail lamps, the position lamp or the licence plate lamp. Check the bulb of the lamp which does not illuminate. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb of the lamp which does not


illuminate. D-14

D-19

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

AC301411AB


54C-170

SYMPTOM PROCEDURES

Step 3. Measure the resistance at the D-14 or D-19 rear combination lamp connector, the A-29 or A-16 headlamp assembly connector, the F-08 or F-10 licence plate lamp connector.


F-10(GR)

Connector: A-16

F-08(GR)

Harness side

Harness side

3 2 1 6 5 4

A-16(B)

F-08

F-10

2 1

2 1

AC210455 AD




A-29(B)

AC210453 AC



D-14

D-19

3 2 1 6 5 4 AC301541AI


Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3


AC301411AB

AC301541BG


54C-171

SYMPTOM PROCEDURES


Connector: A-29


A-29(B)

Connector F-08, F-10 (Harness side)

AC210453 AC

2 1


D-14

D-19

AC301541BM

Resistance between F-08 licence plate lamp connector terminal No.1 and body earth Resistance between F-10 licence plate lamp connector terminal No.1 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

Harness side

Step 4. Check the wiring harness from D-14 or D-19 rear combination lamp connector terminal No.3, A-29 or A-16 headlamp connector terminal No.1 or F-08 or F-10 licence plate lamp connector terminal No.1 to body earth. Connector: A-16


A-16(B) AC210455 AD

D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

AC301411AB

54C-172



Connectors: F-08, F-09, F-10

Connector: A-11X

F-10(GR)

F-08(GR) F-09(GR)

F-09 1 2 3 4


Relay box side

F-10 11 10 9 8 7 6 5 4 3 2 1

2 1

AC301666 AD

NOTE: Prior to the wiring harness inspection, check intermediate connector F-09 , and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

AC301483 AD



54C-173

SYMPTOM PROCEDURES

Step 6. Check the wiring harness from D-14 or D-19 rear combination lamp connector terminal No.2, A-29 or A-16 headlamp assembly connector terminal No.2, F-08 or F-10 licence plate lamp connector terminal No.2 to A-11X front-ECU connector terminal No.4.


D-14

D-19

Connector: A-11X

Harness side D-14

D-19

2 1 6 5 4 3

2 1 6 5 4 3

AC301411AB

Connectors: F-08, F-09, F-10 Relay box side 11 10 9 8 7 6 5 4 3 2 1

F-10(GR) AC301483 AD

F-08(GR)

Connector: A-16

F-09(GR)

F-09 Harness side 3 2 1 6 5 4

A-16(B)

1 2 3 4


F-10 AC210455 AD

Connector: A-29

2 1

AC301666 AD


A-29(B)

AC210453 AC


54C-174

SYMPTOM PROCEDURES

NOTE:

Connector: D-31 Connectors: C-01, C-116, C-117 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

C-01

C-117

AC301408 AE

C-116

C-01

C-116 1 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

5 6 7

3 4

10 11 12 13 14

15

8 9

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

C-117 1 2 3

4 5 6 7 8 9 10

111213

14 1516 17 18 19 20 2122 232425 26 2728 29 32 33 34

35

30 31 36 37

38

AC301396 AN


Prior to the wiring harness inspection, check joint connector C-01 , intermediate connector C-116 , C-117 , D-31 , F-09 , junction block connector C-202 and C-209 , and repair if necessary. Check the output lines for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.

Step 7. Retest the system. Check that the tail lamps, the position lamps and the licence plate lamps illuminate normally. Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent

C-202

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). When the tail lamps do not illuminate : Replace the rear combination lamp socket assembly.

C-209

When the position lamps do not illuminate :

Replace the position lamp socket. When the licence plate lamps do not illuminate :

Harness side C-202 6 5 4 3 2 1 14 13 12 11 10 9 8 7

Replace the licence plate lamp socket. C-209

7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210475 AJ


54C-175

INSPECTION PROCEDURE J-8: The headlamp(s) do not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Headlamps (High-Beam Indicator Lamp) Circuit FRONT-ECU HEADLAMP RELAY: LO

HEADLAMP RELAY: HI

RELAY BOX

HEADLAMP (LH) (RH)

COMBINATION METER


COMMENTS ON TROUBLE SYMPTOM If any of the headlamps or the high-beam indicator does not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.

SB : Sky blue

Possible causes Malfunction of the headlamp bulbs Malfunction of the high-beam indicator bulb Damaged harness wires and connectors


54C-176

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE Step 1. Connector check: A-30 , A-15 headlamp assembly connector or C-05 combination meter connector Connector: A-15


AC210455 AC

Connector: A-30


AC210453 AD

Connector: C-05

C-05(L)


G

G

AC301395 AE


Step 2. Check the bulb(s) of the headlamps or the high-beam indicator lamp. Check the bulb(s) of the defective lamp. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb(s) of the defective lamp.


54C-177

SYMPTOM PROCEDURES

Step 3. Measure the resistance at A-30 , A-15 headlamp assembly connector or C-05 combination meter connector. Connector: A-15

and body earth Resistance between A-15 headlamp assembly connector terminal No.2 and body earth

Connector C-05 (Harness side) A-15(B) 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12


G

AC301541 AO

AC210455 AC

Resistance between C-05 combination meter connector terminal No.8 and body earth OK: 2 W or less

Connector: A-30



AC210453 AD

Connector: C-05

C-05(L)


G

G

G

AC301395 AE


Connector A-15, A-30 (Harness side) 1 3 Y 2

AC301541AH

Resistance between A-30 headlamp assembly connector terminal No.2


54C-178

SYMPTOM PROCEDURES

Step 4. Check the wiring harness from A-30 or A-15 headlamp connector terminal No.2, or C-05 combination meter connector terminal No.8 to body earth.


Connector: A-15


AC210455 AC

Relay box side

Connector: A-30

11 10 9 8 7 6 5 4 3 2 1

A-30(B) Harness side

AC301483 AD

1 3 Y 2

AC210453 AD

Connector: C-05

C-05(L)


G

G

AC301395 AE

Check the earth wires for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.



Step 6. Check the wiring harness from A-30 , A-15 headlamp connector terminal No.1 , No.3 , C-05 combination meter connector terminal No.9 to A-11X front-ECU connector terminal No.6 or No.10 .

54C-179

Connector: A-11X

Connector: A-15

A-15(B) Harness side Relay box side

1 3 Y 2

11 10 9 8 7 6 5 4 3 2 1

AC210455 AC




AC210453 AD



Step 7. Retest the system. Check that the headlamps and the high-beam indicator lamp illuminate/extinguish normally. Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent

C-116

When the high-beam indicator lamp does not illuminate : Replace the combination meter.

C-116 1 2

5 6 7

3 4

10 11 12 13 14

15

8 9

1617 18 1920 21

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

Harness side C-05 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). When the headlamps do not illuminate : Replace the headlamp socket.

AC301396 AJ


54C-180

SYMPTOM PROCEDURES

FLASHER TIMER

INSPECTION PROCEDURE K-1: The turn-signal lamps do not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Turn-Signal Lamp Power Supply Circuit BATTERY

RELAY BOX

ETACS-ECU TURN-SIGNAL LAMP RELAY: RH


· FRONT TURN SIGNAL LAMP (LH) · SIDE TURN SIGNAL LAMP (LH)


· FRONT TURN SIGNAL LAMP (RH) · SIDE TURN SIGNAL LAMP (RH)

COMBINATION METER


COMMENTS ON TROUBLE SYMPTOM If all the turn-signal lamps do not illuminate, the ignition switch (IG1), the turn-signal lamp switch input circuit or the ETACS-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSIS PROCEDURE Step 1. Check that the hazard warning lamps operate. Check that the hazard warning lamps illuminate normally. Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 2.



54C-181

Step 4. Check the wiring harness between C-217 ETACS-ECU connector terminal No.11 and the battery. Connector: C-217 Junction block (Rear view)


20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

AC210476 AC




1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Junction block side


20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC


Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC210474 AB



2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AC301541AU





54C-182

SYMPTOM PROCEDURES

Step 5. Retest the system. Check that the turn-signal lamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the ETACS-ECU. Step 6. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the right turn-signal lamps. TURN SIGNAL - TURN-SIG. RH Turn-signal lamp switch: RH Ignition switch: ON Item No.

Item name

Normal conditions

Item 10

TURN SIG.RH

ON

Item 11

TURN SIG.LH

OFF

Item 30

IG SW(IG1)

ON




Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354C."

Step 7. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the left turn-signal lamps. TURN SIGNAL - TURN-SIG. LH Turn-signal lamp switch: LH Ignition switch: ON Item No.

Item name

Normal conditions

Item 10

TURN SIG.RH

OFF

Item 11

TURN SIG.LH

ON

OK: Normal condition is displayed. Q: Is the check result normal? Normal conditions are displayed for all the items. :


column switch (lighting and turn-signal lamp switch) signal is not received 354C." Step 8. Retest the system. Check that the turn-signal lamps illuminate. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-183

SYMPTOM PROCEDURES

INSPECTION PROCEDURE K-2: The hazard warning lamps do not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Hazard Warning Lamp Circuit BATTERY

RELAY BOX

ETACS-ECU INPUT SIGNAL TURN-SIGNAL LAMP RELAY: RH


· COMBINATION METER · FRONT TURN SIGNAL LAMP (LH) · REAR COMBINATION LAMP (LH) · SIDE TURN SIGNAL LAMP (LH)


· COMBINATION METER · FRONT TURN SIGNAL LAMP (RH) · REAR COMBINATION LAMP (RH) · SIDE TURN SIGNAL LAMP (RH)


COMMENTS ON TROUBLE SYMPTOM If the hazard warning lamps do not illuminate, the hazard warning lamp input signal circuit or the ETACS-ECU may be defective. Possible causes Malfunction of the hazard warning lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSIS PROCEDURE Step 1. Check that the turn-signal lamps operate. Check that the turn-signal lamps illuminate normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure K-1 "The turn

signal lamps do not illuminate 354C."

54C-184



Check conditions




hazard warning lamp switch signal is not received 354C."

Step 3. Retest the system. Check that the hazard warning lamps illuminate. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-185

SYMPTOM PROCEDURES

INSPECTION PROCEDURE K-3: Any of the turn-signal lamps does not illuminate.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Turn-Signal Lamps Circuit

ETACS-ECU

SIDE TURN SIGNAL LAMP (LH)

HEADLAMP ASSEMBLY (FRONT TURN: LH)

REAR COMBINATION LAMP (LH)

COMBINATION METER (LH) (RH)


SB : Sky blue

54C-186

SMART WIRING SYSTEM (SWS) USING SWS MONITOR SYMPTOM PROCEDURES Turn-Signal Lamps Circuit

ETACS-ECU

REAR COMBINATION LAMP (RH)

COMMENTS ON TROUBLE SYMPTOM If any of the turn-signal lamp does not illuminate normally, wiring harness connector(s) or the bulb may be defective.

HEADLAMP ASSEMBLY (FRONT TURN: RH)

SIDE TURN SIGNAL LAMP (RH)

Possible causes Defective turn-signal lamp bulb Damaged harness wires and connectors


54C-187

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE


Step 1. Connector check: A-29 or A16 front turn-signal lamp connector, A-01 or A-04 side turnsignal lamp connector, D-14 or D-19 rear combination lamp connector, C-05 and C-04 combination meter connector

C-04


Harness side

Harness side A-01

C-05

C-04

2 1

A-29

41 4039 38 3736 35 3433 32 31 52 51 50 49 48 47 46 4544 43 42

A-29(B)

G

G

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

3 2 1 6 5 4

AC210453 AJ


A-04(GR)

AC301396 AH

Connectors: D-14, D-19 Harness side D-14

Harness side A-04

A-16

2 1

3 2 1 6 5 4

D-14

D-19

2 1 6 5 4 3

D-19

A-16(B) AC210455 AH

2 1 6 5 4 3

AC301410 AH


Step 2. Check the bulb(s) of the turn-signal lamps or the turn-signal indicator lamps. Check the bulb(s) of the defective lamp. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb(s) of the defective lamp.


54C-188

SYMPTOM PROCEDURES

Step 3. Measure the resistance at the A-29 or A-16 front turn-signal lamp connector, the A-01 or A-04 side turn-signal lamp connector, the D-14 or D-19 rear combination lamp connector, the C-05 and C-04 combination meter connector.


D-14

D-19

2 1 6 5 4 3

D-19 2 1 6 5 4 3


AC301410 AH

A-01(GR)

(1) Disconnect the connector, and measure at the wiring harness side. (2) Measure the resistance between the defective lamp connector terminal and body earth.

Harness side A-01 2 1

A-29

A-29(B)

3 2 1 6 5 4

AC210453 AJ


A-04(GR) 3 2 1 6 5 4

Harness side A-04

A-16

2 1

3 2 1 6 5 4


AC301541AI

A-16(B) AC210455 AH



C-05(L) C-04


2 1

AC301541AB

Harness side C-05

C-04 41 4039 38 3736 35 3433 32 31 52 51 50 49 48 47 46 4544 43 42

G

G

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301396 AH

Resistance between A-01 side turnsignal lamp connector terminal No.1 and body earth Resistance between A-04 side turn-signal lamp connector terminal No.1 and body earth



AC301541BG



11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301541 AP

Resistance between C-05 combination meter terminal No.12 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

54C-189


54C-190

SYMPTOM PROCEDURES

Step 4. Check the wiring harness from A-29 or A-16 front turn-signal lamp connector terminal No.2, A-01 or A-04 side turn-signal lamp connector terminal No.1, D-14 or D-19 rear combination lamp connector terminal No.3, or C-05 combination meter connector terminal No.12 to body earth.


D-14

D-19

2 1 6 5 4 3

D-19 2 1 6 5 4 3


AC301410 AH

A-01(GR)



A-29

A-29(B)

3 4 1 2 5 6 7 8 9 10

3 2 1 6 5 4

AC210453 AJ


A-04(GR) AC301397 AC

Prior to the wiring harness inspection, check intermediate connector C-14 , and repair if necessary. Check the earth wires for open circuit.

Harness side A-04

A-16

2 1

3 2 1 6 5 4

A-16(B) AC210455 AH




C-04



Harness side

41 4039 38 3736 35 3433 32 31 52 51 50 49 48 47 46 4544 43 42

G

AC210476 AC

C-05

C-04

G

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301396 AH



54C-191

SYMPTOM PROCEDURES

Step 6. Check the wiring harness from the A-29 or A-16 front turn-signal lamp connector terminal No.3, the A-01 or A-04 side turn-signal lamp connector terminal No.2, the D-14 or D-19 rear combination lamp connector terminal No.6, the C-05 combination meter connector terminal No.10 or C-04 combination lamp connector terminal No.31 to C217 ETACS-ECU connector terminal No.9 or 14 .

Connectors: C-04, C-05, C-116 C-05(L) C-04

C-116 C-116


Harness side C-04


C-05

41 4039 38 3736 35 3433 32 31 52 51 50 49 48 47 46 4544 43 42

A-29

G

A-29(B)

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

G

AC301396 AI

3 2 1 6 5 4

AC210453 AJ



A-04(GR)

Harness side A-04

A-16

2 1

3 2 1 6 5 4


A-16(B) AC210476 AC AC210455 AH


D-14

D-19

2 1 6 5 4 3

D-19 2 1 6 5 4 3

AC301410 AH


54C-192

SYMPTOM PROCEDURES Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.


Step 7. Retest the system. Check that the turn-signal lamps and the indicator lamps illuminate normally.

1 2 3 4 5 6 7 8 9 10

AC301397 AC

Connectors: C-202, C-205, C-209 Junction block (Front view)

Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). The front turn-signal lamps do not illuminate. :

Replace the socket. The side turn-signal lamps do not illuminate. :

Replace the socket. The rear turn-signal lamps do not illuminate. :

C-202

Replace the socket assembly. The turn-signal indicator lamps do not illuminate. :

C-205

Replace the combination meter. C-209

Harness side C-205

C-202 6 5 4 3 2 1 14 13 12 11 10 9 8 7

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-209 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210475 AH

Connector: D-31 3 4 1 2 5 6 7 8 9 10 1112 13 14 15 16

AC301408 AE

Prior to the wiring harness inspection, check intermediate connector C-14 , C-116 or D-31 and junction block connector C-202 , C-209 or C-205 , and repair if necessary. Check the output lines for open circuit.


54C-193

FOG LAMP

INSPECTION PROCEDURE L-1: The front fog lamps do not illuminate normally.


RELAY BOX



FRONT FOG LAMP (RH)

COMBINATION METER


OPERATION The ETACS-ECU operates this function in accordance with the input signals below. Tail lamp switch Headlamp switch Fog lamp switch If the fog lamps do not illuminate normally, these input signal circuit(s) or the ETACS-ECU may be defective.

SB : Sky blue

Possible causes Malfunction of the column switch Malfunction of the fog lamp switch Malfunction of the front-ECU Malfunction of the ETACS-ECU Damaged harness wires and connectors

54C-194


DIAGNOSIS PROCEDURE Step 1. Check that the tail lamps and headlamps operate. Check that the tail lamps and headlamps illuminate normally. Q: Is the check result normal? YES : Go to Step 2. NO : Repair the tail lamp(s) and headlamp(s).

Refer to trouble symptom chart 354C. Step 2. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU), the ETACS-ECU and the front-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU ETACS ECU FRONT ECU OK: "OK" is displayed for all the items Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 3. "NG" is displayed on the "COLUMN ECU" menu. :


Refer to Inspection Procedure A-3 "Communication with ETACS-ECU is impossible 354C." "NG" is displayed on the "FRONT ECU" menu. :


Step 3. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the fog lamps. LIGHTING - F.FOG LAMP Ignition switch: ON Lighting switch: "TAIL" or "HEAD" Front fog lamp switch: ON Item No.

Item name

Normal conditions

Item 00


Item 01

TAIL LAMP SW

ON when the lighting switch is at TAIL or HEAD

Item 30

IG SW(IG1)

ON

Item 36

F.FOG LAMP

ON

Item 70

FRONT ECU ACK


OK: Normal conditions are displayed for all the items. Q: Is the check result normal? Normal conditions are displayed for all the items. :

Go to Step 4. Normal condition is not displayed for item 00 or 01. : Refer to inspection procedure P-5 "The


Refer to inspection procedure P-2 "The ignition switch (IG1) signal is not received 354C." Normal condition is not displayed for item No.36. :

Refer to inspection procedure P-10 "The front fog lamp switch signal is not received 354C." Normal condition is not displayed for item No.70. :



54C-195

SYMPTOM PROCEDURES


Step 6. Measure the voltage at the A-05X fog lamp relay connector. Connector: A-05X

Relay box side

Relay box side

2

1

2

1

4

3

4

3

Front of vehicle

Front of vehicle

AC301483AC


AC301483AC

(1) Remove the fog lamp relay, and measure at the relay box side. (2) Check the voltage between the fog lamp relay connector and body earth.

Step 5. Check the fog lamp relay. Refer to GROUP 54A - Fog lamp 354A. Q: Is the check result normal? YES : Go to Step 6. NO : Replace the fog lamp relay.

2

1

4

3

Connector A-05X (Relay box side) AC301541AC

Voltage between A-05X fog lamp relay connector terminal No.1 and body earth Voltage between A-05X fog lamp relay connector terminal No.2 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 7.


54C-196

SYMPTOM PROCEDURES

Step 7. Check the wiring harness between A-05X fog lamp relay connector (terminal Nos. 1 and 2) and the battery.


Connector: A-05X

Relay box side

Relay box side 2

1

4

3

11 10 9 8 7 6 5 4 3 2 1

Front of vehicle AC301483 AD AC301483AC





Step 9. Check the wiring harness between A-05X fog lamp relay connector terminal No.3 and A11X front-ECU connector terminal No.11. Connectors: A-05X, A-11X

A-05X

-

Relay box side

2

1

4

3

A-11X 11 10 9 8 7 6 5 4 3 2 1

Front of vehicle

AC301483 AB

Check the output lines for open circuit. Q: Is the check result normal? YES : Go to Step 10. NO : Repair the wiring harness.

Step 10. Retest the system. Check that the fog lamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent


A-11X

A-05X

54C-197


54C-198

SYMPTOM PROCEDURES

INSPECTION PROCEDURE L-2: The rear front fog lamps do not illuminate normally.


REAR FOG LAMP RELAY


ETACS-ECU


OPERATION The ETACS-ECU operates this function in accordance with the input signals below. Tail lamp switch Headlamp switch Rear fog lamp switch If the rear fog lamps do not illuminate normally, these input signal circuit(s) or the ETACS-ECU may be defective. Possible causes Malfunction of the column switch Malfunction of the fog lamp switch Malfunction of the ETACS-ECU

SB : Sky blue


DIAGNOSIS PROCEDURE Step 1. Check that the tail lamps and headlamps operate. Check that the tail lamps and headlamps illuminate normally. Q: Is the check result normal? YES : Go to Step 2. NO : Check the tail lamps and the headlamps

(Refer to trouble symptom chart 354C).


54C-199

SYMPTOM PROCEDURES

Step 2. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU), the ETACS-ECU and the front-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU ETACS ECU FRONT ECU OK: "OK" is displayed for all the items Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 3. "NG" is displayed on the "COLUMN ECU" menu. :


Refer to Inspection Procedure A-3 "Communication with ETACS-ECU is impossible 354C." "NG" is displayed on the "FRONT ECU" menu. :

Refer to Inspection Procedure A-4 "Communication with front-ECU is impossible 354C." Step 3. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the fog lamps. LIGHTING - REAR FOG LAMP Ignition switch: ON Lighting switch: "TAIL" or "HEAD" Rear fog lamp switch: ON Item No. Item name

Normal conditions

Item 00

ON when the lighting switch is at HEAD

Item 01

HEADLAMP SW

TAIL LAMP SW


OK: Normal conditions are displayed for all the items. Q: Is the check result normal? Normal conditions are displayed for all the items. :


column switch (Lighting and turn-signal lamp switch) signal is not received 354C ."

Step 4. Pulse check Check the input signals below, which are related to the rear fog lamps. System switch

Check conditions




When the rear fog lamp switch is turned from off to on



Refer to inspection procedure N-2 "The ignition switch (IG1) signal is not received 354C." The rear fog lamp switch signal is not received. :

Refer to inspection procedure N-10 "The rear fog lamp switch signal is not received 354C." Step 5. Connector check: C-212 rear fog lamp relay connector Connector: C-212 Junction block (Front view)


AC210474 AI


Step 6. Check the rear fog lamp relay. Refer to GROUP 54A - Rear fog lamp 354A. Q: Is the check result normal? YES : Go to Step 7. NO : Replace the rear fog lamp relay.


54C-200

SYMPTOM PROCEDURES

Step 7. Measure the voltage at the C-212 rear fog lamp relay connector. Connector: C-212 Junction block (Front view)

Step 8. Check the wiring harness between C-212 rear fog lamp relay connector (terminal Nos. 3 and 4) and the battery. Connectors: C-201, C-204, C-205, C-212 Junction block (Front view) C-204


C-205

2 1 4 3

AC210474 AI


C-212

(1) Remove the rear fog lamp relay, and measure at the relay box side. (2) Check the voltage between the rear fog lamp relay connector and body earth.

2 1 4 3

Harness side C-201 C-204

5 4 3 2 1 13121110 9 8 7 6

Connector C-212 (Relay box side)

1

C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1

2 1 4 3

28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210475 AE

NOTE: AC301541 AR

Voltage between C-212 rear fog lamp relay connector terminal No.3 and body earth Voltage between C-212 rear fog lamp relay connector terminal No.4 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 9. NO : Go to Step 8.

Connector: C-116

1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Prior to the wiring harness inspection, check intermediate connector C-116 and junction block connectors C-201, C-204 and C-205, and repair if necessary. Check the power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-201

SYMPTOM PROCEDURES


Step 10. Check the wiring harness between C-212 rear fog lamp relay connector terminal No.2 and C-219 ETACS-ECU connector terminal No.74. Connectors: C-201, C-212 Junction block (Front view) C-201


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


C-212

Harness side

Junction block side

C-201

C-212

5 4 3 2 1 13121110 9 8 7 6

2 1 4 3

AC210475 AF



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE

NOTE: Prior to the wiring harness inspection, check junction block connector C-201, and repair if necessary. Check the output lines for open circuit. Q: Is the check result normal? YES : Go to Step 11. NO : Repair the wiring harness.

Step 11. Retest the system. Check that the rear fog lamps illuminate normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54C-202


INSPECTION PROCEDURE L-3: The front fog lamp(s) do not illuminate.


RELAY BOX



FRONT FOG LAMP (RH)

COMBINATION METER


COMMENTS ON TROUBLE SYMPTOM If any of the front fog lamps do not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.

SB : Sky blue

Possible causes Burned-out front fog lamp bulb Damaged harness wires and connectors


DIAGNOSIS PROCEDURE Step 1. Connector check: A-24 or A-19 front fog lamp connector, or C-05 combination meter connector Connector: A-19


AC210455 AE

Connector: A-24

Harness side 2 1

A-24(B) AC210453 AB

Connector: C-05

C-05(L)


G

G

AC301395 AE


54C-203

Step 2. Check the bulbs of the front fog lamps or the front fog lamp indicator lamp. Check the bulb(s) of the defective lamp. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb(s) of the defective lamp.


54C-204

SYMPTOM PROCEDURES

Step 3. Measure the resistance at A-24 or A-19 front fog lamp connector, or C-05 combination meter connector.



Connector: A-19 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

Harness side A-19(B)

AC301541 AP

2 1

AC210455 AE

Connector: A-24


Harness side 2 1

A-24(B) AC210453 AB

Connector: C-05

C-05(L)


G

G

AC301395 AE



2 1 AC301541 AJ



Step 4. Check the wiring harness from A-24 or A-19 front fog lamp connector terminal No.2 or C-05 combination meter connector terminal No.12 to body earth.

54C-205


Connector: A-19


AC210455 AE

Relay box side

Connector: A-24

2

1

4

3

Front of vehicle

Harness side

AC301483AC

2 1

A-24(B) AC210453 AB

Connector: C-05

C-05(L)


G

G

AC301395 AE





54C-206

SYMPTOM PROCEDURES

Step 6. Check the wiring harness from A-24 or A-19 front fog lamp connector terminal No.1 or C-05 combination meter connector terminal No.7 to A05X fog lamp relay connector terminal No.4. Connector: A-19


Step 7. Retest the system. Check that the fog lamp and the front fog lamp indicator lamp illuminate normally. Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent


AC210455 AE

Connector: A-24

Harness side 2 1

A-24(B) AC210453 AB


C-116 C-116 1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

Harness side C-05 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301396 AJ


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). The fog lamps do not illuminate. : Replace the fog lamp(s). The front fog lamp indicator lamp does not illuminate. : Replace the combination meter.


54C-207

SYMPTOM PROCEDURES

INSPECTION PROCEDURE L-4: Any of the rear fog lamps does not illuminate.


REAR FOG LAMP RELAY


ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM If any of the rear fog lamps do not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.

SB : Sky blue

Possible causes Burned-out rear fog lamp bulb Damaged harness wires and connectors


54C-208

SYMPTOM PROCEDURES

DIAGNOSIS PROCEDURE Step 1. Connector check: F-12 rear fog lamp connector or C-05 combination meter connector Connector: C-05

C-05(L)


G

G

AC301395 AE

Connector: F-12 Harness side 2 1

F-12(B)

AC301665 AD


Step 2. Check the bulbs of the rear fog lamps or the rear fog lamp indicator lamp. Check the bulb(s) of the defective lamp. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb(s) of the defective lamp.


54C-209

SYMPTOM PROCEDURES

Step 3. Measure the resistance at the F-12 rear fog lamp connector or C-05 combination meter connector. Connector: C-05


C-05(L)

Step 4. Check the wiring harness from F-12 rear fog lamp connector terminal No.1, C-05 combination meter connector terminal No.12 to body earth.


G

indicator lamp> combination meter connector terminal No.12 and body earth OK: 2 W or less

G

AC301395 AE

Connector: C-05

Harness side


C-05(L)

Connector: F-12

2 1 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

F-12(B)

AC301395 AE

AC301665 AD




F-12(B)

2 1

F-09(GR)

Harness side F-09

F-12

AC301541BN

Resistance between F-12 rear fog lamp relay connector terminal No.1 and body earth Connector C-05 (Harness side)

2 1

AC301666 AF

NOTE: Prior to the wiring harness inspection, check intermediate connector F-09 , and repair if necessary. Check the earth wires for open circuit.

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

1 2 3 4

G

Q: Is the check result normal? YES : The trouble can be an intermittent AC301541 AP

Resistance between C-05

54C-210




AC210474 AI



54C-211

SYMPTOM PROCEDURES

Step 6. Check the wiring harness from F-12 rear fog lamp connector terminal No.2, C-05 combination meter connector terminal No.5 to C-212 rear fog lamp relay connector terminal No.1. Connector: C-05


C-05(L)

C-117 Harness side (front view) C-117 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

1 2 3

4 5 6 7 8 9 10

111213

14 1516 17 18 19 20 2122 232425

G

AC301395 AE

26 2728 29 32 33 34

35

30 31 36 37

38

Harness side C-05


11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

C-201

G

G

AC301396 AK

NOTE: Prior to the wiring harness inspection, check intermediate connector C-117 , F-09 and junction block connector C-201 , and repair if necessary. Check the output lines for open circuit.

C-212

Harness side

Junction block side

C-201

C-212

5 4 3 2 1 13121110 9 8 7 6

2 1 4 3

AC210475 AF


Step 7. Retest the system. Check that the rear fog lamp and the rear fog lamp indicator lamp illuminate normally. Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). The rear fog lamps do not illuminate. : Replace the rear fog lamp(s). The rear fog lamp indicator lamp does not illuminate. : Replace the combination meter.


54C-212

SYMPTOM PROCEDURES

ROOM LAMP

INSPECTION PROCEDURE M-1: The front or rear room lamp does not illuminate or extinguish normally.


ETACS-ECU

REAR ROOM LAMP

FRONT ROOM LAMP


COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) All of the door switches Key reminder switch Driver’s door lock actuator

SB : Sky blue

If this function does not work normally, these input signal circuit(s) or the ETACS-ECU may be defective. Possible causes Malfunction of the door switches Malfunction of the driver’s door lock actuator Malfunction of the ETACS-ECU Damaged harness wires and connectors



"Communication with ETACS-ECU is impossible 354C." Step 2. Check the data list by using the SWS monitor. Check the input signals below, which are related to the front and rear dome lamps. ETACS ECU Ignition switch: OFF Item No.

Item name

Normal conditions

Item 30

IG SW(IG1)

OFF



54C-213

Step 3. Pulse check Check the input signals below, which are related to the front or rear dome lamps. System switch

Check conditions

Key reminder switch When the inserted ignition key is pulled out All of the door switches








"The driver’s door lock actuator switch signal is not received 354C."


54C-214

SYMPTOM PROCEDURES


Harness side


1 2

Junction block side

AC301408 AB

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

Connector: D-11

AC210476 AC

D-11(GR)

Connector: D-05

Harness side 2 1

Harness side 1 2

AC301410 AD


Step 5. Check the bulbs of the front and rear room lamps. Check the bulbs of the front and rear room lamps. Q: Is the check result normal? YES : Go to Step 6. NO : Replace the front or rear room lamp bulb.

AC301408 AB


Harness side 3 2 1


AC210474 AH



AC210476 AC




54C-215




AC210476 AC


AC301410 AD


Harness side 3 2 1

AC210474 AH




54C-216

SYMPTOM PROCEDURES

INSPECTION PROCEDURE M-2: The front and rear room lamp do not illuminate or extinguish normally.


ETACS-ECU

REAR ROOM LAMP

FRONT ROOM LAMP


COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Key reminder switch All of the door switches Driver’s door lock actuator Interior lamp loaded signal

SB : Sky blue

If this function does not work normally, these input signal circuit(s), the interior lamp automatic shutdown function or the ETACS-ECU may be defective. The delay-off setting of this function can be changed by the adjustment function (default setting; 15 seconds). Possible causes Malfunction of the key reminder switch Malfunction of the door switches Malfunction of the driver’s door lock actuator Malfunction of the ETACS-ECU Damaged harness wires and connectors


DIAGNOSIS PROCEDURE Step 1. Check the adjustment function. Check that the room lamp delay-off time has been set to other than "0 second" by the adjustment function. Q: Is the check result normal? YES : Go to Step 2. NO : Use the adjustment function to set the room

lamp delay-off time to other than "0 second" (Refer to GROUP 54B - Adjustment function 354B). Step 2. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu. Q: Is the check result normal? YES : Go to Step 3. NO : Refer to Inspection Procedure A-3

"Communication with ETACS-ECU is impossible 354C." Step 3. Check the data list by using the SWS monitor. Check the input signals below, which are related to the front and rear dome lamps. ETACS ECU Ignition switch: OFF Item No.

Item name

Normal conditions

Item 30

IG SW(IG1)

OFF



54C-217

Step 4. Pulse check Check the input signals below, which are related to the front or rear dome lamps. System switch

Check conditions

Key reminder switch When the inserted ignition key is pulled out All of the door switches










"The driver’s door lock actuator switch signal is not received 354C." The interior lamp loaded signal is not received. :

Refer to inspection procedure N-17 "Interior lamp loaded signal is not detected 354C ."


54C-218

SYMPTOM PROCEDURES


Harness side


1 2

Junction block side

AC301408 AB

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

Connector: D-11

AC210476 AC

D-11(GR)

Connector: D-05

Harness side 2 1

Harness side 1 2

AC301410 AD


Step 6. Check the bulbs of the front and rear dome lamps. Check the bulbs of the front and rear dome lamps. Q: Is the check result normal? YES : Go to Step 7. NO : Replace the front or rear room lamp bulb.

AC301408 AB


Harness side 3 2 1


AC210474 AH



AC210476 AC




54C-219




AC210476 AC


AC301410 AD


Harness side 3 2 1

AC210474 AH



54C-220


INSPECTION PROCEDURE M-3: Interior lamp automatic shutoff function does not work normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Interior Lamp Automatic Shut-off Function Circuit FUSIBLE LINK 1

ETACS-ECU INPUT SIGNAL ·ALL DOOR SWITCH ·FRONT DOOR SWITCH ·IGNITION SWITCH (ACC) ·IGNITION SWITCH (IG1) ·INTERIOR LAMP LOADED SIGNAL

KEEP RELAY


INTERIOR LAMP CUT BACK-UP CIRCUIT

COMBINATION METER

COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU operates the interior lamp automatic shutdown function in accordance with the input signals below. Ignition switch (ACC) Ignition switch (IG1) Driver’s door switch All of the door switches Interior lamp loaded signal If this function does not work normally, these input signal circuit(s) or the ETACS-ECU may be defective. Note that this function can be disabled/ enabled by the adjustment function (default setting; enabled). Possible causes Malfunction of the door switches

· FRONT ROOM LAMP · REAR ROOM LAMP

Malfunction of the room lamp Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the adjustment function. Check that the interior lamp automatic shutdown function has been enabled by using the adjustment function. Q: Is the check result normal? YES : Go to Step 2. NO : Enable the interior lamp automatic

shutdown function by using the adjustment function (Refer to GROUP 54B Adjustment function 354B).



"Communication with ETACS-ECU is impossible 354C." Step 3. Check the data list by using the SWS monitor. Check the input signals below, which are related to the interior lamp automatic shutdown function.

54C-221

Step 4. Pulse check Check the input signals below, which are related to the interior lamp automatic shutdown function. System switch

Check conditions






5. All the door switch signals are not received. :

Refer to inspection procedure N-13 "All the door switch signals are not received 354C ." The interior lamp loaded signal is not received. :

Refer to inspection procedure N-17 "Interior lamp loaded signal is not detected 354C ."

ETACS ECU Ignition switch: OFF Driver’s door: open Item No.

Item name

Normal conditions

Item 30

IG SW(IG1)

OFF

Item 31

IG SW(ACC)

OFF

Item 32

DR DOOR SW

ON

OK: Normal condition is displayed. Q: Is the check result normal? Normal conditions are displayed for all the items. :

Go to Step 4. Normal condition is not displayed for item No.30. :


Refer to inspection procedure N-1 "The ignition switch (ACC) signal is not received 354C." Normal condition is not displayed for item No.32. :

Refer to inspection procedure N-4 "The driver’s door switch signal is not received 354C."

Step 5. Retest the system. Check that the interior lamp automatic shutdown function works normally. Q: Is the check result normal? YES : The trouble can be an intermittent


54C-222


INSPECTION PROCEDURE M-4: The door-ajar warning lamp does not illuminate/extinguish normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. Door Ajar Indicator Lamp Circuit ETACS-ECU

INPUT SIGNAL COMBINATION METER

· ALL DOOR SWITCH · FRONT DOOR SWITCH


OPERATION The ETACS-ECU operates this function in accordance with all the door switch signals. If the door-ajar warning lamp does not work normally, the input signal circuits from all the door switches or the ETACS-ECU may be defective. Possible causes All the door switches are defective. Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the operation of the room lamp. Check that the dome lamps illuminate and extinguish normally. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure M-1 "The

front or rear room lamp does not illuminate/ extinguish 354C ." Or refer to inspection procedure M-2 "The front or rear room lamp does not illuminate/extinguish 354C ."

SB : Sky blue

Step 2. Check the data list by using the SWS monitor. Check the input signals below, which are related to the door-ajar warning lamp. ETACS ECU Driver’s door: open Item No.

Item name

Normal conditions

Item 32

DR DOOR SW

ON


driver’s door switch signal is not received 354C."


54C-223

SYMPTOM PROCEDURES

Step 3. Pulse check Check the input signals below, which are related to the door-ajar warning lamp. System switch

Check conditions





Harness side

Q: Is the check result normal? YES : Go to Step 4. NO : Refer to inspection procedure N-13 "All the

door switch signals are not received 354C ." Step 4. Connector check: C-05 combination meter connector Connector: C-05

C-05(L)


C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


Step 7. Check the wiring harness from C-219 ETACS-ECU connector (terminal Nos. 53 and 71) to C-05 combination meter connector (terminal Nos. 20 and 21). Connector: C-05

C-05(L)

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G


G

AC301395 AE


Step 5. Check the door-ajar warning lamp bulb. Check the door-ajar warning lamp bulb.

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301395 AE


Q: Is the check result normal? YES : Go to Step 6. NO : Replace the door-ajar warning lamp bulb.


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE



54C-224


Step 8. Retest the system. Replace the ETACS-ECU, and then check that the door-ajar warning lamp illuminates/extinguishes normally. (1) Replace the ETACS-ECU. (2) Check that the door-ajar warning lamp illuminates/extinguishes normally. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the combination meter.


INSPECTION PROCEDURE N-1: The ignition switch (ACC) signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Ignition Switch (ACC) Input Circuit IGNITION SWITCH (ACC)

ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM Input signal from the ignition switch (ACC) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Windshield wiper and washer Rear wiper and washer

SB : Sky blue

Interior lamp automatic shutdown function Possible causes Malfunction of the ETACS-ECU Damaged harness wires and connectors


54C-225


DIAGNOSIS PROCEDURE Step 1. Connector check: C-217 ETACS-ECU connector Connector: C-217 Junction block (Rear view)




AC210476 AC


AC210476 AC



Harness side


2 1 6 5 4 3

AC210474 AC

Prior to the wiring harness inspection, check junction block connector C-203, and repair if necessary. Check the power supply line for open circuit. Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Ignition switch: ACC position


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 4. Check the data list by using the SWS monitor. ETACS ECU Ignition switch: ACC


Item No.

Item name

Normal conditions

Item 31

IG SW(ACC)

ON

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1

OK: Normal condition is displayed. AC301541AV




54C-226

SMART WIRING SYSTEM (SWS) USING SWS MONITOR INPUT SIGNAL PROCEDURES

INSPECTION PROCEDURE N-2: The ignition switch (IG1) signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Ignition Switch (IG1) Input Circuit IGNITION SWITCH (IG1)

ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM Input signal from the ignition switch (IG1) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Ignition key cylinder illumination lamp Headlamp automatic shutdown function Turn signal lamp Room lamps Possible causes Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSIS PROCEDURE Step 1. Connector check: C-217 ETACS-ECU connector Connector: C-217 Junction block (Rear view)


AC210476 AC



54C-227





20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Ignition switch: ON position

AC210476 AC




AC210474 AC AC301541AW



malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 4. Check the data list by using the SWS monitor. ETACS ECU Ignition switch: ON Item No.

Item name

Normal conditions

Item 30

IG SW(IG1)

ON

OK: Normal condition is displayed. Q: Is the check result normal? YES : The trouble can be an intermittent


54C-228


INSPECTION PROCEDURE N-3: The back-up lamp switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Back-up Lamp Switch Input Circuit IGNITION SWITCH (IG1)

BACK-UP LAMP SWITCH

ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM Input signal from the back-up lamp switch is used to operate the rear wiper. If the signal is abnormal, the rear wiper will not work normally.

SB : Sky blue



54C-229


DIAGNOSIS PROCEDURE


Step 1. Connector check: B-114 back-up lamp switch connector and C-220 ETACS-ECU connector


Connector: B-114

Harness side Harness side 2 1

:

B-114(B)

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

AC210476 AF

AC301521 AB


(1) Disconnect the connector, and measure at the wiring harness side. (2) Ignition switch: ON (3) Shift lever: R position Connector C-220 (Harness side)

Harness side

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210476 AF AC301541BA


Step 2. Check the back-up lamp switch Check the back-up lamp switch (Refer to GROUP 22B - Transmission 322B). Q: Is the check result normal? YES : Go to Step 3. NO : Replace the inhibitor switch.

(4) Voltage between C-220 ETACS-ECU connector terminal No.39 and body earth OK: System voltage Q: Is the check result normal? YES : Replace the ETACS-ECU. NO : Go to Step 4.


54C-230


Step 4. Measure the voltage at the B-114 back-up lamp switch connector. Connector: B-114

Step 5. Check the wiring harness between B-114 back-up lamp switch connector terminal No.1 and C-220 ETACS-ECU connector terminal No.39. Connector: B-114

Harness side :

Harness side

2 1

2 1

: B-114(B)

AC301521 AB


B-114(B)

AC301521 AB



Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

2 1

AC210476 AF

AC301541AK

(3) Voltage between B-114 back-up lamp switch connector terminal No.2 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 6.


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

AC301395 AC

Connector: C-105

1 2 3 4 5 6 7 8 9 10 11 12 13 1415 16 1718 19 20 21 22

AC301397AF

Prior to the wiring harness inspection, check joint connector C-02 and intermediate connector C-105, and repair if necessary. Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.


54C-231


Step 6. Check the wiring harness between B-114 back-up lamp switch connector terminal No.2 and the ignition switch (IG1). Connector: B-114

Harness side 2 1

:

B-114(B)


malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 7. Check the data list by using the SWS monitor. ETACS ECU Ignition switch: ON Shift lever: R position Item No.

Item name

Item 41

INHIBITOR SW ON

AC301521 AB


Normal conditions

OK: Normal condition is displayed.

C-106(GR)

2 1 3 4 5 6 10 11 12 7 8 9 13 14 15 16 17 18 19

AC301397AG


C-202

Harness side C-202 6 5 4 3 2 1 14 13 12 11 10 9 8 7

C-203 2 1 6 5 4 3

AC210475 AG

Prior to the wiring harness inspection, check intermediate connector C-106, junction block connectors C-202 and C-203, and repair if necessary. Check the power supply line to the ignition switch (IG1) for open circuit.




54C-232


INSPECTION PROCEDURE N-4: The driver’s door switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Driver's Door Switch Input Circuit

ETACS-ECU



COMMENTS ON TROUBLE SYMPTOM Input signal from the driver’s door switch is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Key reminder function Ignition key cylinder illumination lamp Headlamp automatic shutdown function Room lamps Door-ajar indicator lamp

SB : Sky blue

Step 2. Connector check: D-28 door switch (front, LH) connector Connector: D-28

Harness side 3 2 1

Possible causes Malfunction of the driver’s door switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the installation condition. Check that the door switch (front, LH) is installed on the body correctly. Q: Is the check result normal? YES : Go to Step 2. NO : Correct the installation condition.

AC301410 AF


Step 3. Check the door switch (front, LH). Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 4. NO : Replace the door switch (front, LH).


54C-233



Step 5. Check the wiring harness between D-28 door switch (front, LH) connector terminal No.3 and C-217 ETACS-ECU connector terminal No.10. Connector: C-217 Junction block (Rear view)


20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

AC210476 AC


Connector: D-28

Harness side 3 2 1

AC301410 AF


Harness side 7 6 5 15 1413

12

4 3 2 1 11 10 9 8

AC210474 AG

Prior to the wiring harness inspection, check joint connector C-209, and repair if necessary. Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness.


54C-234


Step 6. Check the data list by using the SWS monitor. ETACS ECU Driver’s door: open Item No.

Item name

Normal conditions

Item 32

DR DOOR SW

ON



INSPECTION PROCEDURE N-5: The column switch (lighting, turn-signal lamp and headlamp washer switch) signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Lighting Switch Input Circuit COLUMN SWITCH COLUMN-ECU

LO

HI PASS

LH

DIMMER· PASSING SWITCH

OFF

RH

TURN-SIGNAL LAMP SWITCH

COMMENTS ON TROUBLE SYMPTOM Input signal from the column switch (lighting, turnsignal lamp and headlamp washer switch) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Headlamp and tail lamp Headlamp automatic shutdown function Fog lamp Turn signal lamp Headlamp washer Possible causes Malfunction of the column switch

OFF

HEAD HEAD OFF TAIL TAIL

LIGHTING SWITCH


DIAGNOSIS PROCEDURE Step 1. Check the column switch connector. Check that the wiper and washer switch connector, the lighting switch connector and the switch body connector are in good condition. Q: Is the check result normal? YES : Go to Step 2. NO : Repair the defective connector.


Step 2. Check the column switch (lighting switch and switch body). Refer to GROUP 54A - Column switch 354A. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the column switch.

Step 3. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU OK: "OK" is displayed on the "COLUMN ECU" menu. Q: Is the check result normal? YES : Go to Step 4. NO : Refer to Inspection Procedure A-2

54C-235

Step 4. Check the data list by using the SWS monitor. COLUMN ECU Operate each function of the switch. Item No.

Item name

Normal conditions

Item 00

HEADLAMP SW

ON

Item 01

TAIL LAMP SW

ON

Item 02

DIMMER SW

ON

Item 03

PASSING SW

ON

Item 10

TURN SIG.RH

ON

Item 11

TURN SIG.LH

ON

Item 16

HD WASHER SW

ON

OK: Normal conditions are displayed for all the functions of the switch. Q: Is the check result normal? YES : The trouble can be an intermittent

"Communication with column switch (column-ECU) is impossible 354C."


INSPECTION PROCEDURE N-6: The column switch (windshield wiper washer and rear wiper washer switch) signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Windshield Wiper and Washer Switch Input Circuit COLUMN SWITCH COLUMN-ECU

UPPER SIDE

WINDSHIELD WIPER SWITCH

WINDSHIELD WASHER SWITCH

REAR WIPER SWITCH

REAR WASHER SWITCH

54C-236


COMMENTS ON TROUBLE SYMPTOM Input signal from the column switch (wiper switch) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Windshield wiper and washer Rear wiper and washer Possible causes Malfunction of the column switch Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU OK: "OK" is displayed on the "COLUMN ECU" menu. Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure A-2

"Communication with column switch (column-ECU) is impossible 354C."

Step 2. Check the data list by using the SWS monitor. COLUMN ECU Operate each function of the switch. Item No.

Item name

Normal conditions

Item 05

INT WIPER SW

ON

Item 06

LO WIPER SW

ON

Item 07

HI WIPER SW

ON

Item 08

MIST WIPER SW

ON

Item 09

FRONT WASH.SW

ON

Item 13

REAR WIPER SW

ON

Item 14

REAR WASH.SW

ON

OK: Normal conditions are displayed for all the functions of the switch. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-237


INSPECTION PROCEDURE N-7: The windshield intermittent wiper volume signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Windshield Intermittent Wiper Interval Adjusting Knob Input Circuit ETACSECU

COLUMN SWITCH

WINDSHIELD INTERMITTENT WIPER INTERVAL ADJUSTING KNOB

UPPER SIDE


COMMENTS ON TROUBLE SYMPTOM The intermittent wiper interval is calculated in accordance with the input signal from the windshield intermittent wiper volume. If this signal is abnormal, the wiper interval can not be adjusted. Possible causes Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSIS PROCEDURE Step 1. Connector check: C-310 column switch connector Connector: C-310

Harness side 5 4 3 2 1 10 9 8 7 6

AC301399 AC



54C-238


Step 2. Measure the resistance at the C-310 column switch connector. Connector: C-310

Step 4. Check the wiring harness between C-310 column switch connector terminal No.6 and C219 ETACS-ECU connector terminal No.66. Connector: C-219 Junction block (Rear view)

Harness side

Harness side

5 4 3 2 1 10 9 8 7 6

C-219(GR)

AC301399 AC

(1) Disconnect the connector, and measure at the column switch side.

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE

Connector: C-310

Connector C-310 (Harness side) 5 4 3 2 1 10 9 8 7 6

Harness side 5 4 3 2 1 10 9 8 7 6

AC301399 AC

AC301541BC

(2) Resistance between C-310 column switch connector terminal No.6 and body earth OK: The resistance should rise from 0 to 1 kW when the windshield intermittent wiper volume is rotated from "Fast" to "Slow". Q: Is the check result normal? YES : Go to Step 3. NO : Replace the column switch.



Step 5. Check the data list by using the SWS monitor. ETACS ECU Ignition switch: ACC Wiper switch: INT Item No.

Item name

Normal conditions

Item 37

INT WIPE TIME

2.4 to 18.0 s

OK: The display will be changed as the intermittent wiper volume is rotated. Q: Is the check result normal? YES : The trouble can be an intermittent Harness side

C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE




54C-239

INSPECTION PROCEDURE N-8: When the power window main switch is operated, the switch signals are not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Power Window Main Switch Input Circuit

FUSIBLE LINK 5

ETACS-ECU

POWER WINDOW RELAY

FRONT SIDE

DIAGNOSIS CONNECTOR



SB : Sky blue


54C-240


COMMENTS ON TROUBLE SYMPTOM Input signal from the power window main switch is used in order to check the power window main switch and confirm how the system is communicating with the ETACS-ECU. If the communication line is defective, the power windows will not work normally.

Step 3. Check the wiring harness between C-219 ETACS-ECU connector terminal No.59 and E-05 power window main switch connector terminal No.4. Connector: C-219 Junction block (Rear view)

Possible causes Malfunction of the power window main switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE


Step 1. Check the operation by using the power window main switch. Check if each window can be operated by means of the power window main switch.

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE


Q: Can each power window be operated by means of the power window main switch? YES : Go to Step 2. NO : Go to Step 5.

E-05

E-12

Step 2. Connector check: C-219 ETACS-ECU connector and E-05 power window main switch connector Connector: C-219 Junction block (Rear view)

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC

AC210476 AE

Connector: E-05

Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC



NOTE:

54C-241


Connectors : C-02, C-118

Connector: E-05 C-02

C-118

Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC

C-02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

C-118


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32


AC301396 AG


Step 4. Replace the power window main switch, and then retest the system. Replace the power window main switch, and check that the power window main switch signal is received. (1) Replace the power window main switch. (2) Check that the power window main switch signal is received. Q: Is the check result normal? YES : The procedure is complete. NO : Replace the ETACS-ECU.

Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC



6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301541BH


54C-242





AC210474 AF

C-208

Q: Is the check result normal? YES : Go to Step 8. NO : Repair the defective connector. Harness side

Junction block side

C-203

C-208 3 2 1 4 5

2 1 6 5 4 3

AC210475 AI


E-05

E-12

E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7

E-12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC


54C-243

INPUT SIGNAL PROCEDURES Q: Is the check result normal? YES : Go to Step 11. NO : Go to Step 10.


Step 10. Check the wiring harness between E-05 power window main switch connector terminal No.2 and body earth.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

Connectors: E-05, E-12 AC301395 AH

E-05


E-12



E-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7


E-12

Connector: E-05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC301419 AC

NOTE:

Harness side

Connector: C-118

6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC301418 AC 1 2 3 4 5 6 7 8 9 10 11



12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

AC301395 AH


6 5 4 3 2 1 14 13 12 11 10 9 8 7 AC301541BI

(2) Continuity between E-05 power window main switch connector terminal No.2 and body earth OK: 2W or less




54C-244


Step 11. Check the data list by using the SWS monitor. Fr-ECU, P/W, S/R Ignition switch: ON Item No.

Item name

Normal conditions

Item 71

P/W ECU ACK

INPUT CHECK

OK: Normal conditions are displayed for all the positions of the switch. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE N-9: The front fog lamp switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Front Fog Lamp Switch Input Circuit ETACSECU

FOG LAMP SWITCH

NOTE : WITHOUT REAR FOG LAMP : WITH REAR FOG LAMP


COMMENTS ON TROUBLE SYMPTOM Input signal from the front fog lamp switch is used to operate the front fog lamps. If the signal is abnormal, the front fog lamps will not illuminate and extinguish normally.

SB : Sky blue

Possible causes Malfunction of the front fog lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors


DIAGNOSIS PROCEDURE

54C-245


Step 1. Connector check: C-03 fog lamp switch connector

Connector: C-03

Connector: C-03


Harness side AC301395 AD

6 5 4 3 2 1

AC301395 AD


(1) Remove the fog lamp switch, and measure at the wiring harness side. Connector C-03 (Harness side) 6 5 4 3 2 1

Step 2. Check the front fog lamp switch. Refer to GROUP 54A - Front fog lamp switch 354A . Q: Is the check result normal? YES : Go to Step 3. NO : Replace the fog lamp switch.

*2

*1

Note *1: Without rear fog lamp *2: With rear fog lamp

AC301541 AM

(2) Continuity between C-03 fog lamp switch connector terminal No.2 or 6 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.


54C-246


Step 4. Check the wiring harness from C-03 fog lamp switch connector terminal No.2 or 6 to body earth. Connector: C-03

Step 6. Check the wiring harness from C-219 ETACS-ECU connector No.54 to C-03 fog lamp switch connector terminal No.1 or 5 . Connector: C-03


6 5 4 3 2 1

6 5 4 3 2 1

AC301395 AD AC301395 AD



malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Harness side


C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69


AC210476 AE



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69


Step 7. Check the data list by using the SWS monitor.

AC210476 AE


ETACS ECU Ignition switch: ON Lighting switch: "TAIL" or "HEAD" Front fog lamp switch: ON Item No.

Item name

Normal conditions

Item 36

F.FOG LAMP

ON




54C-247


INSPECTION PROCEDURE N-10: The rear fog lamp switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Rear Fog Lamp Switch Input Circuit ETACSECU

FOG LAMP SWITCH


COMMENTS ON TROUBLE SYMPTOM Input signal from the rear fog lamp switch is used to operate the rear fog lamps. If the signal is abnormal, the rear fog lamps will not illuminate and extinguish normally. Possible causes Malfunction of the fog lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSIS PROCEDURE Step 1. Connector check: C-03 fog lamp switch connector Connector: C-03


AC301395 AD


Step 2. Check the rear fog lamp switch. Refer to GROUP 54A - Rear fog lamp 354A. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the fog lamp switch.

54C-248




Connector: C-03

Harness side

Harness side

6 5 4 3 2 1

C-219(GR) AC301395 AD

(1) Remove the fog lamp switch, and measure at the wiring harness side. Connector C-03 (Harness side)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


Step 6. Check the wiring harness between C-219 ETACS-ECU connector terminal No.21 and C-03 fog lamp switch connector terminal No.1.

6 5 4 3 2 1

Connector: C-03

AC301541 AN

(2) Continuity between C-03 fog lamp switch connector terminal No.2 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.


AC301395 AD


Step 4. Check the wiring harness between C-03 fog lamp switch connector terminal No.2 and body earth. Harness side

Connector: C-03

C-219(GR)

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

Harness side


6 5 4 3 2 1

AC301395 AD





54C-249

Step 7. Pulse check Check the input signal from the rear fog lamp switch. System switch

Check conditions



OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? YES : The trouble can be an intermittent


INSPECTION PROCEDURE N-11: The key reminder switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Key Reminder Switch Input Circuit ETACSECU

KEY REMINDER SWITCH WHEN REMOVING KEY: ON


COMMENTS ON TROUBLE SYMPTOM Input signal from the key reminder switch is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Key reminder function Keyless entry system Ignition key cylinder illumination lamp

SB : Sky blue

Room lamps Possible causes Malfunction of the key reminder switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

54C-250


DIAGNOSIS PROCEDURE

Step 3. Measure the resistance at the C-304 key reminder switch connector.

Step 1. Connector check: C-304 key reminder switch connector

Connector: C-304

Connector: C-304



AC301399 AB


Step 2. Check the key reminder switch. Refer to GROUP 54A - Ignition switch 354A.

AC301399 AB


Connector C-304 (Harness side) 2 1 7 6 5 4 3

Q: Is the check result normal? YES : Go to Step 3. NO : Replace the key reminder switch.

AC301541 BB

(2) Resistance between C-304 key reminder switch connector terminal No.4 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

Step 4. Check the wiring harness between C-304 key reminder switch connector terminal No.4 and the body earth. Connector: C-304


AC301399 AB




54C-251



Step 6. Check the wiring harness between C-304 key reminder switch connector terminal No.6 and C-220 ETACS-ECU connector terminal No.30. Connector: C-220 Junction block (Rear view)


29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

AC210476 AF

AC210476 AF


Connector: C-304


AC301399 AB


Step 7. Pulse check Check the input signal from the key reminder switch. System switch

Check conditions

Key reminder switch





54C-252


INSPECTION PROCEDURE N-12: The hazard warning lamp switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Hazard Warning Lamp Switch Input Circuit ETACSECU



COMMENTS ON TROUBLE SYMPTOM Input signal from the hazard warning lamp switch is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Keyless entry system (encrypted code registration) Hazard warning lamp Possible causes Malfunction of the hazard warning lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSIS PROCEDURE Step 1. Connector check: C-22 hazard warning lamp switch connector Connector: C-22


AC301395 AI


Step 2. Check the hazard warning lamp switch. Refer to GROUP 54A - Hazard warning lamp switch 354A. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the hazard warning lamp switch.


54C-253


Step 3. Measure the resistance at the C-22 hazard warning lamp switch connector.


Connector: C-22

Harness side

Harness side

4 3 2 1

C-219(GR) AC301395 AI



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC210476 AE


Step 6. Check the wiring harness between C-219 ETACS-ECU connector terminal No.55 and C-22 hazard warning lamp switch connector terminal No.1.

4 3 2 1

Connector: C-22 AC301541 AZ

(2) Resistance between C-22 hazard warning lamp switch connector terminal No.2 and body earth OK: 2 W or less



AC301395 AI

Step 4. Check the wiring harness between C-22 hazard warning lamp switch connector terminal No.2 and the body earth.


Connector: C-22

Harness side C-219(GR) Harness side

59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE

4 3 2 1

Check the input line for open circuit. AC301395 AI




54C-254



Check conditions






54C-255

INSPECTION PROCEDURE N-13: All the door switch signals are not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. All Door Switches Input Circuit

ETACS-ECU

FRONT DOOR SWITCH (RH)

REAR DOOR SWITCH (RH)

TAILGATE REAR DOOR SWITCH SWITCH (LH)


COMMENTS ON TROUBLE SYMPTOM Input signals from all the door switches are used to operate the functions below. If the signal(s) are abnormal, these functions will not work normally. Keyless entry system Room lamps


SB : Sky blue

Possible causes Malfunction of the door switches Malfunction of the ETACS-ECU Damaged harness wires and connectors


54C-256


DIAGNOSIS PROCEDURE

Connectors: D-10, D-20, D-28

Step 1. Check the data list by using the SWS monitor. ETACS ECU Driver’s door is open

D-01

Item No.

Item name

Normal conditions

Item 32

DR DOOR SW

ON

D-20 D-28


driver’s door switch signal is not received 354C." Step 2. Connector check: D-28 , D-42 , D-10 or D-20 door switch connectors or F-07 tailgate switch connector, and C-217 ETACS-ECU connector

Harness side D-01

D-20

D-28

3 2 1

3 2 1

3 2 1

AC301411AC

Connector: D-42


Harness side 3 2 1

Junction block side

AC301408 AF

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC

Connector: F-07 Harness side 1

F-07(B)

AC301665 AC


Step 3. Check the installation condition. Check that the door switch is installed on the body correctly. Q: Is the check result normal? YES : Go to Step 4. NO : Correct the installation condition.


54C-257


Step 4. Check the door switch. Refer to GROUP 42 - Door 342.

Connector: D-42

Q: Is the check result normal? YES : Go to Step 5. NO : Replace the door switch.

Harness side 3 2 1

Step 5. Check the wiring harness from terminal No.2 of the D-28 , D-42 , D10 or D-20 door switch connector or terminal No.1 of the F-07 tailgate switch connector to terminal No.7 of the C-217 ETACS-ECU connector.

AC301408 AF



F-05

F-07(B)


AC210476 AC

Harness side Connectors: D-10, D-20, D-28

F-05

F-07

1 2 3 4 5 6 7 8 9 10

1

D-01 D-20

AC301666 AC

D-28

Harness side D-01

D-20

D-28

3 2 1

3 2 1

3 2 1

AC301411AC


54C-258


NOTE:

Step 6. Pulse check Check the input signals from all the door switches.

Connector: C-13

C-13(L)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

AC301397AB

C-205

C-209

Harness side

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-209 7 6 5 15 1413

Check conditions






C-205

System switch

12

4 3 2 1 11 10 9 8

AC210475 AK

Prior to the wiring harness inspection, check intermediate connector F-05 or C-13 and junction block connector C-205 or C-209 , and repair if necessary. Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness between each of

the door switches and the ETACS-ECU.


54C-259

INSPECTION PROCEDURE N-14: The driver’s door lock actuator switch signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Door Lock Actuator Input Circuit

ETACS-ECU

DOOR LOCK ACTUATOR (FRONT: LH)

COMMENTS ON TROUBLE SYMPTOM Input signal from the driver’s door lock actuator is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Key reminder function Central door locking Keyless entry system Room lamps Possible causes Malfunction of the front door lock actuator (LH) Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Connector check: E-11 front door lock actuator (LH) connector Connector: E-11


AC301418 AD



54C-260


Step 2. Check the front door lock actuator (LH). Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the front door lock actuator (RH).

Step 4. Check the wiring harness between E-11 front door lock actuator (LH) connector terminal No.1 and body earth Connector: E-11

Step 3. Measure the resistance at the E-11 front door lock actuator (LH) connector.


Connector: E-11

3 2 1 6 5 4

AC301418 AD

E-11(B)

NOTE:

Harness side

Connector: C-118 3 2 1 6 5 4

AC301418 AD



23 24 25 26 27

28 29 30 31 32

AC301395 AH


3 2 1 6 5 4 AC301541BK

(2) Resistance between E-11 front door lock actuator (LH) connector terminal No.1 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22



Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 44 43 42 41 40 39

AC210476 AF



Step 6. Check the wiring harness between E-11 front door lock actuator (LH) connector (terminal Nos. 2 and 3) and C-220 ETACS-ECU connector (terminal Nos. 36 and 35). Connector: C-220 Junction block (Rear view)

54C-261

Step 7. Pulse check Check the input signal from the driver’s door lock actuator switch. System switch

Check conditions



OK: The MUT-II sounds or the voltmeter needle fluctuates. Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210476 AF

Connector: E-11


AC301418 AD


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

AC301395 AH




54C-262


INSPECTION PROCEDURE N-15: The vehicle speed signal is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Vehicle Speed Sensor Input Circuit ETACS-ECU



COMMENTS ON TROUBLE SYMPTOM Vehicle speed signal is used to operate the windshield wiper (vehicle speed-dependent wiper function). If this signal is abnormal, the windshield wipers do not work normally. Possible causes Malfunction of the vehicles speed sensor Malfunction of the ETACS-ECU Damaged harness wires and connectors

DIAGNOSIS PROCEDURE Step 1. Check the speedometer. Check that the speedometer works normally. Q: Is the diagnosis code set? YES : Go to Step 2. NO : Diagnose the combination meter (Refer to

GROUP 54A - Combination meter 354A ).


54C-263


Step 2. Connector check: B-115 vehicles speed sensor connector Connector: B-115

Step 4. Check the wiring harness between B-115 vehicles speed sensor connector terminal No.2 and the body earth. Connector: B-115


Harness side

3 2 1

B-115(B)

3 2 1

AC301521AC


Step 3. Measure the resistance at the B-115 vehicles speed sensor connector.

AC301521AC


4 5 1 2 3 6 7 8 9 10 1112 13

Connector: B-115


3 2 1

AC301521AC


C-17(GR) AC301397AE

Prior to the wiring harness inspection, check joint connector C-17, and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent




3 2 1

AC301541 AL

(2) Resistance between B-115 vehicles speed sensor connector terminal No.2 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.


59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 74 73 72 71 70 69

AC210476 AE



54C-264


Step 6. Check the wiring harness between B-115 vehicles speed sensor connector terminal No.3 and C-219 ETACS-ECU connector terminal No.63.


Connector: B-115


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

3 2 1 AC301395 AC

Connectors: C-16, C-105 AC301521AC



59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

C-105 C-16(L)

AC210476 AE

C-16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

C-105 1 2 3 4 5 6 7 8 9 10 11 12 13 1415 16 1718 19 20 21 22

AC301398 AD

Prior to the wiring harness inspection, check joint connector C-02, C-16 and intermediate connector C105, and repair if necessary. Check the input line for open circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.


54C-265

Step 7. Pulse check Check the vehicle speed signal. System switch

Check conditions





INSPECTION PROCEDURE N-16: Each switch signal of the keyless entry transmitter is not received.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Transmitter Input Circuit ETACS-ECU


COMMENTS ON TROUBLE SYMPTOM Input signal from the keyless entry transmitter is used to operate the keyless entry system. If the signal is abnormal, the keyless entry system will not work normally.

KEYLESS ENTRY TRANSMITTER

Possible causes Malfunction of the keyless entry transmitter Defective battery of the keyless entry transmitter Malfunction of the ETACS-ECU

54C-266


DIAGNOSIS PROCEDURE Step 1. Pulse check Check whether the ETACS-ECU receives signal from a transmitter or not. For this check, you should use the 2-button-type transmitter (integrated with a key), which cover screw is silver and has already been registered. NOTE: For how to register the keyless entry transmitter encrypted code, refer to GROUP 42 On-vehicle Service 342. System switch

Check conditions

Keyless entry transmitter When the switch is "LOCK/UNLOCK" switch turned from off to on OK: The MUT-II sounds or the voltmeter needle fluctuates. Q: Is the check result normal? YES : Go to Step 2. NO : Go to Step 4.

Step 2. Check the transmitter battery. Refer to GROUP 42 - Keyless entry system 342. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the keyless entry transmitter

battery. Step 3. Register the encrypted code, and then retest the system. (1) Register the keyless entry transmitter again. (2) Check that each signal is received from the keyless entry transmitter. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the keyless entry transmitter. Step 4. Retest the system. Check that each signal is received from the keyless entry transmitter. Q: Is the check result normal? YES : The trouble can be an intermittent



54C-267


INSPECTION PROCEDURE N-17: Interior lamp loaded signal is not detected.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Interior Lamp Automatic Shut-off Function Circuit IGNITION SWITCH (ACC)

FUSIBLE LINK 1


RELAY BOX

ETACS-ECU

KEEP RELAY INTERIOR LAMP CUT BACK-UP CIRCUIT

POWER SOURCE


COMBINATION METER

· FRONT LAMP · REAR LAMP


COMMENTS ON TROUBLE SYMPTOM The interior lamp automatic shutdown function operates in accordance with the interior lamp loaded signal. If this signal is abnormal, the functions below will not work normally. Ignition key cylinder illumination lamp

SB : Sky blue

Room lamps Interior lamp automatic shutdown function Possible causes Malfunction of the ETACS-ECU Damaged wiring harness or connector(s)

54C-268


DIAGNOSIS PROCEDURE


Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu.



AC210476 AC


"Communication with ETACS-ECU is impossible 354C." Step 2. Connector check: C-217 ETACS-ECU connector Connector: C-217 Junction block (Rear view)

(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Ignition switch: ON


AC301541AW


AC210476 AC





54C-269



20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC


AC210476 AC

(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Ignition switch: ACC

Connector C-217 (Junction block side) Harness side

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1

2 1 6 5 4 3

AC210474 AC

Prior to the wiring harness inspection, check junction block connector C-203, and repair if necessary. Check the power supply line to the ignition switch (IG1) for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


AC301541AX



54C-270



Step 7. Pulse check Check the input of the interior lamp loaded signal. System switch

Check conditions



OK: The MUT-II sounds or the voltmeter needle fluctuates. Junction block side 20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

AC210476 AC


1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG


Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC210474 AB

Prior to the wiring harness inspection, check junction block connector C-202 or intermediate connector C116, and repair if necessary. Check the power supply line to the ignition switch (ACC) for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent





54C-271


INSPECTION PROCEDURE N-18: The passenger’s door lock key cylinder switch signal is not detected.

CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal. Door Lock Key Cylinder Switch Input Circuit ETACS-ECU

DOOR LOCK KEY CYLINDER SWITCH (RH)


COMMENTS ON TROUBLE SYMPTOM Input signal from the front passenger’s door lock key cylinder switch is used to operate the central door locking function. If the signal is abnormal, the central door locking function will not work normally. Possible causes Malfunction of the front passenger’s door lock key cylinder switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

SB : Sky blue

DIAGNOSIS PROCEDURE STEP 1. Connector check: E-18 door lock key cylinder switch (RH) connector Connector: E-18 Harness side E-18(B) 3 2 1

AC301412 AD



54C-272


STEP 2. Check the door lock key cylinder switch (RH). Refer to GROUP 42 - Door 342. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the door lock key cylinder switch

STEP 4. Check the wiring harness between E-18 door lock key cylinder switch (RH) connector terminal No.2 and body earth Connector: E-18 Harness side

(RH).

E-18(B) 3 2 1

STEP 3. Measure the resistance at E-18 door lock key cylinder switch (RH) connector. Connector: E-18 AC301412 AD

Harness side E-18(B)


3 2 1

AC301412 AD


2 1 3 4 5 6 10 11 12 7 8 9 13 14 15 16 17 18 19

C-15(GR) AC301397AD

Prior to the wiring harness inspection, check intermediate connector C-15, and repair if necessary. Check the input line for open circuit.



3 2 1

AC301541BL

(2) Resistance between E-18 door lock key cylinder switch (RH) connector terminal No.2 and body earth OK: 2 W or less

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. STEP 5. Connector check: C-220 ETACS-ECU connector Connector: C-220 Junction block (Rear view)

Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4. Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210476 AF



STEP 6. Check the wiring harness between E-18 door lock key cylinder switch (RH) connector (terminal Nos. 1 and 3) and C-220 ETACS-ECU connector (terminal Nos. 28 and 27). Connector: C-220 Junction block (Rear view)

54C-273

STEP 7. Pulse check Check the input signal from the front passenger’s door lock key cylinder switch. System switch

Check conditions

Passenger’s door lock key cylinder switch


OK: The MUT-II sounds or the voltmeter needle fluctuates. Harness side 29 28 27 26 25 24 23 22 21 38 37 3635 34 33 32 31 30 41 40 39 44 43 42

AC210476 AF

Connector: E-18 Harness side E-18(B) 3 2 1

AC301412 AD


2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

C-15(GR) AC301397AD




54C-274

SMART WIRING SYSTEM (SWS) USING SWS MONITOR CHECK AT ECU TERMINAL


ETACS-ECU

AC005554AF

NOTE: Terminal numbers 1 to 20 can not be measured as the ETACS-ECU is mounted on the junction block directly. The values are for reference only. Terminal Check items No.

Check conditions

Normal conditions

1

Output to the power window relay

When the power windows are operative

System voltage

2

Power supply to the central door locking system (battery positive voltage)

Always

System voltage

3

Earth (for ECU)

Always

0V

4



System voltage

5

Output to room lamp

When the room lamp is on

2 V or less

6

Power supply to interior lamp (battery positive voltage)


System voltage

7

Input from all the door switches

One of the door switches: ON (door 0 V open)

8


Ignition switch: ON

9

Output to right turn-signal lamps

When right turn-signal lamps are on System voltage

10

Input from driver’s door switch

Driver’s door switch: ON (door open)

0V

11

Power supply to hazard warning lamp (battery positive voltage)

Always

System voltage

12

Output to central door locking (for locking the doors)

When the door lock actuators lock the doors

System voltage

13

Output to central door locking (for unlocking the doors other than the driver’s door)


System voltage

14

Output to left turn-signal lamps

When the left turn-signal lamps are System voltage on

15

-

-

-

16

Output to rear wiper


System voltage

17

Input of rear wiper automatic stop signal


System voltage

18



System voltage

System voltage


54C-275

CHECK AT ECU TERMINAL Terminal Check items No.

Check conditions

Normal conditions

19

-

-

-

20


Always

System voltage

21

Input from rear fog lamp switch

Rear fog lamp switch: ON

0V

22

Output to central door locking (for unlocking the driver’s door)


System voltage

23

Rear washer output

When rear washer is operating

System voltage

24 to 28 -

-

-

29

Input of collision signal

-

-

30

Input to key reminder switch

Key reminder switch: ON (ignition key removed)

0V

31 to 34 -

-

-

35

Input to driver’s door lock actuator (lock switch)

Driver’s door lock: Locked

0V

36

Input to driver’s door lock actuator (unlock switch)

Driver’s door lock: Unlocked

0V

37, 38

-

-

-

39

Input to back-up lamp switch

Ignition switch: ON Shift lever: R

System voltage

40 to 44 -

-

-

51

When diagnosis code is set (the MUT-II is connected or the diagnosis connector No.1 is earthed)


When input check signal is sent

0 V, 12 V (input signal is fluctuating)

-

Setting diagnosis code or sending input check signal

52

-

-

53

Output to door-ajar indicator lamp

When door-ajar indicator lamp is on 0 V

54

Input from front fog lamp switch

Front fog lamp switch: ON

0V

55

Input from hazard warning lamp switch

Hazard warning lamp switch: ON

0V

56

Earth (for sensor)

Always

0V

57, 58

-

-

-

59


Always


60 to 62 -

-

-

63

Input of vehicle speed signal

When the vehicle is being driven


64, 65

-

-

-

66

Input from windshield intermittent wiper volume

Turn the ignition switch to the ACC position, and move the wiper volume from "Fast" to "Slow."

0 to 2.5 V

67

Input from diagnosis control

When MUT-II is connected

0V

68


Always


69

Output to ignition key cylinder illumination lamp

When ignition key cylinder illumination is on

2 V or less


54C-276

CHECK AT ECU TERMINAL


Check conditions

Normal conditions

70

-

-

-

71

Power supply to interior lamp


System voltage

72, 73

-

-

-

74

Output to rear fog lamp

When rear fog lamp is on

System voltage


Check conditions

Normal conditions

1

System voltage

Always

System voltage

2


Always


3


Always


4

Earth

Always

0V

5

-

-

-

6

Output to windshield intermittent wiper volume

Ignition switch: ACC 0 to 2.5 V Move the wiper volume from "Fast" to "Slow."

7

-

-

8

Back-up output to windshield wiper Windshield low-speed wiper switch 0 V switch or windshield high-speed wiper switch: ON

9


10

Back-up output to headlamp switch Headlamp switch: ON

Column switch

AC005555AB

-

Ignition switch: ON

System voltage 0V

Front-ECU

1 2 3 4 5 6 7 8 9 10 11

2122 23242526 272829 30 31 AC103263 AB

NOTE: Measurement is not possible as the front-ECU is mounted on the relay box directly. The values are for reference only.


54C-277

CHECK AT ECU TERMINAL Terminal Check items No.

Check conditions

Normal conditions

1

Output to headlamp washer

When headlamp washer is operating

System voltage

2

-

-

-

3

Battery power supply (for headlamp Always washer)

System voltage

4

Output to tail lamps

When the tail lamps are on

System voltage

5


Always

System voltage

6

Output to low-beam headlamps

When low-beam headlamps are on System voltage

7

Battery power supply (for tail lamps) Always

System voltage

8, 9

Battery power supply (for headlamps)

Always

System voltage

10

Output to high-beam headlamps

When high-beam headlamps are on System voltage

11

Output to front fog lamps

When front fog lamps are on

System voltage

21

Earth

Always

0V

22


Ignition switch: ON

System voltage

23

-

-

-

24

Output to windshield wiper (high speed operation)

When windshield wipers are operating at high speed

System voltage

25

Output to windshield wiper (low speed operation)

When windshield wipers are operating at low speed

System voltage

26

Back-up input from windshield wiper switch

Windshield low-speed wiper switch 0 V or windshield high-speed wiper switch: ON

27

Back-up input from headlamp switch

Headlamp switch: ON

0V

28



System voltage

29

Input of windshield wiper automatic When windshield wipers are stop signal operating

System voltage

30


Always


31

Output to windshield washer

When windshield washer is operating

System voltage

54C-278

SMART WIRING SYSTEM (SWS) USING SWS MONITOR CHECK AT ECU TERMINAL


1 2 3 4 5 6 7 8 9 10 11 12 13 14 AC103264 AE


Check conditions

Normal conditions

1


-

-

2

Earth

Always

0V

3

-

-

-

4

SWS communication line (to ETACS-ECU)

Always


5

-

-

-

6

Power supply


System voltage

7


-

-

8

Input from power window motor (pulse sensor earth)

-

0V

9




10




11

SWS communication line (power window sub switch)



12

Input from power window motor (power supply to pulse sensor)


5V

13, 14

-

-

-


54C-279

CHECK AT ECU TERMINAL

Power window sub switch

1 2 3 4 5 6 7 8

AC103265 AE

Termin al No.

Check items

Check conditions

Normal conditions

1

Earth

Always

0V

2


-

-

3


-

-

4

Power supply


System voltage

5


-

-

6




7


-

-

8


-

-

Sunroof motor assembly

AC005559AC

Termin al No.

Check items

Check conditions

Normal conditions

1

Battery power supply (for motor)

Always

System voltage

2


Ignition switch: ON

System voltage

3, 4

-

-

-

5

Earth

Always

0V

6

Input from sunroof switch (close or open)

Sunroof switch: Close/open

0V

7

Input from sunroof switch (tilt-up)

Sunroof switch: Tilt up

0V

8

Input from sunroof switch (open)

Sunroof switch: Open

0V

9

-

-

-

10


Always


127(6

25-1

GROUP 25

00 11

PROPELLER SHAFT

12 13 14

CONTENTS

15


25

SPECIAL TOOLS . . . . . . . . . . . . . . . .

25

16


25

PROPELLER SHAFT . . . . . . . . . . . . .

25

17


25

LUBRICANTS . . . . . . . . . . . . . . . . . .

25

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

25


25

SEALANT. . . . . . . . . . . . . . . . . . . . . .

25

21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

PROPELLER SHAFT

25-2

GENERAL INFORMATION


For 4WD vehicles, a 3 way split 4-joint type propeller shaft with centre bearing is used.


Item

Standard value

Limit

Propeller shaft run-out mm

-

0.6

Clearance between snap ring and snap ring groove mm

0.02 - 0.06

-


Item

Specified lubricant

Quantity

Front propeller shaft sleeve yoke

Hypoid gear oil SAE 75W-90 or 75W-85W or As required 80W conforming to API GL-4

DOJ assembly

Repair kit grease

95 5 g

SEALANT M1251000500106

Item

Specified sealant

Rubber packings for DOJ assembly

3M Stud Locking 4170 or equivalent


Tool

Number

Name

Use

MB990840

Universal joint remover and installer

Disassembly and reassembly of universal joint

MD998801

Bearing remover

Removal of centre bearing assembly

MB990840

AC106983

PROPELLER SHAFT

25-3

PROPELLER SHAFT

PROPELLER SHAFT REMOVAL AND INSTALLATION M1251001000223

4 Gear Oil: Hypoid gear oil SAE 75W-90 or 75W-85W or 80W conforming to API GL-4

3

4 3

3

3 N2

N

2

1 13 ± 2 N·m

30 ± 4 N·m

1

5 54 ± 5 N·m

30 ± 4 N·m

13 ± 2 N·m AC203945 AD

1. 2. 3.

Removal steps Heat protector Self locking nut Insulator

<>

>>A<<

4. 5.

Removal steps&RQWLQXHG Spacer Propeller shaft assembly

REMOVAL SERVICE POINT <> PROPELLER SHAFT ASSEMBLY REMOVAL 1. Make mating marks on the differential companion flange and the propeller shaft assembly.

CAUTION Be careful not to bend the joint portion when removing the propeller shaft because this will damage to the joint boot. Joint boot

Joint assembly

Rag

Rear propeller shaft AC101255 AD

2. Insert a rag so as to avoid boot damage, and remove the propeller shaft assembly in a straight and level manner.

PROPELLER SHAFT

25-4

PROPELLER SHAFT

INSTALLATION SERVICE POINT >>A<< PROPELLER SHAFT ASSEMBLY INSTALLATION

Propeller shaft assembly

Differential companion flange

CAUTION Marking

Marking

Oil seal AC300150AC

Transfer

2. When installing a new rear propeller shaft assembly, align the mark on the propeller shaft tube with the mark at the side of the differential companion flange. AC101431 AC

Do not damage the oil seal lips on the transfer case. Remove oil and grease from the threads of the mounting bolts and nuts before tightening, or they will loosen. Be careful not to bend the joint portion when removing the propeller shaft, because this will damage the joint boot. 1. If reusing the propeller shaft, align the mating marks of differential companion flange and propeller shaft assembly to install.


Check the sleeve yoke and centre yoke for wear, damage or cracks. Check the propeller shaft for bends, twisting or damage. Check the universal joint for smooth operation in all directions. Check the centre bearing for smooth movement.

PROPELLER SHAFT RUNOUT

ACX00643AB

PROPELLER SHAFT

25-5

PROPELLER SHAFT

Limit: 0.6 mm


1N 6N 1N

N

8

187 ± 29 N·m

2

2N

4

9 7

3 5 3

12

N 15

10 N 14 N

19 N

17 N

187 ± 29 N·m

18

16

11 13

34 ± 5 N·m

20

14

17 17 16

18 15 19

18

17

15

14 3

1

Universal joint kit

DOJ boot kit

DOJ kit

2

AC203968 AD

<> <>

>>G<< >>F<< >>F<<

1. 2. 3. 4.

Disassembly steps Snap ring Journal bearing Journal Sleeve yoke

<> <>

>>E<< >>E<< >>E<<

5. 6. 7. 8.

Disassembly steps&RQWLQXHG Front propeller shaft Self locking nut Centre yoke Centre bearing assembly

PROPELLER SHAFT

25-6

PROPELLER SHAFT

<> <>

>>D<< >>D<< >>D<<

<>

>>C<< >>B<<

<>

>>A<<

9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Disassembly steps&RQWLQXHG Bolt Self locking nut Companion flange Centre bearing assembly Centre propeller shaft Snap ring Boot band DOJ assembly Rubber packing DOJ boot Washer Rear propeller shaft

PROPELLER SHAFT

25-7

PROPELLER SHAFT

Lubrication and Adhesive Points Rubber mount

CAUTION Do not refill or apply grease excessively. Otherwise, faulty fitting of bearing caps and errors in the selection of snap rings may result.

Repair kit grease: Quantity: 95 ± 5 g

Adhesive: 3M Stud Locking 4170 or equivalent AC203969 AC

PROPELLER SHAFT

25-8

PROPELLER SHAFT


<> CENTRE YOKE REMOVAL

<> SNAP RING REMOVAL Mating marks

Mating marks AC003847AD ACX00645 AD

Make mating marks on the flange yoke and propeller shaft. Then, remove the snap rings. <> JOURNAL BEARING REMOVAL

CAUTION Do not tap the journal bearings to remove them, as this will upset the balance of the propeller shaft.

Make mating marks on the centre yoke and centre propeller shaft, and then remove the centre yoke. <>CENTRE BEARING ASSEMBLY/BOLT REMOVAL 1. Make mating marks on the centre propeller shaft, DOJ assembly and companion flange, and then remove the bolt. Center bearing assembly

MB990840

MD998801

AC101273 AC

MB990840

MB990840

2. Use special tool bearing remover (MD998801) to remove the centre bearing assembly from the centre propeller shaft. <>DOJ ASSEMBLY REMOVAL

MB990840

DOJ assembly MB990840 ACX00646AC

1. Use special tool universal joint remover and installer (MB990840) to press in the journal bearing on one side, and take out the journal bearing on the opposite side. 2. Insert special tool into the other side and press the journal to remove the first journal bearing that was pushed.

DOJ boot AC101274 AC

1. Remove the DOJ boot from the DOJ assembly.

PROPELLER SHAFT

25-9

PROPELLER SHAFT

>>B<< DOJ ASSEMBLY INSTALLATION Outer race

Inner race Outer race

Inner race

Circlip Cage Circlip

Ball AC101275 AC

2. Make mating marks on the outer race, cage and inner race, and then remove the circlip, outer race and ball. NOTE: . Note the positions of the balls so that they can be reinstalled in their original positions. Cage

Inner race

Puller

Cage AC101277AC

1. Apply a thin coat of the specified grease to the ball grooves of the inner and outer races. Specified grease: Repair kit grease 2. Assemble the DOJ assembly as follows: (1) Assemble the outer race, cage, balls, and inner race with their mating marks aligned. (2) Install the circlip.

AC101276 AC

3. Remove the inner race with cage from the centre propeller shaft assembly by using a puller (commercially available). 4. Wipe off the grease and clean the outer race, inner race, cage and balls. <> DOJ BOOT REMOVAL When the DOJ boot is reused, tape the spline part on the rear propeller shaft and then remove the DOJ boot.

AC101278 AC

3. Apply specified grease to the DOJ assembly. Specified grease: Repair kit grease Amount to use: 95 5 g Rubber packing

REASSEMBLY SERVICE POINTS >>A<< DOJ BOOT INSTALLATION 1. Install the boot band. 2. Wrap a plastic tape around the spline part on the centre propeller shaft and then install the DOJ boot.

DOJ assembly AC101279 AF

4. Apply a thin coat of specified adhesive to the groove side of DOJ assembly (shown by arrows in the figure) and install the rubber packing. Specified adhesive: 3M Stud Locking 4170 or equivalent 5. Set the groove side of DOJ assembly (for packing) toward the DOJ boot side and install them.

PROPELLER SHAFT

25-10

PROPELLER SHAFT

Socket wrench

>>D<< CENTRE BEARING ASSEMBLY/ COMPANION FLANGE/SELF-LOCKING NUT INSTALLATION Center bearing assembly

Companion flange

Self-locking nut AC101280 AC

6. Lining up the mating marks on the DOJ assembly and the centre propeller shaft and using the socket wrench, install the DOJ assembly to the centre propeller shaft. Bolt

DOJ boot

AC101281AF

7. Using the bolt, align the bolt holes of the DOJ boot and the DOJ assembly and install DOJ boot to the DOJ assembly. 8. Install the rubber packing of the companion flange side in the same manner as described in (4) above.

AC101283 AC

1. Set the centre bearing assembly in the direction shown in the figure and install it to the centre propeller shaft. 2. Install, lining up the mating marks on the companion flange and the centre propeller shaft. 3. While tightening the self-locking nut, install the centre bearing assembly with the companion flange. >>E<
Center Dust seal yoke

Rubber mount

Selflocking nut

>>C<< BOOT BAND INSTALLATION

CAUTION

AC101284 AC

1. Set the centre bearing assembly in the direction shown in the figure and install it to the centre propeller shaft. 2. Align the mating marks on the centre yoke and the centre propeller shaft. 3. While tightening the self-locking nut, install the centre bearing assembly with the centre yoke.

Mark

Boot Vent plug

AC107071AB

Clamp the boot by holding down the lever at a position nearly opposite to the vent groove provided in the DOJ boot (at arrow marked position on boot). Be sure to remove grease, if present, from around the vent groove. Grease obstructs the ventilation air passage.

PROPELLER SHAFT

25-11

PROPELLER SHAFT

>>F<< JOURNAL/JOURNAL BEARING INSTALLATION

CAUTION

4. Align the mating marks on the centre yoke and rear propeller shaft, and install the propeller shaft journal bearings in the same manner as described in (1) and (2) above. >>G<< SNAP RING INSTALLATION 1. Install a snap ring to one side of the journal. MB990840

AC101285AC

Do not apply grease excessively. Too much grease can result in errors in the selection of snap rings. 1. Apply multi-purpose grease to the following universal joint kit. Shaft and journal grease cup Dust seal lip Needle roller bearing

SNAP RING

ACX00649 AC

2. Use special tool universal joint remover and installer (MB990840) at the opposite side of the installed snap ring to press in the journal bearing toward the snap ring.

CAUTION

CAUTION Be careful when pressing the journal bearings. If they are pressed at an angle, the inside of the journal bearings will be damaged. MB990840

Always use snap rings of equal thickness on both sides.

Snap ring Groove for snap ring

A

ACX00650AC ACX00647AC

2. Use special tool universal joint remover and installer (MB990840) to press the journal bearing into the centre yoke, sleeve yoke or flange yoke until the snap ring groove is fully visible.

MB990840

MB990840 ACX00648 AC

3. Use the special tool to press the opposite side journal bearing into the yoke.

3. Install the snap ring on the opposite side, and measure the clearance of the snap ring groove with a feeler gauge. Standard value (A): 0.02 - 0.06 mm 4. If the clearance exceeds the standard value, adjust by changing the thickness of the snap ring. Thickness mm

Identification colour

1.28

-

1.31

Yellow

1.34

Blue

1.37

Purple

1.40

Brown

127(6

26-1

GROUP 26

00 11

FRONT AXLE

12 13 14


26

15

FRONT AXLE HUB ASSEMBLY . . . .

26


26

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

26


26


26

LUBRICANTS . . . . . . . . . . . . . . . . . .

26

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

26

SPECIAL TOOLS. . . . . . . . . . . . . . . .

26

DRIVE SHAFT ASSEMBLY . . . . . . . .

26


26


16 17 21 22 25

26


26

WHEEL BEARING AXIAL PLAY CHECK . .

26

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

26

26

HUB BOLT REPLACEMENT . . . . . . . . . . .

26

BJ BOOT (RESIN BOOT) REPLACEMENT

26

27 31 32 33 34 35 36 37 42 51 52 54 55

FRONT AXLE

26-2

GENERAL INFORMATION


The front axle consists of front hubs, knuckles, wheel bearings and drive shafts, and it has the following features: The wheel bearing is a double-row angular contact ball bearing which incorporates the oil seals and is highly resistant to a thrust load. The driveshaft incorporates BJ-PTJ type constant velocity joints with high transmission efficiency for low vibration and noise. The dynamic damper has been mounted on the left drive shaft to reduce differential gear noise.

Due to the use of the inner shaft and bracket assembly, the right and left drive shafts are approximately the same in length. This reduces noise, vibration and torque steer.<2WD> Due to the use of the output shaft, the right and left drive shafts are approximately the same in length. This reduces noise, vibration and torque steer.<4WD> ABS rotors for detecting the wheel speed are press-fitted to the BJ outer wheels. NOTE: . PTJ: Pillow Tripod Joint BJ: Birfield Joint

SPECIFICATIONS Item

2WD

Wheel bearing Driveshaft

4WD

Type

Double-row angular contact ball bearing

Bearing (OD x ID) mm

80 x 40

80 x 40

Outer

BJ

BJ

Inner

PTJ

PTJ

LH

383.5 24

361 22

RH

474.5 24

455 22

Joint type Length (joint to joint) diameter mm

CONSTRUCTION DIAGRAM <2WD> Strut assembly PTJ (LH) Drive shaft (LH)

Knuckle

Bracket assembly

Drive shaft (RH)

Front hub

PTJ (RH)

Dynamic damper (LH only) BJ

Inner shaft

ABS rotor Wheel bearing AC106952 AD

FRONT AXLE

26-3

SERVICE SPECIFICATIONS <4WD>

Strut assembly

Output shaft PTJ (LH) Drive shaft (LH)

Knuckle

Drive shaft (RH)

Front hub

Dynamic damper (LH only)

PTJ (RH)

BJ Output shaft

ABS rotor Wheel bearing

AC106953 AD


Item

Standard value

Limit

Wheel bearing axial play mm

-

0.05

Hub starting torque N¼m

-

1.8

Protruding length of stabilizer link mm

9.4 0.4

-

Setting of PTJ boot length mm 2WD

90 3

-

4WD

85 3

-

When the BJ boot band (small) is crimped

2.9

-

When the BJ boot band (large) is crimped

2.9

-

2.4 - 2.8

-

Opening dimension of the special tool (MB991561) mm

Crimped width of the BJ boot band mm


Item

Specified lubricant

PTJ boot grease

Repair kit grease

Quantity 2WD

210 10 g

4WD

150 10 g

FRONT AXLE

26-4

SPECIAL TOOLS

Item

Specified lubricant

BJ boot grease

Repair kit grease

Quantity 2WD

120 10 g

4WD

85 10 g

Dust seal inner grease

Repair kit grease

14 - 20 g

Dust seal outer grease

Repair kit grease

8 - 12 g


Tool

Number

Name

Use

MB990767

End yoke holder

Fixing of the hub

MB991618

Hub bolt remover

Removal of the hub bolt

MB991897

Ball joint remover

Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113)is also used to disconnect knuckle and tie rod end ball joint.

MB990241 A: MB990242 B: MB990244

Axle shaft puller A: Puller shaft B: Puller bar

Removal of the drive shaft

MB991354

Puller body

MB991056 or MB991355

Knuckle arm bridge

B990767

MB991618

AC106827

A B

MB990241AB

MB991354

Removal of the hub Removal of the wheel bearing

FRONT AXLE

26-5

SPECIAL TOOLS

Tool

A

Number

Name

Use

MB991721

Sliding hammer

Removal of the output shaft <4WD>

A: MB991017 B: MB990998 C: MB991000

A, B: Front hub remover and installer C: Spacer

Removal of the hub Provisional holding of the wheel bearing Measurement of hub starting torque Measurement of wheel bearing axial play NOTE: MB991000, which belongs to MB990998, should be used as a spacer.

MB990685

Torque wrench

Measurement of hub starting torque

MB990326

Preload socket

MB990810

Side bearing puller

Removal of the centre bearing bracket Removal of the wheel bearing inner race (outside)

MB991172

Inner shaft installer base

Press-fitting of the inner shaft

MB991248 or MB998801

Inner shaft remover

Removal of the inner shaft

MB991460

Plug

Prevention of transmission fluid drain and of entry of foreign objects

B C AC100320AB

MB990326

MB990810

MB991248

FRONT AXLE

26-6

SPECIAL TOOLS

Tool

Number

Name

Use

MB991561

Boot band crimping tool

BJ boot (resin boot) band installation

MB990925

Bearing and oil seal installer set

Removal of the wheel bearing Removal and installation of the centre bearing Press-fitting of the dust seal outer, inner

MB990890

Rear suspension bushing base

Installation of the wheel bearing Press-fitting of the dust seal outer, inner

MB990883

Rear suspension bushing arbor

Installation of the wheel bearing

MB991561

MB990925

MB990890

MB990883

Tool MB990925

Type

Tool number

O D mm

A

MB990926

39.0

MB990927

45.0

MB990928

49.5

MB990929

51.0

MB990930

54.0

MB990931

57.0

MB990932

61.0

MB990933

63.5

MB990934

67.5

MB990935

71.5

MB990936

75.5

MB990937

79.0

B

MB990938

-

C

MB990939

-

A Installer adapter

C

Brass bar

B Bar (snap-in type)

Tool box ACX02372 AC

FRONT AXLE

26-7

ON-VEHICLE SERVICE

ON-VEHICLE SERVICE WHEEL BEARING AXIAL PLAY CHECK M1261000900213

1. Remove the caliper assembly and suspend it with a wire. 2. Remove the brake disc from the front hub.

MB991618

MB990767

AC102439 AC

AC102438

3. Attach a dial gauge as shown in the illustration, and then measure the axial play while moving the hub in the axial direction. Limit: 0.05 mm 4. If axial play exceeds the limit, disassemble the front hub assembly and check the parts. 5. Install the brake disc, caliper assembly and tighten the caliper assembly mounting bolts to the specified torque 100 10 N¼m.

HUB BOLT REPLACEMENT M1261001000279

1. Remove the caliper assembly and suspend it with wire so that it does not fall. 2. Remove the brake disc.

3. Use the following special tools to remove the hub bolts. End yoke holder (MB990767) Hub bolt remover (MB991618)

MB990767 Plain washer

AC102440 AC

4. Install the plain washer to the new hub bolt, and install the bolt with a nut. 5. Install the brake disc, caliper assembly and tighten the caliper assembly mounting bolts to the specified torque 100 10 N¼m.

FRONT AXLE

26-8

FRONT AXLE HUB ASSEMBLY

FRONT AXLE HUB ASSEMBLY REMOVAL AND INSTALLATION M1261001700331

CAUTION Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be damaged. Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing work. Post-installation Operation Check the dust cover for cracks or damage by pushing it with your finger.

N

6 25 ± 5 N·m

7 12

13

167 ± 9 N·m

10 N 1

8

3 245 ± 29 N·m

11

39 ± 5 N·m

5 4N

9 100 ± 10 N·m

108 ± 10 N·m

2

AC107173 AB

1. <> 2. 3. <> >>B<< 4. >>B<< 5. >>A<< 6.

>>A<< 7.

Removal steps Front ABS sensor Caliper assembly Brake disc Drive shaft nut Washer Self-locking nut (stabilizer bar connection) Stabilizer rubber

<> <>

8. 9. 10. 11. 12. 13.

Removal steps&RQWLQXHG Stabilizer link assembly Lower arm ball joint connection Self-locking nut (tie rod end connection) Drive shaft Nut (hub and knuckle to strut connection) Hub and knuckle

FRONT AXLE

26-9


REMOVAL SERVICE POINTS <> CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, etc.

Bolt Parallel

<> DRIVE SHAFT NUT REMOVAL

CAUTION Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when drive shaft nut is loosened.

MB990767

Knob

Good

Bad

AC106821AB

2. Turn the bolt and knob as necessary to make the jaws of special tool parallel, tighten the bolt by hand and confirm that the jaws are still parallel. NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure. 3. Tighten the bolt with a wrench to disconnect the tie rod end.

AC102462 AC

Use special tool end yoke holder (MB990767) to fix the hub and remove the drive shaft nut. <> SELF-LOCKING NUT (TIE ROD END CONNECTION) REMOVAL

<> DRIVE SHAFT REMOVAL

MB990767

CAUTION Do not remove the nut from ball joint. Loosen it and use the special tool to avoid possible damage to ball joint threads. Hang the special tool with cord to prevent it from falling. Cord

MB991897

Nut

MB990244 (Three) MB990242

MB991354 AC102550 AC

1. Use the following special tools to push out the drive shaft from the hub and knuckle. Puller shaft (MB990242) Puller bar (MB990244) Puller body (MB991354) End yoke holder (MB990767)

Bolt Ball joint

AC208247AD

1. Install special tool ball joint remover (MB991897) as shown in the figure.

Drive shaft

AC102551AC

2. Withdraw the drive shaft from the hub by pulling the bottom of the hub and knuckle towards you. 3. Hang the drive shaft on the vehicle body with a rope.

FRONT AXLE

26-10


INSTALLATION SERVICE POINT >>A<< SELF-LOCKING NUT (STABILIZER BAR CONNECTION) INSTALLATION

>>B<< WASHER/ DRIVE SHAFT NUT INSTALLATION

CAUTION Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearings will be damaged.

A

Washer

AC107031AB AC107031

Tighten the self-locking nut so that the protruding length of the stabilizer link protruding part meets its standard value (A). Standard value (A): 9.4 0.4 mm

MB990767 AC102465AD

1. Be sure to install the drive shaft washer in the specified direction. 2. Using special tool end yoke holder (MB990767), tighten the drive shaft nut to the specified torque. Tightening torque: 245 29 N¼m


Check the hub for cracks and spline for wear. Check the knuckle for cracks. Check for defective bearing. NOTE: If the meshing of the wheel bearing outer race and the knuckle, or of the wheel bearing inner race and the hub, is loose, replace the bearing or damaged parts.

FRONT AXLE

26-11



N

2

1 N

4 5

3 AC101684 AD

1. 2. 3. 4. 5.

<> <>

Disassembly steps Snap ring Hub Dust cover Wheel bearing Knuckle

>>A<<

>>B<< >>C<<

5. 4. 1. 3. 2.

Assembly steps Knuckle Wheel bearing Snap ring Dust cover Hub Hub starting torque check Wheel bearing axial play check

DISASSEMBLY SERVICE POINTS <> HUB REMOVAL <> WHEEL BEARING REMOVAL

CAUTION When the hub has been removed, always replace the wheel bearing with a new part because wheel bearing frictional surface will be damaged when removing the hub.

MB991017

Inner race (outside)

MB991056 or MB991355

Outer oil seal AC102508 AC

MB991000

Tighten the nut with the bolt secured AC100130 AB

Use the following special tools to pull out the hub from the knuckle. Knuckle arm bridge (MB991056 or MB991355) Front hub remover and Installer (MB991017) Spacer (MB991000)

1. Crush the oil seal in two places so that the tabs of the special tool will be caught on the wheel bearing inner race (outside).

FRONT AXLE

26-12



CAUTION When removing the inner race (outside) from the hub, be careful not to let the hub drop. MB990810

>>A<< WHEEL BEARING INSTALLATION 1. Fill the wheel bearing with multipurpose grease. 2. Apply a thin coating of multipurpose grease to the knuckle and bearing contact surfaces.

CAUTION Press the outer race when pressing-in the wheel bearing. Otherwise the wheel bearing will be damaged. MB990883

Inner race (outside)

MB990890

AC102509 AC

2. Remove the wheel bearing inner race (outside) from the front hub by using special tool side bearing puller (MB990810). MB990938 Inner race (outside)

MB990935

MB991056 or MB991355

AC102511 AC

3. Press-in the bearing by using the following special tools. Rear suspension bushing arbor (MB990833) Rear suspension bushing base (MB990890) >>B<< HUB STARTING TORQUE CHECK

AC102510 AC

3. Install the inner race (outside) that was removed from the hub to the wheel bearing, and then use the following special tools to remove the wheel bearing. Installer bar (MB990938) Installer adapter (MB990935) Knuckle arm bridge (MB991056 or MB991355)

MB991017

MB991000

245 ± 29 N·m Tighten the nut with the bolt secured AC210929 AC

1. Tighten the following special tools to the specified torque, and then press-in the hub into the knuckle. Front hub remover and installer (MB991017) Spacer (MB991000) 2. Rotate the hub in order to seat the bearing.

FRONT AXLE FRONT AXLE HUB ASSEMBLY

26-13

>>C<< WHEEL BEARING AXIAL PLAY CHECK MB990685 MB991000

245 ± 29 N·m Tighten the nut with the bolt secured

MB990326 AC100136 AB

3. Measure the hub starting torque by using the following special tools. Torque wrench (MB990685) Preload socket (MB990326) Limit: 1.8 N¼m 4. The starting torque must be within the limit and the hub rotation must be smooth.

MB991017 AC100137 AB

1. Measure to determine whether the wheel bearing axial play is within the limit or not by using the following special tools. Front hub remover and installer (MB991017) Spacer (MB991000) Limit: 0.05 mm 2. If the play is not within the limit range while the nut is tightened to 245 29 N¼m, the bearing, hub and/or knuckle have probably not been installed correctly. Replace the bearing and re-install.


Check the front hub and brake disc mounting surfaces for galling and contamination. Check the knuckle inner surface for galling and cracks.

FRONT AXLE

26-14

DRIVE SHAFT ASSEMBLY

DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION M1261003500366

CAUTION Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be damaged. Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing work. Post-installation Operation Pre-installation Operation Transmission Fluid Draining (Refer to GROUP Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Muffler 315). 22A, On-vehicle Service - Transmission Oil Check the Ball Joint Dust Cover for cracks or Replacement 322A). Transfer Oil Draining <4WD> damage by pushing it with your finger. Transfer Oil Filling<4WD> (Refer to GROUP (Refer to GROUP 22A, On-vehicle Service 22A, On-vehicle Service - Transfer Oil Transfer Oil Replacement 322A). Front Exhaust Pipe Removal (Refer to GROUP Replacement 322A). Transmission Fluid Filling (Refer to GROUP 15, Exhaust Pipe and Muffler 315). 22A, On-vehicle Service - Transmission Oil Replacement 322A). <2WD>

N6

N 14

11

7

25 ± 5 N·m

41 ± 4 N·m

5

10 N

4

3

7 2

8

1N

12 9

39 ± 5 N·m

245 ± 29 N·m

108 ± 10 N·m

AC107141AB

FRONT AXLE

26-15

DRIVE SHAFT ASSEMBLY <4WD>

6N N 14

4

5

25 ± 5 N·m

7

10 N 3

13 N 14

2

11 8

1N

9 245 ± 29 N·m

39 ± 5 N·m 108 ± 10 N·m

AC107142 AB

<>

>>C<< >>C<<

>>B<<

1. 2. 3. 4. 5. 6. 7. 8.

Removal steps Drive shaft nut Washer Front ABS sensor Front ABS sensor bracket Brake hose bracket Self-locking nut Stabilizer rubber Stabilizer link assembly

REMOVAL SERVICE POINTS <> DRIVE SHAFT NUT REMOVAL

CAUTION Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft nut is loosened.

MB990767 AC102462 AC

Use special tool end yoke holder (MB990767) to fix the hub and remove the drive shaft nut.

<> <> <>

>>A<< >>A<<

<>

>>A<<

Removal steps&RQWLQXHG 9. Lower arm ball joint connection 10. Self-locking nut (tie rod end connection) 11. Drive shaft 12. Drive shaft and inner shaft assembly <2WD-RH> 13. Output shaft <4WD> 14. Circlip

FRONT AXLE

26-16


<> SELF-LOCKING NUT (TIE ROD END CONNECTION) REMOVAL

<> DRIVE SHAFT/DRIVE SHAFT AND INNER SHAFT ASSEMBLY <2WD-RH> REMOVAL

CAUTION Do not remove the nut from ball joint. Loosen it and use special tool to avoid possible damage to ball joint threads. Hang special tool with cord to prevent it from falling.

MB990767

MB990244 (Three)

Cord MB990242

MB991354 AC102550 AC

MB991897

Nut

Bolt Ball joint

AC208247AD

1. Install special tool ball joint remover (MB991897) as shown in the figure.

1. Use the following special tools to push out the drive shaft or the drive shaft and inner shaft assembly from the hub. Puller shaft (MB990242) Puller bar (MB990244) Puller body (MB991354) End yoke holder (MB990767)

Bolt Parallel

Drive shaft

Knob

Good AC102551AC

Bad

AC106821AB


2. Remove the drive shaft from the hub by pulling the bottom of the brake disc towards you.

CAUTION Do not pull on the drive shaft; doing so will damage the PTJ; be sure to use the pry bar. When pulling the drive shaft out from the transmission, be careful that the spline part of the drive shaft does not damage the oil seal. Transmission

PTJ assembly Pry bar AC100141 AF

3. Insert a pry bar between the transmission case and the drive shaft, and then pry and remove the drive shaft from the transmission.

FRONT AXLE

26-17


<> OUTPUT SHAFT <4WD> REMOVAL

CAUTION

Bracket assembly

When pulling the output shaft out from the transmission, be careful that the spline part of the output shaft does not damage the oil seal.

MB991721

AC102553 AC

4. If the inner shaft is hard to remove from the transmission, strike the bracket assembly lightly with a plastic hammer and remove the inner shaft.

Output shaft AC102556 AC

Use special tool sliding hammer (MB991721) to remove the output shaft.

INSTALLATION SERVICE POINTS >>A<< OUTPUT SHAFT <4WD>/DRIVE SHAFT/ DRIVE SHAFT AND INNER SHAFT ASSEMBLY <2WD-RH> INSTALLATION

MB991460 AC102554 AC

5. Use special tool plug (MB991460) to prevent the entry of foreign material into the transmission case.

CAUTION When installing the output shaft, the drive shaft or the drive shaft and inner shaft assembly, be careful that the spline part of the output shaft, the drive shaft or the drive shaft and inner shaft assembly do not damage the oil seal. >>B<< SELF-LOCKING NUT INSTALLATION

MB991000 MB991017

A

AC102555 AC

CAUTION Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft is removed. If, however, vehicle weight must be applied to the bearing in moving the vehicle, temporarily secure the wheel bearing by using the following special tools. Spacer (MB991000) Front hub remover and installer (MB991017)

AC107031AB AC107031

Tighten the self-locking nut so that the protruding length of the stabilizer link protruding part meets its standard value (A). Standard value (A): 9.4 0.4 mm

FRONT AXLE

26-18


>>C<< WASHER/DRIVE SHAFT NUT INSTALLATION

CAUTION Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged. Washer

MB990767 AC102465AD

1. Be sure to install the drive shaft washer in the specified direction.

2. Using special tool end yoke holder (MB990767), tighten the drive shaft nut to the specified torque. Tightening torque: 245 29 N¼m

FRONT AXLE

26-19



CAUTION Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly and reassembly. Never disassemble the BJ assembly except when replacing the BJ boot.

18 20

12 8

10

21

9

19

2 N 1N

15

14 13 N

<2WD-RH>

4

Bearing dust seal repair kit

3

12 N 12

<2WD-LH>

8

17

16

<4WD>

4 11

5 11

12 N

10

4 7

12 N

10

6

8N

6

9N

9

Bracket assembly repair kit

2

1

2

15

20 1 15

21 19

14

13

13

Grease for PTJ

2 1

Grease for BJ

4 12

12 PTJ boot repair kit

16 PTJ repair kit

13

12

BJ boot repair kit

AC101959 AD

>>G<< >>G<< <> <>

>>F<< >>E<<

<>

>>D<< >>D<< >>C<<

Disassembly steps PTJ boot band (large) PTJ boot band (small) PTJ case and inner shaft assembly <2WD-RH> 4. PTJ case 5. Inner shaft <2WD-RH> 6. Dust cover <2WD-RH> 7. Bracket assembly <2WD-RH> 8. Dust sear outer <2WD-RH> 9. Dust seal inner <2WD-RH> 10. Centre bearing <2WD-RH> 1. 2. 3.

<> <>

>>B<< >>A<< >>A<< >>A<<

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Disassembly steps&RQWLQXHG Centre bearing bracket <2WD-RH> Circlip Snap ring Spider assembly PTJ boot Damper band Dynamic damper BJ assembly BJ boot band (small) BJ boot band (large) BJ boot

FRONT AXLE

26-20


NOTE: . PTJ: Pillow Tripod Joint BJ: Birfield Joint

LUBRICATION POINTS

Grease: repair kit grease Amount used: <2WD>: 120 ± 10 g <4WD>: 85 ± 10 g

CAUTION

Grease: repair kit grease Amount used: <2WD>: 210 ± 10 g <4WD>: 150 ± 10 g

CAUTION

The drive shaft joint uses special grease. Do not mix old and new or different types of grease.

The drive shaft joint uses special grease. Do not mix old and new or different types of grease.

Grease: repair kit grease

Grease: repair kit grease Amount used: Dust seal inner: 14 - 20 g Dust seal outer: 8 - 12 g

Grease: repair kit grease AC107123 AC

FRONT AXLE

26-21


DISASSEMBLY SERVICE POINTS <> PTJ CASE/SPIDER ASSEMBLY REMOVAL

<> CENTRE BEARING <2WD-RH> REMOVAL

CAUTION

MB990938

Do not disassemble the spider assembly. 1. Wipe off grease from the spider assembly and the inside of the PTJ case. 2. Always clean the spider assembly when the grease contains water or foreign material.

MB990930

<> INNER SHAFT <2WD-RH> REMOVAL Center bearing bracket AC102652 AC

Bar

PTJ case

MB991248 or MD998801

Use the following special tools to remove the centre bearing from the centre bearing bracket. Bar (MB990938) Installer adapter (MB990930) <> PTJ BOOT REMOVAL 1. Wipe off grease from the shaft spline. 2. When reusing the PTJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot.

Bar


PTJ case

>>A<< DYNAMIC DAMPER /DAMPER BAND /PTJ BOOT INSTALLATION

CAUTION MB991248 or MD998801

There should be no grease adhered to the rubber part of the dynamic damper. AC102878 AD

1. Use special tool inner shaft remover (MB991248 or MD998801) to remove the inner shaft assembly from the PTJ case.

L

MB990810

AC101695 AC

AC101694 AC

2. Use special tool side bearing puller (MB990810) to remove the centre bearing bracket from the inner shaft.

1. Install the dynamic damper in the position (L) shown in the figure . L: 237 3 mm <2WD>, 231 3 mm <4WD> 2. Secure the damper bands. 3. Wrap plastic tape around the shaft spline, and then install the PTJ boot band (small) and PTJ boot.

FRONT AXLE

26-22


>>B<< SPIDER ASSEMBLY INSTALLATION

CAUTION The drive shaft joint use special grease. Do not mix old and new or different types of grease. If the spider assembly has been cleaned, take special care to apply the specified grease. 1. Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller. Specified grease: Repair kit grease

Specified grease: Repair kit grease Amount used: Dust seal inner: 14 - 20 g Dust seal outer: 8 - 12 g

MB990890

Dust seal inner

AC101696 AC

Chamfered side

MB990938 MB990934

Dust seal outer MB990890

AC102654AC

2. Install the spider assembly to the shaft from the direction of the spline chamfered side. AC101697AC

>>C<< CENTRE BEARING <2WD-RH> INSTALLATION MB990938 MB990932

2. Use the following special tools to press the dust seals into the centre bearing bracket until they are flush with each other. Rear suspension bushing base (MB990890) Bar (MB990938) Installer adapter (MB990934) 3. Apply repair kit grease to the lip of each dust seal. >>E<< INNER SHAFT <2WD-RH> INSTALLATION

Center bearing bracket AC102655 AC

Inner shaft

Use the following special tools to press-fit the centre bearing into the centre bearing bracket. Bar (MB990938) Installer adapter (MB990932) >>D<< DUST SEAL INNER <2WD-RH> /DUST SEAL OUTER <2WD-RH> INSTALLATION

CAUTION When applying grease, make sure that it does not adhere to anything outside the lip. 1. Apply the specified grease to the rear surface of all dust seals.

MB991172 AC101698 AC

1. Use special tool inner shaft installer base (MB991172) to hold the centre bearing inner race, and then press-in the inner shaft.

FRONT AXLE

26-23


>>G<< PTJ BOOT BAND (SMALL)/PTJ BOOT BAND (LARGE) INSTALLATION Inner shaft

PTJ case

A

AC101699 AD

2. Apply repair kit grease to the inner shaft spline, then press fit it into the PTJ case. NOTE: When press-fitting the inner shaft into the PTJ case, apply a thin coat of repair kit grease to the dust seal outer lip part and the outside edge of the PTJ axial part. >>F<< PTJ CASE INSTALLATION

CAUTION The drive shaft joint use special grease. Do not mix old and new or different types of grease.

AC102656 AC

After applying the specified grease to the PTJ case, insert the drive shaft and apply grease one more time. Specified grease: Repair kit grease Amount to use: <2WD>: 210 10 g <4WD>: 150 10 g NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

AC102657AC

Set the PTJ boot bands at the specified distance in order to adjust the amount of air inside the PTJ boot, and then tighten the PTJ boot band (small), PTJ boot band (large) securely. Standard value (A): <2WD>: 90 3 mm <4WD>: 85 3 mm


Check the drive shaft for damage, bending or corrosion. Check the inner shaft for damage, bending or corrosion. Check the output shaft for damage, bending or corrosion. Check the drive shaft spline part for wear or damage. Check the inner shaft spline part for wear or damage. Check the output shaft spline part for wear or damage. Check the spider assembly for roller rotation, wear or corrosion. Check the groove inside PTJ case for wear or corrosion. Check the dynamic damper for damage or cracking. Check the boots for deterioration, damage or cracking. Check the centre bearing for seizure, discolouration or roughness of rolling surface. Check the dust cover for damage or deterioration.

FRONT AXLE

26-24


BJ BOOT (RESIN BOOT) REPLACEMENT M1261005200338

NOTE: The adjusting bolt should not be turned more than once. Boot A Boot band (small) B

AC102658

1. Remove the boot bands (large and small). NOTE: The boot bands cannot be re-used. 2. Remove the BJ boot. 3. Wrap a plastic tape around the shaft spline, and assemble the boot band and BJ boot.

Projection

AC102661AC

6. Position the BJ boot band (small) so that there is even clearance at either end (A and B).

CAUTION Secure the drive shaft in an upright position and clamp part of the boot band to be crimped securely in the jaws of special tool. Crimp the boot band until special tool touches the stopper.

AC102659

4. Align the centre groove on the BJ boot small end with the shaft groove.

MB991561 AC102663 AC

MB991561 Stopper

W

7. Use the special tool to crimp the boot band (small).

C

Adjusting bolt AC102660 AC

5. Turn the adjusting bolt on special tool boot band crimping tool (MB991561) so that the size of the opening (W) is at the standard value. Standard value (W): 2.9 mm Tighten the adjusting bolt. Loosen the adjusting bolt. NOTE: The value of W will change by approximately 0.7 mm for each turn of the adjusting bolt.

AC102662 AD

8. Check that the crimping amount (C) of the boot band is at the standard value. Standard value (C): 2.4 - 2.8 mm Readjust the value of (W) in step 5 according to the following formula, and then repeat the operation in step 7. W = 5.5 mm - C

FRONT AXLE

26-25


Example: If C = 2.9 mm, then W = 2.6 mm. Remove the BJ boot band, readjust the value of (W) in step 5 according to the following formula, and then repeat the operations in steps 6 and 7 using a new BJ boot band. W = 5.5 mm - C Example: If C = 2.3 mm, then W = 3.2 mm. 9. Check that the boot band is not sticking out past the place where it has been installed. If the boot band is sticking out, remove it and then repeat steps 6 to 8, using a new boot band.

CAUTION The drive shaft joint uses special grease. Do not mix old and new or different types of grease. 10.Fill the inside of the boot with the specified amount of the specified grease. Specified grease: Repair kit grease Amount to use: <2WD>: 120 10 g <4WD>: 85 10 g

Projection D Boot band (large) E

Boot

AC102665AC

13.Position the BJ boot band (large) so that there is even clearance at either end (D and E). 14.Use the special tool to crimp the BJ boot band (large) in the same way as in step 7.

F

AC102664 AC

11.Align the centre groove on the BJ boot big end with the BJ case groove. 12.Follow the same procedure as in step 5 to adjust the size of the opening (W) on the special tool so that it is at the standard value. Standard value (W): 2.9 mm

AC102666 AD

15.Check that the crimping amount (F) of the boot band is at the standard value. Standard value (F): 2.4 - 2.8 mm Readjust the value of (W) in step 12 according to the following formula, and then repeat the operation in step 14. W = 5.8 mm - F Example: If F = 2.9 mm, then W = 2.9 mm. Remove the BJ boot band, readjust the value of (W) in step 12 according to the following formula, and then repeat the operations in steps 13 and 14 using a new BJ boot band. W = 5.8 mm - F Example: If F = 2.3 mm, then W = 3.5 mm. 16.Check that the boot band is not sticking out past the place where it has been installed. If the boot band is sticking out, remove it and then repeat steps 13 to 15, using a new boot band.

127(6

27-1

GROUP 27

REAR AXLE

00 11 12 13

CONTENTS

14 15 16

REAR AXLE <2WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27A

17

REAR AXLE <4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27B

21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

127(6

27A-1

GROUP 27A

00 11

REAR AXLE <2WD>

12 13 14

CONTENTS GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . .

27A 27A

15

ON-VEHICLE SERVICE . . . . . . . . . . .

27A

WHEEL BEARING AXIAL PLAY CHECK . .

27A

REAR HUB ROTARY-SLIDING RESISTANCE CHECK . . . . . . . . . . . . . . . .

27A

SEALANT. . . . . . . . . . . . . . . . . . . . . .

27A

HUB BOLT REPLACEMENT. . . . . . . . . . . .

27A

SPECIAL TOOLS. . . . . . . . . . . . . . . .

27A

REAR AXLE HUB ASSEMBLY . . . . .

27A


27A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

27A

16 17 21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

REAR AXLE <2WD>

27A-2

GENERAL INFORMATION


The rear axle has the following features: The wheel bearing is a unit ball bearing (doublerow angular contact ball bearing) which incorporates the oil seals and is highly resistant to a thrust load. CONSTRUCTION DIAGRAM

ABS rotors for detecting the wheel speeds are press-fitted to the rear hub in vehicles with ABS.

Oil seal Rear hub

Trailing arm spindle Wheel bearing ABS rotor AC300617AB


Item

Limit


0.05

Rear hub rotary-sliding resistance N

19

SEALANT M1271000500249

Item

Specified sealant

Remark

Hub cap


Semi-drying sealant

REAR AXLE <2WD>

27A-3

SPECIAL TOOLS


Tool

Number

Name

Use

MB990767

End yoke holder

Hub fixing

MB991618

Hub bolt remover

Hub bolt removal

MD998801

Remover

Removal of ABS rotor

MD998812

Installer cap

MD998813

Installer 100

MD998815

Installer adapter

B990767

MB991618

REAR AXLE <2WD>

27A-4

ON-VEHICLE SERVICE

ON-VEHICLE SERVICE WHEEL BEARING AXIAL PLAY CHECK M1271000900377

1. Remove the caliper assembly, and suspend the caliper assembly with a wire and remove the brake disc.

4. If limit value is exceeded, loosen the self-locking nut and then tighten it to the specified torque and check the rear hub rotary sliding resistance again. Tightening torque: 175 25 N¼m 5. Replace the rear hub assembly if an adjustment cannot be made to within the limit.

HUB BOLT REPLACEMENT M1271001000214


AC206092 AC

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. Limit: 0.05 mm 3. If the play exceeds the limit, the self-locking nut should be tightened to the specified torque and check the axial play again. Tightening torque: 175 25 N¼m 4. Replace the rear hub assembly if an adjustment cannot be made to within the limit.

REAR HUB ROTARY-SLIDING RESISTANCE CHECK M1271001100222

1. Remove the caliper assembly, and suspend the caliper assembly with a wire and remove the brake disc. 2. Turn the hub a few times to seat the bearing.

MB991618

MB990767 AC301662 AB

2. Use the following special tools to remove the hub bolts. End yoke holder (MB990767) Hub bolt remover (MB991618) NOTE: To retain a space for removing the hub bolts, remove them near the retainer spring mounting position.

Plain washer

MB990767 AC301663 AB

3. Install the plain washer to the new hub bolt, and install the bolt with a nut. AC201814

3. Wind a rope around the hub bolt and turn the hub by pulling at a 90 angle with a spring balance. Measure to determine whether or not the rotarysliding resistance of the rear hub is at the limit value. Limit: 19 N

REAR AXLE <2WD>

27A-5

REAR AXLE HUB ASSEMBLY

REAR AXLE HUB ASSEMBLY REMOVAL AND INSTALLATION M1271002000347

CAUTION Care must be taken not to scratch or damage the teeth of the ABS rotor. The ABS rotor must never be dropped. If the teeth of the ABS rotor are chipped, resulting in a deformation of the ABS rotor, it will not be able to accurately detect the wheel rotation speed, and the system will not function normally. The rear hub assembly should not be dismantled. When removing the rear hub assembly, the wheel bearing inner race may be left at the spindle side. In this case, always replace the rear hub assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play.

1 60 ± 5 N·m

6 2 175 ± 25 N·m

7

4N 3

3

5

Semi-drying sealant: 3M ATD Part No. 8663 or equivalent AC301185 AB

<>

1. 2. 3. <> >>B<< 4.

Removal steps Caliper assembly Brake disc Hub cap Self-locking nut

5.

<> >>A<< 6. 7.

Removal steps&RQWLQXHG Rear hub assembly ABS rotor Hub bolt

REAR AXLE <2WD>

27A-6




<> CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, etc.

>>A<< ABS ROTOR INSTALLATION

<> SELF-LOCKING NUT REMOVAL

CAUTION

CAUTION When installing, take care not to deform the ABS rotor. Iron piece ABS rotor Rear hub assembly

Iron piece AC301112 AB

Do not apply the vehicle weight to the wheel bearing while loosening the self-locking nut, or the wheel bearing will be damaged. <> ABS ROTOR REMOVAL

AC102209 AC

Press-fit the ABS rotor to the rear hub assembly. >>B<< SELF-LOCKING NUT INSTALLATION

CAUTION 175 ± 25 N·m

MD998812

MD998813 AC301113 AB

ABS rotor MD998815 MD998801

Before securely tightening the self-locking nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged. Tighten the self-locking nut to the specified torque.


Rear hub assembly

AC210936 AC

Use the following special tools to press out ABS rotor from the rear hub assembly. Remover (MD998801) Installer cap (MD998812) Installer100 (MD998813) Installer adapter (MD998815)

Check the rear hub assembly for crack or damage. Check the oil seal of the rear hub assembly for crack or damage. Check the ABS rotor for chipped teeth.

27B-1

GROUP 27B

00 11

REAR AXLE <4WD>

12 13 14


27B

15

REAR AXLE HUB ASSEMBLY . . . . .

27B


27B

16


27B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

27B

17

LUBRICANTS . . . . . . . . . . . . . . . . . .

27B

DRIVE SHAFT ASSEMBLY . . . . . . . .

27B

21


27B

SEALANT AND ADHESIVE. . . . . . . .

27B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

27B


27B

SPECIAL TOOLS. . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .

27B 27B

DIFFERENTIAL CARRIER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 27B

REAR AXLE TOTAL BACKLASH CHECK .

27B


27B

GEAR OIL LEVEL CHECK . . . . . . . . . . . . .

27B

WHEEL BEARING END PLAY CHECK . . .

27B

DIFFERENTIAL SUPPORT MEMBER BUSHING REPLACEMENT . . . . . . . . . . . .

27B

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

27B

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

27B

DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . .

27B

22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

REAR AXLE <4WD>

27B-2

GENERAL INFORMATION


The rear axle has the following features. The wheel bearing is a double-row angular contact ball bearing which incorporates the oil seals and is highly resistant to a thrust load. The drive shaft has BJ-TJ constant velocity joints. A smaller BJ side boot is used.

ABS rotors for detecting the wheel speed are press-fitted to the BJ outer wheels. NOTE: . TJ: Tripod Joint BJ: Birfield Joint

SPECIFICATIONS Item Wheel bearing

Drive shaft

Specification Type

Double-row angular contact ball bearing

Bearing (OD x ID) mm

70 40

Type Length (joint to joint) outer diameter mm

Outer

BJ

Inner

TJ

LH

481 22

RH

571 22

CONSTRUCTION DIAGRAM

Differential carrier TJ BJ

Rear hub

Drive shaft

ABS rotor AC300622 AB

REAR AXLE <4WD>

27B-3



Item

Standard value

Limit

Rear axle total backlash mm

-

5

Wheel bearing rotation starting torque N¼m

-

1.0

Wheel bearing end play mm

-

0.05

TJ boot assembly dimension mm

80 3

-

Drive gear backlash mm

0.11 - 0.16

-

Drive gear runout mm

-

0.05

Differential gear backlash mm

0 - 0.076

0.2

Drive pinion turning torque N¼m

0.9 - 1.2

-

With Companion flange (oil seal 1.0 - 1.3 oil seal contacting area) with anti-rust agent

-

Without oil seal

Companion flange (oil seal contacting area) with gear oil applied

0.5 - 0.6

-


Item

Specified lubricant

Quantity

Rear differential gear oil

Hypoid gear oil API classification GL-5 or higher SAE viscosity No. 90, 80W

0.55 L

Drive shaft BJ joint

Repair kit grease

75 10 g

Drive shaft TJ joint

Repair kit grease

110 10 g

SEALANT AND ADHESIVE M1271000500227

Item

Specified sealant and adhesive

Remark

Differential cover

3M ATD Part No. 8661 or equivalent

Semi-drying sealant

Drive gear and differential case mounting part

3M Stud Locking 4170 or equivalent

Anaerobic sealant

REAR AXLE <4WD>

27B-4

SPECIAL TOOLS


Tool

Number

Name

Use

MB991115

Oil seal installer

Press-fitting of the differential carrier oil seal (Use together with MB990938)

MB990767

End yoke holder

Rear axle hub fixing

MB990241 A: MB990242 B: MB990244

Axle shaft puller A: Puller shaft B: Puller bar

Removal of the drive shaft

MB991354

Puller body

A: MB991017 B: MB990998 C: MB991000


Provisional holding of the wheel bearing Measurement of wheel bearing rotation starting torque Measurement of wheel bearing end play NOTE: MB991000, which belongs to MB990998, should be used as a spacer.

MB990883


Removal and installation of the differential support member bushing

MB990884

Mount bushing arbor

B990767

A B

MB990241AB

MB991354

A

B C AC100320AB

MB990883

REAR AXLE <4WD>

27B-5

SPECIAL TOOLS

Tool

Number

Name

Use

MB990909

Working base

Supporting of the differential carrier

MB991116

Working base adapter

MB990810

Side bearing puller

Removal of the side bearing inner race Removal of the companion flange

MB990850

End yoke holder

Companion flange fixing

MB990339

Bearing puller

Removal of drive pinion rear bearing inner race

MB990374

Pinion bearing remover

MB990835 A: MB990836 B: MB990392

Drive pinion setting Adjustment of the drive pinion gauge set height A: Drive pinion gauge assembly B: Cylinder gauge

MB990326

Preload socket

MB990685

Torque wrench

MB990909

MB990810

MB990850

MB990339

A

B

MB990326

Measurement of the wheel bearing rotation starting torque Measurement of the drive pinion turning torque

REAR AXLE <4WD>

27B-6

ON-VEHICLE SERVICE

Tool

Number

Name

Use

MB990728

Bearing installer

Press-fitting of the drive pinion rear bearing inner race

MB990031 or MB990699

Oil seal installer

Press-fitting of the drive pinion oil seal

MB990925 A: MB990926 - MB990937 B: MB990938 C: MB990939

Press-fitting of differential Bearing and oil carrier oil seal seal installer set (Use together with A: Installer adapter MB991115) B: Bar Inspection of final drive gear C: Brass bar tooth contact Removal and installation of drive pinion front/rear bearing outer race For details of each installer, refer to GROUP 26 - Special Tools326.

MB990728

MB990031

A C B

MB990925

ON-VEHICLE SERVICE REAR AXLE TOTAL BACKLASH CHECK M1271001200218

1. Park the vehicle on a flat, level surface. 2. Move the transmission gearshift lever to the neutral position. Apply the parking brake and jack up the vehicle. Mating marks

AC301510AB

AC301509AB

3. Turn the propeller shaft clockwise as far as it will go. Make the mating marks on the companion flange and on the differential carrier.

4. Turn the propeller shaft counterclockwise as far as it will go, and measure the amount of distance between the mating marks. Limit: 5 mm 5. If the backlash exceeds the limit value, remove the differential carrier assembly and check the following. Final drive gear backlash (Refer to327B.) Differential gear backlash (Refer to 327B.)

REAR AXLE <4WD> ON-VEHICLE SERVICE

GEAR OIL LEVEL CHECK M1272001200181

Gear oil

Upper limit Lower limit

27B-7

3. If the play exceeds the limit, the drive shaft nut should be tightened to the specified torque and check the end play again. Tightening torque: 245 29 N¼m 4. Replace the wheel bearing if adjustment cannot be made to within the limit. (Refer to GROUP 34Trailing Arm334.)

DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT

8 mm

M1272001300111 AC102739 AD

Check that gear oil level is not 8 mm below the bottom of filler plug hole. Specified gear oil: Hypoid gear oil API classification GL-5 or higher SAE viscosity Number 90, 80W

1. Remove the drive shaft from the differential carrier. (Refer to 327B). 2. Remove the differential carrier oil seal.

MB990938

WHEEL BEARING END PLAY CHECK M1271000900388


MB991115 AC102740 AC

AC206092 AC

2. Fit the dial gauge as shown in the diagram and move the hub in the axial direction to measure the play. Limit: 0.05 mm

3. Use the following special tools to press-fit a new oil seal. Installer bar (MB990938) Oil seal installer (MB991115) 4. Apply multi-purpose grease to the oil seal lip and drive shaft oil seal seating area. 5. Replace the drive shaft circlip with a new one, and install the drive shaft to the differential carrier. (Refer to 327B).

REAR AXLE <4WD>

27B-8


REAR AXLE HUB ASSEMBLY REMOVAL AND INSTALLATION M1271002000358

2

1

AC301904 AB

Removal steps 1. Rear hub assembly (Refer to GROUP 34, Trailing arm assembly 334). 2. Hub bolt


WHEEL BEARING ROTATION STARTING TORQUE AND AXIAL PLAY CHECK MB990685 245 ± 29 N·m

MB991017 MB991000

Wheel bearing AC102720 AC

1. Tighten the following special tools to the specified torque. Spacer (MB991000) Front hub remover and installer (MB991017) 2. Rotate the rear hub in order to seat the bearing.

MB990326

AC301905AB

3. Measure the wheel bearing rotation starting torque by using the following special tools. Preload socket (MB990326) Torque wrench (MB990685) Limit: 1.0 N¼m 4. The rotation starting torque must be within the limit and wheel bearing must rotate smoothly.

REAR AXLE <4WD> DRIVE SHAFT ASSEMBLY

27B-9

6. If the play is not within the limit range while the nut is tightened to 245 29 N¼m, the bearing, trailing arm and/or rear hub have probably not been installed correctly. Replace the bearing and reinstall.

AC301906

5. Measure to determine whether the wheel bearing axial play is within the specified limit or not. Limit: 0.05 mm

DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION M1271003300147

CAUTION Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be damaged. Be careful not to strike the pole piece at the tip of the rear ABS sensor with tools during servicing work. Pre-installation Operation Differential Gear Oil Draining (Refer to 327B ).

N

Post-installation Operation Differential Gear Oil Filling (Refer to 327B). Rear Wheel Alignment Check and Adjustment (Refer to GROUP 34, On-Vehicle Service Rear Wheel Alignment Check and Adjustment 334).

245 ± 29 N·m

3

1N 2

AC201825 AB

Removal steps

<> >>B<< 1. Drive shaft nut ¼ Rear ABS sensor (Refer to GROUP 35B, Wheel Speed Sensor 335B). ¼ Lower arm and trailing arm connection (Refer to Group 34, Trailing arm assembly 334).

Removal steps&RQWLQXHG ¼ Control link and trailing arm connection (Refer to GROUP 34, Trailing arm assembly 334). <> >>A<< 2. Drive shaft 5. Circlip

REAR AXLE <4WD>

27B-10



CAUTION

<> DRIVE SHAFT NUT REMOVAL

CAUTION

Do not pull on the drive shaft; doing so will damage the TJ; be sure to use the pry bar. When pulling the drive shaft out from the differential carrier, be careful that the spline part of the drive shaft does not damage the oil seal. Differential carrier

MB990767 AC201826 AC

Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage to wheel bearing before tightening drive shaft nut fully. Use special tool end yoke holder (MB990767) to fix the hub and remove the drive shaft nut.

TJ assembly Pry bar AC102552 AE

2. Remove the drive shaft from the differential carrier by using a pry bar.

<> DRIVE SHAFT REMOVAL MB990242 (MB990241)

245 ± 29 N·m

MB990767

MB991354

MB990244 (MB990241) (Three)

MB991017 MB991000

AC102720 AC

AC201827 AC

1. Use the following special tools to push out the drive shaft from the hub. Puller shaft (MB990242) Puller bar (MB990244) Puller body (MB991354) End yoke holder (MB990767)

Wheel bearing

CAUTION Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft is removed. If, however, vehicle weight must be applied to the bearing in moving the vehicle, temporarily secure the wheel bearing by using the following special tools. Front hub remover and installer (MB991017) Spacer (MB991000)

INSTALLATION SERVICE POINTS >>A<< DRIVE SHAFT INSTALLATION

CAUTION When installing the drive shaft, be careful that the spline part of the drive shaft does not damage the oil seal.

REAR AXLE <4WD> DRIVE SHAFT ASSEMBLY

>>B<< DRIVE SHAFT NUT INSTALLATION

27B-11


CAUTION Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage to wheel bearing before tightening drive shaft nut fully.

245 ± 29 N·m

Washer MB990767 AC201828 AC

1. Assemble the drive shaft washer in the illustrated direction. 2. Tighten the drive shaft nut to the torque specification with special tool end yoke holder (MB990767).

Check the drive shaft for damage, bending or corrosion. Check the drive shaft spline part for wear or damage. Check the boots for deterioration, damage or cracking. Check the dust cover for damage or deterioration.

REAR AXLE <4WD>

27B-12



CAUTION Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly and reassembly. Never disassemble the BJ assembly except when replacing the BJ boot.

5N

1N 7

N4

2N 3

8N

10

6

11 N9

4

5

4

1 9

8

10

6 7

11

1 2

2

5

BJ repair kit

4

3

TJ repair kit

5

4

1 2

5

8

7 1

10

2

9 Grease for TJ

Grease for BJ

BJ boot repair kit

TJ boot repair kit AC201162 AB

Disassembly steps

>>C<< 1. TJ boot band (large) >>C<< 2. TJ boot band (small) <> >>B<< 3. TJ case 4. Circlip 5. Snap ring <> >>B<< 6. Spider assembly

Disassembly steps&RQWLQXHG

<> >>A<< 7. TJ boot 8. 9. <> >>A<< 10. 11.

BJ boot band (large) BJ boot band (small) BJ boot BJ assembly

REAR AXLE <4WD>

27B-13


LUIBRICATION POINTS

Grease: repair kit grease Amount used: 110 ± 10 g

CAUTION The drive shaft joint uses special grease. Do not mix old and new or different types of grease.

Grease: repair kit grease Amount used: 75 ± 10 g

CAUTION The drive shaft joint uses special grease. Do not mix old and new or different types of grease.

AC212165 AC

DISASSEMBLY SERVICE POINTS <> TJ CASE/SPIDER ASSEMBLY REMOVAL

CAUTION Do not disassemble the spider assembly. 1. Wipe off grease from the TJ case and spider assembly. 2. If there is water or foreign material in the wiped grease, be sure to clean the spider assembly. <> TJ BOOT/BJ BOOT REMOVAL 1. Wipe off grease from the shaft spline part.

PLASTIC TAPE

ACX02368 AB

2. Wrap plastic tape around the spline part on the TJ side of the drive shaft so that TJ and BJ boots are not damaged when they are removed.

REAR AXLE <4WD>

27B-14


REASSEMBLY SERVICE POINTS >>A<< BJ BOOT/TJ BOOT INSTALLATION Wrap plastic tape around the spline part on the TJ side of the drive shaft, and then install BJ and TJ boots. >>B<< SPIDER ASSEMBLY/TJ CASE INSTALLATION

CAUTION The drive shaft joint uses special grease. Do not mix old and new or different types of grease. If the spider assembly has been cleaned, take special care to apply the specified grease. 1. Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller. Specified grease: Repair kit grease

AC102656 AC

3. After applying the specified grease to the TJ case, insert the driveshaft and apply grease one more time. Specified grease: Repair kit grease Used amount: 110 10 g NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot. >>C<< TJ BOOT BAND (SMALL)/TJ BOOT BAND (LARGE) INSTALLATION

Chamfered side

AC102654AC

2. Install the spider assembly to the shaft from the direction of the spline chamfered side.

A AC102657AC

Set the TJ boot bands at the specified distance in order to adjust the amount of air inside the TJ boot, and then tighten the TJ boot band (large) and TJ boot band (small) securely. Standard value (A): 80 3 mm

REAR AXLE <4WD>

27B-15

DIFFERENTIAL CARRIER ASSEMBLY

DIFFERENTIAL CARRIER ASSEMBLY REMOVAL AND INSTALLATION M1272002000209

Pre-removal Operation Main Muffler and Center Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Muffler 315). Differential Gear Oil Draining Drive Shaft Removal (Refer to 327B).

Post-installation Operation Drive Shaft Installation (Refer to 327B). Differential Gear Oil Filling (Refer to 327B). Main Muffler and Center Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Muffler 315). Rear Wheel Alignment Check and Adjustment (Refer to GROUP 34, On-Vehicle Service-Rear Wheel Alignment Check and Adjustment 334).

6

N

5

90 ± 10 N·m

4

90 ± 10 N·m

7 12 3

N

2N 44 ± 9 N·m 49 ± 9 N·m

10 11 32 ± 2 N·m

1

9 N

8 64 ± 4 N·m

90 ± 10 N·m

70 ± 10 N·m AC203973 AD

<> >>B<< 1. 2. 3. 4. 5. 6.

Removal steps Propeller shaft connection Self-locking nut Dynamic damper Differential support arm connecting bolt Self-locking nut Differential support arm

>>A<< 7. 8. 9. 10. 11. 12.

Removal steps&RQWLQXHG Breather hose assembly Differential mount bracket bolt Lower stopper Upper stopper Differential mount bracket Differential carrier assembly

REAR AXLE <4WD>

27B-16


REMOVAL SERVICE POINTS <> PROPELLER SHAFT DISCONNECTION

DIFFERENTIAL SUPPORT MEMBER BUSHING REPLACEMENT M1272001400066

MB990883 Differential mount bracket Bushing

Mating marks

AC300150 AB

1. Make mating marks on the differential companion flange and the propeller shaft assembly. 2. Suspend the removed propeller shaft from the body with a wire to prevent bending.

Iron piece Hollow portion

INSTALLATION SERVICE POINTS >>A<< BREATHER HOSE ASSEMBLY INSTALLATION

CAUTION Be careful not to apply grease, water or soapy water to the hose inlet. Breather hose assembly Pad Vent plug

Differential case

Drive shaft AC211428AD

Fully insert the breather hose into the vent plug. Install the breather hose pad as shown in the illustration. >>B<< PROPELLER SHAFT INSTALLATION Align the mating marks of differential companion flange and propeller shaft assembly.

AC107255 AB

1. Use special tool rear suspension bushing arbor (MB990883) to remove or install the bushing. 2. Press-fit the bushing with its hollow portion facing in the direction shown. 3. Press-fit the bushing until the bushing outer case end face is flush with the differential mount bracket.

REAR AXLE <4WD>

27B-17


MB990984 Differential support member

MB990984 Differential support arm

Bushing

Bushing

Iron piece Iron piece

LH side MB990883

Differential support member

Bushing Bushing

Marks 45˚ RH side

Iron piece Hollow portion

Bushing

Marks AC107256 AB

AC102751AD

1. Use the following special tools to remove or install the bushing. Mount bushing arbor (MB990984) Rear suspension bushing arbor (MB990883) 2. Press-fit the bushing with its hollow portion facing in the direction shown. 3. Press-fit the bushing until the bushing outer case end face is flush with the differential mount bracket.

1. Use special tool mont bushing arbor (MB990984) to remove or install the bushing. 2. Press-fit the bushing with its marks facing in the direction shown. 3. Press-fit the bushing until the bushing outer case end face is flush with the differential support arm.

REAR AXLE <4WD>

27B-18


DISASSEMBLY M1272002200203

8

6N

9 10 18 17 14 1516 13 12 19 5

17 18

11

2N 10

16 15

9

1

11

9

28 32 27 25 26 24 22

34

31 23 20 N

4N 30 29 N

21

33 N

3

AC301212AB

<> <> <> <> <> <>

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Disassembly steps Inspection before disassembly (Refer to 327B). Filler plug Gasket Drain plug Packing Differential cover Vent plug Bearing cap Differential case assembly Differential side bearing spacer Differential side bearing outer race Differential side bearing inner race Drive gear Lock pin Pinion shaft Pinion gear Pinion washer Side gear

<> <> <>

<>

<> <> <> <>

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Disassembly steps&RQWLQXHG Side gear spacer Differential case Self-locking nut Washer Drive pinion assembly Companion flange Drive pinion front shim (For adjusting preload of drive pinion) Drive pinion spacer Drive pinion rear bearing inner race Drive pinion rear shim (for adjusting drive pinion height) Drive pinion Oil seal Drive pinion front bearing inner race Drive pinion front bearing outer race Drive pinion rear bearing outer race Oil seal Differential carrier

REAR AXLE <4WD>

27B-19


INSPECTION BEFORE DISASSEMBLY 1. Remove the cover. MB990909 and MB991116

2. When runout exceeds the limit value, check for foreign material between drive gear rear side and differential case, or for loose drive gear installation bolts. 3. When step (2) gives normal results, reposition the drive gear and differential case and remeasure. 4. If adjustment is impossible, replace the differential case, or replace the drive gear and pinion as a set. DIFFERENTIAL GEAR BACKLASH

AC102883 AC

2. Hold the following special tools in a vise, and install the differential carrier assembly to the special tool. Working base (MB990909) Working base adapter (MB991116) FINAL DRIVE GEAR BACKLASH

Wedge

Side gear spacer

Side gear spacer AC102885 AC

AC102884

1. With the drive pinion locked in place, use a dial gauge to measure the drive gear backlash in four or more places on the drive gear. Standard value: 0.11 - 0.16 mm 2. If the backlash is not within the standard value, adjust the final drive gear backlash (Refer to 327B). 3. After the adjustment, inspect the final drive gear tooth contact. DRIVE GEAR RUNOUT

AC102886

1. Measure the drive gear runout at the shoulder on the reverse side of the drive gear. Limit: 0.05 mm

1. Insert a wedge between the side gear and the pinion shaft to lock the side gear. 2. While locking the side gear with the wedge, measure the differential gear backlash with a dial indicator on the pinion gear. Use the measurement procedure for the other pinion gear. Standard value: 0 - 0.076 mm Limit: 0.2 mm 3. If the backlash exceeds the limit value, adjust it by replacing the side gear spacers. 4. If adjustment is not possible, replace the side gears and pinion gears as a set. FINAL DRIVE GEAR TOOTH CONTACT Check the tooth contact of drive gear by following the steps below.

AC102887

1. Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth.

REAR AXLE <4WD>

27B-20


3. Check the tooth contact condition of the drive gear and drive pinion.

CAUTION If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check.

MB990939

AC102888 AC

2. Insert special tool brass bar (MB990939) between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear so that the revolution torque (approximately 2.5 - 3.0 N¼m) is applied to the drive pinion. Standard tooth contact pattern Problem 1. Narrow tooth side 2. Drive-side tooth surface (the side applying power during forward movement) 3. Wide tooth side 4. Coast-side tooth surface (the side applying power during reverse movement)

2

1

4

3 ACX01039 AF

Solution

Tooth contact pattern resulting from excessive pinion height 1

2

1

2

4

3

4

AC107261AB

Increase the thickness of the drive pinion rear shim, 3 and position the drive pinion AC107260 AB closer to the center of the The drive pinion is positioned too drive gear. Also, for far from the center of the drive backlash adjustment, gear. position the drive gear farther from the drive pinion. Tooth contact pattern resulting from insufficient pinion height. 2

2

1

4

3

1

4

AC107263 AB

Decrease the thickness of the drive pinion rear shim, 3 and position the drive pinion AC107262 AB farther from the center of The drive pinion is positioned too the drive gear. Also, for close to the center of the drive backlash adjustment, gear. position the drive gear closer to the drive pinion.

REAR AXLE <4WD>

27B-21


NOTE: Check the tooth contact pattern to confirm that the adjustments of the pinion height and backlash have been done properly. Continue to adjust the pinion height and backlash until the tooth contact pattern resembles the standard pattern. If, even after adjustments have been made, the correct tooth contact pattern cannot be obtained, it means that the drive gear and the drive pinion have become worn beyond the allowable limit. Replace the gear set.

<> DIFFERENTIAL SIDE BEARING INNER RACE REMOVAL MB990810

Socket wrench

DISASSEMBLY SERVICE POINTS <> DIFFERENTIAL CASE ASSEMBLY/ DIFFERENTIAL SIDE BEARING SPACER/ DIFFERENTIAL SIDE BEARING OUTER RACE REMOVAL

CAUTION When taking out the differential case assembly, be careful not to drop and damage the differential side bearing spacers and differential side bearing outer races.

AC107274 AB

Use special tool side bearing puller (MB990810) to pull out the side bearing inner races. NOTE: There are two notches provided (at the differential case side) for the claw part of the special tools; use special tool at that position. <> DRIVE GEAR REMOVAL

Mating marks

AC102891 AC AC102889

Use the wooden handle of a hammer to remove the differential case assembly, differential side bearing spacers and differential side bearing outer races. NOTE: Keep the right and left side bearings and side bearing spacers separate, so that they do not become mixed during reassembly.

1. Make the mating marks to the differential case and the drive gear. 2. Loosen the drive gear attaching bolts in a diagonal sequence to remove the drive gear. <> LOCK PIN REMOVAL

AC102892

Drive out the lock pin with a punch.

REAR AXLE <4WD>

27B-22



<> DRIVE PINION REAR BEARING INNER RACE REMOVAL MB990339

MB990850

AC102893AC

Use special tool end yoke holder (MB990850) to hold the companion flange, and then remove the companion flange self-locking nut. <> DRIVE PINION ASSEMBLY/COMPANION FLANGE REMOVAL

CAUTION The mating mark made on the companion flange must not be on the coupling surface of the companion flange and the front propeller shaft. 1. Make mating marks on the drive pinion and companion flange.

MB990374 AC102895AD

Use the following special tools to pull out the drive pinion rear bearing inner race. Bearing puller (MB990339) Pinion bearing remover (MB990374) <> OIL SEAL/DRIVE PINION FRONT BEARING INNER RACE/DRIVE PINION FRONT BEARING OUTER RACE REMOVAL MB990939

MB990810 Drive pinion front bearing outer race

Drive pinion front bearing inner race

Oil seal

AC102896 AC

Companion flange AC102894 AD

2. Use special tool side bearing puller (MB990810) to pull out the companion flange.

Use special tool bras bar (MB990939) to remove the oil seal, drive pinion front bearing inner race, and drive pinion front bearing outer race. <> DRIVE PINION REAR BEARING OUTER RACE REMOVAL MB990939 Drive pinion rear bearing outer race

AC102897AC

Use special tool brass bar (MB990939) to remove the drive pinion rear bearing outer race.

REAR AXLE <4WD>

27B-23


REASSEMBLY M1272002300211

23 15

29 N

27

5

26 25 17 18 21 20 19 22 23 16

36 ± 5 N·m

34 Final drive gear set

18 17

24

49 ± 9 N·m

33 N

37 ± 2 N·m

30 19

28

25

20

24

26

5 1 8 9

4 13

7

3

6 84 ± 4 N·m

10

37 ± 2 N·m

20 15 N

31 N 11 14

12 N

2N 17 18

32 64 ± 4 N·m

17

18

20

Differential gear set

186 ± 29 N·m

AC301213 AB

>>A<< >>B<< >>C<< >>D<<

1. 2. 3. 4. 5. 6.

7. 8. >>E<< 9. 10. 11. >>E<< 12. 13. 14. 15. 16.

Reassembly steps Differential carrier Oil seal Drive pinion rear bearing outer race Drive pinion front bearing outer race Drive pinion height adjustment Drive pinion Drive pinion rear shim (for adjusting drive pinion height) Drive pinion rear bearing inner race Drive pinion spacer Drive pinion turning torque adjustment Drive pinion front shim (for adjusting drive pinion turning torque) Drive pinion assembly Drive pinion front bearing inner race Oil seal Companion flange Washer Self-locking nut Differential case

>>F<<

>>G<< >>H<< >>I<<

>>J<<

>>J<<

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Reassembly steps&RQWLQXHG Differential gear backlash adjustment Side gear spacer Side gear Pinion washer Pinion gear Pinion shaft Lock pin Drive gear Differential side bearing inner race Differential side bearing outer race Differential side bearing spacer Differential case assembly Bearing cap Vent plug Differential cover Packing Drain plug Gasket Filler plug Final drive gear backlash adjustment

REAR AXLE <4WD>

27B-24


Lubrication and Adhesive Points

Vent plug

Adhesive: 3M Stud Locking 4170 or equivalent

2 – 3 mm (bead diameter)

Semi-driying sealant: 3M ATD Part No.8661 or equivalent AC301214 AB

REASSEMBLY SERVICE POINTS >>A<< OIL SEAL PRESS-FITTING

MB990938

MB991115 AC102740 AC

Use the following special tools to press-fit a new oil seal.

Installer bar (MB990938) Oil seal installer (MB991115)

REAR AXLE <4WD>

27B-25


>>B<< DRIVE PINION REAR BEARING OUTER RACE PRESS-FITTING

CAUTION There should be no gear oil adhered to the bearing.

MB990938 MB990935

MB990836

AC102907AD

Use the following special tools to press-fit the drive pinion rear bearing outer race. Installer bar (MB990938) Installer adapter (MB990935)

AC102910 AD

MB990685

MB990326

>>C<< DRIVE PINION FRONT BEARING OUTER RACE PRESS-FITTING MB990938 MB990932 AC102911 AC

AC102908 AD

Use the following special tools to press-fit the drive pinion front bearing outer race. Installer bar (MB990938) Installer adapter (MB990932) >>D<< DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedures: 1. Apply multipurpose grease to the washer of special tool drive pinion gauge asseembly (MB990836).

3. Tighten the nut of special tool a little at a time, while measuring the turning torque of the drive pinion by using the following special tools. Then confirm that the turning torque (without the drive pinion oil seal) is at the standard value. Preload socket (MB990326) Torque wrench (MB990685) Standard value: Bearing division

Turning torque

New

0.9 - 1.2 N¼m

NOTE: Because the special tool preload socket (MB990326) cannot be turned one turn, turn it several times within the range that it can be turned; then, after fitting to the bearing, measure the turning torque. 4. Clean the side bearing seat of the differential carrier and bearing caps. Notch MB990392

MB990836 AC102909 AC

2. Install special tool, drive pinion front and rear bearing inner races to the differential carrier as shown in the illustration.

A MB990836

Thickness gauge

AC102912 AD

REAR AXLE <4WD>

27B-26


5. Place the following special tools in the side bearing seat of the differential carrier, and position the notch as shown in the illustration. Then install the bearing caps. Cylinder gauge (MB990392) Drive pinion gauge assembly (MB990836) 6. Use a thickness gauge to measure the clearance (A) between special tools. 7. Remove the bearing caps and special tools.

C

11.Fit the selected drive pinion rear shim(s) to the drive pinion, and press-fit the drive pinion rear bearing inner race by using special tool bearing installer (MB990728). >>E<< DRIVE PINION TURNING TORQUE ADJUSTMENT/OIL SEAL INSTALLATION Adjust the drive pinion turning torque by the following procedures: 1. Insert the drive pinion into the differential carrier, and then install the following parts in sequence from the carrier rear side: drive pinion spacer, drive pinion front shim , drive pinion front bearing inner race and companion flange. NOTE: Do not install the oil seal.

B

MB990850 AC102913 AC

8. Use a micrometer to measure the shown dimensions (B, C) of special tools.

AC201179 AB

D Cylinder gauge

AC102914 AC

9. Install the bearing cap, and then use a cylinder gauge to measure the inside diameter (D) of the bearing cap. 10.Calculate thickness (F) of the required drive pinion rear shim by the following formula. Select a shim which most closely matches this thickness. F = A + B + C - 1/2D - 86.00 mm

2. Tighten the companion flange self-locking nut to the specified torque while holding the companion flange with special tool end yoke holder (MB990850). Tightening torque: 186 29 N¼m

CAUTION There should be no gear oil adhered to the bearing. MB990326 MB990685

MB990728 Drive pinion rear shim ACX01062AD

MB990728 ACX02432 AD

3. Use the following special tools MB990685 and MB990326 to measure the drive pinion turning torque (without the drive pinion oil seal). Preload socket (MB990326) Torque wrench (MB990685) Standard value:

REAR AXLE <4WD>

27B-27


Bearing division

Turning torque

New

0.9 - 1.2 N¼m

4. If the drive pinion turning torque is not within the standard value, adjust the turning torque by replacing the drive pinion front shim(s) or the drive pinion spacer. NOTE:

MB990031 or MB990699

ACX01064AG

A Identification colour

5. Remove the companion flange and drive pinion again. Then insert the drive pinion front bearing inner race into the differential carrier. Use special tool oil seal installer (MB990031 or MB990699) to press-fit the drive pinion oil seal.

ACX01063 AE

When selecting the drive pinion front shims, if the number of shims is large, reduce the number of shims to a minimum by selecting the drive pinion spacers. Select the drive pinion spacer from the following two types. Height of drive pinion Identification colour spacer (A) mm 57.08

Red

57.72

-

MB990850

AC201179 AB

6. Install the drive pinion assembly and companion flange with the mating marks properly aligned. Tighten the companion flange self-locking nut to the specified torque while holding the companion flange with special tool. Tightening torque: 186 29 N¼m

REAR AXLE <4WD>

27B-28


MB990326

2. Temporarily install the pinion shaft. NOTE: Do not assemble the lock pin yet.

MB990685 Wedge

ACX01062AD

7. Use special tools to measure the drive pinion turning torque (with drive pinion oil seal) to verify that the drive pinion turning torque complies with the standard value. Standard value: Bearing division

Companion flange lubrication

Turning torque

New

None (with antirust agent)

1.0 - 1.3 N¼m

Gear oil applied

0.5 - 0.6 N¼m

8. If the turning torque is not within the standard value, check the tightening torque of the companion flange self-locking nut, and the installation of the oil seal. >>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT Adjust the differential gear backlash by the following procedure:

Side gear spacer

Side gear spacer AC102885 AC

3. Insert a wedge between the side gear and the pinion shaft to lock the side gear. 4. While locking the side gear with the wedge, measure the differential gear backlash with a dial indicator on the pinion gear. Measure by the same procedure for the other pinion gear. Standard value: 0 - 0.076 mm Limit: 0.2 mm 5. If the backlash exceeds the limit value, adjust it by replacing the side gear spacers. 6. If adjustment is not possible, replace the side gears and pinion gears as a set. 7. Check that the backlash is within the limit value and that the differential gear turns smoothly. >>G<< LOCK PIN INSTALLATION 1. Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin.

ACX01066

1. Assemble the side gears, side gear spacers, pinion gears, and pinion washers into the differential case.

ACX02429 AC

2. Stake the lock pin with a punch on both sides.

REAR AXLE <4WD> DIFFERENTIAL CARRIER ASSEMBLY

>>H<< DRIVE GEAR INSTALLATION 1. Clean the drive gear attaching bolts.

Tap

27B-29

>>J<< BEARING CAP INSTALLATION/FINAL DRIVE GEAR BACKLASH ADJUSTMENT Adjust the final drive gear backlash by the following procedure: 1. Assemble the differential case with the side bearing outer race to the differential carrier.

ACX01068 AD

2. Remove the adhesive adhered to the threaded holes of the drive gear by turning the tap (M10 x 1.25). Clean the threaded holes by applying compressed air.

ACX01071AD

2. Press the differential case to one side to measure the clearance of the side bearing outer race and the differential carrier. 3. Select two pairs of side bearing spacers. Determine the thickness by adding 1/2 of the clearance to the pre-load 0.05mm. MB990810 ACX02430 AB

3. Apply the specifed sealant to the threaded holes of the drive gear. Specified sealant: 3M stud locking 4170 or equivalent 4. Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the drive gear attching bolts to the specified torque in a diagonal sequence. Tightening torque: 84 4 N¼m >>I<< DIFFERENTIAL SIDE BEARING INNER RACE INSTALLATION Piece of metal

Piece of metal

MB990728

AC102942 AC

Use special tool bearing installer (MB990728) to press-fit the differential side bearing inner races into the differential case.

Socket wrench

AC107274 AB

4. Remove the side bearing by using special tool side bearing puller (MB990810). NOTE: Hook the claws of special tool with the side bearing inner race by using the notches (two areas) of the differential case side. 5. Assemble the selected side bearing spacers to each side.

REAR AXLE <4WD>

27B-30 Piece of metal

DIFFERENTIAL CARRIER ASSEMBLY Piece of metal

WHEN THE BACKLASH IS SMALL

DECREASED

INCREASED

INCREASED

DECREASED

MB990728

WHEN THE BACKLASH IS LARGE

AC102942 AC

6. Use special tool bearing installer (MB990728) to press-fit the side bearing inner race into the differential case. After installing the outer race, assemble the differential case to the differential carrier. 7. Align the mating marks of differential carrier and the bearing cap with each other and tighten the bearing cap attaching bolts to the specified torque. Tightening torque: 37 2 N¼m

AC107626 AB

9. If the backlash is not within the standard value, move the side bearing spacer as shown in the illustration to adjust the backlash. NOTE: The increment of side bearing spacer must be the same as the decreased amount. 10.Inspect the tooth condition at the final drive gear and replace if required. (Refer to 327B).

AC102886

AC102884

8. Measure the final drive gear backlash at four points or more on the circumference of the drive gear. Standard value: 0.11 - 0.16 mm

11.Measure the drive gear runout. Limit: 0.05 mm 12.If drive gear runout exceeds the limit, remove the differential case and then the drive gears, moving them to different positions and reinstall them. 13.If adjustment is not possible, replace the differential case or drive gear and drive pinion as a set.

31-1

GROUP 31

00 11

WHEEL AND TYRE

12 13 14


31

15

TYRE INFLATION PRESSURE CHECK . . .

31

TYRE WEAR CHECK . . . . . . . . . . . . . . . . .

31

16


31

WHEEL RUNOUT CHECK . . . . . . . . . . . . .

31

17


31

WHEEL AND TYRE . . . . . . . . . . . . . .

31

21

INSTALLATION SERVICE POINT . . . . . . .

31


31

22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

WHEEL AND TYRE

31-2

GENERAL INFORMATION


The wheels and tyres of the following specifications have been established.

SPECIFICATIONS Road wheel and tyre Item

Comfort

Sport

Wheel

Type

Steel type or Aluminium type*

Aluminium type

Size

16 6JJ

16 6JJ

Amount of wheel offset mm

46

46

Pitch circle diameter (PCD) mm

114.3

114.3

Size

215/60R16 95H

215/60R16 95H

Tyre

Spare wheel and tyre Item Spare wheel

Spare tyre

Specification

Type

Steel type

Size

16 4T or 16 6JJ*

Amount of wheel offset mm

40 or 46*

Pitch circle diameter (PCD) mm

114.3

Size

T135/90D16 102M or 215/60R16 95H*

NOTE: The * mark indicates optional item. NOTE: PCD (Pitch Circle Diameter) indicates the pitch circle diameter of the wheel installation holes.


ITEM

LIMIT

Tread depth of tyre mm

Minimum 1.6

Wheel runout

Radial runout mm

1.0 or less

Lateral runout mm

1.0 or less

Wheel runout

Radial runout mm

1.2 or less

Lateral runout mm

1.2 or less

WHEEL AND TYRE

31-3

TROUBLESHOOTING

TROUBLESHOOTING DIAGNOSIS M1311000700363

Symptom

Probable cause

Remedy

Reference page

Rapid wear at shoulders

Under-inflation or lack of rotation

Adjust the tyre pressure.

For tyre inflation pressure, refer to the label on the driver’s side centre pillar.

Under-inflation

Adjust the tyre pressure.

For tyre inflation pressure, refer to the label on the driver’s side centre pillar.

Excessive camber

Check the camber.

Refer to GROUP 33A, On-vehicle service - Front wheel alignment check and adjustment 333.

ACX00923AB

Rapid wear at centre

ACX00924 AB

Over-inflation or lack of rotation

ACX00925 AB

Cracked treads

ACX00926AB

ACX00927AB

Wear on one side

ACX00928 AB

ACX00929 AB

Feathered edge

Incorrect toe-in

Adjust the toe-in.

ACX00930AB

ACX00931 AB

Bald spots

Unbalanced wheel

Balance the wheels.

ACX00932AB

ACX00933 AB

331

WHEEL AND TYRE

31-4

TROUBLESHOOTING

Symptom

Probable cause

Remedy

Reference page

Scalloped wear

Lack of rotation of tyres or worn Rotate the tyres, and or out-of-alignment suspension check the front suspension alignment. ACX00934

Refer to GROUP 33A, On-vehicle service - Front wheel alignment check and adjustment 333.

WHEEL BALANCE ACCURACY M1311001700225

PURPOSE

PROCEDURE

This section contains tips and procedures for achieving accurate wheel balance. Steering wheel vibration and/or body shake can result if any of these procedures are not carefully observed. 1. Wheels and tyres must be properly mounted on a balancer in order to achieve correct balance. Centering the wheel on the shaft of the balancer is essential for proper mounting. 2. Off-the-car wheel balancers must be calibrated periodically to ensure good balancing results. An inaccurately calibrated balancer could cause unnecessary replacement of tyres, shocks, suspension components, or steering components. Check your balancer’s calibration approximately every 100 balances. Your wheel balancer’s instruction manual should include calibration procedures. If the calibration procedures specifically for your balancer are missing, use the generic steps in this section for zero calibration, static balance, and dynamic balance checks. The wheel balancer calibration checks are also described in the flowchart. (Refer to 331).

1. Confirm that the balancer’s cone and the wheel mounting cone are undamaged and free of dirt and rust. 2. On this vehicle, the wheel’s centre hole on the hub side has a chamfered edge. Use a back-mounting cone on your wheel balancer to centre the wheel on the balancer shaft. 3. Install a wheel mounting cone. The appropriate size cone for this vehicle is 67.0 mm. 4. Before balancing the wheel, remove any wheel weights from both sides. Also check both sides for any damage. 5. When installing wheel weights, hammer them at a straight (not diagonal) angle.

Hub/shaft assembly

Clamping cup Wing nut

Spring plate Wheel mounting cone

AC000041AB

Standard passenger car wheel

WHEEL AND TYRE TROUBLESHOOTING

1. After balancing the wheel, loosen the wing nut and turn the wheel 180 against the balancer’s hub. Then re-tighten the wing nut and check the balance again. Repeat wheel balance if necessary. 2. Turn the wheel again 180 against the balancer’s hub. If the wheel becomes out-of-balance each time it is turned against the balancer’s hub, the wheel balancer may require calibration.

1. Mount an undamaged original-equipment alloy rim and tyre assembly (wheel) onto your off-thecar wheel balancer. Balance the wheel. 2. <> Loosen the balancer wing nut, rotate the wheel a half-turn (180), and retighten the nut. Recheck the balance. If the imbalance is 5g or less, the zero calibration is OK. Rebalance the wheel, then go to Step 4 to check static balance. If the imbalance is more than 5g, go to Step 3. 3. Loosen the balancer wing nut, rotate the wheel 1/ 4 turn (90), and retighten the nut. Recheck the wheel balance. If the imbalance is 5g or less, the wheel may not be centred on the balancer, or the balancing cones, the cup, and/or wing nut are damaged, dirty, or inappropriate for the wheel. You may need to refer to the balancer manufacturer’s instructions to verify the correct attachments. After making the necessary corrections, recheck the wheel balance. If OK, then go to Step 4. If the imbalance is more than 5g, the balancer requires calibration. Contact the balancer manufacturer for calibration by their repair representative.

31-5

4. <> Attach a 5g weight to the outer rim. Recheck the balancer. The balancer should detect 5 2g of imbalance 170 to 190 away from the 5g weight. If the imbalance is within specification, the static balance calibration is correct. Go to Step 5 to check the dynamic balance. If the imbalance is out of specification, the balancer requires calibration. Contact the balancer manufacturer for calibration by their repair representative. 5. <> Attach a 5g weight to the inner rim at 180 opposite the 5g weight that was added in Step 4. Recheck the balance. The balancer should detect 5 2g of imbalance 170 to 190 away from both the inner and outer 5g weights. If the imbalance is within specification, the dynamic balance calibration is correct. The balancer calibration checks are complete. If the imbalance is out of specification, the balancer requires calibration. Contact the balancer manufacturer for calibration by their repair representative.

WHEEL AND TYRE

31-6

TROUBLESHOOTING

WHEEL BALANCER CALIBRATION CHECKING FLOW CHART

Balance wheel.

Rotate wheel 1/2 turn.

ZERO CALIBRATION CHECK

Imbalance = more than 5g

Imbalance = 5g or less

Rebalance wheel. Rotate wheel 1/4 turn.

Imbalance = 5g or less

Imbalance = more than 5g

Verify wheel is properly centered. Verify cones, cup, and wing nut are clean, undamaged, and appropriate for wheel. Make necessary corrections, then recheck wheel balance.

Attach a 5g weight to the outer rim. Is the imbalance 5 ± 2g at 170 – 190˚ away from the 5g weight?

YES

NO

Attach a 5g weight to the inner rim at 180˚ opposite the weight on the outer rim. Is the imbalance 5 ± 2g at 170 – 190˚ away from both 5g weights?

YES

Balancer does not require calibration.

STATIC BALANCE CHECK

DYNAMIC BALANCE CHECK

NO

Balancer requires calibration. Contact balancer manufacturer. AC000040 AB

WHEEL AND TYRE

31-7

ON-VEHICLE SERVICE

ON-VEHICLE SERVICE TYRE INFLATION PRESSURE CHECK

WHEEL RUNOUT CHECK

M1311000900293

M1311001100320

NOTE: For information on tyre inflation pressure, refer to the label attached to the centre pillar on the driver’s side. Radial

TYRE WEAR CHECK M1311001000301

Measure the tread depth of the tyres. Minimum limit: 1.6 mm If the remaining tread depth is less than the minimum limit, replace the tyre. NOTE: When the tread depth of the tyres is reduced to 1.6 mm or less, wear indicators will appear.

Lateral

ACX00651AB

Jack up the vehicle so that the wheels are clear of the floor. While slowly turning the wheel, measure wheel runout with a dial indicator. Limit: Item

Steel wheel

Radial runout mm 1.2

Aluminium wheel 1.0

Lateral runout 1.2 1.0 mm If wheel runout exceeds the limit, replace the wheel.

WHEEL AND TYRE INSTALLATION SERVICE POINT M1311001300261

Tighten the wheel nuts to the specified torque. Tightening torque: 98 10 N¼m

127(6

37-1

GROUP 37

00 11

POWER STEERING

12 13 14


37


37

LUBRICANTS . . . . . . . . . . . . . . . . . . SEALANTS . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . .

STEERING COLUMN SHAFT ASSEMBLY SHOCK ABSORBING MECHANISM CHECK

15 37

17

STEERING WHEEL*. . . . . . . . . . . . . .

37

37


37

21

37

STEERING SHAFT* . . . . . . . . . . . . . .

37

22


37

37


37

37

37

27 31

25 26

STEERING WHEEL FREE PLAY CHECK .

37

POWER STEERING GEAR BOX AND LINKAGE* . . . . . . . . . . . . . . . . . . . . . .

STEERING ANGLE CHECK . . . . . . . . . . . .

37


37

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

37


16

TIE ROD END BALL JOINT STARTING TORQUE CHECK . . . . . . . . . .

37


37

32

STATIONARY STEERING EFFORT CHECK

37

TIE ROD END BALL JOINT DUST COVER REPLACEMENT . . . . . . . . .

37

33

STEERING WHEEL RETURN TO CENTRE CHECK . . . . . . . . . . . . . . . . . . . .

37

DRIVE BELT TENSION CHECK. . . . . . . . .

37

FLUID LEVEL CHECK . . . . . . . . . . . . . . . . FLUID REPLACEMENT . . . . . . . . . . . . . . .

34

37

POWER STEERING OIL PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . .

37

37


37

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

37

POWER STEERING SYSTEM AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . .

37


37

OIL PUMP PRESSURE TEST . . . . . . . . . .

37

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

37

POWER STEERING PRESSURE SWITCH CHECK . . . . . . . . . . . . . . . . . . . .

37

POWER STEERING HOSES . . . . . . .

37

TIE ROD END BALL JOINT DUST COVER CHECK . . . . . . . . . . . . . . . . . . . . .


37

37

35 36 37 42 51 52

:$51,1*65(*$5',1*6(59,&,1*2)6833/(0(17$/5(675$,176<67(0656 (48,33('9(+,&/(6

WARNING

Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative). Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRSrelated component.

54 55

POWER STEERING

37-2

GENERAL INFORMATION


FEATURES Power steering has been adopted in all vehicles to make the steering system easier to handle. A 4-spoke steering wheel is used. A steering column has a shock absorbing mechanism and a tilt steering mechanism. Integral-type rack and pinion gear with high rigidity and excellent response is used.

A vane type pump with a fluid flow rate control system which change steering effort according to the engine speed is used. The separate plastic resin oil reservoir is used to reduce weight and to make the fluid level checking easier. The cooler tube assembly is installed on the power steering fluid line to improve the cooling performance of the power steering fluid.

SPECIFICATIONS Item Steering wheel

Steering column

Specification Type

4-spoke type

Outside diameter mm

380

Maximum number of turns

2.7

Column mechanism

Shock absorbing mechanism and Tilt steering mechanism Tilt up: 20 mm Tilt down: 20 mm

Power steering type

Integral type

Oil pump

Type

Vane pump

Basic discharge amount mL/rev.

9.6

Relief pressure MPa

8.8

Reservoir type

Separate type (plastic)

Pressure switch

Equipped

Type

Rack and pinion

Steering gear

Stroke ratio (Rack stroke/Steering wheel 51.45 maximum turning radius) Rack stroke mm

141

POWER STEERING

37-3


CONSTRUCTION DIAGRAM Steering wheel

Steering column shaft assembly

Oil reservoir Pressure hose assembly

Suction hose

Return hose

Oil pump assembly

Steering gear Cooler tube assembly AC300061 AB


Item

Standard value

Limit

Steering wheel free play mm

With engine running

-

30

With engine stopped

10 or less

-

Steering angle

Inside wheel

3450’ 130’

-

Outside wheel (reference)

2920’

-

At the centre of tyre tread mm

12

-

Toe-angle (per wheel)

003’ 05’

-

Tie rod end ball joint starting torque N¼m

0.5 - 2.5

-

Tie rod swing resistance N [Tie rod swing torque N¼m]

6 - 19 [1.5 - 4.9]

-

Stationary steering effort N [Fluctuation allowance N]

29 or less [5.9 or less]

-

Oil pump pressure Oil pump relief pressure MPa (750 100 r/min.) Pressure under no-load conditions

8.8 - 9.5

-

0.8 - 1.0

-

8.8 - 9.5

-

OFF ON

1.5 - 2.0

-

ON OFF

0.7 - 2.0

-

Steering gear total pinion torque N¼m [Change in torque N¼m]

0.7 - 1.6 [0.4 or less]

-

Opening dimension of special tool boot band crimping tool (MB991561) mm

2.9

-

Band crimped width mm

2.4 - 2.8

-

Toe-in

Steering gear retention hydraulic pressure Oil pressure switch operating pressure MPa

POWER STEERING

37-4

LUBRICANTS


Item

Specified lubricant

Power steering fluid

ATF DEXRON III or DEXRON II Approximately 1.0 L

Steering gear

ATF DEXRON III or DEXRON II As required

Bearing

Quantity

O-ring and seal ring Oil seal Special tool (MB991213) Pinion and valve assembly seal ring part

Oil pump

Bellows

Silicon grease

As required

Tie rod end ball joint

Multipurpose grease SAE J310, As required NLGI No.2 or equivalent

Friction surface of rotor vane, ATF DEXRON III or DEXRON II As required cam ring and pump cover O-ring

SEALANTS M1372000500324

Item

Specified sealant

Steering shaft cover assembly bolt hole on the toeboard


Steering gear

3M ATD Part No.8661, 8663 or equivalent

End plug Rack support cover

POWER STEERING

37-5

SPECIAL TOOLS


Tool

Number

Name

Use

MB991897

Ball joint remover

Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113) is also available to disconnect knuckle and tie rod end ball joint.

MB990326

Preload socket

Tie rod end ball joint starting torque check

MB991548

Power steering oil pressure gauge adapter (Pump side)

Oil pump pressure test

MB991549

Power steering oil pressure gauge adapter (Hose side)

MB990662

Power steering oil pressure gauge

MB990784

Ornament remover Cover removal

MB990228 or MB991006

Preload socket

AC106827

MB990326

MB991548

MB991549

MB990662

MB990784

MB991006

Steering gear total pinion torque check and adjustment

POWER STEERING

37-6

SPECIAL TOOLS

Tool

Number

Name

Use

MB991621

Rack support cover Rack support adjustment Rack support cover removal wrench

MB990925

Bearing and oil seal installer set

Oil seal and bearing installation MB990927, MB990938, MB990939 (For details, refer to GROUP 26, Special Tools 326).

MB991120

Needle bearing puller

Needle roller bearing removal

MB991199

Oil seal and bearing installer

Oil seal installation

MB991197

Bar (long type)

MB991202


Needle bearing installation Lower bearing installation

MB991213

Rack installer

Rack installation

MB991203


Oil seal and bearing installation

MB991621

MB990925

MB991120

MB991199 AB

MB991197

MB991202

MB991212

MB991203

POWER STEERING

37-7

ON-VEHICLE SERVICE

Tool

Number

Name

Use

MB991317

Seal ring installer

Seal ring installation

MB990941

Torque tube bearing installer

Lower oil seal installation

MB991561

Boot band crimping Bellows band installation tool

MB990776

Front axle base

MB991317

MB990941

MB991561

Tie rod end ball joint dust cover installation

MB990776

ON-VEHICLE SERVICE STEERING WHEEL FREE PLAY CHECK M1372001000270

1. With the engine running (hydraulic operation), set the front wheels straight ahead.

4. If the free play still exceeds the limit value, set the steering wheel straight ahead with the engine stopped. Load 5 N towards the steering wheel circumference and check the play. Standard value (steering wheel play with the engine stopped): 10 mm or less 5. If the play exceeds the standard value, remove the steering gear (Refer to 337). and check the total pinion torque (Refer to 337).

STEERING ANGLE CHECK M1372001100341

ACX01122AB

2. Measure the play on the steering wheel circumference before the wheels start to move when slightly moving the steering wheel in both directions. Limit: 30 mm 3. When the play exceeds the limit, check for the play on the steering shaft and steering linkage connection. Correct or replace.

AC000756AB

POWER STEERING

37-8

ON-VEHICLE SERVICE

1. Place the front wheel on a turning radius gauge and measure the steering angle. Standard value: Item

Specification

Inside wheel

3450’ 130’

Outside wheel (reference)

2920’

2. If the steering angle is not within the standard value, adjust the toe-in as follows. Standard value: at the centre of tyre tread: 1 2 mm Toe angle (per wheel): 003’ 05’

TIE ROD END BALL JOINT STARTING TORQUE CHECK M1372001500275

CAUTION Do not remove the nut from ball joint. Loosen it and use special tool to avoid possible damage to the ball joint threads. Hang special tool with cord to prevent it from falling. Cord

MB991897

Nut

Jam nut Clip

Bolt Ball joint

AC208247AD

1. Install special tool ball joint remover (MB991897) as shown in the figure. Bolt

AC006074 AB

3. Loosen the jam nut, and unclip the bellows. 4. Adjust the toe-in by turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. 5. Tighten the jam nut to the specified torque, and tighten the bellows by the clip. Tightening torque: 52 2 N¼m 6. Recheck the steering angle.

Parallel

Knob

Good

Bad

AC106821AB


POWER STEERING

37-9

ON-VEHICLE SERVICE

Standard value: Steering effort: 29 N or less Fluctuation allowance: 5.9 N or less 4. If the measured value exceeds the standard value, check and adjust the related parts.

MB990326

STEERING WHEEL RETURN TO CENTRE CHECK M1372001800287 ACX01129 AB

4. Move the ball joint stud several times and install the nut on the stud. Using special tool preload socket (MB990326), measure the ball joint starting torque. Standard value: 0.5 - 2.5 N¼m 5. If the starting torque exceeds the standard value, replace the tie rod end. 6. If the starting torque is under the standard value, check the ball joint for axial play or ratcheting. If no axial play or ratcheting, the ball joint can be reused.

CAUTION Always use a new ball joint nut as it is a selflocking nut. 7. Install the tie rod end to the knuckle, then tighten a new self-locking nut to the specified torque. Tightening torque: 25 5 N¼m

STATIONARY STEERING EFFORT CHECK M1372001700310

1. With the vehicle stopped on a flat and paved surface, turn the steering wheel to the straight ahead position. 2. Start the engine and set the engine idle speed. Standard value: 750 100 r/min

Conduct a road test: 1. Make both gradual and sudden turns and check the steering wheel return.

70˚

70˚

ACX01130AB

2. At a vehicle speed of approximately 35 km/h, turn the steering wheel 90, hold a few seconds, then release. If the steering wheel then returns 70 or more, the return can be judged satisfactory. NOTE: There will be a momentary feeling or "heaviness" when the wheel is turned quickly, but this is not abnormal (Oil pump discharge amount is especially apt to be insufficient during idling).

DRIVE BELT TENSION CHECK M1372001900240

Refer to GROUP 11A, On-vehicle Service - Drive Belt Tension Check 311A.

FLUID LEVEL CHECK M1372002000262

1. Park the vehicle on a flat, level surface. 2. Start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60C. 3. With the engine running, turn the wheel all the way to the left and right several times. ACX01122AB

3. Attach a spring balance to the outer circumference of the steering wheel and measure the steering force required to turn the steering wheel from the straight ahead position to the left and right (within a range of 1.5 turns). Also check to be sure that there is no significant change in the required steering effort.

POWER STEERING

37-10

ON-VEHICLE SERVICE

2. Disconnect the ignition coil connectors (Refer to GROUP 16, Ignition Coil 316).

Fluid level change: Within 5 mm

CAUTION

While engine running

While engine stopped ACX01131AC

4. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. If the change of the fluid level is 5 mm or more, air bleeding should be done.

FLUID REPLACEMENT M1372002100311

1. Raise and support the front wheels. Return hose Return hose Vinyl hose

Perform air bleeding only while cranking the engine. If air bleeding is performed while the engine is running, air could enter the fluid. During air bleeding, refill the steering fluid supply so that the level never falls below the "MIN" mark on the oil reservoir. 3. Turn the steering wheel all the way to the left and right five or six times while using the starter motor to crank the engine intermittently several times (for 15 to 20 seconds). 4. Connect the ignition coil connectors (Refer to GROUP 16, Ignition Coil 316). 5. Start the engine (idling). 6. Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir. 7. Confirm that the fluid is not milky, and that the level is between "MAX" and "MIN" marks. 8. Confirm that there is very little change in the fluid level when the steering wheel is turned left and right.

CAUTION

AC100369AB

2. Disconnect the return hose connection, and then connect a vinyl hose to the return hose, and drain the fluid into a container. 3. Disconnect the ignition coil connectors (Refer to GROUP 16, Ignition Coil 316). 4. While operating the starter motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid. 5. Connect the return hose securely, and then secure with the clip. 6. Fill the oil reservoir with specified fluid up to the lower position of the filler, and then bleed the air. Specified fluid: ATF DEXRON III or DEXRON II

POWER STEERING SYSTEM AIR BLEEDING M1372002200318

Perform air bleeding procedure as necessary after replacing the steering gear or the steering fluid lines. 1. Raise and support the front wheels.

If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled. If air bleeding is not complete, there will be abnormal noises from the pump and the flowcontrol valve, and this condition could cause reduce the life of the power steering components. Fluid level change: Within 5 mm

While engine running

While engine stopped ACX01131AC

9. Confirm that the change in the fluid level is no more than 5 mm when the engine is stopped and when it is running. 10.If the change of the fluid level is 5 mm or more, the air has not been completely bled from the system. The air bleeding procedure must be repeated.

POWER STEERING ON-VEHICLE SERVICE

OIL PUMP PRESSURE TEST M1372002300296

Temperature gauge

Pressure gauge (MB990662)

Shut-off valve (fully closed)

Oil reservoir Adapter (MB991548)

Oil pump

Adapter (MB991549)

37-11

7. If it is not within the standard value, the probable cause is a malfunction of the oil line or steering gear, so check these parts and repair as necessary. 8. Turn the steering wheel all the way to the left or right; then check whether or not the retention hydraulic pressure is the standard value. Standard value: 8.8 - 9.5 MPa 9. If not the standard value, overhaul the steering gear. Remeasure fluid pressure. 10. Remove the special tools, and then tighten the pressure hose to the specified torque. Tightening torque: 57 7 N¼m 11. Bleed the system (Refer to 337).

POWER STEERING PRESSURE SWITCH CHECK M1372007200302

ACX01133 AB

1. Disconnect the pressure hose from the oil pump, and then connect the following special tools. MB990662: Power Steering Oil Pressure Gauge MB991548: Power Steering Oil Pressure Gauge Adapter (Pump Side) MB991549: Power Steering Oil Pressure Gauge Adapter (Hose Side) 2. Bleed air, then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60C. 3. Start the engine and idle it at 750 100 r/min.

CAUTION The pressure gauge shut-off valve must not remain closed for more than 10 seconds. 4. Fully close the shut-off valve of the pressure gauge and measure the oil pump relief pressure to confirm that it is within the standard value range. Open it again immediately after checking the pressure. Standard value: 8.8 - 9.5 MPa 5. If it is not within the standard value, replace the oil pump. 6. Check whether or not the hydraulic pressure is the standard value when no-load conditions are created by fully opening the shut-off valve of the pressure gauge. Standard value: 0.8 - 1.0 MPa

1. Disconnect the pressure hose from the oil pump, and then connect the following special tools. MB990662: Power Steering Oil Pressure Gauge MB991548: Power Steering Oil Pressure Gauge Adapter (Pump Side) MB991549: Power Steering Oil Pressure Gauge Adapter (Hose Side) 2. Bleed air, and then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60C. 3. The engine should be idling.

37-12

POWER STEERING ON-VEHICLE SERVICE

4. Disconnect the connector for the oil pressure switch, and place an ohmmeter at the switch. 5. Gradually close the shut-off valve of the pressure gauge and increase the hydraulic pressure, then check whether or not the hydraulic pressure that activates the switch is the standard value. Standard value: 1.5 - 2.0 MPa 6. Gradually open the shut-off valve and reduce the hydraulic pressure; then check whether or not the hydraulic pressure that deactivates the switch is the standard value. Standard value: 0.7 - 2.0 MPa 7. Remove the special tools, and then tighten the pressure hose to the specified torque. Tightening torque: 57 7 N¼m 8. Bleed the system (Refer to 337).

TIE ROD END BALL JOINT DUST COVER CHECK M1372008600240

WARNING

If the vehicle continues to be driven after

the collision absorbing mechanism has operated, the steering column shaft may be damaged while it is in use. If there is a slack in the one-way capsule, do not attempt to repair it but replace the steering column shaft assembly.

Inspection Procedure 1. Remove the lower and upper column covers.

CAUTION Do not release the tilt lever until the steering column has been installed to complete this inspection procedure. 2. Ensure that the tilt lever is in the lock position. NOTE: If not, place the tilt lever in the lock position. 3. Loosen the two upper steering column mounting bolts by two turns.

1. Press the dust cover with your finger to check whether the dust cover is cracked or damaged. 2. If the dust cover is cracked or damaged, replace the tie rod end. NOTE: If the dust cover is cracked or damaged, the ball joint could be damaged.

STEERING COLUMN SHAFT ASSEMBLY SHOCK ABSORBING MECHANISM CHECK M1372013500067

If a collision accident occurs or severe impact is applied on the steering wheel, the collision energy absorbing mechanism may have operated. Once the mechanism has operated, it will be inoperative even it has suffered no apparent damage. Determine if the steering column shaft can be reused by the following procedure. If the collision energy absorbing mechanism has already operated, replace the steering column shaft assembly. If any excessive radial free play on the steering wheel is found with the tilt lever in the lock position, always check the steering shaft assembly.

Steering column mounting bolt Steering column assembly One way capsule

AC209935 AC

4. Hold the one-way capsules as shown, and then try to lock them. If there is a slack in either of the capsules, replace the steering column shaft assembly. NOTE: When installing a new steering column shaft assembly, place the tilt lever in the lock position, if it is not in place.

POWER STEERING

37-13

STEERING WHEEL

CAUTION Be careful that nothing is pinched between the one-way capsules and the body. Do not release the tilt lever until the steering column has been installed to complete this inspection procedure. 5. If no problem is found during the inspection, tighten the steering column mounting bolts to the specified torque. Tightening torque: 12 2 N¼m

STEERING WHEEL REMOVAL AND INSTALLATION M1372011400150

WARNING

Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,

Service Precautions and Air Bag Module and Clock Spring 352B. When removing and installing the steering wheel, do not let it bump against the air bag module. Post-installation Operation Checking Steering Wheel Position with Wheels Straight Ahead

Section A - A

2

Tab

2 1 Section B - B Tab

1 A B

1

50 ± 5 N·m B

2

A AC107402 AB

<> <>

Removal steps 1. Cover 2. Steering wheel and air bag module assembly

NOTE: For air bag module removal, refer to GROUP 52B, Air Bag Module and Clock Spring 352B.

POWER STEERING

37-14

STEERING WHEEL


<> STEERING WHEEL AND AIR BAG MODULE ASSEMBLY REMOVAL

<> COVER REMOVAL

Clock spring connector

MB990784

A

Steering wheel

AC006295 AB

AC006294 AB

Insert special tool ornament remover (MB990784) at the indicated position to remove the cover. NOTE: The special tool can be inserted through the notch behind the area shown.

1. By sliding section A of the clock spring connector shown in the illustration in the arrow direction, disconnect the connector.

Hexagonal bit socket

AC102792

AC107462 AD

2. Loosen the bolt completely. Then, remove the steering wheel and air bag module assembly. NOTE: Use a hexagonal bit socket or a hexagonal wrench having an effective length of 75 mm or more in the hexagonal section and the diameter of 8 mm or more.

POWER STEERING

37-15

STEERING SHAFT

STEERING SHAFT REMOVAL AND INSTALLATION M1372011500094

WARNING Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Service Precautions and Air Bag Module and Clock Spring 352B. Post-installation Operation Instrument Lower Panel Installation (Refer to GROUP 52A, Instrument Panel 352A). Steering Wheel and Air bag Module Assembly Installation (Refer to 337).

Pre-removal Operation Steering Wheel and Air bag Module Assembly Removal (Refer to 337). Instrument Lower Panel Removal (Refer to GROUP 52A, Instrument Panel 352A).

Section A - A

2

A

3

2 Tab

A

1 5 Section B - B B

B

B

B

Toe board 12 ± 2 N·m

1

4 6 6

Specified sealant: 3M ATD Part No.8513 or equivalent

18 ± 2 N·m

5.0 ± 1.0 N·m AC301263 AB

Removal steps 1. Lower column cover 2. Upper column cover 3. Clock spring and column switch assembly (Refer to GROUP 52B, Air Bag Module and Clock Spring 352B).

Removal steps&RQWLQXHG 4. Shaft cover <> >>A<< 5. Steering column shaft assembly 6. Cover assembly

POWER STEERING

37-16

STEERING SHAFT



<> STEERING COLUMN SHAFT ASSEMBLY REMOVAL

>>A<< STEERING COLUMN SHAFT ASSEMBLY INSTALLATION

CAUTION

CAUTION

The tilt lever should be held in the lock position until the steering column shaft is installed to the vehicle. If the steering column is removed with the tilt lever released, or the tilt lever is released after the steering column shaft was removed from the vehicle, the steering column can not be reinstalled correctly. If the steering column is installed incorrectly, the collision energy absorbing mechanism may be damaged. 1. Ensure that the tilt lever is in the lock position, and remove the steering column mounting bolts.

When reusing the steering column, do not release the tilt lever until the steering column shaft has been installed. When the steering column is replaced, do not release the tilt lever until it has been installed. Do not remove the tilt lever fixing band until the installation has completed. When installing the steering column, do not leave it fixed temporarily at only one point and make sure the column shaft is not shaken strongly. If you fail to do, the collision absorbing mechanism at the column shaft mounting location may be damaged.

Clip

4 1

Steering column shaft

2 3 Tilt lever

AC210969 AD

2. Pinch the steering column shaft clip with pliers, and pull up the shaft towards the direction shown to disengage the steering column shaft assembly.

AC209383 AD

Ensure that the tilt lever is in the lock position, and install the steering column. Tighten the four bolts in the order shown by hand, and then tighten them to the specified torque in the order shown. Tightening torque: 12 2 N¼m

POWER STEERING

37-17

STEERING SHAFT


1 2

4

3

AC210967AD

<> >>A<< 1. >>A<< 2.

Disassembly steps Special bolt Steering lock bracket

DISASSEMBLY SERVICE POINT Reverse screw tap Special bolt Steering lock bracket

Steering lock cylinder

>>A<< 3. 4.

Disassembly steps&RQWLQXHG Steering lock cylinder assembly Steering column shaft assembly

CAUTION The steering lock bracket and bolts must be replaced with new ones when the steering lock is installed. 1. When installing the steering lock cylinder assembly and steering lock bracket to the column tube, temporarily install the steering lock in alignment with the column boss.

ACX01138AB

<> SPECIAL BOLT REMOVAL 1. Drill in the special bolt a hole deep enough for the tap to stand. 2. Remove the special bolt with a left-hand tap.

REASSEMBLY SERVICE POINT >>A<< STEERING LOCK CYLINDER ASSEMBLY/ STEERING LOCK BRACKET/SPECIAL BOLT INSTALLATION

ACX01139 AB

2. After checking that the lock works properly, tighten the special bolts until the head twists off.

37-18

POWER STEERING POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING GEAR BOX AND LINKAGE REMOVAL AND INSTALLATION M1372010900215

WARNING Before removing the steering gear, refer to GROUP 52B, Service Precautions (352B) and Air Bag Module and Clock Spring (352B). Centre the front wheels. Failure to do so may damage the SRS clock spring and render the SRS system inoperative, risking serious injury. Pre-removal Operation Power Steering Fluid Draining (Refer to 337). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Centermember Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember 332). Steering Wheel and Air Bag Module Assembly Removal (Refer to 337). Clock Spring Removal (Refer to GROUP 52B, Air Bag Module and Clock Spring 352B). Stabilizer Link Assembly and Lower Arm Assembly Removal (Refer to GROUP 33A, Lower Arm 333).

Post-installation Operation Stabilizer Link Assembly and Lower Arm Assembly Installation (Refer to GROUP 33A, Lower Arm 333). Centermember Installation (Refer to GROUP 32, Engine Roll Stopper and Centermember 332). Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Clock Spring Installation (Refer to GROUP 52B, Air Bag Module and Clock Spring 352B). Steering Wheel and Air Bag Module Assembly Installation (Refer to 337). Check the dust cover for cracks or damage by pushing it with your finger. Power Steering Fluid Supplying (Refer to 337). Power Steering Fluid Line Bleeding (Refer to 337). Checking Steering Wheel Position with Wheels Straight Ahead. Front Wheel Alignment Adjustment (Refer to GROUP 33A, On-vehicle Service - Front Wheel Alignment Check and Adjustment 333).

POWER STEERING

37-19

POWER STEERING GEAR BOX AND LINKAGE

4 2

1

12 ± 2 N·m

18 ± 2 N·m

11 7

12 ± 2 N·m

15 ± 3 N·m

9

5

10

70 ± 10 N·m

4

6

25 ± 5 N·m

7 8

70 ± 10 N·m

13 57 ± 7 N·m

18 ± 2 N·m

3 12 49 ± 10 N·m 167 ± 9 N·m AC300496 AB

<>

Removal steps 1. Shaft cover 2. Steering column shaft assembly and steering gear connecting bolt 3. Tie rod end and knuckle connection Rear roll stopper connecting bolt (Refer to GROUP 32, Engine Roll Stopper and Centermember 332). 4. Return hose connection 5. Return tube 6. O-ring 7. Pressure hose connection 8. Gasket

<>

>>A<< 9. 10. 11. 12. 13.

Removal steps&RQWLQXHG Crossmember assembly Rear roll stopper (Refer to GROUP 32, Engine Roll Stopper and Centermember 332). Joint cover grommet Steering extension Return tube Crossmember Steering gear

POWER STEERING

37-20


REMOVAL SERVICE POINTS <> TIE ROD END AND KNUCKLE DISCONNECTION

CAUTION Do not remove the nut from ball joint. Loosen it and use special tool to avoid possible damage to ball joint threads. Hang special tool with a cord to prevent it from falling.

3. Tighten the bolt with a wrench to disconnect the tie rod end. <> CROSSMEMBER ASSEMBLY REMOVAL

Piece of wood

Cord

Transmission jack

MB991897

Nut

Bolt Ball joint

AC208247AD

1. Install the special tool ball joint remover (MB991897) as shown in the figure.

AC102600 AD

1. Use a transmission jack to hold the crossmember, and then remove the crossmember mounting nuts and bolts. 2. Lower the crossmember with the rear roll stopper, the stabilizer bar, the return tube, and the steering gear.

INSTALLATION SERVICE POINTS >>A<< JOINT COVER GROMMET INSTALLATION

Bolt Joint cover grommet

Parallel

A Knob

B

Good

Bad

AC106821AB

2. Turn the bolt and knob as necessary to make the jaws of the special tool parallel, tighten the bolt by hand and confirm that the jaws are still parallel. NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure.

Steering gear AC301284AB

Align the joint cover grommet notch (arrow A) with the steering gear lug (arrow B), and then install the steering joint cover to the steering gear.

POWER STEERING

37-21



TIE ROD SWING RESISTANCE CHECK 1. Give 10 hard swings to the tie rod.

STEERING GEAR TOTAL PINION TORQUE CHECK

CAUTION When holding the steering gear in a vice, secure its mounting positions. If it is secured in any other place, the gear housing may become deformed or damaged.

MB991006

AC000996 AC

Using special tool preload socket (MB991006), rotate the pinion gear at the rate of one rotation in approximately 4 to 6 seconds to check the total pinion torque. Standard value: 0.7 - 1.6 N¼m [Change in torque: 0.4 N¼m or less] NOTE: When measuring, remove the bellows from the rack housing. Measure the pinion torque through the whole stroke of the rack. If the measured value is not within the standard range, first adjust the rack support cover, and then check the total pinion torque again. If the total pinion torque cannot be adjusted to within the standard range by adjusting the rack support cover, check the rack support cover, rack support spring, rack support and replace any parts if necessary.

AC000997

2. Measure the tie rod swing resistance [tie rod swing torque] with a spring balance. Standard value: 6 - 19 N [1.5 - 4.9 N¼m] 3. If the measured value exceeds the standard value, replace the tie rod. 4. If the measured value is below the standard value, the tie rod can be re-used if it swings smoothly without excessive play. TIE ROD END BALL JOINT DUST COVER CHECK 1. Check the dust cover for cracks or damage by pushing it with your finger. 2. If the dust cover is cracked or damaged, replace the tie rod end (Refer to 337). NOTE: Cracks or damage of the dust cover may damage the ball joint. If it is damaged during service work, replace the dust cover (Refer to 337).

POWER STEERING

37-22



22 ± 4 N·m

Flare nut

3

13 ± 3 N·m

4

24 23 22 20 21 19 13

4

34

35

33 17

16 5

23 21 19

59 ± 10 N·m

Repair kit grease

12 2

6

18

36

1

52 ± 2 N·m

3

15 14

23 ± 2 N·m -30˚

25 ± 4 N·m 59 ± 10 N·m

7 9

8

4

11 8

11 35 17 31 29 28 32

Steering gear seal kit

8

11

26 27

10 88 ± 10 N·m

25

32 28

29 31 30 AC100244AC

>>O<< 1.

>>N<< >>N<< >>M<< >>L<< >>L<< >>K<< >>J<< <> >>J<< >>I<<

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Disassembly steps Gear mounting rubber Gear housing mounting bushing Feed pipe O-ring Jam nut Tie rod end Clip Bellows band Bellows Tie rod Tab washer Total pinion torque adjustment Jam nut Rack support cover Support spring Rack support End plug Jam nut Valve housing assembly

<> <> <> <> <>

>>H<< 19. 20.

>>G<< 21. >>F<< 22. >>F<< 23. 24.

<> <> <> <> <> <> <>

>>E<< 25. 26.

>>D<< 27. >>D<< 28. 29.

>>C<< 30.

31. 32. <> >>B<< 33. <> >>B<< 34. <> >>A<< 35. 36.

Disassembly steps&RQWLQXHG Lower oil seal Pinion and valve assembly Seal ring Upper bearing Upper oil seal Valve housing Circlip Rack stopper Rack bushing OIL SEAL O-ring Rack assembly Seal ring O-ring Lower bearing Needle bearing Oil seal Gear housing

POWER STEERING

37-23



Fluid: ATF DXRON III or DEXRON II


Grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent


Grease: Repair kit grease Fluid: ATF DXRON III or DEXRON II Sealant: 3M ATD Part No. 8661, 8663 or equivalent

AC200119 AC

Grease: Silicone grease


Grease: Repair kit grease Fluid: ATF DXRON III or DEXRON II

POWER STEERING

37-24


DISASSEMBLY SERVICE POINTS <> RACK SUPPORT COVER REMOVAL

<> UPPER BEARING/UPPER OIL SEAL REMOVAL

MB991621

Socket ACX01145AC

AC103692 AB

Using special tool rack support cover wrench (MB991621), remove the rack support cover from the steering gear. <> LOWER OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL

Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously. <> CIRCLIP REMOVAL

CAUTION If the rack stopper is first turned counterclockwise, the circlip will get caught in the slot in the housing and the rack stopper will not turn. Rack stopper

ACX01143AB

Using a plastic hammer, gently tap the pinion to remove it. <> SEAL RING REMOVAL

CAUTION When cutting the seal ring, be careful not to damage the pinion and valve assembly or the rack.

Circlip ACX01146 AB

1. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing. 2. Turn the rack stopper counterclockwise to remove the circlip. <> RACK STOPPER/RACK BUSHING/OIL SEAL/O-RING/RACK ASSEMBLY REMOVAL

ACX01144 AB

Cut the seal ring and remove it from the pinion and valve assembly or the rack.

ACX01147 AB

1. Pull out the rack slowly. Take out the rack stopper and the rack bushing at the same time.

POWER STEERING

37-25


CAUTION Do not damage the oil seal press fitting surface.

<> OIL SEAL REMOVAL

CAUTION Be careful not to damage the inner surface of the rack cylinder of the gear housing. Rack bushing Gear housing Pipe or similar tool

ACX01148 AB

2. Partially bend the oil seal and remove it from the rack bushing. <> LOWER BEARING REMOVAL

Oil seal AC100259 AB

Use a piece of pipe or similar tool to remove the oil seal from the gear housing.


MB990939 Valve housing

>>A<< OIL SEAL INSTALLATION 1. Apply a coating of ATF DEXRON III or DEXRON II to the both sides of the oil seal.

Lower bearing Gear housing

MB991199

ACX01149 AC

MB991197

Use a brass bar or special tool brass bar (MB990939) to remove the ball bearing from the gear housing. Oil seal

<> NEEDLE BEARING REMOVAL

CAUTION Do not open special tool excessively to prevent damaging housing interior.

AC100260 AC

2. Using the following special tools, press the oil seal into the rack housing. MB991197: Bar (Long type) MB991199: Oil Seal and Bearing Installer

MB991120

Valve housing

Needle bearing

ACX01150 AB

Use special tool needle bearing puller (MB991120) to remove the needle bearing from the rack housing.

>>B<< NEEDLE BEARING/LOWER BEARING INSTALLATION 1. Apply ATF DEXRON III or DEXRON II to housing, bearing and oil seal press fitting surface.

POWER STEERING

37-26


CAUTION Press-fit straight. The valve housing is aluminium, and may become deformed if pressfit on an angle.

4. Align the centre of the oil seal with the rack to prevent the retainer spring from slipping. Slowly insert the rack from power cylinder side. >>D<< OIL SEAL/RACK BUSHING INSTALLATION

MB990938 MB990938

Needle bearing

MB991202

MB991202

MB990927 Lower bearing

ACX01153 AE

2. Press fit needle bearing with the following special tools. MB990938: Bar (Snap-in type) MB991202: Oil Seal and Bearing Installer

Oil seal O-ring Rack bushing ACX01156 AE

1. Apply ATF DEXRON III or DEXRON II to the outer surface of the oil seal. Using the special tool installer adapter (MB990927), press in the oil seal until it is flush with the bushing end face.

>>C<< RACK ASSEMBLY INSTALLATION

CAUTION

Rack

Do not close the vent hole in the rack with grease. Vent hole

Vinyl tape Rack bushing AC100261AB

Seal ring and O-ring ACX01154 AB

1. Apply a coating of repair kit grease to the rack teeth face.

2. Apply ATF DEXRON III or DEXRON II to the oil seal inner surface and the O-ring. 3. Wrap the rack end with plastic tape, and push the rack bushing onto the rack. >>E<< CIRCLIP INSTALLATION

CAUTION Insert the circlip to the rack stopper hole while turning the rack stopper clockwise.

Oil seal

Circlip

Circlip

MB991213 ACX01155 AB

2. Cover rack serrations with special tool rack installer (MB991213). 3. Apply ATF DEXRON III or DEXRON II to special tool, and to the outer surface of the seal ring and the O-ring.

Slot Slot ACX01158 AB

Insert the circlip to the rack stopper hole through cylinder hole. Turn the rack stopper clockwise and insert the circlip firmly.

POWER STEERING

37-27


>>F<< UPPER OIL SEAL/UPPER BEARING INSTALLATION

>>H<< LOWER OIL SEAL INSTALLATION

CAUTION Approximately 1 mm

MB990938

MB990941

Oil seal

MB990938

Housing MB991203

MB991203

Bearing

Oil seal

ACX01161 AC

ACX01159AC

Apply a coating of ATF DEXRON III or DEXRON II to the outside of the upper oil seal/upper bearing. Using the following special tools, press the upper oil seal/ upper bearing into the valve housing. MB990938: Bar (Snap-in type) MB991203: Oil Seal and Bearing Installer >>G<< SEAL RING INSTALLATION

To eliminate a seal malfunction at the valve housing alignment surface, the upper surface of the oil seal should project outward approximately 1 mm from the housing edge surface. Using special tool torque tube bearing installer (MB990941), press the oil seal into the valve housing. >>I<< END PLUG INSTALLATION

End plug

MB991317

End plug

ACX01160 AB ACX01162 AB

Because the seal rings expand after installation, tighten after installing by using special tool seal ring installer (MB991317) to compress the rings, or press down by hand.

1. Apply specified sealant to the threaded part of the end plug. Specified sealant: 3M ATD Part No.8661, 8663 or equivalent 2. Secure the threaded portion of the end plug at two places by using a punch. >>J<< RACK SUPPORT COVER/JAM NUT INSTALLATION 1. Position the rack at its centre. 2. Apply specified sealant to the threaded part of the rack support cover. Specified sealant: 3M ATD Part No.8661, 8663 or equivalent

POWER STEERING

37-28


2. If the total pinion torque or the change in torque is outside the standard value, move the rack support cover 0 - 30, and adjust the pinion torque again. >>L<< TAB WASHER/TIE ROD INSTALLATION

MB991621 AC100273 AC

3. Use special tool rack support cover wrench (MB991621) to tighten the rack support cover to 23 2 N¼m. 4. Turn the rack support cover 30 counterclockwise. 5. Use the special tool to hold the rack support cover, and then tighten the jam nut to 59 10 N¼m.

After installing the tie rod to the rack, fold tab washer end (two locations) to tie rod notch.

>>K<< TOTAL PINION TORQUE ADJUSTMENT

>>M<< BELLOWS BAND INSTALLATION

ACX01163 AB

CAUTION Be sure there is no ratcheting or catching when operating the rack towards the shaft. Measure the total pinion torque through the whole stroke of the rack.

MB991561 Stopper W

MB991006 Adjusting bolt ACX01164 AB

AC100274 AB

1. Using special tool preload socket (MB991006), rotate the pinion shaft at the rate of one rotation in four to six seconds to check the total pinion torque and the change in torque. Standard value: Total pinion torque: 0.7 - 1.6 N¼m [Change in torque: 0.4 N¼m or less]

CAUTION When adjusting, set at the highest value of the standard value range. NOTE: If the total pinion toque cannot be adjusted to the standard value within the specified return angle, check the rack support cover components and replace any parts if necessary.

1. Turn the adjusting bolt of special tool boot band crimping tool (MB991561) to adjust the opening dimension (W) to the standard value. NOTE: The dimension (W) is adjusted by approximately 0.7 mm per one turn. NOTE: Do not turn the adjusting bolt more than one turn. Standard value (W): 2.9 mm : Screw in the adjusting bolt. : Loosen the adjusting bolt.

POWER STEERING

37-29


CAUTION Hold the rack housing, and use special tool to crimp the bellows band securely. Crimp the bellows band until special tool touches the stopper.

>>N<< TIE ROD END/JAM NUT INSTALLATION Edge of bellows assembly groove

Jam nut

MB991561

186 mm AC001011 AH

ACX01165 AB

2. Use special tool boot band crimping tool (MB991561) to crimp the bellows band.

Screw in the tie rod end to achieve the right and left length as illustrated. Lock with the jam nut. NOTE: The jam nuts must be tightened securely only after the steering gear is installed to the vehicle and toe-in is adjusted. >>O<< GEAR MOUNTING RUBBER INSTALLATION

A

220 mm

ACX01166 AB

3. Check that crimped width (A) is within the standard value. Standard value (A): 2.4 - 2.8 mm : Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2). W = 5.5 mm - A [Example: if (A) is 2.9 mm, (W) is 2.6 mm.] : Remove the bellows band, readjust the dimension (W) of step (1) to the value calculated by the following equation, and use a new bellows band to repeat steps (2) to (3). W = 5.5 mm - A [Example: if (A) is 2.3 mm, (W) is 3.2 mm.]

AC100275AB

Install the gear mounting rubber to the rack housing so that the distance is as shown in the illustration.

37-30

POWER STEERING POWER STEERING GEAR BOX AND LINKAGE

TIE ROD END BALL JOINT DUST COVER REPLACEMENT M1372008200305

If the dust cover is damaged accidentally during service work, replace the dust cover as follows:

MB990776

AC001012AB

1. Apply specified grease to the lip and inside of the dust cover. Specified grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent 2. Drive in the dust cover with special tool front axle base (MB990776) until it is fully seated. 3. Check the dust cover for cracks or damage by pushing it with your finger.

POWER STEERING

37-31

POWER STEERING OIL PUMP ASSEMBLY

POWER STEERING OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION M1372005200276

Pre-removal Operation Front Under Cover (RH) and Side Under Cover (RH) Removal (Refer to GROUP 51, Under Cover 351). Power Steering Fluid Draining (Refer to 337).

Post-installation Operation Power Steering Fluid Supplying and Bleeding (Refer to 337). Drive Belt Tension Check (Refer to GROUP 11A, Onvehicle Service - Drive Belt Tension Check 311A). Front Under Cover (RH) and Side Under Cover (RH) Installation (Refer to GROUP 51, Under Cover 351).

12 ± 2 N·m

57 ± 7 N·m

3 4

1 2 5

49 ± 9 N·m

7 22 ± 4 N·m 22 ± 4 N·m

49 ± 9 N·m

6 AC200116 AB

1. 2. >>A<< 3. 4.

Removal steps Pressure switch connector Drive belt Suction hose Pressure hose

REMOVAL SERVICE POINT <> OIL PUMP ASSEMBLY REMOVAL With the engine lifted by the jack, remove the oil pump assembly mounting bolt (lower side) at the pulley side.

<>

5. 6. 7.

Removal steps&RQWLQXHG Oil pump assembly A/C compressor harness Power steering pump bracket

37-32

POWER STEERING POWER STEERING OIL PUMP ASSEMBLY

INSTALLATION SERVICE POINT >>A<< SUCTION HOSE INSTALLATION

Suction hose

AC103338 AC

Install the suction hose so that the marking is positioned as shown in the illustration.


Check the drive belt for cracks. Check the pulley for uneven rotation.

POWER STEERING

37-33



CAUTION Never disassemble the terminal assembly. It cannot be reassembled.

11 28 ± 2 N·m

4

12 13 10 18

2 9

17

8 16 15

9.9 ± 2.1 N·m

: ATF DEXRON III or DEXRON II

15

8

4 5 7 3

3

9 6

10

Oil pump seal kit

1. 2. 3. 4. 5. >>C<< 6. 7. 8. 9.

3

AC100143 AE

13 13 10 2

3

7

28 ± 1 N·m

59 ± 9 N·m

18

5

1

14

11

6

Oil pump cartridge kit

Disassembly steps Pump cover O-ring Snap ring Pulley and shaft Vanes Cam ring Rotor Pin Side plate

Oil pump pulley and shaft kit

>>A<< 10. >>B<< 11. 12.

>>A<< 13. 14.

>>A<< 15. 16. 17. >>A<< 18.

Disassembly steps&RQWLQXHG O-ring Oil seal Terminal assembly O-ring Plug assembly O-ring Flow control spring Suction connector O-ring

POWER STEERING

37-34



>>B<< OIL SEAL INSTALLATION

>>A<< O-RING INSTALLATION

MB990938

Plug assembly

Suction connector

1

MB991203

2 AC000752AB

Terminal assembly

Side plate

Use following special tool to install the oil seal. MB990938: Bar (Snap-in type) MB991203: Oil Seal and Bearing Installer >>C<< CAM RING INSTALLATION

CAUTION

3

Be sure to install the cam ring in the correct direction as shown.

4 5 AC100170 AB

No.

ID Width mm

1

15.8 2.4

2

21.0 1.9

3

14.8 2.4

4

3.8 1.9

5

14.8 1.9

Side plate side

Pump cover side

AC100171AB

Install the cam ring as shown in the illustration.


Check the flow control valve of the pump body for clogging. Check the pulley and shaft for wear or damage. Check the rotor and vane groove for "stepped" wear. Check the contact surface of cam ring and vanes for "stepped" wear. Check the vanes for damage.

POWER STEERING

37-35

POWER STEERING HOSES

POWER STEERING HOSES REMOVAL AND INSTALLATION M1372005700367

Pre-removal and Post-installation Operation Power Steering Fluid Draining and Refilling (Refer to 337). and Bleeding (Refer to 337).

7

12 ± 2 N·m

5 6 4 1

2

12 ± 2 N·m

57 ± 7 N·m

12

12 ± 2 N·m

14

3

12 ± 2 N·m 12 ± 2 N·m

13

13 12 ± 2 N·m

15 12 57 ± 7 N·m

11

9

10

8

15 ± 3 N·m

12 ± 2 N·m AC300498 AC

>>F<< >>E<< >>D<< >>C<< >>B<<

1. 2. 3. 4. 5. 6. 7.

8.

Removal steps Oil reservoir Return hose Suction hose Return hose Return hose Return hose Return tube assembly Front bumper assembly (Refer to GROUP 51, Front Bumper Assembly 351). Cooler tube assembly

>>A<< 9. 10. 11. 12. 13. 14. 15.

Removal steps&RQWLQXHG Tie rod end and knuckle connection (Refer to 337). Stabilizer link (Refer to GROUP 33A, Stabilizer Bar 333). Return hose Return tube O-ring Eye bolt Gasket Pressure hose assembly Return tube

POWER STEERING

37-36

POWER STEERING HOSES

INSTALLATION SERVICE POINTS >>A<< RETURN HOSE INSTALLATION

>>D<< RETURN HOSE INSTALLATION

Return hose

Return tube

Return hose

AC100278 AC

AC100277AB

Install the return hose so that the marking is positioned as shown in the illustration. >>B<< RETURN HOSE INSTALLATION

Install the return hose so that the markings are positioned as shown in the illustration. >>E<< SUCTION HOSE INSTALLATION

Return hose Suction hose

Marking

Return tube AC201792 AC

AC103338 AC

Marking

Install the suction hose so that the marking is positioned as shown in the illustration.

Cooler tube assembly

>>F<< RETURN HOSE INSTALLATION

Return hose

Marking Return tube

AC201922 AC

Install the return hose so that the marking is positioned as shown in the illustration.

Return hose

>>C<< RETURN HOSE INSTALLATION Cooler tube assembly

Return tube Marking

Install the return hose so that the markings are positioned as shown in the illustration.

Return hose Marking

AC201923 AC

AC201791 AC

Install the return hose so that the marking is positioned as shown in the illustration.

21A-1

GROUP 21A

00 11

CLUTCH

12 13 14

CONTENTS GENERAL DESCRIPTION. . . . . . . . .

21A


21A

LUBRICANTS . . . . . . . . . . . . . . . . . .

21A


21A

CLUTCH PEDAL CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .

21A

CLUTCH BLEEDING . . . . . . . . . . . . . . . . .

21A

15

CLUTCH PEDAL. . . . . . . . . . . . . . . . .

21A


21A

CLUTCH CONTROL . . . . . . . . . . . . . .

21A


21A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

21A


21A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

21A

16 17 21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

CLUTCH

21A-2

GENERAL DESCRIPTION

GENERAL DESCRIPTION M1211000100160

The clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control.


Item

Standard value

Clutch pedal height mm

208 2

Clutch pedal clevis pin play mm

1-3

Clutch pedal free play mm

4 - 13

Distance between the clutch pedal and the clutch pedal stopper when the clutch pedal is released mm

105 or more


Item

Specified lubricant

Quantity

Clutch fluid

Brake Fluid DOT 3 or DOT 4

As required

Pushrod assembly

Rubber grease

As required

Boot

Rubber grease

As required

Release cylinder push rod

MITSUBISHI genuine grease Part No.0101011

As required

ON-VEHICLE SERVICE CLUTCH PEDAL CHECK AND ADJUSTMENT

Clutch pedal clevis pin play M1211000900188

Clutch pedal height

B A AC100355 AB

Clutch pedal stopper AC100354 AB

1. Measure the clutch pedal height. Standard value (A): 208 2 mm

2. Measure the clutch pedal clevis pin play. Standard value (B): 1 - 3 mm

CLUTCH

21A-3

ON-VEHICLE SERVICE

Setting nut

Clutch pedal 13 ± 2 N·m AC100356 AB

5. If the clutch pedal free play and the distance between the clutch pedal and the clutch pedal stopper when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system or a faulty master cylinder, release cylinder or clutch. Bleed the air, or disassemble and inspect the master cylinder, release cylinder or clutch.

CLUTCH BLEEDING M1211001400164

Clutch master cylinder bleeding

CAUTION Do not push in the master cylinder pushrod at this time, otherwise the clutch will not operate properly. 3. If the clutch pedal height and clutch pedal clevis pin play are not within the standard value, loosen the setting nut to adjust the clutch pedal height and clevis pin play to the standard value. Clutch pedal free play

CAUTION Use the specified brake fluid. Do not mix brake fluids. Specified fluid: Brake fluid DOT 3 or DOT 4 1. Disconnect the brake tube clamp and remove the brake master cylinder with the brake tubes connected. 2. Remove the brake fluid reservoir with the hoses connected.

C AC100355 AC

Distance between the clutch pedal and the clutch pedal stopper when the clutch is disengaged

D

Clutch pedal stopper

AC100357 AB

4. After completing the adjustments, confirm that the clutch pedal free play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the clutch pedal stopper when the clutch is disengaged are within the standard value ranges. Standard value (C): 4 - 13 mm Standard value (D): 105 mm or more

AC301530AB

3. Connect a hose with a bottle to the bleeder screw. 4. Open the bleed nipple. 5. Depress the clutch pedal slowly. Open the bleeder screw to let air and brake fluid out. Close the bleeder screw. Release the clutch pedal. Repeat until only brake fluid and no air comes out. 6. Check that the brake fluid reservoir level stays between "MAX" and "MIN" marks throughout the clutch bleeding process.

Clutch release cylinder bleeding CAUTION Use the specified brake fluid. Do not mix brake fluids. Specified fluid: Brake fluid DOT 3 or DOT 4 1. Remove the under cover.

CLUTCH

21A-4

CLUTCH PEDAL

4. Depress the clutch pedal slowly. Open the bleeder screw to let air and brake fluid out. Close the bleeder screw. Release the clutch pedal. Repeat until only brake fluid and no air comes out. 5. Check that the brake fluid reservoir level stays between "MAX" and "MIN" marks throughout the clutch bleeding process.

AC301000AB

2. Connect a hose with a bottle to the bleeder screw. 3. Open the bleed nipple.

CLUTCH PEDAL REMOVAL AND INSTALLATION M1211001600179

Post-installation Operation Clutch Pedal Adjustment (Refer to 321A).

2

7 1 4

3 12 ± 2 N·m

5

6 AC301004 AB

1. 2. 3.

Removal steps Instrument panel under cover (Refer to GROUP 52A, Instrument panel 352A). Snap pin Clevis pin Clutch master cylinder mounting nut

4. 5. 6. 7.

Removal steps&RQWLQXHG Clutch pedal assembly mounting bolt Pedal pad Pedal stopper Clutch pedal assembly

CLUTCH

21A-5

CLUTCH CONTROL

CLUTCH CONTROL REMOVAL AND INSTALLATION M1211001900181

Pre-removal Operation Clutch Fluid Draining

Post-installation Operation Clutch Fluid Supplying Clutch Line Bleeding (Refer to 321A). Clutch Pedal Adjustment (Refer to 321A).

15 ± 1 N·m

Release fork

10 Release cylinder push rod

11

Specified grease: MITSUBISHI genuine grease PART No. 0101011

1 4 12 ± 2 N·m

10

30 ± 4 N·m

2

11

N

9

3

5

6

7

12 ± 2 N·m

8

18 ± 3 N·m

AC301448 AB

1. 2. 3. 4. 5.

<>

6.

Clutch master cylinder removal steps Clevis pin assembly Eye bolt Gasket Reservoir hose Clevis pin and pushrod assembly connecting part Clutch master cylinder

7. 8.

Sealer Retainer plate Clutch release cylinder removal steps 10. Clutch pipe 11. Clutch release cylinder Clutch line removal steps 9. Clutch hose 10. Clutch pipe

CLUTCH

21A-6

CLUTCH CONTROL


INSPECTION

<> CLUTCH MASTER CYLINDER REMOVAL 1. Disconnect the brake tube clamp and remove the brake master cylinder with the brake tubes connected. 2. Remove the brake fluid reservoir with the hoses connected. 3. Remove the clutch master cylinder.

M1211002000136

Check the master cylinder or clutch hose for fluid leakage. Check the clutch hose or tube for cracks or clogging.


CLUTCH MASTER CYLINDER

CAUTION Do not disassemble the piston assembly.

13 ± 2 N·m

6

7

3 4 1

N

N

2N

5 8

2

2

4

1

2

3 4 Piston repair kit

Clutch fluid: Brake fluid DOT3 OR DOT4

Grease: Rubber grease AC301952 AB

>>A<<

1. 2. 3. 4.

Disassembly steps Piston stopper ring Piston assembly Pushrod assembly Boot

5. 6. 7. 8.

Disassembly steps&RQWLQXHG Spring pin Nipple Seal Master cylinder body

CLUTCH CLUTCH CONTROL


21A-7


103 ± 0.5 mm AC001144 AG

>>A<< PUSHROD ASSEMBLY INSTALLATION Set the length of the pushrod assembly to the dimension shown to make the adjustment of the clutch pedal easier.

Check inside the cylinder body for rust and scars. Check the piston cup for wear and deformation. Check the piston for rust and scars. Check the pipe connection for clogging.

127(6

55A-1

GROUP 55A

00 11

HEATER, AIR CONDITIONER AND VENTILATION

12 13 14 15 16 17 21

CONTENTS SERVICE SPECIFICATIONS. . . . . . .

55A

LUBRICANTS . . . . . . . . . . . . . . . . . .

55A

SPECIAL TOOLS. . . . . . . . . . . . . . . .

55A


55A


55A

SIGHT GLASS REFRIGERANT LEVEL TEST. . . . . . . . . . . . . . . . . . . . . . . .

55A

MAGNETIC CLUTCH TEST . . . . . . . . . . . .

55A

COMPRESSOR DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .

55A

SIMPLE INSPECTION OF THE A/C PRESSURE SENSOR . . . . . . . . .

55A

CHARGING. . . . . . . . . . . . . . . . . . . . . . . . .

55A

REPLACEMENT PROCEDURE . . . . . . . . .

55A

HEATER CONTROL ASSEMBLY AND A/C SWITCH . . . . . . . . . . . . . . . 55A

25 26


55A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

55A


55A

31

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT . . . . . . . . . . . . . 55A

32


55A

HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . .

55A


55A

BLOWER ASSEMBLY. . . . . . . . . . . . . . . . .

55A


55A

CORRECTING LOW REFRIGERANT LEVEL IN CASE THE SERVICE CAN IN USED . . . . . . . . . . . . . . . . . . . . . . .

55A

DISCHARGING SYSTEM . . . . . . . . . . . . . .

55A

REFILLING OF OIL IN THE A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . .

55A

PERFORMANCE TEST . . . . . . . . . . . . . . .

55A

REFRIGERANT LEAK REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . .

55A


55A

COMPRESSOR NOISE CHECK . . . . . . . .

55A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

55A

POWER RELAY CHECK . . . . . . . . . . . . . .

55A

IDLE-UP OPERATION CHECK . . . . . . . . .

55A

CLEAN AIR FILTER

22

BLOWERMOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR . . . . . . 55A

27

33 34 35 36 37 42 51


55A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

55A

52

EVAPORATOR ASSEMBLY . . . . . . . 55A

54


55

55A-2 COMPRESSOR ASSEMBLY AND TENSION PULLEY . . . . . . . . . . . . . .

55A

REMOVAL AND INSTALLATION . . . . . . . . .

55A

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .

55A


55A

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .

55A

CONDENSER AND CONDENSER FAN MOTOR . . . . . . . . . . . . . . . . . . .


55A

INSPECTION . . . . . . . . . . . . . . . . . . . . . . .

55A

REFRIGERANT LINE. . . . . . . . . . . . . 55A REMOVAL AND INSTALLATION . . . . . . . .

VENTILATORS. . . . . . . . . . . . . . . . . . 55A REMOVAL AND INSTALLATION . . . . . . . .

55A

55A

55A


55A-3



Item

Standard value

Idle speed r/min

750 50

Idle-up speed r/min

850 50

Resistor (for blower motor) W

LO

2.54

ML

1.24

MH

0.6

Air gap (magnetic clutch) mm

0.3 - 0.5


Item

Specified lubricant

Quantity

Compressor refrigerant unit lubricant SUN PAG 56

120 mL

Each connection of refrigerant line

SUN PAG 56

As required

Refrigerant

R134a (HFC-134a)

550 20 g


55A-4

SPECIAL TOOLS


Tool

Tool number

Name

Application

MB991367

Special spanner

Armature mounting nut of compressor removal and installation

MB991386

Pin

MB991223 A:MB991219 B:MB991220 C:MB991221 D:MB991222


B991367

A

B

C

D MB991223 AC



55A-5

TROUBLESHOOTING


Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points 300.

SYMPTOM CHART M1552009900439

NOTE: Refer to GROUP 14, Trouble shooting for the condenser fan. Symptom

Inspection Procedure

Reference Page

When the ignition switch is "ON" the A/C does not operate.

1

355A

Inside/outside air selection is not possible.

2

355A

When the A/C is operating, temperature inside the passenger compartment does not decrease (cool air is not emitted).

3

355A

Blower fan and motor do not turn.

4

355A

Blower air amount cannot be changed.

5

355A

The A/C indicator flashes.

6

355A

Defogger function does not operate.

7

355A

Defogger Timer function does not operate.

8

355A

Malfunction of the A/C-ECU power supply system.

9

355A

Condenser Fan does not operate.

10

Refer to GROUP 14 314

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: When the Ignition Switch is "ON" the A/C does not Operate. COMMENTS ON TROUBLE SYMPTOM The blower system or the compressor system may be defective if there is no cool air coming from the spit hole. TROUBLESHOOTING HINTS Malfunction of blower motor Malfunction of A/C compressor

DIAGNOSIS Check that the blower motor operation when the blower switch is moved to the "HI" position. (1) Turn the ignition switch to the "ON" position. (2) Turn the blower switch to the "HI" position. Q: Does the blower motor operate when the blower switch is moved to the "HI" position? YES : Refer to Inspection procedure 3 "When the

A/C is operating, temperature inside the passenger compartment does not decrease (cool air not emitted) 355A." NO : Refer to Inspection procedure 4 "Blower fan and motor do not turn 355A."

55A-6

HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING

INSPECTION PROCEDURE 2: Inside/Outside Air Selection is not possible.

Outside/Inside Air Selection Damper Control Motor Circit IGNITION SWITCH (IG2)

OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR

A/C-ECU

COMMENTS ON TROUBLE SYMPTOM If the inside/outside air selection damper motor does not operate normally, the inside/outside air selection damper motor system may be defective. TROUBLESHOOTING HINTS Malfunction of the inside/outside air selection damper motor Damaged the wiring harness or connectors Malfunction of the manual air conditioner control panel (A/C-ECU)


DIAGNOSIS STEP 1. Check the defogger and A/C operations. Q: Do the defogger and A/C work normally? YES : Go to Step 2. NO : Refer to Inspection procedure 9

"Malfunction of the A/C-ECU power supply system 355A."


STEP 2. Measure the voltage at the C-311 outside/inside air selection damper control motor connector.

55A-7

STEP 3. Connector check: C-311 outside/inside air selection damper control motor connector Connector: C-311 Harness side


3 2 1 7 6 5 4

3 2 1 7 6 5 4

AC301547AB AC301547AB

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position. Connector C-311 (Harness side)

3 2 1 7 6 5 4

AC301541 BT

(3) Measure the voltage between terminal 7 and body earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 3.



55A-8

TROUBLESHOOTING

STEP 4. Check the wiring harness between C-311 outside/inside air selection damper control motor connector terminal No.7 and the ignition switch (IG2). Connector: C-311 Harness side

Check the outside/inside air selection damper control motor power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


3 2 1 7 6 5 4

STEP 5. Check the outside/inside air selection damper control motor Refer to 355A.

AC301547AB

NOTE:

Q: Does outside/inside air selection damper control motor work normally? YES : Go to Step 6. NO : Replace the outside/inside air selection

damper control motor.

Connector: C-10

STEP 6. Connector check: C-311 outside/inside air selection damper control motor connector and C-06 A/C-ECU

1 2 3 4 5 6 7

Connector: C-311 Harness side 3 2 1 7 6 5 4

AC301397 AM

Connectors: C-203, C-205 Junction Block (Front View) C-203 AC301547AB

Connector: C-06

C-205 C-06(B) Harness side 8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

Harness side C-205

C-203 AC301397 AN

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

2 1 6 5 4 3

AC210475 AR

Prior to the wiring harness inspection, check intermediate connector C-10, junction block connectors C-205 and C-203, and repair if necessary.



STEP 7. Check the wiring harness between C-311 outside/inside air selection damper control motor connector (terminals 6 and 4) and A/C-ECU C-06 (terminals 2 and 3). Connector: C-311 Harness side 3 2 1 7 6 5 4

AC301547AB


C-06(B) C-10

C-10 1 2 3 4 5 6 7

C-06 Harness side 8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

AC301398 BD

NOTE: Prior to the wiring harness inspection, check intermediate connector C-10, and repair if necessary. Check the outside/indside air selection damper control motor earth line for open or short circuit. Q: Is the check result normal? YES : Replace the manual air conditioner control

panel (A/C-ECU). NO : Repair the wiring harness.

55A-9


55A-10

TROUBLESHOOTING

INSPECTION PROCEDURE 3: When the A/C is Operating, Temperature Inside the Passenger Compartment does not Decrease (Cool Air is not Emitted).

A/C Compressor and Air Thermo Sensor Circuit

BATTERY


A/C PRESSURE SENSOR

ENGINEECU

RELAY BOX

A/C COMPRESSOR RELAY

A/C-ECU

A/C REFRIGERANT TEMPERATURE SWITCH

A/C COMPRESSOR ASSEMBLY

RESISTOR MAGNETIC CLUTCH

(OUTLET SIDE)

(INLET SIDE)


SB : Sky blue


55A-11

TROUBLESHOOTING

COMMENTS ON TROUBLE SYMPTOM If cool air is not distributed when the A/C switch is on, the air thermo sensor or the A/C compressor relay system may be defective. TROUBLESHOOTING HINTS Improper amount of refrigerant Malfunction of the air thermo sensor Malfunction of the A/C pressure sensor Malfunction of the A/C compressor relay Malfunction of the A/C refrigerant temperature switch Malfunction of the magnetic clutch Malfunction of the manual air conditioner control panel (A/C-ECU) Damaged the wiring harness or connectors Malfunction of the engine-A/T-ECU

STEP 4. Measure the voltage at the B-27 A/C compressor connector. Connector: B-27

Harness side 1

B-27(B) AC301648 AB

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position. Connector: C-134

DIAGNOSIS STEP 1. Check the defogger and outside/inside air selection damper control motor operation. Q: Do the defogger and outside/inside air selection damper control motor work normally? YES : Go to Step 2. NO : Refer to Inspection procedure 9

"Malfunction of the A/C-ECU power supply system 355A."

Harness side JAE-E 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 1918 17 16 15 14

AC301397AO

(3) Disconnect engine-ECU connector C-134, and earth terminal 8.

STEP 2. Check the blower motor operation. Q: Does the blower motor work normally? YES : Go to Step 3. NO : Refer to Inspection procedure 4 "Blower fan

and motor do not turn 355A."


1

STEP 3. Check the A/C compressor. Check the A/C compressor for compressor oil leaks. Q: Is the check result satisfactory? YES : Go to Step 4. NO : Replace the A/C compressor or the

expansion valve.

AC301541BU


STEP 5. Check the A/C compressor relay continuity. Refer to 355A. Q: Is the A/C compressor relay in good condition? YES : Go to Step 6. NO : Replace the A/C compressor relay.


55A-12

TROUBLESHOOTING

STEP 6. Measure the voltage at B-18X A/C compressor relay connector. Connector: B-18X

STEP 7. Connector check: B-18X A/C compressor relay connector Connector: B-18X

-

-

Relay box side

Relay box side

B-18X

B-18X

2

1

2

1

4

3

4

3

Front of vehicle

Front of vehicle AC301483 AG

(1) Remove the relay, and measure at the relay box side. (2) Turn the ignition switch to the "ON" position.

Connector B-18X (Relay box side) 2

1

4

3

Front of vehicle AC301541BV


AC301483 AG

Q: Is the check result normal? YES : Go to Step 8. NO : Repair or replace the connector.


55A-13

TROUBLESHOOTING

STEP 8. Check the wiring harness between B-18X A/C compressor relay connector terminal No.3 and the ignition switch (IG2).


Connector: B-18X

C-106(GR)

2 1 3 4 5 6 10 11 12 7 8 9 13 14 15 16 17 18 19

AC301397AG

Connectors: C-203, C-205 Junction Block (Front View)

-

C-203 Relay box side B-18X 2

1

4

3

C-205


Harness side C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-203 2 1 6 5 4 3

AC210475 AR

Prior to the wiring harness inspection, check intermediate connector C-106, junction block connectors C-203 and C-205, and repair if necessary. Check the A/C compressor relay power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



55A-14

TROUBLESHOOTING



-

-

Relay box side

Relay box side

B-18X

B-18X

2

1

2

1

4

3

4

3

Front of vehicle


(1) Remove the relay, and measure at the junction block side. Connector B-18X (Relay box side) 2

1

4

3

Front of vehicle AC301541BW


AC301483 AG



55A-15

TROUBLESHOOTING

STEP 11. Check the wiring harness between B18X A/C compressor relay connector terminal No.4 and the battery. Connector: B-18X

STEP 12. Connector check: B-18X A/C compressor relay connector and B-27 A/C compressor connector Connector: B-18X

-

-

Relay box side

Relay box side

B-18X

B-18X

2

1

2

1

4

3

4

3

Front of vehicle


NOTE:

AC301483 AG

Connector: B-27 Connector: A-14

Harness side A-14(GR)

1 2 3 4 5 6 7 8 9 10 11 15 14 12 13 16 17

1

B-27(B) AC301648 AB AC301653AB

Prior to the wiring harness inspection, check intermediate connector A-14, and repair if necessary. Check the A/C compressor relay power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent




55A-16

TROUBLESHOOTING

STEP 13. Check the wiring harness between B18X A/C compressor relay connector terminal No.1 and B-27 A/C compressor connector terminal No.1.

STEP 14. Connector check: C-134 engine-ECU connector and B-18X A/C compressor relay connector Connector: B-18X

Connector: B-18X

Relay box side Relay box side

B-18X

B-18X 2

1

4

3

2

1

4

3

Front of vehicle

Front of vehicle

AC301483 AG AC301483 AG

Connector: C-134 Connector: B-27

Harness side 1


B-27(B)

AC301397AO

AC301648 AB

Check the A/C compressor power supply line for open circuit. Q: Is the check result normal? YES : Go to Step 14. NO : Repair the wiring harness.



55A-17

TROUBLESHOOTING

STEP 15. Check the wiring harness between C134 engine-ECU connector terminal No.8 and B18X A/C compressor relay connector terminal No.2.

STEP 16. Measure the voltage at C-06 A/C-ECU connector. Connectors: C-06, C-134

Connector: B-18X

C-06(B)

C-134

-

Harness side Relay box side

2

1

4

3

C-134

C-06

B-18X 8 7 6 5 4 3 2 1 16 15 14 13 121110 9

JAE-E 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 1918 17 16 15 14

Front of vehicle

AC301398 AU

AC301483 AG

Connector: C-134

(1) Disconnect A/C-ECU connector C-06, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position. (3) Disconnect engine-ECU connector C-134, and earth terminal 8. Connector C-06 (Harness side)


AC301397AO

Check the A/C compressor relay earth line for open or short circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


8 7 6 5 4 3 2 1 16 15 14 13 121110 9

AC301541BX



55A-18

TROUBLESHOOTING

STEP 17. Connector check: B-18X A/C compressor relay connector and C-06 A/C-ECU connector Connector: B-18X

-

Relay box side B-18X 2

1

4

3


Connector: C-06 C-06(B) Harness side 8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

AC301397 AN



STEP 18. Check the wiring harness between B18X A/C compressor relay connector terminal No.1 and C-06 A/C-ECU connector terminal No.7. Connector: B-18X

55A-19

Check the A/C compressor relay output line for open or short circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. STEP 19. Measure the voltage at C-06 A/C-ECU connector. Connector: C-06 -

C-06(B) Harness side

Relay box side 8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

B-18X 2

1

4

3

AC301397 AN



(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position. (3) Turn the blower switch to the "ON" position. Connector C-06 (Harness side)

C-06(B)

8 7 6 5 4 3 2 1 16 15 14 13 121110 9

C-104(B) AC301541BY

(4) Measure the voltage between terminal 8 and body earth. OK: System voltage

C-104 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16


Harness side C-06 8 7 6 5 4 3 2 1 16 15 14 13 121110 9 AC301398 AY

NOTE: Prior to the wiring harness inspection, check intermediate connector C-104, and repair if necessary.


55A-20

TROUBLESHOOTING

STEP 20. Connector check: C-11 resistor connector and C-06 A/C-ECU connector

STEP 21. Check the wiring harness between C-11 resistor connector terminal No.4 and C-06 A/CECU connector terminal No.8.

Connectors: C-06, C-11 Connectors: C-06, C-11 C-06(B) C-06(B) C-11 C-11

Harness side C-06

C-11

8 7 6 5 4 3 2 1 16 15 14 13 121110 9

2 1 4 3

Harness side C-06

C-11

8 7 6 5 4 3 2 1 16 15 14 13 121110 9

2 1 4 3

AC301398 AG AC301398 AG



malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300) NO : Repair the wiring harness. STEP 22. Check the magnetic clutch operation. Refer to 355A. Q: Can the sound of the magnetic clutch (click) be heard? YES : Go to Step 23. NO : Replace the compressor magnet clutch.

STEP 23. Check the refrigerant temperature switch. Refer to 355A. Q: Is the refrigerant temperature switch operating properly? YES : Go to Step 24. NO : Replace the refrigerant temperature switch.

STEP 24. Check the air thermo sensor. Refer to 355A. Q: Is the air thermo sensor in good condition? YES : Go to Step 25. NO : Replace the air thermo sensor.


55A-21

TROUBLESHOOTING

STEP 25. Connector check: C-10 air thermo sensor connector and C-06 A/C-ECU connector Connectors: C-06, C-10

STEP 26. Check the wiring harness between C-10 air thermo sensor connector (terminals 1, 3, 4 and 5) and C-06 A/C-ECU connector (terminals 14, 16 and 13). Connectors: C-06, C-10

C-06(B) C-10

C-06(B) C-10

Harness side C-06 8 7 6 5 4 3 2 1 16 15 14 13 121110 9

C-10 1 2 3 4 5 6 7

Harness side C-06 8 7 6 5 4 3 2 1 16 15 14 13 121110 9

C-10 1 2 3 4 5 6 7

AC301398 AH


AC301398 AH

Check the air thermo sensor output and earth line for open or short circuit. Q: Is the check result normal? YES : Go to Step 27. NO : Repair the wiring harness.

STEP 27. Check the refrigerant level. Refer to 355A. Q: Is the refrigerant level correct? YES : Go to Step 28. NO : Correct the refrigerant level (Refer to On-

vehicle Service 355A). STEP 28. Check the A/C pressure sensor operation. Refer to 355A. Q: Is the A/C pressure sensor operating properly? YES : Go to Step 29. NO : Replace the A/C pressure sensor.


55A-22

TROUBLESHOOTING

STEP 29. Connector check: A-02 A/C pressure sensor connector and C-06 A/C-ECU connector Connector: A-02 A-02(B)

STEP 30. Check the wiring harness between A-02 A/C pressure sensor connector terminal No.2 and C-06 A/C-ECU connector terminal No.15. Connector: A-02 A-02(B)


3 2 1 3 2 1

AC301656 AB AC301656 AB

Connector: C-06 Connector: C-06 C-06(B) C-06(B) Harness side Harness side 8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

AC301397 AN AC301397 AN



1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Prior to the wiring harness inspection, check intermediate connector C-116, and repair if necessary. Check the A/C pressure sensor output line for open or short circuit. Q: Is the check result normal? YES : Go to Step 31. NO : Repair the wiring harness.


55A-23

TROUBLESHOOTING

STEP 31. Connector check: C-134, C-135 engineECU connector and C-06 A/C-ECU connector

STEP 32. Check the wiring harness between C134 engine-ECU connectors terminal No.24 and C-06 A/C-ECU connector terminal No.5.

Connectors: C-06, C-134, C-135 Connectors: C-06, C-104, C-134 C-06(B) C-06(B) C-135 C-134 C-134 C-104(B) Harness side C-06

C-134

C-135

C-104

8 7 6 5 4 3 2 1 16 15 14 13 121110 9

1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

JAE-E 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 1918 17 16 15 14

JAE-E 38 37 36 35 34 33 32 31 46 45 4443 42 41 4039

Harness side C-06

C-134

8 7 6 5 4 3 2 1 16 15 14 13 121110 9

JAE-E 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 1918 17 16 15 14

AC301398 AV AC301398 AW


NOTE: Prior to the wiring harness inspection, check intermediate connector C-104, and repair if necessary. Check the communication line for open or short circuit. Q: Is the check result normal? YES : Go to Step 33. NO : Repair the wiring harness.


55A-24

TROUBLESHOOTING

STEP 33. Check the wiring harness between C135 engine-ECU connectors terminal No.45 and C-06 A/C-ECU connector terminal No.4. Connectors: C-06, C-104, C-135

C-06(B) C-135 C-104(B)

C-104 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

Harness side C-06 8 7 6 5 4 3 2 1 16 15 14 13 121110 9

C-135 JAE-E 38 37 36 35 34 33 32 31 46 45 4443 42 41 4039 AC301398 AX

NOTE: Prior to the wiring harness inspection, check intermediate connector C-104, and repair if necessary. Check the communication line for open or short circuit. Q: Is the check result normal? YES : Replace the manual air conditioner control

panel (A/C-ECU) or engine-ECU. NO : Repair the wiring harness.


55A-25

INSPECTION PROCEDURE 4: Blower Fan and Motor do not Turn.

Blower Motor Circuit FUSIBLE LINK 1


BLOWER RELAY

BLOWER SWITCH

BLOWER MOTOR


COMMENTS ON TROUBLE SYMPTOM If the blower fan and motor does not turn when the blower switch is operated, the blower switch may be defective. TROUBLESHOOTING HINTS Malfunction of the blower relay Malfunction of the blower switch Damaged the wiring harness or connectors Malfunction of the blower motor

DIAGNOSIS STEP 1. Check that the blower motor operates when the blower switch is moved to the "4 (HI) " position. (1) Turn the ignition switch to the "ON" position. (2) Turn the blower switch to the "4 (HI) " position. Q: Does the blower motor operate when the blower switch is moved to the "4 (HI) " position? YES : Refer to Inspection procedure 5 "Blower air

amount cannot be changed 355A." NO : Go to Step 2.


55A-26

TROUBLESHOOTING

STEP 2. Measure the resistance at the C-12 blower motor connector. Connector: C-12

STEP 3. Connector check: C-12 blower motor connector Connector: C-12

Harness side

Harness side

1 2

1 2 AC301397AQ

(1) Disconnect the connector, and measure at the wiring harness side. Connector C-12 (Harness side)

AC301397AQ


STEP 4. Check the wiring harness between C-12 blower motor connector terminal No.2 and body earth.

1 2

Connector: C-12

AC301541 BZ

(2) Measure the resistance between terminal 2 and body earth. OK: 2 ohm or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 3.

Harness side

1 2 AC301397AQ

Check the blower motor earth line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



55A-27

TROUBLESHOOTING

STEP 5. Measure the voltage at C-12 blower motor connector.

STEP 7. Measure the voltage at C-207 blower relay connector. Connector: C-207 Junction block (Front view)

Connector: C-12

Harness side

1 2


AC301397AQ

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position. (3) Turn the blower switch to the "4 (HI) " position.

AC210474 AJ

(1) Remove the relay, and measure at the junction block side. (2) Turn the ignition switch to the "ON" position.



3 2 1 4 5

1 2

AC301541CB AC301541CA


STEP 6. Check the blower relay continuity. Refer to 355A. Q: Is the blower relay continuity in good condition? YES : Go to Step 7. NO : Replace the blower relay.


STEP 8. Connector check: C-207 blower relay connector Connector: C-207 Junction block (Front view)



AC210474 AJ


55A-28

TROUBLESHOOTING

STEP 9. Check the wiring harness between C-207 blower relay connector terminal No.1 and the ignition switch (IG2). Connectors: C-203, C-207 Junction block (Front view)

STEP 10. Measure the resistance at C-207 blower relay connector. Connector: C-207 Junction block (Front view)

C-203


C-207

AC210474 AJ

(1) Remove the relay, and measure at the junction block side. Harness side

Junction block side

C-203

C-207

2 1 6 5 4 3

3 2 1 4 5

AC210475 AS


3 2 1 4 5 AC301541CC

NOTE: Prior to the wiring harness inspection, check junction block connector C-203, and repair if necessary. Check the blower relay power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


(2) Measure the resistance between terminal 3 and body earth. OK: 2 ohm or less Q: Is the check result normal? YES : Go to Step 13. NO : Go to Step 11.

STEP 11. Connector check: C-207 blower relay connector. Connector: C-207 Junction block (Front view)


AC210474 AJ



55A-29

TROUBLESHOOTING

STEP 12. Check the wiring harness between C207 blower relay connector terminal No.3 and earth. Connectors: C-205, C-207 Junction block (Front view)

STEP 13. Measure the voltage at C-207 blower relay connector. Connector: C-207 Junction block (Front view)


C-205 C-207

AC210474 AJ


Junction block side

C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-207 3 2 1 4 5

Connector C-207 (Junction block side) 3 2 1 4 5

AC210475 AT AC301541CD

NOTE: Prior to the wiring harness inspection, check junction block connectors C-205, and repair if necessary. Check the blower relay earth line for open circuit.





STEP 14. Connector check: C-207 blower relay connector Connector: C-207 Junction block (Front view)


AC210474 AJ



55A-30

TROUBLESHOOTING

STEP 15. Check the wiring harness between C207 blower relay connector terminal No.5 and fusible link (1). Connectors: C-204, C-207 Junction block (Front view)

STEP 16. Check the blower switch continuity. Refer to 355A. Q: Is the blower switch continuity in good condition? YES : Go to Step 17. NO : Replace the blower switch.

STEP 17. Connector check: C-08 blower switch connector and C-207 blower relay connector

C-204(B)

Connector: C-08

C-207

Harness side

Junction block side

Harness side C-204

C-207

1

3 2 1 4 5

3 2 1 6 5 4 AC301397 AR


AC210475 AU

Junction block side

Connector: C-116

3 2 1 4 5

1 2

5 6 7

3 4


8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC210474 AJ

AC301395 AG

NOTE: Prior to the wiring harness inspection, check intermediate connectors C-116 and junction block connector C-204, and repair if necessary. Check the blower relay power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



55A-31

TROUBLESHOOTING

STEP 18. Check the wiring harness between C-08 blower switch connector terminal No.2 and C-207 blower relay connector terminal No.4.

STEP 19. Connector check: C-12 blower motor connector and C-08 blower switch connector Connectors: C-08, C-12

Connector: C-08

C-12 Harness side

C-08

3 2 1 6 5 4 AC301397 AR


Harness side

C-203

C-207

Harness side

C-08

C-12

3 2 1 6 5 4

1 2

AC301398 AL

Junction block side

C-203

C-207

2 1 6 5 4 3

3 2 1 4 5

AC210475 AS

NOTE: Prior to the wiring harness inspection, check junction block connectors C-203, and repair if necessary. Check the blower relay output line for open circuit. Q: Is the check result normal? YES : Go to Step 19. NO : Repair the wiring harness.



55A-32

TROUBLESHOOTING

STEP 20. Check the wiring harness between C-12 blower motor connector terminal No.1 and C-08 blower switch connector terminal No.6.

STEP 21. Check the blower fan and motor operation. Refer to 355A. Q: Is the check result normal? YES : The trouble can be an intermittent


malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Replace the blower motor. C-12 C-08

Harness side C-08

C-12

3 2 1 6 5 4

1 2

AC301398 AL

Check the blower motor power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



55A-33

INSPECTION PROCEDURE 5: Blower Air Amount cannot be Changed.

Blower Switch and Resistor Circuit BLOWER RELAY

BLOWER SWITCH

RESISTOR

BLOWER MOTOR


COMMENTS ON TROUBLE SYMPTOM If the blower air amount can not be changed when the blower switch is operated, the blower switch may be defective. TROUBLESHOOTING HINTS Malfunction of the resistor Damaged the wiring harness or connectors Malfunction of the blower switch

DIAGNOSIS STEP 1. Check that the blower motor operates when the blower switch is moved to the "4 (HI)" position. (1) Turn the ignition switch to the "ON" position. (2) Turn the blower switch to the "4 (HI) " position. Q: Does the blower motor operate when the blower switch is moved to the "4 (HI)" position? YES : Go to STEP 2. NO : Refer to Inspection procedure 4 "Blower fan

and motor do not turn 355A."

STEP 2. Check the blower switch continuity. Refer to 355A. Q: Is the blower switch continuity in good condition? YES : Go to Step 3. NO : Replace the blower switch.

STEP 3. Check the resistor resistance value. Refer to 355A. Q: Is the measured value at the standard value? YES : Go to Step 4. NO : Replace the resistor.


55A-34

TROUBLESHOOTING

STEP 4. Connector check: C-08 blower switch connector and C-11 resistor connector Connectors: C-08, C-11

STEP 5. Check the wiring harness between C-08 blower switch connector (terminals 1, 4 and 5) and C-11 resistor connector (terminals 4, 1 and 3). Connectors: C-08, C-11

C-08

C-11 C-08

C-11

Harness side C-08

C-11

3 2 1 6 5 4

2 1 4 3

Harness side C-08

C-11

3 2 1 6 5 4

2 1 4 3

AC301398 AM


AC301398 AM

Check the blower switch output line for open circuit. Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness.


55A-35

TROUBLESHOOTING

STEP 6. Connector check: C-11 resistor connector and C-12 blower motor connector

STEP 7. Check the wiring harness between C-12 blower motor connector (terminal 1) and C-11 resistor connector (terminal 2).

Connectors: C-11, C-12 Connectors: C-11, C-12

C-11 C-11

C-12

C-12

Harness side C-11

C-12

2 1 4 3

1 2

Harness side C-11

C-12

2 1 4 3

1 2

AC301398 AN AC301398 AN


Check the blower motor power supply line for open circuit. Q: Is the check result normal? YES : No action to be taken. NO : Repair the wiring harness.


55A-36

TROUBLESHOOTING

INSPECTION PROCEDURE 6: The A/C Indicator Flashes.

A/C Pressure Sensor and Air Thermo Sensor Circuit AIR THERMO SENSOR

(OUTLET SIDE)

(INLET SIDE)

AIR THERMO SENSOR

A/C PRESSURE SENSOR

A/C-ECU


COMMENTS ON TROUBLE SYMPTOM If the A/C indicator flashes then the possible causes may be due to a defective A/C pressure system or insufficient refrigerant gas. TROUBLESHOOTING HINTS Malfunction of the A/C pressure sensor Malfunction of the air thermo sensor Malfunction of the manual air conditioner control panel (A/C-ECU)

DIAGNOSIS

SB : Sky blue

STEP 2. Check the air thermo sensor. Refer to 355A. Q: Is the air thermo sensor in good condition? YES : Go to Step 3. NO : Replace the air thermo sensor.

STEP 3. Check the refrigerant level. Refer to 355A. Q: Is the refrigerant level correct? YES : Replace the manual air conditioner control

panel (A/C-ECU). NO : Correct the refrigerant level (Refer to 355A

STEP 1. Check the A/C pressure sensor operation. Refer to 355A. Q: Is the A/C pressure sensor operating properly? YES : Go to Step 2. NO : Replace the A/C pressure sensor.

).


55A-37

INSPECTION PROCEDURE 7: Defogger Function does not Operate.

Defogger Circuit IGNITION SWITCH (IG2)

FUSIBLE LINK 1

DEFOGGER RELAY

A/C-ECU DEFOGGER SWITCH

DEFOGGER


COMMENTS ON TROUBLE SYMPTOM If the defogger does not operate when the defogger switch is turned on, the defogger relay system may be defective. TROUBLESHOOTING HINTS Malfunction of the defogger relay Malfunction of the defogger Damaged the wiring harness or connectors Malfunction of the manual air conditioner control panel (A/C-ECU)

SB : Sky blue

DIAGNOSIS STEP 1. Check the A/C and outside/inside air selection damper control motor operation. Q: Do the A/C and outside/inside air selection damper control motor work normally? YES : Go to Step 2. NO : Refer to Inspection procedure 9

"Malfunction of the A/C-ECU Power Supply system 355A."


55A-38

TROUBLESHOOTING

STEP 2. Measure the voltage at defogger connector F-04.

STEP 4. Measure the voltage at defogger relay connector C-206. Connector: C-206 Junction block (Front view)

Connector: F-04 F-04(B) Harness side

1 Junction block side 3 2 1 4 5

AC301658 AB

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position. (3) Turn the defogger switch to the "ON " position. (operate for approx. 11 minutes)

AC210474 AK

(1) Remove the relay, and measure at the junction block side. Connector C-206 (Junction block side) 3 2 1 4 5


AC301541CF

1 AC301541CE


STEP 3. Check the defogger relay continuity. Refer to 355A.


STEP 5. Connector check: C-206 defogger relay connector Connector: C-206 Junction block (Front view)

Q: Is the Defogger relay continuity in good condition? YES : Go to Step 4. NO : Replace the defogger relay. Junction block side 3 2 1 4 5 AC210474 AK



55A-39

TROUBLESHOOTING

STEP 6. Check the wiring harness between C-206 defogger relay connector terminal No.5 and the fusible link (1). Connectors: C-204, C-206 Junction block (Front view)

Check the defogger relay power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


C-204(B)

STEP 7. Measure the voltage at defogger relay connector C-206. Connector: C-206 Junction block (Front view)

C-206

Junction block side

Harness side C-204

Junction block side

C-206

3 2 1 4 5

3 2 1 4 5

1

AC210474 AK

(1) Remove the relay, and measure at the junction block side. (2) Turn the ignition switch to the "ON" position. AC210475 AV

Fusible link: No.1


3 2 1 4 5 AC301541CG AC301515 AB



1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Prior to the wiring harness inspection, check intermediate connector C-116 and junction block connector C-204, and repair if necessary.


55A-40

TROUBLESHOOTING


STEP 10. Connector check: C-206 defogger relay connector and C-06 A/C-ECU connector. Connector: C-06 C-06(B) Harness side

Junction block side

8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

3 2 1 4 5

AC301397 AN

AC210474 AK


STEP 9. Check the wiring harness between C-206 defogger relay connector terminal No.1 and ignition switch (IG2). Connectors: C-203, C-206 Junction block (Front view)

2 1 6 5 4 3

3 2 1 4 5


C-206

C-203

Junction block side

AC210474 AK

C-203

Harness side


Junction block side C-206 3 2 1 4 5

AC210475 AW

NOTE: Prior to the wiring harness inspection, check junction block connector C-203, and repair if necessary. Check the defogger relay power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



55A-41

TROUBLESHOOTING

STEP 11. Check the wiring harness between C206 defogger relay connector terminal No.3 and C-06 A/C-ECU connector terminal No.1. Connector: C-06

STEP 12. Connector check: C-206 defogger relay connector and F-04 defogger connector Connector: C-206 Junction block (Front view)


Junction block side 8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

3 2 1 4 5 AC210474 AK AC301397 AN

Connector: F-04

Connectors: C-205, C-206 Junction Block (Front view)

F-04(B) Harness side

1

C-205 C-206

Harness side

AC301658 AB

Junction block side

C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-206 3 2 1 4 5

AC210475 AX

NOTE: Prior to the wiring harness inspection, check junction block connector C-205, and repair if necessary. Check the defogger relay earth line for open or short circuit. Q: Is the check result normal? YES : Go to Step 12. NO : Repair the wiring harness.



55A-42

TROUBLESHOOTING

STEP 13. Check the wiring harness between C206 defogger relay connector terminal No.4 and F-04 defogger connector terminal No.1. Connectors: C-206, C-209 Junction block (Front view)

STEP 14. Measure the resistance at defogger connector F-01. Connector: F-01 Harness side

1

C-206 AC301658 AC


C-209

Harness side C-209 7 6 5 15 1413

12

4 3 2 1 11 10 9 8



3 2 1 4 5

1 AC210475 AY


AC301541CO

(2) Measure the resistance value between terminal 1 and earth. OK: 2 ohm or less Q: Is the check result normal? YES : Go to Step 17. NO : Go to Step 15.

1

AC301658 AB

NOTE: Prior to the wiring harness inspection, check junction block connector C-209, and repair if necessary. Check the defogger relay output line for open circuit.

STEP 15. Connector check: F-01 defogger connector Connector: F-01 Harness side

1

Q: Is the check result normal? YES : Replace the manual air conditioner control


AC301658 AC



STEP 16. Check the wiring harness between F-01 defogger connector terminal No.1 and earth. Connector: F-01

55A-43

STEP 17. Check the defogger. Refer to GROUP 54A, Rear window defogger 354A. Q: Does the defogger work normally? YES : Replace the manual air conditioner control

Harness side

panel (A/C-ECU). NO : Repair the defogger.

1

AC301658 AC

Check the defogger earth line for open circuit. Q: Is the check result normal? YES : Check that the defogger system works

normally. NO : Repair the wiring harness.

INSPECTION PROCEDURE 8: Defogger Timer Function does not Operate. COMMENTS ON TROUBLE SYMPTOM Turn ON the defogger switch. If the defogger does not shut off after roughly 11 minutes then the defogger timer is malfunctioning. TROUBLESHOOTING HINTS Malfunction of the manual air conditioner control panel (A/C-ECU)

Check the performance of the defogger timer operations. (1) Turn the ignition switch to the "ON" position. (2) Turn the defogger switch to the "ON" position (operate for approx. 11 minutes) Q: Does the defogger timer function work normally? YES : Intermittent malfunction NO : Replace the manual air conditioner control

panel (A/C-ECU).

55A-44


INSPECTION PROCEDURE 9: Malfunction of the A/C-ECU Power Supply System.

A/C-ECU Power Supply Circuit IGNITION SWITCH (IG2)

A/C-ECU


COMMENTS ON TROUBLE SYMPTOM The A/C-ECU power system may be defective if the air conditioner, defogger, and outside/inside air selection damper motor all do not operate normally.

TROUBLESHOOTING HINTS Damaged the wiring harness or connectors Malfunction of the manual air conditioner control panel (A/C-ECU)


55A-45

TROUBLESHOOTING

DIAGNOSIS STEP 1. Measure the voltage at A/C-ECU connector C-06.

STEP 3. Check the wiring harness between C-06 A/C-ECU connector terminal No.10 and the ignition switch (IG2). Connector: C-06

Connector: C-06 C-06(B) C-06(B) Harness side Harness side

8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

AC301397 AN AC301397 AN

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position.

Connectors: C-203, C-205 Junction Block (Front View) C-203


C-205 8 7 6 5 4 3 2 1 16 15 14 13 121110 9

Harness side AC301541CH


C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-203 2 1 6 5 4 3

AC210475 AR

STEP 2. Connector check: C-06 A/C-ECU connector Connector: C-06 C-06(B)

NOTE: Prior to the wiring harness inspection, check junction block connectors C-203 and C-205, and repair if necessary. Check the A/C-ECU power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

Harness side


8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

AC301397 AN



55A-46

TROUBLESHOOTING

STEP 4. Measure the resistance at the C-06 A/CECU connector.

STEP 5. Connector check: C-06 A/C-ECU connector

Connector: C-06

Connector: C-06

C-06(B)

C-06(B)

Harness side

Harness side

8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

AC301397 AN

(1) Disconnect the connector, and measure at the wiring harness side. Connector C-06 (Harness side)

AC301397 AN


STEP 6. Check the wiring harness between C-06 A/C-ECU connector terminal No.12 and the earth.

8 7 6 5 4 3 2 1 16 15 14 13 121110 9

Connector: C-06 C-06(B)

AC301541CN

(2) Measure the resistance between terminal 12 and body earth. OK: 2 ohm or less Q: Is the check result normal? YES : Replace the manual air conditioner control

panel (A/C-ECU). NO : Go to Step 5.

Harness side 8 7 6 5 4 3 2 1 16 15 14 13 12 1110 9

AC301397 AN

Check the A/C-ECU earth line for open circuit. Q: Is the check result normal? YES : Replace the manual air conditioner control



55A-47

TROUBLESHOOTING


1

2

3

4

5

6

7

8

9 10 11 12 13 14 15 16

AC300861AB

Terminal No. Check item

Checking requirement

Normal condition

1

Defogger switch: ON

0V

Defogger switch: OFF

System voltage

When the damper is moved to the inside air recirculation position

0V

When the damper is moved to the outside air inside air intake position

System voltage


System voltage


0V

Output to the engine-A/T-ECU (A/C1)

A/C stopped

0V

A/C switch: ON Blower switch: ON

System voltage

Output to the engine-A/T-ECU (A/C2)

When the A/C is under low load System voltage When the A/C is under high load

0V

6

Power supply to the A/C illumination

Lighting switch: ON

System voltage

7

-

-

-

8

Blower switch (lo)

blower switch: lo

System voltage

9

-

-

-

10


Ignition switch: ON

System voltage

11

Earth to the A/C illumination

Always

0V

12

Earth

Always

0V

13

Air thermo sensor (outlet side)

Sensor probe temperature 25C 2.2 V (1.5k ohm)

14

Air thermo sensor (inlet side)

Sensor probe temperature 25C 2.2 V (1.5k ohm)

15

-

-

-

16

Earth to the air thermo sensor

Always

0V

2

3

4

5

Rear defogger switch Inside/outside air changeover damper motor (outside air)

Inside/outside air changeover damper motor (inside air)


55A-48

ON-VEHICLE SERVICE

ON-VEHICLE SERVICE SIGHT GLASS REFRIGERANT LEVEL TEST M1552008400345

1. Start the engine. 2. Operate the air-conditioner, and then set the temperature to maximum cooling. 3. Hold the engine speed at 1500 r/min.

MAGNETIC CLUTCH TEST M1552008500386

1. Disconnect the magnetic clutch connector to the magnetic clutch. Magnetic cluch connector

Sufficient or excess Insufficient refrigerant refrigerant Bubbles

AC005671AC

AC005963 AC

4. Check the refrigerant level (bubble state) through the sight glass.

CAUTION Use the low-pressure service valve.

2. Connect positive battery voltage directly to the connector for the magnetic clutch. 3. If the magnetic clutch is normal, there will be a "click." If the pulley and armature do not make contact ("click"), there is a malfunction.

COMPRESSOR DRIVE BELT ADJUSTMENT

Items

State

Insufficient

Many bubbles are seen. If refrigerant is extremely low, it appears white.

Refer to GROUP 11, On-vehicle Service - Drive Belt Tension Check 311A.

Sufficient or excess refrigerant

No bubbles are seen.

SIMPLE INSPECTION OF THE A/C PRESSURE SENSOR

NOTE: (1) If insufficient, replenish the refrigerant as follows. a. Replenish until bubbles disappear from the sight glass. b. After the bubbles disappear from the sight glass, replenish 100 g of refrigerant. (2) If excessive, replenish the refrigerant as follows. a. Drain the refrigerant until bubbles can be seen through the sight glass. b. Replenish until bubbles disappear from the sight glass. c. After the bubbles disappear from the sight glass, replenish 100 g of refrigerant.

M1552001000313

M1552014700088

1. Assemble a manifold gauge onto the high pressure service valve. 2. Turn ON the engine and then turn ON the air conditioner switch.


55A-49

ON-VEHICLE SERVICE A/C pressure sensor 1

2

CHARGING M1552001200340

3

High-pressure valve

Low-pressure valve

AC206295 AB

Gauge manifold

Output voltage (V) 5

Charging hose Adapter (yellow) valve Charging hose (blue) Switch R-134a R-12 connection connection port port

4 3 2 1 0

1 2 3 Refrigerant pressure (MPa) AC208297AB

3. Check to see that the voltage between the A/C pressure sensor terminal No.2 and body earth reflects the specifications of the Figure. NOTE: The allowance shall be defined as five percents.

Vacuum Quick pump joint adaptor Vacuum (for low pump pressure)

Power supply plug

Switch Low-pressure service valve

A Sleeve

AC212526AB

1. With the handles turned back all the way (valve closed), install the adaptor valve to the lowpressure side of the gauge manifold. 2. Connect the charging hose (blue) to the adaptor valve. 3. Connect the quick joint (for low-pressure) to the charging hose (blue).

55A-50

HEATER, AIR CONDITIONER AND VENTILATION ON-VEHICLE SERVICE

CAUTION Use tools that are suited to R134a. To install the quick joint, press section when connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose. 4. Connect the quick joint (for low-pressure) to the low- pressure service valve. NOTE: The low-pressure service valve should be connected to the flexible suction hose. 5. Close the high and low-pressure valves of the gauge manifold.

CAUTION Do not operate the compressor for evacuation.

Vacuum pump adaptor switch

CAUTION Be sure to connect the power plug of the vacuum pump to the vacuum pump adapter, and then connect the power plug of the adapter to a 100-V outlet. 6. Install the vacuum pump adaptor to the vacuum pump. 7. Connect the charging hose (yellow) to the R-134a connection port of the vacuum pump adaptor. 8. Tighten the adaptor valve handle (valve open). 9. Open the low-pressure valve of the gauge manifold. 10.Turn the power switch of the vacuum pump to the ON position. NOTE: Even if the vacuum pump power switch is turned ON, the vacuum pump will not operate because of the power supply connection in step (6).

Low-pressure service valve

Vacuum pump

AC212535 AB

11.Turn the vacuum pump adaptor switch to the R134a side to start the vacuum pump. 12.Evacuate to a vacuum reading of 100 kPa or higher (takes approx. 10 minutes).

CAUTION Do not operate the compressor in the vacuum condition; damage may occur. 13.Loosen the valve of the adapter valve fully (valve closed), and turn off the vacuum pump adapter switch. Then leave it for five minutes. 14.Check the system for proper sealing (negative pressure should not decrease). Valve open Valve close Charging valve Adaptor valve Service can AC212536 AB

15.Connect the service can valve to the service can with the handle loosened fully (valve closed). 16.Turn the handle of the adaptor valve back all the way (valve closed), remove it from the gauge manifold and install the service can.


55A-51

ON-VEHICLE SERVICE

17.Tighten the handle of the charging valve (valve closed) to puncture the service can.

CAUTION If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is charged in gas state. Charging valve

Service can (Refrigerant container)


CAUTION If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is charged in gas state. 24.Tighten the handle of the adaptor valve (valve open) to charge the required volume of refrigerant. 25.After charging with refrigerant, turn the handle of the adaptor valve back all the way (valve closed). 26.Tighten the charging valve handle (valve closed). Remove the quick joint (for low-pressure) from the low-pressure service valve. 27.Remove the service can. NOTE: If the service can is not emptied completely, keep the handles of the charging valve and adaptor valve closed for the next charging.

CORRECTING LOW REFRIGERANT LEVEL IN CASE THE SERVICE CAN IN USED M1552014600081

Valve open

Charge valve

Valve close Adaptor valve AC212537AB

18.Turn the handle of the charging valve back (valve open) and tighten the handle of the adaptor valve (valve open) to charge the system with refrigerant. 19.If the refrigerant is not drawn in, turn the handle of the adaptor valve back all the way (valve closed). 20.Check for gas leaks using a leak detector. If a gas leak is detected, re-tighten the connections, and then repeat the charging procedure from evacuation in step (11).

CAUTION The leak detector for R-134a should be used. 21.Start the engine. 22.Operate the A/C and set to the lowest temperature (MAX. COOL). 23.Fix the engine speed at 1,500 r/min.

Charging hose (blue) Service can (Refrigerant container)

Quick joint (for low-pressure) AC300372AB

1. Install the charge valve with the handle turned all the way back (valve open) to the service can. 2. Install the adaptor valve with the handle turned all the way back (valve close) to the charging valve. 3. Connect the charging hose (blue) to the adaptor valve. 4. Connect the charging hose (blue) to the quick joint (for low-pressure). 5. Tighten the handle of the charge valve (valve close), and pierce the service can. 6. Turn the handle of the adaptor valve to bleed the air.


55A-52

ON-VEHICLE SERVICE

Quick joint (for low-pressure)

Compressor oil: SUN PAG 56 Quantity Evaporator: 60 mL Condenser: 15 mL Flexible suction hose: 10 mL Receiver: 10 mL

PERFORMANCE TEST


M1552001400333 AC300373 AB

7. Install the quick joint (for low-pressure) to the lowpressure service valve. NOTE: The low-pressure service valve should be connected to the suction hose. 8. Start the engine. 9. Operate the air conditioner and set at the lowest temperature (MAX. COOL). 10.Fix the engine speed at 1,500 r/min. 11.Tighten the handle of the adaptor valve (valve open), and replenish refrigerant while checking the quantity through the sight glass. 12.After replenishing is completed, turn the handle of the adaptor valve all the way back (valve close), and remove the quick joint. NOTE: When there is remainder of refrigerant in the service can, keep it for next use with the charge value and the valve of the adaptor valve being closed.

1. The vehicles to be tested should be in a place that is not in direct sunlight. Low-pressure valve

Gauge manifold Charging hose (red) Charging hose (blue)

Lowpressure service valve

M1552013000086

REFILLING OF OIL IN THE A/C SYSTEM M1552020000022

Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too much oil will increase discharge air temperature. When a compressor is installed at the factory, it contains 120 mL of compressor oil. While the A/C system is in operation, the oil is carried through the entire system by the refrigerant. Some of this oil will be trapped and retained in various parts of the system. When the following system components are changed, it is necessary to add oil to the system to replace the oil being removed with the component.

A

Adaptor valve (for lowpressure)

DISCHARGING SYSTEM Use the refrigerant recovery unit to discharge refrigerant gas front the system. NOTE: Refer to the Refrigerant Recovery and Recycling Unit instruction Manual for operation of the unit.

High-pressure valve

Sleeve

Highpressure service valve

Adaptor valve (for highpressure)

AC001388 AB

2. Close the high and low-pressure valve of the gauge manifold. 3. Connect the charging hose (blue) to the lowpressure valve and connect the charging hose (red) to the high-pressure valve of the gauge manifold.

CAUTION To connect the quick joint, press section A firmly against the service valve until a click is heard. When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose. 4. Install the quick joint (for low-pressure) to the charging hose (blue), and connect the quick joint (for high-pressure) to the charging hose (red). NOTE: The high-pressure service valve is on the A/C pipe and the low-pressure service valve is on the suction hose.


55A-53

ON-VEHICLE SERVICE

5. Connect the quick joint (for low-pressure) to the low-pressure service valve and connect the quick joint (for high-pressure) to the high-pressure service valve. 6. Start the engine. 7. Set the A/C controls as follows: A/C switch: A/C - ON position Mode selection: FACE position Temperature control: MAXIMUM COOLING position Air selection: RECIRCULATION position Blower switch: "4" (Fast) position 8. Adjust engine speed to 1,500 r/min with A/C clutch engaged. 9. Engine should be warmed up with doors and windows opened.

Thermometer

AC200070AB

10.Insert a thermometer in the centre air outlet and operate the engine for 20 minutes. NOTE: If the clutch cycles, take the reading before the clutch disengages. 11.Note the discharge air temperature.

Performance Temperature Chart Garage ambient temperature C

20

25

30

35

Discharge air temperature C

8.0 - 11.0

12.0 - 16.0

17.0 - 21.0

22.5 - 27.5

Compressor high pressure kPa

740 - 840

950 - 1,050

1,160 - 1,300

1,360 - 1,550

Compressor low pressure kPa

150 - 190

190 - 240

240 - 300

300 - 375

LOW CHARGE

REFRIGERANT LEAK REPAIR PROCEDURE M1552001500266

LOST CHARGE If the system has lost all charge due to a leak: 1. Evacuate the system (Refer to 355A). 2. Charge the system with approximately 550 g of refrigerant. 3. Check for leaks. 4. Discharge the system. 5. Repair leaks.

CAUTION Replacement filter-drier units must be sealed while in storage. The drier used in these units will saturate water quickly upon exposure to the atmosphere. When installing a drier, have all tools and supplies ready for quick assembly to avoid keeping the system open any longer than necessary. 6. Replace receiver drier. 7. Evacuate and charge system.

If the system has not lost all of its refrigerant charge; locate and repair all leaks. If it is necessary to increase the system pressure to find the leak (because of an especially low charge) add refrigerant. If it is possible to repair the leak without discharging the refrigerant system, use the procedure for correcting low refrigerant level.

HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The following precautions must be observed. The system must be completely discharged before opening any fitting of connection in the refrigeration system. Open fittings with caution even after the system has been discharged. If any pressure is noticed as a fitting is loosened, allow trapped pressure to bleed off very slowly. Never attempt to rebend formed lines to fit. Use the correct line for the installation you are servicing. A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter of the hose.

55A-54


Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so that they are at least 80 mm from the exhaust manifold. It is good practice to inspect all flexible hose lines at least once a year to make sure they are in good condition and properly routed. On standard plumbing fittings with O-rings, these Orings are not reusable.

5. Recheck compressor noise as in Step 1. 6. If noise still exists, loosen compressor mounting bolts and retighten. Repeat Step 1. 7. If noise continues, replace compressor and repeat Step 1.

POWER RELAY CHECK M1552008800280

BLOWER RELAY CONTINUITY CHECK

COMPRESSOR NOISE CHECK M1552008700261

You must first know the conditions when the noise occurs. These conditions are: weather, vehicle speed, in gear or neutral, engine temperature or any other special conditions. Noises that develop during A/C operation can often be misleading. For example: what sounds like a failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a loose clutch assembly. Verify accessory drive belt tension (power steering or alternator). Improper accessory drive belt tension can cause a misleading noise when the compressor is engaged and little or no noise when the compressor is disengaged. Drive belts are speed-sensitive. That is, at different engine speeds, and depending upon belt tension, belts can develop unusual noises that are often mistaken for mechanical problems within the compressor.

Blower relay

1 2 3 4 5

5 4 1

ADJUSTMENT 1. Select a quiet area for testing. Duplicate conditions as much as possible. Switch the compressor on and off several times to clearly identify compressor noise. To duplicate high ambient conditions (high head pressure), restrict air flow through the condenser. Install a manifold gauge set to make sure discharge pressure doesn’t exceed 2,070 kPa. 2. Tighten all compressor mounting bolts, clutch mounting bolt, and compressor drive belt. Check to assure clutch coil is tight (no rotation or wobble). 3. Check refrigerant hoses for rubbing or interference that can cause unusual noises. 4. Check refrigerant charge (Refer to 355A).

3

AC212555 AB

Battery voltage

Tester connection

Specified condition

Not applied

4-5

Open circuit


Less than 2 ohms


55A-55

ON-VEHICLE SERVICE

A/C COMPRESSOR RELAY CONTINUITY CHECK

FAN CONTROL RELAY CONTINUITY CHECK

A/C compressor relay

Fan control relay

1 3

2 4

1 4 2

1

3

2

4

4

Front of vehicle

2

3

AC212554 AB

3

1

AC212554AC

Battery voltage

Tester connection

Specified condition

Battery voltage

Tester connection

Specified condition

Not applied

1-4

Open circuit

Not applied

2-4

Open circuit


Less than 2 ohms


Less than 2 ohms

IDLE-UP OPERATION CHECK M1552001600348

1. Before inspection and adjustment, set vehicle in the following condition: Engine coolant temperature: 80 - 90 C Lamps, electric cooling fan and accessories: Set to OFF Transmission: Neutral ("N" or "P" for vehicles with A/T) Steering wheel: Straightforward 2. Check whether or not the idle speed is the standard value. Refer to GROUP 13A, On-vehicle Service - Basic Idle Speed Adjustment 313A . Standard value: 750 50 r/min

55A-56


3. When the A/C is running after turning the A/C switch to ON, and the blower switch to the 3(MH) or 4(HI) position, check to be sure that the idle speed is at the standard value. Standard value: 850 50 r/min NOTE: It is not necessary to make an adjustment, because the idling speed is automatically adjusted by the ISC system. If, however, a deviation from the standard value occurs for some reason, check the ISC system.

CLEAN AIR FILTER REPLACEMENT PROCEDURE M1552020100029

1. Remove the glove box. (Refer to GROUP 52A, Instrument Panel 352A)

AC301365AC

2. Remove the two screws as shown, and replace the clean air filter. 3. Install the glove box.

HEATER, AIR CONDITIONER AND VENTILATION HEATER CONTROL ASSEMBLY AND A/C SWITCH

55A-57

HEATER CONTROL ASSEMBLY AND A/C SWITCH REMOVAL AND INSTALLATION M1552002400314

Section A – A Instrument panel

Clip

Center cover

2 1

A A

3 4

5

NOTE : Clip position

>>B<<

1.

>>A<<

2. 3.

AC106926AB

Removal steps Air mixing door control cable connection Mode selection damper control cable connection Knob

4. 5.

Removal steps&RQWLQXHG Centre panel Manual air conditioner control panel assembly


55A-58

HEATER CONTROL ASSEMBLY AND A/C SWITCH

INSTALLATION SERVICE POINT >>A<< BLOWER VENT CHANGEOVER DAMPER CABLE Mode selection damper link

2. Set the heater unit’s air mix door lever to the MAX HOT position (turn the damper lever as the left illustration) and attach the cable. 3. Set the mode locator to the heater unit case and secure with a clip.


BLOWER SWITCH CONTINUITY CHECK Mode locator

DEF position

FACE position

1 4

AC106925AC

1. Set the heater control assembly’s blower vent changeover knob to the DEF position. 2. Set the heater unit’s blower vent changeover damper relay to the DEF position (turn the damper relay to the left until it stops) and install the cable. 3. Set the mode locator to the heater unit case and secure with a clip. >>B<< AIR MIX DOOR CABLE CONNECTION Air mix damper lever

2 5

3 6

AC100615AB

Switch position

Tester connection

0 (OFF)

1 - 2, 2 - 4, 2 - 5, 2 - 6 Open circuit

1 (LO)

1-2

Less than 2 ohms

2 (ML)

2-4

Less than 2 ohms

3 (MH)

2-5

Less than 2 ohms

4 (HI)

2-6

Less than 2 ohms

Mode locator

MAX. COOL position MAX HOT position

AC106924 AC

1. Turn the heater control assembly’s temperature adjustment knob all the way to the HOT side.

Specified condition


55A-59

HEATER CONTROL ASSEMBLY AND A/C SWITCH


3

2

4 8

1 7

6 AC100614 AB

5

<>

1. 2. 3. 4. 5.

<>

6.

Disassembly steps Switch panel Rear window defogger switch Air conditioner switch Inside/outside air selection switch Mode selection damper control cable Air mixing damper control cable

DISASSEMBLY SERVICE POINT <> BLOW VENT CHANGEOVER DAMPER CABLE AND AIR MIX DAMPER CABLE REMOVAL

(-) flat-tipped screwdriver

Clip claw

AC100619AB

Insert a flat-tipped screwdriver into the clip through the inside of the control base and prize out the clip claw to disconnect the cables.

7. 8.

Disassembly steps&RQWLQXHG Blower switch assembly Manual air conditioner control panel (A/C-ECU)

55A-60

HEATER, AIR CONDITIONER AND VENTILATION HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT REMOVAL AND INSTALLATION M1552011600253

WARNING When removing and installing the heater unit, do not let it bump against the SRS-ECU or the components. Pre-removal and Post-installation Operation Refrigerant draining and Refilling (Refer to Charging 355A and Discharging 355A). Engine coolant Draining and Refilling (Refer to GROUP 14, On vehicles service 314). Instrument Panel Removal and Installation (Refer to GROUP 52A, Instrument Panel 352A). Air cleaner cover and air flow sensor assembly Removal and Installation (Refer to GROUP 14, Air cleaner 315).


55A-61

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT

-Pipe coupling

5

7

9

10 N

8

6, 7 12 ± 2 N·m

6

11

O ring

A/C compressor oil: SUN PAG 56

4

1

2 3

AC200906 AB

<>

1. 2. 3. 4. 5. 6.

Removal steps Intake duct Joint duct Blower assembly Foot duct Heater hose connection Liquid pipe B connection

REMOVAL SERVICE POINT <> FLEXIBLE SUCTION HOSE AND LIQUID PIPE B DISCONNECTION

CAUTION As the compressor oil and receiver are highly moisture absorbent, use a non-porous material to plug the hose and nipples. To prevent the entry of dust or other foreign bodies, plug the dismantled hose and the nipples of the expansion valves.

<>

Removal steps&RQWLQXHG 7. Flexible suction hose connection 8. O ring 9. Centre duct 10. Foot duct 11. Heater unit


55A-62

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT

HEATER UNIT DISASSEMBLY AND REASSEMBLY M1551005400194

-Pipe coupling

2 8 3, 4

O ring


N

5 3

7

4

9

6

1 AC106930 AC

1. 2. 3. 4. 5.

Disassembly steps Evaporator cover Heater core Expansion valve Joint O ring

6. 7. 8. 9.

Disassembly steps&RQWLQXHG Evaporator Air thermo sensor clip Air thermo sensor Heater case

HEATER, AIR CONDITIONER AND VENTILATION HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT

55A-63

BLOWER ASSEMBLY DISASSEMBLY AND REASSEMBLY M1551005500168

1

4

5

2

3 AC301387AB

1. 2.

Disassembly steps Outside/inside air selection damper control motor Hose

3. 4. 5.

Disassembly steps&RQWLQXHG Blower motor Clean air filter Blower case


55A-64

BLOWERMOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR

BLOWERMOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR REMOVAL AND INSTALLATION M1551002800308

1

2

3 AC200968AB

1.

2.

Blower motor removal step Blower motor Resistor removal step Glove box (Refer to GROUP 52A, Instrument Panel 352A). Resistor

3.

Outside/inside air selection damper control motor removal step Glove box (Refer to GROUP 52A, Instrument Panel 352A). Outside/inside air selection damper control motor


RESISTER CHECK

Standard value: Measurement terminal

1 2 3 4

Standard value (W)

Between terminals 2 and 4 2.54 (LO) Between terminals 1 and 2 1.24 (ML) Between terminals 2 and 3 0.6 (MH)

AC103700

Use an ohmmeter to measure the resistance between the terminals. Check that the measured value is at the standard value.

HEATER, AIR CONDITIONER AND VENTILATION BLOWERMOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR

BLOWER FAN AND MOTOR CHECK

55A-65

OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR CHECK

CAUTION

INSIDE AIR

OUTSIDE AIR

AC100626 AB

When battery voltage is applied between the terminals, check that the motor operates. Also, check that there is no abnormal noise.

AC201501AB

Cut off the battery voltage when the damper is in the inside/outside air position. Lever position Battery connection

Lever operation

At the inside position


The lever moves from the inside position to the outside position

At the outside position


The lever moves from the outside position to the inside position


55A-66

EVAPORATOR ASSEMBLY

EVAPORATOR ASSEMBLY REMOVAL AND INSTALLATION M1552003600184

Pre-removal and Post-installation Operation Refrigerant draining and Refilling (Refer to Charging 355A and Discharging 355A). Air cleaner cover and air flow sensor assembly Removal and Installation (Refer to GROUP 14, Air cleaner 315). Section A – A Clip

Front floor console lower side cover

Section B – B Clip

-Pipe coupling

Front floor console lower side cover

11

1, 2, 4, 5

12 2

B

B A

<> <> <> <> <>

1. 2. 3. 4. 5. 6.

5

12 ± 2 N·m

1

4

8

6N

6N

9


A

O ring


6N 3

13

10

Removal steps Flexible suction hose connection Liquid pipe B connection Expansion valve cover Expansion valve Joint O ring Glove box (Refer to GROUP 52A, Instrument Panel 352A, 352A ).

7 7. 8. 9. 10. 11. 12. 13.

AC200376AC

Removal steps&RQWLQXHG Joint duct Foot duct Front floor console lower side cover Evaporator cover Air thermo sensor clip Air thermo sensor Evaporator


55A-67

EVAPORATOR ASSEMBLY

REMOVAL SERVICE POINT <> FLEXIBLE SUCTION HOSE AND LIQUID PIPE B DISCONNECTION


AIR THERMO SENSOR INSPECTION

CAUTION As the compressor oil and receiver are highly moisture absorbent, use a non-porous material to plug the hose and nipples. To prevent the entry of dust or other foreign bodies, plug the dismantled hose and the nipples of the expansion valves.

Outlet

Inlet RESISTANCE 25 (kΩ) 20 15 10 5 0 -10 0 10 20 30 40 TEMPERATURE (˚C) AC100770 AB

INLET SIDE Measure the resistance between connector terminals 1 and 3 under at least two different temperatures. The resistance values should generally match those in the graph. NOTE: . The temperature at the check should not exceed the range in the graph. OUTLET SIDE Measure the resistance between connector terminals 4 and 5 under at least two different temperatures. The resistance values should generally match those in the graph. NOTE: The temperature at the check should not exceed the range in the graph.


55A-68

COMPRESSOR ASSEMBLY AND TENSION PULLEY

COMPRESSOR ASSEMBLY AND TENSION PULLEY REMOVAL AND INSTALLATION M1552004100223

Pre-removal Operation Refrigerant Discharging (Refer to 355A).

Post-installation Operation Drive Belt Tension Adjustment (Refer to GROUP 11A, Onvehicles Service - Drive Belt Tension Check 311A). Refrigerant Charging (Refer to 355A).

6 -Pipe coupling

5

N

1, 2

3

O ring

2


1 12 ± 2 N·m

4

AC300862 AB

<> <>

1. 2. 3.

Removal steps <> Flexible suction hose connection Flexible discharge hose connection <> O ring

>>A<<

4. 5. 6.

Removal steps&RQWLQXHG Drive belt A/C compressor A/C compressor bracket

REMOVAL SERVICE POINTS <> FLEXIBLE SUCTION HOSE AND FLEXIBLE DISCHARGE HOSE DISCONNECTION

Auto-tensioner

CAUTION As the compressor oil and receiver are highly moisture absorbent, use a non-porous material to plug the hose and nipples. To prevent the entry of dust or other foreign bodies, plug the dismantled hoses and compressor nipples. <> DRIVE BELT REMOVAL The following operations will be needed due to the serpentine drive system with the drive belt autotensioner.

Hole B

Hole A

AC107640AC


HEATER, AIR CONDITIONER AND VENTILATION COMPRESSOR ASSEMBLY AND TENSION PULLEY

CAUTION To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk. Auto-tensioner

L-shaped hexagon wrench

AC107641AB

2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt. <> COMPRESSOR REMOVAL Take care not to spill any compressor oil when removing the compressor.

INSTALLATION SERVICE POINT >>A<< A/C COMPRESSOR INSTALLATION If a new compressor is installed, first adjust the amount of oil according to the procedures described below, and then install the compressor. 1. Measure the amount (X mL) of oil within the removed compressor.

55A-69

2. Drain (from the new compressor) the amount of oil calculated according to the following formula, and then install the new compressor. New compressor oil amount = 120 mL 120 mL-X mL = Y mL NOTE: Y mL indicates the amount of oil in the refrigerant line, the condenser, the evaporator, etc. NOTE: When replacing the following parts at the same times as the compressor, subtract the rated oil amount of the each part from Y mL and discharge from the new compressor. Quantity: Evaporator: 60 mL Condenser: 15 mL Suction hose: 10 mL Receiver: 10 mL


COMPRESSOR MAGNETIC CLUTCH OPERATION CHECK Magnetic cluch connector

AC005671AC

Connect the compressor connector terminal to the battery positive (+) terminal and earth the battery’s negative (-) terminal to the compressor unit. At that time, the magnetic clutch should make a definite operating sound.


55A-70



10 3N

9

2

8 7 6

N

4 16 ± 1 N·m

1. 2. 3.

<>

1

11

5

>>D<< >>C<<

4.

AC100630 AB

Cooling temperature switch disassembly steps Snap ring Refrigerant temperature switch O ring Magnetic clutch disassembly Air gap adjustment Self-locking nut

>>B<< >>A<<

5. 6. 7. 8. 9. 10. 11.

Magnetic clutch disassembly Armature Snap ring Rotor Snap ring Field core Shim A/C compressor




>>A<< FIELD CORE ATTACHMENT

MB991386

Field core projection

MB991367

Compressor unit pin hole AC100633 AB

Use the special tools to remove the self-locking nut. Special spanner (MB991367) Pin (MB991386)

AC100634 AB

Line up the pin hole on the compressor unit with the field core projection and attach.


55A-71


>>B<< SNAP RING INSTALLATION


Snap ring

Clutch coil

Rotor

REFRIGERANT TEMPERATURE SWITCH CAUTION Do not heat more than necessary.

Tapered part AC001412 AB

Thermometer

Using snap ring pliers, fit the snap ring so that the snap ring’s tapered part is on the outside.

Engine oil

>>C<< SELF-LOCKING NUT INSTALLATION AC100787 AB

MB991386

MB991367

1. Dip the metal part of the cooling temperature switch into engine oil and increase the oil temperature using a gas burner or similar.

120˚C

150˚C

Contiunity No continuity

AC100633 AB

Use the special tools to install the self-locking nut. Special spanner (MB991367) Pin (MB991386)

Oil temprature

AC100810 AD

>>D<< AIR GAP ADJUSTMENT

2. When the oil temperature reaches the standard value, check that voltage is supplied between the terminals. Standard value:

Thickness gauge

AC100637AB

Apply voltage from the battery to the magnetic clutch and check that the clutch air gap is inside the standard value. If outside the standard value, use a shim to adjust the gap. Standard value: 0.3 - 0.5 mm

Item

Temperature

Less than 2 ohms

Slightly below 150C

No continuity

150C or more

NOTE: When the oil temperature is 150C or more and there is no continuity, the resistance will not be 2W or lower until the oil temperature reduces to 120C or less.


55A-72

CONDENSER AND CONDENSER FAN MOTOR

CONDENSER AND CONDENSER FAN MOTOR REMOVAL AND INSTALLATION M1552006700351

Pre-removal and Post-installation Operation Refrigerant draining and Refilling (Refer to Charging 355A and Discharging 355A). Air cleaner cover and air flow sensor assembly Removal and Installation (Refer to GROUP 14, Air cleaner 315).

9

-Pipe coupling

12

10

11

4.9 ± 0.9 N·m

2 1, 2

O ring A/C compressor oil: SUN PAG 56

1 N

3

13

6 5 7N 4

8

AC300948 AC

<> <> >>A<<

1. 2. 3. 4. 5. 6. 7. 8.

Condenser removal steps Liquid pipe A connection Flexible discharge hose connection O ring Condenser assembly Receiver Clamp O ring Condenser

9. 10. 11. 12.

13.

Fan shroud assembly removal steps Fan shroud assembly Fan Fan motor Fan shroud Air guide panel removal steps Front bumper (Refer to 51, Front bumper 351). Air guide panel

HEATER, AIR CONDITIONER AND VENTILATION CONDENSER AND CONDENSER FAN MOTOR

REMOVAL SERVICE POINT <> FLEXIBLE SUCTION HOSE AND LIQUID PIPE A DISCONNECTION

CAUTION As the compressor oil and receiver are highly moisture absorbent, use a non-porous material to plug the hose and nipples. To prevent the entry of dust or other foreign bodies, plug the dismantled hose and condenser assembly nipples.

55A-73


CONDENSER FAN MOTOR CHECK 1

2

INSTALLATION SERVICE POINT >>A<< CONDENSER INSTALLATION When replacing the condenser, refill it with a specified amount of compressor oil and install it. (to the vehicle). Compressor oil: SUN PAG 56 Quantity: 15 mL

AC103523 AC

Check to be sure that the condenser fan motor operates when battery voltage is applied to terminal 2 and terminal 1 earthed.


55A-74

REFRIGERANT LINE

REFRIGERANT LINE REMOVAL AND INSTALLATION M1552006400372

Pre-removal and Post-installation Operation Refrigerant Draining and Refilling (Refer to Charging and Discharging 355A). Air cleaner cover and air flow sensor assembly Removal and Installation (Refer to GROUP 14, Air cleaner 315). Radiator Grille Removal and Installation (Refer to GROUP 51, Radiator Grille 351).

7N

-Pipe coupling

13 ± 1 N·m Low-pressure side service valve

3

Hign-Pressure Side Service Valve

4

5 1, 2, 3, 5, 6

7N

O-ring

6 4.9 ± 0.9 N·m

2 1

7N

O-ring

3

12 ± 2 N·m

A/C compressoroil: SUN PAG 56

25 ± 4 N·m

7N <> <> <>

>>A<<

1. 2. 3. 4.

Removal steps Flexible discharge hose Flexible suction hose Liquid pipe B Evaporator cover

AC301420 AB

<> <>

5. 6. 7.

Removal steps&RQWLQXHG Liquid pipe A A/C pressure sensor O ring



<> HOSE/PIPE DISCONNECTION

>>A<< SUCTION HOSE INSTALLATION When replacing the suction hose, refill them with a specified amount of compressor oil, and then install them. Compressor oil: SUN PAG 56 Quantity: Suction hose: 10 cm3

CAUTION As the compressor oil and receiver are highly moisture absorbent, use a non-porous material to plug the hose and nipples. To prevent the entry of other foreign bodies, plug the condenser, compressor, and expansion valve nipples.


55A-75

VENTILATORS

VENTILATORS REMOVAL AND INSTALLATION M1553001600307

1

2

3 1

4 5

6

9 8

7

10 AC106927AB

1. 2. 3.

Defroster nozzle and distribution duct removal steps Instrument panel (Refer to 52A 352A.) Side defroster duct Defroster nozzle Distribution duct

4. 5. 6.

Foot duct and rear heater duct removal steps Under cover (Refer to GROUP 52A, Instrument panel 352A.) Foot duct Rear heater duct A Rear heater duct B upper side

55A-76

HEATER, AIR CONDITIONER AND VENTILATION VENTILATORS Foot duct and rear heater duct removal steps&RQWLQXHG Glove box (Refer to GROUP 52A, Instrument panel 352A.) 7. Foot duct 10. Rear heater duct A Floor carpet Front seat assembly (Refer to GROUP 52A, Front seat assembly 352A.) Front floor console (Refer to GROUP 52A, Floor console 352A .) 11. Rear heater duct B lower side 12. Rear heater duct B CROSS-SECTION A-A

13

13

A A

A A

AC101905AD

Rear ventilation duct removal steps Rear bumper assembly (Refer to GROUP 51, Rear bumper 351.) 13. Rear ventilation duct

55-1

GROUP 55


00 11 12 13 14 15 16 17

CONTENTS

21 22

HEATER, AIR CONDITIONER AND VENTILATION . . . . . . . . . 55A

25 26

AUTOMATIC AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . 55B

27 31 32 33 34 35 36 37 42 51 52 54 55

127(6

55B-1

GROUP 55B

00 11

AUTOMATIC AIR CONDITIONER

12 13 14 15 16

CONTENTS

17 SERVICE SPECIFICATIONS. . . . . . . SPECIAL TOOL . . . . . . . . . . . . . . . . .

55B


55B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

55B

55B SENSORS . . . . . . . . . . . . . . . . . . . . . . 55B

TROUBLESHOOTING . . . . . . . . . . . . AUTOMATIC AIR CONDITIONER PANEL ASSEMBLY (A/C-ECU) . . . . REMOVAL AND INSTALLATION . . . . . . . .

HEATER UNIT . . . . . . . . . . . . . . . . . .

55B

55B 55B


55B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

55B

EVAPORATOR ASSEMBLY . . . . . . . 55B

55B

DISASSEMBLY AND REASSEMBLY. . . . .

55B

AIR MIXING DOOR MOTOR, AIR OUTLET CHANGEOVER DAMPER MOTOR AND BLOWER MOTOR . . . 55B

22 25 26 27


55B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

55B

31

AMBIENT TEMPERATURE SENSOR 55B

32

55B


21

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

55B

33

OTHER PARTS. . . . . . . . . . . . . . . . . . 55B

34

OTHER PARTS . . . . . . . . . . . . . . . . . . . . . .

55B

35 36 37 42 51 52 54 55


55B-2



Item

Standard value

Resistance value for air mixing damper control motor and potentiometer kW

MAX HOT

Approximately 5.35

MAX COOL

Approximately 0.65

Resistance value for mode selection damper control motor and potentiometer kW

DEF position

Approximately 0.65

FACE position

Approximately 5.35


Tool

Number

Name

Use

MB991502

MUT-II subassembly

Automatic A/C check

MB991529

Diagnosis code check harness

Automatic A/C check with a voltmeter

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222



B991502

MB991529

MB991223


55B-3

TROUBLESHOOTING

TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW


M1554004700102


How to read diagnosis code Connect the MUT-II to the 16-pin diagnosis connector to read diagnosis code (Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points 300).

How to erase diagnosis code Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points 300.

DIAGNOSIS CODE CHART M1554004900140

Code No.

Diagnostic item

Reference page

11

Interior temperature senor system (open circuit)

355B

12

Interior temperature sensor system (short circuit)

13

Outside thermo sensor system (open circuit)

14

Outside thermo sensor system (short circuit)

15

Heater water temperature sensor system (open circuit)

16

Heater water temperature sensor system (short circuit)

21

Air thermo sensor system (open circuit)

22

Air thermo sensor system (short circuit)

31

Air mixing damper control motor and potentiometer sensor system

355B

32

Mode selection damper control motor and potentiometer sensor system

355B

41

Air mixing damper control motor and potentiometer activating system

355B

42

Mode selection damper control motor and potentiometer activating 355B system

355B 355B 355B

55B-4

AUTOMATIC AIR CONDITIONER TROUBLESHOOTING


Diagnosis code No.11, 12: Interior temperature sensor system

Interior Temperature Sensor Circuit A/C-ECU

INTERIOR TEMPERATURE SENSOR


COMMENTS ON TROUBLE SYMPTOM This code is set when the interior temperature sensor circuit is open (Code No.11) or is short (Code No.12). Possible causes Malfunction of the interior temperature sensor Damaged the wiring harness or connectors Malfunction of the auto air conditioner control panel (A/C-ECU)

SB : Sky blue

DIAGNOSIS Step 1. Check the interior temperature sensor. Refer to 355B. Q: Is the check result normal? YES : Go to Step 2. NO : Replace the interior temperature sensor.


Step 2. Connector check: C-27 A/C-ECU connector and C-127 interior temperature sensor connector Connector: C-27

55B-5

Step 3. Check the wiring harness between C-27 A/C-ECU connector (terminals 1 and 20) and C127 interior temperature sensor connector (terminals 2 and 1). Connector: C-27

C-27(B) C-27(B)


10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

Connector: C-127 Connector: C-127


2 1

2 1 AC301395 AM AC301395 AM


Check the sensor signal line and earth line for open or short circuit. Q: Is the check result normal? YES : Replace the auto air conditioner control

panel (A/C-ECU) NO : Repair the wiring harness.


55B-6

TROUBLESHOOTING

Diagnosis code 13, 14: Outside thermo sensor system

Outside Thermo Sensor Circuit A/C-ECU

OUTSIDE THERMO SENSOR


COMMENTS ON TROUBLE SYMPTOM This code is set when the outside thermo sensor circuit is open (Code No.13) or is short (Code No.14).

SB : Sky blue

Step 2. Connector check: A-18 outside thermo sensor connector and C-27 A/C-ECU connector Connector: A-18

Possible causes Malfunction of the outside thermo sensor Damaged the wiring harness and connectors Malfunction of the auto air conditioner control panel (A/C-ECU) DIAGNOSIS

Harness side

2

1

A-18(BR)

Step 1. Check the outside thermo sensor. Refer to 355B. Q: Is the check result normal? YES : Go to Step 2. NO : Replace the outside thermo sensor.

AC301653AC


Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS



Step 3. Check the wiring harness between A-18 outside thermo sensor connector (terminals 1 and 2) and C-27 A/C-ECU connector (terminals 20 and 7). Connector: A-18

Harness side

2

1

A-18(BR) AC301653AC


Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS


1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Prior to the wiring harness inspection, check intermediate connector C-116, and repair if necessary. Check the sensor signal line and earth line for open or short circuit. Q: Is the check result normal? YES : Replace the auto air conditioner control


55B-7


55B-8

TROUBLESHOOTING

Diagnosis code 15, 16: Heater water temperature sensor system

Heater Water Temperature Sensor Circuit HEATER WATER TEMPERATURE SENSOR

A/C-ECU


COMMENTS ON TROUBLE SYMPTOM This code is set when the heater water temperature sensor circuit is open (Code No.15) or is short (Code No.16). Possible causes Malfunction of the heater water temperature sensor Damaged the wiring harness or connectors Malfunction of the auto air conditioner control panel (A/C-ECU)

SB : Sky blue

DIAGNOSIS Step 1. Check the heater water temperature sensor. Refer to 355B. Q: Is the check result normal? YES : Go to Step 2. NO : Replace the heater water temperature

sensor.


55B-9

TROUBLESHOOTING

Step 2. Connector check: C-27 A/C-ECU connector and C-314 heater water temperature connector Connector: C-27

Step 3. Check the wiring harness between C-27 A/C-ECU connector (terminals 4 and 20) and C314 heater water temperature sensor connector (terminals 2 and 1). Connectors: C-27, C-36

C-27(B) C-27(B) C-36

Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

Connector: C-314 C-36 1 2 3 4 5 6 7 8 9 10 11 12 13

Harness side

1 2

Harness side C-27 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301544 AB


AC301398 AO

Connector: C-314

Harness side

1 2

AC301544 AB

NOTE: Prior to the wiring harness inspection, check intermediate connector C-36, and repair if necessary. Check the sensor signal line and earth line for open or short circuit. Q: Is the check result normal? YES : Replace the auto air conditioner control



55B-10

TROUBLESHOOTING

Diagnosis code 21, 22: Air thermo sensor system

Air Thermo Sensor Circuit HEATER WATER TEMPERATURE SENSOR

AIR THERMO SENSOR

A/C-ECU


COMMENTS ON TROUBLE SYMPTOM This code is set when the air thermo sensor circuit is open (Code No.21) or is short (Code No.22). Possible causes Malfunction of the air thermo sensor Damaged the wiring harness or connectors Malfunction of the auto air conditioner control panel (A/C-ECU)

SB : Sky blue

DIAGNOSIS Step 1. Check the air thermo sensor. Refer to 355B. Q: Is the check result normal? YES : Go to Step 2. NO : Replace the air thermo sensor.


Step 2. Connector check: C-27 A/C-ECU connector and C-316 air thermo sensor connector Connector: C-27 C-27(B)

Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

Connector: C-316

Harness side

1 2

AC301544 AC


55B-11


55B-12

TROUBLESHOOTING

Step 3. Check the wiring harness between C-27 A/C-ECU connector (terminals 8 and 20) and C316 air thermo sensor connector (terminals 1 and 2).

Check the sensor signal line and earth line for open or short circuit. Q: Is the check result normal? YES : Replace the auto air conditioner control

panel (A/C-ECU) Connectors: C-27, C-36

NO : Repair the wiring harness.

C-27(B) C-36

C-36 1 2 3 4 5 6 7 8 9 10 11 12 13

Harness side C-27 10 9 8 7 6 5 4 3 2 1 20191817161514131211 AC301398 AO

Connectors: C-314, C-316 C-314

C-316

Harness side C-314

C-316

1 2

1 2 AC301545 AB

NOTE: Prior to the wiring harness inspection, check intermediate connector C-36 and heater water temperature sensor connector C-314, and repair if necessary.


55B-13

TROUBLESHOOTING

Diagnosis code 31: Air mixing damper control motor potentiometer system

Air Mixing Damper Control Motor Potentiometer Circuit MODE SELECTION DAMPER CONTROL MOTOR AND POTENTIOMETER

AIR MIXING DAMPER CONTROL MOTOR AND POTENTIOMETER

HEATER WATER TEMPERATURE SENSOR

A/C-ECU


COMMENTS ON TROUBLE SYMPTOM This code is set when the air mixing damper control motor potentiometer does not send any signal to the A/C-ECU due to short or open circuit. Possible causes Malfunction of the air mixing damper control motor and potentiometer Damaged the wiring harness or connectors Malfunction of the auto air conditioner control panel (A/C-ECU)

SB : Sky blue

DIAGNOSIS Step 1. Check the air mixing damper control motor and potentiometer. Refer to 355B. Q: Is the check result normal? YES : Go to Step 2. NO : Replace the air mixing damper control

motor and potentiometer.


55B-14

TROUBLESHOOTING

Step 2. Connector check: C-27 A/C-ECU connector and C-313 air mixing damper control motor and potentiometer connector Connector: C-27 C-27(B)

Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

Connector: C-313 Harness side 1 2 6 5 4 3

AC301544 AD



Step 3. Check the wiring harness between C-27 A/C-ECU connector (terminals 10, 5 and 20) and C-313 air mixing damper control motor and potentiometer connector (terminals 2, 5 and 6).

Check the potentiometer power supply, earth and signal line for open or short circuit. Q: Is the check result normal? YES : Replace the auto air conditioner control

panel (A/C-ECU). Connectors: C-27, C-36


C-27(B) C-36

C-36 1 2 3 4 5 6 7 8 9 10 11 12 13


Connectors: C-313, C-314, C-315

C-315 C-313

C-314

Harness side C-313

2 1 6 5 4 3

C-314 1 2

C-315

1 2 6 5 4 3

AC301545 AC

NOTE: Prior to the wiring harness inspection, check intermediate connector C-36, mode selection damper control motor and potentiometer connector C-315 and heater water temperature sensor connector C-314, and repair if necessary.

55B-15


55B-16

TROUBLESHOOTING

Diagnosis code 32: Mode selection damper control motor potentiometer system

Mode Selection Damper Control Motor Potentiometer Circuit MODE SELECTION DAMPER CONTROL MOTOR AND POTENTIOMETER

HEATER WATER TEMPERATURE SENSOR

A/C-ECU


COMMENTS ON TROUBLE SYMPTOM This code is set when the mode selection damper control motor potentiometer does not send any signal to the A/C-ECU due to short or open circuit.

SB : Sky blue

Step 2. Connector check: C-27 A/C-ECU connector and C-315 mode selection damper control motor and potentiometer connector Q: Is the check result normal?

Possible causes Malfunction of the mode selection damper control motor and potentiometer Malfunction of the auto air conditioner control panel (A/C-ECU) Damaged the wiring harness or connectors DIAGNOSIS


Harness side

Step 1. Check the mode selection damper control motor and potentiometer. Refer to 355B. Q: Is the check result normal? YES : Go to Step 2. NO : Replace the mode selection damper control


10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS


1 2 6 5 4 3

AC301544 AE

YES : Go to Step 3. NO : Repair the connector.


Step 3. Check the wiring harness between C-27 A/C-ECU connector (terminals 10, 6 and 20) and C-315 mode selection damper control motor and potentiometer connector (terminals 2, 5 and 6).

Check the potentiometer power supply, earth and signal line for open or short circuit. Q: Is the check result normal? YES : Malfunction of the auto air conditioner

control panel (A/C-ECU) Connectors: C-27, C-36


C-27(B) C-36

C-36 1 2 3 4 5 6 7 8 9 10 11 12 13



C-315 C-314

Harness side C-314

C-315

1 2

2 1 6 5 4 3

AC301545 AD

NOTE: Prior to the wiring harness inspection, check intermediate connector C-36 and heater water temperature sensor connector C-314, and repair if necessary.

55B-17


55B-18

TROUBLESHOOTING

Diagnosis code 41: Air mixing damper control motor system

Air MIxing Damper Control motor Circuit AIR MIXING DAMPER CONTROL MOTOR AND POTENTIOMETER

A/C-ECU MOTOR DRIVE CIRCUIT


COMMENTS ON TROUBLE SYMPTOM This code is set when the air mixing damper cannot be rotated to the preset opening angle. Possible causes Malfunction of the air mixing damper control motor and potentiometer Malfunction of the auto air conditioner control panel (A/C-ECU) Damaged the wiring harness or connectors DIAGNOSIS Step 1. Check the air mixing damper control motor and potentiometer. Refer to 355B. Q: Is the check result normal? YES : Go to Step 2. NO : Replace the air mixing damper control


SB : Sky blue

Step 2. Connector check: C-26 A/C-ECU connector and C-313 air mixing damper control motor and potentiometer connector Connector: C-26

C-26(B) Harness side 28 27 26 25 24 23 22 21 36 35 34 33 323130 29

AC301397 AV


AC301544 AD



Step 3. Check the wiring harness between C-26 A/C-ECU connector (terminals 22 and 25) and C313 air mixing damper control motor and potentiometer connector (terminals 3 and 1). Connectors: C-26, C-36

C-36 C-26(B)

C-36 1 2 3 4 5 6 7 8 9 10 11 12 13

Harness side C-26 28 27 26 25 24 23 22 21 36 35 34 33 323130 29 AC301398 AP


AC301544 AD

NOTE: Prior to the wiring harness inspection, check intermediate connector C-36, and repair if necessary. Check the motor activating lines for open or short circuit. Q: Is the check result normal? YES : Malfunction of the auto air conditioner

control panel (A/C-ECU). NO : Repair the wiring harness.

55B-19


55B-20

TROUBLESHOOTING

Diagnosis code 42: Mode selection damper control motor system

Mode Selection Damper Control Motor And Potentiometer Circuit MODE SELECTION DAMPER CONTROL MOTOR AND POTENTIOMETER



COMMENTS ON TROUBLE SYMPTOM This code is set when the mode selection damper cannot be rotated to the preset opening angle. Possible causes Malfunction of the mode selection damper control motor and potentiometer Malfunction of the auto air conditioner control panel (A/C-ECU) Damaged the wiring harness or connectors DIAGNOSIS Step 1. Check the mode selection damper control motor and potentiometer. Refer to 355B. Q: Is the check result normal? YES : Go to Step 2. NO : Replace the mode selection damper control


SB : Sky blue

Step 2. Connector check: C-26 A/C-ECU connector and C-315 mode selection damper control motor and potentiometer connector Connector: C-26

C-26(B) Harness side 28 27 26 25 24 23 22 21 36 35 34 33 323130 29

AC301397 AV


2 1 6 5 4 3

AC301544 AE



Step 3. Check the wiring harness between C-26 A/C-ECU connector (terminals 21 and 24) and C315 mode selection damper control motor and potentiometer connector (terminals 3 and 1). Connectors: C-26, C-36

C-36 C-26(B)

C-36 1 2 3 4 5 6 7 8 9 10 11 12 13



2 1 6 5 4 3

AC301544 AE

NOTE: Prior to the wiring harness inspection, check intermediate connector C-36, and repair if necessary. Check the motor activating lines for open or short circuit. Q: Is the check result normal? YES : Replace the auto air conditioner control


55B-21


55B-22

TROUBLESHOOTING


Symptom


Reference page

Communication with the MUT-II is not possible.

1

355B

The air conditioner does not work at all.

2

355B

A/C outlet air temperature cannot be set.

3

355B

The blower does not work.

4

355B

The blower air volume cannot be changed.

5

355B

When sunlight intensity changes, air outlet temperature does not change.

6

355B

The A/C indicator flashes.

7

355B

The inside/outside air changeover is impossible.

8

355B

Defogger function does not operate.

9

355B

Malfunction of the A/C-ECU power supply system.

10

355B

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Communication with the MUT-II is not possible.

Data Link Connector Circuit A/C-ECU



SB : Sky blue


55B-23

TROUBLESHOOTING

COMMENTS ON TROUBLE SYMPTOM If communication with all other systems is not possible, there is a high possibility that there is a malfunction of the diagnosis line. If only the A/C system can not communicate with the MUT-II, the diagnosis line between the A/C-ECU and the diagnosis connector may be defective. Possible causes Damaged the wiring harness or connectors Malfunction of the auto air conditioner control panel (A/C-ECU) DIAGNOSIS

Step 4. Check the wiring harness between C-27 A/C-ECU connector (terminal 17 and 18) and C-24 diagnosis connector (terminal 11 and 1). Connector: C-24

Harness side 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

C-24(B)

Step 1. Check the communication with other systems. Q: Is the communication with the other systems possible using the MUT-II? YES : Go to Step 2. NO : Check the diagnosis line using the MUT-II,

AC301395 AF


and repair if necessary. STEP 2. Check operations of the air conditioner, defogger and outside/inside air selection damper control motor. Q: Does the air conditioner, defogger or outside/ inside air selection damper control motor operate? YES : Go to Step 3. NO : Refer to Inspection procedure 10

"Malfunction of the A/C-ECU power supply system 355B." Step 3. Connector check: C-27 A/C-ECU connector and C-24 diagnosis connector Connector: C-24

Harness side 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

C-24(B) AC301395 AF


Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS


Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

Check the communication lines for open or short circuit. Q: Is the check result normal? YES : Replace the auto air conditioner control



55B-24

TROUBLESHOOTING

INSPECTION PROCEDURE 2: The air conditioner does not work at all.

A/C Compressor Circuit IGNITION SWITCH (IG2)

BATTERY

A/C PRESSURE SENSOR

RELAY BOX

A/C COMPRESSOR RELAY

ENGINE-ECU

A/C REFRIGERANT TEMPERATURE SWITCH

MAGNETIC CLUTCH

A/C COMPRESSOR ASSEMBLY

A/C-ECU


CIRCUIT OPERATION If cool air is not distributed when the A/C switch is on, A/C compressor relay system may be defective. Possible causes Improper amount of refrigerant

SB : Sky blue

Malfunction of the A/C pressure sensor Malfunction of the A/C compressor relay Malfunction of the magnetic clutch Malfunction of the A/C refrigerant temperature switch Damaged the wiring harness or connectors


55B-25

TROUBLESHOOTING

Malfunction of the auto air conditioner control panel (A/C-ECU) DIAGNOSIS

STEP 5. Measure the voltage at B-27 A/C compressor connector. Connector: B-27

Step 1. Use the MUT-II to confirm a diagnosis code. On completion, check that the diagnosis code is not reset.

Harness side 1

Q: Is the check result normal? YES : Go to Step 2. NO : Refer to diagnosis code chart 355B.

B-27(B) AC301648 AB

Step 2. Check the blower operation. (1) Turn the ignition switch to the ON position. (2) Blower knob: Other than OFF (3) Check that the air comes out of the blower.

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position. Connector: C-134

Q: Is the check result normal? YES : Go to Step 3. NO : Refer to Inspection Procedure 4 "The blower

does not work." STEP 3. Check the defogger and outside/inside air selection damper control motor operation. Q: Do the defogger and outside/inside air selection damper control motor work normally? YES : Go to Step 4. NO : Refer to Inspection procedure 10


AC301397AO

(3) Disconnect engine-ECU connector C-134, and earth terminal 8.

"Malfunction of the A/C-ECU power supply system 355B." STEP 4. Check the A/C compressor. Check the A/C compressor for compressor oil leaks. Q: Is the check result satisfactory? YES : Go to Step 5. NO : Replace the A/C compressor or the


1

expansion valve. AC301541BU

(4) Voltage between terminal 1 and body earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 17. NO : Go to Step 6.

STEP 6. Check the A/C compressor relay continuity. Refer to GROUP 55A, On vehicle service, power relay 355A. Q: Is the A/C compressor relay in good condition? YES : Go to Step 7. NO : Replace the A/C compressor relay.


55B-26

TROUBLESHOOTING


STEP 8. Connector check: B-18X A/C compressor relay connector. Connector: B-18X

-

-

Relay box side

Relay box side

B-18X

B-18X

2

1

2

1

4

3

4

3

Front of vehicle


(1) Remove the relay, and measure at the relay block side. (2) Turn the ignition switch to the "ON" position.

Connector B-18X (Relay box side) 2

1

4

3

Front of vehicle AC301541BV


AC301483 AG



55B-27

TROUBLESHOOTING

STEP 9. Check the wiring harness between B-18X A/C compressor relay connector terminal No.3 and the ignition switch (IG2).


Connector: B-18X

C-106(GR)

2 1 3 4 5 6 10 11 12 7 8 9 16 13 14 15 17 18 19

AC301397AG


-

C-203 Relay box side B-18X 2

1

4

3

C-202


Harness side C-202 6 5 4 3 2 1 14 13 12 11 10 9 8 7

C-203 2 1 6 5 4 3

AC210475 AG

Prior to the wiring harness inspection, check junction block connectors C-203, C-202 and intermediate connector C-106, and repair if necessary. Check the A/C compressor relay power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



55B-28

TROUBLESHOOTING



-

-

Relay box side

Relay box side

B-18X

B-18X

2

1

2

1

4

3

4

3

Front of vehicle


(1) Remove the relay, and measure at the relay block side. Connector B-18X (Relay box side) 2

1

4

3

Front of vehicle AC301541BW


AC301483 AG



55B-29

TROUBLESHOOTING

STEP 12. Check the wiring harness between B18X A/C compressor relay connector terminal No.4 and the battery. Connector: B-18X

STEP 13. Connector check: B-18X A/C compressor relay connector and B-27 A/C compressor connector Connector: B-18X

-

-

Relay box side

Relay box side

B-18X

B-18X

2

1

2

1

4

3

4

3

Front of vehicle


NOTE:

AC301483 AG

Connector: B-27 Connector: A-14

Harness side A-14(GR)

1 2 3 4 5 6 7 8 9 10 11 15 14 12 13 16 17

1

B-27(B) AC301648 AB AC301653AB

Prior to the wiring harness inspection, check intermediate connector A-14, and repair if necessary. Check the A/C compressor relay power supply line for open circuit. Q: Is the check result normal? YES : Check that the air conditioner works

normally. NO : Repair the wiring harness. Check that the

air conditioner works normally.



55B-30

TROUBLESHOOTING

STEP 14. Check the wiring harness between B18X A/C compressor relay connector terminal No.1 and B-27 A/C compressor connector terminal No.1.

STEP 15. Connector check: C-134 engine-ECU connector and B-18X A/C compressor relay connector Connector: C-134

Connector: B-18X


AC301397AO

Connector: B-18X


1

4

3

Front of vehicle

AC301483 AG

Connector: B-27

Relay box side B-18X

Harness side 1

2

1

4

3


B-27(B) AC301648 AB

Check the A/C compressor relay power supply line for open circuit. Q: Is the check result normal? YES : Go to Step 15. NO : Repair the wiring harness.

Check the A/C compressor relay earth line for open circuit. Q: Is the check result normal? YES : Go to Step 16. NO : Repair the connector.


55B-31

TROUBLESHOOTING

STEP 16. Check the wiring harness between C134 engine-ECU connector terminal No.8 and B18X A/C compressor relay connector terminal No.2.

STEP 17. Measure the voltage at C-26 A/C-ECU connector. Connectors: C-26, C-134

Connector: B-18X

C-134

C-26(B)

-

Harness side C-26

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

C-134

JAE-E 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 1918 17 16 15 14


1

4

3

Front of vehicle

AC301398 BA

AC301483 AG

Connector: C-134

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position. (3) Disconnect engine-ECU connector C-134, and earth terminal 8.

Connector C-26 (Harness side) Harness side JAE-E 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 1918 17 16 15 14

28 27 26 25 24 23 22 21 36 35 34 33 323130 29 AC301397AO



AC301541CP

(4) Continuity between terminal 33 and body earth. OK: System voltage Q: Is the check result normal? YES : Go to Step 20. NO : Go to Step 18.


55B-32

TROUBLESHOOTING

STEP 18. Connector check: B-18X A/C compressor relay connector and C-26 A/C-ECU connector Connector: B-18X

-


1

4

3


Connector: C-26

C-26(B) Harness side 28 27 26 25 24 23 22 21 36 35 34 33 323130 29

AC301397 AV



STEP 19. Check the wiring harness between B18X A/C compressor relay connector terminal No.1 and C-26 A/C-ECU connector terminal No.33.

55B-33



Connector: B-18X

STEP 20. Check the magnetic clutch operation. Refer to 355A. Q: Can the sound of the magnetic clutch (click) be heard? YES : Go to Step 21. NO : Replace the compressor magnet clutch.

STEP 21. Check the refrigerant temperature switch. Refer to 355A.

-

Relay box side

Q: Is the refrigerant temperature switch operating properly? YES : Go to Step 22. NO : Replace the refrigerant temperature switch.

B-18X 2

1

4

3

Front of vehicle

STEP 22. Check the refrigerant level. Refer to 355A. AC301483 AG


Q: Is the refrigerant level correct? YES : Go to Step 23. NO : Correct the refrigerant level (Refer to On-

vehicle Service 355A). STEP 23. Check the A/C pressure sensor operation. Refer to 355A.

C-26(B)

Q: Is the A/C pressure sensor operating properly? YES : Go to Step 24. NO : Replace the A/C pressure sensor.

C-104(B)

C-104 1 2 3 4 5 6 7 8 9 10 1112 13 1415 16

Harness side C-26 28 27 26 25 24 23 22 21 36 35 34 33 323130 29

AC301398 AQ

NOTE: Prior to the wiring harness inspection, check intermediate connector C-104, and repair if necessary. Check the A/C compressor relay output line for open circuit.


55B-34

TROUBLESHOOTING

STEP 24. Connector check: A-02 A/C pressure sensor connector and C-27 A/C-ECU connector Connector: A-02 A-02(B)

STEP 25. Check the wiring harness between A-02 A/C pressure sensor connector terminal No.2 and C-27 A/C-ECU connector terminal No.11. Connector: A-02 A-02(B)


3 2 1 3 2 1

AC301656 AB AC301656 AB

Connector: C-27 Connector: C-27 C-27(B) C-27(B)


10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS



1 2

5 6 7

3 4

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Prior to the wiring harness inspection, check intermediate connector C-116, and repair if necessary. Check the A/C pressure sensor signal line for open circuit. Q: Is the check result normal? YES : Go to Step 26. NO : Repair the wiring harness.


55B-35

TROUBLESHOOTING

STEP 26. Connector check: C-134, C-135 engineECU connector and C-26 A/C-ECU connector

STEP 27. Check the wiring harness between C134 engine-ECU connector terminal No.24 and C26 A/C-ECU connector terminal No.32.

Connectors: C-26, C-134, C-135 Connectors: C-26, C-104, C-134

C-135 C-134

C-26(B)

C-134

C-26(B) C-104(B) Harness side C-104

C-26

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

C-134

JAE-E 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 1918 17 16 15 14

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Harness side C-26

C-135

JAE-E 38 37 36 35 34 33 32 31 46 45 4443 42 41 4039

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

C-134 JAE-E 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 1918 17 16 15 14

AC301398 AR AC301398 BB


NOTE: Prior to the wiring harness inspection, check intermediate connector C-104, and repair if necessary. Check the communication line for open circuit. Q: Is the check result normal? YES : Go to Step 28. NO : Repair the wiring harness.


55B-36

TROUBLESHOOTING

STEP 28. Check the wiring harness between C135 engine-ECU connector terminal No.45 and C26 A/C-ECU connector terminal No.34. Connectors: C-26, C-104, C-135

C-135 C-26(B) C-104(B) C-104 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Harness side C-135

C-26 28 27 26 25 24 23 22 21 36 35 34 33 323130 29

JAE-E 38 37 36 35 34 33 32 31 46 45 4443 42 41 4039

AC301398 BC

NOTE: Prior to the wiring harness inspection, check intermediate connector C-104, and repair if necessary. Check the communication line for open circuit. Q: Is the check result normal? YES : Replace the A/C-ECU or engine-ECU. NO : Repair the wiring harness.

INSPECTION PROCEDURE 3: A/C outlet air temperature cannot be set. COMMENTS ON TROUBLE SYMPTOM When the blower air temperature can not be changed even if the preset temperature is changed, the sensors, the air mixing damper control motor and potentiometer or the A/C-ECU may be defective. Possible causes Malfunction of the A/C-ECU

DIAGNOSIS Read diagnosis code by using the MUT-II. Q: Is the diagnosis code set? YES : Refer to diagnosis code chart 355B. NO : Replace the auto air conditioner control

panel (A/C-ECU).


55B-37

INSPECTION PROCEDURE 4: The blower does not work.

Blower Motor Circuit FUSIBLE LINK 1


BLOWER RELAY

BLOWER LINEAR CONTROLLER

A/C-ECU

COMMENTS ON TROUBLE SYMPTOM If the blower motor does not operate, the blower motor circuit system may be defective. Possible causes Malfunction of the blower motor (blower linear controller). Malfunction of the auto air conditioner control panel (A/C-ECU) Damaged the wiring harness or connectors


DIAGNOSIS Step 1. MUT-II actuator test Carry out the actuator test. Item 01, 02, 03, 04: Blower motor Q: Does the blower motor work normally? YES : Replace the auto air conditioner control



55B-38

TROUBLESHOOTING

Step 2. Measure the voltage at the C-32 blower linear controller connector.

Step 4. Measure the voltage at C-207 blower relay connector. Connector: C-207 Junction block (Front view)

Connector: C-32

Harness side


2 1 6 5 4 3 AC301397 AT

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the ON position. Connector C-32 (Harness side)

AC210474 AJ

(1) Remove the relay, and measure at the junction block side. (2) Turn the ignition switch to the ON position.


2 1 6 5 4 3

3 2 1 4 5 AC301541CI


Step 3. Check the blower relay. Refer to GROUP 55A, On-vehicle Service - Power relay check 355A.

AC301541CB


Step 5. Connector check: C-207 blower relay connector Connector: C-207 Junction block (Front view)

Q: Is the blower relay in good condition? YES : Go to Step 4. NO : Replace the blower relay. Junction block side 3 2 1 4 5


AC210474 AJ


55B-39

TROUBLESHOOTING

Step 6. Check the wiring harness between C-207 blower relay connector terminal No.1 and the ignition switch (IG2). Connectors: C-203, C-207 Junction block (Front view)

Step 7. Measure the voltage at C-207 blower relay connector. Connector: C-207 Junction block (Front view)

C-203


C-207

AC210474 AJ


Junction block side

C-203

C-207

2 1 6 5 4 3

3 2 1 4 5

Connector C-207 (Junction block side) 3 2 1 4 5

AC210475 AS AC301541CD

NOTE: Prior to the wiring harness inspection, check junction block connector C-203, and repair if necessary. Check the blower relay power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent






AC210474 AJ


55B-40

TROUBLESHOOTING

Step 9. Check the wiring harness between C-207 blower relay connector terminal No.5 and fusible link (1). Connectors: C-204, C-207 Junction block (Front view)

Check the blower relay power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


C-204(B)

Step 10. Measure the resistance at C-207 blower relay connector. Connector: C-207 Junction block (Front view)

C-207

Junction block side

Harness side C-204

C-207

1

3 2 1 4 5


AC210474 AJ

(1) Remove the relay, and measure at the junction block side. AC210475 AU


Fusible link: No.1

3 2 1 4 5 AC301541CC AC301515 AB


1 2

5 6 7

3 4

(2) Measure the resistance between terminal 3 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 13. NO : Go to Step 11.

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Prior to the wiring harness inspection, check intermediate connectors C-116 and junction block connector C-204, and repair if necessary.


55B-41

TROUBLESHOOTING


Step 13. Connector check: C-207 blower relay connector and C-32 blower linear controller connector Connector: C-207 Junction block (Front view)



AC210474 AJ


AC210474 AJ

Connector: C-32

Step 12. Check the wiring harness between C-207 blower relay connector terminal No.3 and body earth. Connectors: C-205, C-207 Junction block (Front view)

Harness side 2 1 6 5 4 3 AC301397 AT


C-205 C-207

Harness side

Junction block side

C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-207 3 2 1 4 5

AC210475 AT

NOTE: Prior to the wiring harness inspection, check junction block connector C-205, and repair if necessary. Check the blower relay earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



55B-42

TROUBLESHOOTING

Step 14. Check the wiring harness between C-207 blower relay connector terminal No.4 and C-32 blower linear controller connector terminal No.6.

Step 15. Measure the resistance at the C-32 blower linear controller connector. Connector: C-32



C-207

(1) Disconnect the connector, and measure at the wiring harness side. Harness side

Junction block side

C-203

C-207

2 1 6 5 4 3

3 2 1 4 5

Connector C-32 (Harness side) 2 1 6 5 4 3

AC210475 AS

AC301541CJ

(2) Continuity between terminal 3 and body earth OK: 2W or less

Connector: C-32

Q: Is the check result normal? YES : Go to Step 18. NO : Go to Step 16. Harness side

Step 16. Connector check: C-32 blower liner controller

2 1 6 5 4 3 AC301397 AT

NOTE: Prior to the wiring harness inspection, check junction block connector C-203, and repair if necessary. Check the blower linear controller power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


Connector: C-32




55B-43

TROUBLESHOOTING

Step 17. Check the wiring harness between C-32 blower linear controller connector terminal No.3 and body earth. Connector: C-32

Step 19. Check the wiring harness between C-27 A/C-ECU connector terminal No.2 and C-32 blower linear controller connector terminal No.5. Connectors: C-27, C-32

Harness side

C-32

C-27(B)

2 1 6 5 4 3 AC301397 AT

Check the blower linear controller earth line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Step 18. Connector check: C-27 A/C-ECU connector and C-32 blower linear controller connector Connectors: C-27, C-32

Harness side C-27 10 9 8 7 6 5 4 3 2 1 20191817161514131211

C-32 2 1 6 5 4 3

AC301398 AT

Check the communication line for open or short circuit. Q: Is the check result normal? YES : Replace the air conditioner control panel (A/

C-32

C-27(B)

Harness side C-27 10 9 8 7 6 5 4 3 2 1 20191817161514131211

C-32 2 1 6 5 4 3

AC301398 AT


C-ECU) or the blower motor (blower linear controller). NO : Repair the wiring harness.


55B-44

TROUBLESHOOTING

INSPECTION PROCEDURE 5: The blower air volume cannot be changed. Blower Motor Circuit BLOWER RELAY

BLOWER LINEAR CONTROLLER

A/C-ECU Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

COMMENTS ON TROUBLE SYMPTOM If the blower air volume can not be changed when the blower switch is operated, the circuit between blower motor and A/C-ECU may be defective. Possible causes Blower motor (blower linear controller) Damaged the wiring harness or connectors Malfunction of the auto air conditioner control panel (A/C-ECU)

Step 2. Connector check: C-27 A/C-ECU connector and C-32 blower linear controller connector Connectors: C-27, C-32

C-32

C-27(B)

Step 1. MUT-II actuator test Carry out the actuator test. Item 01, 02, 03, 04: Blower motor Q: Does the blower motor work normally? YES : Replace the auto air conditioner control

panel (A/C-ECU)

Harness side

NO : Go to Step 2. C-27

10 9 8 7 6 5 4 3 2 1 20191817161514131211

C-32 2 1 6 5 4 3

AC301398 AT



Step 3. Check the wiring harness between C-27 A/C-ECU connector terminal No.2 and C-32 blower linear controller connector terminal No.5. Connectors: C-27, C-32

C-32

C-27(B)

Harness side C-27 10 9 8 7 6 5 4 3 2 1 20191817161514131211

C-32 2 1 6 5 4 3

AC301398 AT

Check the communication line for open or short circuit. Q: Is the check result normal? YES : Replace the air conditioner control panel (A/

C-ECU) or the blower motor (blower linear controller). NO : Repair the wiring harness.

55B-45

55B-46


INSPECTION PROCEDURE 6: When sunlight intensity changes, blower air temperature does not Change.

Photo Sensor Circuit A/C-ECU

PHOTO SENSOR


CIRCUIT OPERATION When the blower air temperature can not be changed even if the preset temperature is changed, the sensors may be defective. TROUBLESHOOTING HINTS Malfunction of the photo sensor Damaged the wiring harness or connectors Malfunction of the A/C-ECU

DIAGNOSIS STEP 1. Check the defogger and outside/inside air selection damper control motor operation. Q: Do the defogger and outside/inside air selection damper control motor work normally? YES : Go to Step 2. NO : Refer to Inspection procedure 10

"Malfunction of the A/C-ECU power supply system 355B."

SB : Sky blue

Step 2. Use the MUT-II to confirm a diagnosis code. On completion, check that the diagnosis code is not reset. Q: Is the check result normal? YES : Go to Step 3. NO : Carry the diagnosis code procedures. Refer

to 355B. Step 3. Check the MUT-II data list. Item 14: Photo sensor OK: Check that the volume of insolation takes inverse proportion with the MUT-II displayed voltage. Q: Is the check result normal? YES : Replace the auto air conditioner control



55B-47

TROUBLESHOOTING

STEP 4. Connector check: C-27 A/C-ECU connector and C-123 photo sensor connector. Connector: C-27

STEP 5. Check the wiring harness between C-123 photo sensor connector (terminal 1, 2) and C-27 A/C-ECU connector (terminal 19, 9). Connector: C-27

C-27(B) C-27(B)


10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

Connector: C-123 Connector: C-123


2 1 2 1 AC301395 AN AC301395 AN


Check the photo sensor signal lines for open or short circuit. Q: Is the check result normal? YES : Replace the Photo sensor. NO : Repair the wiring harness.


55B-48

TROUBLESHOOTING

INSPECTION PROCEDURE 7: The A/C indicator flashes.

A/C-ECU


A/C PRESSURE SENSOR


CIRCUIT OPERATION If the A/C indicator flashes then the possible causes may be due to a defective A/C pressure system or insufficient refrigerant gas. TROUBLESHOOTING HINTS Malfunction of the A/C pressure sensor Malfunction of the outside thermo sensor Malfunction of the A/C-ECU

DIAGNOSIS STEP 1. Check the A/C pressure sensor operation. Refer to GROUP 55A, On vehicle service - A/C pressure sensor check 355A. Q: Is the A/C pressure sensor operating properly? YES : Go to Step 2. NO : Replace the A/C pressure sensor.

SB : Sky blue

STEP 2. Check the outside thermo sensor. Refer to 355B. Q: Is the outside thermo sensor in good condition? YES : Go to Step 3. NO : Replace the air thermo sensor.

STEP 3. Check the refrigerant level. Refer to GROUP 55A, On vehicle service - sight glass refrigerant level test 355A. Q: Is the refrigerant level correct? YES : Replace the auto air conditioner control

panel (A/C-ECU). NO : Correct the refrigerant level. (Refer to

GROUP 55A, On-vehicle Service355A).


55B-49

TROUBLESHOOTING

INSPECTION PROCEDURE 8: The inside/outside air changeover is impossible.

Outside/Inside Air Selection Damper Control Motor Circuit IGNITION SWITCH (IG2)




COMMENTS ON TROUBLE SYMPTOM When inside air cannot be changed to outside air vice versa even if its changeover switch is on, the outside/inside air selection damper control motor system may be defective. Possible causes Malfunction of the outside/inside air selection damper control motor Damaged the wiring harness or connectors Malfunction of the auto air conditioner control panel (A/C-ECU)

SB : Sky blue

DIAGNOSIS Step 1. MUT-II actuator test Carry out the actuator test. Item 13, 14: outside/inside air selection damper control motor Q: Does the blower motor work normally? YES : Replace the auto air conditioner control

panel (A/C-ECU) NO : Go to Step 2.


55B-50

TROUBLESHOOTING

Step 2. Measure the voltage at C-311 outside/ inside air selection damper control motor connector.

Step 3. Connector check: C-311 outside/inside air selection damper control motor connector Connector: C-311 Harness side


3 2 1 7 6 5 4

3 2 1 7 6 5 4

AC301547AB AC301547AB

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the ON position. Connector C-311 (Harness side)

3 2 1 7 6 5 4

AC301541 BT




Step 4. Check the wiring harness between C-311 outside/inside air selection damper control motor connector terminal No.7 and the ignition switch (IG2). Connector: C-311 Harness side

55B-51

Check the motor power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


3 2 1 7 6 5 4

Step 5. Check the outside/inside air selection damper control motor Refer to GROUP 55A, Resistor, blower motor and inside/outside air selection damper control motor 355A. AC301547AB


Q: Is the check result normal? YES : Go to Step 6. NO : Replace the outside/inside air selection

damper control motor. Step 6. Connector check: C-26 A/C-ECU connector and C-311 outside/inside air selection damper control motor connector Connector: C-26

1 2 3 4 5 6 7 8 9 10 11 12 13

AC301397 AU



C-203

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

AC301397 AV

Connector: C-311

C-205


Harness side C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-203 2 1 6 5 4 3

AC301547AB

Q: Is the check result normal? YES : Go to Step 7. NO : Repair the connector. AC210475 AR

Prior to the wiring harness inspection, check intermediate connector C-36 and junction block connectors C-203 and C-205, and repair if necessary.


55B-52

TROUBLESHOOTING

Step 7. Check the wiring harness between C-26 A/C-ECU connector (terminals 23 and 26) and C311 outside/inside air selection damper control motor connector (terminals 6 and 4). Connectors: C-26, C-36

C-36 C-26(B)

C-36 1 2 3 4 5 6 7 8 9 10 11 12 13


Connector: C-311 Harness side 3 2 1 7 6 5 4

AC301547AB

NOTE: Prior to the wiring harness inspection, check intermediate connector C-36, and repair if necessary. Check the motor activating lines for open or short circuit. Q: Is the check result normal? YES : Replace the auto air conditioner control



55B-53

TROUBLESHOOTING

INSPECTION PROCEDURE 9: Defogger function does not operate.

Defogger Circuit IGNITION SWITCH (IG2)

FUSIBLE LINK 1

DEFOGGER RELAY

DEFOGGER

A/C-ECU DEFOGGER SWITCH


CIRCUIT OPERATION If the defogger does not operate when the defogger switch is turned on, the defogger relay system may be defective. TROUBLESHOOTING HINTS Malfunction of the A/C-ECU Malfunction of the defogger relay Damaged the wiring harness or connectors Malfunction of the defogger

SB : Sky blue

DIAGNOSIS STEP 1. Check the A/C and outside/inside air selection damper control motor operation. Q: Do the A/C and outside/inside air selection damper control motor work normally? YES : Go to Step 2. NO : Refer to Inspection procedure 10

"Malfunction of the A/C-ECU power supply system 355B."


55B-54

TROUBLESHOOTING

STEP 2. Measure the voltage at F-04 defogger connector.

STEP 4. Measure the voltage at C-206 defogger relay connector. Connector: C-206 Junction block (Front view)


1 Junction block side 3 2 1 4 5

AC301658 AB

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the defogger switch to the "ON" position.

AC210474 AK

(1) Remove the relay, and measure at the junction block side. Connector C-206 (Junction block side)


3 2 1 4 5

1 AC301541CF AC301541CE


STEP 3. Check the defogger relay continuity. Refer to 355A. Q: Is the defogger relay in good condition? YES : Go to Step 4. NO : Replace the defogger relay.



Junction block side 3 2 1 4 5 AC210474 AK



55B-55

TROUBLESHOOTING

STEP 6. Check the wiring harness between C-206 defogger relay connector terminal No.5 and the fusible link (1). Connectors: C-204, C-206 Junction block (Front view)

Check the defogger relay power supply line for open or short circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


C-204(B)

STEP 7. Measure the voltage at C-206 defogger relay connector. Connector: C-206 Junction block (Front view)

C-206

Junction block side

Harness side C-204

Junction block side

C-206

3 2 1 4 5

3 2 1 4 5

1

AC210474 AK

(1) Remove the relay, and measure at the junction block side. (2) Turn the ignition switch to the "ON" position. AC210475 AV

Fusible link: No.1


3 2 1 4 5 AC301541CG AC301515 AB


1 2

5 6 7

3 4


8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Prior to the wiring harness inspection, check intermediate connectors C-116 and junction block connector C-204, and repair if necessary.


55B-56

TROUBLESHOOTING


STEP 10. Connector check: C-206 defogger relay connector and C-27 A/C-ECU connector Connector: C-27 C-27(B)


Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

AC210474 AK



STEP 9. Check the wiring harness between C-206 defogger relay connector No.1 and ignition switch (IG2). Connectors: C-203, C-206 Junction block (Front view)


C-206

C-203 2 1 6 5 4 3

3 2 1 4 5 AC210474 AK

C-203

Harness side

Junction block side

Junction block side C-206 3 2 1 4 5

AC210475 AW

NOTE: Prior to the wiring harness inspection, check junction block connector C-203, and repair if necessary. Check the defogger power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



55B-57

TROUBLESHOOTING

STEP 11. Check the wiring harness between C206 defogger relay connector No.3 and C-27 A/CECU connector No.16. Connector: C-27

STEP 12. Connector check: C-206 defogger relay connector and F-04 defogger connector Connector: C-206 Junction block (Front view)

C-27(B)


Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC210474 AK AC301397 AS

Connector: F-04

Connectors: C-205, C-206 Junction Block (Front view)

F-04(B) Harness side

1

C-205 C-206

Harness side

AC301658 AB

Junction block side

C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-206 3 2 1 4 5

AC210475 AX

NOTE: Prior to the wiring harness inspection, check junction block connector C-205, and repair if necessary. Check the defogger relay line for open or short circuit. Q: Is the check result normal? YES : Go to Step 12. NO : Repair the wiring harness.



55B-58

TROUBLESHOOTING

STEP 13. Check the wiring harness between C206 defogger relay connector terminal No.4 and F-04 defogger connector terminal No.1. Connectors: C-206, C-209 Junction block (Front view)

STEP 14. Measure the resistance at F-01 defogger connector. Connector: F-01 Harness side

1

C-206 AC301658 AC


C-209

Harness side C-209 7 6 5 15 1413

12

4 3 2 1 11 10 9 8



3 2 1 4 5

1 AC210475 AY

Connector: F-04 F-04(B)

AC301541CO

(2) Continuity between terminal 1 and body earth. OK: 2 ohm or less Q: Is the check result normal? YES : Go to Step 17. NO : Go to Step 15.

Harness side

1

STEP 15. Connector check: F-01 defogger connector AC301658 AB

NOTE: Prior to the wiring harness inspection, check junction block connector C-209, and repair if necessary. Check the defogger power supply line for open or short circuit.

Connector: F-01 Harness side

1

Q: Is the check result normal? YES : Replace the auto air conditioner control

panel (A/C-ECU).

AC301658 AC

NO : Repair the wiring harness. Q: Is the check result normal? YES : Go to Step 16. NO : Repair the connector.


STEP 16. Check the wiring harness between F-01 defogger connector terminal No.1 and earth.

55B-59

STEP 17. Check the defogger. Refer to GROUP 54A, Defogger355A. Q: Does the defogger work normally? YES : The trouble can be an intermittent

Connector: F-01

malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair the defogger.

Harness side

1

AC301658 AC

Check the defogger earth line for open or short circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction 300). NO : Repair or replace the wiring harness.


55B-60

TROUBLESHOOTING

INSPECTION PROCEDURE 10: Malfunction of the A/C-ECU power supply system.

A/C-ECU Power Supply Circuit IGNITION SWITCH (IG2)

FUSIBLE LINK 1

A/C-ECU BATTERY BACK-UP


CIRCUIT OPERATION The A/C-ECU power system may be defective if the air conditioner, defogger, and outside/inside air selection damper motor all do not operate normally.

SB : Sky blue

TROUBLESHOOTING HINTS Damaged the wiring harness or connectors Malfunction of the A/C-ECU


55B-61

TROUBLESHOOTING

DIAGNOSIS STEP 1. Measure the voltage at A/C-ECU connector C-26.

STEP 3. Check the wiring harness between C-26 A/C-ECU connector terminal No.28 and the ignition switch (IG2). Connector: C-26

Connector: C-26

C-26(B) C-26(B)

Harness side

Harness side

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

AC301397 AV AC301397 AV

(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position.

NOTE: Connectors: C-203, C-205 Junction Block (Front View) C-203


C-205

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

Harness side

AC301541CK


C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-203 2 1 6 5 4 3

Q: Is the check result normal? YES : Go to Step 4. NO : Go to Step 2. AC210475 AR

STEP 2. Connector check: C-26 A/C-ECU connector Connector: C-26

Prior to the wiring harness inspection, check junction block connectors C-205 and C-203, and repair if necessary. Check the A/C-ECU power supply line for open or short circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


C-26(B) Harness side 28 27 26 25 24 23 22 21 36 35 34 33 323130 29

AC301397 AV



55B-62

TROUBLESHOOTING

STEP 4. Measure the resistance at C-26 A/C-ECU connector. Connector: C-26

STEP 6. Check the wiring harness between C-26 A/C-ECU connector terminal No.27 and the earth. Connector: C-26

C-26(B)

C-26(B)

Harness side

Harness side

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

AC301397 AV

(1) Remove the relay, and measure at the junction block side.

AC301397 AV

Check the A/C-ECU earth line for open or short circuit. Q: Is the check result normal? YES : Replace the auto air conditioner control



STEP 7. Measure the voltage at C-27 A/C-ECU connector.

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

Connector: C-27 AC301541CL

C-27(B)

(2) Continuity between terminal 27 and body earth. OK: 2 ohm or less Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 5.

Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

STEP 5. Connector check: C-26 A/C-ECU connector


Connector: C-26

Connector C-27 (Harness side) C-26(B) Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

28 27 26 25 24 23 22 21 36 35 34 33 323130 29

AC301397 AV

AC301541CM


(2) Measure the voltage between terminal 3 and earth. OK: System voltage Q: Is the check result normal? YES : Replace the auto air conditioner control NO :

panel (A/C-ECU). Go to Step 8.


55B-63

TROUBLESHOOTING

STEP 8. Connector check: C-27 A/C-ECU connector Connector: C-27

NOTE: Connectors: C-202, C-204 Junction block (Front view) C-204(B)

C-27(B)

C-202

Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS


Harness side C-202

STEP 9. Check the wiring harness between C-27 A/C-ECU connector terminal No.3 and fusible link (1).

C-204

6 5 4 3 2 1 14 13 12 11 10 9 8 7

1

Connector: C-27

AC210475 BA

C-27(B)


C-02 Harness side 10 9 8 7 6 5 4 3 2 1 20191817161514131211

AC301397 AS

Fusible link: No.1 C-116 C-02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 2324 25 2627 28 2930 3132 33

C-116 1 2

AC301515 AB

5 6 7

3 4

8 9

10 1112 1314

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

1617 18 19 20 21

AC301396 AM

Prior to the wiring harness inspection, check junction block connectors C-202, C-204, intermediate connectors C-116 and joint connector C-02, and repair if necessary.

Check the A/C-ECU power supply (battery backup) line for open or short circuit. Q: Is the check result normal? YES : The trouble can be an intermittent



55B-64

TROUBLESHOOTING


Item No.

Check items

Inspection conditions

Normal condition

11

Interior temperature sensor

Turn the ignition switch to the ON position.

Room temperature is the same as MUT-II displayed temperature.

12

Outside thermo sensor


Outside temperature is the same as MUT-II displayed temperature.

13

Heater water temperature sensor


Heater core wall surface temperature is the same as MUT-II displayed temperature.

14

Photo sensor

Turn the ignition switch to The volume of insolation the ON position. takes inverse proportion with Change the volume of the MUT-II displayed voltage. insolation.

16

Air thermo sensor


17

Air mixing damper control motor and potentiometer

Turn the ignition switch to Opening angle: approximately the ON position. 100% Door position: MAX HOT

Evaporator outlet temperate is the same as MUT-II displayed temperature

Turn the ignition switch to Opening angle: approximately the ON position. 0% Door position: MAX HOT 18

Mode selection damper control motor and potentiometer

Turn the ignition switch to Opening angle: approximately the ON position. 0% Damper position: FACE Turn the ignition switch to Opening angle: approximately the ON position. 60% Damper position: FOOT Turn the ignition switch to Opening angle: approximately the ON position. 80% Damper position: FOOT/ DEF Turn the ignition switch to Opening angle: approximately the ON position. 100% Damper position: DEF

ACTUATOR TEST TABLE M1554005200100

Item No.

Check items

Drive content

01

Blower motor

Stop

02

Low speed

03

Middle speed

04

High speed


55B-65

TROUBLESHOOTING

Item No.

Check items

Drive content

05

Air mixing damper control motor

Open angle: Approximately 0% (MAX COOL)

06

Opening angle: approximately 50%

07

Open angle: Approximately 100% (MAX COOL)

08

Mode selection damper control motor FACE

09

FOOT

10

DEF

11

Compressor output

OFF

12

ON

13

Outside air

14

outside/inside air selection damper control motor

15

Idle-up

OFF (A/C high pressure)

16

Inside air ON (A/C low pressure)

CHECK AT ENGINE-A/T ECU TERMINALS M1554005400148

JAE-E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

JAE-E 31 3233 34 3536 37 38 39 40 41 42 43 44 45 46

JAE-E 71 72 73 7475 76 7778 79 8081 8283 84 8586 87 88 89 90 91 92 AC301466AB

Terminal No.

Check items

Check conditions

Normal conditions

8

Output to A/C compressor

A/C compressor relay: OFF

System voltage

A/C compressor relay: ON

0V

Air conditioner switch: OFF

4.9 - 5.1 V

Air conditioner switch: ON

0V

21

Output to fan controller

24

Input from A/C-ECU (A/C1)

When the A/C is in operation (When the air System voltage thermo sensor detects 3C or more).

42

Input from A/C pressure sensor

2.6MPa

3.9 V

45

Input from A/C-ECU (A/C2)

When the A/C is under low load

System voltage

81

A/C pressure sensor power supply

Always

4.9 - 5.1 V

92

A/C pressure sensor earth

Always

0V


55B-66

TROUBLESHOOTING

CHECK AT A/C-ECU TERMINALS M1554005400159

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

21 2223 24 25 26 27 28 29 30 31 32 33 34 35 36

AC300196 AB


Check conditions

Normal conditions

1

Interior temperature sensor

Sensor temperature: 25C (4kW)

2.1- 2.7V

2

Output to blower pulse controller

When the blower is operating.

0 - 2.5V (Effective alternating voltage)

3

Back-up power supply

Always

System voltage

4

Input from heater water temperature sensor


2.1 - 2.7V

5

Input from air mixing damper control motor potentiometer

When the damper flaps is moving to the MAX HOT position.

4.1 - 4.6 V

6

Input from mode selection damper control motor potentiometer

When the damper is moved to the DEF position.

4.1 - 4.6 V

7

Input from the outside thermo sensor Sensor temperature: 25C (4kW)

2.1 - 2.7 V

8

Input from the air thermo sensor


2.1 - 2.7 V

9

Photo sensor (-)

Brightness is 0 lux

4.9 - 5.1 V

Brightness is 100000 lux or more

Approximately 0 V

10

Potentiometer power supply

Always

5V

11

Input from the A/C pressure sensor

2.6 Mpa

3.9 V

12 - 15

-

-

-

16

Rear defogger

When the rear defogger is operating. 2.0 V or less When the rear defogger is stopped

System voltage

17

Diagnosis set

Ignition switch: ON

A voltmeter needle fluctuates between 0 and 12 V.

18

Input from diagnosis

Ignition switch: ON

Approximately 5 V

19

Photo sensor (+)

Always

0V

20

Sensors and potentiometers earth

Always

0V

21

Air outlet changeover damper motor (FACE)

When the damper is moved to the FACE position.

10 V


Faint voltage (0.5 V)

When the damper flaps is moving to the MAX COOL position.

10 V



22

Air mix damper motor (MAX COOL)


55B-67

TROUBLESHOOTING Terminal Check items No.

Check conditions

Normal conditions

23


10 V (When the motor is stopped)


2.0 or less

24

25

26

outside/inside air selection damper control motor (outside)

Mode selection damper control motor When the damper is moved to the and potentiometer (DEF) FACE position.

Air mixing damper control motor and potentiometer (MAX HOT)

outside/inside air selection damper control motor (inside)



10 V

When the damper flaps is moving to the MAX COOL position.



10 V


2.0 V or less


10 V (When the motor is stopped)

27

Earth

Always

Continuity exists.

28

IG2 power supply

Ignition switch: ON

System voltage

29

Illumination earth

Always

Continuity exists.

30

ILL power supply

Lighting switch: ON

System voltage

31

-

-

-

32

Input from the engine-A/T-ECU (A/C2)

When the A/C is under low load

System voltage

33

Input from the compressor relay

Compressor: ON

System voltage

34

Input from the engine-A/T-ECU (A/C1)

When the A/C is stopped

0V

35

-

-

-

36

ACC power supply


System voltage

When the A/C is operating (When the System voltage compressor is operating)


55B-68

AUTOMATIC AIR CONDITIONER PANEL ASSEMBLY (A/C-ECU)

AUTOMATIC AIR CONDITIONER PANEL ASSEMBLY (A/C-ECU) REMOVAL AND INSTALLATION M1554010900042

2 5

4

1

3

AC301496 AB

1. 2.

Removal steps Centre panel (Refer to GROUP 52A, Instrumental Panel352A). Knob Panel

3. 4. 5.

Removal steps&RQWLQXHG Rear defogger knob Outside/inside air selection knob Automatic air conditioner control panel (A/C-ECU)


55B-69

HEATER UNIT

HEATER UNIT REMOVAL AND INSTALLATION M1554009100097

Refer to GROUP 55A, Heater Unit Blower assembly 355A.


12

2

13 14

8 7

10

9

3 6 N

4 1

11 5

AC301506AB

1. 2. 3. 4. 5. 6. 7. 8.

Disassembly steps Evaporator cover Heater core Expansion valve Joint Evaporator O ring Air thermo sensor Heater water temperature sensor

Disassembly steps&RQWLQXHG Aspirator hose Aspirator Wiring harness Mode selection damper control motor and potentiometer 13. Air mixing damper control motor and potentiometer 14. Heater case 9. 10. 11. 12.

55B-70

AUTOMATIC AIR CONDITIONER AIR MIXING DOOR MOTOR, AIR OUTLET CHANGEOVER DAMPER MOTOR AND BLOWER MOTOR

AIR MIXING DOOR MOTOR, AIR OUTLET CHANGEOVER DAMPER MOTOR AND BLOWER MOTOR REMOVAL AND INSTALLATION M1554011100050

1

2

3

AC301512 AB

1.

Air mixing damper control motor and potentiometer removal steps Foot duct Air mixing damper control motor and potentiometer

2.

3.

Mode selection damper control motor and potentiometer removal steps Mode selection damper control motor and potentiometer Blower motor removal steps Blower motor


CHECK THE AIR MIXING DAMPER CONTROL MOTOR AND POTENTIOMETER

AC301517

Check the air mixing damper control motor Battery Battery Lever operation connection connection (+) terminal (-) terminal 1

3

Rotate to the HOT position.

3

1

Rotate to the COOL position.

AUTOMATIC AIR CONDITIONER AIR MIXING DOOR MOTOR, AIR OUTLET CHANGEOVER DAMPER MOTOR AND BLOWER MOTOR

Potentiometer check When the resistances between terminals 2 and 5 as well as terminals 5 and 6 are measured at the air mixing damper motor check, the resistance value should change gradually within the standard value. Standard value: Approximately 0.65 - 5.35 kW

MODE SELECTION DAMPER CONTROL MOTOR AND POTENTIOMETER CHECK

55B-71

Potentiometer check When the resistances between terminals 2 and 5 as well as terminals 5 and 6 are measured at the mode selection damper control motor check, the resistance value should change gradually within the standard value. Standard value: Approximately 0.65 - 5.35 kW

BLOWER MOTOR CHECK Execute actuator test item No.01 to 04 by using MUTII with the vehicle body, and check that the blower motor works normally. (Refer to 355B).

AC301519

Mode selection damper control motor check Battery Battery Lever operation connection connection (+) terminal (-) terminal 1

3

Rotate to the DEF position.

3

1

Rotate to the FACE position.


55B-72

SENSORS

SENSORS REMOVAL AND INSTALLATION M1554001900077

3

1

2

AC301526AB

1.

Interior temperature sensor removal steps Instrument lower panel (Refer to GROUP 52A, Instrumental Panel 352A). Interior temperature sensor

2.

<>

>>A<<

3.

Heater water temperature sensor removal steps Foot duct (Refer to GROUP 55A, Ventilator 355A). Heater water temperature sensor Photo sensor removal steps Instrument lower panel (Refer to GROUP 52A, Instrumental Panel 352A). Photo sensor

REMOVAL SERVICE POINTS <> PHOTO SENSOR REMOVAL

Tape String

AC301536 AB

Binding the photo sensor connector with a cord and rapping a tape around the connector as its surface is

flatly to pull out the photo sensor toward the instrument panel upper.


55B-73

EVAPORATOR ASSEMBLY

INSTALLATION SERVICE POINTS >>A<< PHOTO SENSOR INSTALLATION Defroster nozzle

Check to see that the resistance shown in the graph is almost satisfied when measuring the resistance between the terminals under two or more different temperature conditions.

HEATER WATER TEMPERATURE SENSOR CHECK Resis tance (kΩ)

Photo sensor harness

Tape

AC301539AB

20 15 10

Tape the photo sensor under the defroster nozzle.

5

INSPECTION

0 20 40 60 -10 0 Temperature (˚C)

M1552014300767

INTERIOR TEMPERATURE SENSOR CHECK Resis tance (kΩ)

80 AC103488 AB

15

Check to see that the resistance shown in the graph is almost satisfied when measuring the resistance between the terminals under two or more different temperature conditions.

10

PHOTO SENSOR CHECK

20

5 0 20 40 60 -10 0 Temperature (˚C)

80 AC103488 AB

Check that the blower rotation comes down if the photo sensor is covered with hands, when the automatic A/C is operating (in summer sunbeam). If not the rotation comes down, replace the photo sensor.

EVAPORATOR ASSEMBLY REMOVAL AND INSTALLATION M1552003600195

Refer to GROUP 55A, Evaporator assembly 355A).


AIR THERMO SENSOR CHECK Resistance 25 (kΩ) 20 15 10 5 0 -10 0 10 20 30 40 Temperature (˚C) AC103661AB

Check to see that the resistance shown in the graph is almost satisfied when measuring the resistance

between the terminals under two or more different temperature conditions. NOTE: The temperature should be within the shown range.


55B-74

AMBIENT TEMPERATURE SENSOR

AMBIENT TEMPERATURE SENSOR INSPECTION M1552014300745

Ambient air temperature sensor

AC301106 AC

Resistance 50 (kΩ) 40 30 20 10 0 -30 -20 0 20 40 60 Temperature (˚C) AC103489AB

Check to see that the resistance shown in the graph is almost satisfied when measuring the resistance between the sensor terminals under two or more different temperature conditions.

AUTOMATIC AIR CONDITIONER OTHER PARTS

55B-75

OTHER PARTS OTHER PARTS

Item

The following maintenance service points are the same as for the manual A/C.

Reference page

Heater unit and blower assembly

355A

Item

Blower motor and outside/inside 355A air selection damper control motor

M1554004000073

On-vehicle service

Reference page Refrigerant level 355A test Magnetic clutch test

355A

Compressor drive belt adjustment

355A

A/C pressure sensor simple check

355A

Charging

355A

Correcting low refrigerant level in case the service can in used

355A

Discharging system

355A

Refilling of oil in the A/C system

355A

Performance test 355A Refrigerant leak 355A repair procedure Compressor noise check

355A

Power relay continuity check

355A

Idle-up operation 355A check Clean air filter replacement procedure

355A

Evaporator and air thermo sensor 355A A/C compressor

355A

Condenser and condenser fan motor

355A

Refrigerant line

355A

Ventilators

355A

127(6

52A-1

GROUP 52A

00 11

INTERIOR

12 13 14

CONTENTS SPECIAL TOOL . . . . . . . . . . . . . . . . .

52A

HEADLINING . . . . . . . . . . . . . . . . . . . 52A REMOVAL AND INSTALLATION . . . . . . . .

INSTRUMENT PANEL ASSEMBLY*.

15 52A

52A


52A


52A

INSIDE REAR VIEW MIRROR . . . . . . 52A FRONT SEAT ASSEMBLY* . . . . . . . . 52A

FLOOR CONSOLE ASSEMBLY . . . .

52A


52A


52A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

52A


52A


52A

TRIMS. . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . .

52A 52A

REAR SEAT ASSEMBLY. . . . . . . . . . 52A

52A


52A

TAILGATE TRIM . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . .

52A 52A

17 21 22 25 26 27


52A


52A

31

FRONT SEAT BELT* . . . . . . . . . . . . . 52A

32

DOOR TRIM . . . . . . . . . . . . . . . . . . . . 52A REMOVAL AND INSTALLATION . . . . . . . .

16


52A

33

REAR SEAT BELT . . . . . . . . . . . . . . . 52A

34


52A

35 36 37

:$51,1*65(*$5',1*6(59,&,1*2)6833/(0(17$/5(675$,176<67(0656 (48,33('9(+,&/(6

WARNING (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from rendering the SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRSrelated component. NOTE The SRS includes the following components: front impact sensors, side impact sensors, SRS-ECU, SRS warning lamp, air bag module, clock spring and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

42 51 52 54 55

INTERIOR

52A-2

SPECIAL TOOL


Tool

Tool number

Name

Use

MB990784

Ornament remover

Removal of switch, trim, etc.

MB990784

INSTRUMENT PANEL ASSEMBLY REMOVAL AND INSTALLATION M1521001700394

WARNING For removal and installation of the passenger’s side air bag module, always observe the service procedures described in GROUP 52B, Air Bag Module and Clock Spring 352B. The following bolts and screws are used for installing the instrument panel. Bolts and screws are indicated as marks shown in the illustration in the sections of "Removal and Installation" and "Disassembly and Assembly." Name

Symbol

Size (D L) mm

Colour

Tapping screw

a

5 12

-

b

5 16

-

c

5 16

Black

d

5 12

-

e

5 20

-

Shape

AC104450

AC104436

Washer assembly bolt

f

6 16

-

g

6 16

-

h

6 16 (Earth)

-

i

8 20

-

j

10 60

-

AC104417

AC200304

INTERIOR

52A-3

INSTRUMENT PANEL ASSEMBLY

CAUTION Refer to GROUP 52B-SRS Service Precautions 352B and Air bag Module and Clock Spring 352B before removing the passenger side air bag module. Do not subject the SRS-ECU to any shocks when removing or installing the instrument panel. Pre-removal and Post-installation Operation Removal and Installation of Front Floor Console (Refer to 352A). Removal and Installation of Steering Wheel and Air Bag Module Assembly (Refer to 337).

2 5

c

4

6

3

1

d

26

d

2

d

d

44 ± 10 N·m

d

25

44 ± 10 N·m

j

12 j

d

10 25

g

e d

11

9

h

15

g

24 N

17

8

13

22

20 c f

18 a

7

a

16

b

19 AC301272 AB

21

<>

1. 2. 3. 4. 5. 6. 7. 8.

23

14

b

Removal steps Instrument panel clock garnish Instrument panel air outlet (centre) Clock Instrument panel driver’s side garnish Meter bezel Combination meter Junction block cover Hood lock release handle (Refer to 342). Instrument panel parcel box

9. 10. 11. 12.

<>

>>A<<

13. 14. 15.

Removal steps&RQWLQXHG Floor harness (RH) and junction block connection Instrument lower panel Instrument panel air outlet (LH) Instrument lower panel bracket Column cover Air mix door cable, blow vent changeover damper cable connection (Refer to 355A). Knob Centre panel Centre panel assembly

INTERIOR

52A-4


16. 17. 18. 19. 20. 21. 22. 23. 24.

Removal steps&RQWLQXHG Manual air conditioner control panel Radio plug Centre lower panel Centre lower box Centre lower cover Front scuff plate, cowl side trim (Refer to 352A). Back bone spacer Glove box stopper Glove box Connector block

Removal steps&RQWLQXHG 25. Instrument panel side cover Roof harness connection Instrument panel harness earth connection Instrument panel and body harness connection Steering shaft harness connector and clamp Stop lamp switch harness connector (Refer to 335A). SRS-ECU harness connector (Refer to 352B). Shift lock cable clamp Steering shaft installation bolt (Refer to 337). 26. Instrument panel assembly

INTERIOR

52A-5


CLIP AND CLAW POSITIONS

A D B B

D C

A

C E G

E

G

F

F

H

I

H I J

J

H K

NOTE (1) : Clip position (2) : Claw position Section A – A Instrument panel side cover

Section B – B

Clip Meter bezel

Instrument panel drive's side garnish Section G – G

Clip

Clumn cover

Instrument lower panel Claw Section I – I

Center panel Claw

Clip

Instrument panel assembly

Claw

Center panel Section J – J

Section K – K Clip

Radio plug

Meter bezel

Section H – H


Instrument panel clock garnish Clip

Claw

Section F – F

Section E – E Instrument panel assembly

Section D – D Instrument panel assembly

Section C – C

Instrument panel side cover


Clip

K

Claw


H

Junction brock cover

Clip Instrument panel assembly Centr lower panel AC301617 AB

52A-6

INTERIOR INSTRUMENT PANEL ASSEMBLY


INSTALLATION SERVICE

<> INSTRUMENT PANEL AIR OUTLET REMOVAL

>>A<< CENTRE PANEL ASSEMBLY INSTALLATION Air mix door cable and blow vent changeover damper cable connection (Refer to 355A).

Ball

Spring

AC103520AB

The instrument panel air outlet may remain on the instrument panel side when disassembling the lower panel of the instrument panel and the instrument panel garnish. Carefully disassemble the parts remaining on the instrument panel side to prevent the ball and spring from falling. Assemble the ball and spring according to the figure to the left if they fall off.

INTERIOR

52A-7



2

1 10

a

a

11 15 f

11 a

f

11 a

11

1

a

a

a

a

3 a

a

a

a

9

f

a

6

a

7

a f

f

a

g

14

a

f

12

5 a f

a

a

f

13

4

e

a a a

8

a

AC212544AB

1. 2. 3. 4. 5. 6. 7. 8.

Disassembly steps Side defroster duct Defroster nozzle assembly Distribution duct Front deck crossmember Passenger’s side air bag module bracket Passenger’s side air bag module Passenger’s side air bag module cover Glove box striker

Disassembly steps&RQWLQXHG Instrument panel reinforcement Meter bracket Instrument panel holder Instrument panel under cover passenger’s side 13. Side air outlet assembly (RH) 14. Centre cover driver’s side Instrument panel harness connector clamp 15. Instrument panel 9. 10. 11. 12.

INTERIOR

52A-8

FLOOR CONSOLE ASSEMBLY

FLOOR CONSOLE ASSEMBLY REMOVAL AND INSTALLATION M1521002200295

1 7 6

8

5

3

4 C

11 C

C

11

C

2 9 13

B

B

A

A

D D

12 11 ± 2 N·m

11 ± 2 N·m NOTE : Clip position

10

Section A – A

Section B – B

Section C – C

Section D – D

3

Clip

9

Clip

12

13 11

11

12

Clip

12

Clip AC301787 AB

1. 2. 3. 4. 5. 6.

Removal steps Shift knob Floor console panel cover Front floor console panel Harness connector Heated seat switch Coin holder

7. 8. 9. 10. 11. 12. 13.

Removal steps&RQWLQXHG Ashtray Shift lever cover Rear floor console assembly Rear floor console bracket Front floor console lower side cover Front floor console Front floor console bracket

INTERIOR

52A-9

FLOOR CONSOLE ASSEMBLY


7 5 1

4

6 3 2

11

10

9 8

AC106397AH

1. 2. 3. 4. 5. 6.

Disassembly steps Lid assembly Tray outer Tray inner Lock knob Lid inner Hinge assembly

7. 8. 9. 10. 11.

Disassembly steps&RQWLQXHG Lid cover Hinge support bracket Rear console box Rear console Rear console panel

INTERIOR

52A-10

TRIMS

TRIMS REMOVAL AND INSTALLATION M1521001100381

16

9

4

15

5

6 44 ± 10 N·m

10

14 44 ± 10 N·m

12

8

11 13 7 2

17

3 19

1

18 1. 2.

<>

3. 4. 5. 6. 7. 8. 9.

Front scuff plate Cowl side trim Rear seat cushion assembly (Refer to 352A). Rear scuff plate Front door opening trim Rear door opening trim Front pillar trim Centre pillar trim lower Front seat belt shoulder anchor bolt Centre pillar trim upper

20 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

AC301338 AB

Convenience hook Parcel strap hook A Ventilation cap Quarter trim lower Rear seat belt shoulder anchor bolt Quarter trim upper cap Quarter trim upper Rear end trim Luggage floor box Parcel strap hook B Rear seat board

INTERIOR

52A-11

TRIMS

CLIP AND CLAW POSITION D

D

F

F

D D

D

D

E

E

B B

C

G

G

C C A

A

C

NOTE : Clip position Section A – A

Section B – B

Clip

Section C – C Front pillar trim

Front scuff plate, rear scuff plate

Section D – D Center pillar trim upper

Clip Clip Cowl side trim Section E – E

Clip Section G – G

Section F – F Qauter trim upper

Qauter trim lower

Rear end trim

Clip Clip Clip

AC301349 AB

INTERIOR

52A-12

TRIMS

REMOVAL SERVICE POINT <> FRONT PILLAR TRIM REMOVAL Section A – A Front pillar trim Front pillar trim A A Instrument panel AC101299AC

Unclip the front pillar trim and slide out it in the direction shown.

INTERIOR

52A-13

DOOR TRIM

DOOR TRIM REMOVAL AND INSTALLATION M1521006400116

3

2 A

1 View A

B

B

Section B – B

Section C – C Clip

1

3 Clip

C

3 NOTE :Clip position

C

AC106408 AB

<>

1. 2.

Removal steps Speaker garnish Door inside handle cover

3.

Removal steps&RQWLQXHG Delta cover (Refer to 351). Door trim assembly

INTERIOR

52A-14

DOOR TRIM

3

2 A

1

View A

B

B Section B – B

Section C – C

1

Clip

3

Clip

C

3 NOTE : Clip position

C AC106406 AB

1.

Removal steps Speaker garnish

<>

2. 3.

Removal steps&RQWLQXHG Door inside handle cover Door trim assembly

INTERIOR

52A-15

DOOR TRIM

REMOVAL SERVICE POINT <> DOOR INSIDE HANDLE COVER REMOVAL Tapping screw cap

Door inside handle cover A

B

Special tool insertion position

A

B MB990784

AC100003AF

1. Insert a flat-tipped screwdriver into the back end of the tapping screw cap of the door inside handle cover. 2. Try the screwdriver in the direction of the arrow. Remove the cap, then remove the tapping screw.

Section B – B Section A – A Door inside handle cover Door trim

Claw

Claw Door inside handle cover

Claw AC100004 AD

3. Insert the special tool ornament remover (MB990784) in the gap between the door inside handle cover and door inside handle in the area shown. Then remove the thumb clamp of the door inside handle cover and door inside handle. 4. Insert a special tool from the back end of the door inside handle cover to lift it in the direction of the arrow. Then remove the door inside handle cover.

INTERIOR

52A-16

DOOR TRIM


3 6 5

2

4

7 3 6 2

1

5

4

7

1 AC212484 AB

1. 2. 3. 4.

Disassembly steps Door weather-strip Arm rest assembly Power window switch panel assembly Arm rest

5. 6. 7.

Disassembly steps&RQWLQXHG Door harness Power window switch Door trim

INTERIOR

52A-17

TAILGATE TRIM

TAILGATE TRIM REMOVAL AND INSTALLATION M1521006500094

4 2

1

4

3

5 AC102381AC

1. 2. 3.

Removal steps Tailgate upper trim Tailgate trim Tailgate lower trim

4. 5.

Removal steps&RQWLQXHG Tailgate side trim Tailgate pull handle

INTERIOR

52A-18

TAILGATE TRIM

CLIP AND CLAW POSITION B Tailgate upper trim

A

B

A H

Tailgate side trim

H

Tailgate side trim

Tailgate trim

E

C

E

D G

F

C

F

D G

Tailgate lower trim

NOTE : Clip position : Claw position

Tailgate pull handle A Section B – B Claw

Section A – A Clip

Section C – C

Tailgate trim

Tailgate side trim Claw

Tailgate upper trim

Tailgate upper trim

Section D – D

Tailgate lower trim

Section E – E

Tailgate trim

Section F – F Tailgate side trim Tailgate lower trim

Tailgate lower trim

Clip

Clip

Section G – G Tailgate trim Clip

Craw Tailgate lower trim

Claw Tailgate side trim

Tailgate lower trim

Claw

View A

Section H – H

Tailgate lower trim Section I – I

I

Clip

Tailgate lower trim

I Claw Tailgate side trim

Tailgate pull handle

Tailgate pull handle AC102835 AC

INTERIOR

52A-19

HEADLINING

HEADLINING REMOVAL AND INSTALLATION M1521001400304

Pre-removal and Post-installation Operation Removal and Installation of Front Pillar Trim, Centre Pillar Trim Upper, Quarter Trim Upper (Refer to 352A).

8

9

7 6 2 4 1 5 3 5

1. 2. 3. 4.

<>

5.

6

Removal steps Assist grip Rear room lamp assembly Front room lamp/map lamp assembly Sun roof switch cover Sun visor holder

REMOVAL SERVICE POINT <> SUN VISOR HOLDER REMOVAL

MB990784 Sun visor holder MB990784

AC005512 AD

Insert the special tool ornament remover (MB990784) into side claws of the sun visor holder through the both sides to remove the hinges.

AC301290 AB

6. 7. 8. 9.

Removal steps&RQWLQXHG Sun visor assembly Front headlining trim Rear headlining trim Headlining

INTERIOR

52A-20

INSIDE REAR VIEW MIRROR

INSIDE REAR VIEW MIRROR M1521002600185


2. Push the claw B toward arrow 2 direction to unlock, and pull out the mirror toward arrow 3 direction.

3 Claw A 2 Cover 1 Claw B

AC209066 AD

1. Disengage the claw A and lower the cover toward arrow 1 direction.

INTERIOR

52A-21

FRONT SEAT ASSEMBLY

FRONT SEAT ASSEMBLY REMOVAL AND INSTALLATION M1522001300311

CAUTION For the removal of the front seat assembly on vehicles with the side air bags, refer to GROUP 52B Service Precautions (Refer to 352B) and Air Bag Module and Clock Spring (Refer to 352B). Pre-removal and Post-installation Operation Removal and Installation of Rear Floor Console Assembly (Refer to 352A).

1

1

7

44 ± 10 N·m

2

30 ± 5 N·m Claw

7

3

44 ± 10 N·m

Section A – A

8 3

4, 5 Section B – B

3

6

A

30 ± 5 N·m

7

7 4

A Claw NOTE : Claw position

B

5

6

B

3

5 4

1. 2.

3. 4. 5.

Headrest Heated seat switch Front seat assembly removal steps Front seat anchor cover Seat anchor cover outer Seat anchor cover inner

AC301693 AB

6. 7.

>>A<<

8.

Front seat assembly removal steps&RQWLQXHG Harness connector Harness connector Front seat assembly

INTERIOR

52A-22

FRONT SEAT ASSEMBLY

INSTALLATION SERVICE POINT >>A<< FRONT SEAT ASSEMBLY INSTALLATION


HEATED SEAT SWITCH CHECK

AC301696AB

1. Temporarily tighten the nuts and bolts in all mounting locations shown in the illustration with no load applied to the front seat cushion and check the operation of the seat slide. 2. Tighten the nuts and bolts in all mounting locations to the specified torque. Switch position Driver’s seat side

Front passenger’s seat side

ACX00625

1. Check for continuity between terminals.

Tester connection

Specified condition

HI

1 - 3, 1 - 5, 1 - 8, 3 - 5, 3 - 8, 5 - 8

Less than 2 ohms

OFF

1 - 3, 1 - 5, 1 - 8, 3 - 5, 3 - 8, 5 - 8

Open circuit

LO

3 - 5, 3 - 8, 5 - 8

Less than 2 ohms

HI

4 - 5, 4 - 8, 4 - 9, 5 - 8, 5 - 9, 8 - 9

Less than 2 ohms

OFF

4 - 5, 4 - 8, 4 - 9, 5 - 8, 5 - 9, 8 - 9

Open circuit

LO 2. Check that the indicator is lighted at HI or LO when battery voltage is supplied to terminal 5, and terminal 8 is grounded.

5 - 8, 5 - 9, 8 - 9 Less than 2 ohms 3. Check that indicator is lighted when battery voltage is supplied to terminals 2 and 6.

INTERIOR

52A-23

FRONT SEAT ASSEMBLY

SEAT CUSHION HEATER CHECK

HEATED SEAT RELAY CONTINUITY CHECK

Heated seat relay 1 2 3

AC200099

Measure the resistance between terminals. Standard value: Measured Resistance Note terminals value 2-3 1-3

Junction block

Approximately At room 4.8 W 10 % temperature 20 C

4

1 2 3 4

5.2 W 10 %

1 3

2

SEATBACK HEATER CHECK AC300127 AB

1 2

AC200100

Measure the resistance between terminals. Standard value: Approximately 4.8 W 10 % (At room temperature 20 C)

Battery voltage

Tester connection

Specified condition

Not applied

1-4

Open circuit


Less than 2 ohms

INTERIOR

52A-24

FRONT SEAT ASSEMBLY


12

Section A – A

21 17 16

20 15

Claw

27

N

10, 11

44 ± 10 N·m

18

14 13 9

19 N

18

6 7 4

5

8 12 ± 2 N·m A

26 23

7.6 ± 0.7 N·m

A

1 3 2 10

22

24

A

11 NOTE : Claw position

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

25

A 44 ± 10 N·m

24

Disassembly steps Reclining knob Pin Height adjuster knob Heater harness assembly Front seat cushion assembly Front seat cushion cover Front seat cushion pad Front seat cushion frame Seat cushion heater Reclining cover Shield cover Front seatback assembly Lumbar support cap

27

<>

AC301697 AB

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Disassembly steps&RQWLQXHG Lumbar support lever Headrest guide Front seatback cover Front seatback pad Lumber support clip Lumber support Front seatback frame Seatback heater Inner seat belt Shaft Pin Slide handle Shaft protector Seat slide adjuster

INTERIOR

52A-25

REAR SEAT ASSEMBLY

REMOVAL SERVISE POINT < HEADREST GUIDE REMOVAL

ACX01300

REAR SEAT ASSEMBLY REMOVAL AND INSTALLATION M1522001800264

1

1 5

1

44 ± 10 N·m

95 ± 15 N·m

4

2 44 ± 10 N·m

44 ± 10 N·m

3 44 ± 10 N·m

6 AC300146 AB

INTERIOR

52A-26

REAR SEAT ASSEMBLY 1.

>>A<<

2. 3.

Headrest Removal steps Rear seat cushion assembly Inner seat belt and centre seat belt installation bolt

INSTALLATION SERVICE POINT >>A<< REAR SEAT CUSHION ASSEMBLY INSTALLATION Rear seat cushion assembly

Rear seat hook AC005521AB

Fit the rear seat cushion into the rear seat hook securely.

4. 5. 6.

Removal steps&RQWLQXHG Rear seatback assembly (LH) Rear seatback assembly (RH) Rear seat hook

INTERIOR

52A-27

REAR SEAT ASSEMBLY


19

11 20

23 25 26

24

44 ± 10 N·m

12

31 27

29

30

8 12

9

22

10 18

44 ± 10 N·m

28

7 17 16 15

44 ± 10 N·m

13

32 2

28 14

44 ± 10 N·m

14

4

3 21

6

5

1N AC200082AB AB

1. 2. 3.

4. 5. 6. 7. 8. 9.

Rear seat cushion disassembly steps Hog ring Rear seat cushion cover Rear seat cushion pad Rear seatback (LH side) disassembly steps Arm rest assembly Arm rest cup holder Arm rest board Tether anchor garnish Reclining knob Cap

<>

10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Rear seatback (LH side) disassembly steps&RQWLQXHG Reclining knob garnish Centre seat belt garnish Headrest guide Rear seatback cover Reclining cover Rear seatback pad Rear seatback frame assembly Arm rest bushing Reclining cable Centre seat belt cover

INTERIOR

52A-28

REAR SEAT ASSEMBLY

20. 21.

22. 23. 24.

Rear seatback (LH side) disassembly steps&RQWLQXHG Centre seat belt Reclining adjuster Rear seatback (RH side) disassembly steps Tether anchor garnish Reclining knob Cap

REMOVAL SERVICE POINT <> HEADREST GUIDE REMOVAL

ACX01300

<>

25. 26. 27. 28. 29. 30. 31. 32.

Rear seatback (RH side) disassembly steps&RQWLQXHG Reclining knob garnish Headrest guide Rear seatback cover Reclining adjuster cover Rear seatback pad Rear seatback frame Reclining cable Reclining adjuster

INTERIOR

52A-29

FRONT SEAT BELT

FRONT SEAT BELT REMOVAL AND INSTALLATION M1523001300314

CAUTION SRS: Before removing and installing the seat belts with pre-tensioner, refer to GROUP 52B, Seat Belt with Pre-tensioner (Refer to 352B). Pre-removal and Post-installation Operation Turn the ignition key to the LOOK (OFF) position. Disconnect the negative battery terminal.

4

5

44 ± 10 N·m

1

44 ± 10 N·m

3

2

6

44 ± 10 N·m

44 ± 10 N·m AC301332 AC

1. 2. 3.

Outer seat belt removal steps Sash guide cover Centre pillar trim lower (Refer to 352A). Bracket Outer seat belt (Refer to GROUP 52B, Seat Belt with Pre-tensioner 352B).

4. 5.

6.

Outer seat belt removal steps Centre pillar trim upper (Refer to 352A). Adjustable seat belt anchor Inner seat belt removal steps Shield cover (Refer to 352A). Inner seat belt

INTERIOR

52A-30

REAR SEAT BELT

REAR SEAT BELT REMOVAL AND INSTALLATION M1523001600315

6

44 ± 10 N·m

5 44 ± 10 N·m

8

7

3 4

44 ± 10 N·m 44 ± 10 N·m

44 ± 10 N·m

1

2 1

1. 2. 3.

Removal steps Rear seatback assembly (Refer to 352A). Inner seat belt Centre seat belt inner Centre seat belt garnish Quarter trim upper (Refer to 352A ).

AC301334 AB

4. 5. 6. 7. 8.

Removal steps&RQWLQXHG Centre seat belt outer (Refer to 352A). Sash guide cover Seat belt shoulder anchor bolt Seat belt lower anchor bolt Outer seat belt

52-1

GROUP 52

INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM(SRS)

00 11 12 13 14 15 16 17 21 22

CONTENTS

25 26

INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . 52B

27 31 32 33 34 35 36 37 42 51 52 54 55

127(6

15-1

GROUP 15

00 11

INTAKE AND EXHAUST

12 13 14 15 16

CONTENTS

17 GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATION . . . . . . . .

15

15

AIR CLEANER . . . . . . . . . . . . . . . . . .

15

INTAKE MANIFOLD . . . . . . . . . . . . .

15

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

15

EXHAUST MANIFOLD . . . . . . . . . . . .

15


15

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

15

EXHAUST PIPE AND MAIN MUFFLER . . . . . . . . . . . . . . . . . . . . . .

15

27


15

31

15

SPECIAL TOOL . . . . . . . . . . . . . . . . .



15

15

21 22 25 26

32 33 34 35 36 37 42 51 52 54 55

INTAKE AND EXHAUST

15-2

GENERAL INFORMATION


The exhaust pipe is divided into three parts.


Item

Standard value

Limit

Manifold distortion of the installation surface mm

0.15 or less

0.20


Tool

Number

Name

Use

MD998770

Oxygen sensor wrench

Removal and installation of oxygen sensor

INTAKE AND EXHAUST

15-3

AIR CLEANER

AIR CLEANER REMOVAL AND INSTALLATION M1151002100442

CAUTION Parts marked by * are made of recycled-paper mixed plastic material, so observe the following precautions. Avoid any shock or load to these parts when removing and installing them. When installing, securely set the air cleaner cover and the resonator clamp to the air cleaner body. NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state and local laws 3.9 ± 1.0 N·m

11

6 12

1*

5 3.9 ± 1.0 N·m

Clamp 8.8 ± 1.0 N·m

N

3*

9

8.8 ± 1.0 N·m

4*

10*

8 7

2* 11 ± 1 N·m 8.8 ± 1.0 N·m

13

22 ± 4 N·m AC203703 AB

1. 2. 3. 4. 5. 6. 7.

Removal steps Resonator Air cleaner element Air duct Air cleaner body Air flow sensor connector Breather hose connection Air cleaner cover and air flow sensor assembly

8. 9. 10. 11. 12. 13.

Removal steps&RQWLQXHG Air flow sensor assembly Gasket Air cleaner cover Resonator Air intake hose Air cleaner bracket

INTAKE AND EXHAUST

15-4

INTAKE MANIFOLD

INTAKE MANIFOLD REMOVAL AND INSTALLATION M1151003000686

Pre-removal Operation Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) 313A.] Throttle Body Removal (Refer to GROUP 13A, Throttle Body 313A). Fuel Delivery Pipe and Fuel Injector assembly Removal (Refer to GROUP 13A, Injector 313A).

Post-installation Operation Fuel Delivery Pipe and Fuel Injector assembly Installation (Refer to GROUP 13A, Injector 313A). Throttle Body Installation (Refer to GROUP 13A, Throttle Body 313A). Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Check and Adjustment 317). Fuel Leak Check

2 5.0 ± 1.0 N·m

1 3

5.0 ± 1.0 N·m

4 11 ± 1 N·m

5 6

10 8

13 ± 1 N·m

7 N9 (Engine oil)

1. 2. 3. 4.

AC301313 AB

Removal steps Purge control solenoid valve connector EGR control solenoid valve connector Detonation sensor connector Accelerator cable connection

5. 6. 7. 8. 9. 10.

Removal steps&RQWLQXHG Earth cable connection Emission control equipment hose PCV hose Oil level gauge and guide O-ring Detonation sensor connector clamp

INTAKE AND EXHAUST

15-5

INTAKE MANIFOLD

11 ± 1 N·m

11

9.0 ± 1.0 N·m

14 36 ± 6 N·m

20 ± 2 N·m

20 ± 2 N·m

16 36 ± 6 N·m

12 13 N

36 ± 6 N·m

17 N

20 ± 2 N·m

15

31 ± 3 N·m

11. 12. 13. 14.

Removal steps Vacuum hose and pipe assembly EGR valve EGR valve gasket Brake booster vacuum hose connection

INSPECTION Check the following points; replace the part if a problem is found. Intake Manifold Check 1. Check for damage or cracking of any part.

AC301314 AB

Removal steps&RQWLQXHG 15. Intake manifold stay 16. Intake manifold assembly 17. Intake manifold gasket

M1151003100553

2. Clogging of the negative pressure (vacuum) outlet port, or clogging of the exhaust gas recirculation passages. 3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm

INTAKE AND EXHAUST

15-6

EXHAUST MANIFOLD

EXHAUST MANIFOLD REMOVAL AND INSTALLATION M1151003300535

8N 7

29 ± 3 N·m

14 ± 1 N·m

6

1

44 ± 5 N·m

29 ± 3 N·m 14 ± 1 N·m

49 ± 5 N·m 35 ± 6 N·m

2

5 44 ± 5 N·m

4N

49 ± 10 N·m

3

AC301312 AB

Removal steps

<> >>A<< 1. Oxygen sensor 2. Exhaust manifold cover 3. Front exhaust pipe connection 4. Exhaust pipe gasket

5. 6. 7. 8.

Removal steps&RQWLQXHG Exhaust manifold bracket Engine hanger Exhaust manifold Exhaust manifold gasket

INTAKE AND EXHAUST EXHAUST MANIFOLD

REMOVAL SERVICE POINT <> OXYGEN SENSOR REMOVAL

MD998770

Oxygen sensor AC212566 AB

Use special tool oxygen sensor wrench (MD998770) to remove the oxygen sensor.

INSTALLATION SERVICE POINT >>A<< OXYGEN SENSOR INSTALLATION

MD998770


Use special tool oxygen sensor wrench (MD998770) to install the oxygen sensor.


Check the following points; replace the part if a problem is found. Exhaust Manifold Check 1. Check for damage or cracking of any part. 2. Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm

15-7

INTAKE AND EXHAUST

15-8

EXHAUST PIPE AND MAIN MUFFLER

EXHAUST PIPE AND MAIN MUFFLER REMOVAL AND INSTALLATION M1151008700282

13 ± 2 N·m

5 13 ± 2 N·m

6 1 13 ± 2 N·m

8

5

13 ± 2 N·m

10 N

11 3

N

2 7N 9N 49 ± 10 N·m

4

45 ± 5 N·m

59 ± 10 N·m

49 ± 10 N·m AC301054 AB

1. 4. 5. 6.

2. 4. 7. 8.

Exhaust main muffler removal steps Exhaust main muffler Exhaust pipe gasket Hanger Exhaust pipe damper Centre exhaust pipe removal steps Centre exhaust pipe Exhaust pipe gasket Exhaust pipe gasket Hanger

Front exhaust pipe removal steps Centre under cover (front) (Refer to GROUP 51, Under Cover 351). 3. Front exhaust pipe 9. Exhaust pipe gasket 10. Exhaust pipe gasket 11. Hanger

17-1

GROUP 17

00 11

ENGINE AND EMISSION CONTROL

12 13 14 15 16 17 21

CONTENTS ENGINE CONTROL . . . . . . . . . .

17

22

CRANKCASE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . .

17

25


17

GENERAL INFORMATION (CRANKCASE EMISSION CONTROL SYSTEM) . . . . .

17

26


17

COMPONENT LOCATION (CRANKCASE EMISSION CONTROL SYSTEM) . . . . .

17

27


17

POSITIVE CRANKCASE VENTILATION SYSTEM CHECK . . . . . . . . . . . . . . . . . .

17

31

17

POSITIVE CRANKCASE VENTILATION (PCV) VALVE CHECK . . . . . . . . . . . . . .

17

ACCELERATOR CABLE CHECK AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . .

ACCELERATOR CABLE AND PEDAL . . . . . . . . . . . . . . . . . . . . . .

17


17

EMISSION CONTROL . .

17


17

EMISSION CONTROL DEVICE REFERENCE TABLE . . . . . . . . . .

17


17

SPECIAL TOOL . . . . . . . . . . . . . . .

17

VACUUM HOSE. . . . . . . . . . . . . . .

17

VACUUM HOSE PIPING DIAGRAM . . .

17

VACUUM CIRCUIT DIAGRAM . . . . . . .

17

VACUUM HOSE CHECK. . . . . . . . . . . .

17

VACUUM HOSE INSTALLATION . . . . .

17

EVAPORATIVE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . 17

32 33 34

GENERAL INFORMATION (EVAPORATIVE EMISSION CONTROL SYSTEM) . . . . . 17

35

COMPONENT LOCATION (EVAPORATIVE EMISSION CONTROL SYSTEM) . . . . . 17

36

PURGE CONTROL SYSTEM CHECK. .

17

PURGE PORT VACUUM CHECK . . . . .

17

37

PURGE CONTROL SOLENOID VALVE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .

17

CANISTER . . . . . . . . . . . . . . . . . . . . . . .

17

51


17

52

EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . 17

54

GENERAL INFORMATION (EGR SYSTEM). . . . . . . . . . . . . . . . . . .

17

COMPONENT LOCATION (EGR SYSTEM) . . . . . . . . . . . . . . . . . . .

17


42

55

17-2 EGR SYSTEM CHECK. . . . . . . . . . . . . . . . .

17

EGR VALVE CHECK. . . . . . . . . . . . . . . .

17

EGR PORT VACUUM CHECK . . . . . . . .

17

EGR CONTROL SOLENOID VALVE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .

17


CATALYTIC CONVERTER . . . . . . REMOVAL AND INSTALLATION. . . . . .

17 17 17


17-3

ENGINE CONTROL

ENGINE CONTROL GENERAL INFORMATION M1171000100255

A cable-type accelerator mechanical suspendedtype pedal has been adopted.


Items

Standard value

Accelerator cable play mm

1.0 - 2.0

Engine idle speed r/min

750 100

ON-VEHICLE SERVICE

7. If there is too much slack or no slack, adjust play by the following procedures.

ACCELERATOR CABLE CHECK AND ADJUSTMENT

Adjusting nut

M1171000900284

1. Turn A/C and lights OFF. Inspect and adjust at no load. 2. Warm engine until stabilized at idle. 3. Confirm idle speed is at standard value. Standard value: 750 100 r/min 4. Stop engine. [ignition switch: LOCK (OFF) position]. 5. Confirm there are no sharp bends in the accelerator cable. 6. Check the inner cable for correct slack. Standard value: 1.0 - 2.0 mm

Plate

Accelerator cable AC301055 AB

(1) Loosen the adjusting bolt to release the cable. (2) Move the plate until the inner cable play is at the standard value, and then tighten the adjusting bolt. (3) After adjusting, check that the throttle lever is touching the stopper.


17-4

ENGINE CONTROL

ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION M1171001200329

Post-installation Operation Adjusting the Accelerator Cable (Refer to 317). 5.0 ± 1.0 N·m

3 1

2 12 ± 2 N·m

9 7

10

11

6

N5

4

8

7

12 N

13 AC301187 AB

1. 2. 3.

1. 4.

Accelerator cable assembly removal steps Inner cable connection (Accelerator pedal side) Inner cable connection (Throttle body side) Accelerator cable assembly Accelerator pedal assembly removal steps Inner cable connection (Accelerator pedal side) Accelerator pedal assembly

INSTALLATION SERVICE POINT >>A<< ACCELERATOR PEDAL PAD INSTALLATION

CAUTION To prevent damages to the Pedal Pad, warm the thumb area of the Pedal Pad with a dryer, etc. prior to assembling it. NOTE: If it is difficult to assemble, apply soapy water to the thumb area to enhance the assembling process.

5. 6. 7. 8. 9. 10. 11. >>A<< 12. 13.

Accelerator pedal assembly removal steps&RQWLQXHG Push-on spring nut Accelerator arm and accelerator pedal pad assembly Bushing Spring Stopper Accelerator pedal bracket Accelerator arm Accelerator pedal pad Accelerator pedal stopper


17-5

EMISSION CONTROL

EMISSION CONTROL GENERAL INFORMATION M1173000100370

The emission control system consists of the following subsystems: Items Name

Crankcase emission control system Evaporative emission control system Exhaust emission control system Specification

Crankcase emission control system

Positive crankcase ventilation (PCV) valve

Variable flow type (Purpose: HC reduction)

Evaporative emission control system

Canister Purge control solenoid valve

Equipped Duty cycle type solenoid valve (Purpose: HC reduction)

Exhaust emission control system

Air-fuel ratio control device - MPI system

Oxygen sensor feedback type (Purpose: CO, HC, NOx reduction)

Exhaust gas recirculation system EGR valve EGR control solenoid valve

Equipped Single type Duty cycle type solenoid valve (Purpose: NOx reduction)

Catalytic converter

Monolith type (Purpose: CO, HC, NOx reduction)

EMISSION CONTROL DEVICE REFERENCE TABLE M1173006600135

Related parts

Crankcase emission control system

PCV valve

Evaporative emission control system


MPI system component

Air/fuel ratio Catalytic control converter system

Exhaust gas recirculation system

Catalytic converter

EGR valve



Items

Standard value

Purge control solenoid valve coil resistance (at 20C) W

30 - 34

EGR control solenoid valve coil resistance (at 20C) W

29 - 35


17-6

EMISSION CONTROL


Tool

Number

Name

Use

MD998770

Oxygen sensor wrench

Removal and installation of oxygen sensor

VACUUM HOSE VACUUM HOSE PIPING DIAGRAM M1173000900321

Air cleaner Air

To fuel tank

Fuel pressure From regulator fuel pump

PCV valve

EGR valve Canister


Catalytic converter



Oxygen sensor (rear) Catalytic converter AK204364AB


17-7

EMISSION CONTROL

VACUUM CIRCUIT DIAGRAM M1173007100207

Intake manifold

Throttle body

To combustion chamber

From air cleaner

B

W R

Fuel pressure regulator G Vacuum hose colour B: Black G: Green R: Red W: White Y: Yellow

EGR valve


VACUUM HOSE CHECK M1173007300137

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.

VACUUM HOSE INSTALLATION M1173007200099

1. When connecting the vacuum hoses, they should be securely inserted onto the nipples. 2. Connect the hoses correctly, using the vacuum hose piping diagram as a guide.

Y

Canister

B B Purge control solenoid valve

AK201210 AC

CRANKCASE EMISSION CONTROL SYSTEM GENERAL INFORMATION (CRANKCASE EMISSION CONTROL SYSTEM) M1173005000237

The crankcase emission control system prevents blow-by gases from escaping inside the crankcase into the atmosphere. Fresh air is sent from the air cleaner into the crankcase through the breather hose. The air becomes mixed with the blow-by gases inside the crankcase. The blow-by gas inside the crankcase is drawn into the intake manifold through the positive crankcase ventilation (PCV) valve. The PCV valve lifts the plunger according to the intake manifold vacuum so as to regulate the flow of blow-by gas properly. In other words, the blow-by gas flow is regulated during low load engine operation to maintain engine stability, while the flow is increased during high load operation to improve the ventilation performance.


17-8

EMISSION CONTROL

SYSTEM DIAGRAM Air cleaner Air Ventilation hose

Breather hose

PCV valve

AK204365AB

COMPONENT LOCATION (CRANKCASE EMISSION CONTROL SYSTEM) M1173007400156

PCV valve

AKX00336 AD

PCV valve AK204366AB

POSITIVE CRANKCASE VENTILATION SYSTEM CHECK M1173001100179

1. 2. 3. 4.

Remove the ventilation hose from the PCV valve. Remove the PCV valve from the rocker cover. Reinstall the PCV valve at the ventilation hose. Start the engine and run at idle.

5. Place a finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt. NOTE: At this moment, the plunger in the PCV valve moves back and forth. 6. If vacuum is not felt, clean the PCV valve or replace it.


17-9

EMISSION CONTROL

POSITIVE CRANKCASE VENTILATION (PCV) VALVE CHECK

EVAPORATIVE EMISSION CONTROL SYSTEM

M1173001200187

GENERAL INFORMATION (EVAPORATIVE EMISSION CONTROL SYSTEM) M1173005100320

PCV valve

AK100010 AC

1. Insert a thin rod into the PCV valve from the side shown in the illustration (rocker cover installation side), and move the rod back and forth to check that the plunger moves. 2. If the plunger does not move, there is a clogging in the PCV valve. In this case, clean or replace the PCV valve.

The evaporative emission control system prevents fuel vapours generated in the fuel tank from escaping into the atmosphere. Fuel vapours from the fuel tank flow through the fuel tank pressure control valve and vapour pipe/hose to be stored temporarily in the canister. When driving the vehicle, fuel vapours stored in the canister flow through the purge solenoid and purge port and go into the intake manifold to be sent to the combustion chamber. When the engine coolant temperature is low or when the intake air quantity is small (when the engine is at idle, for example), the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold. This does not only insure the driveability when the engine is cold or running under low load but also stabilize the emission level.

SYSTEM DIAGRAM

Throttle body

Engine-ECU From fuel tank

Canister Air flow sensor OFF Purge control ON Solenoid valve

Battery

Engine coolant temperature sensor Control relay

Intake air temperature sensor Barometric pressure sensor

AK204367AB


17-10

EMISSION CONTROL

COMPONENT LOCATION (EVAPORATIVE EMISSION CONTROL SYSTEM)

PURGE PORT VACUUM CHECK M1173001500133

M1173007500164

Vacuum hose

Plug


AK201225 AD AK201217 AC

PURGE CONTROL SYSTEM CHECK M1173001400211

1. Disconnect the vacuum hose (red stripe) from the throttle body and connect a hand vacuum pump to the nipple. 2. Plug the vacuum hose (red stripe).

Vacuum hose

Vacuum

Plug

AK201220AC

Engine speed (r/min) AK100011AC

1. Disconnect the vacuum hose (red stripe) from throttle body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum. When engine is cold (Engine coolant temperature: 40C or less) Engine condition Normal condition At idle

Vacuum is maintained.

3,000 r/min When engine is hot (Engine coolant temperature: 80C or higher) Engine condition Normal condition At idle

Vacuum is maintained.

3,000 r/min (within 3 minutes after engine starts)

Vacuum will leak.

3. Start the engine. 4. Check that a fairly constant negative pressure is generated regardless of the engine speed. 5. If no negative pressure is generated, the port is probably blocked and should be cleaned.


17-11

EMISSION CONTROL

PURGE CONTROL SOLENOID VALVE CHECK M1173001700193

NOTE: When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. A

2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage. Battery voltage

Normal condition

Applied

Vacuum leaks

Not applied Vacuum maintained 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 30 - 34 W (at 20C) Battery AK100012 AC

AK100013

1. Disconnect the vacuum hose from the solenoid valve.


17-12

EMISSION CONTROL

CANISTER REMOVAL AND INSTALLATION M1173004800296

Pre-removal and Post-installation Operation Air Cleaner Cover and Air Intake Hose Removal and Installation (Refer to GROUP 15 - Air Cleaner 315).

3 2 6

4

1

5

8

7

AC301056 AB

1. 2. 3. 4.

Removal steps Purge hose connection Vapour hose Vent connector Vapour hose

5. 6. 7. 8.

Removal steps&RQWLQXHG Hose clamp Canister Fuel high-pressure hose clamp Canister bracket

EXHAUST GAS RECIRCULATION (EGR) SYSTEM GENERAL INFORMATION (EGR SYSTEM) M1173005200264

The exhaust gas recirculation (EGR) system lowers the nitrogen oxide (NOx) emission level. When the air/fuel mixture combustion temperature is high, a large quantity of nitrogen oxides (NOx) is generated in the combustion chamber. Therefore, this system recirculates part of emission gas from the exhaust port of the cylinder head to the combustion chamber through the intake manifold to decrease the air/fuel mixture combustion temperature, resulting in reduction of NOx. The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability.

OPERATION The EGR valve is being closed and does not recirculate exhaust gases under one of the following conditions. Otherwise, the EGR valve is opened and recirculates exhaust gases. The engine coolant temperature is low. The engine is at idle. The throttle valve is widely opened.


17-13

EMISSION CONTROL

SYSTEM DIAGRAM

EGR control Solenoid valve OFF Engine-ECU EGR valve


ON

Air flow sensor

Control relay

Engine coolant temperature sensor Crank angle sensor

Battery

AK204368 AB

COMPONENT LOCATION (EGR SYSTEM)

EGR SYSTEM CHECK

M1173007600172

M1173002600326

Three-way terminal Green stripe


EGR valve

AK201234AC

EGR valve

AK200375AE

1. Disconnect the vacuum hose (Green stripe) from the EGR valve, and then connect a hand vacuum pump via the three-way terminal. 2. When the engine is hot or cold, check the condition of vacuum by racing the engine. When engine is cold (Engine coolant temperature: 20C or less) Throttle valve Normal vacuum condition

AK201237AC

Open quickly

No vacuum will generate (the same as barometric pressure.)

When engine is hot (Engine coolant temperature: 80C or higher) Throttle valve Normal vacuum condition Open quickly

It will momentarily rise over 13 kPa


17-14

EMISSION CONTROL

EGR PORT VACUUM CHECK

3. Disconnect the three-way terminal.

M1173002900145

Green stripe white stripe

EGR valve

AK200376 AC AK201247 AC

4. Connect the hand vacuum pump to the EGR valve nipple. 5. Check whether the engine stalls or the idling is unstable when a vacuum of 30 kPa or higher is applied during idling.

1. Disconnect the vacuum hose (White stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple. 2. Plug the vacuum hose (White stripe).

EGR VALVE CHECK M1173002800212

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. Apply 67 kPa of vacuum, and check that the vacuum is maintained.

Vacuum

Engine speed (r/min) AK100011AC

3. Start the engine. 4. Check that a fairly constant negative pressure is generated regardless of the engine speed. 5. If no negative pressure is generated, the port is probably blocked and should be cleaned.

AKX00348

4. Apply a vacuum and check the passage of air by blowing through one side of the EGR passage. Vacuum

Passage of air

5.3 kPa or less

Air is not blown out

27 kPa or more Air is blown out 5. Replace the gasket, and tighten to the specified torque. Tightening torque: 20 2 N¼m

ENGINE AND EMISSION CONTROL EMISSION CONTROL

EGR CONTROL SOLENOID VALVE CHECK M1173003100216

NOTE: When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. A

2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage. Battery voltage

B nipple condition

Normal condition

Not applied

Open

Vacuum maintained

Applied

Open

Vacuum leaks

B C

Closed

Battery AK201251AB

AK100016

1. Disconnect the vacuum hose from the solenoid valve.

17-15

Vacuum maintained 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 29 - 35 W (at 20C)


17-16

EMISSION CONTROL

REMOVAL AND INSTALLATION M1173010500153

Pre-removal and Post-installation Operation Air Cleaner Cover and Air Intake Hose Removal and Installation (Refer to GROUP 15 - Air Cleaner 315).

1 2

20 ± 2 N·m

3N

AC301219 AB

1.

Removal steps Vacuum hose connection

2. 3.

Removal steps&RQWLQXHG EGR valve EGR valve gasket

CATALYTIC CONVERTER REMOVAL AND INSTALLATION M1173003900353

44 ± 5 N·m

2 N

5

1

4 3N

59 ± 10 N·m

6 49 ± 10 N·m

<>

>>A<<

1. 2. 3.

Removal steps Oxygen sensor Centre exhaust pipe connection Exhaust pipe gasket

AC212565 AC

4. 5. 6.

Removal steps&RQWLQXHG Front exhaust pipe connection Exhaust pipe gasket Catalytic converter


17-17

EMISSION CONTROL



<> OXYGEN SENSOR REMOVAL

>>A<< OXYGEN SENSOR INSTALLATION

MD998770


Use special tool oxygen sensor wrench (MD998770) to remove the oxygen sensor.

MD998770


Use special tool oxygen sensor wrench (MD998770) to install the oxygen sensor.

127(6

14-1

GROUP 14

00 11

ENGINE COOLING

12 13 14

CONTENTS GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATION . . . . . . . .

14

FAN CONTROLLER CHECK . . . . . . . . . . .

14

16

14

FAN CONTROL RELAY CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

17

RADIATOR FAN MOTOR CHECK . . . . . . .

14

THERMOSTAT . . . . . . . . . . . . . . . . . .

14


14

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

14

25

WATER PUMP . . . . . . . . . . . . . . . . . .

14

26

14

27 31

LUBRICANT. . . . . . . . . . . . . . . . . . . .

14

SEALANT. . . . . . . . . . . . . . . . . . . . . .

14

SPECIAL TOOL . . . . . . . . . . . . . . . . .

15

14

21 22


14



14

WATER HOSE AND WATER PIPE . .

14

14


14

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

14

32

ENGINE COOLANT LEAK CHECK . . . . . . RADIATOR CAP VALVE OPENING PRESSURE CHECK. . . . . . . . . . . . . . . . . .

14

ENGINE COOLANT REPLACEMENT . . . .

14

RADIATOR . . . . . . . . . . . . . . . . . . . . .

14

33

CONCENTRATION MEASUREMENT . . . .

14


14

34 35 36 37 42 51 52 54 55

ENGINE COOLING

14-2

GENERAL INFORMATION


The cooling system is designed to keep every part of the engine at appropriate temperature in whatever condition the engine may be operated. The cooling method is of the water-cooled, pressure forced circulation type in which the water pump pressurizes coolant and circulates it throughout the engine. If the coolant temperature exceeds the prescribed Item Radiator

temperature, the thermostat opens to circulate the coolant through the radiator as well so that the heat absorbed by the coolant may be radiated into the air. The water pump is of the centrifugal type and is driven by the drive belt from the crankshaft. The radiator is the corrugated fin, down flow type. Specification

Performance kJ/h

225,628


Item

Standard value

Limit

High-pressure valve opening pressure of radiator cap kPa

93 - 123

Minimum 83

Range of coolant antifreez concentration of radiator %

30 - 60

-

Thermostat

Valve opening temperature of thermostat C

82 1.5

-

Full-opening temperature of thermostat C

95

-

Valve lift mm

8.5 or more

-


Item

Specified coolant

Quantity L

Engine coolant (including condense tank)

DIAQUEEN SUPER LONG LIFE COOLANT or an 7.0 equivalent

SEALANT M1141000500302

Item

Specified sealant

Thermostat case, Water outlet fitting

MITSUBISHI GENUINE Part No.MD970389 or equivalent

Cylinder block drain plug

3M Nut Locking Part No.4171 or equivalent

ENGINE COOLING

14-3

SPECIAL TOOL


Tool

Number

Name

Use

MB991871

LLC changer

Coolant refilling

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222


Making voltage and resistance measurement during troubleshooting A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection

MB991871

A

B

C

D MB991223 AC

TROUBLESHOOTING INSPECTION CHART FOR TROUBLE SYMPTOMS M1141005600337

Trouble symptom


Reference page

Radiator fan and condenser fan do not operate

1

314

Radiator fan and condenser fan do not change speed or stop

2

314

Radiator fan does not operate

3

314

Condenser fan does not operate

4

314

ENGINE COOLING

14-4

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1: Radiator Fan and Condenser Fan do not Operate

Radiator Fan and Condenser Fan Drive Circut

ENGINE-ECU

FUSIBLE LINK 2 ENGINE CONTROL RELAY

FAN CONTROL RELAY

FAN CONTROLLER

CONDENSER FAN MOTOR

RADIATOR FAN MOTOR


AC301898 AB

CIRCUIT OPERATION The fan controller is powered from fusible link (2). The engine-ECU uses input signals from the A/C switch, the engine coolant temperature sensor and the output shaft speed sensor to control the speed of the radiator fan motor and condenser fan motor. The engine-ECU controls the fan controller to activate the radiator fan motor and the condenser fan motor.

TECHNICAL DESCRIPTION The cause could be a malfunction of the fan controller power supply or earth circuit. The cause could also be a malfunction of the fan controller or the engine-ECU. TROUBLESHOOTING HINTS Malfunction of fusible link (2) Malfunction of fan control relay Malfunction of engine control relay Malfunction of fan controller

ENGINE COOLING

14-5


Malfunction of radiator fan motor Malfunction of engine-ECU Damaged wiring harness or connector

STEP 5. Measure at fan control relay A-10X connector. Connector: A-10X

DIAGNOSIS A-10X

STEP 1. Check fusible link (2). 3

Q: Is the check result normal? YES : Go to Step 2. NO : Replace fusible link (2).

2

4 1

Front of vehicle

STEP 2. Check continuity at fan control relay A10X. Refer to 314. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the fan control relay.

STEP 3. Check the radiator fan motor. Refer to 314. Q: Is the check result normal? YES : Go to Step 4. NO : Replace the radiator fan motor.

STEP 4. Check at fan control relay A-10X connector. Q: Is the check result normal? YES : Go to Step 5. NO : Repair or replace the fan control relay.

AC301900AB

(1) Check the power supply line for short or open circuit. (2) Disconnect the fan control connector, and measure the voltage between terminal 4 and earth at the relay box side. OK: System voltage Q: Is the check result normal? YES : Go to Step 6. NO : Check the wiring harness between fan

control relay A-10X (terminal 4) and fusible link (2), and repair if necessary. STEP 6. Measure at fan control relay A-10X connector. Connector: A-10X

A-10X 3 2

4 1

Front of vehicle AC301900AB

(1) Disconnect the fan control connector, and measure the voltage between terminal 1 and earth at the relay box side. OK: System voltage Q: Is the check result normal? YES : Go to Step 10. NO : Go to Step 7.

STEP 7. Check continuity at engine control relay B-17X. Refer to 313A. Q: Is the check result normal? YES : Go to Step 8. NO : Replace the engine control relay.

14-6

ENGINE COOLING INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

STEP 8. Check at engine control relay A-17X connector. Q: Is the check result normal? YES : Go to Step 9. NO : Repair or replace the engine control relay.

STEP 9. Check the wiring harness between fan control relay A-10X (terminal 1) and engine control relay A-17X (terminal 1). Connector: A-10X

A-10X 3 2

4 1


Connector: B-17X

B-17X 1

3

2

4


(1) Check the power supply line for short or open circuit. NOTE: Connector: C-17

1 2 3 4 5 6 7 8 9 10 11 12 13

AC301918 AB

Connector: A-14

1 2

3 4 5 6 7 8 9 10 11 15 12 13 14 16 17

AC301917AB

Prior to the wiring harness inspection, check joint connector C-17 and front wiring harness (LH) and control wiring harness combination connector A14, and repair if necessary.

ENGINE COOLING

14-7

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Q: Is the check result normal? YES : Go to Step 10. NO : Check the wiring harness between fan

control relay A-10X (terminal 1) and engine control relay A-17X (terminal 1), and repair if necessary. STEP 10. Measure at fan control relay A-10X connector.

STEP 12. Measure at fan controller connector A20. Connector: A-20

A-20 3 2 1

Connector: A-10X AC301902 AB

A-10X 3

(1) Check the power supply line for short or open circuit.

2

4 1


(1) Check the earth line for open circuit. (2) Disconnect the fan control connector, and measure the resistance between terminal 3 and earth at the relay box side. OK: Continuity exists. Q: Is the check result normal? YES : Go to Step 11. NO : Check the wiring harness between fan

control relay A-10X (terminal 3) and body earth, and repair if necessary. STEP 11. Check fan controller connector A-20. Q: Is the check result normal? YES : Go to Step 12. NO : Repair the fan controller connector.

Connector A-20 (Conponent side) 3 2

1

AC201418 AF

(2) Disconnect the fan controller connector, and measure the voltage between terminal 3 and earth at the wiring harness side. Turn the ignition switch to the ON position. OK: System voltage Q: Is the check result normal? YES : Go to Step 13. NO : Check the wiring harness between fan

controller A-20 (terminal 3) and fan control relay A-10X (terminal 2), and repair if necessary.

ENGINE COOLING

14-8



STEP 14. Measure at engine-ECU connector C134. Connector: C-134

A-20 3 2 1

Engine-ECU

AC301902 AB

(1) Check the earth line for open circuit.

Connector A-20 (Conponent side) 3 2

C-134


1

AC301901AB

AC201414 AF

(2) Disconnect the fan controller connector, and measure the resistance between terminal 1 and body earth at the wiring harness side. OK: Continuity exists. Q: Is the check result normal? YES : Go to Step 14. NO : Check the wiring harness between fan

Connector C-134 (harness side) 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

controller A-20 (terminal 1) and body earth, and repair if necessary.

AC301903 AB

(1) Connect the engine-ECU connector, and measure the voltage between terminal 21 and body earth. Engine: Idling A/C switch: ON OK: 0.7 V or more (A/C compressor is working) Q: Is the check result normal? YES : Go to Step 17. NO : Go to Step 15.

STEP 15. Check engine-ECU connector C-134. Q: Is the check result normal? YES : Go to Step 16. NO : Repair the engine-ECU connector.


STEP 16. Check the wiring harness between fan controller A-20 (terminal 2) and engine-ECU C134 (terminal 21). Connector: A-20

14-9

Q: Is the check result normal? YES : Go to Step 17. NO : Check the wiring harness between fan

controller A-20 (terminal 2) and engine-ECU C-134 (terminal 21), and repair if necessary. STEP 17. Verify that the condition described by the customer exists.

A-20

Q: Does a malfunction take place again? YES : An intermittent malfunction is suspected

3 2 1

AC301902 AB

Connector: C-134

Engine-ECU

C-134


AC301901AB

(1) Check the output line for short or open circuit. NOTE: Connector: A-14

1 2

3 4 5 6 7 8 9 10 11 15 12 13 14 16 17

AC301917AB

Prior to the wiring harness inspection, check front wiring harness (LH) and control wiring harness combination connector A-14, and repair if necessary.

(Refer to GROUP 00, How to cope with intermittent malfunctions 300). NO : Replace the engine-ECU.

14-10


INSPECTION PROCEDURE 2: Radiator Fan and Condenser Fan do not Change Speed or Stop Radiator Fan and Condenser Fan Drive Circuit Refer to 314. CIRCUIT OPERATION The fan controller is powered from fusible link (2). The engine-ECU uses input signals from the A/C switch, the engine coolant temperature sensor and the output shaft speed sensor to control the speed of the radiator fan motor and condenser fan motor. The engine-ECU controls the fan controller to activate the radiator fan motor and the condenser fan motor. TECHNICAL DESCRIPTION The fan controller has variable control of the radiator fan motor and the condenser fan motor speeds using signals transmitted from the engine-ECU. TROUBLESHOOTING HINTS Malfunction of fan control relay Malfunction of fan controller Malfunction of engine-ECU

DIAGNOSIS STEP 1. Check continuity at fan control relay A10X. Refer to 314. Q: Is the check result normal? YES : Go to Step 2. NO : Replace the fan control relay.

STEP 2. Check at fan control relay A-10X connector. Q: Is the check result normal? YES : Go to Step 3. NO : Repair or replace the fan control relay.

STEP 3. Measure at fan control relay A-10X connector. Connector: A-10X

A-10X 3 2

4 1


(1) Check the power supply line for short or open circuit. (2) Disconnect the fan control connector, and measure the voltage between terminal 4 and earth at the relay box side. OK: System voltage Q: Is the check result normal? YES : Go to Step 4. NO : Check the wiring harness between fan

control relay A-10X (terminal 4) and fusible link (2), and repair if necessary. STEP 4. Measure at fan control relay A-10X connector. Connector: A-10X

A-10X 3 2

4 1


(1) Disconnect the fan control connector, and measure the voltage between terminal 1 and earth at the relay box side. OK: System voltage Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.

ENGINE COOLING

14-11


STEP 5. Check the wiring harness between fan control relay A-10X (terminal 1) and engine control relay A-17X (terminal 1). Connector: A-10X

A-10X 3


control relay A-10X (terminal 1) and engine control relay A-17X (terminal 1), and repair if necessary. STEP 6. Measure at fan control relay A-10X connector.

2

4

Connector: A-10X

1


A-10X 3

Connector: B-17X

2

4 1

Front of vehicle B-17X 1

3

2

4

AC301900AB


(1) Check the power supply line for short or open circuit. NOTE: Connector: C-17

(1) Check the earth line for open circuit. (2) Disconnect the fan controller connector, and measure the resistance between terminal 3 and earth at the relay box side. OK: Continuity exists. Q: Is the check result normal? YES : Go to Step 7. NO : Check the wiring harness between fan

control relay A-10X (terminal 3) and body earth, and repair if necessary. STEP 7. Check fan controller connector A-20. Q: Is the check result normal? YES : Go to Step 8. NO : Repair the fan controller connector.

1 2 3 4 5 6 7 8 9 10 11 12 13

AC301918 AB

Connector: A-14

1 2

3 4 5 6 7 8 9 10 11 15 12 13 14 16 17

AC301917AB

Prior to the wiring harness inspection, check joint connector C-17 and front wiring harness (LH) and control wiring harness combination connector A14, and repair if necessary.

ENGINE COOLING

14-12



STEP 10. Measure at engine-ECU connector C134. Connector: C-134

A-20 3 2 1

Engine-ECU

AC301902 AB

(1) Check the power supply line for short or open circuit. (2) Disconnect the fan controller connector, and measure the voltage between terminal 3 and earth at the wiring harness side. Turn the ignition switch to the ON position. OK: System voltage

C-134



controller A-20 (terminal 3) and fan control relay A-10X (terminal 2), and repair if necessary. STEP 9. Measure at fan controller connector A20.

AC301901AB

Connector C-134 (harness side) 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

Connector: A-20

AC301903 AB

A-20 3 2 1

AC301902 AB

(1) Check the earth line for open circuit. (2) Disconnect the fan controller connector, and measure the resistance between terminal 1 and body earth at the wiring harness side. OK: Continuity exists. Q: Is the check result normal? YES : Go to Step 10. NO : Check the wiring harness between fan

controller A-20 (terminal 1) and body earth, and repair if necessary.

(1) Connect the engine-ECU connector, and measure the voltage between terminal 21 and body earth. Engine: Idling A/C switch: ON OK: 0.7 V or more (A/C compressor is working) Q: Is the check result normal? YES : Go to Step 12. NO : Go to Step 11.

STEP 11. Check engine-ECU connector C-134. Q: Is the check result normal? YES : Go to Step 12. NO : Repair the engine-ECU connector.


STEP 12. Check the wiring harness between fan controller A-20 (terminal 2) and engine-ECU C134 (terminal 21). Connector: A-20

14-13


controller A-20 (terminal 2) and engine-ECU C-134 (terminal 21), and repair if necessary. STEP 13. Verify that the condition described by the customer exists.

A-20

Q: Does a malfunction take place again? YES : An intermittent malfunction is suspected

3 2 1

AC301902 AB

Connector: C-134

Engine-ECU

C-134


AC301901AB

(1) Check the output line for short or open circuit. NOTE: Connector: A-14

1 2

3 4 5 6 7 8 9 10 11 15 12 13 14 16 17

AC301917AB

Prior to the wiring harness inspection, check front wiring harness (LH) and control wiring harness combination connector A-14, and repair if necessary.

(Refer to GROUP 00, How to cope with intermittent malfunctions 300). NO : Replace the engine-ECU.

14-14


INSPECTION PROCEDURE 3: Radiator Fan does not Operate TECHNICAL DESCRIPTION The cause could be a malfunction of the radiator fan motor or an open circuit between the fan controller and the radiator fan motor. TROUBLESHOOTING HINTS Malfunction of radiator fan motor

DIAGNOSIS STEP 1. Check the radiator fan motor. Refer to 314. Q: Is the radiator fan motor in good condition? YES : Go to Step 2. NO : Replace the radiator fan motor.

STEP 2. Check the fan controller Refer to 314. Q: Is the fan controller in good condition? YES : Go to Step 3. NO : Replace the radiator fan controller.

STEP 3. Verify that the condition described by the customer exists. Q: Does a malfunction take place again? YES : An intermittent malfunction is suspected

(Refer to GROUP 00, How to cope with intermittent malfunctions 300). NO : Return to Step 1.

INSPECTION PROCEDURE 4: Condenser Fan does not Operate CIRCUIT OPERATION The fan controller is powered from fusible link (2). The engine-ECU judges the required revolution speed of radiator fan motor and condenser fan motor using the input signals transmitted from A/ C switch, automatic compressor controller, vehicle speed sensor and engine coolant temperature sensor. The engine-ECU activates the fan controller to drive the radiator fan motor and condenser fan motor. TECHNICAL DESCRIPTION The cause could be a malfunction of the condenser fan motor or fan controller. TROUBLESHOOTING HINTS Malfunction of condenser fan motor Malfunction of fan controller

DIAGNOSIS STEP 1. Check the condenser fan motor. Refer to GROUP 55, Condenser and Condenser Fan Motor 355A. Q: Is the condenser fan motor in good condition? YES : Go to Step 2. NO : Replace the condenser fan motor, then go

to Step 3. STEP 2. Check the fan controller. Refer to 314. Q: Is the fan controller in good condition? YES : Go to Step 3. NO : Replace the fan controller, then go to Step

3. STEP 3. Check the symptoms. Q: Does the condenser fan operate correctly? YES : The procedure is complete. NO : Return to Step 1.

ENGINE COOLING

14-15

ON-VEHICLE SERVICE

ON-VEHICLE SERVICE ENGINE COOLANT LEAK CHECK M1141001000281

WARNING When pressure testing the cooling system, slowly release cooling system pressure to avoid getting burned by hot coolant. CAUTION Be sure to completely clean away any moisture from the places checked. When the tester is taken out, be careful not to spill any coolant. Be careful when installing and removing the tester and when testing not to deform the filler neck of the radiator.

Cap adapter Adapter

2. Increase the pressure until the indicator of the gauge stops moving. Minimum limit: 83 kPa Standard value: 93 - 123 kPa 3. Replace the radiator cap if the reading does not remain at or above the limit.

ENGINE COOLANT REPLACEMENT M1141001200401

WARNING When removing the radiator cap, use care to avoid contact with hot coolant or steam. Place a shop towel over the cap and turn the cap counterclockwise a little to let the pressure escape through the vinyl tube. After relieving the steam pressure, remove the cap by slowly turning it counterclockwise. 1. Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap. Intake side

ACX01844 AC

1. Check that the coolant level is up to the filler neck. Install a radiator tester and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections. 2. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP VALVE OPENING PRESSURE CHECK


AC200630 AC

<4WD>

M1141001300356

NOTE: Be sure that the cap is clean before testing. Rust or other foreign material on the cap seal will cause an improper reading.

Cap adapter

30 ± 3 N·m

Water feed tube assembly AC301654 AB

AC211643 AB

1. Use a cap adapter to attach the cap to the tester.

2. Drain the water in the water jacket by unplugging the drain plug of the cylinder block. On 4WD, drain engine coolant from the water feed tube assembly of the transfer. 3. Remove the reserve tank and drain the coolant. 4. Drain the coolant then clean the path of the coolant by injecting water into the radiator from the radiator cap area.

ENGINE COOLING

14-16

ON-VEHICLE SERVICE


10.Start the engine and let it warm up until the thermostat opens. 11.After repeatedly revving the engine up to 3,000 r/ min several times, then stop the engine. 12.Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim. Reinstall the cap.

CAUTION AC200625 AC

5. Apply the designated sealant to the screw area of the cylinder block drain plug, and then tighten to the standard torque. Specified sealant: 3M Nut Locking Part No.4171 or equivalent Tightening torque: 44 5 N¼m 6. Securely tighten the drain plug of the radiator. 7. Assemble the reserve tank.

CAUTION Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause corrosion of the aluminium components.

MB991871

Air hose

Do not overfill the reserve tank. 13.Add coolant to the reserve tank between the "FULL" and "LOW" mark if necessary.

CONCENTRATION MEASUREMENT M1141001100330

Measure the temperature and specific gravity of the engine coolant to check the antifreeze concentration. Standard value: 30 - 60% (allowable concentration range) Recommended antifreeze: DIAQUEEN SUPER LONG LIFE COOLANT or equivalent

CAUTION If the concentration of the anti-freeze is below 30 %, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 60%, both the anti-freezing and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range.

FAN CONTROLLER CHECK M1141007400038

AC200579AC

8. By referring to the section on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60 %. Use special tool LLC changer (MB991871) to refill the coolant. A convenient mixture is a 50 % water and 50 % antifreeze solution (freezing point: -31C). Recommended antifreeze: DIAQUEEN SUPER LONG LIFE COOLANT or equivalent Quantity: 7.0 L NOTE: For how to use special tool MB991871, refer to its manufacturer’s instructions. 9. Reinstall the radiator cap.

AC103011

1. Remove the fan controller connector. 2. Turn the ignition switch to the "ON" position, and measure the voltage between the harness-side connector terminals. Standard value: System voltage

ENGINE COOLING

14-17

ON-VEHICLE SERVICE

FAN CONTROL RELAY CONTINUITY CHECK

Fan controller

M1141006200257

Fan control relay 1 2

AC103010 AD

3. Connect the fan controller connector, and disconnect the condenser fan motor connector. 4. Ensure that the A/C switch is off, and start the engine and run it at idle. 5. Measure the voltage between the fan controllerside connector terminals. Standard value: 1V or less

AC211776

WARNING Stay clear of the fan when the fan starts running. 6. Turn the A/C switch to the "ON" position. 7. Measure the voltage between the fan controllerside connector terminals while the fan is running. The voltage should repeat the values below. Standard value: 8.2 2.6 V System voltage 2.6 V 8. If the voltage does not repeatedly change as indicated, replace the fan controller.

4

2 1

3 4

3

2 1

AC301712 AB

Battery voltage

Terminal No.to Continuity test be connected to results tester

Not applied

4-2

Open circuit

Connect terminal No.1 and battery (-) terminal. Connect terminal No.3 and battery (+) terminal.

4-2

Less than 2 ohms

RADIATOR FAN MOTOR CHECK M1141007100059

2 1

Radiator fan motor AC103006AE

1. Remove the radiator fan motor connector.

ENGINE COOLING

14-18

THERMOSTAT

2. Check to see that the fan motor of the radiator turns when applying battery power between the connector terminals of the radiator fan motor. Also check to see that there is no abnormal sound coming from the radiator fan motor at this time.

3. If the radiator fan motor is defective, replace it.

THERMOSTAT REMOVAL AND INSTALLATION M1141002400378

Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling (Refer to 314). Air Cleaner Removal and Installation (Refer to GROUP 15, Air Cleaner 315). Battery Removal and Installation

5

1 13 ± 2 N·m

2

4 3

1. 2.

Removal steps Engine coolant temperature gauge unit connector Engine coolant temperature sensor connector

<>

>B<< >>A<<

3. 4. 5.

AC301429 AB

Removal steps&RQWLQXHG Radiator lower hose connection Water inlet fitting Thermostat

ENGINE COOLING

14-19

THERMOSTAT


2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

<> RADIATOR LOWER HOSE DISCONNECTION


THERMOSTAT CHECK

Mating marks

AC200641AC

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

INSTALLATION SERVICE POINTS >>A<< THERMOSTAT INSTALLATION

CAUTION Make absolutely sure that no oil adheres to the rubber ring of the thermostat. Also do not fold or scratch the rubber ring during installation.

ACX00400 AB

1. Immerse the thermostat in water, and heat the water while stirring. Check the thermostat valve opening temperature. Standard value: Valve opening temperature: 82 1.5C

Jiggle valve

Valve lift ACX00401AC

Rubber ring AC000279 AB

Install the thermostat so that the jiggle valve is facing straight up. Be careful not to fold or scratch the rubber ring. >>B<< RADIATOR LOWER HOSE CONNECTION Projection

Water inlet pipe, water outlet fitting or radiator

Mating marks AC200642 AC

1. Insert each hose as far as the projection of the water inlet fitting.

2. Check that the amount of valve lift is at the standard value when the water is at the fullopening temperature. NOTE: Measure the valve height when the thermostat is fully closed, and use this measurement to compare the valve height when the thermostat is fully open. Standard value: Full-opening temperature: 95C Amount of valve lift: 8.5 mm or more

ENGINE COOLING

14-20

WATER PUMP

WATER PUMP REMOVAL AND INSTALLATION M1141002700391

Pre-removal Operation Engine Coolant Draining (Refer to 314). Timing Belt Removal (Refer to GROUP 11A, Timing Belt 311A).

2

Post-installation Operation Timing Belt Installation (Refer to GROUP 11A, Timing Belt 311A). Engine Coolant Refilling (Refer to 314).

N4

1 Bolt specifications

22 ± 4 N·m

8 × 70

3N 23 ± 3 N·m

2

8 × 22

8 × 14 8 × 25

14 ± 1 N·m

8 × 22 Screw diameter × length mm AC301467AB

1. 2.

Removal steps Alternator brace Water pump

INSTALLATION SERVICE POINT >>A<< O-RING INSTALLATION Water pump

O-ring

Water inlet pipe AC103005 AD

Fit the O-ring to the groove in the water inlet pipe. Then lubricate the O-ring and the inside of the water pump with water, and then insert the pipe to the water pump.

>>A<<

3. 4.

Removal steps&RQWLQXHG Water pump gasket O-ring

ENGINE COOLING

14-21

WATER HOSE AND WATER PIPE

WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION M1141003300385

Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to 314 ). Air Cleaner Removal and Installation (Refer to GROUP 15, Air Cleaner 315). Thermostat Removal and Installation (Refer to 314).

N

9 8

N

9

13 ± 2 N·m

6

4

7 3 13 ± 2 N·m

2 23 ± 4 N·m

1

5

5 Ø3 mm

2

Ø3 mm

Sealant: Mitsubishi Genuine Part No. MD970839 or equivalent AC301428 AB

<>

>>C<< >>B<< >>B<<

1. 2. 3. 4. 5.

Removal steps Radiator upper hose connection Water outlet fitting Water hose Water hose Thermostat case assembly

6. 7.

>>A<<

8. 9.

Removal steps&RQWLQXHG Heater hose connection Transfer water return hose connection <4WD> Water inlet pipe assembly O-ring

ENGINE COOLING

14-22

WATER HOSE AND WATER PIPE

REMOVAL SERVICE POINT <> RADIATOR UPPER HOSE DISCONNECTION

Mating marks

>>B<< THERMOSTAT CASE ASSEMBLY/WATER OUTLET FITTING INSTALLATION 1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface. 2. Apply a bead of the specified sealant. Specified Sealant: MITSUBISHI GENUINE PART No.MD970389 or equivalent 3. With the sealant still wet (within 15 minutes after the sealant is applied), install the thermostat case or water outlet fitting. Do not apply the sealant in an area more than the required.

AC200641AC

After making mating marks on the radiator hose and hose clamp, disconnect the radiator hose.

>>C<< RADIATOR UPPER HOSE CONNECTION Projection

INSTALLATION SERVICE POINTS >>A<< O-RING INSTALLATION

CAUTION Water pump or thermostat case

Water inlet pipe, water outlet fitting or radiator O-ring

Water inlet pipe AC200644 AC

Do not allow engine oil or other grease to adhere to the O-ring Insert the O-ring to the water pipe, and coat the outer portion of the O-ring with water or engine coolant.


1. Insert each hose as far as the projection of the water outlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.


WATER PIPE AND HOSE CHECK Check the water pipe and hose for cracks, damage and clogs. Replace them if necessary.

ENGINE COOLING

14-23

RADIATOR

RADIATOR REMOVAL AND INSTALLATION M1141001500424

Post-installation Operation Air Cleaner Installation (Refer to GROUP 15, Air Cleaner 315). Engine Coolant Refilling and Level Check (Refer to 314 ).

Pre-removal Operation Engine Coolant Draining (Refer to 314). Air Cleaner Removal (Refer to GROUP 15, Air Cleaner 315).

12 ± 2 N·m 12 ± 2 N·m

7

7

2

8

3 10

5

4

1

9

9

6 12 14 13 11

<> <>

>>A<< >>A<<

1. 2. 3. 4. 5. 6. 7. 8. 9.

Radiator removal steps Drain plug Radiator cap Rubber hose Reserve tank assembly Radiator upper hose Radiator lower hose Upper insulator Radiator assembly Lower insulator

<>

>>A<<

AC301650 AB

Radiator removal steps 10. Fan controller 11. Cooling fan assembly Radiator fan motor removal steps 3. Rubber hose 5. Radiator upper hose 11. Cooling fan assembly 12. Radiator fan 13. Radiator fan motor 14. Shroud assembly

ENGINE COOLING

14-24

RADIATOR



<> RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION

>>A<< RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION Projection

Mating marks

AC200641AC

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

Water inlet pipe, water outlet fitting or radiator


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.

42-1

GROUP 42

00 11

BODY

12 13 14

CONTENTS HOOD. . . . . . . . . . . . . . . . . . . . .

42

15

TAILGATE WINDOW GLASS . . . . REMOVAL AND INSTALLATION. . . . . .

ON-VEHICLE SERVICE. . . . . . . . . ADJUSTMENT OF CLEARANCE AROUND HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT OF HOOD HEIGHT . . .

42 42

42 42

ROOF WINDOW GLASS . . . . . . . . REMOVAL AND INSTALLATION. . . . . .

DOOR . . . . . . . . . . . . . . . . . . . .

42 42

16 17

42 42

42

21 22 25


42


42 42

SEALANT . . . . . . . . . . . . . . . . . . . .

42

27

FENDER. . . . . . . . . . . . . . . . . . .

42

SPECIAL TOOLS . . . . . . . . . . . . . .

42

31

SPECIAL TOOL . . . . . . . . . . . . . . .

42


42

32

FENDER. . . . . . . . . . . . . . . . . . . . .



42 42

42 42

FUEL FILLER LID . . . . . . . . . . .

42

HOOD. . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION .

42

WINDOW GLASS . . . . . . . . . . .

42

ADHESIVE . . . . . . . . . . . . . . . . . . .

42

SPECIAL TOOL . . . . . . . . . . . . . . .

42

GENERAL . . . . . . . . . . . . . . . . . . .

42

WINDSHIELD. . . . . . . . . . . . . . . . .

42 42


QUARTER WINDOW GLASS . . . . REMOVAL AND INSTALLATION . . . . .

42 42

DOOR FIT ADJUSTMENT . . . . . . . . . . . DOOR WINDOW GLASS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT. . . . . . . . . . . . . . . . POWER WINDOW SAFETY MECHANISM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . POWER WINDOW OPERATING CURRENT CHECK . . . . . . . . . . . . . . . . POWER WINDOW RELAY CHECK. . . . CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION . . . . . . . . . . . . . . . . . . . . . POWER WINDOW CHECK . . . . . . . . . . CENTRAL DOOR LOCKING SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . DOOR OUTSIDE HANDLE PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR INSIDE HANDLE PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . .

42 42 42 42 42

26

33 34 35 36 37 42 51

42 42

52

42

54

42

55

42


42-2 DOOR ASSEMBLY . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . .

DOOR GLASS AND REGULATOR REMOVAL AND INSTALLATION . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . .

DOOR HANDLE AND LATCH . . . REMOVAL AND INSTALLATION . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . .

WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . .

42 42 42

TAILGATE HANDLE AND LATCH

42 42 42

KEYLESS ENTRY SYSTEM. . .

42

SPECIAL TOOLS. . . . . . . . . . . . . .

42


42


42 42

42 42 42

42 42

TAILGATE . . . . . . . . . . . . . . . .

42


42

SEALANTS . . . . . . . . . . . . . . . . . .

42

SPECIAL TOOL . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . .


KEYLESS ENTRY SYSTEM CHECK . . KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION . . . . . . HOW TO REPLACE THE TRANSMITTER BATTERY. . . . . . . . . . . . . . . . . . . . . . . . ENABLING/DISABLING THE ANSWERBACK FUNCTION . . . . . . . . . HOW TO REGISTER SECRET CODE .

42 42 42

42 42 42 42

SUNROOF ASSEMBLY . . . . . .

42


42


42

42 42

ON-VEHICLE SERVICE. . . . . . . . . ON-VEHICLE SERVICE . . . . . . . . TAILGATE FIT ADJUSTMENT . . . . . . . . TAILGATE HANDLE PLAY CHECK . . . . ADJUSTMENT OF TAILGATE HEIGHT .

TAILGATE . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . .

42 42 42 42 42 42

42 WATER TEST . . . . . . . . . . . . . . . . . . . . 42 SUNROOF FIT ADJUSTMENT . . . . . . . 42 SUNROOF CHECK . . . . . . . . . . . . . . . . 42 SUNROOF SAFETY FUNCTION CHECK 42 ROOF LID GLASS OPERATION CURRENT CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . 42 SUNROOF INITIALIZATION . . . . . . . . . 42

SUNROOF ASSEMBLY. . . . . . . . . REMOVAL AND INSTALLATION. . . . . .

42 42

BODY

42-3

HOOD

HOOD ON-VEHICLE SERVICE

ADJUSTMENT OF HOOD HEIGHT M1421007400101

ADJUSTMENT OF CLEARANCE AROUND HOOD

A

M1421007200107

A

Y0215AU

Section A – A Hood AC103720

ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER

16.5 mm

M1421007300104

Hood bumper

X0424CA

AC005948AF

Rotate the hood bumper by using the arrow mark on the hood bumper as a guide to adjust the hood height. If the hood bumper is rotated just one turn, the hood height changes by approximately 3 mm.

AC005947

BODY

42-4

HOOD

HOOD REMOVAL AND INSTALLATION M1421001600301

2 6

8

21 ± 4 N·m

11 ± 2 N·m

3

1 9 7 11 ± 2 N·m

6

6

3

5 1

4

1 2 9.0 ± 2.0 N·m

AC107422AB

Removal 1. Hood bumper Hood latch and hood lock release cable removal steps Radiator grille (Refer to GROUP 51, Radiator grille 351). 2. Hood latch Splash shield (Refer to 342). 3. Hood lock release handle 4. Hood lock release cable

Hood and hood hinge removal steps 5. Hood insulator 6. Hood weatherstrip Washer hose (Refer to GROUP 51, Windshield washer 351). 7. Hood 8. Hood support rod Front deck garnish (Refer to GROUP 51, Windshield wiper 351). 9. Hood hinge

BODY

42-5

HOOD

Clip positions

7

5 Section A – A

7 A

Clip

A

5 Note : Clip positions

AC200023 AB

BODY

42-6

FENDER

FENDER SPECIAL TOOL M1421000600212

Tool

Number

Name

Use

MB990784

Ornament remover

Side turn-signal lamp removal

MB990784

FENDER REMOVAL AND INSTALLATION M1421001900283

Pre-removal and Post-installation Operation Front Bumper Removal and Installation (Refer to GROUP 51, Front Bumper 351). Front Deck Garnish Removal and Installation (Refer to GROUP 51, Windshield Wiper 351).

4 3

1 2

Note : Clip positions AC301492 AB

Removal Steps Side sill garnish (Refer to GROUP 51, Garnish 351). 1. Splash shield 2. Front pillar pad

Removal Steps&RQWLQXHG

<> >>A<< 3. Side turn signal lamp Headlamp assembly (Refer to GROUP 54A, Headlamp 354A). 4. Fender

BODY

42-7

FENDER



<> SIDE TURN SIGNAL LAMP REMOVAL

>>A<< SIDE TURN SIGNAL LAMP INSTALLATION

: Front of vehicle

Hook

A A

Claw

Fender panel

Fender panel

Side turn signal lamp

: Front of vehicle Section A – A

MB990784

Fender panel

Claw AC101384 AC

Use an appropriate tool such as MB990874 to pry out the tab from the fender, and remove the side turn signal lamp.

AC005719 AB

Engage the hook with the fender panel, and install the side turn signal lamp.

BODY

42-8

FUEL FILLER LID

FUEL FILLER LID REMOVAL AND INSTALLATION M1421002500255

Pre-removal and Post-installation Operation Rear Seat Removal and Installation (Refer to GROUP 52A, Rear Seat 352A). Front Seat Assembly (Driver’s Seat Side) Removal and Installation (Refer to GROUP 52A, Front Seat 352A). Front Seat Belt Anchor Bolt (Driver’s Side) Removal and Installation (Refer to GROUP 52A, Front Seat Belt 352A ). Front Scuff Plate (Driver’s Side), Rear Scuff Plate (Driver’s Side), Centre Pillar Lower Trim (Driver’s Side) Removal and Installation (Refer to GROUP 52A, Trims 352A). Floor Console Removal and Installation (Refer to GROUP 52A, Floor Console 352A).

3

4

Fuel filler lid height and clearance adjustment

5 3

1

2

5.0 ± 1.0 N·m AC107424 AB

Removal steps 1. Fuel filler lid panel assembly 2. Clip 3. Fuel filler lid hook assembly 4. Fuel filler lid lock release handle

Removal steps&RQWLQXHG Quarter lower trim (Refer to GROUP 52A, Trims 352A). Protector C (Refer to GROUP 36, Parking brake 336). 5. Fuel filler lid lock release cable

BODY

42-9

WINDOW GLASS

WINDOW GLASS ADHESIVE M1422000500069

Item

Specified adhesive

Windshield

3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or equivalent 3M ATD Part No.8608 Super Fast Urethane Primer or equivalent

Quarter window glass Tailgate window glass Roof window glass


Tool

Number

Name

Use

MB990480

Window glass holder Window glass removal and installation

MB990480

GENERAL M1422000100340

The windshield, quarter window glass, tailgate window glass and roof window glass are attached by an urethane-base adhesive to the window frame. This adhesive provides improved glass holding and sealing, and also gives body openings a greater structural strength. ITEMS Name

Remark

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

Dam

Available as service part

Anti-rust solvent (or Tectyl 506T.Valvoline Oil Company)

For rust prevention

Isopropyl alcohol

For grease removal from bonded surface

Steel piano wire

Dia. length... 0.6mm 1m For cutting adhesive

Glass adhesive knife

For cutting adhesive

Adhesive gun

For pressing-out adhesive

HANDLING OF AUTO WINDOW SEALER Keep the sealant in a cool place, not exposed to the direct rays of the sun. Do not place any heavy article on the sealant nor press it, otherwise it will become deformed. Avoid storing the sealant for more than 6 months, because it will lose its sealing effect.

BODY PINCH-WELD FLANGE SERVICING Before servicing the body pinch-weld flange, remove old adhesive completely. If the flange requires painting, bake it after painting is completed.

BODY

42-10

WINDOW GLASS

WINDOW GLASS INSTALLATION Window glass installation procedure

Body side

Window glass side

Reusing the glass

Replace the glass

Cleaning of adhesion surface Cut off the residual adhesive until the thickness is less than 2 mm. clean the adhesion surface with isopropyl alcohol, and let dry for 3 minutes or more.

Cleaning of adhesion surface Completely cut off all of the residual adhesive. clean the adhesive surface with isopropyl alcohol, and let dry for 3 minutes or more.

Cleaning of adhesion surface Clean off any dirt adhering to the adhesion surface with isopropyl alcohol, and let dry for 3 minutes or more.

Attaching of dual lock fastener Attach the dual lock fastener to set the positions for the glass to be installed.

Gluing of window dam, window spacer, dual lock fastener and glass stopper Glue the window dam, window spacer, dual lock fastener and glass stopper to the glass, following the standard position all the way around the inside edge of the glass.

Application of primer Apply the primer to the adhesion surface of the body, and let dry for 3 minutes or more.

Application of primer Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After application, let dry for 3 to 30 minutes.

Application of adhesive Within 30 minutes after applying the primer , apply the adhesive evenly all the way around the inside edge of the glass.

Installing the glass After applying the adhedive, lighty press the glass evenly so that it adheres completely.

Cleaning After removing excess adhesive from the body or glass with a spatula, etc. clean off with isopropyl alcohol.

Checking for water leaks Carry out a shower test to check that no water will leaks through. AC300393

BODY

42-11

WINDOW GLASS

WINDSHIELD REMOVAL AND INSTALLATION M1422001000294

Pre-removal and Post-installation Operation Front Deck Garnish Removal and Installation (Refer to GROUP 51, Windshield Wiper 351). Roof Drip Moulding Removal and Installation (Refer to GROUP 51, Moulding 351). Front Pillar Trim Removal and Installation (Refer to GROUP 52A, Trims 352A).

4N 3N

2

4N

N5

1

AC301503

N5

Apply the primer and adhesive along the fictitious lines (seal line) between each of the marks. Section A – A A 15 A

Ceramic line

B

Seal line center

Units: mm Seal line center

Section B – B

2

Primer

B

2

Primer

2

Section C – C

15

15 Mark Seal line center

Seal line C

Primer

C Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent AC301615 AB

Removal steps 1. Harness connector (Refer to GROUP 51, Wiper deicer 351). <> >>B<< 2. Windshield


>>A<< 3. Windshield moulding >>A<< 4. Glass stopper >>A<< 5. Windshield spacer

BODY

42-12

WINDOW GLASS

REMOVAL SERVICE POINT <> WINDSHIELD REMOVAL 1. To protect the body (paint surface), apply cloth tape to all body areas around the installed windshield. 2. Make mating marks on the windshield and body.

Keep glass adhesive knife at right angles with the windshield edge, and put the blade at windshield edge and surface. Then cut away adhesive along the windshield edge. MB990480

ACX00475AB

ACX00474 AB

3. Using piano wire. (1) Using a sharp-point drill, make a hole in the windshield adhesive. (2) Pass the piano wire from the inside of the vehicle through the hole.

5. Use special tool (MB990480) to remove the windshield.

CAUTION

CAUTION Do not let the piano wire touch the edge of the windshield. (3) Pull the piano wire alternately from the inside and outside along the windshield to cut the adhesive. ACX00476 AB

CAUTION

AC002060

Glass adhesive knife

Be careful not to remove more adhesive than is necessary. 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. 6. Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm around the entire circumference of the body flange. 7. Finish the flange surfaces so that they are smooth.

CAUTION Allow the cleaned area to dry for at least three minutes. Do not touch any surface that has been cleaned. 8. When reusing the windshield, remove the adhesive still adhering to the windshield, and clean with isopropyl alcohol. 9. Clean the body side in the same way. AC207478 AD

Inserting the glass adhesive knife too deeply into windshield adhesive may damage windshield. 4. Using glass adhesive knife

BODY

42-13

WINDOW GLASS

INSTALLATION SERVICE POINTS >>A<< WINDSHIELD SPACER/GLASS STOPPER/ WINDSHIELD MOULDING INSTALLATION

CAUTION Leave the degreased parts for 3 or more minutes to dry well, before starting on the next step. Do not touch the degreased parts. 1. Use isopropyl alcohol to degrease the inside and outside of the windshield and the body flanges. Glass stopper and windshield spacer installation position Windshield end line Seal line 18.1 mm

Glass stopper

Windshield

Align the glass stopper end with the windshield mark.

Ceramic line

Windshield center line

Seal line Windshield spacer Ceramic line

Ceramic line 65 mm 43.9 mm

43.9 mm

Seal line

Windshield center line Seal line

Windshield spacer

Align the windshield spacer end with the ceramic notch. AC300403AB

2. The inner side of the windshield is curved, therefore, make a point to assemble the glass stopper and windshield spacer without any lifting and assemble in the position shown. 3. Install the windshield moulding.

>>B<< WINDSHIELD INSTALLATION 1. When replacing the windshield, temporarily set the windshield against the body, and place a mating mark on the windshield and body.

BODY

42-14

WINDOW GLASS

CAUTION The primer strengthens the adhesive, so be sure to apply it evenly around the entire circumference. However, a too thick application will weaken the adhesive. Do not touch the coated surface. 2. Soak a sponge in the primer, and apply evenly to the windshield and the body in the specified places. 3. Allow the windshield to dry for at least three minutes after applying primer.

4. 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. 5. Align the mating marks on the windshield and the body, and lightly press the windshield evenly so that it adheres completely. 6. Use a spatula or similar tool to remove any excessive adhesive. Clean the surface with isopropyl alcohol. Avoid moving the vehicle until the adhesive sets. 7. Bond the windshield to the body, and install the roof drip moulding quickly before the adhesive cures. (Refer to GROUP51, Moulding 351).

CAUTION 10 mm 15 mm ACX00480 AB

Do not move the vehicle unless absolutely necessary. When testing for water leakage, do not pinch the end of the hose to spray the water. 8. Wait 30 minutes or more, and then test for water leakage.

BODY

42-15

WINDOW GLASS

QUARTER WINDOW GLASS REMOVAL AND INSTALLATION M1422002500225

Pre-removal and Post-installation Operation Quarter Trim Upper Removal and Installation (Refer to GROUP 52A, Trims 352A).

2N 1 N3

N4

3N Units: mm

Apply the primer and adhesive along the fictitious lines (seal line) between each of the marks. Ceramic line

Align the tape end with the quarter window glass mark.

C

A A

Seal line

C Ceramic line Mark Seal line B B

Section A – A

1

Seal line center

Primer

Section B – B Seal line center

Section C – C

1 15

Seal line center

1 15 15 Primer Primer

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent Adhesive tape: Double-sided tape [ 15 mm width, 15 mm length and 0.8 mm thickness ] AC107211AB

Removal steps

<> >>B<< 1. Quarter window glass assembly >>A<< 2. Dual lock fastener

Removal steps&RQWLQXHG >>A<< 3. Clip >>A<< 4. Gasket

BODY

42-16

WINDOW GLASS


MB990480

<> QUARTER WINDOW GLASS REMOVAL

AC103605 AC

Cloth tape

AC103600AC

1. Apply cloth tape to protect the quarter window glass.

4. Make mating marks on the quarter window glass and body. 5. Use special tool (MB990480) to remove the quarter window glass.

CAUTION

AC002060

2. Use glass adhesive knife to cut away adhesive.

CAUTION Glass adhesive knife

AC301614 AB

Inserting the adhesive knife too deeply into windshield adhesive may damage quarter window glass. 3. Keep the glass adhesive knife at right angles with body flange (from inside the vehicle), and put the blade at body flange. Then cut away adhesive along the body flange.

ACX00476 AB

Be careful not to remove more adhesive than is necessary. 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. 6. Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm around the entire circumference of the body flange. 7. Finish the flange surfaces so that they are smooth.

CAUTION Allow the cleaned area to dry for at least three minutes. Do not touch any surface that has been cleaned. 8. When reusing the quarter window glass, remove the adhesive still adhering to the quarter window glass, and clean with isopropyl alcohol. 9. Clean the body side in the same way.

BODY

42-17

WINDOW GLASS

INSTALLATION SERVICE POINTS >>A<< GASKET/CLIP/DUAL LOCK FASTENER INSTALLATION 1. Carry out the following procedure to re-install quarter window glass.

CAUTION Do not forget gasket. (1) Fit clips into body.

CAUTION Leave the degreased parts for 3 or more minutes to dry well, before starting on the next step. Do not touch the degreased parts. 2. Use isopropyl alcohol to degrease the inside and outside of the quarter window glass and the body flanges.

Dual lock fastener Cut off these convex parts Body flange end line

AC107213AB AC103606 AC

(2) Cut away clip fitting convex on quarter window glass. NOTE: Convex gets broken when quarter window glass is removed.

3. Assemble the dual lock fastener according to the standard location of the body flange. 4. Assemble the dual lock fastener to the quarter window glass relative to the body flange dual lock fastener. >>B<< QUARTER WINDOW GLASS INSTALLATION Remove the quarter window glass using the same procedure as for the windshield removal (Refer to 342).

BODY

42-18

WINDOW GLASS

TAILGATE WINDOW GLASS REMOVAL AND INSTALLATION M1422003700158

Pre-removal and Post-installation Operation Tailgate Trim Removal and Installation (Refer to GROUP 52A, Tailgate Trim 352A). Rear Wiper Arm Assembly Removal and Installation (Refer to GROUP 51, Rear Wiper and Washer 351).

N3

1

N4

2N

Section B – B

Section A – A

Apply the primer and adhesive along the fictitious lines (seal line) between each of the marks. A

Seal line center

1

15

Units: mm

Seal line center

Primer

A

15

1 Ceramic line

C

C Primer Section C – C

MARK Mark

Seal line

1

Primer

B B

Seal line center

15 Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent AC107209AB

Removal steps Harness connector <> >>B<< 1. Tailgate window glass >>A<< 2. Dual lock fastener


>>A<< 3. Glass stopper >>A<< 4. Window dam

BODY

42-19

WINDOW GLASS

REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS

<> TAILGATE WINDOW GLASS REMOVAL Remove the tailgate window glass using the same procedure as for the windshield. (Refer to 342).

>>A<< WINDOW DAM/GLASS STOPPER/DUAL LOCK FASTENER INSTALLATION

CAUTION Leave the degreased parts for 3 or more minutes to dry well, before starting on the next step. Do not touch the degreased parts. 1. Use isopropyl alcohol to degrease the inside and outside edges of the tailgate window glass and the surface of the tailgate flange. Glass stopper, window dam and dual lock fastener installation position Glass end line Install the window dam along the glass end line.

Glass end line Seal line 25.5 ± 0.5 mm

Align the window dam end with the ceramic notch.

Seal line

Ceramic line

Glass stopper Seal line

Align the glass stopper and with the tailgate window glass mark.

Window dam

Tailgate window glass Dual lock fastener

Align the dual lock fastener and with the tailgate window glass mark.

2. Assemble the window dam, glass stopper and dual lock fastener to the tailgate window glass location shown.

Ceramic line AC107210 AB

BODY

42-20

WINDOW GLASS

Flange convex at the tailgate flange

Dual lock fastener AC107208AB

3. Assemble the dual lock fastener in alignment with the protrusion of the tailgate flange.

>>B<< TAILGATE WINDOW GLASS INSTALLATION Install the tailgate window glass in the same way as for the windshield installation (Refer to 342).

BODY

42-21

WINDOW GLASS

ROOF WINDOW GLASS REMOVAL AND INSTALLATION M1422004300045

1

AC301504

Seal line A A A

Section A – A

A

A

A

A

A

Seal line center

1

6 mm

Primer 15 mm

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent Adhesive tape: Double-sided tape [ 6 mm width, 0.5 mm thickness ] AC301821 AB

<>

>>A<<

1.

Removal steps Frame assembly (Refer to GROUP 52A - Headlining 352A). Roof window glass assembly

REMOVAL SERVICE POINT <> ROOF WINDOW GLASS ASSEMBLY REMOVAL Remove by the same procedure as for the quarter window glass (Refer to 342).

BODY

42-22

DOOR

INSTALLATION SERVICE POINT >>A<< ROOF WINDOW GLASS ASSEMBLY INSTALLATION Install by the same procedure as for the windshield (Refer to 342).

DOOR SERVICE SPECIFICATIONS M1423000300079

Item

Standard value

Power window operation current (Power supply voltage 14.5 0.5 V, at 25 C) A

51

Door outside handle play mm

Front door

2.6 2.5

Rear door

1.3 1.3

Front door

10.4 9.6

Rear door

10 9.6

Door inside handle play mm

SEALANT M1423000500073

Item

Specified sealant

Door waterproof film



Tool

Number

Name

Use

MB990480

Window glass holder

Removal of power window regulator and motor assembly

MB990900 or MB991164

Door hinge adjusting wrench

Door alignment

MB990480

MB990900

BODY

42-23

DOOR

Tool A

Number

Name

Use

MB990925 A: MB990939

Bearing and oil seal installer set A: Brass bar

Door striker adjustment

MB990211

Sliding hammer

MB990241 A: MB990243

Axle shaft puller A: Body puller

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222


MB990925AF

MB990211

A MB990241AE

A

B

Terminal voltage measurement A: For checking connector pin contact pressure B: For checking power supply circuit C: For checking power supply circuit D: For connecting a locally sourced tester

C

D MB991223 AD


The door system is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to GROUP 54B, Diagnosis 354B or GROUP 54C, Diagnosis 354C.

ON-VEHICLE SERVICE DOOR FIT ADJUSTMENT M1423001100164

CAUTION Attach protection tape to the fender and door edges where the hinge is installed. Do not rotate special tool (MB991164) with a torque of over 98 N¼m.

MB990900 or MB991164

AC000592 AB

BODY

42-24

DOOR

1. Use special tool (MB990900 or MB991164) to loosen the hinge mounting bolts on the body side, and then adjust the clearance around the door so that it is uniform on all sides. 2. If a door is not flush with its surrounding panels, loosen the door-side door hinge mounting bolts and obtain the flushness by moving the door. NOTE: Weld point

MB990939 Temporary bolt

Washer

Striker AC006109AB

Bolt

Door hinge

Weld point

Washer

(1) Adjustment by using the striker (toward the inside of the vehicle and vertical direction) Install an appropriate bolt instead of the striker mounting bolt, and use special tool (MB990939) and a hammer to tap the bolt to the desired direction.

AC206498 AE

If the door hinge mounting bolt washers are welded, grind off the welding according to the procedure below beforehand. . 1. Remove the door hinge (Refer to 342). 2. Use a chisel or grinder to release the door hinge mounting bolt washer, which is welded to the door hinge. 3. On completion, paint the affected area with a suitable touch-in brush to prevent corrosion. 4. Install the door hinge (Refer to 342). 3. When the door is stiff to lock and unlock:

MB990211 MB990243

Striker AC006110 AB

(2) Adjustment by using the striker (toward the outside of the vehicle) Use special tools (MB990211 and MB990243) to pull the striker toward the outside of the vehicle. Shim Striker

AC006111AB

(3) Adjustment by using shims (forward and rearward) Increase or decrease the number of shims so that the striker engages with the door latch properly.

BODY

42-25

DOOR

DOOR WINDOW GLASS ADJUSTMENT M1423001000305

Check that the door glass moves while contacting the door glass channel when it is raised and lowered fully. If not, adjust the door window according to the following procedures. 1. Remove the door trim assembly (Refer to GROUP 52A, Door trim 352A). 2. Remove the waterproof film. (Refer to 342).

1. Remove the door trim assembly. (Refer to GROUP 52A, Door trim 352A). 2. Remove the waterproof film. (Refer to 342). 3. Remove the window regulator assembly from the door window glass, and then raise and lower the door window glass by hand to check the operation force. NOTE: Insert a cushion or similar object to prevent damage to the glass if it should happen to fall down. Runchannel

Adjusting hole

Y0238AU

Door sash

Adjusting hole

Y0239AU

Lower sash

AC006112 AB

3. Loosen the door glass mounting screw via the adjusting hole with the door window glass fully closed, then lower the window glass a little. 4. Fully close the door window glass again and tighten the door glass mounting screw firmly via the adjusting hole.

GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT M1429000900080

If the window glass automatically starts moving downwards at the wrong time while it is being raised, carry out the following adjustment or replacement procedures.

AC003777AB

4. If the door window glass does not move up and down smoothly, check or repair the following points. Check the installation condition of the runchannel. Repair any twisting in the door sash. Check the installation condition of the lower sash or the centre sash. 5. If repair or adjustment is not possible, replace the door assembly.

BODY

42-26

DOOR

POWER WINDOW SAFETY MECHANISM CHECK

POWER WINDOW RELAY CHECK M1429001800183

M1429001000251

Power window relay

Junction block

AC103294

1. Place a wooden board about 10 mm thick as shown. Then, raise the window glass. 2. Check that the window lowers by about 150 mm when the window clamps the board. If this doesn’t happen, carry out troubleshooting. Refer to GROUP 54B, Diagnosis 354B, refer to GROUP 54C, Diagnosis 354C. NOTE: If the anti-trap function (safety mechanism) is activated consecutively three times or more, make the power window switch learn the fully closed position of the power window (Refer to 342).

POWER WINDOW OPERATING CURRENT CHECK M1429001100162

AC208065AC

1. Remove the power window fuse and connect an ammeter as shown in the illustration. 2. When the power window switch is pressed to the “UP” position, a large amount of current flows at the time the window starts to close and when it is fully closed, so measure the operation current in the interval between these two points. Standard value: 5 1A (Power supply voltage 14.5 0.5V, 25C) 3. If the operation current is outside the standard value, refer to GROUP 54B, Diagnosis 354B, refer to GROUP 54C, Diagnosis 354C.

1 2 3

5 1

AC207981

4

4

3

5 AC106844 AC300331 AB

BATTERY VOLTAGE

TESTER CONNECTION

SPECIFIED CONDITION

Not applied

4-5

Open circuit

Connect terminal No.1 and the positive battery terminal. Connect terminal No.3 and the negative battery terminal.

Less than 2 ohms

CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION M1429001700108

1. Pull the power window switch to the UP position to fully close the door window glass, and keep pulling the switch for 10 additional seconds. 2. Release the power window switch from the UP position and immediately press it to the DOWN position. The condition of the circuit breaker is good if the door window glass starts to move downwards within 60 seconds.

BODY

42-27

DOOR

POWER WINDOW CHECK M1429004400173

Check the system as described below. If the system does not work, carry out troubleshooting. Refer to GROUP 54B, Diagnosis 354B or GROUP 54C, Diagnosis 354C. Operate the power window switch of each seat to check that the power window works. Turn on the power window lock switch of the power window main switch, and operate the front passenger’s and rear power window sub switches to check that the power windows do not work. Turn on the power window lock switch of the power window main switch, and operate the power window main switch to check that each power window operates.

2. If the door outside handle play is not within the standard value range, check the door outside handle or the door latch assembly. Replace if necessary.

DOOR INSIDE HANDLE PLAY ADJUSTMENT M1423001500270

Section A – A A

A B

CENTRAL DOOR LOCKING SYSTEM INSPECTION M1427001100111

Check that the central door locking system works by operating the key cylinder and the inside lock knob (driver’s door).Carry out troubleshooting if the system does not activate. Refer to GROUP 54B, Diagnosis 354B, refer to GROUP 54C, Diagnosis 354C.

DOOR OUTSIDE HANDLE PLAY CHECK M1423001600255

Y0705AU

AC006114 AB

1. Check that the door inside handle play is within the standard value range. Standard value (B): Front door: 10.4 9.6 mm Rear door: 10 9.6 mm 2. If the door inside handle play is outside the standard value range. 3. Remove the door trim assembly (Refer to GROUP 52A, Door trim 352A). 4. Remove the waterproof film (Refer to 342). Inner cable

A

Outer cable end

AC006113AB

1. Check that the door outside handle play is within the standard value range. Standard value (A): Front door: 2.6 2.5 mm Rear door: 1.3 1.3 mm

Clip

Door inside handle Inside handle rod

AC100404 AB

5. Adjust the door inside handle play with the outer cable end connecting the door inside handle and inside lock cable.

BODY

42-28

DOOR

DOOR ASSEMBLY REMOVAL AND INSTALLATION M1423002200261

Post-installation Operation Door Fit Adjustment (Refer to 342).

4

7

27 ± 5 N·m

8

11 ± 2 N·m

5 21 ± 4 N·m

1

3

2 9.0 ± 2.0 N·m

27 ± 5 N·m 21 ± 4 N·m

1

9 1.5 ± 0.5 N·m

4

11 ± 2 N·m

6 27 ± 5 N·m

5

5, 6

7

21 ± 4 N·m

8

1 1.5 ± 0.5 N·m

2 27 ± 5 N·m 21 ± 4 N·m

6

9.0 ± 2.0 N·m

3

1

9 AC103073 AC

Removal 1. Damper Door assembly removal steps Scuff Plate and Cowl Side Trim (Refer to GROUP 52A, Trims 352A). 2. Harness connector 3. Door check connecting bolt 4. Door assembly

Door assembly removal steps 5. Door upper hinge 6. Door lower hinge Striker removal steps >>A<< 7. Striker 8. Striker shim Door switch removal 9. Door switch

BODY

42-29

DOOR



>>A<< STRIKER INSTALLATION

DOOR SWITCH CHECK

Latch center Striker center +1.5 mm

2

3

1 -1.5 mm Striker

Latch

AC006126AB

Align the centre of the striker and latch within 1.5 mm, and install.

AC211414 AC

SWITCH POSITION

TESTER CONNECTION

SPECIFIED CONDITION

Released (ON)

1 - switch body, Less than 2 2 - switch body, ohms 3 - switch body

Depressed (OFF)

1 - switch body, Open circuit 2 - switch body, 3 - switch body

BODY

42-30

DOOR

DOOR GLASS AND REGULATOR REMOVAL AND INSTALLATION M1429001300285

Pre-removal Operation Door Trim Assembly Removal (Refer to GROUP 52A, Door Trim 352A). Waterproof Film Removal (Refer to 342).

Post-installation Operation Door Window Glass Adjustment (Refer to 342). Waterproof Film Installation (Refer to 342). Door Trim Assembly Installation (Refer to GROUP 52A, Door Trim 352A).

1 AC101370

4 4

2 2

3

3 AC300452 AB

Power window switch removal steps Post-installation operation check 1. Power window switch (Refer to GROUP 52A, Door trim 352A).

>>B<<

Door window regulator assembly removal steps >>B<< Post-installation operation check <> >>A<< 2. Window regulator assembly <> 3. Power window motor assembly

BODY

42-31

DOOR Door window glass removal steps Window glass runchannel (Refer to 342). Lower sash (Refer to 342). Door latch assembly (Refer to 342). Door beltline moulding (Refer to 342 ). Door beltline inner weatherstrip (Refer to 342). 4. Door window glass



<> WINDOW REGULATOR ASSEMBLY/ POWER WINDOW MOTOR ASSEMBLY REMOVAL 1. Remove the door window glass installation bolts.

>>A<< WINDOW REGULATOR ASSEMBLY INSTALLATION

CAUTION If tinting film is adhered to the door window glass, attach special tool MB990480 to the outside of the glass to prevent the film from peeling off.

7 3

4

2 1 6

MB990480

5

1 4

6 AC100009AB

2. Lift the door window glass, and attach special tool MB990480 to the glass as shown to prevent the glass from falling. 3. Remove the window regulator assembly and power window motor assembly.

3 2 5 AC102851AC

When installing the window regulator assembly, tighten the bolts to the specified torque in the order shown. >>B<< Post-installation operation check When the following procedures are carried out, make the power window switch learn the fully closed position of the power window. (Refer to 342). Power window regulator removal or replacement Power window switch removal or replacement

BODY

42-32

DOOR


How to make the power window switch learn the fully closed position of the power window How to make the power window switch learn the fully closed position when the power window switch is removed, or the power window regulator assembly is removed or replaced 1. If the anti-trap function (safety mechanism) is activated consecutively three times or more, the fully closed position that the power window switch has learned will be erased (initialized). 2. Operate the power window switch and fully open the door window glass.

CAUTION The anti-trap function does not work until the power window switch completes learning the fully closed position (It is because the anti-trap function is reset). 3. Operate the power window switch and fully close the door window glass. The power window activates for 0.7 seconds and stops automatically when the power window switch is pressed once. Repeat this operation until the door window glass fully closes and release the switch once. Then, hold the power window switch to the fully closed side again for one second so that the power window switch completes learning the fully closed position.

NOTE: If the power window switch is operated to open the door window glass while the switch is learning, learning will be cancelled. If this happens, return to step 2. How to make the power window switch learn the fully closed position when the power window switch is replaced with a new one

CAUTION The anti-trap function does not work until the power window switch completes learning the fully closed position (It is because the anti-trap function is reset). Operate the power window main switch to fully close the door window glass by one-shot up action so that the power window switch will complete learning (Initialization is not needed). NOTE: When the power window sub switch of each seat is replaced, operate the power window main switch to fully close the applicable power window by one-shot up action (It is because the power window sub switch does not have one-shot up/down function).

BODY

42-33

DOOR

DOOR HANDLE AND LATCH REMOVAL AND INSTALLATION M1423004600306

Pre-removal Operation Door Trim Assembly Removal (Refer to GROUP 52A Door Trim 352A).

Post-installation Operation Door Inside Handle Play Check (Refer to 342). Door Outside Handle Play Check (Refer to 342). Door Trim Assembly Installation (Refer to GROUP 52A, Door Trim 352A).

3 4

3

5.0 ± 1.0 N·m

5.0 ± 1.0 N·m 9.0 ± 2.0 N·m

7

6

9.0 ± 2.0 N·m

8 5

8 1 2 5.0 ± 1.0 N·m

1

5 5.0 ± 1.0 N·m

9

9

2 AC101531AD

Door handle and door latch assembly removal steps >>C<< 1. Door inside handle Waterproof film (Refer to 342). >>B<< 2. Lower sash 3. Door outside handle 4. Door lock key cylinder 5. Door latch assembly

Door handle and door latch assembly removal steps&RQWLQXHG 6. Inside lock cable 7. Inside lock rod 8. Inside handle rod Door check removal steps Waterproof film (Refer to 342). >>A<< 9. Door check

BODY

42-34

DOOR

INSTALLATION SERVICE POINTS >>A<< DOOR CHECK INSTALLATION


FRONT DOOR LOCK ACTUATOR CHECK Front door

Lock

Identification mark

Unlock

View A 1 2 3 4 5 6

Lever ACX00541AB

Install the door check so that the identification mark faces upwards. ITEM

Unlock

IDENTIFICATION MARK

Front Door Rear Door

39L

Right door

39R

Left door

40L

Right door

40R

Lever

>>B<< LOWER SASH INSTALLATION Securely insert the rear lower sash into the window rear sash. >>C<< DOOR INSIDE HANDLE INSTALLATION Clip

B

Door inside handle AC100404 AB

1. Install the inside lock cable to the door inside handle as follows: (1) Install the inner cable end in the inside lock cable to the clip in the door inside handle. (2) Turn the inside lock knob to the door lock position. (3) Install the outer cable end to the door inside handle securely. (4) Install the clip to the inner cable. 2. Install the inside handle rod to the door inside handle. 3. Install the door inside handle to the door.

AC005657AD

Actuator Operation Check LEVER BATTERY LEVER POSITION CONNECTION OPERATION At the "LOCK" position

Connect terminal No.6 and the negative battery terminal. Connect terminal No.4 and the positive battery terminal.

The lever moves from the "LOCK" position to the "UNLOCK" position.

At the "UNLOCK" position


The lever moves from the "UNLOCK" position to the "LOCK" position.

Outer cable end

Inside handle rod

Lock

View B 1 2 3 4 5 6

Left door

Inner cable

A

Actuator Switch Check LEVER TESTER SPECIFIED POSITION CONNECTION CONDITION At the "LOCK" position

1-3

Less than 2 ohms


1-2

Less than 2 ohms

BODY

42-35

DOOR







REAR DOOR LOCK ACTUATOR CHECK Rear door

View A

Lock

1 2 3 4 5 6

Unlock Lever

A

Lock View B 1 2 3 4 5 6

Unlock B

Lever AC005658 AD







BODY

42-36

DOOR







DOOR LOCK KEY CYLINDER SWITCH CHECK

1

2

3 AC101318

SWITCH POSITION

TESTER CONNECTION

SPECIFIED CONDITION

LOCK

1-2

Less than 2 ohms

NEUTRAL (OFF)

1 - 2, 2 - 3

Open circuit

UNLOCK

2-3

Less than 2 ohms

BODY

42-37

DOOR

WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP REMOVAL AND INSTALLATION M1423003100278

5

4

: Sectional view of clip position

6 7

A

3

A

Section A – A

2

7 1

Door

2

Note : The convex position of the door

Sealant: 3M ATD Part No. 8633 or equivalent AC103084 AC

Waterproof film removal steps Door trim assembly (Refer to GROUP 52A, Door Trim 352A). 1. Pull handle bracket 2. Waterproof film Door inner opening weatherstrip removal steps Cowl side trim (Refer to GROUP 52A, Trims 352A). 3. Door inner opening weatherstrip (body side) Door outer opening weatherstrip removal steps Front door check mounting bolt (body side) (Refer to 342). <> >>C<< 4. Door outer opening weatherstrip

Door beltline inner weatherstrip removal steps Door trim assembly (Refer to GROUP 52A, Door Trim 352A). 5. Door beltline inner weatherstrip Door window glass runchannel removal steps Door trim assembly (Refer to GROUP 52A, Door Trim 352A). 1. Pull handle bracket 2. Waterproof film 5. Door beltline inner weatherstrip >>B<< 6. Door window glass runchannel Door beltline moulding removal steps Door mirror assembly (Refer to GROUP 51, Door Mirror 351). 7. Door beltline moulding

BODY

42-38

DOOR

DOUBLE-SIDED TAPE POSITION B

b

B

a A

A

Clip hole Clip hole

Door outer opening weatherstrip

Section A – A

Section B – B Door outer opening weatherstrip Door outer opening weatherstrip

Adhesive tape: Double-sided tape a [ 7 mm width, 100 mm length and 0.8 mm thickness ], b [ 7 mm width, 130 mm length and 0.8 mm thickness ] AC103492 AC

BODY

42-39

DOOR

5 7

: Sectional view of clip position

8N 4

A

6

A

3

2

Section A – A

7

Door

1

Note : The convex position of the door

2

Sealant: 3M ATD Part No. 8633 or equivalent AC103491AC

Waterproof film removal steps Door trim assembly (Refer to GROUP 52A, Door Trim 352A). 1. Pull handle bracket 2. Waterproof film Door inner opening weatherstrip removal steps Rear seat (Refer to GROUP 52A, Trims 352A). Scuff plate (Refer to GROUP 52A, Trims 352A). 3. Door inner opening weatherstrip (body side) Door outer opening weatherstrip removal steps Rear door check mounting bolt (body side) (Refer to 342). <> >>C<< 4. Door outer opening weatherstrip

Door beltline inner weatherstrip removal steps Door trim assembly (Refer to GROUP 52A, Door Trim 352A). 5. Door beltline inner weatherstrip Door window glass runchannel removal steps Door trim assembly (Refer to GROUP 52A, Door Trim 352A). 1. Pull handle bracket 2. Waterproof film 5. Door beltline inner weatherstrip 6. Door window glass runchannel Door beltline moulding removal 7. Door beltline moulding Door tape removal steps Door trim assembly (Refer to GROUP 52A, Door Trim 352A). >>A<< 8. Door tape

BODY

42-40

DOOR

DOUBLE-SIDED TAPE POSITION 20 mm B

Clip hole a

c

7 mm

b B Clip hole A

A

d Clip hole

Door outer opening weatherstrip

C C

Clip hole Section A – A Door outer opening weatherstrip

Section B – B Door outer opening weatherstrip

Section C – C Door outer opening weatherstrip

Adhesive tape: Double-sided tape a, d [ 7 mm width and 0.8 mm thickness ], b [ 7 mm width, 110 mm length and 0.8 mm thickness ], c [ 7 mm width, 62 mm length and 0.8 mm thickness ] AC103128 AC

BODY

42-41

DOOR

REMOVAL SERVICE POINT <> DOOR OUTER OPENING WEATHERSTRIP REMOVAL

>>B<< DOOR WINDOW GLASS RUNCHANNEL INSTALLATION Section A – A

Door panel

Fabricated tool

15 mm 4 mm

Runchannel 8 mm Thickness: 1 mm

Door mirror claw position ACX00555AB

Notch

Door mirror

Make a fabricated tool as shown in the illustration to remove the door weatherstrip.

Door mirror claw position

A

INSTALLATION SERVICE POINTS >>A<< DOOR TAPE INSTALLATION

Runchannel

A

AC103753 AC

Assemble the run channel cut-out area with the thumb of the door mirror.

Door tape

A

Section A – A Door panel

Door tape

>>C<< DOOR OUTER OPENING WEATHERSTRIP INSTALLATION The clip colour identifies the left and right weatherstrips so be sure to see the colours so as to install correctly.

A

Adjust the end of the door tape to the corner end of the door panel.

AC106848AB

Apply the door tape in the location shown in the Figure of the instructions.

APPLICABLE SIDE

IDENTIFICATION COLOUR

Left door

Natural (White)

Right door

Pink

BODY

42-42

TAILGATE

TAILGATE SERVICE SPECIFICATIONS M1421000300244

Item

Standard value

Tailgate handle play mm

2.3 to 5.9

SEALANTS M1424000500076

Item

Specified sealant

Tailgate waterproof film


Tailgate hinge

3M ATD Part No.8531 Heavy drip check sealer, 3M ATD Part No.8646 Automotive joint and seam sealer or equivalent


Tool A

Number

Name

Use

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222


Terminal voltage measurement A: For checking connector pin contact pressure B: For checking power supply circuit C: For checking power supply circuit D: For connecting a locally sourced tester

B

C

D MB991223 AD


The tailgate system is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to GROUP 54B, Diagnosis 354B or GROUP 54C, Diagnosis 354C.

ON-VEHICLE SERVICE TAILGATE FIT ADJUSTMENT M1424000900115

1. If the striker and latch mesh badly, replace the striker and striker installation blots with replacement parts (striker: MR523105, striker installation blot: MU000474).

AC203659

2. Move the replaced striker forward and backward or to the left and right to adjust, after bolt the striker temporarily.

BODY

42-43

TAILGATE

3. After adjusting, tighten the bolts to the specified torque [24 4 N¼m]. NOTE: Grind here

2. If it deviates from the standard value, remove the lower tailgate trim (Refer to GROUP 52A, tailgate trim 352A) and waterproof film (Refer to 342 ). 3. Remove the holder from the tailgate handle and adjust according to the tailgate latch rod and tailgate handle connection position.

ADJUSTMENT OF TAILGATE HEIGHT M1424003500075

A AC203660AB

A

When the bolt head interferes with the rear end trim, rasp the interference area with a round file.

Section A – A 17.4mm

Bumper

AC201556

4. If uneven clearance is present between tailgate and body, reposition the hinge to adjust the clearance.

TAILGATE HANDLE PLAY CHECK M1424002400116

Section A – A Holder A

Rod A

B

AC103270 AC

1. Check the tailgate handle play. Standard value (B): 2.3 - 5.9 mm

Body AC103269 AC

Turn the tailgate bumper using the arrow of the tailgate bumper as a guideline to adjust the height of the tailgate. The bumper height is altered by approximately 3mm by turning the tailgate bumper one rotation.

BODY

42-44

TAILGATE

TAILGATE REMOVAL AND INSTALLATION M1424001100156

CAUTION Do not disassemble or throw the tailgate gas spring into fire. Punch a hole in the gas spring before disposal to release the gas inside. Ensure the tailgate gas spring piston rod does not come into contact with foreign material. Pre-removal Operation Tailgate Spoiler Assembly Removal (Refer to GROUP 51, Tailgate Spoiler 351). Tailgate Trim Assembly Removal (Refer to GROUP 52A, Tailgate Trim 352A). Rear Wiper Motor Removal (Refer to GROUP 51, Rear Wiper and Washer 351).

Post-installation Operation Tailgate Fit Adjustment (Refer to 342). Rear Wiper Motor Installation (Refer to GROUP 51, Rear Wiper and Washer 351). Tailgate Trim Assembly Installation (Refer to GROUP 52A, Tailgate Trim 352A). Tailgate Spoiler Assembly Installation (Refer to GROUP 51, Tailgate Spoiler 351).

7

3 4 9.0 ± 2.0 N·m

7

Sealant: 3M ATD Part No. 8633 or equivalent

12 ± 2 N·m 9.0 ± 2.0 N·m

8

2 7

12 ± 2 N·m

5 3 6

12 ± 2 N·m

1 AC102859 AC

BODY

42-45

TAILGATE

<>

Tailgate assembly removal steps 1. Bumper 2. Rear washer hose 3. Waterproof film 4. Tailgate wiring harness 5. Tailgate gas spring 6. Tailgate assembly


Tailgate assembly removal steps Headlining (Refer to GROUP 52A, Headlining 352A). >>B<< 7. Tailgate hinge Tailgate opening weatherstrip removal >>A<< 8. Tailgate opening weatherstrip

>>B<< TAILGATE HINGE INSTALLATION

<> TAILGATE GAS SPRING REMOVAL Tailgate hinge

Bolt Pin AC104148 AC

AC103607 AD

As shown in the Figure, slide the pin upward, then remove the tailgate gas spring in the direction of the arrow to unscrew the bolt.

INSTALLATION SERVICE POINTS >>A<< TAILGATE OPENING WEATHERSTRIP INSTALLATION Tailgate opening weatherstrip

Positioning mark

AC103272AD

Assemble so the tailgate opening weatherstrip marking is at the centre of the body.

Apply the specified sealing agent to the tailgate hinge assembly surface to assembly the tailgate hinge. Specified Adhesive: 3M ATD Part No.8531 Heavy drip check sealer, 3M ATD Part No.8646 Automotive joint and seam sealer or equivalent

BODY

42-46

TAILGATE

TAILGATE HANDLE AND LATCH REMOVAL AND INSTALLATION M1424001700147

Pre-removal Operation Tailgate Handle Play Check (Refer to 342).

4

3

4

5.0 ± 1.0 N·m

2

5.0 ± 1.0 N·m

7 6 5 9.0 ± 2.0 N·m

22 ± 4 N·m

6

1 AC102861AC

Striker removal steps Rear end trim (Refer to GROUP 52A, Trims 352A). >>A<< 1. Striker Tailgate handle and lock key cylinder removal steps Lower tailgate trim (Refer to GROUP 52A, Tailgate Trim 352A). Waterproof film (Refer to 342). 2. Tailgate Lock Actuator Connection 3. Tailgate lock key cylinder 4. Tailgate handle

Tailgate latch removal steps Lower tailgate trim (Refer to GROUP 52A, Tailgate Trim 352A). Waterproof film (Refer to 342). 5. Bolt (earth) 6. Tailgate latch assembly Tailgate lock actuator removal steps Lower tailgate trim (Refer to GROUP 52A, Tailgate Trim 352A). Waterproof film (Refer to 342). 7. Tailgate lock actuator

BODY

42-47

TAILGATE


TAILGATE LATCH CHECK

>>A<< STRIKER INSTALLATION

Lock

Latch center Striker center

Lever

1 +1.5 mm

Unlock

-1.5 mm

2 Striker

Latch

AC006126AB

Assemble so the distance between the centre of the striker and centre of the latch is 1.5mm or less.


TAILGATE LOCK ACTUATOR CHECK

Lever A View A

Unlock Lock AC103292 AC

LEVER POSITION

BATTERY CONNECTION

LEVER OPERATION

At the "LOCK" position






AC103291AD

LEVER POSITION

TESTER CONNECTION

SPECIFIED CONDITION

At the "LOCK" position

1 - 2 (Earth)

Open circuit


Less than 2 ohms

BODY

42-48


KEYLESS ENTRY SYSTEM SPECIAL TOOLS M1428000600257

Tool

Number

Name

Use

MB991502

MUT-II sub-assembly

Encrypted code registration

MB991529


B991502

MB991529


The keyless entry system is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to GROUP 54B, Diagnosis 354B or GROUP 54C, Diagnosis 354C.

ON-VEHICLE SERVICE KEYLESS ENTRY SYSTEM CHECK M1428001400074

Check the system as described below. If the system does not work, carry out troubleshooting. Refer to GROUP 54B, Diagnosis 354B, refer to GROUP 54C, Diagnosis 354C. Operate the transmitter to check that the doors and tailgate can be locked and unlocked. Operate the transmitter to check that the answerback function works in response to door and tailgate locking/unlocking. NOTE: . The adjustment function allows you to change the answerback setting as follows. Prior to that check, confirm which setting is activated. The hazard warning lamps flash twice when locked and once when unlocked. The room lamp flashes twice when locked and illuminates for 15 seconds when unlocked. The hazard warning lamps do not flash when locked and flash once when unlocked. The room lamp flashes twice when locked and illuminates for 15 seconds when unlocked. The hazard warning lamps flash twice when locked and do not flash when unlocked. The room lamp flashes twice

when locked and illuminates for 15 seconds when unlocked. The hazard warning lamps do not flash when both locked and unlocked. The room lamp flashes twice when locked and illuminates for 15 seconds when unlocked.

KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION M1428004000097

Push the transmitter unlock button and check to see that the doors and tailgate lock within 30 seconds. If it doesn’t, then execute troubleshooting remedies. Refer to GROUP 54B, Diagnosis 354B, refer to GROUP 54C, Diagnosis 354C.

HOW TO REPLACE THE TRANSMITTER BATTERY M1428000900236

CAUTION Do not allow water or dust to enter the inside of the transmitter when it is open. Also, do not touch the precision electronic device. Battery

Claw

Screw

AC000509AB

1. Remove the set screw to remove the battery from the transmitter.

BODY KEYLESS ENTRY SYSTEM

2. Install a battery with its (+) side face-down. Battery required for replacement: Coin type battery CR2032 3. Insert the claw first, and assemble the transmitter. 4. Verify that the keyless entry system operates.

ENABLING/DISABLING THE ANSWERBACK FUNCTION M1428003200195

If the keyless entry system locks or unlocks the doors, the room lamp flashes or illuminates, the hazard warning lamp flashes (hazard answerback function). The hazard answerback function can be enabled or disabled according to the following procedure:

ENABLING/DISABLING THE HAZARD ANSWERBACK FUNCTION The hazard answerback function can be enabled or disabled by one of the two following procedures. 1. Enter the hazard answerback customize mode by performing one of the following steps. If the ETACS-ECU enters the customize mode, its buzzer will sound once. (1) Turn the ignition switch to “LOCK”(OFF) position. (2) Turn off the hazard warning lamp switch.

CAUTION Before connecting or disconnecting the earth, turn the ignition switch to the "LOCK" (OFF) position. Diagnosis connector

MB991529 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC107528 AC

(3) Connect the diagnosis connector to the special tool (MB991529). (4) Close the driver's side door. (5) Keep the windshield washer switch on for at least ten seconds. Then the ETACS-ECU buzzer will sound once.

42-49

2. If the transmitter “LOCK” button is pushed consecutively twice (within two seconds), the ETACS-ECU buzzer will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACSECU buzzer will sound once. Disable the hazard answerback function when the doors are locked: The ETACSECU buzzer will sound twice. 3. If the transmitter “UNLOCK” button is pushed consecutively twice (within two seconds), the ETACS-ECU buzzer will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU buzzer will sound once. Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU buzzer will sound twice. 4. Exit the hazard answerback customize mode by observing one of the following steps. (1) Disconnect diagnosis connector terminal (1) form the earth. (2) Turn the ignition switch to position other then “LOCK”(OFF), or remove the ignition key. (3) Open the driver's side door, (4) Any other warning buzzer output occurs. NOTE: If any operation is not done for at least three minutes after the ETACS-ECU has entered the customize mode, the hazard answerback customize mode will be canceled automatically. 1. Enter the hazard answerback customize mode by performing one of the following steps. If the ETACS-ECU enters the customize mode, its buzzer will sound once. (1) Turn the ignition switch to “LOCK”(OFF) position. (2) Turn off the hazard warning lamp switch.

BODY

42-50


CAUTION Before connecting or disconnecting the MUT-II, turn the ignition switch to the "LOCK" (OFF) position.

(4) Any other warning buzzer output occurs. NOTE: If any operation is not done for at least three minutes after the ETACS-ECU has entered the customize mode, the hazard answerback customize mode will be canceled automatically.

HOW TO REGISTER SECRET CODE M1428001000269

16 Pin

MB991502 AC107200AC

(3) Connect the MUT-II to the diagnosis connector. (4) Close the driver’s side door. (5) Keep the windshield washer switch on for at least ten seconds. Then the ETACS-ECU buzzer will sound once. 2. If the transmitter “LOCK” button is pushed consecutively twice (within two seconds), the ETACS-ECU buzzer will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACSECU buzzer will sound once. Disable the hazard answerback function when the doors are locked: The ETACSECU buzzer will sound twice. 3. If the transmitter “UNLOCK” button is pushed consecutively twice (within two seconds), the ETACS-ECU buzzer will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU buzzer will sound once. Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU buzzer will sound twice. 4. Exit the hazard answerback customize mode by observing one of the following steps. (1) Disconnect MUT-II from the diagnosis connector. (2) Turn the ignition switch to position other then “LOCK”(OFF), or remove the ignition key. (3) Open the driver's side door,

Each individual secret code is registered inside the transmitter, and so it is necessary to resister these codes with the EEPROM inside the receiver in the following cases. When the transmitter or ETACS-ECU is replaced If more transmitters are to be used If it appears that a problem is occurring because of faulty registration of a code. A maximum of four different codes can be stored in the EEPROM memory (four different transmitters can be used). When the code for the first transmitter is registered, the previously registered codes for all transmitters are cleared. Therefore, if you are using four transmitters or are adding more transmitters, the codes for all transmitters must be registered at the same time.

When the MUT-II is not used 1. Check that the doors lock normally when the key is used. 2. Insert the ignition key.

CAUTION Before connecting or disconnecting the earth, turn the ignition switch to the "LOCK" (OFF) position. Diagnosis connector

MB991529 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC107528 AC

3. Connect the diagnosis connector to the special tool (MB991529). NOTE: This will connect terminal (1) of the diagnosis connector to earth, and the system will be in secret code registration standby mode.

BODY

42-51



Ground connected Within 10 seconds

Hazard warning switch

ON

1

2

3

4

5

6

OFF ACX00571 AG

4. Press the hazard warning lamp switch six times within 10 seconds. NOTE: Once the process is completed six times, then it will operate with all doors and tailgate lock and unlock operations once and then go to the save mode. NOTE: The hazard warning lamp switch is turned on and off alternately whenever it is pushed. 5. Press the transmitter switch, and then press it two times within 10 seconds of the first press. This will register the code. 6. Once the program is saved, it will operate once with the all doors and tailgate lock and unlock operations. 7. If you are using two or more transmitters or have added a second transmitter, the same registration procedure should be carried out within one minute after registering the code for the first transmitter. 8. Registration mode will be canceled under the following conditions: When the secret code for four transmitters has been registered; When one minute has passed after registration mode started; When the diagnosis connector is disconnected from earth When the key is removed from the key cylinder; 9. After the registration is completed, remove the ignition key and close all the doors, and then check that the keyless entry system operates normally.

When the MUT-II is used 1. Check that the doors lock normally when the key is used. 2. Insert the ignition key.

16 Pin

MB991502 AC107200AC

3. Connect the MUT-II to the diagnosis connector. MUT-II connected Within 10 seconds

Hazard warning switch

ON

1

2

3

4

5

6

OFF ACX00571 AB

4. Press the hazard warning switch six times within 10 seconds. NOTE: Once the process is completed six times, then it will operate with all doors and tailgate lock and unlock operations once and then go to the save mode. NOTE: The hazard warning lamp switch is turned on and off alternately whenever it is pushed. 5. Press the transmitter switch, and then press it two times within 10 seconds of the first press. This will register the code. 6. Once the program is saved, it will operate once with the all doors and tailgate lock and unlock operations. 7. If you are using two or more transmitters or have added a second transmitter, the same registration procedure should be carried out within one minute after registering the code for the first transmitter. 8. Registration mode will be canceled under the following conditions: When the secret code for four transmitters has been registered; When one minute has passed after registration mode started; When the MUT-II is disconnected from the diagnosis connector

BODY

42-52

SUNROOF ASSEMBLY

When the key is removed from the key cylinder;

9. After the registration is completed, remove the ignition key and close all the doors, and then check that the keyless entry system operates normally.

SUNROOF ASSEMBLY SERVICE SPECIFICATIONS M1421000300255

Item

Standard value

Roof lid glass operation current A (at 20 C)

7 or less

TROUBLESHOOTING CHECK CHART FOR TROUBLE SYMPTOMS M1426002000095

Symptom


Reference page

Sunroof does not work at all.

1

342

Any of the sunroof switch positions is defective.

2

342

Sunroof anti-trap function does not work normally.

3

342

BODY

42-53

SUNROOF ASSEMBLY

INSPECTION PROCEDURE 1: The sunroof does not work at all.


Sunroof-ECU Power Supply Circuit

FUSIBLE LINK 5


SUNROOF MOTOR ASSEMBLY CONTROL CIRCUIT

SUNROOF SWITCH


COMMENTS ON TROUBLE SYMPTOM If the sunroof does not work at all, these power supply circuit(s), these earth circuit(s), sunroof switch or the sunroof motor assembly (sunroof ECU) may be defective.

Possible causes Malfunction of the sunroof switch Malfunction of the sunroof motor assembly (sunroof ECU) Damaged harness wires and connectors

BODY

42-54

SUNROOF ASSEMBLY

Diagnostic procedure

STEP 3. Measure the resistance at the D-06 sunroof switch connector.

STEP 1. Connector check: D-06 sunroof switch connector Connector: D-06

Connector: D-06

D-06(B)

D-06(B)



AC301408 AC

AC301408 AC



STEP 2. Check the sunroof switch. Refer to sunroof switch continuity check342.

6 5 4 3 2 1

Q: Is the check result normal? YES : Go to Step 3. NO : Replace the sunroof switch.

Connector D-06 (Harness side)

AC301721AB

(2) Continuity between D-06 sunroof switch connector terminal No.4 and body earth OK: 2W or less Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.

BODY

42-55

SUNROOF ASSEMBLY

STEP 4. Check the wiring harness between D-06 sunroof switch connector terminal No.4 and body earth. Connector: D-06

STEP 6. Measure the voltage at the D-09 sunroof motor assembly connector. Connector: D-09

D-06(B)

Harness side

Harness side

4 3 2 1 10 9 8 7 6 5

6 5 4 3 2 1

AC301408 AD AC301408 AC

NOTE:

(1) Disconnect the sunroof motor assembly connector, and measure at the harness side.


4 3 2 1 10 9 8 7 6 5 1 2 3 4 5

AC210476 AD


AC301722 AB

Prior to the wiring harness inspection, check intermediate connector C-218, and repair if necessary. Check the earth wires for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. STEP 5. Connector check: D-09 sunroof motor assembly connector Connector: D-09

Harness side 4 3 2 1 10 9 8 7 6 5

AC301408 AD


4 3 2 1 10 9 8 7 6 5 Connector D-09 (Harness side)

AC301723 AB

(2) Check the voltage between the sunroof motor assembly connector and body earth. Voltage between D-09 sunroof motor assembly connector terminal No.1 and body earth. Voltage between D-09 sunroof motor assembly connector terminal No.2 and body earth. OK: Battery positive voltage Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 7.

BODY

42-56

SUNROOF ASSEMBLY

STEP 7. Check the wiring harness between D-09 sunroof motor assembly connector (terminal Nos. 1 and 2) and the battery.

Connector: C-203, C-210 Junction Block (Front View) C-203

Connector: D-09

Harness side 4 3 2 1 10 9 8 7 6 5

C-210

AC301408 AD


2 1 6 5 4 3



3 2 1 AC210475 AZ


C-116

1 2

5 6 7

3 4

8 9

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

1 2 3 4 5

1617 18 1920 21

AC301396 AB

AC210476 AD

Prior to the wiring harness inspection, check the junction block connectors C-203, C-210 and the intermediate connectors C-218, C-116 and repair if necessary. Check the power supply line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent


BODY

42-57

SUNROOF ASSEMBLY

STEP 8. Measure the resistance at the D-09 sunroof motor assembly connector. Connector: D-09

STEP 9. Check the wiring harness between D-09 sunroof motor assembly connector terminal No.5 and body earth. Connector: D-09


4 3 2 1 10 9 8 7 6 5

4 3 2 1 10 9 8 7 6 5

AC301408 AD

(1) Disconnect the sunroof motor assembly connector, and measure at the harness side.

AC301408 AD

NOTE: Connector: C-218 Junction block (Rear view)

4 3 2 1 10 9 8 7 6 5

1 2 3 4 5


(2) Check the resistance between the sunroof motor assembly connector and body earth. Resistance between D-09 sunroof motor assembly connector terminal No.5 and body earth. OK: 2W or less Q: Is the check result normal? YES : Go to Step 10. NO : Go to Step 9.

AC210476 AD

AC301724 AB

Prior to the wiring harness inspection, check intermediate connector C-218, and repair if necessary. Check body earth line for open circuit. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. STEP 10. Connector check: D-06 sunroof switch connector Connector: D-06

D-06(B)


AC301408 AC


BODY

42-58

SUNROOF ASSEMBLY

STEP 11. Retest the system. The sunroof assembly should now work normally. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the sunroof motor assembly.

INSPECTION PROCEDURE 2: Any of the sunroof switch positions is defective.


Sunroof Switch Circuit SUNROOF MOTOR ASSEMBLY CONTROL CIRCUIT

SUNROOF SWITCH


COMMENTS ON TROUBLE SYMPTOM If any of the sunroof switch positions is defective, the communication line between the sunroof switch and the sunroof motor assembly (sunroof-ECU) may be defective.

SB : Sky blue

Possible causes Malfunction of the sunroof switch Malfunction of the sunroof motor assembly (sunroof ECU) Damaged harness wires and connectors

BODY

42-59

SUNROOF ASSEMBLY

Diagnostic procedure


STEP 1. Connector check: D-06 sunroof switch connector

Q: Which switch position is defective? "TILT UP" : Go to Step 5. "OPEN" : Go to Step 6. "CLOSE/DOWN" : Go to Step 7.

Connector: D-06

D-06(B)


STEP 5. Check the wiring harness between D-09 sunroof motor assembly connector terminal No.7 and D-06 sunroof switch connector terminal No.3. Connectors: D-06, D-09

AC301408 AC

D-09

D-06(B)


STEP 2. Check the sunroof switch. Refer to sunroof switch continuity check342. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the sunroof switch.

Harness side D-06

STEP 3. Connector check: D-09 sunroof motor assembly connector

6 5 4 3 2 1

D-09 4 3 2 1 10 9 8 7 6 5

Connector: D-09

AC301409 AC

Harness side 4 3 2 1 10 9 8 7 6 5

AC301408 AD


Check the communication line for open circuit. Q: Is the check result normal? YES : Replace the sunroof motor assembly. NO : Repair the wiring harness.

BODY

42-60

SUNROOF ASSEMBLY

STEP 6. Check the wiring harness between D-09 sunroof motor assembly connector terminal No.8 and D-06 sunroof switch connector terminal No.5. Connectors: D-06, D-09

Connectors: D-06, D-09 D-09

D-06(B)

Harness side D-06 6 5 4 3 2 1

STEP 7. Check the wiring harness between D-09 sunroof motor assembly connector terminal No.6 and D-06 sunroof switch connector terminal No.6.

D-09

D-06(B)

Harness side D-09

4 3 2 1 10 9 8 7 6 5

D-06 6 5 4 3 2 1

D-09 4 3 2 1 10 9 8 7 6 5

AC301409 AC


AC301409 AC


INSPECTION PROCEDURE 3: Sunroof anti-trap function does not work normally.

CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal. OPERATION This function is activated by the sunroof motor assembly (sunroof-ECU). COMMENTS ON TROUBLE SYMPTOM If the sunroof anti-trap function does not work, the sunroof motor assembly (sunroof-ECU) may be defective. Possible causes Malfunction of the sunroof motor assembly (sunroof ECU)

Diagnostic procedure Retest the system. Check that the sunroof anti-trap function work normally. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Replace the sunroof motor assembly.

BODY SUNROOF ASSEMBLY

ON-VEHICLE SERVICE WATER TEST M1426000900241

Check if there are any leaks in the sunroof by the following 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. Hose

Approx 30 cm

42-61

5. Adjust the roof lid glass height according to the number of the adjusting plate pieces. Check to see that the height of the roof lid glass is even with the body. 6. After adjustment, check to be sure that the sunroof operates smoothly.

SUNROOF CHECK M1426004700089

Check to see that the sunroof operates by pressing the sunroof switch. Perform troubleshooting if operations malfunction. (Refer to 342).

SUNROOF SAFETY FUNCTION CHECK M1426004400107

ACX00572 AB

3. Hold the end of the hose approximately 30 cm above the roof and let the water run onto the weatherstrip for 5 minutes or more. 4. Check if any water leaks can be found in the room while watering. Even though there are any water leaks around the roof lid glass, it can be acceptable as long as water is caught in the drip area.

1. Close the roof lid glass by applying an approximately 10mm thickness wood chip placed at a right angle to the roof lid glass. 2. Check to see if the roof lid glass opens after the motor turns when the roof lid glass catches the wooden chip. (Refer to 342).

ROOF LID GLASS OPERATION CURRENT CHECK M1426003200133

SUNROOF FIT ADJUSTMENT M1426001000252

1. Fully close the roof lid glass. 2. Fully open the sunshade. 3. Remove the decoration cover (Refer to 342).

AC102847AC

4. To adjust the roof lid glass in the front/back or left/ right direction, loosen the nuts securing the roof lid glass assembly, then move the roof lid glass assembly to the front/back or left/right. Check to see that the space between the roof lid glass and body is even across the entire circumference.

AC107524AC

1. Remove the fuse of the sunroof, then connect the circuit tester as shown in the Figure. 2. Turn ON the sunroof switch, then measure the operating current of the intermediary segment when the sunroof is moving, with the sunroof fully closed, when the sunroof is fully opened and when the sunroof is tilted fully up. Standard value: 7 A or less (at 20 C) 3. Check the following areas if the operating current of exceeds the standard value. Sunroof installation, deformation and appearance of any foreign substances. Drive cable installation. Tilting of roof lid glass.

42-62

BODY SUNROOF ASSEMBLY

SUNROOF INITIALIZATION M1426004600093

1. Assemble the roof lid glass assembly and sunroof motor assembly to the sunroof assembly. 2. Connect the sunroof motor assembly connector and sunroof switch connector to the wire ring harness connector on the vehicle side. 3. Fully open the roof lid glass by pressing the sunroof switch, then fully close the sunroof by pressing the close switch again.

4. Continuously press the close switch for a minimum of 3 seconds after the sunroof is fully closed. 5. Press the open switch to fully open the sunroof, then press the close switch to fully close the sunroof. NOTE: Do not stop the sunroof before the sunroof is fully opened or fully closed in Step 5, above. If the fully open or closed operation is interrupted/stopped, start over from Step 3.

BODY

42-63

SUNROOF ASSEMBLY

SUNROOF ASSEMBLY REMOVAL AND INSTALLATION M1426001200278

Post-installation Operation Sunroof Water Test (Refer to 342). Sunroof Fit Adjustment (Refer to 342). Sunroof Initializing Adjustment (Refer to 342). Section A – A

4

Claw

2 9 3

A

2

Section B – B

6

A

1

Claw

9 8

5

6 7 5 B B

7 Note : Claw positions

1.

2. 3. 4. 5. 6.

Removal Deflector assembly Roof lid glass assembly removal steps Decoration cover Adjusting plate Roof lid glass assembly Sunroof switch removal steps Sunroof switch cover Sunroof switch

AC

Drain pipe removal steps 5. Sunroof switch cover Headlining (Refer to GROUP 52A, Headlining 352A). Cowl side trim (Refer to GROUP 52A, Trims 352A). >>A<< 7. Drain pipe

BODY

42-64

SUNROOF ASSEMBLY

5. 8. 5. 6.

>>A<< 7. 9.

Sunroof motor assembly removal steps Sunroof switch cover Headlining (Refer to GROUP 52A, Headlining 352A). Sunroof motor assembly Sunroof assembly removal steps Sunroof switch cover Sunroof switch Headlining (Refer to GROUP 52A 352A). Drain pipe connection Sunroof assembly

INSTALLATION SERVICE POINTS >>A<< DRAIN PIPE INSTALLATION


SUNROOF SWITCH CONTINUITY CHECK Up

Grommet

Open

25 ± 5 mm

Close/ Down

1 2 3 4 5 6

1 2 3 4 5 6 AC002392 AD

Install the grommet, and then position the drain pipe so that it protrudes from the grommet as shown in the illustration.

AC005659 AB

SWITCH POSITION

TESTER CONNECTION

SPECIFIED CONDITION

Open

4-5

Less than 2 ohms

OFF

3 - 4, 3 - 5, 3 - 6, 4 - 5, 4 - 6, 5 - 6

Open circuit

Up

3-4

Less than 2 ohms

Close/Down

4-6

Less than 2 ohms

BODY

42-65

SUNROOF ASSEMBLY

DISASSEMBLY AND ASSEMBLY M1426001400250

10

13

5N 3 4N

8

7 1

2 6 12 12 13

11

9

10 1. 2. 3. 4. >>A<< 5. 6.

Disassembly steps Deflector assembly Decoration cover (Refer to 342). Adjusting plate Roof lid glass assembly Weatherstrip Weatherstrip inner Sunroof motor assembly

AC102840 AD

7. 8. 9. 10. 11. 12. 13.

Disassembly steps&RQWLQXHG Operating unit Sun shade assembly Lifter link Guide assembly Drip plate Seal tape Frame assembly

BODY

42-66

SUNROOF ASSEMBLY

INSTALLATION SERVICE POINT >>A<< WEATHERSTRIP INNER INSTALLATION 1. Degrease the weatherstrip inner assembling surface of the roof lid glass side with unleaded gasoline.

A A 400 mm

Glass centre line

Section A – A

Weatherstrip inner

20 mm AC102846 AC

2. Assemble the weatherstrip inner in the location shown.

127(6

33-1

GROUP 33

00 11

FRONT SUSPENSION

12 13 14 15 16

CONTENTS

17 GENERAL DESCRIPTION. . . . . . . . .

33

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

33


33

21


33

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

33

22

LUBRICANT. . . . . . . . . . . . . . . . . . . .

33

LOWER ARM . . . . . . . . . . . . . . . . . . .

33

25


33

SPECIAL TOOLS. . . . . . . . . . . . . . . .

33

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

33

26

33

BALL JOINT DUST COVER REPLACEMENT . . . . . . . . . . . . . . . . . . . . .

33

27

FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .

33

LOWER ARM REAR BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . .

33

LOWER ARM BALL JOINT AXIAL PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

STABILIZER BAR* . . . . . . . . . . . . . . .

33

BALL JOINT DUST COVER CHECK . . . . .

33


33

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

33

STABILIZER LINK BALL JOINT DUST COVER REPLACEMENT . . . . . . . . . . . . . .

34

33

35


STRUT ASSEMBLY. . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . .

33 33

31 32 33

36 37 :$51,1*65(*$5',1*6(59,&,1*2)6833/(0(17$/5(675$,176<67(0656 (48,33('9(+,&/(6

WARNING

Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative). Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRSrelated component.

42 51 52 54 55

FRONT SUSPENSION

33-2

GENERAL DESCRIPTION


The front suspension is a McPherson strut with coil spring. The shock absorber is gas-filled hydraulic double-acting type.


Stiffener plate

Coil spring Stabilizer bar Strut assembly

Crossmember

Lower arm

AC301358AB

SPECIFICATIONS COIL SPRING Item

2WD

4WD

Wire diameter mm

14

14

Average diameter mm

160

160

Free length mm

300

305

FRONT SUSPENSION

33-3



Item Toe-in

Standard value At the centre of tyre tread mm

12


003’ 05’

Toe-out angle on turns (inner wheel when outer wheel at 20)

2200’ 130’

Steering angle

Inner wheel

3450’ 130’

Outer wheel (reference)

2920’

Camber

-010’ 30’*

Caster

315’ 30’*

Kingpin inclination

1225’ 130’

Side slip mm (per 1m)

03

Lower arm ball joint starting torque N¼m

0 - 3.9

Protruding length of stabilizer link thread part mm

9.4 0.4

Stabilizer link ball joint turning torque N¼m

0.5 - 1.5

NOTE: *: difference between right and left wheels must be less than 30’


Item Lower arm ball joint

Lip portion of dust cover Inside of dust cover

Stabilizer link ball joint

Inside of dust cover

Specified lubricant

Quantity

Multipurpose grease SAE J310, NLGI No.2 or equivalent

As required

FRONT SUSPENSION

33-4

SPECIAL TOOLS


Tool

Number

Name

Use

MB991004

Wheel alignment gauge attachment

Wheel alignment measurement

A: MB991237 B: MB991238

A: Spring compressor body B: Arm set

Coil spring compression

MB991680 A: MB991681 B: MB991682

Wrench set A: Wrench B: Socket

Strut assembly disassembly and reassembly

MB991006

Preload socket

Lower arm ball joint starting torque check

MB990800

Ball joint remover and installer

Lower arm ball joint dust cover installation

MB991004

A B

A

MB991237

B

MB991680

MB991006

MB990800

FRONT SUSPENSION

33-5

ON-VEHICLE SERVICE

Tool

Number

Name

Use

MB990883


Lower arm bushing removal and press-fitting

MB990972

Torsion bar bushing remover base

MB990887

Ring

MB990890

Rear suspension bushing base

MB990326

Preload socket

MB990883

MB990971

MB990890

Stabilizer link ball joint turning torque check

MB990326

ON-VEHICLE SERVICE FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT M1331000900400

Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, wheels, and tires should be serviced to normal condition before measuring wheel alignment. TOE-IN Standard value: at the centre of tyre tread: 1 2 mm Toe angle (per wheel): 003’ 05’

Jam nut Clip

AC006074 AB

1. Adjust the toe-in by undoing the clip and jam nut, and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. 2. Install the clip and tighten the jam nut to the specified torque.

FRONT SUSPENSION

33-6

ON-VEHICLE SERVICE

Tightening torque: 52 2 N¼m 3. Confirm that the toe-in is at the standard value. 4. Use a turning radius gauge to check that the steering angle is at the standard value. STEERING ANGLE Standard value: Item

Specification

Inner wheels

3450’ 130’

Outer wheels (reference)

2920’

TOE-OUT ANGLE ON TURNS To check the steering linkage, especially after the vehicle has been involved in an accident or if an accident is presumed, it is advisable to check the toe-out angle on turns in addition to the wheel alignment. Conduct this test on the left turn as well as on the right turn. Standard value: Item

Specification

Toe-out angle on turns (inner wheel when outer wheel at 20)

2200’ 130’

CAUTION Never subject the wheel bearings to the vehicle load when the driveshaft nuts are loosened. NOTE: MB991004

AC001079 AB

For vehicles with aluminium wheels, attach the camber/caster/kingpin gauge to the driveshaft by using special tool wheel alignment gauge attachment (MB991004). Tighten the special tool to the same torque 245 29 N¼m as the driveshaft nut. SIDE SLIP Measure the side slip with a side slip tester. Standard value: 0 3 mm (per 1 m)

LOWER ARM BALL JOINT AXIAL PLAY CHECK M1332011300063

CAMBER, CASTER AND KINGPIN INCLINATION Standard value: Item

Specification

Camber

-010’ 30’*

Caster

315’ 30’*

Kingpin inclination

1225’ 130’

NOTE: *: difference between right and left wheels must be less than 30’ NOTE: Camber and caster are preset at the factory and cannot be adjusted.

1. Raise the vehicle. 2. Remove the stabilizer link from the lower arm. 3. Move the lower arm up and down with your hands to check for an excessive play in the axial direction of the ball joint. If there is an excessive play, replace the lower arm assembly.

BALL JOINT DUST COVER CHECK M1332008600309

1. Press the dust cover with your finger to check that there are no cracks or damage in the dust cover. 2. If the dust cover is cracked or damaged, replace the lower arm assembly. NOTE: If the dust cover is cracked or damaged, it is possible that there may also be damage to the ball joint.

FRONT SUSPENSION

33-7

STRUT ASSEMBLY

STRUT ASSEMBLY REMOVAL AND INSTALLATION M1332001100284

CAUTION Be careful when handling the pole piece at the tip of the front ABS sensor so as not to damage it by striking against other parts. Pre-removal Operation Washer Tank Assembly Removal (Refer to GROUP 51, Windshield Wiper and Washer 351).

N

Post-installation Operation Washer Tank Assembly Installation (Refer to GROUP 51, Windshield Wiper and Washer 351). Front Wheel Alignment Adjustment (Refer to 333).

4

5

44 ± 5 N·m

6

1

2

7 3

167 ± 9 N·m AC202820 AB

1. 2. 3. 4.

Removal steps Front ABS sensor harness bracket Brake hose bracket Knuckle connection Strut mounting nut

5. 6. 7.

Removal steps&RQWLQXHG Insulator clip Stiffener plate Strut assembly


Check for oil leaks from the strut assembly. Check the strut assembly for damage or deformation.

FRONT SUSPENSION

33-8

STRUT ASSEMBLY


60 ± 10 N·m

1 2 3 8

4 5

7 9 6

10

AC301222 AB

<> >>A<< 1. 2. 3. 4. 5.

Disassembly steps Self-locking nut Strut insulator assembly Bearing Upper spring seat Upper spring pad

<>

6. 7. 8. 9. 10.

Disassembly steps&RQWLQXHG Dust cover Bump stopper Coil spring Lower spring pad Strut assembly

FRONT SUSPENSION

33-9

STRUT ASSEMBLY


<> STRUT ASSEMBLY DISPOSAL


WARNING Wear goggles when drilling to protect your eyes from flying metal debris.

CAUTION Install special tool arm set (MB991238) evenly, and so that the maximum length will be attained within the installation range. Do not use an impact wrench to tighten the bolt of special tool spring compressor body (MB991237), otherwise the special tool will break.

MB991238

AC001087

MB991237

AC001085 AB

The gas must be discharged from the strut assembly before discarding it. Place the strut assembly horizontally with its piston rod extended. Then drill a hole of approximately 3 mm in diameter at the location shown in the illustration and discharge the gas.

1. Use following special tools to compress the coil spring. MB991237: Spring Compressor Body MB991238: Arm Set


WARNING Do not use an impact wrench to remove the self-locking nut. Vibration of the impact wrench will cause special tools (MB991237 and MB991238) to slip and cause personal injury.

Do not use an impact wrench to tighten the bolt of special tool spring compressor body (MB991237), otherwise the special tool will break.

>>A<< SELF-LOCKING NUT INSTALLATION 1. Ensure that the bearing is seated correctly.

CAUTION

MB991238

MB991237

MB991682 MB991681 AC001085 AB

AC006091 AB

2. Use following special tools to secure the strut, and then remove the self-locking nut. MB991681: Wrench MB991682: Socket

2. Install following special tools to the strut assembly same as its removal. MB991237: Spring Compressor Body MB991238: Arm Set 3. While the coil spring is being compressed by the special tools, temporarily tighten the self-locking nut.

FRONT SUSPENSION

33-10

STRUT ASSEMBLY


Check the bearing for wear or rust. Check the rubber parts for damage or deterioration. Check the spring for deformation, deterioration or damage. Check the shock absorber for deformation.

Rod

AC006091 AB

4. Align the hole in the strut assembly lower spring seat with the hole in the upper spring seat. NOTE: Using a rod as shown facilitates the alignment. 5. Align both ends of the coil spring with the grooves in the spring seat, and then loosen the special tools.

CAUTION Do not use an impact wrench to tighten the selflocking nut, otherwise the self-locking nut will be damaged.

MB991682 MB991681

AC006091 AB

6. Using following special tools, tighten the selflocking nut to 60 10 N¼m. MB991681: Wrench MB991682: Socket

FRONT SUSPENSION

33-11

LOWER ARM

LOWER ARM REMOVAL AND INSTALLATION M1332001600308

CAUTION *

: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition. Post-installation Operation Check the dust cover for cracks or damage by pushing it with your finger. Front Wheel Alignment Check and Adjustment (Refer to 333).

6

N

AC107030

2

Specified grease : Multipurpose grease SAE J310, NLGI No.2 or equivalent

3

4

5

186 ± 10 N·m*

6

167 ± 9 N·m 39 ± 5 N·m

AC107017

5

1

108 ± 10 N·m AC200961 AB

1. >>A<< 2. 3. 4.

Removal steps Lower arm and knuckle connection Self-locking nut Stabilizer rubber Stabilizer link assembly

5. 6.

Removal steps&RQWLQXHG Lower arm and crossmember connection Lower arm assembly

FRONT SUSPENSION

33-12

LOWER ARM

INSTALLATION SERVICE POINT >>A<< SELF-LOCKING NUT INSTALLATION A

2. If the dust cover is cracked or damaged, replace the lower arm assembly. NOTE: Cracks or damage to the dust cover may cause damage to the ball joint. When it is damaged during service work, replace the dust cover.

BALL JOINT DUST COVER REPLACEMENT M1332008200259

AC107031AB AC107031

Tighten the self-locking nut until the stabilizer link thread part protruding length meets the standard value. Standard value (A): 9.4 0.4 mm

INSPECTION

If the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Remove the dust cover. 2. Apply specified grease to the lip and the inside of a new dust cover. Specified grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent Grease amount for the inside the dust cover (reference): 8 - 10g

M1332001700264

Check the bushing for wear and deterioration. Check the lower arm for bend or breakage. Check all bolts for condition and straightness. LOWER ARM BALL JOINT STARTING TORQUE CHECK

MB990800 Dust cover

MB991006 AC006135 AB

3. Using special tool ball Joint remover and installer (MB990800), drive in the dust cover until it is fully seated. AC001091 AB

1. After shaking the ball joint stud several times, use special tool preload socket (MB991006) to measure the starting torque of the ball joint. Standard value: 0 - 3.9 N¼m 2. If the measured value is not within the standard value, or if the ball joint is difficult to turn or does not turn smoothly, replace the lower arm assembly. LOWER ARM BALL JOINT DUST COVER CHECK 1. Check the dust cover for cracks or damage by pushing it with your finger.

Dust cover

22 mm

AC107030 AB

4. Position the dust cover as shown in the illustration. Make sure that there is no abnormal bulge or pressure applied on the dust cover. 5. Check the dust cover for cracks or damage by pushing it with your finger.

FRONT SUSPENSION

33-13

LOWER ARM

LOWER ARM REAR BUSHING REPLACEMENT

MB990883 M1332008100337

MB990972

Bushing

Lower arm assembly

Outer tube

MB990887 MB990890 AC107098 AB

Replace the bushing as follows:

Lower arm assembly 30˚

MB990883 Projection AC006138 AC

MB990972 Lower arm assembly

MB990887

MB990890

AC006137 AC

1. Use following special tools to drive out the bushing. MB990883: Rear Suspension Bushing Arbor MB990972: Torsion Bar Bushing Remover Base MB990887: Ring MB990890: Rear Suspension Bushing Base

2. Position the bushing so that its projection is as shown, and then use the special tools to press in the bushing. 3. Press the bushing until its outer tube is flush with the lower arm assembly surface.

FRONT SUSPENSION

33-14

STABILIZER BAR

STABILIZER BAR REMOVAL AND INSTALLATION M1332004000253

CAUTION Before removing the steering wheel and air bag module assembly, refer to GROUP 52B - Service Precautions and Air Bag Module and Clock Spring. Also, put the front wheels in straight-ahead position. Failure to do so may damage the SRS clock spring and render the SRS air bag inoperative, which results serious driver injury. *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition. Pre-removal Operation Side Under Cover and Centre Under Cover Removal (Refer to GROUP 51, Under Cover 351). Steering Wheel and Air Bag Module Assembly Removal (Refer to GROUP 37A, Steering Wheel 337). Clock Spring Removal (Refer to GROUP 52B, Air Bag Modules and Clock Spring 352B). Centre Member Removal (Refer to GROUP 32, Engine Roll Stopper, Centre Member 332). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315).

Post-installation Operation Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Centre Member Installation (Refer to GROUP 32, Engine Roll Stopper, Centre Member 332). Clock Spring Installation (Refer to GROUP 52B, Air Bag Modules and Clock Spring 352B). Steering Wheel and Air Bag Module Assembly Installation (Refer to GROUP 37A, Steering Wheel 337). Check the dust covers for cracks or damage by pushing it with your finger. Checking Steering Wheel Position with Wheels Straight Ahead Front Wheel Alignment Check and Adjustment (Refer to 333). Side Under Cover and Centre Under Cover Installation (Refer to GROUP 51, Under Cover 351).

FRONT SUSPENSION

33-15

STABILIZER BAR

9

18 ± 2 N·m

3

4 AC107102

Specified grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent

21 ± 4 N·m

5 11

6 7

1

8 10

9 2 49 ± 10 N·m

52 ± 7 N·m* 167 ± 9 N·m 39 ± 5 N·m

AC107023

167 ± 9 N·m

1. 2. 3. 4.

<>

>>A<<

5.

Removal steps Power steering hose clamp Rear roll stopper connecting bolt Steering shaft cover Steering gear and joint connecting bolt Fixture

<>

>>A<< >>B<<

<> <>

>>A<<

6. 7. 8. 9. 10. 11.

AC200962 AB

Removal steps&RQWLQXHG Bushing Self-locking nut Stabilizer rubber Stabilizer link Stabilizer rubber Stabilizer bar

FRONT SUSPENSION

33-16

STABILIZER BAR

REMOVAL SERVICE POINT <> FIXTURE/BUSHING/STABILIZER LINK/ STABILIZER BAR REMOVAL Carry out the following operations to ensure working space in order to remove the fixtures, the bushings, the stabilizer links and the stabilizer bar.

>>B<< SELF-LOCKING NUT INSTALLATION A

Piece of wood

AC107031AB AC107031

Transmission jack

AC102600 AD

1. Use a transmission jack to hold the crossmember, and then remove the crossmember mounting nuts and bolts.

CAUTION Be careful not to lower the crossmember excessively, otherwise the power steering return hose bracket may deform. 2. Lower the crossmember until the fixtures, the bushings, the stabilizer links and the stabilizer bar can be removed.



Check the bushings for wear and deterioration. Check the stabilizer bar for deterioration or damage. Check all bolts for condition and straightness. STABILIZER LINK BALL JOINT TURNING TORQUE CHECK MB990326

INSTALLATION SERVICE POINTS >>A<< STABILIZER BAR/BUSHING/FIXTURE INSTALLATION Outside of vehicle

Approximately 10 mm Identification mark

Bushing (LH)

Fixture (LH) AC006141AD

Align the stabilizer bar identification mark with the right end of the bushing (LH).

AC001129 AB

1. After shaking the ball joint stud several times, install the nut to the stud and use special tool preload socket (MB990326) to measure the turning torque of the ball joint. Standard value: 0.5 - 1.5 N¼m 2. When the measured value exceeds the standard value, replace the stabilizer link. 3. When the measured value is lower than the standard value, check that the ball joint turns smoothly without excessive play. If so, it is possible to re-use that ball joint.

FRONT SUSPENSION

33-17

STABILIZER BAR

STABILIZER LINK BALL JOINT DUST COVER CHECK 1. Check the dust cover for cracks or damage by pushing it with your finger. 2. If the dust cover is cracked or damaged, replace the stabilizer link. NOTE: Cracks or damage of the dust cover may cause damage to the ball joint. When it is damaged during service work, replace the dust cover (Refer to 333).

STABILIZER LINK BALL JOINT DUST COVER REPLACEMENT M1332008300104

Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows:

Clip ring AC006188AB

1. Remove the clip ring and the dust cover. 2. Apply specified grease to the inside of a new dust cover. Specified grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent 3. Wrap plastic tape around the stabilizer link stud, and then install the dust cover to the stabilizer link. 4. Secure the dust cover by the clip ring. 5. Check the dust cover for cracks or damage by pushing it with finger.

127(6

34-1

GROUP 34

00 11

REAR SUSPENSION

12 13 14

CONTENTS GENERAL DESCRIPTION. . . . . . . . .

34


34

LUBRICANT. . . . . . . . . . . . . . . . . . . .

34

SPECIAL TOOLS. . . . . . . . . . . . . . . .

34


34

15

TRAILING ARM ASSEMBLY . . . . . . .

34


34


34

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

34

TRAILING ARM BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . .

21

34

22

SHOCK ABSORBER ASSEMBLY . . .

34

25


34

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

34

26

16 17

REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .

34


34

LOWER ARM PILLOW BALL BUSHING AXIAL PLAY CHECK . . . . . . . . . . . . . . . . .

27

34

STABILIZER BAR. . . . . . . . . . . . . . . .

34

31


34

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

34

32

STABILIZER LINK BALL JOINT DUST COVER REPLACEMENT . . . . . . . . . . . . . .

34

33

STABILIZER LINK BALL JOINT DUST COVER INSPECTION . . . . . . . . . . . . . . . .

CONTROL LINK, UPPER ARM AND LOWER ARM . . . . . . . . . . . . . . . . . . .

34

34


34

INSPECTION . . . . . . . . . . . . . . . . . . . . . . .

34

LOWER ARM BUSHING AND LOWER ARM PILLOW BALL BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . .

34

34

REAR SUSPENSION CROSSMEMBER . . . . . . . . . . . . . . . .

34


34

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

34

35 36 37 42 51 52 54 55

REAR SUSPENSION

34-2

GENERAL DESCRIPTION


A trailing arm type multi-link suspension has been adopted as the rear suspension. The shock absorber is a hydraulic, cylindrical double-acting type.


Rear suspension crossmember Shock absorber Stabilizer bar Bump rubber Upper arm

Coil spring

Lower arm

Control link

Trailing arm bracket Trailing arm

AC301439 AB

SPECIFICATION COIL SPRING Item

2WD

4WD

Wire diameter mm

11

11

Average diameter mm

91

91

Free length mm

342

350


Item Toe-in

Standard value At the centre of tyre tread mm

32


008’ 05’

Camber

-040’ 30’ (Difference between right and left within 30’)

Thrust angle

000’ 09’

Control link pillow ball bushing starting torque N¼m

0.5 - 3.0

Upper arm pillow ball bushing starting torque N¼m 0.5 - 3.0 Lower arm pillow ball bushing starting torque N¼m 0.5 - 3.0 Stabilizer link ball joint turning torque N¼m

1.7 - 3.1

REAR SUSPENSION

34-3

LUBRICANT


Item

Specified lubricant

Quantity

Stabilizer link ball joint (inside of dust cover)

Multipurpose grease SAE J310, NLGI No.2 or equivalent

As required


Tool

Number

Name

Use

MB991014


Wheel alignment measurement <2WDvehicles with aluminium wheels>

MB991004


Wheel alignment measurement <4WDvehicles with aluminium wheels>

MB990326

Preload socket

Pillow ball bushing starting torque check Stabilizer link ball joint turning torque check

MB991447

Bushing remover and installer

Lower arm bushing removal and press-fitting

MB991448

Bushing remover and installer base

MB991449

Bushing remover and installer supporter

MB991004

MB991004

MB990326

REAR SUSPENSION

34-4

SPECIAL TOOLS

Tool B A

Number

Name

Use

MB990957 A: MB990969 B: MB990971

Lower arm bushing remover and installer A: Guide B: Base

Lower arm pillow ball bushing removal and press-fitting

MB990996

Lower arm bushing arbor

MB990767

End yoke holder

Rear axle hub fixing

MB990241 A: MB990243 B: MB990244 C: MB990242

Axle shaft puller A: Puller body B: Puller bar C: Puller shaft

Drive shaft removal <4WD>

MB991354

Puller body

Removal of the drive shaft <4WD> Rear hub assembly removal <4WD>

A: MB991017 B: MB990998 C: MB991000


Provisional holding of the wheel bearing <4WD>

MB990590 A: MB990212 B: MB990211

Rear axle shaft oil seal remover A: Adapter B: Sliding hammer

Rear hub assembly removal <4WD>

MB990560

Bearing remover

Wheel bearing inner race removal <4WD>

MB990957

B990996

B990767

A

B

C

MB990241

MB991354

A

B C AC100320AB

B

A

MB990590

MB990560

REAR SUSPENSION

34-5

SPECIAL TOOLS

Tool

Number

Name

Use

MB990934

Adapter

Wheel bearing removal <4WD>

MB990938

Bar

MB991400

Rear wheel bearing and hub installer

Wheel bearing pressfitting <4WD> Rear hub assembly press-fitting <4WD>

MB991401

Rear wheel bearing and hub installer base

Wheel bearing pressfitting <4WD>

MB991411

Rear wheel bearing and hub installer

Rear hub assembly press-fitting <4WD>

MB991444

Bushing remover and installer arbor

Trailing arm bushing removal and press-fitting

MB991445

Bushing remover and installer base

A: MB991237 B: MB991239

A: Spring compressor body B: Arm set

B990938

MB991400

MB991401

MB991411

B991444

A B

MB991237

Coil spring removal and installation

REAR SUSPENSION

34-6

ON-VEHICLE SERVICE

ON-VEHICLE SERVICE REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT M1341011000349

Measure wheel alignment with an alignment equipment on level earth. The rear suspension, wheels, and tyres should be serviced to the normal condition prior to wheel alignment measurement. CAMBER Standard value: -0 40’ 30’ (Left/right deviation within 30’) NOTE: Camber is preset at the factory and cannot be adjusted.

CAUTION Never subject the wheel bearings to the vehicle load when the trailing arm spindle self-locking nuts (2WD), the driveshaft nuts (4WD), or the special tool wheel alignment gauge attachment (MB991004 or MB991014) are loosened. NOTE: <2WD-vehicles with aluminium wheels> MB991014

NOTE: <4WD-vehicles with aluminium wheels> MB991004

AC001079 AE

For 4WD-vehicles with aluminium wheels, attach the camber/caster/kingpin gauge to the driveshaft by using special tool wheel alignment gauge attachment (MB991004). Tighten the special tool to the same torque 245 29 N¼m as the driveshaft nut. TOE-IN Standard value: At the centre of tyre tread: 3 2 mm Toe angle (per wheel): 008’ 05’ If toe-in is not within the standard value, adjust by following procedures.

CAUTION To prevent bushings from breakage, the toe adjusting bolt should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. AC001079 AD

For 2WD-vehicles with aluminium wheels, attach the camber/caster/kingpin gauge to the trailing arm spindle by using special tool wheel alignment gauge attachment (MB991014). Tighten the special tool to the same torque 175 25 N¼m as the trailing arm spindle self-locking nut.

Toe adjusting bolt Control link

120 ± 10 N·m Control link AC107070 AC

Carry out adjustment by turning the toe adjusting bolt (control link mounting bolt which is located on the inner side of the body). NOTE: . LH: Clockwise viewed from the front Toe-in RH: Clockwise viewed from the front Toe-out Turning the toe adjusting bolt by one groove of the scale, toe can be changed approximately 2.6 mm (single side toe angle equivalent to 16’).

REAR SUSPENSION

34-7

CONTROL LINK, UPPER ARM AND LOWER ARM

LOWER ARM PILLOW BALL BUSHING AXIAL PLAY CHECK M1341016900046

1. Raise the vehicle. 2. Remove the stabilizer link and shock absorber from the lower arm assembly. 3. Move the lower arm up and down with your hands to check for an excessive play in the axial direction of the pillow ball bushing. If there is an excessive play, replace the lower arm pillow ball bushing (Refer to 334).

4. After inspection, install the stabilizer link and shock absorber to the lower arm assembly (Refer to 334).

STABILIZER LINK BALL JOINT DUST COVER INSPECTION M1341012800252

1. Check dust covers for cracks or damage by pushing it with your finger. 2. If a dust cover is cracked or damaged, replace the stabilizer link. NOTE: Cracks or damage to the dust cover may cause damage to the ball joint.

CONTROL LINK, UPPER ARM AND LOWER ARM REMOVAL AND INSTALLATION M1341004800161

CAUTION *

: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition. Post-installation Operation Rear Wheel Alignment Check and Adjustment (Refer to 334).

120 ± 10 N·m*

39± 5 N·m 95 ± 15 N·m*

3

5

2 120 ± 10 N·m*

90 ± 10 N·m*

6

120 ± 10 N·m*

1 95 ± 15 N·m*

4

<> >>A<< 1. >>A<< 2.

Control link and upper arm removal steps Control link Upper arm

95 ± 15 N·m*

AC107089 AC

<>

3. 4. 5. 6.

Lower arm removal steps Stabilizer link connection Lower arm and trailing arm connection Shock absorber connection Lower arm

REAR SUSPENSION

34-8




<> CONTROL LINK REMOVAL

Check the bushings for wear and deterioration. Check the control link, upper arm and lower arm for bending or breakage. Check all bolts for condition and straightness. CONTROL LINK/UPPER ARM/LOWER ARM PILLOW BALL BUSHING STARTING TORQUE CHECK

Mating mark

Control link pillow ball bushing AC107125 AB

After making a mating mark on the toe-in adjusting bolt, remove the control link. <> LOWER ARM AND TRAILING ARM DISCONNECTION

Upper arm pillow ball bushing

Lower arm pillow ball bushing

Piece of wood

AC107126 AB

After supporting the lower arm with a jack, separate the lower arm and the trailing arm.

INSTALLATION SERVICE POINT >>A<< UPPER ARM/CONTROL LINK INSTALLATION

AC107127 AC

Check each pillow ball bushing as follows. 1. Insert the mounting bolt to the pillow ball bushing. In the opposite direction, insert a washer, then install the mounting nut. MB990326

Identification colour Upper arm

Control link AC102498 AC

Trailing arm

AC300343 AB

Install the upper arm/control link as shown so that its identification colour faces the trailing arm.

2. After rotating the inner sleeve (contained washer) several times, measure the starting torque of the pillow ball bushing using special tool preload socket (MB990326). Standard value: 0.5 - 3.0 N¼m 3. If the measured value exceeds the standard value, replace the control link, the upper arm, or the lower arm pillow ball bushing.

REAR SUSPENSION

34-9


4. If the measured value is lower than the standard value, check that the pillow ball bushing turns smoothly without excessive play. If there is no excessive play and it turns smoothly, the pillow ball bushing can be reused.

LOWER ARM BUSHING AND LOWER ARM PILLOW BALL BUSHING REPLACEMENT M1341011800196

Lower arm pillow ball bushing

MB991447: Bushing Remover and Installer MB991448: Bushing Remover and Installer Base MB991449: Bushing Remover and Installer Supporter After press fitting, the space between the edges of the bushing outer sleeve and of the lower arm should be 1.5 mm. LOWER ARM PILLOW BALL BUSHING REPLACEMENT MB990996 3 mm

Lower arm bushing

Lower arm MB990969 MB990971 AC107128 AC

Replace the lower arm bushing and lower arm pillow ball bushing as follows. LOWER ARM BUSHING REPLACEMENT

CAUTION Because the outside of both edges of the bushing are different, be careful not to mistake the direction. Driving Out MB991447 Lower arm MB991449 MB991448 AC006168 AC

Press-Fitting MB991447

1.5 mm

Lower arm MB991449 MB991448 AC006169 AC

Use following special tools to drive out and press fit the bushing.

AC102522 AC

Use following special tools to drive out and press fit the bushing. MB990957: Lower Arm Bushing Remover and Installer MB990969: Guide MB990971: Base MB990996: Lower Arm Bushing Arbor After press fitting, the space between the edges of the bushing outer sleeve and of the lower arm should be 3 mm.

REAR SUSPENSION

34-10

TRAILING ARM ASSEMBLY

TRAILING ARM ASSEMBLY REMOVAL AND INSTALLATION <2WD> M1341002200323

CAUTION *

: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Pre-removal Operation Brake Fluid Draining Rear ABS Sensor Removal (Refer to GROUP 35B, ABS Sensor 335B). Rear Brake Caliper Assembly Removal (Refer to GROUP 35A, Rear Disc Brake Assembly 335A). Rear Hub Assembly Removal (Refer to GROUP 27A, Rear Axle Hub Assembly 327A).

Post-installation Operation Rear Hub Assembly Installation (Refer to GROUP 27A, Rear Axle Hub Assembly 327A). Rear Brake Caliper Assembly Installation (Refer to GROUP 35A, Rear Disc Brake Assembly 335A). Rear ABS Sensor Installation (Refer to GROUP 35B, ABS Sensor 335B). Brake Fluid Supplying and Bleeding (Refer to GROUP 35A, On-vehicle Service - Bleeding 335A). Rear Wheel Alignment Check and Adjustment (Refer to 334). Parking Brake Lever Stroke Adjustment (Refer to GROUP 36, On-vehicle Service - Parking Brake Lever Stroke Check and Adjustment 336).

6

120 ± 10 N·m* 15 ± 2 N·m

90 ± 10 N·m* 120 ± 10 N·m*

9

10

11

2

5

39 ± 5 N·m

4 8

3

63 ± 7 N·m

95 ± 15 N·m* 95 ± 15 N·m

1 7

AC301223 AB

1.

2. 3. 4.

Removal steps Parking brake cable connection (Refer to GROUP 36, Parking Brake Cable 336). Brake hose and trailing arm connection Lower arm and stabilizer link connection Lower arm and shock absorber connection

5. 6.

<>

7. 8. 9.

Removal steps&RQWLQXHG Control link and trailing arm connection Upper arm and trailing arm connection Lower arm and trailing arm connection Rear parking brake assembly Trailing arm and trailing arm bracket connecting bolt

REAR SUSPENSION

34-11

TRAILING ARM ASSEMBLY Removal steps&RQWLQXHG 10. Trailing arm 11. Trailing arm bracket

REMOVAL SERVICE POINT <> LOWER ARM AND TRAILING ARM DISCONNECTION

Piece of wood

AC107126 AB

After supporting the lower arm with a jack, separate the lower arm and trailing arm connection.

REAR SUSPENSION

34-12


REMOVAL AND INSTALLATION <4WD> M1341002200334

CAUTION *:

Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Pre-removal Operation Brake Fluid Draining Rear ABS Sensor Removal (Refer to GROUP 35B, ABS Sensor 335B).

120 ± 10 N·m*

4 120 ± 10 N·m* 90 ± 10 N·m*

9

Post-installation Operation Rear ABS Sensor Installation (Refer to GROUP 35B, ABS Sensor 335B). Brake Fluid Supplying and Bleeding (Refer to GROUP 35A, On-vehicle Service - Bleeding 335A). Rear Wheel Alignment Check and Adjustment (Refer to 334). Parking Brake Lever Stroke Adjustment (Refer to GROUP 36, On-vehicle Service - Parking Brake Lever Stroke Check and Adjustment 336).

15 ± 2 N·m

60 ± 5 N·m

17

14 7

3

N 16

39 ± 5 N·m

1 12

6 15

5 95 ± 15 N·m

10 N

95 ± 15 N·m* 63 ± 7 N·m

8

13 245 ± 29 N·m

2 1. 2. 3. 4. 5. 6. 7.

<>

8.

11

Removal steps Brake hose and trailing arm connection Parking brake cable Rear brake caliper assembly Upper arm and trailing arm connection Lower arm and stabilizer link connection Lower arm and shock absorber connection Control link and trailing arm connection Lower arm and trailing arm connection

AC300347 AB

9.

<>

>>C<<

<> <>

>>B<<

<>

>>A<<

10. 11. 12. 13. 14. 15. 16. 17.

Removal steps&RQWLQXHG Trailing arm and trailing arm bracket connecting bolt Drive shaft nut Brake disc Drive shaft connection Rear hub assembly Rear parking brake assembly Trailing arm bracket Snap ring Wheel bearing Trailing arm

REAR SUSPENSION

34-13


REMOVAL SERVICE POINTS <> LOWER ARM AND TRAILING ARM DISCONNECTION

Use special tool end yoke holder (MB990767) to fix the rear axle hub, and then remove the drive shaft nut. <> DRIVE SHAFT DISCONNECTION MB990242 (MB990241) MB990767

MB990244 (MB990241) (Three)

Piece of wood

AC107126 AB

MB991354

After supporting the lower arm with a jack, separate the lower arm and trailing arm connection. <> DRIVE SHAFT NUT REMOVAL

CAUTION Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage to the wheel bearing before tightening the drive shaft nut fully. MB990767

AC102719 AC

1. Use following special tools to push out the drive shaft from the hub. MB990241: Axle Shaft Puller MB990242: Puller Shaft MB990244: Puller Bar MB990767: End Yoke Holder MB991354: Puller Body 2. Hang the drive shaft on the vehicle body with a rope.

CAUTION 245 ± 29 N·m

AC102718 AC

MB991017 MB991000

Wheel bearing AC102720 AC

MB990767 AC201826 AC

Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft is removed. If, however, vehicle weight must be applied to the bearing in moving the vehicle, temporarily secure the wheel bearing by using special tools front hub remover and installer, and spacer (MB991000 and MB991017).

REAR SUSPENSION

34-14


<> REAR HUB ASSEMBLY REMOVAL MB990938

CAUTION Replace the wheel bearing with a new part because wheel bearing frictional surface will be damaged when removing the hub.

MB990934 Trailing arm

MB990211 AC103550AC

MB991354 MB990244 (Three)

AC203557 AC

Use following special tools to pull out the rear hub assembly. MB990211: Sliding Hammer MB990241: Axle Shaft Puller MB990244: Puller Bar MB991354: Puller Body

2. Use following special tools to remove the wheel bearing from the trailing arm. MB990934: Adapter MB990938: Bar

INSTALLATION SERVICE POINTS >>A<< WHEEL BEARING INSTALLATION MB991400 Wheel bearing

<> WHEEL BEARING REMOVAL Wheel bearing inner race (outside)

Trailing arm

Socket

MB991401

MB990560

Rear hub assembly AC103549 AC

1. Use special tool bearing remover (MB990560) to remove the wheel bearing inner race (outside) from the rear hub assembly. AC103551 AC

Use following special tools to press-in the wheel bearing. MB991400: Rear Wheel Bearing and Hub Installer MB991401: Rear Wheel Bearing and Hub Installer Base

REAR SUSPENSION

34-15


>>B<< REAR HUB ASSEMBLY INSTALLATION

CAUTION If the wheel bearing inner race has been pushed out, set the wheel bearing to the trailing arm again before installing the rear hub assembly.

2. Use special tool end yoke holder (MB990767) to fix the rear axle hub, and the tighten the drive shaft nut fully.


Check the bushings for wear and deterioration. Check the trailing arm for bending or damage. MB991400

TRAILING ARM BUSHING REPLACEMENT

Rear hub assembly

M1341011300209

Driving Out MB991444 Trailing arm

Trailing arm

MB991411 MB991445 AC102542AD

1. Use following special tools to drive out the trailing arm bushing. MB991444: Bushing Remover and Installer Arbor MB991445: Bushing Remover and Installer Base AC103682 AC

Use following special tools to press-in the rear hub assembly. MB991400: Rear Wheel Bearing and Hub Installer MB991411: Rear Wheel Bearing and Hub Installer Parallel

>>C<< DRIVE SHAFT NUT INSTALLATION

CAUTION

AC102539 AC

Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage to the wheel bearing before tightening the drive shaft nut fully. 245 ± 29 N·m MB990767

Washer

AC102721 AC

1. Assemble the drive shaft washer in the illustrated direction.

2. Set the installation direction and installation location of the trailing arm bushing. (1) Place the long projection end of the trailing arm bushing inner pipe towards the inside of the vehicle. (2) Make sure that the hollow of the trailing arm bushing is located as shown in the illustration.

REAR SUSPENSION

34-16


Press-Fitting MB991444 16.2 ± 0.5 mm Trailing arm

MB991445 AC102542AE

3. Using the special tools, press the trailing arm bushing into the position shown.

REAR SUSPENSION

34-17

SHOCK ABSORBER ASSEMBLY

SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION M1341002500238

CAUTION *

: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.

3 44 ± 5 N·m

39± 5 N·m

1

5

4 95 ± 15 N·m*

95 ± 15 N·m*

2 AC107092 AB

<>

1. 2. 3.

Removal steps Stabilizer link connection Lower arm and trailing arm connection Shock absorber mounting nut

4.

>>A<< 5.

Removal steps&RQWLQXHG Shock absorber and lower arm connecting bolt Shock absorber assembly

REAR SUSPENSION

34-18




<> LOWER ARM AND TRAILING ARM DISCONNECTION

>>A<< SHOCK ABSORBER ASSEMBLY INSTALLATION

Spring seat stepped section

Piece of wood

AC006176AB

AC107126 AB

After supporting the lower arm with a jack, separate the lower arm and trailing arm connection.

Install the spring seat stepped section so that it points towards the rear side of the vehicle.


Check the rubber parts for cracks and wear. Check the shock absorber for malfunctions, oil leakage, or abnormal noise.


25 ± 5 N·m

7

1 11

2

8

5 3 12

9 4

13

6

10

AC209952 AC

<> >>D<< 1. 2. 3. >>C<< 4. 5. 6. 7. 8.

Disassembly steps Self-locking nut Washer Upper bushing B Bracket assembly Collar Upper bushing A Plate Bump rubber

>>A<< 9. 10.

>>B<< 11. >>A<< 12. <>

13.

Disassembly steps&RQWLQXHG Upper spring pad Dust cover Coil spring Lower spring pad Shock absorber

REAR SUSPENSION

34-19



<> SHOCK ABSORBER DISPOSAL


WARNING Wear goggles when drilling to protect your eyes from flying metal debris.

CAUTION To hold the coil spring securely, install special tool arm set (MB991239) evenly, and so that the space between both arms of the special tool will be maximum within the installation range. Do not use an impact wrench to tighten the bolt of special tool spring compressor body (MB991237). It will break the special tool.

MB991237

AC102270 AC

The gas must be discharged from the shock absorber before discarding it. Place the shock absorber horizontally with its piston rod extended. Then drill a hole of approximately 3 mm in diameter at the location shown in the illustration and discharge the gas.

MB991239 AC001070 AB

1. Use following special tools to compress the coil spring. MB991237: Spring Compressor Body MB991239: Arm Set

REASSEMBLY SERVICE POINTS >>A<< LOWER SPRING PAD/UPPER SPRING PAD INSTALLATION Upper spring pad stepped section

WARNING Do not use an impact wrench to remove the self-locking nut. Vibration of the impact wrench will cause special tools (MB991237 and MB991239) to slip and cause personal injury. Spring seat stepped section

AC107186AB

Piston rod

AC102268AC

2. While holding the piston rod, remove the selflocking nut.

Align the stepped section of the lower spring pad with the stepped section of the spring seat of the shock absorber, and install the lower spring pad. Align the stepped section of the upper spring pad with the end of the coil spring, and install the upper spring pad.

REAR SUSPENSION

34-20


>>B<< COIL SPRING INSTALLATION

>>C<< BRACKET ASSEMBLY INSTALLATION

CAUTION Do not use an impact wrench to tighten the bolt of special tool spring compressor body (MB991237). It will break the special tool.

MB991237

Lower bushing inner pipe

Bracket assembly mounting bolt

MB991239 AC001070 AB

1. Use following special tools to compress the coil spring, and install it to the lower spring pad. MB991237: Spring Compressor Body MB991239: Arm Set 2. Align the end of the coil spring with the stepped section of the lower spring pad.

Lower bushing inner pipe AC107187 AB

Install the bracket assembly so that the lower bushing inner pipe of the shock absorber and the line between the bracket mounting bolts are straight when looking from above. >>D<< SELF-LOCKING NUT INSTALLATION 1. Temporarily tighten the self-locking nut.

CAUTION Do not use an impact wrench to tighten the selflocking nut, otherwise the self-locking nut will be damaged. 2. Remove the special tools, and then tighten the self-locking nut to 25 5 N¼m.

REAR SUSPENSION

34-21

STABILIZER BAR

STABILIZER BAR REMOVAL AND INSTALLATION M1341003000236

Post-installation Operation Press the dust cover with your finger to check that there are no cracks or damage in the dust cover.

4 <2WD>

2 3 12 ± 2 N·m

39 ± 5 N·m

4 <4WD> 12 ± 2 N·m

1 2

39 ± 5 N·m

3

1

39 ± 5 N·m

1 Specified grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent AC301224 AB

>>A<<

1. 2.

Removal steps Stabilizer link Fixture

>>A<< >>A<<

3. 4.

Removal steps&RQWLQXHG Bushing Stabilizer bar

REAR SUSPENSION

34-22

STABILIZER BAR

INSTALLATION SERVICE POINT >>A<< STABILIZER BAR/BUSHING/FIXTURE INSTALLATION Outside of vehicle

Bushing (LH)

Stopper

Fixture (LH) AC200960 AC

Install the stabilizer bar, the bushings and the fixtures so that the stoppers come inboard of the bushings.


Check the bushings for wear and deterioration. Check the stabilizer bar for deterioration or damage. Check all bolts for condition and straightness. STABILIZER LINK BALL JOINT TURNING TORQUE CHECK

3. If the measured value is lower than the standard value, check that the ball joint turns smoothly without excessive play. If so, it is possible to reuse that ball joint. STABILIZER LINK BALL JOINT DUST COVER CHECK 1. Check the dust cover for cracks or damage by pushing it with your finger. 2. If the dust cover is cracked or damaged, replace the stabilizer link. NOTE: Cracks or damage of the dust cover may cause damage to the ball joint. When it is damaged during service work, replace the dust cover (Refer to 334).

STABILIZER LINK BALL JOINT DUST COVER REPLACEMENT M1341010900220

Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows:

MB990326

Clip ring AC006188AB

AC001129 AB

1. After shaking the ball joint stud several times, install the nut to the stud and use special tool preload socket (MB990326) to measure the turning torque of the ball joint. Standard value: 1.7 - 3.1 N¼m 2. If the measured value exceeds the standard value, replace the stabilizer link.

1. Remove the clip ring and the dust cover. 2. Apply specified grease to the inside of a new dust cover. Specified grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent 3. Wrap plastic tape around the stabilizer link stud, and then install the dust cover to the stabilizer link. 4. Secure the dust cover by the clip ring. 5. Check the dust cover for cracks or damage by pushing it with finger.

REAR SUSPENSION

34-23

REAR SUSPENSION CROSSMEMBER

REAR SUSPENSION CROSSMEMBER REMOVAL AND INSTALLATION M1341006800156

Pre-removal Operation Main Muffler, Centre Exhaust Pipe Removal (Refer to GROUP 15, Exhaust pipe and Main Muffler 315). Control Link, Upper Arm, Lower Arm Removal (Refer to 334). Stabilizer Bar Removal (Refer to 334). Fuel Filler Neck Protector Removal (Refer to GROUP 13B, Fuel Tank 313B).

Post-installation Operation Fuel Filler Neck Protector Installation (Refer to GROUP 13B, Fuel Tank 313B). Stabilizer Bar Installation (Refer to 334). Control Link, Upper Arm, Lower Arm Installation (Refer to 334). Main Muffler, Centre Exhaust Pipe Installation (Refer to GROUP 15, Exhaust pipe and Main Muffler 315). Rear Wheel Alignment Check and Adjustment (Refer to 334).

5

90 ± 10 N·m

3

2

N

90 ± 10 N·m

4

N

1

44 ± 9 N·m

95 ± 15 N·m AC107129 AB

1. 2.

Removal steps Dynamic damper <4WD> Differential support arm connecting bolt <4WD>

3. 4. 5.

Removal steps&RQWLQXHG Rear suspension crossmember Differential support arm <4WD> Plug


Check the crossmember for cracks or deformation. Check all bolts for condition and straightness.

127(6

36-1

GROUP 36

00 11

PARKING BRAKES

12 13 14

CONTENTS GENERAL INFORMATION . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS . . . . . . . . . . .

ON-VEHICLE SERVICE. . . . . . . . . . . PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT . . . . . . . . . . . LINING RUNNING-IN . . . . . . . . . . . . . . . . . PARKING BRAKE SWITCH CHECK . . . . .

36

15

PARKING BRAKE LEVER . . . . . . . . .

36


36

PARKING BRAKE CABLE. . . . . . . . .

36


36

36 36

36

16 17 21 22

36

PARKING BRAKE LINING AND DRUM . . . . . . . . . . . . . . . . . . . . . . . . .

36

36


36

36

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

36

25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

PARKING BRAKES

36-2

GENERAL INFORMATION


The parking brake is of a mechanical rear-wheel acting type, and its operation utilises a parking brake lever.

SPECIFICATIONS Item

Specification

Type

Drum-in disc

Clearance adjustment

Automatic

CONSTRUCTION DIAGRAM Drum-in disc brake

Parking brake lever

Parking brake cable

AC301225 AB

SPECIFICATIONS SERVICE SPECIFICATIONS M1361000300359

Item

Standard value

Limit

Parking brake lever stroke

4 - 5 notches

-

Rear brake lining thickness mm

2.8

1.0

Rear drum inside diameter mm

168.0

169.0

PARKING BRAKES ON-VEHICLE SERVICE

36-3

ON-VEHICLE SERVICE PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT M1361000900317

Pull the parking brake lever with a force of approximately 200 N and count the number of notches. Standard value: 4 - 5 notches 1. If the parking brake lever stroke is not the standard value, adjust as described below. (1) Remove the floor console assembly (Refer to GROUP 52A, Rear Floor Console 352A). Cable rod

CAUTION If the parking brake lever stroke is below the standard value and the braking is too firm, the rear brakes may drag. (4) Adjust the parking brake lever stroke to the standard value by turning the adjusting nut. After the adjustment, ensure that there is no free play between the adjusting nut and the parking brake lever. (5) After the parking brake lever stroke is adjusted, raise the rear of the vehicle. Release the parking brake, turn the rear wheels to confirm that the rear brakes are not dragging.

LINING RUNNING-IN M1361001100239

CAUTION Adjusting nut

AC107239 AD

(2) Loosen the adjusting nut to move it to the cable rod end so that the cable will be free. Adjuster

AC202320 AC

(3) Remove the rear brake adjusting hole plug. Then insert a flat-tipped screwdriver to turn the adjuster to the arrow direction (to expand the shoe) until the parking brake shoe makes contact and the disc can no longer be turned. Back off the adjuster to the opposite direction by five notches.

Carry out running-in in a place with good visibility, and pay careful attention to safety. Carry out running-in by the following procedure when replacing the parking brake linings or the rear brake disc rotors, or when brake performance is insufficient. 1. Adjust the parking brake lever stroke to the specified value. Specified value: 4 - 5 notches [Operation force: Approx. 200 N] 2. Hook a spring balance onto the centre of the parking brake lever grip and pull it with a force of 100 - 150 N in a direction perpendicular to the handle. 3. Drive the vehicle at a constant speed of 35 - 50 km/h for 100 metres. 4. Release the parking brake and let the brakes cool for 5 - 10 minutes. 5. Repeat the procedure in steps 2 to 4 four or five times.

PARKING BRAKES

36-4

ON-VEHICLE SERVICE

PARKING BRAKE SWITCH CHECK M1361003300347

AC300397

1. Remove the floor console assembly (Refer to GROUP 52A, Rear Floor Console 352A). 2. Check for continuity between the parking brake switch terminal and the switch mounting bolt. When parking brake lever is pulled

Less than 2 W

When parking brake lever is released

Open circuit

PARKING BRAKES

36-5

PARKING BRAKE LEVER

PARKING BRAKE LEVER REMOVAL AND INSTALLATION M1361001300307

Pre-removal Operation Rear Floor Console Assembly Removal (Refer to GROUP 52A, Floor Console 352A).

Post-installation Operation Parking Brake Lever Stroke Adjustment (Refer to 336). Rear Floor Console Assembly Installation (Refer to GROUP 52A, Floor Console 352A).

4

1 5 3 2

AC107292 AC107457AC

Section A - A

A

Section B - B

B A

Ratchet pawl B AC107247

1. 2. 3. 4. 5.

Removal steps Adjusting nut Parking brake switch connector Parking brake cable connection Parking brake lever assembly Parking brake switch

AC107249

AC107248

PARKING BRAKES

36-6

PARKING BRAKE CABLE

PARKING BRAKE CABLE REMOVAL AND INSTALLATION M1361001900462

Pre-removal Operation Rear Floor Console Assembly Removal (Refer to GROUP 52A, Floor Console 352A).

Post-installation Operation Parking Brake Lever Stroke adjustment (Refer to 336). Rear Floor Console Assembly Installation (Refer to GROUP 52A - Floor Console 352A).

3

1 2 AC301226 AB

Removal steps Shoe and lining assembly (Refer to 336). Loosen the adjusting nuts. Turn up the driver’s side carpet.

1. 2. 3.

Removal steps&RQWLQXHG Parking brake cable connection Parking brake cable connection Parking brake cable

PARKING BRAKES

36-7

PARKING BRAKE LINING AND DRUM

PARKING BRAKE LINING AND DRUM REMOVAL AND INSTALLATION M1361002500274

Post-installation Operation Parking Brake Lever Stroke Check and Adjustment (Refer to 336). Lining Running-in (Refer to 336). Floor Console Installation (Refer to GROUP 52A, Floor Console 352A).

12

15

13 5

4

14

60 ± 5 N·m

3 8

1

9

16 63 ± 7 N·m

13 11 10

6

2

7

AC300145 AB

13

13

7 16 Brake grease: Multipurpose grease

<>

Removal steps 1. Rear brake caliper assembly 2. Rear brake disc >>B<< 3. Shoe-to-anchor spring >>B<< 4. Shoe-to-anchor spring 5. Shoe guide plate 6. Adjusting wheel spring >>A<< 7. Adjuster assembly 8. Strut 9. Strut-to-shoe spring 10. Shoe hold-down cup

Removal steps&RQWLQXHG Shoe hold-down spring Shoe hold-down pin Shoe and lining assembly Clip Rear hub assembly (For 2WD, refer to GROUP 27A, Rear Hub Assembly 327A. For 4WD, refer to GROUP 27B, Rear Hub Assembly 327B). 16. Backing plate 11. 12. 13. 14. 15.

PARKING BRAKES

36-8

PARKING BRAKE LINING AND DRUM


INSPECTION

<> REAR BRAKE CALIPER ASSEMBLY REMOVAL Remove the rear brake caliper assembly and support it with wire or something similar.

M1361002600226

PARKING BRAKE LINING AND BRAKE DRUM CHECK

INSTALLATION SERVICE POINTS >>A<< ADJUSTER ASSEMBLY INSTALLATION

ACX00708AB

Shoe adjusting bolt AC202301AC

Install the adjuster so that the shoe adjusting bolt for the left hand wheel is attached towards the rear of the vehicle, and the shoe adjusting bolt for the right hand wheel is towards the front of the vehicle.

1. Measure the thickness of the brake lining at several places. Standard value: 2.8 mm Limit: 1.0 mm 2. If the thickness of the brake lining is below the limit, replace the shoe and lining assemblies on both sides of the vehicle. Never replace only one side.

>>B<< SHOE-TO-ANCHOR SPRING INSTALLATION

Front of the vehicle

ACX00709

Blue paint

Yellow paint AC202302AC

The shoe-to-anchor springs are not interchangeable as their constants are different. The one with blue paint mark should be install at the front of the vehicle, and the other with yellow paint at the rear of the vehicle, respectively. NOTE: The illustration shows the left rear wheel. The right rear wheel is symmetrical to that.

3. Measure the inside diameter of the brake disc in two places or more. Standard value: 168.0 mm Limit: 169.0 mm 4. If the inside diameter exceeds the limit, or if it is excessively worn on one side, replace the brake disc.

35-1

GROUP 35

SERVICE BRAKES

00 11 12 13

CONTENTS

14 15 16

BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A

17

ANTI-SKID BRAKING SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . 35B

21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

127(6

35A-1

GROUP 35A

00 11

BASIC BRAKE SYSTEM

12 13 14 15 16

CONTENTS


35A


35A

LUBRICANTS . . . . . . . . . . . . . . . . . .

35A

SEALANT. . . . . . . . . . . . . . . . . . . . . .

35A

SPECIAL TOOLS. . . . . . . . . . . . . . . .

35A


35A

BRAKE PEDAL CHECK AND ADJUSTMENT ..................................

35A

BRAKE BOOSTER OPERATING TEST . . .

35A

CHECK VALVE OPERATION CHECK . . . .

35A

BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . .

35A

BRAKE FLUID LEVEL SENSOR CHECK. .

35A

DISC BRAKE PAD CHECK AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . .

35A

DISC BRAKE ROTOR CHECK. . . . . . . . . .

35A

BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A

21


35A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

35A

22

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER . . . . . . . . . . . . . . . 35A

25


35A

MASTER CYLINDER . . . . . . . . . . . . . . . . .

35A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

35A

26 27 31

FRONT DISC BRAKE ASSEMBLY . . 35A

32


35A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

35A


35A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

35A

34

REAR DISC BRAKE ASSEMBLY . . . 35A

35


35A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

35A


35A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

35A

33

36 37 42 51 52 54 55

BASIC BRAKE SYSTEM

35A-2

GENERAL INFORMATION


The brake system offers high dependability and durability along with improved braking performance and brake sensitivity. CONFIGURATION DIAGRAM

Brake booster Hydraulic unit (Integrated with ABS-ECU)

Parking brake

Master cylinder

Rear disc brake

Front disc brake

AC300584 AC

SPECIFICATIONS Item Master cylinder Brake booster

Specification Type

Tandem type

I.D. mm

25.4

Type

Vacuum type, tandem

Effective dia. of power cylinder mm

205 + 230

Boosting ratio

7.5

Rear wheel hydraulic control method

Electronic brake-force distribution (EBD)

Front brakes

Floating caliper, 2 piston, ventilated disc

Type

Disc effective diameter thickness mm 246 24

Rear disc brakes

Wheel cylinder I.D. mm

42.9


Automatic

Type

Floating caliper, 1 piston, solid disc

Disc effective dia. thickness mm

226 10

Wheel cylinder I.D. mm

38.1


Automatic

BASIC BRAKE SYSTEM

35A-3



Item

Standard value

Limit

Brake pedal height mm

150 - 153

-

Brake pedal free play mm

3-8

-

Brake pedal to floor board clearance mm

100 or more

-

Disc brake pad thickness mm

10.0

2.0

Front

24.0

22.4

Rear

10.0

8.4

Front

-

0.04

Rear

-

0.05

Disc brake drag force N

Front/Rear

68 or less

-


Front/Rear

-

0.05

10.15 - 10.40

-

Disc brake disc thickness mm Disc brake disc run-out mm

Brake booster push rod protruding length mm (When applying negative pressure of 66.7 kPa to the brake booster)


Item

Specified lubricant

Brake fluid

DOT3 or DOT4

Guide pin

Repair kit grease

Lock pin Guide pin boot inner surface Lock pin boot inner surface Piston boot mounting grooves Brake piston boot inner surface Guide pin bush inner surface

SEALANT M1351000500329

Item

Specified sealant

Remark

Rear hub cap <2WD>

3M ATD Part No.8661, 8663 or equivalent

Semi-drying sealant

Fitting thread part

BASIC BRAKE SYSTEM

35A-4

SPECIAL TOOLS


Tool

A B

Number

Name

Use

MB991568

Push rod adjusting Adjustment of the brake booster push rod protrusion amount socket

MB990964 A: MB990520

Brake tool set A: Disc brake piston expander

Pushing-in of the disc brake piston

MB990964

ON-VEHICLE SERVICE BRAKE PEDAL CHECK AND ADJUSTMENT M1351000900394

BRAKE PEDAL HEIGHT 1. Turn up the carpet, etc. under the brake pedal.

Clevis

AC006217AD

A AC200515 AC

2. Measure the brake pedal height as illustrated. Standard value (A): 150 - 153 mm [From the surface of floor board to the face of pedal pad] 3. If the brake pedal height is not within the standard value, follow the procedure below. (1) Disconnect the stop lamp switch connector. (2) Remove the brake booster (Refer to 335A ). NOTE: With the master cylinder and brake pipe connected, remove the brake booster only.

(3) Adjust the brake pedal height by turning the clevis. NOTE: When the clevis is turned 180, the pedal height is changed approximately 2.4 mm. (4) Install the brake booster (Refer to 335A). (5) Measure the brake pedal height, and ensure that the measured value is within the standard value. When it is out of the standard value, repeat Step (2) - (5).

BASIC BRAKE SYSTEM

35A-5

ON-VEHICLE SERVICE

CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR BOARD

Stopper

1. Turn up the carpet, etc. under the brake pedal.

0.5 - 1.0 mm AC101091AD

(6) Screw in the stop lamp switch until its thread contacts the stopper, and fix the stop lamp switch by turning it approximately one quarter of a turn clockwise. (7) Check that the clearance between the stop lamp switch and the stopper is as shown.

CAUTION Check that the stop lamp does not illuminate when the brake pedal is not depressed. (8) Connect the connector at the stop lamp switch. 4. Return the carpet, etc.

BRAKE PEDAL FREE PLAY

C AC107452AC

2. Start the engine, depress the brake pedal with approximately 490 N of force, and measure the clearance between the brake pedal and the floor board. Standard value (C): 100 mm or more [From the surface of floor board to the face of pedal pad] 3. If the clearance is outside the standard value, check for air trapped in the brake line, thickness of the disc brake pad, clearance between the lining and the drum and dragging in the parking brake. And then adjust and replace defective parts as required. 4. Return the carpet etc. to its original position.

BRAKE BOOSTER OPERATING TEST M1351001000327

1. For simple checking of the brake booster operation, carry out the following tests:

B AC200011AC

1. Turn the ignition switch to the "LOCK" (OFF) position, depress the brake pedal two or three times. After eliminating the vacuum in the brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (free play) is within the standard value range. Standard value: 3 - 8 mm 2. If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary: Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod Brake pedal height Installation position of the stop lamp switch, etc.

Good

No good

AC000870 AE

(1) Run the engine for one or two minutes, and then stop it. 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 unchanged, the booster is defective. Go to step 2.

BASIC BRAKE SYSTEM

35A-6

ON-VEHICLE SERVICE When engine is stopped

When engine is started

CAUTION If the check valve is defective, replace it as an assembly unit together with the vacuum hose. Valve

Spring

A

B Intake manifold side (does not hold)

AC000871AE

(2) With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective. Go to step 3. Good

No good

Booster side (holds)

AC000873 AE

2. Check the operation of the check valve by using a vacuum pump. Vacuum pump connection

Accept/reject criteria

Connection at the brake booster side (A)

A negative pressure (vacuum) is created and held.

Connection at the intake A negative pressure manifold side (B) (vacuum) is not created.

BLEEDING AC000872 AE

(3) With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective. 2. If the above three tests are okay, the booster is OK. If one of the above three tests is not okay, the check valve, vacuum hose, or booster is defective. Check the check valve (Refer to 335A), vacuum hose for leaks, high volume engine vacuum applied to booster. Repair or replace as necessary. If these are OK, replace the booster and repeat this test starting at Step 1.

M1351001400400

CAUTION Use only brake fluid DOT 3 or DOT 4. Never mix the specified brake fluid with other fluid as it will influence the braking performance significantly. MASTER CYLINDER BLEEDING The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier (When brake fluid is not contained in the master cylinder). 1. Fill the reserve tank with brake fluid. 2. Keep the brake pedal depressed.

CHECK VALVE OPERATION CHECK M1351009000321

CAUTION The check valve should not be removed from the vacuum hose. 1. Remove the vacuum hose (Refer to 335A).

Outlet

Outlet AC301227 AB

3. Have another person cover the master cylinder outlet with a finger.

BASIC BRAKE SYSTEM ON-VEHICLE SERVICE

4. With the outlet still closed, release the brake pedal. 5. Repeat steps 2 - 4 three or four times to fill the inside of the master cylinder with brake fluid. BRAKE LINE BLEEDING

4

1

35A-7

CAUTION Whenever a pad must be replaced, replace both LH and RH wheel pads as a set to prevent the vehicle from pulling to one side when braking. If there is a significant difference in the thicknesses of the pads on the left and right sides, check the sliding condition of the piston and slide pins.

2

3 AC301228 AB

Start the engine and bleed the air in the sequence shown in the figure.

BRAKE FLUID LEVEL SENSOR CHECK M1351009100351

AC102357

The brake fluid level sensor is in good condition if there is no continuity when the float surface is above "MIN" and if there is continuity when the float surface is below "MIN".

DISC BRAKE PAD CHECK AND REPLACEMENT M1351002300343

NOTE: When new

When worn

Pad

Wear indicator

Brake disc AC000879 AD

The brake pads have indicators that contact the brake disc when the brake pad thickness becomes 2 mm, and emit a squealing sound to warn the driver.

AC301229 AB

1. Check the brake pad thickness through the caliper body check port. Standard value: 10.0 mm Minimum limit: 2.0 mm

BASIC BRAKE SYSTEM

35A-8

ON-VEHICLE SERVICE

CAUTION Do not wipe off the special grease that is on the lock pin or allow it to contaminate the lock pin.

3 2 1

5 3

3 2

5 4 1 3

AC301229 AC

2. Remove the guide/lock pin bolt. Pivot the caliper assembly and hold it with wires.

AC301230 AB

3. Remove the following parts from caliper support. (1) Pad assembly or Pad and wear indicator assembly (2) Pad assembly (3) Clip (4) Inner shim (5) Outer shim 4. In order to measure the brake drag force after pad installation, measure the rotary-sliding resistance of the hub with the pads removed. For the front brakes, refer to 335A. For the rear brakes, refer to 335A. 5. Install the pads and caliper assembly, and then check the brake drag force. For the front brakes, refer to 335A. For the rear brakes, refer to 335A.

BASIC BRAKE SYSTEM ON-VEHICLE SERVICE

35A-9

DISC BRAKE ROTOR CHECK M1351002900293

CAUTION Disc brakes must be kept within the allowable service values in order to maintain normal brake operation. Before turning the brake disc, the following conditions should be checked. Inspection item

Remark

Scratches, rust, saturated lining materials and wear

If the vehicle is not driven for a long period of time, sections of the discs that are not in contact with the pads will become rusty, causing noise and shuddering. If grooves and scratches resulting from excessive disc wear are not removed prior to installing a new pad assembly, there will be inadequate contact between the disc and the lining (pad) until the pads conform to the disc.

Run-out

Excessive run-out of the discs will increase the pedal depression resistance due to piston kick-back.

Change in thickness (parallelism)

If the thickness of the disc changes, this will cause pedal pulsation, shuddering and surging.

Inset or warping (flatness)

Overheating and improper handling while servicing will cause warping or distortion.

BRAKE DISC THICKNESS CHECK

2. If the disc thickness is less than the limits, replace it with a new one.

ACX00668

1. Using a micrometer, measure disc thickness at eight positions, approximately 45 apart and 10 mm in from the outer edge of the disc. Standard value: 24.0 mm 10.0 mm Minimum limit: 22.4 mm 8.4 mm NOTE: Thickness variation (at least 8 positions) should not be more than 0.015 mm.

BASIC BRAKE SYSTEM

35A-10

ON-VEHICLE SERVICE

CAUTION After a new brake disc is installed, always grind the brake disc with on-the-car type brake lathe. If this step is not carried out, the brake disc run-out exceeds the specified value, resulting in judder.

M12 Flat washer

ACX00669

3. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc. Limit: 0.04 mm 0.05 mm Chalk marks

M12 Flat washer

AC006226AD

When the on-the-car type lathe is used, first install M12 flat washer on the stud bolt in the brake disc side according to the figure, and then install the adapter. If the adapter is installed with M12 flat washer not seated, the brake disc rotor may be deformed, resulting in inaccurate grinding. Grind the brake disc with all wheel nuts diagonally and equally tightened to the specified torque 100 N¼m. When all numbers of wheel nuts are not used, or the tightening torque is excessive or not equal, the brake disc rotor or drum may be deformed, resulting in judder. 3. If thickness variation exceeds the specification, turn rotor with an on-the-car type brake lathe ("MAD, DL-8700PF" or equivalent). If the calculated final thickness after turning the rotor is less than the standard value, replace the disc. BRAKE DISC RUN-OUT CHECK AND CORRECTION 1. Remove the brake caliper assembly, and then hold it with wire. 2. Temporarily install the disc with the hub nut.

AC201323 AC

4. If the brake disc run-out exceeds the limit, correct it as follows: (1) Chalk phase marks on the wheel stud and the brake disc, which run-out is excessive as shown.

AC102407

(2) Remove the brake disc. Then place a dial gauge as shown, and measure the wheel bearing axial play by pushing and pulling the wheel hub. Limit: 0.05 mm (3) If the axial play exceeds the limit, disassemble the hub and knuckle/trailing arm assembly to check each part.

BASIC BRAKE SYSTEM

35A-11

ON-VEHICLE SERVICE

(4) If the axial play does not exceed the limit, dephase the brake disc and secure it. Then recheck the brake disc run-out.

CAUTION After a new brake disc is installed, always grind the brake disc with on-the-car type brake lathe. If this step is not carried out, the brake disc run-out exceeds the specified value, resulting in judder.

M12 Flat washer

M12 Flat washer

AC006226AD

When the on-the-car type lathe is used, first install M12 flat washer on the stud bolt in the brake disc side according to the figure, and then install the adapter. If the adapter is installed with M12 flat washer not seated, the brake disc rotor may be deformed, resulting in inaccurate grinding. Grind the brake disc with all wheel nuts diagonally and equally tightened to the specified torque 100 N¼m. When all numbers of wheel nuts are not used, or the tightening torque is excessive or not equal, the brake disc rotor or drum may be deformed, resulting in judder. 5. If the run-out cannot be corrected by changing the phase of the brake disc, replace the brake disc or grind it with the on-the-car type brake lathe ("MAD, DL-8700PF" or equivalent).

BASIC BRAKE SYSTEM

35A-12

BRAKE PEDAL

BRAKE PEDAL REMOVAL AND INSTALLATION M1351003400354

Post-installation Operation Brake Pedal Adjustment (Refer to 335A).

8 9 12 ± 2 N·m

5 12 ± 2 N·m

2 6

4

3

1

7

14 ± 3 N·m AC301350AB

1. 2. 3. 4. 5.

Removal steps Harness connector Stop lamp switch Adjuster Pedal stopper Snap pin

6. 7. 8. 9.

Removal steps&RQWLQXHG Pin assembly Pedal pad Reinforced bracket Brake pedal and pedal support member


STOP LAMP SWITCH CHECK

No continuity

2. There should be no continuity between the terminals when the plunger is pushed in as shown. There should be continuity when it is released. Continuity

4 mm AC006235AB

1. Connect an ohmmeter between the stop lamp switch connector terminals.

BASIC BRAKE SYSTEM

35A-13

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER REMOVAL AND INSTALLATION M1351003700355

Pre-removal Operation Air Intake Hose and Air Cleaner Removal (Refer to GROUP 15, Air Cleaner 315). Brake Fluid Draining

12 ± 2 N·m

Post-installation Operation Brake Fluid Supplying and Air Bleeding (Refer to 335A ). Brake Pedal Adjustment (Refer to 335A). Air Intake Hose and Air Cleaner Installation (Refer to GROUP 15, Air Cleaner 315).

14

2

16 ± 1 N·m

14

9

3M ATD Part No. 8661, 8663 or equivalent

5

1 4 3

5 10

15 ± 2 N·m

6 8

14 ± 3 N·m

11 10 ± 2 N·m

13

6 7

15 ± 2 N·m

12

AC301351AB

>>C<<

1. 2. 3. 4. 5. 6. 7. 8. 1. 6. 7. 8.

Master cylinder removal steps Brake fluid level sensor connector Reservoir cap assembly Reservoir Brake fluid level sensor Reservoir hose Brake pipe connection Bracket Master cylinder Brake booster removal steps Brake fluid level sensor connector Brake pipe connection Bracket Master cylinder

>>B<< >>A<< 9. 10. 11. 12. 13.

>>A<<

9. 14.

Brake booster removal steps Push rod protrusion amount check and adjustment Vacuum hose (with built-in check valve) Snap pin Pin assembly Brake booster Sealer Fitting removal steps Vacuum hose (with built-in check valve) Fitting

BASIC BRAKE SYSTEM

35A-14


INSTALLATION SERVICE POINTS >>A<< VACUUM HOSE CONNECTION Insert vacuum hose with its paint mark facing upward. >>B<< PUSH ROD PROTRUSION AMOUNT CHECK AND ADJUSTMENT Rod spline

Angle-nose pliers

A

Measuring distance A

MB991568

AC200306AC

2. If the protrusion amount is not within the standard value range, adjust the push rod length by turning the push rod. Use special tool push rod adjusting socket (MB991568) to turn the push rod while holding the rod spline with angle-nose pliers.

Block gauge AC102457BD

1. Use the vacuum pump to measure dimension "A" applying a negative pressure of 66.7 kPa to the brake booster. Standard value (A): 10.15 - 10.40 mm NOTE: When a negative pressure of 66.7 kPa is not applied to the brake booster, the push rod protrusion amount (A) should be 8.85 - 9.10 mm.

>>C<< RESERVOIR HOSE CONNECTION Paint mark Paint mark

Master cylinder AC200460AC

Insert the reservoir hose with its paint mark facing front of the vehicle.

BASIC BRAKE SYSTEM

35A-15


MASTER CYLINDER M1351004200320

DISASSEMBLY AND REASSEMBLY 4

N

1

4

2

5 6

3 5N

Master cylinder kit

7

6N

3

7 6 AC102644 AE

1. 2. 3. 4.

Disassembly steps Spring pin Nipple Reservoir seal Piston retainer

5

Brake fluid: DOT 3 or DOT 4

Disassembly steps &RQWLQXHG 5. Primary piston assembly 6. Secondary piston assembly 7. Master cylinder body


Check the inner surface of master cylinder body for rust or pitting. Check the primary and secondary pistons for rust, scoring, wear or damage.

BASIC BRAKE SYSTEM

35A-16

FRONT DISC BRAKE ASSEMBLY

FRONT DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION M1351006000377

Pre-removal Operation Brake Fluid Draining

Post-installation Operation Brake Fluid Supplying and Air Bleeding (Refer to 335A ). 100 ± 10 N·m

4 30 ± 5 N·m

N

1

2 3 AC301353 AB

Removal steps 1. Brake hose connection 2. Gasket

INSTALLATION SERVICE POINT >>A<< BRAKE CALIPER ASSEMBLY INSTALLATION


>>A<< 3. Brake caliper assembly 4. Brake disc

CAUTION Do not let any oil, grease or other contamination get onto the friction surfaces of the pads and brake discs. 2. After re-installing the caliper support to the knuckle, install the pad clips and the pads to the caliper support.

MB990520 Spring balance AC000906AF

1. In order to measure the brake drag torque, measure the hub torque with the pads removed by the following procedure. Use a spring balance to measure the hub torque in the forward direction. Record hub torque with pads removed.

AC301354 AB

3. Clean the piston and insert into cylinder with special tool disc brake piston expander (MB990520). 4. Be careful that the piston boot does not become caught, when lowering the caliper assembly and installing the guide pin bolt.

BASIC BRAKE SYSTEM FRONT DISC BRAKE ASSEMBLY

5. Check the brake drag force as follows. (1) Start the engine and hold the brake pedal down for 5 seconds. (Pedal depression force: approximately 200 N) (2) Stop the engine. (3) Turn the brake disc forward 10 times.

35A-17

(5) Calculate the drag force of the disc brake [difference between hub torque with pads installed and hub torque with pads removed]. Standard value: 68 N or less 6. If the brake drag force exceeds the standard value, disassemble and clean the piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin and guide pin.


BRAKE DISC CHECK Disc wear (Refer to 335A). Disc run-out (Refer to 335A). Spring balance AC000908 AE

(4) Use a spring balance to measure the hub torque with pads installed in the same direction as earlier.

BASIC BRAKE SYSTEM

35A-18

FRONT DISC BRAKE ASSEMBLY


14

14 12

11

74 ± 10 N·m

1

2

14

5

13 9

8

7

Clip set

14

6 7.9 ± 0.9 N·m

3

74 ± 10 N·m

4

9 5

10

8 7

6 AC202238 AD

1

2

5 9 11 8 7

11

13

9

2

7

5

6

6 3 9

10 5 Caliper kit

7

4 6

5

12

5. 6. 7. 8.

Disassembly steps Lock pin Bushing Guide pin Caliper support (including pad, clip, and shim) Pin boot Boot ring Piston boot Piston

7 Grease

Shim set

Pad set

1. 2. 3. 4.

<> <>

8

<>

9. 10. 11. 12. 13. 14.

Caliper seal kit

Disassembly steps&RQWLQXHG Piston seal Caliper body Pad and wear indicator assembly Pad assembly Outer shim Clip


35A-19

LUBRICATION POINTS

Piston seal

Grease: Repair kit grease

! CAUTION The piston seal inside the caliper seal kit is coated with a special grease. Do not wipe this grease off. Brake fluid: DOT 3 or DOT 4

AC202239 AD



35A-20


DISASSEMBLY SERVICE POINTS When disassembling the disc brakes, disassemble both sides (left and right) as a set. <> PISTON BOOT/PISTON REMOVAL

CAUTION Blow air little by little to remove the pistons. The pistons will rush out if a force of air is applied suddenly. If one piston has been removed completely, it will become impossible to remove the second piston.


Check the cylinder for wear, damage or rust. Check the piston surface for wear, damage or rust. Check the caliper body or sleeve for wear. Check the pad for damage or adhesion of grease, check the backing metal for damage. PAD WEAR CHECK

WARNING

Always replace both brake pads on each

wheel as a set. Failure to do so will result in uneven braking, which may cause unreliable brake operation. If there is significant difference in the thickness of the pads on the left and right sides, check the sliding condition of the piston and slide pins.

AC202257

Remove the pistons and the piston boots by pumping in air from the brake hose connection. Be sure to use the handle of a plastic hammer and adjust the height of the two pistons so that the pistons protrude evenly. <> PISTON SEAL REMOVAL ACX00690

CAUTION Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder.

AC301355AB

1. Remove the piston seal with your finger tip. 2. Clean the piston surface and inner cylinder with alcohol or brake fluid DOT 3 or DOT 4.

1. Measure thickness at the thinnest and most worn area of the pad. Standard value: 10.0 mm Minimum limit: 2.0 mm 2. Replace the pad assembly if pad thickness is less than the limit value.

BASIC BRAKE SYSTEM

35A-21

REAR DISC BRAKE ASSEMBLY

REAR DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION M1351007000239

Pre-removal Operation Brake Fluid Draining

Post-installation Operation Brake Fluid Supplying and Air Bleeding (Refer to 335A ).

1

15 ± 2 N·m

60 ± 5 N·m

2

3 AC201830 AC

Removal steps 1. Brake hose connection

Removal steps&RQWLQXHG >>A<< 2. Brake caliper assembly 3. Brake disc

INSTALLATION SERVICE POINT >>A<< BRAKE CALIPER ASSEMBLY INSTALLATION

CAUTION Do not let any oil, grease or other contamination get onto the friction surfaces of the pads and brake discs. 2. After re-installing the caliper support to the backing plate, install the pad clips and the pads to the caliper support.

AC201814

1. In order to measure the brake drag torque, measure the hub torque with the pads removed by the following procedure. Use a spring balance to measure the hub torque in the forward direction. Record hub torque with pads removed.

MB990520

AC301357 AB

3. Clean the piston and insert into cylinder with special tool disc brake piston expander (MB990520). 4. Be careful that the piston boot does not become caught, when lowering the caliper assembly and installing the lock pin.

35A-22

BASIC BRAKE SYSTEM REAR DISC BRAKE ASSEMBLY

5. Check the brake drag force as follows. (1) Start the engine and hold the brake pedal down for 5 seconds. (Pedal depression force: approximately 200 N) (2) Stop the engine. (3) Turn the brake disc forward 10 times.

(5) Calculate the drag force of the disc brake [difference between hub torque with pads installed and hub torque with pads removed]. Standard value: 68 N or less 6. If the brake drag force exceeds the standard value, disassemble and clean the piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin and guide pin.


BRAKE DISC CHECK Disc wear (Refer to 335A). Disc run-out (Refer to 335A). AC201815

(4) Use a spring balance to measure the hub torque with pads installed in the same direction as earlier.

BASIC BRAKE SYSTEM

35A-23

REAR DISC BRAKE ASSEMBLY


13

12

44 ± 5 N·m

3

13 14

7.9 ± 0.9 N·m

15 10 5

1

11 7

44 ± 5 N·m

13 Clip set

13 6

5

9

2 2 9

5

8 8 6

5

4

Grease AC203578 AE

10 3

11

5 9

1

Seal and boot repair kit

12

15

14

8 4

2 5

7 12

11

6

15 Grease

Brake caliper kit

<> <>

1. 2. 3. 4. 5. 6. 7. 8.

Shim set

Pad set

Disassembly steps Lock pin Bushing Guide pin Caliper support Pin boot Boot ring Piston Piston boot

<>

9. 10. 11. 12. 13. 14. 15.

Disassembly steps&RQWLQXHG Piston seal Caliper body Pad and wear indicator assembly Inner shim Clip Pad assembly Outer shim

35A-24


LUBRICATION POINTS

Piston seal

AC203550



! CAUTION The piston seal inside the seal and boot kit is coated with a special grease. Do not wipe this grease off. Brake fluid: DOT 3 or DOT 4



AC202232 AC


DISASSEMBLY SERVICE POINTS When disassembling the disc brakes, disassemble both sides (left and right) as a set. <> PISTON BOOT/PISTON REMOVAL

CAUTION

35A-25

<> PISTON SEAL REMOVAL

CAUTION Do not use a flat-tipped screwdriver or similar tool to remove piston seal. These may damage the inner side of the cylinder.

Blow air little by little to remove the piston. The piston will rush out if a force of air is applied suddenly.

ACX00689

ACX00697

Place a piece of wood, etc. against the caliper body as shown. Blow compressed air through the brake hose to remove the piston boot and piston.

1. Remove the piston seal with your finger tip. 2. Clean the piston surface and inner cylinder with alcohol or brake fluid DOT 3 or DOT 4.


Refer to 335A.

127(6

35B-1

GROUP 35B

00 11

ANTI-SKID BRAKING SYSTEM (ABS)

12 13 14 15 16 17 21

CONTENTS GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . .

35B 35B

SPECIAL TOOLS. . . . . . . . . . . . . . . .

35B


35B


35B

ABS SENSOR OUTPUT VOLTAGE MEASUREMENT . . . . . . . . . . . . . . . . . . . .

35B

HYDRAULIC UNIT CHECK . . . . . . . . . . . .

35B

IN THE EVENT OF A DISCHARGED BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .

22 35B

25

HYDRAULIC UNIT . . . . . . . . . . . . . . . 35B

26


35B

ABS SENSOR. . . . . . . . . . . . . . . . . . . 35B

27 31


35B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

35B

32

G-SENSOR . . . . . . . . . . . . . . . . . . . . . 35B

33


35B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

35B

34 35 36 37 42 51 52 54 55


35B-2

GENERAL INFORMATION


FEATURES

EBD CONTROL

The 4ABS ensures directional stability and controllability during hard braking. This ABS uses a 4-sensor 3-channel system that controls the right and left front wheels independently of each other and controls the rear wheels simultaneously (select low control*). The basic system is the same as that of former COLT/LANCER. 4WD models are equipped with G-sensor. NOTE: *Select low control: Control system that compares the speeds of the right and left wheels and performs the same fluid pressure control on both wheels according to the speed of the wheel that is likely to be locked. The system has the following features: EBD (Electronic Brake-force Distribution system) control has been added to provide the ideal braking force for the rear wheels. Fail-safe function which ensures that safety is maintained Diagnostic function which provides improved serviceability

In ABS, electronic control is used so the rear wheel brake hydraulic pressure during braking is regulated by rear wheel control solenoid valves in accordance with the vehicle’s rate of deceleration, and the front and rear wheel slippage which are calculated from the signals received from the various ABS sensors. EBD control is a control system which provides a high level of control for both vehicle braking force and vehicle stability. The system has the following features: Because the system provides the optimum rear wheel braking force regardless of vehicle load conditions and the condition of the road surface, the system reduces the required pedal depression force, particularly when the vehicle is heavily loaded or driven on road surfaces with high frictional coefficients. Because the duty placed on the front brakes is reduced, the increases in pad temperature can be controlled during front brakes application to improve the wear resistance characteristics of the pad. Control valves such as the proportioning valve are no required.

SPECIFICATIONS Item

Specification

ABS control method

4-sensor, 3-channel

Number of ABS rotor teeth Front

43

Rear

43

Type

Magnet coil type

ABS sensor

Maximum gap between sensor and rotor 0.85 mm 0.89 0.96


35B-3



ABS warning lamp

Hydraulic unit and ABS-ECU Diagnosis connector

ABS sensor (rear)

Stop lamp switch ABS rotor (front)

G-sensor <4WD>

ABS rotor (rear)

ABS sensor (front)

AC301089 AC


Item

Standard value

ABS sensor internal resistance kW

1.24 - 1.64

G-sensor output voltage <4WD> V

Stationary vehicles

2.4 - 2.6

Arrow facing downward

3.4 - 3.6


35B-4

SPECIAL TOOLS


Tool

Number

Name

Use

MB991502

MUT-II sub assembly

Checking the ABS (Diagnosis display using the MUT-II)

MB991529


Checking the ABS (Diagnosis display using the ABS warning lamp)

MB991348

Test harness set

Checking the G-sensor <4WD>

B991502

MB991529

MB991348

TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING M1352011100511


NOTES WITH REGARD TO DIAGNOSIS M1352012600177

1. The ABS is a system which controls the brake pressure by means of the operation of the ECU. Accordingly, the following symptoms may occur at times, but these are a sign of normal ABS operation, and do not indicate a malfunction. Phenomenon

Explanation of phenomenon

When the engine starts, a knocking sound can be heard coming This sound occurs as a result of system from the engine compartment. operation checking, and is not a malfunction.

Sound of the motor inside the ABS hydraulic unit operation. (whine) Sound is the generated along with vibration of the brake pedal. (scraping) When ABS operates, sound is generated from the vehicle chassis due to repeated brake application and release. (Thump: suspension; squeak: tyres)

This is the sound of normal system operation, and is not a malfunction.

Shocks are felt if the brake pedal is depressed when driving at low speed.

This is due to system operation checking (starting-of check when the vehicle speed reaches a certain number of km/h) and is not a malfunction.


35B-5

TROUBLESHOOTING

2. For road surfaces such as snow-covered roads and gravel roads, the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the customer to drive safely on such roads by lowering the vehicle speed and not being too overconfident. 3. Diagnosis detection condition can vary depending on the diagnosis code. Make sure that checking requirements listed in the "Comment" are satisfied when checking the trouble symptom again.

NOTE: The ABS waning lamp may remain on until the vehicle reaches a speed of several km/h. This is limited to cases where diagnosis code Nos. 21 to 24, 41 to 44, or 53 to 55 have been recorded because of a previous problem occurring. In this case, the ABS-ECU keeps the warning lamp illuminated until the problem corresponding to that diagnosis code can be detected. 4. If the illumination is other than the above, check the diagnosis codes.

ABS WARNING LAMP INSPECTION


M1352012000197

READING DIAGNOSIS CODES When Using the MUT-II Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points 300. When Using the ABS Warning Lamp 1. Turn the ignition switch to the "LOCK" (OFF) position. Diagnosis connector Approx. 3 s

Approx. 3 s

ABS Illuminated warning lamp Not illuminated Ignition switch

MB991529 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC107528 AH

START ON ACC AC301359 AB

Check that the ABS warning lamp illuminates as follows. 1. When the ignition switch is turned to the "ON" position, the ABS warning lamp illuminates for approximately 3 seconds and then switches off. 2. When the ignition switch is turned to the "START" position, the ABS warning lamp remains illuminated. 3. When the ignition switch is turned from the "START" position back to the "ON" position, the ABS warning lamp illuminates for approximately 3 seconds and then switches off.

2. Use special tool diagnosis code check harness (MB991529) to earth terminal number 1 (diagnosis control terminal) of the diagnosis connector. 3. Turn the ignition switch to the "ON" position.

ABS warning lamp

AC301437 AB

4. Read out a diagnosis code by observing how the warning lamp flashes.


35B-6

TROUBLESHOOTING

When the diagnosis code No.24 is set

When no diagnosis code is set 0.5 sec.

1.5 secs.

0.25 sec.

0.5 sec. Illuminated

Illuminated

Switched off

Switched off

Pause time 3 secs.

Tens signal

Place division 2 secs.

Units signal

ACX01778 AD

ACX01777 AD

5. Turn the ignition switch to the "LOCK" (OFF) position.

6. Disconnect special tool diagnosis code check harness (MB991529).

ERASING DIAGNOSIS CODES When Using the MUT-II Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points 300.

Diagnosis connector

When not Using the MUT-II NOTE: If the ABS-ECU functions have stopped due to the fail-safe function, the diagnosis code cannot be erased. 1. Turn the ignition switch to the "LOCK" (OFF) position.

MB991529 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC107528 AH

2. Use special tool diagnosis code check harness (MB991529) to earth terminal number 1 of the diagnosis connector.

Ignition switch

Stop lamp switch

ABS warning lamp

ON OFF(OFF)

ON OFF

ON OFF 3 sconds

ABS-ECU memory Within 3 sconds

Within Within Within Within Within Within Within Within Within Within 1 1 1 1 1 1 1 1 1 1 seconds seconds seconds seconds seconds seconds seconds seconds seconds seconds

1st

3. Depress the brake pedal and hold it. 4. Turn the ignition switch to the "ON" position. 5. After turning the ignition switch to the "ON", release the pedal within three seconds. Repeat this process of pressing and releasing the brake pedal 10 continuous times.

2nd

3rd

4th

5th

6th

7th

8th

9th

1 seconds

10th

Erasing of ABS-ECU diagnosis codes complete. AC000937AD

6. Turn the ignition switch to the "LOCK" (OFF) position. 7. Disconnect special tool diagnosis code check harness (MB991529).


35B-7

TROUBLESHOOTING

INSPECTION CHART FOR DIAGNOSIS CODE M1352011300559

Follow the inspection chart that is appropriate for the diagnosis code. Diagnosis code Inspection item Diagnostic content No. Open circuit or short circuit

Reference page

335B

11

Front right ABS sensor

12

Front left ABS sensor

13

Rear right ABS sensor

14

Rear left ABS sensor

16

ABS-ECU power supply system ABS-ECU power supply voltage below or above the specified value. Not displayed if the voltage recovers.

335B

21

Front right ABS sensor

335B

22

Front left ABS sensor

23

Rear right ABS sensor

24

Rear left ABS sensor

32

G sensor system <4WD>

335B

33

Stop lamp switch system

335B

41

ABS front right solenoid valve

335B

42

ABS front left solenoid valve

43

ABS rear right solenoid valve

44

ABS rear left solenoid valve

51

Valve relay problem (stays on)

Replace the hydraulic unit (Integrated with ABS-ECU).

52

Valve relay problem (stays off)

335B

53

Motor relay problem (stays off)

54

Motor relay problem (stays on)


55

Motor system (seized pump motor)

335B

63

ABS-ECU abnormality Improperly installed ABS-ECU <2WD>


NOTE: diagnosis code No.16, 52, 63 . Code No.16 is cleared from the memory by turning the ignition switch to the "ACC" position. When the system is properly reset, this code is also cleared from the memory. Code No.52 and 63 are cleared from the memory by turning the ignition switch to the "ACC" position.


35B-8

TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE PROCEDURES Code No.11, 12, 13 and 14: ABS Sensor (Open Circuit or Short Circuit) ABS Sensor Circuit ABS SENSOR (FRONT: LH)

(FRONT: RH)

(REAR: LH)

(REAR: RH)

ABS-ECU



OPERATION A toothed ABS rotor generates a voltage pulse as it moves across the pickup field of each ABS sensor. The amount of voltage generated at each wheel is determined by the clearance between the ABS rotor teeth and the ABS sensor, and by the speed of rotation. The ABS sensors transmit the frequency of the voltage pulses and the amount of voltage generated by each pulse to the ABS-ECU. The hydraulic unit modulates the amount of braking force individually applied to each wheel cylinder.

DIAGNOSIS CODE SET CONDITIONS Diagnosis codes No.11, 12, 13 and 14 are set when signal is not input due to breakage of the wires of the four ABS sensors. PROBABLE CAUSES The most likely causes for these diagnosis codes to set are: Malfunction of the ABS sensor Damaged wiring harness or connector Malfunction of the hydraulic unit (integrated with ABS-ECU)


35B-9

TROUBLESHOOTING

DIAGNOSIS STEP 1. Using MUT-II, check data list item 11, 12, 13, 14: ABS sensor. Set MUT-II to data reading mode, and check the data list items by driving the vehicle. Item 01: Front right ABS sensor Item 02: Front left ABS sensor Item 03: Rear right ABS sensor Item 04: Rear left ABS sensor OK: The reading on the speedometer nearly matches the indication on MUT-II, when driving.

STEP 3. Measure the resistance at ABS-ECU connector B-03. Connector: B-03

B-03 (GR)

Harness side

Q: Is the ABS sensor input normal? YES : This malfunction is intermittent. Refer to

GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope With Intermittent Malfunction 300. NO : Go to Step 2. STEP 2. Inspect the ABS sensor. Refer to 335B.

AC301441AB

(1) Disconnect ABS-ECU connector B-03 and measure at the harness side. Connector B-03 (harness side)

Check items: ABS sensor internal resistance: 1.24 - 1.64 kW Insulation between the ABS sensor body and the connector terminals Q: Is the ABS sensor damaged? YES : Replace it and then go to Step 8. NO : Go to Step 3.

AC301683 AB

(2) Measure the resistance between ABS-ECU connector terminals 16 and 26, 9 and 10, 27 and 28, or 11 and 17. Standard Value: 1.24 - 1.64 kW Q: Is the resistance between terminals 16 and 26, 9 and 10, 27 and 28, or 11 and 17 within the standard value? When resistances between all terminals are within the standard value : Erase the diagnosis code

memory, and recheck if any diagnosis code sets. If diagnosis code No.11, 12, 13 or 14 sets, replace the hydraulic unit (integrated with ABS-ECU). Then go to Step 8. When resistance between terminals 16 and 26 is not within the standard value : Go to Step 4. When resistance between terminals 9 and 10 is not within the standard value : Go to Step 5. When resistance between terminals 27 and 28 is not within the standard value : Go to Step 6. When resistance between terminals 11 and 17 is not within the standard value : Go to Step 7.


35B-10

TROUBLESHOOTING

STEP 4. Check the harness wires between ABSECU connector B-03 (terminals 16 and 26) and ABS sensor connector A-13 (terminals 1 and 2).

Q: Is any harness wire between ABS-ECU connector B-03 (terminals 16 and 26) and ABS sensor connector A-13 (terminals 1 and 2) damaged? YES : Repair it and go to Step 8. NO : This malfunction is intermittent. Refer to

GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope with Intermittent Malfunction300.

Connector: A-13 A-13 (B) Harness side

AC301443 AB

Connector: B-03

B-03 (GR)

Harness side

AC301441AB

NOTE: Connector : A-14

A-14(GR)

AC210455 AG

After inspecting ABS-ECU connector B-03, intermediate connector A-14 and ABS sensor connector A-13, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 8.

ANTI-SKID BRAKING SYSTEM (ABS) TROUBLESHOOTING

STEP 5. Check the harness wires between ABSECU connector B-03 (terminals 10 and 9) and ABS sensor connector A-31 (terminals 1 and 2). Connector: A-31

35B-11


1 2 3 4 5 6 7 8 9 10

A-31 (B) Harness side AC301397 AC

Connector : C-104 AC301444 AB

Connector: B-03 C-104 (B) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

B-03 (GR)

AC301397AL

After inspecting ABS-ECU connector B-03, intermediate connectors C-14 and C-104, and ABS sensor connector A-31, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 8.

Harness side

AC301441AB


GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope with Intermittent Malfunction300.


35B-12

TROUBLESHOOTING

STEP 6. Check the harness wires between ABSECU connector B-03 (terminals 28 and 27) and ABS sensor connector D-22 (terminals 1 and 2).

NOTE: Connector : C-104

Connector: B-03

C-104 (B) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

B-03 (GR)

AC301397AL

Connector: C-117

Harness side

AC301441AB

Connector: D-22

C-117

1 2 3 D-22 (B)

Harness side

111213

4 5 6 7 8 9 10

14 1516 17 1819 20 2122 2324 25 26 27 28 29 32 33 34

35

30 31 36 37

38

AC301446AB AC301396 AC

Connector : D-24

D-24 1 2 3 4 5 6 7 8

AC301410 AG

After inspecting ABS-ECU connector B-03, intermediate connectors C-104, C-117 and D-24, and ABS sensor connector D-22, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 8. Q: Is any harness wire between ABS-ECU connector B-03 (terminals 28 and 27) and ABS sensor connector D-22 (terminals 1 and 2) damaged?

YES : Repair it and then go to Step 8. NO : This malfunction is intermittent. Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunction300.


35B-13

TROUBLESHOOTING



Connector: B-03

C-104 (B) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

B-03 (GR)

AC301397AL

Connector: C-117

Harness side

AC301441AB

Connector: D-13

C-117

1 2 3

D-13 (B)

111213

4 5 6 7 8 9 10

14 1516 17 1819 20 2122 2324 25

Harness side

AC301445 AB

26 27 28 29 32 33 34

35

30 31 36 37

38

AC301396 AC

Connector : D-24

D-24 1 2 3 4 5 6 7 8

AC301410 AG

After inspecting ABS-ECU connector B-03, intermediate connectors C-104, C-117 and D-24, and ABS sensor connector D-13, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 8. Q: Is any harness wire between ABS-ECU connector B-03 (terminals 11 and 17) and ABS sensor connector D-13 (terminals 1 and 2) damaged? YES : Repair it and then go to Step 8. NO : Go to Step 8.

35B-14


STEP 8. Recheck for the diagnosis code. Q: Is diagnosis code No.11, 12, 13 or 14 set? YES : Start over at Step 1. NO : The procedure is complete.

Code No.16: ABS-ECU Power Supply System (ABS-ECU Power Supply Voltage or Valve Relay Power Supply Voltage below or above the Specified Value) ABS-ECU Power Supply Circuit IGNITION SWITCH (IG2)

ABS-ECU POWER SOURCE Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

SB : Sky blue AC301687 AB

OPERATION The ABS-ECU power is supplied to the ABS-ECU (terminal 20) from the ignition switch (IG2) through the multi-purpose fuse number 12 in the junction block.

DIAGNOSIS

DIAGNOSIS CODE SET CONDITIONS Output is provided when ABS-ECU power supply voltage drops below or rises above the specified value. Output is not provided if the power supply voltage meets the specified voltage.

Q: Is the battery damaged? YES : Charge or replace the battery and then go

PROBABLE CAUSES The most likely causes for this diagnosis code to set are: Malfunction of battery Damaged wiring harness or connector Malfunction of hydraulic unit and ABS-ECU

STEP 1. Check the battery. Refer to GROUP 54A, Battery - On-vehicle Service - Battery Test 354A.

to Step 4. NO : Go to Step 2.

STEP 2. Check the charging system. Refer to GROUP 16, Charging System - Diagnosis 316. Q: Is the charging system damaged? YES : Repair the Charging System and then go to

Step 4. NO : Go to Step 3.


35B-15

TROUBLESHOOTING

STEP 3. Check the harness wire between junction block connector C-203 terminal 2 and ABS-ECU connector B-03 terminal 20.


Connector: B-03 2 1 3 4 5 6 7 8 9 10 11 12 16 13 14 15 17 18 19

C-106(GR)

B-03 (GR) AC301397AG

Connector: C-202 Junction block (Front view) Harness side

AC301441AB

Harness side 6 5 4 3 2 1 14 13 12 11 10 9 8 7


AC210474 AB


AC210474 AC

After inspecting ABS-ECU connector B-03, intermediate connector C-106, and junction block connector C-202 and C-203, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 4. Q: Is the harness wire between junction block connector C-203 terminal 2 and ABS-ECU connector B-03 terminal 20 damaged? YES : Repair it and go to Step 4. NO : Erase the diagnosis code memory, and

recheck if any diagnosis code sets. If diagnosis code No.16 sets, replace the hydraulic unit (integrated with ABS-ECU) and then go to Step 4 . If diagnosis code No.16 is not set then an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunction 300. STEP 4. Recheck for the diagnosis code. Q: Is diagnosis code No.16 set? YES : Start over at Step 1. NO : The procedure is complete.


35B-16

TROUBLESHOOTING

Code No.21, 22, 23, 24: ABS Sensor ABS Sensor Circuit ABS SENSOR (FRONT: LH)

(FRONT: RH)

(REAR: LH)

(REAR: RH)

ABS-ECU



OPERATION A toothed ABS rotor generates a voltage pulse as it moves across the pickup field of each ABS sensor. The amount of voltage generated at each wheel is determined by the clearance between the ABS rotor teeth and the ABS sensor, and by the speed of rotation. The ABS sensors transmit the frequency of the voltage pulses and the amount of voltage generated by each pulse to the ABS-ECU. The hydraulic unit modulates the amount of braking force individually applied to each wheel cylinder.

DIAGNOSIS CODE SET CONDITIONS Diagnosis codes No.21, 22, 23 and 24 are set in the following cases: Open circuit is not found but no input is received by one or more of the four ABS sensors at 10 km/ h or more. ABS sensor output drops due to a malfunctioning ABS sensor or warped ABS rotor. PROBABLE CAUSES The most likely causes for these diagnosis codes to set are: Malfunction of the ABS sensor Damaged wiring harness or connector Malfunction of the hydraulic unit (integrated with ABS-ECU) Malfunction of the ABS rotor


35B-17

TROUBLESHOOTING

Malfunction of the wheel bearing Excessive clearance between the ABS sensor and ABS rotor Teeth lack or clogging of the ABS rotor

STEP 4. Measure the resistance at the ABS-ECU connector B-03. Connector: B-03

DIAGNOSIS STEP 1. Using MUT-II, check data list item 11, 12, 13, 14: ABS sensor. Set MUT-II to data reading mode, and check the data list items by driving the vehicle. Item 01: Front right ABS sensor Item 02: Front left ABS sensor Item 03: Rear right ABS sensor Item 04: Rear left ABS sensor OK: The reading on the speedometer nearly matches the indication on MUT-II, when driving. Q: Is the ABS sensor input normal? YES : This malfunction is intermittent. Refer to

GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope With Intermittent Malfunction 300. NO : Go to Step 2.

B-03 (GR)

Harness side

AC301441AB


STEP 2. Check the ABS sensor installation. Q: Is the ABS sensor bolted securely in place at the front knuckle or the trailing arm ? YES : Go to Step 3. NO : Install it properly (Refer to 335B) and go

to Step 11. STEP 3. Inspect the ABS sensor and ABS rotor. Refer to 335B. Check items: ABS sensor internal resistance: 1.24 - 1.64 kW Insulation between the ABS sensor body and the connector terminals Toothed ABS rotor check Q: Is the ABS sensor or ABS rotor damaged? YES : Replace it and then go to Step 11. NO : Go to Step 4.

AC301683 AB

(2) Measure the resistance between ABS-ECU connector terminals 16 and 26, 9 and 10, 11 and 17, or 27 and 28. Standard Value: 1.24 - 1.64 kW Q: Is the resistance between terminals 16 and 26, 9 and 10, 27 and 28, or 11 and 17 within the standard value? When resistances between all terminals are within the standard value : Go to Step 9. When resistance between terminals 16 and 26 is not within the standard value : Go to Step 5. When resistance between terminals 9 and 10 is not within the standard value : Go to Step 6. When resistance between terminals 27 and 28 is not within the standard value : Go to Step 7. When resistance between terminals 11 and 17 is not within the standard value : Go to Step 8.


35B-18

TROUBLESHOOTING

STEP 5. Check the harness wires between ABSECU connector B-03 (terminals 16 and 26) and ABS sensor connector A-13 (terminals 1 and 2).


GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope With Intermittent Malfunction 300.

Connector: A-13 A-13 (B) Harness side

AC301443 AB

Connector: B-03

B-03 (GR)

Harness side

AC301441AB

NOTE: Connector : A-14

A-14(GR)

AC210455 AG

After inspecting ABS-ECU connector B-03, intermediate connector A-14 and ABS sensor connector A-13, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 11.


STEP 6. Check the harness wires between ABSECU connector B-03 (terminals 10 and 9) and ABS sensor connector A-31 (terminals 1 and 2). Connector: A-31

35B-19


1 2 3 4 5 6 7 8 9 10

A-31 (B) Harness side AC301397 AC

Connector : C-104 AC301444 AB

Connector: B-03 C-104 (B) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

B-03 (GR)

AC301397AL

After inspecting ABS-ECU connector B-03, intermediate connectors C-14 and C-104, and ABS sensor connector A-31, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 11.

Harness side

AC301441AB




35B-20

TROUBLESHOOTING



Connector: B-03

C-104 (B) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

B-03 (GR)

AC301397AL

Connector: C-117

Harness side

AC301441AB

Connector: D-22

C-117

1 2 3 D-22 (B)

Harness side

111213

4 5 6 7 8 9 10

14 1516 17 1819 20 2122 2324 25 26 27 28 29 32 33 34

35

30 31 36 37

38

AC301446AB AC301396 AC

Connector : D-24

D-24 1 2 3 4 5 6 7 8

AC301410 AG

After inspecting ABS-ECU connector B-03, intermediate connectors C-104, C-117 and D-24, and ABS sensor connector D-22, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 11.

Q: Is any harness wire between ABS-ECU connector B-03 (terminals 28 and 27) and ABS sensor connector D-22 (terminals 1 and 2) damaged? YES : Repair it and then go to Step 11. NO : This malfunction is intermittent. Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points - How to Cope With Intermittent Malfunction 300.


35B-21

TROUBLESHOOTING



Connector: B-03

C-104 (B) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

B-03 (GR)

AC301397AL

Connector: C-117

Harness side

AC301441AB

Connector: D-13

C-117

1 2 3

D-13 (B)

111213

4 5 6 7 8 9 10

14 1516 17 1819 20 2122 2324 25

Harness side

AC301445 AB

26 27 28 29 32 33 34

35

30 31 36 37

38

AC301396 AC

Connector : D-24

D-24 1 2 3 4 5 6 7 8

AC301410 AG

After inspecting ABS-ECU connector B-03, intermediate connectors C-104, C-117 and D-24, and ABS sensor connector D-13, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 11. Q: Is any harness wire between ABS-ECU connector B-03 (terminals 11 and 17) and ABS sensor connector D-13 (terminals 1 and 2) damaged? YES : Repair it and then go to Step 11. NO : Go to Step 11.

35B-22


STEP 9. Check the ABS sensor output voltage. Refer to 335B. Output Voltage: When measured with a voltmeter: 42 mV or more When measured with an oscilloscope (maximum voltage): 200 mV or more Q: Does the voltage meet the specification? YES : Erase the diagnosis code memory, and

recheck if any diagnosis code sets. If diagnosis code No.21, 22, 23 or 24 sets, replace the hydraulic unit (integrated with ABS-ECU). Then go to Step 11. NO : Go to Step 10.

STEP 10. Check the wheel bearing. : Refer to GROUP 26, On-vehicle Service Wheel Bearing Axial Play Check 326. : Refer to GROUP 27A, On-vehicle Service - Wheel Bearing Axial Play Check 327A. : Refer to GROUP 27B, On-vehicle Service - Wheel Bearing Axial Play Check 327B. Q: Is the check result normal? YES : Go to Step 11. NO : Replace it and then go to Step 11.

STEP 11. Recheck for the diagnosis code. Q: Is diagnosis codes No.21, 22, 23 or 24 set? YES : Start over at Step 1. NO : The procedure is complete.


35B-23

TROUBLESHOOTING

Code No.32 G-sensor System <4WD>

G-sensor Circuit IGNITION SWITCH (IG2)

G SENSOR

ABS-ECU


SB : Sky blue

AC301688 AB

OPERATION The G-sensor detects the acceleration level in the forward/reverse direction of the vehicle, converts the signals into voltage signals and then sends that signal to the ABS-ECU. DIAGNOSIS CODE SET CONDITIONS This code is set in the following case. When the G-sensor output is 1.0V or lower or 4.0V or higher (disconnected G-sensor or Gsensor short circuit) If the G-sensor output power does not change (G-sensor output fastening).

PROBABLE CAUSES The most likely causes for this diagnosis code to set are: Malfunction of the G-sensor Damaged wiring harness or connector Malfunction of the hydraulic unit (integrated with ABS-ECU)


35B-24

TROUBLESHOOTING

DIAGNOSIS STEP 1. Using MUT-II, check the data list item 32: G-sensor. Set MUT-II to data reading mode, and check the data list item. Item 32: G-sensor OK: When vehicle is stationary (level): 2.4 - 2.6 V When vehicle is being driven: 1.0 - 4.0 V

STEP 3. Check the harness wire between junction block connector C-202 terminal 8 and Gsensor connector D-35 terminal 1. Connector: C-202 Junction block (Front view)

Harness side

Q: Is the G-sensor input normal? YES : This malfunctions is intermittent. Refer to

GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope with Intermittent Malfunction 300. NO : Go to Step 2.

6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC210474 AB

Connector: D-35

Harness side

STEP 2. Measure the voltage at G-sensor connector D-35.

D-35 (B)

Connector: D-35

Harness side D-35 (B)

AC301440 AB


AC301440 AB

(1) Disconnect G-sensor connector D-35, and check at the harness side. (2) Turn the ignition switch to the "ON" position. Connector D-35 (harness side)

C-106(GR)

AC301397AG

After inspecting the junction block connector C-202, intermediate connector C-106, and G-sensor connector D-35, inspect the wire. If any of these connector is damaged, repair or replace it. Then go to Step 8.

AC301684AB


2 1 3 4 5 6 10 11 12 7 8 9 13 14 15 16 17 18 19

Q: Is the harness wire between junction block connector C-202 terminal 8 and G-sensor connector D-35 terminal 1 damaged? YES : Repair it and go to Step 8. NO : This malfunctions is intermittent. Refer to

GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope with Intermittent Malfunction 300.


35B-25

TROUBLESHOOTING

STEP 4. Measure the resistance at G-sensor connector D-35. Connector: D-35

STEP 5. Check the harness wire between Gsensor connector D-35 terminal 3 and ABS-ECU connector B-03 terminal 8. Connector: D-35

Harness side Harness side D-35 (B) D-35 (B)

AC301440 AB

(1) Disconnect G-sensor connector D-35, and check at the harness side.

AC301440 AB

Connector: B-03

Connector D-35 (harness side) B-03 (GR)

AC301684AC

Harness side

(2) Measure the resistance between terminal 3 and earth. OK: 2 W or less Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.

AC301441AB

Q: Is the harness wire between G-sensor connector D35 terminal 3 and ABS-ECU connector B-03 terminal 8 damaged? YES : Repair it and go to Step 8. NO : Erase the diagnosis code memory, and

recheck if any diagnosis code sets. If diagnosis code No.32 sets, replace the hydraulic unit (integrated with ABS-ECU) and then go to Step 8 .


35B-26

TROUBLESHOOTING

STEP 6. Check G-sensor output voltage.

Label

STEP 7. Check the harness wire between Gsensor connector D-35 terminal 2 and ABS-ECU connector B-03 terminal 15. Connector: D-35

Harness side

MB991348

D-35 (B) Connector: D-35 (Harness side) AC301440 AB

Label

Connector: B-03

B-03 (GR)

AC103662AK

(1) Disconnect G-sensor connector D-35, and connect special tool harness set (MB991348) between the disconnected connectors. (2) Turn the ignition switch to the "ON" position. (3) Measure the voltage between terminal 2 and earth. OK: When vehicle is stationary (level): 2.4 2.6 V When vehicle is being driven: 1.0 - 4.0 V Q: Is G-sensor output voltage normal? YES : Go to Step 7. NO : Replace the G-sensor and go to Step 8.

Harness side

AC301441AB

Q: Is the harness wire between G-sensor connector D35 terminal 2 and ABS-ECU connector B-03 terminal 15 damaged? YES : Repair it and go to Step 8. NO : Erase the diagnosis code memory, and

recheck if any diagnosis code sets. If diagnosis code No.32 sets, replace the hydraulic unit (integrated with ABS-ECU) and then go to Step 8 . STEP 8. Recheck for the diagnosis code. Q: Is diagnosis code No.32 set? YES : Start over at Step 1. NO : The procedure is complete.


35B-27

TROUBLESHOOTING

Code No.33 : Stop Lamp Switch System

Stop Lamp Switch Circuit BATTERY

RELAY BOX

STOP LAMP SWITCH

STOP LAMPS

ABS-ECU


OPERATION The "ON" signal when the brake pedal is pressed or the "OFF" signal when the brake pedal is released is input to the ABS-ECU (terminal 3). DIAGNOSIS CODE SET CONDITIONS Diagnosis code No.33 is set in the following cases: Stop lamp switch is not operating properly and remains in ON state for more than 15 minutes.


Stop lamp switch system harness is damaged and no signal is input to ABS-ECU. PROBABLE CAUSES The most likely causes for this diagnosis code to set are: Malfunction of the stop lamp switch Damaged wiring harness or connector Malfunction of the hydraulic unit (integrated with ABS-ECU)


35B-28

TROUBLESHOOTING

DIAGNOSIS STEP 1. Check the stop lamp operation. Q: Does the stop lamp come on and go out correctly? YES : Go to Step 4. NO : Go to Step 2.

STEP 2. Check the stop lamp switch installation condition. Q: Is the stop lamp switch installed properly? YES : Go to Step 3. NO : Repair it and then go to Step 7.

STEP 3. Check the stop lamp switch continuity. (1) Remove the stop lamp switch (Refer to GROUP 35A, Brake Pedal 335A).

No continuity

Continuity

4 mm ACX00671AE

(2) Connect an ohmmeter to stop lamp switch terminals 1 and 2, and check whether there is continuity when the plunger of the stop lamp switch is pushed in and when it is released. (3) The stop lamp switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within 4 mm from the outer case edge surface, and if there is continuity when it is released. Q: Is the stop lamp switch continuity correct? YES : Check the stop lamp circuit and repair and

then go to Step 7. NO : Replace the stop lamp switch and then go to

Step 7.

STEP 4. Using MUT-II, check data list item 36: Stop lamp switch. Set MUT-II to data reading mode, and check the data list item. Item 36: Stop lamp switch OK: Brake pedal stepped down: ON Brake pedal released: OFF Q: Is the stop lamp switch input normal? YES : This malfunction is intermittent. Refer to

GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope With Intermittent Malfunction 300. NO : Go to Step 5.


STEP 5. Measure the voltage at ABS-ECU connector B-03. Connector: B-03

B-03 (GR)

Harness side

AC301441AB

(1) Disconnect ABS-ECU connector B-03 and measure at the harness side. (2) Depress the brake pedal to turn on the stop lamp switch. Connector B-03 (harness side)

AC301683 AC

(3) Measure the voltage between terminal 3 and earth. OK: System voltage Q: Is the check result normal? YES : Erase the diagnosis code memory, and

recheck if any diagnosis code sets. If diagnosis code No.33 set, replace the hydraulic unit (integrated with ABS-ECU). Then go to Step 7. NO : Go to Step 6.

35B-29


35B-30

TROUBLESHOOTING

STEP 6. Check the harness wire between ABSECU connector B-03 terminal 3 and stop lamp switch connector C-101 terminal 1.

NOTE:

Connector: B-03

B-03 (GR) AC301397

Connector : C-104 Harness side

AC301441AB

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Connector : C-101

Harness side

C-104 (B)

AC301397AL

C-101

AC301395 AL

After inspecting ABS-ECU connector B-03, intermediate connectors C-16 and C-104, and stop lamp switch connector C-101, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 7. Q: Is the harness wire between ABS-ECU connector B-03 terminal 3 and stop lamp switch connector C101 terminal 1 damaged? YES : Repair it and then go to Step 7. NO : This malfunction is intermittent. Refer to

GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope With Intermittent Malfunction 300. STEP 7. Recheck for the diagnosis code. Q: Is diagnosis code No.33 set? YES : Start over at Step 1. NO : The procedure is complete.


35B-31

TROUBLESHOOTING

Code No.41, 42, 43, and 44: ABS Solenoid Valve inside Hydraulic Unit (Open Circuit or Short Circuit) Code No.52: Valve Relay Problem (Stays off) Code No.53: Motor Relay Problem (Stays off) Code No.55: Motor System (Seized Pump Motor) Solenoid Valve and Motor power Supply Circuit FUSIBLE LINK 3

HYDRAULIC UNIT MOTOR

SOLENOID VALVE POWER SOURCE

ABS SOLENOID VALVES

MOTOR POWER SOURCE

ABS-ECU



OPERATION Power is continuously supplied to the ABS-ECU through fusible link number 3 to operate the solenoid valve and motor. DIAGNOSIS CODE SET CONDITIONS These codes are set if the power supply circuit of solenoid valve or motor is open or shorted.

PROBABLE CAUSES The most likely causes for these diagnosis codes to set are: Damaged wiring harness or connector Malfunction of the hydraulic unit (integrated with ABS-ECU)


35B-32

TROUBLESHOOTING

DIAGNOSIS STEP 1. Measure the voltage at ABS-ECU connector B-03.

STEP 2. Check the harness wires between fusible link number 3 and ABS-ECU connector B-03 (terminals 1 and 19).

Connector: B-03 Fusible link No.3

B-03 (GR)

AC208065AD

Connector: B-03

Harness side

B-03 (GR)

AC301441AB


Harness side

AC301441AB

NOTE: AC301683 AD

(2) Measure the voltage between terminal 1 and earth, and 19 and earth. OK: System voltage

Connector : A-14

A-14(GR)

Q: Is the check result normal? YES : Erase the diagnosis code memory, and

recheck if any diagnosis code sets. If diagnosis code No.41, 42, 43, 44, 52, 53, or 55 set, replace the hydraulic unit (integrated with ABS-ECU). Then go to Step 3. If diagnosis code No.41, 42, 43, 44, 52, 53, or 55 is not set, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points How to Cope with Intermittent Malfunction 300. NO : Go to Step 2.

AC210455 AG

After inspecting intermediate connector A-14, inspect the wire. If the connector is damaged, repair or replace it. Then go to Step 3. Q: Is any harness wire between fusible link number 3 and ABS-ECU connector B-03 (terminal 1 and 19) damaged? YES : Repair it and go to Step 3. NO : This malfunction is intermittent. Refer to



35B-33

TROUBLESHOOTING

STEP 3. Recheck for the diagnosis code. Q: Is diagnosis code No.41, 42, 43, 44, 52, 53 or 55 set? YES : Start over at Step 1. NO : The procedure is complete.

INSPECTION CHART FOR TROUBLE SYMPTOMS M1352011400567

NOTE: If steering movements are made when driving at high speed, or when driving on road surfaces with low frictional resistance, or when passing over bumps, the ABS may operate although sudden braking is not being applied. Because of this, when getting information from the customer, check if the problem occurred while driving under such conditions as these. Trouble symptoms Communication between MUT-II and the whole system is not possible.

NOTE: During ABS operation, the brake pedal may vibrate a little or may not be able to be pressed. Such conditions are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking. This is normal.


Reference page

-

GROUP 13A, Diagnosis 313A

Communication between MUT-II and the ABS-ECU is 1 not possible.

335B

When the ignition switch is turned to the "ON" position (Engine stopped), the ABS warning lamp does not illuminate.

2

335B

The ABS warning lamp remains illuminated after the 3 engine is started.

335B

Faulty ABS operation

335B

4


35B-34

TROUBLESHOOTING


INSPECTION PROCEDURE 1: Communication between MUT-II and the ABS-ECU is not Possible. Diagnosis Connector Circuit IGNITION SWITCH (IG2)

ABS-ECU POWER SOURCE



OPERATION The diagnostic output is made from the ABSECU (terminal 13) to the diagnosis output terminal (terminal 7) of the diagnosis connector.


When the diagnosis connector’s diagnosis test mode control terminal (terminal 1) is grounded, the ABS-ECU (terminal 4) will go into diagnosis mode.


35B-35

TROUBLESHOOTING

COMMENT ON TROUBLE SYMPTOM When communication with the MUT-II is not possible, the cause is probably an open circuit in the ABSECU power circuit or an open circuit in the diagnostic output circuit.

STEP 2. Check the harness wire between junction block connector C-202 terminal 8 and ABS-ECU connector B-03 terminal 20. Connector: B-03

PROBABLE CAUSES The most likely causes for this case are: Blown fuse Damaged wiring harness or connector Malfunction of the hydraulic unit (Integrated with ABS-ECU)

B-03 (GR)

DIAGNOSIS Harness side

STEP 1. Measure the voltage at ABS-ECU connector B-03. Connector: B-03 AC301441AB

Connector: C-202 Junction block (Front view) B-03 (GR)


6 5 4 3 2 1 14 13 12 11 10 9 8 7

AC210474 AB

NOTE: AC301441AB

(1) Disconnect ABS-ECU connector B-03 and measure at the harness side. (2) Start the engine. Connector B-03 (harness side)

Connector: C-106

2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

C-106(GR)

AC301397AG

AC301683 AE


After inspecting ABS-ECU connector B-03, junction block connector C-202 and intermediate connector C-106, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 5. Q: Is the harness wire between junction block connector C-202 terminal 8 and ABS-ECU connector B-03 terminal 20 damaged? YES : Repair it and go to Step 5. NO : This malfunction is intermittent. Refer to



35B-36

TROUBLESHOOTING

STEP 3. Check the harness wires between ABSECU connector B-03 (terminals 4 and 13) and diagnosis connector C-24 (terminals 1 and 7).


Connector: B-03

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

B-03 (GR)

AC301395 AC

Connector : C-104 Harness side

AC301441AB

C-104 (B) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Connector: C-24

AC301397AL

Connector: C-105

1 2 3 4 5 6 7 8 9 10 11 12 13 1415 16 1718 19 20 21 22

Harness side 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

C-24(B) AC301395 AF

AC301397AF

After inspecting ABS-ECU connector B-03, diagnosis connector C-24, and intermediate connectors C-02, C-104 and C-105, inspect the wires. If any of these connectors is damaged, repair or replace it. Then go to Step 5. Q: Is any of the harness wires between ABS-ECU connector B-03 (terminals 4 and 13) and diagnosis connector C-24 (terminals 1 and 7) damaged? YES : Repair it and go to Step 5. NO : Go to Step 4.


STEP 4. Check the harness wires between ABSECU connector B-03 (terminals 2 and 18) and earth (No.9). Connector: B-03

B-03 (GR)

Harness side

AC301441AB

Relay box

Earth (No.9) AC208089AC

Q: Is any of the harness wires between ABS-ECU connector B-03 (terminals 2 and 18) and earth (No.9) damaged? YES : Repair it and then go to Step 5. NO : Check the troubleshooting condition. To

reproduce the troubleshooting state replace the hydraulic unit (integrated with ABSECU).Then go to Step 5. If the state of failure is not reproduced then a intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunction 300.

35B-37

STEP 5. Retest the system. Q: Does the MUT-II communicate with the ABS system? YES : The procedure is complete. NO : Start over at Step 1.

35B-38


INSPECTION PROCEDURE 2: When the Ignition Key is Turned to the "ON" position (Engine Stopped), the ABS Warning Lamp does not Illuminate. ABS Warning Lamp Circuit IGNITION SWITCH (IG1)

COMBINATION METER

ABS-ECU



OPERATION The ABS warning lamp is lit up by transistor control in the ABS-ECU. However, the relationship of the reverse circuit movement in the combination meter will vary from usual in terms of transistor ON/OFF and ABS warning lamp ON/ OFF, in that the ABS warning lamp will lamp up when the transistor is turned OFF for this circuit. This is how the ABS warning lamp lights up even when the ABS-ECU connector is connected improperly or if the ABS-ECU function has terminated. The ABS-ECU also lights up the ABS warning lamp during the initial check (approximately 3 seconds) when the ignition switch is turned to the "ON" position in addition to when the system is malfunctioning.

COMMENT ON TROUBLE SYMPTOM Possible causes include the combination meter power circuit, disconnected earth circuit, dead lamp bulb, or short circuited ABS warning lamp. PROBABLE CAUSES The most likely causes for this case are: Blown fuse Damaged wiring harness or connector Burnt out ABS warning lamp bulb Combination meter defect Malfunction of the hydraulic unit (integrated with ABS-ECU)


35B-39

TROUBLESHOOTING

DIAGNOSIS

STEP 3. Measure the voltage at combination meter connector C-04.

STEP 1. Check the ABS warning lamp circuit at ABS-ECU connector B-03.

Connector: C-04

C-04

Connector: B-03 Harness side (front view) B-03 (GR)

AC301395 AK

(1) Disconnect connector C-04, and check at the harness side. (2) Turn the ignition switch to the "ON" position.

Harness side

Connector C-04 (harness side) AC301441AB

(1) Disconnect ABS-ECU connector B-03. (2) Turn the ignition switch to the "ON" position. Q: Does the ABS warning lamp illuminate? YES : To check and reproduce the state of

malfunction replace the hydraulic unit (integrated with ABS-ECU). Then go to Step 7. If the malfunction is not reproduced, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope with Intermittent Malfunction 300. NO : Go to Step 2. STEP 2. Check the ABS warning lamp bulb. (1) Remove the combination meter (Refer to GROUP 54A, Combination Meter 354A). (2) Check the ABS warning lamp bulb. Q: Is the bulb burned out? YES : Replace the bulb and then go to Step 7. NO : Go to Step 3.

AC301685 AB



35B-40

TROUBLESHOOTING

STEP 4. Check the harness wire between junction block connector C-203 terminal 6 and combination meter C-04 terminal 42. Connector: C-04

STEP 5. Check the harness wire between the combination meter connector C-05 terminal 12 and earth (No.6). Connector: C-05

C-04

C-05(L)



11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301395 AK

AC301395 AE


Earth (No.6) Harness side 2 1 6 5 4 3

AC210474 AC

NOTE:

Junction block

AC208084AE

Q: Is the harness wire between combination meter connector C-05 terminal 12 and earth (No.6) damaged? YES : Repair the harness wire and go to Step 7. NO : Go to Step 6.


Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE

After inspecting junction block connectors C-203 and C-205, and combination meter connector C-04, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 7. Q: Is the harness wire between junction block connector C-203 terminal 6 and combination meter C-04 terminal 42 damaged? YES : Repair the harness wire and go to Step 7. NO : This malfunction is intermittent. Refer to



STEP 6. Check the harness wire between the combination meter connector C-05 terminal 18 and ABS-ECU connector B-03 terminal 12. Connector: C-05

C-05(L)


G

G

AC301395 AE

Connector: B-03

B-03 (GR)

Harness side

AC301441AB


1 2 3 4 5 6 7 8 9 10 11 12 13 1415 16 1718 19 20 21 22

AC301397AF

After inspecting combination meter connector C-05, ABS-ECU connector B-03 and intermediate connector C-105, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 7. Q: Is the harness wire between the combination meter connector C-05 terminal 18 and ABS-ECU connector B-03 terminal 12 damaged? YES : Repair the harness wire and go to Step 7. NO : Replace the combination meter and go to

Step 7.

35B-41

STEP 7. Retest the system. Q: Does the ABS warning lamp illuminate for 3 seconds when the ignition switch is turned to the "ON" position with engine stopped or upon startup? YES : The procedure is complete. NO : Start over at Step 1.


35B-42

TROUBLESHOOTING

INSPECTION PROCEDURE 3: The ABS Warning Lamp Remains Illuminated after the Engine is Started. NOTE: This diagnosis procedure is limited to cases where communication with the MUT-II is possible (ABSECU power supply is normal) and no diagnosis code outputs. ABS Warning Lamp Circuit IGNITION SWITCH (IG1)

COMBINATION METER

ABS-ECU



OPERATION Refer to 335B. COMMENT ON TROUBLE SYMPTOM Disconnected ABS warning lamp output line of ABSECU is suspected.

PROBABLE CAUSES The most likely causes for this case are: Damaged wiring harness or connector Malfunction of the hydraulic unit (integrated with ABS-ECU) Malfunction of the combination meter


35B-43

TROUBLESHOOTING

DIAGNOSIS STEP 1. Check the ABS warning lamp circuit at ABS-ECU connector B-03.

STEP 2. Check the harness wire between the combination meter connector C-05 terminal 18 and ABS-ECU connector B-03 terminal 12. Connector: C-05

C-05(L)

Connector: B-03


B-03 (GR)

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301395 AE

Connector: B-03

Harness side

B-03 (GR)

AC301441AB

(1) Disconnect ABS-ECU connector B-03. Connector B-03 (harness side) Harness side

AC301441AB

AC301683AF

(2) Connect ABS-ECU connector B-03 terminal number 12 to earth. (3) Turn the ignition switch to the "ON" position.


1 2 3 4 5 6 7 8 9 10 11 12 13 1415 16 1718 19 20 21 22

Q: Does the ABS warning lamp go off? YES : To check and reproduce the state of

malfunction replace the hydraulic unit (integrated with ABS-ECU). Then go to Step 3. If the malfunction is not reproduced, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/ Inspection Service Points - How to Cope With Intermittent Malfunction 300. NO : Go to Step 2.

AC301397AF

After inspecting combination meter connector C-05, ABS-ECU connector B-03 and intermediate connector C-105, inspect the wire. If any of these connectors is damaged, repair or replace it. Then go to Step 3. Q: Is the harness wire between combination meter connector C-05 terminal 18 and ABS-ECU connector B-03 terminal 12 damaged? YES : Repair the harness wire and then go to Step

3. NO : Replace the combination meter (printed

circuit board) and then go to Step 3.

35B-44


STEP 3. Retest the system. Q: Does the ABS warning lamp turn off in 3 seconds after start-up? YES : The procedure is complete. NO : Start over at Step 1.

INSPECTION PROCEDURE 4: Faulty ABS Operation COMMENT ON TROUBLE SYMPTOM The cause depends on driving and road surface conditions, so diagnosis may be difficult. However, if no diagnosis code is set, carry out the following inspection.

DIAGNOSIS Check the hydraulic unit (Refer to 335B). If the hydraulic unit (integrated with ABS-ECU) is malfunctioning, replace it. Then check that the malfunction symptom is eliminated.

PROBABLE CAUSES The most likely cause for this case is: Malfunction of the hydraulic unit


The following items can be read by the MUT-II from the ABS-ECU input data. When the system is normal. Item No.

Check item

Checking requirements

Normal valve

11

Front-right ABS sensor

Perform a test run

12

Front-left ABS sensor

13

Rear-right ABS sensor

Vehicle speeds displayed on the speedometer and MUT-II are identical.

14

Rear-left ABS sensor

21

ABS-ECU power supply voltage

Ignition switch: ON

10 - 16 V

32

G-sensor <4WD>

Ignition switch: ON When vehicle is parked on a level surface.

2.4 - 2.6 V

When vehicle is accelerated

4.0 - 1.0 V

When vehicle is decelerated

1.0 - 4.0 V

Depress the brake pedal.

ON

Release the brake pedal.

OFF

36

Stop lamp switch

When the ABS-ECU shut off ABS operation. When the diagnosis system stops the ABS-ECU, the MUT-II display data will be unreliable.


35B-45

TROUBLESHOOTING

ACTUATOR TEST REFERENCE TABLE M1352011600527

Lock lever

The MUT-II activates the following actuators for testing. NOTE: If the ABS-ECU runs down, actuator testing cannot be carried out. NOTE: Actuator testing is only possible when the vehicle is stationary. ACTUATOR TEST SPECIFICATIONS AC200022AE

Activation pattern

Start of activation Solenoid valve

Pump motor

End of activation

ABS-ECU connector

A B C

1. Move the lock lever of the ABS-ECU connector as shown in the illustration, and then disconnect the ABS-ECU connector. Connector cover

1s

0.05 s ON

2s 0.01 s

OFF

AC103604AC

NOTE A: Hydraulic pressure increases B: Hydraulic pressure holds C: Hydraulic pressure decreases

2. Insert the flat-tipped screwdriver to the aperture (arrow area as shown in the illustration) between ABS-ECU connector and connector cover to disengage the claw and remove the connector cover. AC100172 AG

TERMINAL VOLTAGE CHECK CHART

No. Item 01

Solenoid valve for frontleft wheel

02

Solenoid valve for frontright wheel

03

Solenoid valve for rearleft wheel

04

Solenoid valve for rearright wheel

Solenoid valves and pump motors in the hydraulic unit (simple inspection mode)

AC300659

CHECK AT ABS-ECU M1352011800554

Use the following steps to remove the connector cover and measure the terminal voltage.

1. Measure the voltages between earth terminal (2) or (18) and each respective terminal. 2. The terminal layouts are shown in the illustrations below. NOTE: Do not measure terminal voltage for approximately three seconds after the ignition switch is turned to the "ON" position. The ABS-ECU performs the initial check during that period.


35B-46

TROUBLESHOOTING

Terminal No. Check item

Checking requirements

Normal condition

1

Solenoid valve power Always supply

System voltage

3

Stop lamp switch input

Stop lamp switch: "ON"

System voltage

Stop lamp switch: "OFF"

Approximately 0 V

4

Diagnosis changeover When the MUT-II is connected input When the MUT-II is not connected

Approximately 0 V

8

G-sensor earth <4WD>

Approximately 0 V

12

ABS-ECU warning Ignition lamp transistor output switch: "ON"

13

MUT-II

Always

System voltage

When the lamp is switched off

Approximately 0 V

When the lamp is illuminated

System voltage

When the MUT-II is connected

Serial communication with MUT-II

When the MUT-II is not connected

Approximately 0 V

15

G-sensor input <4WD>

Ignition switch: "ON" Horizontal state of vehicle

2.4 - 2.6 V

19

Motor power supply

Always

System voltage

20

ABS-ECU power supply


System voltage

Ignition switch: "START"

Approximately 0 V


RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS

AC300662

1. Turn the ignition switch to the "LOCK" (OFF) position and disconnect the ABS-ECU connectors before checking resistance and continuity. 2. Check the resistance and continuity between the terminals indicated in the table below. 3. The terminal layout is shown in the illustration. ABS-ECU terminal No. Signal

Normal condition

9 - 10

Front-right ABS sensor

1.24 - 1.64 kW

11 - 17

Rear-right ABS sensor

1.24 - 1.64 kW

16 - 26

Front-left ABS sensor

1.24 - 1.64 kW

27 - 28

Rear-left ABS sensor

1.24 - 1.64 kW

2 - body earth

Earth

Less than 2 W

18 - body earth

Earth

Less than 2 W

35B-47


35B-48

ON-VEHICLE SERVICE

ON-VEHICLE SERVICE ABS SENSOR OUTPUT VOLTAGE MEASUREMENT M1352001600485

Lift up the vehicle and release the parking brake.

11 10 9 8 7 6 5 4 3 17 16 15 14 13 12 28 27 26 25 24 23 22 21 20

2

1

19

18

3. If the output voltage is lower than that given above, the cause may be the following, so check or replace the ABS sensor if necessary. ABS sensor pole piece-to-ABS rotor clearance too large Faulty ABS sensor WAVE PATTERN INSPECTION USING AN OSCILLOSCOPE After checking the connection of the ABS sensor harness and the connector, take a reading of the output voltage wave patterns for each ABS sensor using an oscilloscope as follows. Start the engine, the transmission shift lever to 1st gear, and then spin the wheel. NOTE:

When turned by hand

Harness connector

AC201294 AH

1. Disconnect the ABS-ECU connector, and measure the output voltage at the harness side connector. 2. Manually turn the wheel to be measured 1/2 to 1 turn/second. Measure the output voltage with a voltmeter or oscilloscope. Terminal No. Front left Front right

Rear left

Rear right

16

9

27

11

26

10

28

17

Output voltage: 42 mV or higher when measured using a multimeter 120 mVP-P or higher when measured using a oscilloscope

When idling (5 − 6 km/h), with 1st gear

[10.0 ms/DIV IV/DIV]

AC000949 AF

.

You can also take a reading of the wave pattern by actually driving the vehicle in this condition. The output voltage will be lower when the wheel speed is lower, and will become higher as the wheel speed becomes higher.


35B-49

ON-VEHICLE SERVICE

POINTS IN WAVEFORM MEASUREMENT Symptom Probable causes Too small or zero waveform amplitude

Remedy

Faulty ABS sensor or excessive gap between it and the ABS rotor

Replace ABS sensor

Waveform amplitude fluctuates Axle hub eccentric or with large excessively (This is no problem if runout the minimum amplitude is 100 mV Faulty ABS-ECU earth or more)

Replace hub assembly

Noisy or disturbed waveform

Open circuit in ABS sensor

Replace ABS sensor

Open circuit in harness

Repair harness wire

Incorrectly mounted ABS sensor

Mount ABS sensor correctly

ABS rotor with missing or damaged teeth

Replace ABS rotor

Repair harness wires

NOTE: The ABS sensor cable moves in relation to motion of the front or rear suspension. Therefore, it is likely that it has an open circuit only when driving on rough roads but it functions normally when driving on smooth roads. It is recommended to observe sensor output voltage waveform also under special conditions, such as driving on a rough road.

HYDRAULIC UNIT CHECK M1352001700460

CAUTION The roller of the braking force tester and the tyre should be dry during testing. When testing the front brakes, apply the parking brake. When testing the rear brakes, stop the front wheels with chocks. 1. Jack up the vehicle. Then support the vehicle with rigid racks at the specified jack-up points or place the front or rear wheels on the rollers of the braking force tester. 2. Release the parking brake, and feel the drag force (drag torque) on each road wheel. When using the braking force tester, take a reading of the brake drag force.

CAUTION To prevent damage to MUT-II, always turn the ignition switch to the "LOOK" (OFF) position before connecting or disconnecting the MUT-II.

16 Pin

MB991502 AC107200AC

3. Turn the ignition switch to the "LOCK" (OFF) position and set the MUT-II as shown in the illustration. 4. After checking that the shift lever is in neutral, start the engine. 5. Use the MUT-II to force-drive the actuator. NOTE: The ABS system will switch to the MUT-II mode and the ABS warning lamp will illuminate. NOTE: When the ABS has been interrupted by the fail-safe function, the MUT-II actuator testing cannot be used.


35B-50

ON-VEHICLE SERVICE

Depressed Pedal operation

MUT-II actuator test (Item No.01, 02, 03, 04) start

Released Increase in pressure Solenoid valve position

2 seconds

Steady pressure 1 seconds

Reduction in pressure Checking the brake force

Lock 3 seconds

Drag force when the pedal is free

Approx. 0.05 seconds AC000954 AE

6. Turn the wheel by hand and check the change in braking force when the brake pedal is depressed. When using the braking force tester, depress the brake pedal until the braking force is at the following values, and check that the braking force changes to the brake drag force inspected in step 2 when the actuator is force-driven. The result should be as shown in the diagram above. Diagnosis Table

Front wheel

785 - 981 N

Rear wheel 588 - 784 N 7. If the result of inspection is abnormal, repair according to the Diagnosis Table below.

MUT-II Display

Operation

Inspection result

Judgment Probable cause Remedy

01 FR VALBE 02 FL VALBE 03 RR VALBE 04 RL VALBE

Depress brake pedal to lock wheel. Using the MUT-II, select the wheel to be checked and force the actuator to operate. Turn the selected wheel manually to check the change of brake force.

Brake force is released for three seconds after wheels have been locked.

Normal

-

-

Wheel does not Abnormal lock when brake pedal is depressed.

Clogged brake line other than hydraulic unit

Check and clean brake line

Clogged hydraulic circuit in hydraulic unit

Replace hydraulic unit assembly

Brake force is not released

Incorrect hydraulic unit brake tube connection

Connect correctly

Hydraulic unit Replace solenoid valve hydraulic unit not functioning assembly correctly 8. After inspection, disconnect the MUT-II immediately after turning the ignition switch to the "LOCK" (OFF) position.

ANTI-SKID BRAKING SYSTEM (ABS) ON-VEHICLE SERVICE

IN THE EVENT OF A DISCHARGED BATTERY M1352003500495

WARNING If the ABS is not operating, the vehicle posture will be unstable during braking, Do not drive the vehicle with the ABS-ECU connector disconnected or with the ABS not operating for any other reason. If the engine is started using a booster cable when the battery is completely flat, and the vehicle is then driven without waiting for the battery to be recharged, the engine may misfire and it may not be possible to drive the vehicle. This is because the ABS consumes a large amount of current when carrying out its initial checks. If this happens, recharge the battery fully.

35B-51


35B-52

HYDRAULIC UNIT

HYDRAULIC UNIT REMOVAL AND INSTALLATION M1352008600420

NOTE: The ABS-ECU is integrated in the hydraulic unit. Pre-removal Operation Brake Fluid Draining

Post-installation Operation Brake Fluid Filling Bake Line Bleeding (Refer to GROUP 35A, On-vehicle Service - Bleeding 335A). Hydraulic Unit Check (Refer to 335B).

2

15 ± 2 N·m

3 1 2

25 ± 6 N·m

2

4 25 ± 6 N·m 25 ± 6 N·m AC300471 AB

<>

1. >>A<< 2. <> 3. 4.

Removal steps Harness connector Brake pipe connection Hydraulic unit and ABS-ECU Hydraulic unit bracket assembly


35B-53

HYDRAULIC UNIT



<> HARNESS CONNECTOR DISCONNECTION

>>A<< BRAKE PIPE CONNECTION

2

Lock lever

3

4 5

1

6 AC100240AD AC200022AE

Move the lock lever of the ABS-ECU connector as shown in the illustration, and then disconnect the harness connector. <> HYDRAULIC UNIT AND ABS-ECU REMOVAL

WARNING The hydraulic unit is heavy. Use care when removing it. CAUTION The hydraulic unit cannot be disassembled. Never loosen its nuts or bolts. Do not drop or shock the hydraulic unit. Do not turn the hydraulic unit upside down or lay it on its side.

Connect the brake pipes to the hydraulic unit as shown in the illustration. 1. From the master cylinder (secondary) 2. To the front brake (LH) 3. To the rear brake (RH) 4. To the rear brake (LH) 5. To the front brake (RH) 6. From the master cylinder (primary)


35B-54

ABS SENSOR

ABS SENSOR REMOVAL AND INSTALLATION M1352020700038

Post-installation Operation ABS Sensor Output Voltage Measurement (Refer to 335B).

3

1

4 3

2

4 <>

1. 2.

Front ABS sensor removal steps Front ABS sensor Front ABS rotor (Refer to GROUP 26, Driveshaft 326).

<>

3. 4.

AC301105 AB

Rear ABS sensor removal steps Rear ABS sensor Rear ABS rotor (Refer to GROUP 27A, Rear Hub Assembly 327A for 2WD, or GROUP 27B, Driveshaft 327B for 4WD).


35B-55

ABS SENSOR

REMOVAL SERVICE POINT <> FRONT ABS SENSOR/REAR ABS SENSOR REMOVAL

3. If the internal resistance of the ABS sensor is not within the standard value, replace it with a new ABS sensor.

CAUTION

ACX01120

AC100242 AE

Be careful when handling the projection at the tip of the ABS sensor and the toothed edge of the ABS rotor so as not to damage them by contacting other parts.


ABS SENSOR CHECK 1. Check whether any metallic foreign material has adhered to the projection at the ABS sensor tip. Remove any foreign material. Also check whether the pole piece is damaged. Replace it with a new one if it is damaged. NOTE: The projection can become magnetized due to the magnet inside the ABS sensor, causing foreign material to easily adhere to it. The projection may not be able to correctly sense the wheel rotation speed if foreign matter is on it or if it is damaged.

4. Remove all connections from the ABS sensor. The circuit should be open between terminals (1) and (2) and the body of the ABS sensor. If the circuit is not open, replace with a new ABS sensor. 5. Check the ABS 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 gently bend and pull the cable near the clamp.

TOOTHED ABS ROTOR CHECK

AC000965

Check whether the ABS rotor teeth are broken or deformed. Replace the BJ assembly of the driveshaft, or the ABS rotor (2WD-rear side), respectively, if the teeth are damaged or deformed.

AC201428 AD

2. Measure the resistance between the ABS sensor terminals. Standard value: 1.24 - 1.64 kW


35B-56

G-SENSOR

G-SENSOR REMOVAL AND INSTALLATION M1352010100251

CAUTION Do not drop or apply a shock on the G-sensor. Pre-removal and Post-installation Operation Rear Floor Console Assembly Removal and Installation (Refer to GROUP 52A, Floor Console Assembly 352A ).

G-sensor

AC200354AC


G-SENSOR CHECK

Label

MB991348

Connector: D-35 (Harness side)

Label

AC103662 AJ

1. Disconnect the G-sensor connector and connect special tool Test Harness Set (MB991348), between the disconnected connectors.

2. Turn the ignition switch to the "ON" position, and then read the voltage between terminals number 2 and number 3. Standard Value: 2.4 - 2.6 V 3. With special tool Test Harness Set (MB991348) connected, rotate so that the arrow faces straight down. Read output voltage between terminals number 2 and number 3. Standard Value: 1.0 - 4.0 V 4. If the voltage deviates from the standard value, make sure that nothing is wrong with the power supply wire and earth wire and then replace the G-sensor.

00-1

GROUP 00

00 11

GENERAL

12 13 14

CONTENTS HOW TO USE THIS MANUAL. . . . . .

00

15

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . . .

00

SRS SERVICE PRECAUTIONS . . . . .

00

17

HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS. . . .

00

VEHICLE IDENTIFICATION . . . . . . .

00

SUPPORT LOCATIONS FOR LIFTING AND JACKING . . . . . . . . . . . . . . . . . . 00

GENERAL DATA AND SPECIFICATIONS . . . . . . . . . . . . . . .

00

STANDARD PART/TIGHTENINGTORQUE TABLE . . . . . . . . . . . . . . . .

PRECAUTIONS BEFORE SERVICE.

16

00

21 22 25

00

26 27 31 32 33 34 35 36 37 42 51 52 54 55

GENERAL

00-2



SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components. For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to separate manuals covering the engine and the transmission. ON-VEHICLE SERVICE "On-vehicle Service" is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed. INSPECTION Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well.

DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance.

LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time). DANGER, WARNING, AND CAUTION DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows: If a DANGER is not followed, the result is severe bodily harm or even death. If a WARNING is not followed, the result could be bodily injury. If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment.

INDICATION OF TIGHTENING TORQUE Tightening torques (units: N¼m) are set to take into account the central value and the allowable tolerance. The central value is the target value, and the allowable tolerance provides the checking range for tightening torques. If bolts and nuts are not provided with tightening torques, refer to 300.

MODEL INDICATIONS The following abbreviations are used in this manual for identification of model types. MPI: Indicates the multipoint injection. DOHC: Indicates an engine with the double overhead camshaft. M/T: Indicates the manual transmission. A/C: Indicates the air conditioner.

GENERAL HOW TO USE THIS MANUAL

127(6

00-3

00-4

GENERAL HOW TO USE THIS MANUAL

EXPLANATION OF MANUAL CONTENTS Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished.

Component diagram A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts.

Maintenance and servicing procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures procedures. · Removal steps : The part designation number corresponds to the number in the illustration to indicate removal steps. · Disassembly steps : The part designation number corresponds to the number in the illustration to indicate disassembly.

· Installation steps :

Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. · Reassembly steps : Specified in case reassembly is impossible in reverse order of dissasembly steps. Omitted if reassembly is possible in reverse order of dissasembly steps.

Classifications of major maintenance / service points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.) <> : Indicates that there are essential points for removal or disassembly. >>A<< : Indicates that there are essential points for installation or reassembly.

Symbols for lubrication, sealants and adhesives Symbols are used to show the locations for lubrication and for application of sealants and adhesives. These symbols are included in the diagram of component parts or on the page following the component parts page. The symbols do not always have accompanying text to support that symbol.

: Grease (Multi-purpose grease unless there is a brand or type specified) : Sealant or adhesive : Brake fluid or automatic transmission fluid : Engine oil, gear oil or air conditioning compressor oil : Adhesive tape or butyl rubber tape AC301960

GENERAL

00-5

HOW TO USE THIS MANUAL Indicates the group number.

Indicates the section title.

Indicates the group title.

Indicates the page number.


FRONT DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation • Brake Fluid Draining

Post- installation Operation • Brake Fluid Supplying and Air Bleeding (Refer to .)

100 ± 10 N·m

Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the "Standard Parts tightening-torque Table".

30 ± 5 N·m

<2-piston type>

<1-piston type>

Mark denotes nonreusable part.

Grease Brake caliper kit

1. 2. >>A<< 3. 4.

Pad set

Shim kit

Repair kit or parts sets are shown. (Only very frequently used parts are shown.)

Seal and boot repair kit

Removal steps Brake hose connection Gasket Brake caliper assembly Brake disc

INSTALLATION SERVICE POINT >>A<< DISC BRAKE ASSEMBLY INSTALLATION 1. To check the brake drag force after mounting the pad, measure the hub torque in the advancing direction using a spring balance with the pad is removed.

Operating procedures, cautions, etc. On removal, installation, disassembly and reassembly are described.

CAUTION Do not allow any oil, grease or other contamination to contact the friction surfaces of the pads and brake discs. 2. After re-installing the caliper support to the knuckle, install the pad clips and the pads to the caliper support.

The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures.


PISTON SEAL GREASE·REPAIR KIT GREASE

Indicates (by symbols) where lubrication is necessary.

AC300860

GENERAL

00-6

HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS

HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS M1001000200429

CONTENTS OF TROUBLESHOOTING Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline described below. Even in systems for which the MUT-II cannot be used, some of these systems still follow this outline. 1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed.

Diagnosis method Gathering information from the customer. Check trouble symptom. Reoccurs Read the diagnosis code.

No diagnosis code or communication with MUT-II not possible

Does not reoccur

Diagnosis code displayed.

Diagnosis code displayed.

After taking note of the malfunction code, erase the diagnosis code memory.

No diagnosis code.

Recheck trouble symptom. Read the diagnosis codes. Diagnosis code displayed.

Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group.)

Read the diagnosis code.

Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group.)

No diagnosis code. INTERMITTENT MALFUNCTIONS

AC300864AB

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms are shown. 3. DIAGNOSIS FUNCTION Details which are different from those in the "Diagnosis function 300" section are described.

4. DIAGNOSIS CODE CHART Diagnostic trouble codes and diagnostic items are shown. 5. DIAGNOSIS CODE PROCEDURES Indicates the inspection procedures corresponding to each diagnosis code (Refer to How to read inspection procedure 300).

GENERAL

00-7


6. TROUBLE SYMPTOM CHART If there are trouble symptoms even though the MUTII does not find any diagnosis codes, Inspection procedures for each trouble symptom will be found by means of this chart. 7. SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptoms classified in the Symptom Chart (Refer to How to read inspection procedure 300).

ERASING DIAGNOSIS CODE (BY USING THE MUT-II)

CAUTION Before connecting or disconnecting the MUT-II, turn the ignition switch to the "LOCK" (OFF) position. Steering shaft

8. SERVICE DATA REFERENCE TABLE Inspection items and normal judgment values have been provided in this chart as reference information. 9. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items, and judgment values have been provided in this chart as reference information. 10. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are described here.

DIAGNOSIS FUNCTION HOW TO READ DIAGNOSIS CODE

CAUTION Before connecting or disconnecting the MUT-II, turn the ignition switch to the "LOCK" (OFF) position. Steering shaft

MUT-II

AC300830 AB

Connect the MUT-II to the diagnosis connector, and erase the diagnosis code. ERASING DIAGNOSIS CODE (BY USING NO MUT-II)

CAUTION Some diagnosis codes can not be erased according to the procedure below. If you attempt to erase a diagnosis code, refer to an applicable GROUP. 1. Turn the ignition switch to the "LOCK" (OFF) position. 2. Disconnect the negative battery cable, wait for at least 10 minutes, and then reconnect it. 3. Start the engine and let it run at idle for 10 minutes. INPUT SIGNAL CHECK (WHEN USING THE MUTII)

MUT-II


AC300830 AB

Connect the MUT-II to the diagnosis connector, and read the diagnosis code. NOTE: The ABS warning lamp may flash when the ignition switch is turned ON with the MUT-II connected. This is because the diagnosis display function of the ABS warning lamp is activated by grounding the diagnosis connector terminal No.1, and is not detrimental in any way.

Steering shaft

MUT-II

AC300830 AB

1. Connect the MUT-II to the diagnosis connector, and erase the diagnosis code.

00-8

GENERAL HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS

2. If the MUT-II buzzer sounds once when each switch is operated (ON/OFF), the input signal for that switch circuit system is normal.

INPUT SIGNAL CHECK (WHEN USING A VOLTMETER) Steering shaft MB991529

1

2

3

4

5

6

7

8

9 10 11 12 13 14 15 16

AC300831AB

1. Use the special tool diagnosis code check harness (MB9915299) to connect the ETACS terminal (terminal 9) and the earth terminals (terminals 4 and 5) of the diagnosis connector to the voltage meter. 2. If the needle of the voltage meter flickers once when each switch is operated (ON/OFF), the input signal for that switch circuit system is normal.


00-9

HOW TO USE THE INSPECTION PROCEDURES The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, the wiring harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.

Code No. P0100 Air Flow Sensor System

Air flow sensor circuit

Battery


Air flow sensor

Relevant circuit(s) of the component which the Code No. indicates are described. J/C (1)

Engine-ECU Wire colour code B : Black LG : Light green G : Green R : Red P : Pink V : Violet

L : Blue

W : White

Y : Yellow

SB : Sky blue

BR : Brown

O : Orange

GR : Gray

AC301964AB

00-10


Explains about the basic operation of the components.

Start of diagnosis procedure

Describes inspection procedure. MULTIPORT FUEL INJECTION (MFI) TROUBLESHOOTING

Explains about technical details.

Describes the conditions for that diagnosis code being set.

DIAGNOSIS PROCEDURE OPERATION · Power is supplied to the air flow sensor (terminal No. 4) from the engine control relay (terminal No. 1) STEP 1. MUT-II data list and earthed to the engine-ECU (terminal No. 5). · Refer to Date list reference table · A power voltage of 5 V is applied to the air flow M1131152000735 P. 13A-288. sensor output terminal (terminal No. 3) from the a. Item 12: Air flow sensor. engine-ECU (terminal No. 90). · An air flow sensor filter reset signal is inputted to Q: Is the check result normal? the air flow sensor (terminal No. 7) from the engineYES : Intermittent malfunction (Refer to GROUP ECU (terminal No. 19). 00 – How to Use Troubleshooting/ Inspection Service Points M1001000200429). FUNCTION NO : Go to Step 2 M1131750100051s2. · Air flow sensor outputs a puls signal proprtional to STEP 2. Connector check: B-08 air flow sensor the intake Air flow rate. connector · The engine-ECU determines the basic injection timing of the injector using the pulse signal output Connector: B-08 from the air flow sensor and the engine speed signal. · When the throttle position sensor output is low, the engine-ECU causes the power transisitor in the unit to be ON to send an air flow sensor filter reset signal, the air flow sensor resets the filter circuit to improve the ability of the air flow sensor to measure the air flow rate in the area where the intake air flow Harness side connector rate is low. TROUBLE JUDGEMENT

Describes possible causes(s) for that diagnosis code.

Check Condition · Engine speed is 500 r/min or more.

Q: Is the check result normal? YES : Go to Step 3 M1131750100051s3. NO : Repair.

Judgement Criterion · Sensor output frequency of 3.3 Hz or less for 2 seconds. PROBABLE CAUSE · Failed air flow sensor · Open/short circuit in air flow sensor circuit or loose connector contact · Failed engine-ECU

AC301965AB

HARNESS CHECK Check for an open or short circuit in the harness between the terminals which were faulty according to the connector measurements. Carry out this inspection while referring to the Electrical Wiring Manual. Here, "Check the wiring harness between

the power supply and terminal xx" also includes checking for blown fuse. For inspection service points when there is a blown fuse, refer to "Inspection Service Points for a Blown Fuse 300 ." MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure from the beginning.

GENERAL

00-11


CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring, unless there are instructions to the contrary. IF INSPECTING WITH THE CONNECTOR CONNECTED

IF INSPECTING WITH THE CONNECTOR DISCONNECTED

MD998459

MB991219

ACX00865AB

AC300881AB

Be sure to use special tool harness connector (MD998459). Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.

Use the special tool inspection harness (MB991219) (inspection harness for connector pin contact pressure in the harness set for inspection). The inspection harness for connector pin contact pressure should be used. the test bar should never be forcibly inserted, as it may cause a defective contact.

CAUTION

AC300890

Connector

AC300882AB

Check by inserting the multi-meter test probe from the harness side. Note that if the connector (control unit, etc.) is too small to permit insertion of the test probe, it should not be forced; use the backprobing tool for this purpose.

At this time, be careful not to short the connector pins with the test bars. To do so may damage the circuits inside the ECU. Touch the pin directly with the test bar.

GENERAL

00-12


CONNECTOR INSPECTION SERVICE POINTS

CONNECTOR PIN INSPECTION

VISUAL INSPECTION Connector disconnected or improperly connected

AC300898

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even if the connector body is connected, and the pins may pull out of the reverse side of the connector. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.

Stretched or broken wires

CONNECTOR ENGAGEMENT INSPECTION

MB991219 Harness wire breakage at terminal section Low contact pressure Good Bad

AC300899AB

AC300896AB

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

Use the special tool inspection harness (MB991219) (connector pin connection pressure inspection harness of the inspection harness set) to inspect the engagement of the male pins and females pins. (Pin drawing force: 1 N or more)


INSPECTION SERVICE POINTS FOR A BLOWN FUSE

00-13

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS NOTE: If determining the cause is difficult, the flight recorder function of the MUT-II can also be used.

Battery

Fuse

Load switch

Short-circuit occurrence section

Load

AC300900AB

Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Close the switches of all circuits which are connected to this fuse. If the resistance is almost 0 W at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 W, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following. Harness being clamped by the vehicle body Damage to the outer casing of the harness due to wear or heat Water getting into the connector or circuitry Human error (mistakenly shorting a circuit, etc.)

AC300901

Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascertained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the customer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trouble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration, temperature or some other factor. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the

GENERAL

00-14

VEHICLE IDENTIFICATION

trouble symptom occurs. The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which generates diagnosis codes or trouble symptoms). Gently shake the connector up, down and to the left and right.

Gently shake the wiring harness up, down and to the left and right. Gently rock each sensor and relay, etc. by hand. Gently shake the wiring harness at suspensions and other moving parts.

VEHICLE IDENTIFICATION M1001000400553

VEHICLE IDENTIFICATION CODE PLATE 1

Item

Content

1

MODEL

CU2WXNMM CU2W: L6 Vehicle model XNMML6: Model series

3

2

5

No.

4

6

2

ENGINE

4G63

Engine model

3

EXT

W83A

Exterior code

4

TRANS AXLE F5M42 4687

F5M42:Trans mission model 4687: Rear differential (a decimal point is omitted)

5

COLOUR

W83

W83: Body colour code

6

INT

62A

62A: Interior code

7

OPT

ZP3

ZP3: Equipment code

7

AC301477AB

The vehicle information code plate is riveted to the back of the hood. The plate shows model code, engine model, transmission model and body colour code.

For monotone colour vehicles, the body colour code shall be indicated.

MODELS Model code

Engine model

Price class

Transmission model

Fuel supply system

CU2W

4G63-DOHC (1,997 mL)

Comfort

F5M42 <2WD, 5M/T>

MPI

XNMML6 XNMMZL6 XNHMZL6

Sport

W5M42 <4WD, 5M/T>

GENERAL

00-15

VEHICLE IDENTIFICATION

MODEL CODE

CU 2 W X N M M Z L 6

1

2 3 4 5 6 7 8 9 10

No.

Item

Content

7

Specification engine feature

M: MPI-DOHC

8

Special feature

None: 2WD Z: 4WD

9

Steering wheel location

L: Left hand

10

Destination

6: For Europe

CHASSIS NUMBER

AC301363 AB

No.

Item

Content

1

Development

CU: MITSUBISHI OUTLANDER

2

Engine type

2: 1,997 mL petrol engine

3

Sort

W: Wagon

4

Body style

X: 5-door hatchback

5

Transmission type

N: 5-speed manual transmission

6

Trim level

M: COMFORT H: SPORT

AC300903AB

The chassis number is stamped on the toeboard inside the engine compartment.

J

M B

X

N

CU

2

W

3

U

000001

1

2

4

5

6

7

8

9

10

11

3

AC301362AB

No.

Item

Content

1

Fixed figure

J

Asia

2

Distribution channel

M

Japan channel

3

Destination

B

For Europe, left hand drive

4

Body style

X

5-door hatchback

5

Transmission type

N

5-speed manual transmission

6

Development order

CU

OUTLANDER

7

Engine

2

1,997 mL petrol engine

8

Soft

W

Station wagon

9

Model year

3

2003

10

Plant

U

Mizushima

11

Serial number

-

-

GENERAL

00-16

GENERAL DATA AND SPECIFICATIONS

ENGINE MODEL STAMPING

This engine model numbers is as shown as follow. Engine model

Engine displacement

4G63

1,997 mL

The engine serial number is stamped near the engine model number.

AC300905AC

The engine model is stamped on the cylinder block.

GENERAL DATA AND SPECIFICATIONS M1001000900417

8 7 9

1

3

4 6

2

5 AC300072AB

Items

CU2W XNMML6

Vehicle dimensions mm

Front track

1

1,495

Overall width

2

1,750

Front overhang

3

945

Wheel base

4

2,625

Rear overhang

5

975

Overall length

6

4,545

Earth clearance (unladen)

7

195

Overall height (unladen)

8

1,620/1,670*

Rear track

9

1,505

Vehicle weight kg Kerb weight

1,435

1,535

Max. gross vehicle weight

1,970

2,070

Max. axle weight rating-front

1,050

Max. axle weight rating-rear

1,065

Max. trailer weight

With brake

1,500

Without brake

570

Max. trailer-nose weight Seating capacity

XNMMZL6

75 5

XNHMZL6

GENERAL

00-17

PRECAUTIONS BEFORE SERVICE

Items

CU2W XNMML6

Engine Transmission Fuel system

XNMMZL6

Model code

4G63

Total displacement mL

1,997

Model code

F5M42

Type

5-speed manual

Fuel supply system

MPI

XNHMZL6

W5M42

NOTE: *: Vehicles with roof rails

PRECAUTIONS BEFORE SERVICE M1001000500389

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to review when servicing SRS: 1. Be sure to read GROUP 52B - Supplemental Restraint System (SRS). For safe operation, please follow the directions and heed all warnings. 2. Wait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected. 3. Warning labels must be heeded when servicing or handling SRS components. Warning labels can be found in the following locations. Front impact sensor Hood Sun visor Glove box SRS-ECU Steering wheel Clock spring Steering joint cover Air bag module (Driver’s or front passenger’s) Side air bag module (Driver’s side or front passenger’s side) Side impact sensor Seat belt pre-tensioner

Instrument panel 4. Always use the designated special tools and test equipment. 5. Store components removed from the SRS in a clean and dry place. The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do not place anything on top of it. 6. Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module and clock spring). 7. Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure that the system functions properly. 8. Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag (Refer to GROUP 52B - Air Bag Module Disposal Procedures). 2. Observe the following when carrying out operations on places where SRS components are installed, including operations not directly related to the SRS air bag. 1. When removing or installing parts, do not allow any impact or shock to the SRS components. 2. If heat damage may occur during paint work, remove the SRS-ECU, the air bag module, clock spring, the front impact sensor, the side impact sensor, and the seat belt pretensioner. SRS-ECU, air bag module, clock spring, front impact sensor, the side impact sensor: 93 C or more Seat belt pre-tensioner: 90 C or more

GENERAL

00-18

PRECAUTIONS BEFORE SERVICE

SERVICING ELECTRICAL SYSTEM

VEHICLE WASHING

CAUTION Before connecting or disconnecting the negative (-) cable, be sure to turn off the ignition switch and the lighting switch (If this is not done, there is the possibility of semiconductor parts being damaged).

Approximately 40 cm

AC300832AB

AC300693

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 shortcircuiting.

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to note the following information in order to avoid damage to plastic components, etc. Spray nozzle distance: Approx. 40 cm or more Spray pressure: 3,900 kPa or less Spray temperature: 82C or less Time of concentrated spray to one point: within 30 sec.

MUT-II MUT-II Sub-assembly

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

Rom pack

PRE-INSPECTION CONDITION "Pre-inspection condition" refers to the condition that the vehicle must be in before proper engine inspection can be carried out. If you see the words "Set the vehicle to the pre-inspection condition". In this manual, it means to set the vehicle to the following condition. Engine coolant temperature 80 to 90C Lamps, electric cooling fan and all accessories: OFF M/T: Neutral

AC300834AB

Refer to the "MUT-II REFERENCE MANUAL" or "MUT-II OPERATING INSTRUCTIONS" for instructions on handling the MUT-II.

CAUTION

16-pin

MUT-II AC107200AG

Turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the MUT-II. Connect the MUT-II to the diagnosis connector as shown in the illustration.

GENERAL PRECAUTIONS BEFORE SERVICE

IN ORDER TO PREVENT VEHICLES FROM FIRE "Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/ repairs that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance with MMC’s information/Instructions".

ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided. Recommended Precautions The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them. Other precautions: Avoid prolonged and repeated contact with oils, particularly used engine oils.

00-19

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. Do not wear heavily soiled clothing and oilimpregnated foot-wear. Overalls must be cleaned regularly and kept separately from personal clothing. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Obtain First Aid treatment immediately for open cuts and wounds. Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised. Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work. If skin disorders develop, obtain medical advice without delay.

GENERAL

00-20

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) M1001009800020

The Supplemental Restraint System (SRS) and seat belt with pre-tensioner is designed to supplement the driver’s and front passenger’s seat belts to help reduce the risk or severity of injury to the driver and front passenger by activating and deploying both front air bags in certain frontal collisions. The SRS consist of four air bag modules, SRS air bag control unit (SRS-ECU), two front impact sensors, two side impact sensors, SRS warning lamp, clock spring and seat belt pre-tensioner. Front air bags are located in the centre of the steering wheel and above the glove box. Side air bag are located inside the front seatback assemblies. Each air bag is made up of a folded air bag and an inflator unit. The SRS-ECU under the front floor console monitors the system and has a front air bag safing G-

sensor, front air bag analog G-sensor and a side air bag safing G-sensor. The front impact sensor is assembled outside the headlamp support panel to monitor impact in case of front impact. The side impact sensors inside the centre pillars monitor the shock incurred by the sides of the vehicle. The warning lamp on the instrument panel indicates the operational status of the SRS. The clock spring is installed in the steering column. The seat belt pretensioner is built into the driver’s and passenger’s front seat belt retractor. Only authorized service personnel should do work on or around the SRS components. Those service personnel should read this manual carefully before starting any such work.

SRS warning lamp

Seat belt with pre-tensioner

Driver's air bag module

Passenger's (front) air bag module Side air bag module Side impact sensor

Clock spring

SRS-ECU

Side impact sensor Side air bag module Front impact sensor AC301343 AB

GENERAL

00-21

SRS SERVICE PRECAUTIONS

SRS SERVICE PRECAUTIONS M1001006000047

DANGER In order to avoid injury to yourself or others from accidental deployment of the air bag during servicing, read and carefully follow all the precautions and procedures described in this manual. CAUTION

CAUTION SRS-ECU connector

Do not use any electrical test equipment on or near SRS components, except those specified on 352B. AC300634 AB

CAUTION Never Attempt to Repair the Following Components: 1. SRS air bag control unit (SRS-ECU) 2. Front impact sensor 3. Clock spring 4. Driver’s and front passenger’s air bag modules 5. Side air bag module 6. Side impact sensor 7. Seat belt with pre-tensioner NOTE: If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the INDIVIDUAL COMPONENTS SERVICE procedures in this manual, starting at page 352B . SRS-ECU terminal No. Destination of harness

Do not attempt to repair the wiring harness connectors of the SRS. If a defective wiring harness is found, repair or replace it by referring to the table below.

Remedy

1, 2

Instrument panel wiring harness Front wiring harness (RH) Front impact sensor (RH)

Correct or replace each wiring harness.

3, 4

Instrument panel wiring harness Front wiring harness (LH) Front impact sensor (LH)


7

Instrument panel wiring harness Earth

Correct or replace the instrument panel wiring harness.

8

Instrument panel wiring harness SRS warning lamp


9, 10

Instrument panel wiring harness Air bag module (Front passenger’s side)


11, 12

Instrument panel wiring harness Clock spring Air bag module (Driver’s side)

Correct or replace instrument panel wiring harness. Replace the clock spring.

13

Instrument panel wiring harness Junction block (fuse No.3)


16



00-22

GENERAL SRS SERVICE PRECAUTIONS

SRS-ECU terminal No.

Destination of harness

Remedy

20

Instrument panel wiring harness Diagnosis connector


21, 22

Floor wiring harness (RH) Side air Correct or replace the floor wiring bag module (LH) harness.

23, 24

Floor wiring harness (RH) Side air Correct or replace the floor wiring bag module (RH) harness.

27, 28

Floor wiring harness (RH) Seat belt pre-tensioner (Front passenger’s side)

Connect or replace the floor wiring harness.

29, 30

Floor wiring harness (LH) Seat belt pre-tensioner (driver’s side)


34, 36

Floor wiring harness (LH) Side impact sensor (LH)


40, 42

Floor wiring harness (RH) Side impact sensor (RH)


GENERAL SRS SERVICE PRECAUTIONS

CAUTION

DANGER Insulating tape Battery

Battery cable

00-23

SRS-Harness connector

AC300580AB

After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work. In addition, insulate the negative battery terminal with a tape. The condenser inside the SRS-ECU is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected. CAUTION The SRS components and seat belt with pretensioner should not be subjected to heat, so remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag modules, and seat belt pre-tensioner before drying or baking the vehicle after painting. SRS-ECU, air bag modules, clock spring, impact sensors: 93C or more Seat belt with pre-tensioner 90C or more

CAUTION Whenever you finish servicing the SRS, always erase the diagnosis code and check warning lamp operation to make sure that the system functions properly.

SRS-ECU harness connector (rear side)

AC300673AB

If checks are carried out by using the SRS-ECU harness connector, observe the following procedures: Insert the special tool (probe in the harness set) MB991222 into connector from harness side (rear side), and connect the tester to this probe. If any tool than special tool is used, damage to the harness and other components will result. Never insert the probe directly to the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the probe, the plating may break, which will cause drops in reliability.

GENERAL

00-24

SUPPORT LOCATIONS FOR LIFTING AND JACKING

SUPPORT LOCATIONS FOR LIFTING AND JACKING M1001000700093

SUPPORT POSITIONS FOR A GARAGE JACK, AXLE STANDS, SINGLE-POST LIFT OR DOUBLE-POST LIFT AND PLATE TYPE LIFT CAUTION Do not support the vehicles at locations other than specified supporting points. Doing so will cause damage, etc. GARAGE JACK

CAUTION Never support any point other than the specified one, or that point will be deformed. <2WD>

Rear suspension crossmember

<4WD>

Rear differential

AC300835

GENERAL SUPPORT LOCATIONS FOR LIFTING AND JACKING

00-25

AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT

CAUTION If rubber attachments with grooves that are too thick are used at the front support positions, the front fender may become bent, so be sure to use rubber attachments with groove thicknesses of 18 mm or less. If attachments which are not high enough are used, they may damage areas such as the side step. Be sure to use attachments which are high enough, or remove the side step if not using attachments. AXLE STANDS Bolts

Bolts

Rubber Rubber

SINGLE-POST LIFT OR DOUBLE-POST LIFT Bolts

Bolts

AC300836AB

GENERAL

00-26

STANDARD PART/TIGHTENING-TORQUE TABLE

PLATE TYPE LIFT

CAUTION To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift. Support the side sill flange with a lift.

STANDARD PART/TIGHTENING-TORQUE TABLE M1001001100362

Each torque value in the table is a standard value for tightening under the following conditions. 1. Bolts, nuts and washers are all made of steel and plated with zinc. 2. The threads and bearing surface of bolts and nuts are all in dry condition. The values in the table are not applicable:

1. If toothed washers are inserted. 2. If plastic parts are fastened. 3. If bolts are tightened to plastic or die-cast inserted nuts. 4. If self-tapping screws or self-locking nuts are used.

Standard bolt and nut tightening torque Thread size Torque N¼m Bolt nominal diameter (mm)

Pitch (mm)

Head mark "4"

Head mark "7"

Head mark "8"

M5

0.8

2.5 0.5

5.0 1.0

6.0 1.0

M6

1.0

5.0 1.0

9.0 2.0

10 2

M8

1.25

12 2

22 4

25 4

M10

1.25

24 4

44 10

53 7

M12

1.25

41 8

83 12

98 12

M14

1.5

73 12

140 20

155 25

M16

1.5

110 20

210 30

235 35

M18

1.5

165 25

300 40

340 50

M20

1.5

225 35

410 60

480 70

M22

1.5

300 40

555 85

645 95

M24

1.5

395 55

735 105

855 125

Flange bolt and nut tightening torque Thread size Torque N¼m Bolt nominal diameter (mm)

Pitch (mm)

Head mark "4"

Head mark "7"

Head mark "8"

M6

1.0

5.0 1.0

10 2

12 2

M8

1.25

13 2

24 4

27 5

M10

1.25

26 4

49 9

58 7

M10

1.5

24 4

45 8

55 10

M12

1.25

46 8

95 15

105 15

M12

1.75

43 8

83 12

98 12

NOTE: . Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques. Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the bolt strength.

52B-1

GROUP 52B


00 11 12 13 14 15 16 17


52B

SRS CONTROL UNIT (SRS-ECU) . . . 52B REMOVAL AND INSTALLATION . . . . . . . . 52B

21 22 25

SERVICE PRECAUTIONS. . . . . . . . .

52B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B

SPECIAL TOOLS. . . . . . . . . . . . . . . .

52B

AIR BAG MODULE(S) AND CLOCK SPRING . . . . . . . . . . . . . . . . . 52B

27

TEST EQUIPMENTS . . . . . . . . . . . . .

52B

REMOVAL AND INSTALLATION . . . . . . . . 52B

31

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B


52B SIDE IMPACT SENSOR . . . . . . . . . . . 52B

SRS MAINTENANCE. . . . . . . . . . . . . 52B


WARNING/CAUTION LABELS . . . . . 52B FRONT IMPACT SENSORS . . . . . . . 52B REMOVAL AND INSTALLATION . . . . . . . . 52B

32 33

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B

34

SEAT BELTS WITH PRE-TENSIONER . . . . . . . . . . . . . . . . 52B

35

POST-COLLISION DIAGNOSIS . . . . 52B INDIVIDUAL COMPONENT SERVICE . . . . . . . . . . . . . . . . . . . . . . 52B

26


36

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B

37

AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES . . . . . . . . 52B

42

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 52B

51 52 54

WARNING

Carefully read and observe the information in the SERVICE PRECAUTIONS prior to any service. For information concerning diagnosis or maintenance, always observe the procedures in the SRS Diagnosis or the SRS Maintenance sections, respectively. If any SRS components are removed or replaced in connection with any service procedures, be sure to follow the procedures in the INDIVIDUAL COMPONENT SERVICE section for the comportments involved. If you have any questions about the SRS, please contact your local distributor.

55

52B-2

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) GENERAL INFORMATION


The Supplemental Restraint System (SRS) and seat belt with pre-tensioner is designed to supplement the driver’s and front passenger’s seat belts to help reduce the risk or severity of injury to the driver and front passenger by activating and deploying both front air bags in certain frontal collisions. The SRS consist of four air bag modules, SRS air bag control unit (SRS-ECU), two front impact sensors, two side impact sensors, SRS warning lamp, clock spring and seat belt pre-tensioner. Front air bags are located in the centre of the steering wheel and above the glove box. Each air bag is made up of a folded air bag and an inflator unit. Side air bags are located inside the front seatback assemblies. The SRS-ECU under the front floor console monitors the system and has a front air bag

safing G-sensor, front air bag analog G-sensor and a side air bag safing G-sensor. The front impact sensor is assembled outside the headlamp support panel to monitor impact in case of front impact. The side impact sensors inside the centre pillars monitor the shock incurred by the sides of the vehicle. The warning lamp on the instrument panel indicates the operational status of the SRS. The clock spring is installed in the steering column. The seat belt pretensioner is built into the driver’s and passenger’s front seat belt retractor. Only authorized service personnel should do work on or around the SRS components. Those service personnel should read this manual carefully before starting any such work.

SRS warning lamp

Seat belt with pre-tensioner

Driver's air bag module

Passenger's (front) air bag module Side air bag module Side impact sensor

Clock spring

SRS-ECU

Side impact sensor Side air bag module Front impact sensor AC301343 AB

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SERVICE PRECAUTIONS

52B-3

SERVICE PRECAUTIONS M1524000300369

DANGER In order to avoid injury to yourself or others from accidental deployment of the air bag during servicing, read and carefully follow all the precautions and procedures described in this manual. CAUTION

CAUTION SRS-ECU connector

Do not use any electrical test equipment on or near SRS components, except those specified on 352B. AC300634 AB

CAUTION Never Attempt to Repair the Following Components: 1. SRS air bag control unit (SRS-ECU) 2. Front impact sensor 3. Clock spring 4. Driver’s and front passenger’s air bag modules 5. Side air bag module 6. Side impact sensor 7. Seat belt with pre-tensioner NOTE: If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the INDIVIDUAL COMPONENTS SERVICE procedures in this manual, starting at page 352B . SRS-ECU terminal No. Destination of harness

Do not attempt to repair the wiring harness connectors of the SRS. If a defective wiring harness is found, repair or replace it by referring to the table below.

Remedy

1, 2

Instrument panel wiring harness Front wiring harness (RH) Front impact sensor (RH)


3, 4

Instrument panel wiring harness Front wiring harness (LH) Front impact sensor (LH)


7

Instrument panel wiring harness Earth


8

Instrument panel wiring harness SRS warning lamp


9, 10

Instrument panel wiring harness Air bag module (Front passenger’s side)


11, 12

Instrument panel wiring harness Clock spring Air bag module (Driver’s side)

Correct or replace instrument panel wiring harness. Replace the clock spring.

13



16




52B-4

SERVICE PRECAUTIONS

SRS-ECU terminal No.

Destination of harness

Remedy

20

Instrument panel wiring harness Diagnosis connector


21, 22

Floor wiring harness (RH) Side air Correct or replace the floor wiring bag module (LH) harness.

23, 24

Floor wiring harness (RH) Side air Correct or replace the floor wiring bag module (RH) harness.

27, 28

Floor wiring harness (RH) Seat belt pre-tensioner (Front passenger's side)


29, 30

Floor wiring harness (LH) Seat belt pre-tensioner (driver's side)


34, 36

Floor wiring harness (LH) Side impact sensor (LH)


40, 42

Floor wiring harness (RH) Side impact sensor (RH)


CAUTION

DANGER Insulating tape Battery

Battery cable

AC300580AB

After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work. In addition, insulate the negative battery terminal with a tape. The condenser inside the SRS-ECU is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected.

The SRS components and seat belt with pretensioner should not be subjected to heat, so remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag modules, and seat belt pre-tensioner before drying or baking the vehicle after painting. SRS-ECU, air bag modules, clock spring, impact sensors: 93C or more Seat belt with pre-tensioner: 90C or more

CAUTION Whenever you finish servicing the SRS, always erase the diagnosis code and check warning lamp operation to make sure that the system functions properly.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SERVICE PRECAUTIONS

CAUTION SRS-Harness connector

SRS-ECU harness connector (rear side)

AC300673AB

If checks are carried out by using the SRS-ECU harness connector, observe the following procedures: Insert the special tool (probe in the harness set) MB991222 into connector from harness side (rear side), and connect the tester to this probe. If any tool than special tool is used, damage to the harness and other components will result. Never insert the probe directly to the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the probe, the plating may break, which will cause drops in reliability.

52B-5


52B-6

SPECIAL TOOLS


Tool

No.

Name

Application

MB990784

Ornament remover

Removal of cover.

MB991502

MUT-II sub assembly

Reading and erasing diagnosis code Reading trouble period Reading erase times

MB991865

Dummy resistor

SRS air bag and seat belt with pre-tensioner circuit check

MB991866

Resistor harness

SRS air bag circuit check

MB991884

Resistor harness (For Pre-tensioner)

Seat belt with pre-tensioner circuit check

MB991885

Pre-tensioner adapter harness

Deployment of seat belt with pre-tensioner inside the vehicle Deployment of seat belt with pre-tensioner outside the vehicle

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222


Checking the continuity and measuring the voltage at the SRS-ECU harness connector

MB990784

B991502

MB991865

MB991866

MB991884

MB991885

A

B

C

D MB991223AW


52B-7

TEST EQUIPMENTS

Tool

No.

Name

Application

MB686560

SRS air bag adapter harness

Deployment of air bag module (Front passenger’s side) inside the vehicle Deployment of air bag module (Front passenger’s side) outside the vehicle

MB686560

TEST EQUIPMENTS M1524000800278

Tool

Name

Application

Digital multi-meter

Checking SRS electrical circuitry (Use multi-meter for which the maximum test current is 2 mA or less at minimum range of resistance measurement

AC300683



SRS WARNING LAMP CHECK M1524004300297

SRS warning lamp


DIAGNOSIS CODES CHECK CAUTION Turn off the ignition switch before connecting or disconnecting the MUT-II. Connect the MUT-II to the diagnosis connector (16pin) under the instrument under cover, then check diagnosis codes (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points 300).

ERASING DIAGNOSIS CODE CAUTION Turn off the ignition switch before connecting or disconnecting the MUT-II. Connect the MUT-II to the diagnosis connector and erase the diagnosis code.

AC301667 AB

1. Check that the SRS warning lamp comes on when the ignition switch is turned ON. 2. Check that the SRS warning lamp illuminates for about 7 seconds and then goes out. 3. If this is not the cause, check the diagnosis codes.

52B-8

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) TROUBLESHOOTING

CHECK CHART FOR DIAGNOSIS CODES M1524003300476

Inspect according to the inspection chart that is appropriate for the diagnosis code. Code No.

Diagnosis item

Reference Page

11

Front impact sensor short-circuited

352B

12

One front impact sensor open-circuited

352B

13

Two front impact sensor open-circuited

352B

14

Analog G-sensor malfunction

352B

15

Safing G-sensor (for frontal collision) short-circuited

352B

16

Safing G-sensor (for frontal collision) open-circuited

352B

17

Safing G-sensor (for side collision) malfunction

352B

21*2

Driver’s air bag module (squib) system (short-circuited between terminals of the squib circuit)

352B

22*2

Driver’s air bag module (squib) system (open-circuited in the 352B squib circuit)

24*2

Passenger’s (front) air bag module (squib) system (shortcircuited between terminals of the squib circuit)

352B

25*2

Passenger’s (front) air bag module (squib) system (opencircuited in the squib circuit)

352B

26*2

Driver’s pre-tensioner (squib) system (short-circuited between terminals of the squib circuit)

352B

27*2

Driver’s seat belt pre-tensioner (squib) system (opencircuited in the squib circuit)

352B

28*2

Passenger’s (front) seat belt pre-tensioner (squib) system (short-circuit between terminals of the squib circuit)

352B

29*2

Passenger’s (front) seat belt pre-tensioner (squib) system (open-circuited in the squib circuit)

352B

31

SRS-ECU capacitor circuit voltage too high

352B

32

SRS-ECU capacitor circuit voltage too low

352B

34*1

SRS-ECU connector lock out of order

352B

35

Ignition of the air bag completed

352B

41*1

Power supply voltage (IG1 (A) voltage) drops abnormally.

352B

42*1

Power supply voltage (IG1 (B) voltage) drops abnormally.

352B

43*1

SRS warning lamp circuit open-circuited

Lamp does not illuminate

352B

Lamp does not switch off

352B

44*1

SRS warning lamp circuit malfunction

352B

45

SRS-ECU non-volatile memory (EEPROM) and A/D converter system

352B

51

Driver’s air bag squib activating circuit short-circuited

352B

52

Driver’s air bag squib activating circuit open-circuited

352B

54

Passenger’s (front) air bag squib activating circuit shortcircuited

352B

55

Passenger’s (front) air bag squib activating circuit opencircuited

352B


52B-9

TROUBLESHOOTING

Code No.

Diagnosis item

Reference Page

56

Driver’s seat belt pre-tensioner (squib ignition drive circuit) system detected short

352B

57

Driver’s seat belt pre-tensioner (squib ignition drive circuit) system detected open

352B

58

Passenger’s seat belt pre-tensioner (squib ignition drive circuit) system detected short

352B

59

Passenger’s seat belt pre-tensioner (squib ignition drive circuit) system detected open

352B

61

Driver's air bag module (squib) system (short-circuited to the 352B power supply)

62

Driver's air bag module (squib) system (short-circuited to the 352B earth)

64

Passenger's (front) air bag module (squib) system (shortcircuited to the power supply)

352B

65

Passenger's (front) air bag module (squib) system (shortcircuited to the earth)

352B

66

Driver's seat belt pre-tensioner (squib) system (shortcircuited to the power the supply)

352B

67

Driver's seat belt pre-tensioner (squib) system (shortcircuited to the earth)

352B

68

Passenger's (front) seat belt pre-tensioner (squib) system (short-circuited to the power supply)

352B

69

Passenger's (front) seat belt pre-tensioner (squib) system (short-circuited to the earth)

352B

71*2

Side air bag module (squib) (RH) system (short-circuited between terminals of the squib circuit)

352B

72*2

Side air bag module (squib) (RH) system (open-circuited in the squib circuit)

352B

73

Side air bag squib (RH) drive circuit shorted

352B

74

Side air bag squib (RH) drive circuit open

352B

75

Side air bag module (squib) (RH) system (short-circuited to the power supply)

352B

76

Side air bag module (squib) (RH) system (short-circuited to the earth)

352B

79

Side impact sensor (LH) communication error

352B

81*2

Side air bag module (squib) (LH) system (short-circuited between terminals of the squib circuit)

352B

82*2

Side air bag module (squib) (LH) system (open-circuited in the squib circuit)

352B

83

Side air bag squib (LH) drive circuit shorted

352B

84

Side air bag squib (LH) drive circuit open

352B

85

Side air bag module (squib) (LH) system (short-circuited to the power supply)

352B

86

Side air bag module (squib) (LH) system (short-circuited to the earth)

352B

52B-10


Code No.

Diagnosis item

Reference Page

89

Side impact sensor (RH) communication error

352B

91*1

Side impact sensor (LH) voltage error

352B

92

G-sensor of side impact sensor (LH) failure

352B

93

Side impact sensor (LH) communication impossible

352B

94*1

Side impact sensor (RH) voltage error

352B

95

G-sensor of side impact sensor (RH) failure

352B

96

Side impact sensor (RH) communication impossible

352B

NOTE: . 1. *1: If the vehicle condition returns to normal, the diagnosis code will be automatically erased, and the SRS warning lamp will return to normal. 2. *2: However, if no diagnosis code resets, the SRS warning lamp will be switched off (The diagnosis code will be retained). 3. If the vehicle has a discharged battery, it will store the diagnosis code 41 or 42. When these diagnosis codes are read, check the battery.


Code No.11: Front impact sensor short-circuited Code No.12: One front impact sensor open-circuited Code No.13: Two front impact sensor open-circuited Front Impact Sensor Circuit SRS-ECU MICROCOMPUTER

INTERFACE CIRCUIT

FRONT IMPACT SENSOR (LH)

FRONT IMPACT SENSOR (RH)

Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet AC301793AB


OPERATION When the left and right front impact sensors detect a collision, the switches inside the sensors turns ON. SRS-ECU judges how severe a collision is by detecting signals from the front impact sensors and the front air bag analog G-sensor. If the impact is over a predetermined level, the SRSECU outputs an ignition signal. At this time, if the front air bag safing G-sensor is on, the SRS air bag will inflate.

52B-11

52B-12


DIAGNOSIS CODE SET CONDITIONS These diagnosis codes are set if these is abnormal resistance between the input terminals of the front impact sensors. The most likely causes for these codes to be set are shown in the table below: Code No. Trouble causes 11

Short circuit in front impact sensor or harness Short circuit in front impact sensor harness leading to the vehicle body earth Short circuit in front impact sensor harness leading to the power supply

12

Open circuit in either left or right from impact sensor or harness Short circuit in front impact sensor harness leading to the power supply

13

Open circuit in both left and right front impact sensor or harness Short circuit in front impact sensor harness leading to the power supply

PROBABLE CAUSES Malfunction of the front impact sensor Damaged wiring harnesses or connectors Malfunction of the SRS-ECU


52B-13

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 2. Measure the resistance at SRS-ECU connector C-115.

STEP 1. Check the front impact sensor.

Connector: C-115 SRS-ECU

Harness side connector (front view)

Center lower panel C-115 (Y)

4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

(1) Disconnect SRS-ECU connector C-115 and measure at the harness side (rear side).

CAUTION C-115 Harness side connector (rear view) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

AC201934

(1) Measure the resistance between terminals and check whether it is within the standard value. Standard value: 820 82 W

AC300941AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (2) Measure the resistance between terminal 3 and terminal 4. OK: 820 82 W Q: Is the check result normal? YES : Go to Step 4. NO : Go to Step 3.

AC200633

(2) Check for continuity between the terminal and bracket. OK: No continuity Q: Does the resistance meet the value above, and is there no continuity? YES : Go to Step 2. NO : Replace front impact sensor. Refer to

352B.


52B-14

TROUBLESHOOTING

STEP 3. Connector check: SRS-ECU connector C-115, front impact sensor (LH) connector A-17 and intermediate connector C-116

STEP 4. Measure the resistance at SRS-ECU connector C-115. Connector: C-115

Connector: C-115

SRS-ECU SRS-ECU




4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

Connector: A-17


AC301661AC

(1) Disconnect SRS-ECU connector C-115 and measure at the harness side (rear side).

CAUTION C-115 Harness side connector (rear view)

A-17 (Y)


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

2 1

AC301613 AC

Connector: C-116

1 2

5 6 7

3 4

AC300942 AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (2) Measure the resistance between terminal 1 and terminal 2. OK: 820 82 W

8 9

1617 18 1920 21

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

AC301395 AG

Q: Is the check result normal? YES : Check the harness wires for open or short

circuit between SRS-ECU connector C-115 (terminal No.3 and 4) and front impact sensor (LH) connector A-17 (terminal No.1 and 2), and repair if necessary. Then go to Step 6. NO : Repair or replace it. Then go to Step 6.


check the diagnosis code. If diagnosis code 11, 12 or 13 sets, replace the SRS-ECU. Refer to 352B. Then go to Step 6 . NO : Go to Step 5.


STEP 5. Connector check: SRS-ECU connector C-115, front impact sensor (RH) connector A-28 and intermediate connector C-14 Connector: C-115 SRS-ECU


Harness side connector (front view) 4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

CONNECTOR: A-28

A-28 (Y) Harness side connector (front view) 2 1

AC210453 AH

Connector: C-14

1 2 3 4 5 6 7 8 9 10

AC301397 AC


circuit between SRS-ECU connector C-115 (terminal No.1 and 2) and front impact sensor (RH) connector A-28 (terminal No.1 and 2), and repair if necessary. Then go to Step 6. NO : Repair or replace it. Then go to Step 6.

52B-15

STEP 6. Recheck the diagnosis code. Q: Is any of diagnosis code 11, 12 or 13 set? YES : Return to Step 1. NO : The procedure is complete (If no

malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points 300).


52B-16

TROUBLESHOOTING

Code No.14: Analog G-sensor malfunction Code No.15: Safing G-sensor (for frontal collision) short-circuited Code No.16: Safing G-sensor (for frontal collision) open-circuited Code No.17: Safing G-sensor (for side collision) malfunction Code No.31: SRS-ECU capacitor circuit voltage too high Code No.32: SRS-ECU capacitor circuit voltage too low Code No.45: SRS-ECU non-volatile memory (EEPROM) and A/D converter system Code No.51: Driver’s air bag squib activating circuit short-circuited Code No.52: Driver’s air bag squib activating circuit open-circuited Code No.54: Passenger’s (front) air bag squib activating circuit short-circuited Code No.55: Passenger’s (front) air bag squib activating circuit open-circuited Code No.56: Driver’s seat belt pre-tensioner (squib ignition drive circuit) system detected short Code No.57: Driver’s seat belt pre-tensioner (squib ignition drive circuit) system detected open Code No.58: Passenger’s seat belt pre-tensioner (squib ignition drive circuit) system detected short Code No.59: Passenger’s seat belt pre-tensioner (squib ignition drive circuit) system detected open Code No.73: Side air bag squib (RH) drive circuit shorted Code No.74: Side air bag squib (RH) drive circuit open Code No.83: Side air bag squib (LH) drive circuit shorted Code No.84: Side air bag squib (LH) drive circuit open DIAGNOSIS CODE SET CONDITIONS PROBABLE CAUSE These diagnosis codes are set when a fault is Malfunction of the SRS-ECU detected in the SRS-ECU. The most likely causes for this code to be set are shown in the table below: Code No. Part/Circuit integral to SRSTrouble causes ECU 14

Analog G-sensor

When the analog G-sensor is not operating When the characteristics of the analog G-sensor are abnormal When the output from the analog G-sensor is abnormal

15

Safing G-sensor (for frontal collision)

Short circuit in the safing G-sensor

16

Open circuit in the safing G-sensor

17

Safing G-sensor (for side collision)

When the safing G-sensor is not operating When the characteristics of the safing G-sensor are abnormal When the output from the safing G-sensor is abnormal

31

Capacitor circuit

Voltage at the capacitor terminal is higher than the specified value for five seconds or more

32

Voltage at the capacitor terminal is lower than the specified value for five seconds or more (This is not detected if diagnosis code No.41 or 42 indicating battery positive voltage drop has been output).

45

Non-volatile memory (EEPROM) and A/D converter

When the non-volatile memory (EEPROM) and A/D converter system are abnormal

51

Driver’s air bag module (squib ignition drive circuit)

Short circuit in the squib ignition drive circuit

Front passenger’s air bag module (squib ignition drive circuit)


52 54 55

Open circuit in the squib ignition drive circuit Open circuit in the squib ignition drive circuit


52B-17

Code No.

Part/Circuit integral to SRSECU

Trouble causes

56

Driver’s seat belt pre-tensioner (squib ignition drive circuit)


Passenger’s seat belt pretensioner (squib ignition drive circuit)


Side air bag module (RH) (squib ignition drive circuit)


Side air bag module (LH) (squib ignition drive circuit)


57 58 59 73 74 83 84

DIAGNOSIS PROCEDURE Replace the SRS-ECU (Refer to 352B).




52B-18

TROUBLESHOOTING

Code No.21: Driver’s air bag module (squib) system (short-circuited between terminals of the squib circuit)

Driver's Air Bag Module (Squib) Circuit SRS-ECU MICROCOMPUTER

NOTE CONNECTOR COUPLED: ON CONNECTOR UNCOUPLED: OFF

AIR BAG DRIVE CIRCUIT

CONNECTOR LOCK SWITCH

CLOCK SPRING

AIR BAG MODULE (SQUIB) (DRIVER'S SIDE)




OPERATION The SRS-ECU judges how severe a collision is by detecting signals from the front impact sensors and the front air bag analog G-sensor. If the impact is over a predetermined level, the SRSECU outputs an ignition signal. At this time, if the front air bag safing G-sensor is on, the SRS air bag will inflate. The ignition signal is input to the air bag module via the clock spring to inflate the air bag.


DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if one driver’s air bag squib wire shorted to the other. However, if no diagnosis code resets, the SRS warning lamp will be switched off (diagnosis code will be retained). PROBABLE CAUSES Improper engaged connector or defective short spring* Short circuit in the clock spring Short circuit between the driver’s air bag module (squib) circuit terminals Damaged connector(s) Malfunction of the SRS-ECU


52B-19

TROUBLESHOOTING

NOTE: *: The squib circuit connectors integrate a "short" spring (which prevents the air bag from deploying unintentionally due to static electricity by shorting the positive wire to the earth wire in the squib circuit when the connectors are disconnected). Therefore, if connector C-115, C-307 or C-306 is damaged or improperly engaged, the short spring may not be released when the connector is connected.

STEP 3. Connector check: SRS-ECU connector C-115, clock spring connector C-307 and driver’s air bag module connector C-306 (1) Disconnect the negative battery terminal. Connector: C-115 SRS-ECU

Center lower panel

DIAGNOSIS PROCEDURE

C-115 (Y)

STEP 1. Using MUT-II, read the diagnosis code.

4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

CAUTION To prevent damage to MUT-II, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting MUT-II. (1) Turn the ignition switch to the "ON" position. (2) Check if the diagnosis code is set. (3) Turn the ignition switch to the "LOOK" (OFF) position.


AC301661AC

Connectors: C-306, C-307 Clock spring C-307 (Y)

Harness side connector (front view) C-306 2

Q: Is diagnosis code 34 set? YES : Go to Step 2. NO : Go to Step 3.

1

C-307 C-306

4 3 2 1

AC301399 AH

STEP 2. Connector check: SRS-ECU connector C-115 Connector: C-115 SRS-ECU



AC301661AC

Q: Is the connector correctly engaged? YES : Go to Step 3. NO : Engage the connector correctly. Then go to

Step 7.

(2) Disconnect connectors C-115, C-307 and C-306, and then reconnect them. (3) Connect the negative battery terminal. (4) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 21 set? YES : Go to Step 4. NO : The procedure is complete. It is assumed

that diagnosis code 21 set as connector C115, C-307 or C-306 was engaged improperly.


52B-20

TROUBLESHOOTING

STEP 4. Check the driver’s air bag module. (1) Disconnect the negative battery terminal.

STEP 5. Check the clock spring. (1) Disconnect the negative battery terminal. MB991865 (Dummy resistor : 3 Ω)

C-306 Air bag module connector

MB991866 (Resistor harness)

A 1 2 3 4

Steering wheel

(Rear view) AC300156AB

(2) By sliding the A section (in the figure) of air bag module connector C-306 in the arrow direction, disconnect the connector. MB991865 (Dummy resistor : 3Ω)


C-306 Air bag module connector AC300945AB

(3) Connect special tool dummy resistor (MB991865) to special tool resistor harness (MB991866).

CAUTION Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Insert special tool (MB991866) into clock spring side air bag module connector C-306 by backprobing. (5) Connect the negative battery terminal. (6) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 21 set? YES : Go to Step 5. NO : Replace the driver’s air bag module (Refer

to 352B). Then go to Step 7.

C-307 Clock spring connector

AC300949AB

(2) Disconnect the clock spring connector C-307. (3) Connect special tool dummy resistor (MB991865) to special tool resistor harness (MB991866).

CAUTION Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Insert special tool (MB991866) into clock spring harness side connector C-307 (terminal No.3 and 4) by backprobing. (5) Connect the negative battery terminal. (6) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 21 set? YES : Go to Step 6. NO : Replace the clock spring (Refer to 352B

). Then go to Step 7.


52B-21

TROUBLESHOOTING

STEP 6. Measure the resistance at the SRS-ECU connector C-115. Connector: C-115

C-115 Harness side connector (rear view)

SRS-ECU



4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

(1) Disconnect SRS-ECU connector C-115.

DANGER Connector: C-307 Clock spring

C-307 (Y)


AC301399 AF

To prevents the air bag from deploying unintentionally, disconnect the clock spring connector C-307 to short the squib circuit. (2) Disconnect the clock spring connector C-307.

CAUTION C-115 Harness side connector (front view) Terminal Cable tie A A

4 mm or more

AC300953 AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Measure the resistance between C-115 harness side connector terminals 11 and 12. OK: Open circuit Q: Is the check result normal? YES : Erase the diagnosis code memory, and

4 3 2 1

Section A-A

CAUTION

Short spring AC300951 AB

Insert an insulator such as a cable tie to a depth of 4 mm or more, otherwise the short spring will not be released. (3) Insert a cable tie [3 mm wide, 0.5 mm thick] between terminals 11, 12 and the short bar to release the short spring.

check the diagnosis code. If diagnosis code 21 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 7 . NO : Repair the harness wires between SRSECU connector C-115 (terminal No.11 and 12) and clock spring connector C-307 (terminal No.3 and 4). Then go to Step 7. STEP 7. Recheck the diagnosis code. Q: Is diagnosis code 21 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-22

TROUBLESHOOTING

Code No.22: Driver’s air bag module (squib) system (open-circuited in the squib circuit)





CLOCK SPRING





OPERATION The SRS-ECU judges how severe a collision is by detecting signals from the front impact sensors and the front air bag analog G-sensor. If the impact is over a predetermined level, the SRSECU outputs an ignition signal. At this time, if the front air bag safing G-sensor is on, the SRS air bag will inflate. The ignition signal is input to the air bag module via the clock spring to inflate the air bag. DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if driver’s air bag squib wire(s) are open-circuited. However, if no diagnosis code resets, the SRS warning lamp will be switched off (diagnosis code will be retained).


PROBABLE CAUSES Open circuit in the clock spring Open circuit due to improper neutral position of the clock spring Open circuit in the driver's air bag module (squib) circuit Disengaged driver's air bag module (squib) connector Improper connector contact Malfunction of the SRS-ECU


52B-23

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP 1. Check the driver’s air bag module. (1) Disconnect the negative battery terminal.

STEP 2. Check the clock spring. (1) Disconnect the negative battery terminal. (2) Disconnect the clock spring connector C-307. MB991865 (Dummy resistor : 3 Ω)



A

1 2 3 4

(Rear view) Steering wheel

AC300156AB

(2) By sliding the A section (in the figure) of air bag module connector C-306 in the arrow direction, disconnect the connector. MB991865 (Dummy resistor : 3Ω)




CAUTION Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Insert special tool (MB991866) into clock spring side air bag module connector C-306 by backprobing. (5) Connect the negative battery terminal. (6) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 22 set? YES : Go to Step 2. NO : Replace the driver’s air bag module (Refer



AC300949AB





52B-24

TROUBLESHOOTING

STEP 3. Measure the resistance between the SRS-ECU connector C-115 (terminal No.11 and 12) and the clock spring connector C-307 (terminal No.3 and 4). Connector: C-115 SRS-ECU



4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

Connector: C-307 Clock spring

C-307 (Y)

Harness side connector (front view) 4 3 2 1

AC301399 AF

(1) Disconnect SRS-ECU connector C-115 and clock spring connector C-307.



1 2 3 4

AC300955 AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened.

(2) Measure the resistance between the following terminals. SRS-ECU connector C-115 terminal No.11 and the clock spring connector C-307 terminal No.3 SRS-ECU connector C-115 terminal No.12 and the clock spring connector C-307 terminal No.4 OK: Less than 2 W Q: Are the check results normal? YES : Erase the diagnosis code memory, and




52B-25

TROUBLESHOOTING

Code No.24: Passenger’s (front) air bag module (squib) system (short-circuited between terminals of the squib circuit) Passenger's (Front) Air Bag Module (Squib) Circuit SRS-ECU MICROCOMPUTER


AIR BAG DRIVE CIRCUIT CONNECTOR LOCK SWITCH


AIR BAG MODULE (SQUIB) (PASSENGER'S SIDE)

OPERATION The SRS-ECU judges how severe a collision is by detecting signals from the front impact sensors and the front air bag analog G-sensor. If the impact is over a predetermined level, the SRSECU outputs an ignition signal. At this time, if the front air bag safing G-sensor is on, the SRS air bag will inflate. The ignition signal is input to the air bag module via the clock spring to inflate the air bag. DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if one passenger’s (front) air bag squib wire shorted to the other. However, if no diagnosis code resets, the SRS warning lamp will be switched off (diagnosis code will be retained). PROBABLE CAUSES Improper engaged connector or defective short spring* Short circuit between the passenger's air bag module (squib) circuit terminals Damaged connector(s) Malfunction of the SRS-ECU


AC301794 AB

NOTE: *: The squib circuit connectors integrate a "short" spring (which prevents the air bag from deploying unintentionally due to static electricity by shorting the positive wire to the earth wire in the squib circuit when the connectors are disconnected).Therefore, if connector C-115 or C-09 is damaged or improperly engaged, the short spring may not be released when the connector is connected. DIAGNOSIS PROCEDURE STEP 1. Check the diagnosis code.

CAUTION To prevent damage to MUT-II, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting MUT-II. (1) Turn the ignition switch to the "ON" position. (2) Check if the diagnosis code is set. (3) Turn the ignition switch to the "LOOK" (OFF) position. Q: Is diagnosis code 34 set? YES : Go to Step 2. NO : Go to Step 3.


52B-26

TROUBLESHOOTING

STEP 2. Connector check: SRS-ECU connector C-115 Connector: C-115

STEP 4. Check the passenger's air bag module. (1) Disconnect the negative battery terminal. Connector: C-09

SRS-ECU Glove box striker



Harness side connector (front view) C-09 (R) 2 1

AC301661AC


AC301718 AC

(2) Unclip passenger’s air bag module connector C09. MB991865 (Dummy resistor : 3 Ω)

Step 6. STEP 3. Connector check: SRS-ECU connector C-115 and passenger’s air bag module connector C-09 (1) Disconnect the negative battery terminal.

C-09 Harness side connector MB991866 (Resistor harness)

Connector: C-115

C-09 Passenger's air bag module connector

SRS-ECU



AC301661AC

Connector: C-09 Glove box striker


AC301718 AC

(2) Disconnect connectors C-115 and C-09, and then reconnect them. (3) Connect the negative battery terminal. (4) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 24 set? YES : Go to Step 4. NO : The procedure is complete. It is assumed

that diagnosis code 24 set as connector C115 or C-09 was engaged improperly.

AC300956AB


CAUTION Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Disconnect the passenger's air bag module connector C-09 and insert special tool (MB991866) into the harness side connector by backprobing. (5) Connect the negative battery terminal. (6) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 24 set? YES : Go to Step 5. NO : Replace the passenger's air bag module

(Refer to 352B). Then go to Step 6.


52B-27

TROUBLESHOOTING

STEP 5. Measure the resistance at SRS-ECU connector C-115.





CAUTION

4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

(1) Disconnect SRS-ECU connector C-115. Connector: C-09 Glove box striker

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

AC300971AB



AC301718 AC

(2) Unclip passenger’s air bag module connector C09.

DANGER To prevents the air bag from deploying unintentionally, disconnect the passenger’s air bag module connector C-09 to short the squib circuit. (3) Disconnect the passenger’s air bag module connector C-09.

CAUTION C-115 Harness side connector (front view) Terminal Section A-A

Cable tie A A

4 mm or more

Short spring

AC300958AB

Insert an insulator such as a cable tie to a depth of 4 mm or more, otherwise the short spring will not be released. (4) Insert a cable tie [3 mm wide, 0.5 mm thick] between terminals 9, 10 and the short spring to release the short spring.

check the diagnosis code. If diagnosis code 24 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 6 . NO : Repair the harness wires between SRSECU connector C-115 (terminal No.9 and 10) and passenger’s air bag module connector C-09 (terminal No.1 and 2). Then go to Step 6. STEP 6. Recheck the diagnosis code. Q: Is diagnosis code 24 set? YES : Return to Step 1. NO : The procedure is complete. (If no



52B-28

TROUBLESHOOTING

Code No.25: Passenger’s (front) air bag module (squib) system (open-circuited in the squib circuit) Passenger's (Front) Air Bag Module (Squib) Circuit SRS-ECU MICROCOMPUTER







AC301794 AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if passenger’s (front) air bag squib wire(s) are open-circuited. However, if no diagnosis code resets, the SRS warning lamp will be switched off (diagnosis code will be retained). PROBABLE CAUSES Open circuit in the passenger's air bag module (squib) circuit Improper connector contact Malfunction of the SRS-ECU


DIAGNOSIS PROCEDURE STEP 1. Check the passenger’s air bag module. (1) Disconnect the negative battery terminal. Connector: C-09 Glove box striker

C-09 (R) AC301718 AB

(2) Unclip passenger’s air bag module connector C09. MB991865 (Dummy resistor : 3 Ω) C-09 Harness side connector MB991866 (Resistor harness) C-09 Passenger's air bag module connector

AC300956AB


CAUTION Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Disconnect the passenger's air bag module connector C-09, and insert special tool (MB991866) into the harness side connector by backprobing. (5) Connect the negative battery terminal. (6) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 25 set? YES : Go to Step 2. NO : Replace the passenger's air bag module


52B-29


52B-30

TROUBLESHOOTING

STEP 2. Measure the resistance between SRSECU connector C-115 (terminal No.9 and 10) and the passenger’s air bag module connector C-09 (terminal No.1 and 2). Connector: C-09 Glove box striker


AC301718 AC

(1) Unclip passenger’s air bag module connector C09. Connector: C-115 SRS-ECU



AC301661AC

(2) Disconnect SRS-ECU connector C-115 and passenger's air bag module connector C-09.

CAUTION C-09 Harness side connector (rear view) C-115 Harness side 1 2 connector (rear view) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

AC300973 AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Measure the resistance between the following terminals. SRS-ECU connector C-115 terminal No.9 and the passenger’s air bag module connector C09 terminal No.1 SRS-ECU connector C-115 terminal No.10 and the passenger’s air bag module connector C-09 terminal No.2 OK: Less than 2 W

Q: Are the check results normal? YES : Erase the diagnosis code memory, and

check the diagnosis code. If diagnosis code 25 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3 . NO : Repair the harness wires between SRSECU connector C-115 (terminal No.9 and 10) and passenger’s air bag module connector C-09 (terminal No.1 and 2). Then go to Step 3. STEP 3. Recheck the diagnosis code. Q: Is diagnosis code 25 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-31

TROUBLESHOOTING

Code No.26: Driver’s pre-tensioner (squib) system (short-circuited between terminals of the squib circuit)

Driver's Seat Belt Pre-Tensioner (Squib) SRS-ECU MICROCOMPUTER AIR BAG DRIVE CIRCUIT



SEAT BELT PRETENSIONER (LH)




OPERATION The SRS-ECU judges how severe a collision is by detecting signals from the front impact sensors and the front air bag analog G-sensor. If the impact is over a predetermined level, the SRS-ECU outputs an ignition signal. At this time, if the front air bag safing G-sensor is on, the pre-tensioner will deploy. DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if one driver’s pretensioner squib wire shorted to the other.

PROBABLE CAUSES Improper engaged connector or defective short spring* Short circuit between the driver's seat belt pretensioner (squib) circuit terminals Damaged connector(s) Malfunction of the SRS-ECU NOTE: *: The squib circuit connectors integrate a "short" spring (which prevents the air bag from deploying unintentionally due to static electricity by shorting the positive wire to the earth wire in the squib circuit when the connectors are disconnected). Therefore, if connector C-114 or D-29 is damaged or improperly engaged, the short spring may not be released when the connector is connected.


52B-32

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP 1. Check the diagnosis code.

CAUTION To prevent damage to MUT-II, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting MUT-II. (1) Turn the ignition switch to the "ON" position. (2) Check if the diagnosis code is set. (3) Turn the ignition switch to the "LOOK" (OFF) position.

STEP 3. Connector check: SRS-ECU connector C-114 and driver’s seat belt pre-tensioner connector D-29 (1) Disconnect the negative battery terminal. Connector: C-114 SRS-ECU


Harness side connector (front view) 24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

Q: Is diagnosis code 34 set? YES : Go to Step 2. NO : Go to Step 3.

AC301661AE

STEP 2. Connector check: SRS-ECU connector C-114

Connector: D-29

Connector: C-114 Harness side connector (front view)

SRS-ECU



2 1

AC301410 AI

24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

D-29 Driver's seat belt pre-tensioner connector

AC301661AE


Flat-tip screw driver Locking button

Step 7. D-29 Harness side connector AC300147AE

(2) Disconnect connectors C-114 and D-29, and then reconnect them. For connector D-29, use a flattipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector. (3) Connector the negative battery terminal. (4) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 26 set? YES : Go to Step 4. NO : The procedure is complete. It is assumed

that diagnosis code 26 set as connector C114 or D-29 was engaged improperly.


STEP 4. Check the driver’s seat belt pretensioner. (1) Disconnect the negative battery terminal. Connector: D-29

Harness side connector (front view) 2 1

AC301410 AI

D-29 Driver's seat belt pre-tensioner connector Flat-tip screw driver Locking button

D-29 Harness side connector AC300147AE

(2) Disconnect driver’s seat belt pre-tensioner connector D-29. Use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector. MB991884

MB991865 MB991885 (Dummy resistor : 3 Ω)

MB991884 (Resistor harness) D-29 Harness side connector

AC300975AD

(3) Connect special tool dummy resistor (MB991865) to special tool resistor harness (MB991884). (4) Connect special tool (MB991884) to the D-29 harness side connector. (5) Connect the negative battery terminal. (6) Erase diagnosis code memory, and then check the diagnosis code. Q: Is diagnosis code 26 set? YES : Go to Step 5. NO : Replace the driver’s seat belt pre-tensioner


52B-33


52B-34

TROUBLESHOOTING

STEP 5. Measure the resistance at the SRS-ECU connector C-114.

CAUTION C-114 Harness side connector (front view) Terminal

Connector: C-114 SRS-ECU Section A-A


Cable tie

A


AC301661AE


DANGER Connector: D-29

A

4 mm or more

Short spring

AC300977AB

Insert an insulator such as a cable tie to a depth of 4mm or more, otherwise the short bar will not be released. (3) Insert a cable tie [3 mm wide, 0.5 mm thick] between terminals 29, 30 and the short bar to release the short spring.

CAUTION Harness side connector (front view)

C-114 Connector harness side (rear view)

2 1

AC301410 AI

To prevents the air bag from deploying unintentionally, disconnect the driver’s seat belt pre-tensioner connector D-29 to short the squib circuit. D-29 Driver's seat belt pre-tensioner connector Flat-tip screw driver Locking button

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

AC300985AB



(2) Disconnect driver’s seat belt pre-tensioner connector D-29. Use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector.

check the diagnosis code. If diagnosis code 26 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 7 . NO : Go to Step 6.


STEP 6. Connector check: SRS-ECU connector C-114, driver’s seat belt pre-tensioner connector D-29 and intermediate connector D-31 Connector: C-114 SRS-ECU



AC301661AE

Connector: D-29 Foward Harness side connector (front view) D-29 (B)

2 1

AC301767 AC

Connector: D-31 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

AC301408 AE

Q: Is the check result normal? YES : Check the harness wires for short circuit

between SRS-ECU connector C-114 (terminal No.29 and 30) and driver’s seat belt pre-tensioner connector D-29 (terminal No.1 and 2), and repair if necessary. Then go to Step 7. NO : Repair or replace it. Then go to Step 7.

52B-35

STEP 7. Recheck the diagnosis code. Q: Is diagnosis code 26 set? YES : Return to Step 1. NO : The procedure is complete (If no


52B-36


Code No.27: Driver’s seat belt pre-tensioner (squib) system (open-circuited in the squib circuit)








OPERATION The SRS-ECU judges how severe a collision is by detecting signals from the front impact sensors and the front air bag analog G-sensor. If the impact is over a predetermined level, the SRS-ECU outputs an ignition signal. At this time, if the front air bag safing G-sensor is on, the pre-tensioner will deploy.

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if driver’s seat belt pretensioner squib wire(s) are open-circuited. PROBABLE CAUSES Improper connector contact Open circuit in the driver’s seat belt pre-tensioner (squib) circuit Malfunction of the SRS-ECU


DIAGNOSIS PROCEDURE STEP 1. Check the driver’s seat belt pretensioner. (1) Disconnect the negative battery terminal. Connector: D-29


AC301410 AI






AC300975AD

(3) Connect special tool dummy resistor (MB991865) to special tool resistor harness (MB991884). (4) Connect special tool (MB991884) to the D-29 harness side connector. (5) Connect the negative battery terminal. (6) Erase diagnosis code memory, and then check the diagnosis code. Q: Is diagnosis code 27 set? YES : Go to Step 2. NO : Replace the driver’s seat belt pre-tensioner


52B-37


52B-38

TROUBLESHOOTING

STEP 2. Measure the resistance between SRSECU connector C-114 (terminal No.29 and 30) and the driver’s seat belt pre-tensioner D-29 (terminal No.1 and 2).

MB991884

Connector: C-114 SRS-ECU D-29



Harness side connector AC201287AJ

(2) Connect D-29 harness side connector to special tool resistor harness (MB991884).

CAUTION

AC301661AE


Connector: D-29

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42


Special tool MB991884 1 2

2 1

AC300989AB AC301410 AI



(1) Disconnect SRS-ECU connector C-114 and driver’s seat belt pre-tensioner connector D-29, and measure at the wiring harness side. For connector D-29, use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector.

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Measure the resistance between the following terminals. SRS-ECU connector C-114 terminal No.29 and special tool terminal No.1 SRS-ECU connector C-114 terminal No.30 and special tool terminal No.2 OK: Less than 2 W Q: Are the check results normal? YES : Erase the diagnosis code memory, and

recheck if any diagnosis code sets. If diagnosis code 27 sets, replace the SRSECU (Refer to 352B). Then go to Step 4. NO : Go to Step 3.


STEP 3. Connector check: SRS-ECU connector C-114, driver’s seat belt pre-tensioner connector D-29 and intermediate connector D-31 Connector: C-114 SRS-ECU



AC301661AE


2 1

AC301767 AC

Connector: D-31 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

AC301408 AE

Q: Is the check result normal? YES : Check the harness wires for open circuit

between SRS-ECU connector C-114 (terminal No.29 and 30) and driver’s seat belt pre-tensioner connector D-29 (terminal No.1 and 2), and repair if necessary. Then go to Step 4. NO : Repair or replace it. Then go to Step 4.

52B-39

STEP 4. Recheck the diagnosis code. Q: Is diagnosis code No.27 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-40

TROUBLESHOOTING

Code No.28: Passenger’s (front) seat belt pre-tensioner (squib) system (short-circuit between terminals of the squib circuit) Passenger's (Front) Seat Belt Pre-tensioner (Squib) SRS-ECU MICROCOMPUTER




SEAT BELT PRE-TENSIONER (RH)

OPERATION The SRS-ECU judges how severe a collision is by detecting signals from the front impact sensors and the front air bag analog G-sensor. If the impact is over a predetermined level, the SRS-ECU outputs an ignition signal. At this time, if the front air bag safing G-sensor is on, the pre-tensioner will deploy. DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if one passenger’s seat belt pre-tensioner squib wire shorted to the other. PROBABLE CAUSES Improper engaged connector or defective short spring* Short circuit between the passenger's seat belt pre-tensioner (squib) circuit terminals Damaged connector(s) Malfunction of the SRS-ECU


AC301795 AB

NOTE: *: The squib circuit connectors integrate a "short" spring (which prevents the air bag from deploying unintentionally due to static electricity by shorting the positive wire to the earth wire in the squib circuit when the connectors are disconnected). Therefore, if connector C-114 or D-43 is damaged or improperly engaged, the short spring may not be released when the connector is connected. DIAGNOSIS PROCEDURE STEP 1. Check the diagnosis code.



52B-41

TROUBLESHOOTING

STEP 2. Connector check: SRS-ECU connector C-114 Connector: C-114 SRS-ECU

STEP 3. Connector check: SRS-ECU connector C-114 and passenger’s seat belt pre-tensioner connector D-43 (1) Disconnect the negative battery terminal. Connector: C-114 SRS-ECU



C-114 (Y)

24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

AC301661AE

Q: Is connector correctly engaged? YES : Go to Step 3. NO : Engage the connector correctly. Then go to


Center lower panel

AC301661AE

Connector: D-43

Step 6.


AC301408AI

D-43 Passenger's seat belt pre-tensioner connector Flat-tip screw driver Locking button

D-43 Harness side connector

AC300147AF

(2) Disconnect connectors C-114 and D-43, and then reconnect them. For connector D-43, use a flattipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector. (3) Connector the negative battery terminal. (4) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 28 set? YES : Go to Step 4. NO : The procedure is complete. It is assumed



52B-42

TROUBLESHOOTING

STEP 4. Check the passenger’s seat belt pretensioner. (1) Disconnect the negative battery terminal. Connector: D-43


AC301408AI



AC300147AF

(2) Disconnect passenger’s seat belt pre-tensioner connector D-43. Use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector. MB991865 MB991884 MB991885 (Dummy resistor : 3 Ω)


AC300975AE

(3) Connect special tool dummy resistor (MB991865) to special tool resistor harness (MB991884). (4) Connect special tool (MB991884) to the D-43 harness side connector. (5) Connect the negative battery terminal. (6) Erase diagnosis code memory, and then check the diagnosis code. Q: Is diagnosis code 28 set? YES : Go to Step 5. NO : Replace the passenger’s seat belt pre-

tensioner (Refer to 352B). Then go to Step 6.


52B-43

TROUBLESHOOTING


CAUTION C-114 Harness side connector (front view)


Terminal Cable tie



A

24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

AC301661AE


DANGER Connector: D-43

Section A-A

A

Short bar

4 mm or more AB AC300994 AB

Insert an insulator such as a cable tie to a depth of 4 mm or more, otherwise the short bar will not be released. (3) Insert a cable tie [3 mm wide, 0.5 mm thick] between terminals 27, 28 and the short bar to release the short spring.

CAUTION Harness side connector (front view)


2 1

AC301408AI

To prevents the air bag from deploying unintentionally, disconnect the passenger’s seat belt pre-tensioner connector D-43 to short the squib circuit. D-43 Passenger's seat belt pre-tensioner connector Flat-tip screw driver Locking button


21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

AC300996AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Measure the resistance between C-114 harness side connector terminals 27 and 28. OK: Open circuit. Q: Is the check result normal? YES : Erase the diagnosis code memory, and

AC300147AF

(2) Disconnect passenger’s seat belt pre-tensioner connector D-43. Use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector.

check diagnosis code. If diagnosis code 28 sets, replace the SRS-ECU (Refer to 352B ). Then go to Step 6 . NO : Repair the harness wires between SRSECU connector C-114 (terminal No.27 and 28) and passenger’s seat belt pre-tensioner connector D-43 (terminal No.1 and 2). Then go to Step 6.


52B-44

TROUBLESHOOTING

STEP 6. Recheck for diagnosis code. Q: Is diagnosis code 28 set? YES : Return to Step 1. NO : The procedure is complete (If no


Code No.29: Passenger’s (front) seat belt pre-tensioner (squib) system (open-circuited in the squib circuit) Passenger's (Front) Seat Belt Pre-tensioner (Squib) SRS-ECU MICROCOMPUTER







AC301795 AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the passenger’s seat belt pre-tensioner squib wire(s) are open-circuited. PROBABLE CAUSES Open circuit in the passenger’s seat belt pretensioner (squib) circuit Improper connector contact Malfunction of the SRS-ECU


DIAGNOSIS PROCEDURE STEP 1. Check the passenger’s seat belt pretensioner. (1) Disconnect the negative battery terminal. Connector: D-43


AC301408AI



AC300147AF



AC300975AE



52B-45


52B-46

TROUBLESHOOTING

STEP 2. Measure the resistance between SRSECU connector C-114 (terminal No.27 and 28) and the passenger’s seat belt pre-tensioner connector D-43 (terminal No.1 and 2). Connector: C-114


C-114 (Y)

C-114 Harness side connector (rear view) 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

SRS-ECU

Center lower panel

CAUTION

24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

AC301661AE

Connector: D-43


Special tool MB991884 1 2

AC300997AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Measure the resistance between the following terminals. SRS-ECU connector C-114 terminal No.27 and the special tool terminal No.2 SRS-ECU connector C-114 terminal No.28 and the special tool terminal No.1 OK: Less than 2 W Q: Are the check results normal? YES : Erase the diagnosis code memory, and

2 1

AC301408AI



check the diagnosis code. If diagnosis code 29 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3 . NO : Repair the harness wires between SRSECU connector C-114 (terminal No.27 and 28) passenger’s seat belt pre-tensioner connector D-43 (terminal No.1 and 2). Then go to Step 3. STEP 3.Recheck the diagnosis code.

AC300147AF

(1) Disconnect SRS-ECU connector C-114 and passenger’s seat belt pre-tensioner connector D43. For connector D-43, use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector. MB991884

D-43

Harness side connector AC201287AK

(2) Connect D-43 harness side connector to special tool resistor harness (MB991884).

Q: Is diagnosis code 29 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-47

Code No.34: SRS-ECU connector lock out of order DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if a poor connection at the SRS-ECU is detected. However, if the vehicle condition returns to normal, diagnosis code number 34 will be automatically erased, and the SRS warning lamp will go out. PROBABLE CAUSES Damaged connectors Malfunction of the SRS-ECU DIAGNOSIS PROCEDURE STEP 1. Connector check: SRS-ECU connector C-114 and C-115. (1) Disconnect SRS-ECU connectors C-114 and C115. Connectors: C-114, C-115 SRS-ECU

Center lower panel C-115 (Y) C-114 (Y)

AC301661AF

SRS-ECU Harness side connector (front view) Connector lock switch terminal

AC301001AB

(2) Check the connector lock switch terminal inside the harness side connector for improper contact or deformation. Q: Are the SRS-ECU connector C-114 and C-115 in good condition? YES : Erase the diagnosis code memory, and

check the diagnosis code. If diagnosis code 34 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 2 . NO : Repair or replace the SRS-ECU connector C-114 and C-115. Then go to Step 2.

STEP 2. Recheck the diagnosis code. Q: Is diagnosis code 34 set? YES : There is no action to be taken. NO : The procedure is complete (If no


52B-48


Code No.35: Ignition of the air bag completed DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set after the air bag has deployed. If this diagnosis code is set before the air bag has deployed, the cause is probably a malfunction inside the SRS-ECU. PROBABLE CAUSE Malfunction of the SRS-ECU

DIAGNOSIS PROCEDURE Replace the SRS-ECU. (Refer to 352B). Check the diagnosis code. Q: Is diagnosis code 35 set? YES : There is no action to be taken. NO : The procedure is complete.


52B-49

Code No.41: Power supply voltage (IG1 (A) voltage) drops abnormally.

IG1 Power Supply Circuit System (Fuse No.2 Circuit) IGNITION SWITCH (IG1)

SRS-ECU POWER SOURCE CIRCUIT

D.C.-D.C. CONVERTER

BACK-UP CAPACITOR

MICROCOMPUTER WARNING LAMP DRIVE CIRCUIT


COMBINATION METER


NOTE CONNECTOR COUPLED: ON CONNECTOR UNCOUPLED: OFF AC301798 AB


52B-50

TROUBLESHOOTING

OPERATION The SRS-ECU is powered from the ignition switch (IG1). The SRS-ECU power is supplied from two circuits. Even if one circuit is shut off, the air bag can inflate. DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the voltage between the IG1 terminals (fuse No.2 circuit) and earth is lower than a predetermined value for a continuous period of 5 second or more. However, if the vehicle condition returns to normal, diagnosis code number 41 will be automatically erased, and the SRS warning lamp will switch off. PROBABLE CAUSES Damaged wiring harnesses or connectors Malfunction of the SRS-ECU

STEP 2. Measure the voltage at the SRS-ECU connector C-115. (1) Disconnect the negative battery terminal. Connector: C-115 SRS-ECU



AC301661AC

(2) Disconnect SRS-ECU connector C-115. (3) Connect the negative battery terminal. (4) Turn the ignition switch to the "ON" position.

CAUTION

DIAGNOSIS PROCEDURE STEP 1. Check junction block fuse number 2.

C-115 Harness side connector (rear view) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Junction block Fuse No.2 AC301002AB

AC201423AC

Q: Is the fuse burned out? YES : Go to Step 4. NO : Go to Step 2.

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (5) Measure the voltage between C-115 harness side connector terminal 16 and body earth. OK: 9 V or more. Q: Is the check result normal? YES : Erase the diagnosis code memory, and



52B-51

TROUBLESHOOTING

STEP 3. Connector check: SRS-ECU connector C-115, ignition switch connector C-303, junction block connector C-203 and C-205. Connector: C-115 SRS-ECU



4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

Connector: C-303

STEP 4. Check a burned-out fuse. (1) Replace the fuse. (2) Turn the ignition switch to the "ON" position, wait for at least one minute and then turn the ignition switch to the "LOCK" (OFF) position. (3) Check the fuse. Q: Is the fuse in good condition? YES : Go to Step 10. NO : Go to Step 5.

STEP 5. Measure the resistance at the junction block connector C-205. Connector: C-205 Junction block (Front view)

Clock spring C-303


Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1

3 2 1 6 5 4

28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE AC301399 AG


(1) Disconnect junction block connector C-205, and measure at the wiring harness side.

CAUTION

C-203

C-205 Harness side connector (rear view) 1 2 3 4 5 6 7 8 9 10 11121314 1516 171819 20 212223242526 2728

C-205

AC301014AB

Harness side C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-203 2 1 6 5 4 3

AC210475 AR

Q: Is the check result normal? YES : Check the harness wire for open circuit

between SRS-ECU connector C-115 (terminal No.16) and the ignition switch connector C-303 (terminal No.2), and repair if necessary. Then go to Step 10. NO : Repair or replace it. Then go to Step 10.

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (2) Measure the resistance between terminal 24 and body earth. OK: Open circuit Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 8.


52B-52

TROUBLESHOOTING

STEP 6. Measure the resistance at junction block connector C-205. Connector: C-205 Junction block (Front view)

STEP 7. Connector check: junction block connector C-205 and combination meter connector C-04 Connector: C-205 Junction block (Front view)


14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE


CAUTION

AC210474 AE

Connector: C-04

C-04

C-205 Harness side connector (rear view)Y1729AU 1 2 3 4 5 6 7 8 9 10 11 12 13 14


15 16 17 18 19 20 21 22 23 24 25 26 27 28

AC301395 AK

AC301015AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (2) Measure the resistance between terminal 25 and body earth. OK: Open circuit Q: Is the check result normal? YES : Check the other circuit, which flows through

fuse number 2. NO : Go to Step 7.

Q: Is the check result normal? YES : Check the harness wire for short circuit

between junction block connector C-205 (terminal No.25) and combination meter connector C-04 (terminal No.42), and repair if necessary. Then go to Step 10. NO : Repair or replace it. Then go to Step 10.


52B-53

TROUBLESHOOTING


STEP 9. Connector check: SRS-ECU connector C-115 and junction block connector C-205 Connector: C-115


SRS-ECU




4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AB

(1) Disconnect SRS-ECU connector C-115, and measure at the wiring harness side.

AC301661AC



Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE

AC201665 AF

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (2) Measure the resistance between terminal 16 and body earth. OK: Open circuit Q: Is the check result normal? YES : Erase the diagnosis code memory, and

check the diagnosis code. If diagnosis code 41 sets, replace the SRS-ECU. (Refer to 352B). Then go to Step 10 . NO : Go to Step 9.


between SRS-ECU connector C-115 (terminal No.16) and junction block connector C-205 (terminal No.24), and repair if necessary. Then go to Step 10. NO : Repair or replace it. Then go to Step 10. STEP 10. Recheck the diagnosis code. Q: Is diagnosis code 41 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-54

TROUBLESHOOTING

Code No.42: Power supply voltage (IG1 (B) voltage) drops abnormally.

IG1 Power Supply Circuit System (Fuse No.3 Circuit) IGNITION SWITCH (IG1)


D.C.-D.C. CONVERTER

BACK-UP CAPACITOR



COMBINATION METER


NOTE CONNECTOR COUPLED: ON CONNECTOR UNCOUPLED: OFF AC301798 AC


52B-55

TROUBLESHOOTING

OPERATION The SRS-ECU is powered from the ignition switch (IG1). The SRS-ECU power is supplied from two circuits. Even if one circuit is shut off, the air bag can inflate. DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the voltage between the IG1 terminals (fuse No.3 circuit) and earth is lower than a predetermined value for a continuous period of 5 second or more. However, if the vehicle condition returns to normal, diagnosis code number 42 will be automatically erased, and the SRS warning lamp will switch off. PROBABLE CAUSES Damaged wiring harnesses or connectors Malfunction of the SRS-ECU DIAGNOSIS PROCEDURE

STEP 2. Measure the voltage at SRS-ECU connector C-115. (1) Disconnect the negative battery terminal. Connector: C-115 SRS-ECU



AC301661AC

(2) Disconnect SRS-ECU connector C-115. (3) Connect the negative battery terminal. (4) Turn the ignition switch to the "ON" position.


STEP 1. Check junction block fuse number 3.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Fuse No.3 AC301016 AB

Junction block

Q: Is the fuse burned out? YES : Go to Step 4. NO : Go to Step 2.

AC201425AD

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (5) Measure the voltage between C-115 harness side connector terminal 13 and body earth. OK: 9 V or more Q: Is the check result normal? YES : Erase the diagnosis connector memory, and

check the diagnosis code. If diagnosis code 42 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 8. NO : Go to Step 3.


52B-56

TROUBLESHOOTING

STEP 3. Connector check: SRS-ECU connector C-115, ignition switch connector C-303, junction block connector C-203 and C-205 Connector: C-115 SRS-ECU



4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

Connector: C-303

STEP 4. Check a burned-out fuse. (1) Replace the fuse. (2) Turn the ignition switch to the "ON" position, wait for at least one minute and then turn the ignition switch to the "LOCK" (OFF) position. (3) Check the fuse. Q: Is the fuse in good condition? YES : Go to Step 8. NO : Go to Step 5.

STEP 5. Measure the resistance at the junction block connector C-205. Connector: C-205 Junction block (Front view)

Clock spring C-303


Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1

3 2 1 6 5 4

28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE AC301399 AG




C-203

1 2 3 4 5 6 7 8 9 10 11121314 1516 171819 20 212223242526 2728

C-205

AC301017AB

Harness side C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-203 2 1 6 5 4 3

AC210475 AR

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (2) Measure the resistance between terminal 7 and body earth. OK: Open circuit Q: Is the check result normal? YES : Check the other circuit, which flows through

fuse number 3. Q: Is the check result normal? YES : Check the harness wire for open circuit

between SRS-ECU connector C-115 (terminal No.13) and the ignition switch connector C-303 (terminal No.2), and repair if necessary. Then go to Step 8. NO : Repair or replace it. Then go to Step 8.

NO : Go to Step 6.


52B-57

TROUBLESHOOTING


STEP 7. Connector check: SRS-ECU connector C-115 and junction block connector C-205 Connector: C-115

SRS-ECU


SRS-ECU




4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC


AC301661AC


CAUTION C-115 Harness side connector (rear view) 1 2 3 4 5 6 7 8 9 10 11 12

Harness side

13 14 15 16 17 18 19 20

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE

AC202026 AH

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (2) Measure the resistance between terminal 13 and body earth. OK: Open circuit Q: Is the check result normal? YES : Erase the diagnosis code memory, and

check the diagnosis code. If diagnosis code 42 sets, replace the SRS-ECU. (Refer to 352B). Then go to Step 8 . NO : Go to Step 7.


between SRS-ECU connector C-115 (terminal No.13) and junction block connector C-205 (terminal No.7), and repair if necessary. Then go to Step 8. NO : Repair or replace it. Then go to Step 8. STEP 8. Recheck the diagnosis code. Q: Is diagnosis code 42 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-58

TROUBLESHOOTING

Code No.43: SRS warning lamp circuit open-circuited (Lamp does not Illuminate). SRS Warning Lamp Drive Circuit IGNITION SWITCH (IG1)

COMBINATION METER

CONNECTOR LOCK SWITCH SRS-ECU WARNING LAMP DRIVE CIRCUIT MICROCOMPUTER



OPERATION Power for the SRS warning lamp is supplied from the ignition switch (IG1). The SRS warning lamp illuminates when the ignition switch is turned to the "ON" position and goes out after approximately 7 seconds if there is not a malfunction in the SRS system.

SB : Sky blue

AC301799AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set when an open circuit is detected for a continuous period of 5 seconds while the SRS-ECU is monitoring the SRS warning lamp and the lamp is OFF (transistor OFF). However, if the vehicle condition returns to normal, diagnosis code 43 will be automatically erased, and the SRS warning lamp will go out. PROBABLE CAUSES Damaged wiring harnesses or connectors Malfunction of the SRS-ECU Malfunction of the combination meter


52B-59

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP 1. Check the SRS warning lamp. (1) Disconnect the negative battery terminal.

STEP 2. Measure the resistance at the SRS-ECU connector C-115. (1) Disconnect the negative battery terminal. Connector: C-115

Connector: C-115

SRS-ECU SRS-ECU




4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

(2) Disconnected the SRS-ECU connector C-115. (3) Connect the negative battery terminal. (4) Turn the ignition switch to the "ON" position. Q: Does the warning lamp illuminate? YES : Erase the diagnosis code memory, and



AC301661AC

(2) Disconnected the SRS-ECU connector C-115. (3) Connect the negative battery terminal. (4) Turn the ignition switch to the "ON" position.


3 4 1 2 5 6 7 8 9 10 11 12 13 1415 16 17 18 19 20

AC201527 AG

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (5) Measure the resistance between C-115 harness side connector terminal 7 and earth. OK: Less than 2 W Q: Is the check result normal? YES : Go to Step 3. NO : Go to Step 4.


52B-60

TROUBLESHOOTING

STEP 3. Check the harness for open circuit between ignition switch connector C-303 (terminal No.2) and combination meter C-04 (terminal No.42), and between combination meter C-05 (terminal No.11) and SRS-ECU connector C115 (terminal No.8). Connector: C-303


C-205

Clock spring C-303

Harness side connector (front view) 3 2 1 6 5 4

Harness side C-205

AC301399 AG

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-203 2 1 6 5 4 3

Connectors: C-04, C-05 C-05(L) C-04 AC210475 AR

NOTE: After inspecting intermediate connectors C05, C-04, C-205 and C-203 inspect the wiring harness. If intermediate connectors C-05, C-04, C205 and C-203 are damaged, repair or replace them. Then go to Step 5 . Q: Is the check result normal? YES : Replace the combination meter (Refer to Harness side C-05

C-04 41 4039 38 3736 35 3433 32 31 52 51 50 49 48 47 46 4544 43 42

G

G

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

G

AC301396 AH




AC301661AC

GROUP 54A - Combination Meters Assembly and Vehicle Speed Sensor 354A). Then go to Step 5 . NO : Repair the harness wires between SRSECU connector C-115 (terminal No.8) and the ignition switch connector C-303 (terminal No.2). Then go to Step 5.


STEP 4. Connector check: SRS-ECU connector C-115 and earth Connector: C-115 SRS-ECU



AC301661AC

Blower assembly

AC208080AE

Q: Is the check result normal? YES : Repair the harness wires between SRS-

ECU connector C-115 (terminal No.7) and earth. Then go to Step 5. NO : Repair or replace it. Then go to Step 5.

52B-61




52B-62

TROUBLESHOOTING

Code No.43: SRS warning lamp circuit open-circuited (Lamp does not Switch Off). SRS Warning Lamp Drive Circuit IGNITION SWITCH (IG1)

COMBINATION METER




OPERATION Power for the SRS warning lamp is supplied from the ignition switch (IG1). The SRS warning lamp illuminates when the ignition switch is turned to the "ON" position and goes out after approximately 7 seconds if there is not a malfunction in the SRS system.

SB : Sky blue

AC301799AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set when a short to earth occurs in the harness between the SRS warning lamp and SRS-ECU while SRS-ECU is monitoring the lamp and the lamp is ON. However, if the vehicle condition returns to normal, diagnosis code 43 will be automatically erased, and the SRS warning lamp will go out. PROBABLE CAUSES Damaged wiring harnesses or connectors Malfunction of the SRS-ECU Malfunction of the combination meter


52B-63

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP 1. Connector check: SRS-ECU connector C-115 Connector: C-115

Q: Does the SRS warning lamp go out? YES : Go to Step 3. NO : Replace the combination meter (Refer to

GROUP 54A - Combination Meters Assembly and Vehicle Speed Sensor 354A). Then go to Step 4 .

SRS-ECU



STEP 3. Check the harness for short circuit to earth between SRS-ECU connector C-115 (terminal No.8) and combination meter connector C-05 (terminal No.11). Connector: C-115 SRS-ECU

AC301661AC

(1) Disconnect SRS-ECU connectors C-115. C-115 SRS-ECU Harness side connector (front view) Terminal



AC301661AC

Connector: C-05

C-05(L)

Short spring AC302001AB

(2) Check the short spring for the warning lamp inside the harness side connector for improper contact or deformation. Q: Is the check result normal? YES : Then go to Step 2. NO : Repair or replace the SRS-ECU connector

STEP 2. Check the SRS warning lamp. (1) Disconnect the negative battery cable. C-05(L)


G

G

AC301395 AE

check the diagnosis code. If diagnosis code 43 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 4 . NO : Repair the harness wire between SRS-ECU connector C-115 (terminal No.8) and combination meter connector C-05 (terminal No.11). Then go to Step 4. STEP 4. Recheck the diagnosis code.

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12

G

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 1514 13 12


C-115. Then go to Step 4.

Connector: C-05


G

AC301395 AE

(2) Disconnect the combination meter connector C05. (3) Connect the negative battery cable. (4) Turn the ignition switch to the "ON" position.

Q: Is diagnosis code 43 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-64

TROUBLESHOOTING

Code No.44: SRS warning lamp circuit malfunction SRS Warning Lamp Drive Circuit IGNITION SWITCH (IG1)

COMBINATION METER




CIRCUIT OPERATION Power for the SRS warning lamp is supplied from the ignition switch (IG1). The SRS warning lamp illuminates when the ignition switch is turned to the "ON" position and goes out after approximately 7 seconds if there is not a malfunction in the SRS system. DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set under one of the following cases while the SRS-ECU is monitoring the warning lamp drive circuit: When a short circuit occurs in the warning lamp drive circuit. When a malfunction is detected in the output transistor inside the SRS-ECU.

SB : Sky blue

AC301799AB

However, if the vehicle condition returns to normal, diagnosis code 44 will be automatically erased, and the SRS warning lamp will go out. PROBABLE CAUSES Damaged wiring harnesses or connectors Malfunction of the SRS-ECU DIAGNOSIS PROCEDURE Check the SRS warning lamp drive circuit system. Refer to 352B.


52B-65

TROUBLESHOOTING

Code No.61: Driver’s air bag module (squib) system (short-circuited to the power supply)





CLOCK SPRING







DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the driver’s air bag squib wire(s) are short-circuited to the power supply. However, if no diagnosis code resets, the SRS warning lamp will be switched off (diagnosis code will be retained). PROBABLE CAUSES Malfunction of the clock spring Damaged harness wires and connectors Short to the power supply in the driver's air bag module (squib) harness Malfunction of the SRS-ECU


52B-66

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 2. Check the clock spring. (1) Disconnect the negative battery terminal.


MB991865 (Dummy resistor : 3 Ω)



1 2 3 4

A Steering wheel

AC300156AB

(2) By sliding the A section (in the figure) of air bag module connector C-306 in arrow direction, disconnect the connector. MB991865 (Dummy resistor : 3Ω)




CAUTION Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Insert special tool (MB991866) into clock spring side air bag module connector C-306 by backprobing. (5) Connect the negative battery terminal. (6) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 61 out put? YES : Go to Step 2. NO : Replace the driver’s air bag module (Refer


(Rear view)


AC300949AB





STEP 3. Measure the voltage at the SRS-ECU connector C-115. Connector: C-115 SRS-ECU



AC301661AC






C-307 (Y)

52B-67


AC301399 AF

To prevents the air bag from deploying unintentionally, disconnect the clock spring connector C-307 to short the squib circuit. (2) Disconnect the clock spring connector C-307. (3) Turn the ignition switch to the "ON" position.


AC301030AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Measure the voltage between C-115 harness side connector terminals 11, 12 and body earth. OK: 0 V


52B-68

TROUBLESHOOTING

Code No.62: Driver’s air bag module (squib) system (short-circuited to the earth)





CLOCK SPRING







DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the driver’s air bag squib wire(s) are short-circuited to the earth. However, if no diagnosis code resets, the SRS warning lamp will be switched off (diagnosis code will be retained). PROBABLE CAUSES Malfunction of the clock spring Damaged harness wires and connectors Short to the earth in the driver’s air bag module (squib) harness Malfunction of the SRS-ECU


52B-69

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 2. Check the clock spring. (1) Disconnect the negative battery terminal.


MB991865 (Dummy resistor : 3 Ω)



1 2 3 4

A Steering wheel

AC300156AB

(2) By sliding the A section (in the figure) of air bag module connector C-306 in arrow direction, disconnect the connector. (3) Connect special tool dummy resistor (MB991865) to special tool resistor harness (MB991866).

CAUTION MB991865 (Dummy resistor : 3Ω)



Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Insert special tool (MB991866) into clock spring side air bag module connector C-306 by backprobing. (5) Connect the negative battery terminal. (6) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 62 set? YES : Go to Step 2. NO : Replace the driver’s air bag module (Refer


(Rear view)


AC300949AB





52B-70

TROUBLESHOOTING

STEP 3. Check the driver’s air bag module circuit at the SRS-ECU connector C-115. Connector: C-115 SRS-ECU



4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC






C-307 (Y)


AC301399 AF

To prevents the air bag from deploying unintentionally, disconnect the clock spring connector C-307 to short the squib circuit. (2) Disconnect the clock spring connector C-307.


AC301033AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Check for continuity between C-115 harness side connector terminals 11, 12 and body earth. OK: Open circuit


52B-71

TROUBLESHOOTING

Code No.64: Passenger’s (front) air bag module (squib) system (short-circuited to the power supply) Passenger's (Front) Air Bag Module (Squib) Circuit SRS-ECU MICROCOMPUTER







AC301794 AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the passenger’s (front) air bag squib wire(s) are short-circuited to the power supply. However, if no diagnosis code resets, the SRS warning lamp will be switched off (diagnosis code will be retained). PROBABLE CAUSES Damaged harness wires and connectors Short to the power supply in the passenger’s air bag module (squib) harness Malfunction of the SRS-ECU


52B-72

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP1. Check the passenger’s air bag module. (1) Disconnect the negative battery terminal. Connector: C-09 Glove box striker


AC301718 AC


AC300956AB








AC301661AC


CAUTION

52B-73


check the diagnosis code. If diagnosis code 64 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3 . NO : Repair the harness wires between SRSECU connector C-115 (terminal No.9 and 10) and passenger’s air bag module connector C-09 (terminal No.1 and 2). Then go to Step 3. STEP 3. Recheck the diagnosis code. Q: Is diagnosis code 64 set? YES : Return to Step 1. NO : The procedure is complete (If no




AC301718 AC

To prevents the air bag from deploying unintentionally, disconnect the passenger’s air bag module connector C-09 to short the squib circuit. (2) Disconnect the passenger’s air bag module connector C-09. (3) Turn the ignition switch to the "ON" position.


AC301034 AB



52B-74

TROUBLESHOOTING

Code No.65: Passenger’s (front) air bag module (squib) system (short-circuited to the earth) Passenger's (Front) Air Bag Module (Squib) Circuit SRS-ECU MICROCOMPUTER







AC301794 AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the passenger’s (front) air bag squib wire(s) are short-circuited to the earth. However, if no diagnosis code resets, the SRS warning lamp will be switched off (diagnosis code will be retained). PROBABLE CAUSES Damaged harness wires and connectors Short to the earth in the passenger’s air bag module (squib) harness Malfunction of the SRS-ECU


DIAGNOSIS PROCEDURE STEP 1. Check the passenger’s air bag module. (1) Disconnect the negative battery terminal. Connector: C-09 Glove box striker


AC301718 AC


AC300956AB




52B-75


52B-76

TROUBLESHOOTING

STEP 2. Measure the resistance at the SRS-ECU connector C-115. Connector: C-115 SRS-ECU



AC301661AC


CAUTION


check the diagnosis code. If diagnosis code 65 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3 . NO : Repair the harness wires between SRSECU connector C-115 (terminal No.9 and 10) and passenger's air bag module connector C-09 (terminal No.1 and 2). Then go to Step 3. STEP 3. Recheck the diagnosis code. Q: Is diagnosis code 65 set? YES : Return to Step 1. NO : The procedure is complete (If no




AC301718 AC

To prevents the air bag from deploying unintentionally, disconnect the passenger’s air bag module connector C-09 to short the squib circuit. (2) Unclip passenger’s air bag module connector C09.


AC301035AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Measure the resistance between C-115 harness side connector terminals 9, 10 and body earth. OK: Open circuit


52B-77

TROUBLESHOOTING

Code No.66: Driver’s seat belt pre-tensioner (squib) system (short-circuited to the power supply)









DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the driver’s seat belt pretensioner wire(s) are short-circuited to the power supply. PROBABLE CAUSES Damaged wiring harnesses or connectors Short to the power supply in the driver’s seat belt pre-tensioner (squib) harness Malfunction of the SRS-ECU


52B-78

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 2. Measure the voltage at the SRS-ECU connector C-114.

STEP 1. Check the driver’s seat belt pretensioner. (1) Disconnect the negative battery terminal.


Connector: D-29 Center lower panel C-114 (Y)



AC301661AE

2 1

AC301410 AI

D-29 Driver's seat belt pre-tensioner connector Flat-tip screw driver

(1) Disconnect SRS-ECU connector C-114. (2) Disconnect driver’s seat belt pre-tensioner connector D-29. Use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector. (3) Turn the ignition switch to the "ON" position.

CAUTION

Locking button






AC300975AD

(3) Connect special tool dummy resistor (MB991865) to special tool resistor harness (MB991884). (4) Connect special tool (MB991884) to the D-29 harness side connector. (5) Connect the negative battery terminal. (6) Erase diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 66 set? YES : Go to Step 2. NO : Replace the driver’s seat belt pre-tensioner


21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

AC301037AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Measure the voltage between C-114 harness side connector terminals 29, 30 and body earth. OK: 0 V Q: Is the measured voltage within the specified range? YES : Erase the diagnosis code memory, and



STEP 3. Connector check: SRS-ECU connector C-114, driver’s seat belt pre-tensioner connector D-29 and intermediate connector D-31. Connector: C-114 SRS-ECU



AC301661AE


2 1

AC301767 AC

Connector: D-31 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

AC301408 AE

Q: Is the check result normal? YES : Check the harness wires for short circuit to

power supply between SRS-ECU connector C-114 (terminal No.1 and 2) and driver’s seat belt pre-tensioner connector D-29 (terminal No.29 and 30), and repair if necessary. Then go to Step 4. NO : Repair or replace it. Then go to Step 4.

52B-79



52B-80


Code No.67: Driver’s seat belt pre-tensioner (squib) system (short-circuited to the earth)









DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the driver’s seat belt pretensioner wire(s) are short-circuited to the earth. PROBABLE CAUSES Damaged wiring harnesses or connectors Short to the earth in the driver’s seat belt pretensioner (squib) harness Malfunction of the SRS-ECU


DIAGNOSIS PROCEDURE STEP 1. Check the driver’s seat belt pretensioner. (1) Disconnect the negative battery terminal. Connector: D-29


AC301410 AI






AC300975AD

(3) Connect special tool dummy resistor (MB991865) to special tool resistor harness (MB991884). (4) Connect special tool (MB991884) to the D-29 harness side connector. (5) Connect the negative battery terminal. (6) Erase diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 67 set? YES : Go to Step 2. NO : Replace the driver’s seat belt pre-tensioner


52B-81


52B-82

TROUBLESHOOTING


CAUTION C-114 Harness side connector (rear view) 2122 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

SRS-ECU

Center lower panel C-114 (Y) AC201666 AI AC301661AD

(1) Disconnect SRS-ECU connector C-114. Connector: D-29

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Measure the resistance between C-114 harness side connector terminals 29, 30 and body earth. OK: Open circuit Q: Is the check result normal? YES : Erase the diagnosis code memory, and


AC301410 AI



(2) Disconnect driver’s seat belt pre-tensioner connector D-29. Use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector.



STEP 3. Connector check: SRS-ECU connector C-114, driver’s seat belt pre-tensioner connector D-29 Connector: C-114 SRS-ECU



AC301661AE


2 1

AC301767 AC

Connector: D-31 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

AC301408 AE

Q: Is the check result normal? YES : Check the harness wires for short circuit to

the earth between SRS-ECU connector C114 (terminal No.29 and 30) and driver’s seat belt pre-tensioner connector D-29 (terminal No.1 and 2), and repair if necessary. Then go to Step 4. NO : Repair or replace it. Then go to Step 4 .

52B-83




52B-84

TROUBLESHOOTING

Code No.68: Passenger’s (front) seat belt pre-tensioner (squib) system (short-circuited to the power supply) Passenger's (Front) Seat Belt Pre-tensioner (Squib) SRS-ECU MICROCOMPUTER







AC301795 AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if passenger’s (front) seat belt pre-tensioner wire(s) are short-circuited to the power supply. PROBABLE CAUSES Damaged wiring harnesses or connectors Short to the power supply in the passenger’s seat belt pre-tensioner (squib) harness Malfunction of the SRS-ECU




AC301408AI



AC300147AF



AC300975AE



52B-85


52B-86

TROUBLESHOOTING

STEP 2. Measure the voltage at the SRS-ECU connector C-114.





CAUTION

24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

AC301661AE


21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

AC301038AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Measure the voltage between C-114 harness side connector terminals 27, 28 and body earth. OK: 0 V Q: Is the check result normal? YES : Erase the diagnosis code memory, and


AC301408AI

D-43 Passenger's seat belt pre-tensioner connector Flat-tip screw driver

check the diagnosis code. If diagnosis code 68 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3 . NO : Repair the harness wires between SRSECU connector C-114 (terminal No.27 and 28) and passenger’s seat belt pre-tensioner connector D-43 (terminal No.1 and 2). Then go to Step 3. STEP 3. Recheck the diagnosis code.

Locking button


Q: Is diagnosis code 68 set? YES : Return to Step 1. NO : The procedure is complete (If no AC300147AF

(2) Disconnect passenger’s seat belt pre-tensioner connector D-43. Use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector. (3) Turn the ignition switch to the "ON" position,



52B-87

TROUBLESHOOTING

Code No.69: Passenger’s (front) seat belt pre-tensioner (squib) system (short-circuited to the earth) Passenger's (Front) Seat Belt Pre-tensioner (Squib) SRS-ECU MICROCOMPUTER







AC301795 AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if passenger’s (front) seat belt pre-tensioner wire(s) are short-circuited to the earth. PROBABLE CAUSES Damaged wiring harnesses or connectors Short to the earth in the passenger’s seat belt pre-tensioner (squib) harness Malfunction of the SRS-ECU


52B-88

TROUBLESHOOTING



AC301408AI



AC300147AF



AC300975AE


tensioner. (Refer to 352B). Then go to Step 3.


52B-89

TROUBLESHOOTING


CAUTION C-114 Harness side connector (rear view) 2122 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

SRS-ECU



24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

AC301661AE


AC201663 AG

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Measure the resistance between C-114 harness side connector terminals 27, 28 and body earth. OK: Open circuit Q: Is the check result normal? YES : Erase the diagnosis code memory, and


AC301408AI

D-43 Passenger's seat belt pre-tensioner connector Flat-tip screw driver

check the diagnosis code. If diagnosis code 69 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3 . NO : Repair the harness wires between SRSECU connector C-114 (terminal No.27 and 28) and passenger’s seat belt pre-tensioner connector D-43 (terminal No.1 and 2). Then go to Step 3. STEP 3. Recheck the diagnosis code.

Locking button


Q: Is diagnosis code 69 set? YES : Return to Step 1. NO : The procedure is complete (If no AC300147AF

(2) Disconnect passenger’s seat belt pre-tensioner connector D-43. Use a flat-tipped screwdriver to pull out the locking button at the harness side connector, and then disconnect the connector.



52B-90

TROUBLESHOOTING

Code No.71: Side air bag module (squib) (RH) system (short-circuited between terminals of the squib circuit) Side Air Bag Module (RH) (Squib) Circuit SRS-ECU MICROCOMPUTER




SIDE AIR BAG MODULE (SQUIB) (RH)


AC301796AB

OPERATION The SRS-ECU judges how severe a collision is by detecting signals from the left and right side impact sensors. If the impact is over a predetermined level, the SRS-ECU outputs an ignition signal. At this time, if the side air bag safing G-sensor is on, the SRS side air bag will inflate. The ignition signal is input to the side air bag module to inflate the side air bag.

NOTE: *: The squib circuit connectors integrate a "short" spring (which prevents the air bag from deploying unintentionally due to static electricity by shorting the positive wire to the earth wire in the squib circuit when the connectors are disconnected). Therefore, if connector C-114 or D-40 is damaged or improperly engaged, the short spring may not be released when the connector is connected.

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if one side air bag squib (RH) wire shorted to the other.

STEP 1. Check the diagnosis code.

PROBABLE CAUSES Improper engaged connector or defective short spring* Short between the side air bag module (RH) (squib) circuit terminals Damaged connector(s) Malfunction of the SRS-ECU

DIAGNOSIS PROCEDURE




52B-91

STEP 4. Check the side air bag module (RH). (1) Disconnect the negative battery terminal. Connector: D-40





2 1

D-40 (R)

AC202027AM

AC301661AE


Step 6. STEP 3. Connector check: SRS-ECU connector C-114 and side air bag module (RH) connector D40 (1) Disconnect the negative battery terminal.

(2) Disconnect the side air bag module (RH) connector D-40. MB991865 (Dummy resistor : 3 Ω) D-40 Harness side connector MB991866 (Resistor harness)



D-40 Side air bag module (RH) connector


AC301661AE

Connector: D-40 Harness side connector (front view)

AC301039AB


CAUTION Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Insert special tool (MB991866) into the D-40 harness side connector by backprobing. (5) Connect the negative battery terminal. (6) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 71 set? YES : Go to Step 5. NO : Replace the seat back assembly of the front

2 1

D-40 (R)

seat (RH) (Refer to GROUP 52A - Front Seat 352A). Then go to Step 6. AC202027AM

(2) Disconnect connectors C-114 and D-40, and then reconnect them. (3) Connect the negative battery terminal. (4) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 71 out put? YES : Go to Step 4. NO : The procedure is complete. It is assumed



52B-92

TROUBLESHOOTING



SRS-ECU



24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

AC301661AE


DANGER Connector: D-40 Harness side connector (front view)

D-40 (R)

AC202027AM

To prevents the air bag from deploying unintentionally, disconnect the side air bag module (RH) connector D-40 to short the squib circuit. (2) Disconnect side air bag module connector D-40.

CAUTION C-114 Harness side connector (front view) Terminal Cable tie A A

4 mm or more

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

AC301042AB


2 1

Section A-A

CAUTION

Short spring AC301041AB

Insert an insulator such as a cable tie to a depth of 4mm or more, otherwise the short spring will not be released. (3) Insert a cable tie [3 mm wide, 0.5 mm thick] between terminals 23, 24 and the short spring to release the short spring. (4) Measure at the wiring harness side.

check the diagnosis code. If diagnosis code 71 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 6 . NO : Repair the harness wires between SRSECU connector C-114 (terminal No.23 and 24) and side air bag module (RH) connector D-40 (terminal No.1 and 2). Then go to Step 6. STEP 6. Recheck the diagnosis code. Q: Is diagnosis code 71 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-93

TROUBLESHOOTING

Code No.72: Side air bag module (squib) (RH) system (open-circuited in the squib circuit) Side Air Bag Module (RH) (Squib) Circuit SRS-ECU MICROCOMPUTER







AC301796AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the side air bag squib (RH) wire(s) are open-circuited. PROBABLE CAUSES Open circuit in the side air bag module (RH) (squib) circuit Improper connector contact Malfunction of the SRS-ECU

52B-94


DIAGNOSIS PROCEDURE STEP 1. Check the side air bag module (RH). (1) Disconnect the negative battery terminal. Connector: D-40 Harness side connector (front view) 2 1

D-40 (R)

AC202027AM

(2) Disconnect the side air bag module (RH) connector D-40. MB991865 (Dummy resistor : 3 Ω) D-40 Harness side connector MB991866 (Resistor harness) D-40 Side air bag module (RH) connector

AC301039AB



seat (RH) (Refer to GROUP 52A - Front Seat 352A). Then go to Step 3.


STEP 2. Measure the resistance between SRSECU connector C-114 (terminal No.23 and 24) and the side air bag module (RH) connector D-40 (terminal No.1 and 2). Connector: C-114 SRS-ECU



AC301661AE




Connector: D-40 Harness side connector (front view) 2 1

D-40 (R)

AC202027AM

(1) Disconnect SRS-ECU connector C-114 and side air bag module (RH) connector D-40.

CAUTION D-40 Harness side connector (rear view) C-114 Harness side connector (rear view)

52B-95

1 2

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

AC301043AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (2) Measure the resistance between the following terminals. SRS-ECU connector C-114 terminal No.23 and the side air bag module (RH) connector D-40 terminal No.2 SRS-ECU connector C-114 terminal No.24 and the side air bag module (RH) connector D-40 terminal No.1 OK: Less than 2 W


52B-96

TROUBLESHOOTING

Code No.75: Side air bag module (squib) (RH) system (short-circuited to the power supply) Side Air Bag Module (RH) (Squib) Circuit SRS-ECU MICROCOMPUTER







AC301796AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the side air bag squib (RH) wire(s) are short-circuited to the power supply. PROBABLE CAUSES Damaged wiring harnesses or connectors Short to the power supply in the side air bag module (RH) (squib) harness Malfunction of the SRS-ECU



D-40 (R)

AC202027AM


AC301039AB




52B-97


52B-98

TROUBLESHOOTING




AC301661AE


DANGER





D-40 (R)

AC202027AM

To prevents the air bag from deploying unintentionally, disconnect the side air bag module (RH) connector D-40 to short the squib circuit. (2) Disconnect side air bag module (RH) connector D-40. (3) Turn the ignition switch to the "ON" position.

CAUTION


AC301044 AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Measure the voltage between C-114 harness side connector terminals 23 and 24 and body earth. OK: 0 V


52B-99

TROUBLESHOOTING

Code No.76: Side air bag module (squib) (RH) system (short-circuited to the earth) Side Air Bag Module (RH) (Squib) Circuit SRS-ECU MICROCOMPUTER







AC301796AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the side air bag squib (RH) wire(s) are short-circuited to the earth. PROBABLE CAUSES Damaged wiring harnesses or connectors Short to earth in the side air bag module (RH) (squib) harness Malfunction of the SRS-ECU

52B-100



D-40 (R)

AC202027AM


AC301039AB








AC301661AE


DANGER

52B-101





D-40 (R)

AC202027AM

To prevents the air bag from deploying unintentionally, disconnect the side air bag module (RH) connector D-40 to short the squib circuit. (2) Disconnect side air bag module (RH) connector D-40.

CAUTION


AC301045AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Measure the resistance between C-114 harness side connector terminals 23, 24 and body earth. OK: Open circuit

52B-102


Code No.79: Side impact sensor (LH) communication error Code No.93: Side impact sensor (LH) communication impossible

Side Impact Sensor (LH) Power Supply Circuit SIDE IMPACT SENSOR (LH)

ANALOG G SENSOR

CONSTANT VOLTAGE CIRCUIT

SRS-ECU INTERFACE CIRCUIT MICROCOMPUTER



OPERATION The side impact sensor includes an analog G sensor and CPU, etc. The CPU monitors the analog G sensor output signal. If the CPU judges that the side air bags should be deployed, it sends a fire signal to the SRS-ECU to deploy the side air bags. Besides that, the CPU diagnoses the internal components of the side impact sensor. If a malfunction occurs, it requests the SRS-ECU to set a diagnosis code.

DIAGNOSIS PROCEDURE

DIAGNOSIS CODE SET CONDITIONS These diagnosis codes are set if communication between the side impact sensor (LH) and the SRSECU is not possible or communication is faulty.

Q: Is diagnosis code 89 or 96 set? YES : Replace the side impact sensor (LH) with a

PROBABLE CAUSES Damaged wiring harnesses or connectors Malfunction of the side impact sensor (LH) Malfunction of the SRS-ECU

STEP 1. Check the side impact sensor (LH). (1) Disconnect the negative battery terminal. (2) Replace the side impact sensor (LH) with the side impact sensor (RH). (3) Connect the negative battery terminal. (4) Erase diagnosis code memory, and check the diagnosis code.

new one (Refer to 352B). Then go to Step 3. NO : Go to Step 2.


STEP 2. Check the harness wires for open circuit or short circuit between SRS-ECU connector C114 (terminal No.34 and 36) and side impact sensor (LH) connector D-27 (terminal No.1 and 2). Connector: C-114 SRS-ECU



AC301661AE


Front seat belt

2 1

D-27 Front seat AC201281AE

Connector: D-31 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

AC301408 AE

NOTE: After inspecting intermediate connector D-31 inspect the wiring harness. If the intermediate connector D-31 is damaged, repair or replace it. Then go to Step 3. If any harness wires between SRS-ECU connector C-114 and side impact sensor (LH) connector D-27 are damaged, repair or replace it.

52B-103


check the diagnosis code. If diagnosis code 79 or 93 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3. NO : Repair the harness wires between SRSECU connector C-114 (terminal No.34 and 36) and side impact sensor (LH) connector D-27 (terminal No.1 and 2). Then go to Step 3. STEP 3. Recheck the diagnosis code. Q: Is diagnosis code 79 or 93 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-104

TROUBLESHOOTING

Code No.81: Side air bag module (squib) (LH) system (short-circuited between terminals of the squib circuit)

Side Air Bag Module (LH) (Squib) Circuit SRS-ECU MICROCOMPUTER




SIDE AIR BAG MODULE (SQUIB) (LH)

OPERATION The SRS-ECU judges how severe a collision is by detecting signals from the left and right side impact sensors. If the impact is over a predetermined level, the SRS-ECU outputs an ignition signal. At this time, if the side air bag safing G-sensor is on, the SRS side air bag will inflate. The ignition signal is input to the side air bag module to inflate the side air bag. DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if one side air bag squib (LH) wire shorted to the other. PROBABLE CAUSES Improper engaged connector or defective short spring* Short circuit between the side air bag module (LH) (squib) circuit terminals Damaged connector(s) Malfunction of the SRS-ECU


AC301797AB

NOTE: *: The squib circuit connectors integrate a "short" spring (which prevents the air bag from deploying unintentionally due to static electricity by shorting the positive wire to the earth wire in the squib circuit when the connectors are disconnected). (Refer to 352B). Therefore, if connector C-114 or D-08 is damaged or improperly engaged, the short spring may not be released when the connector is connected. DIAGNOSIS PROCEDURE STEP 1. Check the diagnosis code. Q: Is diagnosis code 34 set? YES : Go to Step 2. NO : Go to Step 3.



52B-105

STEP 4. Check the side air bag module (LH). (1) Disconnect the negative battery terminal. Connector: D-08





2 1

D-08 (R) AC202027AO

AC301661AE


Step 6. STEP 3. Connector check: SRS-ECU connector C-114 and side air bag module (LH) connector D08 (1) Disconnect the negative battery terminal.

(2) Disconnect the side air bag module (LH) connector D-08. MB991865 (Dummy resistor : 3 Ω) D-08 Harness side connector MB991866 (Resistor harness)

Connector: C-114 D-08 Side air bag module (LH) connector

SRS-ECU



AC301661AE


AC301039AC


CAUTION Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Insert special tool (MB991866) into the D-08 harness side connector by backprobing. (5) Connect the negative battery terminal. (6) Erase diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 81 set? YES : Go to Step 5. NO : Replace the seat back assembly of the front

2 1

seat (LH) (Refer to GROUP 52A - Front Seat 352A). Then go to Step 6.

D-08 (R) AC202027AO

(2) Disconnect connectors C-114 and D-08, and then reconnect them. (3) Connect the negative battery terminal. (4) Erase the diagnosis code memory, and check the diagnosis code. Q: Is diagnosis code 81 out put? YES : Go to Step 4. NO : The procedure is complete. It is assumed



52B-106

TROUBLESHOOTING



SRS-ECU


CAUTION


AC301661AE


DANGER Connector: D-08 Harness side connector (front view)

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

AC301047AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Check for continuity between C-114 harness side connector terminals 21 and 22. OK: Open circuit Q: Is the check result normal? YES : Erase the diagnosis code memory, and

2 1

D-08 (R) AC202027AO

To prevents the air bag from deploying unintentionally, disconnect the side air bag module (LH) connector D-08 to short the squib circuit. (2) Disconnect left hand side air bag module (LH) connector D-08.

CAUTION

Terminal

A

Short spring



C-114 Harness side connector (front view) A

check the diagnosis code. If diagnosis code 81 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 6 . NO : Repair the harness wires between SRSECU connector C-114 (terminal No.21 and 22) and side air bag module (LH) connector D-08 (terminal No.1 and 2). Then go to Step 6.

Cable tie Section A-A

4 mm or more AC301046 AB

Insert an insulator such as a cable tie to a depth of 4mm or more, otherwise the short spring will not be released. (3) Insert a cable tie [3 mm wide, 0.5 mm thick] between terminals 21, 22 and the short spring to release the short spring.


52B-107

TROUBLESHOOTING

Code No.82: Side air bag module (squib) (LH) system (open-circuited in the squib circuit)








AC301797AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the side air bag squib (LH) wire(s) are open-circuited. PROBABLE CAUSES Open circuit in the side air bag module (squib) (LH) circuit Improper connector contact Malfunction of the SRS-ECU


52B-108

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP 1. Check the side air bag module (LH). (1) Disconnect the negative battery terminal. Connector: D-08 Harness side connector (front view) 2 1

D-08 (R) AC202027AO

(2) Disconnect the side air bag module (LH) connector D-08. MB991865 (Dummy resistor : 3 Ω) D-08 Harness side connector MB991866 (Resistor harness) D-08 Side air bag module (LH) connector

AC301039AC


CAUTION Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Insert special tool (MB991866) into the D-08 harness side connector by backprobing. (5) Connect the negative battery terminal. (6) Erase diagnosis code memory, and then check the diagnosis code. Q: Is diagnosis code 82 set? YES : Go to Step 2. NO : Replace the seat back assembly of the front



STEP 2. Measure the resistance between the SRS-ECU connector C-114 (terminal No.21 and 22) and the side air bag module (LH) connector D-08 (terminal No.1 and 2). Connector: C-114 SRS-ECU



24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

AC301661AE

(1) Disconnect SRS-ECU connector C-114. Connector: D-08 Harness side connector (front view) 2 1

D-08 (R) AC202027AO

(2) Disconnect side air bag module (LH) connector D-08.

CAUTION D-08 Harness side connector C-114 Harness (rear view) side connector (rear view) 1 2

2122

23 24

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

AC202032 AH

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Measure the resistance between the following terminals. SRS-ECU connector C-114 (terminal No.21) and the side air bag module (LH) connector D-08 (terminal No.1) SRS-ECU connector C-114 (terminal No.22) and the side air bag module (LH) connector D-08 (terminal No.2) OK: Less than 2 W

52B-109


check the diagnosis code. If diagnosis code 82 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3 . NO : Repair the harness wires between SRSECU connector C-114 (terminal No.21 and 22) and side air bag module (LH) connector D-08 (terminal No.1 and 2). Then go to Step 3. STEP 3. Recheck the diagnosis code. Q: Is diagnosis code 82 set? YES : Return to Step 1. NO : The procedure is complete (If no



52B-110

TROUBLESHOOTING

Code No.85: Side air bag module (squib) (LH) system (short-circuited to the power supply)








AC301797AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the side air bag squib (LH) wire(s) are short-circuited to the power supply. PROBABLE CAUSES Damaged wiring harnesses or connectors Short to the power supply in the side air bag module (LH) (squib) harness Malfunction of the SRS-ECU



D-08 (R) AC202027AO


AC301039AC




52B-111


52B-112

TROUBLESHOOTING




AC301661AE


DANGER





D-08 (R) AC202027AO

To prevents the air bag from deploying unintentionally, disconnect the side air bag module (LH) connector D-08 to short the squib circuit. (2) Disconnect left hand side air bag module (LH) connector D-08. (3) Turn the ignition switch to the "ON" position.

CAUTION


AC301050AB



52B-113

TROUBLESHOOTING

Code No.86: Side air bag module (squib) (LH) system (short-circuited to the earth)








AC301797AB

DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the side air bag squib (LH) wire(s) are short-circuited to the earth. PROBABLE CAUSES Damaged wiring harnesses or connectors Short to earth in the left hand side air bag module (squib) harness Malfunction of the SRS-ECU


52B-114

TROUBLESHOOTING


D-08 (R) AC202027AO


AC301039AC








AC301661AE


52B-115





D-08 (R) AC202027AO

(2) Disconnect side air bag module (LH) connector D-08.

CAUTION


AC301058AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (3) Check for continuity between C-114 harness side connector terminals 21, 22 and body earth. OK: Open circuit

52B-116


Code No.89: Side impact sensor (RH) communication error Code No.96: Side impact sensor (RH) communication impossible

Side Impact Sensor (RH) Circuit

ANALOG G SENSOR

SIDE IMPACT SENSOR (RH)






DIAGNOSIS PROCEDURE

DIAGNOSIS CODE SET CONDITIONS These diagnosis codes are set if communication between the side impact sensor (RH) and the SRSECU is not possible or faulty.

Q: Is diagnosis code 79 or 93 out put? YES : Replace the side impact sensor (RH) with a

PROBABLE CAUSES Damaged wiring harnesses or connectors Malfunction of the side impact sensor (RH) Malfunction of the SRS-ECU

STEP 1. Check the side impact sensor (RH). (1) Disconnect the negative battery terminal. (2) Replace the side impact sensor (RH) with the side impact sensor (LH). (3) Connect the negative battery terminal. (4) Erase diagnosis code memory, and check the diagnosis code.

new one (Refer to 352B). Go to Step 3. NO : Go to Step 2.


STEP 2. Check the harness wires for open circuit or short circuit between SRS-ECU connector C114 (terminal No.40 and 42) and side impact sensor (RH) connector D-41 (terminal No.1 and 2). Connector: C-114 SRS-ECU



AC301661AE


Front seat belt

2 1

D-41

Front seat AC201282 AH

NOTE: If any harness wires between SRS-ECU connector C-114 and side impact sensor (RH) connector D-41 are damaged, repair or replace it. Then go to Step 3. Q: Is the check result normal? YES : Erase the diagnosis code memory, and

check the diagnosis code. If diagnosis code 89 or 96 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3. NO : Repair the harness wires between SRSECU connector C-114 (terminal No.40 and 42) and side impact sensor (RH) connector D-41 (terminal No.1 and 2). Then go to Step 3.

52B-117

STEP 3. Recheck the diagnosis code. Q: Is diagnosis code 89 or 96 set? YES : Return to Step 1. NO : The procedure is complete (If no


52B-118


Code No.91: Side impact sensor (LH) voltage error

Side Impact Sensor (LH) Power Supply Circuit SIDE IMPACT SENSOR (LH)

ANALOG G SENSOR






DIAGNOSIS CODE SET CONDITIONS This diagnosis code will set when the power supply voltage to the side impact sensor (LH) remains less than a predetermined value for 5 seconds. However, if the system returns to normal condition, code number 91 will be erased automatically and the SRS warning lamp will go out. PROBABLE CAUSES Damaged wiring harness or connectors Malfunction of the side air bag module (LH) (squib) Malfunction of the SRS-ECU


52B-119

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP 1. Measure the voltage at the side impact sensor (LH) connector D-27. (1) Disconnect the negative battery terminal. Connector: D-27

STEP 2. Check the harness wires for open circuit or short circuit between SRS-ECU connector C114 (terminal No.34 and 36) and side impact sensor (LH) connector D-27 (terminal No.1 and 2). Connector: C-114 SRS-ECU

Front seat belt


24 23 22 21 33 32 31 30 29 28 27 26 25 42 41 40 39 38 37 36 35 34

D-27 Front seat AC201281AF

(2) Disconnect side impact sensor (LH) connector D27, and measure at the wiring harness side. (3) Connect the negative battery terminal. (4) Turn the ignition switch to the "ON" position.


AC301661AE


Front seat belt

CAUTION

2 1

D-27

D-27 Harness side connector (rear view)

Front seat AC201281AE

1 2

Connector: D-31

AC201627AM

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (5) Measure the voltage between D-27 harness side connector terminal 2 and the earth. OK: 9 V or more Q: Is the check result normal? YES : Replace the side impact sensor (LH) (Refer

to 352B). Then go to Step 3. NO : Go to Step 2.

1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

AC301408 AE

NOTE: After inspecting intermediate connector D-31 inspect the wiring harness. If the intermediate connector D-31 is damaged, repair or replace it. Then go to Step 3. Q: Is the check result normal? YES : Erase the diagnosis code memory, and

check the diagnosis code. If diagnosis code 91 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3 . NO : Repair the harness wires between SRSECU connector C-114 (terminal No.34 and 36) and side impact sensor (LH) connector D-27 (terminal No.1 and 2). Then go to Step 3.

52B-120




Code No.92: G-sensor of side impact sensor (LH) failure Code No.95: G-sensor of side impact sensor (RH) failure DIAGNOSIS CODE SET CONDITIONS These diagnosis codes are set if the followings are detected from the analog G-sensor inside the side impact sensor output. Analog G-sensor is not operating. Analog G-sensor characteristics are abnormal. Analog G-sensor inside the side impact sensor output is abnormal. PROBABLE CAUSE Malfunction of side impact sensor (LH) (for diagnosis code 92) and side impact sensor (RH) (for diagnosis code 95)

DIAGNOSIS PROCEDURE Replace side impact sensor (LH) (for diagnosis code 92) and side impact sensor (RH) (for diagnosis code 95). (Refer to 352B). Check the diagnosis code. Q: Is any of diagnosis code 92 or 95 set? YES : Replace the SRS-ECU (Refer to 352B

). NO : The procedure is complete.


52B-121

Code No.94: Side Impact Sensor (RH) voltage error

Side Impact Sensor (RH) Circuit

ANALOG G SENSOR

SIDE IMPACT SENSOR (RH)






DIAGNOSIS CODE SET CONDITIONS This diagnosis code is set if the power supply voltage of the side impact sensor (RH) drops below the rated value for a continuous period of 5 seconds or more. However, diagnosis code number 94 will be automatically cleared and the SRS warning lamp will switch off if the condition returns to normal. PROBABLE CAUSES Damaged wiring harnesses or connectors Malfunction of the side air bag module (RH) (squib) Malfunction of the SRS-ECU


52B-122

TROUBLESHOOTING

DIAGNOSIS PROCEDURE STEP 1. Measure the voltage at the side impact sensor (RH) connector D-41. (1) Disconnect the negative battery terminal. Connector: D-41 Harness side connector (front view)

STEP 2. Check the harness wires for open circuit or short circuit between SRS-ECU connector C114 (terminal No.40 and 42) and side impact sensor (RH) connector D-41 (terminal No.1 and 2). Connector: C-114

Front seat belt

2 1

D-41

SRS-ECU




(2) Disconnect side impact sensor (RH) connector D41, and measure at the wiring harness side. (3) Connect the negative battery terminal. (4) Turn the ignition switch to the "ON" position.

CAUTION

AC301661AE


Front seat belt

2 1

D-41

D-41 Harness side connector (rear view)


1 2

AC201627 AN

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (5) Measure the voltage between the D-41 harness side connector terminal 2 and body earth. OK: 9 V or more Q: Is the check result normal? YES : Replace the side impact sensor (RH) (Refer

Q: Are the harness wires between SRS-ECU connector C-114 (terminal No.40 and 42) and side impact sensor (RH) connector D-41 (terminal No.1 and 2) in good condition? YES : Erase the diagnosis code memory, and

check the diagnosis code. If diagnosis code 94 sets, replace the SRS-ECU (Refer to 352B). Then go to Step 3 . NO : Repair the harness wires between SRSECU connector C-114 (terminal No.40 and 42) and side impact sensor (RH) connector D-41 (terminal No.1 and 2). Then go to Step 3.

to 352B). Then go to Step 3. NO : Go to Step 2.




52B-123

TROUBLESHOOTING

CHECK CHART FOR TROUBLE SYMPTOMS M1524003400417

Trouble


Reference page

Communication with MUT-II MB991502 is not possible (Communication with all systems is not possible).

GROUP 13A Troubleshooting 313A

Communication with MUT-II MB991502 is not possible (Communication is not possible with SRS).

1

352B

When the ignition switch is turned to the "ON" position (engine stopped), the SRS warning lamp does not illuminate.

Refer to diagnosis code No.43.

352B

After the ignition switch is turned to the "ON" Refer to diagnosis code No.43. position, the SRS warning lamp does not go off within approximately 7 seconds.

352B


52B-124

TROUBLESHOOTING

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Communication with MUT-II MB991502 is not possible. (Communication is not possible with SRS).

SRS-ECU Power Supply Circuit IGNITION SWITCH (IG1)


D.C.-D.C. CONVERTER

BACK-UP CAPACITOR


MUT-II INTERFACE CIRCUIT







52B-125

TROUBLESHOOTING

OPERATION The SRS-ECU is powered from the ignition switch (IG1). The SRS-ECU power is supplied from two circuits. Even if one circuit is shut off, the air bag can inflate. The SRS system diagnosis can be done by connecting MUT-II MB991502 to the diagnosis connector. COMMENTS ON TROUBLE SYMPTOM If communication is not possible with the SRS only, the cause is probably an open circuit in the on-board diagnostic output circuit of the SRS or in the power circuit (including earth circuit). PROBABLE CAUSES Damaged wiring harnesses or connectors Malfunction of the SRS-ECU Incorrect MUT-II (MUT-II) ROM pack DIAGNOSIS PROCEDURE STEP 1. Check that the MUT-II can communicate with the other systems. Q: Can the MUT-II communicate with the other systems? YES : Go to Step 2. NO : Refer to GROUP 13A - Troubleshooting

313A.

STEP 2. Measure the resistance between SRSECU connector C-115 (terminal No.20) and diagnosis connector C-24 (terminal No.7) Connector: C-115 SRS-ECU



4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

CONNECTOR: C-24 Center lower panel


C-24 (B)

1 2 3 4 5 6 7 8 9 10 111213141516

AC208056 AF

(1) Disconnect SRS-ECU connector C-115 and diagnosis connector C-24, and measure at the wiring harness side.

CAUTION C-115 Harness side C-24 Connector connector (rear view) (front view) 1 2 3 4 1 2 3 4 5 6 7 8 9 10 111213141516

5 6 7 8 9 10 1112 131415 1617 181920

AC201667AI

Do not insert a test probe into the terminal from of the SRS-ECU connector C-115 its front side directly as the connector contact pressure may be weakened. (2) Measure the resistance between the following terminals. SRS-ECU connector C-115 (terminal No.20) and diagnosis connector C-24 (terminal No.7) OK: Less than 2 W Q: Is the check results normal? YES : Go to Step 3. NO : Go to Step 5.


52B-126

TROUBLESHOOTING

STEP 3. Check the earth circuit to the SRS-ECU. Connector: C-115

STEP 4. Check the power supply circuit to the SRS-ECU. Connector: C-115

SRS-ECU

SRS-ECU Center lower panel

Center lower panel

C-115 (Y) C-115 (Y) AC301661AB



AC301661AB

(1) Disconnect SRS-ECU connector C-115, and measure at the wiring harness side. (2) Connect the negative battery terminal. (3) Turn the ignition switch to the "ON" position.


AC301059AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (2) Check for continuity between terminal 7 and body earth. OK: Less than 2 W Q: Is the check result normal? YES : Go to Step 4. NO : Go to Step 6.

AC301060 AB

Do not insert a test probe into the terminal from its front side directly as the connector contact pressure may be weakened. (4) Measure the voltage between terminals 13, 16 and body earth. OK: 9 V or more Q: Is the check result normal? YES : Recheck the trouble symptom. If it is not

solved, replace the SRS-ECU (Refer to 352B). Then go to Step 8. NO : Go to Step 7.


52B-127

TROUBLESHOOTING

STEP 5. Connector check: SRS-ECU connector C-115 and diagnosis connector C-24 Connector: C-115

STEP 6. Connector check: SRS-ECU connector C-115 and earth Connector: C-115

SRS-ECU

SRS-ECU




4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413


AC301661AC

AC301661AC

CONNECTOR: C-24 Center lower panel


Blower assembly

C-24 (B)

1 2 3 4 5 6 7 8 9 10 111213141516

AC208056 AF

AC208080AE

Q: Is the check result normal? YES : Check the harness wire for open circuit

Connector: C-02

between SRS-ECU connector C-115 (terminal No.7) and earth, and repair if necessary. Then go to Step 8. NO : Repair or replace it. Then go to Step 8. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 2627 282930 3132 33

AC301395 AC


circuit between SRS-ECU connector C-115 (terminal No.20) and diagnosis connector C24 (terminal No.7), and repair if necessary. Then go to Step 8. NO : Repair or replace it. Then go to Step 8.


52B-128

TROUBLESHOOTING

STEP 7. Connector check: SRS-ECU connector C-115 and ignition switch connector C-303 Connector: C-115 SRS-ECU



4 3 2 1 12 1110 9 8 7 6 5 20 19 18 17 16 15 1413

AC301661AC

Connector: C-303 Clock spring C-303

Harness side connector (front view) 3 2 1 6 5 4

AC301399 AG


C-205

Harness side C-205 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-203 2 1 6 5 4 3

AC210475 AR


circuit between SRS-ECU connector C-115 (terminal No.13 and 16) and ignition switch connector C-303 (terminal No.2), and repair if necessary. Then go to Step 8. NO : Repair or replace it. Then go to Step 8.

STEP 8. Retest the system. Q: Does the MUT-II communicate normally with the SRS system? YES : The procedure is complete (If no

malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points 300). NO : There is no action to be taken.


52B-129

SRS MAINTENANCE

SRS MAINTENANCE M1524003900263

The SRS must be inspected by an authorized dealer 10 years after the date of vehicle registration.

FRONT IMPACT SENSORS

SRS WARNING LAMP CHECK SRS warning lamp

Front impact sensors

AC300581AB

AC301667 AB

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. If no, consult page 352B.

SRS COMPONENT VISUAL CHECK DANGER

SIDE IMPACT SENSOR

Insulating tape Battery

Battery cable

1. Check the front side member and front impact sensor for deformation or rust. 2. Check the front impact sensor for dents, cracks, deformation or rust. 3. Check the sensor harnesses for binding, the connectors for damage, and the terminals for deformation. NOTE: The figures show front impact sensors (LH). The side impact sensors (RH) is symmetrical with the side impact sensors (LH).

WARNING The SRS may not activate if the impact sensors are not installed properly, which could result in serious injury or death to the vehicle’s driver or front passenger. Side impact sensor

AC300580AB

Wait at least 60 seconds after disconnecting the battery cable before doing any further work (Refer to 352B).

Center pillar

Turn the ignition key to the "LOCK" position, disconnect the negative battery cable and tape the terminal. AC201282 AF

1. Check the centre pillar for deformation or rust. 2. Check the side impact sensors for dents, cracks, deformation and rust. 3. Check the connector for damage and the terminals for deformation. NOTE: The figures show side impact sensors (RH). The side impact sensors (LH) is symmetrical with the side impact sensors (RH).

52B-130

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS MAINTENANCE

SRS CONTROL UNIT (SRS-ECU) WARNING The SRS may not activate if the SRS-ECU is not installed properly, which could result in serious injury or death to the vehicle’s driver or front passenger.

Inflator case

SRS-ECU Connector

AC300582 AB

1. Check the SRS-ECU case and brackets for dents, cracks, deformation or rust. 2. Check the connector for damage, and check the terminals for deformation or rust. Replace the SRS-ECU if it fails the visual checks above (Refer to 352B).

AIR BAG MODULES, STEERING WHEEL AND CLOCK SPRING WARNING The removed air bag module should be stored in a clean, dry place with the pad cover face up.

Inflator case Connector

AC300170AB

3. Check the connector for damage and deformed terminals, and check the harness for binding. 4. Check the air bag inflator case for dents, cracks or deformation. 5. Check the harness (built into the steering wheel) and connectors for damage, and check the terminals for deformation. Case

1. Remove the air bag module, steering wheel and clock spring (Refer to 352B). 2. Check the pad cover for dents, cracks or deformation. Protective tubes AC300585AB

6. Check the clock spring connectors and protective tube for damage, and terminals for deformities. 7. Visually check the case for damage.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS MAINTENANCE

WARNING If the clock spring’s mating mark is not properly aligned, the steering wheel may not be completely rotational during a turn, or the flat cable within the clock spring may be severed, obstructing normal operation of the SRS and possibly leading to serious injury to the vehicle’s driver or front passenger.

52B-131

DANGER The SRS may not activate if any of the above components is not installed properly, which could result in serious injury or death to the vehicle’s driver or front passenger. 11.Check the steering wheel for excessive free play. 12.REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION (Refer to 352B ).

FRONT SEATBACK ASSEMBLY WITH SIDE AIR BAG MODULE

Air bag module deployment section

Mating marks AC300168 AB

8. Align the mating marks of the clock spring and, after turning the vehicle’s front wheels to straightahead position, install the clock spring to the column switch. Mating Marks Alignment; Turn the clock spring clockwise fully. Then turn it back approximately 3 3/4 turns counterclockwise to align the mating marks.

AC300172AB

1. Check the side air bag module deployment section in the seat for dents and deformation. 2. Check the harness for binds, the connector for damage and the terminals for deformation.

SEAT BELT WITH PRE-TENSIONER 1. Check the seat belt pre-tensioner for dents or deformation. 2. Check that the seat belt pre-tensioner is installed correctly to the vehicle body.

Air bag module AC300586 AB

9. Install the steering column covers, steering wheel and air bag module (Refer to 352B). 10.Check the steering wheel for noise, binding or difficult operation.


52B-132

SRS MAINTENANCE

INSTRUMENT PANEL WIRING HARNESS/FRONT WIRING HARNESS/FLOOR WIRING HARNESS Clock spring connector

Air bag module connector

SRS-ECU connector

Air bag module connector

Front impact sensor connector (LH)

Front impact sensor connector (RH)

Side impact sensor connector (RH)

Side air bag module connector

Seat belt pre-tensioner connector (RH)

Seat belt pre-tensioner connector (LH)

Side impact sensor connector (LH)

AC301669AB

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) POST-COLLISION DIAGNOSIS

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 352B).

52B-133

POST-INSTALLATION INSPECTION SRS warning lamp

AC301667 AB

Reconnect the negative battery terminal. 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. If no, consult page 352B.

POST-COLLISION DIAGNOSIS M1524001100391

Whether or not the air bags have deployed, check and service the vehicle after collision as follows:

SRS-ECU MEMORY CHECK CAUTION

16 Pin

MB991502 AC107200 AF

Refer to that the ignition switch is "LOCK" (OFF) when connecting or disconnecting MUT-II. 1. Connect the MUT-II to the diagnosis connector (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points 300 ).

2. Read (and write down) all displayed diagnosis codes (Refer to 352B). NOTE: If battery power supply has been shut down by the collision, the MUT-II cannot communicate with the SRS-ECU. Check and, repair if necessary, the instrument panel wiring harness before the next job.


52B-134

POST-COLLISION DIAGNOSIS

3. Use the MUT-II to read the data list (how long trouble(s) have continued and how often memory have been erased). Data list No

Service Data Item

Applicability

92

Number indicating how often the memory is Maximum time to be stored: 250 cleared

93

How long a problem has lasted (How long it Maximum time to be stored: 9,999 minutes takes from the occurrence of the problem till (approximately 7 days) the first air bag squib igniting signal)

94

How long a problem has lasted (How long it takes from the first air bag squib igniting signal till now).

4. Erase the diagnosis codes and after waiting 5 seconds or more read (and write down) all displayed diagnosis codes.

REPAIR PROCEDURE WHEN FRONT AIR BAGS DEPLOY IN A COLLISION. 1. Replace the following parts with new ones. SRS-ECU (Refer to 352B). Air bag modules (Refer to 352B). Seat belt with pre-tensioner (Refer to 352B). Front impact sensors (Refer to 352B). Instrument panel (Refer to GROUP 52A Instrument Panel Assembly , ). 2. Check the following parts and replace if there are any malfunctions. Clock spring (Refer to 352B). Steering wheel, steering column and shaft assembly (1) Check the wiring harness (built into the steering wheel) and connectors for damage, and terminals for deformation. (2) Install the air bag module to check fit or alignment with the steering wheel. (3) Check the steering wheel for noise, binds or difficult operation and excessive free play. (4) Check the steering column shaft shock absorbing mechanism (Refer to GROUP 37A - On-Vehicle Service 337). 3. Check the harness for binding, connectors for damage, poor connections, and terminals for deformation (Refer to352B).

WHEN SIDE AIR BAGS DEPLOY IN A COLLISION. 1. Replace the following parts with new ones. SRS-ECU (Refer to 352B). Side impact sensors (Refer to 352B). Front seatback assembly (Refer to GROUP 52A - Front Seat Assembly 352A). 2. Check the harness for binding, connectors for damage, poor connections, and terminals for deformation (Refer to352B). WHEN AIR BAGS DO NOT DEPLOY IN LOWSPEED COLLISION. Check the SRS components. If visible damage such as dents, cracks, or deformation are found on the SRS components, replace them with new ones. Concerning parts removed for inspection, replacement with new parts and cautions in working, refer to INDIVIDUAL COMPONENT SERVICE, 352B

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) POST-COLLISION DIAGNOSIS

Front impact sensor

52B-135

Air bag modules Inflator case

Front impact sensors

AC300581AB

1. Check the front side member and front impact sensor for deformation or rust. 2. Check the front impact sensor for dents, cracks, deformation or rust. 3. Check the sensor harnesses for binding, the connectors for damage, and the terminals for deformation. NOTE: The figures show front impact sensors (LH). The side impact sensors (RH) is symmetrical with the side impact sensors (LH). SRS-ECU SRS-ECU

Connector

Inflator case Connector

AC300170AB

1. Check the pad cover for dents, cracks or deformation. 2. Check the connector for damage, terminals deformities, and the harness for binding. 3. Check the air bag inflator case for dents, cracks or deformities. 4. Check the air bag modules for proper installation. Front seatback assembly (Side air bag module)

AC300582 AB

1. Check the SRS-ECU case and brackets for dents, cracks or deformation. 2. Check the connector for damage, and the terminals for deformation. 3. Check the SRS-ECU and bracket for installation condition.


AC300172AB

1. Check the side air bag module deployment section in the seat for dents and deformation. 2. Check the connectors for damage, the terminals for deformation, and the harness for binds.


52B-136

INDIVIDUAL COMPONENT SERVICE

Clock spring

3. Check the connector for damage and the terminals for deformation. NOTE: The figures show side impact sensors (RH). The side impact sensors (LH) is symmetrical with the side impact sensors (RH).

Case

Protective tubes AC300585AB

1. Check the clock spring connectors and protective tube for damage, and the terminals for deformation. 2. Visually check the case for damage. Side impact sensor

Steering wheel, steering column and shaft assembly 1. Check the wiring harness (built into the steering wheel) and the connectors for damage, and the terminals for deformation. 2. Install the air bag module to check fit or alignment with the steering wheel. 3. Check the steering wheel for noise, binding or difficult operation and excessive free play. 4. Check the steering column shaft shock absorbing mechanism (Refer to GROUP 37A - On-Vehicle Service 337). Seat belt with pre-tensioner 1. Check the seat belt for damage or deformation. 2. Check the seat belt with pre-tensioner for cracks or deformation. 3. Check that the unit is installed correctly to the vehicle body.

Center pillar

AC201282 AG

1. Check the centre pillar for deformation or rust. 2. Check the side impact sensors for dents, cracks, deformation and rust.

Harness connector (Front wiring harness, instrument panel wiring harness and floor wiring harness) Check harnesses for binding, connectors for damage and terminals for deformation (Refer to 352B).

INDIVIDUAL COMPONENT SERVICE M1524002900323

WARNING

If heat damage may occur during paint work, remove the SRS-ECU, the air bag modules,

the clock spring, front seats, and the seat belt with pre-tensioner. Recheck the SRS system operability after reinstalling them (Refer to GROUP 00 - Maintenance Service). SRS-ECU, air bag module, clock spring and impact sensor: 93 C or more Seat belt with pre-tensioner: 90C or more If the SRS components are removed for the purpose of check, sheet metal repair, painting, etc., they should be stored in a clean, dry place until they are reinstalled. If the SRS components are to be removed or replaced as a result of maintenance, troubleshooting etc., follow the service procedures that follow. (Front impact sensor; refer to 352B, SRS-ECU; refer to 352B, Air bag modules and clock spring; refer to 352B, Side impact sensor; refer to 352B, Seat belt with pre-tensioner; refer to 352B).


52B-137

WARNING/CAUTION LABELS

WARNING/CAUTION LABELS M1524003000107

Caution labels on the SRS are attached in the vehicle as shown. Follow label instructions when servicing the SRS. If the label(s) are dirty or damaged, replace with new one(s). Driver's air bag module B

Steering wheel

A Passenger's (front) air bag module

Clock spring C

Sun visor

SRS-ECU

Glove box

G

F E F D Steering joint cover

Side impact sensors (left and right)

Side air bag module (driver's and front passenger's seat)

Seat belt with pre-tensioner (driver's and passenger's seat)

J

H

Center pillar

I

K

Hood

Front impact sensors (left and right) Battery

L

Instrument panel

M

N

Front bumper

AC301342 AB


52B-138

FRONT IMPACT SENSORS

FRONT IMPACT SENSORS REMOVAL AND INSTALLATION M1524001500258

WARNING

Disconnect the negative battery terminal and wait for 60 seconds or more before starting

work. Furthermore, the disconnected battery terminal should be covered with tape to insulate it. Never attempt to disassemble or repair the front impact sensor. If faulty, replace it. Do not drop or subject the front impact sensor to impact or vibration. If denting, cracking, deformation, or rust are discovered in the front impact sensor, replace it with a new front impact sensor. Discard the old one. After deployment of an air bag, replace the front impact sensor with a new one. Pre-removal Operation Turn the ignition key to the "LOCK" (OFF) position. Disconnect the Negative Battery Terminal.

1

1

5.0 ± 1.0 N·m AC300078AB

1.

>>A<< >>B<< >>C<<

1.

Removal step Front impact sensor Installation steps Pre-installation inspection Front impact sensor Negative battery cable connection Post-installation inspection

NOTE: The figure on the left indicates the left front impact sensor.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) FRONT IMPACT SENSORS

INSTALLATION SERVICE POINTS >>A<>B<
WARNING The SRS may not activate properly if a front impact sensor is not installed properly. 1. Securely connect the connector. 2. Position the front impact sensor facing toward the front of the vehicle as shown by the arrow on the label, and install it securely.

52B-139


WARNING If a dent, crack, deformation or rust is detected, replace with a new sensor. 1. Check the front impact sensor for dents, cracks, deformation or rust.

WARNING Always replace the sensor with a new one if the resistance shows a short or open circuit.

>>C<
2. Measure the resistance between terminals and check whether it is within the standard value. Standard value: 820 82 W

AC301667 AB

3. Does the SRS warning lamp illuminate for about 7 seconds, and then remain extinguished for at least 5 seconds after turning OFF? 4. If no, refer to troubleshooting (Refer to352B).

AC300130

3. Check the continuity between the terminal and bracket. If there is a continuity, the insulation is malfunctioned, and replace the sensor with a new one. 4. Check the head lamp support pane for deformation and rust.


52B-140

SRS CONTROL UNIT (SRS-ECU)

SRS CONTROL UNIT (SRS-ECU) REMOVAL AND INSTALLATION M1524002100350

WARNING


work. Furthermore, the disconnected battery terminal should be covered with tape to insulate it. Never attempt to disassemble or repair the SRS-ECU. If faulty, replace it. Do not drop or subject the SRS-ECU to impact or vibration. If denting, cracking, deformation, or rust are discovered in the SRS-ECU, replace it with a new front impact sensor. Discard the old one. After deployment of an air bag, replace the SRS-ECU with a new one. Never use an ohmmeter on or near the SRS-ECU, and use only the special test equipment described on 352B.

Pre-removal Operation Turn the ignition switch to the "LOCK" (OFF) position. Disconnect the Negative Battery Terminal.

5.0 ± 1.0 N·m

1

2

5.0 ± 1.0 N·m

5.0 ± 1.0 N·m

AC300137 AB

1. 2.

Removal steps Front floor console (Refer to GROUP 52A - Floor console assembly 352A). SRS-ECU SRS-ECU bracket

>>A<<

>>B<<

2. 1.

Installation steps SRS-ECU bracket SRS-ECU Front floor console (Refer to GROUP 52A - Floor console assembly 352A). Negative battery cable connection Post-installation inspection

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG MODULE(S) AND CLOCK SPRING


52B-141


>>A<< SRS-ECU INSTALLATION

WARNING The SRS may not activate if SRS-ECU is not installed properly. >>B<< POST-INSTALLATION INSPECTION 1. Connect the negative battery cable. 2. Turn the ignition key to "ON" position. SRS warning lamp

WARNING If any problems are found, replace the SRSECU. Check the SRS-ECU and brackets for dents, cracks or deformation. Check the SRS-ECU connector for damage, and the terminals for deformation. NOTE: For the checks other than the items above, refer to "Troubleshooting" (Refer to 352B).

AC301667 AB


AIR BAG MODULE(S) AND CLOCK SPRING REMOVAL AND INSTALLATION M1524002400403

WARNING


work. Also, the disconnected battery terminal should be insulated with tape (Refer to 352B). Never attempt to disassemble or repair the air bag modules and clock spring. If faulty, just replace with new one(s). Do not drop the air bag modules or clock spring or allow contact with water, grease or oil. Replace if a dent, crack, deformation or rust are present. Store the air bag modules on a flat surface with the deployment surface facing up. Do not place anything on top of them. Do not store the air bag modules in a place more than 93C. When the driver’s and front passenger’s air bags have been deployed, replace the driver’s and passenger’s air bag modules with new ones. Put on gloves and safety glasses when handling deployed air bags. When discarding the undeployed air bag module(s), be sure to deploy the air bag(s) in advance as specified in the service procedure (Refer to 352B).

For removal and installation of the front seatback assembly with side air bag module, refer to GROUP 52A Front Seat 352A.


52B-142

AIR BAG MODULE(S) AND CLOCK SPRING

2 3

4

7.5 ± 0.5 N·m 0.69 ± 0.15 N·m

C

C

Column switch

A A 1

D

B

5

B

D

5 Section A - A Claw 3

Section B - B Claw 1

1 3

Section C - C

3

Section D - D 50 ± 5 N·m

Claw

Claw

NOTE : Claw positions

<> <> <> <> <>

<>

Air bag module removal steps 1. Cover 2. Steering wheel and air bag module assembly 3. Steering wheel 4. Air bag module Clock spring removal steps 1. Cover 2. Steering wheel and air bag module assembly Column cover lower (Refer to GROUP 37A - Steering shaft 337 ). 5. Clock spring Air bag module installation steps >>A<< Pre-installation inspection 4. Air bag module

AC300120 AC

Air bag module installation steps 3. Steering wheel >>C<< 2. Steering wheel and air bag module assembly 1. Cover Negative battery cable connection >>D<< Post-installation inspection Clock spring installation steps >>A<< Pre-installation inspection >>B<< 5. Clock spring Column cover lower (Refer to GROUP 37A - Steering shaft 337 ). >>C<< 2. Steering wheel and air bag module assembly 1. Cover


52B-143


>>D<<

Clock spring installation steps Negative battery cable connection Post-installation inspection

2

1

AC300153 AB

Air bag module removal steps Instrument panel assembly (Refer to GROUP 52A - Instrument panel 352A). Distribution duct (Refer to GROUP 52A - Instrument panel352A). 1. Air bag module bracket <> 2. Air bag module Air bag module installation steps >>A<< Pre-installation inspection 2. Air bag module

Air bag module installation steps 1. Air bag module bracket Distribution duct (Refer to GROUP 52A - Instrument panel 352A). Instrument panel assembly (Refer to GROUP 52A - Instrument panel 352A). Negative battery cable connection >>D<< Post-installation inspection

REMOVAL SERVICE POINTS <>COVER REMOVAL

<> STEERING WHEEL AND AIR BAG MODULE ASSEMBLY REMOVAL

MB990784


A AC300154AB

Insert the special tool ornament remover (MB990784) as shown in the illustration to remove the cover.

Steering wheel

AC300156AB

1. By sliding the A section (in the figure) of the air bag module connector in the arrow direction, disconnect the connector.


52B-144


INSTALLATION SERVICE POINTS Hexagonal bit socket

>>A<< PRE-INSTALLATION INSPECTION

WARNING When discarding the air bag module or seat back assembly, deploy the air bag as specified in the service procedure (Refer to 352B). AC102792

AC107462 AC

2. Insert the hexagonal bit socket into the arrow section in the figure. Completely loosen the bolt, and then remove the steering wheel air bag module assembly. NOTE: Use a hexagonal bit socket or a hexagonal wrench having an effective length of 75 mm or more in the hexagonal section and the diameter of 8 mm or more. <> DRIVER’S AIR BAG MODULE REMOVAL

WARNING

The air bag module must not be measured

with such equipment as an ohmmeter, nor disassembled. The removed air bag module should be stored in a clean, dry place with the deployment surface facing up. <> CLOCK SPRING REMOVAL

WARNING The removed clock spring should be stored in a clean, dry place. <> AIR BAG MODULE REMOVAL (FRONT PASSENGER’S SIDE)

WARNING

When the passenger’s air bag module is

removed, do not damage the engagement of the pawls. The removed passenger’s air bag module should be stored in a clean, dry place with facing the deployment surface facing up.

1. Even new air bag modules, clock spring and front seat back assembly require inspection before installation. 2. Connect the negative battery cable.

WARNING Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the MUT-II. 3. Connect the MUT-II to the diagnosis connector (16- pin). 4. Turn the ignition switch to the "ON" position. 5. Read a diagnosis code to refer to that the SRS is operating properly except an open in the air bag module circuit. 6. Turn the ignition switch to "LOCK" (OFF) position.

WARNING Wait at least 60 seconds after the disconnection of the battery cable before any further job (Refer to 352B). 7. Disconnect the negative battery cable and insulate with tape. >>B<< CLOCK SPRING INSTALLATION 1. Confirm that the steering wheel is at the straightahead position.

WARNING Unless the mating marks are properly aligned, the steering wheel gets stuck amid a turn or the flat cable in the clock spring is cut. These hinder the SRS air bag from proper operation, resulting in serious injury to the vehicle's driver.

Mating marks AC300168 AB

2. Align the mating marks of the clock spring.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG MODULE(S) AND CLOCK SPRING

(1) Turn the clock spring clockwise fully. Then turn it back approximately 3 3/4 turns counterclockwise to align the mating marks. (2) Then install the clock spring to the column switch. >>C<< STEERING WHEEL AND AIR BAG MODULE ASSEMBLY INSTALLATION

CAUTION Be sure when installing the steering wheel, that the harness of the clock spring does not become caught or tangled. 1. Refer to first that the clock spring has been centered properly. Then, install the steering wheel. 2. After clamping, turn the steering wheel all the way in both directions to confirm that steering is normal. >>D<< POST-INSTALLATION INSPECTION 1. Connect the negative battery cable. 2. Turn the ignition key to "ON" position.

52B-145


AIR BAG MODULE CHECK

WARNING

If any component damage is found during

the following inspection, replace the air bag module(s) with a new one. Dispose of the old one according to the specified procedure (Refer to 352B). Never attempt to measure the circuit resistance of he air bag module (squib) even if you are using the specified tester. If the circuit resistance is measured with a tester, accidental air bag module(s) deployment will result in serious personal injury. 1. Check the pad cover for dents, cracks or deformation. Inflator case

SRS warning lamp

Connector AC301667 AB

3. Does the SRS warning lamp illuminate for about 7 seconds, and then remain extinguished for at least 5 seconds after turning OFF? 4. If no, refer to troubleshooting (Refer to 352B). Inflator case Connector

AC300170AB

2. Check the connectors for damage, the terminals for deformation, and the harness for binds. 3. Check the air bag inflator case for dents, cracks or deformation. 4. Install the air bag module (driver’s side) to the steering wheel and check fit and alignment with the wheel. 5. Install the air bag module (front passenger’s side) to the instrument panel and front deck crossmember and check fit and alignment.


52B-146


FRONT SEATBACK ASSEMBLY WITH SIDE AIR BAG MODULE CHECK

WARNING

If any improper part is found during the

following inspection, replace the front seatback assembly with a new one. Dispose of the old one according to the specified procedure (Refer to 352B). Never attempt to measure the circuit resistance of the air bag module (squib) even if you are using the specified tester. If the circuit resistance is measured with a tester, accidental air bag deployment will result in serious personal injury.

1. Check the connectors and protective tube for damage, and the terminals for deformation. 2. Visually check the case for damage. 3. Check to see that there is a charge (continuity) between the C-308 clock spring connector terminal 1 and C-305 horn switch.

CAUTION

C-306 Air bag module connector (driver's side)


Plobe (MB991222)

Clock spring

AC300172AB

1. Check the air bag module deployment section for dents or deformation. 2. Check the connector for damage, the terminals for deformation, and the harness for binds. CLOCK SPRING CHECK Case

C-308 Clock spring connector 1 2 3 4 5 6

Protective tube C-306 Air bag module connector C-305 Horn switch AC300312AB

If any malfunction is found in the following inspections, replace the clock spring with a new one.

C-306 Air bag module connector (driver's side)

Digital multi-meter

AC300374 AB

Do not directly insert a probe, etc. into the terminal from the front of the connector. 4. Insert the special tool probe in the harness set (MB991222) from behind the C-306 air bag module connector (driver’s side). 5. As shown in the Figure, connect the circuit tester to the special tool probe in the harness set (MB991222) and check to see that there is a charge between the terminals.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SIDE IMPACT SENSOR

52B-147

SIDE IMPACT SENSOR REMOVAL AND INSTALLATION M1524004600243

WARNING


work. Furthermore, the disconnected battery terminal should be covered with tape to insulate it. Never attempt to disassemble or repair the side impact sensors. If faulty, replace it. Do not drop or subject the side impact sensors to impact or vibration. If denting, cracking, deformation, or rust are discovered in the side impact sensors, replace it with a new front impact sensor. Discard the old one. After deployment of an air bag, replace the side impact sensors with a new one. Never use an ohmmeter on or near the side impact sensors, and use only the special test equipment described on 352B.

Pre-removal Operation Turn the ignition key to the "LOCK" (OFF) position. Disconnect the Negative Battery Terminal.

Center pillar 5.0 ± 1.0 N·m 1

Front of vehicle

AC300142 AB

1.

>>A<< >>B<<

1.

Removal steps Centre pillar trim lower (Refer to GROUP 52A - Trims 352A). Seat belt pre-tensioner (Refer to GROUP 52A - Front seat belt 352A). Side impact sensor Installation steps Pre-installation inspection Side impact sensor

>>C<<

Installation steps&RQWLQXHG Seat belt pre-tensioner (Refer to GROUP 52A - Front seat belt 352A). Centre pillar trim lower (Refer to GROUP 52A - Trims 352A). Negative battery cable connector Post-installation inspection

NOTE: The figure shows the side impact sensor (RH).

52B-148

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SEAT BELTS WITH PRE-TENSIONER

INSTALLATION SERVICE POINTS >>A<< PRE-INSTALLATION INSPECTION Even new side impact sensor requires inspection before installation. (Refer to the previous item "INSPECTION" >>B<< SIDE IMPACT SENSOR INSTALLATION

WARNING The side impact sensor, unless properly installed, does not operate properly, thereby resulting in serious injury or death of the vehicle’s occupants.


WARNING If any problems, replace the sensor. 1. Check the side impact sensor and bracket for dents, cracks or deformation. 2. Check the connector for damage, and terminal for deformation. 3. Check that there is no bending or corrosion in the centre pillar. NOTE: For the checks other than the items above, refer to Troubleshooting (Refer to 352B) .

>>C<< POST-INSTALLATION INSPECTION 1. Connect the negative battery cable. 2. Turn the ignition key to "ON" position. SRS warning lamp

AC301667 AB


SEAT BELTS WITH PRE-TENSIONER REMOVAL AND INSTALLATION M1524004100237

WARNING

Never attempt to disassemble or repair the seat belt pre-tensioner. If faulty, replace it. Be extremely careful when handling the seat with pre-tensioner. Do not subject it to

shocks, drop it, bring it close to strong magnets or allow contact with water, grease or oil. Always replace it with a new part if any dents, cracks or deformation is found. Do not place anything on top of the seat belt pre-tensioner. Do not expose the seat belt pre-tensioner to temperatures over 90C. After operating the seat belt pre-tensioner, replace the seat belt pre-tensioner with a new part. Gloves and protective goggles should be worn when handling a seat belt pre-tensioner once it has been used. If disposing of a seat belt with pre-tensioner which has not yet been operated, its seat belt pre-tensioner should be operated first before disposal (Refer to 352B).


52B-149

Pre-removal Operation Turn the ignition key to the "LOCK" (OFF) position. Disconnect the Negative Battery Terminal.

2

44 ± 10 N·m

5

1

4 6

3 44 ± 10 N·m AC300144AB

1. 2. 3.

<>

4. 5. 6.

>>A<< 6.

Removal steps Sash guide cover Seat belt shoulder anchor bolt Seat belt lower anchor bolt Centre pillar trim, lower (Refer to GROUP 52A - Trims 352A). Pre-tensioner connector connection Bracket Seat belt with pre-tensioner Installation steps Pre-installation inspection Seat belt with pre-tensioner

Installation steps&RQWLQXHG 5. Bracket >>B<< 4. Pre-tensioner connector connection Centre pillar trim, lower (Refer to GROUP 52A - Trims 352A). 3. Seat belt lower anchor bolt 2. Seat belt shoulder anchor bolt 1. Sash guide cover Negative battery cable connection >>C<< Post-installation inspection

NOTE: The figure shows the seat belt with pretensioner (RH).

52B-150


REMOVAL SERVICE POINTS <>PRE-TENSIONER CONNECTOR DISCONNECTION Pre-tensioner connector Flat-tip screw driver

>>B<< PRE-TENSIONER CONNECTOR CONNECTION Connect the pretensioner connector then securely lock the locking button of the harness-side connector. >> C<< POST-INSTALLATION INSPECTION 1. Connect the negative battery cable. 2. Turn the ignition key to "ON" position. SRS warning lamp

Locking button Harness side connector AC300147AB

1. Use a flat-tipped screwdriver to pull out forward and unlock the locking button of the harness-side connector. 2. Disconnect the pretensioner connector.

INSTALLATION SERVICE POINTS >>A<< PRE-INSTALLATION INSPECTION

WARNING When discarding the seat belt with pretensioner, operate the pre-tensioner as specified in the service procedure (Refer to 352B). 1. Even new seat belt with pre-tensioner require inspection before installation. 2. Connect the negative battery cable.

CAUTION Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the MUT-II. 3. Connect the MUT-II to the diagnosis connector (16- pin). 4. Turn the ignition switch to the ON position. 5. Read a diagnosis code to refer to that the SRS is operating properly except an open in the seat belt with pre-tensioner circuit. 6. Turn the ignition switch to "LOCK" (OFF) position.

DANGER Wait at least 60 seconds after the disconnection of the battery cable before any further job (Refer to 352B). 7. Disconnect the negative battery cable and insulate with tape.

AC301667 AB



WARNING

If any component damage is found during

the following inspection, replace the seat belt with pre-tensioner with a new one. Dispose of the old one according to the specified procedure (Refer to 352B). Never attempt to measure the circuit resistance of the seat belt pre-tensioner even if you are using the specified tester. If the circuit resistance is measured with a tester, accidental seat belt pre-tensioner operation will result in serious personal injury. 1. Check the pre-tensioner deployment section for dents and deformation. 2. Check the harness and connector for damage and the terminals for deformation.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES

52B-151

AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES M1524001200354

Before disposing of an air bag or a vehicle equipped with an air bag, follow the procedures below to deploy the air bag.

3. Remove the column cover lower (Refer to GROUP 37A - Steering shaft 337).

UNDEPLOYED AIR BAG MODULE DISPOSAL

WARNING If the vehicle is to be scrapped or otherwise disposed of, deploy the air bags and operate the seat belt pretensioner inside the vehicle. If the vehicle will continue to be used and only the air bag modules and seat belt pre-tensioner are to be disposed of, deploy the air bags and operate the seat belt pre-tensioner outside the vehicle. Since a large amount of smoke is produced when the air bag is deployed and the seat belt pre-tensioner is operated, avoid residential areas whenever possible. Since there is loud noise when the air bags are deployed and when the seat belt pre-tensioner are operated, avoid residential areas whenever possible. If anyone is nearby, give warning of the impending noise. Suitable ear protection should be worn by personnel performing these procedures or by people in the immediate area.

DEPLOYMENT INSIDE THE VEHICLE (when disposing of a vehicle) 1. Move the vehicle to an isolated spot.

DANGER Wait at least 60 seconds after the disconnection of the battery cable before any further job (Refer to 352B). 2. Disconnect the negative and positive battery cables from the battery terminals, and then remove the battery from the vehicle.

C-307 Clock spring connector (4-pin)

C-307 Harness side connector (4-pin, yellow)

AC300379 AB

4. Remove the connection between the C-307 clock spring connector (4-pin) and the harness side connector (4-pin, yellow). NOTE: Once disconnected from the instrument panel wiring harness, both electrodes of the clock spring connector short automatically. This prevents the driver’s air bag from accidental deployment caused by static, etc. Deployment wires Connector

6m or longer AC300381AB

5. Obtain two suitable wires, which are 6 meters or longer, as deployment wires. Then connect the wires at one end to short. 6. Touch the vehicle’s body with bare hands to discharge static in you.

52B-152


WARNING

C-307 Clock spring connector (4-pin)

C-307 Harness side connector (4-pin, yellow) Deployment wire Connection

Insulator tape AC300384 AB

7. Cut with a pliers, etc. the instrument panel wiring harness shown in the figure of the instructions, while the C-307 clock spring connector is disconnected. NOTE: The disconnection location should be sufficiently away from the C-307 harness side connector with consideration to the expansion harness connection location upon disconnections. 8. Connect the deployment wires on the two instrument panel wiring harnesses disconnected, cover the connection areas with insulation tape and then pull out the deployment wires outside the vehicle. 9. Connect the C-307 harness side connector connected with an expansion harness to the C307 clock spring connector.

WARNING

Before deploying the air bag in this

manner, first check to be sure that there is no one in or near the vehicle. Wear safety glasses. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although not poisonous, do not inhale gas from the air bag deployment. See Deployed Air Bag Module and Operated Seat Belt Pretensioner Disposal (Refer to 352B) for post-deployment handling instructions. If the air bag module fails to deploy, do not go near the module. Contact your distributor. 11.At a location as far away from the vehicle as possible, 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. 12.After deployment, dispose of the air bag module according to the Deployed Air Bag Module and Operated Seat Belt Pre-tensioner Disposal (Refer to 352B). DEPLOYMENT INSIDE THE VEHICLE (when disposing of a vehicle) 1. Move the vehicle to an isolated spot.

Cover

DANGER Wait at least 60 seconds after the disconnection of the battery cable before any further job (Refer to 337).

Deployment wire 6m or longer

AC300388AB

If the glass is scratched, air bag deployment could cause it to crack and fly out of the vehicle, so always put a cover over the vehicle. 10.To suppress the operation sound as much as possible completely close all door windows, close the doors and put the cover on the vehicle.

2. Disconnect the negative and positive battery cables from the battery terminals, and then remove the battery from the vehicle. 3. Remove the glove box (Refer to GROUP 52A Instrument Panel 352A).


52B-153

WARNING Cover

Glove box striker

C-09 Air bag module connector (2-pin, red)

Deployment wire 6m or longer AC300418 AB

4. Remove the connection between the C-09 air bag module (front passenger’s side) connector (2-pin, red) and the harness side connector (2-pin, red). NOTE: Once disconnected from the instrument panel wiring harness, both electrodes of the passenger’s air bag module short automatically. This prevents the passenger’s air bag from accidental deployment caused by static, etc.

AC300388AB

If the glass is scratched, air bag deployment could cause it to crack and fly out of the vehicle, so always put a cover over the vehicle. 7. To suppress the operation sound as much as possible completely close all door windows, close the doors and put the cover on the vehicle.

WARNING

Connection Deployment wires 6 m Long or more

MB686560 Insulator tape

AC300419AB

5. Connect deployment wires longer than 6 m to each special tool SRS air bag adapter harness (MB686560) and insulate the connections with plastic tape. Also, connect the deployment wires in the other ends to short, thereby preventing the passenger’s air bag from accidental deployment caused by static etc.

MB686560

C-09 Air bag module connector (2-pin, red) Deployment wires AC300420AB

6. Connect the C-09 air bag module (front passenger’s side) connector (2-pin, red) to special tool SRS air bag adapter harness (MB686560) and move the deployment wires out of the vehicle.


manner, first check to be sure that there is no one in or near the vehicle. Wear safety glasses. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although not poisonous, do not inhale gas from the air bag deployment. See Deployed Air Bag Module and Operated Seat Belt Pretensioner Disposal (Refer to 352B") for post-deployment handling instructions. If the air bag module fails to deploy, do not go near the module. Contact your distributor. 8. At a location as far away from the vehicle as possible, 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. 9. After deployment, dispose of the air bag module according to the Deployed Air Bag Module and Operated Seat Belt Pre-tensioner Disposal (Refer to 352B).


52B-154

AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES

DEPLOYMENT INSIDE THE VEHICLE (when disposing of a vehicle) 1. Move the vehicle to an isolated spot.

WARNING Wait at least 60 seconds after disconnecting the battery cables before doing any further work (Refer to 337). 2. Disconnect the negative and positive battery cables from the battery terminals, and then remove the battery from the vehicle.

WARNING

MB686560

Deployment wires

D-08 or D-40 Side air bag module connector (2-pin, red) AC300444 AB

5. Connect the D-08 or D-40 side air bag module connector (2-pin, red) to special tool SRS air bag adapter harness (MB686560) and move the deployment wire out of the vehicle.

D-08 or D-40 Harness side connector (2-pin, red)

WARNING Cover

D-08 or D-40 Side air bag connector (2-pin, red)

AC300442AB

The side air bag modules for both the driver’s side and passenger’s side should be deployed. 3. Remove the connection between the D-08 or D-40 side air bag module connector (2-pin, red) and the harness side connector (2-pin, red). NOTE: Once disconnected from the side air bag wiring harness, both electrode of the side air bag module connector short automatically. This prevents the side air bag from accidental deployment caused by static etc. Connection Deployment wires MB686560

6 m Long or more

Insulator tape AC300419AB



AC300388AB

If the glass is scratched, air bag deployment could cause it to crack and fly out of the vehicle, so always put a cover over the vehicle. 6. To suppress the operation sound as much as possible completely close all door windows, close the doors and put the vehicle.


WARNING

D-29 or D-43 Seat belt pre-tensioner connector (2-pin)


manner, first check to be sure that there is no one in or near the vehicle. Wear safety glasses. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although not poisonous, do not inhale gas from the air bag deployment. See Deployed Air Bag Module and Operated Seat Belt Pretensioner Disposal (Refer to 352B") for post-deployment handling instructions. If the air bag module fails to deploy, do not go near the module. Contact your distributor. 7. At a location as far away from the vehicle as possible, 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. 8. After deployment, dispose of the front seatback assembly (air bag module) according to the Deployed Air Bag Module and Operated Seat Belt Pre-tensioner Disposal (Refer to 352B). DEPLOYMENT INSIDE THE VEHICLE (when disposing of a vehicle) 1. Move the vehicle to an isolated spot.

DANGER Wait at least 60 seconds after disconnecting the battery cables before doing any further work (Refer to 337). 2. Disconnect the negative and positive battery cables from the battery terminals, and then remove the battery from the vehicle. 3. Remove the centre pillar lower trim (Refer to GROUP 52A - TRIMS 352A).

52B-155

Flat-tip screw driver Locking buttom D-29 or D-43 Harness side connector (2-pin, black)

AC300446AB

4. Execute the following steps to disconnect the connection between D-29 or D-43 seat belt pretensioner connector (2-pin) and harness side connector (2-pin, black). NOTE: Once disconnected from the seat belt pretensioner wiring harness, both electrode of the side air bag module connector short automatically. This prevents the seat belt pre-tensioner from accidental deployment caused by static etc. (1) Use a flat-tipped screwdriver to pull out forward and unlock the locking button of the harness-side connector (2-pin, black). (2) Disconnect the D-29 or D-43 harness side connector. Connection Deployment wires MB991885 6 m Long or more



MB991885 D-29 or D-43 Seat belt pre-tensioner 2-pin connector

Deployment wires AC300448AB

52B-156


6. Connect the D-29 or D-43 seat belt pre-tensioner 2-pin connector (red) to special tool SRS air bag adapter harness (MB991885) and move the deployment harness out of the vehicle.

WARNING

9. After operation, dispose of the seat belt pretensioner according to the Deployed Air Bag Module operated seat belt pre-tensioner Disposal (Refer to 352B). DEPLOYMENT OUTSIDE THE VEHICLE

Cover

WARNING

This should be carried out in a wide, flat

area at least 6 m away from obstacles and other people. Do not deploy outside if wind is high. Even in a soft wind, ignite to windward of the air bag modules.


AC300388AB

If the glass is scratched, seat belt pretensioner operation could cause it to crack and fly out of the vehicle, so always put a cover over the vehicle. 7. To suppress the operation sound as much as possible completely close all door windows, close the doors and put the cover on the vehicle.

WARNING Before operating the seat belt pretensioner in this manner, first check to be sure that there is no one in or near the vehicle. Wear safety glasses. The inflator will be quite hot immediately following the operation, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although no poisonous, do not inhale gas from the seat belt pre-tensioner operation. See Deployed Air Bag and Operated Seat Belt pre-tensioner Disposal (Refer to 352B ) for post-operation handling instructions. If the seat belt pre-tensioner fails to operate, do not go near the seat belt pretensioner. Contact your distributor. 8. At a location as far away from the vehicle as possible, disconnect the two connected wires from each the, and connect them to the two terminals of the battery (which has been removed from the vehicle) to operating the seat belt pretensioner.

DANGER Wait at least 60 seconds after disconnecting the battery cables before doing any further work (Refer to 337). 1. Disconnect the negative and positive battery cables from the battery terminals, and then remove the battery from the vehicle.

WARNING Once disconnected, both electrodes of the driver’s air bag module connector short automatically to prevent accidental deployment caused by static etc. Still, in consideration of the accidental deployment, store the air bag module on flat place with deployment surface facing up. Also, do not put anything on it. 2. Remove the air bag module from the vehicle (Refer to 352B). Deployment wires Shorted

6 m or longer AC300458 AB

3. Obtain two suitable wires, which are 6 meters or longer, as deployment wires. Then connect the wires at one end to short. 4. Touch the vehicle’s body with bare hands to discharge static in you.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES Deployment wires Air bag module

52B-157

8. Place three old tyres without wheels on the tyre secured with the driver’s air bag module.

WARNING

Before deployment, check carefully to be

sure that no one is nearby. The inflator will be quite hot immediately Connection Insulator tape

AC300459 AB

5. Using pliers, cut the driver’s air bag module connector from the harnesses. Connect the deployment wires to each harness that has been cut and insulate the connections with plastic tape. Driver's air bag module

following the deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although not poisonous, do not inhale gas from air bag deployment. See Deployed Air Bag Module and Operated Seat Belt Pretensioner Disposal (Refer to 352B") for post-deployment handling instructions. If the air bag fails to deploy, do not go near the module. Contact your distributor.


6. Install a nut to the bolt behind the driver’s air bag module and tie thick wire there for securing. 7. Route the deployment wires connected to the driver’s air bag module beneath an old tyre and wheel assembly. Then, using the wire tied to the bolt, secure the driver’s air bag module to the tyre and wheel assembly with the deployment surface facing up. Tyre without wheels

Air bad module inside

Deployment wires AC300478 AB

Deployment wires

Vehicle battery

AC300493AB

9. At a location as far away from the air bag module 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. 10.Discard the deployed air bag module as specified in Deployed Air Bag Module and Operated Seat Belt Pre-tensioner Disposal (Refer to 352B).


52B-158

AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES

DEPLOYMENT OUTSIDE THE VEHICLE

Front passenger's air bag module

WARNING


area at least 6 m away from obstacles and other people. Do not deploy outside if wind is high. Even in a soft wind, ignite to windward of the air bag modules. DANGER Wait at least 60 seconds after disconnecting the battery cables before doing any further work (Refer to 337). 1. Disconnect the negative and positive battery cables from the battery terminals, and then remove the battery from the vehicle.

WARNING Once disconnected, both electrodes of the front passenger’s air bag module connector short automatically to prevent accidental deployment caused by static etc. Still, in consideration of the accidental deployment, store the air bag module on flat place with deployment surface facing up. Also, do not put anything on it.


4. Connect the deployment wires to special tool SRS air bag adapter harness (MB686560), pass it beneath the tyre and wheel assembly, and connect it to the air bag module.

CAUTION The adapter harness below the wheel should be loose. If it is too tight, the reaction when the air bag deploys could damage the adapter harness. During deployment, the connector of special tool SRS air bag adapter harness (MB686560) must not be between the tyres. 5. Pass the thick wire through the air bag module mounting hole, and then secure the air bag module to an old tyre with a wheel in it so that the pad on the module is facing upwards.

2. Remove the air bag module from the vehicle (Refer to 352B). Tyres without wheels Connection Deployment wires MB686560

6 m Long or more




6. Place three old tyres without wheels on top of the tyre secured to the air bag module, and secure all tyres together with ropes (four locations).


WARNING


sure that no one is nearby. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although not poisonous, do not inhale gas from air bag deployment. See Deployed Air Bag Module and Operated Seat Belt Pretensioner Disposal (Refer to 352B") for post-deployment handling instructions. If the air bag fails to deploy, do not go near the module. Contact your distributor.

52B-159

WARNING Once disconnected, both electrodes of the side air bag module connector short automatically to prevent accidental deployment caused by static etc. Still, in consideration of the accidental deployment, store the air bag module on flat place with deployment surface facing up. Also, do not put anything on it. 2. Remove the front seatback assembly with side air bag module from the vehicle (Refer to 352B ). Connection Deployment wires 6 m Long or more

MB686560 Insulator tape

AC300419AB


7. At a location as far away from the air bag module 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. 8. Discard the deployed air bag module as specified in Deployed Air Bag Module and Operated Seat Belt Pre-tensioner Disposal (Refer to 352B).


Front seatback assembly

DEPLOYMENT OUTSIDE VEHICLE

WARNING



MB686560 AC300528AB

4. Place the front seatback assembly with its back contact with the earth. 5. Connect the special tool SRS air bag adapter harness (MB686560) with the deployment wires to the side air bag module connector.

52B-160


WARNING


sure that no one is nearby. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although not poisonous, do not inhale gas from air bag deployment. See Deployed Air Bag Module and Operated Seat Belt Pretensioner Disposal (Refer to 352B) for post-deployment handling instructions. If the air bag fails to deploy, do not go near the module. Contact your distributor.

WARNING Store the operated seat belt pre-tensioner the correct way up with its operation surface upper most on a flat surface. Do not place anything on top of them. 2. Remove the seat belt pre-tensioner from the vehicle (Refer to 352B). D-29 or D-43 Seat belt pre-tensioner connector (2-pin)

Flat-tip screw driver Locking buttom D-29 or D-43 Harness side connector (2-pin, black)

AC300446AB

3. Use a flat-tipped screwdriver to unlock the locking button of the harness-side connector (2-pin, black) by with drawing it toward you in two stages. 4. Disconnect the D-29 or D-43 harness side connector. Deployment wires

Connection AC300532 AB

6. Disconnect the deployment wires as far from the front seatback assembly possible and connect the harnesses to the battery removed from the vehicle. Then, deploy. 7. Remove the deployed air bag module from the seatback assembly and discard as specified in the Deployed air bag module and Operated Seat Back Pre-tensioner (Refer to 352B). DEPLOYMENT OUTSIDE THE VEHICLE

WARNING



Deployment wires MB991885 6 m Long or more


5. Connect deployment wires longer than 6 m to each special tool SRS air bag adapter harness (MB991885) and insulate the connections with plastic tape. Also, connect the deployment wires in the other ends to short, thereby preventing the passenger’s air bag from accidental deployment caused by static etc. 6. Connect the special tool SRS air bag adapter harness (MB991885), which the deployment wires is attached to, to the seat belt pre-tensioner connector.

CAUTION The adapter harness below the wheel should be loose. If it is too tight, the reaction when the seat belt pre-tensioner operates could damage the adapter harness. 7. Pass the thick wires through the hole on the seat belt pre-tensioner bracket and secure them to the front (raised part) of the wheel on two place.


Tyres without wheels

Seat belt Deployment wires

AC300552AB

8. Pull the seat belt out the outside of the tyre, and then place one tyre without a wheel inside on top of the existing tyre.

WARNING

Deployment wires Vehicle battery AC300555 AB

Before operation, check carefully to be sure that no one is nearby. The inflator will be quite hot immediately following the operation, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although not poisonous, do not inhale gas from seat belt pre-tensioner operation. See Deployed Air Bag Module and Operated Seat Belt pre-tensioner Disposal (Refer to 352B) for post-operation handling instructions. If the seat belt pre-tensioner fails to operate, do not go near the seat belt pretensioner. Contact your distributor. 9. At a location as far away from the air bag module 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 operated seat belt pre-tensioner.

52B-161

10.Discard the operated seat belt pre-tensioner as specified in Deployed Air Bag Module and Seat Belt pre-tensioner Disposal (Refer to 352B).

DEPLOYED AIR BAG MODULE AND OPERATED SEAT BELT PRE-TENSIONER DISPOSAL After deployment and operation, the air bag module and seat belt pre-tensioner should be disposed of in the same manner as any other scrap parts, adhering to local laws and/or legislation. Observe the following precautions during air bag or seat belt pre-tensioner disposal: 1. The inflator will be quite hot immediately following deployment, so wait at least 30 minutes to allow it cool before attempting to handle it. 2. Do not put water or oil on the air bag after deployment or on the seat belt pre-tensioner after operation.

WARNING If after following these precautions, any material does get into the eyes or on the skin, immediately rinse the affected area with a large amount of clean water. If any irritation develops, seek medical attention. 3. There may be material on the deployed air bag module or the operated seat belt pre-tensioner, that could irritate the eye and/or skin. Wear gloves and safety glasses when handling a deployed air bag module or the operated seat belt pretensioner.

Strong plastic bag Air bag module

AC300562 AB

4. Tightly seal the air bag module and seat belt pretensioner in a strong plastic bag for disposal. 5. Be sure to always wash your hands after completing this operation.

127(6

32-1

GROUP 32

00 11

POWER PLANT MOUNT

12 13 14 15 16

CONTENTS

17 GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATION . . . . . . . . SPECIAL TOOL . . . . . . . . . . . . . . . . . ENGINE MOUNTING . . . . . . . . . . . . .

32

32

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

32

32 32 32


32

INSPECTION . . . . . . . . . . . . . . . . . . . . . . .

32

TRANSMISSION MOUNTING . . . . . .


32

21 22

ENGINE ROLL STOPPER, CENTERMEMBER . . . . . . . . . . . . . . .

32


32

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

32

26

CROSSMEMBER . . . . . . . . . . . . . . . .

32

27


32

31

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

32

25

32 33 34 35 36 37 42 51 52 54 55

POWER PLANT MOUNT

32-2

GENERAL INFORMATION


The liquid-filled transmission mount improves riding comfort by its refined insulator. Installation of roll mount in the upper area limits engine rolling. Further more, large diameter insulator reduces idle vibration.

The inertia axial system has been adopted for the engine mount system. Pressurized liquid-filled longitudinally installed cylindrical engine mount is adopted to reduce vibration during acceleration and cornering.

CONSTRUCTION DIAGRAM Engine mount

Transmission mount

AC301341

<2WD>

<4WD>

Rear roll stopper

Roll rod

Front roll stopper

Roll rod bracket

Centermember

AC107318 AC301640 AB


Item

Standard value

Protruding length of stabilizer link thread part mm

9.4 0.4

POWER PLANT MOUNT

32-3

SPECIAL TOOL


Tool

Number

Name

Use

MB991897

Ball joint remover

Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113) is also available to disconnect knuckle and tie rod end ball joint.

AC106827

ENGINE MOUNTING REMOVAL AND INSTALLATION M1321001100417

CAUTION *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal Operation Raise the engine and transmission assembly until its weight is not applied to the insulator, and support it securely.

12 ± 2 N·m 44 ± 10 N·m

1 N 70 ± 4 N·m 44 ± 10 N·m

2

AC301670AB

1. 2.

Removal steps Pressure hose clamp Engine mounting

POWER PLANT MOUNT

32-4

TRANSMISSION MOUNTING


Check the engine mounting for cracks or damage.

TRANSMISSION MOUNTING REMOVAL AND INSTALLATION M1321001400388

CAUTION *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal Operation Raise the engine and transmission assembly until its weight is not applied to the insulator, and support it securely. Air Cleaner Removal (Refer to GROUP 15, Air Cleaner 315). Centermember and Front Roll Stopper Removal (Refer to 332). Rear Roll Stopper Removal (Refer to 332).

Post-installation Operation Rear Roll Stopper Installation (Refer to 332). Centermember and Front Roll Stopper Installation (Refer to 332). Air Cleaner Installation (Refer to GROUP 15, Air Cleaner 315).

82 ± 7 N·m

47 ± 7 N·m

2

1

2

AC301677 AB

>>A<<

1. 2.

Removal steps Transmission mounting Transmission mounting stopper

POWER PLANT MOUNT TRANSMISSION MOUNTING

INSTALLATION SERVICE POINT >>A<< TRANSMISSION MOUNTING STOPPER INSTALLATION Engine side

Transmission mounting stopper

Transmission mounting

AC200645AD

Install the transmission mounting stopper so that its arrow points upward.

32-5


Check the transmission mounting insulator for cracks, separation or deformation.

POWER PLANT MOUNT

32-6

ENGINE ROLL STOPPER, CENTERMEMBER

ENGINE ROLL STOPPER, CENTERMEMBER REMOVAL AND INSTALLATION M1321002300265

CAUTION *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. <2WD>

<4WD>

11 11 ± 1 N·m

7 8 9

45 ± 5 N·m

70 ± 10 N·m

45 ± 5 N·m 52 ± 7 N·m

6

52 ± 7 N·m

5 52 ± 7 N·m

12

10

45 ± 5 N·m

1 4 2 3

69 ± 10 N·m

52 ± 7 N·m

69 ± 10 N·m AC301682 AB

1. 2.

>>A<<

3. 4.

5. 6. 7.

Front roll stopper and centermember removal steps Under cover (Refer to GROUP 51, Under cover 351). Front roll stopper connecting bolt Centermember and front roll stopper assembly Centermember Front roll stopper Rear roll stopper removal steps <2WD> Rear roll stopper connecting bolt Rear roll stopper connecting bolt Rear roll mount bracket assembly

Rear roll stopper removal steps <2WD>&RQWLQXHG 8. Clamp bracket 9. Rear roll mount bracket 10. Rear roll stopper Rear roll rod bracket removal steps <4WD> Front exhaust pipe (Refer to GROUP 15, Exhaust pipe 315). 5. Rear roll mount connecting bolt 11. Rear roll rod Transfer assembly (Refer to GROUP 22A, Transfer 322A). 12. Rear roll rod bracket

POWER PLANT MOUNT ENGINE ROLL STOPPER, CENTERMEMBER

INSTALLATION SERVICE POINT >>A<< FRONT ROLL STOPPER INSTALLATION

Hole

Front of vehicle

AC208360 AC

Install the front roll stopper so that its hole points towards the front side of the vehicle.

32-7


Check the roll stopper for cracks, separation or deformation. Check the centermember for cracks or damage.

POWER PLANT MOUNT

32-8

CROSSMEMBER

CROSSMEMBER REMOVAL AND INSTALLATION M1321003200346

CAUTION Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so that they are facing straight forward, and remove the ignition key. If you fail to do this, the SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious injury. *1: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. *2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the earth in the unladen condition. Pre-removal Operation Centermember Removal (Refer to 332). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Steering Wheel Air Bag Module Assembly Removal (Refer to GROUP 37, Steering Wheel 337). Power Steering Fluid Draining (Refer to GROUP 37A, Onvehicle Service 337).

Post-installation Operation Centermember Installation (Refer to 332). Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315). Steering Wheel Air Bag Module Assembly Installation (Refer to 37, Steering Wheel 337). Power Steering Fluid Supplying (Refer to GROUP 37A, On-vehicle Service 337). Power Steering Fluid Line Bleeding (Refer to GROUP 37A, On-vehicle Service 337). Press the dust cover with a finger to check whether the dust cover cracked or damaged. Checking Steering Wheel Position with Wheels Straight Ahead. Front Wheel Alignment Check and Adjustment (Refer to GROUP 37A, On-vehicle Service 337).

POWER PLANT MOUNT

32-9

CROSSMEMBER

<4WD>

13

12 ± 2 N·m

45 ± 5 N·m ¹

9

70 ± 10 N·m

70 ± 10 N·m

10

52 ± 7 N·m ¹

18 ± 2 N·m

15 52 ± 7 N·m ¹

5

57 ± 7 N·m

7 16

45 ± 5 N·m ¹

N

<2WD>

13

18

14

6 25 ± 4 N·m

8 12

11 N

21 ± 4 N·m

17 21 ± 4 N·m 52 ± 7 N·m ¹

2N 108 ± 10 N·m

3 4 19 1 186 ± 10 N·m ² 39 ± 5 N·m 167 ± 9 N·m 49 ± 10 N·m

>>B<<

Removal steps 1. Lower arm and knuckle connection 2. Self-locking nut 3. Stabilizer link assembly 4. Lower arm assembly 5. Return hose connection 6. Eye bolt 7. Pressure hose connection 8. Gasket 9. Shaft cover 10. Steering shaft assembly and gear box connecting bolt

<>

<> >>A<<

AC301765 AB

11. 12. 13. 14. 15. 16. 17. 18. 19.

Removal steps&RQWLQXHG Self-locking nut Tie rod end and knuckle connection Rear roll rod connection bolt Rear roll stopper <2WD> Rear roll rod <4WD> Rear roll rod bracket <4WD> Crossmember assembly Stabilizer bar Steering gear and linkage Crossmember

POWER PLANT MOUNT

32-10

CROSSMEMBER


<> CROSSMEMBER ASSEMBLY REMOVAL

<> TIE ROD END AND KNUCKLE DISCONNECTION

CAUTION Do not remove the nut from ball joint. Loosen it and use special tool ball joint remover (MB991897) to avoid possible damage to ball joint threads. Hang special tool ball joint remover (MB991897) with a cord to prevent it from falling.

Transmission jack AC200018 AC

Retain the crossmember with a transmission jack, and then remove the crossmember mounting bolt.

Cord

INSTALLATION SERVICE POINTS MB991897

Nut

Outside of vehicle

Bolt Ball joint

>>A<< STABILIZER BAR/BUSHING/FIXTURE INSTALLATION Approximately 10 mm Identification mark

AC208247AD

1. Install the special tool ball joint remover (MB991897) as shown in the figure. Bolt

Bushing (LH)

Fixture (LH) AC006141AD

Parallel

Align the stabilizer bar identification mark with the right end of the bushing (LH). Knob

Good

>>B<< SELF-LOCKING NUT INSTALLATION Bad

AC106821AB

2. Turn the bolt and knob as necessary to make the jaws of the special tool ball joint remover (MB991897) parallel, tighten the bolt by hand and confirm that the jaws are still parallel. NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure. 3. Tighten the bolt with a wrench to disconnect the tie rod end.

A

AC107031AB AC107031



Check the crossmember for cracks and damage.

21-1

GROUP 21

CLUTCH

00 11 12 13

CONTENTS

14 15 16

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A

17

CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B

21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

127(6

22-1

GROUP 22

MANUAL TRANSMISSION

00 11 12 13 14 15

CONTENTS

16 17

MANUAL TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A MANUAL TRANSMISSION OVERHAUL . . . . . . . . . . . . . . . . . . 22B

21 22 25 26 27 31 32 33 34 35 36 37 42 51 52 54 55

127(6

51-1

GROUP 51

00 11

EXTERIOR

12 13 14

CONTENTS FRONT BUMPER ASSEMBLY .

51

REMOVAL AND INSTALLATION . . . . . DISASSEMBLY AND REASSEMBLY . .

51 51

REAR BUMPER ASSEMBLY . .

51

REMOVAL AND INSTALLATION . . . . . DISASSEMBLY AND REASSEMBLY . .

51 51

RADIATOR GRILLE . . . . . . . . . REMOVAL AND INSTALLATION . . . . .

15


WINDSHIELD WIPER AND WASHER . . . . . . . . . . . . . . . . .

51

16 17

51

21

SERVICE SPECIFICATION . . . . . .

51

22


51

51

WINDSHIELD WIPER. . . . . . . . . . .

51


51 51 51

26

GARNISHES . . . . . . . . . . . . . . .

51

WINDSHIELD WASHER. . . . . . . . .

ADHESIVE . . . . . . . . . . . . . . . . . . .

51


51 51 51

31

SPECIAL TOOL . . . . . . . . . . . . . . .

51

REAR WIPER AND WASHER . . . . . .

51

GARNISHES . . . . . . . . . . . . . . . . .

51 51

SERVICE SPECIFICATION . . . . . .

51


51

34


51

35

CHECK OF REAR WIPER OPERATION WHEN SELECTOR LEVER IS AT THE "R" POSITION . . . . . . . . . . . . . . . . . . . . . . . 51

36


MOULDINGS . . . . . . . . . . . . . . .

51

SPECIAL TOOL . . . . . . . . . . . . . . .

51

MOULDINGS . . . . . . . . . . . . . . . . .

51 51

REAR WIPER AND WASHER . . . .

TAILGATE SPOILER. . . . . . . . .

51


SPECIAL TOOL . . . . . . . . . . . . . . .

51

TAILGATE SPOILER. . . . . . . . . . . REMOVAL AND INSTALLATION . . . . .

51 51

ROOF RAIL . . . . . . . . . . . . . . . .

51


51

UNDER COVER . . . . . . . . . . . . .

51


WIPER DEICER . . . . . . . . . . . .

51 51 51

25 27 32 33

37 42 51

51

52


51

54


51

WIPER DEICER . . . . . . . . . . . . . . .

51 51

INSPECTION . . . . . . . . . . . . . . . . . . . . .


55

51-2 HEADLAMP WASHER . . . . . . . . . . .

51

DOOR MIRROR . . . . . . . . . . . .

51


51


51

HEADLAMP WASHER . . . . . . . . .

51


51

DOOR MIRROR . . . . . . . . . . . . . . .

51

REMOVAL AND INSTALLATION . . . . . .

51

INSPECTION. . . . . . . . . . . . . . . . . . . . . .

51

MARK . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . .

51 51


51

INSPECTION . . . . . . . . . . . . . . . . . . . . .

51

EXTERIOR

51-3

FRONT BUMPER ASSEMBLY

FRONT BUMPER ASSEMBLY REMOVAL AND INSTALLATION M1511001400422

3

6

Splash shield

3 Splash shield

Front under cover

0.8 ± 0.1 N·m

Front under cover

2

1N

5 4 4

4 AC301935 AB

Removal steps Radiator grille (Refer to 351). 1. Rubber nut 2. Licence plate garnish 3. Splash shield mounting clips

Removal steps&RQWLQXHG 4. Front under cover mounting clips Fog lamp connector connection 5. Front bumper assembly 6. Front bumper beam

EXTERIOR

51-4



10

5

11

4

8

3N N

9

2

1

7

6

12

AC300676 AB

Disassembly steps 1. Centre cover <> >>A<< 2. Rivets A <> >>A<< 3. Rivets B 4. Front bumper side plate 5. Front bumper centre reinforcement 6. Oil cooler duct

Disassembly steps&RQWLQXHG 7. Air intake bezel (Vehicles without fog lamp) 8. Fog lamp bezel 9. Fog lamp assembly 10. Front bumper core 11. Three-diamond mark 12. Front bumper face

EXTERIOR

51-5




<> RIVETS A / RIVETS B REMOVAL

>>A<< RIVETS B / RIVETS A INSTALLATION Unit: mm

Rivet A

Drill

Ø12 Bumper face

Rivet

Ø4.0

AC005971

Rivet B Ø8.0 AC100411AB

Ø4.0

Use a drill (f 4.0 mm) to make a hole in the rivet to break it, and then remove the rivet.

AC005972

Recommended tool Front bumper face

Front bumper side plate

Y0412AU

Front bumper face Section C

1 Rivet 2 Recommended tool

3 Flange 4 Rivet

18E0192 AC005885 AB

Use recommended tool shown in the illustration to connect the rivet by the following procedure. 1. Insert rivets A and rivets B into the front bumper face and front bumper upper plate. 2. Place the recommended tool over section C of rivet. 3. While pushing the flange surface of the rivet with the recommended tool, press the handle of the tool. 4. The thin part of section C of the rivet will break and the rivet will then be attached.

EXTERIOR

51-6

REAR BUMPER ASSEMBLY

REAR BUMPER ASSEMBLY REMOVAL AND INSTALLATION M1511001900375

Section A – A

5

4 6

4

A

2

A

3 4

3

1 5

AC300293 AC300454 AB

Removal steps Rear combination lamp Rear end trim 1. Mud guard 2. Rear splash shield 3. Tapping screw Ventilation cap (Refer to GROUP 52A, Trims 352A).

<>

Removal steps&RQWLQXHG 4. Clips Rear bumper harness connector connection 5. Rear bumper assembly 6. Rear bumper beam

EXTERIOR REAR BUMPER ASSEMBLY

REMOVAL SERVICE POINT <> CLIPS REMOVAL Section A – A Clip

Claw

Claw

A A Plier Quarter trim lower

AC200942 AB

Remove the clip with a pair of pliers by removing the thumb of the clip from the cabin side.

51-7

EXTERIOR

51-8



6

5

4

3N

N3

9 7

10 2

1

8 AC300244 AB

Disassembly steps 1. Side cover 2. Muffler cover <> >>A<< 3. Rivets 4. Rear bumper side plate 5. Rear bumper harness

Disassembly steps&RQWLQXHG 6. Rear bumper reinforcement 7. Licence plate lamp assembly 8. Reflector 9. Licence plate bracket 10. Rear bumper face

EXTERIOR

51-9




<> RIVETS REMOVAL

>>A<< RIVETS INSTALLATION Drill

Bumper face

Recommended tool Rear bumper face

Rivet

Rear bumper side plate AC100411AB

Use a drill (f 4.0 mm) to make a hole in the rivet to break it, and then remove the rivet.

Y0412AU

Rear bumper face Section A

1 Rivet 2 Recommended tool

3 Flange 4 Rivet

18E0192 AC005876 AB

Use recommended tool shown in the illustration to connect the rivet by the following procedure. 1. Insert the rivet into the base material (rear bumper face, rear bumper side plate). 2. Place the recommended tool over section A of rivet. 3. While pushing the flange surface of the rivet with the recommended tool, press the handle of the tool. 4. The thin part of section A of the rivet will break and the rivet will then be attached.

EXTERIOR

51-10

RADIATOR GRILLE

RADIATOR GRILLE REMOVAL AND INSTALLATION M1511002900204

Section A – A

Section B – B Clip

2 Front bumper assembly

2 Headlight Clip Section C – C

2 1 Front bumper assembly

2

B

A

2

1

A

1 B C

C

<>

Removal steps 1. Clips >>A<< 2. Radiator grilles

AC200008 AB

EXTERIOR

51-11

GARNISHES

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<> CLIPS REMOVAL

>>A<< RADIATOR GRILL INSTALLATION Install the radiator grill with the clips installed.

Section A – A Flat-tipped screwdriver Front bumper assembly

Clip Claw Radiator grill Radiator grill

A

A

A

A

AC201231AB

To remove the clips from the radiator grill gently pull forward the radiator grill, and use a flat-tipped screwdriver to hold the thumb of the clip in the direction of the arrow.

GARNISHES ADHESIVE M1511000500352

Application

Brand

Side sill garnish

Double-sided tape [5.0 mm width 0.8 mm thickness, 5.0 width 1.2mm thickness]


Tool

MB990784

Number

Name

Application

MB990784

Ornament remover

Removal of side sill garnish

EXTERIOR

51-12

GARNISHES

GARNISHES GARNISH REMOVAL AND INSTALLATION M1511004100088

Section A – A

Splash shield

Clip

1 Section B – B B

1

Clip

1 B

A

A

AC301940 AB

Removal steps Front deck garnish (Refer to 351). <> >>A<< 1. Side sill garnish

DOUBLE-SIDED TAPE AFFIXED LOCATION B

A

B Side sill garnish

AC107438AB AC107438

Double-sided tape: Generic products A : 5.0 mm width, 0.8 mm thickness, B : 5.0 mm width, 1.2 mm thickness

EXTERIOR

51-13

GARNISHES

REMOVAL SERVICE POINT <> SIDE SILL GARNISH REMOVAL Gently lift and remove the side sill garnish. If there is any double-sided tape remaining on the side sill garnish, remove according to the following instructions.

Double-sided tape

AC103187

Protection tape AC200049AB

1. Attach protection tape all the way along the edges of the double-sided tape which is still adhering to the body.

1. Scrape off the double-sided tape on the side sill garnish with a resin spatula as possible. 2. Wipe the side sill garnish surface and clean it with a rag moistened with isopropyl alcohol. 3. Remove only a small portion of the residual adhesive. 4. Adhere the double-sided tape as specified on the side sill garnish. (Refer to double-sided tape adherence location).

Double-sided tape

INSTALLATION SERVICE POINT >>A<< SIDE SILL GARNISH INSTALLATION. Backing paper

AC200050AB

2. Scrape off the double-sided tape with a resin spatula as possible. 3. Peel off the protection tape. 4. Wipe the body surface and clean it with a rag moistened with isopropyl alcohol.

Adhesive tape AC103247 AC

1. Tear off the double-sided tape backing paper. NOTE: If you attach the adhesive tape to the edge of the backing paper, it will be easy to tear off. 2. Install the side sill garnish. NOTE: If the double-sided tape is difficult to affix in cold temperature, etc., warm the bonding surfaces of the body and side sill garnish to about 40 - 60C before affixing the tape. 3. Firmly press in the side sill garnish.

EXTERIOR

51-14

MOULDINGS

MOULDINGS SPECIAL TOOL M1511000601006

Tool

Number

Name

Application

MB990449

Window moulding remover Removal of drip moulding

MB990449

MOULDINGS REMOVAL AND INSTALLATION M1511004700132

Section A – A C

1

1, 2 3

C

Clip

C Section B – B

B

A

B

C

2

1, 2

B A Clip A

B Section C – C

1, 3

A

Clip

AC301945 AB

Roof drip moulding removal steps <> >>A<< 1. Roof drip moulding

Roof drip moulding removal steps Roof rail (Refer to 351). <> >>A<< 2. Front roof drip moulding <> >>A<< 3. Centre roof drip moulding

EXTERIOR MOULDINGS

51-15



<> ROOF DRIP MOULDING REMOVAL

>>A<< ROOF DRIP MOULDING INSTALLATION Install the clips to the roof drip moulding before installing the moulding to the vehicle body.

CAUTION If the moulding has become warped, it should not be reused.

MB990449

AC003626 AB

Use special tool MB990449 to pry out the moulding.

EXTERIOR

51-16

TAILGATE SPOILER

TAILGATE SPOILER SPECIAL TOOL M1511000601017

Tool

Number

Name

Application

MB990784

Ornament remover

Removal of tailgate spoiler

MB990784

TAILGATE SPOILER REMOVAL AND INSTALLATION M1511020800043

Section A – A

3

1

Clip

A

5.1 ± 0.2 N·m

A

2 3

5.1 ± 0.2 N·m

Removal steps Tailgate upper trim (Refer to GROUP 52A, Tailgate trim 352A). High-mounted stop lamp connector connection

AC103231 AC

Removal steps&RQWLQXHG Rear washer hose connection 1. Tailgate spoiler assembly 2. High-mounted stop lamp assembly 3. Tailgate spoiler

EXTERIOR

51-17

ROOF RAIL

ROOF RAIL REMOVAL AND INSTALLATION M1511016600165

3

2 4

1

8.5 ± 1.5 N·m

8.5 ± 1.5 N·m

6 5

5.0 ± 1.0 N·m 5.0 ± 1.0 N·m AC300386 AB

F F C C

B

F F

2

3

C C

B

A B

A

B

D

D E

E

NOTE : Claw positions

Section A – A

Section B – B

Section C – C

1 Claw

1 Claw

1

Claw

Claw Claw

4 4

4 Section D – D

Section E – E

Section F – F Claw

Claw

2

4 Claw

2

4 Claw

2

4

EXTERIOR

51-18

UNDER COVER Removal steps&RQWLQXHG 4. Roof rail 5. Front roof rail bracket 6. Centre roof rail bracket

Removal steps 1. Front roof rail cover 2. Centre roof rail cover 3. Rear roof rail cover

UNDER COVER REMOVAL AND INSTALLATION M1511019600108

Splash shield

5

4 3

2

Splash shield

Front bumper assembly

1

AC107344 AB

1 Removal steps 1. Front bumper assembly mounting clips 2. Front under cover (LH)

Removal steps&RQWLQXHG 3. Front under cover (RH) 4. Side under cover (LH) 5. Side under cover (RH)

EXTERIOR

51-19


WINDSHIELD WIPER AND WASHER SERVICE SPECIFICATION M1511000300295

Item

Standard value

Stop position of the windshield wiper arm/blade assembly (Distance between the edge of the wiper blade and the end of the deck garnish) mm

25 5


The windshield wiper and washer are controlled by the smart wiring system (SWS). For troubleshooting, refer to GROUP 54B, SWS Diagnosis 354B.

NOTE: Even when the ETACS-ECU has failed, the windshield wiper can work at low speed in fail-safe mode. (Normally, the windshield wiper operates when the ignition switch is at the "ACC" or "ON" position. But, if it enters the fail-safe mode, the wiper can operate only when the ignition switch is at the "ON" position).

EXTERIOR

51-20


WINDSHIELD WIPER REMOVAL AND INSTALLATION M1511007900124

Section B – B

View A

Windshield

6

B

Claw

C

B

Section C – C


6

4

C

: Claw position

Clip Section D – D

5

6

2 4

Claw

1 3 27 ± 2 N·m

A

D D

6

5

7.4 ± 1.4 N·m

8 9

7

AC107419AB

Wiper blade removal steps 1. Wiper blade assembly >>B<< 2. Wiper blade

Windshield wiper motor and link assembly removal steps >>A<< 3. Wiper arm and blade assembly 4. Hood weather strip

EXTERIOR

51-21

WINDSHIELD WIPER AND WASHER Windshield wiper motor and link assembly removal steps&RQWLQXHG 5. Roof drip moulding and front deck garnish connection 6. Front deck garnish 7. Windshield wiper motor and link assembly 8. Link assembly 9. Windshield wiper motor assembly

>>B<< WIPER BLADE ASSEMBLY INSTALLATION

A

A

NOTE: For removal and installation of the wiper and washer switch, refer to GROUP 54A, Column switch 354A.

INSTALLATION SERVICE POINTS >>A<< WIPER BLADE INSTALLATION

CAUTION

Front deck garnish terminal AC000427AD

Install the wiper blade at the specified position (standard value). Standard value: (A) 25 5 mm


Backing A Wiper blade

A

Backing

Section A – A

WINDSHIELD WIPER MOTOR CHECK Inspect the windshield wiper motor by removing the harness connector with the motor attached to the vehicle. Wiper motor at low-speed and high-speed operation

Wiper blade 1 2 3 4 5

Backing Backing A Wiper blade A

Backing

AC103612 AC

For good windshield wiper wiping performance, use a passenger-side windshield wiper without an curve in the backing of the wiper blade. The windshield wiper on the driver’s side should be a wiper blade with a curved backing.

Check operation 1 2 3 4 5

High speed

1 2 3 4 5

Low speed

AC200893 AB

Connect the battery to the windshield wiper motor to inspect the operation of motor rotation in low or high speed.

EXTERIOR

51-22


Wiper motor at stop position operation

1 2 3 4 5

Stop position check 1 2 3 4 5

Switch position

Tester connection

Specified condition

OFF

6 - 11, 6 - 10, Open circuit 6 - 9, 6 - 8


6 - 11

Less than 2 ohms


6 - 10

Less than 2 ohms

Windshield lowspeed wiper switch

6-9

Less than 2 ohms

Windshield highspeed wiper switch

6-8

Less than 2 ohms

WINDSHIELD INTERMITTENT WIPER VOLUME CHECK

(A) Low speed

1 2 3 4 5

(B) Automatical stop

AC200895 AB

1. Connect the battery to the windshield wiper motor as shown in the illustration (A). 2. Run the windshield wiper motor at low speed, then disconnect the battery in the middle of the motor turning and check to see that the motor stops. 3. As shown in the illustration (B), connect the terminals of the windshield wiper motor connectors. 4. Check to see that the windshield wiper motor runs at low speed and then stops at the automatic stop position. WINDSHIELD WIPER SWITCH CHECK 1 2 3 4 5 6 7 8 9 10 11

1 2 3 4 5 6 7 8 9 10 11

AC201004

Check that the resistance varies between 0 and 1 when the windshield intermittent volume is turned from FAST to SLOW by after measuring resistance between connector terminals 3 and 6 at the column switch.

AC000417

Check continuity between the switch terminals.

EXTERIOR

51-23


WINDSHIELD WASHER REMOVAL AND INSTALLATION M1511008200236

Section A – A

1

2

Claw Claw

3 1 2 A A

3

5.0 ± 1.0 N·m

6

7

5

4

AC200400AB

Windshield washer nozzle removal steps Connection of windshield washer hose 1. Windshield washer nozzle Washer hose removal steps 2. Front splash shield (LH) mounting clip Connection of windshield washer nozzle 3. Windshield washer hose

Washer tank removal steps Front under cover (RH) (Refer to 351). 2. Front splash shield (RH) mounting clip Connection of front washer hose and rear washer hose 4. Washer tank assembly 5. Windshield washer motor Head lamp washer motor (Refer to 351). 6. Rear washer motor 7. Washer tank

EXTERIOR

51-24

WINDSHIELD WIPER AND WASHER Washer motor removal steps Front under cover (LH) (Refer to 351). Connection of front washer hose and rear washer hose 5. Windshield washer motor 6. Rear washer motor

1 2

NOTE: For removal and installation of the wiper and washer switch, refer to GROUP 54A, Column switch 354A. AC107604AC


WINDSHIELD WASHER MOTOR CHECK

1. Remove the washer tank assembly with the washer hose attached. Then fill the washer tank with water. 2. Check to see that the water is vigorously sprayed when connecting the positive battery terminal to terminal number 2 and terminal number 1 to the negative battery terminal.

WINDSHIELD WASHER FLUID EJECTION CHECK Move the nozzle to adjust the position so that the spray is in the area shown in the illustration. Units: mm

Windshield washer nozzle perpendicular

Windshield washer nozzle perpendicular 50

50

120

120

50 50 70

285

310

60

130

120

Windshield ceramic line terminal 70 90

120

110

600

Windshield washer nozzle

AC107158 AC

EXTERIOR

51-25


WINDSHIELD WASHER SWITCH CHECK 1 2 3 4 5 6 7 8 9 10 11

Switch position

Tester connection

Specified condition

OFF

6-7

Open circuit


6-7

Less than 2 ohms

AC000417


REAR WIPER AND WASHER SERVICE SPECIFICATION M1511000300303

Item

Standard value

Rear wiper arm and blade assembly stop position (Distance from end wiper blade and the end of tailgate galss) mm

30 5

ON-VEHICLE SERVICE


The rear wiper and washer are controlled by the smart wiring system (SWS). For troubleshooting, refer to GROUP 54B, SWS Diagnosis 354B.

CHECK OF REAR WIPER OPERATION WHEN SELECTOR LEVER IS AT THE "R" POSITION M1511022100039

1. When the selector lever is moved to the "R" position with the rear wiper switch at the "INT" position, the wiper should operate twice or three times at low speed after approximately one second. 2. If not, troubleshoot the system (Refer to GROUP 54B, Diagnosis 354B).

EXTERIOR

51-26


REAR WIPER AND WASHER REMOVAL AND INSTALLATION M1511008500141

Pre-removal and Post-installation Operation Washer Tank Assembly and Rear Washer Motor Removal and Installation (Refer to 351).

6 5

3 1 2

4

5.4 ± 1.4 N·m

7.4 ± 1.4 N·m AC300618 AB

Wiper blade assembly removal steps 1. Wiper blade assembly >>B<< 2. Wiper blade Rear wiper motor removal steps >>A<< 3. Wiper arm and blade assembly Tailgate lower trim (Refer to GROUP 52A, Tailgate trim 352A). Tailgate waterproof film (Refer to GROUP 42, Tailgate 342). 4. Rear wiper motor assembly Rear washer nozzle removal steps High-mounted stop lamp assembly (Refer to GROUP 54A, High-mounted stop lamp 354A). 5. Rear washer nozzle

Washer hose removal steps Cowl side trim, front scuff plate, centre pillar trim lower, rear scuff plate, rear pillar trim and rear shelf trim (Refer to GROUP 52A, Trims 352A). Tailgate lower trim, tailgate side trim, tailgate upper trim (Refer to GROUP 52A, Tailgate trim 352A). High-mounted stop lamp assembly (Refer to GROUP 54A, High-mounted stop lamp 354A). 6. Rear washer hose

NOTE: For removal and installation of the wiper and washer switch, refer to GROUP 54A, Column switch 354A.

EXTERIOR

51-27



INSPECTION

>>A<< REAR WIPER ARM AND BLADE ASSEMBLY INSTALLATION

REAR WIPER MOTOR CHECK

M1511008600171

End of tailgate galss A

1 AC100519 AC

Before installing the rear wiper arm and blade assembly, operate the rear wiper motor so that the motor stops at the predetermined park position. Install the rear wipe arm and blade assembly and adjust the rear wiper blade position so that the blade end stops at the predetermined position (standard position). Standard value: (A) 30 5 mm >>B<< WIPER BLADE INSTALLATION

CAUTION Backing

Section A – A

Wiper blade Wiper blade

Backing

2

3

4

(A) Operation check 1 2 3 4

(B) Stop position check

1 2 3 4

AC103246 AC

Inspect the rear wiper motor by removing the harness connector with the motor attached to the vehicle. Wiper motor operation Connect the battery to the rear wiper motor as shown in the illustration (A) and check the motor operation.

A A Backing

AC101090AD

Use a curved backing like that shown for the backing of a wiper blade to ensure sustained wiper wiping performance.

Wiper motor at stop position operation 1. Connect the battery to the rear wiper motor as shown in the illustration (A). 2. Disconnect the battery cable from the rear windshield wiper motor while it is turning and then check to see that the motor stops. 3. Re-connect the battery as shown in Figure (B). 4. Check to see that the rear windshield wiper motor runs and then stops at the automatic stop position.

EXTERIOR

51-28


REAR WASHER MOTOR CHECK

2. Check to see that the water is vigorously sprayed when connecting the positive battery terminal to terminal number 2 and terminal number 1 to the negative battery terminal.

1 2

AC107605 AC

1. Remove the rear washer tank assembly with the washer hose attached. Then fill the washer tank with water. REAR WASHER FLUID EJECTION CHECK Move the nozzle to adjust the position so that the spray is in the area shown in the illustration.

Rear washer nozzle

Rear washer nozzle perpendicular

Units: mm

25 Ceramic line terminal

130 210

50 30 50 25

AC100520 AC

EXTERIOR

51-29

WIPER DEICER

REAR WIPER AND WASHER SWITCH CHECK 1 2 3 4 5 6 7 8 9 10 11

Switch position

Tester connection

Specified condition

OFF

4 - 6, 5 - 6

Open circuit

Rear wiper switch 4 - 6

Less than 2 ohms

Rear washer switch

Less than 2 ohms

5-6

AC000417


WIPER DEICER GENERAL INFORMATION M1511000100495

Wiper Deicer operation The defogger relay switch is activated (ON) by turning on the A/C-ECU built-in defogger switch when the ignition switch is in the "ON" position. When the defogger relay is turned ON, power is supplied to the rear defogger and wiper deicer, and



the heater of the wiper deicer starts operations. The defogger comes with a timer function and will automatically turn OFF the switch approximately about 11 minutes or about 20 minutes after the defogger switch is turned ON. The wiper deicer operations are also terminated along with the rear defogger, at this time.

EXTERIOR

51-30

WIPER DEICER

SYMPTOM PROCEDURES INSPECTION PROCEDURE : Wiper Deicer Does not Operate

Wiper deicer Circuit

DEFOGGER RELAY

BATTERY

DEFOGGER

RELAY BOX

WIPER DEICER RELAY

WIPER DEICER


COMMENTS ON TROUBLE SYMPTOM The wiper deicer should work for approximately 11 minutes or 20 minutes when the rear defogger switch is turned on. If the wiper deicer does not work for the specified period, the defogger relay circuit and the power supply and/ or earth circuit to the wiper deicer may be defective.

The wiper deicer itself or its relay may be also defective. Possible causes Malfunction of the wiper deicer Malfunction of the wiper deicer relay Damaged harness wires and connectors

EXTERIOR

51-31

WIPER DEICER

DIAGNOSIS PROCEDURE STEP 1. Check the defogger. Check that the rear defogger works normally. Q: Is the check result normal? YES : Go to Step 2. NO : 7URXEOHVKRRWWKHUHDUGHIRJJHU5HIHUWR

*5283$-6\PSWRPFKDUW355ARU *5283%-7URXEOHV\PSWRPFKDUW 355B

STEP 3. Check the wiper deicer relay. Check that the wiper deicer relay works normally (Refer to wiper deicer relay check 351). Q: Is the check result normal? YES : Go to Step 4. NO : Replace the wiper deicer relay.

STEP 4. Connector check: B-32 wiper deicer connector Connector: B-32

B-32(B)

STEP 2. Connector check: A-08X wiper deicer relay connector

B-32 Harness side

2 1

Connector: A-08X

AC301521AE


STEP 5. Check the wiper deicer. Check that the wiper deicer works normally (Refer to wiper deicer check 351).

Relay box side

2

1

4

3

Q: Is the check result normal? YES : Go to Step 6. NO : Replace the wiper deicer.

Front of vehicle

AC301483AH


EXTERIOR

51-32

WIPER DEICER

STEP 6. Measure the resistance at the A-08X wiper deicer relay connector. Connector: A-08X

STEP 7. Check the wiring harness between A-08X wiper deicer relay connector terminal No.3 and body earth. Connector: A-08X

Relay box side

2

1

4

3

Relay box side

Front of vehicle

2

1

4

3

Front of vehicle AC301483AH


AC301483AH


2

1

4

3

Connector A-08X (relay box side)


AC301834 AB

(2) Resistance between A-08X wiper deicer relay connector terminal No.3 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 7.

EXTERIOR

51-33

WIPER DEICER

STEP 8. Measure the voltage at the A-08X wiper deicer relay connector. (1) Turn the ignition switch to the ON position. (2) Defogger switch: ON

STEP 9. Connector check: C-205 junction block connector Connector: C-205 Junction block (Front view)

Connector: A-08X

Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE

Q: Is the check result normal? YES : Go to Step 10. NO : Repair the defective connector. Relay box side

2

1

4

3

Front of vehicle

AC301483AH


2

1

4

3


AC301835 AB

(4) Voltage between A-08X wiper deicer relay connector terminal No.2 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 11. NO : Go to Step 9.

EXTERIOR

51-34

WIPER DEICER

STEP 10. Check the wiring harness between A08X wiper deicer relay connector terminal No.2 and C-205 junction block connector terminal No.3.


Connector: A-08X

C-116

1 2 Relay box side

5 6 7

3 4

10 11 12 13 14

15

8 9

1617 18 1920 21

2

1

22 23 24 25 26

27 28 29

30 31 32 33

4

3

34 35 36 37

38 39 40

41 4243

Front of vehicle

AC301396 AB

AC301483AH


Prior to the wiring harness inspection, check intermediate connector C-116, and repair if necessary. Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE

Check the power supply line for open circuit.

EXTERIOR

51-35

WIPER DEICER

STEP 11. Measure the voltage at B-32 wiper deicer connector. (1) Turn the ignition switch to the ON position. (2) Defogger switch: ON Connector: B-32

B-32(B)

STEP 12. Measure the voltage at the A-08X wiper deicer relay connector. Connector: A-08X

B-32 Harness side

2 1

AC301521AE


Relay box side

2

1

4

3

Front of vehicle

2 1 Connector B-32 (haness side)

AC301483AH

(1) Disconnect the connector, and measure at the relay box side. AC301837AB

(4) Voltage between B-32 wiper deicer connector terminal No.2 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 15. NO : Go to Step 12.

2

1

4

3


AC301836 AB

(2) Voltage between A-08X wiper deicer relay connector terminal No.1 and body earth OK: System voltage Q: Is the check result normal? YES : Go to Step 14. NO : Go to Step 13.

EXTERIOR

51-36

WIPER DEICER

STEP 13. Check the wiring harness between A08X wiper deicer relay connector terminal No.2 and the battery. Connector: A-08X

Relay box side

2

1

4

3

Front of vehicle

AC301483AH



EXTERIOR

51-37

WIPER DEICER

STEP 14. Check the wiring harness between A08X wiper deicer relay connector terminal No.4 and B-32 wiper deicer connector terminal No.2.


Connector: A-08X

C-106(GR)

2 1 3 4 5 6 7 8 9 10 11 12 16 13 14 15 17 18 19

AC301397AG

Connector: C-116

Relay box side

2

1

4

3

Front of vehicle

AC301483AH

Connector: B-32

B-32(B)

C-116 B-32 Harness side

2 1

1 2

5 6 7

3 4

8 9

10 11 12 13 14

15

22 23 24 25 26

27 28 29

30 31 32 33

34 35 36 37

38 39 40

41 4243

1617 18 1920 21

AC301396 AB AC301521AE

Check the power supply line for open circuit.

Prior to the wiring harness inspection, check intermediate connectors C-106 and C-116, and repair if necessary. Q: Is the check result normal? YES : The trouble can be an intermittent


EXTERIOR

51-38

WIPER DEICER

STEP 15. Measure the resistance at B-32 wiper deicer connector. Connector: B-32

B-32(B)

B-32 Harness side

2 1

STEP 16. Check the wiring harness between B-32 wiper deicer connector terminal No.1 and body earth. Connector: B-32

B-32(B)

B-32 Harness side

2 1

AC301521AE


AC301521AE

Check the earth wires for open circuit. NOTE: Connector: C-17

4 5 1 2 3 6 7 8 9 10 1112 13

2 1 Connector B-32 (haness side)

AC301838AB

(2) Resistance between B-32 wiper deicer connector terminal No.1 and body earth OK: 2 W or less Q: Is the check result normal? YES : The trouble can be an intermittent

malfunction (Refer to GROUP 00 - How to Cope with Intermittent Malfunction 300). NO : Go to Step 16.

C-17(GR) AC301397AE

Prior to the wiring harness inspection, check joint connector C-17, and repair if necessary. Q: Is the check result normal? YES : The trouble can be an intermittent


EXTERIOR

51-39

HEADLAMP WASHER

WIPER DEICER

WIPER DEICER RELAY CHECK

INSPECTION

Wiper deicer relay M1511019100396

WIPER DEICER CHECK Windshield

1

2

AC211776

Windshield wiper motor AC301953 AB

There should be continuity between the wiper deicer connector terminal Nos.1 and 2.

1 2

1

3 4

2

4 3

AC301954 AB

Battery voltage

Terminal number to be connected to tester

Continuity test results

Not applied

1-4

Open circuit

Connect terminal No.3 and battery (-) terminal. Connect terminal No.2 and battery (+) terminal.

1-4

Less than 2 ohms

HEADLAMP WASHER TROUBLESHOOTING M1511000700293

The headlamp washer is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to GROUP 54B, Troubleshooting 354B.

EXTERIOR

51-40

HEADLAMP WASHER

HEADLAMP WASHER REMOVAL AND INSTALLATION M1511009700041

Pre-removal and Post-installation Operation Radiator Grille Removal and Installation (Refer to 351 ). Front Bumper Extension Removal and Installation (Refer to 351). Under Cover Removal and Installation (Refer to 351).

2

1 13

15 14

7 3

8

6

N 10

8 10 N

5 9

9

4 11 12

12 11

AC300298 AB

Removal steps Washer fluid draining 1. Headlamp washer hose connection 2. Headlamp washer motor connector 3. Headlamp washer hose 4. Headlamp washer joint 5. Headlamp washer hose 6. Headlamp washer motor 7. Headlamp washer motor packing Front bumper (Refer to 351).

Removal steps&RQWLQXHG 8. Headlamp washer cover 9. Headlamp washer nozzle 10. O-ring 11. Headlamp washer actuator assembly 12. Headlamp washer hose 13. Headlamp washer joint 14. Headlamp washer hose 15. Headlamp washer joint

EXTERIOR

51-41

MARK


HEADLAMP WASHER MOTOR CHECK

2. Check to see that the water is vigorously sprayed when connecting the positive battery terminal to terminal number 1 and terminal number 2 to the negative battery terminal.

1 2

AC300406 AB

1. Remove the headlamp washer motor connector.

MARK REMOVAL AND INSTALLATION M1511011800391

2 1

3

AC300472 AC

1. Front three-diamond mark

>>A<< 2. Rear three-diamond mark >>A<< 3. Outlander mark and 4WD mark

EXTERIOR

51-42

MARK

INSTALLATION SERVICE POINT >>A<< ATTACHMENT OF EACH POINT

ATTACHED POSITION OUTLANDER mark and 4WD nark

Units: mm

Tailgate panel end line 50

AC301886 AB

Three-diamond mark Units: mm

66 ± 1

Press line

Center line of vehicle

AC200088 AB

1. Remove grease on the marked surface of the body with unleaded gasoline. 2. Peel off the protection sheet on the back of the mark to paste it on the installation position.

CAUTION Carry out this work in a location which has an ambient temperature of 20 - 38C and which is free from dust. If ambient temperature is lower than 20C, heat the mark and the vehicle body (application location) to 20 - 30C. Be sure to pressure the mark immediately after the pasting is done.

EXTERIOR

51-43

DOOR MIRROR

DOOR MIRROR GENERAL INFORMATION M1511000100503

Remote Controlled Mirror Operation The mirror on the door mirror moves up/down and left/right by operating the remote controlled door mirror switch when the ignition switch is in the "ON" or "ACC" position. Heated Door Mirror operation The defogger relay switch is activated (ON) by turning on the A/C-ECU built-in defogger switch when the ignition switch is in the "ON" position. When the defogger relay is turned ON, power is supplied to the defogger and door mirror, and the heater of the door mirror (heated door mirror) starts

operations. The defogger comes with a timer function and will automatically turn OFF the switch approximately about 11 minutes or about 20 minutes after the defogger switch is turned ON. The heated door mirror operations are also terminated along with the defogger, at this time.




SYMPTOM

INSPECTION REFERENCE PROCEDURE PAGE

All heated door mirrors do not operate

1

351

The right or left heated door mirror does not operate

2

351

EXTERIOR

51-44

DOOR MIRROR

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: All Heated Door Mirrors do not Operate

Heated door mirror Circuit

DEFOGGER RELAY

DEFOGGER

REMOTE CONTROLLED MIRROR (LH)

MIRROR HEATER

MIRROR HEATER

REMOTE CONTROLLED MIRROR (RH)


COMMENTS ON TROUBLE SYMPTOM The heated door mirrors should work for approximately 11 minutes or 20 minutes when the rear defogger switch is turned on. If the mirror heater does not work for the specified period, the defogger relay circuit (heated door mirror power supply circuit) may be defective.

SB : Sky blue

Possible causes Damaged harness wires and connectors

EXTERIOR

51-45

DOOR MIRROR

DIAGNOSIS PROCEDURE STEP 1. Check the defogger. Check that the rear defogger system should work normally.


Q: Is the check result normal? YES : Go to Step 2. NO : Troubleshoot the rear defogger (Refer to

GROUP 55A - Trouble symptom chart 355A or GROUP 55B - Trouble symptom chart 355B).

Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE


00 - How to Cope with Intermittent Malfunction 300). NO : Repair the defective connector.

EXTERIOR

51-46

DOOR MIRROR

INSPECTION PROCEDURE 2: Right or Left Heated Door Mirror does not Operate

Heated door mirror Circuit

DEFOGGER RELAY

DEFOGGER

REMOTE CONTROLLED MIRROR (LH)

MIRROR HEATER

MIRROR HEATER

REMOTE CONTROLLED MIRROR (RH)


COMMENTS ON TROUBLE SYMPTOM If either of the heated door mirrors does not work, the door mirror assembly may be defective. Possible causes Malfunction of the door mirror assembly Damaged harness wires and connectors

DIAGNOSIS PROCEDURE STEP 1. Verify the operation of each heated door mirror. Q: Which door mirror does not heat? Door mirror (RH) : Go to Step 2. Door mirror (LH) : Go to Step 9.

SB : Sky blue

STEP 2. Check the door mirror assembly (RH). Check that the heater element of the door mirror assembly (RH) is in good condition (Refer to the heated door mirror check 351). Q: Is the check result normal? YES : Go to Step 3. NO : Replace the door mirror assembly (RH).

EXTERIOR

51-47

DOOR MIRROR

STEP 3. Connector check: E-16 door mirror assembly (RH) connector Connector: E-16

STEP 5. Check the wiring harness between E-16 door mirror assembly (LH) connector terminal No.2 and body earth. Connector: E-16

E-16 Harness side

2 1 7 6 5 4 3

E-16 Harness side AC301412 AE


2 1 7 6 5 4 3

AC301412 AE


STEP 4. Measure the resistance at the E-16 door mirror assembly (RH) connector. Connector: E-16

E-16 Harness side

2 1 7 6 5 4 3

C-15(GR)

AC301412 AE


C-15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

AC301398 AC

Prior to the wiring harness inspection, check intermediate connector C-15, and repair if necessary.

2 1 7 6 5 4 3


Connector E-16 (harness side) AC301694 AC

(2) Resistance between E-16 door mirror assembly connector terminal No.2 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.

00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness.

EXTERIOR

51-48

DOOR MIRROR

STEP 6. Measure the voltage at the E-16 door mirror assembly (RH) connector. (1) Turn the ignition switch to the ON position. (2) Defogger switch: ON

STEP 8. Check the wiring harness between E-16 door mirror assembly (RH) connector terminal No.1 and C-205 junction block connector terminal No.3.

Connector: E-16

Connector: E-16

E-16 Harness side

E-16 Harness side

2 1 7 6 5 4 3

2 1 7 6 5 4 3

AC301412 AE


AC301412 AE


Harness side

2 1 7 6 5 4 3

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE

Connector E-16 (harness side) AC301695 AB

(4) Voltage between E-16 door mirror assembly connector terminal No.1 and body earth OK: System voltage

Check the power supply line for open circuit. NOTE: Connector: C-15


00 - How to Cope with Intermittent Malfunction 300). NO : Go to Step 7. STEP 7. Connector check: C-205 junction block connector Connector: C-205 Junction block (Front view)

C-15(GR)

C-15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE


AC301398 AC


EXTERIOR

51-49

DOOR MIRROR Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Cope with Intermittent Malfunction 300). NO : Repair the wiring harness. STEP 9. Connector check: E-06 door mirror assembly (LH) connector Connector: E-06

STEP 11. Measure the resistance at the E-06 door mirror assembly (LH) connector. Connector: E-06

E-06 Harness side

2 1 7 6 5 4 3 AC301418 AE


E-06 Harness side

2 1 7 6 5 4 3 AC301418 AE


STEP 10. Check the door mirror assembly (LH). Check that the heater element of the door mirror assembly (LH) is in good condition (Refer to the heated door mirror check 351). Q: Is the check result normal? YES : Go to Step 11. NO : Replace the door mirror assembly (LH).

2 1 7 6 5 4 3 Connector E-06 (harness side) AC301694 AB

(2) Resistance between E-06 door mirror assembly connector terminal No.2 and body earth OK: 2 W or less Q: Is the check result normal? YES : Go to Step 14. NO : Go to Step 12.

EXTERIOR

51-50

DOOR MIRROR

STEP 12. Check the wiring harness between E-06 door mirror assembly (LH) connector terminal No.4 and body earth. Connector: E-06


E-06 Harness side

Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1

2 1 7 6 5 4 3

28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE AC301418 AE



STEP 14. Measure the voltage at the E-06 door mirror assembly (LH) connector. (1) Turn the ignition switch to the ON position. (2) Defogger switch: ON Connector: E-06

E-06 Harness side

C-118

2 1 7 6 5 4 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32

AC301418 AE


AC301396 AE

Prior to the wiring harness inspection, check intermediate connector C-118, and repair if necessary. Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP


2 1 7 6 5 4 3 Connector E-06 (harness side) AC301695 AC

(4) Voltage between E-06 door mirror assembly connector terminal No.1 and body earth OK: System voltage Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP

00 - How to Cope with Intermittent Malfunction 300). NO : Go to Step 15.

EXTERIOR DOOR MIRROR

STEP 15. Check the wiring harness between E-06 door mirror assembly (LH) connector terminal No.1 and C-205 junction block connector terminal No.3. Connector: E-06

E-06 Harness side

2 1 7 6 5 4 3 AC301418 AE


Harness side 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC210474 AE

Check the power supply line for open circuit. NOTE: Connector: C-118

C-118

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32 AC301396 AE


51-51



EXTERIOR

51-52

DOOR MIRROR

DOOR MIRROR REMOVAL AND INSTALLATION M1511006700053

Section A – A

Section B – B

1 7

Claw

Claw

Clip

3 6 4

A

1

3 5

B B A

2

AC201696 AB

Door mirror removal steps 1. Delta cover 2. Tweeter >>A<< 3. Door mirror assembly 4. Door mirror body assembly <> 5. Mirror

Remote controlled mirror switch removal steps 6. Instrument panel lower cover (Refer to GROUP 52A, Instrument panel 352A). 7. Remote controlled mirror switch

EXTERIOR

51-53

DOOR MIRROR



<> MIRROR REMOVAL

>>A<< DELTA COVER INSTALLATION

CAUTION

CAUTION Section A – A Pivot plate

A

Mirror

Clip Flat-tipped screwdriver

Claw

Flat-tipped screwdriver

Mirror

A Delta cover Section A – A

A

Delta cover A

Clip

Protective tape

Door panel Notch

AC107642 AB

If the delta cover is placed with the clip on the door panel, the clip may be pushed into the door panel and fall off. Thus, special care is necessary. Install the delta cover with the clip installed.

Claw Claw AC103244 AC

The thumb of the mirror is prone to breakage when working in cold temperatures. Always warm up the mirror thumb and thumb periphery to 20C or higher before handling. Slant the mirror upward with your hands. Then insert a flat-tipped screwdriver wrapped with protective tape between the pivot plate and mirror through the cut-out from behind the mirror. Now pry off the mirror thumb and remove the mirror as shown.

EXTERIOR

51-54

DOOR MIRROR

INSPECTION

>>B<< DOOR MIRROR ASSEMBLY INSTALLATION

M1511006800050

ELECTRIC REMOTE CONTROL MIRROR OPERATION CHECK

CAUTION Section A – A

Door panel

Runchannel

Door mirror claw position

Notch

Door mirror Door mirror claw position

Runchannel

Check that the mirror moves as described in the table when each terminal is connected to the battery.

A

A

AC103753 AC

When assembling the door mirror, check to see that the thumb of the door mirror is inserted in the cut-out of the front door run channel.

Battery connection

Direction operation

Connect terminal 5 to the negative battery terminal. Connect terminal 7 to the positive battery terminal.

Up

Connect terminal 5 to the positive battery terminal. Connect terminal 7 to the negative battery terminal.

Down

Connect terminal 5 to the negative battery terminal. Connect terminal 6 to the positive battery terminal.

Right

Connect terminal 5 to the positive battery terminal. Connect terminal 6 to the negative battery terminal.

Left

EXTERIOR

51-55

DOOR MIRROR

DOOR MIRROR CONTROL SWITCH CONTINUITY CHECK

HEATED DOOR MIRROR CHECK

CAUTION When relocating the car between locations with extremely different temperatures (warm and cold), leave the car in the location for a while to adapt to the temperature prior to checking it.

3 4 1 2 5 6 7 8 9 10 11

AC005970

Switch position

Tester connection

OFF

9 - 2, 9 - 3, 9 - 6, Open circuit 9 - 10, 9 - 11, 1 - 2, 1 - 3, 1 - 6, 1 - 10, 1 - 11

Left side OFF

Up

Right side

Specified condition

9 - 6, 9 - 10, 9 - 11, 1 - 6, 1 - 10, 1 - 11

Open circuit

1 - 6, 9 - 11

Less than 2 ohms

Resistance (Ω) 12 10 8 6 4 2 0 -10

Down

1 - 11, 6 - 9

Less than 2 ohms

Right

1 - 6, 9 - 10

Less than 2 ohms

Left

1 - 10, 6 - 9

Less than 2 ohms

OFF

9 - 2, 9 - 3, 9 - 6, Open circuit 1 - 2, 1 - 3, 1 - 6

Up

1 - 6, 3 - 9

Less than 2 ohms

Down

1 - 3, 6 - 9

Less than 2 ohms

Right

1 - 6, 2 - 9

Less than 2 ohms

Left

1 - 2, 6 - 9

Less than 2 ohms

Upper limit value

Lower limit value 0 10 20 Temperature (˚C)

30

40

AC201611 AC

Check to see that the resistance shown in the graph is almost satisfied when measuring the resistance of terminal 1 and 2 of the door mirror connectors under 2 or more different temperature conditions.

127(6

Airtrek Workshop Manual

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