1 Mitsubishi Lancer Evo IX.

15-1
GROUP 15
INTAKE AND EXHAUST

CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . SPECIAL TOOL . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .
TURBOCHARGER SUPERCHARGING PRESSURE CHECK. . . . . . . . . . . . . . . . . . SUPERCHARGING PRESSURE CONTROL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . WASTE GATE ACTUATOR CHECK . . . . . WASTE GATE SOLENOID VALVE CHECK AIR BY-PASS VALVE CHECK . . . . . . . . . . INLET MANIFOLD VACUUM CHECK . . . .
15-2 15-2 15-2 15-2

15-2 15-3 15-3 15-4 15-4 15-4
REMOVAL AND INSTALLATION . . . . . . . .
15-5
INTERCOOLER . . . . . . . . . . . . . . . . .
15-6
15-6
INLET MANIFOLD . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
15-7
15-7 15-9
EXHAUST MANIFOLD AND TURBOCHARGER . . . . . . . . . . . . . . .

15-10
15-10 15-12
EXHAUST PIPE AND MAIN MUFFLER 15-13

REMOVAL AND INSTALLATION . . . . . . . . 15-13
AIR CLEANER . . . . . . . . . . . . . . . . . .
15-5
15-2
INTAKE AND EXHAUST

GENERAL INFORMATION
GENERAL INFORMATION
M1151000100480
SUPERCHARGING PRESSURE CONTROL

By controlling the duty of the waste gate solenoid valve, the waste gate actuator functions to control the supercharging pressure. This allows a supercharged pressure matching the engine operation state to be attained. Control is carried out to prevent excessive supercharging and thereby prevent engine damage.
SERVICE SPECIFICATIONS
M1151000300699
Item Turbocharger supercharging pressure (waste gate solenoid valve not operating) kPa Initial activation pressure of waste gate actuator (at the stroke of approximately 1 mm) kPa Waste gate solenoid valve coil resistance (at 20C) Initial activation pressure of air bypass valve kPa Manifold distortion of the installation surface mm
Standard value 96 121
Limit
Approximately 100 29 35 Approximately 59 0.15 or less 0.20
SPECIAL TOOL
M1151000600463
Tool
Number MD998770
Name Oxygen sensor wrench
Use Removal and installation of oxygen sensor
ON-VEHICLE SERVICE
TURBOCHARGER SUPERCHARGING PRESSURE CHECK
M1151001000282
Plug Vacuum terminal
CAUTION Two persons should be in the vehicle when the test is conducted; the person in the passenger seat should read the indications shown by the pressure meter.
Waste gate actuator
AK305234 AB
INTAKE AND EXHAUST

ON-VEHICLE SERVICE
15-3
1. Disconnect the hose (black) from the vacuum terminal, and connect the plug to the hose. Connect a pressure gauge to the vacuum terminal nipple. 2. Drive at full-throttle acceleration in second gear and then measure the supercharging pressure when the engine speed in about 3,000 r/min. Standard value: 96 121 kPa 3. If the supercharging pressure deviates from the standard value, check the following items for possible cause. Malfunction of the waste gate actuator Leakage of supercharging pressure Malfunction of the turbocharger 4. When the indicated supercharging is more than standard value, supercharging control may be faulty, therefore check the followings. Malfunction of the waste gate actuator Malfunction of waste gate valve Disconnection or cracks of the waste gate actuator rubber hose
4. Applying a negative pressure with the hand vacuum pump, check tightness both when the hose end is closed and when it is open. Engine state Hose end Normal state Negative pressure leaks. Negative pressure is maintained. Negative pressure leaks. Stop Opened (Ignition switch: ON) Closed
Idling (after warm-up)
NOTE: If this check indicates an abnormal condition, the turbocharger waste gate actuator, turbocharger waste gate solenoid or hose is broken.
WASTE GATE ACTUATOR CHECK

M1151001200178
SUPERCHARGING PRESSURE CONTROL SYSTEM CHECK

M1151001100160
Vacuum terminal Boost hose
Three-way joint
AK200367
1. Connect a manual pump (pressure-application type) to nipple.
Waste gate actuator
AK305236 AB
1. Disconnect the hose (black) from the vacuum terminal, and connect a three-way joint between the hose and the vacuum terminal. 2. Connect a hand vacuum pump to the three-way joint. 3. Disconnect the hose from the turbocharger waste gate actuator control boost nipple and plug the nipple.
CAUTION In order to avoid damage to the diaphragm, do not apply a pressure of 117 kPa or higher. 2. While gradually applying pressure, check the pressure that begins to activate (approximately 1 mm stroke) the waste gate actuator rod. Standard value: Approximately 100 kPa
3. If there is a significant deviation from the standard value, check the actuator or the waste gate valve, replace actuator or turbocharger assembly if necessary.
15-4
OPERATION CHECK
A B
INTAKE AND EXHAUST

ON-VEHICLE SERVICE
M1151001300131
WASTE GATE SOLENOID VALVE CHECK
Measure the resistance between solenoid valve terminals Standard value: 29 35 (at 20C)
AIR BY-PASS VALVE CHECK

M1151001600121
Battery
AK200441AC
1. Connect a hand vacuum pump to the solenoid valve nipple A. 2. Using a jumper wire, connect between the solenoid valve terminal and battery terminal. 3. Connecting and disconnecting the jumper wire at the battery negative terminal to apply a negative pressure, check tightness. Jumper wire Connected B nipple Normal condition condition Opened Closed Disconnected Opened Negative pressure leaks. Negative pressure is held. Negative pressure is held.
AK200443
1. Remove the air bypass valve. 2. Connect the hand vacuum pump to the nipple of the air bypass valve. 3. Apply a negative pressure of approximately 54 kPa, and check that air tightness is maintained. 4. Also check operation of the valve. Standard value: Negative pressure Approximately 59 kPa Valve operation It starts opening
INLET MANIFOLD VACUUM CHECK

Refer to GROUP 11A On-vehicle Service P.11A-12.
M1151001800192
COIL RESISTANCE CHECK
AK200442
INTAKE AND EXHAUST

AIR CLEANER
15-5
AIR CLEANER
REMOVAL AND INSTALLATION
M1151002100594
CAUTION Parts marked by * are made of recycled-paper mixed plastic material, so observe the following precautions.
1. Avoid any shock or load to these parts when removing and installing them. 2. Engage the case hinges securely when assembling these parts. NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state and local laws
11
12
4.0 1.0 Nm
6* 3 7 8* 4
9.0 1.0 Nm
4.0 1.0 Nm
13
4.0 1.0 Nm 9.0 1.0 Nm
9.0 1.0 Nm
9.0 1.0 Nm 9.0 1.0 Nm
10
Removal steps Intake air duct Battery Air cleaner assembly Airflow sensor assembly Gasket Air cleaner housing cover Air cleaner element
9
AC210412 AB
1. 2. 3. 4. 5. 6. 7.
Removal steps (Continued) Air cleaner housing Air cleaner bracket Waste gate solenoid valve Air pipe C, air by-pass hose and air by-pass valve 12. Vacuum hose connection 13. Air intake hose 8. 9. 10. 11.
15-6
INTAKE AND EXHAUST

INTERCOOLER
INTERCOOLER
M1151002400045
Pre-removal and Post-installation Operation Intake Air Duct and Air Cleaner Assembly Removal and Installation (Refer to P.15-5).
12 1 Nm
6.0 1.0 Nm
6.0 1.0 Nm
6.0 1.0 Nm 6.0 1.0 Nm
11 7
6.0 1.0 Nm
5
6.0 1.0 Nm
3
6.0 1.0 Nm 12 1 Nm
2 6
12 1 Nm
6.0 1.0 Nm
8
12 1 Nm
13 12
12 1 Nm
6.0 1.0 Nm
10
6.0 1.0 Nm
9
AC210413 AB
1. 2. 3. 4. 5. 6. 7.
Removal steps Vacuum hose connection Air by-pass valve Air by-pass hose Air hose E Air pipe C Air hose D Under cover (Refer to GROUP 51, Front Bumper Assembly P.51-2). Air hose A
8. 9. 10. 11. 12. 13.
Removal steps (Continued) Front bumper assembly (Refer to GROUP 51, Front Bumper Assembly P.51-2). Air pipe B Bracket Air hose C Air pipe A Air hose B Intercooler assembly
INTAKE AND EXHAUST

INLET MANIFOLD
15-7
INLET MANIFOLD
M1151003001601
Pre-removal Operation Fuel Discharge Prevention (Refer to GROUP 13A, On-vehicle Service P.13A-398). Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service P.14-15). Intake Air Duct Removal (Refer to P.15-5). Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9). Throttle Body Removal (Refer to GROUP 13A, Throttle Body P.13A-413). Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-7). Front Exhaust Pipe Removal (Refer to P.15-13).
Post-installation Operation Front Exhaust Pipe Installation (Refer to P.15-13). Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-7). Throttle Body Installation (Refer to GROUP 13A, Throttle Body P.13A-413). Strut Tower Bar Installation (Refer to GROUP 42, Strut Tower Bar P.42-9). Intake Air Duct Installation (Refer to P.15-5). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service P.14-15). Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2). Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service P.17-2).
2
5.0 1.0 Nm
3.0 0.5 Nm
6
11 1 Nm
10 4 3 10
N7 N (Engine oil)
9 11
13 1 Nm
13 12 N 14
Removal steps Rocker cover centre cover Control wiring harness connection Vacuum hose connection Vacuum hoses connection Fuel return hose connection Fuel high-pressure hose connection O-ring Delivery pipe, fuel injector, fuel return pipe and fuel pressure regulator assembly
(Engine oil)
AC310728 AB
1. 2. 3. 4. 5. >>A<< 6. >>A<< 7. <<A>> 8.
Removal steps (Continued) Insulators Insulators Oil level gauge and guide assembly O-ring Brake booster vacuum hose connection 14. Purge hoses connection 9. 10. 11. 12. 13.
15-8
INTAKE AND EXHAUST

INLET MANIFOLD
11 1 Nm
20 2 Nm
26
N 24
36 6 Nm 20 2 Nm
23
31 N
21
11 1 Nm
25 19 17
21
11 1 Nm
30 18 16
11 1 Nm
15
20 2 Nm
29
27 28
36 6 Nm
9.0 1.0 Nm
22 4 Nm
22
24 4 Nm
21 20
11 1 Nm
AC504960AB
31 3 Nm
15. 16. 17. 18. 19. 20. 21.
Removal steps Detonation sensor connector Purge control solenoid valve Vacuum hose Fuel pressure solenoid valve PCV hose Alternator (Refer to GROUP 16, Charging System Alternator Assembly P.16-12). EGR solenoid valve connector EGR solenoid valve, vacuum pipe and hose assembly
22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
Removal steps (Continued) Inlet manifold stay EGR valve EGR valve gasket Earth cable connection Harness connection Crank angle sensor connector Harness bracket Alternator brace stay Inlet manifold Inlet manifold gasket
INTAKE AND EXHAUST

INLET MANIFOLD
15-9
REMOVAL SERVICE POINT <<A>> DELIVERY PIPE, FUEL INJECTOR, FUEL RETURN PIPE AND FUEL PRESSURE REGULATOR ASSEMBLY REMOVAL
CAUTION Be careful not to drop the fuel injector when the delivery pipe is removed. The delivery pipe must be removed with the fuel injector, fuel return pipe and fuel pressure regulator attached.
Be careful not to damage the O-ring. After installing, check that the fuel high-pressure hose turns smoothly. 3. If the fuel high-pressure hose does not turn smoothly, the O-ring may be trapped. Remove the fuel high-pressure hose, re-install the fuel high-pressure hose into the delivery pipe and check again. 4. Tighten the fuel high-pressure hose to the specified torque. Tightening torque: 5.0 1.0 Nm
INSTALLATION SERVICE POINT >>A<< O-RING/ FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION Do not let the engine oil get into the delivery pipe, or it will be damaged. 1. Apply a drop of new engine oil to the O-ring. 2. Turn the fuel high-pressure hose to the right and left to install to the delivery pipe.
INSPECTION
M1151003100694
Check the following points; replace the part if a problem is found.
Inlet Manifold Check

1. Check for damage or cracking of any part. 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
15-10
INTAKE AND EXHAUST

EXHAUST MANIFOLD AND TURBOCHARGER

M1151008900060
Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Radiator Removal (Refer to GROUP 14, Radiator P.14-24). Air Intake Hose Removal (Refer to P.15-5). Air Pipe A, Air Pipe B, Air Pipe C, Air Hose A and Air Hose D Removal (Refer to P.15-6). Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-7). Front Exhaust Pipe Removal (Refer to P.15-13).
Post-installation Operation Front Exhaust Pipe Installation (Refer to P.15-13). Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-7). Air Pipe A, Air Pipe B, Air Pipe C, Air Hose A and Air Hose D Installation (Refer to P.15-6). Air Intake Hose installation (Refer to P.15-5). Radiator Installation (Refer to GROUP 14, Radiator P.14-24). Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2).
23 3 Nm 64 5 Nm
1
23 3 Nm 29 3 Nm
25 N 24
49 5 Nm 14 1 Nm 17 2 Nm
3 17
N 20
N 18
31 2 Nm
8N
49 5 Nm
19
7
11 1 Nm
2
44 5 Nm
21
N8
10 1 Nm
4
59 5 Nm
15
N 11 N 14
42 7 Nm
5N 12
42 7 Nm
16
N 10
35 6 Nm
13
6
N 23
9.0 1.0 Nm 14 1 Nm
19 1 Nm
22
10 1 Nm
AC210648 AB
1. <<A>> >>D<< 2. 3. 4.
Removal steps Exhaust manifold cover Oxygen sensor (Front) Turbocharger heat protector Turbocharger water feed pipe connection
<>
Removal steps (Continued) 5. Gaskets 6. Turbocharger water return hose connection 7. Turbocharger oil feed pipe 8. Gaskets
INTAKE AND EXHAUST

EXHAUST MANIFOLD AND TURBOCHARGER 9. >>C<< 10. 11. 12. 13. >>B<< 14. 15. 16. Removal steps (Continued) Starter motor (Refer to GROUP 16, Starting System Starter Motor Assembly P.16-20). Turbocharger oil return pipe Turbocharger oil return pipe gasket Turbocharger oil return pipe gasket Vacuum hose connection Air outlet fitting Air outlet fitting gasket Vacuum hose connection Exhaust fitting bracket
15-11
Removal steps (Continued) 17. Turbocharger and exhaust fitting assembly 18. Turbocharger gasket >>A<< 19. Turbocharger assembly 20. Exhaust fitting gasket 21. Exhaust fitting assembly 22. Turbocharger water return pipe and hose assembly 23. Gaskets 24. Exhaust manifold 25. Exhaust manifold gasket
REMOVAL SERVICE POINTS <<A>> OXYGEN SENSOR (FRONT) REMOVAL
INSTALLATION SERVICE POINTS >>A<< TURBOCHARGER ASSEMBLY INSTALLATION
MD998770
ACX02426 AB
Use special tool oxygen sensor wrench (MD998770) to remove the oxygen sensor (front).
AC210649AB
1. Clean the oil pipe and water pipe fitting, the inside of eye bolts, and individual pipe for clogs.
<> TURBOCHARGER OIL FEED PIPE REMOVAL

CAUTION Take care not to allow foreign objects to get into the oil passage hole of the turbocharger assembly after the turbocharger oil feed pipe is removed.
CAUTION Take care not to allow foreign objects to get into the turbocharger assembly.
2. Clean or use compressed air to remove any carbon particles stuck to the oil passage of the turbocharger assembly. 3. Refill new engine oil at the oil feed pipe fitting hole of the turbocharger assembly.
15-12
INTAKE AND EXHAUST

>>B<< AIR OUTLET FITTING GASKET INSTALLATION

Turbocharger assembly Protrusion
Use special tool oxygen sensor wrench (MD998770) to install the oxygen sensor (front).
INSPECTION
M1151009400013
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
View A A
AC210650 AB
Install the gasket so that its protrusion faces in the direction shown in the illustration.
>>C<< TURBOCHARGER OIL RETURN PIPE GASKET INSTALLATION

Turbocharger oil return pipe
Turbocharger Assembly Check
Compressor wheel
AC210683AB
Turbocharger oil return pipe gasket protrusion

AC210682AB
Install the gasket so that its protrusion faces in the direction shown in the illustration.
>>D<< OXYGEN SENSOR (FRONT) INSTALLATION
1. Visually check the turbine wheel and the compressor wheel for cracking or other damage. 2. Check whether the turbine wheel and the compressor wheel can be easily turned by hand. 3. Check for oil leakage from the turbocharger assembly. 4. Check whether or not the turbocharger waste gate regulating valve remains open. If any problem is found, replace the part after disassembly.
MD998770
ACX02426 AB
INTAKE AND EXHAUST

EXHAUST PIPE AND MAIN MUFFLER
15-13
EXHAUST PIPE AND MAIN MUFFLER

M1151008700390
13 2 Nm
5 1
13 2 Nm
11
49 10 Nm
8
45 5 Nm 59 10 Nm
7
50 5 Nm 13 2 Nm
11
10 N
AC310642AB
1. 3. 5. 2. 3. 4. 6.
Exhaust main muffler removal steps Exhaust main muffler Exhaust pipe gasket Exhaust muffler hangers Centre exhaust pipe removal steps Centre exhaust pipe Exhaust pipe gasket Exhaust pipe gasket Exhaust pipe hanger
7. 8. 9. 10. 11.
Front exhaust pipe removal steps Under cover (Refer to GROUP 51, Front Bumper Assembly P.51-2). Crossmember bar (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-7). Springs Front exhaust pipe Seal ring Exhaust pipe gasket Exhaust pipe hangers
NOTES
16-1
GROUP 16
ENGINE ELECTRICAL
CONTENTS CHARGING SYSTEM . . . . . . . .
GENERAL INFORMATION . . . . . . SERVICE SPECIFICATIONS. . . . . SPECIAL TOOL . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . .
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . OUTPUT CURRENT TEST . . . . . . . . . . REGULATED VOLTAGE TEST. . . . . . . WAVEFORM CHECK USING AN OSCILLOSCOPE. . . . . . . . . . . . . . .
16-2
16-2 16-3 16-4 16-5 16-5 16-6 16-8 16-9 16-12 16-12 16-15 16-17
IGNITION SYSTEM . . . . . . . . .
GENERAL INFORMATION . . . . . . SERVICE SPECIFICATIONS . . . . . SPECIAL TOOL . . . . . . . . . . . . . . . ON-VEHICLE SERVICE . . . . . . . . .
IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK . . . . . . . . . . . . . IGNITION COIL RELAY CHECK <RH DRIVE VEHICLES> . . . . . . . . . . . . SPARK PLUG CABLE CHECK . . . . . . . SPARK PLUG CHECK AND CLEANING CAMSHAFT POSITION SENSOR CHECK CRANK ANGLE SENSOR CHECK . . . . DETONATION SENSOR CHECK . . . . . IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN OSCILLOSCOPE . . . . . . . . . . . . . . .
16-26
16-26 16-27 16-28 16-28 16-28 16-28 16-29 16-29 16-30 16-30 16-30 16-30 16-34 16-34 16-35 16-35 16-36 16-36 16-37 16-37
ALTERNATOR ASSEMBLY . . . . .
REMOVAL AND INSTALLATION . . . . . DISASSEMBLY AND REASSEMBLY . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM . . . . . . . . .
GENERAL INFORMATION . . . . . . SERVICE SPECIFICATIONS. . . . . STARTER MOTOR ASSEMBLY . .
REMOVAL AND INSTALLATION . . . . .
16-18
16-18
IGNITION COIL. . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION. . . . . .
CAMSHAFT POSITION SENSOR .

16-19 16-20 16-20 REMOVAL AND INSTALLATION. . . . . .
CRANK ANGLE SENSOR . . . . . . .

STARTER MOTOR ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . .

DISASSEMBLY AND REASSEMBLY . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
DETONATION SENSOR . . . . . . . .
16-20 16-22 16-24 REMOVAL AND INSTALLATION. . . . . .
16-2
GENERAL INFORMATION
ENGINE ELECTRICAL
CHARGING SYSTEM
CHARGING SYSTEM
The charging system uses the alternator output to keep the battery charged at a constant level under various electrical loads. 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.
M1161000100652
OPERATION
Voltage
Approximately 14.4 V
Time
AK400075AB
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
G Field coil Voltage regulator S L + FR Charge warning lamp Ignition switch Battery
AK304222 AB
ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
ALTERNATOR SPECIFICATIONS
Item Type Rated output V/A Voltage regulator Specifications Battery voltage sensing 12/90 Electronic built-in type
M1161000300407
Item Alternator output line voltage drop (at 30 A) V Regulated voltage ambient 20C temperature at voltage regulator V 20C 60C 80C Output current
Standard value 14.2 15.4 13.9 14.9 13.4 14.6 13.1 14.5
Limit maximum 0.3 70 % of normal output current
16-4
SPECIAL TOOL
ENGINE ELECTRICAL
CHARGING SYSTEM
M1161000600356
Tool
Number MB991502
Name M.U.T.-II sub assembly
Use Checking the idle speed
B991502
MB991824
MB991827
MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826
DO NOT USE
MB991910
M.U.T.-III sub assembly A: Vehicle communication interface (V.C.I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A (Vehicles with CAN communication system) D: M.U.T.-III main harness B (Vehicles without CAN communication system) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
Checking the idle speed
CAUTION M.U.T.-III main harness B (MB991911) should be used. M.U.T.-III main harness A should not be used for this vehicle.
MB991911
MB991825
MB991826 MB991955
MB991519
Alternator test harness
Checking the alternator ("S" terminal voltage)
ENGINE ELECTRICAL
CHARGING SYSTEM
16-5
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST
M1161000900681
Ammeter (clamp-type) Alternator
Voltmeter (digital-type)
"B" terminal
Battery
AK203361AE
This test determines whether the wiring from the alternator "B" terminal to the battery (+) terminal (including the fusible link) 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 GROUP 11A On-vehicle Service P.11A-7.) 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. 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 then connect the (-) lead of the voltmeter to the battery (+) cable].
6. Reconnect the negative battery cable. 7. Connect the M.U.T.-II/III. 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 discoloured due to overheating, repair and then test again.
16-6
12.After the test, run the engine at idle. 13.Turn off all lamps and the ignition switch. 14.Remove the M.U.T.-II/III.
ENGINE ELECTRICAL
CHARGING SYSTEM
15.Disconnect the negative battery cable. 16.Disconnect the ammeter and voltmeter. 17.Connect the negative battery cable.
OUTPUT CURRENT TEST

M1161001000692
Load Voltmeter Ammeter (clamp-type)
Charge warning lamp
Ignition switch
B FR L S G Alternator + Battery Engine-ECU
AK401826 AD
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 GROUP 54A Battery On-vehicle Service P.54A-5). 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 GROUP 11A On-vehicle Service P.11A-7.) 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.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-7
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 the M.U.T.-II/III. 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 lamp 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 M.U.T.-II/III. 16.Disconnect the negative battery cable. 17.Disconnect the ammeter and voltmeter. 18.Connect the negative battery cable.
16-8
REGULATED VOLTAGE TEST
ENGINE ELECTRICAL
CHARGING SYSTEM
M1161001100871
Load Ammeter (clamp-type) MB991519 Ignition switch Charge warning lamp
Blue
B FR L S G + Battery Voltmeter (digital-type) + Black Yellow Red Alternator
Engine-ECU
AK401827AC
This test determines whether the voltage regulator is 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 GROUP 54A Battery On-vehicle Service Charging P.54A-4). Drive belt tension (Refer to GROUP 11A On-vehicle Service P.11A-7.) 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 the M.U.T.-II/III. 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.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-9
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. 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 M.U.T.-II/III. 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 20 20 60 80 Voltage V 14.2 15.4 13.9 14.9 13.4 14.6 13.1 14.5
WAVEFORM CHECK USING AN OSCILLOSCOPE

M1161001200209
MEASUREMENT METHOD
Alternator CH1
Connect the oscilloscope special patterns pick-up to the alternator "B" terminal.
"B" terminal
AK100002 AC
16-10
STANDARD WAVEFORM
Observation Conditions Function Pattern height Variable knob Pattern selector Engine speed
ENGINE ELECTRICAL
CHARGING SYSTEM
Special pattern Variable Adjust while viewing the waveform. Raster Curb idle speed
(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,
ENGINE ELECTRICAL
CHARGING SYSTEM
16-11
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. Abnormal waveform Example 1 Problem cause Open diode
AKX00191
Example 2
Short in diode
AKX00192
Example 3
Broken wire in stator coil
AKX00193
Example 4
Short in stator coil
AKX00194
16-12
ALTERNATOR ASSEMBLY
ENGINE ELECTRICAL
CHARGING SYSTEM
M1161001401358
CAUTION If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the caliper with tool or parts, because the caliper paint will be scratched.
Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9). Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper and Centremember P.32-7). Front Exhaust Pipe Assembly Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Post-installation Operation Front Exhaust Pipe Assembly Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper and Centremember P.32-7). Strut Tower Bar Installation (Refer to GROUP 42, Strut Tower Bar P.42-9). Drive Belt Tension Check (Refer to GROUP 11A, On-vehicle Service Drive Belt Tension Check P.11A-7). Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2).
ENGINE ELECTRICAL
CHARGING SYSTEM
5.0 1.0 Nm
16-13
3 1 2
5.0 1.0 Nm 11 1 Nm
11 6
13 1 Nm
7 9 10 5
22 4 Nm
4 17
9.0 1.0 Nm 20 2 Nm
9.0 1.0 Nm 24 4 Nm (Engine oil)
18
14
N 12
16
44 10 Nm 8.8 1.0 Nm
15
13
AC406359AB
<<A>>
1. 2. 3. 4. 5. 6. 7. 8. 9.
Removal steps Fuel injector connectors Accelerator cable connection Fuel injector, delivery pipe, fuel return pipe and fuel pressure regulator assembly Insulators Insulators Fuel pressure solenoid valve connector Fuel pressure solenoid valve Detonation sensor connector Purge control solenoid valve connector
<>
10. 11. 12. 13. 14. 15. 16. 17. 18.
<<C>>
Removal steps (Continued) Purge control solenoid valve Oil level gauge and guide assembly O-ring Drive belt Alternator connector and terminal Engine front mounting bracket (Refer to GROUP 32, Engine Mounting P.32-4). Alternator Water pump pulley Crank angle sensor connector Alternator bracket
16-14
ENGINE ELECTRICAL
CHARGING SYSTEM
REMOVAL SERVICE POINTS <<A>> FUEL INJECTOR, DELIVERY PIPE, FUEL RETURN PIPE AND FUEL PRESSURE REGULATOR ASSEMBLY REMOVAL
After loosening the delivery pipe mounting bolts, move the fuel injector, delivery pipe, fuel return pipe and the fuel pressure regulator as an assembly aside in order to make room for the alternator removal.
1. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto-tensioner. 2. Rotate the auto-tensioner anti-clockwise and align hole A with hole B.
CAUTION To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
<> DRIVE BELT REMOVAL

The following operations will be needed due to the introduction of the serpentine drive system with the drive belt auto-tensioner.
Autotensioner
Autotensioner L-shaped hexagon wrench
AC210998AB
3. Insert an L-shaped hexagon wrench, etc. into the hole to fix and then remove the drive belt.
Hole B Hole A
AC210996 AB
<<C>> ALTERNATOR REMOVAL

Raise the engine with a floor jack and remove the alternator upward from the engine room.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-15
DISASSEMBLY AND REASSEMBLY

M1161001600199
1 3 4
5 7 6
10 9 8
12
14 13 11
AK202845 AB
<<A>> <>
1. 2. >>B<< 3. 4. 5. 6. 7.
Disassembly steps Front bracket assembly Alternator pulley Rotor Rear bearing Bearing retainer Front bearing Front bracket
Disassembly steps (Continued) 8. Stator 9. Plate <<C>> >>A<< 10. Regulator assembly 11. Brush 12. Rubber packing 13. Rectifier 14. Rear bracket <<C>>
16-16
ENGINE ELECTRICAL
CHARGING SYSTEM
DISASSEMBLY SERVICE POINTS <<A>> FRONT BRACKET ASSEMBLY REMOVAL
CAUTION 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.
AK202718
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.
REASSEMBLY SERVICE POINTS >>A<< REGULATOR ASSEMBLY INSTALLATION
<> ALTERNATOR PULLEY REMOVAL
Wire
AK202779 AB
Rear bracket Brush

AK202714
CAUTION Perform operation carefully not to damage the rotor. Clamp the rotor in a vise with the pulley facing up to remove the pulley.
Wire
AK202830 AB
<<C>> STATOR / REGULATOR ASSEMBLY REMOVAL

Rectifier assembly Solder
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. NOTE: Holding the brush with the wire facilities installation of the rotor.
Solder
AK202778 AB
ENGINE ELECTRICAL
CHARGING SYSTEM
16-17
>>B<< ROTOR INSTALLATION
3. If continuity is present, replace the rotor.
STATOR
Wire
AK202779 AB
Remove the brush holding wire after the rotor has been installed.
AK202716
INSPECTION
M1161001700129
1. Check the continuity between coil leads. If there is no continuity, replace the stator.
ROTOR
AK202717 AK202735
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 2. Check the continuity between the slip rings and core.
2. Check the continuity between coil and core. If there is no continuity, replace the stator.
RECTIFIER ASSEBMLY
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.
AK202736
If continuity is present for both terminals, the diode is shorted. Replace the rectifier assembly.
16-18
ENGINE ELECTRICAL
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
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.
M1162000100309
ENGINE ELECTRICAL
STARTING SYSTEM
16-19
SYSTEM DIAGRAM
Holding coil Pull-in coil
Plunger Lever
B
Ignition switch
Overrunning clutch
M S
Pinion gear
+ Battery
Armature
Brush Yoke
AK202970 AB
STARTER MOTOR SPECIFICATIONS

Item Type Rated output kW/V No. of pinion teeth Specifications Reduction drive with planetary gear 1.2/12 8
M1162000300080
Item Pinion gap mm Commutator run-out mm Commutator diameter mm Undercut depth mm
Standard value 0.5 2.0 0.05 29.4 0.5
Limit 0.1 28.8 0.2
16-20
STARTER MOTOR ASSEMBLY
ENGINE ELECTRICAL
STARTING SYSTEM
M1162001000781
Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51, Front Bumper P.51-2). Crossmember Bar Removal and Installation (Refer to GROUP 32, Engine Roll Stopper and Centremember P.32-7). Front Exhaust Pipe Assembly Removal and Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13).
3
13 2 Nm
30 3 Nm
4.9 1.0 Nm
30 3 Nm
1
4.9 1.0 Nm
AC210296 AB
1.
Removal steps Starter cover
2. 3.
Removal steps (Continued) Starter connector and terminal Starter assembly
STARTER MOTOR ASSEMBLY INSPECTION

M1162001100249
PINION GAP ADJUSTMENT

Switch B S M Battery
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.
Starter motor
Wire
AKX01239 AF
ENGINE ELECTRICAL
STARTING SYSTEM
16-21
MAGNETIC SWITCH HOLD-IN TEST

Stopper
B S
Pinion Pinion gap
AKX00198 AC
Battery
Starter motor
Wire
AKX01245 AF
4. Check the pinion-to-stopper clearance (pinion gap) with a feeler gauge. Standard value: 0.5 2.0 mm
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 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.
AKX00199
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket.
FREE RUNNING TEST

Carbon-pile rheostat Ammeter A Battery Voltmeter
MAGNETIC SWITCH PULL-IN TEST

S B S M Battery
B M
Starter motor
AKX01247AF
Starter motor
Wire
AKX01243 AF
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.
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.
16-22
ENGINE ELECTRICAL
STARTING SYSTEM
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Current: maximum 95 Amps
MAGNETIC SWITCH RETURN TEST
2. Connect a 12-volt battery between the M-terminal and body.
B S M Battery
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.
WARNING
Starter motor
Wire
AKX01249AF

M1162001200246
2 14 12 11
10 13
5.8 1.6 Nm
19
5.8 1.6 Nm
1 16 17
18 15
8 21 9 6 7
3
3.4 1.0 Nm
AK304626AB
ENGINE ELECTRICAL
STARTING SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. 9. Disassembly steps Screw Magnetic switch Screw Bolt Rear bracket Brush holder Rear bearing Armature Yoke assembly
16-23
<<A>>
Disassembly steps (Continued) 10. Packing A 11. Packing B 12. Plate 13. Planetary gear 14. Lever <> >>A<< 15. Snap ring <> >>A<< 16. Stop ring 17. Overrunning clutch 18. Internal gear 19. Planetary gear shaft 20. Front bracket
DISASSEMBLY SERVICE POINTS <<A>> MAGNETIC SWITCH REMOVAL

B terminal S terminal
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 Snap ring Pinion gear Overrunning clutch
M terminal
Field coil lead
AK202890 AB
CAUTION Do not clamp the yoke assembly with a vise. Disconnect the lead from the M terminal of the magnetic switch.
AK202791 AB
2. Remove the snap ring with snap ring pliers, then remove the stop ring and overrunning clutch.
<> SNAP RING/STOP RING REMOVAL

Socket wrench
STARTER MOTOR PARTS CLEANING

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.
Stop ring
Pinion Gear Overrunning clutch
AK202790 AB
16-24
ENGINE ELECTRICAL
STARTING SYSTEM
REASSEMBLY SERVICE POINTS >>A<< STOP RING/SNAP RING INSTALLATION
Segment
Undercut Mica
Stop ring
Overrunning clutch
Stop ring
AK202711 AB
Snap ring
AK202911 AB
Use a suitable puller to pull the stop ring until it gets over the snap ring.
3. Measure the depth of the undercut between segments. Standard value: 0.5 mm Limit: 0.2 mm
INSPECTION
M1162001300180
BRUSH HOLDER
COMMUTATOR
AK202897
AK202712
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
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
Lock
AK202710 AB
AK202715
2. Measure the diameter of the commutator. Standard value: 29.4 mm Limit: 28.8 mm
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.
ENGINE ELECTRICAL
STARTING SYSTEM
16-25
BRUSHES
Brush height
AK202734 AK202846 AB
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.
4. Check the insulation between commutator segments and armature coils. The armature coils are properly insulated if no continuity is present.
ARMATURE COIL
1. Check the armature coil for short circuit as follows:
Growler
AK202713
5. Check continuity between a segment and another. There is no open circuit in the tested coil if there is continuity.
MAGNETIC SWITCH
A
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.
M terminal
AK202891 AB
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.
16-26
B terminal
ENGINE ELECTRICAL
IGNITION SYSTEM
B terminal
M terminal
AK202892 AB
M terminal
AK202893 AB
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.
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.
IGNITION SYSTEM
GENERAL INFORMATION
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 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 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.
M1163000100614
ENGINE ELECTRICAL
IGNITION SYSTEM
16-27
SYSTEM DIAGRAM
Air flow sensor Intake air temperature sensor Engine coolant temperature sensor Ignition coil B Camshaft position sensor Crank angle sensor Barometric pressure sensor Detonation sensor Vehicle speed sensor Ignition switch-ST
AK101074 AH
Ignition switch Ignition coil A
Engine-ECU Battery Spark plug
Cylinder No.
IGNITION COIL SPECIFICATION

Item Type Specification Molded 2-coil
SPARK PLUG SPECIFICATIONS

Item NGK Specifications ILFR7H
M1163000300403
IGNITION COIL
Item Secondary coil resistance k Standard value 8.5 11.5
SPARK PLUG
Item Spark plug gap mm Standard value 0.5 0.6 Limit 0.75
SPARK PLUG CABLE

Item Resistance k Standard value Limit Maximum 19
16-28
SPECIAL TOOL
ENGINE ELECTRICAL
IGNITION SYSTEM
M1163000600288
Tool
Number MD998773
Name Detonation sensor wrench
Use Detonation sensor removal and installation
ON-VEHICLE SERVICE
IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK
Check by the following procedure, and replace if there is a malfunction.
M1163001200614
SECONDARY COIL RESISTANCE CHECK
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 When current is flowing When current is not flowing Continuity between 1 2 Continuity No continuity
AKX01264
IGNITION COIL RELAY CHECK <RH DRIVE VEHICLES>

M1163006500029
Measure the resistance between the high-voltage terminals of the ignition coil. Standard value: 8.5 11.5 k
PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK

NOTE: .
CAUTION The top and bottom of the ignition coil relay are difficult to identify. The triangle mark on the relay surface should be uppermost.
1.5 V
1 2 3
AC311402AB
1. Removal the ignition coil relay.

AK501917 AB
An analogue-type circuit tester should be used. Connect the negative (-) prove of the circuit tester to terminal No. 1.
ENGINE ELECTRICAL
IGNITION SYSTEM
16-29
Relay side
3. Check the continuity between ignition coil relay connector terminals 1 and 4 while alternately connecting and disconnecting the jumper leads from the battery terminals. Jumper leads Connected Disconnected Continuity between terminals 1 and 4 Less than 2 Open circuit
AC311403 AB
2. Use the jumper leads to connect ignition coil relay terminal 3 to the negative battery terminal and terminal 2 to the positive battery terminal.
4. If there is a malfunction, replace the ignition coil relay.
SPARK PLUG CABLE CHECK

Measure the resistance of the all spark plug cables. 1. Check cap and coating for cracks. 2. Measure resistance. Limit: Maximum 19 k
M1163001400157
AKX00382
SPARK PLUG CHECK AND CLEANING

M1163004300728
CAUTION When pulling off the spark plug cable from the plug always hold the cable cap, not the cable. 1. Remove the spark plug cables and ignition coils. 2. Remove the spark plugs.
CAUTION 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.
Iridium tip
Platinum tip
AK501797AB
3. Check the plug gap and replace if the limit is exceeded. Standard value: 0.5 0.6mm Limit: 0.75 mm
16-30
ENGINE ELECTRICAL
IGNITION SYSTEM
CAUTION Be careful not to allow foreign matter in cylinders. 4. Clean the engine plug holes.
5. Install the spark plugs. 6. Install the spark plug cables and ignition coils.
CAMSHAFT POSITION SENSOR CHECK

Check the camshaft position sensor system if self-diagnosis code, No. P0340 is shown. (Refer to GROUP 13A Troubleshooting Inspection procedure for diagnosis code P.13A-166.)
M1163004400305
CRANK ANGLE SENSOR CHECK

Check the crank angle sensor system if self-diagnosis code, No. P0335 is shown. (Refer to GROUP 13A Troubleshooting Inspection procedure for diagnosis code P.13A-155.)
M1163004500368
DETONATION SENSOR CHECK

Check the detonation sensor system if self-diagnosis code, No. P0325 is shown. (Refer to GROUP 13A Troubleshooting Inspection procedure for diagnosis code P.13A-151.)
M1163002900070
IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN OSCILLOSCOPE

M1163001700288
MEASUREMENT METHOD
1. Clamp the spark plug cable (No. 1 cylinder or No. 3 cylinder) with the secondary pickup. NOTE: . 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.
ENGINE ELECTRICAL
IGNITION SYSTEM
16-31
STANDARD WAVEFORM
Observation Conditions Function Secondary Pattern height Pattern selector Engine revolutions High (or Low) Raster Curb idle speed
kV
Spark line (point A)
Ignition voltage (point D)
Secondary ignition voltage wave pattern Wave damping reduction section (point B)
Dwell section
0 Point C Time
AKX00278AC
16-32
ENGINE ELECTRICAL
IGNITION SYSTEM
Observation Conditions (The only change from above condition is the pattern selector.) Pattern selector Display
kV
NO. 1 cylinder
NO. 3 cylinder ignition noise
NO. 4 cylinder
NO. 2 cylinder ignition noise
Secondary ignition voltage wave pattern 0 2 Neutral section
Time
AKX01275 AD
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 Length Long Short Height High Low Slope Plug gap Condition of Compression electrode force Small Large Large Small Large Normal Large wear Large wear Normal Low High High Low Concentration Ignition of air mixture timing Rich Lean Lean Rich Advanced Retarded Retarded Advanced Spark plug cable Leak High resistance High resistance Leak
Plug is fouled Coil and condenser Normal Abnormal Coil Normal Abnormal
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5) Number of vibrations 3 or more Except above Number of vibrations 5 6 or higher Except above Ignition voltage High Low Plug gap Large Small
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends. Condition of Compression electrode force Large wear Normal High Low Concentration Ignition of air mixture timing Lean Rich Retarded Advanced Spark plug cable High resistance Leak
ENGINE ELECTRICAL
IGNITION SYSTEM
16-33
EXAMPLES OF ABNORMAL WAVEFORMS
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.
AKX00280
Example 1 Wave characteristics Spark line is high and short. Cause of problem Spark plug gap is too large.
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).
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.
AKX00284
Example 5 Wave characteristics No waves in wave damping section. Cause of problem Layer short in ignition coil.
AKX00282
16-34
IGNITION COIL
ENGINE ELECTRICAL
IGNITION SYSTEM
M1163004000909
Pre-removal and Post-installation Operation Rocker Cover Centre Cover Removal and Installation (Refer to GROUP 11A, Camshaft and Valve Stem Seal P.11A-17).
10 2 Nm
1 2 1 4 5
25 4 Nm
4 3
AC210297 AB
1. 2. 3.
Removal steps Ignition coil connectors Spark plug cable No. 1 Spark plug cable No. 3
4. 5.
Removal steps (Continued) Ignition coils Spark plugs
ENGINE ELECTRICAL
IGNITION SYSTEM
16-35
CAMSHAFT POSITION SENSOR

M1163003400829
10.5 0.5 Nm
5 6N
2 1
10.5 0.5 Nm
AC407255 AC505000 AB
1. 2. 3.
Removal steps <exhaust side> Camshaft position sensor connector Camshaft position sensor O-ring
4. 5. 6.
Removal steps <inlet side> Camshaft position sensor connector Camshaft position sensor O-ring
16-36
CRANK ANGLE SENSOR
ENGINE ELECTRICAL
IGNITION SYSTEM
M1163004800143
CAUTION If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the caliper with tool or parts, because the caliper paint will be scratched.
Pre-removal and Post-installation Operation Timing Belt Removal and Installation (Refer to GROUP 11A,Timing Belt P.11A-36). Radiator Reserve Tank Assembly Removal and Installation (Refer to GROUP 14, Radiator P.14-24).
12 2 Nm 22 4 Nm 22 4 Nm 12 2 Nm
1 6
8.8 1.0 Nm
22 4 Nm
4
49 9 Nm
49 9 Nm
40 5 Nm
AC210409AB
1. 2.
Removal steps Power steering pressure switch connector Power steering oil pump heat protector
<<A>>
3. 4. 5. 6.
Removal steps (Continued) Power steering oil pump, bracket and oil reservoir assembly Power steering oil pump bracket Crank angle sensor connector Crank angle sensor
ENGINE ELECTRICAL
IGNITION SYSTEM
16-37
REMOVAL SERVICE POINT <<A>> POWER STEERING OIL PUMP, BRACKET AND OIL RESERVOIR ASSEMBLY REMOVAL
NOTE: Tie the removed power steering oil pump, bracket and oil reservoir assembly with a rope and set aside where they cannot hinder the removal of the power steering oil pump bracket.
Remove the power steering oil pump, bracket and oil reservoir assembly with the hoses attached from the power steering oil pump bracket.
DETONATION SENSOR
M1163002800664
Pre-removal and Post-installation Operation Inlet Manifold Stay Removal and Installation (Refer to GROUP 15, Inlet Manifold P.15-7).
Inlet manifold stay 23 2 Nm
1 2
AC210411AB
<<A>>
>>A<<
1. 2.
Removal steps Detonation sensor connector Detonation sensor
INSTALLATION SERVICE POINT >>A<< DETONATION SENSOR INSTALLATION

Detonation sensor
REMOVAL SERVICE POINT <<A>> DETONATION SENSOR REMOVAL

Detonation sensor
MD998773
AC100807AB
MD998773
AC100807AB
Use special tool detonation sensor wrench (MD998773) to install the detonation sensor.
Use special tool detonation sensor wrench (MD998773) to remove the detonation sensor.
NOTES
17-1
GROUP 17
ENGINE AND EMISSION CONTROL

CONTENTS ENGINE CONTROL . . . . . . . . . .
GENERAL INFORMATION . . . . . . SERVICE SPECIFICATIONS. . . . . ON-VEHICLE SERVICE. . . . . . . . .
ACCELERATOR CABLE CHECK AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . .
17-2
17-2 17-2 17-2 17-2
COMPONENT LOCATION (CRANKCASE EMISSION CONTROL SYSTEM) . . . . . POSITIVE CRANKCASE VENTILATION SYSTEM CHECK . . . . . . . . . . . . . . . . . . POSITIVE CRANKCASE VENTILATION (PCV) VALVE CHECK . . . . . . . . . . . . . .
17-8 17-8 17-9
EVAPORATIVE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . 17-9

GENERAL INFORMATION (EVAPORATIVE EMISSION CONTROL SYSTEM) . . . . . 17-9 COMPONENT LOCATION (EVAPORATIVE EMISSION CONTROL SYSTEM) . . . . . 17-10 PURGE CONTROL SYSTEM CHECK. . 17-10 PURGE PORT VACUUM CHECK . . . . . 17-11 PURGE CONTROL SOLENOID VALVE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-11 CHECK VALVE CHECK. . . . . . . . . . . . . 17-12 FUEL VAPOUR CANISTER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . 17-12
ACCELERATOR CABLE AND PEDAL 17-3

REMOVAL AND INSTALLATION . . . . . 17-3
EMISSION CONTROL MPI . . . .

GENERAL INFORMATION . . . . . . EMISSION CONTROL DEVICE REFERENCE TABLE . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS. . . . . SPECIAL TOOL . . . . . . . . . . . . . . . VACUUM HOSE. . . . . . . . . . . . . . .
VACUUM HOSE PIPING DIAGRAM . . . VACUUM CIRCUIT DIAGRAM . . . . . . . VACUUM HOSE CHECK. . . . . . . . . . . . VACUUM HOSE INSTALLATION . . . . .
17-4
17-4
17-5 17-5 17-5 17-6 17-6 17-7 17-7 17-7
EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . .

GENERAL INFORMATION (EGR SYSTEM) . . . . . . . . . . . . . . . . . . . COMPONENT LOCATION (EGR SYSTEM) . . . . . . . . . . . . . . . . . . . EGR SYSTEM CHECK . . . . . . . . . . . . . EGR VALVE CHECK . . . . . . . . . . . . . . . EGR PORT VACUUM CHECK. . . . . . . . EGR CONTROL SOLENOID VALVE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . EGR VALVE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . .
17-13 17-13 17-14 17-14 17-15 17-15 17-15 17-16 17-17 17-17
CRANKCASE EMISSION CONTROL SYSTEM. . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION (CRANKCASE EMISSION CONTROL SYSTEM) . . . . .
17-8 17-8
CATALYTIC CONVERTER . . . . . .
17-2
GENERAL INFORMATION

ENGINE CONTROL
ENGINE CONTROL
M1171000100341 M1171000300185
A cable-type accelerator mechanical suspended-type pedal has been adopted. Item Accelerator cable play mm Engine idle speed r/min
Standard value 12 800 50

Adjusting bolts
ON-VEHICLE SERVICE
ACCELERATOR CABLE CHECK AND ADJUSTMENT
M1171000900488
Plate
1. Turn off air conditioner and all lamps. Inspect and adjust at no load. 2. Start engine and allow to idle unit it reaches normal operating temperature. 3. Confirm the idle speed is at standard value. Standard value: 800 50 r/min 4. Stop the engine [ignition switch in the ''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 2 mm
5.0 1.0 Nm
AC210289AB AC210289
7. If there is too much slack or no slack, adjust the cable as follows: (1) Loosen the adjusting bolts to release the cable. (2) Move the plate until the inner cable play is at the standard value, and then tighten the adjusting bolts to specified torque. Tightening torque: 5.0 1.0 Nm

ENGINE CONTROL
17-3
ACCELERATOR CABLE AND PEDAL

M1171001200608
Post-installation Operation Adjusting the Accelerator Cable (Refer to P.17-2).
<L.H. drive vehicles> 5.0 1.0 Nm 11 1 Nm
10
5.0 1.0 Nm
5 9 1
11
12 2 Nm
8 4N 6 2
<R.H. drive vehicles> 5.0 1.0 Nm
6 12 1 3
10
11 8 6 2
N
5 3N
9
12 2 Nm
12
>>B<< 1. 2. >>A<< 3. 4. 5. Accelerator pedal removal steps Inner cable connection (Accelerator pedal side) Accelerator pedal assembly Accelerator pedal pad Push-on spring nut Accelerator pedal arm assembly 6. 7. 8. 9.
AC505002 AB
Accelerator pedal removal steps Bushing Spring Stopper Accelerator pedal bracket
17-4

EMISSION CONTROL <MPI> Accelerator cable removal steps >>B<< 1. Inner cable connection (Accelerator pedal side) 10. Inner cable connection (Throttle lever side) 11. Accelerator cable assembly Accelerator pedal stopper removal 12. Accelerator pedal stopper
INSTALLATION SERVICE POINTS >>A<< ACCELERATOR PEDAL PAD INSTALLATION

Warm the peg of the accelerator pedal pad with a dryer before installing the pad. NOTE: If it is difficult to fit, apply soapy water to the peg lightly.
>>B<< INNER CABLE INSTALLATION

Plastic bushing Rubber dumper
Accelerator cable
Accelerator pedal arm

AC210048 AB
Securely fit the plastic bushing on the inner cable of the accelerator cable to the accelerator pedal arm as shown.
EMISSION CONTROL <MPI>

GENERAL INFORMATION
The emission control system consists of the following subsystems: Items Name Crankcase emission control system Evaporative emission control system
M1173000100541
Crankcase emission control system Evaporative emission control system Exhaust emission control system Specification Variable flow type (Purpose: HC reduction) Equipped Duty cycle type solenoid valve Equipped (Purpose: HC reduction) Oxygen sensor feedback type (Purpose: CO, HC, NOx reduction) Equipped Single type Duty cycle type solenoid valve (Purpose: NOx reduction) Monolith type (Purpose: CO, HC, NOx reduction)
Positive crankcase ventilation (PCV) valve Canister Purge control solenoid valve Check valve Air-fuel ratio control device - MPI system Exhaust gas recirculation system EGR valve EGR control solenoid valve Catalytic converter
Exhaust emission control system

17-5
EMISSION CONTROL DEVICE REFERENCE TABLE

M1173006600180
Related parts
Crankcase emission control system
Evaporative emission control system
Air/fuel ratio Catalytic control converter system
Exhaust gas recirculation system
PCV valve Purge control solenoid valve Check valve MPI system component Catalytic converter EGR valve EGR control solenoid valve
M1173000300448
Items Purge control solenoid valve coil resistance (at 20C) EGR control solenoid valve coil resistance (at 20C)
Standard value 30 34 29 35
SPECIAL TOOL
M1173000600256
Tool
Number MD998770
Name Oxygen sensor wrench
Use Removal and installation of oxygen sensor
17-6
VACUUM HOSE

VACUUM HOSE PIPING DIAGRAM

M1173000900796
Canister From fuel tank Check valve
Purge control solenoid valve
Fuel pressure control solenoid valve Fuel pressure regulator To fuel tank EGR control solenoid valve From fuel pump PCV valve EGR valve
Injector Air inlet
Oxygen sensor (front)
Catalytic converter Catalytic converter Oxygen sensor (rear)

AK501844 AB

17-7
VACUUM CIRCUIT DIAGRAM

M1173007100586
Inlet manifold
Throttle body
To combustion chamber
From air cleaner
Y Fuel pressure control solenoid valve B B W G L Air by-pass valve EGR control solenoid valve R Fuel pressure regulator Y EGR valve Y B
Waste gate actuator R Canister Check valve B Brown B
Waste gate solenoid valve
Purge control solenoid valve W
Air cleaner
Vacuum hose colour B: Black G: Green L: Light blue R: Red W: White Y: Yellow
AK501843 AB
VACUUM HOSE CHECK

M1173007300193
VACUUM HOSE INSTALLATION

M1173007200141
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.
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.
17-8

CRANKCASE EMISSION CONTROL SYSTEM

GENERAL INFORMATION (CRANKCASE EMISSION CONTROL SYSTEM)
M1173005000691
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 inlet manifold through the positive crankcase ventilation (PCV) valve. The PCV valve lifts the plunger according to the inlet 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.
SYSTEM DIAGRAM
Ventilation hose PCV valve Breather hose
AK501845 AB
COMPONENT LOCATION (CRANKCASE EMISSION CONTROL SYSTEM)

M1173007400297
POSITIVE CRANKCASE VENTILATION SYSTEM CHECK

M1173001100373
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.
PCV valve
AK304227AB

17-9
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.
PCV valve
AK300021AC
EVAPORATIVE EMISSION CONTROL SYSTEM

GENERAL INFORMATION (EVAPORATIVE EMISSION CONTROL SYSTEM)
M1173005100717
5. Place a finger at the opening of the PCV valve and check that vacuum of the inlet 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.
POSITIVE CRANKCASE VENTILATION (PCV) VALVE CHECK

M1173001200336
PCV valve
AK300022 AC
The evaporative emission control system prevents fuel vapors generated in the fuel tank from escaping into the atmosphere. Fuel vapors from the fuel tank flow through the fuel tank pressure control valve and vapor pipe/hose to be stored temporarily in the canister. When driving the vehicle, fuel vapors stored in the canister flow through the purge solenoid and purge port and go into the inlet manifold to be sent to the combustion chamber. When the engine coolant temperature is low or when the inlet 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 vapor flow to the inlet manifold. This does not only insure the driveability when the engine is cold or running under low load but also stabilize the emission level.
17-10
SYSTEM DIAGRAM

Throttle body
Engine-ECU From fuel tank Canister Check valve Air flow sensor OFF Purge control ON solenoid valve Engine coolant temperature sensor Engine control relay Intake air temperature sensor Barometric pressure sensor Battery
AK401830AB
COMPONENT LOCATION (EVAPORATIVE EMISSION CONTROL SYSTEM)

M1173007500302
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 negative pressure of 53 kPa, and check the condition of the negative pressure. When engine is cold (Engine coolant temperature: 40C or less) Engine condition Normal condition At idle 3,000 r/min Negative pressure is maintained.
Purge control solenoid valve
AK304229AB
PURGE CONTROL SYSTEM CHECK

M1173001400664
Throttle body
When engine is hot (Engine coolant temperature: 80C or higher) Engine condition Normal condition At idle Negative pressure is maintained.
3,000 r/min (within 3 minutes Negative pressure after engine starts) will leak.
Red stripe
AK304230AB

17-11
PURGE PORT VACUUM CHECK

M1173001500252
Throttle body
Red stripe Battery

AK100012 AC AK304231AB
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).
1. Disconnect the vacuum hose from the solenoid valve. 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 negative pressure with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage. Battery voltage Applied Not applied Normal condition Negative pressure leaks Negative pressure 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.
PURGE CONTROL SOLENOID VALVE CHECK

M1173001700405
AK100013
NOTE: When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position.
5. Measure the resistance between the terminals of the solenoid valve. Standard value: 30 34 (at 20C)
17-12
CHECK VALVE CHECK

M1173006200085
Connect a hand vacuum pump to the check valve, apply negative pressure and check the airtightness. Connect nipple colour Black Brown Normal condition Negative pressure leaks Negative pressure is maintained
AK200373
FUEL VAPOUR CANISTER REMOVAL AND INSTALLATION

M1173004200186
Pre-removal Operation Air Pipe C, Air Hose D Removal (Refer to GROUP 15, Intercooler P.15-6). Battery and Battery Tray Removal Air Cleaner Assembly Removal (Refer to GROUP 15, Air Cleaner P.15-5).
Post-installation Operation Air Cleaner Assembly Installation (Refer to GROUP 15, Air Cleaner P.15-5). Battery and Battery Tray Installation Air Pipe C, Air Hose D Installation (Refer to GROUP 15, Intercooler P.15-6).
3 2
6 4 5 8
AC310639 AB
1. 2. 3. 4.
Removal steps Emission vacuum hose connection Fuel vapour control line hose Fuel vapour control check valve Fuel vapour control line hose
5. 6. 7. 8.
Removal steps (Continued) Fuel vapour control line clamp Fuel vapour canister Fuel high-pressure hose clamp Fuel vapour canister bracket

17-13
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

GENERAL INFORMATION (EGR SYSTEM)
M1173005200684
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 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 inlet 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.
SYSTEM DIAGRAM
Engine-ECU Barometric pressure sensor EGR control Solenoid valve OFF Air flow sensor Engine coolant temperature sensor Crank angle sensor
ON
EGR valve
Engine control relay
Battery
AK501846 AB
17-14

M1173007600309
COMPONENT LOCATION (EGR SYSTEM)
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 Open quickly No vacuum will generate (the same as barometric pressure.)
EGR control solenoid valve

AK304234AB
EGR valve
When engine is hot (Engine coolant temperature: 80C or higher) Throttle valve Normal vacuum condition Open quickly It will momentarily rise over 13 kPa
AK304235AB
3. Disconnect the three-way terminal.
EGR SYSTEM CHECK

M1173002600393
Three-way terminal
Green stripe
Green stripe
AK304237AB
AK304236AB
4. Connect the hand vacuum pump to the EGR valve nipple (Green stripe). 5. Check whether the engine stalls or the idling is unstable when a vacuum of 27 kPa or higher is applied during idling.

17-15
EGR VALVE CHECK

M1173002800308
2. Plug the vacuum hose (White stripe).
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 negative pressure of 67 kPa, and check that the negative pressure is maintained.
Vacuum
Engine speed (r/min)

AK100011AC
3. Start the engine. 4. Check that a fairly constant vacuum is generated regardless of the engine speed. 5. If no vacuum is generated, the port is probably blocked and should be cleaned.
AKX00348
4. Apply negative pressure and check the passage of air by blowing through one side of the EGR passage. Vacuum 5.3 kPa or less 27 kPa or more Passage of air Air is not blown out Air is blown out
EGR CONTROL SOLENOID VALVE CHECK

M1173003100368
NOTE: When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position.
B A
5. Replace the gasket, and tighten to the specified torque. Tightening torque: 20 2 Nm
EGR PORT VACUUM CHECK

M1173002900242
C Battery
Throttle body
AK100015 AF
White stripe
AK304238 AB
1. Disconnect the vacuum hose (White stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple.
1. Disconnect the vacuum hose from the solenoid valve. 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 negative pressure with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.
17-16
Battery voltage Nipple condition Applied Both nipples open

Normal condition Negative pressure leaks
Nipple "B" closed Negative pressure maintained Not applied Both nipples open Nipple "C" closed Negative pressure leaks Negative pressure maintained
AK304447
EGR VALVE REMOVAL AND INSTALLATION

M1173010500272
6.0 1.0 Nm
6.0 1.0 Nm
20 2 Nm
3 4N
AC210292 AB
Removal steps <<A>> >>A<< Strut tower bar 1. Intercooler air hose E
Removal steps (Continued) 2. Vacuum hose connection 3. EGR valve 4. EGR valve gasket

17-17
REMOVAL SERVICE POINT <<A>> STRUT TOWER BAR REMOVAL

1. Remove the strut tower bar. (Refer to GROUP 42, Strut Tower Bar P.42-9). 2. After removing the strut tower bar, install the top of the strut assembly temporarily with the strut tower bar mounting nuts.
INSTALLATION SERVICE POINT >>A<< STRUT TOWER BAR INSTALLATION

1. Remove the nuts that are temporarily securing the strut assembly. 2. Install the strut tower bar. (Refer to GROUP 42, Strut Tower Bar P.42-9).
CATALYTIC CONVERTER
M1173003900472
13 2 Nm 49 10 Nm
44 5 Nm
4 3
6 5 2
13 2 Nm
59 10 Nm
50 5 Nm
AC310641 AB
<<A>>
>>A<<
1. 2. 3. 4.
Removal steps Oxygen sensor (Rear) Spring Front exhaust pipe Seal ring
5. 6. 7.
Removal steps (Continued) Gasket Catalytic converter Gasket
17-18

REMOVAL SERVICE POINT <<A>> OXYGEN SENSOR (REAR) REMOVAL
INSTALLATION SERVICE POINT >>A<< OXYGEN SENSOR (REAR) INSTALLATION
MD998770
MD998770
ACX02426 AB
ACX02426 AB
Use special tool oxygen sensor wrench (MD998770) to remove the oxygen sensor (rear).
Use special tool oxygen sensor wrench (MD998770) to install the oxygen sensor (rear).
42-1
GROUP 42
BODY
CONTENTS HOOD. . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE. . . . . . . . . 42-3
42-3
WINDOW REPAIR . . . . . . . . . . . . . WINDSHIELD . . . . . . . . . . . . . . . . .

42-10 42-12 42-12 42-17 42-17
ADJUSTMENT OF CLEARANCE AROUND HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3 ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER 42-3 ADJUSTMENT OF HOOD HEIGHT . . . 42-3
REAR WINDOW GLASS . . . . . . . .

HOOD. . . . . . . . . . . . . . . . . . . . . . .
42-4 42-4
DOOR . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS . . . . . SEALANT . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . ON-VEHICLE SERVICE . . . . . . . . .
DOOR FIT ADJUSTMENT . . . . . . . . . . . DOOR WINDOW GLASS ADJUSTMENT GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT. . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . .
42-20
42-20 42-20 42-21 42-22 42-22 42-22 42-23 42-23 42-24 42-24 42-24 42-24 42-25 42-25 42-25
FENDER. . . . . . . . . . . . . . . . . . .
SPECIAL TOOL . . . . . . . . . . . . . . . FENDER. . . . . . . . . . . . . . . . . . . . .
42-5
42-5 42-6 42-6
FUEL FILLER LID . . . . . . . . . . .

REMOVAL AND INSTALLATION .
42-8
42-8
STRUT TOWER BAR . . . . . . . .

REMOVAL AND INSTALLATION .
42-9
42-9
WINDOW GLASS . . . . . . . . . . .
ADHESIVE . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . .
42-9
42-9 42-10
Continued on next page
42-2
DOOR ASSEMBLY . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-26 42-26 42-27 42-27 42-27 42-29 42-30 42-30 42-31 TRUNK LID HEIGHT ADJUSTMENT. . . 42-36 42-37 42-37 42-39
TRUNK LID . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION. . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
DOOR GLASS AND REGULATOR

REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
KEYLESS ENTRY SYSTEM . .

SERVICE SPECIFICATIONS . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . ON-VEHICLE SERVICE . . . . . . . . .
42-39
42-39 42-40 42-41
DOOR HANDLE AND LATCH. . . .

REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP 42-33

REMOVAL AND INSTALLATION . . . . . 42-33
TRUNK LID . . . . . . . . . . . . . . . .
SPECIAL TOOL . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . .
42-35
42-35
42-35 TRUNK LID ADJUSTMENT. . . . . . . . . . 42-35 ADJUSTMENT OF CLEARANCE AROUND TRUNK LID . . . . . . . . . . . . . . . . . . . . . . 42-36 TRUNK LID STRIKER ADJUSTMENT . 42-36
42-41 KEYLESS ENTRY SYSTEM CHECK. . . 42-41 KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION . . . . . . . . . . . 42-41 ENABLING/DISABLING THE ANSWERBACK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . 42-41 HOW TO REGISTER SECRET CODE . 42-43 42-46 42-46 42-47
TRANSMITTER. . . . . . . . . . . . . . . .
TRANSMITTER . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
BODY
HOOD
42-3
HOOD
ON-VEHICLE SERVICE
ADJUSTMENT OF CLEARANCE AROUND HOOD
M1421007200129
ADJUSTMENT OF HOOD HEIGHT

M1421007400123
Y0215AU
Section A A Hood
AC005945
ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER

M1421007300126
17 mm
Hood bumper
X0424CA
AC005948AB
Rotate the hood bumper by using 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
42-4
HOOD
M1421001600419
BODY
HOOD
CAUTION Use the special bolts when securing the hinge to the hood. They have special coating for anti-corrosion.
Section A A A B B Clip A C C Clip B Clip C Section B B Section C C
10
A
10
11
10
11
11
14
Note : Clip A positions : Clip B positions : Clip C positions
14 12 14
11
14
14
AC211580
17
21 4 Nm 11 2 Nm
15 1 8 3 10 6 2 3
9.0 2.0 Nm
16
11 2 Nm
13 11 9 7 1 8 5
AC311076 AB
4
Removal 1. Hood bumper Hood lock release cable removal steps Front bumper assembly (Refer to GROUP 51, Front Bumper Assembly P.51-2). Splash shield (Refer to P.42-6). 2. Hood latch cover
Hood lock release cable removal steps (Continued) 3. Hood latch 4. Hood lock release handle 5. Hood lock release cable Hood and hood hinge removal steps 6. Hood weatherstrip <Right side> 7. Hood weatherstrip <Left side> 8. Headlamp weatherstrip
BODY
FENDER Hood and hood hinge removal steps Washer hose (Refer to GROUP 51, Windshield Wiper and Washer P.51-23). 9. Hood support rod 10. Hood heat protector panel 11. Hood heat protector
42-5
Hood and hood hinge removal steps 12. Hood outlet garnish 13. Hood hinge bolt (Hood side) 14. Hood 15. Shim 16. Hood hinge 17. Hood weather strip
FENDER
SPECIAL TOOL
M1421000600256
Tool
Number MB990784
Name Ornament remover
Use Side turn-signal lamp removal
MB990784
42-6
FENDER
M1421001900409
BODY
FENDER
CAUTION Use the special fasteners to secure the fender. They have special coating for anti-corrosion.
Pre-removal and Post-installation Operation Front Bumper Assembly Removal and Installation (Refer to GROUP 51, Front Bumper Assembly P.51-2). Front Deck Garnish Removal and Installation (Refer to GROUP 51, Windshield Wiper and Washer P.51-20). Side Air Dam Removal and Installation (Refer to GROUP 51, Side Air Dam P.51-8).
5 2
AC211637 AB
Removal steps 1. Splash shield <<A>> >>A<< 2. Side turn-signal lamp 3. Delta garnish (Refer to GROUP 51, Garnish and Moulding P.51-10).
Removal steps (Continued) 4. Fender 5. Front fender bracket
BODY
FENDER
42-7
REMOVAL SERVICE POINT <<A>> SIDE TURN-SIGNAL LAMP REMOVAL

Front of vehicle Side turn-signal lamp
INSTALLATION SERVICE POINT >>A<< SIDE TURN-SIGNAL LAMP INSTALLATION

Hook Fender
Claw
Fender MB990784
AC005980AD
: Front of vehicle
AC005719 AB
Use special tool ornament remover (MB990784) to prize out the tab from the fender, and remove the side turn-signal lamp.
Engage the claw with the fender, and install the side turn-signal lamp.
42-8
BODY
FUEL FILLER LID
FUEL FILLER LID

M1421002500277
Pre-removal and Post-installation Operation Rear Seat Removal and Installation (Refer to GROUP 52A, Rear Seat P.52A-20.) Front Scuff Plate (Driver's Seat Side), Rear Scuff Plate (Driver's Side), Centre Pillar Lower Trim (Driver's Side), Quarter Trim (Driver's Side) Removal and Installation (Refer to GROUP 52A, Trims P.52A-10.)
18M0109
W0570AQ
Fuel filler lid height and clearance adjustment
1 2
Removal steps Fuel filler lid panel assembly Clip Fuel filler lid hook assembly
5.0 1.0 Nm
3
AC005973 AC005996 AC
1. 2. 3.
4. 5.
Removal steps (Continued) Fuel filler lid lock release cable Fuel filler lid lock release handle
BODY
STRUT TOWER BAR
42-9
STRUT TOWER BAR

M1421005600132
N
Plate Strut tower bar
44 5 Nm
Plate
AC211421 AB
WINDOW GLASS
ADHESIVE
M1422000500111
Item Windshield Rear window glass
Specified adhesive 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or equivalent 3M ATD Part No.8608 Super Fast Urethane Primer or equivalent
42-10
SPECIAL TOOLS
BODY
WINDOW GLASS
M1422000600293
Tool
Number MB990480
Name Glass holder
Use Removal and installation of window glass
MB990480
MB990784
Ornament remover
Removal of rear window lower moulding
MB990784
WINDOW REPAIR
M1422005600038
ITEMS
The windshield and rear 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. Name Remark Adhesive Primer Spacers Dam Anti-rust solvent (or Tectyl 506T.Valvoline Oil Company) Isopropyl alcohol Steel piano wire Glass adhesive knife Adhesive gun 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or equivalent 3M ATD Part No.8608 Super Fast Urethane Primer or equivalent Available as service part Available as service part For rust prevention For grease removal from bonded surface Dia. length... 0.6mm 1m For cutting adhesive For cutting adhesive 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
WINDOW GLASS
42-11
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 and window spacer Glue the window dam and window spacer to the glass, following the standard position all the way around the inside edge of the glass.
Application of primer Do not apply primer on residual adhesive as doing so may affect adhesion. apply enough primer on adhesion surface evenly taking care not to apply it on the residual adhesive. after applying primer, let it dry for 3 minutes or more.
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 adhesive, lightly 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 leaks through.
AC306636 AD
42-12
WINDSHIELD
BODY
WINDOW GLASS
Pre-removal and Post-installation Operation Front Deck Garnish Removal and Installation (Refer to GROUP 51,Windshield Wiper and Washer P.51-20). Roof Drip Moulding Removal and Installation (Refer to GROUP 51, Garnish and Moulding P.51-10). Inside Rear View Mirror Removal and Installation (Refer to GROUP 52A, Inside Rear View Mirror P.52A-18). Front Pillar Trim Removal and Installation (Refer to GROUP 52A, Trims P.52A-10). Headlining Removal and Installation (Refer to GROUP 52A, Headlining P.52A-17).
N3
2N 1
N5
3N
N6
A A B B Section A A Seal line centre Ceramic line Seal line C 16 C Primer Section C C Seal line centre Primer 16 Seal line
Y0496AU X0111AU
5N
Y0495AU
Units: mm Section B B Seal line centre
1
Primer 13
X0112AU
Ceramic line Apply the primer and adhesive along the fictitious lines (seal line) between each of the marks. Mark
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
AC006003 AC
BODY
WINDOW GLASS <<A>> >>B<< >>A<< >>A<< >>A<< >>A<< >>A<< 1. 2. 3. 4. 5. 6. Removal steps Windshield Windshield moulding Window dam Glass stopper Spacer Windshield spacer
42-13
CAUTION
REMOVAL SERVICE POINT <<A>> 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.
AC002060
Glass adhesive knife
AC207478 AD
ACX00474 AB
Inserting the glass adhesive knife too deeply into windshield adhesive may damage windshield. 4. Using glass adhesive knife 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
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.
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.
ACX00475AB
5. Use special tool glass holder (MB990480) to remove the windshield.
42-14
CAUTION
BODY
WINDOW GLASS
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.
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.
INSTALLATION SERVICE POINTS >>A<< WINDSHIELD SPACER/SPACER/GLASS STOPPER/WINDOW DAM/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.
BODY
WINDOW GLASS
Glass stopper, spacer, windshield spacer and window dam installation position Align the window dam and with the seal line mark.
42-15
Glass stopper
Glass end line
17.5 mm
Align the glass stopper end with the ceramic notch. Seal line Ceramic line
Mark 13 mm
Ceramic line Windshield Glass end line Window dam Section A A Seal line centre 14 mm
Y0628AU
Windshield spacer
Y0497AU
Align the spacer and with glass end line A B B A Align the windshield spacer end with the ceramic notch.
10138AU
Section B B
14 mm
Spacer
10139AU AC006029AB
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 in the Figure of the instructions. 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.
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. Do not apply the primer on the remaining adhesive because of weakening the adhesive.
2. Soak a sponge in the primer, and apply evenly to the windshield in the specified places. If the adhesive does not remain on the body flange surface because of the panel replacement on the body side, apply evenly to the body side in the specified places. 3. Allow the windshield to dry for at least three minutes after applying primer.
42-16
BODY
WINDOW GLASS
10 mm 15 mm
ACX00480 AB
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, Garnish and Moulding P.51-10).
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.
CAUTION 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
WINDOW GLASS
42-17
REAR WINDOW GLASS

M1422001600155
Pre-removal and Post-installation Operation Roof Drip Moulding Removal and Installation (Refer to GROUP 51, Garnish and Moulding P.51-10). High-mounted Stop Lamp Assembly Removal and Installation <Rear Shelf Mounted Type> (Refer to GROUP 54A, High Mount Stop lamp P.54A-69). Rear Pillar Trim and Rear Shelf Trim Removal and Installation (Refer to GROUP 52A, Trims P.52A-10). Headlining Removal and Installation (Refer to GROUP 52A, Headlining P.52A-17).
N 10
7
N8
Section A A
7 1 1
N2
6
N9
A
2N 4N
N3
Y0564AU
3N
A
2N 5N
3N
Y0500AU
N4
B
2N
Apply the primer and adhesive along the fictitious lines (seal line) between each of the marks.
Section B B Seal line centre
Ceramic line
16 mm
7
Primer
Y0501AU Y0502AU
Mark
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
AC006056 AB
Removal steps <<A>> >>B<< 1. Rear window lower moulding 2. Clip 3. Grommet A
Removal steps (Continued) 4. Grommet B 5. Grommet C 6. Connecting the harness connector
42-18
<> >>A<< >>A<< >>A<< >>A<< 7. 8. 9. 10. Removal steps (Continued) Rear window glass Rear window upper moulding Window dam Glass stopper
BODY
WINDOW GLASS
REMOVAL SERVICE POINTS <<A>> REAR WINDOW LOWER MOULDING REMOVAL

CAUTION If the drip moulding has become warped, it should not be reused.
INSTALLATION SERVICE POINTS >>A<< GLASS STOPPER/WINDOW DAM/REAR WINDOW UPPER MOULDING/REAR WINDOW GLASS INSTALLATION
1. When replacing the rear window glass, temporarily set the rear window glass against the body, and place a mating mark on the rear window glass and 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 rear window glass and the body flanges.
MB990784
AC006073AB
Use special tool ornament remover (MB990784) to lever out the moulding.
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.
3. Soak a sponge in the primer, and apply evenly to the rear window glass and the body in the specified places. 4. Allow the rear window glass to dry for at least 3 minutes after applying primer.
<> REAR WINDOW GLASS REMOVAL

Remove the rear window glass using the same procedure as for the windshield (Refer to P.42-12).
BODY
WINDOW GLASS
42-19
Glass stopper and window dam installation position Glass end line Glass stopper Align the window dam end with the ceramic notch.
18 mm
Align the glass stopper end with the ceramic notch. Seal line Ceramic line Rear window glass
Mark 19 mm
Ceramic line
Y0629AU
Window dam
Section A - A
19 mm
Window dam
A
Y0630AU
A
AC006075 AB
5. Install the glass stopper and window dam to the specified positions so that there are no adrift or bent surfaces inside the rear window glass. 6. Install the rear window upper moulding. 7. Install the glass in the same manner as the windshield. (Refer to P.42-12).
>>B<< REAR WINDOW LOWER MOULDING INSTALLATION

Install the clips to the rear window lower moulding, and then fix the rear window moulding to the vehicle body.
42-20
M1423000300206
BODY
DOOR
DOOR
Item Power window operation current (Power supply voltage 14.5 0.5 V, at 25 C) A Door outside handle play mm Front door Rear door Door inside handle play mm Front door Rear door Standard value 51 2.3 0 - 3.3 (target value: 1.3) 10.4 9.6 10 9.6
SEALANT
M1423000500095
Item Door waterproof film
Specified sealant 3M ATD Part No.8633 or equivalent
BODY
DOOR
42-21
SPECIAL TOOLS
M1423000600627
Tool
Number MB990480
Name Window glass holder
Use Removal of power window regulator assembly
MB990480
MB990900 or MB991164
Door hinge adjusting wrench
Door alignment
MB990900
MB990925 A: MB990939
MB990925AF
Bearing and oil seal installer set A: Brass bar
Door striker adjustment
MB990211
Sliding hammer
MB990211
MB990241 A: MB990243
A
MB990241AE
Axle shaft puller A: Body puller
MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe
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
DO NOT USE
MB991223 AZ
MB992006
Extra fine probe
Continuity check and voltage measurement at harness wire or connector
MB992006
42-22
TROUBLESHOOTING
M1423000700312
BODY
DOOR
NOTE:
Weld point Washer
The door system is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to GROUP 54B, Troubleshooting P.54B-13 or GROUP 54C, Troubleshooting P.54C-4.
ON-VEHICLE SERVICE
DOOR FIT ADJUSTMENT
M1423001100313
Bolts
Door hinge
Weld point
Washer
AC206498 AF
CAUTION Attach protection tape to the fender and door edges where the hinge is installed. Do not rotate special tool door adjusting wrench (MB991164) with a torque of over 98 Nm.
MB990900 or MB991164
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 P.42-26). 2. Use a chisel or grinder to release the door hinge mounting bolt washers, which are 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 P.42-26). 3. When the door is stiff to lock and unlock
AC000592 AB
1. Use the special tool door adjusting wrench (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.
MB990939 Temporary bolts Striker

AC006109AB
(1) Adjustment by using the striker (toward the inside of the vehicle and vertical direction) Install temporary bolts instead of the striker mounting bolts, and use special tool brass bar (MB990939) and a hammer to tap the bolt to the desired direction.
MB990211 MB990243
Striker
AC006110 AB
(2) Adjustment by using the striker (toward the outside of the vehicle)
BODY
DOOR
42-23
Use special tools slide hammer (MB990211) and body puller (MB990243) to pull the striker toward the outside of the vehicle.
Shim Striker
GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT

M1429000900154
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.
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. 1. Remove the door trim assembly (Refer to GROUP 52A, Door trim P.52A-12). 2. Remove the waterproof film (Refer to P.42-33). 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 Door sash
DOOR WINDOW GLASS ADJUSTMENT

M1423001000394
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 P.52A-12). 2. Remove the waterproof film (Refer to P.42-33). 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.
<Front> <Rear>
Lower sash
AC003777AB
Adjusting hole
Adjusting hole
Y0238AU
Y0239AU
AC006112 AB
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. NOTE: The lower sash cannot normally be adjusted, but it may be possible to adjust the sash span slightly within the range allowed by manufacturing tolerances by pushing the lower sash outwards while re-installing it. 5. If repair or adjustment is not possible, replace the door assembly.
4. Fully close the door window glass again and tighten the door glass mounting screw firmly via the adjusting hole.
42-24
POWER WINDOW OPERATING CURRENT CHECK
M1429001100269
BODY
DOOR
BATTERY VOLTAGE Not applied Connect terminal No. 3 and the negative battery terminal. Connect terminal No. 1 and the positive battery terminal.
Tester connection 45
Specified condition Open circuit Less than 2 ohms
AC006115AB
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 (A): 5 1A (Power supply voltage 14.5 0.5V, 25C) 3. If the operation current is outside the standard value, refer to P.42-23.
CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION

M1429001000273
POWER WINDOW RELAY CHECK

M1429001800202
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.
POWER WINDOW CHECK

Junction block (front view)
Power window relay Power window relay
5 4 1 3
1 2 3 4 5
Check the system as described below. If the system does not work, carry out troubleshooting. Refer to GROUP 54B, Troubleshooting P.54B-13 or GROUP 54C, Troubleshooting P.54C-4. 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.
M1429004400203
AC305140 AB
BODY
DOOR
42-25
CENTRAL DOOR LOCKING SYSTEM INSPECTION

M1427001100207
DOOR INSIDE HANDLE PLAY ADJUSTMENT

M1423001500292
Check that the central door locking system works by operating the key cylinders (drivers and passengers door) and the inside lock knob (drivers door). Carry out troubleshooting if the system does not activate. Refer to GROUP 54B, Troubleshooting P.54B-13 or GROUP 54C, Troubleshooting P.54C-4.
Section A A A A B
DOOR OUTSIDE HANDLE PLAY CHECK

M1423001600404
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 P.52A-12). 4. Remove the waterproof film (Refer to P.42-33).
Inner cable Outer cable end Clip
AC006113AB
1. Check that the door outside handle play is within the standard value range. Standard value (A): Front door: 2.3 mm Rear door: 0 3.3 mm (target value: 1.3 mm) 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 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.
42-26
DOOR ASSEMBLY
M1423002200283
BODY
DOOR
Post-installation Operation Door Fit Adjustment (Refer to P.42-22.)

<FRONT DOOR>
1 7 8
27 5 Nm
5
11 2 Nm
1
21 4 Nm
2
27 5 Nm 11 2 Nm
3
1.5 0.5 Nm
9 10
Y0652AU
6
21 4 Nm
<REAR DOOR> 11 2 Nm
4
27 5 Nm
5, 6
5 1
21 4 Nm
7 8
1.5 0.5 Nm
2
27 5 Nm
ACX00503
3
21 4 Nm 11 2 Nm
9 10
Y0655AU AC006125AB
Removal 1. Damper mail Door assembly removal steps 2. Harness connector 3. Door check connecting bolt 4. Door assembly 5. Door upper hinge 6. Door lower hinge
Striker removal steps >>A<< 7. Striker 8. Striker shim Door switch removal steps 9. Door switch cap 10. Door switch
BODY
DOOR
42-27
M1423006000322
INSTALLATION SERVICE POINT >>A<< STRIKER INSTALLATION

Striker centre +1.5 mm Latch centre
INSPECTION DOOR SWITCH CHECK
2 1
-1.5 mm Striker
Latch
AC305098AB
Align the centre of the striker and latch within 1.5 mm, and install.
AC211414 AC
Switch position Released (ON)
Tester connection
Specified condition
1 switch body, Less than 2 2 switch body, ohms 3 switch body 1 switch body, Open circuit 2 switch body, 3 switch body
Depressed (OFF)
DOOR GLASS AND REGULATOR

M1429001300467
Post-installation Operation Door Window Glass Adjustment (Refer to P.42-23).

<FRONT DOOR> <REAR DOOR>
4 3
5 6
1 1 2 2
AC212124 AB
42-28
<FRONT DOOR>
BODY
DOOR
View A
7
C B B B C A C C C B C C C
Section B - B
Section C - C
Door trim NOTE : Clip positions : Claw positions <REAR DOOR> View D F E E E F F F Door trim Clip Claw
AC305108 AB
7
D
Section E - E
Section F - F
Door trim NOTE : Clip positions : Claw positions Clip Claw
Door trim
AC305109 AB
Door window regulator assembly removal steps Door trim assembly (Refer to GROUP 52A, Door Trim P.52A-12). Waterproof film (Refer to P.42-33). <<A>> >>B<< 1. Window regulator assembly <<A>> >>B<< 2. Power window motor assembly Door window glass removal steps Window glass runchannel (Refer to P.42-33). 3. Door window glass
Stationary window glass removal steps Window glass runchannel (Refer to P.42-33). Door beltline inner weatherstrip (Refer to P.42-33). 3. Door window glass <> >>A<< 4. Centre sash upper 5. Stationary window glass 6. Stationary window weatherstrip Power window switch removal steps 7. Power window switch panel assembly
BODY
DOOR
42-29
REMOVAL SERVICE POINTS <<A>> WINDOW REGULATOR ASSEMBLY/POWER WINDOW MOTOR ASSEMBLY REMOVAL
1. Remove the door window glass installation bolts.
INSTALLATION SERVICE POINTS >>A<< CENTRE SASH UPPER INSTALLATION

Securely insert the centre sash upper into the window rear sash (door).
CAUTION If film or others are adhered to the door window glass, attach special tool window glass holder (MB990480) to the outside of the glass to prevent the film from peeling off.
MB990480
>>B<< POWER WINDOW MOTOR ASSEMBLY INSTALLATION/WINDOW REGULATOR ASSEMBLY

<FRONT DOOR> 1 4 7 3 2 6 <REAR DOOR>
5
Y1536AU
AC100009AB
2. Lift the door window glass, and attach special tool window glass holder (MB990480) to the glass as shown to prevent the glass from falling. 3. Remove the window regulator assembly and power window motor assembly
1 4 3 2 5
Y1476AU AC100010AB
<> CENTRE SASH UPPER REMOVAL
When installing the window regulator assembly, tighten the bolts in the order shown in the illustration.
INSPECTION
Door outer opening weatherstrip Door centre sash
AC000602AB
M1429001400282
1. Remove the door outer opening weatherstrip from the centre sash upper only. 2. Remove the centre sash upper mounting screws, and then remove the centre sash upper from the door panel.
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 (initialised). 2. Operate the power window switch and fully open the door window glass.
42-30
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.
BODY
DOOR
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 (Initialisation 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).
DOOR HANDLE AND LATCH

M1423004600458
Pre-removal Operation Door Trim Removal (Refer to GROUP 52A, Door trim P.52A-12).
Post-installation Operation Door Inside Handle Play Check (Refer to P.42-25). Door Outside Handle Play Check (Refer to P.42-25). Door Trim Installation (Refer to GROUP 52A, Door trim P.52A-12).
<REAR DOOR>
<FRONT DOOR>
2 3 2
9.0 2.0 Nm
7
N
9.0 2.0 Nm
5 1
1
5.0 1.0 Nm
5.0 1.0 Nm
4
AC300270 AB
BODY
DOOR Door handle and door latch assembly removal steps >>C<< 1. Door inside handle Waterproof film (Refer to P.42-33). 2. Door outside handle 3. Door lock key cylinder >>B<< 4. Lower sash
42-31
Door handle and door latch assembly removal steps (Continued) 5. Door latch assembly 6. Inside lock cable (Front door) 7. Inside lock rod (Rear door) 8. Inside handle rod Door check removal steps Waterproof film (Refer to P.42-33). >>A<< 9. Door check
INSTALLATION SERVICE POINTS >>A<< DOOR CHECK INSTALLATION
Identification mark
ACX00541AB
Install the door check so that the identification mark faces upwards. Item Front Door Rear Door Left door Right door Left door Right door Identification mark 39L 39R 40L 40R
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.
INSPECTION
M1423004700541
FRONT DOOR LOCK ACTUATOR CHECK

Front door <Left side> Unlock Lock
>>B<< LOWER SASH INSTALLATION

Securely insert the rear lower sash into the window rear sash.
Lever
View A
1 2 3 4 5 6
>>C<< DOOR INSIDE HANDLE INSTALLATION

Inner cable Outer cable end Clip
<Right side> Unlock
A Lock
View B Lever
1 2 3 4 5 6
Door inside handle Inside handle rod
AC100404 AB
AC305111 AB
42-32
ACTUATOR OPERATION CHECK Lever Battery connection Lever position operation At the "LOCK" position Connect terminal No.4 and the negative battery terminal. Connect terminal No.6 and the positive battery terminal. 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.
BODY
DOOR
REAR DOOR LOCK ACTUATOR CHECK

Rear door <Left side> Lock Unlock
View A Lever
1 2 3 4 5 6
The lever moves from the "UNLOCK" position to the "LOCK" position.
A <Right side> Unlock Lock
At the "UNLOCK" position
View B Lever
ACTUATOR SWITCH CHECK <LH DRIVE VEHICLES (DRIVERS SIDE)> Lever position Tester Specified connection condition At the "LOCK" position At the "UNLOCK" position 12 13 Less than 2 ohms Less than 2 ohms
1 2 3 4 5 6
B
AC305112 AB
ACTUATOR OPERATION CHECK Lever Battery connection Lever position operation At the "LOCK" position Connect terminal No.4 and the negative battery terminal. Connect terminal No.6 and the positive battery terminal. 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.
ACTUATOR SWITCH CHECK <RH DRIVE VEHICLES (DRIVERS SIDE)> Lever position Tester Specified connection condition At the "LOCK" position At the "UNLOCK" position 23 13 Less than 2 ohms Less than 2 ohms
At the "UNLOCK" position
The lever moves from the "UNLOCK" position to the "LOCK" position.
BODY
DOOR
42-33
Tester connection 12 1 2, 2 3 23 Specified condition Less than 2 ohms Open circuit Less than 2 ohms
DOOR LOCK KEY CYLINDER SWITCH CHECK <PASSENGERS SIDE>
Switch position LOCK NEUTRAL (OFF) UNLOCK
3 AC101318
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP

M1423003100449
<FRONT DOOR>
6 5 3 4
A A : Sectional view of clip position
: Sectional view of clip position
1
<Front door>
Section A A
6 1
Door Sealant: 3M ATD Part No.8633 or equivalent
AC304409AB
42-34
Waterproof film removal steps Front door trim (Refer to GROUP 52A, Door trim P.52A-12). Speaker (Refer to GROUP 54A, Speaker P.54A-78). 1. Waterproof film Door inner opening weatherstrip removal steps Scuff plate, centre pillar lower trim and cowl side trim (Refer to GROUP 52A, Trims P.52A-10). 2. Door inner opening weatherstrip (Body side) Door outer opening weatherstrip removal steps Front door check mounting bolt (Door side) (Refer to P.42-26). <<A>> >>A<< 3. Door outer opening weatherstrip
BODY
DOOR Door window glass runchannel removal 4. Door window glass runchannel Door beltline inner weatherstrip removal steps Front door trim (Refer to GROUP 52A, Door trim P.52A-12). 5. Door beltline inner weatherstrip Door beltline moulding removal steps Door mirror assembly (Refer to GROUP 51, Door mirror P.51-35). Door window glass (Refer to P.42-27). 6. Door beltline moulding
<REAR DOOR>
6
A A
4 5
3 7
B B
Section A A
1 7
<Rear door> Door Section B B Door
1 4
Sealant: 3M ATD Part No.8633 or equivalent
AC304418AB
BODY
TRUNK LID Waterproof film removal steps Rear door trim (Refer to GROUP 52A, Door trim P.52A-12). 1. Waterproof film Door inner opening weatherstrip removal steps Scuff plate, centre pillar lower trim and cowl side trim (Refer to GROUP 52A, Trims P.52A-10). 2. Door inner opening weatherstrip (Body side) Door outer opening weatherstrip removal steps Rear door check mounting bolt (Door side) (Refer to P.42-26). 3. Retainer weatherstrip
42-35
Door outer opening weatherstrip removal steps (Continued) <<A>> >>A<< 4. Door outer opening weatherstrip Door window glass runchannel removal 5. Door window glass runchannel Door beltline inner weatherstrip removal steps Rear door trim (Refer to GROUP 52A, Door trim P.52A-12). Centre sash upper (Refer to P.42-27). 6. Door beltline inner weatherstrip Door beltline moulding removal steps Door window glass (Refer to P.42-27). Stationary glass (Refer to P.42-27). 7. Door beltline moulding
REMOVAL SERVICE POINT <<A>> DOOR OUTER OPENING WEATHERSTRIP REMOVAL

15 mm 4 mm
Make a fabricated tool as shown in the illustration to remove the door weatherstrip.
Fabricated tool
INSTALLATION SERVICE POINT >>A<< DOOR OUTER OPENING WEATHERSTRIP INSTALLATION

The clip colour identifies the left and right weatherstrips so be sure to use the colours so as to install correctly. Applicable side Identification colour Pink Natural (White) Right door Left door
8 mm Thickness: 1 mm
ACX00555AB
TRUNK LID
SPECIAL TOOL
M1421000600245
Tool
Number MB991244
Name
Use
Torsion bar remover and Removal and installation of installer trunk lid torsion bar
MB991244
ON-VEHICLE SERVICE
TRUNK LID ADJUSTMENT
M1421001000042
1. If the clearance around the trunk lid panel assembly is not uniform and locking and unlocking of the trunk lid is difficult, make adjustments to the trunk lid bumpers (refer to
P.42-36) and trunk lid hinges (refer to P.42-36). 2. If the clearance around the trunk lid panel assembly is uniform, but locking and unlocking of the trunk lid is difficult, make adjustments to the trunk lid bumpers (refer to P.42-36) and trunk lid striker (refer to P.42-36).
42-36
Trunk lid panel assembly
BODY
TRUNK LID
TRUNK LID STRIKER ADJUSTMENT

M1421008200036
Trunk lid striker A A A A
AC202324
Side outer panel

AC202898 AB
Section A A Trunk lid panel assembly Side outer panel
After checking the trunk lid release cable for proper routing, loosen the trunk lid striker mounting bolts. Change the position of the trunk lid striker relative to the trunk lid latch assembly so that trunk lid locking and unlocking effort is correct.
TRUNK LID HEIGHT ADJUSTMENT

M1421008300066
AC202325 AC202913 AB
3. If there is a difference in height between the side outer panels and the side edges of the trunk lid panel assembly, check the trunk lid hinges and, if necessary, replace them 4. If the clearance around the trunk lid panel assembly is not uniform, and the trunk lid can be locked and unlocked smoothly, make adjustments to the trunk lid bumpers (refer to P.42-36) and trunk lid hinges (Refer to P.42-36). 5. If the locking and unlocking of the trunk lid still is difficult after making the above adjustments, adjust the trunk lid striker (Refer to P.42-36).
A A
Trunk lid bumper Section A A Trunk lid bumper
ADJUSTMENT OF CLEARANCE AROUND TRUNK LID

M1421008100039
14 mm Trunk lid panel assembly

AC207187AD
Trunk lid hinge

AC202897 AB
Loosen the trunk lid panel assembly mounting bolts and move the trunk lid panel assembly to make the clearance around the trunk lid uniform.
Turn each trunk lid bumper until the height shown in the drawing is reached. If the trunk lid panel height on one side is different from that on the other side (even after the trunk lid bumpers have been adjusted to the height indicated in the drawing), turn the trunk lid bumper(s) slightly to make fine adjustments to the trunk lid panel height NOTE: When the bumper is new, one full turn of the trunk lid bumper changes the height approximately 3 mm. Turn it clockwise to reduce height. Turn it anticlockwise to increase height
BODY
TRUNK LID
42-37
TRUNK LID
M1421002200243
11 9 10
Section A A
15 mm
AC308423
Section B B A A B
12 8 5
6
B
14 mm
Y0636AU
2 3 7
8.8 2.0 Nm
4
Trunk lid weatherstrip removal steps Rear end trim (Refer to GROUP 52A, Trims P.52A-10). >>B<< 1. Trunk lid weatherstrip Trunk lid release cable and trunk lid release handle removal steps Trunk rear side trim (Refer to GROUP 52A, Trims P.52A-10). Rear seat (Refer to GROUP 52A, Rear Seat Assembly P.52A-20). Centre pillar lower trim (Refer to GROUP 52A, Trims P.52A-10). Cowl side trim (Refer to GROUP 52A, Trims P.52A-10). Accelerator pedal stopper (Refer to GROUP 17, Accelerator Pedal P.17-3). 2. Trunk lid release handle 3. Trunk lid release cable
AC006098
AC310064 AB
Trunk lid striker removal steps Rear end trim (Refer to GROUP 52A, Trims P.52A-10). 4. Trunk lid striker Trunk lid panel removal steps 5. Trunk lid bumper 6. Trunk lid lock cylinder 7. Trunk lid latch assembly 8. Trunk lid hinge mounting bolt 9. Trunk lid panel assembly Trunk lid latch removal 7. Trunk lid latch assembly Trunk lid hinge removal steps Rear shelf trim (Refer to GROUP 52A, Trims P.52A-10). Rear seat (Refer to GROUP 52A, Rear Seat Assembly P.52A-20). 9. Trunk lid panel assembly <<A>> >>A<< 10. Trunk lid torsion bar <RH> <<A>> >>A<< 11. Trunk lid torsion bar <LH> 12. Trunk lid hinge
42-38
Grease application area
BODY
TRUNK LID
7
AC305143 AB
REMOVAL SERVICE POINT <<A>> TRUNK LID TORSION BAR REMOVAL

Trunk lid torsion bar <RH>
INSTALLATION SERVICE POINTS >>A<< TRUNK LID TORSION BAR INSTALLATION

Trunk lid torsion bar <LH> Colour mark
Trunk lid torsion bar <RH> A Trunk lid hinge <LH> B
MB991244 Trunk lid torsion bar <LH>

AC205068 AB
1. Attach the special tool torsion bar remover and installer (MB991244) to the illustrated portion of the trunk lid torsion bar <RH> on the right hand of the vehicle, then use the tool to detach the trunk lid torsion bar <RH> from the trunk lid hinge <LH> 2. Remove the trunk lid torsion bar <LH> in the same way as the trunk lid torsion bar <RH>.
Hole View F
Trunk lid torsion bar <LH>
Trunk lid hinge <RH>
E A
D C
Trunk lid torsion bar <LH> MB991244
B
AC305282 AB
Install the trunk lid torsion bars using the following procedure.
BODY
KEYLESS ENTRY SYSTEM
42-39
CAUTION Install the trunk lid torsion bar <LH> before the trunk lid torsion bar <RH>. If the sequence is reversed, the trunk lid torsion bar <LH> will not be able to be installed because the special tool torsion bar remover and installer (MB991244) will interfere with the trunk lid torsion bar <RH> during installation of the trunk lid torsion bar <LH>.
1. Identify the LH and RH torsion bars by the colour mark made at the centre of each torsion bar. Trunk lid torsion bar LH RH Mark colour Green Yellow
>>B<< TRUNK LID WEATHERSTRIP INSTALLATION
Marking section
Joint section AC006104AB
2. Insert the left end of the trunk lid torsion bar <LH> in the hole in the trunk lid hinge <LH>. 3. Press portion A of the trunk lid torsion bar <LH> right end against point A on the trunk lid hinge <RH> as shown in View F in the drawing. 4. Twist the portion B of the trunk lid torsion bar <LH> right end using the special tool torsion bar remover and installer (MB991244) until it is moved from point B and pressed against point C of the trunk lid hinge <RH> as shown in View F. Then force the portion into point D. 5. Twist the portion A of the trunk lid torsion bar <LH> right end until it reaches point E on the trunk lid hinge <RH> as shown in View F. 6. Attach the trunk lid torsion bar <RH> to the trunk lid hinge <LH> using the same method as the trunk lid torsion bar <LH>.
Install the trunk lid weatherstrip so that the marking and the joint are aligned with the body centre line,
INSPECTION
M1421004800133
TRUNK LID LATCH SWITCH CONTINUITY CHECK
Trunk lid latch assembly

AC305142 AB
Switch position ON (Latch open) OFF (Latch shut)
Tester connection 1 Earth
Specified condition Less than 2 ohms Open circuit

M1428000300148
Item Voltage of transmitter battery V
Standard value 2.5 3.2
42-40
SPECIAL TOOLS
BODY
M1428000600462
Tool
Number MB991502
Name M.U.T.-II sub-assembly
Use Encrypted code registration
B991502
MB991529
Diagnosis code check harness
MB991529
MB991824
MB991827
DO NOT USE
MB991910
MB991911
M.U.T.-III sub-assembly A: Vehicle communication interface (V.C.I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A (applicable to vehicles with CAN communication) D: M.U.T.-III main harness B (applicable to vehicles without CAN communication) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
Encrypted code registration
MB991825
MB991826 MB991955
BODY
42-41
TROUBLESHOOTING
M1428000700287
The keyless entry system is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to GROUP 54B, Troubleshooting P.54B-13 or GROUP 54C, Troubleshooting P.54C-4.
ENABLING/DISABLING THE ANSWERBACK FUNCTION

M1428003200355
ON-VEHICLE SERVICE
KEYLESS ENTRY SYSTEM CHECK
Check the system as described below. If the system does not work, carry out troubleshooting. Refer to GROUP 54B, Troubleshooting P.54B-13 or GROUP 54C, Troubleshooting P.54C-4. Operate the transmitter to check that the doors can be locked and unlocked. Operate the transmitter to check that the answerback function works in response to doors 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 lamp flashes twice when locked and once when unlocked. The room lamp flashes twice when locked and illuminates for 15 seconds when unlocked. The hazard warning lamp 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 lamp flashes 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 lamp do not flash when both locked and unlocked. The room lamp flashes twice when locked and illuminates for 15 seconds when unlocked.
M1428001400137
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.
<WHEN USING THE TRANSMITTER AFTER DIAGNOSIS CONNECTOR (1) IS EARTHED>

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.
Steering shaft Diagnosis connector
MB991529
AC305133AB
KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION

Push the transmitter unlock button and check to see that the doors lock within 30 seconds. If it doesn't, then execute troubleshooting remedies. Refer to GROUP 54B, Troubleshooting P.54B-13 or GROUP 54C, Troubleshooting P.54C-4.
M1428004000183
(3) Connect the diagnosis connector to the special tool diagnosis code check harness (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. 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.
42-42
BODY
Enable the hazard answerback function when the doors are locked: The ETACS-ECU buzzer will sound once. Disable the hazard answerback function when the doors are locked: The ETACS-ECU 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.
CAUTION Before connecting or disconnecting the M.U.T.-II, turn the ignition switch to the "LOCK" (OFF) position.
Steering shaft 16-Pin
MB991502
AC304777AC
<WHEN THE TRANSMITTER IS USED AFTER CONNECTING M.U.T.-II TO THE DIAGNOSIS CONNECTOR>
(3) Connect the M.U.T.-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 ETACS-ECU buzzer will sound once. Disable the hazard answerback function when the doors are locked: The ETACS-ECU 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 M.U.T.-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. (4) Any other warning buzzer output occurs.
BODY
42-43
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.
<WHEN THE TRANSMITTER IS USED AFTER CONNECTING SPECIAL TOOL V.C.I. (MB991824) TO THE DIAGNOSIS CONNECTOR>
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 ETACS-ECU buzzer will sound once. Disable the hazard answerback function when the doors are locked: The ETACS-ECU 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 V.C.I. 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. (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.
CAUTION Before connecting or disconnecting the V.C.I., turn the ignition switch to the "LOCK" (OFF) position.
AC211686
16-Pin
MB991911
HOW TO REGISTER SECRET CODE

M1428001000667
MB991824
AC309970 AC
(3) Connect the V.C.I. to the diagnosis connector. (4) Turn the V.C.I. power switch to the "ON" position. (5) Close the driver's side door. (6) Keep the windshield washer switch on for at least ten seconds. Then the ETACS-ECU buzzer will sound once.
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.
42-44
BODY
WHEN THE SPECIAL TOOL DIAGNOSIS CODE CHECK HARNESS (MB991529) IS 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.
Steering shaft Diagnosis connector
MB991529
AC305133AB
3. Connect the diagnosis connector to the special tool diagnosis code check harness (MB991529). NOTE: This will connect terminal (1) of the diagnosis connector to earth, and the system will be in secret code registration standby mode.
Ground connected
6. Once the program is saved, it will operate once with the all doors lock and unlock operations. 7. If you are using two or more transmitters or have added a second transmitter, the next transmitter should be registered within one minute after registering the code for the previous transmitter. The registration procedure is common for all the transmitters. 8. Registration mode will be cancelled under the following conditions: When the secret code for four transmitters has been registered; When passing one minute after finishing the registration of all transmitters; When the diagnosis connector is disconnected from earth; When the key is removed from the key cylinder; When no secret codes have been registered for more then one minute after the registration mode is entered; 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 M.U.T.-II IS USED

1. Check that the doors lock normally when the key is used. 2. Insert the ignition key.
Within 10 seconds
Hazard warning switch
ON OFF
CAUTION Before connecting or disconnecting the M.U.T.-II, turn the ignition switch to the "LOCK" (OFF) position.
Steering shaft 16-Pin
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 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.
MB991502
AC304777AC
3. Connect the M.U.T.-II to the diagnosis connector.
BODY
42-45
2. Insert the ignition key.

M.U.T.-II connected
Within 10 seconds
CAUTION Before connecting or disconnecting the V.C.I., turn the ignition switch to the "LOCK" (OFF) position.
6
AC211686
Hazard warning switch
ON 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 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 lock and unlock operations. 7. If you are using two or more transmitters or have added a second transmitter, the next transmitter should be registered within one minute after registering the code for the previous transmitter. The registration procedure is common for all the transmitters. 8. Registration mode will be cancelled under the following conditions: When the secret code for four transmitters has been registered; When passing one minute after finishing the registration of all transmitters; When the M.U.T.-II is disconnected from the diagnosis connector; When the key is removed from the key cylinder; When no secret codes have been registered for more then one minute after the registration mode is entered; 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.
16-Pin
MB991911
MB991824
AC309970 AC
3. Connect the V.C.I. to the diagnosis connector.

V.C.I. connected Within 10 seconds
Hazard warning lamp switch
ON OFF
ACX00571 AQ
WHEN THE SPECIAL TOOL V.C.I. (MB991824) IS USED

1. Check that the doors lock normally when the key is used.
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 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 lock and unlock operations.
42-46
BODY
7. If you are using two or more transmitters or have added a second transmitter, the next transmitter should be registered within one minute after registering the code for the previous transmitter. The registration procedure is common for all the transmitters. 8. Registration mode will be cancelled under the following conditions: When the secret code for four transmitters has been registered; When passing one minute after finishing the registration of all transmitters; When the V.C.I. is disconnected from the diagnosis connector; When the key is removed from the key cylinder; When no secret codes have been registered for more then one minute after the registration mode is entered; 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.
TRANSMITTER
TRANSMITTER
M1428002800086
DISASSEMBLY SERVICE POINT BATTERY REMOVAL

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.
Transmitter assembly
Case
Master key
AC303199
Case side Battery Master key side

AC304118
AC304142AB
Since the battery is incorporated into the transmitter assembly, disassemble the transmitter assembly to remove the battery.
BODY
42-47
ASSEMBLY SERVICE POINT BATTERY INSTALLATION

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.
1. Install a new battery to the transmitter assembly with its (+) side facing towards the case side. Battery required for replacement: Coin type battery CR1616 2. Check the transmitter operation.
INSPECTION
M1428003800067
TRANSMITTER BATTERY CHECK
Case
AC004486
Master key
AC303199
Measure the voltage of the battery. If the voltage of the battery is not within the standard value, replace the battery. Standard value: 2.5 3.2 V
-
()
(+)
Case side Battery Master key side

AC304118
AC304142AD
NOTES
51-1
GROUP 51
EXTERIOR
CONTENTS
FRONT BUMPER ASSEMBLY . . . . .
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . . DISASSEMBLY AND REASSEMBLY. . . . .
51-2
51-2 51-2 51-3
WINDSHIELD WIPER AND WASHER

SERVICE SPECIFICATION . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE . . . . . . . . . . . . . . . WINDSHIELD INTERMITTENT WIPER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
51-18
51-18 51-18 51-19 51-19 51-19 51-20 51-20 51-21 51-23 51-23 51-24
REAR BUMPER ASSEMBLY . . . . . .

REMOVAL AND INSTALLATION . . . . . . . . DISASSEMBLY AND REASSEMBLY. . . . .
51-5
51-5 51-6
SIDE AIR DAM . . . . . . . . . . . . . . . . . .

ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . .
51-8
51-8 51-8
GARNISHES AND MOULDINGS. . . .

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . .
51-10
51-10 51-10
MARK . . . . . . . . . . . . . . . . . . . . . . . . .
51-25
51-25
DOOR SASH TAPE . . . . . . . . . . . . . .

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . DOOR SASH TAPE . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . .
51-12
51-12 51-12 51-12
DOOR MIRROR . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATION . . . . . . . . . . . . SPECIAL TOOL. . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . DIAGNOSIS TROUBLESHOOTING FLOW TROUBLE SYMPTOM CHART . . . . . . . . . . SYMPTOM PROCEDURES . . . . . . . . . . . . DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
51-27
51-27 51-27 51-27 51-27 51-27 51-28 51-35 51-35 51-36
REAR SPOILER. . . . . . . . . . . . . . . . .
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION . . . . . . . .
51-16
51-16 51-16
51-2
ADHESIVE
EXTERIOR
FRONT BUMPER ASSEMBLY

M1511000501195
Item Front three-diamond mark
Specification Double-sided tape: Generic products 0.8 mm thickness

M1511001401113
AC407353
7
A C A C Section A A
6 1 3 6 4
Section B B Clip
B B B B
1, 2
Section C C Clip
Clip Fender
2
B
AC504541AB
Removal steps 1. Side under cover 2. Centre under cover 3. Under cover centre bracket 4. Front under cover
Removal steps (Continued) 5. Splash shield mounting clips Water spray hose connection 6. Front bumper assembly 7. Front bumper stay assembly
EXTERIOR
51-3

M1511001601117
AC407316
View A
Section B B
10
1
Screw
1
B B Hook Double-sided tape: Generic products 0.8 mm thickness
AC504538
10 11 12
18 19
7N
N 13
21 9 13 N
20
22
15
5
C
14 15 16 N 17
Section C C
4 5
21
Clip
12
6
AC309968
N2
3
AC504539AB
Disassembly steps 1. Front three-diamond mark 2. Front bumper nut 3. Front licence plate garnish 4. Front bumper cover A 5. Front bumper cover B 6. Air dam skirt panel 7. Clip A 8. Front bumper centre net 9. Front bumper lower plate 10. Grille side cover 11. Front bumper upper plate
Disassembly steps (Continued) 12. Front bumper upper support 13. Clip B 14. Air intake cover 15. Front bumper net <<A>> >>A<< 16. Rivets 17. Bumper side net (LH) 18. Oil cooler duct (RH) 19. Bumper side net (RH) 20. Front bumper side plate 21. Front bumper upper reinforcement 22. Front bumper face
51-4
DISASSEMBLY SERVICE POINT <<A>> RIVETS REMOVAL
Drill
EXTERIOR
ASSEMBLY SERVICE POINT >>A<< RIVETS ASSEMBLY

Rivet tool Front bumper face
Bumper face
Rivet
Front bumper side plate

AC100411AB
Front bumper face Portion A
Use a drill (4.0 mm) to make a hole in the rivet to break it, and then remove the rivet.
1 Rivet 2 3 Flange 4 Rivet

AC305178AC
Rivet tool
Use the rivet tool shown in the illustration to attach the rivet by the following procedures. 1. Insert the rivet into the front bumper face and front bumper side plate. 2. Place the rivet tool over portion A of the rivet. 3. While pushing the flange surface of the rivet with the rivet tool, press the handle of the tool. 4. The thin part of portion A is cut out and the rivet is held in position.
EXTERIOR
REAR BUMPER ASSEMBLY
51-5

M1511001901011
Pre-removal and Post-installation Operation Rear Combination Lamp Removal and Installation (Refer to GROUP 54A, Rear Combination Lamp P.54A-67.) Rear End Trim Removal and Installation (Refer to GROUP 52A, Trims P.52A-10.) Trunk Room Side Trim Lid Removal and Installation (Refer to GROUP 52A, Trims P.52A-10.)
Section A A
Clip
Splash shield
1 3
AC504546AB
Removal steps 1. Splash shield mounting screw
Removal steps (Continued) 2. Rear bumper bracket 3. Rear bumper assembly
51-6
EXTERIOR
M1511002100639

8
AC407263
6N 5N 9
N1
10
4 2
AC504547AB
Disassembly steps <<A>> >>A<< 1. Rivets A <<A>> >>A<< 2. Rivets B Licence plate lamp assembly 3. Rear bumper face support side reinforcement 4. Rear bumper under cover
Disassembly steps (Continued) 5. Clip A 6. Clip B 7. Licence plate lamp bracket 8. Rear bumper reinforcement 9. Rear bumper side plate 10. Rear bumper face
EXTERIOR
51-7
DISASSEMBLY SERVICE POINT <<A>> RIVETS A AND B REMOVAL

Drill
ASSEMBLY SERVICE POINT >>A<< RIVETS A AND B ASSEMBLY

Rivet tool Rear bumper face
Bumper face
Rivet
Rear bumper side plate

AC100411AB
Y0412AU
Rear bumper face Portion A
Use a drill (4.0 mm) to make a hole in the rivet to break it, and then remove the rivet.
1 Rivet 2 3 Flange 4 Rivet

18E0192 AC005876AE
Rivet tool
Use the rivet tool shown in the illustration to attach the rivet by the following procedures. 1. Insert the rivet into the rear bumper face and rear bumper side plate. 2. Place the rivet tool over portion A of the rivet. 3. While pushing the flange surface of the rivet with the rivet tool, press the handle of the tool. 4. The thin part of portion A is cut out and the rivet is held in position.
51-8
ADHESIVE
EXTERIOR
SIDE AIR DAM
SIDE AIR DAM

M1511000500932
Item Side air dam
Specification Double-sided tape: General products 5 mm width and 1.2 mm thickness

M1511005500153
Section A A Clip
1
A A
Adhesive tape: double-sided tape [ 5 mm width and 1.2 mm thickness ]
AC310080 AB
REMOVAL <<A>> >>A<< 1. Side air dam
EXTERIOR
SIDE AIR DAM
51-9
REMOVAL SERVICE POINT <<A>> SIDE AIR DAM REMOVAL

Gently lift and remove the side air dam. If there is any double-sided tape remaining on the side air dam, remove according to the following instructions. <Remove double-sided tape remaining on the body surface>
AC304145
Double-sided tape
Protection tape
AC304143 AB
1. Attach protection tape all the way along the edges of the double-sided tape which is still adhering to the body.
Double-sided tape
1. Scrape off the double-sided tape on the side air dam 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 air dam.
INSTALLATION SERVICE POINT >>A<< SIDE AIR DAM INSTALLATION.

Backing paper
AC304144 AB
Adhesive tape
AC310126 AB
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. <Remove double-sided tape remaining on side air dam and adhere double-sided tape (when re-using side air dam)>
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 air dam. NOTE: If the double-sided tape is difficult to affix in cold temperature, etc., warm the bonding surfaces of the body and side air dam to about 40 60C before affixing the tape. 3. Firmly press in the side air dam.
51-10
SPECIAL TOOL
Tool Number MB990449
EXTERIOR
GARNISHES AND MOULDINGS

M1511000601136
Name
Use
Window moulding remover Removal of drip moulding
MB990449

Section A A Section B B
M1511004400238
Section C C
Section D D
2
Clip
Y0622AU
2
Clip
Clip
Y0623AU W0740AU
Clip
Y0624AU
Section E E
Section F F
2 2
Clip
Y0729AU
N
C
Clip
D E
N5
B
W0772AQ
N 10
B
N4 N3
A
8N
7
F
AC310124 AB
<<A>> >>C<< >>B<< >>B<< >>B<<
Removal 1. Delta outer garnish Roof drip moulding removal steps 2. Roof drip moulding 3. Front drip moulding clip A 4. Front drip moulding clip B 5. Front drip moulding clip C
>>B<< >>A<< >>A<< >>A<<
Roof drip moulding removal steps 6. Rear drip moulding clip 7. Drip moulding clip A 8. Drip moulding clip B 9. Drip moulding clip C 10. Roof drip moulding clip
EXTERIOR
51-11
REMOVAL SERVICE POINT <<A>> ROOF DRIP MOULDING REMOVAL

CAUTION If the moulding has become warped, it should not be reused.
Front pillar outer
Portion B
Portion A
AC003629AD
2. After installing the clip to the front pillar outer in alignment with its portion A, cut from portion B.
MB990449
AC003626AB
Use special tool window moulding remover (MB990449) to pry out the moulding.
INSTALLATION SERVICE POINTS >>A<< DRIP MOULDING CLIP C/DRIP MOULDING CLIP B/DRIP MOULDING CLIP A INSTALLATION
1. The drip moulding clips A, B and C differ according to where they are used, so check the identification colour before installation. Applicable location Drip moulding clip A Drip moulding clip B Drip moulding clip C Identification colour Yellow Blue Milky white
>>B<< REAR DRIP MOULDING CLIP/FRONT DRIP MOULDING CLIP C/FRONT DRIP MOULDING CLIP B/FRONT DRIP MOULDING CLIP A INSTALLATION
The front drip moulding clips A, B, C and rear drip moulding clip differ according to where they are used, so check the identification colour before installation. Applicable location Front drip moulding clip A Front drip moulding clip B Front drip moulding clip C Rear drip moulding clip Identification colour Orange Purple Blue Grey
>>C<< ROOF DRIP MOULDING INSTALLATION

Install the clips to the roof drip moulding before installing the moulding to the vehicle body.
51-12
SPECIAL TOOL
EXTERIOR
DOOR SASH TAPE
DOOR SASH TAPE

M1511000601664
Tool
Number MB990528
Name
Use
Stripe tape spatula Installation of door sash tape
MB990528
DOOR SASH TAPE

M1511024100176
Pre-removal and Post-installation Operation Door Trim Assembly Removal and Installation (Refer to GROUP 52A P.52A-12). Door Beltline Weatherstrip Inner Removal and Installation (Refer to GROUP 42 P.42-33). Door Opening Weatherstrip Outer Removal and Installation (Refer to GROUP 42 P.42-33). Door Window Glass Runchannel Removal and Installation (Refer to GROUP 42 P.42-33). Door Beltline Moulding Removal and Installation (Refer to GROUP 42 P.42-33).
Y1897AU
4N
3N
AC403531 AB
<<A>> <<A>>
>>A<< >>A<<
1. 2.
Removal steps Front door sash tape upper Front door sash tape rear
<<A>> <<A>>
>>A<< >>A<<
3. 4.
Rear door sash tape upper Rear door sash tape front
EXTERIOR
DOOR SASH TAPE
51-13
REMOVAL SERVICE POINT <<A>> DOOR SASH TAPES REMOVAL

CAUTION Pay attention to keep from getting burned by hot door panel or tapes.
1. Use a hair drier to warm the tape. 2. Peel the tip of the tape with your finger, and then peel off the tape parallel to the application surface.
<Pushing direction> 3 to 7 cm/sec. MB990528 10 to 20 mm Door sash tape Backing paper <Pulling direction> 3 to 7 cm/sec. 10 to 20 mm MB990528 30 to 45 Door sash tape Backing paper
AC303428 AB
40 to 50
INSTALLATION SERVICE POINT >>A<< DOOR SASH TAPES INSTALLATION

CAUTION The ambient temperature should be 20 to 30C. Ensure that the working area is clean. Ideally, the tape application should be done at ambient temperature of 25C. If ambient temperature is less than 15C, heat the tape and application surface to a temperature of 20 to 30C. If ambient temperature is 35C or higher, cool down them. The adhesive property of the tape is deteriorated at low temperature, so the tape may come adrift easily. Meanwhile, it gets softened at hot temperature. When beginning to apply the tape, pay particular attention. If the end of the tape cannot be applied to the specified position with an accuracy of less than 1 mm, it may cause the poor appearance or adhesion.
Use the special tool stripe tape spatula (MB990528) to apply the tape with a steady pace and pressure. If you do not apply the tape with a steady pace or pressure, or abort the application, a shallow groove (lateral groove called as "Shock line") may be present on the tape surface. Meanwhile, if you apply it too quickly, air bubbles may be formed under the tape. 1. Wrap a soft cloth (synthetic fibre) around the tip of the special tool. 2. Use isopropyl alcohol to degrease the tape application surface. 3. Wipe away dirt from the tape.
51-14
EXTERIOR
DOOR SASH TAPE
3.5 mm 3.5 mm
Tape overlap: 3.0 mm RH only
Tape overlap: 3.0 mm 3.5 mm 3.5 mm
Tape perforateline
Backing paper cut-line
Tape perforateline
Front door sash tape rear Front door sash tape upper
Rear door sash tape upper Rear door sash tape front
Backing paper cut-line 3.5 mm
RH only
RH only
Backing paper cut-line 3.5 mm
5.0 mm
Tape perforateline 7.0 mm
: Tape locating points : T-stud for door opening weatherstrip attaching locations (5 pieces in all).
AC403580AC
4. Apply the door sash tapes according to the procedures shown below. (1) Align a tape with specified application position. If necessary, use a magnet to secure it.
NOTE: . Align the front door sash tape upper at the rear end. Align the rear door sash tape upper at the front end. Align the front door sash tape rear/rear door sash tape front at the upper end.
EXTERIOR
DOOR SASH TAPE
51-15
(2) As for the front/rear door sash tape upper, peel off the backing paper under the tape by the backing paper cut-line and apply the tape temporarily.
Backing paper
(5) As for the front door sash tape rear/rear door sash tape front, peel off the application tape in the direction of 180 from bottom to top. (6) Remove unnecessary part of the tape at tape perforate-line.
60 120
Door sash tape
MB990528
AC303110AB
Hemming part
AC303415AB
(3) Peel off the backing paper and cut it as necessary.
(7) Press the folded area of the tape at 3 steps securely(60, 120 and holding), rolling in toward the vehicle inside direction.
Tape pasting onto corner (viewed from inside) A section
MB990528 Door sash tape Backing paper
AC402197AD
(4) While peeling off the remaining backing paper, press the tape by a special tool (MB990528). NOTE: . Apply the front door sash tape upper from rear to front. Apply the rear door sash tape upper from front to rear. Apply the front door sash tape rear/rear door sash tape front from top to bottom.
AC303443AE
(8) As for the front door sash tape rear/rear door sash tape front, roll in the A section of the tape upper corner toward the vehicle inside with your palm securely.
51-16
ADHESIVE
EXTERIOR
REAR SPOILER
REAR SPOILER
M1511000500512
Item Rear spoiler assembly <Type A> Rear spoiler assembly <Type B>
Specification Double-sided tape: Generic products 3 mm thickness Double-sided tape: Generic products 1.6 mm thickness

M1511006100211
<TYPE A>
4 3
1 3 1
Adhesive tape affixed location
4 3
Double-sided tape: Generic products, 3 mm thickness

AC310062AC
Removal steps Trunk lid bumper (Refer to GROUP 42, Trunk Lid P.42-37). 1. Cap <<A>> >>A<< 2. Rear spoiler assembly 3. Gasket
Removal steps (Continued) 4. Rear spoiler High-mounted stop lamp (Refer to GROUP 54A, High-mounted Stop Lamp P.54A-69).
EXTERIOR
REAR SPOILER
51-17
<Type B>
5.2 0.2 Nm
5.2 0.2 Nm
5.2 0.2 Nm
1
Adhesive tape affixed location
5.2 0.2 Nm
Double-sided tape: Generic products, 1.6 mm thickness

AC504553AB
Removal steps Trunk lid bumper (Refer to GROUP 42, Trunk Lid P.42-37). 1. Cap <<A>> >>A<< 2. Rear spoiler assembly
INSTALLATION SERVICE POINT >>A<< REAR SPOILER ASSEMBLY INSTALLATION

Install by the same procedure as described in SIDE AIR DAM INSTALLATION (Refer to P.51-8).
REMOVAL SERVICE POINT <<A>> REAR SPOILER ASSEMBLY REMOVAL

Remove by the same procedure as described in SIDE AIR DAM REMOVAL (Refer to P.51-8).
51-18
SERVICE SPECIFICATION
EXTERIOR

M1511000300422
Item 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
Standard value 69 5
SPECIAL TOOLS
M1511000601783
Tool
Number MB991502
Use Check the windshield intermittent wiper interval
B991502
MB991824
MB991827
DO NOT USE
MB991910
MB991911
M.U.T.-III sub-assembly A: Vehicle Communication Interface (V. C. I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A (Vehicles with CAN communication system) D: M.U.T.-III main harness B (Vehicles without CAN communication system) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
Check the windshield intermittent wiper interval
MB991825
MB991826 MB991955
EXTERIOR
51-19
Use
Tool
Number MB991529
Name
Diagnosis code check Input signal check by using a harness voltmeter
MB991529
MB991223 a. MB991219 b. MB991220 c. MB991221 d. MB991222
Harness set a. Check harness b. LED harness c. LED harness adapter d. Probe
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
DO NOT USE
MB991223BA
MB992006
Extra fine probe
MB992006
TROUBLESHOOTING
M1511000700323
ON-VEHICLE SERVICE
WINDSHIELD INTERMITTENT WIPER INSPECTION
M1511021900054
The windshield wiper and washer are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to GROUP 54B, Troubleshooting P.54B-13 or GROUP 54C, Troubleshooting P.54C-4. NOTE: Even when the ETACS-ECU has failed, the windshield wiper can work at low speed as fail-safe mode. (Normally, the windshield wiper operates when the ignition switch is at the "ACC" position. But, if it enters the fail-safe mode, the wiper can operate only when the ignition switch is at the "ON" position.)
1. If the windshield intermittent wiper interval adjusting knob is operated, the wiper interval should change. 2. Holding the windshield intermittent wiper interval adjusting knob, input the simulated vehicle speed with M.U.T.-II / III and check that the wiper interval changes as the vehicle speed changes. 3. If not, carry out the troubleshooting (Refer to GROUP 54B, Troubleshooting P.54B-13 or GROUP 54C, Troubleshooting P.54C-4).
51-20
WINDSHIELD WIPER
EXTERIOR
M1511007900209
View A
6
B A A B
Section A A
6, 7
Note :Indicates the clip (A) locations.
Clip (A) :Indicates the clip (B) locations. Section B B
1 2 5 4
A
3, 4 3
Clip (B)
6
27 3 Nm
4 8
8.9 1.9 Nm 7.4 1.4 Nm
7 9
AC211876AF
Wiper blade assembly removal steps >>B<< 1. Wiper blade assembly >>A<< 2. Wiper blade Windshield wiper motor and link assembly removal steps 3. Cover 4. Wiper arm
<<A>>
Windshield wiper motor and link assembly removal steps (Continued) 5. Hood weather strip 6. Front deck garnish (Passenger's side) 7. Front deck garnish (Driver's side) 8. Windshield wiper motor assembly 9. Link assembly
EXTERIOR
51-21
NOTE: For removal and installation of the wiper and washer switch, refer to GROUP 54A, Column switch P.54A-73.
>>B<< WIPER BLADE ASSEMBLY INSTALLATION
REMOVAL SERVICE POINT <<A>> WINDSHIELD WIPER MOTOR ASSEMBLY REMOVAL

1. Remove the windshield wiper motor assembly mounting bolts.
CAUTION Be careful not to damage the windshield glass when removing the windshield wiper motor assembly.
Windshield wiper motor assembly
Front deck garnish terminal

AC000427AD
Install the wiper blade at the specified position (standard value). Standard value: (A) 69 5 mm
INSPECTION
M1511008000209
FRONT WIPER MOTOR CHECK

Link assembly connection Flat-tipped screwdriver
AC310927AB
Inspect the windshield wiper motor by removing the harness connector with the motor attached to the vehicle.
2. Use the flat-tipped screwdriver to disengage the link between the windshield wiper motor assembly and the link assembly.
WIPER MOTOR AT LOW OR HIGH SPEED OPERATION
INSTALLATION SERVICE POINTS >>A<< WIPER BLADE INSTALLATION

Backing Wiper blade
Wiper blade Backing Section A A
1 2 3 4 5
A A Backing
Check operation
1 2 3 4 5
AC101090AD
Low speed
CAUTION Ensure that the backings are bent in the shown direction, and then install the backings to the wiper blade.
1 2 3 4 5
High speed AC310929 AB
Connect the battery to the windshield wiper motor to inspect the operation of motor rotation in low or high speed.
51-22
EXTERIOR
WIPER MOTOR AT STOP POSITION OPERATION
Switch position OFF
Tester connection
Specified condition
6 11, 6 10, Open circuit 6 9, 6 8, 6 7 6 11 6 10 Less than 2 ohms
Windshield mist wiper switch

1 2 3 4 5
Windshield intermittent wiper switch Windshield low-speed wiper switch Windshield high-speed wiper switch Windshield washer switch
69
Stop position check
1 2 3 4 5
68
(A) Low speed
67
1 2 3 4 5
(B) Automatic stop AC310930 AB
WINDSHIELD INTERMITTENT WIPER VOLUME CHECK
1. Connect the battery to the windshield wiper motor to rotate the motor in a low speed as shown in the illustration (A) and disconnect the battery during rotation to stop the motor. 2. Connect between the terminals and the battery as shown in the illustration (B) and confirm whether the motor stops at the automatic stop position after rotating in a low speed.
WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH CHECK

1 2 3 4 5 6 7 8 9 10 11
AC000417
1 2 3 4 5 6 7 8 9 10 11
AC201004
Check continuity between the switch terminals.
Check that the resistance varies between 0 and 1 k when the windshield intermittent volume is turned from FAST to SLOW after measuring resistance between connector terminals 3 and 6 at the column switch.
EXTERIOR
51-23
WINDSHIELD WASHER
M1511008200407
4
5.0 1.0 Nm
2 1
AC310066 AB
Washer hose removal steps Splash shield <Right side> (Refer to GROUP 42, Fender P.42-6). Cowl side trim, front scuff plate, centre pillar trim, lower, rear scuff plate (Refer to GROUP 52A, Trim P.52A-10). Rear seat (Refer to GROUP 52A, Seat P.52A-20). 1. Front washer hose
Windshield washer nozzle removal steps Connection of washer hose 2. Windshield washer nozzle Washer tank and washer motor removal steps Rear end trim, trunk side trim (Refer to GROUP 52A, Trim P.52A-10). Connection of front washer hose 3. Washer tank assembly 4. Washer tank bracket 5. Front washer motor
51-24
EXTERIOR
NOTE: For removal and installation of the wiper and washer switch, refer to GROUP 54A, Column switch P.54A-73.
INSPECTION
M1511008300200
FRONT 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.
1 2
WINDSHIELD WASHER FLUID EJECTION CHECK

Move the nozzle to adjust the position so that the spray is in the area shown in the illustration.
CAUTION On RH drive vehicles, the illustration is symmetrical.

AC211378
Units: mm 25 90 130 25 50 25 40 25 90 50 25 25 50 25
110 25
35
75
25
85
<Right>
<Left>
440 220
430 220
Ceramic line terminal Windshield washer nozzle perpendicular 600
Windshield washer nozzle perpendicular
Windshield washer nozzle
AC309919 AB
EXTERIOR
MARK
51-25
MARK
M1511011801424
2 1 3
AC504528AC
Removal 1. Front three-diamond mark (Refer to P.51-3). >>A<< 2. Rear three-diamond mark
Removal (Continued) >>A<< 3. LANCER mark >>A<< 4. Evolution mark
51-26
INSTALLATION SERVICE POINT >>A<< MARK APPLICATION
1. Installation position
Rear three-diamond mark
EXTERIOR
MARK
Attach each mark to the position shown in the illustration.
84 1 mm
Trunk lid press line
Centre line of vehicle

AC309915AF
LANCER mark, Evolution mark
Trunk lid end line
48 1 mm
41 1 mm 12 1 mm 35 1 mm
Trunk lid end line

AC210731AE
2. Installation procedure (1) Use 3M ATD Part number 8906 or equivalent to clean the mark installation surfaces on the body.
CAUTION When attaching the marks, the ambient temperature should be 20 38C and the air should be completely free of dust. If the ancient temperature is lower than 20C, the marks and the places on the vehicle body where the marks are to be attached should be heated to 20 38C. (2) Peel off the protection sheet on the back of the marks to paste it on the installation position.
EXTERIOR
DOOR MIRROR
51-27
DOOR MIRROR
SERVICE SPECIFICATION
M1511000300347
Item Heated door mirror operation current
Standard value 5.9 7.8
SPECIAL TOOL
M1511000601103
Tool
Number MB990784
Name Ornament remover
Use Removal of remote controlled mirror switch
MB990784
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points P.00-5.
M1511014600169
TROUBLE SYMPTOM CHART

M1511015000245
Symptom All heated door mirrors do not operate Right or left heated door mirror does not operate
Inspection procedure 1 2
Reference page P.51-28 P.51-29
51-28
SYMPTOM PROCEDURES
EXTERIOR
DOOR MIRROR
Inspection Procedure 1: All Heated Door Mirrors do not Operate
Heated door mirror circuit REAR WINDOW DEFOGGER RELAY

REAR WINDOW DEFOGGER
REMOTE CONTROLLED MIRROR (LH)
MIRROR HEATER
MIRROR HEATER
REMOTE CONTROLLED MIRROR (RH)
NOTE LH drive vehicles RH drive vehicles
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
COMMENTS ON TROUBLE SYMPTOM

The heated door mirrors should works for approximately 11 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.
DIAGNOSIS PROCEDURE
STEP 1. Check the rear window defogger. Check that the rear window defogger system should work normally.
Q: Is the check result normal? YES : Go to Step 2. NO : Troubleshoot the rear window defogger
PROBABLE CAUSE
Damaged harness wire and connector
(Refer to GROUP 55, Troubleshooting P.55-63).
EXTERIOR
DOOR MIRROR
51-29
STEP 2. Connector check: C-214 junction block connector

Connector: C-214 Junction block (Front view)
Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP
00 How to Cope with Intermittent Malfunction P.00-5). NO : Repair the defective connector.
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
AC304913 AC
Inspection Procedure 2: Right or Left Heated Door Mirror does not Operate
Heated door mirror circuit REAR WINDOW DEFOGGER RELAY

REAR WINDOW DEFOGGER
REMOTE CONTROLLED MIRROR (LH)
MIRROR HEATER
MIRROR HEATER
REMOTE CONTROLLED MIRROR (RH)
NOTE LH drive vehicles RH drive vehicles
SB : Sky blue
51-30
EXTERIOR
DOOR MIRROR
If either of the heated door mirrors does not work, the door mirror assembly may be defective.
PROBABLE CAUSES
Malfunction of the door mirror assembly Damaged harness wires and connectors
STEP 3. Check the door mirror assembly (RH). Check that the heater element of the door mirror assembly (RH) is in good condition (Refer to P.51-36).
Q: Is the check result normal? YES : Go to Step 4. NO : Replace the door mirror assembly (RH).
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.
STEP 4. Resistance measurement at the E-10 door mirror assembly (RH) connector.
Connector: E-10
STEP 2. Connector check: E-10 door mirror assembly (RH) connector

Connector: E-10
Harness side
AC304817 AC
(1) Disconnect the connector, and measure at the wiring harness side.
Harness side Connector E-10 (harness side)

AC304817 AC
Q: Is the check result normal? YES : Go to Step 3. NO : Repair the defective connector.
AC304821 AC
(2) Resistance between E-10 door mirror assembly connector terminal No.4 and body earth OK: 2 or less
Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.
EXTERIOR
DOOR MIRROR
51-31
Connector: E-10
STEP 5. Check the wiring harness between E-10 door mirror assembly (RH) connector terminal No.4 and body earth.
Connector: E-10
(2) Rear window defogger switch: ON
Harness side
Harness side
AC304817 AC
AC304817 AC
Check the earth wires for open circuit. NOTE:

Connector: C-110
Connector E-10 (harness side)

AC304826 AC
AC304819 AC
Prior to the wiring harness inspection, check intermediate connector C-110 and repair if necessary.
(4) Voltage between E-10 door mirror assembly connector terminal No.1 and body earth OK: System voltage
00 How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness.
00 How to Cope with Intermittent Malfunction P.00-5). NO : Go to Step 7.
STEP 6. Voltage measurement at the E-10 door mirror assembly (RH) connector. (1) Turn the ignition switch to the ON position.

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
AC304913 AD
51-32
EXTERIOR
DOOR MIRROR
STEP 8. Check the wiring harness between E-10 door mirror assembly (RH) connector terminal No.1 and C-214 junction block connector terminal No.3.
Connector: E-10
STEP 9. Connector check: E-03 door mirror assembly (LH) connector

Connector: E-03
Harness side Harness side

AC304818 AC
AC304817 AC
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 P.51-36).
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
Q: Is the check result normal? YES : Go to Step 11. NO : Replace the door mirror assembly (LH).
AC304913 AD
Check the power supply line for open circuit. NOTE:

Connector: C-110
STEP 11. Resistance measurement at the E-03 door mirror assembly (LH) connector.
Connector: E-03
Harness side
AC304818 AC AC304819 AC
AC310825 AB
(2) Resistance between E-03 door mirror assembly connector terminal No.4 and body earth OK: 2 or less
EXTERIOR
DOOR MIRROR Q: Is the check result normal? YES : Go to Step 14. NO : Go to Step 12.
51-33
STEP 12. Check the wiring harness between E-03 door mirror assembly (LH) connector terminal No.4 and body earth.
Connector: E-03
STEP 14. Measure the voltage at the E-03 door mirror assembly (LH) connector. (1) Turn the ignition switch to the ON position. (2) Rear window defogger switch: ON
Connector: E-03

AC304818 AC
AC304818 AC
Check the earth wires for open circuit. NOTE:

Connector: C-17

AC304828 AC
AC304820 AC
(4) Voltage between E-03 door mirror assembly connector terminal No.1 and body earth OK: System voltage

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
AC304913 AD
51-34
EXTERIOR
DOOR MIRROR Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP
STEP 15. Check the wiring harness between E-03 door mirror assembly (LH) connector terminal No.1 and C-214 junction block connector terminal No.3.
Connector: E-03
Harness side
AC304818 AC
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
AC304913 AD
Check the power supply line for open circuit. NOTE:

Connector: C-17
AC304820 AC
EXTERIOR
DOOR MIRROR
51-35
DOOR MIRROR
M1511006400461
8 7
5 6
Section A A Claw
1 3
2 2
A Note : Claw positions A
1
AC304733 AC
Door mirror removal steps 1. Cover 2. Delta inner cover 3. Harness connector 4. Door mirror assembly 5. Door mirror body assembly <<A>> >>A<< 6. Mirror
Remote controlled mirror switch removal steps 7. Instrument panel ornament (Refer to GROUP 52A, Instrument Panel P.52A-2). 8. Remote controlled mirror switch
51-36
REMOVAL SERVICE POINT <<A>> MIRROR REMOVAL
Section A A Flat-tipped screwdriver Mirror
EXTERIOR
DOOR MIRROR
INSTALLATION SERVICE POINT >>A<< MIRROR INSTALLATION

Section A A Flat-tipped screwdriver Mirror
Pivot Plate
Pivot plate
A A
A A
A A
A A
Protective tape Notch
00007256 AC000441AB
00007258 AC000442 AB
Push the top of the mirror with your hand to tilt it and attach the protective tape as shown in the illustration. Then insert a flat-tipped screwdriver in between the notch at the rear of the mirror and the pivot plate, and disengage the bottom of the mirror.
While supporting the clip position on the underside of the pivot plate with a flat-tipped screwdriver, press the clip at the front of the mirror to engage the bottom of the mirror.
INSPECTION
M1511006500372
ELECTRIC REMOTE CONTROL MIRROR OPERATION CHECK
Battery connection Connect terminal 5 to the negative battery terminal. Connect terminal 7 to the positive battery terminal. Connect terminal 7 to the negative battery terminal. Connect terminal 5 to the positive battery terminal.
Direction operation Mirror glass should face upward Mirror glass should face downward Mirror glass should face to the right Mirror glass should face to the left
1 2 3 4 5 6 7
AC202548
Check that the mirror moves as described in the table when each terminal is connected to the battery.
Connect terminal 5 to the negative battery terminal. Connect terminal 6 to the positive battery terminal. Connect terminal 6 to the negative battery terminal. Connect terminal 5 to the positive battery terminal.
EXTERIOR
DOOR MIRROR
51-37
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 OFF
Tester connection
Specified condition
1 2 3 4 5 6 7
AC202548
9 2, 9 3, 9 6, Open circuit 9 10, 9 11, 1 2, 1 3, 1 6, 1 10, 1 11 9 6, 9 10, 9 Open circuit 11, 1 6, 1 10, 1 11 1 6, 9 11 1 11, 6 9 1 6, 9 10 1 10, 6 9 9 2, 9 3, 9 6, Open circuit 1 2, 1 3, 1 6 1 6, 3 9 1 3, 6 9 1 6, 2 9 1 2, 6 9 Less than 2 ohms Less than 2 ohms
Left side OFF
The resistance value between door mirror connector terminals 1 and 4 should meet the standard value with the ambient temperature at a steady 25C. Standard value: 5.9 7.8
Up Down Right Left Right side OFF Up Down Right Left
NOTES
13A-1
GROUP 13A
MULTIPORT FUEL INJECTION (MPI)

CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . .
DIAGNOSIS TROUBLESHOOTING FLOW DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . INSPECTION CHART FOR DIAGNOSIS CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13A-2 13A-5 13A-6 13A-9

13A-9 13A-9 13A-17
FUEL PUMP OPERATION CHECK . . . . . . 13A-399 COMPONENT LOCATION . . . . . . . . . . . . . 13A-400 ENGINE CONTROL RELAY CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-401 FUEL PUMP RELAY CONTINUITY CHECK 13A-402 FUEL PUMP RESISTOR CHECK . . . . . . . . 13A-403 INTAKE AIR TEMPERATURE SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-403 ENGINE COOLANT TEMPERATURE SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13A-403 THROTTLE POSITION SENSOR CHECK . 13A-404 OXYGEN SENSOR CHECK . . . . . . . . . . . . 13A-404 INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A-406 INJECTOR RESISTOR CHECK . . . . . . . . . 13A-407 IDLE SPEED CONTROL SERVO (STEPPER MOTOR) CHECK . . . . . . . . . . . 13A-408 FUEL PRESSURE SOLENOID VALVE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-409 OIL FEEDER CONTROL VALVE CHECK. . 13A-410
INSPECTION PROCEDURE FOR DIAGNOSIS CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-19 INSPECTION CHART FOR TROUBLE SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13A-233 SYMPTOM PROCEDURES . . . . . . . . . . . . 13A-237 DATA LIST REFERENCE TABLE . . . . . . . 13A-372 ACTUATOR TEST REFERENCE TABLE. . 13A-378 CHECK AT THE ENGINE-ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . 13A-379 INSPECTION PROCEDURE USING OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13A-385
INJECTOR . . . . . . . . . . . . . . . . . . . . . 13A-411
REMOVAL AND INSTALLATION . . . . . . . . 13A-411
ON-VEHICLE SERVICE. . . . . . . . . . . 13A-395

THROTTLE BODY (THROTTLE VALVE AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13A-395 THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13A-395 BASIC IDLE SPEED ADJUSTMENT . . . . . 13A-396 FUEL PRESSURE TEST . . . . . . . . . . . . . . 13A-396 FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-398
THROTTLE BODY ASSEMBLY . . . . . 13A-413

ENGINE CONTROL RESISTOR, RELAY . . . . . . . . . . . . . . . . . . . . . . . . 13A-415

ENGINE-ECU . . . . . . . . . . . . . . . . . . . 13A-416
13A-2

GENERAL INFORMATION
GENERAL INFORMATION
The Multipoint Fuel Injection System consists of sensors which detect the engine conditions, the engine-ECU which controls the system based on signals from these sensors, and actuators which operate under the control of the engine-ECU. The engine-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.
M1131000102428
FUEL INJECTION CONTROL

The injector drive times and injector timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continually-changing 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 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.
IDLE SPEED 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 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. The RAM data inside the engine-ECU that is related to the sensors and actuators can be read by means of the M.U.T.-II/III. In addition, the actuators can be force-driven under certain circumstances.

GENERAL INFORMATION
13A-3
OTHER CONTROL FUNCTIONS

1. Fuel Pump Control Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running. 2. A/C Relay Control Turns the compressor clutch of the A/C ON and OFF. 3. Oil feeder control valve control The engine-ECU effects duty cycle control on the engine oil feeder control valve, in accordance with the engine speed. This regulates the supply of engine oil to the intake rocker starft, which switches the cams. 4. Fan Motor Control The revolutions of the radiator fan and condenser fan are controlled in response to the engine coolant temperature and vehicle speed. 5. Purge Control Solenoid Valve Control (Refer to GROUP 17 Engine And Emission Control Evaporative Emission Control System P.17-9). 6. EGR Control Solenoid Valve Control (Refer to GROUP 17 Engine And Emission Control Exhaust Gas Recirculation (EGR) System P.17-13).
GENERAL SPECIFICATIONS
Items Throttle body Throttle bore mm Throttle position sensor Idle speed control servo Engine-ECU Sensors Identification No. Air flow sensor Barometric pressure sensor Intake air temperature sensor Engine coolant temperature Oxygen sensor Vehicle speed sensor Intake camshaft position sensor Exhaust camshaft position sensor Crank angle sensor Detonation sensor Power steering fluid pressure switch Actuators Engine control relay type Fuel pump relay type Injector type and number Injector identification mark Oil feeder control valve EGR control solenoid valve Purge control solenoid valve Fuel pressure control solenoid valve Waste gate solenoid valve Fuel pressure Regulator pressure kPa regulator Specifications 60 Variable resistor type Stepper motor type E6T46983 Karman vortex type Semiconductor type Thermistor type Thermistor type Zirconia type Magnetic resistive element type Hall element type Hall element type Hall element type Piezoelectric type Contact switch type Contact switch type Contact switch type Electromagnetic type, 4 MDL 560P Duty cycle type solenoid valve Duty cycle type solenoid valve Duty cycle type solenoid valve ON/OFF type solenoid valve Duty cycle type solenoid valve 294
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 Intake camshaft position sensor 7 Exhaust camshaft position sensor 8 Crank angle sensor 9 Barometric pressure sensor 10 Engine coolant temperature sensor 11 Detonation sensor Power supply Ignition switch-IG Ignition switch-ST A/C switch A/C load signal Power steering fluid pressure switch Alternator FR terminal Clutch switch Transmission oil temperature sensor Vehicle speed sensor EngineECU 1 Injector 2 Idle speed control servo (Stepper motor) 3 Fuel pressure control solenoid valve 4 Waste gate solenoid valve 5 EGR control solenoid valve 6 Purge control solenoid valve 7 Oil feeder control valve Engine control relay Fuel pump relay 2 Fuel pump relay 3 A/C relay Ignition coil Fan controller Condenser fan relay(High) Condenser fan relay(Low) Engine warning lamp Diagnosis output Alternator G terminal Air flow sensor reset signal Oxygen sensor heater (Front) Oxygen sensor heater (Rear) Tachometer Transmission oil temperature warning lamp
Canister By-pass valve Check valve
5 Throttle position sensor 2 Idle speed control servo (Stepper motor)
6 Purge control solenoid valve 3 Air flow sensor 9 Barometric pressure sensor 4 Intake air temperature sensor
Fuel pressure regulator To fuel tank 7 Exhaust camshaft position sensor 1 Oxygen sensor (front)
3 Fuel pressure control solenoid valve

From fuel pump 7 Oil feeder control valve 6 Intake camshaft position sensor 1 Injector
5 EGR control solenoid valve
EGR valve
10 Engine coolant temperature sensor Air inlet Waste gate actuator 4 Waste gate solenoid valve Catalytic converter 8 Crank angle sensor 11 Detonation sensor 2 Oxygen sensor (rear) Catalytic converter
AK501871AB

13A-5
M1131000301452
Items Basic idle speed r/min Throttle position sensor adjusting voltage mV Throttle position sensor resistance k Idle speed control servo coil resistance (at 20C) Intake air temperature sensor 20C resistance k 0C 20C 40C 60C 80C Engine coolant temperature sensor resistance k 20C 0C 20C 40C 60C 80C Oxygen sensor output voltage (at racing) V Oxygen sensor heater resistance (at 20C) Fuel pressure kPa Front Rear Vacuum hose disconnection Vacuum hose connection Fuel pressure control solenoid valve resistance (at 20C) Fuel pump resistance Injector coil restance (at 20C) Injector fuel leakage rate Drop/minute Resistor (for injector) resistance (at 20C) Oil feeder control valve (at 20C) Specifications 800 50 535 735 3.5 6.5 28 33 13 17 5.3 6.7 2.3 3.0 1.0 1.5 0.56 0.76 0.30 0.42 14 17 5.1 6.5 2.1 2.7 0.9 1.3 0.48 0.68 0.26 0.36 0.6 1.0 4.5 8.0 11 18 289 309 at curb idle Approximately 230 at curb idle 28 36 0.45 0.65 23 1 or less 5.8 6.2 6.9 7.2
13A-6

SPECIAL TOOLS
SPECIAL TOOLS
M1131000601583
Tool
Number MB991502
Use Reading diagnosis code MPI system inspection Measurement of fuel pressure
B991502
MB991824
MB991827
M.U.T.-III sub assembly A: Vehicle communication interface (V.C.I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A (Vehicles with CAN communication system) D: M.U.T.-III main harness B (Vehicles without CAN communication system) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
Reading diagnosis code MPI system inspection Measurement of fuel pressure
DO NOT USE
MB991910
CAUTION If you connect M.U.T.-III main harness A to a vehicle without CAN communication system to use the M.U.T.-III, a pulse signal may interfere with the simulated vehicle speed lines, thus causing the M.U.T.-III inoperative. Therefore, use the M.U.T.-III main harness B (MB991911) instead.
MB991911
MB991825
MB991826 MB991955
MB991348
Test harness set
Inspection using an oscilloscope
MB991348

SPECIAL TOOLS
13A-7
Use Measurement of voltage during troubleshooting Inspection using an oscilloscope Check of idle control servo
Tool
Number MB991709
Name Test harness
MD998478
Test harness (3-pin, triangle) Measurement of voltage during Troubleshooting Inspection using an oscilloscope Measurement of voltage during Troubleshooting Adjusting of throttle position sensor
MD991536
Check harness for throttle position sensor adjustment
MB991536
MD998464
Test harness (4-pin, square) Measurement of voltage during Troubleshooting Inspection of oxygen sensor (front) Measurement of voltage during Troubleshooting Inspection of oxygen sensor (rear) Check at the ECU terminals A: Connector pin contact inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection
MB991658
Test harness
MB991658
MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe
MB991223
13A-8
Tool Number MD998709

SPECIAL TOOLS
Name Adaptor hose
Use Measurement of fuel pressure
MD998742
Hose adaptor
MB991637
Fuel pressure gauge set
MB991637
MB991981
MB991981
MD998706
Injector test set
Checking the spray condition of injectors
MD998706
MB991607
Injector test harness
MB991607
MD998741
Injector test adaptor
MD998741
MB991976
Clip
MB991976

TROUBLESHOOTING
13A-9
TROUBLESHOOTING
Refer to P.00-5, 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
M1131150001572 M1131155501527
ENGINE WARNING LAMP (CHECK ENGINE LAMP)

<L.H.drive vehicles>
Engine warning lamp (check engine lamp) <R.H.drive vehicles>
Engine warning lamp (check engine lamp)

AK501993AB
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.
13A-10

TROUBLESHOOTING
ENGINE WARNING LAMP INSPECTION ITEMS Code No. Diagnosis item P0090 P0100 P0105 P0110 P0115 P0120 P0125* P0130 P0135 P0136 P0141 P0170 P0201 P0202 P0203 P0204 P0234 P0243 P0300 P0301* P0302* P0303* P0304* P0325 P0335 P0340 P0403 P0421 P0443 P0500 P0505 P0551* P0710 P1012 P1021 P1603* Engine-ECU Fuel pressure control valve system Air flow sensor system Barometric pressure sensor system Intake air temperature sensor system Engine coolant temperature sensor system Throttle position sensor system Feedback system monitor Oxygen sensor (front) system Oxygen sensor heater (front) system Oxygen sensor (rear) system Oxygen sensor heater (rear) system Abnormal fuel system No. 1 injector system No. 2 injector system No. 3 injector system No. 4 injector system Turbocharger wastegate system malfunction Waste gate solenoid valve system Random cylinder misfire detection system No. 1 cylinder misfire detection system No. 2 cylinder misfire detection system No. 3 cylinder misfire detection system No. 4 cylinder misfire detection system Detonation sensor system Crank angle sensor system Exhaust camshaft position sensor system EGR control solenoid valve system Warm up catalyst malfunction Purge control solenoid valve system Vehicle speed sensor system Idle speed control system Power steering fluid pressure switch system Transmission oil temperature sensor system Intake camshaft position sensor system Oil feeder control valve system Battery back-up line system

TROUBLESHOOTING
13A-11
NOTE: . If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication between M.U.T.-II/III 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

Refer to P.00-5, GROUP 00 How to Use Troubleshooting/Inspection Service Points.
INSPECTION USING M.U.T.-II/III DATA LIST AND ACTUATOR TESTING

1. Carry out inspection by means of the data list and the actuator test function, if there is an abnormality, check and repair the chassis harness and components. 2. After repairing, re-check using the M.U.T.-II/III 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 M.U.T.-II/III, and then start the engine again and carry out a road test to confirm that the problem has disappeared.
DIAGNOSIS USING DIAGNOSIS 2 MODE

1. Switch the diagnosis mode of the engine control unit to DIAGNOSIS 2 mode using the M.U.T.-II/III. 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 "LOCK" (OFF) position and then back to "ON" position again. NOTE: By turning the ignition switch to "LOCK" (OFF) position, 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 analyzing this "Freeze frame" data with the M.U.T.-II/III, an effective troubleshooting can be performed. The display items of freeze frame data are shown below.
13A-12
DISPLAY ITEM LIST Item No. Data 21 22 24 81 82 88

TROUBLESHOOTING
Unit C r/min. km/h % % OL CL OL-DRV. OL-SYS. CL- HO2S %
Engine coolant temperature sensor Engine speed Vehicle speed Long-term fuel compensation (long-term fuel trim) Short-term fuel compensation (short-term fuel trim) Fuel control condition Open loop Closed loop Open loop due to drive condition Open loop due to system malfunction Closed loop based on one oxygen sensor
87
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.
DRIVE CYCLE
By carrying out the test drive in the following three drive cycle patterns, the all monitoring can be accomplished for the diagnosis codes that is required by the vehicle driving to identify the fault. In other words, doing such a drive allows to regenerate any kind of trouble which involves illuminating the engine warning lamp (check engine lamp) and to verify the repair procedure has eliminated the trouble [the engine warning lamp (check engine lamp) is no longer illuminated].
CAUTION Two technicians should always be in the vehicle when carrying out a test drive. NOTE: Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the diagnosis code if it has been output.
DRIVE CYCLE PATTERN LIST Procedure Monitor item 1 2 3 Catalytic converter monitor Oxygen sensor (front) monitor Other monitor Diagnosis code P0421 P0130 P0136, P0201, P0202, P0203, P0204, P0300, P0301, P0302, P0303, P0304, P0325, P0500, P0551

TROUBLESHOOTING
13A-13
Procedure 1
Catalytic converter monitor Diagnosis code No. Drive cycle pattern P0421 One trip monitor [from start to ignition switch to "LOCK" (OFF) position] will be completed while traveling with the following drive cycle pattern. It will take 16 minutes or more.
6 minutes or more 90 km/h or more (3) Vehicle speed (2) (4) 10 minutes or more 55 - 80 km/h (5,6) Stopping and braking permitted (1) (7) Time
Engine Start
Ignition switch : "LOCK" (OFF) position
AK301815 AB
Inspection condition Test procedure
Atmospheric temperature: 10C or more 1. Engine: start 2. Accelerate until the vehicle speed is 90 km/h or more. 3. Travel for 6 minutes or more while keeping the vehicle speed at 90 km/h or more. 4. Decelerate until the vehicle speed is within 80 km/h or less. 5. While traveling at 55 80 km/h for 10 minutes or more, fully close the throttle at least once in 2 minutes and decelerate for 10 seconds or more. Do not repeat deceleration too often. Vehicle speed may go below 55 km/h after the deceleration. Stopping and braking are permitted. (If stopped or drive at 55 km/h or less for more than 5 minutes the monitoring may be stopped. In this case please restart monitoring from the beginning.) 6. After completing the above deceleration, bring the vehicle speed back to 55 80 km/h and keep it in the range until starting the deceleration again. Repeat the above deceleration at least 5 times. 7. Return the vehicle to the shop, then turn the ignition switch to "LOCK" (OFF) position.
13A-14
Procedure 2
Oxygen sensor (front) monitor Diagnosis code No. Drive cycle pattern P0130

TROUBLESHOOTING
One trip monitor [from start to ignition switch to "LOCK" (OFF) position] will be completed while traveling with the following drive cycle pattern. It will take 16 minutes or more.
16 minutes or more 55 - 80 km/h (3) Vehicle speed
(2)
Stopping and braking permitted
(1)
(4) Time Ignition switch : "LOCK" (OFF) position
Engine Start
AK301816AB
Inspection conditions Test procedure
Engine coolant temperature: After engine warm up Atmospheric temperature: 10C or more 1. Engine: start 2. Accelerate until the vehicle speed is 55 80 km/h. 3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 55 80km/h and travel for 16 minutes or more. Stopping and braking during this operation are permitted. 4. Return the vehicle to the shop, then turn the ignition switch to "LOCK" (OFF) position.

TROUBLESHOOTING
13A-15
Procedure 3
Other monitor Diagnosis code No. Drive cycle pattern P0136, P0201, P0202, P0203, P0204, P0300, P0301, P0302, P0303, P0304, P0325, P0500, P0551 One trip monitor [from start to ignition switch to "LOCK" (OFF) position] will be completed while traveling with the following drive cycle pattern. It will take 21 minutes or more.
16 minutes or more 55 km/h or more (3)
Vehicle speed
(2)
5 minutes or more Engine: Idling Transmission: Neutral (4) (5) Time
(1)
Engine Start
Ignition switch : "LOCK" (OFF) position
AK301817AB
Inspection conditions Test procedure
Engine coolant temperature: After engine warm up Atmospheric temperature: 10C or more 1. Engine: start 2. Accelerate until the vehicle speed is 55 km/h. 3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 55 km/h and travel for 16 minutes or more. 4. Return the vehicle to the shop. 5. After stopping the vehicle, continue idling for 5 minutes, and then turn the ignition switch to "LOCK" (OFF) position. 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: P0421 Oxygen sensor: P0130 Oxygen sensor heater: P0135, P0141
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 M.U.T.-II/III. (If the ECU has judged a item before, the M.U.T.-II/III displays "Complete").
13A-16

TROUBLESHOOTING
FAIL-SAFE FUNCTION REFERENCE TABLE

When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning item Air flow sensor Control contents during malfunction 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. Controls as if the barometric pressure is 101 kPa.
Intake air temperature sensor Barometric pressure sensor
Throttle position sensor No increase in fuel injection amount during acceleration due to the throttle position sensor signal. Engine coolant temperature sensor Intake camshaft position sensor Exhaust camshaft position sensor Controls as if the engine coolant temperature is 80C. Turns the oil feeder control valve OFF, and sets the valve timing to the most retarded angle. 1. Injects fuel simultaneously into all cylinders (provided that the TDC of the No. 1 cylinder is not detected even once after the ignition switch has been turned "ON"). 2. Cuts the supply of fuel 4 seconds after detecting a failure (provided that the TDC of the No. 1 cylinder is not detected even once after the ignition switch has been turned "ON"). Air-fuel ratio feedback control (closed loop control) is not performed. 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. Fixes the ignition timing as that for regular gasoline. Cuts off the fuel supply to cylinders with an abnormal ignition.
Oxygen sensor (front) Oxygen sensor (rear) Detonation sensor Ignition coil (incorporating power transistor) Alternator FR terminal Misfiring
Does not control the output of the alternator according to an electrical load. (works as a normal alternator) If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be shut down.

TROUBLESHOOTING
13A-17
M1131151001962
INSPECTION CHART FOR DIAGNOSIS CODE

Code No. P0090 P0100 P0105 P0110 P0115 P0120 P0125* P0130 P0135 P0136 P0141 P0170 P0201 P0202 P0203 P0204 P0234 P0243 P0300 P0301* P0302* P0303* P0304* P0325 P0335 P0340 P0403 P0421 P0443 P0500 P0505 P0513 P0551* P0622 P0710 Diagnosis item Fuel pressure control solenoid valve system Air flow sensor system Barometric pressure sensor system Intake air temperature sensor system Engine coolant temperature sensor system Throttle position sensor system Feedback system monitor Oxygen sensor (front) system Oxygen sensor heater (front) system Oxygen sensor (rear) system Oxygen sensor heater (rear) system Abnormal fuel system No. 1 Injector system No. 2 Injector system No. 3 Injector system No. 4 Injector system Turbocharger wastegate system malfunction Waste gate solenoid valve system Random cylinder misfire detection system No. 1 cylinder misfire detection system No. 2 cylinder misfire detection system No. 3 cylinder misfire detection system No. 4 cylinder misfire detection system Detonation sensor system Crank angle sensor system Exhaust camshaft position sensor system EGR control solenoid valve system Warm up catalyst malfunction Purge control solenoid valve system Vehicle speed sensor system Idle speed control system Immobilizer system Power steering fluid pressure switch system Alternator FR terminal system Transmission oil temperature sensor system Reference page P.13A-19 P.13A-24 P.13A-35 P.13A-45 P.13A-52 P.13A-60 P.13A-70 P.13A-75 P.13A-82 P.13A-88 P.13A-95 P.13A-101 P.13A-105 P.13A-111 P.13A-117 P.13A-123 P.13A-129 P.13A-130 P.13A-135 P.13A-139 P.13A-142 P.13A-145 P.13A-148 P.13A-151 P.13A-155 P.13A-166 P.13A-175 P.13A-180 P.13A-182 P.13A-187 P.13A-190 P.13A-195 P.13A-197 P.13A-203 P.13A-208
13A-18
Code No. P1012 P1021 P1603* Diagnosis item

TROUBLESHOOTING
Reference page P.13A-216 P.13A-225 P.13A-230
Intake camshaft position system Oil feeder control valve system Battery back-up line system
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.

TROUBLESHOOTING
13A-19
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No. P0090: Fuel Pressure Control Solenoid Valve System
Fuel pressure control solenoid valve circuit
Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4 4 1
B-Y 2
3 To engine-ECU
R-Y
B-28 (MU802722) 1 2
Fuel pressure control solenoid valve 2
W-B
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
48
Engine-ECU
NOTE *1: L.H. drive vehicles *2: R.H. drive vehicles 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 PU: Purple
AK501799 AB
13A-20
OPERATION

TROUBLESHOOTING
Power is supplied from the engine control relay (terminal No. 4) to the fuel pressure control solenoid valve (terminal No. 1). The engine-ECU (terminal No. 48) causes the power transistor in the unit to be ON to supply power to the fuel pressure control solenoid valve (terminal No. 2).
STEP 2. Connector check: B-28 fuel pressure control solenoid valve connector
Connector : B-28 2 1 Harness side connector
FUNCTION
In response to a signal from the engine-ECU, the fuel pressure control solenoid valve switches the pressure to be introduced into the fuel pressure regulator between the intake manifold negative pressure and atmospheric pressure.
B-28(B)
AK305002AB
TROUBLE JUDGMENT
Check Condition Battery voltage is 10 V or more. Judgment Criterion Surge voltage cannot be detected within 1 seconds from the time when the fuel pressure control solenoid valve has changed from ON to OFF.
Q: Is the check result normal? YES : Go to Step 3 . NO : Repair or replace the connector.
STEP 3. Perform resistance measurement at B-28 fuel pressure control solenoid valve connector.
PROBABLE CAUSES
Failed fuel pressure control solenoid valve Open/short circuit in fuel pressure control solenoid valve circuit or loose connector contact Failed engine-ECU
B-28(B)
AK305002AB
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III actuator test Item No. 09: Fuel pressure control solenoid valve OK: Operating sound can be heard and the valve vibrates.
Disconnect connector, and measure at solenoid valve side. Resistance between terminal No. 1 and No. 2. OK: 28 36 (at 20C)
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the fuel pressure control solenoid
valve.
00 How to Use Troubleshooting/Inspection Service Points) P.00-5. NO : Go to Step 2 .

TROUBLESHOOTING
13A-21
STEP 4. Perform voltage measurement at B-28 fuel pressure control solenoid valve connector.
Q: Is the check result normal? YES : Check and repair harness between B-28
(terminal No. 1) fuel pressure control solenoid valve connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector. STEP 6. Perform voltage measurement at C-119 engine-ECU connector.
B-28(B)
AK305002AB
Disconnect connector, and measure at harness 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 .
Connector: C-119 <L. H. drive vehicles>
STEP 5. Connector check: B-12X engine control relay connector

Connector : B-12X Relay boxs triangle marks
C-119 (GR) <R. H. drive vehicles>
B-12X
2 4
1 3 C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
Harness side connector

AK305003 AB

AK501994 AB
B-28(B)
AK305002AB
13A-22

TROUBLESHOOTING Q: Is the check result normal? YES : Check and repair harness between B-28
STEP 7. Connector check: C-119 engine-ECU connector

(terminal No. 2) fuel pressure control solenoid valve connector and C-119 (terminal No. 48) engine-ECU connector. Check output line for open/short circuit. NO : Repair or replace the connector. STEP 8. Connector check: C-119 engine-ECU connector
Connector: C-119
<L. H. drive vehicles>
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Connector : B-28 2 1 Harness side connector C-119 (GR)

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
B-28(B)
AK305002AB

AK501994 AB

TROUBLESHOOTING
13A-23
STEP 9. Check harness between B-28 (terminal No. 2) fuel pressure control solenoid valve connector and C-119 (terminal No. 48) engine-ECU connector.
STEP 10. Check harness between B-28 (terminal No. 1) fuel pressure control solenoid valve connector and B-12X (terminal No. 4) engine control relay connector.
B-28(B)
AK305002AB
B-28(B)
AK305002AB
Connector : B-12X
Relay boxs triangle marks
B-12X
2 4
1 3

AK305003 AB
Check power supply line for damage.

Q: Is the check result normal? YES : Go to Step 11 . NO : Repair the damaged harness wire.
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
STEP 11. M.U.T.-II/III actuator test Item No. 09: Fuel pressure control solenoid valve OK: Operating sound can be heard and the valve vibrates.
AK501994 AB
Check output line for damage.

00 How to Use Troubleshooting/Inspection Service Points P.00-5). NO : Replace the engine-ECU.
13A-24

TROUBLESHOOTING
Code No. P0100: Air Flow Sensor System
Air flow sensor circuit Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4 4 1
B-Y 2
3 To engine-ECU
R-Y
4 B-105 (MU802552) 1 2 3 4 5 6 7 Air flow sensor
L-B
W-B
C-121 (MU803783)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
19
34
61
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
5V Engine-ECU
AK501800 AB

TROUBLESHOOTING
13A-25
OPERATION
Power is supplied to the air flow sensor (terminal No. 4) from the engine control relay (terminal No. 4) and earthed to the engine-ECU (terminal No. 34) 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. 61). An air flow sensor filter reset signal is inputted to the air flow sensor (terminal No. 7) from the engine-ECU (terminal No. 19).
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 12: Air flow sensor
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.
00 How to Use Troubleshooting/Inspection Service Points P.00-5). NO : Go to Step 2 .
STEP 2. Connector check: B-105 air flow sensor connector

Connector : B-105 B-105(B)
7 6 5 4 3 2 1
AK305005AB
TROUBLE JUDGMENT
Check Condition Engine speed of 500 r/min. or more. Judgment Criterion The sensor output frequency of 3.3 Hz or more for 2 seconds.
STEP 3. Perform voltage measurement at B-105 air flow sensor connector.

PROBABLE CAUSES
Failed air flow sensor Open/short circuit in air flow sensor circuit or loose connector contact Failed engine-ECU
7 6 5 4 3 2 1
AK305005AB
Disconnect connector, and measure at harness side. Ignition switch: "ON" Voltage between terminal No. 3 and earth. OK: 4.9 5.1 V
13A-26

TROUBLESHOOTING
STEP 4. Perform voltage measurement at C-119 engine-ECU connector.


C-119 (GR) <R. H. drive vehicles> <R. H. drive vehicles>
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
Measure engine-ECU terminal voltage. Ignition switch: "ON" Voltage between terminal No. 61 and earth. OK: 4.9 5.1 V
7 6 5 4 3 2 1
AK305005AB
(terminal No. 3) air flow sensor connector and C-119 (terminal No. 61) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-27

STEP 7. Check harness between B-105 (terminal No. 3) air flow sensor connector and C-119 (terminal No. 61) engine-ECU connector.
7 6 5 4 3 2 1
Harness side connector Connector: C-119 <L. H. drive vehicles>
AK305005AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
<R. H. drive vehicles>
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Check output line for short circuit.

13A-28

TROUBLESHOOTING
STEP 8. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 12: Air flow sensor

B-12X
2 4
1 3

AK305003 AB

Connector : B-105 B-105(B) Connector : B-105 B-105(B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK305005AB
AK305005AB
(terminal No. 4) air flow sensor connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector. STEP 11. Perform resistance measurement at B-105 air flow sensor connector.
7 6 5 4 3 2 1
AK305005AB
Disconnect and measure at harness side. Resistance between terminal No. 5 and earth. OK: 2 or less

TROUBLESHOOTING
13A-29

7 6 5 4 3 2 1
Harness side connector C-121 (GR) <R. H. drive vehicles> Connector: C-121 <L. H. drive vehicles>
AK305005AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Check earthing line for open circuit and damage.

13A-30

TROUBLESHOOTING
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK305005AB
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: 6 9 V
AK305005AB

Connector: C-121 <L. H. drive vehicles> <R. H. drive vehicles> C-121 (GR)
C-121 (GR) C-121 (GR) <R. H. drive vehicles>

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Check reset signal line for short circuit.

Q: Is the check result normal? YES : Replace the air flow sensor. NO : Repair the damaged harness wire.
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

TROUBLESHOOTING
13A-31

7 6 5 4 3 2 1
AK305005AB
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.)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
13A-32

TROUBLESHOOTING
STEP 20. Perform output wave pattern measurement at B-105 air flow sensor connector (Using an oscilloscope).
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK305005AB
AK305005AB
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 P.13A-385) and noise should not be displayed in the waveform.
C-121 (GR)
STEP 21. Replace the 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 : The check is end.
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Connector : B-12X
Check reset signal line for open circuit and damage.

B-12X
2 4
1 3

AK305003 AB

TROUBLESHOOTING
13A-33
STEP 23. Check harness between B-105 (terminal No. 4) air flow sensor connector and B-12X (terminal No. 4) engine control relay connector.

7 6 5 4 3 2 1
Harness side connector Connector : B-12X
AK305005AB
B-12X
2 4
1 3
Harness side connector C-119 (GR)

AK305003 AB

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
13A-34

TROUBLESHOOTING

7 6 5 4 3 2 1
AK305005AB

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
7 6 5 4 3 2 1

AK501994 AB
AK305005AB

(terminal No. 5) air flow sensor connector and C-121 (terminal No. 34) engine-ECU connector. Check earthing line for damage. No : Repair or replace the connector.

TROUBLESHOOTING
13A-35
Code No. P105: Barometric Pressure Sensor System
Barometric pressure sensor circuit
B-105 (MU802552) 1 2 3 4 5 6 7 Barometric pressure sensor (Incorporated in air flow sensor)
GR
Y-L
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
42
51
34
C-121 (MU803783)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
5V 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 PU: Purple
AK501801 AB
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. 42) and earthed to the engine-ECU (terminal No. 34) from the air flow sensor (terminal No. 5). The sensor signal is inputted to the engine-ECU (terminal No. 51) from the barometric pressure sensor output terminal (terminal No. 2) of the air flow sensor connector.
TROUBLE JUDGMENT
Check Condition 2 seconds after the ignition switch has been placed in the "ON" position or the engine has started up. Judgment Criterion The sensor output voltage of 4.5 V or more (Barometric pressure above 114 kPa or equivalent) for 2 seconds. or The sensor output voltage 0.2 V or less (Barometric pressure below 53 kPa or equivalent) for 2 seconds.
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.
PROBABLE CAUSES
Failed barometric pressure sensor Open/short circuit in barometric pressure sensor circuit or loose connector contact Failed engine-ECU
13A-36
DIAGNOSIS PROCEDURE

TROUBLESHOOTING

STEP 1. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 25: Barometric pressure sensor


7 6 5 4 3 2 1
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
AK305005AB

AK501994 AB

7 6 5 4 3 2 1
AK305005AB

TROUBLESHOOTING
13A-37


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
7 6 5 4 3 2 1
AK305005AB
(terminal No. 1) air flow sensor connector and C-119 (terminal No. 42) engine-ECU connector. Check power supply line for open circuit. NO : Repair or replace the connector.
13A-38

TROUBLESHOOTING
STEP 8. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 25: Barometric pressure sensor
7 6 5 4 3 2 1
AK305005AB
STEP 9. Perform resistance measurement at B-105 air flow sensor connector.

7 6 5 4 3 2 1
Harness side connector C-119 (GR) <R. H. drive vehicles>
AK305005AB
Disconnect connector, and measure at harness side. Resistance between terminal No. 5 and earth. OK: 2 or less
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Check power supply line for short circuit.


TROUBLESHOOTING
13A-39

7 6 5 4 3 2 1
AK305005AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Check earthing line for open circuit or damage.

13A-40

TROUBLESHOOTING

7 6 5 4 3 2 1
AK305005AB
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
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
7 6 5 4 3 2 1
AK305005AB
(terminal No. 1) air flow sensor connector and C-119 (terminal No. 42) engine-ECU connector. Check power supply line for damage. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-41

7 6 5 4 3 2 1
AK305005AB
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
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
7 6 5 4 3 2 1
AK305005AB
(terminal No. 5) air flow sensor connector and C-119 (terminal No. 34) engine-ECU connector. Check earthing line for damage. NO : Repair or replace the connector.
13A-42

TROUBLESHOOTING

7 6 5 4 3 2 1
AK305005AB
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 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
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

TROUBLESHOOTING
13A-43

7 6 5 4 3 2 1
AK305005AB

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
Measure engine-ECU terminal voltage. Ignition switch: "ON" Voltage between terminal No. 51 and earth. OK: 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

AK501994 AB
Check output line for short circuit and damage.

Q: Is the check result normal? YES : Replace the air flow sensor. NO : Repair the damaged harness wire.
13A-44

TROUBLESHOOTING


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
7 6 5 4 3 2 1
AK305005AB
(terminal No. 2) air flow sensor connector and C-119 (terminal No. 51) engine-ECU connector. Check output line for open circuit and damage. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-45
Code No. P0110: Intake Air Temperature Sensor System
Intake air temperature sensor circuit
B-105 (MU802552) 1 2 3 4 5 6 7 Intake air temperature sensor (Incorporated in air flow sensor)
R-L
34 C-121 (MU803783)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
62 C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
AK501802 AB
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. 62) The power voltage is earthed to the engine-ECU (terminal No. 34) from the air flow sensor (terminal No. 5).
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 of 4.6 V or more (intake air temperature below 45C or equivalent) for 2 seconds. or The sensor output voltage of 0.2 V or loss (intake air temperature above 125 C or equivalent) for 2 seconds.
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.
13A-46
PROBABLE CAUSES

TROUBLESHOOTING
Failed intake air temperature sensor Open/short circuit in intake air temperature sensor circuit or loose connector contact Failed engine-ECU
STEP 4. Perform resistance measurement at B-105 air flow sensor connector.

DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list Item No. 13: Intake air temperature sensor OK: At ambient temperature or equivalent.
7 6 5 4 3 2 1
AK305005AB


7 6 5 4 3 2 1
AK305005AB
C-121 (GR)
STEP 3. Check intake air temperature sensor itself. Check intake air temperature sensor itself (Refer to P.13A-403).
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the air flow sensor.
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

TROUBLESHOOTING
13A-47
STEP 7. M.U.T.-II/III data list Item No. 13: Intake air temperature sensor OK: At ambient temperature or equivalent.
7 6 5 4 3 2 1
AK305005AB

7 6 5 4 3 2 1
AK305005AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

13A-48

TROUBLESHOOTING


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK305005AB
AK305005AB
Measure engine-ECU terminal voltage. Disconnect B-105 air flow sensor connector. Ignition switch: "ON" Voltage between terminal No. 62 and earth. OK: 4.5 4.9 V
(terminal No. 6) air flow sensor connector and C-119 (terminal No. 62) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-49

7 6 5 4 3 2 1
AK305005AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

13A-50

TROUBLESHOOTING

7 6 5 4 3 2 1
AK305005AB
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
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

TROUBLESHOOTING
13A-51

7 6 5 4 3 2 1
AK305005AB

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
7 6 5 4 3 2 1

AK501994 AB
AK305005AB

(terminal No. 5) air flow sensor connector and C-121 (terminal No. 34) engine-ECU connector. Check earthing line for damage. NO : Repair or replace the connector.
13A-52

TROUBLESHOOTING
Code No. P0115: Engine Coolant Temperature Sensor System
Engine coolant temperature sensor circuit
B-107 (MU802406) 1 2 Engine coolant temperature sensor
Y-W
49 C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
44
Engine-ECU 5V
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 PU: Purple
AK501803 AB
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. 44). The power voltage is earthed to the engine-ECU (terminal No. 49) from the engine coolant temperature sensor (terminal No. 2).
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 the engine has started up. Judgment Criteria The sensor output voltage of 4.6 V or more (engine coolant temperature of 45C or equivalent) for 2 seconds, or The sensor output voltage of 0.1 V or less (engine coolant temperature of 140C or more, or equivalent) for 2 seconds.
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.

TROUBLESHOOTING
13A-53
Check Conditions Ignition switch: "ON" Engine speed of 50 r/min. or more 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). Thereafter, the sensor output voltage is 1.6 V or more for 5 minutes.
STEP 3. Perform resistance measurement at B-107 engine coolant temperature sensor connector.
Connector : B-107
B-107(B) 2 1 Harness side connector
PROBABLE CAUSES
Failed engine coolant temperature sensor Open/short circuit in engine coolant temperature sensor circuit or loose connector contact Failed engine-ECU
AK305008AB
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list Item No. 21: Engine coolant temperature sensor OK: Engine cold state: At ambient temperature or equivalent. Engine hot state: At 80 120C
Disconnect connector, and measure at sensor side. Resistance between terminal No. 1 and No. 2. OK: Engine coolant temperature at 20C: 14 17 k Engine coolant temperature at 0C: 5.1 6.5 k Engine coolant temperature at 20C: 2.1 2.7 k Engine coolant temperature at 40C: 0.9 1.3 k Engine coolant temperature at 60C: 0.48 0.68 k Engine coolant temperature at 80C: 0.26 0.36 k
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the engine coolant temperature
STEP 2. Connector check: B-107 engine coolant temperature sensor connector

Connector : B-107
sensor.
AK305008AB
13A-54

TROUBLESHOOTING
STEP 4. Perform voltage measurement at B-107 engine coolant temperature sensor connector.
Connector : B-107

AK305008AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Connector : B-107
AK305008AB
Measure engine-ECU terminal voltage. Disconnect B-107 engine coolant temperature sensor. Ignition switch: "ON" Voltage between terminal No. 44 and earth. OK: 4.5 4.9 V

TROUBLESHOOTING
13A-55


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
Connector : B-107
AK305008AB
(terminal No. 1) engine coolant temperature sensor connector and C-119 (terminal No. 44) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.
13A-56

TROUBLESHOOTING
STEP 8. Check harness between B-107 (terminal No. 1) engine coolant temperature sensor connector and C-119 (terminal No. 44) engine-ECU connector.
Connector : B-107
STEP 9. M.U.T.-II/III data list Item No. 21: Engine coolant temperature sensor OK: Engine cold state: At ambient temperature or equivalent. Engine hot state: At 80 120C
B-107(B) 2 1 Harness side connector Connector: C-119 <L. H. drive vehicles>
AK305008AB
STEP 10. Perform resistance measurement at B-107 engine coolant temperature sensor connector.
Connector : B-107
B-107(B) 2 1 C-119 (GR) <R. H. drive vehicles> Harness side connector
AK305008AB
Disconnect connector and measure at harness side. Resistance between terminal No. 2 and earth. OK: 2 or less
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB


TROUBLESHOOTING
13A-57

Q: Is the check result normal?
Connector : B-107
B-107(B) 2 1 Harness side connector C-119 (GR) <R. H. drive vehicles> Connector: C-119 <L. H. drive vehicles>
AK305008AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
YES : Go to Step 12 . NO : Repair or replace the connector.
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

13A-58

TROUBLESHOOTING
STEP 13. Perform voltage measurement at B-107 engine coolant temperature sensor connector.
Connector : B-107

AK305008AB
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
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

TROUBLESHOOTING
13A-59
Connector : B-107

B-107(B) 2 1 Harness side connector Connector: C-119 <L. H. drive vehicles> C-119 (GR)
AK305008AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Connector : B-107
B-107(B) C-119 (GR)

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
2 1 Harness side connector
AK305008AB

AK501994 AB

Q: Is the check result normal? YES : Check harness between B-107 (terminal
No. 2) engine coolant temperature sensor connector and C-119 (terminal No. 49) engine-ECU connector. Check earthing line for damage. NO : Repair or replace the connector.
13A-60

TROUBLESHOOTING
Code No. P0120: Throttle Position Sensor System
Throttle position sensor circuit
B-03 (MU802724) 1 2 3 4 Throttle position sensor
GR
42 C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
78
49 C-117 (MU803783)
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
AK501804 AB
OPERATION
The power voltage of 5 V is applied to the throttle position sensor (terminal No. 1) from the engine-ECU (terminal No. 42). The power voltage is earthed to the engine-ECU (terminal No. 49) from the throttle position sensor (terminal No. 4). The sensor signal is inputted to the engine-ECU (terminal No. 78) from the throttle position sensor output terminal (terminal No. 2).
TROUBLE JUDGMENT
Check Condition Ignition switch: "ON" (Exclude 2 seconds after the ignition switch has been in "ON" position or just after the engine has started up.) Judgment Criterion The sensor output voltage is 0.2 V or less for 2 seconds. Check Conditions Engine speed of 1,000 r/min. or less. Volumetric efficiency 60% or less. Judgment Criterion The sensor output voltage is 2.0 V or more for 2 seconds.
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.

TROUBLESHOOTING
13A-61
PROBABLE CAUSES
Failed throttle position sensor Open/short circuit in throttle position sensor circuit or loose connector contact Failed engine-ECU
STEP 3. Check throttle position sensor itself. Check throttle position sensor itself (Refer to P.13A-404).
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the throttle position sensor.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 14: Throttle position sensor
STEP 4. Perform voltage measurement at B-03 throttle position sensor connector.

4 3 2 1 Harness side connector

AK305010 AB
STEP 2. Connector check: B-03 throttle position sensor connector


AK305010 AB
13A-62

TROUBLESHOOTING


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB

AK305010 AB
(terminal No. 1) throttle position sensor connector and C-119 (terminal No. 42) engine-ECU connector. Check power supply line for open circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-63

STEP 8. Check harness between B-03 (terminal No. 1) throttle position sensor connector and C-119 (terminal No. 42) engine-ECU connector.
4 3 2 1 C-119 (GR) <R. H. drive vehicles> Harness side connector Connector: C-119 <L. H. drive vehicles>
AK305010 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Check power supply line for short circuit.

13A-64

TROUBLESHOOTING
STEP 9. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 14: Throttle position sensor

STEP 10. Perform resistance measurement at B-03 throttle position sensor connector.
C-119 (GR) Connector : B-03 <R. H. drive vehicles> B-03(B)

AK305010 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

TROUBLESHOOTING
13A-65
STEP 12. Check harness between B-03 (terminal No. 4) throttle position sensor connector and C-119 (terminal No. 49) engine-ECU connector.
Connector : B-03
B-03(B)
4 3 2 1 4 3 2 1 Harness side connector Connector: C-119 <L. H. drive vehicles>

AK305010 AB
AK305010 AB
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
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

13A-66

TROUBLESHOOTING

4 3 2 1 Harness side connector C-119 (GR) <R. H. drive vehicles>

AK305010 AB
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
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK305010 AB
(terminal No. 1) throttle position sensor connector and C-119 (terminal No. 42) engine-ECU connector. Check power supply line for damage. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-67

4 3 2 1 Harness side connector C-119 (GR) <R. H. drive vehicles>

AK305010 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: 0.536 0.735 V Accelerator pedal fully depressed: 4.5 5.0 V
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
STEP 18. Adjust throttle position sensor Adjust throttle position sensor (Refer to P.13A-395).
Q: Is the adjusted value normal? YES : Go to Step 19 . NO : Adjust throttle position sensor.

AK305010 AB
(terminal No. 4) throttle position sensor connector and C-119 (terminal No. 49) engine-ECU connector. Check earthing line for damage. NO : Repair or replace the connector.
13A-68

TROUBLESHOOTING

STEP 20. Perform voltage measurement at C-117 engine-ECU connector

C-117 (GR)
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

AK501996 AB
Measure engine-ECU terminal voltage. Ignition switch: "ON" Voltage between terminal No. 78 and earth. OK: Accelerator pedal fully released: 0.536 0.735 V Accelerator pedal fully depressed: 4.5 5.0 V

AK305010 AB
(terminal No. 2) throttle position sensor connector and C-117 (terminal No. 78) engine-ECU connector. Check output line for short circuit and damage. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-69


C-117 (GR)
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

AK501996 AB

AK305010 AB
(terminal No. 2) throttle position sensor connector and C-117 (terminal No. 78) engine-ECU connector. Check output line for open circuit and damage. NO : Repair or replace the connector.
13A-70

TROUBLESHOOTING
Code No. P0125: Feedback system monitor
OPERATION
Refer to P0201 injector circuit P.13A-105. Refer to P0202 injector circuit P.13A-111. Refer to P0203 injector circuit P.13A-117. Refer to P0204 injector circuit P.13A-123. Refer to P0130 Oxygen sensor (front) circuit P.13A-75.
Failed fuel system Failed exhaust system Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code
Q: Is any other diagnosis code than P0125 output? YES : Inspection chart for diagnosis code (Refer
FUNCTION
The engine-ECU effects air-fuel ratio feedback control in accordance with the signals from the oxygen sensor (front). If the heated oxygen sensor (front) has deteriorated, corrections will be made by the oxygen sensor (rear). Diagnosis code P0125 becomes stored in memory if a failure is detected in the above air-fuel ratio feedback control system.
to P.13A-17). NO : Go to Step 2 . STEP 2. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 12: Air flow sensor b. Item No. 21: Engine coolant temperature sensor c. Item No. 25: Barometric pressure sensor d. Item No. 59: Oxygen sensor (rear)
Q: Are the check results normal? YES : Go to Step 3 . NO : Perform the diagnosis code classified check
TROUBLE JUDGMENT
Check Conditions The engine coolant temperature is approximately 76C or more. Within the range of air-fuel ratio feedback operation. Not in slowing down operation. Judgment Criterion The oxygen sensor output voltage is not deviated from 0.5 V for 30 seconds.
procedure for the sensor that has shown an abnormal data valve (Refer to Inspection Chart for Diagnosis Codes P.13A-17). 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.
PROBABLE CAUSES
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.
STEP 4. Check for leakage of exhaust emission from exhaust manifold.

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 P.13A-395).

TROUBLESHOOTING
13A-71
STEP 6. Connector check: B-113 oxygen sensor (front) connector, C-117 and C-119 engine-ECU connector
Connector : B-113
Connector: C-117, C-119 <L. H. drive vehicles>
Oxygen sensor(front)
C-117 (GR) C-119 (GR) B-113(B)

74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
AK305011AB
C-117 Harness side connector

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501997 AB
STEP 7. Check oxygen sensor (front) itself. Check oxygen sensor (front) itself (Refer to P.13A-404).
Q: Is the check result normal? YES : Go to Step 8 . NO : Replace the oxygen sensor (front).
13A-72

TROUBLESHOOTING
STEP 8. Check harness between B-113 oxygen sensor (front) connector and C-117 engine-ECU connector.
Connector : B-113
STEP 9. Connector check: Injector connector

Connector : B-17,B-18,B-20,B-22
B-22(B) B-20(B) B-18(B) B-17(B)
AK305012 AB
a. b. c. d.
B-22 (No. 1 injector connector) B-20 (No. 2 injector connector) B-18 (No. 3 injector connector) B-17 (No. 4 injector connector)
Q: Are the check results normal? YES : Go to Step 10 . NO : Repair or replace the connector.
2 1 4 3 Harness side connector Connector: C-117 <L. H. drive vehicles> B-113(B)
STEP 10. Check injector itself. Check Injector itself (Refer to P.13A-406).
AK305011AB
Q: Is the check result normal? YES : Go to Step 11 . NO : Replace the injector.
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
AK501996 AB

TROUBLESHOOTING
13A-73
STEP 11. Connector check: B-12X engine control relay connector and C-119 engine-ECU connector.
STEP 12. Check harness between B-12X engine control relay connector and injector connector.
B-12X
2 4
1 3
B-12X
2 4
1 3

AK305003 AB

AK305003 AB
Connector : B-17,B-18,B-20,B-22 Connector: C-119 <L. H. drive vehicles> B-22(B) B-20(B) B-18(B) B-17(B)
AK305012 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
NOTE: Before checking harness, check intermediate connector C-105, and repair if necessary. a. Check harness between B-12X (terminal No. 4) engine control relay connector and B-22 (terminal No. 1) No. 1 injector connector. b. Check harness between B-12X (terminal No. 4) engine control relay connector and B-20 (terminal No. 1) No. 2 injector connector. c. Check harness between B-12X (terminal No. 4) engine control relay connector and B-18 (terminal No. 1) No. 3 injector connector. d. Check harness between B-12X (terminal No. 4) engine control relay connector and B-17 (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 the damaged harness wire.
13A-74

TROUBLESHOOTING Q: Are the check results normal? YES : Go to Step 14 . NO : Repair the damaged harness wire.
STEP 13. Check harness between injector connector and C-121 engine-ECU connector.
B-22(B) B-20(B) B-18(B) B-17(B)
STEP 14. Fuel pressure measurement. Fuel pressure measurement (Refer to P.13A-396).
Q: Is the check result normal? YES : Replace the engine-ECU. NO : Repair.
2 1 Harness side connector Connector: C-121 <L. H. drive vehicles>
AK305012 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
a. Check harness between B-22 (terminal No. 2) No. 1 injector connector and C-121 (terminal No. 1) engine-ECU connector. b. Check harness between B-20 (terminal No. 2) No. 2 injector connector and C-121 (terminal No. 9) engine-ECU connector. c. Check harness between B-18 (terminal No. 2) No. 3 injector connector and C-121 (terminal No. 24) engine-ECU connector. d. Check harness between B-17 (terminal No. 2) No. 4 injector connector and C-121 (terminal No. 2) engine-ECU connector.

TROUBLESHOOTING
13A-75
Code No. P0130: Oxygen Sensor (front) System
Oxygen sensor (front) circuit
B-113 MU802605 1 2 3 4
From Engine control relay
To engine-ECU B W
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
49
71
C-117 (MU803783)
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
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 PU: Purple
AK501805 AB
OPERATION
The sensor signal is inputted to the engine-ECU (terminal No. 71) from the oxygen sensor (front) output terminal (terminal No. 4). The oxygen sensor (front) (terminal No. 2) is earthed with engine-ECU (terminal No. 49).
TROUBLE JUDGMENT
Check Conditions After 3 or more minutes from when the engine has started up. Engine coolant temperature approximately 80C or more. Volumetric efficiency 25% or more. Engine speed of 1,200 r/min. or more. Judgment Criterion 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.
FUNCTION
The oxygen sensor (front) 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 (front) 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.
PROBABLE CAUSES
Failed oxygen sensor (front) Open/short circuit in oxygen sensor (front) circuit or loose connector contact Failed engine-ECU
13A-76
DIAGNOSIS PROCEDURE

TROUBLESHOOTING
STEP 3. Perform resistance measurement at B-113 oxygen sensor (front) connector

Connector : B-113
STEP 1. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 11: Oxygen sensor (front)
STEP 2. Connector check: B-113 oxygen sensor (front) connector

Connector : B-113
2 1 4 3 Harness side connector Oxygen sensor(front)
B-113(B)
AK305011AB
B-113(B)
AK305011AB

TROUBLESHOOTING
13A-77

STEP 5. Check harness between B-113 (terminal No. 2) oxygen sensor connector and C-119 (terminal No. 49) engine-ECU connector.
Connector : B-113
Oxygen sensor(front) C-119 (GR) <R. H. drive vehicles>
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
2 1 4 3 Harness side connector Connector: C-119

AK501994 AB
B-113(B)
AK305011AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
13A-78

TROUBLESHOOTING

STEP 7. Perform voltage measurement at B-113 oxygen sensor (front) connector.

Connector : B-113 <R. H. drive vehicles> C-119 (GR)
Oxygen sensor(front) C-119 (GR)

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Connector : B-113 2 1 4 3 Harness side connector
B-113(B)
AK305011AB
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
B-113(B)
AK305011AB

13A-79
(terminal No. 2) oxygen sensor (front) connector and C-119 (terminal No. 49) engine-ECU connector. Check earthing line for damage. NO : Repair or replace the connector. STEP 9. Perform voltage measurement at B-113 oxygen sensor (front) connector.
Connector : B-113

C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
Harness side connector 2 1 4 3 Harness side connector

AK501996 AB
B-113(B) Connector : B-113

AK305011AB
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.
STEP 10. Check oxygen sensor (front) itself Check oxygen sensor itself (Refer to P.13A-404).
B-113(B)
AK305011AB
13A-80

TROUBLESHOOTING
(terminal No. 4) oxygen sensor (front) connector and C-117 (terminal No. 71) engine-ECU connector. Check output line for damage. NO : Repair or replace the connector. STEP 12. Perform voltage measurement at C-117 engine-ECU connector.

C-117 (GR) <R. H. drive vehicles> C-117 (GR)

74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
Connector : B-113 C-117 (GR)

74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
Measure engine-ECU terminal voltage. Transmission: Neutral Engine: After warm-up Voltage between terminal No. 71 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.
B-113(B)
AK305011AB

13A-81
(terminal No. 4) oxygen sensor (front) connector and C-117 (terminal No. 71) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.

C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
13A-82

TROUBLESHOOTING
Code No. P0135: Oxygen Sensor Heater (front) System
Oxygen sensor heater (front) circuit
Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4 4 1
B-Y 2 Engine control relay 3

To engine-ECU
B-113 MU802605 1 2 3 4
R-Y
To engine-ECU
L-R 3 C-121 (MU803783)

3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
Engine-ECU NOTE *1: L.H. drive vehicles *2: R.H. drive vehicles 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 PU: Purple
AK501806 AB
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. 4).
The heater (terminal No. 3) of the oxygen sensor (front) connector is controlled by the power transistor in the engine-ECU (terminal No. 3).

TROUBLESHOOTING
13A-83
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.
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-113 oxygen sensor (front) connector
Connector : B-113
TROUBLE JUDGMENT
Check Conditions The engine coolant temperature is 20C or higher. The oxygen sensor heater: (front) is ON. The engine speed of 50 r/min. or more. A/C relay: OFF Radiator fan: OFF The system voltage is 11 16 V. Judging Criterion The heater current of oxygen sensor heater (front) 0.2 A or less or 3.5 A or more for 4 seconds.
PROBABLE CAUSES
Failed oxygen sensor heater (front) Open/short circuit in oxygen sensor heater (front) circuit or loose connector contact Failed engine-ECU STEP 2. Perform resistance measurement at B-113 oxygen sensor (front) connector.
Connector : B-113
B-113(B)
AK305011AB
Disconnect connector, and measure at sensor side. Resistance between terminal No. 1 and No. 3. OK: 4.5 8.0
B-113(B)
AK305011AB
13A-84

TROUBLESHOOTING
STEP 3. Perform voltage measurement at B-113 oxygen sensor (front) connector.

Connector : B-113

B-12X
2 4
1 3

AK305003 AB
Connector : B-113
B-113(B) Oxygen sensor(front)

AK305011AB
2 1 4 3 Harness side connector B-113(B)
AK305011AB
(terminal No. 1) oxygen sensor (front) connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-85


C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

AK501995 AB
Measure engine-ECU terminal voltage. Ignition switch: "ON" Voltage between terminal No. 3 and earth. OK: System voltage
13A-86

TROUBLESHOOTING Q: Is the check result normal? YES : Replace the engine-ECU. NO : Repair the damaged harness wire.
STEP 7. Check harness between B-113 (terminal No. 3) oxygen sensor connector and C-121 (terminal No. 3) engine-ECU connector.
Connector : B-113

C-121 (GR) <R. H. drive vehicles> 2 1 4 3 Harness side connector Connector: C-121 <L. H. drive vehicles> C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
B-113(B)
AK305011AB

AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Check earthing line for open/short circuit.

TROUBLESHOOTING
13A-87
STEP 9. Check harness between B-113 (terminal No. 1) oxygen sensor (front) connector and B-12X (terminal No. 4) engine control relay connector.
Connector : B-113
STEP 10. Check harness between B-113 (terminal No. 3) oxygen sensor (front) connector and C-121 (terminal No. 3) engine-ECU connector.
Connector : B-113
Oxygen sensor(front) Oxygen sensor(front)
2 1 4 3 Harness side connector Connector : B-12X
B-113(B)

AK305011AB
B-113(B)
AK305011AB
Connector: C-121 Relay boxs triangle marks <L. H. drive vehicles>
B-12X
2 4
1 3

AK305003 AB

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Check earthing line for damage.
13A-88

TROUBLESHOOTING
STEP 11. Check the trouble symptoms.

Q: Does trouble symptom persist? YES : Replace the engine-ECU. NO : Intermittent malfunction (Refer to GROUP
00 How to Use Troubleshooting/Inspection Service Points P.00-5).
Code No. P0136: Oxygen Sensor (rear) System
Oxygen sensor (rear) circuit
C-137 MU801446
1 2 3 4
Oxygen sensor (rear)
From engine control relay
To engine-ECU B W
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
49
73
C-117 (MU803783)
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
Engine-ECU
AK501807AB
OPERATION
The sensor signal is inputted to the engine-ECU (terminal No. 73) from the oxygen sensor (rear) output terminal (terminal No. 1). The oxygen sensor (rear) (terminal No. 2) is earthed with engine-ECU (terminal No. 49).
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.

TROUBLESHOOTING
13A-89
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.
STEP 2. Connector check: C-137 oxygen sensor (rear) connector

Connector : C-137 C-137
Oxygen sensor(rear) 4 3 2 1 Harness side connector

AK305013AB
TROUBLE JUDGMENT
Check Conditions Above 3 minutes later after the engine has started up. The engine coolant temperature is 80C or higher. The volumetric efficiency is 25% or more. The engine speed is 1,200 r/min. or more. Judgment Criterion 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 engine-ECU, the sensor output voltage is 4.5 V or more.
STEP 3. Perform resistance measurement at C-137 oxygen sensor (rear) connector.

PROBABLE CAUSES
Failed oxygen sensor (rear) Open/short circuit in oxygen sensor (rear) circuit or loose connector contact Failed engine-ECU
Oxygen sensor(rear)
AK305013AB
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 59: Oxygen sensor (rear)
13A-90

TROUBLESHOOTING

STEP 5. Check harness between C-137 (terminal No. 2) oxygen sensor (rear) connector and C-119 (terminal No. 49) engine-ECU connector.
Oxygen sensor(rear) 4 3 2 1 Harness side connector Connector: C-119 <L. H. drive vehicles>
AK305013AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB


TROUBLESHOOTING
13A-91
STEP 6. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 59: Oxygen sensor (rear)

STEP 7. Perform voltage measurement at C-137 oxygen sensor (rear) connector.

C-119 (GR) Connector : C-137 <R. H. drive vehicles> C-137

AK305013AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
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. 2 and earth. OK: 0.5 V or less

AK501994 AB

AK305013AB
Q: Is the check result normal? YES : Check and repair harness between C-137
(terminal No. 2) oxygen sensor (rear) connector and C-119 (terminal No. 49) engine-ECU connector. Check earthing line for damage. NO : Repair or replace the connector.
13A-92

TROUBLESHOOTING



AK305013AB
Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness. Engine: After warm-up Voltage between terminal No. 1 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.
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
STEP 10. Check oxygen sensor (rear) itself Check oxygen sensor (rear) itself (Refer to P.13A-404).
Q: Is the check result normal? YES : Go to Step 11 . NO : Replace the oxygen (rear) sensor.

AK501996 AB

AK305013AB
(terminal No. 1) oxygen sensor (rear) connector and C-117 (terminal No. 73) engine-ECU connector. Check output line for damage. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-93


C-117 (GR)
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

AK501996 AB
Measure engine-ECU terminal voltage. Transmission: Neutral Engine: After warm-up Voltage between terminal No. 73 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.

AK305013AB
(terminal No. 1) oxygen sensor (rear) connector and C-117 (terminal No. 73) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.
13A-94

TROUBLESHOOTING

C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

TROUBLESHOOTING
13A-95
Code No. P0141: Oxygen Sensor Heater (rear) System
Oxygen sensor heater (rear) circuit
Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y 1 B-12X 1 3 2 4 4
B-Y 2 Engine control relay 3

To engine-ECU
C-137 MU801446
1 2 3 4
R-Y
28
To engine-ECU J/C (6) C-105 R-Y
29
L-Y C-121 (MU803783)

3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
26
Engine-ECU NOTE *1: L.H. drive vehicles *2: R.H. drive vehicles 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 PU: Purple
AK501808 AB
OPERATION
Power is supplied to the heater power terminal (terminal No. 3) of the oxygen sensor (rear) connector from the engine control relay (terminal No. 4).
The heater (terminal No. 4) of the oxygen sensor (rear) connector is controlled by the power transistor in the engine-ECU (terminal No. 26).
13A-96
FUNCTION

TROUBLESHOOTING
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.
STEP 2. Perform resistance measurement at C-137 oxygen sensor (rear) connector.

TROUBLE JUDGMENT
Check Conditions The engine coolant temperature is 20C or higher. The oxygen sensor heater (rear) is ON. The engine speed is 50 r/min. or more. A/C relay: OFF Radiator fan: OFF The system voltage is 11 16 V. Judgment Criterion The heater current of oxygen sensor (rear) heater 0.2 A or less or 3.5 A or more for 4 seconds.

AK305013AB
Disconnect connector, and measure at sensor side. Resistance between terminal No. 3 and No. 4. OK: 11 18
Q: Is the check result normal? YES : Go to Step 3 . NO : Replace the oxygen (rear) sensor.
PROBABLE CAUSES
Failed oxygen sensor heater (rear) Open/short circuit in oxygen sensor (rear) circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE
Oxygen sensor(rear)
STEP 1. Connector check: C-137 oxygen sensor (rear) connector


AK305013AB

AK305013AB

TROUBLESHOOTING
13A-97


B-12X
2 4
1 3

AK305003 AB
Connector : C-137 <R. H. drive vehicles> C-137
C-121 (GR)

AK305013AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
Q: Is the check result normal? YES : Check intermediate connector C-105, and
repair if necessary. If intermediate connector are normal, check and repair harness between C-137 (terminal No. 3) oxygen sensor (rear) connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

AK501995 AB
13A-98

TROUBLESHOOTING

STEP 7. Check harness between C-137 (terminal No. 4) oxygen sensor connector and C-121 (terminal No. 26) engine-ECU connector.
Oxygen sensor(rear) 4 3 2 1 Harness side connector C-121 (GR) <R. H. drive vehicles> Connector: C-121 <L. H. drive vehicles>
AK305013AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

Q: Is the check result normal? YES : Replace the engine-ECU. NO : Repair the damaged harness wire.

TROUBLESHOOTING
13A-99

STEP 9. Check harness between C-137 (terminal No. 3) oxygen sensor (rear) connector and B-12X (terminal No. 4) engine control relay connector.
Oxygen sensor(rear) 4 3 2 1 Harness side connector C-121 (GR) <R. H. drive vehicles> Connector : B-12X
AK305013AB
B-12X
2 4
1 3

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
AK305003 AB

AK501995 AB
NOTE: Before checking harness, check intermediate connector C-105, and repair if necessary. Check power supply line for damage.
13A-100

TROUBLESHOOTING
STEP 10. Check harness between C-137 (terminal No. 4) oxygen sensor (rear) connector and C-121 (terminal No. 26) engine-ECU connector.

Oxygen sensor(rear) 4 3 2 1 Harness side connector Connector: C-121 <L. H. drive vehicles>
AK305013AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-101
Code No. P0170: Abnormal Fuel System
OPERATION
Refer to P0201 injector circuit P.13A-105. Refer to P0202 injector circuit P.13A-111. Refer to P0203 injector circuit P.13A-117. Refer to P0204 injector circuit P.13A-123.
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.
STEP 2. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 12: Air flow sensor b. Item No. 13: Intake air temperature sensor c. Item No. 21: Engine coolant temperature sensor d. Item No. 22: Barometric pressure sensor
TROUBLE JUDGMENT
Check Condition In learning air-fuel ratio Judgment Criteria Fuel injection amount correction value remains unusually low for more than 5 seconds. or Fuel injection amount correction value remains unusually high for more than 5 seconds.
procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes P.13A-17). STEP 3. Check for intake of air from intake hose and intake manifold.
PROBABLE CAUSES
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
Q: Is any other diagnosis code than P0170 output? YES : Inspection Chart for Diagnosis Code (Refer
(Refer to P.13A-395). STEP 6. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 11: Oxygen sensor (front)
Q: Is the check result normal? YES : Go to Step 7 . NO : Check oxygen sensor (front) system (Refer
to P.13A-17). NO : Go to Step 2 .
to Code No. P0130 P.13A-75).
13A-102

TROUBLESHOOTING
STEP 7. Connector Check: Injector connector
STEP 9. Connector check: B-12X engine control relay connector and C-119 engine-ECU connector
B-22(B) B-20(B) B-18(B) B-17(B) 2 4 2 1 Harness side connector

AK305012 AB
B-12X
1 3

AK305003 AB
a. b. c. d.
B-22 (No. 1 injector connector). B-20 (No. 2 injector connector). B-18 (No. 3 injector connector). B-17 (No. 4 injector connector).

<R. H. drive vehicles> C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

TROUBLESHOOTING
13A-103
STEP 10. Check harness between B-12X engine control relay connector and injector connector.
B-12X
2 4
1 3
B-22(B) B-20(B) B-18(B) B-17(B)

AK305003 AB
AK305012 AB
B-22(B) B-20(B) B-18(B) B-17(B)
AK305012 AB
NOTE: Before checking harness, check intermediate connector C-105, and repair if necessary. a. Check harness between B-12X (terminal No. 4) engine control relay connector and B-22 (terminal No. 1) No. 1 injector connector. b. Check harness between B-12X (terminal No. 4) engine control relay connector and B-20 (terminal No. 1) No. 2 injector connector. c. Check harness between B-12X (terminal No. 4) engine control relay connector and B-18 (terminal No. 1) No. 3 injector connector. d. Check harness between B-12X (terminal No. 4) engine control relay connector and B-17 (terminal No. 1) No. 4 injector connector. Check power supply line for damage.
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
a. Check harness between B-22 (terminal No. 2) No. 1 injector connector and C-121 (terminal No. 1) engine-ECU connector. b. Check harness between B-20 (terminal No. 2) No. 2 injector connector and C-121 (terminal No. 9) engine-ECU connector. c. Check harness between B-18 (terminal No. 2) No. 3 injector connector and C-121 (terminal No. 24) engine-ECU connector. d. Check harness between B-17 (terminal No. 2) No. 4 injector connector and C-121 (terminal No. 2) engine-ECU connector.
13A-104

TROUBLESHOOTING
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 P.17-11).
Q: Is the check result normal? YES : Go to Step 13 . NO : Replace the purge control solenoid valve.
STEP 13. Fuel pressure measurement Fuel pressure measurement (Refer to P.13A-396).

TROUBLESHOOTING
13A-105
Code No. P0201: No. 1 Injector System

Injector circuit
Battery
B-Y
6 <A-13> (*1) or 13 <C-31> (*2)
B-Y 1
B-Y 2
B-12X 1 3 2 4
4 R-Y 28
3 To engine-ECU J/C (6) C-105
29 B-119 MU802607 1 2 3 4 5 6 R Injector No.1 B-22 MU802722 1 2 2 O

1 1
R-Y 3 Injector resistor
R-W Injector No.2 B-20 (MU802722) 1 2 2 W-R 9

1
R-L
1
R-B 1 Injector No.4 B-17 (MU802722) 1 2 2 2 R 24 2
Injector No.3 B-18 (MU802722) 1 2
C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
NOTE Engine-ECU *1: L.H. drive vehicles *2: R.H. drive vehicles 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 PU: Purple
AK501809AB
13A-106
OPERATION

TROUBLESHOOTING
Power is supplied to the injector (terminal No. 1) from the engine control relay (terminal No. 4) via the injector resistor. 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).
STEP 2. Connector check: B-22 No. 1 injector connector

Connector : B-22
B-22(B)
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.
AK305012 AC
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 detected for 2 seconds.
STEP 3. Perform resistance measurement at B-22 No. 1 injector connector.

Connector : B-22
B-22(B)
PROBABLE CAUSES
Failed No. 1 injector Open/short circuit in injector circuit or loose connector contact Failed engine-ECU
AK305012 AC
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III actuator test Item No. 01: No. 1 injector OK: Idling state varies.
Disconnect connector, and measure at injector side. Resistance between terminal No. 1 and No. 2. OK: 2 3
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the No. 1 injector.

TROUBLESHOOTING
13A-107
STEP 4. Perform voltage measurement at B-22 No. 1 injector connector.

Connector : B-22
STEP 7. Check harness between B-119 (terminal No. 1) injector resistor connector and B-22 (terminal No. 1) No. 1 injector connector.
Connector : B-119 <L.H.drive vehicles>
B-22(B)
AK305012 AC
B-119(B) <R.H.drive vehicles>
B-119(B) 3 2 1 6 5 4 Harness side connector Connector : B-22

AK305016AB

B-12X
2 4
1 3
B-22(B)

AK305003 AB
2 1 Harness side connector Connector : B-12X
AK305012 AC
STEP 6. Check injector resistor itself. Check injector resistor itself (Refer to P.13A-407).
Q: Is the check result normal? YES : Go to Step 7 . NO : Replace the injector resistor.
B-12X
2 4
1 3

AK305003 AB
Check power supply line for open/short circuit.
13A-108

TROUBLESHOOTING
repair if necessary. If intermediate connector are normal, check and repair harness between B-119 (terminal No. 3) injector resistor connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair the damaged harness wire. STEP 8. Check harness between B-119 (terminal No. 1) injector resistor connector and B-22 (terminal No. 1) No. 1 injector connector.
STEP 9. Check harness between B-119 (terminal No. 3) injector resistor connector and B-12X (terminal No. 4) engine control relay connector.
B-119(B) 3 2 1 6 5 4 Harness side connector B-119(B) Connector : B-12X <R.H.drive vehicles>

AK305016AB

AK305016AB
B-12X
2 4
1 3

AK305003 AB
B-22(B)
AK305012 AC


TROUBLESHOOTING
13A-109

STEP 11. Check harness between B-22 (terminal No. 2) No. 1 injector connector and C-121 (terminal No. 1) engine-ECU connector.
Connector : B-22
B-22(B)
AK305012 AC
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Check output line for open/short circuit and damage.

13A-110

TROUBLESHOOTING
STEP 12. Perform signal wave pattern measurement at C-121 engine-ECU connector (Using an oscilloscope).
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Engine: Idling Transmission: Neutral Voltage between terminal No. 1 and earth. OK: Waveforms should be display on Inspection procedure using an oscilloscope (Refer to P.13A-385).

TROUBLESHOOTING
13A-111

Injector circuit
Battery
B-Y
6 <A-13> (*1) or 13 <C-31> (*2)
B-Y 1
B-Y 2
B-12X 1 3 2 4
4 R-Y 28

1 1

1
R-L
1
Injector No.3 B-18 (MU802722) 1 2
C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
AK501809AB
13A-112
OPERATION

TROUBLESHOOTING

Connector : B-20
B-20(B)
FUNCTION
AK305012 AD
TROUBLE JUDGMENT
STEP 3. Perform resistance measurement B-20 No. 2 injector connector.

Connector : B-20
B-20(B)
PROBABLE CAUSES
Failed No. 2 injector Open/short circuit in No. 2 injector circuit or loose connector contact Failed engine-ECU
AK305012 AD
DIAGNOSIS PROCEDURE

TROUBLESHOOTING
13A-113

Connector : B-20
B-20(B)
AK305012 AD

AK305016AB

B-12X
2 4
1 3
B-20(B)

AK305003 AB
AK305012 AD
STEP 6. Check injector resistor itself. Check injector resistor itself (Refer to P.13A-407)
B-12X
2 4
1 3

AK305003 AB
13A-114

TROUBLESHOOTING

AK305016AB

AK305016AB
B-12X
2 4
1 3

AK305003 AB
B-20(B)
AK305012 AD


TROUBLESHOOTING
13A-115

Connector : B-20
B-20(B)
AK305012 AD
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Check output line for open/short circuit or damage.

13A-116

TROUBLESHOOTING
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Engine: Idling Transmission: Neutral Voltage between terminal No. 9 and earth. OK: Waveform should be display on Inspection procedure using an oscilloscope (Refer to P.13A-385).

TROUBLESHOOTING
13A-117

Injector circuit
Battery
B-Y
6 <A-13> (*1) or 13 <C-31> (*2)
B-Y 1
B-Y 2
B-12X 1 3 2 4
4 R-Y 28

1 1

1
R-L
1
Injector No.3 B-18 (MU802722) 1 2
C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
AK501809AB
13A-118
OPERATION

TROUBLESHOOTING

Connector : B-18
B-18(B)
FUNCTION
AK305012 AE
TROUBLE JUDGMENT

Connector : B-18
B-18(B)
PROBABLE CAUSES
AK305012 AE
DIAGNOSIS PROCEDURE

TROUBLESHOOTING
13A-119

Connector : B-18
B-18(B)
AK305012 AE

AK305016AB

B-12X
2 4
1 3
B-18(B)

AK305003 AB
AK305012 AE
B-12X
2 4
1 3

AK305003 AB
13A-120

TROUBLESHOOTING

AK305016AB

AK305016AB
B-12X
2 4
1 3

AK305003 AB
B-18(B)
AK305012 AE


TROUBLESHOOTING
13A-121

Connector : B-18
B-18(B)
AK305012 AE
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

13A-122

TROUBLESHOOTING
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

TROUBLESHOOTING
13A-123

Injector circuit
Battery
B-Y
6 <A-13> (*1) or 13 <C-31> (*2)
B-Y 1
B-Y 2
B-12X 1 3 2 4
4 R-Y 28

1 1

1
R-L
1
Injector No.3 B-18 (MU802722) 1 2
C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
AK501809AB
13A-124
OPERATION

TROUBLESHOOTING

Connector : B-17
B-17(B)
FUNCTION
AK305012 AF
TROUBLE JUDGMENT

Connector : B-17
B-17(B)
PROBABLE CAUSES
AK305012 AF
DIAGNOSIS PROCEDURE

TROUBLESHOOTING
13A-125
STEP 4. Perform voltage measurement at B-17 No. 4 injector connector

Connector : B-17
B-17(B)
AK305012 AF

AK305016AB

B-12X
2 4
1 3
B-17(B)

AK305003 AB
AK305012 AF
B-12X
2 4
1 3

AK305003 AB
13A-126

TROUBLESHOOTING

AK305016AB

AK305016AB
B-12X
2 4
1 3

AK305003 AB
B-17(B)
AK305012 AF


TROUBLESHOOTING
13A-127

Connector : B-17
B-17(B)
AK305012 AF
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

13A-128

TROUBLESHOOTING
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

TROUBLESHOOTING
13A-129
Code No. P0234: Turbocharger Wastegate System Malfunction
FUNCTION
The engine-ECU checks that the engine is not overcharged by always monitoring intake air volume. The engine-ECU protects the engine by shutting off fuel when an overcharged condition is detected.
DIAGNOSIS PROCEDURE
STEP 1. Check turbocharger supercharging pressure. Check turbocharger supercharging pressure (Refer to GROUP 15 On-vehicle Service Turbocharger Supercharging Pressure P.15-2).
Q: Is the check result normal? YES : Go to Step 2 . NO : Repair or replace.
TROUBLE JUDGMENT
Check Condition Waste gate solenoid valve is normal. Judgment Criterion The volumetric efficiency continues to be the status having more than the specified valve for the stipulated period.
PROBABLE CAUSES
Failed turbocharger wastages actuator Failed supercharging pressure control system Failed engine-ECU
STEP 2. Check supercharging pressure control system. Check supercharging pressure control system (Refer to GROUP 15 On-vehicle Service Supercharging Pressure Control System P.15-3).
Q: Is the check result normal? YES : Go to Step 3 . NO : Repair or replace.
STEP 3. M.U.T.-II/III diagnosis code. Reconfirmation of diagnosis code.

Q: Is the diagnosis code? YES : Replace the engine-ECU. NO : Intermittent malfunction (Refer to GROUP
13A-130

TROUBLESHOOTING
Code No. P0243: Waste Gate Solenoid Valve System
Waste gate solenoid valve circuit

Battery
B-Y
6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4
4 1
B-Y
2
3 To engine-ECU
R-Y
1 B-26
1 2
2
Waste gate solenoid valve
LG C-119 (MU801824)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
41
Engine-ECU
AK501810AB
OPERATION
Power is supplied from the engine control relay (terminal No. 4) to the waste gate solenoid valve (terminal No. 1). The engine-ECU (terminal No. 41) causes the power transistor in the unit to be ON to supply power to the waste gate solenoid valve (terminal No. 2).
FUNCTION
In response to a signal from the engine-ECU, the waste gate solenoid valve controls the turbo charge pressure to be introduced into the waste gate actuator of the turbo charger.
TROUBLE JUDGMENT
Check Condition Battery voltage is 10 V or more.

TROUBLESHOOTING
13A-131
Judgment Criterion Surge voltage cannot be detected within 1 seconds from the time when the waste gate solenoid valve has changed from ON to OFF.
STEP 3. Perform resistance measurement at B-26 waste gate solenoid valve connector.
Connector : B-26
PROBABLE CAUSES
Failed waste gate solenoid valve Open/short circuit in waste gate solenoid valve sensor circuit or loose connector contact Failed engine-ECU
B-26(GR)

AK305018 AB
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III actuator test Item No. 12: Waste gate solenoid valve OK: Operating sound can be heard and the valve vibrates.
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the waste gate solenoid valve.
STEP 4. Perform voltage measurement at B-26 waste gate solenoid valve connector.
Connector : B-26
STEP 2. Connector check: B-26 waste gate solenoid valve connector

Connector : B-26 B-26(GR)
B-26(GR)

AK305018 AB

AK305018 AB
13A-132

TROUBLESHOOTING


B-12X
2 4
1 3

AK305003 AB
Connector : B-26 <R. H. drive vehicles> B-26(GR)
C-119 (GR)

AK305018 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
(terminal No. 1) waste gate solenoid valve connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

AK501994 AB

TROUBLESHOOTING
13A-133


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
Connector : B-26
B-26(GR)

AK305018 AB
(terminal No. 2) waste gate solenoid valve connector and C-119 (terminal No. 41) engine-ECU connector. Check output line for open/short circuit. NO : Repair or replace the connector.
13A-134

TROUBLESHOOTING
STEP 9. Check harness between B-26 (terminal No. 2) waste gate solenoid valve connector and C-119 (terminal No. 41) engine-ECU connector.
Connector : B-26
STEP 10. Check harness between B-26 (terminal No. 1) waste gate solenoid valve connector and B-12X (terminal No. 4) engine control relay connector.
Connector : B-26
B-26(GR) B-26(GR)
2 1 Harness side connector Connector: C-119 <L. H. drive vehicles> Connector : B-12X Relay boxs triangle marks 2 1
AK305018 AB
AK305018 AB
B-12X
2 4
1 3
Harness side connector C-119 (GR) <R. H. drive vehicles>

AK305003 AB

C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
STEP 11. M.U.T.-II/III actuator test Item No. 12: Waste gate solenoid valve OK: Operating sound can be heard and the valve vibrates.
AK501994 AB


TROUBLESHOOTING
13A-135
Code No. P0300: Random Cylinder Misfire Detected
OPERATION
Refer to P0201 injector circuit P.13A-105. Refer to P0202 injector circuit P.13A-111. Refer to P0203 injector circuit P.13A-117. Refer to P0204 injector circuit P.13A-123.
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
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.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list Item No. 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
TROUBLE JUDGMENT
Check Conditions The engine speed is 500 6,500 r/min. The engine coolant temperature is 10C or higher. The barometric pressure is 76 kPa or more. The volumetric efficiency is 30 55%. 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 0.06 V/10ms to 0.06 V/10ms. Judgment Criteria Misfire has occurred more frequently than allowed during the last 200 revolutions (When the catalyst temperature is higher than 950C). or Misfire has occurred in 15 or more of the last 1,000 revolutions (corresponding to 1.5 times the limit of emission standard).
Code No. P0335 P.13A-155). STEP 2. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 21: Engine coolant temperature sensor b. Item No. 81: Long-term fuel compensation c. Item No. 82: Short-term fuel compensation
procedure for the sensor that has shown an abnormal data valve (Refer to, Inspection Chart for Diagnosis Codes P.13A-17). STEP 3. Check ignition coil spark.
Q: Is the check result normal? YES : Go to Step 4 . NO : Check ignition circuit system (Refer to
PROBABLE CAUSES
Ignition system related part(s) failed Failed crank angle sensor
Inspection procedure 30 <L.H. drive vehicles>P.13A-356 or Inspection procedure 31 <R.H. drive vehicles>P.13A-363).
13A-136

TROUBLESHOOTING
STEP 4. Connector check: Injector connector

B-22(B) B-20(B) B-18(B) B-17(B)
AK305012 AB
a. b. c. d.
B-22 (No. 1 injector connector) B-20 (No. 2 injector connector) B-18 (No. 3 injector connector) B-17 (No. 4 injector connector)

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

TROUBLESHOOTING
13A-137
B-22(B) B-20(B) B-18(B) B-17(B)
AK305012 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
a. Check harness between B-22 (terminal No. 2) No. 1 injector connector and C-121 (terminal No. 1) engine-ECU connector. b. Check harness between B-20 (terminal No. 2) No. 2 injector connector and C-121 (terminal No. 9) engine-ECU connector. c. Check harness between B-18 (terminal No. 2) No. 3 injector connector and C-121 (terminal No. 24) engine-ECU connector. d. Check harness between B-17 (terminal No. 2) No. 4 injector connector and C-121 (terminal No. 2) engine-ECU connector. Check output line for damage.
13A-138

TROUBLESHOOTING
STEP 9. Connector check: B-119 injector resistor connector and C-121 engine-ECU connector
STEP 10. Check harness between B-119 injector resistor connector and injector connector.
B-119(B) <R.H.drive vehicles> <R.H.drive vehicles>
B-119(B)
B-119(B) 3 2 1 6 5 4 Harness side connector Connector: C-121 <L. H. drive vehicles>

AK305016AB
B-119(B) 3 2 1 6 5 4 Harness side connector Connector : B-17,B-18,B-20,B-22

AK305016AB
B-22(B) B-20(B) B-18(B) B-17(B)
2 1 Harness side connector C-121 (GR) <R. H. drive vehicles>
AK305012 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
a. Check harness between B-119 (terminal No. 1) injector resistor connector and B-22 (terminal No. 1) No. 1 injector connector. b. Check harness between B-119 (terminal No. 4) injector resistor connector and B-20 (terminal No. 1) No. 2 injector connector. c. Check harness between B-119 (terminal No. 5) injector resistor connector and B-18 (terminal No. 1) No. 3 injector connector. d. Check harness between B-119 (terminal No. 6) injector resistor connector and B-17 (terminal No. 1) No. 4 injector connector. Check output line for damage.

AK501995 AB

TROUBLESHOOTING
13A-139
STEP 11. Fuel pressure measurement. Fuel pressure measurement (Refer to fuel pressure test P.13A-396).
STEP 13. Check for skipped timing belt teeth.

STEP 12. Check for intake of air from intake hose and inlet manifold.
STEP 14. Exhaust gas recirculation system check. Exhaust gas recirculation system check (Refer to GROUP 17 Exhaust gas recirculation (EGR) system P.17-14).
Q: Is the check result normal? YES : Replace the engine-ECU NO : Repair.
Code No. P0301: No. 1 Cylinder Misfire Detection System
OPERATION
Refer to P0201 injector circuit P.13A-105.
PROBABLE CAUSES
Ignition system related part(s) failed Low compression pressure Failed engine-ECU
FUNCTION
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
TROUBLE JUDGMENT
Inspection procedure 30 <L.H. drive vehicles>P.13A-356 or Inspection procedure 31 <R.H. drive vehicles>P.13A-363). STEP 2. Connector check: B-22 No. 1 injector connector
Connector : B-22
B-22(B)
AK305012 AC
13A-140

TROUBLESHOOTING
STEP 3. Check No. 1 injector itself. Check Injector itself (Refer to P.13A-406).
STEP 5. Check harness between B-22 (terminal No. 2) No. 1 injector connector and C-121 (terminal No. 1) engine-ECU connector
Connector : B-22

B-22(B)
AK305012 AC
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-141
STEP 8. Check harness between B-119 (terminal No. 1) injector resistor connector and B-22 (terminal No. 1) No.1 injector connector.
B-119(B) B-119(B) <R.H.drive vehicles> <R.H.drive vehicles>
B-119(B) B-119(B) 3 2 1 6 5 4 Harness side connector Connector: C-121 <L. H. drive vehicles> Connector : B-22
AK305016AB
3 2 1 6 5 4 Harness side connector

AK305016AB
B-22(B)
AK305012 AC
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
13A-142

TROUBLESHOOTING
OPERATION
DIAGNOSIS PROCEDURE
FUNCTION
TROUBLE JUDGMENT
Connector : B-20
B-20(B)
AK305012 AD
PROBABLE CAUSES

TROUBLESHOOTING
13A-143

Connector : B-20
B-20(B)
AK305012 AD
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

13A-144

TROUBLESHOOTING
AK305016AB

AK305016AB
B-20(B)
AK305012 AD

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
AK501995 AB

TROUBLESHOOTING
13A-145
OPERATION
DIAGNOSIS PROCEDURE
FUNCTION
TROUBLE JUDGMENT
Connector : B-18
B-18(B)
AK305012 AE
PROBABLE CAUSES
13A-146

TROUBLESHOOTING

Connector : B-18
B-18(B)
AK305012 AE
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-147
AK305016AB

AK305016AB
B-18(B)
AK305012 AE

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
AK501995 AB
13A-148

TROUBLESHOOTING
OPERATION
DIAGNOSIS PROCEDURE
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
FUNCTION
TROUBLE JUDGMENT
Connector : B-17
B-17(B)
AK305012 AF
PROBABLE CAUSES

TROUBLESHOOTING
13A-149

Connector : B-17
B-17(B)
AK305012 AF
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

13A-150

TROUBLESHOOTING
AK305016AB

AK305016AB
B-18(B)
AK305012 AE

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
AK501995 AB

TROUBLESHOOTING
13A-151
Code No. P0325: Detonation Sensor System
Detonation sensor circuit
C-117 (MU803783)
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
Engine-ECU
91
B B-108 MU802661 2 1 1 2
Detonation sensor
AK501811AB
OPERATION
The sensor signal is inputted to the engine-ECU (terminal No. 91) from the detonation sensor (terminal No. 1).
TROUBLE JUDGMENT
Check Conditions Ignition switch: "ON" Excluding for 2 seconds after ignition switch is set to "ON" position or 2 seconds after engine start is completed. The engine speed is 2,000 r/min. or more. The volumetric efficiency is 30% or more. Judgment Criterion The change amount of the detonation sensor output voltage (the detonation sensor peak voltage in every half a turn of the crankshaft) is below 0.06 V or less in 200 consecutive times.
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.
13A-152
PROBABLE CAUSES

TROUBLESHOOTING
Failed detonation sensor Open/short circuit in detonation sensor circuit or loose connector contact Failed engine-ECU
STEP 2. Perform resistance measurement at B-108 detonation sensor connector.

Connector : B-108
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-108 detonation sensor connector
Connector : B-108 Detonation sensor
Detonation sensor 2 1 Harness side connector
B-108(GR)
AK305019AB
B-108(GR) 2 1 Harness side connector

AK305019AB
Q: Is the check result normal? YES : Go to Step 3 . NO : Check and repair harness between B-108
(terminal No. 2) detonation sensor connector and body earth. Check earthing line for open circuit and damage.

TROUBLESHOOTING
13A-153

C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
13A-154

TROUBLESHOOTING Q: Is the check result normal? YES : Go to Step 5 . NO : Repair the damaged harness wire.
STEP 4. Check harness between B-108 (terminal No. 1) detonation sensor connector and C-117 (terminal No. 91) engine-ECU connector.
Connector : B-108

Q: Does trouble symptom persist? YES : Go to Step 6 . NO : Intermittent malfunction (Refer to GROUP
Detonation sensor
STEP 6. Replace the detonation sensor. After replacing the detonation sensor, re-check the trouble symptoms.
Q: Does trouble symptom persist? YES : Replace the engine-ECU. NO : The check is end.
B-108(GR) 2 1 Harness side connector Connector: C-117 <L. H. drive vehicles>

AK305019AB
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

TROUBLESHOOTING
13A-155
Code No. P0335: Crank Angle Sensor System
Crank angle sensor circuit Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4 4 R-Y 3 1
B-Y 2
Engine control relay 3

To engine-ECU
B-117 MU802603 1 2 3
Crank angle sensor
BR-G
C-121 (MU803783)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
34
43
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
5V NOTE *1: L.H. drive vehicles *2: R.H. drive vehicles Engine-ECU
AK501812 AB
OPERATION
Power is supplied to the crank angle sensor (terminal No. 3) from the engine control relay (terminal No. 4) and is earthed to the engine-ECU (terminal No. 34) 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. 43).
13A-156
FUNCTION

TROUBLESHOOTING
The crank angle sensor detects the crank angle (position) and inputs a pulse signal to the engine-ECU. In response to the signal, the engine-ECU controls the injector, etc.
STEP 2. Connector check: B-117 crank angle sensor connector

Connector : B-117
TROUBLE JUDGMENT
Check Condition Engine in cranking state. Judgment Criterion The sensor output voltage remains unchanged (no pulse signal is inputted) for 2 seconds.
Crank angle sensor
PROBABLE CAUSES
Failed crank angle sensor Open/short circuit in crank angle sensor circuit or loose connector contact Failed engine-ECU
B-117(B)
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 22: Crank angle sensor
2 1 3 Harness side connector
AK305020AB

TROUBLESHOOTING
13A-157
STEP 3. Perform voltage measurement at B-117 crank angle sensor connector.

Connector : B-117

Crank angle sensor
C-119 (GR) <R. H. drive vehicles> B-117(B)
AK305020AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Connector : B-117
Crank angle sensor
B-117(B)
AK305020AB
Measure engine-ECU terminal voltage. Disconnect B-117 crank angle sensor connector. Ignition switch: "ON" Voltage between terminal No. 43 and earth. OK: 4.9 5.1 V
13A-158


(terminal No. 2) crank angle sensor connector and C-119 (terminal No. 43) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector. STEP 6. Connector check: C-119 engine-ECU connector
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
Connector : B-117

AK501994 AB
Crank angle sensor
B-117(B)
AK305020AB

TROUBLESHOOTING
13A-159
STEP 7. Check harness between B-117 (terminal No. 2) crank angle sensor connector and C-119 (terminal No. 43) engine-ECU connector.
Connector : B-117
STEP 8. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 22: Crank angle sensor
Crank angle sensor
STEP 9. Perform voltage measurement at B-117 crank angle sensor connector.

B-117(B) Connector : B-117
2 1 3 Harness side connector Connector: C-119 <L. H. drive vehicles>
AK305020AB
Crank angle sensor
B-117(B)
AK305020AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
13A-160

TROUBLESHOOTING

STEP 11. Perform resistance measurement at B-117 crank angle sensor connector.
Connector : B-117
B-12X
2 4
1 3

AK305003 AB
Crank angle sensor
Connector : B-117
B-117(B)
Crank angle sensor
AK305020AB
B-117(B)
AK305020AB
(terminal No. 3) crank angle sensor connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-161

Connector : B-117
Crank angle sensor C-121 (GR) <R. H. drive vehicles>
B-117(B)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
2 1 3 Harness side connector Connector: C-119

AK501995 AB
AK305020AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
13A-162

TROUBLESHOOTING

STEP 14. Perform output wave pattern measurement at B-117 crank angle sensor connector (Using an oscilloscope).
Connector : B-117 B-12X
2 4
1 3

AK305003 AB
Crank angle sensor
B-117(B)
AK305020AB
Use special tool test harness (MD998478) 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 P.13A-385), 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.

TROUBLESHOOTING
13A-163
STEP 16. Check harness between B-117 (terminal No. 3) crank angle sensor connector and B-12X (terminal No. 4) engine control relay connector.
Connector : B-117
STEP 17. Connector check: C-119 and C-121 engine-ECU connectors

Crank angle sensor C-119 (GR) <R. H. drive vehicles> C-121 (GR)
B-117(B)
2 1 3 Harness side connector Connector : B-12X
C-121 (GR) C-119 (GR)

AK305020AB
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
B-12X
2 4
1 3

AK501998 AB

AK305003 AB

13A-164

TROUBLESHOOTING
Connector : B-117
Connector : B-117
Crank angle sensor
Crank angle sensor
B-117(B)
B-117(B)
AK305020AB
AK305020AB
C-121 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501994 AB
AK501995 AB

TROUBLESHOOTING
13A-165
STEP 20. Check the crankshaft sensing blade

Q: Is the check result normal? YES : Go to Step 21 . NO : Replace the crankshaft sensing blade.
STEP 21: M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 22: Crank angle sensor
00 How to Use Troubleshooting/Inspection Service Points P.00-5). NO : Replace the crank angle sensor.
13A-166

TROUBLESHOOTING
Code No. P0340: Exhaust Camshaft Position Sensor System
Exhaust camshaft position sensor circuit
Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4 4 R-Y 3

B-106 MU802337
B-Y 1 2

To engine-ECU
1 2 3
Exhaust camshaft position sensor
L-R
C-121 (MU803783)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
34
50
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
5V Engine-ECU
AK501813 AB
OPERATION
Power is supplied to the exhaust camshaft position sensor (terminal No. 3) from the engine control relay (terminal No. 4) and is earthed to the engine-ECU (terminal No. 34) from the exhaust
camshaft position sensor (terminal No. 1). A power voltage of 5 V is applied to the exhaust camshaft position sensor output terminal (terminal No. 2) from the engine-ECU (terminal No. 50).

TROUBLESHOOTING
13A-167
FUNCTION
The exhaust camshaft position sensor detects the top dead center on the compression stroke of the No. 1 cylinder and inputs a pulse signal to the engine-ECU.
STEP 2. Perform voltage measurement at B-106 exhaust camshaft position sensor connector.
Connector: B-106 3 2 1 B-106 (B) Harness side connector
TROUBLE JUDGMENT
Check Conditions Ignition switch: "ON" Engine speed of 50 r/min. or more. Judgment Criterion The sensor output voltage remains unchanged (no pulse signal is inputted) for 2 seconds.
AK501999 AB
PROBABLE CAUSES
Failed exhaust camshaft position sensor Open/short circuit in exhaust camshaft position sensor circuit or loose connector contact Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-106 exhaust camshaft position sensor connector
AK501999 AB
13A-168

TROUBLESHOOTING

STEP 4. Perform voltage measurement at B-106 exhaust camshaft position sensor connector.
Connector: B-106 3 2 1
B-12X
2 4
1 3
B-106 (B)

AK305003 AB AK501999 AB
AK501999 AB
(terminal No. 3) exhaust camshaft position sensor connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-169


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
AK501999 AB
AK501999 AB
Measure engine-ECU terminal voltage. Disconnect B-106 exhaust camshaft position sensor connector. Ignition switch: "ON" Voltage between terminal No. 50 and earth. OK: 4.9 5.1 V
(terminal No. 2) exhaust camshaft position sensor connector and C-119 (terminal No. 50) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.
13A-170

TROUBLESHOOTING

STEP 8. Check harness between B-106 (terminal No. 2) camshaft position sensor connector and C-119 (terminal No. 50) engine-ECU connector.
C-119 (GR) <R. H. drive vehicles> Connector: C-119 <L. H. drive vehicles>
AK501999 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB



TROUBLESHOOTING
13A-171
STEP 10. Perform resistance measurement at B-106 exhaust camshaft position sensor connector.
STEP 12. Check harness between B-106 (terminal No. 1) camshaft position sensor connector and C-121 (terminal No. 34) engine-ECU connector.
AK501999 AB
AK501999 AB


8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
13A-172

TROUBLESHOOTING
STEP 13. Perform output wave pattern measurement at B-106 exhaust camshaft position sensor connector (Using an oscilloscope).
STEP 15. Check harness between B-106 (terminal No. 3) exhaust camshaft position sensor connector and B-12X (terminal No. 4) engine control relay connector.
AK501999 AB
AK501999 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 P.13A-385), 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.
Connector : B-12X
B-12X
2 4
1 3

AK305003 AB

STEP 14. Connector check: B-12X engine control relay connector.

B-12X
2 4
1 3

AK305003 AB

TROUBLESHOOTING
13A-173

STEP 17. Check harness between B-106 (terminal No. 2) exhaust camshaft position sensor connector and C-119 (terminal No. 50) engine-ECU connector.
C-121 (GR)
AK501999 AB
C-121 (GR) C-119 (GR)

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501998 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

13A-174

TROUBLESHOOTING
STEP 18. Check harness between B-106 (terminal No. 1) exhaust camshaft position sensor connector and C-121 (terminal No. 34) engine-ECU connector.
STEP 19. Check the exhaust camshaft position sensing cylinder.

Q: Is the check result normal? YES : Go to Step 20 . NO : Replace the exhaust camshaft position
sensing cylinder. STEP 20. Check the trouble symptoms.

Q: Does trouble symptom persist? YES : Replace the exhaust camshaft position
sensor.
NO : Intermittent malfunction (Refer to GROUP
AK501999 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-175
Code No. P0403: Exhaust Gas Recirculation (EGR) Control Solenoid Valve
EGR control solenoid valve circuit
Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4 4 R-Y 1
B-Y 2
To engine-ECU B-14 2
R-Y 1 B-101 1 2 2 G-O 6 G-O C-121 (MU803784)

3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
Engine-ECU
AK501814 AB
13A-176
OPERATION

TROUBLESHOOTING
Power is supplied to the EGR control solenoid valve (terminal No. 1) from the engine control relay (terminal No. 4). 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).
STEP 2. Connector check: B-101 EGR control solenoid valve connector

FUNCTION
In response to the signal from the engine-ECU, the EGR control solenoid valve controls the operation of the EGR valve.
B-101(BR)
AK305024 AB
TROUBLE JUDGMENT
Check Condition The battery voltage is 10 V or more. Judgment Criterion When the EGR control solenoid valve is turned to "LOCK" (OFF) position from "ON" position, none of solenoid coil surge voltage (system voltage of +2 V) is detected.
STEP 3. Perform resistance measurement at B-101 EGR control solenoid valve connector.
PROBABLE CAUSES
Failed EGR control solenoid valve Open/short circuit in EGR control solenoid valve circuit or loose connector contact Failed engine-ECU
B-101(BR)
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III actuator test Item No. 10: EGR control solenoid valve OK: Operating sound can be heard and the valve vibrates.
AK305024 AB
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the EGR control solenoid valve.

TROUBLESHOOTING
13A-177
STEP 4. Perform voltage measurement at B-101 EGR control solenoid valve connector.

B-12X B-101(BR)
2 4
1 3

AK305003 AB
AK305024 AB
Connector : B-101
B-101(BR)
AK305024 AB
Q: Is the check result normal? YES : Check intermediate connector B-14, and
repair if necessary. If intermediate connector is normal, check and repair harness between B-101 (terminal No. 1) EGR control solenoid valve connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.
13A-178

TROUBLESHOOTING


C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

AK501995 AB
Connector : B-101
B-101(BR)
AK305024 AB
repair if necessary. If intermediate connector is normal, check and repair harness between B-101 (terminal No. 2) EGR control solenoid valve connector and C-121 (terminal No. 6) engine-ECU connector. Check output line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-179

STEP 9. Check harness between B-101 (terminal No. 2) EGR control solenoid valve connector and C-121 (terminal No. 6) engine-ECU connector.
B-101(BR)
C-121 (GR) <R. H. drive vehicles> Connector: C-121 <L. H. drive vehicles>
AK305024 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
NOTE: Before checking harness, check intermediate connector B-14, and repair if necessary. Check output line for damage.
13A-180

TROUBLESHOOTING
STEP 10. Check harness between B-101 (terminal No. 1) EGR control solenoid valve connector and B-12X (terminal No. 4) engine control relay connector.
STEP 11. M.U.T.-II /III actuator test Item No. 10: EGR control solenoid valve OK: Operating sound can be heard and the valve vibrates.
B-101(BR)
AK305024 AB
Connector : B-12X
B-12X
2 4
1 3

AK305003 AB
NOTE: Before checking harness, check intermediate connector B-14, and repair if necessary. Check power supply line for damage.
Code No. P0421: Warm up Catalyst Malfunction
FUNCTION
The signal from the oxygen sensor (rear) differs from the oxygen sensor (front). That is because the catalytic converter purifies exhaust gas. When the catalytic converter has deteriorated, the signal from the oxygen sensor (front) becomes similar to the oxygen sensor (rear). The engine-ECU compares the output of the front and rear oxygen sensor signals.
TROUBLE JUDGMENT
Check Conditions The engine speed is 3,000 r/min. or less. The accelerator pedal is fully depressed. Airflow sensor output is 8 gm/s or higher.
3 seconds or longer has elapsed after the above-mentioned conditions have been met. Engine running, intake air temperature is 10C or higher. Under the closed-loop control. Vehicle speed is 1.5 km/h or more. The engine-ECU monitors for this condition for 7 cycles of 10 seconds each during the drive cycle. Short-term fuel trim is higher than 25% or lower than +25%. Accumulated air flow sensor output is 2,931 g or higher. Judgment Criterion The oxygen sensor (rear) signal frequency divided by oxygen sensor (front) signal frequency = 0.8 or more.

TROUBLESHOOTING
13A-181
PROBABLE CAUSES
Catalytic converter deteriorated Failed oxygen sensor (front) Failed oxygen sensor (rear) Failed engine-ECU
STEP 3. M.U.T.-II/III data list Item No. 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.).
DIAGNOSIS PROCEDURE
STEP 4. Replace the oxygen sensor (rear). After replacing the oxygen sensor (rear), re-check the trouble symptoms.
Q: Is the check result normal? YES : The check is end. NO : Go to Step 5 .
STEP 2. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 11: Oxygen sensor (front) b. Item No. 59: Oxygen sensor (rear)
Q: Is the check result normal? YES : Go to Step 3 . NO : Perform the diagnosis code classified check
STEP 5. Replace the catalytic converter. After replacing the catalytic converter, re-check the trouble symptoms.
Q: Is the check result normal? YES : The check is end. NO : Replace the engine-ECU.
procedure for the sensor that has shown an abnormal data valve (Refer to Inspection Chart for Diagnosis Codes P.13A-17).
13A-182

TROUBLESHOOTING
Code No. P0443: Purge Control Solenoid Valve System
Purge control solenoid valve circuit
Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4 4 1
B-Y 2
To engine-ECU
R-Y
B-02 MU802779 1 2
Purge control solenoid valve 1
Y-G
C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
16
Engine-ECU
AK501815 AB
OPERATION
Power is supplied to the purge control solenoid valve (terminal No. 2) from the engine control relay (terminal No. 4).
The engine-ECU (terminal No. 16) 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).

TROUBLESHOOTING
13A-183
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. Perform resistance measurement at B-02 purge control solenoid valve connector.
Connector : B-02
TROUBLE JUDGMENT
Check Conditions Ignition switch: "ON" The battery voltage is 10 V or more. Judgment Criterion The surge voltage (system voltage +2 V) of solenoid coil is not detected when the purge control solenoid valve is turned to OFF from ON.
2 1 Harness side connector B-02(B)

AK305025AB
PROBABLE CAUSES
Failed purge control solenoid valve Open/short circuit in purge control solenoid value circuit or loose connector contact Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III actuator test Item No. 08: Purge control solenoid valve OK: Operating sound can be heard and the valve vibrates
STEP 4. Perform voltage measurement at B-02 purge control solenoid valve connector.
Connector : B-02

AK305025AB
STEP 2. Connector check: B-02 purge control solenoid valve connector

Connector : B-02

AK305025AB
13A-184

TROUBLESHOOTING


B-12X
2 4
1 3

AK305003 AB
Connector : B-02 <R. H. drive vehicles>
C-121 (GR)

AK305025AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
(terminal No. 2) purge control solenoid valve connector and B-12X (terminal No. 4) engine control relay connector. Check power line for open/short circuit. NO : Repair or replace the connector.

AK501995 AB

TROUBLESHOOTING
13A-185


C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

AK501995 AB
Connector : B-02

AK305025AB
(terminal No. 1) purge control solenoid valve connector and C-121 (terminal No. 16) engine-ECU connector. Check output line for open/short circuit. NO : Repair or replace the connector.
13A-186

TROUBLESHOOTING
STEP 9. Check harness between B-02 (terminal No. 1) purge control solenoid valve connector and C-121 (terminal No. 16) engine-ECU connector.
Connector : B-02
STEP 10. Check harness between B-02 (terminal No. 2) purge control solenoid valve connector and B-12X (terminal No. 4) engine control relay connector.
Connector : B-02
2 1 Harness side connector Connector: C-121 <L. H. drive vehicles> B-02(B)

AK305025AB

AK305025AB
Connector : B-12X
B-12X
2 4
1 3

AK305003 AB

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
STEP 11. M.U.T.-II/III actuator test Item No. 08: purge control solenoid valve OK: Operating sound can be heard and the valve vibrates.
AK501995 AB


TROUBLESHOOTING
13A-187
Code No. P0500: Vehicle Speed Sensor System
Vehicle speed sensor circuit Ignition switch C-208 1 2 3 4 5 6

R LOCK ST ACC IG1 IG2
Engine-ECU 5V
C-117 (MU803783)
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
2 B-W
80 C-211 6 2 J/B 7.5A

25 C-214
B-Y
B-W*1 O*2
C-124 18 (*1) or 16 (*2) B-27 6
C-124 17 (*1) or 25 (*2) B-R
Meter and gauge
B-W
B-27 8
B-W 1 B-04 (MU802723)
B-Y 3
1 2 3
Vehicle speed sensor
B-27 5
AK501816 AB
13A-188
OPERATION

TROUBLESHOOTING
A power voltage of 5 V is applied to the vehicle speed sensor (terminal No. 3) from the engine-ECU (terminal No. 80).
STEP 2. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 24: Vehicle speed sensor
Q: Is the check result normal? YES : Go to Step 3 . NO : Intermittent malfunction (Refer to GROUP
FUNCTION
The vehicle speed sensor converts the vehicle speed to the voltage, and then input it into the engine-ECU.
00 - How to Use Troubleshooting/Inspection Service Points P.00-5). STEP 3. Connector check: C-117 engine-ECU connector
TROUBLE JUDGMENT
Check Conditions 2 seconds later after the engine has started up. The engine speed is 2,000 4,000 r/min. The volumetric efficiency is 60 80%. Judgment Criterion The sensor output voltage remains unchanged (no pulse signal is inputted) for 2 seconds.
PROBABLE CAUSES
Failed Vehicle speed sensor Open/short circuit in vehicle speed sensor circuit or loose connector contact Failed engine-ECU
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
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
54A Combination Meter Assembly On-vehicle Service P.54A-53).

AK501996 AB

TROUBLESHOOTING
13A-189
STEP 4. Check harness between C-117 (terminal No. 80) engine-ECU connector and B-04 (terminal No. 3) vehicle speed sensor connector.

C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
Connector : B-04 3 2 1 Harness side connector
B-04(B)
Transmission assembly
AK305027AB
NOTE: Before checking harness, check intermediate connectors B-27 and C-124, and repair if necessary. Check output line for open circuit and damage.
13A-190

TROUBLESHOOTING
Code No P0505: Idle Speed Control Servo System
Idle speed control servo circuit Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y 1 B-12X 1 3 2 4 4
B-Y 2
3
To engine-ECU
R-Y
R-Y B-104 1 2 3 4 5 6 2
R-Y 5 Idle speed control servo
Y-L
R-G
LG
14 C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
28
15
29
Engine-ECU
AK501817AB

TROUBLESHOOTING
13A-191
OPERATION
The power is supplied to the idle speed control servo (terminal No. 2 and No. 5) from the engine control relay (terminal No. 4). The engine-ECU (terminal No. 14, No. 15, No. 28 and No. 29) 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 Criterion Actual idle speed has continued to be higher than the target idle speed by 100 r/min. or more for 10 seconds.
PROBABLE CAUSES
Failed idle speed control servo Open/short circuit in idle speed control servo circuit or loose connector contact Failed engine-ECU
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
STEP 1. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 45: Idle speed control servo
TROUBLE JUDGMENT
Check Conditions Vehicle speed has reached 1.5 km/h at least once. Under the closed loop idle speed control. Judgment Criterion Actual idle speed has continued to be higher than the target idle speed by 300 r/min. or more for 10 seconds. Check Conditions Vehicle speed has reached 1.5 km/h at least once. During idle speed closed loop control. The highest temperature at the last drive is 45C or less. Engine coolant temperature is approximately 80C or less. Battery voltage is 10 V or more. The barometric pressure is 76 kPa or higher. Intake air temperature is 10C or more. Judgment Criterion Actual idle speed has continued to be higher than the target idle speed by 200 r/min. or more for 10 seconds. Check Conditions During idle speed closed loop control. Engine coolant temperature is approximately 80C or less. Battery voltage is 10 V or more. Power steering fluid pressure switch is off. Volumetric efficiency is 40% or lower. The barometric pressure is 76 kPa or higher. Intake air temperature is 10C or more.
STEP 2. Connector check: B-104 idle speed control servo connector

Connector : B-104 3 6 2 1 5 4
Harness side connector B-104 (B)
AK305029AB
STEP 3. Check idle speed control servo itself. Check idle speed control servo itself (Refer to P.13A-408).
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the idle speed control servo.
13A-192

TROUBLESHOOTING
STEP 4. Perform voltage measurement at B-104 idle speed control servo connector.
Connector : B-104 3 6 2 1 5 4

B-12X
2 4
1 3

AK305029AB AK305003 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
Connector : B-104 3 6 2 1 5 4
AK305029AB
(terminal No. 2 or No. 5) idle speed control servo connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-193

1. Harness between idle speed control servo terminal No. 1 and engine-ECU connector terminal No. 14 2. Harness between idle speed control servo terminal No. 3 and engine-ECU connector terminal No. 28 3. Harness between idle speed control servo terminal No. 4 and engine-ECU connector terminal No. 15 4. Harness between idle speed control servo terminal No. 6 and engine-ECU connector terminal No. 29 Check power supply line for open/short circuit. STEP 7. Connector check: C-121 engine-ECU connector
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Connector : B-104 3 6 2 1 5 4 C-121 (GR) <R. H. drive vehicles>
AK305029AB
Disconnect connector, and measure at harness side. Ignition switch: "ON" Voltage between terminal No. 14 and earth, between terminal No. 15 and earth, between terminal No. 28 and earth, also voltage between terminal No. 29 and earth. OK: System voltage
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
idle speed control servo and C-121 engine-ECU.
13A-194

TROUBLESHOOTING Q: Is the check result normal? YES : Go to Step 9 . NO : Repair the damaged harness wire.
STEP 8. Check harness between B-104 idle speed control servo and C-121 engine-ECU connector.
Connector : B-104 3 6 2 1 5 4
STEP 9. Check harness between B-104 (terminal No. 2 or No. 5) idle speed control servo connector and B-12X (terminal No. 4) engine control relay connector.
Connector : B-104 3 6 2 1 5 4
AK305029AB
AK305029AB
Connector : B-12X
B-12X C-121 (GR) <R. H. drive vehicles>
2 4
1 3

AK305003 AB

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
STEP 10. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 45: Idle speed control servo
1. Harness between idle speed control servo terminal No. 1 and engine-ECU connector terminal No. 14 2. Harness between idle speed control servo terminal No. 3 and engine-ECU connector terminal No. 28 3. Harness between idle speed control servo terminal No. 4 and engine-ECU connector terminal No. 15 4. Harness between idle speed control servo terminal No. 6 and engine-ECU connector terminal No. 29 Check output line for damage.

TROUBLESHOOTING
13A-195
Code No. P0513: Immobilizer System
Immobilizer system circuit
C-207-1 1 2 3 4 C-207-1 3 Immobilizer-ECU C-207 MU801547

1 2 3 4 5 6 7
7 GR C-124 21 R-W 98 C-117 (MU803783)

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
Engine-ECU
AK501818 AB
OPERATION
The signals are sent and received between engine-ECU (terminal No. 98) and immobilizer-ECU (terminal No. 7).
TROUBLE JUDGMENT
Check Condition Ignition switch: "ON" Judgment Criterion When the communication error between the engine-ECU and the immobilizer-ECU continues for 2 seconds or more.
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.
PROBABLE CAUSES
Open/short circuit in immobilizer system circuit or loose connector contact Failed immobilizer-ECU Failed engine-ECU
13A-196
DIAGNOSIS PROCEDURE

TROUBLESHOOTING
STEP 1. Connector check: C-207 immobilizer-ECU connector and C-117 engine-ECU connector
Connector : C-207
2 1 7 6 5 4 3 Harness side connector
STEP 2. Check harness between C-207 (terminal No. 7) immobilizer-ECU connector and C-117 (terminal No. 98) engine-ECU connector.
Connector : C-207
2 1 7 6 5 4 3 Harness side connector
C-207
AK305030 AB
C-207
AK305030 AB
C-117 (GR) C-117 (GR) <R. H. drive vehicles> <R. H. drive vehicles>
C-117 (GR) C-117 (GR)

74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99 74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

AK501996 AB
NOTE: Before checking harness, check intermediate connector C-124, and repair if necessary. Check output line for open/short circuit and damage.

TROUBLESHOOTING
13A-197

Q: Does trouble symptom persist? YES : Go to Step 4 . NO : Intermittent malfunction (Refer to GROUP
STEP 4. Replace the immobilizer-ECU. After replacing the immobilizer-ECU, re-check the trouble symptoms.
Code No. P0551: Power Steering Fluid Pressure Switch System
Power steering fluid pressure switch circuit
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
Engine-ECU
54
R-W
5 <A-13> (*1) or 15 <C-31> (*2)
R-W
A-40 1 Power steering fluid pressure switch
AK501819AB
CONDITION
The battery voltage is applied to the power steering fluid pressure switch (terminal No. 1) from the engine-ECU (terminal No. 54).
13A-198
FUNCTION

TROUBLESHOOTING
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.
STEP 1. Connector check: A-40 power steering fluid pressure switch connector
Connector: A-40 A-40 (B)
TROUBLE JUDGMENT
Check Conditions The engine coolant temperature is 30C or higher. Drive for 4 seconds or more with the vehicle speed is 50 km/h or more. Stop the vehicle (vehicle speed is 1.5 km/h or less). Repeat 10 times is more. Judgment Criterion The power steering fluid pressure switch remains in "ON" position.
1 Harness side connector
AK502001AB
STEP 2. Perform voltage measurement at A-40 power steering fluid pressure switch connector.
PROBABLE CAUSES
Failed power steering fluid pressure switch Open/short circuit in power steering fluid pressure switch circuit or loose connector contact Failed engine-ECU
DIAGNOSIS PROCEDURE
NOTE: . *1: L.H. drive vehicles *2: R.H. drive vehicles
AK502001AB

TROUBLESHOOTING
13A-199


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
AK502001AB
Q: Is the check result normal? YES : Check intermediate connector A-13*1 or
C-31*2, and repair if necessary. If intermediate connector is normal, check and repair harness between A-40 (terminal No. 1) power steering fluid pressure switch connector and C-119 (terminal No. 54) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.
13A-200

TROUBLESHOOTING

STEP 6. Check harness between A-40 (terminal No. 1) power steering fluid pressure switch connector and C-119 (terminal No. 54) engine-ECU connector.
1 Harness side connector Connector: C-119 <L. H. drive vehicles>
AK502001AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
NOTE: Before checking harness, check intermediate connector A-13*1 or C-31*2, and repair if necessary. Check output line for short circuit.

TROUBLESHOOTING
13A-201
STEP 7. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 27: Power steering fluid pressure switch


Connector: C-119 <L. H. drive vehicles> <R. H. drive vehicles>
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Measure engine-ECU terminal voltage. Engine: Idling Voltage between terminal No. 54 and earth. OK: System voltage (Steering wheel: Stationary) 1 V or less (Steering wheel: Turned)
13A-202

TROUBLESHOOTING
STEP 10. Check harness between A-40 (terminal No. 1) power steering fluid pressure switch connector and C-119 (terminal No. 54) engine-ECU connector.

1 Harness side connector Connector: C-119 <L. H. drive vehicles>
C-119 (GR)
AK502001AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
NOTE: Before checking harness, check intermediate connector A-13*1 or C-31*2, and repair if necessary. Check output line for damage.
Q: Is the check result normal? YES : Replace the power steering fluid pressure
switch.
NO : Repair the damaged harness wire.

TROUBLESHOOTING
13A-203
Code No. P0622: Alternator FR Terminal System
Alternator FR terminal circuit
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
Engine-ECU
52
B-14 5
4 B-25 (MU802066)
M
2 3
IC Voltage regulator
Alternator
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
AK501820 AB
OPERATION
The energized state of the alternator field coil is inputted from the alternator (terminal No. 4) to the engine-ECU (terminal No. 52).
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.
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).
PROBABLE CAUSES
Open circuit in alternator FR terminal circuit Failed engine-ECU
13A-204
DIAGNOSIS PROCEDURE

TROUBLESHOOTING

STEP 1. Connector check: B-14 intermediate connector

5 4 3 2 1 10 9 8 7 6
Female side connector
C-119 (GR)
AK305035AC
STEP 2. Perform voltage measurement at B-14 intermediate connector.

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)

AK501994 AB
1 2 3 4 5 6 7 8 9 10
Male side connector
AK401753 AB
Disconnect connector, and measure at male connector side. Ignition switch: "ON" Voltage between terminal No. 5 and earth. OK: System voltage

TROUBLESHOOTING
13A-205
STEP 4. Check harness between B-14 (terminal No. 5) intermediate connector and C-119 (terminal No. 52) engine-ECU connector.

5 4 3 2 1 10 9 8 7 6

Connector : B-14
AK305035AC
Female side connector Connector: C-119 <L. H. drive vehicles>
B-14(B)
5 4 3 2 1 10 9 8 7 6
AK305035AC
Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness. Ignition switch: "ON" Voltage between terminal No. 5 and earth. OK: System voltage
STEP 7. Connector check: B-25 alternator connector

C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
Connector : B-25

AK501994 AB

4 3
2 1 B-25(GR)
AK305036 AB
13A-206

TROUBLESHOOTING
STEP 8. Check harness between B-25 (terminal No. 4) alternator connector and B-14 (terminal No. 5) intermediate connector.
Connector : B-25

5 4 3 2 1 10 9 8 7 6
2 1 B-25(GR)
AK305036 AB
Harness side connector Connector : B-14 B-14(B)
AK305035AC
5 4 3 2 1 10 9 8 7 6
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. 5 and earth. OK: Switching the headlamps to ON from OFF causes the voltage to fall.
AK305035AC

Q: Is the check result normal? YES : Replace the alternator. NO : Repair the damaged harness wire.

Connector : B-25
2 1 B-25(GR)
AK305036 AB

TROUBLESHOOTING
13A-207
STEP 11. Check harness between B-25 (terminal No. 4) alternator connector and B-14 (terminal No. 5) intermediate connector.
Connector : B-25
STEP 12. Check harness between B-14 (terminal No. 5) intermediate connector and C-119 (terminal No. 52) engine-ECU connector.
1 2 3 4 5
2 1 B-25(GR)
AK305036 AB
6 7 8 9 10
Harness side connector Connector : B-14 B-14(B)
Male side connector Connector: C-119 <L. H. drive vehicles>
AK401753 AB
5 4 3 2 1 10 9 8 7 6
AK305035AC

C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB


Q: Does trouble symptom persist? YES : Replace the alternator. NO : Intermittent malfunction (Refer to Group 00
How to Use troubleshooting/Inspection Service Points P.00-5).
13A-208

TROUBLESHOOTING
Code No. P0710: Transmisson Oil Temperature Sensor System
Transmission oil temperature sensor circuit
B-30 (MU802406) 1 2 Transmission oil temperature sensor
2 B G-R
B-27 1 B 49 C-119 (MU803782)

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
2 G-R 96 C-117 (MU803783)

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
AK501821 AB
OPERATION
A power voltage of 5 V is applied to the transmission oil temperature sensor output terminal (terminal No. 1) from the engine-ECU (terminal No. 96). The power voltage is earthed to the engine-ECU (terminal No. 49) from the transmission oil temperature sensor (terminal No. 2).
The transmission oil temperature sensor is a kind of resistor, which has characteristics to reduce its resistance as the transmission oil temperature rises. Therefore, the sensor output voltage varies with the transmission oil temperature, and becomes lower as the transmission oil temperature rises.
TROUBLE JUDGMENT
Check Conditions 2 seconds later after the ignition switch has been in "ON" position or the engine has started up. The engine coolant temperature of 82C or more. Judgment Criteria The sensor output voltage of 4.8 V or more (transmission oil temperature of 40C or equivalent) for 2 seconds, or
FUNCTION
The transmission oil temperature sensor converts the transmission oil temperature into a voltage signal, and inputs the voltage to the engine-ECU. The engine-ECU controls the boost pressure, based on this signal.

TROUBLESHOOTING
13A-209
The sensor output voltage of 0.1 V or less (transmission oil temperature of 150C or more, or equivalent) for 2 seconds.
STEP 2. Perform resistance measurement at B-30 transmission oil temperature sensor connector.
Connector: B-30
PROBABLE CAUSES
Failed transmission oil temperature sensor Open/short circuit in transmission oil temperature sensor circuit or loose connector contact Failed engine-ECU
B-30 (B) 2 1 Harness side connector

AK502000 AB
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-30 transmission oil temperature sensor connector
Connector: B-30

AK502000 AB
Disconnect connector, and measure at sensor side. Resistance between terminal No. 1 and No. 2. OK: Transmission oil temperature at 20C: 14 17 k Transmission oil temperature at 0C: 5.1 6.5 k Transmission oil temperature at 20C: 2.1 2.7 k Transmission oil temperature at 40C: 0.9 1.3 k Transmission oil temperature at 60C: 0.48 0.68 k Transmission oil temperature at 80C: 0.26 0.36 k
Q: Is the check result normal? YES : Go to Step 3 . NO : Replace the transmission oil temperature
sensor.
13A-210

TROUBLESHOOTING
STEP 3. Perform voltage measurement at B-30 transmission oil temperature sensor connector.
Connector: B-30


AK502000 AB
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
Measure engine-ECU terminal voltage. Disconnect B-30 transmission oil temperature sensor. Ignition switch: "ON" Voltage between terminal No. 96 and earth. OK: 4.5 4.9 V

TROUBLESHOOTING
13A-211


C-117 (GR)
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

AK501996 AB
Connector: B-30

AK502000 AB
repair if necessary. If intermediate connector is normal, check and repair harness between B-30 (terminal No. 1) transmission oil temperature sensor connector and C-117 (terminal No. 96) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.
13A-212

TROUBLESHOOTING
STEP 7. Check harness between B-30 (terminal No. 1) transmission oil temperature sensor connector and C-117 (terminal No. 96) engine-ECU connector.
Connector: B-30

B-30 (B) 2 1 Harness side connector Connector: C-117 <L. H. drive vehicles>
AK502000 AB
STEP 9. Perform resistance measurement at B-30 transmission oil temperature sensor connector.
Connector: B-30

AK502000 AB
Disconnect connector and measure at harness side. Resistance between terminal No. 2 and earth. OK: 2 or less
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
NOTE: Before checking harness, checking intermediate connector B-27, and repair if necessary. Check output line for short circuit.

TROUBLESHOOTING
13A-213

STEP 11. Check harness between B-30 (terminal No. 2) transmission oil temperature sensor connector and C-119 (terminal No. 49) engine-ECU connector.
Connector: B-30
B-30 (B) 2 1 C-119 (GR) <R. H. drive vehicles> Connector: C-119 <L. H. drive vehicles> Harness side connector
AK502000 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
NOTE: Before checking harness, checking intermediate connector B-27, and repair if necessary. Check earthing line for open circuit and damage.
13A-214

TROUBLESHOOTING
STEP 12. Perform voltage measurement at B-30 transmission oil temperature sensor connector.
Connector: B-30


AK502000 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: Transmission oil temperature at 20C: 3.9 4.5 V Transmission oil temperature at 0C: 3.2 3.8 V Transmission oil temperature at 20C: 2.3 2.9 V Transmission oil temperature at 40C: 1.3 1.9 V Transmission oil temperature at 60C: 0.7 1.3 V Transmission oil temperature at 80C: 0.3 0.9 V
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
Connector: B-30

AK502000 AB
repair if necessary. If intermediate connector is normal, check harness between B-30 (terminal No. 1) transmission oil temperature sensor connector and C-117 (terminal No. 96) engine-ECU connector. Check output line for damage. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-215
STEP 14. Connector check: C-117 and C-119 engine-ECU connector

C-117 (GR) C-119 (GR)

74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501997 AB
13A-216

TROUBLESHOOTING
Code No. P1012: Intake Camshaft Position Sensor System
Intake camshaft position sensor circuit
Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4 4 R-Y 3

B-124 MU802337
B-Y 1 2

To engine-ECU
1 2 3
Intake camshaft position sensor
L-R
C-121 (MU803783)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
34
53
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
5V Engine-ECU
AK501813 AC
OPERATION
Power is supplied to the intake camshaft position sensor (terminal No. 3) from the engine control relay (terminal No. 4) and is earthed to the engine-ECU (terminal No. 34) from the intake
camshaft position sensor (terminal No. 1). A power voltage of 5 V is applied to the intake camshaft position sensor output terminal (terminal No. 2) from the engine-ECU (terminal No. 53).

TROUBLESHOOTING
13A-217
FUNCTION
The intake camshaft position sensor detects the top dead center on the compression stroke of the No. 1 cylinder and inputs a pulse signal to the engine-ECU.
STEP 2. Perform voltage measurement at B-124 intake camshaft position sensor connector.
Connector: B-124
TROUBLE JUDGMENT
Check Condition Engine: During the engine cranking and the driving. Judgment Criterion The sensor output voltage remains unchanged (no pulse signal is inputted) for 4 seconds.
B-124 (B) 3 2 1 Harness side connector
AK502002 AB
PROBABLE CAUSE
Failed intake camshaft position sensor Open/short circuit in intake camshaft position sensor circuit or loose connector contact Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-124 intake camshaft position sensor connector
Connector: B-124

AK502002 AB
13A-218

TROUBLESHOOTING

STEP 4. Perform voltage measurement at B-124 intake camshaft position sensor connector.
Connector: B-124
B-12X
2 4
1 3 B-124 (B) 3 2 1 Harness side connector

AK502002 AB

AK305003 AB
Connector: B-124
B-124 (B)

AK502002 AB
(terminal No. 3) intake camshaft position sensor connector and B-12X (terminal No. 4) engine control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-219


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
Connector: B-124
Connector: B-124

AK502002 AB

AK502002 AB
Measure engine-ECU terminal voltage. Disconnect B-124 intake camshaft position sensor connector. Ignition switch: "ON" Voltage between terminal No. 53 and earth. OK: 4.9 5.1 V
(terminal No. 2) intake camshaft position sensor connector and C-119 (terminal No. 53) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.
13A-220

TROUBLESHOOTING

STEP 8. Check harness between B-124 (terminal No. 2) intake camshaft position sensor connector and C-119 (terminal No. 53) engine-ECU connector.
Connector: B-124
B-124 (B) 3 2 1 C-119 (GR) <R. H. drive vehicles> Connector: C-119 <L. H. drive vehicles> Harness side connector
AK502002 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB



TROUBLESHOOTING
13A-221
STEP 10. Perform resistance measurement at B-124 intake camshaft position sensor connector.
Connector: B-124
Connector: B-124
B-124 (B) 3 2 1 Harness side connector 3 2 1

AK502002 AB
B-124 (B) Harness side connector Connector: C-121 <L. H. drive vehicles>
AK502002 AB


8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
13A-222

TROUBLESHOOTING
STEP 13. Perform output wave pattern measurement at B-124 intake camshaft position sensor connector (Using an oscilloscope).
Connector: B-124
STEP 15. Check harness between B-124 (terminal No. 3) intake camshaft position sensor connector and B-12X (terminal No. 4) engine control relay connector.
Connector: B-124
B-124 (B) 3 2 1 Harness side connector 3 2 1

AK502002 AB
B-124 (B) Harness side connector Connector : B-12X
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 P.13A-385), 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.
AK502002 AB
B-12X
2 4
1 3

AK305003 AB


B-12X
2 4
1 3

AK305003 AB

TROUBLESHOOTING
13A-223

Connector: B-124
B-124 (B) 3 2 1 C-119 (GR) <R. H. drive vehicles> Connector: C-119 <L. H. drive vehicles> C-121 (GR) Harness side connector
AK502002 AB
C-121 (GR) C-119 (GR)

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501998 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

13A-224

TROUBLESHOOTING
Connector: B-124
STEP 19. Check the intake camshaft position sensing cylinder.

Q: Is the check result normal? YES : Go to Step 20 . NO : Replace the intake camshaft position
sensing cylinder. STEP 20. Check the trouble symptoms.

B-124 (B)
Q: Does trouble symptom persist? YES : Replace the intake camshaft position

AK502002 AB
sensor.
NO : Intermittent malfunction (Refer to GROUP
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-225
Code No. P1021: Oil Feeder Control Valve System
Oil feeder control valve circuit
Battery B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
B-Y B-12X 1 3 2 4 4 R-Y 28 1
B-Y 2 Engine control relay 3 To engine-ECU J/C (6) C-105 33
R-Y B-123 MU802779 1 2 2 P-B C-121 (MU803784)

3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
1 Oil feeder control valve
32
Engine-ECU
AK501822 AB
13A-226
OPERATION

TROUBLESHOOTING
Power is supplied to the oil feeder control valve (terminal No. 1) from the engine control relay (terminal No. 4). The engine-ECU (terminal No. 32) makes the power transistor in the unit be in ON position, and that makes currents go on the oil feeder control valve (terminal No. 2).
STEP 2. Perform resistance measurement at B-123 oil feeder control valve connector.
Connector: B-123
B-123 (B)
FUNCTION
The oil feeder control valve controls the phase angle of the intake camshaft by the signal from the engine-ECU.
AK502003 AB
TROUBLE JUDGMENT
Check Condition The oil feeder control valve does not operate. Judgment Criterion The oil feeder control valve drive terminal voltage of the engine-ECU is not normal for 4 seconds or more.
Disconnect connector, and measure at control valve side. Resistance between terminal No. 1 and No. 2. OK: 6.9 7.9 (at 20C)
Q: Is the check result normal? YES : Go to Step 3 . NO : Replace the oil feeder control valve.
PROBABLE CAUSE
Failed oil feeder control valve Open/short circuit in oil feeder control valve circuit or loose connector contact Failed engine-ECU
STEP 3. Perform voltage measurement at B-123 oil feeder control valve connector.
Connector: B-123
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-123 oil feeder control valve connector
Connector: B-123 2 1 Harness side connector
B-123 (B)
AK502003 AB
B-123 (B)
Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 1 and earth. OK: System voltage
AK502003 AB

TROUBLESHOOTING
13A-227


B-12X
2 4
1 3

AK305003 AB
Connector: B-123 <R. H. drive vehicles>
C-121 (GR)
B-123 (B)

AK502003 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
repair if necessary. If intermediate connector is normal, check and repair harness between B-123 (terminal No. 1) oil feeder control valve connector and B-12X (terminal No. 4) engine control relay connector. Check power line for open/short circuit. NO : Repair or replace the connector.

AK501995 AB
Disconnect connector, and measure at harness side. Ignition switch: ON Voltage between terminal No. 32 and earth. OK: System voltage
13A-228

TROUBLESHOOTING


C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

AK501995 AB
Connector: B-123
B-123 (B)

AK502003 AB
(terminal No. 2) oil feeder control valve connector and C-121 (terminal No. 32) engine-ECU connector. Check output line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-229
STEP 8. Check harness between B-123 (terminal No. 2) oil feeder control valve connector and C-121 (terminal No. 32) engine-ECU connector.
Connector: B-123
STEP 9. Check harness between B-123 (terminal No. 1) oil feeder control valve connector and B-12X (terminal No. 4) engine control relay connector.
Connector: B-123
B-123 (B) B-123 (B) 2 1 Harness side connector Connector: C-121 <L. H. drive vehicles> Connector : B-12X Relay boxs triangle marks 2 1
AK502003 AB
AK502003 AB
B-12X
2 4
1 3

AK305003 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

13A-230

TROUBLESHOOTING
Code No. P1603: Battery Back-up Line System
Battery back-up circuit Battery
W W
Relay box
8 20A
B-Y
6 <A-13> (*1) or 13 <C-31> (*2)
R-B
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
60
Back-up power supply
Engine-ECU
NOTE *1: L.H. drive vehicles *2: R.H. drive vehicles 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
AK501823 AB
OPERATION
Power is directly supplied to the engine-ECU (terminal No. 60) from the battery.
TROUBLE JUDGMENT
Check Condition Ignition switch: "ON" Judgment Criterion The battery back-up line voltage 6 V or less.
FUNCTION
The engine-ECU is check the open circuit of battery back-up line.

TROUBLESHOOTING
13A-231
PROBABLE CAUSES
Open/short circuit in battery back-up line circuit or loose connector contact Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code Temporarily place the ignition switch in "LOCK" (OFF) position, and 10 seconds after that, place it in "ON" position again.
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 P.00-5).
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Q: Is the check result normal? YES : Go to Step 3 . NO : Check intermediate connector A-13, <L.H.
drive vehicles> or C-31 <R.H. drive vehicles>, and repair if necessary. If intermediate connector is normal, check and repair harness between battery and C-119 (terminal No. 60) engine-ECU connector. Check power supply line for open/short circuit.
13A-232

TROUBLESHOOTING


C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

TROUBLESHOOTING
13A-233
M1131151501655
INSPECTION CHART FOR TROUBLE SYMPTOMS

Items Trouble symptom Inspection procedure No. 1 2
Communication with M.U.T.-II/III is impossible Engine warning lamp Starting
Communication with all system is not possible Communication with engine-ECU only is not possible
The engine warning lamp does not illuminate right after the ignition switch 3 is turned to the "ON" position The engine warning lamp remains illuminating and never goes out Starting impossible (starter inoperative) Starting impossible (Starter operative but no initial combustion) 4 The starter is impossible to operate. 5 The starter is operative and cranks the engine, but none of initial combustion is in the cylinders and the engine is not started. 6
Starting impossible The initial combustion occurs, but (Initial combustion but no complete the engine stalls soon due to the incomplete combustion. combustion) Improper starting (Long time to start) Improper idling Unstable idling (Rough idling, hunting) It is long cranking to start the engine.
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. The proper idling speed is not satisfied. The engine stalls during the idling in no relation to the vehicle movement. 9
Improper idling speed Engine stalled during idling (Die out) Engine stalls
The engine stalls when starting the The engine stalls during the car operation, or when the accelerator pedal is depressed from the idling. (Pass out) The engine stalls when decelerating
The engine stalls at the deceleration. 10
13A-234
Items

TROUBLESHOOTING
Trouble symptom
Inspection procedure No. 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". The engine cannot obtain the acceleration corresponding to the degree of throttle opening although the engine is smooth at the constant speed. The engine speed increase is delayed when the accelerator pedal is initially depressed at the starting. The vehicle body is repeated to vibrate jollity in the forward and backward directions at the constant speed or acceleration. The large impact feeling occurs at the acceleration. The large impact feeling occurs at the deceleration. Sharp sound like a hammer striking on the cylinder walls during the driving can be heard and wrongly affects the driving. The basic ignition timing is deviated from the datum value. 13 14 15
Driving
Hesitation, sag
Poor acceleration
Stumble
Surge
The feeling of impact or vibration when accelerating The feeling of impact or vibration when decelerating Knocking
Ignition timing offset Stopping Run on (Dieseling)
16
The engine continues to run after the 17 ignition switch is in "LOCK (OFF)" position. The exhaust gas is extremely rank odor, white smoke or black smoke. The concentration of CO & HC is high during the idling. The battery is soon rundown or the charging ability of battery is small. The temperature of engine cooling water is extremely high. The fan motor is abnormally rotated when the ignition switch is in "ON" position in no relation to the engine cooling water temperature. 18
Exhaust gas
Odor, white smoke, black smoke, high-concentration CO/HC during idling Battery rundown Overheating Abnormal rotation of fan Motor
Charging performance Cooling performance
19 20 21

TROUBLESHOOTING
13A-235
Inspection procedure No.
Items
Trouble symptom
A/C performance
Poor A/C Performance
The temperature of air cooling from A/C is not efficient or very far from the target temperature.
22
PROBLEM SYMPTOMS TABLE

Inspection Trouble symptom procedure No. 1 2 3 4 5 6 7 8 Communication with all system is not possible Communication with engine-ECU only is not possible The engine warning lamp does not illuminate right after the ignition switch is turned "ON" position The engine warning lamp remains illuminating and never goes out Starting impossible (No initial combustion) Starting impossible (Starter operative but no initial combustion) Starting impossible (Initial combustion but no complete combustion) Starting impossible (Long time to start) Unstable idling (Rough idling, hunting) Improper idling speed (Too high or too low) Engine stalls during idling (Die out) 9 10 11 12 The engine stalls when starting the car (pass out) The engine stalls when decelerating Engine does not revolve up Hesitation, sag Poor acceleration Stumble Surge 13 14 15 16 17 18 19 20 21 22 23 24 The feeling of impact or vibration when accelerating The feeling of impact or vibration when decelerating Knocking Ignition timing offset Run on (Dieseling) Odor, white smoke, black smoke, high-concentration CO/HC during idling Battery rundown Overheating Abnormal rotation of fan motor Poor A/C performance Engine-ECU power supply, engine control relay, ignition switch-IG1 system Fuel pump system P.13A-283 P.13A-285 P.13A-285 P.13A-287 P.13A-288 P.13A-289 P.13A-291 P.13A-296 P.13A-297 P.13A-300 P.13A-302 P.13A-313 P.13A-275 P.13A-277 P.13A-279 P.13A-281 P.13A-268 Reference page P.13A-237 P.13A-240 P.13A-243 P.13A-252 P.13A-255 P.13A-262 P.13A-264
13A-236
Inspection Trouble symptom procedure No. 25 26 27 28 29 30 31

TROUBLESHOOTING
Reference page P.13A-324 P.13A-330 P.13A-341 P.13A-344 P.13A-352 P.13A-356 P.13A-363
Radiator fan control relay system Condenser fan control relay system A/C switch system A/C compressor relay system A/C load signal system Ignition circuit system <L.H. drive vehicles> Ignition circuit system <R.H. drive vehicles>

TROUBLESHOOTING
13A-237
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with All System is not Possible
Diagnosis connector circuit
Fusible link (1)
W-R
C-126 1 W-R C-211 1 15 15A 12 C-214 J/B
G-R (*1) or W (*2) C-14

1 2 3 4 5 6 7 8 9 10 1112 13 14 1516
16 Diagnosis connector 4 B B 5
AK305249 AC
OPERATION
Battery voltage is applied to diagnosis connector (terminal No.16). Diagnosis connector (terminals No. 4 and 5) are earthed to the vehicle body.

Failure is possibly caused by failed power supply circuit or failed earthing circuit of diagnosis connector.
13A-238
PROBABLE CAUSES

TROUBLESHOOTING
Failed diagnosis connector Open/short circuit in diagnosis connector circuit. Failed M.U.T.-II/III
STEP 3. Perform voltage measurement at C-14 diagnosis connector.

Connector: C-14 C-14 (B)
DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-14 diagnosis connector
1 2 3 4 5 6 7 8 9 10 1112 13 14 1516
AK203591AD
1 2 3 4 5 6 7 8 9 10 1112 13 14 1516
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-126, C-211
AK203591AD
STEP 2. Perform resistance measurement at C-14 diagnosis connector.

and C-214, and repair if necessary. If connectors are normal, check and repair harness between C-14 (terminal No. 16) diagnosis connector and battery. Check power supply line for open/short circuit. STEP 4. Replace M.U.T.-II/III. After replacing the M.U.T.-II/III, re-check the trouble symptoms.
Q: Does trouble symptom persist? YES : Go to Step 5 . NO : The check is end.
1 2 3 4 5 6 7 8 9 10 1112 13 14 1516
AK203591AD
Disconnect connector, and measure at harness side. Resistance between terminal No. 4 and earth, also between terminal No. 5 and earth. OK: 2 or less
Q: Is the check result normal? YES : Go to Step 3 . NO : Check and repair harness between C-14
(terminal No. 4) diagnosis connector and body earth, also between C-14 (terminal No. 5) diagnosis connector and body earth. Check earthing line for open circuit and damage.

TROUBLESHOOTING
13A-239
STEP 5. Check harness between C-14 (terminal No. 16) diagnosis connector and battery.
1 2 3 4 5 6 7 8 9 10 1112 13 14 1516
AK203591AD
NOTE: Before checking harness, check intermediate connectors C-126, C-211 and C-214, and repair if necessary. Check power supply line for damage.
(terminal No. 4 and No. 5) diagnosis connector and body earth. Check earthing line for damage. NO : Repair the damaged harness wire.
13A-240

TROUBLESHOOTING
Inspection Procedure 2: Communication with Engine-ECU only is not Possible.
Diagnosis connector circuit
C-117 (MU803783)
75 76 77 71 72 73 74 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
Engine-ECU
85 *1 O 20 J/C (6) C-105 19 O *2
23 C-124
9 (*1) or 14 (*2) J/C (2) <C-101> (*1) or <C-23> (*2)

10 (*1) or 15 (*2)
O
C-14
1 2 3 4 5 6 7 8 9 10 1112 13 14 1516
Diagnosis connector
AK501824 AB
OPERATION
There is data communication between diagnosis connector output terminal (terminal No. 7) and engine-ECU (terminal No. 85).

Failure is possibly caused by failed power supply circuit or failed earthing circuit of engine-ECU.

TROUBLESHOOTING
13A-241
PROBABLE CAUSES
Open/short circuit in engine-ECU power circuit Short circuit in diagnosis connector circuit Failed engine-ECU

DIAGNOSIS PROCEDURE
NOTE: . *1: L.H. drive vehicles *2: R.H. drive vehicles STEP 1. Check engine warning lamp. Ignition switch: OFF ON
Q: Is lamp illuminating for few seconds? YES : Go to Step 2 . NO : Check engine-ECU power supply, engine
control relay and ignition switch IG1 system (Refer to Inspection Procedure 23 P.13A-302).
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
13A-242

TROUBLESHOOTING
STEP 3. Check harness between C-14 (terminal No. 7) diagnosis connector and C-117 (terminal No. 85) engine-ECU connector.
STEP 4. Check the trouble symptom.

1 2 3 4 5 6 7 8 9 10 1112 13 14 1516
AK203591AD
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
NOTE: Before Checking harness, check intermediate connectors C-105*1, C-124 and C-101*1 or C-23*2, and repair if necessary. Check communication line for open/short circuit and damage.

TROUBLESHOOTING
13A-243
Inspection Procedure 3: The Engine Warning Lamp does not Illuminate Right after the Ignition Switch is Turned to the "ON" Position
Engine warning lamp (check engine lamp) circuit Ignition switch

C-208
R ST IG1 IG2 LOCK ACC
1 2 3 4 5 6
B-W C-211 6 2 7.5A 25 C-214 *2 J/B
*1 Y-R
Y-R
19 J/C (4) O C-23 17
9
C-01
Check engine
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Engine warning lamp (check engine lamp) 17
W-L C-124 9 W-L

22
C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
Engine-ECU
AK501825 AB
13A-244
OPERATION

TROUBLESHOOTING
Battery voltage is applied to engine warning lamp of combination meter connector (terminal No. 9) from ignition switch. Engine-ECU (terminal No. 22) makes power transistor in unit be in "ON" position, and that makes currents go on engine warning lamp of combination meter connector (terminal No. 17).
STEP 3. Connector check: C-01 combination meter connector

Connector: C-01 <L. H. drive vehicles> C-01

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.
PROBABLE CAUSES
Engine warming lamp bulb burnt out Failed ignition switch Open/short circuit in engine warning lamp circuit or loose connector contact Failed engine-ECU
C-01
DIAGNOSIS PROCEDURE
STEP 1. Check engine start-up.
Q: Is engine started? YES : Go to Step 2 . NO : Check engine-ECU power supply, engine
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AK301236 AC
control relay and ignition switch IG1 system (Refer to Inspection Procedure 23 P.13A-302). STEP 2. Check engine warning lamp for burnt-out bulb.
Q: Is the check result normal? YES : Go to Step 3 . NO : Replace the engine warning lamp.

TROUBLESHOOTING
13A-245
STEP 4. Perform voltage measurement at C-01 combination meter connector.

C-01
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AK301236 AC
Disconnect connector, and measure at the harness side. Ignition switch: "ON" Voltage between terminal No. 9 and earth. OK: System voltage
13A-246

TROUBLESHOOTING
STEP 5. Connector check: C-208 ignition switch connector

C-208
<R. H. drive vehicles> <R. H. drive vehicles> C-01
C-208

AK305251AB
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AK301236 AC
Q: Is the check result normal? YES : Check intermediate connectors C-23 <L.H.
drive vehicles> or C-214 and C-211, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-01 (terminal No. 9) combination meter connector and C-208 (terminal No. 2) ignition switch connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-247


C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

AK501995 AB
13A-248

TROUBLESHOOTING
STEP 8. Connector check: C-01 combination meter connector

C-01 C-121 (GR)

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AK301236 AC
repair if necessary. If intermediate connector is normal, check and repair harness between C-01 (terminal No. 17) combination meter connector and C-121 (terminal No. 22) engine-ECU connector. Check output line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-249

C-208
C-208

AK305251AB
13A-250

TROUBLESHOOTING
STEP 10. Check harness between C-01 (terminal No. 9) combination connector and C-208 (terminal No. 2) ignition switch connector.
C-208 C-01
C-208
C-01

AK305251AB
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AK301236 AC
NOTE: Before checking harness, check intermediate connectors C-23 <L.H. drive vehicles>, C-211and C-214, and repair if necessary. Check power supply line for damage.
Q: Is the check result normal? YES : Go to Step 11. NO : Repair the damaged harness wire.

TROUBLESHOOTING
13A-251
STEP 11. Check harness between C-01 (terminal No. 17) combination connector and C-121 (terminal No. 22) engine-ECU connector.
<R. H. drive vehicles> C-121 (GR)

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-01

AK501995 AB
NOTE: Before checking harness, check intermediate connector C-124, and repair if necessary. Check output line for damage.
Q: Is the check result normal? YES : Go to Step 12. NO : Repair the damaged harness wire.
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AK301236 AC

13A-252

TROUBLESHOOTING
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and never goes out
Engine warning lamp (check engine lamp) circuit Ignition switch

C-208
R ST IG1 IG2 LOCK ACC
1 2 3 4 5 6
B-W C-211 6 2 7.5A 25 C-214 *2 J/B
*1 Y-R
Y-R
19 J/C (4) O C-23 17
9
C-01
Check engine
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Engine warning lamp (check engine lamp) 17
W-L C-124 9 W-L

22
C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
Engine-ECU
AK501825 AB

TROUBLESHOOTING
13A-253
OPERATION
Battery voltage is applied to engine warning lamp (terminal No. 9) from ignition switch. Engine-ECU (terminal No. 22) makes power transistor in unit be in "ON" position, and that makes currents go on engine warning lamp (terminal No. 17).


Engine-ECU has detected failed sensor or failed actuator. Or failure is possibly caused by short circuit or other faults.
PROBABLE CAUSES
Short circuit in between engine warning lamp and engine-ECU circuit. Failed engine-ECU
C-121 (GR)
DIAGNOSIS PROCEDURE
Q: Diagnosis code set? YES : Inspection chart for diagnosis code (Refer
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
13A-254

TROUBLESHOOTING

C-01
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AK301236 AC
Q: Is the check result normal? YES : Go to Step 4 . NO : Check intermediate connector C-124, and
repair if necessary. If intermediate connector is normal, check and repair harness between C-01 (terminal No. 17) combination meter connector and C-121 (terminal No. 22) engine-ECU connector. Check output line for short circuit. STEP 4. Check the trouble symptoms.

TROUBLESHOOTING
13A-255
Inspection Procedure 5: Starting Impossible (No Initial Combustion)
Starter circuit Ignition switch

LOCK ACC IG2 IG1
C-208 1 2 3 4 5 6
R ST
Battery 5 B-Y C-123 7 B-R
B-L
B-R
B-14 3 B-R B-19 1 B-21 1 B-21 (MU801211)

OFF M ON
B-R
Starter B-19 1
68 C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
Engine-ECU
AK501826 AB
OPERATION
If the ignition switch is turned to "START" position, battery voltage is applied to starter (terminal No. 1). If the ignition switch is turned to "START" position, battery voltage is applied to engine-ECU (terminal No. 68) from ignition switch. Because of this, engine-ECU detects that the engine is cranked.
COMMENT ON TROUBLE SYMPTOM

Failure is possibly caused by failed starter itself or failed related circuit.
PROBABLE CAUSES
Failed battery Failed starter motor Open/short circuit in starter associated circuit or loose connector contact
13A-256
DIAGNOSIS PROCEDURE

TROUBLESHOOTING

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 P.54A-5).
STEP 2. M.U.T.-II/III data list Item No. 18: Cranking signal OK: ON (Ignition switch: ST) OFF (Ignition switch: ON)

C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Disconnect connector, and measure at the harness side. Ignition switch: ST Voltage between terminal No. 68 and earth. OK: System voltage
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

TROUBLESHOOTING
13A-257

C-208
C-208

AK305251AB
13A-258
STEP 6. Check ignition switch.

TROUBLESHOOTING
C-208
C-208
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK305251AB
Check ignition switch (Refer to GROUP 54A Ignition Switch Ignition Switch Inspection P.54A-30).
Q: Is the check result normal? YES : Check intermediate connectors C-123, and
repair if necessary. If intermediate connectors are normal, check and repair harness between C-119 (terminal No. 68) inhibitor switch connector and C-208 (terminal No. 5) ignition switch connector. Check power supply line for open/short circuit. NO : Replace the ignition switch.

TROUBLESHOOTING
13A-259
STEP 7. Connector check: C-208 ignition switch connector and B-21 starter connector
STEP 8. Connector check: B-21 starter connector

Connector: B-21 1 B-21(B) Harness side connector
C-208
AK305254 AB
STEP 9. Perform voltage measurement at B-21 starter connector.

Connector: B-21 C-208 1 B-21(B) Harness side connector

AK305251AB
AK305254 AB
Disconnect connector, and measure at the harness side. Ignition switch: ST Voltage between terminal No. 1 and earth. OK: System voltage
AK305254 AB
Q: Is the check result normal? YES : Check intermediate connectors C-123 and
B-14, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-208 (terminal No. 5) ignition switch connector and B-21 (terminal No. 1) starter connector. Check output line for short circuit. NO : Repair or replace the connector.
13A-260

TROUBLESHOOTING

STEP 11. Connector check: B-19 starter connector

Connector: B-19 1 Harness side connector
C-208 B-19 (B)

AK502004 AB
STEP 12. Perform voltage measurement at B-19 starter connector.

C-208 Connector: B-19 1 Harness side connector

AK305251AB
B-19 (B)
AK502004 AB
Disconnect connector, and measure at the harness side. Voltage between terminal No. 1 and earth. OK: System voltage
AK305254 AB
Q: Is the check result normal? YES : Check intermediate connectors B-14 and
(terminal No. 1) starter connector and battery. Check power supply line for open/short circuit.
C-123, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-208 (terminal No. 5) ignition switch connector and B-21 (terminal No. 1) starter connector. Check output line for open circuit and damage. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-261
STEP 13. Check harness between C-208 (terminal No. 5) ignition switch connector and B-21 (terminal No. 1) starter connector.
STEP 14. Check harness between B-19 (terminal No. 1) starter connector and battery.
Connector: B-19 1 Harness side connector
C-208 B-19 (B)

AK502004 AB

Q: Is the check result normal? YES : Replace the starter. NO : Repair the damaged harness wire.
C-208

AK305251AB
AK305254 AB
NOTE: Before checking harness, check intermediate connectors B-14 and C-123, and repair if necessary. Check output line for damage.
13A-262

TROUBLESHOOTING
Inspection Procedure 6: Starting impossible (Starter Operative but No Initial Combustion)
OPERATION
Refer to inspection procedure, ignition circuit system <L. H. drive vehicles>P.13A-356 or ignition circuit system <R. H. drive vehicles>P.13A-363
STEP 4. M.U.T.-II/III actuator test Item No. 07: Fuel pump OK: Operating sound of fuel pump can be heard.
Q: Is the check result normal? YES : Go to Step 5 . NO : Check fuel pump system (Refer to

Failure is possibly caused by failed ignition circuit, failed fuel feed or other faults.
Inspection Procedure 24 P.13A-313). STEP 5. Check timing belt for breakage. Engine: Cranking OK: Camshaft rotates.
Q: Is the check result normal? YES : Go to Step 6 . NO : Replace the timing belt.
PROBABLE CAUSES
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 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 .
Battery On-vehicle Service Battery test P.54A-5).
STEP 7. Check idling speed control for operating sound. Check idle speed control servo for operating sound (Refer to P.13A-408).
Q: Is the check result normal? YES : Clean throttle body (throttle valve portion)
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
NO : Check idle speed control servo system
(Refer to code No. P0505 P.13A-190). STEP 8. M.U.T.-II/III data list Item No. 18: Cranking signal OK: ON (Ignition switch: ST) OFF (Ignition switch: ON)
control relay and ignition switch IG1 system (Refer to Inspection Procedure 23 P.13A-302). STEP 3. M.U.T.-II/III diagnosis code
Q: Diagnosis code set? YES : Inspection chart for diagnosis codes (Refer
to P.13A-17).
NO : Go to Step 4 .

TROUBLESHOOTING
13A-263

C-208
C-208
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK305251AB
repair if necessary. If intermediate connector is normal, check and repair harness between C-208 (terminal No. 9) ignition switch connector and C-119 (terminal No. 68) engine-ECU connector. Check output line for open/short circuit. NO : Repair or replace the connector. STEP 10. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 22: Crank angle sensor
Q: Is the check result normal? YES : Go to Step 11 . NO : Check crank angle sensor system (Refer to
Code No. P0335 P.13A-155).
13A-264

TROUBLESHOOTING
STEP 11. Check injector for operating sound. Check injector for operating sound (Refer to P.13A-406).
Q: Can operating sound be heard? YES : Go to Step 12 . NO : Check the injector system of the defective
STEP 12. Check ignition coil spark

Q: Is the check result normal? YES : Go to Step 13 . NO : Check ignition circuit system (refer to
cylinder (Refer to Code No. 0201: No. 1 injector system P.13A-105). (Refer to Code No. 0202: No. 2 injector system P.13A-111). (Refer to Code No. 0203: No. 3 injector system P.13A-117). (Refer to Code No. 0204: No. 4 injector system P.13A-123).
inspection procedure 30 <L. H. drive vehicles>P.13A-356 or inspection procedure 31 <R. H. drive vehicles>P.13A-363). STEP 13. Replace the 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 : The check is end.
Inspection Procedure 7: Starting Impossible (Initial Combustion but no Complete Combustion), Starting (Long Time to Start)

Failure is possibly caused by poor ignition, incorrect air-fuel ratio at cranking, improper fuel pressure or other faults.
PROBABLE CAUSES
Failed battery Failed ignition system Failed fuel system Failed air-fuel ratio control system 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
Battery On-vehicle Service Battery Test P.54A-5).

Q: Diagnosis code set? YES : Inspection chart for diagnosis codes (Refer
to P.13A-17).
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 1. Check battery condition.
Q: Have the battery terminal been disconnected? YES : After warm-up engine, idle for about 10
STEP 4. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 13: Intake air temperature sensor b. Item No. 21: Engine coolant temperature sensor c. Item No. 25: Barometric pressure sensor
minutes. NO : Go to Step 2 .
procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes P.13A-17).

TROUBLESHOOTING
13A-265
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 10. Check timing marks of timing belt.

Q: Is the check result normal? YES : Go to Step 11 . NO : Align timing marks.

STEP 6. Check idle speed control servo for operating sound. Check idle speed control servo for operating sound (Refer to P.13A-408).
Q: Is the check result normal? YES : Clean throttle body (throttle valve portion)
(Refer to P.13A-395). NO : Check idle speed control servo system (Refer to Code No. P0505 P.13A-190). STEP 7. M.U.T.-II/III actuator test Refer to Actuator Test Reference Table P.13A-378. a. Item No. 07: Fuel pump OK: Operating sound of fuel pump can be heard.
Inspection Procedure 24 P.13A-313). STEP 8. Check air intake from intake hose and intake manifold.
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
STEP 9. Check injector for operating sound. Check injector for operating sound at engine cranking (Refer to P.13A-406).
Measure engine-ECU terminal voltage. Voltage between terminal No. 46 and earth also between terminal No. 58 and earth. OK: System voltage
cylinder (Refer to Code No. 0201: No. 1 injector system P.13A-105). (Refer to Code No. 0202: No. 2 injector system P.13A-111). (Refer to Code No. 0203: No. 3 injector system P.13A-117). (Refer to Code No. 0204: No. 4 injector system P.13A-123).
13A-266

TROUBLESHOOTING

STEP 13. Connector check: B-103 and B-114 ignition coil connectors.
Connector : B-103, B-114 3 2 1 Harness side connector B-114(GR)
B-103(GR)
AK305047AB

C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
STEP 15. Check spark plug.

Q: Is the check result normal? YES : Go to Step 16 . NO : Replace the spark plug.

AK501994 AB
(terminal No. 46 and No. 58) engine-ECU connector and body earth. Check earth line for open circuit and damage. NO : Repair or replace the connector.
STEP 16. Check spark plug cable itself. Check spark plug cable itself (Refer to GROUP 16 Ignition System On-vehicle Service P.16-29).
Q: Is the check result normal? YES : Go to Step 17 . NO : Replace the spark plug cable.
STEP 17. Check ignition coil itself. Check ignition coil itself (Refer to GROUP 16 Ignition System On-vehicle Service P.16-28).
Q: Is the check result normal? YES : Go to Step 18 . NO : Replace the ignition coil.

TROUBLESHOOTING
13A-267
STEP 18. Check harness between ignition coil connector terminal No. 2 of each cylinder and body earth.
STEP 19. Check spray condition of injector. Check each injector for spray condition (Refer to P.13A-406).
B-103(GR)
AK305047AB
STEP 20. Check compression pressure. Check compression pressure (Refer to GROUP 11A On-vehicle Service P.11A-11).
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 P.17-15).
C-121 (GR)
STEP 22. Check EGR valve itself. Check EGR valve itself (Refer to GROUP 17 Emission Control System Exhaust Gas Recirculation (EGR) System P.17-15).
Q: Is the check result normal? YES : Go to Step 23 . NO : Replace the EGR valve.
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
STEP 23. Replace the engine-ECU. After replacing the engine-ECU, re-check the trouble symptoms.
Q: Does trouble symptom persist? YES : Check for foreign matters (water, kerosene,

Q: Is the check result normal? YES : Check and repair harness between ignition

coil connector terminal No. 3 of each cylinder and C-121 engine-ECU connector. Check signal line for open/short circuit and damage. NO : Repair the damaged harness wire.
13A-268

TROUBLESHOOTING
Inspection Procedure 8: Unstable Idling (Rough Idling, hunting), Improper Idling Speed (Too High or too Low), Engine Stalls During Idling (Die Out)

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.
STEP 4. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. 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
PROBABLE CAUSES
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
system (Refer to Code No. P0551 P.13A-197). STEP 5. Check idle speed control servo for operating sound. Check idle speed control servo for operating sound (Refer to P.13A-408).
Q: Is the check result normal? YES : Go to Step 6 . NO : Check idle speed control servo system
(Refer to Code No. P0505 P.13A-190). STEP 6. Check throttle body (throttle valve portion) for contamination.
DIAGNOSIS PROCEDURE
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 .
(Refer to P.13A-395). STEP 7. Check air intake from intake hose and intake manifold.

to P.13A-17).
NO : Go to Step 3 .
STEP 3. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 12: Air flow sensor b. Item No. 13: Intake air temperature sensor c. Item No. 14: Throttle position sensor d. Item No. 21: Engine coolant temperature sensor e. Item No. 25: Barometric pressure sensor
Procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes P.13A-17).
cylinder. (Refer to Code No. P0201: No. 1 injector system P.13A-105). (Refer to Code No. P0202: No. 2 injector system P.13A-111). (Refer to Code No. P0203: No. 3 injector system P.13A-117). (Refer to Code No. P0204: No. 4 injector system P.13A-123).

TROUBLESHOOTING
13A-269


Q: Is the check result normal? YES : Go to Step 11 . NO : Check the oxygen sensor (front) system
(Refer to Code No. P0130 P.13A-75). STEP 11. Perform voltage measurement at C-119 engine-ECU.
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
(terminal No. 46 and No. 58) engine-ECU connector and body earth. Check earthing line for open circuit and damage. NO : Repair or replace the connector.
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
Measure engine-ECU terminal voltage. Ignition switch: "ON" Voltage between terminal No. 46 and earth, also between terminal No. 58 and earth. OK: 0.5 V or less
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TROUBLESHOOTING

STEP 14. Connector check: C-121 engine-ECU connector and B-25 alternator connector.
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

AK501995 AB
Measure engine-ECU terminal voltage. Engine: Idling after warm-up Transmission: Neutral Radiator fan: Not operating Voltage between terminal No. 8 and earth. OK: Switching the head lamps to ON from OFF causes the voltage to increase by 0.2 3.5 V.
Connector : B-25
2 1 B-25(GR)
AK305036 AB

TROUBLESHOOTING
13A-271
STEP 15. Check harness between C-121 (terminal No. 8) engine-ECU connector and B-25 (terminal No. 1) alternator connector.

C-121 (GR) C-121 (GR)

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26 8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB AK501995 AB
Connector : B-25
Measure engine-ECU terminal voltage. Engine: Idling after warm-up Transmission: Neutral Radiator fan: Not operating Voltage between terminal No. 8 and earth. OK: Switching the head lamps to ON from OFF causes the voltage to fall.
2 1 B-25(GR)
AK305036 AB
NOTE: Before checking harness, check intermediate connector B-14 and repair if necessary. Check output line for open/short circuit and damage.
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TROUBLESHOOTING
STEP 17. Connector check: C-119 engine-ECU connector and B-25 alternator connector.
STEP 18. Check harness between C-119 (terminal No. 52) engine-ECU connector and B-25 (terminal No. 4) alternator connector.
C-119 (GR) <R. H. drive vehicles> <R. H. drive vehicles> C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60 AK501994 AB

AK501994 AB
Connector : B-25 Connector : B-25
2 1 B-25(GR)
AK305036 AB
2 1 B-25(GR)
AK305036 AB
NOTE: Before checking harness, check intermediate connector B-14, and repair if necessary. Check output line for open/short circuit and damage.

TROUBLESHOOTING
13A-273

Q: Does trouble symptom persist? YES : Replace the alternator. NO : Intermittent malfunction (Refer to GROUP
STEP 21. Connector check: B-103 and B-114 ignition coil connectors.
STEP 20. Perform voltage measure at C-119 engine-ECU connector.

B-103(GR)
AK305047AB


C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
STEP 24. Check spark plug cable. Check spark plug cable itself (Refer to GROUP 16 Ignition System On-vehicle Service P.16-29).

AK501994 AB
Measure engine-ECU terminal voltage. Engine: Idling A/C switch: ON (A/C compressor ON) Voltage between terminal No. 65 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 29 P.13A-352).
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TROUBLESHOOTING
STEP 27. Check injector for spray condition. Check each injector for spray condition (Refer to P.13A-406).
B-103(GR)
AK305047AB
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 P.17-11).
C-121 (GR)
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 P.17-15).
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Check earthing line for open/short circuit and damage.

coil connector terminal No. 3 of each cylinder and C-121 engine-ECU. Check signal line for open/short and damage. NO : Repair the damaged harness wire.
STEP 32. M.U.T.-II/III actuator test Item No. 07: Fuel pump OK: Operating sounds of fuel pump can be heard.
inspection Procedure 24 P.13A-313).

TROUBLESHOOTING
13A-275
STEP 33. Replace the engine-ECU After engine-ECU is replaced, re-check for trouble symptoms.
Q: Does trouble system persist? YES : Check for foreign matters (water, kerosene,

Inspection Procedure 9: The Engine Stalls when Starting the Car (Pass Out)

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.
STEP 4. Check air intake from intake hose and intake manifold.
PROBABLE CAUSES
Failed ignition system Failed intake system Failed emission gas cleaning system Failed engine-ECU STEP 5. Connector check: B-103 and B-114 ignition connectors
DIAGNOSIS PROCEDURE
B-103(GR)
AK305047AB
to P.13A-17). NO : Go to Step 2 . STEP 2. Check EGR control solenoid valve itself. Check EGR control solenoid valve itself (Refer to GROUP 17 Emission Control System Exhaust Gas Recirculation (EGR) System P.17-15).

Q: Is the check result normal? YES : Replace the engine-ECU. NO : Go to Step 7 .
STEP 7. Check spark plug. STEP 3. Check EGR valve itself. Check EGR valve itself (Refer to GROUP 17 Emission Control System Exhaust Gas Recirculation (EGR) System P.17-15).
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the EGR valve. Q: Is the check result normal? YES : Go to Step 8 . NO : Replace the spark plug.
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TROUBLESHOOTING
STEP 8.Check spark plug cable itself. Check spark plug cable itself (Refer to GROUP 16 Ignition System On-vehicle Service P.16-29).
B-103(GR)
AK305047AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-277
Inspection Procedure 10: The Engine Stalls when Decelerating

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 CAUSES
Failed idle speed system Failed ignition system Failed emission control system Throttle valve fouled Failed engine-ECU

DIAGNOSIS PROCEDURE
(Refer to P.13A-395). STEP 7. Connector check: B-103 and B-114 ignition coil connectors
to P.13A-17). NO : Go to Step 2 . STEP 2. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 14: Throttle position sensor
Q: Is the check result normal? YES : Go to Step 3 . NO : Check throttle position sensor system
B-103(GR)
AK305047AB
(Refer to Code No. P0120 P.13A-60). STEP 3. M.U.T.-II/III data list Item No. 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).

(Refer to Code No. P0505 P.13A-190). 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 P.17-15).

13A-278

TROUBLESHOOTING
B-103(GR)
AK305047AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-279
Inspection Procedure 11: Engine does not Revole Up

Failure is possibly caused by failed fuel system, ignition system or other faults.

PROBABLE CAUSES
Failed ignition system Failed fuel system Timing belt out of place Failed engine-ECU

DIAGNOSIS PROCEDURE
to P.13A-17).
NO : Go to Step 2 .

Q: Is the check result normal? YES : Go to Step 3 . NO : Align match marks.
STEP 3. Connector check: B-103 and B-114 ignition coil connectors

B-103(GR)
AK305047AB
13A-280

TROUBLESHOOTING

B-103(GR)
AK305047AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-281
Inspection Procedure 12: Hesitation, Sag,Poor Acceleration, Stumble or Surge

Failure is possibly caused by failed ignition system, improper air-fuel ratio, improper compression pressure or other faults.
PROBABLE CAUSES
Failed air-fuel ratio control system Failed ignition system Failed fuel system Failed intake and exhaust system Failed emission control system Failed turbocharger system Throttle valve fouled Improper compression pressure Failed engine-ECU
STEP 3. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 13: Intake air temperature sensor b. Item No. 14: Throttle position sensor c. Item No. 21: Engine coolant temperature sensor d. Item No. 25: Barometric pressure sensor
procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes P.13A-17). 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 P.17-11).
DIAGNOSIS PROCEDURE
to P.13A-17).
NO : Go to Step 2 .
STEP 5. Check EGR control solenoid valve itself. Check EGR control solenoid valve itself (Refer to GROUP 17 Emission Control System Exhaust Gas Recirculation (EGR) SystemP.17-15).
cylinder. (Refer to code No. P0201: No. 1 injector system P.13A-105). (Refer to code No. P0202: No. 2 injector system P.13A-111). (Refer to code No. P0203: No. 3 injector system P.13A-117). (Refer to code No. P0204: No. 4 injector system P.13A-123).
to Code No. P0130 P.13A-75).
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TROUBLESHOOTING

B-103(GR) B-103(GR)
AK305047AB AK305047AB


C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

coil connector terminal No. 3 of each cylinder and C-121 engine-ECU connector. Check signal line for open or short circuit or damage. NO : Repair the damaged harness wire.

TROUBLESHOOTING
13A-283
STEP 17. Check supercharging pressure control system. Check supercharging pressure control system (Refer to GROUP 15 Intake Exhaust On-vehicle Service P.15-3).
(Refer to P.13A-395). STEP 15. M.U.T.-II/III actuator test. Item No. 12: Waste gate solenoid valve OK: Operating sound is audible on actuation.
Q: Is the check result normal? YES : Go to Step 16 . NO : Check waste gate solenoid valve system
STEP 18. M.U.T.-II/III actuator test. Item No. 09: Fuel pressure control solenoid valve OK: Operating sound is audible on actuation.
Q: Is the check result normal? YES : Go to Step 19 . NO : Check fuel pressure control solenoid valve
(Refer to Code No. P0243 P.13A-130). STEP 16. Check turbo charger supercharging pressure. Check turbo charger output pressure (Refer to GROUP 15 Intake Exhaust On-vehicle Service P.15-2).
system (Refer to Code No. P0443 P.13A-182). STEP 19.Fuel pressure measurement. Fuel pressure measurement (Refer to P.13A-396).
Inspection Procedure 13: The Feeling of Impact or Vibration when Accelerating

Failure is possibly caused by failed ignition leak with rise in spark plug-required voltage at acceleration.
DIAGNOSIS PROCEDURE
PROBABLE CAUSES
Failed ignition system Failed engine-ECU
to P.13A-17).
NO : Go to Step 2 .
13A-284

TROUBLESHOOTING

B-103(GR) B-103(GR)
AK305047AB AK305047AB


C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-285
Inspection Procedure 14: The Feeling of Impact or Vibration when Decelerating

Failure is possibly caused by insufficient air intake due to failed idle speed control system.
PROBABLE CAUSES
Failed idle speed system Throttle valve body fouled Failed engine-ECU
STEP 2. Check idle speed control servo for operating sound. Check idle speed control servo for operating sound (Refer to P.13A-408).
(Refer to Code No. P0505 P.13A-190). STEP 3. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 14: Throttle position sensor
Q: Is the check result normal? YES : Go to Step 4 . NO : Check throttle position sensor system
DIAGNOSIS PROCEDURE
(Refer to Code No. P0120 P.13A-60). STEP 4. Check throttle body (throttle valve portion) contamination.
Q: Is the check result normal? YES : Replace the engine-ECU. NO : Clean throttle body (throttle valve portion)
Inspection Procedure 15: Knocking

Failure is possibly caused by failed detonation control, improper thermal value of spark plug or other faults.

PROBABLE CAUSES
Defective detonation sensor Failed detonation control system Failed ignition system Defective spark plug Failed engine-ECU
B-103(GR)
AK305047AB
DIAGNOSIS PROCEDURE
to P.13A-17).
NO : Go to Step 2 .
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TROUBLESHOOTING
Q: Is the check result normal? YES : Check detonation sensor (Refer to Code
No. P0325 P.13A-151).

NO : Go to Step 4 .

B-103(GR)
AK305047AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-287
Inspection Procedure 16: Ignition Timing Offset

Failure is possibly caused by failed crank angle sensor, failed exhaust camshaft position sensor, improper installed timing belt or other faults.
STEP 2. Perform output wave pattern measurement of crank angle sensor and exhaust camshaft position sensor (Using an oscilloscope).
Connector : B-117
PROBABLE CAUSE
Failed crank angle sensor Failed exhaust camshaft position sensor Improperly installed timing belt Failed engine-ECU
DIAGNOSIS PROCEDURE
Crank angle sensor

to P.13A-17).
NO : Go to Step 2 .
B-117(B)
2 1 3 Harness side connector Connector: B-106
AK305020AB
3 2 1 B-106 (B) Harness side connector
AK501999 AB
Crank Angle Sensor Use special tool test harness (MD998478) to connect B-117 crank angle sensor connector, and measure at pick-up harness. Engine: Idling Transmission: Neutral Voltage between terminal No. 2 and earth. Exhaust camshaft Position Sensor Use special tool test harness (MB991709) to connect B-106 exhaust camshaft position sensor connector, and measure at pick-up harness. Engine: Idling Transmission: Neutral Voltage between terminal No. 2 and earth.
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TROUBLESHOOTING
OK: Output waveform timings of both sensors are the same as the check procedure (Refer to P.13A-385) using an oscilloscope.
STEP 6. Check crank angle sensor vane.

Q: Is the check result normal? YES : Go to Step 7 . NO : Replace the crank angle sensor vane.

STEP 7. Check exhaust camshaft position sensing cylinder.

Q: Is the check result normal? YES : Go to Step 8 . NO : Replace the exhaust 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 : The check is end.
STEP 4. Check crank angle sensor and exhaust camshaft position sensor mounted conditions.

STEP 9. Replace exhaust camshaft position sensor. After replacing the exhaust camshaft position sensor, re-check the trouble symptoms.
Inspection Procedure 17: Run on (Dieseling)

Failure is possibly caused by leakage from injector.
DIAGNOSIS PROCEDURE
STEP 1. Check injector for spray condition. Check each injector for spray condition (Refer to P.13A-406).
Q: Does trouble symptom persist? YES : Replace the engine-ECU. NO : Replace the injector.
PROBABLE CAUSES
Failed injector Failed engine-ECU

TROUBLESHOOTING
13A-289
Inspection Procedure 18: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC During Idling

Failure is possibly caused by improper air-fuel ratio, deteriorated catalyst, failed ignition system, failed fuel system, failed compression pressure or other faults.
PROBABLE CAUSES
Failed air-fuel control system 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 4. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 12: Air flow sensor b. Item No. 13: Intake air temperature sensor c. Item No. 21: Engine coolant temperature sensor d. Item No. 25: Barometric pressure sensor
procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Codes P.13A-17). STEP 5. Check air intake from intake hose and intake manifold.
DIAGNOSIS PROCEDURE
to P.13A-17). NO : Go to Step 2 . STEP 2. Check injector for operating sound. Check injector for operating sound (Refer to P.13A-406).
STEP 6. Check for emission leakage from exhaust manifold.


cylinder. (Refer to Code No. P0201: No. 1 injector system P.13A-105). (Refer to Code No. P0202: No. 2 injector system P.13A-111). (Refer to Code No. P0203: No. 3 injector system P.13A-117). (Refer to Code No. P0204: No. 4 injector system P.13A-123). STEP 3. Check ignition timing. Check ignition timing (Refer to GROUP 11A On-vehicle Service P.11A-9).
Q: Is the check result normal? YES : Go to Step 4 . NO : Check for offset ignition timing (Refer to
(Refer to P.13A-395). STEP 8. M.U.T.-II/III data list Refer to Data List Reference Table P.13A-372. a. Item No. 11: Oxygen sensor (front)
to Code No. P0130 P.13A-75).
13A-290

TROUBLESHOOTING
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 P.17-11).

STEP 10. Check EGR control solenoid valve itself. Check the EGR control solenoid valve itself (Refer to GROUP 17 Emission Control System Exhaust Gas Recirculation (EGR) System P.17-15).
STEP 18. Check injector for spraying condition. Check each injector for spray condition (Refer to P.13A-406).
Q: Does trouble symptom persist? YES : Go to Step 19 . NO : Replace the injector.
STEP 13. Check positive crankcase ventilation valve itself. Check positive crankcase ventilation valve itself (Refer to GROUP 17 Emission Control System Evaporative Emission Control System P.17-9).
Q: Is the check result normal? YES : Go to Step 14 . NO : Replace the positive crankcase ventilation
STEP 19. Replace catalytic converter. After replacing the catalytic converter re-check the trouble symptoms.
valve.

TROUBLESHOOTING
13A-291
Inspection Procedure 19: Battery Rundown

Failure is possibly caused by failed alternator, failed generation control circuit or other faults.

PROBABLE CAUSES
Failed battery Alternator G terminal short-circuit Failed alternator Failed engine-ECU
1 2 3 4 5 6 7 8 9 10
DIAGNOSIS PROCEDURE
STEP 1. Check battery voltage. Measure battery voltage during cranking. OK: 8 V or more
Male side connector
AK401753 AB
Disconnect connector, and measure at male connector side. Ignition switch: "ON" Voltage between terminal No. 9 and earth. OK: System voltage
STEP 2. Connector check: B-14 intermediate connector

5 4 3 2 1 10 9 8 7 6
AK305035AC
13A-292

TROUBLESHOOTING


C-208
5 4 3 2 1 10 9 8 7 6
AK305035AC
Disconnect connector, and measure at female connector side. Ignition switch: "ON" Voltage between terminal No. 10 and earth. OK: System voltage
C-208

Connector : B-25 3 2 1 6 5 4 Harness side connector
AK305251AB

M
2 1 B-25(GR)
AK305036 AB
1 2 3 4 5 6 7 8 9 10
AK401753 AB
Male side connector
Q: Is the check result normal? YES : Check intermediate connectors C-01, C-23
<L.H. drive vehicles>, C-124, C-211 and C-214, and repair if necessary. If intermediate connectors are normal, check and repair harness between B-14 (terminal No. 9) intermediate connector and C-208 (terminal No. 2) ignition switch connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-293
STEP 7. Check harness between B-14 (terminal No. 10) intermediate connector and B-25 (terminal No. 1) alternator connector.
STEP 8. Check harness between B-14 (terminal No. 9) intermediate connector and B-25 (terminal No. 3) alternator connector.
5 4 3 2 1 10 9 8 7 6
5 4 3 2 1 10 9 8 7 6
AK305035AC
Female side connector Connector : B-25
Female side connector Connector : B-25
AK305035AC
2 1 B-25(GR)
AK305036 AB
2 1 B-25(GR)
AK305036 AB


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TROUBLESHOOTING
STEP 9. Check harness between B-25 (terminal No. 3) alternator connector and C-208 (terminal No. 2) ignition switch connector.
Connector : B-25

2 1 B-25(GR)
AK305036 AB
C-208 C-121 (GR)

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
Harness side connector <R. H. drive vehicles>

AK501995 AB
C-208

AK305251AB
NOTE: Before checking harness, check intermediate connectors C-01, C-23 <L.H. drive vehicles>, C-124, C-211 and C-214, and repair if necessary. Check power supply line for damage.
Q: Is the check result normal? YES : Replace the alternator. NO : Repair the damaged harness wire.

TROUBLESHOOTING
13A-295


C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

AK501995 AB
1 2 3 4 5 6 7 8 9 10
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 head lamps to ON from OFF causes the voltage to increase by 0.2 3.5 V.
Male side connector
AK401753 AB
Q: Is the check result normal? YES : Go to Step 13 . NO : Replace the alternator.

(terminal No. 10) intermediate connector and C-121 (terminal No. 8) engine-ECU connector. Check output line for short circuit.
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TROUBLESHOOTING
Inspection Procedure 20: Overheating

Failure is possibly caused by failed engine cooling system, failed fan controller, failed engine coolant temperature sensor or other faults.
STEP 3. M.U.T.-II/III actuator test Item No. 21: Fan controller OK: Fan motor rotating
Q: Is the check result normal? YES : Go to Step 4 . NO : Check radiator fan control relay system
PROBABLE CAUSES
Insufficient or deteriorated engine coolant Failed fan controller Failed engine coolant temperature sensor Failed thermostat Failed water pump Failed radiator core Failed engine-ECU
(Refer to Inspection Procedure 25 P.13A-324). STEP 4. M.U.T.-II/III data list Item No. 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 : Go to Step 5 . NO : Check engine coolant temperature sensor
DIAGNOSIS PROCEDURE
to P.13A-17). 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 On-vehicle Service P.14-15).
Q: Is the check result normal? YES : Go to Step 3 . NO : Replace or add engine coolant.
system (Refer to Code No. P0115 P.13A-52). STEP 5. Check thermostat. Check thermostat (Refer to GROUP 14 Thermostat P.14-19).
Q: Is the check result normal? YES : Go to Step 6 . NO : Replace the thermostat.
STEP 6. Check water pump. Check water pump.

Q: Is the check result normal? YES : Replace the radiator. NO : Replace the water pump.

TROUBLESHOOTING
13A-297
Inspection Procedure 21: Abnormal Rotation of Fan Motor
Fan controller circuit
5V
A-17 (MU802322) Fan controller 1 2 3
2 L A-13 (*1) 2
C-31 (*2) 14 L C-121 (MU803784)

3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
18
Engine-ECU
AK501827AB
OPERATION
The control (duty) signal is inputted to the fan controller (terminal No. 2) from the engine-ECU (terminal No. 18).
PROBABLE CAUSES
Failed fan controller Open/short circuit in fan controller circuit or loose connector contact Failed engine-ECU
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 5 V.)
DIAGNOSIS PROCEDURE
13A-298

TROUBLESHOOTING

STEP 2. Check at C-121 engine-ECU connector.

C-121 (GR) C-121 (GR)

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26 8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB AK501995 AB
Disconnect connector, and measure at harness side. Ignition switch: "ON" Short-circuit terminal No. 18 to earth. OK: Fan motor stops rotating.


TROUBLESHOOTING
13A-299

STEP 6. Check harness between A-17 (terminal No. 2) fan controller connector and C-121 (terminal No. 18) engine-ECU connector.
Connector: A-17
A-17 (GR)
3 2 1 Harness side connector C-121 (GR) <R. H. drive vehicles> Connector: C-121 <L. H. drive vehicles>
AK305256 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
AK501995 AB
Q: Is the check result normal? YES : Replace the fan controller. NO : Go to Step 5 .
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
STEP 5. Connector check: A-17 fan controller connector

Connector: A-17

AK501995 AB
NOTE: Before checking harness, check intermediate connector A-13*1 or 31*2, and repair if necessary. Check output line for open circuit.
Q: Is the check result normal? YES : Replace the fan controller. NO : Repair the damaged harness wire.
A-17 (GR)

AK305256 AB
13A-300

TROUBLESHOOTING
Inspection Procedure 22: Poor A/C Performance

Failure is possibly caused by short /overcharged A/C refrigerant, failed A/C control system, failed fan control system or other faults.
PROBABLE CAUSES
Short or overcharged A/C refrigerant Failed A/C compressor Failed fan controller Failed A/C-ECU Failed engine-ECU
STEP 3. M.U.T.-II/III data list Item No. 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
DIAGNOSIS PROCEDURE
Procedure 27 P.13A-341). STEP 4. M.U.T.-II/III data list Item No. 49: A/C relay a. Engine: Idling b. A/C set temperature: Maximum Hot when temperature in cabin is 25C or less Maximum Cool when temperature in cabin is 25C or more 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 55
to P.13A-17). NO : Go to Step 2 . 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)
Troubleshooting P.55-29).
NO : Check A/C compressor relay (Refer to
Inspection procedure 28 P.13A-344).

TROUBLESHOOTING
13A-301
STEP 5. Check charged amount of A/C refrigerant. Check charged amount of A/C refrigerant (Refer to GROUP 55 On-vehicle Service P.55-104).
Q: Is the check result normal? YES : Go to Step 6 . NO : Adjust charged amount of A/C refrigerant.
STEP 6. M.U.T.-II/III actuator test Item No. 21: Fan controller OK: Fan motor rotates.
Q: Is the check result normal? YES : Check A/C load signal system (Refer to

NO : Check radiator fan control relay system
(Refer to Inspection Procedure 25 P.13A-324).
13A-302

TROUBLESHOOTING
Inspection Procedure 23: Engine-ECU Power Supply, Engine Control Relay, Ignition Switch-IG1 System
Power supply and ignition switch-IG circuit Battery W W
Relay box
8 20A Ignition switch

R LOCK ACC IG2
C-208 1 2 3 4 5 6
B-Y 6 <A-13> (*1) or 13 <C-31> (*2)
ST IG1
2 B-W C-211 6
B-Y 1
B-Y 2 Engine control relay 4 3
8 7.5A 1 C-210 L (*1) or B-W (*2)
J/B
B-12X 1 3 2 4
R-Y 28 J/C (6) C-105 B B B 58 46 R-Y 47 Power supply 30 R-Y 59 57 60 Back-up power supply 99 31 R R-B B-R C-123 4
Engine-ECU
C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
C-117 (MU803783)
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
AK501828 AB

TROUBLESHOOTING
13A-303
OPERATION
The battery voltage is applied to the engine control relay (terminal No. 1 and No. 4). The engine-ECU (terminal No. 57) 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 engine-ECU, the sensor and the actuator from the engine control relay (terminal No. 4). The engine-ECU (terminal No. 46, No. 58) is grounded to the vehicle body.

B-12X
2 4
1 3

AK305003 AB
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.
STEP 3. Check engine control relay. Check engine control relay (Refer to P.13A-401).
Q: Is the check result normal? YES : Go to Step 4 . NO : Replace the engine control relay.
PROBABLE CAUSES
Failed engine control relay Open/short circuit in engine control relay circuit or loose connector contact Failed engine-ECU
STEP 4. Perform voltage measurement at B-12X engine control relay connector.

DIAGNOSIS PROCEDURE
NOTE: . *1: L.H. drive vehicles *2: R.H. drive vehicles STEP 1. Check battery voltage. Measure battery voltage during cranking. OK: 8 V or more
B-12X
2 4
1 3

AK305003 AB
Remove relay, and measure at relay box side. Voltage between terminal No. 1 and earth, also between terminal No. 2 and earth. OK: System voltage
Q: Is the check result normal? YES : Go to Step 5 . NO : Check intermediate connector A-13*1 or
C-31*2, and repair if necessary. If intermediate connector is normal, check and repair harness between B-12X (terminal No. 1, No. 2) engine control relay connector and battery. Check power supply line for open/short circuit.
13A-304

TROUBLESHOOTING


C-117 (GR)
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

AK501996 AB

TROUBLESHOOTING
13A-305

C-208
C-208

AK305251AB
13A-306

TROUBLESHOOTING
C-208
C-208
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

AK305251AB
Check ignition switch (Refer to GROUP 54A Ignition Switch Ignition Switch Inspection P.54A-30).
Q: Is the check result normal? YES : Check intermediate connectors C-123,
C-210 and C-211, then repair if necessary. If intermediate connectors are normal, check and repair harness between C-117(terminal No. 99) engine-ECU connector and C-208 (terminal No. 2) ignition switch connector. Check power supply line for open/short circuit. NO : Replace the ignition switch.

TROUBLESHOOTING
13A-307


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
Disconnect connector, and measure at harness side. Voltage between terminal No. 60 and earth. OK: System voltage
C-31*2 and repair if necessary. If intermediate connector is normal, check and repair harness between C-119 (terminal No. 60) engine-ECU connector and battery. Check power supply line for short circuit.
13A-308

TROUBLESHOOTING
STEP 11. Perform resistance measurement at C-119 engine-ECU connector.


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
Disconnect connector, and measure at harness side. Resistance between terminal No. 46 and earth, and No. 58 and earth. OK: 2 or less
(terminal No. 46 and No. 58) engine-ECU connector and body earth. Check earthing line for open circuit and damage.

TROUBLESHOOTING
13A-309


C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

AK501994 AB
Connector : B-12X
Connector : B-12X
B-12X
2 4
1 3
B-12X
2 4
1 3

AK305003 AB

AK305003 AB
Disconnect connector, and measure at harness side. Voltage between terminal No. 57 and earth. OK: System voltage
Q: Is the check result normal? YES : Go to Step 14 . NO : Check and repair harness between B-12X
Disconnect connector, and measure at harness side. Using jumper wire, connect C-119 (terminal No. 57) engine-ECU connector and earth. Voltage between terminal No. 47 and earth, and No. 59 and earth. OK: System voltage
Q: Is the check result normal? YES : Go to Step 15 . NO : Check intermediate connector C-105 and
(terminal No. 3) engine control relay connector and C-119 (terminal No. 57) engine-ECU connector. Check earthing line for open/short circuit.
repair if necessary. If intermediate connector is normal, check and repair harness between C-119 (terminal No. 47 and No. 59) engine-ECU connector and B-12X (terminal No. 4) engine control relay connector.
13A-310

TROUBLESHOOTING
STEP 15. Check harness between C-208 (terminal No. 2) ignition switch connector and C-117 (terminal No. 99) engine-ECU connector.
C-208 C-117 (GR) <R. H. drive vehicles>
C-208
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB

AK305251AB

TROUBLESHOOTING
13A-311
STEP 16. Check harness between B-12X (terminal No. 1, No. 2) engine control relay connector and battery.
STEP 17. Check harness between B-12X (terminal No. 3) engine control relay connector and C-119 (terminal No. 57) engine-ECU connector.
B-12X
2 4
1 3 B-12X 2 4 1 3

AK305003 AB

AK305003 AB
NOTE: Before checking harness, check intermediate connector A-13*1 or C-31*2, and repair if necessary. Check power supply line for damage.
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB

13A-312

TROUBLESHOOTING
STEP 18. Check harness between B-12X (terminal No. 4) engine control relay connector and C-119 (terminal No. 47 and No. 59) engine-ECU connector.

B-12X
2 4
1 3

AK305003 AB
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
NOTE: Before checking harness, check intermediate connector C-105, and repair if necessary. Check output line for damage.

TROUBLESHOOTING
13A-313
Inspection Procedure 24: Fuel Pump System

Fuel pump circuit Battery W W C-208 15 15A GR Relay box 1 2 3 4 5 6
R ST IG1 LOCK ACC IG2
Ignition switch
2 C-129 1 (*1) or 12 (*2) C-210 2

4 3
B-W C-211 6 C-221 1 2 3 4

OFF
C-223 1 2 3 4
OFF
1
ON
8 7.5A J/B
ON
Fuel pump relay (1)
Fuel pump relay (2)
11 C-214 BR (*1) or B (*2)
13 C-214
14 C-214
R-W
1
1 C-123 R-W R-W

4
OFF
B-121 MU802601 1 2
2
B-120 Fuel pump resistor 1 3 2 4
ON
Fuel pump relay (3)

3
R R W C-123 5
C-123 2
D-12 (MU802058) 1 2 3 4 5 M
R-B Fuel pump and fuel gauge unit

D-33 1 C-113 (*1) W or C-112 (*2) 1
D-34 4
W 55 C-119 (MU803782)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
21 C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
NOTE *1: L.H. drive vehicles *2: R.H. drive vehicles
Engine-ECU
AK501829 AB
13A-314
OPERATION

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
NOTE: . *1: L.H. drive vehicles *2: R.H. drive vehicles STEP 1. M.U.T.-II/III actuator test Refer to Actuator Test Reference Table P.13A-378. a. Item No. 07: Fuel pump
The battery voltage is applied to the fuel pump relay (1) (terminal No. 3) form the ignition switch. When the ignition switch is turned to the "ON" position, the battery voltage is applied to the fuel pump relay (2) (terminal No. 1) from the fuel pump relay 1 (terminal No. 1). Battery voltage is applied to the fuel pump relay (2) (terminal No. 3) from the ignition switch. During cranking and while the engine is running, the engine-ECU turns ON the power transistor in the engine-ECU in order to earth the coil of the fuel pump relay (2). Consequently, the fuel pump relay 2 turns ON, and the fuel pump relay (2) (terminal No. 4) supplies the battery voltage to the fuel pump and the fuel pump circuit resistor. While the engine operates with a low load, the engine-ECU turns ON the power transistor in the engine-ECU in order to earth the coil of the fuel pump relay (3). Consequently, the fuel pump relay (3) turns OFF, and the fuel pump resistor (terminal No. 2) supplies the battery voltage to the fuel pump (terminal No. 5). While the engine operates with a high load, the engine-ECU turns OFF the power transistor in the engine-ECU, causing the fuel pump relay (3) to turn ON. Consequently, the fuel pump relay (3) (terminal No. 1) supplies power directly to the fuel pump (terminal No. 5).
STEP 2. M.U.T.-II/III actuator test Refer to Actuator Test Reference Table P.13A-378. a. Item No. 13: Fuel pump 3
00 How to Use Troubleshooting/Inspection Service Points P.00-5.) NO : Go to Step 18 .
STEP 3. Connector check: C-223 fuel pump relay (1) connector and C-221 fuel pump relay (2) connector.
Connector: C-221, C-223
C-223 C-221 Junction blocks triangle marks 2 1 4 3 Harness side connector
FUNCTION
The engine-ECU turns the fuel pump relay ON during cranking and engine operation, and supplies the drive power to the fuel pump. When operating with a low load, the engine-ECU supplies power to the fuel pump via the resistor. When operating with a high load, power is directly supplied and the fuel pump fuel discharge amount is increased.
PROBABLE CAUSES
Failed fuel pump relay Failed fuel pump Failed fuel pump resistor Open/short circuit in fuel pump drive circuit or loose connector contact Failed engine-ECU
AK305258 AB

TROUBLESHOOTING
13A-315
STEP 4. Connector check: B-121 fuel pump resistor connector.

Connector: B-121 <L. H. drive vehicles>
STEP 7. Perform voltage measurement at C-223 fuel pump relay (1) connector.
Connector: C-223
C-223 Junction blocks triangle marks 2 1 4 3 Harness side connector
B-121(B)
AK305260 AB
B-121(B)
Remove relay, and measure at junction block side. Ignition switch: "ON" Voltage between terminal No. 4 and earth. OK: System voltage
AK305259 AB
C-210 and repair if necessary. If intermediate connector is normal, check and repair harness between C-223 (terminal No. 4) fuel pump relay (1) connector and battery. Check power supply line for open/short circuit. STEP 8. Perform voltage measurement at C-223 fuel pump relay (1) connector.
Connector: C-223
STEP 5. Check fuel pump relay (1) and fuel pump relay (2). Fuel pump relay (1) and fuel pump relay (2), continuity check (Refer to P.13A-402).
Q: Is the check result normal? YES : Go to Step 6 . NO : Replace the fuel pump relay.
STEP 6. Check fuel pump resistor. Check fuel pump resistor (Refer to P.13A-403).
Q: Is the check result normal? YES : Go to Step 7 . NO : Replace the fuel pump resistor.
AK305260 AB
13A-316

TROUBLESHOOTING
STEP 9. Check harness between C-223 (terminal No. 3) fuel pump relay (1) connector and C-208 (terminal No. 2) ignition switch connector.
Connector: C-223
STEP 10. Perform resistance measurement at C-223 fuel pump relay (1) connector.
Connector: C-223
AK305260 AB
AK305260 AB
C-208
repair if necessary. If intermediate connector normal, check and repair harness between C-223 (terminal No. 2) fuel pump relay (1) connector and body earth. Check earthing line for open circuit and damage.
C-208

AK305251AB
NOTE: Before checking harness, check intermediate connector C-211 repair if necessary. Check power supply line for open/short circuit.
Q: Is the check result normal? YES : Check ignition switch (Refer to GROUP 54
Ignition switch Ignition switch Inspection P.54A-30). NO : Repair the damaged harness wire.

TROUBLESHOOTING
13A-317
STEP 11. Perform voltage measurement at C-221 fuel pump relay (2) connector.
Connector: C-221 Junction blocks triangle marks C-221

AK305261AB
Connector: C-223
C-223 Junction blocks triangle marks 2 1 4 3 Harness side connector <R. H. drive vehicles>
C-121 (GR)
AK305260 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
Remove relay, and measure at junction block side. Ignition switch: "ON" Voltage between terminal No. 1 and earth and No. 3 and earth. OK: System voltage

AK501995 AB
(terminal No. 1 and No. 3) fuel pump relay (1) connector and C-221 (terminal No. 1 and No. 3) fuel pump relay (2) connector. Check power supply line for open/short circuit.
AK305261AB
C-214, and repair if necessary. If intermediate connector normal, check and repair harness between C-221 (terminal No. 2) fuel pump relay (2) connector and C-121 (terminal No. 21) engine-ECU connector. Check earthing line for open/short circuit.
13A-318

TROUBLESHOOTING

STEP 14. Perform voltage measurement at B-121 fuel pump resistor connector.
B-121(B)
B-121(B)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
AK305259 AB
Disconnect connector, and measure at harness side. Ignition switch: "ON" Voltage between terminal No. 21 and earth. OK: Fuel pump operates (Operation sounds are heard)
Q: Is the check result normal? YES : Go to Step 14 . NO : Replace the engine-ECU.
AK305261AB
Q: Is the check result normal? YES : Go to Step 15 . NO : Check intermediate connectors C-123,
C-214, and repair if necessary. If intermediate connector are normal, check and repair harness between C-221 (terminal No. 4) fuel pump relay (2) connector and B-121 (terminal No. 1) fuel pump resistor connector. Check power supply line for open/short circuit.

TROUBLESHOOTING
13A-319
STEP 15. Check connector: D-12 fuel pump connector.

Connector: D-12 3 2 1 5 4 Harness side connector D-12 (GR)
STEP 16. Perform voltage measurement at D-12 fuel pump connector.

AK203611 AD
AK203611 AD
B-121(B)
B-121(B)
AK305259 AB
Q: Is the check result normal? YES : Go to Step 17 . NO : Check intermediate connectors C-113*1,
C-112*2 C-123 and D-33, and repair if necessary. If intermediate connector are normal, check and repair harness between B-121 (terminal No. 2) fuel pump resistor connector and D-12 (terminal No. 5) fuel pump connector. Check power supply line for open/short circuit.
13A-320

TROUBLESHOOTING
STEP 17. Perform resistance measurement at D-12 fuel pump connector.

STEP 18. Check connector: B-120 fuel pump relay (3) connector.
B-120
AK203611 AD
Q: Is the check result normal? YES : Replace fuel pump. NO : Check intermediate connector D-34, and
repair if necessary. If intermediate connector is normal, check and repair harness between D-12 (terminal No. 4) fuel pump connector and body earth. Check earthing line for open circuit and damage.
B-120 Junction blocks triangle marks 2 1 4 3 Harness side connector
AK305262 AB
STEP 19. Check fuel pump relay (3). Fuel pump relay (3) continuity check (Refer to P.13A-402).
Q: Is the check result normal? YES : Go to Step 20 . NO : Replace the fuel pump relay (3).

TROUBLESHOOTING
13A-321
STEP 20. Perform voltage measurement at B-120 fuel pump relay (3) connector.
Remove relay, and measure at junction block side. Ignition switch: "ON" Voltage between terminal No. 2 and earth, and No. 4 and earth. OK: System voltage
B-120
repair if necessary. If intermediate connector is normal, check and repair harness between B-120 (terminal No. 2 and No. 4) fuel pump relay (3) connector and B-121 (terminal No. 1) fuel pump resistor connector. Check power supply line for damage. STEP 21. Connector check: C-119 engine-ECU connector.
Connector: C-119 B-120 <L. H. drive vehicles>
Junction blocks triangle marks 2 1 4 3 Harness side connector Connector: B-121 <L. H. drive vehicles> <R. H. drive vehicles> B-121(B)
AK305262 AB
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60
B-121(B)

AK501994 AB
Q: Is the check result normal? YES : Go to Stop 22 . NO : Repair or replace the connector.
AK305259 AB
13A-322

TROUBLESHOOTING

B-120
<R. H. drive vehicles> C-119 (GR) <R. H. drive vehicles>
B-120 Junction blocks triangle marks C-119 (GR)

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB
AK305262 AB
Disconnect connector, and measure at harness side. Ignition switch: "ON" Disconnect C-121 (terminal No. 21) engine-ECU connector and earth. Voltage between terminal No. 55 and earth. OK: System voltage
(terminal No.55) engine-ECU connector and B-120 (terminal No.3) fuel pump relay (3) connector. Check earthing line for open circuit and damage.

TROUBLESHOOTING
13A-323
STEP 23. Check harness between B-120 (terminal No. 2 and No. 4) fuel pump relay (3) connector and B-121 (terminal No. 1) fuel pump resistor connector. NOTE: Before checking harness, check intermediate connector C-123, and repair if necessary. Check power supply line for damage.
B-121(B)
<R. H. drive vehicles> B-120 B-121(B)
AK305259 AB
B-120 Junction blocks triangle marks 2 1 4 3 Harness side connector
AK305262 AB
13A-324

TROUBLESHOOTING
Inspection Procedure 25: Radiator Fan Control Relay System

Radiator fan control relay circuit
Battery W W
8 20A B-Y
Relay relay
6 <A-13> (*1) or 13 <C-31> (*2)
B-Y 1 B-12X 1 3 3 R-Y A-17 (MU802322) 1 2 3 28 Fan control circuit 2 L A-13 2 (*1) or 1 (*2) L-B 31 4 Engine-ECU R-Y B-W R-Y Fan controller Fusible link (2) 2 4 4
B-Y 2
33 A-13 (*1) 3 C-31 (*2) 12 1
Engine control system
Radiator fan control relay A-09X 1 2 4 3
C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
2 L B
AK501830 AB

TROUBLESHOOTING
13A-325
OPERATION
The battery voltage is applied to the fan control relay (terminal No. 1) form the engine control relay (terminal No. 4) and is earthed to the vehicle body from the radiator fan control relay (terminal No. 3). The battery voltage is applied to the radiator fan control relay (terminal No. 4). When the radiator fan control relay is in "ON" position, the battery voltage is supplied to the fan controller (terminal No.3) from the radiator fan control relay (terminal No. 2).
STEP 2. Check radiator fan control relay. Check radiator fan control relay (Refer to GROUP 14 On-vehicle Service P.14-17).
Q: Is the check result normal? YES : Go to Step 3 . NO : Replace the fan control relay.
STEP 3. Perform resistance measurement at A-09X radiator fan control relay connector.
Connector: A-09X
1 4 Harness side connector 3 2
FUNCTION
When the engine control relay turns "ON", the radiator fan control relay turns "ON" simultaneously, and power is supplied to the fan controller. The radiator fan motor is driven when the fan motor drive signal is input to the fan controller from the engine-ECU.
A-09X
AK305263 AB
PROBABLE CAUSES
Failed radiator fan control relay Failed fan controller Failed radiator fan motor Failed engine-ECU
Remove relay, and measure at relay box side. Resistance between terminal No.3 and earth. OK: 2 or less
Q: Is the check result normal? YES : Go to Step 4 . NO : Check and repair harness between A-09X
DIAGNOSIS PROCEDURE
NOTE: . *1: L.H. drive vehicles *2: R.H. drive vehicles STEP 1. Connector check: A-09X radiator fan control relay connector.
Connector: A-09X
(terminal No. 3) radiator fan control relay connector and body earth. Check and earthing line for open circuit and damage. STEP 4. Perform voltage measurement at A-09X radiator fan control relay connector.
Connector: A-09X
A-09X
AK305263 AB
A-09X
AK305263 AB
Remove relay, and measure at relay box side. Ignition switch: "ON" Voltage between terminal No. 1 and earth. OK: System voltage
13A-326

TROUBLESHOOTING

STEP 6. Perform voltage measurement at A-09X radiator fan control relay connector.
Connector: A-09X
B-12X
2 4
1 3 A-09X

AK305003 AB
AK305263 AB
Connector: A-09X
Remove relay, and measure at relay box side. Voltage between terminal No. 4 and earth. OK: System voltage
Q: Is the check result normal? YES : Go to Step 7 . NO : Check and repair harness between battery
A-09X
AK305263 AB
and A-09X (terminal No. 4) radiator fan control relay connector. Check power supply line for open/short circuit. STEP 7. Connector check: A-17 fan controller connector
Connector: A-17
Q: Is the check result normal? YES : Check intermediate connectors A-13*1 or
C-31* and C-105, and repair if necessary. If intermediate connectors are normal, check and repair harness between B-12X (terminal No. 4) engine control relay connector and A-09X (terminal No. 1) radiator fan control relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.
A-17 (GR)

AK305256 AB

TROUBLESHOOTING
13A-327
STEP 8. Perform voltage measurement at A-17 fan controller connector.

Connector: A-17

A-17 (GR)
B-12X
2 4
1 3

AK305256 AB

AK305003 AB
STEP 11. Check harness between B-12X (terminal No. 4) engine control relay connector and A-09X (terminal No. 1) radiator fan control relay connector.
STEP 9. Check harness between A-09X (terminal No. 2) radiator fan control relay connector and A-17 (terminal No. 3) fan controller connector.
Connector: A-09X
B-12X
2 4
1 3

AK305003 AB
Connector: A-09X
A-09X
AK305263 AB
Connector: A-17
A-09X A-17 (GR)

AK305263 AB

AK305256 AB
Check output line for open/short circuit.

NOTE: Before checking harness, check intermediate connectors A-13*1 or C-31*2 and C-105, and repair if necessary. Check power supply line for damage.
Q: Is the check result normal? YES : Check and repair harness between A-09X
(terminal No. 3) radiator fan control relay connector and body earth. Check earthing line for damage. NO : Repair the damaged harness wire.
13A-328

TROUBLESHOOTING

STEP 14. M.U.T.-II/III actuator test Item No. 21: Fan controller OK: Radiator fan motor rotates
00 How to Use Troubleshooting/Inspection Service Points P.00-5.) NO : Replace the engine-ECU.

C-121 (GR) Connector: C-121 <R. H. drive vehicles> <L. H. drive vehicles>
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
STEP 13. Check radiator fan motor drive. Disconnect C-121 engine-ECU connector. Ignition switch: "ON" OK: Radiator fan motor rotates at a high speed
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

TROUBLESHOOTING
13A-329
STEP 16. Check harness between A-09X (terminal No. 4) radiator fan control relay connector and battery.
Connector: A-09X
STEP 18. Check harness between A-17 (terminal No. 2) fan controller connector and C-121 (terminal No. 18) engine-ECU connector.
Connector: A-17
A-17 (GR)
A-09X
AK305263 AB

AK305256 AB

STEP 17. Check harness between A-09X (terminal No. 2) radiator fan control relay connector and A-17 (terminal No. 3) fan controller connector.
Connector: A-09X
3 2 1 <R. H. drive vehicles> C-121 (GR) 4 Harness side connector
A-09X
AK305263 AB
C-121 (GR) Connector: A-17

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
A-17 (GR)

AK305256 AB
NOTE: Before checking harness, check intermediate connectors A-13*1 or C-31*2 and repair if necessary. Check output line for short circuit.
Q: Is the check result normal? YES : Replace the radiator fan motor and fan

Q: Is the check result normal? YES : Replace the radiator fan motor and fan
controller.
controller.
13A-330

TROUBLESHOOTING
Inspection Procedure 26: Condenser Fan Relay System
Condenser fan relay system Ignition switch C-208

R ST IG1 LOCK ACC IG2
Battery W W
1 2 3 4 5 6
L-B
4 C-211 2 J/B 13 C-210 17 (*1) or 10 (*2)
25 30A
11 30A
5 7.5A W-B
B-R
B-R
J/B (2) C-101 W-B 16*1 10*2 C-129 2
W-B W-B A-07X 1 3 2 4 1 B-Y A-34 MU802601 1 2 A-35 MU802661 1 2 B 2 C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
2 Condenser fan relay (high) 3 G-R
A-06X 1 3 2 4
2 Condenser fan relay (low)
1 W L
2 Condenser fan motor
G-R 1<A-29> (*1) 5<A-29> (*1)
7<C-31> (*2) 30
16<C-31> (*2) 31
Engine-ECU
AK501831 AB

TROUBLESHOOTING
13A-331
OPERATION
The battery voltage is applied on the engine-ECU (terminal No. 31) form the condenser fan control relay (low). The battery is applied on the engine-ECU (terminal No. 30) from the condenser fan control relay (high).
STEP 3. Connector check: A-06X condenser fan relay (low) connector.

Connector: A-06X
Relay box's triangle marks 2 A-06X 4 1 3
FUNCTION
The engine-ECU condenser fan control relay turns "ON" with the signal from the engine-ECU, and power is supplied to the condenser fan motor.
AK305265 AB
PROBABLE CAUSES
Failed condenser fan relay (high) Failed condenser fan relay (low) Failed condenser fan motor Open/short circuit in condenser fan control relay circuit or loose connector contact Failed engine-ECU
STEP 4. Check condenser fan relay (low). Check condenser fan relay (low) (Refer to GROUP 55 On-vehicle Service P.55-107).
Q: Is the check result normal? YES : Go to Step 5 . NO : Replace the condenser fan relay (low).
DIAGNOSIS PROCEDURE
NOTE: . *1: L.H. drive vehicles *2: R.H. drive vehicles STEP 1. Check condenser fan motor. Check condenser fan motor (Refer to GROUP 55 Heater, Air conditioner and Ventilation Condenser and condenser fan motor Inspection P.55-127).
Q: Is the check result normal? YES : Go to Step 2 . NO : Replace the condenser fan motor.
STEP 5. Perform voltage measurement at A-06X condenser fan relay (low) connector.
Connector: A-06X
AK305265 AB
STEP 2. M.U.T.-II/III actuator test Item No. 38: Condenser fan (low) OK: Condenser fan motor rotates (low)
13A-332

TROUBLESHOOTING
STEP 6. Connector check: C-208 ignition switch connector.


Connector: A-06X
C-208
AK305265 AB
C-208 C-208
<R. H. drive vehicles> 3 2 1 6 5 4 Harness side connector

AK305251AB
C-208
Check ignition switch (Refer to GROUP 54A Ignition switch Ignition switch Inspection P.54A-30).
AK305251AB
C-129, C-210 and C-211, and repair if necessary. If intermediate connectors are normal, check and repair harness between A-06X (terminal No. 2) condenser fan relay (low) connector and C-208 (terminal No. 4) ignition switch connector. Check power supply for open circuit and damage. NO : Replace the ignition switch.

TROUBLESHOOTING
13A-333
STEP 8. Perform voltage measurement at A-06X condenser fan relay (low) connector.
Connector: A-06X

AK305265 AB
Q: Is the check result normal? YES : Check and repair harness between battery
and A-08X (terminal No. 4) condenser fan relay connector. Check power supply for open circuit and damage. NO : Go to Step 9 .
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
13A-334

TROUBLESHOOTING
STEP 10. Connector check: C-121 engine-ECU connector.

STEP 11. Perform voltage measurement at A-34 condenser fan motor connector.
Connector: A-34 2 1 Harness side connector
A-34(B)
AK305266 AB
Connector: A-06X
Relay box's triangle marks 2 1 3
A-06X
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
AK305265 AB

AK501995 AB
Connector: A-06X
Relay box's triangle marks 2 1 3 C-121 (GR) <R. H. drive vehicles>

AK305265 AB
A-06X
C-31*2, and repair if necessary. If intermediate connectors are normal, check and repair harness between A-06X (terminal No. 3) condenser fan relay (low) connector and C-121 (terminal No. 31) engine-ECU connector. Check power supply for open circuit and damage. NO : Repair or replace the connector.
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
Disconnect connector, and measure at harness side. Disconnect C-121 engine-ECU connector, and earth terminal No. 31. Ignition switch: "ON"
AK501995 AB

TROUBLESHOOTING
13A-335
Voltage between terminal No. 2 and earth. OK: System voltage

Q: Is the check result normal? YES : Go to Step 12 . NO : Check and repair harness between A-06X
STEP 13. Check harness between A-06X (terminal No. 3) condenser fan relay (low) connector and C-121 (terminal No. 31) engine-ECU connector.
Connector: A-06X
(terminal No. 3) condenser fan relay (low) connector and C-121 (terminal No. 31) engine-ECU connector. Check power supply for open circuit. STEP 12. Connector check: A-34 condenser fan motor connector.
AK305265 AB
A-34(B)
AK305266 AB
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
13A-336

TROUBLESHOOTING
STEP 14. M.U.T.-II/III actuator test Item No. 38: Condenser fan (high) OK: Condenser fan motor rotates (high speed)
STEP 16. Check condenser fan relay (high). Check condenser fan relay (high) (Refer to GROUP 55 On-vehicle Service P.55-107).
Q: Is the check result normal? YES : Go to Step 17 . NO : Replace the condenser fan relay (high).
STEP 15. Connector check: A-07X condenser fan relay (high) connector.
Connector: A-07X Relay boxs triangle marks
STEP 17. Perform voltage measurement at A-07X condenser fan relay (high) connector.
2 2 A-07X 4 1 3 A-07X 4
1 3

AK305267AB

AK305267AB

TROUBLESHOOTING
13A-337
STEP 18. Connector check: C-208 ignition switch connector.


2 A-07X C-208 4
1 3

AK305267AB
C-208 C-208
<R. H. drive vehicles> 3 2 1 6 5 4 Harness side connector

AK305251AB
C-208

AK305251AB
Check ignition switch (Refer to GROUP 54 ignition switch P.54A-30).

C-129, C-210 and C-211 and repair if necessary. If intermediate connectors are normal, check and repair harness between A-07X (terminal No. 2) condenser fan relay (high) connector and C-208 (terminal No. 4) ignition switch connector. Check power supply for open circuit and damage. NO : Replace the ignition switch.
13A-338

TROUBLESHOOTING
STEP 20. Perform voltage measurement at A-07X condenser fan relay (high) connector.

2 A-07X 4
1 3

AK305267AB
Q: Is the check result normal? YES : Check and repair harness between battery
and A-07X (terminal No. 4) condenser fan relay (high) connector. Check power supply for open circuit and damage. NO : Go to Step 21 .
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

TROUBLESHOOTING
13A-339
STEP 22. Connector check: C-121 engine-ECU connector.

STEP 23. Perform voltage measurement at A-34 condenser fan motor connector.
A-34(B)
AK305266 AB
Connector: A-07X
2 A-07X 4
1 3

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
AK305267AB

AK501995 AB
Harness side connector Connector: A-07X
2 A-07X 4
1 3 C-121 (GR) <R. H. drive vehicles>

AK305267AB
C-31*2, and repair if necessary. If intermediate connectors are normal, check and repair harness between A-07X (terminal No. 3) condenser fan relay (high) connector and C-121 (terminal No. 30) engine-ECU connector. Check power supply for open circuit and damage. NO : Repair or replace the connector.
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
Disconnect connector, and measure at harness side. Disconnect C-121 engine-ECU connector, and earth terminal No. 30. Ignition switch: "ON"
13A-340

TROUBLESHOOTING
Voltage between terminal No. 2 and earth. OK: System voltage

Q: Is the check result normal? YES : Go to Step 24 . NO : Check intermediate connectors A-29*1 or
STEP 25. Check harness between A-07X (terminal No. 3) condenser fan relay (high) connector and C-121 (terminal No. 30) engine-ECU connector.
C-31*2, and repair if necessary. If intermediate connectors are normal, check and repair harness between A-07X (terminal No. 3) condenser fan relay (high) connector and C-121 (terminal No. 30) engine-ECU connector. Check power supply for open circuit and damage. STEP 24. Connector check: A-34 condenser fan motor connector.
2 A-07X 4
1 3

AK305267AB
A-34(B)
AK305266 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

TROUBLESHOOTING
13A-341
STEP 26. Connector check: A-35 condenser fan motor connector.

STEP 27. Perform resistance measurement at A-35 condenser fan motor connector.
A-35(GR)
A-35(GR)
AK305443 AB
AK305443 AB
Inspection Procedure 27: A/C Switch System
A/C Switch circuit
A/C-ECU
C-117 (MU803783)
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
83
Engine-ECU
AK501832 AB
13A-342
OPERATION

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
The battery voltage is applied to the engine-ECU (terminal No. 83) from the A/C-ECU (terminal No. 1).
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 CAUSES
Failed A/C Failed A/C system Open/short circuit in A/C circuit or loose connector contact Failed engine-ECU
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
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. 83 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 2 . NO : Check A/C system (Refer to GROUP 55
Troubleshooting Check Chart for Trouble Symptoms P.55-29)

TROUBLESHOOTING
13A-343

STEP 3. M.U.T.-II/III data list Item No. 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)
C-117 (GR)
74 73 72 71 77 76 75 90 89 88 87 86 85 84 83 82 81 80 79 78 98 97 96 95 94 93 92 91 100 99

AK501996 AB
13A-344

TROUBLESHOOTING
Inspection Procedure 28: A/C Compressor Relay System
A/C compressor relay Circuit
Ignition switch C-208

R LOCK ACC IG2
1 2 3 4 5 6
ST IG1
4 L-B C-211 2
Battery W W
5 7.5A
J/B
13 C-210 W-B 17 (*1) or 11 (*2)
9 10A
L-G
Relay box
J/C (2) C-101 14 (*1) or 8 (*2)
C-31 (*2) 4 A-29 (*1) 6

1
W-B 3<C-124> (*1) or 1<C-122> (*2) W-B

2
L-G B-13X
1 3
2 4
4 B-Y A-13 (*1) 1 C-31 (*2) 6 1 A/C refrigerant temperature switch
A/C compressor relay
3 P
B-Y A/C compressor assembly A-36 MU802653
20
C-121 (MU803784)
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
1 NOTE *1: L.H. drive vehicles *2: R.H. drive vehicles
Magnetic clutch
Engine-ECU
AK501833 AB

TROUBLESHOOTING
13A-345
OPERATION
The battery voltage is applied to the A/C compressor relay (terminal No. 1). The battery voltage is applied to the A/C compressor relay (terminal No. 2) from the ignition switch. The engine-ECU (terminal No. 20) 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. 4) from the A/C compressor relay assembly (terminal No. 1).
STEP 1. Connector check: B-13X A/C compressor relay connector

Connector: B-13X Relay boxs triangle marks
B-13X
2 4
1 3

AK305270AB
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.
STEP 2. A/C compressor relay check. Check A/C compressor relay (Refer to GROUP 55 On-vehicle Service Power Relay Check P.55-107).
Q: Is the check result normal? YES : Go to Step 3 . NO : Replace the A/C compressor relay.
PROBABLE CAUSES
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
STEP 3. Perform voltage measurement at B-13X A/C compressor relay connector.

DIAGNOSIS PROCEDURE
B-13X
2 4
1 3

AK305270AB
13A-346

TROUBLESHOOTING

STEP 5. Perform voltage measurement at B-13X A/C compressor relay connector.

B-13X C-208
2 4
1 3

AK305270AB
Q: Is the check result normal? YES : Go to Step 6 . NO : Check intermediate connector A-29*1or
C-208

AK305251AB
C-31*2, and repair if necessary. If intermediate connector is normal, check and repair harness between B-13X (terminal No. 1) A/C compressor relay connector and battery. Check power supply line for open/short circuit. STEP 6. Connector check: A-36 A/C compressor assembly connector
Connector: A-36 1 Harness side connector
Connector: B-13X
B-13X
2 4
1 3

AK305270AB
A-36 (B)
AK502005 AB
Q: Is the check result normal? YES : Check intermediate connectors C-124*1or
C-122*2, C-210 and C-211, and repair if necessary. If intermediate connectors are normal, check and repair harness between B-13X (terminal No. 2) A/C compressor relay connector and C-208 (terminal No. 4) ignition switch connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-347
STEP 7. Perform voltage measurement at A-36 A/C compressor assembly connector.

Connector: A-36 1 Harness side connector

A-36 (B)
AK502005 AB
Connector: B-13X
B-13X
2 4
1 3

AK305270AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
Disconnect connector, and measure at harness side. Remove B-13X (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

AK501995 AB
C-31*2, and repair if necessary. If intermediate connector is normal, check and repair harness between A-36 (terminal No. 1) A/C compressor assembly connector and B-13X (terminal No. 4) A/C compressor relay connector. Check output line for open/short circuit.
13A-348

TROUBLESHOOTING

STEP 10. Check harness between B-13X (terminal No. 3) A/C compressor relay connector and C-121 (terminal No. 20) engine-ECU connector.
B-13X
2 4
1 3

AK305270AB
<R. H. drive vehicles> Connector: C-121 <L. H. drive vehicles>
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB


TROUBLESHOOTING
13A-349
STEP 11. M.U.T.-II/III data list Item No. 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)
STEP 13. Check harness between B-13X (terminal No. 3) A/C compressor relay connector and C-121 (terminal No. 20) engine-ECU connector.
B-13X
2 4
1 3

AK305270AB

C-121 (GR) <R. H. drive vehicles> C-121 (GR)

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
AK501995 AB
13A-350

TROUBLESHOOTING

STEP 15. Check harness between C-208 (terminal No. 4) ignition switch connector and B-13X (terminal No. 2) A/C compressor relay connector.
C-208 C-208
<R. H. drive vehicles> <R. H. drive vehicles>
C-208 C-208

AK305251AB

AK305251AB
Connector: B-13X
B-13X
2 4
1 3

AK305270AB
NOTE: Before checking harness, check intermediate connectors C-124*1or C-122*2, C-210 and C-211, and repair if necessary. Check power supply line for damage.

TROUBLESHOOTING
13A-351
STEP 16. Check harness between battery and B-13X (terminal No. 1) A/C compressor relay connector.
STEP 17. Check harness between B-13X (terminal No. 4) A/C compressor relay connector and A-36 (terminal No. 1) A/C compressor assembly connector.
B-13X
2 4
1 3 B-13X 2 4 1 3

AK305270AB

AK305270AB
NOTE: Before checking harness, check intermediate connector A-29*1or C-31*2, and repair if necessary. Check power supply line for damage.
Connector: A-36
A-36 (B)
AK502005 AB
NOTE: Before checking harness, check intermediate connector A-13*1or C-31*2, and repair if necessary. Check output line for damage.
Q: Is the check result normal? YES : Replace the A/C compressor magnet clutch. NO : Repair the damaged harness wire.
13A-352

TROUBLESHOOTING
Inspection Procedure 29: A/C Load Signal System
A/C load signal circuit C-37 (MU801584)

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
A/C-ECU
32 G-Y 5<C-124> (*1) or 4<C-122> (*2) G-Y 65 C-119 (MU803782)

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 67 68 60 61 62 63 64 65 66
Engine-ECU
AK501834 AB
OPERATION
The A/C load signal is inputted to the engine-ECU (terminal No. 65) from the A/C-ECU (terminal No. 32).
PROBABLE CAUSES
Failed A/C-ECU Open/short circuit in A/C load signal circuit or loose connector contact Failed engine-ECU
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.

TROUBLESHOOTING
13A-353
DIAGNOSIS PROCEDURE

C-121 (GR) <R. H. drive vehicles> C-121 (GR) <R. H. drive vehicles>
C-121 (GR) C-121 (GR)

8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26 8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK501995 AB

AK501995 AB
Measure engine-ECU terminal voltage. Engine: Idling A/C switch: ON (A/C compressor in driven state) Voltage between terminal No. 65 and earth OK: 1 V or less (when the A/C is under low load) System voltage (when the A/C is under high load)

13A-354

TROUBLESHOOTING

STEP 5. Perform voltage measurement at C-37 A/C-ECU connector.

Connector: C-37
28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29
C-37 (B)
AK502007 AB
Measure A/C-ECU terminal voltage. Engine: Idling A/C switch: ON (A/C compressor in driven state) Voltage between terminal No. 32 and earth OK: System voltage (when the A/C is under high load)

C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
STEP 6. Connector Check: C-37 A/C-ECU connector

AK501995 AB
Connector: C-37
28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29
C-37 (B)
AK502007 AB

TROUBLESHOOTING
13A-355
STEP 7. Check harness between C-37 (terminal No. 32) A/C-ECU connector and C-119 (terminal No. 65) engine-ECU connector.
Connector: C-37
28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29
STEP 8. Connector check: C-37 A/C-ECU connector

Connector: C-37
28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29
C-37 (B) C-37 (B)

AK502007 AB AK502007 AB
Connector: C-119 Connector: C-119 <L. H. drive vehicles> <L. H. drive vehicles>
C-119 (GR) C-119 (GR)

47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60 47 46 45 44 43 42 41 59 58 57 56 55 54 53 52 51 50 49 48 68 67 66 65 64 63 62 61 60

AK501994 AB AK501994 AB
NOTE: Before checking harness, check intermediate connector C-124*1 or C-122*2, and repair if necessary. Check output line for short circuit.
Q: Is the check result normal? YES : Check Air conditioner (Refer to GROUP 55
Q: Is the check result normal? YES : Check intermediate connector C-124*1 or
Troubleshooting Check Chart For Trouble Symptoms P.55-29). NO : Repair the damaged harness wire.
C-122*2, and repair if necessary. If intermediate connector is normal, check and repair harness between C-37 (terminal No. 32) A/C-ECU connector and C-119 (terminal No. 65) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.
13A-356

TROUBLESHOOTING
Inspection Procedure 30: Ignition Circuit System <L. H. drive vehicles>
Ignition circuit Ignition switch C-208

R LOCK ACC IG1 IG2
1 2 3 4 5 6
ST
2 B-W C-211 6 1 10 A 10 C-214 C-129 18 W A-29 4 W-R Ignition coil 1 B-103 (MU802064) 1 W-R 1 Ignition coil 2 B-114 (MU802064)
J/B
Y-G
1 2 3
1 2 3
Spark plug
B B-Y
B B-G
B 11
B 12 C-121 (MU803784)
Engine-ECU
3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
AK501836 AB

TROUBLESHOOTING
13A-357
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. 11 and No. 12).

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.
B-103(GR)
AK305047AB
PROBABLE CAUSES
Failed ignition coil Failed spark plug Failed spark plug cable Open/short circuit in ignition primary circuit or loose connector contact Failed engine-ECU
STEP 5. Perform voltage measurement at B-103 and B-114 ignition coil connectors.
DIAGNOSIS PROCEDURE
B-103(GR)
AK305047AB

13A-358

TROUBLESHOOTING

Connector: C-208
Connector : B-103, B-114 3 2 1 Harness side connector
C-208
B-114(GR)

Connector : B-103, B-114
B-103(GR)
AK305446 AB
AK305047AB
3 2 1 Harness side connector B-114(GR)
Disconnect connector, and measure at harness side. Engine: Cranking Voltage between terminal No. 3 and earth. OK: 0.5 4.0 V
B-103(GR)
AK305047AB
Q: Is the check result normal? YES : Check intermediate connectors A-29,
C-129, C-211 and C-214, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-208 (terminal No. 2) ignition switch connector and B-114 (terminal No. 1) ignition coil connector, also between C-208 (terminal No. 2) ignition switch connector and B-103 (terminal No. 1) ignition coil connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-359

Connector: C-121

Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK502032 AB

AK502032 AB
B-103(GR)
AK305047AB
B-103(GR)
AK305047AB
Measure engine-ECU terminal voltage. Disconnect B-103 and B-114 ignition coil connectors. Engine: Cranking Voltage between terminal No. 11 and earth, also between terminal No. 12 and earth. OK: 0.5 4.0 V
(terminal No. 3) ignition coil connector and C-121 (terminal No. 12) engine-ECU connector, also between B-103 (terminal No. 3) ignition coil connector and C-121 (terminal No. 11) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.
13A-360

TROUBLESHOOTING

Connector: C-121
STEP 11. Check harness between B-114 (terminal No. 3) ignition coil connector and C-121 (terminal No. 12) engine-ECU connector, also between B-103 (terminal No. 3) ignition coil connector and C-121 (terminal No. 11) engine-ECU connector.
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
B-103(GR)
AK305047AB

AK502032 AB
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK502032 AB



TROUBLESHOOTING
13A-361
STEP 13. Perform resistance measurement at B-103 and B-114 ignition coil connectors.
STEP 14. Check harness between C-208 (terminal No. 2) ignition switch connector and B-103 (terminal No. 1) ignition coil connector, also between C-208 (terminal No. 2) ignition switch connector and B-114 (terminal No. 1) ignition coil connector.
Connector: C-208
B-103(GR)
C-208
AK305047AB

Connector : B-103, B-114
AK305446 AB
(terminal No. 2) ignition coil connector and body earth, also between B-114 (terminal No. 2) ignition coil connector and body earth. Check earthing line for open circuit and damage.
B-103(GR)
AK305047AB
NOTE: Before checking harness, check intermediate connectors A-29, C-129, C-211 and C-214, and repair if necessary. Check power supply line for damage.
13A-362

TROUBLESHOOTING
B-103(GR)
AK305047AB
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK502032 AB


TROUBLESHOOTING
13A-363
Inspection Procedure 31: Ignition Circuit System <R. H. drive vehicles>

Ignition circuit Ignition switch
R ST
C-208
LOCK ACC IG1 IG2
Battery 2 W W B-W C-211 6 8 Relay box 20A B-Y Engine control system B-10X 1 3 2 4
OFF ON
1 2 3 4 5 6
J/B
1 10A B-R 10 C-214 C-123 9 W 2 Ignition coil relay
C-31 13 B-Y 1
4 W-R W-R Ignition coil 1 B-103 (MU802064) 1 W-R 1
B B
3 B
Ignition coil 2 B-114 (MU802064)
1 2 3
1 2 3
Spark plug
B B-Y
B B-G
B 11 12 C-121 (MU803784) Engine-ECU

3 4 5 6 7 8 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35
AK501855 AB
13A-364
OPERATION

TROUBLESHOOTING
The battery voltage is applied to the ignition coil relay (terminal No. 2) from the ignition switch and is earthed to the vehicle body from the ignition coil relay (terminal No. 3). The battery voltage is applied to the ignition coil relay (terminal No. 1) from the battery 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. 11 and No. 12).


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.
B-103(GR)
AK305047AB
PROBABLE CAUSES
Failed ignition coil Failed ignition coil relay Failed spark plug Failed spark plug cable Open/short circuit in ignition primary circuit or loose connector contact Failed engine-ECU
DIAGNOSIS PROCEDURE
B-103(GR)
AK305047AB

TROUBLESHOOTING
13A-365
STEP 6. Connector check: B-10X ignition coil relay connector

Connector: B-10X
Relay box's triangle marks

Connector: C-208 3 2 1 6 5 4 C-208 Harness side connector
2 B-10X(B) 4
1 3

AK305448 AB
AK305279 AB
Connector: B-10X
STEP 7. Check ignition coil relay. Check ignition coil relay (Refer to GROUP 16 Ignition System On-vehicle Service P.16-28).
Q: Is the check result normal? YES : Go to Step 8 . NO : Replace the ignition coil relay.
2 B-10X(B) 4
1 3
AK305279 AB
STEP 8. Perform voltage measurement at B-10X ignition coil relay connector.

Connector: B-10X
2 B-10X(B) 4
1 3
C-211 and C-214, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-208 (terminal No. 2) ignition switch connector and B-10X (terminal No. 2) ignition coil relay connector. Check power supply line for open/short circuit. NO : Repair or replace the connector.
AK305279 AB
13A-366

TROUBLESHOOTING
STEP 10. Perform resistance measurement at B-10X connector.

Connector: B-10X
STEP 11. Perform voltage measurement at B-10X ignition coil relay connector.
Connector: B-10X
2 B-10X(B) 4
1 3 B-10X(B)
2 4
1 3
AK305279 AB
AK305279 AB
Remove relay, and measure at relay box side. Resistance between terminal No. 3 and earth. OK: 2 or less
Q: Is the check result normal? YES : Go to Step 11 . NO : Check and repair harness between B-10X
(terminal No. 3) ignition coil relay connector and body earth. Check earthing line for open circuit and damage.
B-103(GR)
AK305047AB
Q: Is the check result normal? YES : Check and repair harness between B-10X
(terminal No. 4) ignition coil relay connector and B-103 (terminal No. 1) ignition coil connector, also between B-10X (terminal No. 4) ignition coil relay connector and B-114 (terminal No. 1) ignition coil connector. Check power supply line for open/short circuit. NO : Check intermediate connector C-31 and repair if necessary. If intermediate connector is normal, check and repair harness between B-10X (terminal No. 1) ignition coil relay connector and battery. Check power supply line for open/short circuit.

TROUBLESHOOTING
13A-367

Connector: C-121
B-103(GR)
AK305047AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
Disconnect connector, and measure at harness side. Engine: Cranking Voltage between terminal No. 3 and earth. OK: 0.5 4.0 V

AK502033 AB
B-103(GR)
AK305047AB
Measure engine-ECU terminal voltage. Disconnect B-103 and B-114 ignition coil connectors. Engine: Cranking Voltage between terminal No. 11 and earth, also between terminal No. 12 and earth. OK: 0.5 4.0 V
13A-368

TROUBLESHOOTING

Connector: C-121

Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK502033 AB

AK502033 AB
B-103(GR)
AK305047AB
(terminal No. 3) ignition coil connector and C-121 (terminal No. 12) engine-ECU connector, also between B-103 (terminal No. 3) ignition coil connector and C-121 (terminal No. 11) engine-ECU connector. Check output line for open circuit. NO : Repair or replace the connector.

TROUBLESHOOTING
13A-369

STEP 18. Perform resistance measurement at B-103 and B-114 ignition coil connectors.
Connector : B-103, B-114 B-103(GR)
AK305047AB
Connector: C-121
B-103(GR)
AK305047AB
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26
AK502033 AB

(terminal No. 2) ignition coil connector and body earth, also between B-114 (terminal No. 2) ignition coil connector and body earth. Check earthing line for open circuit and damage.
13A-370

TROUBLESHOOTING
STEP 19. Check harness between C-208 (terminal No. 2) ignition switch connector and B-10X (terminal No. 2) ignition coil relay connector.
Connector: C-208 3 2 1 6 5 4 C-208 Harness side connector
STEP 20. Check harness between battery and B-10X (terminal No. 1) ignition coil relay connector.
Connector: B-10X
2 B-10X(B) 4
1 3
AK305448 AB
AK305279 AB
Connector: B-10X
NOTE: Before checking harness, check intermediate connector C-31 and repair if necessary. Check power supply line for damage.
2 B-10X(B) 4
1 3
AK305279 AB
STEP 21. Check harness between B-10X (terminal No. 4) ignition coil relay connector and B-103 (terminal No. 1) ignition coil connector, also between B-10X (terminal No. 4) ignition coil relay connector and B-114 (terminal No. 1) ignition coil connector.
Connector: B-10X
2 B-10X(B) 4
1 3
AK305279 AB
B-103(GR)
AK305047AB


TROUBLESHOOTING
13A-371
B-103(GR)
AK305047AB
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 25 24 35 34 33 32 31 30 29 28 27 26

AK502033 AB

13A-372

TROUBLESHOOTING
M1131152002117
DATA LIST REFERENCE TABLE

Item No. Inspection item Inspection condition Normal condition Inspection procedure No. Reference page
11
Oxygen sensor
Engine: After 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.
Excessive deceleration from 4,000 r/min At excessive acceleration Idle operation 2,500 r/min
200 mV or less 600 1,000 mV 400 mV or less 600 1,000 mV (altered)
Code No. P0130
P.13A-7 5
12
Air flow sensor *1
Engine coolant Idle operation temperature: 80 2,500 r/min 95C Acceleration Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral Intake air temperature: 20C Intake air temperature: 0C Intake air temperature: 20C Intake air temperature: 40C Intake air temperature: 80C
17 43 Hz 40 100 Hz According to acceleration, frequency is amplified.
13
Intake air Ignition switch: temperature "ON" or engine sensor running
20C 0C 20C 40C 80 C 535 735 mV Increased according to accelerator pedal stroke 4,500 5,000 mV System voltage
Code No. P0110
P.13A-4 5
14
Throttle position sensor
Ignition switch: "ON"
Release accelerator pedal fully Depress accelerator pedal gradually
Code No. P0120
P.13A-6 0
Depress accelerator pedal fully 16 Power supply voltage Cranking signal (ignition switch-ST) Ignition switch: "ON"
Procedure P.13A-3 No. 23 02 Procedure P.13A-3 No. 23 02
18
Engine: Stopped Engine: Cranking
OFF ON

TROUBLESHOOTING
Item No. Inspection item Inspection condition Normal condition
13A-373
Inspection procedure No. Reference page
21
Engine Ignition switch: coolant "ON" or engine temperature running sensor
Coolant temperature: 20C Coolant temperature: 0C Coolant temperature: 20C Coolant temperature: 40C Coolant temperature: 80C
20C 0C 20C 40C 80C Matched
Code No. P0115
P.13A-5 2
22
Crank angle sensor
Engine: Cranking Tachometer: Connected Engine: Idle operation
Compare engine speed on tachometer with the value displayed on M.U.T.-II/III Coolant temperature: 20C Coolant temperature: 0C Coolant temperature: 20C Coolant temperature: 40C Coolant temperature: 80C
1,200 1,400 r/min 1,200 1,400 r/min 1,200 1,400 r/min 1,050 1,250 r/min 750 950 r/min 101 kPa 95 kPa 88 kPa 81 kPa OFF ON OFF OFF Procedure P.13A-3 No. 27 41 Code P.13A-1 No.P0551 97 Code P.13A-3 No.P0105 5
25
Barometric pressure sensor
Altitude: 0 m Altitude: 600 m Altitude: 1,200 m Altitude: 1,800 m Steering wheel: Not operated Steering wheel: Operated AC switch: OFF AC switch: ON A/C compressor is not driven A/C compressor is driven
27
Power Engine: Idle steering fluid operation pressure switch A/C switch Engine: Idle
28
ON
34
Air flow Engine: After sensor reset engine warm-up signal
Idle operation 3,000 r/min
ON OFF
Code No. P0100
P.13A-2 4
13A-374
Item No. Inspection item Inspection condition

TROUBLESHOOTING
Normal condition Inspection procedure No. Reference page
37
Volumetric efficiency
Engine coolant Idle operation temperature: 80 2,500 r/min 95C Excessive acceleration Lamps, electric cooling fan and all accessories: OFF Engine: Cranking Coolant temperature: 0C (all cylinders in simultaneous injecting operation) Coolant temperature: 20C Coolant temperature: 80C
15 35% 15 35% According to acceleration, volumetric efficiency is increased. 18 307 ms
41
Injectors *2
7.0 12 ms 2.9 4.9 ms 1.5 2.7 ms 1.2 2.4 ms Increased
Injectors *3
Engine coolant Idle operation temperature: 80 2,500 r/min 95C Excessive acceleration Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral Engine: After warm-up Install timing light (for use to measure actual ignition timing) Idle operation 2,500 r/m
44
Ignition advance
0 10 BTDC 20 40 BTDC
45
Idle speed control (stepper motor) servo position *4
Engine coolant A/C switch: OFF temperature: 80 A/C switch: OFF ON 95C 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 Increased 10 70 steps

TROUBLESHOOTING
13A-375
49
A/C relay
Engine: After warm-up, idle operation after warm-up
A/C switch: OFF A/C switch: ON A/C compressor is not driven A/C compressor is driven
OFF OFF
Procedure P.13A-3 No. 28 44
ON
59
Engine: After warm-up
At excessive acceleration Idling without load 2,500 r/min without any load
0 mV or less 600 1,000 mV (altered) 0 5CA 8 12CA 19 6.7 gm/s 7.9 12.1 gm/s According to acceleration, frequency is amplified.
Code P.13A-8 No.P0136 8
7E
Variable Engine: After valve timing warm-up phase angle Air flow sensor
12 *5
Engine coolant Idle operation temperature: 80 2,500 r/min 95C Acceleration Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral Intake air temperature: 20C Intake air temperature: 0C Intake air temperature: 20C Intake air temperature: 40C Intake air temperature: 80C
13 *5
Intake air Ignition switch: temperature "ON" or engine sensor running
20C 0C 20C 40C 80 C 20C 0C 20C 40C 80C
Code No. P0110
P.13A-4 5
21 *5
Engine Ignition switch: coolant "ON" or engine temperature running sensor
Coolant temperature: 20C Coolant temperature: 0C Coolant temperature: 20C Coolant temperature: 40C Coolant temperature: 80C
Code No. P0115
P.13A-5 2
13A-376
Item No. Inspection item Inspection condition

TROUBLESHOOTING
Normal condition Inspection procedure No. Reference page
22 *5
Crank angle sensor
Engine: Cranking Tachometer: Connected Engine: Idle operation
Compare engine speed on tachometer with the value displayed on M.U.T.-II/III Coolant temperature: 20C Coolant temperature: 0C Coolant temperature: 20C Coolant temperature: 40C Coolant temperature: 80C
Matched
1,200 1,400 r/min 1,200 1,400 r/min 1,200 1,400 r/min 1,050 1,250 r/min 750 950 r/min Approximately 40 Code No. km/h P0500 12.5 to 12.5% Code No. P0170 P.13A-1 87 P.13A-1 01
24 *5 81 *5
Vehicle speed sensor Long-term fuel compensati on Shot-term fuel compensati on Calculation load value
Drive 40 km/h
Engine: After warm-up 2,500 r/min without any load (during closed loop)
82 *5
Engine: After warm-up 2,500 r/min without any load (during closed loop)
20 to 20%
Code No. P0170
P.13A-1 01
87 *5 88 *5 8A *5
Idle operation 2,500 r/min 2,500 r/min Acceleration Set to Idle position Release accelerator pedal gradually
15 35% 15 35% Closed loop Open loop drive condition 0 1% Increased according to accelerator pedal stroke 80 100%
Fuel control Engine: After condition warm-up Throttle position sensor (Throttle opening angle) Ignition switch: "ON"
Code No. P0120
P.13A-6 0
Release accelerator pedal fully

TROUBLESHOOTING
13A-377
A1 *5
Oxygen sensor
Engine: After 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.
Excessive deceleration from 4,000 r/min At excessive acceleration Idle operation 2,500 r/min
0.2 V or less 0.6 1 V 0.2 V or less 0.6 1 V
Code No. P0130
P.13A-7 5
A2 *5
At excessive acceleration
0 V or less 0.6 Code P.13A-8 No.P0136 8 1 V (altered)
NOTE: . *1: On the new vehicle (mileage: 500 km or less), air flow sensor output frequency may be higher by approximately 10%. *2: Injector drive time ranges shown are when power voltage is 11 V and the cranking speed is 250 r/min. or less. *3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approximately 10%. *4: On the new vehicle (mileage: 500 km or less), the number of steps of stepper motor may be larger by approximately 30 steps. *5: When service data in check mode is selected, the data is not displayed.
13A-378

TROUBLESHOOTING
M1131152501324
ACTUATOR TEST REFERENCE TABLE

Item Inspection No. item Drive content Inspection conditions Normal condition Code No. /Inspection procedure No. Reference page
01 02 03 04 07
Injector
Cut off No. 1 injector Cut off No. 2 injector Cut off No. 3 injector Cut off No. 4 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 Code No. P0202 Code No. P0203 Code No. P0204
P.13A-10 5 P.13A-11 1 P.13A-11 7 P.13A-12 3 P.13A-31 3
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
Procedure No. 24
08
Purge control solenoid valve Fuel pressure control solenoid valve EGR control solenoid valve Waste gate solenoid valve Fuel pump relay 3
Switch solenoid valve from OFF to ON Switch solenoid valve from OFF to ON
Ignition switch: "LOCK" (OFF)
When the valve Code No. is actuated, P0443 operating noise is audible When the valve Code No. is actuated, P0090 operating noise is audible When the valve Code No. is actuated, P0403 operating noise is audible. When the valve Code No. is actuated, P0243 operating noise is audible Sound of Operation is heard 5 BTDC Procedure No. 24
P.13A-18 2
09
P.13A-19
10
Switch solenoid valve from OFF to ON Switch solenoid valve from OFF to ON
P.13A-17 5
12
P.13A-13 0
13
Fuel pump Relay Ignition switch: "ON" 3 turns from OFF to ON Engine: Idle operation Install timing light
P.13A-31 3
17
Basic ignition Switch timing engine-ECU to ignition timing adjusting mode

TROUBLESHOOTING Item Inspection No. item Drive content Inspection conditions Normal condition
13A-379
Code No. /Inspection procedure No. Reference page
21 37
Fan controller Condenser fan (high) Condenser fan (low)
Actuate fan motor Condenser fan motor is driven. Condenser fan motor is driven.
Ignition switch: "ON" A/C switch: ON Ignition switch: "ON"
Fan motor is rotated Fan motor rotates at high speed Fan motor rotates at low speed
Procedure No. 25 Procedure No. 26
P.13A-32 4 P.13A-33 0
38
CHECK AT THE ENGINE-ECU TERMINALS

M1131153500744
TERMINAL VOLTAGE CHECK CHART

Needle-nosed wire probe
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.
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.
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.
13A-380
Terminal No. 1 9 24 2 3 6 Check item No. 1 injector No. 2 injector No. 3 injector No. 4 injector Oxygen sensor heater (front) EGR control solenoid valve

TROUBLESHOOTING
Engine-ECU Connector Terminal Arrangement Check condition (Engine condition) While engine is idling after having warmed up, suddenly depress the accelerator pedal. Normal condition From 11 14 V, momentarily drops slightly
Engine: Idling after warming up Engine r/min: 5,000 r/min Ignition switch: "ON" While engine is idling, suddenly depress the accelerator pedal. Engine: Warm, idle (radiator fan: OFF) Headlamp: OFF ON Stop lamp: OFF ON Rear defogger switch: OFF ON
1 V or less System voltage System Voltage From system voltage, momentarily drops Voltage increases by 0.2 3.5 V
Alternator G terminal Ignition coil No. 1, No. 4 Ignition coil No. 2, No. 3 Stepper motor coil <A1> Stepper motor coil <A2> Stepper motor coil <B1> Stepper motor coil <B2> Purge control solenoid valve Fan controller
11 12 14 28 15 29 16
Engine r/min: 3,000 r/min
0.3 3.0 V
Engine: Soon after the warmed up engine System voltage 1V or is started less (Changes repeatedly) A/C switch: OFF ON (A/C compressor is operating) Headlight switch: OFF ON
Ignition switch: "ON" Running at 3,500 r/min while engine is warming up after having been started. Radiator fan is not operating Radiator fan is operating
System voltage 1 V or less 0 0.3 V 0.7 V or more 01V 69V System voltage or Momentarily 6 V or more 1 V or less System voltage 1 V or less 1 V or less System voltage (After several seconds have elapsed) 1 V or less System voltage
18 19 20
Air flow sensor reset Engine: Idle speed signal Engine r/min: 3,000 r/min A/C relay Engine: Idle speed A/C switch: OFF ON (A/C compressor is operating) Ignition switch: "ON" Engine: Idle speed
21 22
Fuel pump relay 2
Engine warning lamp Ignition switch: "LOCK" (OFF) "ON"
26
Oxygen sensor heater (rear)
Engine: Idling after warming up Engine: Racing

TROUBLESHOOTING
13A-381
Normal condition System voltage 1 V or less System voltage
Terminal No. 30
Check item Condenser fan motor relay (high)
Check condition (Engine condition) Fan inactive state (Engine coolant temperature: 90C or less) Fan high-speed rotation state (Engine coolant temperature: 105C or less)
31
Condenser fan motor relay (low)
Fan inactive state (Engine coolant temperature: 90C or less)
Fan low-speed rotation state (Engine coolant 1 V or less temperature: 95 100C or less) 33 41 Oil feeder control valve Ignition switch: "ON" High-load running System voltage 4.0 10 V
Waste gate solenoid Ignition switch: "ON" System voltage valve Engine: After warm-up, idle operation (When 1 V or less using premium gasoline) Sensor impressed voltage Crank angle sensor Engine coolant temperature sensor Ignition switch: "ON" Engine: Cranking Engine: Idling speed Ignition switch: "ON" 4.9 5.1 V 0.4 4.0 V 1.5 2.5 V 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
42 43 44
45 47 59 48
Tachometer signal Power supply Fuel pressure control solenoid valve Exhaust camshaft position sensor
Engine r/min: 3,000 r/min Ignition switch: "ON" Ignition switch: "ON" Engine: Cranking Idle operation (within approximately 2 minutes or less) Engine: Cranking Engine: Idling Altitude: 0 m Altitude: 600 m Altitude: 1,200 m Altitude: 1,800 m
0.3 3.0 V System voltage System voltage 1 V or less System voltage 0.4 3.0 V 1.5 3.0 V 3.8 4.2 V 3.5 3.9 V 3.3 3.7 V 3.0 3.4 V
50 51
Barometric pressure Ignition switch: "ON" sensor
13A-382
Terminal No. 52 Check item Alternator FR terminal

TROUBLESHOOTING
Check condition (Engine condition) Engine: Warm, idle (radiator fan: OFF) Headlamp: OFF ON Stop lamp: OFF ON Rear defogger switch: OFF ON
Normal condition Voltage decreases
53 54
Intake camshaft position sensor Power steering fluid pressure switch
Engine: Cranking Engine: Idling Engine: Idling after warming up
0.4 3.0 V 1.5 3.0 V When steering wheel System voltage is stationary When steering wheel 1 V or less is turned
55 57 60 61 62
Fuel pump relay 3
While engine is idling, suddenly depress the accelerator pedal.
Temporarily rises slightly from 1 V or less. System voltage 1 V or less System voltage 2.2 3.2 V
Control relay (Power Ignition switch: "LOCK" (OFF) supply) Ignition switch: "ON" Backup power supply Air flow sensor Intake air temperature sensor Ignition switch: "LOCK" (OFF) Engine: Idle speed Engine r/min: 2,500 r/min Ignition switch: "ON"
When intake air 3.8 4.4 V temperature is 20C When intake air temperature is 0C When intake air temperature is 20C When intake air temperature is 40C When intake air temperature is 60C When intake air temperature is 80C 3.2 3.8 V 2.3 2.9 V 1.5 2.1 V 0.8 1.4 V 0.4 1.0 V
65 68 71 73 78
A/C load signal Ignition switch-ST Oxygen sensor (front) Oxygen sensor (rear) Throttle position sensor
Refer to GROUP 55 - Troubleshooting (Inspection at the Automatic compressor - ECU Terminal) Engine: Cranking 8 V or more Engine: Running at 2,500 r/min after warmed 0 0.8 V (Changes up (Check using a digital type voltmeter) repeatedly) Engine: Idling after warmed up (Check using 0 0.6 V (Changes a digital type voltmeter) repeatedly) Ignition switch: "ON" Set throttle valve to idle Position Fully open throttle valve 0.535 0.735 V 4.4 5.3 V 0 5 V Changes repeatedly
80
Vehicle speed sensor
Ignition switch: "ON" Move the vehicle forword slowly

TROUBLESHOOTING
13A-383
Normal condition 0.5 V or less
Terminal No. 83
Check item A/C switch
Check condition (Engine condition) Engine: Idle speed Turn the A/C switch OFF
Turn the A/C switch System voltage ON (A/C compressor is operating) 96 Transmission oil temperature sensor Ignition switch: "ON" Transmission oil 3.9 4.5 V temperature is 20C Transmission oil temperature is 0C Transmission oil temperature is 20C Transmission oil temperature is 40C Transmission oil temperature is 60C Transmission oil temperature is 80C 99 Ignition switch-IG Ignition switch: "ON" 3.2 3.8 V 2.3 2.9 V 1.3 1.9 V 0.7 1.3 V 0.3 0.9 V System voltage
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-384
Terminal No. 1 47 9 47 24 47 2 47 47 48 14 47 28 47 15 47 29 47 6 47 16 47 41 47 3 47 26 47 33 47 Inspection item No. 1 injector No. 2 injector No. 3 injector No. 4 injector

TROUBLESHOOTING
Engine-ECU Harness Side Connector Terminal Arrangement Normal condition (Check condition) 2 3 (At 20C)
Fuel pressure control solenoid valve Stepper motor coil (A1) Stepper motor coil (A2) Stepper motor coil (B1) Stepper motor coil (B2) EGR control solenoid valve Purge control solenoid valve Waste gate solenoid valve Oxygen sensor heater (rear) Oxygen sensor heater (front) Oil feeder control valve
28 36 (At 20C) 26 33 (At 20C)
29 35 (At 20C) 30 34 (At 20C) 29 35 (At 20C) 11 18 (At 20C) 4.5 8.0 (At 20C) 6.9 7.9 (At 20C) Continuity (2 or less)
46 Body ECU earth earth 58 Body earth 42 62 Intake air temperature sensor
13 17 k (When intake air temperature is 20C) 5.3 6.7 k (When intake air temperature is 0C) 2.3 3.0 k (When intake air temperature is 20C) 1.0 1.5 k (When intake air temperature is 40C) 0.56 0.76 k (When intake air temperature is 60C) 0.30 0.42 k (When intake air temperature is 80C)
42 44
Engine coolant temperature sensor
14 17 k (When coolant temperature is 20C) 5.1 6.5 k (When coolant temperature is 0C) 2.1 2.7 k (When coolant temperature is 20C) 0.9 1.3 k (When coolant temperature is 40C) 0.48 0.68 k (When coolant temperature is 60C) 0.26 0.36 k (When coolant temperature is 80C)

TROUBLESHOOTING
13A-385
Terminal No. 42 96
Inspection item Transmission oil temperature sensor
Normal condition (Check condition) 14 17 k (When transmission oil temperature is 20C) 5.1 6.5 k (When transmission oil temperature is 0C) 2.1 2.7 k (When transmission oil temperature is 20C) 0.9 1.3 k (When transmission oil temperature is 40C) 0.48 0.68 k (When transmission oil temperature is 60C) 0.26 0.36 k (When transmission oil temperature is 80C)
INSPECTION PROCEDURE USING OSCILLOSCOPE

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.
M1131154501483
AIR FLOW SENSOR (AFS) Measurement Method

Oscilloscope 1 2 3 4 5 6 7 Special patterns pickup
AK000786 AE
1. Disconnect the air flow sensor connector, and connect the special tool test harness (MB991709) in between (All terminals should be connected). 2. Connect the oscilloscope special patterns pickup to air flow sensor connector terminal No. 3.
Alternate Method (Test harness not available) Standard Wave Pattern 1. Connect the oscilloscope special patterns pickup
to engine-ECU terminal No. 61. Observation conditions Function Special patterns Pattern height Pattern selector Engine speed Low Display Idle
13A-386
Standard wave pattern (V) 10 T1

TROUBLESHOOTING
T T2
The time (cycle time) T is reduced when the amount of intake air increases. Times T1 and T2 are equal.
Time
AK202334 AC
Observation conditions (from conditions above engine is increased by racing.) (V) 10
Time
AK202335 AB
Wave Pattern Observation Points

Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
Examples of Abnormal Wave Patterns
Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency. However, when an ignition leak occurs during acceleration, the wave pattern will be distorted temporarily, even if the air flow sensor is normal.
AKX01597

TROUBLESHOOTING
13A-387
INTAKE CAMSHAFT POSITION SENSOR Measurement Method

Intake camshaft position sensor Oscilloscope connector Special patterns pick-up
1 2 3
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. To check the state of the intake camshaft position sensor output signal, observe its synchronicity with the crankshaft position sensor output signal.
1 2 3
Crank angle sensor connector

AK000840AD
Alternate Method (Test harness not available)

1. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 53 (When checking the camshaft position sensor signal wave pattern).
Standard Wave Pattern

Observation condition Function Pattern height Pattern selector Engine speed Special patterns Low Display Idle
Standard wave pattern (V) 2 engine revolutions (1 camshaft revolution) at retard angle at advance angle
Crank angle sensor output wave pattern
0 T phase angle
Intake camshaft position sensor output wave pattern
(Time)
AK403888 AC
13A-388

TROUBLESHOOTING

For the engine at 2,500 r/min, make sure that the time difference "T", between the output waveform of the crank angle sensor and that of the intake camshaft position sensor, is shorter on the rising edge.
Wave pattern characteristics Wave pattern is displaced to the left or right.
EXHAUST CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR Measurement Method
Exhaust camshaft Oscilloscope position sensor connector 1 2 3 Special patterns pick-up
1 2 3
AKX01597
Crank angle sensor connector

AK000840AE
Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started.
1. Disconnect the exhaust 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 exhaust 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.

AKX01602
Example 2 Cause of problem Loose timing belt Failure of the fuel pump camshaft
1. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 50 (When checking the exhaust camshaft position sensor signal wave pattern). 2. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 42 (When checking the crank angle sensor signal wave pattern).

TROUBLESHOOTING
13A-389

Observation condition Function Pattern height Pattern selector Engine speed
Standard Wave Pattern (V)
Special patterns Low Display Idle

2 engine revolutions (1 camshaft revolution) 75 BTDC 5 BTDC
The time (cycle time) T is reduced when the engine speed increases
0 Camshaft position sensor output wave pattern
0 TDC: Top dead centre No.1 TDC No.3 TDC No.4 TDC No.2 TDC
Time
AK202336 AB

Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
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-390
INJECTOR Measurement Method

TROUBLESHOOTING
2. Connect the oscilloscope special patterns pickup to terminal No. 2 of the injector connector.
Oscilloscope

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. 9 (When checking the No. 2 cylinder). 3. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 24 (When checking the No. 3 cylinder). 4. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 2 (When checking the No. 4 cylinder).
1 2 Special patterns pickup
AK101807AC
1. Disconnect the injector connector, and then connect the special tool test harness (MB991348) in between (All terminals should be connected).

Observation conditions Function Special patterns Pattern height Variable knob Pattern selector Engine speed
Standard wave pattern (V) Point A.
Variable Adjust while viewing the wave pattern Display Idle
50
Solenoid back electromotive force (Approx.710V) Point B Injector drive time

Time
Power voltage 0 Drive signal: ON Drive signal: OFF

AK202347AB

TROUBLESHOOTING
13A-391

Point A: Height of solenoid back electromotive force Contrast with standard wave pattern Probable cause
Solenoid coil back Short in the injector electromotive force is solenoid low or doesn't appear at all. Point B: Injector drive time
1. Disconnect the idle speed control servo connector, and connect the special tool test harness (MB991709) in between. 2. Connect the oscilloscope special patterns pickup to the idle speed control servoside connector terminal No. 1, No. 3, No. 4 and No. 6 respectively.

1. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 14, connection terminal No. 28, connection terminal No. 15, and connection terminal No. 29 respectively.

Observation conditions Function Special patterns
When idling When racing
AKX01605AE
Pattern height Pattern selector Engine condition
High Display When the engine coolant temperature is 20C or below, turn the ignition switch from "LOCK" (OFF) position to ON (without starting the engine). While the engine is idling, turn the A/C switch to ON. Immediately after starting the warm engine.
The injector drive time will be synchronized with the M.U.T.-II/III 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.
IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) Measurement Method

Oscilloscope 1 2 3 4 5 6 Special patterns pickup
AK201856AB
13A-392
Standard wave pattern

TROUBLESHOOTING
(V)
30
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
Stepper motor control signal wave pattern
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 Induced electromotive force does not appear or is extremely small. Contrast with standard wave pattern Coil reverse electromotive force does not appear or is extremely small. Probable cause Motor is malfunctioning Probable cause Short in the coil
Normal side
AKX01609AF
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
Examples of Abnormal Wave Pattern
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.
AKX01608AE

TROUBLESHOOTING
13A-393
IGNITION COIL AND POWER TRANSISTOR Measurement Method

Oscilloscope
1. Disconnect the ignition coil connector, and connect the special tool test harness (MB991348) in between (All terminals should be connected). 2. Connect the oscilloscope special patterns pickup to terminal No. 3 of each ignition coil connector in turn.
1 2 3 Special patterns pickup

1. Connect the oscilloscope special patterns pickup to engine-ECU terminal No. 11 (No. 1 No. 4), connection terminal No. 12 (No. 2 No.3) respectively.
CH1
AK201750 AB

Observation condition Function Pattern height Pattern selector Engine r/min
Standard wave pattern (V) 6 4 2 0 4 Power transistor control signal wave pattern T1 2 0 Ignition period 75 BTDC T 5 BTDC Compression top dead center
Special patterns Low Display Approximately 1,200 r/min
OFF Dwell section T : Revolution time corresponding to a crank angle of 180 T1 : Time computed by the engine-ECU : Spark advance angle
ON
AK204435 AC
13A-394

TROUBLESHOOTING

Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2). Condition of wave pattern Probable cause build-up section and maximum voltage Rises from approximately 2 V to approximately 4.5 V at the top-right 2 V rectangular wave Normal
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.
Normal wave pattern
Open-circuit in ignition primary circuit Power transistor malfunction
VB
Rectangular wave at power voltage
AKX01613AD
Normal wave pattern
2V
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.
AKX01612AD

ON-VEHICLE SERVICE
13A-395
ON-VEHICLE SERVICE
THROTTLE BODY (THROTTLE VALVE AREA) CLEANING
M1131001000990
1. Remove the air intake hose from the throttle body. 2. Spray cleaning fluid on a clean cloth.
Throttle position sensor
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.
MB991536
AK201752AB
15 mm 15 mm
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. 5. Adjust the basic idle speed (Refer to P.13A-396).
(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 tools yellow clip on the sensor output) and the terminal No. 4 (special tools 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
THROTTLE POSITION SENSOR ADJUSTMENT

M1131001100801
1 Throttle position sensor
2 3 4
AK304569AB
Equipment side connector
AK304568AB
1. Connect the M.U.T.-II/III to the diagnosis connector. When not using the M.U.T.-II/III, proceed as follows.
4. If not within the standard value, loosen the throttle position sensor mounting bolts. Then rotate the sensor body to adjust. 5. Turn the ignition switch to "LOCK" (OFF) position. 6. Remove the M.U.T.-II/III. If the M.U.T.-II/III is not used, remove the special tool, and then connect the throttle position sensor connector. 7. If a diagnosis code is displayed, erase the diagnosis code by using the M.U.T.-II/III 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-396

ON-VEHICLE SERVICE
M1131001800888
BASIC IDLE SPEED ADJUSTMENT

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 M.U.T.-II/III to the diagnosis connector (16-pin). NOTE: When the M.U.T.-II/III 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 M.U.T.-II/III Actuator test. NOTE: This holds the idle speed control servo at the basic step to adjust the basic idle speed. 5. Check the idle speed. Standard value: 800 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 P.13A-395).
Speed adjust screw
6. If not within the standard value range, turn the speed adjusting screw (SAS) to make the necessary adjustment. 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 M.U.T.-II/III clear key, and release the idle speed control servo from the Actuator test mode. NOTE: Unless the idle speed control servo is released, the Actuator test mode will continue 27 minutes. 8. Turn the ignition switch to "LOCK" (OFF) position. 9. Disconnect the M.U.T.-II/III. 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

M1131001901286
1. Release residual pressure from the fuel pipe line to prevent fuel gush out (Refer to P.13A-398).
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.
High-pressure fuel hose
AK304571AB
2. Disconnect the high-pressure fuel hose at the delivery pipe side.
AK304570 AB

ON-VEHICLE SERVICE
13A-397
MB 991637 Gasket MD 998709 Delivery pipe Delivery pipe MD 998742 High-pressure fuel hose
AKX01458AG
O-ring or gasket MD 998709
MD 998742 High-pressure fuel hose

AKX01457AF
MB 991981
4. Install the assembled fuel pressure measurement tools between the fuel rail and fuel high-pressure hose.
Gasket MD 998709 Delivery pipe
MD 998742 High-pressure fuel hose

AK305430AB
3. Assemble the fuel pressure measurement tools as follows. <When using the fuel pressure gauge set (special tool)> 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 or MB991981) into the special tool that has already assembled as described in (a) above. <When using the fuel pressure gauge> 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.
CAUTION To prevent damage to the M.U.T.-II/III, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the M.U.T.-II/III. 5. Connect the M.U.T.-II/III 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 M.U.T.-II/III 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 230 kPa
Fuel pressure regulator
Vacuum hose
AK304572AB
11.Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed by a finger. Standard value: 289 309 kPa 12.Check to see that fuel pressure at idle does not drop even after the engine has been raced several times.
13A-398

ON-VEHICLE SERVICE
13.Racing the engine repeatedly, hold the fuel return 14.If any of fuel pressure measured in steps 10 to 13 hose lightly with fingers to feel that fuel pressure is out of specification, troubleshoot and repair is present in the return hose. according to the table below. NOTE: If the fuel flow rate is low, there will be no fuel pressure in the return hose. Symptom Probable cause Remedy Fuel pressure too low Fuel pressure drops after racing No fuel pressure in fuel return hose Fuel pressure too high 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 Binding valve in fuel pressure regulator Clogged fuel return 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 Fuel pressure drops gradually after Leaky injector engine is stopped Leaky fuel regulator valve seat Fuel pressure drops sharply immediately after engine is stopped Check valve in fuel pump is held open Replace fuel pump Replace fuel pressure regulator Clean or replace hose or pipe Replace vacuum hose or clean nipple
Remedy Replace injector Replace fuel pressure regulator Replace fuel pump
16.Release residual pressure from the fuel pipe line (Refer to P.13A-398).
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. 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: 5.0 1.0 Nm
20.Check for any fuel leaks by following the procedure in step 7. 21.Disconnect the M.U.T.-II/III.
FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES)

M1131000900718
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 P.52A-20). 2. Remove the protector.
Fuel pump module connector
Y0915AU Y2015AU
WARNING
AC208407AB

ON-VEHICLE SERVICE
13A-399
3. Disconnect the fuel pump module connector. 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 module connector. 6. Install the protector and rear seat assembly (Refer to GROUP 52A Rear Seat Assembly P.52A-20).
1 4 2 5 3
FUEL PUMP OPERATION CHECK

M1131002000818
AC208409
CAUTION
<When using the M.U.T.-II>
16-pin
M.U.T.-II
AC207179AD
<When using the M.U.T.-III>
16-pin
MB991911 MB991824
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) Remove the rear seat assembly (Refer to GROUP 52A Rear Seat Assembly P.52A-20). (3) Remove the protector. (4) Disconnect the fuel pump module connector. (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. 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 module connector. (8) Install the protector and rear seat assembly (Refer to GROUP 52A Rear Seat Assembly P.52A-20).
MB991827
AC210056AG
To prevent damage to the M.U.T.-II/III, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the M.U.T.-II/III. 1. Check the operating of the fuel pump by using the M.U.T.-II/III to force-drive the fuel pump.
13A-400
COMPONENT LOCATION

ON-VEHICLE SERVICE
M1131002101573
Name A/C relay
Symbol I
Name Fuel pump resistor
Symbol <L.H. drive D vehicles> <R.H. drive vehicles> H
A/C switch Air flow sensor (with intake air temperature sensor and barometric pressure sensor) Crank angle sensor Detonation sensor Diagnosis connector EGR control solenoid valve Engine control relay Engine coolant temperature sensor Engine-ECU
X R
Idle speed control servo (stepper motor) F Ignition coil (integrated power transister) M
A N W L I O Y
Ignition coil relay <R.H. drive vehicles> Injector Oil feeder control solenoid valve Oxygen sensor (front) Oxygen sensor (rear) Power steering fluid pressure switch Purge control solenoid valve Injector resistor
I E B K T J G
<L.H. drive D vehicles> <R.H. drive vehicles> H
Engine warming lamp (check engine lamp) Exhaust camshaft position sensor Fan control relay Fuel pressure control solenoid valve Fuel pump relay (1) and (2) Fuel pump relay (3)
V N I C U
Intake camshaft position sensor Throttle position sensor Transmission oil temperature sensor Vehicle speed sensor Waste gate solenoid valve
N F Q P S
<L.H. drive D vehicles> <R.H. drive vehicles> H

ON-VEHICLE SERVICE
13A-401
U
J K L M N O P Q R S
AK304573AC
ENGINE CONTROL RELAY CONTINUITY CHECK

M1131050000754
Tester Connection Terminal 23 14
Battery Voltage No Voltage No Voltage
Normal State
Continuity No continuity
1 Engine control relay 3
2 4

AK304574 AB
Voltage Continuity (Connect positive (+) terminal of battery to terminal No. 2 and negative () terminal of battery to terminal No. 3.)
13A-402

ON-VEHICLE SERVICE
M1131033000762
FUEL PUMP RELAY CONTINUITY CHECK

<L. H. drive vehicles> Fuel pump relay (1) Junction block's triangle marks
1 3 Fuel pump relay (2)
2 4 Fuel pump relay(3)

AK304575 AB
Fuel pump relay (1) and (2) Tester Battery Connection Voltage Terminal 14 23 No Voltage No Voltage
Normal State
Junction block's triangle marks Fuel pump relay(3)
1 3
2 4
AK304576AB
Fuel pump relay (3) Tester Battery Connection Voltage Terminal 34 12 No Voltage No Voltage
Normal State

ON-VEHICLE SERVICE
13A-403
FUEL PUMP RESISTOR CHECK

M1131052700049
1.0 1.5 k (at 40C) 0.56 0.76 k (at 60C) 0.30 0.42 k (at 80C)
Fuel pump resistor connector
Intake air temperature sensor
Fuel pump resistor

AKX01621AD
<R. H. drive vehicles> Fuel pump resistor connector
3. Measure resistance while heating the sensor using a hair drier. Normal condition: Temperature (C) Resistance (k) Higher Smaller 4. If the value deviates from the standard value or the resistance remains unchanged, replace the air flow sensor assembly.
Fuel pump resistor
1 2 Equipment side connector

AK304577AB
1. Disconnect the fuel pump resistor connector. 2. Measure the resistance between terminals. Standard value: 0.45 0.65 3. If the resistance is out of specification, replace the fuel pump resistor.
ENGINE COOLANT TEMPERATURE SENSOR CHECK

M1131003101060
CAUTION Be careful not to touch the connector (resin section) with the tool when removing and installing.
1 2 Equipment side connector Engine coolant sensor
INTAKE AIR TEMPERATURE SENSOR CHECK

M1131002801118
1 2 3 4 5 6 7

AK304579 AB
1. Remove the engine coolant temperature sensor.

Air flow sensor
AK304578AB
1. Disconnect the air flow sensor connector. 2. Measure resistance between terminals No. 5 and No. 6. Standard value: 13 17 k (at 20C) 5.3 6.7 k (at 0C) 2.3 3.0 k (at 20C)
AKX01622
13A-404

ON-VEHICLE SERVICE
2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance. Standard value: 14 17 k (at 20C) 5.1 6.5 k (at 0C) 2.1 2.7 k (at 20C) 0.9 1.3 k (at 40C) 0.48 0.68 k (at 60C) 0.26 0.36 k (at 80C) 3. If the resistance deviates from the standard value greatly, replace the sensor.
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 doesnt change smoothly, replace the throttle position sensor. NOTE: For the throttle position sensor adjustment procedure, refer to P.13A-395.
OXYGEN SENSOR CHECK

M1131005001434
AKX01623AD
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 Nm
THROTTLE POSITION SENSOR CHECK

M1131003200796
1 2 3 4 Equipment side connector Oxygen sensor (front) connector

AK304581 AB
1 Throttle position sensor
2 3 4
AK304568AB
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 k
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 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.

ON-VEHICLE SERVICE
13A-405

Black Oxygen sensor equipment side connector 1 2 3 4 Equipment side connector Oxygen sensor (rear) connector
White Oxygen sensor (rear) MD998464

AK305450 AB AK304582 AB
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.
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 at 20C) between terminal No. 3 and No. 4 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.
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 8 V 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 and turbocharger. P.15-10.
Oxygen sensor
MB991658
AK301808 AB
6. Connect a digital voltage meter between terminal No. 1 and No. 2. 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.
13A-406

ON-VEHICLE SERVICE
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 12 V is applied to the oxygen sensor heater. NOTE: If the sufficiently high temperature (of approximately 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. 3 and the terminal No. 4 of the oxygen sensor with a (+) terminal and () terminal of 12 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 P.15-13.
Measurement of Resistance between Terminals

1. Disconnect the injector connector. 2. Measure the resistance between terminals. Standard value: 2 3 (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 P.13A-398). 2. Remove the injector.
Fuel pressure regulator MD998741 High-pressure fuel hose MB991607
MD998706 Return hose MB991976
INJECTOR CHECK
M1131005201267
Check the Operation Sound

Battery
Injector
AK301464 AC
Injector
AK304583 AB
1. Use a stethoscope to listen to the operation sound (clicking) of the injectors while the engine is idling or cranking.
3. Assemble the following special tools as shown in Fig. Injector test set (MD998706) Injector test harness (MB991607) Injector test adaptor (MD998741) Injector test holder assembly (MB991976) 4. Connect the M.U.T.-II/III 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 M.U.T.-II/III actuator test to drive the fuel pump.
Fuel pressure regulator
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.
High-pressure fuel hose Return hose
Battery
Injector
AK301465AC
7. Activate the injector and check the atomized spray condition of the fuel.

ON-VEHICLE SERVICE
13A-407
M1131052800046
The condition can be considered satisfactory unless it is extremely poor. 8. Stop the actuation of the injector, and check for leakage from the injectors nozzle. Standard value: 1 drop or less per minute 9. Without the fuel pump operation, operate the injector to draw the fuel out. 10.If the spraying is extremely poor or the fuel leakage from the injector nozzle deviates from the standard value, replace the injector. 11.Disconnect the M.U.T.-II/III.
INJECTOR RESISTOR CHECK

Injector resistor
Injector resistor
1 2 3 4 5 6 Equipment side connector Injector resistor connector

AK304584AB
1 2 3 4 5 6
AK202415AC
1. Disconnect the injector resistor connector.
13A-408

ON-VEHICLE SERVICE
2. Measure the resistance between terminals. Measurement terminals Resistance 13 43 53 63 5.8 6.2 (At 20C)
3. If the resistance is out of specification, replace the injector resistor.
Check the Coil resistance
IDLE SPEED CONTROL SERVO (STEPPER MOTOR) CHECK

M1131005400804
Check the Operation Sound

1 2 4 5 3 6
1 2 3 4 5 6
Equipment side connector Idle speed control servo

AK304586 AB
1 2 3 4 5 6
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 switched "ON" position (but without starting the engine). 3. If the operation sound cannot be heard, check the stepper motors activation circuit. If the circuit is normal, it is probable that there is a malfunction of the stepper motor or of the engine-ECU.
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 (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 (at 20C)

ON-VEHICLE SERVICE
13A-409
Operation Check
FUEL PRESSURE SOLENOID VALVE CHECK

M1131005800114
OPERATION CHECK
1 2 Equipment side connector Fuel pressure solenoid valve
AKX01626
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 red and black clip. (2) Connect the negative () terminal of the power supply to the blue and black clip. (3) Connect the negative () terminal of the power supply to the blue and yellow clip. (4) Connect the negative () terminal of the power supply to the red and yellow clip. (5) Connect the negative () terminal of the power supply to the red and black clip. (6) Repeat the tests in sequence from (5) to (1). 6. If, as a result of these tests, vibration is detected, the stepper motor can be considered to be normal.
AK304587AB
1. Remove the vacuum hose from the solenoid valve. 2. Disconnect the harness connector.
B nipple
Battery
AK202416 AC
3. Connect a hand vacuum pump to the solenoid valves A nipple. 4. Connect the solenoid valve terminal and battery terminal with a jumper wire. 5. Disconnect the jumper wire between the batterys () terminals, apply a negative pressure, and inspect the tightness. Standard valve: Battery voltage B nipple Normal condition No applied Open Close Applied Open Vacuum leak Vacuum maintained Vacuum maintained
13A-410
COIL RESISTANCE CHECK

ON-VEHICLE SERVICE
1. Disconnect the oil feeder control valve connector.
CAUTION To prevent the coil from burning, keep the duration of the voltage application as short as possible. 2. Apply battery voltage to the terminals of the connector at the oil feeder control valve, and make sure the oil feeder control valve makes a clicking sound.
AK304596
MEASUREMENT OF RESISTANCE BETWEEN TERMINALS

1. Disconnect the oil feeder control valve connector. 2. Measure the resistance between the terminals of the connector at the oil feeder control valve. Standard value: 6.9 7.9 (at 20C) 3. If resistance is outside the standard value, replace the oil feeder control valve.
OIL FEEDER CONTROL VALVE CHECK

M1131053800072
OPERATION CHECK
Oil feeder control valve
AK502034 AB

INJECTOR
13A-411
INJECTOR
M1131007100854
Pre-removal Operation Fuel Discharge Prevention (Refer to P.13A-398). Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9). Air Hose E, Air By-pass Hose, Air Pipe C Removal (Refer to GROUP 15, Intercooler P.15-6).
Post-installation Operation Air Hose E, Air By-pass Hose, Air Pipe C Installation (Refer to GROUP 15, Intercooler P.15-6). Strut Tower Bar Installation (Refer to GROUP 42, Strut Tower Bar P.42-9). Fuel Leakage Check
5.0 1.0 Nm
2 3 4N 12 10 15 N 13 11 6 12 N 15 N 5
N8
10
3,7
O-ring
9
11 1 Nm 5.0 1.0 Nm
14 N 7
8.9 1.9 Nm O-ring Engine oil
13
AC210060AD
1. >>A<< 2. 3. 4. 5. 6. 7.
>>A<<
Removal steps Accelerator cable assembly connection (Throttle body side) Control wiring harness connection Fuel high-pressure hose connection O-ring Fuel return hoses connection Vacuum hose connection Fuel pressure regulator
<<A>> <<A>> >>A<<
8. 9. 10. 11. 12. 13 14. 15.
Removal steps (Continued) O-ring Fuel return pipe Delivery pipe Insulators Insulators Injectors O-ring Grommets
13A-412

INJECTOR
REMOVAL SERVICE POINT <<A>> DELIVERY PIPE/INJECTORS REMOVAL

CAUTION Do not drop the injector. Remove the delivery pipe with the injectors attached to it.
INSTALLATION SERVICE POINT >>A<< INJECTORS/FUEL PRESSURE REGULATOR/FUEL HIGH-PRESSURE 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.
2. Turn the injector to the right and left to install to the delivery pipe. Repeat for fuel pressure regulator and fuel high-pressure hose. Be careful not to damage the O-ring. After installing, check that the item turns smoothly. 3. If it does not turn smoothly, the O-ring may be pinched, remove the item, re-install it into the delivery pipe and check again. 4. Tighten the fuel pressure regulator and fuel high-pressure hose to the specified torque. Tightening torque: 8.9 1.9 Nm <Fuel pressure regulator> 5.0 1.0 Nm <Fuel high-pressure hose>

THROTTLE BODY ASSEMBLY
13A-413

M1131007700759
Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service Engine Coolant Replacement P.14-15). Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9). Air Hose E, Air By-pass Hose, Air Pipe C Removal (Refer to GROUP 15, Intercooler P.15-6).
Post-installation Operation Air Hose E, Air By-pass Hose, Air Pipe C Installation (Refer to GROUP 15, Intercooler P.15-6). Strut Tower Bar Installation Refer to GROUP 42, Strut Tower Bar P.42-9). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service Engine Coolant Replacement P.14-15). Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2). Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service Accelerator Cable Check and Adjustment P.17-2).
5.0 1.0 Nm 19 3 Nm
1 4 7N
2 3 5 6 5
AC310860AB
1. 2. 3. 4.
Removal steps Accelerator cable connection Throttle position sensor connector Idle speed control servo connector Vacuum hoses connection
>>A<<
5. 6. 7.
Removal steps (Continued) Water hoses connection Throttle body Throttle body gasket
13A-414

INSTALLATION SERVICE POINT >>A<<THROTTLE BODY GASKET INSTALLATION

CAUTION Poor idling etc. may result if the throttle body gasket is installed incorrectly.
Up
Install the throttle body gasket as shown in the illustration.
Towards front of vehicle
AC200313AB

ENGINE CONTROL RESISTOR, RELAY
13A-415
ENGINE CONTROL RESISTOR, RELAY

M1131034600024
Pre-removal Operation Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9). Harness Connector Disconnection
Post-installation Operation Harness Connector Connection Strut Tower Bar Installation (Refer to GROUP 42, Strut Tower Bar P.42-9).
5.0 1.0 Nm
Electric pump relay 5.0 1.0 Nm
<L.H. drive vehicles>
1
5.0 1.0 Nm
2.5 0.5 Nm
2
5.0 1.0 Nm
4
<R.H. drive vehicles> 5.0 1.0 Nm
2
5.0 1.0 Nm
2.5 0.5 Nm
Electric pump relay
5.0 1.0 Nm
1
2. 3. 4.
AC310757 AB
1.
Removal steps Electric pump relay (Refer to GROUP 22A, Sensor, Switch and Relay P.22A-168). Fuel pump relay
Removal steps (Continued) Injector resistor Bracket Fuel pump resistor
13A-416

ENGINE-ECU
ENGINE-ECU
M1131033800230
CAUTION When the engine-ECU is replaced, always refer to GROUP 54A, General Information Immobilizer System Encrypted Code Registration Criteria Table P.54A-6.
Pre-removal and Post-installation Operation Glove Box Assembly Removal and Installation (Refer to GROUP 52A, Instrument Panel P.52A-2). Harness Cover Removal and Installation (Refer to GROUP 52A, Instrument Panel P.52A-2).
5.0 1.0 Nm
AC505253AB
1. 2.
Removal steps Engine-ECU connectors Engine-ECU
13-1
GROUP 13
FUEL
CONTENTS MULTIPORT FUEL INJECTION (MPI) . . . . . . . . . . . . . . . . . . . . 13A FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B
NOTES
35-1
GROUP 35
SERVICE BRAKES
CONTENTS SERVICE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A ANTI-SKID BRAKING SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . 35B
NOTES
35A-1
GROUP 35A
SERVICE BRAKES
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . SEALANT. . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .
BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE BOOSTER OPERATING TEST . . . CHECK VALVE OPERATION CHECK . . . . BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE FLUID LEVEL SENSOR CHECK. . FRONT DISC BRAKE PAD CHECK AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . DISC BRAKE ROTOR CHECK. . . . . . . . . . BRAKE DISC THICKNESS CHECK . . . . . . BRAKE DISC RUN-OUT CHECK AND CORRECTION . . . . . . . . . . . . . . . . . . . . . .
35A-2 35A-3 35A-4 35A-4 35A-4 35A-5

35A-5 35A-6 35A-7 35A-7 35A-8
BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A-14

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-14 35A-15
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER . . . . . . . . . . 35A-16

REMOVAL AND INSTALLATION . . . . . . . . MASTER CYLINDER . . . . . . . . . . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-16 35A-18 35A-18
FRONT DISC BRAKE ASSEMBLY . . 35A-19

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-19 35A-19 35A-20 35A-21
REAR DISC BRAKE ASSEMBLY . . . 35A-22

35A-8 35A-10 35A-11 35A-12 REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-22 35A-22 35A-23 35A-24
35A-2
SERVICE BRAKES
GENERAL INFORMATION
GENERAL INFORMATION
M1351000100536
CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Top components such as Brembo brakes, EBD and sports ABS improve braking power and braking stability.
CONSTRUCTION DIAGRAM
Brake booster assembly Brake modulator hydraulic unit (integrated with ABS-ECU)
10064AU
Rear disc brake Brake master cylinder assembly Front disc brake
AC211387AD
Parking brake
SERVICE BRAKES
35A-3
SPECIFICATIONS
Item Master cylinder Brake booster Type I.D. mm Type Effective dia. of power cylinder mm Boosting ratio Rear wheel hydraulic control method Front brakes Type Disc effective dia. thickness mm Wheel cylinder I.D. mm Pad thickness mm Clearance adjustment Rear brakes Type Disc effective dia. thickness mm Wheel cylinder I.D. mm Pad thickness mm Clearance adjustment Specification Tandem type 26.9 Vacuum type, tandem 205 + 230 4.5 (Brake pedal depressing force: 230 N) Electronic brake-force distribution (EBD) 4-opposed piston, ventilated disc 263 32 40.0 2, 46.0 2 10.0 Automatic 2-opposed piston, ventilated disc 252 22 40.0 2 9.0 Automatic
M1351000300574
Item Brake pedal height mm Brake pedal free play mm Brake pedal to floorboard clearance mm Front disc brake pad thickness mm Front disc brake disc thickness mm Front disc brake disc run-out mm Front disc brake drag force N Rear disc brake pad thickness mm Rear disc brake disc thickness mm Rear disc brake disc run-out mm Rear disc brake drag force N Front wheel bearing axial play mm Rear wheel bearing axial play mm Brake booster push rod protruding amount mm
Standard value 169.1 172.1 38 90 or more 10.0 32.0 69 or less 9.0 22.0 69 or less 8.98 9.23
Limit Minimum 2.0 Minimum 29.8 0.03 Minimum 2.0 Minimum 20.4 0.03 0.05 0.05
35A-4
SERVICE BRAKES
LUBRICANTS
LUBRICANTS
M1351000400504
Item Brake fluid Pad assembly
Specified lubricant DOT3 or DOT4 Repair kit grease
SEALANT
M1351000500415
Item Fitting
Specified sealant 3M ATD Part No.8661 or equivalent
Remark Semi-drying sealant
SPECIAL TOOLS
M1351000600434
Tool
Number MB991568
Name
Use
Push rod adjusting Adjustment of the brake booster socket push rod protrusion amount
A B
MB990964 A: MB990520 B: MB990619
Brake tool set A: Disc brake piston expander B: Installer
Pushing-in of the disc brake piston Installation of the drum brake wheel cylinder piston cup
MB990964
MB990998
Front hub remover Provisional holding of the wheel and installer bearing
MB990998
SERVICE BRAKES
ON-VEHICLE SERVICE
35A-5
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
M1351000900510
BRAKE PEDAL HEIGHT

1. Turn up the carpet, etc. under the brake pedal.
NOTE: When the clevis is turned 180 degrees, the pedal height is changed approximately 2.4 mm. (5) Install the brake booster (Refer to P.35A-16). (6) Measure the brake pedal height, and ensure that the measured value is within the specified value. When it is out of the specified value, repeat Step (3) - (6).
Stopper
A
AC006215AB
2. Measure the brake pedal height as illustrated. Standard value (A): 169.1 172.1 mm [From the surface of melting sheet (floorboard) 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) Loosen the stop lamp switch by turning it approximately 1/4 turn anticlockwise. (3) Remove the brake booster (Refer to P.35A-16). NOTE: With the master cylinder and brake pipe connected, remove the brake booster only.
Stopper
0.5 - 1.0 mm
AC309282AE
(7) Insert the stop lamp switch until its threaded part touches the stopper. Then lock the stop lamp switch by turning it approximately 1/4 turn clockwise, and confirm that the clearance between the switch plunger and the stopper is as shown.
Clevis
AC006217AB
(4) Adjust the brake pedal height by turning the clevis.
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.
35A-6
BRAKE PEDAL FREE PLAY
SERVICE BRAKES
ON-VEHICLE SERVICE
Standard value (C): 90 mm or more [From the surface of the floorboard to the face of pedal pad] 3. If the clearance is outside the standard value, check for air trapped in the brake line and thickness of the disc brake pad. And then bleed the air and replace the disc brake pad as required. 4. Return the carpet etc. to its original position.
B
AC006219AB
BRAKE BOOSTER OPERATING TEST

M1351001000435
1. With the engine stopped, depress the brake pedal two or three times, After eliminating the vacuum in the power brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (the free play) is within the standard value. Standard value (B): 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.
1. For simple checking of the brake booster operation, carry out the following tests:
Good No good
AC000870 AB
CLEARANCE BETWEEN BRAKE PEDAL AND FLOORBOARD

1. Turn up the carpet, etc. under the brake pedal.
(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.
When engine is stopped When engine is started
AC000871AB
C
AC006220AB
2. Start the engine, depress the brake pedal with approximately 500 N of force, and measure the clearance between the brake pedal and the floorboard.
(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.
SERVICE BRAKES
ON-VEHICLE SERVICE
Good No good
35A-7
2. Check the operation of the check valve by using a vacuum pump. Vacuum pump connection Accept/reject criteria
Connection at the brake A negative pressure booster side (A) (vacuum) is created and held.
AC000872 AB
Connection at the intake A negative pressure manifold side (B) (vacuum) is not created.
(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 operation (Refer to P.35A-7), 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.
BLEEDING
M1351001400552
CAUTION Use only brake fluid DOT 3 or DOT 4. Never mix the specified brake fluid with other fluid as it will affect the braking performance significantly.
MASTER CYLINDER BLEEDING

The master cylinder 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

M1351009000462
CAUTION The check valve should not be removed from the vacuum hose.
1. Remove the vacuum hose (Refer to P.35A-16).
CAUTION If the check valve is defective, replace it as an assembly unit together with the vacuum hose.
AC000876
Valve A
Spring B Intake manifold side (does not hold)
Booster side (holds)
3. Have another person cover the master cylinder outlet with a finger. 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.
AC000873AE
35A-8
DISC BRAKE BLEEDING
SERVICE BRAKES
ON-VEHICLE SERVICE
CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly.
Air bleeder screw
Start the engine and bleed the air in the sequence shown in the figure.
BRAKE FLUID LEVEL SENSOR CHECK

M1351009100447
Connect a vinyl tube to the outer end of the air bleeder screw to bleed the circuit of air. Then, connect the vinyl tube to the inner end and bleed the circuit of air. Except for these, the conventional procedures shall be followed. After the circuit has been bled of air, tighten both air bleeder screws securely.
BRAKE LINE BLEEDING
CAUTION Be sure to filter/strain the brake fluid being added to the master cylinder reservoir tank. Debris may damage the hydraulic unit.
4 1
;
AC211983 AB
AC006224AB
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".
FRONT DISC BRAKE PAD CHECK AND REPLACEMENT

M1351002300484
NOTE:
When new Pad When worn
Wear indicator
Brake disc
AC000879 AB
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.
AC211984 AB
SERVICE BRAKES
ON-VEHICLE SERVICE
CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly. 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 moving parts.
Front Rear
(2) Remove the pad from the caliper. (3) To measure brake drag force after new pads have been installed, use a spring scale to measure the turning sliding resistance of the hub with the pads removed.
Pads
;
AC211987
35A-9
MB990520
Pads
AC211985 AB
1. Check the brake pad thickness through the caliper body check port. Standard value: <Front> 10.0 mm <Rear> 9.0 mm Minimum limit: 2.0 mm
AC211988 AB
(4) Clean the piston and, using special tool piston expander (MB990520), push the piston into the cylinder.
Front Rear
AC211989 AB AC211986
2. When the thickness is less than the limit, always replace the pads at an axle set. (1) Holding the cross spring with one hand, pull the pin out of the caliper.
(5) Apply repair kit grease to the portions of the pads indicated. At this time, make sure that the grease will not be applied to any other surfaces. (6) Mount the pads to the caliper so that its side with the wear indicator is on the outside of the vehicle. With the rear pads, ensure that the arrow on the pad faces in the same direction as the brake disc turns when the vehicle moves forward.
35A-10
Pins Cross spring
SERVICE BRAKES
ON-VEHICLE SERVICE
(8) Using a spring scale, measure the turning sliding resistance of the hub in the forward direction. (9) Find the brake disc drag force [the difference in measurements taken in step(3) and in step(8)]. Standard value: 69 N or less (10)If that drag force exceeds the standard value, disassemble the caliper assembly. Then check the piston for contamination or rust, and confirm if the piston or the piston seal is deteriorated.
AC211990 AB
(7) Holding the cross spring with one hand, fit pins in the caliper.
DISC BRAKE ROTOR CHECK

M1351002900408
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
Scratches, rust, saturated lining materials and wear
Remark 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. Excessive run-out of the discs will increase the pedal depression resistance due to piston kick-back. If the thickness of the disc changes, this will cause pedal pulsation, shuddering and surging. Overheating and improper handling while servicing will cause warping or distortion.
Run-out Change in thickness (parallelism) Inset or warping (flatness)
SERVICE BRAKES
ON-VEHICLE SERVICE
35A-11
BRAKE DISC THICKNESS CHECK

M1351002400469
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
ACX00668AB
1. Using a micrometer, measure disc thickness at eight positions, approximately 45 degrees apart and 10 mm from the outer edge of the disc. Standard value: <Front> 32.0 mm <Rear> 22.0 mm Minimum limit: <Front> 29.8 mm <Rear> 20.4 mm NOTE: Thickness variation (at least 8 positions) should not be more than 0.015 mm.
M12 flat washer
AC006226 AB
When the on-the-car type lathe is used, first install a 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 Nm. 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. 2. If the disc thickness is less than the limits, replace it with a new one. If thickness variation exceeds the specification, turn rotor with an on-the-car type brake lathe ("Accuturn-8750" or equivalent). If the calculated final thickness after turning the rotor is less than the standard value, replace the disc.
35A-12
BRAKE DISC RUN-OUT CHECK AND CORRECTION
SERVICE BRAKES
ON-VEHICLE SERVICE
M1351009400534
CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly. 1. Remove the brake assembly, and then hold it with wire. 2. Temporarily install the disc with the hub nut.
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.
<Front>
AC102438 AC
<Rear>
ACX00669AB
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: 0.03 mm
AC205869AC
Chalk marks
(2) Remove the brake disc. Then place a dial gauge as shown, and measure the 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 assembly to check each part. (4) If the axial play does not exceed the limit, dephase the brake disc and secure it. Then recheck the brake disc run-out.
AC210711AB
SERVICE BRAKES
ON-VEHICLE SERVICE
35A-13
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.
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 ("Accuturn-8750" or equivalent).
M12 flat washer
M12 flat washer
AC006226 AB
When the on-the-car type lathe is used, first install a 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 Nm. 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.
35A-14
SERVICE BRAKES
BRAKE PEDAL
BRAKE PEDAL
M1351003400473
Post-installation Operation Brake Pedal Adjustment (Refer to P.35A-5).
12 2 Nm
3 2 5
14 3 Nm
7 4 6
AC211554 AB
1. 2. 3. 4.
Removal steps Harness connector Stoplamp switch Brake pedal clip Brake pedal stopper
5. 6. 7. >>A<< 8.
Removal steps (Continued) Brake booster pin Brake pin assembly Brake pedal pad Brake pedal assembly
SERVICE BRAKES
BRAKE PEDAL
35A-15
M1351003500254
INSTALLATION SERVICE POINT >>A<< BRAKE PEDAL ASSEMBLY INSTALLATION
INSPECTION STOPLAMP SWITCH CHECK
B A
No continuity
A
Continuity
4 mm
AC006235AB
AC006234 AB
Tighten the brake booster mounting nuts (A), and then the brake pedal assembly mounting bolts (B). NOTE: The brake pedal assembly cannot be positioned correctly if the brake pedal assembly mounting bolts (B) are tightened first, as their holes are oblong holes.
1. Connect an ohmmeter between the stop lamp switch connector terminals. 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.
35A-16
SERVICE BRAKES
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

M1351003700537
Pre-removal Operation Brake Fluid Draining Air Intake Hose and Air Cleaner Removal (Refer to GROUP 15, Air Cleaner P.15-5). Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9).
Post-installation Operation Brake Pedal Adjustment (Refer to P.35A-5). Air Intake Hose and Air Cleaner Installation (Refer to GROUP 15, Air Cleaner P.15-5). Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9). Brake Fluid Supplying and Air Bleeding (Refer to P.35A-7).
7 4 3
15 2 Nm
2 11 12 8
1 5 6
10 2 Nm
10
9
22 3 Nm 14 3 Nm
5
15 2 Nm
AC310837AB
7 13
16 1 Nm
13 13
1. 2. 3. 4. 5. 6. 1. 2. 5. 6. Master cylinder removal steps Clutch hose connection Brake fluid level indicator switch connector Brake fluid reservoir cap Brake fluid level indicator switch Brake tube connection Brake master cylinder assembly Brake booster removal steps Clutch hose connection Brake fluid level indicator switch connector Brake tube connection Brake master cylinder assembly
16 1 Nm 3M ATD part No. 8661 or equivalent
>>B<< >>A<<
Brake booster removal steps Push rod protrusion amount check and adjustment 7. Brake booster vacuum hose (With built-in check valve) 8. Brake booster pin 9. Brake booster pin assembly 10. Clevis Remove A/C liquid pipe B from the retaining clip (Refer to GROUP 55, Refrigerant Line P.55-128). 11. Brake booster assembly 12. Brake booster body seal
SERVICE BRAKES
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER >>A<< Fitting removal steps Brake booster vacuum hose (With built-in check valve) 13. Brake booster vacuum hose fitting 7.
35A-17
INSTALLATION SERVICE POINTS >>A<< BRAKE BOOSTER VACUUM HOSE CONNECTION

Insert the brake booster vacuum hose to the brake booster assembly with its paint mark facing upward, and then secure the hose by using the hose clip.
1. Measure dimension (A). Standard value (A): 8.98 9.23 mm NOTE: When a negative pressure of 66.7 kPa is applied to the brake booster, the push rod should protrude 10.27 - 10.53 mm.
>>B<< PUSH ROD PROTRUSION AMOUNT CHECK AND ADJUSTMENT
Rod spline
Angle-nose pliers
MB991568 Measuring distance A

AC006238AB
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
AC006237AB
35A-18
MASTER CYLINDER
SERVICE BRAKES
M1351004200449

1 3 4 2 9 7
Master cylinder kit
5 8 6 3 9
N N
10
10
AC006239 AB
Brake fluid: DOT 3 or DOT 4
Disassembly steps Brake fluid reservoir cap Brake fluid reservoir filter Brake master cylinder pin Brake fluid reservoir Brake master cylinder to reservoir seal 6. Brake master cylinder pin 7. Piston retainer 8. Primary piston assembly 1. 2. 3. 4. 5.
Disassembly steps (Continued) 9. Secondary piston assembly 10. Master cylinder body
INSPECTION
Check the inner surface of master cylinder body for rust or pitting. Check the primary and secondary pistons for rust, scoring, wear or damage. Check the diaphragm for cracks and wear.
M1351004300338
SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY
35A-19

M1351006000526
Pre-removal Operation Brake Fluid Draining Post-installation Operation Brake Fluid Supplying and Air Bleeding (Refer to P.35A-7).
108 10 Nm
30 5 Nm
2 3
AC211991 AB
1. 2. >>A<< 3. 4.
Removal steps Brake hose connection Gasket Brake caliper assembly Brake disc
2. If that drag force exceeds the standard value, disassemble the caliper assembly. Then check the piston for contamination or rust, and confirm if the piston or the piston seal is deteriorated.
INSTALLATION SERVICE POINT >>A<< BRAKE CALIPER ASSEMBLY INSTALLATION

1. Find the drag force of the disc brake (Refer to P.35A-8). Standard value: 69 N or less
INSPECTION
M1351006100341
BRAKE DISC CHECK Disc wear (Refer to P.35A-11). Disc run-out (Refer to P.35A-12).
35A-20
SERVICE BRAKES
M1351006200586

5 6 6 7N 9N 8
10 4 3 5
14 2 Nm
Grease: Repair kit grease

AC211994 AB
6 6 10
7 9 8 9 7 7 1 9 5 5
2
Brake caliper kit Seal and boot repair kit Shim set
3 2 1
3 1 2 4
Clip set Pad set
SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Disassembly steps Pin Pad anti-squeak spring Pad and wear indicator assembly Pad assembly Shim Caliper bleeder Piston boot Piston Piston seal Caliper body
35A-21
<> PISTON SEAL REMOVAL

CAUTION To prevent damage to inner cylinder, do not use a flat-tipped screwdriver or other tool. 1. Remove the piston seal with finger tip. 2. Clean the piston surface and inner cylinder with alcohol or brake fluid DOT 3 or DOT 4.
<<A>> <<A>> <>
INSPECTION
M1351006300431
DISASSEMBLY SERVICE POINTS

CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly. When disassembling the disc brakes, disassemble both sides (left and right) as a set.
Check the cylinder for wear, damage or rust. Check the piston surface for wear, damage or rust. Check the caliper body 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
<<A>> PISTON BOOT/PISTON REMOVAL

CAUTION Do not remove one piston completely before trying to remove the other piston, because it will become impossible to remove other pistons.
Wood block
wheel as a set (both front wheels or both rear wheels). 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 moving parts.
AC212148AB
Remove the pistons by pumping in air slowly from the brake hose connection. Be sure to use a wood block and adjust the height of the four pistons so that the pistons protrude evenly.
ACX00690
Measure thickness at the thinnest, most worn area of the pad. Replace the pad assembly if pad thickness is less than the limit value. Standard value: 10.0 mm Minimum limit: 2.0 mm
35A-22
SERVICE BRAKES
REAR DISC BRAKE ASSEMBLY

M1351007000411
Pre-removal Operation Brake Fluid Draining
54 5 Nm 15 2 Nm
Post-installation Operation Brake Fluid Filling and Air Bleeding (Refer to P.35A-7).
1 2N 3
4
1. 2. >>A<< 3. 4. Removal steps Brake hose connection Gasket Brake caliper assembly Brake disc
AC403344AB
Standard value: 69 N or less 2. If that drag force exceeds the standard value, disassemble the caliper assembly. Then check the piston for contamination or rust, and confirm if the piston or the piston seal is deteriorated.
INSTALLATION SERVICE POINT >>A<< BRAKE CALIPER ASSEMBLY INSTALLATION

1. Find the drag force of the disc brake (Refer to P.35A-8).
INSPECTION
M1351007100300
BRAKE DISC CHECK

Disc wear: Refer to P.35A-11. Disc run-out: Refer to P.35A-12.
SERVICE BRAKES
35A-23

M1351007200374
14 2 Nm
5 2
4 3 5
6 1
10
N
7
N
Grease: Repair kit grease
AC211995 AB
6 8 9 7
10
2 9 6 1 7 5
9
Shim set
Brake caliper kit
Seal and boot repair kit
3 1 2 1 2
Clip set Pad set
4 3
1. 2. 3. 4. 5.
Disassembly steps Pin Pad anti-squeak spring Pad and wear indicator assembly Pad assembly Shim
<<A>> <<A>> <>
6. 7. 8. 9. 10.
Disassembly steps (Continued) Caliper bleeder Piston boot Piston Piston seal Caliper body
35A-24
DISASSEMBLY SERVICE POINTS
SERVICE BRAKES
INSPECTION
M1351007300296
CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly. When disassembling the disc brakes, disassemble both sides (left and right) as a set.
Check the cylinder for wear, damage or rust. Check the piston surface for wear, damage or rust. Check the caliper body for wear. Check the pad for damage or adhesion of grease, check the backing metal for damage.
<<A>> PISTON BOOT/PISTON REMOVAL

Wooden plate
PAD WEAR CHECK

WARNING Always replace both brake pads on each
wheel as a set (both front wheels or both rear wheels). 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 moving parts.
AC212149AB
Remove the pistons by pumping in air slowly from the brake hose connection. Be sure to use a wood plate and adjust the height of the two pistons while so that the pistons protrude evenly.
<> PISTON SEAL REMOVAL

CAUTION To prevent damage to inner cylinder, do not use a flat-tipped screwdriver or other tool.
1. Remove the piston seal with finger tip. 2. Clean the piston surface and inner cylinder with alcohol or brake fluid DOT 3 or DOT 4.
ACX00690
Measure thickness at the thinnest, most worn area of the pad. Replace the pad assembly if pad thickness is less than the limit value. Standard value: 9.0 mm Minimum limit: 2.0 mm
35B-1
GROUP 35B
ANTI-SKID BRAKING SYSTEM (ABS)

CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . 35B-2 35B-3 ABS SENSOR. . . . . . . . . . . . . . . . . . . 35B-146 35B-4 35B-5
REMOVAL AND INSTALLATION . . . . . . . . 35B-146 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35B-147
HYDRAULIC UNIT . . . . . . . . . . . . . . . 35B-143

REMOVAL AND INSTALLATION . . . . . . . . 35B-143
ON-VEHICLE SERVICE. . . . . . . . . . . 35B-138

WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT . . . . . . . . . . . 35B-138 HYDRAULIC UNIT CHECK . . . . . . . . . . . . 35B-140 IN THE EVENT OF A DISCHARGED BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . 35B-142
G-SENSOR . . . . . . . . . . . . . . . . . . . . . 35B-148
REMOVAL AND INSTALLATION . . . . . . . . 35B-148 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35B-149
STEERING WHEEL SENSOR*. . . . . . 35B-150

REMOVAL AND INSTALLATION . . . . . . . . 35B-150
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
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 SRS-related component. NOTE The SRS includes the following components: 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 (*).
35B-2

GENERAL INFORMATION
GENERAL INFORMATION
M1352000100584
Top components such as Brembo brakes, EBD and sports ABS improve braking power and braking stability.
SPORTS ABS
4-wheel independent control optimises the brake force to each wheel to achieve a balance of improved braking force and braking stability. A steering wheel sensor was added to monitor the steering angle status. Braking force is altered in response to the steering status to improve the quality of steering when cornering. The steering wheel sensor, lateral G-sensor and longitudinal G-sensor accurately monitor driving conditions and optimise ABS control to match the specific driving conditions.
EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION SYSTEM)

Rear brake power is electronically controlled to optimise performance in accordance with road and load conditions and to ensure optimal distribution of braking force between the front and rear brakes. Rear brake fluid pressure control employs a brake modulator hydraulic unit solenoid valve that made it possible to eliminate the pressure control valves (proportioning valves). Effective use of rear wheel brake force reduces temperature build-up in the front brakes under hard braking conditions. Independent control of the left and right rear brakes when braking during cornering achieves a balance of improved vehicle stability and braking force.
SPECIFICATIONS
Item ABS control method Number of rotor teeth Wheel speed sensor Type Gap between sensor and rotor mm Front Rear Front Rear Specification 4-sensor, 4-channel 43 43 Magnet coil type 0.85 (Non-adjustable type) 0.60 (Non-adjustable type)

35B-3
<L.H. drive vehicles> <R.H. drive vehicles>
ABS warning lamp
ABS warning lamp Steering wheel sensor
Parking brake switch
Hydraulic unit and Brake modulator (ABS-ECU)
Wheel speed sensor Diagnosis connector Stop lamp switch Lateral G-sensor Longitudinal G-sensor Wheel speed sensor
AC310670 AC
M1352000300685
Item Wheel speed sensor internal resistance k G-sensor output voltage V Stationary Vehicles Arrow facing downward
Standard value 1.24 1.64 2.4 2.6 3.4 3.6
35B-4

SPECIAL TOOLS
SPECIAL TOOLS
M1352000600794
Tool
Number MB991502
Use Checking the ABS (Diagnosis display using the M.U.T.-II)
B991502
MB991824
MB991827
DO NOT USE
MB991910
M.U.T.-III sub-assembly A: Vehicle communication interface (V. C. I). B: M.U.T.-III USB cable C: M.U.T.-III main harness A (Vehicles with CAN communication system) D: M.U.T.-III main harness B (Vehicles without CAN communication system) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
Checking the ABS (Diagnosis display using the M.U.T.-III)
MB991911
MB991825
MB991826 MB991955
MB991529
Diagnosis code check harness
Checking the ABS (Diagnosis display using the ABS warning lamp)
MB991529

TROUBLESHOOTING
35B-5
Use Checking the G-sensor
Tool
Number MB991348
Name Test harness set
MB991348
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points P.00-5.
M1352011100641
NOTES WITH REGARD TO DIAGNOSIS

M1352012600207
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. Explanation of phenomenon
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) Shocks are felt if the brake pedal is depressed when driving at low speed. This is the sound of normal system operation, and is not a malfunction.
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.
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.
35B-6

TROUBLESHOOTING
M1352012000249
ABS WARNING LAMP INSPECTION

<R.H. drive vehicles>
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. 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.
DIAGNOSIS FUNCTION
M1352011200819
READING DIAGNOSIS CODES WHEN USING THE M.U.T.-II/III

Approx. 3 s Approx. 3 s
WHEN USING THE ABS WARNING LAMP

1. Turn the ignition switch to the "LOCK" (OFF) position.
ABS Illuminated warning lamp Not illuminated Ignition switch START ON ACC
AC311051 AB
Diagnosis connector
MB991529
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
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.
AC211895AB
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.

TROUBLESHOOTING
35B-7
4. Read out a diagnosis code by observing how the warning lamp flashes.
ABS warning lamp <R.H. drive vehicles>
ABS warning lamp

AC311052 AB
When the diagnosis code No.24 is set

1.5 secs. 0.5 sec. Illuminated Switched off Pause time 3 secs. Tens signal Place division 2 secs. Units signal ACX01777 AD 0.5 sec.
When no diagnosis code is set

0.25 sec. Illuminated Switched off ACX01778 AD
5. Turn the ignition switch to the "LOCK" (OFF) position.
6. Disconnect special tool diagnosis code check harness (MB991529).
35B-8
ERASING DIAGNOSIS CODES WHEN USING THE M.U.T.-II/III

TROUBLESHOOTING
Diagnosis connector
WHEN NOT USING THE M.U.T.-II/III

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
AC211895AB
2. Use special tool diagnosis code check harness (MB991529) to earth terminal number 1 of the diagnosis connector.
ON Ignition switch OFF(OFF)
Stop lamp switch
ON OFF
ABS warning lamp
ON OFF 3 seconds
ABS-ECU memory Within 3 seconds

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 1 seconds
1st
2nd
3rd
4th
5th
6th
7th
8th
9th
10th
Erasing of ABS-ECU diagnosis codes complete. AC000937AD
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.
6. Turn the ignition switch to the "LOCK" (OFF) position. 7. Disconnect special tool diagnosis code check harness (MB991529).

TROUBLESHOOTING
35B-9
INSPECTION CHART FOR DIAGNOSIS CODE

Follow the inspection chart that is appropriate for the diagnosis code. Diagnosis code No. 11 12 13 14 16 Inspection item Front right wheel speed sensor (Open circuit or short-circuit) Front left wheel speed sensor (Open circuit or short-circuit) Rear right wheel speed sensor (Open circuit or short-circuit) Rear left wheel speed sensor (Open circuit or short-circuit) ABS-ECU power supply system (abnormal voltage drop or rise) Front right wheel speed sensor system Front left wheel speed sensor system Rear right wheel speed sensor system Rear left wheel speed sensor system Longitudinal G-sensor system <LH drive vehicle> P.35B-22, <RH drive vehicle> P.35B-58 <LH drive vehicle> P.35B-29, <RH drive vehicle> P.35B-65 <LH drive vehicle> P.35B-19, <RH drive vehicle> P.35B-55 <LH drive vehicle> P.35B-11, <RH drive vehicle> P.35B-47 Reference page <LH drive vehicle> P.35B-11, <RH drive vehicle> P.35B-47
M1352011300797
21 22 23 24 32
41 42 43 44 51
Front right solenoid valve system Front left solenoid valve system Rear right solenoid valve system Rear left solenoid valve system Valve relay ON problem
Replace the brake modulator hydraulic unit (Integrated with ABS-ECU). <LH drive vehicle> P.35B-29, <RH drive vehicle> P.35B-65 Replace the brake modulator hydraulic unit (Integrated with ABS-ECU). <LH drive vehicle> P.35B-29, <RH drive vehicle> P.35B-65 Replace the brake modulator hydraulic unit (Integrated with ABS-ECU). <LH drive vehicle> P.35B-32, <RH drive vehicle> P.35B-68
52 53 54
Valve relay problem (stays off) Motor relay problem (stays off) Motor relay ON problem
55
Motor system (seized pump motor)
63
ABS-ECU abnormality
71
Lateral G-sensor system
35B-10
Diagnosis code No. 81 82 83 . Inspection item

TROUBLESHOOTING
Reference page <LH drive vehicle> P.35B-39, <RH drive vehicle> P.35B-75
Steering wheel sensor (ST-1) system Steering wheel sensor (ST-2) system Steering wheel sensor (ST-N) system
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.

TROUBLESHOOTING
35B-11
DIAGNOSTIC TROUBLE CODE PROCEDURES <L.H. drive vehicle>
Code No.11: Front Right Wheel Speed Sensor (Open Circuit or Short Circuit) Code No.12: Front Left Wheel Speed Sensor (Open Circuit or Short Circuit) Code No.13: Rear Right Wheel Speed Sensor (Open Circuit or Short Circuit) Code No.14: Rear Left Wheel Speed Sensor (Open Circuit or Short Circuit) Code No.21: Front Right Wheel Speed Sensor System Code No.22: Front Left Wheel Speed Sensor System Code No.23: Rear Right Wheel Speed Sensor System Code No.24: Rear Left Wheel Speed Sensor System
Wheel Speed Sensor Circuit ABS-ECU
(FRONT: LH)
(FRONT: RH)
(REAR: LH)
(REAR: RH)
WHEEL SPEED SENSOR 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
OPERATION
A toothed wheel speed rotor generates a voltage pulse as it moves across the pickup field of each wheel speed sensor.
The amount of voltage generated at each wheel is determined by the clearance between the wheel speed rotor teeth and the wheel speed sensor, and by the speed of rotation.
35B-12

TROUBLESHOOTING
The wheel speed 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
STEP 1. M.U.T.-II/III data list.
DIAGNOSIS CODE SET CONDITIONS

Diagnosis codes 11, 12, 13, 14 are set when signal is not input due to breakage of the wires of one or more of the four wheel speed sensors. Diagnosis codes 21, 22, 23, 24 are set in the following cases: Open circuit is not found but no input is received by one or more of the four wheel speed sensors at 10 km/h or more. Sensor output drops due to a malfunctioning wheel speed sensor or warped wheel speed rotor.
CAUTION To prevent damage to M.U.T.-II/III, always turn the ignition switch to the "LOOK" (OFF) position before connecting or disconnecting M.U.T.-II/III.
<Using the M.U.T.-II>
16-PIN
M.U.T.-II
AC207179AB
PROBABLE CAUSES
The most likely causes for these diagnosis codes to set are: Diagnosis codes 11, 12, 13, 14 Malfunction of the wheel speed sensor Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU) Diagnosis codes 21, 22, 23, 24 Malfunction of the wheel speed sensor Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU) Malfunction of the wheel speed rotor Malfunction of the wheel bearing Excessive clearance between the wheel speed sensor and wheel speed rotor
<Using the M.U.T.-III>
16-PIN
MB991911 MB991824
MB991827
AC210056AC
(1) Connect M.U.T.-II/III as shown in the illustration. (2) Start the engine. (3) Set M.U.T.-II/III to the data reading mode, and

TROUBLESHOOTING
35B-13
check the data list items by driving the vehicle. Item 11 (diagnosis code 11 or 21 is set): Front right wheel speed sensor Item 12 (diagnosis code 12 or 22 is set): Front left wheel speed sensor Item 13 (diagnosis code 13 or 23 is set): Rear right wheel speed sensor Item 14 (diagnosis code 14 or 24 is set): Rear left wheel speed sensor OK: The reading on the speedometer nearly matches the indication on M.U.T.-II/III, when driving. (4) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the wheel speed sensor input normal? YES : This malfunction is intermittent. Refer to
STEP 4. Check wheel speed sensor circuit. Resistance measurement at the ABS-ECU connector B-118.
Connector: B-118
B-118 (B)
Connector B-118 (harness side)

12 34 11 10
9 8 7 6 5 4 3 2 1
GROUP 00, How to Use Troubleshooting/Inspection Service Points How to Cope With Intermittent Malfunction P.00-5. NO : Go to Step 2. STEP 2. Check the wheel speed sensor installation.
Q: Is the wheel speed sensor bolted securely in place at the front knuckle or the rear knuckle? YES : Go to Step 3. NO : Install it properly (Refer to P.35B-146). Then
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC212153AB
go to Step 15
STEP 3. Inspect the wheel speed sensor and/or wheel speed rotor. Refer to P.35B-147. Check items: Wheel speed sensor internal resistance: 1.24 1.64 k Insulation between the wheel speed sensor body and the connector terminals Toothed wheel speed rotor check
Q: Is the wheel speed sensor or wheel speed rotor damaged? YES : Replace it (Refer to P.35B-146). Then go to
(1) Disconnect the connector B-118 and measure at the harness side. (2) Measure the resistance between the ABS-ECU connector terminals. If diagnosis code 11 or 21 is set: between terminals 29 and 30 If diagnosis code 12 or 22 is set: between terminals 22 and 31 If diagnosis code 13 or 23 is set: between terminals 8 and 9 If diagnosis code 14 or 24 is set: between terminals 6 and 7 Standard Value: 1.24 1.64 k
Q: Is the resistance within the standard value? YES : Go to Step 13. NO <The resistance between terminals 22 and 31 is not within the standard value.> : Go to Step 5. NO <The resistance between terminals 29 and 30 is not within the standard value.> : Go to Step 7. NO <The resistance between terminals 6 and 7 is not within the standard value.> : Go to Step 9. NO <The resistance between terminals 8 and 9 is not within the standard value.> : Go to Step 11.
Step 15. NO : Go to Step 4.
35B-14

TROUBLESHOOTING
STEP 5. Check the following connectors.

Connector: B-118
STEP 6. Check the following harness wires.
Connector: B-118
B-118 (B)
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1
Harness side
12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
ABS-ECU connector B-118
Connector: A-03
Connector: A-29
A-03 (B)
A-29 (B)
1 2 3 4 5 6 7 8
Harness side
2 1
AC211899AC
AC211262 AX
Intermediate connector A-29
Connector: A-03
The wire between ABS-ECU connector B-118 (terminal 22) and front wheel speed sensor (LH) connector A-03 (terminal 2) The wire between ABS-ECU connector B-118 (terminal 31) and front wheel speed sensor (LH) connector A-03 (terminal 1)
Q: Is any harness wire damaged? YES : Repair or replace it and then go to Step 15. NO : Go to Step 15.
A-03 (B)
Harness side
2 1
AC211899AC
Front wheel speed sensor (LH) connector A-03 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
Q: Are the connectors and terminals in good condition? YES : Go to Step 6. NO : Repair it and then go to Step 15.

TROUBLESHOOTING
35B-15

Connector: B-118
Connector: B-118
B-118 (B)
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1
Harness side
12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector: A-27
Connector: C-111
A-27 (B)
Harness side
5 4 3 2 1 13121110 9 8 7 6
Harness side
2 1
AC211900AC
AC211266 BN
Connector: C-122
The wire between ABS-ECU connector B-118 (terminal 29) and front wheel speed sensor (RH) connector A-27 (terminal 1) The wire between ABS-ECU connector B-118 (terminal 30) and front wheel speed sensor (RH) connector A-27 (terminal 2)
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AC211265 DD
Intermediate connectors C-111, C-122
Connector: A-27
A-27 (B)
Harness side
2 1
AC211900AC
Front wheel speed sensor (RH) connector A-27 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-16

TROUBLESHOOTING

Connector: B-118
Connector: B-118
B-118 (B)
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1
Harness side
12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector: D-13
Connector: C-113
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1 2524 23 22 21 20 19 18 17 16 1514
D-13 (B) Harness side

1 2
AC211902AE
AC211266 BO
Connector: C-122
The wire between ABS-ECU connector B-118 (terminal 6) and rear wheel speed sensor (LH) connector D-13 (terminal 1) The wire between ABS-ECU connector B-118 (terminal 7) and rear wheel speed sensor (LH) connector D-13 (terminal 2)
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AC211265 DD
Connectors: D-13, D-34
D-34 D-13 (B) Connector D-13 (Harness side)

1 2
Connector D-34
1 2 3 4 5 6 7 8
AC211902AD
Intermediate connectors C-113, C-122, D-34 Rear wheel speed sensor (LH) connector D-13 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.

TROUBLESHOOTING
35B-17
STEP 12. Check the following harness wires:

Connector: B-118
Connector: B-118
B-118 (B)
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1
Harness side
12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector: D-06 D-06 (B)
Connector: C-113
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1 2524 23 22 21 20 19 18 17 16 1514
Harness side
1 2
AC211902AG
AC211266 BO
Connector: C-122
The wire between ABS-ECU connector B-118 (terminal 8) and rear wheel speed sensor (RH) connector D-06 (terminal 1) The wire between ABS-ECU connector B-118 (terminal 9) and rear wheel speed sensor (RH) connector D-06 (terminal 2)
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AC211265 DD
Connectors: D-06, D-34 D-06 (B)
STEP 13. Measure the wheel speed sensor output voltage. Refer to P.35B-138. Output Voltage: When measured with a voltmeter: 42 mV or more When measured with an oscilloscope (maximum voltage): 120 mV or more
D-34
Connector D-06 (Harness side)

1 2
Connector D-34
1 2 3 4 5 6 7 8
Q: Does the voltage meet the specification? YES : Replace the brake modulator hydraulic unit
AC211902AF
Intermediate connectors C-113, C-122, D-34 Rear wheel speed sensor (RH) connector D-06 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 15. NO : Go to Step 14.
35B-18

TROUBLESHOOTING
STEP 14. Check the wheel bearing. Refer to GROUP 26, On-vehicle Service Wheel Bearing Axial Play Check <Front>P.26-6 or GROUP 27, On-vehicle Service Wheel Bearing Axial Play Check <Rear>P.27-30. If play on the wheel bearing is not within the limit, replace the wheel bearing. Limit: 0.05 mm
Q: Is play on the wheel bearing within the standard value? YES : Go to Step 15. NO : Replace it and then go to Step 15.
STEP 15. Check whether the diagnosis code is reset.

16-PIN
M.U.T.-II
AC207179AB
16-PIN
MB991911 MB991824
MB991827
AC210056AC
Check again if the diagnosis code is set. (1) Turn the ignition switch to the "ON" position. (2) Erase the diagnosis code. (3) Turn the ignition switch to the "LOCK" (OFF) position. (4) Turn the ignition switch to the "ON" position. (5) Check if the diagnosis code is set. (6) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Do the diagnosis codes 11, 12, 13, 14, 21, 22, 23 or 24 reset? YES : Go to Step 1. NO : The procedure is complete.

TROUBLESHOOTING
35B-19
Code No.16: ABS-ECU Power Supply System (abnormal voltage drop or rise)
Power Supply Circuit IGNITION SWITCH (IG2)
ABS-ECU POWER SUPPLY
SB : Sky blue
OPERATION
The ABS-ECU power is supplied to the ABS-ECU (terminal 10) from the ignition switch (IG2) through the multi-purpose fuse number 12 in the junction block.
DIAGNOSIS STEP 1. Check the battery. Refer to GROUP 54A, Battery On-vehicle Service Battery Test P.54A-5.
Q: Is the battery damaged? YES : Charge or replace the battery and then go

Output is provided when ABS-ECU power supply voltage drops below or rises above the normal value. Output is not provided if power supply voltage returns to normal voltage.
to Step 5.
NO : Go to Step 2.
PROBABLE CAUSES
The most likely causes for this diagnosis code to set are: Malfunction of battery Damaged wiring harness and connector Malfunction of brake modulator hydraulic unit and ABS-ECU
STEP 2. Check the charging system. Refer to GROUP 16, Charging System On-vehicles Service P.16-5.
Q: Is the charging system damaged? YES : Repair the Charging System and then go to
Step 5.
NO : Go to Step 3.
35B-20

TROUBLESHOOTING Q: Are the connectors and terminals in good condition? YES : Go to Step 4. NO : Repair it and then go to Step 5.

Connector: B-118
B-118 (B)
STEP 4. Check the following harness wire.

Connector: B-118
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
B-118 (B)
AC211901AD
33 32 31 30 29 28 27 26 25 24 23
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
Connector: C-124
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector: C-211
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
AC211265 AR
Intermediate connector C-124
Harness side Junction block (Front view)

2 1 6 5 4 3
Connectors: C-210, C-211 C-211
AC211269 AL
The wire between ABS-ECU connector B-118 (terminal 10) and junction block connector C-211 (terminal 2)
Q: Is the harness wire damaged? YES : Repair or replace it and then go to Step 5. NO : Go to Step 5.
C-210
Junction block (Front view) Connector C-210 (Harness side)

6 5 4 3 2 1 14 13 12 11 10 9 8 7
Connector C-211 (Harness side)

2 1 6 5 4 3
AC212152 AC
Junction block connectors C-210, C-211 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.

TROUBLESHOOTING
35B-21

16-PIN
(2) Erase the diagnosis code. (3) Turn the ignition switch to the "LOCK" (OFF) position. (4) Turn the ignition switch to the "ON" position. (5) Check if the diagnosis code is set. (6) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Does diagnosis code No.16 reset? YES : Start over at Step 1. NO : The procedure is complete.
M.U.T.-II
AC207179AB
16-PIN
MB991911 MB991824
MB991827
AC210056AC
Check again if the diagnosis code is set. (1) Turn the ignition switch to the "ON" position.
35B-22

TROUBLESHOOTING
Code No.32: Longitudinal G-Sensor System
Longitudinal G-Sensor Circuit IGNITION SWITCH (IG2)
G-SENSOR (LONGITUDINAL)
ABS-ECU
SB : Sky blue
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.
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 and connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)

This code is set in the following case. When the G-sensor output is 0.5 V or lower or 4.5 V or higher (disconnected G-sensor or G-sensor short circuit)

TROUBLESHOOTING
35B-23
DIAGNOSIS STEP 1.M.U.T.-II/III data list.
(2) Start the engine. (3) Set M.U.T.-II/III to data reading mode for following item. Item 32: Longitudinal G-sensor OK: When vehicle is stationary (level): 2.4 2.6 V When vehicle is being driven: 1.0 4.0 V
Q: Is the longitudinal G-sensor input normal? YES : This malfunction is intermittent. Refer to
16-PIN
GROUP 00, How to Use Troubleshooting/Inspection Service Points How to Cope With Intermittent Malfunction P.00-5. NO : Go to Step 2.
M.U.T.-II
AC207179AB
STEP 2. Check the power supply circuit. Voltage measurement at longitudinal G-sensor connector D-38.
Connector: D-38
16-PIN
D-38 (B)
MB991911 MB991824 Connector D-38 (Harness side)

3 2 1
MB991827
AC210056AC
(1) Connect M.U.T.-II/III as shown in the illustration.

AC212253AB
(1) Disconnect connector D-38, and check at the harness side. (2) Turn the ignition switch to the "ON" position. (3) Measure the voltage between terminal 1 and earth. OK: System voltage
35B-24

TROUBLESHOOTING
STEP 3. Check the earth circuit. Resistance measurement at longitudinal G-sensor connector D-38.
Connector: D-38
Connector: D-38
D-38 (B) Harness side D-38 (B)

3 2 1
AC208854AE
Longitudinal G-sensor connector D-38

AD
3 2 1
C-214
AC212253AC
(1) Disconnect connector D-38, and check at the harness side. (2) Measure the resistance between terminal 3 and earth. OK: 2 ohms or less
Q: Is the resistance 2 ohms or less. YES : Go to Step 8. NO : Go to Step 6.
Junction block (Front view)

2 1 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
AC212152AD

TROUBLESHOOTING
35B-25

Connector: D-38
Connector: D-38

3 2 1
AC208854AE

3 2 1
AC208854AE
Connector: C-211
Connector: C-124

2 1 6 5 4 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
AC211269 AL
The wire between longitudinal G-sensor connector D-38 (terminal 1) and junction block connector C-211 (terminal 2)
AC211265 AR
Connector: B-118
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
ABS-ECU connector B-118 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-26

TROUBLESHOOTING

Connector: D-38
STEP 8. Check longitudinal G-sensor output voltage.
Label

3 2 1
AC208854AE
MB991348
Connector: B-118
Connector: D-38 (Harness side)
B-118 (B)
Label
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
AC103662AG
The wire between longitudinal G-sensor connector D-38 (terminal 3) and ABS-ECU connector B-118 (terminal 15)
(1) Disconnect connector D-38, and then connect special tool harness set (MB991348) between terminals of the disconnected connectors. (2) Turn the ignition switch to the "ON" position. (3) Measure the voltage between terminal 2 and earth. OK: When the longitudinal G-sensor is placed on a level plane: 2.4 2.6 volts When the longitudinal G-sensor is placed with its label positioned as shown: 3.4 3.6 volts
Q: Is the longitudinal G-sensor output voltage normal? YES : Go to Step 9. NO : Replace the longitudinal G-sensor (Refer to
P.35B-148). Then go to Step 11.

TROUBLESHOOTING
35B-27

Connector: D-38
Connector: D-38

3 2 1
AC208854AE

3 2 1
AC208854AE
Connector: B-118
Connector: C-122
B-118 (B)
Harness side
12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
AC211265 DD
Connector: B-118
Q: Is the harness wire damaged? YES : Repair or replace it and then go to Step 11. NO : Replace the brake modulator hydraulic unit
B-118 (B)
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 11.
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
35B-28

TROUBLESHOOTING

16-PIN
M.U.T.-II
AC207179AB
16-PIN
MB991911 MB991824
MB991827
AC210056AC

TROUBLESHOOTING
35B-29
Code No.41: Front Right Solenoid Valve inside Hydraulic Unit Code No.42: Front Left Solenoid Valve inside Hydraulic Unit Code No.43: Rear Right Solenoid Valve inside Hydraulic Unit Code No.44: Rear Left Solenoid Valve inside Hydraulic Unit 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
SOLENOID VALVE POWER SUPPLY
MOTOR POWER SUPPLY
ABS-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
OPERATION
Power is continuously supplied to the ABS-ECU through fusible link number 3 to operate the solenoid valve and motor.
PROBABLE CAUSES
The most likely causes for these diagnosis codes to set are: Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)

These codes are displayed if the power supply circuit of solenoid valve or motor is open or shorted.
35B-30
DIAGNOSIS

TROUBLESHOOTING
STEP 1. Check the solenoid valve or motor power supply circuit. Voltage measurement at ABS-ECU connector B-118.
Connector: B-118
Connector: B-118
B-118 (B)
Harness side B-118 (B)

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD

Connector B-118 (Harness side)
12 34 11 10
9 8 7 6 5 4 3 2 1
1 2
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211262AY
AC212153AD
(1) Disconnect ABS-ECU connector B-118 and measure at the harness side. (2) Measure the voltage between terminal 11 and earth, and 33 and earth. OK: System voltage
Q: Is the check result normal? YES : Replace the brake modulator hydraulic unit
Intermediate connector A-12 Check the connectors, for loose, corroded or damaged terminals, or terminals pushed back in the connector.

TROUBLESHOOTING
35B-31
Fusible link: No.3

No.3
16-PIN
M.U.T.-II
AC208825 AL
AC207179AB
Connector: B-118 <Using the M.U.T.-III>
B-118 (B) 16-PIN Harness side

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
The wire between fusible link No.3 and ABS-ECU connector B-118 (terminal 11) The wire between fusible link No.3 and ABS-ECU connector B-118 (terminal 33)
MB991911 MB991824
MB991827
AC210056AC
Q: Do diagnosis codes 41, 42, 43, 44, 52, 53 or 55 reset? YES : Return to Step 1. NO : The procedure is complete.
35B-32

TROUBLESHOOTING
Code No.71: Lateral G-Sensor System

Lateral G-Sensor Circuit IGNITION SWITCH (IG2)
G-SENSOR (LATERAL)
ABS-ECU
SB : Sky blue
OPERATION
The lateral G-sensor detects the acceleration level in the left/right direction of the vehicle, converts the signals into voltage signals and then sends that signal to the ABS-ECU.
If the lateral G-sensor output power does not change (lateral G-sensor output fastening).
PROBABLE CAUSES
The most likely causes for diagnosis code to set are: Malfunction of the lateral G-sensor Damaged wiring harness and connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)

This code is set in the following cases: When the G-sensor output is 0.5 V or lower or 4.5 V or higher (disconnected lateral G-sensor or lateral G-sensor short circuit)

TROUBLESHOOTING
35B-33
DIAGNOSIS
STEP 1.M.U.T.-II/III data list.
(2) Start the engine. (3) Set M.U.T.-II/III to data reading mode for following item. Item 71: Lateral G-sensor OK: When vehicle is stationary (level): 2.4 2.6 V When vehicle is being driven: 1.0 4.0 V
Q: Is the lateral G-sensor input normal? YES : This malfunction is intermittent. Refer to
16-PIN
M.U.T.-II
AC207179AB
STEP 2. Check the power supply circuit. Voltage measurement at lateral G-sensor connector D-37.
Connector: D-37
16-PIN D-37 (B)

3 2 1
MB991827
AC210056AC AC212253AD
35B-34

TROUBLESHOOTING
STEP 3. Check the earth circuit. Resistance measurement at lateral G-sensor connector D-37.
Connector: D-37
Connector: D-37
D-37 (B)

3 2 1
AC208854AF
Lateral G-sensor connector D-37
Connectors: C-211, C-214

AD
C-211
3 2 1
C-214
AC212253AE
Q: Is the resistance 2 ohms or less? YES : Go to Step 8. NO : Go to Step 6.

2 1 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
AC212152AD

TROUBLESHOOTING
35B-35

Connector: D-37

Connector: D-37

3 2 1
AC208854AF

3 2 1
AC208854AF
Connector: C-211
Connector: C-122

2 1 6 5 4 3
AC211269 AL
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
The wire between lateral G-sensor connector D-37 (terminal 1) and junction block connector C-211 (terminal 2)
AC211265 DD
Connector: B-118
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
35B-36
Connector: D-37

TROUBLESHOOTING
STEP 8. Check lateral G-sensor output voltage.
Label

3 2 1
AC208854AF
MB991348
Connector: B-118
Label
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
AC103662AP
The wire between lateral G-sensor connector D-37 (terminal 3) and ABS-ECU connector B-118 (terminal 24)
(1) Disconnect connector D-37, and then connect special tool harness set (MB991348) between terminals of the disconnected connectors. (2) Turn the ignition switch to the "ON" position. (3) Measure the voltage between terminal 2 and earth. OK: When the lateral G-sensor is placed on a level plane: 2.4 2.6 volts When the lateral G-sensor is placed with its label positioned as shown: 3.4 3.6 volts
Q: Is the lateral G-sensor output voltage normal? YES : Go to Step 9. NO : Replace the lateral G-sensor (Refer to

TROUBLESHOOTING
35B-37

Connector: D-37
Connector: D-37

3 2 1
AC208854AF

3 2 1
AC208854AF
Connector: B-118
Connector: C-122
B-118 (B)
Harness side
12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
AC211265 DD
Connector: B-118
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
35B-38

TROUBLESHOOTING

16-PIN
M.U.T.-II
AC207179AB
16-PIN
MB991911 MB991824
MB991827
AC210056AC

TROUBLESHOOTING
35B-39
Code No.81: Steering Wheel Sensor (ST-1) System Code No.82: Steering Wheel Sensor (ST-2) System Code No.83: Steering Wheel Sensor (ST-N) System
Steering Wheel Sensor Circuit IGNITION SWITCH (IG2) ABS-ECU
STEERING WHEEL SENSOR
ST-1
ST-2
ST-N
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
OPERATION
The steering wheel sensor monitors the steering angle and sends the ST-1, ST-2 and ST-N signals. The ABS-ECU calculates the steering angle by reading the signals from the steering wheel sensor.

Diagnosis code No.81 (ST-1), No.82 (ST-2) and No.83 (ST-N) are set if there is a fault in the steering wheel sensor, an open circuit or short circuit in the signal lines, or the internal circuit in the hydraulic unit and ABS-ECU is defective.
35B-40
PROBABLE CAUSES

TROUBLESHOOTING
The most likely causes for these diagnosis codes to set are: Malfunction of the steering wheel sensor Damaged wiring harness and connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)
(2) Start the engine. (3) Set M.U.T.-II/III to data reading mode for following items. Item 74: Steering wheel (STN) Item 75: Steering wheel (ST1) Item 76: Steering wheel (ST2) OK: Item Check item No. 74 Checking requirement Display
DIAGNOSIS
Steering Steering: Neutral ON wheel sensor position and (ST-N) position near by 360 Steering: Except OFF for above
75
Steering Steering: Turn wheel sensor laterally slowly. (ST-1) Steering wheel sensor (ST-2)
16-PIN
76
Display ON and OFF alternately
M.U.T.-II
AC207179AB
Q: Is the steering wheel sensor input normal? YES : This malfunction is intermittent. Refer to
16-PIN
MB991911 MB991824
MB991827
AC210056AC

TROUBLESHOOTING
35B-41
STEP 2. Check the power supply circuit. Voltage measurement at steering wheel sensor connector C-230.
Connector: C-230
STEP 3. Check the earth circuit. Resistance measurement at steering wheel sensor connector C-230.
Connector: C-230

1 5 4 3 2

1 5 4 3 2
AC212249AB
AC212249AC
(1) Disconnect connector C-230, and check at the harness side. (2) Turn the ignition switch to the "ON" position. (3) Measure the voltage between terminal 2 and earth. OK: System voltage
(1) Disconnect connector C-230, and check at the harness side. (2) Measure the resistance between terminal 3 and earth. OK: 2 ohms or less
35B-42


Connector: C-230

Connector: C-230 Harness side
1 5 4 3 2
AC211267AL
Steering wheel sensor connector C-230
Harness side
1 5 4 3 2
AC211267AL
Connector: C-211
C-210
Junction block (Front view) Connector C-210 (Harness side)

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

2 1 6 5 4 3
AC211269 AL
The wire between steering wheel sensor connector C-230 (terminal 2) and junction block connector C-211 (terminal 2)
AC212152 AC

2 1 6 5 4 3
Junction block connectors C-210, C-211
Connector: C-101 C-101 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AC211265DE
Joint connector C-101 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.

TROUBLESHOOTING
35B-43

Connector: C-230
Connector: C-230
Harness side
1 5 4 3 2
AC211267AL
Harness side
1 5 4 3 2
AC211267AL
Earth
Connector: C-06 C-06 (GR)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
No.3
AC211266BP
AC211896 AB
35B-44
Earth

TROUBLESHOOTING
STEP 8. Check steering wheel sensor output voltage.

Connector: C-230
Connector C-230 (Harness side) NO.14

1 5 4 3 2
The wire between steering wheel sensor connector C-230 (terminal 3) and earth (No.3, No.14)
AC212249AD
AC211898AB
(1) Connect steering wheel sensor connector C-230. (2) Turn the ignition switch to the "ON" position.
Variations in voltage when turning the steering wheel Voltage 2.7 - 4.4 V
0.8 - 2.1 V Time

AC211894 AB
(3) Measure the voltage, by backprobing, between terminal 1 and earth, terminal 4 and earth, and terminal 5 and earth. OK: The voltage should measure as indicated in the figure.
Q: Is the steering wheel sensor output voltage normal? YES : Go to Step 9. NO : Replace the steering wheel sensor (Refer to

TROUBLESHOOTING
35B-45

Connector: C-230
Connector: C-230
Harness side
1 5 4 3 2
AC211267AL
Harness side
1 5 4 3 2
AC211267AL
Connector: B-118
Connector: C-122
B-118 (B)
Harness side
12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
AC211265 DD
Connector: B-118
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
If diagnosis code No.81 (ST-1) is set: The wire between steering wheel sensor connector C-230 (terminal 5) and ABS-ECU connector B-118 (terminal 26) If diagnosis code No.82 (ST-2) is set: The wire between steering wheel sensor connector C-230 (terminal 4) and ABS-ECU connector B-118 (terminal 17) If diagnosis code No.83 (ST-N) is set: The wire between steering wheel sensor connector C-230 (terminal 1) and ABS-ECU connector B-118 (terminal 4)
Q: Is any harness wire damaged? YES : Repair or replace it and then go to Step 11. NO : Replace the brake modulator hydraulic unit
35B-46

TROUBLESHOOTING

16-PIN
Q: Does diagnosis code No.81, 82 and/or 83 reset? YES : Return to Step 1. NO : The procedure is complete.
M.U.T.-II
AC207179AB
16-PIN
MB991911 MB991824
MB991827
AC210056AC

TROUBLESHOOTING
35B-47
DIAGNOSTIC TROUBLE CODE PROCEDURES <R.H. drive vehicle>
Code No.11: Front Right Wheel Speed Sensor (Open Circuit or Short Circuit) Code No.12: Front Left Wheel Speed Sensor (Open Circuit or Short Circuit) Code No.13: Rear Right Wheel Speed Sensor (Open Circuit or Short Circuit) Code No.14: Rear Left Wheel Speed Sensor (Open Circuit or Short Circuit) Code No.21: Front Right Wheel Speed Sensor System Code No.22: Front Left Wheel Speed Sensor System Code No.23: Rear Right Wheel Speed Sensor System Code No.24: Rear Left Wheel Speed Sensor System
Wheel Speed Sensor Circuit ABS-ECU
(FRONT: LH)
(FRONT: RH)
(REAR: LH)
(REAR: RH)
WHEEL SPEED SENSOR
OPERATION
A toothed wheel speed rotor generates a voltage pulse as it moves across the pickup field of each wheel speed sensor.
The amount of voltage generated at each wheel is determined by the clearance between the wheel speed rotor teeth and the wheel speed sensor, and by the speed of rotation. The wheel speed sensors transmit the frequency of the voltage pulses and the amount of voltage generated by each pulse to the ABS-ECU.
35B-48

TROUBLESHOOTING
The hydraulic unit modulates the amount of braking force individually applied to each wheel cylinder.
DIAGNOSIS
STEP 1. M.U.T.-II/III data list

Diagnosis codes 11, 12, 13, 14 are set when signal is not input due to breakage of the wires of one or more of the four wheel speed sensors. Diagnosis codes 21, 22, 23, 24 are set in the following cases: Open circuit is not found but no input is received by one or more of the four wheel speed sensors at 10 km/h (6 mph) or more. Sensor output drops due to a malfunctioning wheel speed sensor or warped wheel speed rotor.
<Using the M.U.T.-II> Steering shaft
MB991502
AC311157AB
PROBABLE CAUSES
The most likely causes for these diagnosis codes to set are: Diagnosis codes 11, 12, 13, 14 Malfunction of the wheel speed sensor Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU) Diagnosis codes 21, 22, 23, 24 Malfunction of the wheel speed sensor Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU) Malfunction of the wheel speed rotor Malfunction of the wheel bearing Excessive clearance between the wheel speed sensor and wheel speed rotor
16-PIN
MB991911 MB991824
MB991827
AC311153AB
(1) Connect M.U.T.-II/III as shown in the illustration. (2) Start the engine. (3) Set M.U.T.-II/III to the data reading mode, and

TROUBLESHOOTING
35B-49
check the data list items by driving the vehicle. Item 11 (diagnosis code 11 or 21 is set): Front right wheel speed sensor Item 12 (diagnosis code 12 or 22 is set): Front left wheel speed sensor Item 13 (diagnosis code 13 or 23 is set): Rear right wheel speed sensor Item 14 (diagnosis code 14 or 24 is set): Rear left wheel speed sensor OK: The reading on the speedometer nearly matches the indication on M.U.T.-II/III, when driving. (4) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the wheel speed sensor input normal? YES : This malfunction is intermittent. Refer to
STEP 4. Check wheel speed sensor circuit. Resistance measurement at the ABS-ECU connector B-118.
Connector: B-118
B-118 (B)
GROUP 00, How to Use Troubleshooting/Inspection Service Points How to Cope With Intermittent Malfunction P.00-5. NO : Go to Step 2. STEP 2. Check the wheel speed sensor installation.
Q: Is the wheel speed sensor bolted securely in place at the front knuckle or the rear knuckle? YES : Go to Step 3. NO : Install it properly (Refer to P.35B-146). Then

12 34 11 10
9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311124 AB
go to Step 15
STEP 3. Inspect the wheel speed sensor and/or wheel speed rotor. Refer to P.35B-147. Check items: Wheel speed sensor internal resistance: 1.24 1.64 k Insulation between the wheel speed sensor body and the connector terminals Toothed wheel speed rotor check
Q: Is the wheel speed sensor or wheel speed rotor damaged? YES : Replace it (Refer to P.35B-146). Then go to
(1) Disconnect the connector B-118 and measure at the harness side. (2) Measure the resistance between the ABS-ECU connector terminals. If diagnosis code 11 or 21 is set: between terminals 29 and 30 If diagnosis code 12 or 22 is set: between terminals 22 and 31 If diagnosis code 13 or 23 is set: between terminals 8 and 9 If diagnosis code 14 or 24 is set: between terminals 6 and 7 Standard Value: 1.24 1.64 k
Q: Is the resistance within the standard value? YES : Go to Step 13. NO <The resistance between terminals 22 and 31 is not within the standard value.> : Go to Step 5. NO <The resistance between terminals 29 and 30 is not within the standard value.> : Go to Step 7. NO <The resistance between terminals 6 and 7 is not within the standard value.> : Go to Step 9. NO <The resistance between terminals 8 and 9 is not within the standard value.> : Go to Step 11.
Step 15 . NO : Go to Step 4.
35B-50

TROUBLESHOOTING

Connector: B-118
Connector: B-118
B-118 (B) Harness side

12 34 11 10
9 8 7 6 5 4 3 2 1

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Connector: A-03
Connector: C-31
A-03 (B)
C-31
AC311160AB
Harness side
2 1
AC211899AC
Connector: A-03
The wire between ABS-ECU connector B-118 (terminal 22) and front wheel speed sensor (LH) connector A-03 (terminal 2) The wire between ABS-ECU connector B-118 (terminal 31) and front wheel speed sensor (LH) connector A-03 (terminal 1)
A-03 (B)
Harness side
2 1
AC211899AC
Front wheel speed sensor (LH) connector A-03 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.

TROUBLESHOOTING
35B-51

Connector: B-118
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Connector: A-03
Connector: C-111
A-03 (B) C-111 Harness side

2 1
AC211899AC
AC311161AB
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
The wire between ABS-ECU connector B-118 (terminal 29) and front wheel speed sensor (RH) connector A-27 (terminal 1) The wire between ABS-ECU connector B-118 (terminal 30) and front wheel speed sensor (RH) connector A-27 (terminal 2)
C-122 (L)
AC311160AC
Intermediate connectors C-111, C-122
Connector: A-27
A-27 (B)
Harness side
2 1
AC211900AC
Front wheel speed sensor (RH) connector A-27 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-52

TROUBLESHOOTING

Connector: B-118
Connector: D-13
Harness side
1 2

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
D-13
AC311163AB AC311127AB
33 32 31 30 29 28 27 26 25 24 23
Connector: C-112
Rear wheel speed sensor (LH) connector D-13 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
C-112 (RG)
Connector: B-118
AC311161AC
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
C-122 (L) Connector: D-13

AC311160AC
AC311127AB
Harness side
1 2
Connector: D-34
D-13 D-34
AC311163AB
AC311162AB
Intermediate connectors C-112, C-122, D-34
The wire between ABS-ECU connector B-118 (terminal 6) and rear wheel speed sensor (LH) connector D-13 (terminal 1) The wire between ABS-ECU connector B-118 (terminal 7) and rear wheel speed sensor (LH) connector D-13 (terminal 2)

TROUBLESHOOTING
35B-53
Harness side
1 2
Connector: D-06
Connector: B-118
D-06 (B)

12 34 11 10
9 8 7 6 5 4 3 2 1
AC311163AC AC311127AB
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
Connector: C-112
Rear wheel speed sensor (RH) connector D-06 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
C-112 (RG)
STEP 12. Check the following harness wires:
Connector: B-118
AC311161AC
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
C-122 (L) Connector: D-06

AC311160AC
AC311127AB
Harness side
1 2
Connector: D-34 D-06 (B)
D-34
AC311163AC
AC311162AB
Intermediate connectors C-112, C-122, D-34
The wire between ABS-ECU connector B-118 (terminal 8) and rear wheel speed sensor (RH) connector D-06 (terminal 1) The wire between ABS-ECU connector B-118 (terminal 9) and rear wheel speed sensor (RH) connector D-06 (terminal 2)
35B-54

TROUBLESHOOTING
STEP 13. Measure the wheel speed sensor output voltage. Refer to P.35B-138. Output Voltage: When measured with a voltmeter: 42 mV or more When measured with an oscilloscope (maximum voltage): 120 mV or more
Q: Does the voltage meet the specification? YES : Replace the brake modulator hydraulic unit

MB991502
AC311157AB
STEP 14. Check the wheel bearing. Refer to GROUP 26, On-vehicle Service Wheel Bearing End Play Check <Front>P.26-6 or GROUP 27, On-vehicle Service Wheel Bearing End Play Check <Rear>P.27-30. If play on the wheel bearing is not within the limit, replace the wheel bearing. Limit: 0.05 mm (0.002 inch)
Q: Is play on the wheel bearing within the standard value? YES : Go to Step 15. NO : Replace it and then go to Step 15.
16-PIN
MB991911 MB991824
MB991827
AC311153AB
Q: Do the diagnosis codes 11, 12, 13, 14, 21, 22, 23 or 24 reset? YES : Go to Step 1. NO : The procedure is complete.

TROUBLESHOOTING
35B-55
Code No.16: ABS-ECU Power Supply System (abnormal voltage drop or rise)
Power Supply Circuit IGNITION SWITCH (IG2)
OPERATION
The ABS-ECU power is supplied to the ABS-ECU (terminal 10) from the ignition switch (IG2) through the multi-purpose fuse number 12 in the junction block.
DIAGNOSIS STEP 1. Check the battery. Refer to GROUP 54A, Battery On-vehicle Service Battery Test P.54A-5.
Q: Is the battery damaged? YES : Charge or replace the battery and then go

Output is provided when ABS-ECU power supply voltage drops below or rises above the normal value. Output is not provided if power supply voltage returns to normal voltage.
to Step 5.
NO : Go to Step 2.
PROBABLE CAUSES
The most likely causes for this diagnosis code to set are: Malfunction of battery Damaged wiring harness and connector Malfunction of brake modulator hydraulic unit and ABS-ECU
STEP 2. Check the charging system. Refer to GROUP 16, Charging System On-vehicles Service P.16-5.
Q: Is the charging system damaged? YES : Repair the Charging System and then go to
Step 5.
NO : Go to Step 3.
35B-56


Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
Connector: B-118
33 32 31 30 29 28 27 26 25 24 23
AC311127AB

12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Connector: C-211
C-122 (L)
AC311160AC

2 1 6 5 4 3
AC311165AB
C-211 C-210
The wire between ABS-ECU connector B-118 (terminal 10) and junction block connector C-211 (terminal 2)

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

2 1 6 5 4 3
AC311164AB

TROUBLESHOOTING
35B-57

MB991502
AC311157AB
16-PIN
MB991911 MB991824
MB991827
AC311153AB
35B-58

TROUBLESHOOTING
Code No.32: Longitudinal G-Sensor System
Longitudinal G-Sensor Circuit IGNITION SWITCH (IG2)
G-SENSOR (LONGITUDINAL)
ABS-ECU
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.
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 and connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)

This code is set in the following case. When the G-sensor output is 0.5 V or lower or 4.5 V or higher (disconnected G-sensor or G-sensor short circuit)

TROUBLESHOOTING
35B-59
DIAGNOSIS STEP 1. M.U.T.-II/III data list.
(3) Set M.U.T.-II/III to data reading mode for following item. Item No.32: Longitudinal G-sensor OK: When vehicle is stationary (level): 2.4 2.6 V When vehicle is being driven: 1.0 4.0 V
Q: Is the longitudinal G-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 P.00-5. NO : Go to Step 2. STEP 2. Check the power supply circuit. Voltage measurement at longitudinal G-sensor connector D-38.
Connector: D-38
MB991502
AC311157AB
16-PIN
D-38 (B)

3 2 1
MB991827
AC311153AB AC311166AB
(1) Connect M.U.T.-II/III as shown in the illustration. (2) Start the engine.
35B-60

TROUBLESHOOTING
STEP 3. Check the earth circuit. Resistance measurement at longitudinal G-sensor connector D-38.
Connector: D-38
Connector: D-38
D-38 (B) D-38 (B)
Harness side
3 2 1
AC311167AB

AD
C-211
3 2 1
C-214
AC311166AC
Connector C-211 (Harness side) Junction block (Front view) Connector C-214 (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 2 1 6 5 4 3
AC311164AC

TROUBLESHOOTING
35B-61

Connector: D-38

Connector: D-38
D-38 (B)
Harness side
3 2 1
AC311167AB
D-38 (B)
Harness side
3 2 1
AC311167AB
Connector: C-211
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

2 1 6 5 4 3
C-122 (L)
AC311165AB AC311160AC
The wire between longitudinal G-sensor connector D-38 (terminal 1) and junction block connector C-211 (terminal 2)
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
35B-62
Connector: D-38

TROUBLESHOOTING
STEP 8. Check longitudinal G-sensor output voltage.
Label
D-38 (B)
Harness side
3 2 1
AC311167AB
MB991348
Connector: B-118
Label

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
AC103662AG
(1) Disconnect connector D-38, and then connect special tool harness set (MB991348) between terminals of the disconnected connectors. (2) Turn the ignition switch to the "ON" position. (3) Measure the voltage between terminal 2 and earth. OK: When the longitudinal G-sensor is placed on a level plane: 2.4 2.6 volts When the longitudinal G-sensor is placed with its label positioned as shown: 3.4 3.6 volts
Q: Is the longitudinal G-sensor output voltage normal? YES : Go to Step 9. NO : Replace the longitudinal G-sensor (Refer to

TROUBLESHOOTING
35B-63

Connector: D-38
Connector: D-38
D-38 (B)
Harness side
3 2 1
AC311167AB
D-38 (B)
Harness side
3 2 1
AC311167AB
Connector: B-118
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
B-118 (B) Harness side C-122 (L)

AC311160AC
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
35B-64

TROUBLESHOOTING

MB991502
AC311157AB
16-PIN
MB991911 MB991824
MB991827
AC311153AB

TROUBLESHOOTING
35B-65
Code No.41: Front Right Solenoid Valve inside Hydraulic Unit Code No.42: Front Left Solenoid Valve inside Hydraulic Unit Code No.43: Rear Right Solenoid Valve inside Hydraulic Unit Code No.44: Rear Left Solenoid Valve inside Hydraulic Unit 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
SOLENOID VALVE POWER SUPPLY
MOTOR POWER SUPPLY
ABS-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
OPERATION
Power is continuously supplied to the ABS-ECU through fusible link number 3 to operate the solenoid valve and motor.
PROBABLE CAUSES
The most likely causes for these diagnosis codes to set are: Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)

These codes are displayed if the power supply circuit of solenoid valve or motor is open or shorted.
35B-66
DIAGNOSIS

TROUBLESHOOTING
Connector: B-118
STEP 1. Check the solenoid valve or motor power supply circuit. Voltage measurement at ABS-ECU connector B-118.
Connector: B-118 B-118 (B) Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
B-118 (B)

1 2
Connector B-118 (Harness side)

12 34 11 10
9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311169AB
AC311168AB
(1) Disconnect ABS-ECU connector B-118 and measure at the harness side. (2) Measure the voltage between terminal 11 and earth, and 33 and earth. OK: System voltage
Q: Is the check result normal? YES : Replace the brake modulator hydraulic unit
Intermediate connector A-12 Check the connectors, for loose, corroded or damaged terminals, or terminals pushed back in the connector.

TROUBLESHOOTING
35B-67
Fusible link: No.3

No.3
MB991502
AC208825 AL
AC311157AB

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
16-PIN
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
The wire between fusible link No.3 and ABS-ECU connector B-118 (terminal 11) The wire between fusible link No.3 and ABS-ECU connector B-118 (terminal 33)
MB991911 MB991824
MB991827
AC311153AB
Q: Do diagnosis codes 41, 42, 43, 44, 52, 53 or 55 reset? YES : Return to Step 1. NO : The procedure is complete.
35B-68

TROUBLESHOOTING
Code No.71: Lateral G-Sensor System

Lateral G-Sensor Circuit IGNITION SWITCH (IG2)
G-SENSOR (LATERAL)
Wire colour code B : Black LG : Light green G : Green L : Blue ABS-ECU W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
OPERATION
The lateral G-sensor detects the acceleration level in the left/right direction of the vehicle, converts the signals into voltage signals and then sends that signal to the ABS-ECU.
If the lateral G-sensor output power does not change (lateral G-sensor output fastening).
PROBABLE CAUSES
The most likely causes for diagnosis code to set are: Malfunction of the lateral G-sensor Damaged wiring harness and connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)

This code is set in the following cases: When the G-sensor output is 0.5 V or lower or 4.5 V or higher (disconnected lateral G-sensor or lateral G-sensor short circuit)

TROUBLESHOOTING
35B-69
DIAGNOSIS
STEP 1. M.U.T.-II/III data list
(2) Start the engine. (3) Set M.U.T.-II/III to data reading mode for following item. Item No.71: Lateral G-sensor OK: When vehicle is stationary (level): 2.4 2.6 V When vehicle is being driven: 1.0 4.0 V
Q: Is the lateral G-sensor input normal? YES : This malfunction is intermittent. Refer to
MB991502
AC311157AB
STEP 2. Check the power supply circuit. Voltage measurement at lateral G-sensor connector D-37.
Connector: D-37
16-PIN D-37 (B)

3 2 1
MB991827
AC311153AB AC311166AD
35B-70

TROUBLESHOOTING
STEP 3. Check the earth circuit. Resistance measurement at lateral G-sensor connector D-37.
Connector: D-37
Connector: D-37
D-37 (B) D-37 (B) Harness side

3 2 1
AC311167AC
Connectors: C-211, C-214 Connector D-37 (Harness side)

AD
C-211
3 2 1
C-214
AC311166AE
Connector C-211 (Harness side) Junction block (Front view) Connector C-214 (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 2 1 6 5 4 3
AC311164AC

TROUBLESHOOTING
35B-71

Connector: D-37

Connector: D-37

3 2 1
AC311167AC

3 2 1
AC311167AC
Connector: C-211
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

2 1 6 5 4 3
C-122 (L)
AC311165AB AC311160AC
The wire between lateral G-sensor connector D-37 (terminal 1) and junction block connector C-211 (terminal 2)
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
35B-72
Connector: D-37

TROUBLESHOOTING
STEP 8. Check lateral G-sensor output voltage.
Label
MB991348

3 2 1
AC311167AC
Connector: B-118
Label

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
AC103662AP
(1) Disconnect connector D-37, and then connect special tool harness set (MB991348) between terminals of the disconnected connectors. (2) Turn the ignition switch to the "ON" position. (3) Measure the voltage between terminal 2 and earth. OK: When the lateral G-sensor is placed on a level plane: 2.4 2.6 volts When the lateral G-sensor is placed with its label positioned as shown: 3.4 3.6 volts
Q: Is the lateral G-sensor output voltage normal? YES : Go to Step 9. NO : Replace the lateral G-sensor (Refer to

TROUBLESHOOTING
35B-73

Connector: D-37
Connector: D-37

3 2 1
AC311167AC

3 2 1
AC311167AC
Connector: B-118
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

AC311160AC
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
35B-74

TROUBLESHOOTING

MB991502
AC311157AB
16-PIN
MB991911 MB991824
MB991827
AC311153AB

TROUBLESHOOTING
35B-75
Code No.81: Steering Wheel Sensor (ST-1) System Code No.82: Steering Wheel Sensor (ST-2) System Code No.83: Steering Wheel Sensor (ST-N) System
ST-1
ST-2
ST-N
OPERATION
The steering wheel sensor monitors the steering angle and sends the ST-1, ST-2 and ST-N signals. The ABS-ECU calculates the steering angle by reading the signals from the steering wheel sensor.

Diagnosis code No.81 (ST-1), No.82 (ST-2) and No.83 (ST-N) are set if there is a fault in the steering wheel sensor, an open circuit or short circuit in the signal lines, or the internal circuit in the hydraulic unit and ABS-ECU is defective.
35B-76
PROBABLE CAUSES

TROUBLESHOOTING
The most likely causes for these diagnosis codes to set are: Malfunction of the steering wheel sensor Damaged wiring harness and connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)
(2) Start the engine. (3) Set M.U.T.-II/III to data reading mode for following items. Item No.74: Steering wheel (STN) Item No.75: Steering wheel (ST1) Item No.76: Steering wheel (ST2) OK: Item Check item No. 74 Checking requirement Display
DIAGNOSIS
Steering Steering: Neutral ON wheel sensor position and (ST-N) position near by 360 Steering: Except OFF for above
75
Steering Steering: Turn wheel sensor laterally slowly. (ST-1) Steering wheel sensor (ST-2)
76
Display ON and OFF alternately
MB991502
AC311157AB
Q: Is the steering wheel sensor input normal? YES : This malfunction is intermittent. Refer to
16-PIN
MB991911 MB991824
MB991827
AC311153AB

TROUBLESHOOTING
35B-77
STEP 2. Check the power supply circuit. Voltage measurement at steering wheel sensor connector C-230.
Connector: C-230
STEP 3. Check the earth circuit. Resistance measurement at steering wheel sensor connector C-230.
Connector: C-230

1 5 4 3 2

1 5 4 3 2
AC311195AB
AC311195AC
(1) Disconnect connector C-230, and check at the harness side. (2) Turn the ignition switch to the "ON" position. (3) Measure the voltage between terminal 2 and earth. OK: System voltage
(1) Disconnect connector C-230, and check at the harness side. (2) Measure the resistance between terminal 3 and earth. OK: 2 ohms or less
35B-78


Connector: C-230
Harness side
1 5 4 3 2

Connector: C-230
Harness side
AC311196AB
1 5 4 3 2

AC311196AB
C-211 Connector: C-211 C-210
Harness side Junction block (Front view) Junction block (Front view)
2 1 6 5 4 3
AC311165AB

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

2 1 6 5 4 3
The wire between steering wheel sensor connector C-230 (terminal 2) and junction block connector C-211 (terminal 2)
AC311164AB
Connector: C-101
C-101 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AC311161AE

TROUBLESHOOTING
35B-79

Connector: C-230
Connector: C-230
Harness side
1 5 4 3 2
Harness side
1 5 4 3 2
AC311196AB
AC311196AB
Earth
Connector: C-06 C-06 (GR)
Windshield wiper arm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AC311161AF
AC311200AB
The wire between steering wheel sensor connector C-230 (terminal 3) and earth
35B-80

TROUBLESHOOTING
STEP 8. Check steering wheel sensor output voltage.

Connector: C-230
Connector: C-230
Harness side
1 5 4 3 2
AC311196AB
Connector: C-138 Connector C-230 (Harness side)

1 5 4 3 2
C-138
AC311195AD AC311160AE
(1) Connect steering wheel sensor connector C-230. (2) Turn the ignition switch to the "ON" position.
Connector: B-118
0.8 - 2.1 V Time

AC211894 AB
12 34
11 10
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB

TROUBLESHOOTING
35B-81
Connector: C-230

Harness side
1 5 4 3 2
MB991502
AC311196AB AC311157AB

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
16-PIN
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
If diagnosis code No.81 (ST-1) is set: The wire between steering wheel sensor connector C-230 (terminal 5) and ABS-ECU connector B-118 (terminal 26) If diagnosis code No.82 (ST-2) is set: The wire between steering wheel sensor connector C-230 (terminal 4) and ABS-ECU connector B-118 (terminal 17) If diagnosis code No.83 (ST-N) is set: The wire between steering wheel sensor connector C-230 (terminal 1) and ABS-ECU connector B-118 (terminal 4)
MB991911 MB991824
MB991827
AC311153AB
Q: Does diagnosis code No.81, 82 and/or 83 reset? YES : Return to Step 1. NO : The procedure is complete.
35B-82

TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS

M1352011400750
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 Inspection procedure No. Communication between the M.U.T.-II/III and all the system is not possible. Communication between the M.U.T.-II/III and the ABS-ECU is not possible. When the ignition key is turned to the "ON" position (Engine stopped), the ABS warning lamp does not illuminate. 1
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 <LH drive vehicle> P.35B-83, <RH drive vehicle> P.35B-109 <LH drive vehicle> P.35B-87, <RH drive vehicle> P.35B-113 <LH drive vehicle> P.35B-92, <RH drive vehicle> P.35B-118 <LH drive vehicle> P.35B-97, <RH drive vehicle> P.35B-123 <LH drive vehicle> P.35B-99, <RH drive vehicle> P.35B-125 <LH drive vehicle> P.35B-103, <RH drive vehicle> P.35B-129 <LH drive vehicle> P.35B-108, <RH drive vehicle> P.35B-134
The ABS warning lamp remains illuminated after the 4 engine is started. In the inspection with the M.U.T.-II/III data list, the 5 parking brake switch is not turned ON or turned OFF. The neutral position learning of the steering wheel sensor is not detected. Faulty ABS operation 6

TROUBLESHOOTING
35B-83
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS <L.H. drive vehicle>
INSPECTION PROCEDURE 1: Communication between the M.U.T.-II/III and all the Systems is Not Possible.
Diagnosis Connector Power Supply and Earth Circuit FUSIBLE LINK 1
DIAGNOSIS CONNECTOR
FRONT SIDE
SB : Sky blue
OPERATION
A battery positive voltage is applied on the diagnosis connector power terminal (terminal 16). The earth terminals (terminal 4, 5) are earthed to the vehicle body.

The cause is probably a defect in power supply circuit or the earth circuit.
PROBABLE CAUSES
The most likely causes for this case are: Malfunction of the diagnosis connector Damaged wiring harness or connector
35B-84
DIAGNOSIS

TROUBLESHOOTING
Connector: C-14
STEP 1. Check the power supply circuit. Voltage measurement at diagnosis connector C-14.
Connector: C-14
C-14(B)
AC100188AG
C-14(B)
Diagnosis connector C-14
C-212 (B) Diagnosis connector C-214
AC212151AB
Connector C-212 (harness side)

1
Measure the voltage between terminal 16 and earth. OK: System voltage

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
AC212152 AB
Connector: C-126
Harness side
3 2 1
C-126
AC211265DG
Intermediate connector C-126 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.

35B-85
STEP 4. Check the earth circuit. Resistance measuremen at diagnosis connector C-14.
Connector: C-14

Connector: C-14
C-14(B)
C-14(B)
AC100188AG

Diagnosis connector
AC212151AC
Harness side
1
AC211269 BR
Measure the resistance between terminal 4 and earth, and terminal 5 and earth. OK: 2 ohms or less
Q: Is the resistance 2 ohms or less? YES : Replace the M.U.T.-II and then go to Step 7. NO : Go to Step 5.
The wire between diagnosis connector C-14 (terminal 16) and junction block connector C-212 (terminal 1)
STEP 5. Check the following connector.
Connector: C-14
C-14(B)
AC100188AG
Diagnosis connector C-14 Check the connector, for loose, corroded or damaged terminals, or terminals pushed back in the connector.
Q: Are the connector and terminals in good condition? YES : Go to Step 6. NO : Repair it and then go to Step 7.
35B-86

TROUBLESHOOTING

Connector: C-14
STEP 7. Retest the system.

Q: Does the M.U.T.-II/III communicate with the whole system? YES : The procedure is complete. NO : Return to Step 1.
C-14(B)
AC100188AG
Earth
No.7
AC211897AC
The wire between diagnosis connector C-14 (terminal 4) and earth (No.7) The wire between diagnosis connector C-14 (terminal 5) and earth (No.7)

TROUBLESHOOTING
35B-87
INSPECTION PROCEDURE 2: Communication between the M.U.T.-II/III and the ABS-ECU is not possible.
ABS-ECU Power Supply /Earth and Diagnosis Connector Circuit IGNITION SWITCH (IG2)
DIAGNOSIS CONNECTOR
FRONT SIDE
SB : Sky blue
35B-88
OPERATION

TROUBLESHOOTING
DIAGNOSIS
STEP 1. Check the power supply circuit. Voltage measurement at ABS-ECU connector B-118.
Connector: B-118
The diagnosis code is set by the ABS-ECU (terminal 2) to the diagnostic output terminal (terminal 7) of the diagnosis connector. When the diagnosis connector's diagnosis test mode control terminal (terminal 1) is earthed, the ABS-ECU will go into diagnosis mode.

When communication with the M.U.T.-II/III is not possible, the cause is probably an open circuit in the ABS-ECU power circuit or an open circuit in the diagnostic output circuit.
B-118 (B)
PROBABLE CAUSES
The most likely causes for this case are: Blown fuse Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (Integrated with ABS-ECU)
12 34 11 10
9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC212153AC
(1) Disconnect ABS-ECU connector B-118 and measure at the harness side. (2) Start the engine. (3) Measure the voltage between terminal 10 and earth. OK: System voltage

TROUBLESHOOTING
35B-89
Connector: B-118
B-118 (B)

Connector: C-211
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD

Connector: B-118
2 1 6 5 4 3
AC211269 AL
C-210
B-118 (B)

12 11 10
Harness side
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13

6 5 4 3 2 1 14 13 12 11 10 9 8 7
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
The wire between junction block connector C-211 (terminal 2) and ABS-ECU connector B-118 (terminal 10)
AC212152 AC

2 1 6 5 4 3
Connector: C-124
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
AC211265 AR
35B-90

TROUBLESHOOTING
STEP 4. Check the earth circuit. Resistance measurement at ABS-ECU connector B-118.
Connector: B-118
Connector: B-118
B-118 (B) B-118 (B) Harness side

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Earth
12 34
11 10
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC212153AE
NO.14
AC211898AC
Connector: B-118
The wire between ABS-ECU connector B-118 (terminal 12) and earth (No.14) The wire between ABS-ECU connector B-118 (terminal 34) and earth (No.14)
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
ABS-ECU connector B-118 Check the connector, for loose, corroded or damaged terminals, or terminals pushed back in the connector.

TROUBLESHOOTING
35B-91
Connector: C-14
Connector: B-118 C-14(B) B-118 (B)

AC100188AG
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
Connectors: C-23, C-101, C-105, C-124 C-101 (L)

33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector: C-14 C-23 (B) C-124
C-105 C-14(B) Connector C-105

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 28 2930 31 32 33
Connector C-23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AC100188AG
Connector C-124
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
Connector C-101
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
The wire between ABS-ECU connector B-118 (terminal 2) and diagnosis connector C-14 (terminal 7) The wire between ABS-ECU connector B-118 (terminal 5) and diagnosis connector C-14 (terminal 1)
AC212218 AB
Joint connectors C-23, C-101, C-105 Intermediate connector C-124
Connector: B-118
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 9. STEP 9. Retest the system.
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
Q: Does the M.U.T.-II/III communicate with the ABS system? YES : The procedure is complete. NO : Return to Step 1.
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
35B-92

TROUBLESHOOTING
INSPECTION PROCEDURE 3: 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
SB : Sky blue
OPERATION
The ABS warning lamp power is supplied from the ignition switch. The ABS-ECU earths the circuit to illuminate the lamp.
The ABS-ECU illuminates the ABS warning lamp for 3 seconds while running self-check. This lamp is illuminated for 3 seconds upon start-up or when the ignition switch is turned to the "ON" position with engine stopped.

TROUBLESHOOTING
35B-93
When the ABS-ECU connector is disconnected, the circuit is earthed to illuminate the lamp. The ABS-ECU controls the continuity to the ABS warning lamp by turning the power transistor in the unit "OFF" and "ON," respectively.
(2) Turn the ignition switch to the "ON" position.

Q: Does the ABS warning lamp illuminate? YES : Replace the brake modulator hydraulic unit

The cause may be an open circuit in the ABS warning lamp power supply circuit, a blown ABS warning lamp bulb, or a short circuit to earth between the ABS warning lamp and the ABS-ECU.
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 10. NO : Go to Step 2. STEP 2. Check the power supply circuit. Voltage measurement at combination meter connector C-01.
Connector: C-01
PROBABLE CAUSES
The most likely causes for this case are: Blown fuse Damaged wiring harness or connector Burnt out ABS warning lamp bulb Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)
DIAGNOSIS
STEP 1. Check the ABS warning lamp circuit at ABS-ECU connector B-118.
Connector: B-118 Connector C-01 (harness side)
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
AC212218 AC
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
(1) Disconnect ABS-ECU connector B-118.
(1) Disconnect combination meter connector C-01 and measure at the harness side. (2) Start the engine. (3) Measure the voltage between terminal 9 and earth. OK: System voltage
35B-94



C-23 (B)
Connector: C-211

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side Junction block (Front view) Connector: C-01 C-01

2 1 6 5 4 3
AC211269 AL
Connector C-23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AC212218AE
Combination meter connector C-01
Harness side
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC211265DF
The wire between junction block connector C-211 (terminal 6) and combination meter connector C-01 (terminal 9)
C-214

2 1 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
AC212152AD
Junction block connectors C-211, C-214 Joint connector C-23 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.

TROUBLESHOOTING
35B-95
STEP 5. Check the earth circuit. Resistance measurement at combination meter connector C-02.

Connector: C-02
Harness side
515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC211265 AI
Earth

515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
No.7
AC212218AD
(1) Disconnect combination meter connector C-02 and measure at the harness side. (2) Measure the resistance between terminal 48 and earth. OK: 2 ohms or less
AC211897AB
The wire between combination meter connector C-02 (terminal 48) and earth (No.7)
Connector: C-02
Harness side
515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC211265 AI
Combination meter connector C-02 Check the connector for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-96

TROUBLESHOOTING

Connector: C-01 C-01

Harness side
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC211265DF
AC211265DF
Connector: B-118
Connector: C-122
B-118 (B)
Harness side
12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
AC211265 DD
Connector: B-118
The wire between combination meter connector C-01 (terminal 13) and ABS-ECU connector B-118 (terminal 27)
Q: Is the harness wire damaged? YES : Repair or replace it and then go to Step 10. NO : Replace the combination meter (Refer to
B-118 (B)
GROUP 54A, Combination Meter Assembly P.54A-58). Then go to Step 10. STEP 10. Retest the system.
AC211901AD
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
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 start-up? YES : The procedure is complete. NO : Return to Step 1.

TROUBLESHOOTING
35B-97
INSPECTION PROCEDURE 4: The ABS Warning Lamp Remains Illuminated after the Engine is Started. NOTE: This diagnosis procedure is limited to cases where communication with the M.U.T.-II is possible (ABS-ECU power supply is normal) and no diagnosis code is set.
ABS WARNING LAMP CIRCUIT

Refer to P.35B-92.
DIAGNOSIS
CIRCUIT OPERATION
Refer to P.35B-92.

The cause is probably the ABS-ECU malfunction.
PROBABLE CAUSES
The most likely causes for this case are: Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)
C-122 (L)

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AC212218AF
Combination meter connector C-01 Intermediate connector C-122
Connector: B-118
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
35B-98

TROUBLESHOOTING

Connector: B-118
B-118 (B)
Harness side
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC211265DF
Connector: B-118 Connector B-118 (harness side) B-118 (B)

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD AC212153AF
(1) Disconnect ABS-ECU connector B-118 and check at the harness side connector. (2) Turn the ignition switch to the "ON" position. (3) Earth terminal 27 and check the ABS warning lamp.
Q: Does the ABS warning lamp go off? YES : Replace the brake modulator hydraulic unit
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 4. NO : Replace the combination meter (Refer to GROUP 54A, Combination Meter Assembly P.54A-58). Then go to Step 4. STEP 4. Retest the system.
Q: Does the ABS warning lamp turn off in 3 seconds after start-up? YES : The procedure is complete. NO : Return to Step 1.

TROUBLESHOOTING
35B-99
INSPECTION PROCEDURE 5: In the Inspection with the M.U.T.-II/III Data List, the Parking Brake Switch is not Turned ON or Turned OFF.
Parking Brake Switch Circuit ABS-ECU
PARKING BRAKE SWITCH
OPERATION
The ABS-ECU monitors the parking brake switch to optimise the ABS control.
PROBABLE CAUSES
The most likely causes for this case are: Damaged wiring harness or connector Malfunction of the parking brake switch Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)

The cause may be an open or a short circuit between the parking brake switch and the ABS-ECU.
35B-100
DIAGNOSIS

TROUBLESHOOTING
(3) Set M.U.T.-II/III to data reading mode for following item. Item No.29: Parking brake switch OK: Checking requirement Pull the parking brake lever Release the parking brake lever Display ON OFF
Q: Is the parking brake switch input normal? YES : This malfunction is intermittent. Refer to
16-PIN
M.U.T.-II
AC207179AB
STEP 2. Check the parking brake switch circuit at ABS-ECU connector B-118.
Connector: B-118
16-PIN
B-118 (B)
MB991911 MB991824 Connector B-118 (harness side)

12 34 11 10
9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
MB991827
AC210056AC AC212153AG
(1) Disconnect ABS-ECU connector B-118 and measure at the harness side.

TROUBLESHOOTING
35B-101
(2) Check for continuity between terminal 1 and earth with pulling or releasing the parking brake lever. OK: If the parking brake lever is pulled, there should be no continuity, and if the parking brake lever is released, there should be continuity (less than 2 ohms).
Q: Does continuity exist when the parking brake lever is released, and dose continuity not exist when the parking brake lever is pulled? YES : Go to Step 3. NO : Go to Step 4.

Connector: B-118
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector: B-118
B-118 (B)
C-23 (B) C-124
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector C-23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
ABS-ECU connector B-118 Check the connector for loose, corroded or damaged terminals, or terminals pushed back in the connector.
Q: Are the connector and terminals in good condition? YES : Replace the brake modulator hydraulic unit
Connector C-124
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
AC212218 AG
Intermediate connector C-124 Joint connector C-23
Connector: D-28
D-28 (B)
Harness side
1
AC211902AH
Parking brake switch connector D-28 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-102

TROUBLESHOOTING

Q: Does the parking brake switch turn ON/OFF normally in the inspection by M.U.T.-II/III data list? YES : The procedure is complete. NO : Return to Step 1.

Connector: D-28
D-28 (B)
Harness side
1
AC211902AH
Connector: B-118
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
The wire between parking brake switch connector D-28 (terminal 1) and ABS-ECU connector B-118 (terminal 1)
Q: Is the harness wire damaged? YES : Repair or replace it and then go to Step 6. NO : Replace the parking brake switch (Refer to
GROUP 36, Parking Brake Lever P.36-4). Then go to Step 6.

TROUBLESHOOTING
35B-103
INSPECTION PROCEDURE 6: The Neutral Position Learning of the Steering Wheel Sensor is not Detected.
ST-1
ST-2
ST-N
CIRCUIT OPERATION
The ABS system detects the neutral position learning of the steering wheel sensor by the signal from the stop lamp.

The diagnosis is difficult because it depends on driving condition and road surface, if the diagnosis code has not been set, carry out the following checks (refer to TROUBLESHOOTING HINTS).
35B-104
PROBABLE CAUSES

TROUBLESHOOTING
The most likely causes for this case are: Damaged wiring harness or connector Malfunction of the stop lamp switch system Tyres are not all the same diameter Malfunction of suspension Malfunction of the steering wheel sensor installation Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)
16-PIN
DIAGNOSIS
STEP 1. Check the front tyres.
Q: Are the tyre diameters different? YES : Replace the appropriate tyre and then go to
M.U.T.-II
AC207179AB
Step 13. NO : Go to Step 2. STEP 2. Check the front suspension.

Q: Is the front suspension abnormal? YES : Repair the front suspension and then go to
16-PIN
Step 13.
NO : Go to Step 3.
MB991911 MB991824
MB991827
AC210056AC

TROUBLESHOOTING
35B-105
(3) Set M.U.T.-II/III to data reading mode for following item. Item No.37: Steering wheel sensor neutral position learning OK: Checking requirement After driving straight at vehicle speed over than 10 km/h Before driving with ignition switch ON Display ON OFF

0.8 - 2.1 V Time

AC211894 AB
Q: Is the steering wheel sensor straight ahead position learning input normal? YES : Go to Step 5. NO : Confirm the steering wheel sensor is
correctly installed. Then go to Step 4. STEP 4. Check for steering wheel sensor output voltage.
Connector: C-230
P.35B-150). and then go to Step 13. STEP 5. Check the stop lamp.
Q: Does the stop lamp turn on and off normally? YES : Go to Step 9. NO : Go to Step 6.
STEP 6. Check the stop lamp switch installation condition.

1 5 4 3 2
Q: Is the stop lamp switch installed correctly? YES : Check the stop lamp switch (Refer to
GROUP 35A, Brake pedal P.35A-15). Then go to Step 7. NO : Repair the installation of the stop lamp switch (Refer to GROUP 35A, On-vehicle Service - Brake pedal Check and Adjustment P.35A-5). Then go to Step 13.
AC212249AD
(1) Connect steering wheel sensor connector C-230.
35B-106

TROUBLESHOOTING

Fuse: No.10
No.10 C-102 C-129
AC208825AN

2 4 1 3
Connector: C-102
Connector C-129
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
C-102 Harness side

2 4
AC212218AH
1 3
AC211265DH
Intermediate connectors C-129 Stop lamp switch connector C-102 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
The wire between relay box in engine compartment (fuse No.10) and stop lamp switch connector C-102 (terminal 2) The wire between stop lamp switch connector C-102 (terminal 1) and stop lamps

TROUBLESHOOTING
35B-107
STEP 9. Check the stop lamp switch circuit. Measure the voltage at ABS-ECU connector B-118.
Connector: B-118

Connector: B-118
B-118 (B) B-118 (B)

11 10
Harness side
12 34
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connectors: C-102, C-105, C-124 Connector B-118 (harness side)

12 34 11 10
9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
C-124 C-102 C-105
AC212153AH
(1) Disconnect ABS-ECU connector B-118 and measure at the harness side. (2) Depress the brake pedal to turn on the stop lamp switch. (3) Measure the voltage between terminal 19 and earth. OK: System voltage
Q: IIs the check result normal? YES : Go to Step 12. NO : Go to Step 10.

2 4 1 3
Connector C-105
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 28 2930 31 32 33
Connector C-124
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
AC212218AI
Joint connector C-105 Intermediate connector C-124 Stop lamp switch connector C-102 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-108

TROUBLESHOOTING

Connector: C-102
Connector: B-118
B-118 (B)
C-102
Harness side
Harness side
2 4 1 3
12 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
AC211265DH
34
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector: B-118
B-118 (B)
Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 13. NO : Repair it and then go to Step 13.
AC211901AD
33 32 31 30 29 28 27 26 25 24 23
The wire between stop lamp switch connector C-102 (terminal 1) and ABS-ECU connector B-118 (terminal 19)

Q: Is the neutral position learning of the steering wheel sensor detected by the ABS system? YES : The procedure is complete. NO : Return to Step 1.
INSPECTION PROCEDURE 7: Faulty ABS Operation
COMMENT ON TROUBLE SYMPTOM (COMMENT)

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 brake modulator hydraulic unit (Refer to P.35B-140). If the brake modulator 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 brake modulator hydraulic unit

TROUBLESHOOTING
35B-109
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS <R.H. drive vehicle>
INSPECTION PROCEDURE 1: Communication between the M.U.T.-II/III and all the Systems is Not Possible.
Diagnosis Connector Power Supply and Earth Circuit FUSIBLE LINK 1
DIAGNOSIS CONNECTOR
FRONT SIDE
SB : Sky blue
OPERATION
A battery positive voltage is applied on the diagnosis connector power terminal (terminal 16). The earth terminals (terminal 4, 5) are earthed to the vehicle body.

The cause is probably a defect in power supply circuit or the earth circuit.
PROBABLE CAUSES
The most likely causes for this case are: Malfunction of the diagnosis connector Damaged wiring harness or connector
35B-110
DIAGNOSIS

TROUBLESHOOTING
Connector: C-14
STEP 1. Check the power supply circuit. Voltage measurement at diagnosis connector C-14.
Connector: C-14
C-14(B)
AC311202 AB
C-14(B)
C-212 (B) Diagnosis connector C-214
AC311203AB
Measure the voltage between terminal 16 and earth. OK: System voltage

1

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
AC311164AD
Connector: C-126 Harness side

3 2 1
C-126
AC311160AF

35B-111
STEP 4. Check the earth circuit. Resistance measurement at diagnosis connector C-14.
Connector: C-14

Connector: C-14
C-14(B)
C-14(B)
AC311202 AB
Diagnosis connector Harness side Junction block (Front view)

1
AC311203AC
AC311165AC
Q: Is the resistance 2 ohms or less? YES : Replace the M.U.T.-II/III and then go to Step
The wire between diagnosis connector C-14 (terminal 16) and junction block connector C-212 (terminal 1)
7.
NO : Go to Step 5.
Connector: C-14
C-14(B)
AC311202 AB
Diagnosis connector C-14 Check the connector, for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-112

TROUBLESHOOTING

Connector: C-14

Q: Does the M.U.T.-II/III communicate with the whole system? YES : The procedure is complete. NO : Return to Step 1.
C-14(B)
AC311202 AB
Earth
AC311200AB
The wire between diagnosis connector C-14 (terminal 4) and earth The wire between diagnosis connector C-14 (terminal 5) and earth

TROUBLESHOOTING
35B-113
INSPECTION PROCEDURE 2: Communication between the M.U.T.-II/III and the ABS-ECU is not possible.
ABS-ECU Power Supply /Earth and Diagnosis Connector Circuit IGNITION SWITCH (IG2)
DIAGNOSIS CONNECTOR
FRONT SIDE
OPERATION
The diagnosis code is set by the ABS-ECU (terminal 2) to the diagnostic output terminal (terminal 7) of the diagnosis connector.
When the diagnosis connector's diagnosis test mode control terminal (terminal 1) is earthed, the ABS-ECU will go into diagnosis mode.
35B-114

TROUBLESHOOTING

When communication with the M.U.T.-II/III is not possible, the cause is probably an open circuit in the ABS-ECU power circuit or an open circuit in the diagnostic output circuit.
Connector: B-118
PROBABLE CAUSES
The most likely causes for this case are: Blown fuse Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (Integrated with ABS-ECU)

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
DIAGNOSIS
STEP 1. Check the power supply circuit. Voltage measurement at ABS-ECU connector B-118.
Connector: B-118
C-211 C-210
B-118 (B)

12 34 11 10
9 8 7 6 5 4 3 2 1

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

2 1 6 5 4 3
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311164AB
Connector: C-122
AC311168AC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
(1) Disconnect ABS-ECU connector B-118 and measure at the harness side. (2) Start the engine. (3) Measure the voltage between terminal 10 and earth. OK: System voltage
C-122 (L)
AC311160AC

35B-115
STEP 4. Check the earth circuit. Resistance measurement at ABS-ECU connector B-118.
Connector: B-118

Connector: C-211
B-118 (B)
Harness side Junction block (Front view) Connector: B-118

2 1 6 5 4 3
AC311165AB
12 34 11 10
9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
Connector B-118 (harness side) B-118 (B) Harness side

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
AC311168AD
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
The wire between junction block connector C-211 (terminal 2) and ABS-ECU connector B-118 (terminal 10)
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
ABS-ECU connector B-118 Check the connector, for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-116

TROUBLESHOOTING

Connector: B-118
Connector: C-14

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
C-14(B)
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
AC311202 AB
Earth
AC311161AG
Connectors: C-21, C-105, C-122, C-124 C-21 C-105 C-124
AC311204 AB
The wire between ABS-ECU connector B-118 (terminal 12) and earth The wire between ABS-ECU connector B-118 (terminal 34) and earth
C-122 (L)
Connector C-21
Connector C-105
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 28 2930 31 32 33
Connector C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Connector C-124
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
AC311205AB
Joint connectors C-21, C-23, C-105 Intermediate connectors C-122, C-124

TROUBLESHOOTING
35B-117
Connector: B-118

Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13

AC311127AB
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Connector: C-14
C-14(B)
AC311202 AB
The wire between ABS-ECU connector B-118 (terminal 2) and diagnosis connector C-14 (terminal 7) The wire between ABS-ECU connector B-118 (terminal 5) and diagnosis connector C-14 (terminal 1)
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 9. STEP 9. Retest the system.
Q: Does the M.U.T.-II/III communicate with the ABS system? YES : The procedure is complete. NO : Return to Step 1.
35B-118

TROUBLESHOOTING
INSPECTION PROCEDURE 3: 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
SB : Sky blue
OPERATION
The ABS warning lamp power is supplied from the ignition switch. The ABS-ECU earths the circuit to illuminate the lamp.
The ABS-ECU illuminates the ABS warning lamp for 3 seconds while running self-check. This lamp is illuminated for 3 seconds upon start-up or when the ignition switch is turned to the "ON" position with engine stopped.

TROUBLESHOOTING
35B-119
When the ABS-ECU connector is disconnected, the circuit is earthed to illuminate the lamp. The ABS-ECU controls the continuity to the ABS warning lamp by turning the power transistor in the unit "OFF" and "ON," respectively.

Q: Does the ABS warning lamp illuminate? YES : Replace the brake modulator hydraulic unit

The cause may be an open circuit in the ABS warning lamp power supply circuit, a blown ABS warning lamp bulb, or a short circuit to earth between the ABS warning lamp and the ABS-ECU.
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 10. NO : Go to Step 2. STEP 2. Check the power supply circuit. Voltage measurement at combination meter connector C-01.
Connector: C-01
PROBABLE CAUSES
The most likely causes for this case are: Blown fuse Damaged wiring harness or connector Burnt out ABS warning lamp bulb Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)
DIAGNOSIS
Connector: B-118
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
AC311206AB
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
(1) Disconnect ABS-ECU connector B-118.
(1) Disconnect combination meter connector C-01 and measure at the harness side. (2) Start the engine. (3) Measure the voltage between terminal 9 and earth. OK: System voltage
35B-120

TROUBLESHOOTING

Connector: C-01

Connector: C-211

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC311161AD
Harness side Junction block (Front view) Connector: C-01

2 1 6 5 4 3
AC311165AB
C-211

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-214 Connector C-211 (Harness side) Junction block (Front view) Connector C-214 (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 2 1 6 5 4 3
AC311161AD
The wire between junction block connector C-211 (terminal 6) and combination meter connector C-01 (terminal 9)
AC311164AC

TROUBLESHOOTING
35B-121
STEP 5. Check the earth circuit. Resistance measurement at combination meter connector C-02.


515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC311161AH
Earth

515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC311206AC
(1) Disconnect combination meter connector C-02 and measure at the harness side. (2) Measure the resistance between terminal 48 and earth. OK: 2 ohms or less
AC311200AB
The wire between combination meter connector C-02 (terminal 48) and earth (No.7)
Connector: C-02
C-02 (L)

515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC311161AH
Combination meter connector C-02 Check the connector for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-122

TROUBLESHOOTING

Connector: C-01

Connector: C-01

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC311161AD

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC311161AD
Connector: B-118
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

AC311160AC
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Connector: B-118
Q: Is the harness wire damaged? YES : Repair or replace it and then go to Step 10. NO : Replace the combination meter (Refer to

12 34 11 10
9 8 7 6 5 4 3 2 1
GROUP 54A, Combination Meter Assembly P.54A-56). Then go to Step 10. STEP 10. Retest the system.
AC311127AB
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
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 start-up? YES : The procedure is complete. NO : Return to Step 1.

TROUBLESHOOTING
35B-123
INSPECTION PROCEDURE 4: The ABS Warning Lamp Remains Illuminated after the Engine is Started. NOTE: This diagnosis procedure is limited to cases where communication with the M.U.T.-II/III is possible (ABS-ECU power supply is normal) and no diagnosis code is set.
ABS WARNING LAMP CIRCUIT

Refer to P.35B-118.
DIAGNOSIS
CIRCUIT OPERATION
Refer to P.35B-118.
Connector: C-01

The cause is probably the ABS-ECU malfunction.
PROBABLE CAUSES
The most likely causes for this case are: Damaged wiring harness or connector Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC311161AD
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
C-122 (L)
AC311160AC
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
35B-124

TROUBLESHOOTING

Connector: C-01
Connector: B-118

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC311161AD
B-118 (B)
Connector: B-118 Connector B-118 (harness side) B-118 (B) Harness side
12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
12 34
11 10
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
33 32 31 30 29 28 27 26 25 24 23
AC311127AB AC311168 AE
(1) Disconnect ABS-ECU connector B-118 and check at the harness side connector. (2) Turn the ignition switch to the "ON" position. (3) Earth terminal 27 and check the ABS warning lamp.
Q: Does the ABS warning lamp go off? YES : Replace the brake modulator hydraulic unit
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 4. NO : Replace the combination meter (Refer to GROUP 54A, Combination Meter Assembly P.54A-56). Then go to Step 4. STEP 4. Retest the system.
Q: Does the ABS warning lamp turn off in 3 seconds after start-up? YES : The procedure is complete. NO : Return to Step 1.

TROUBLESHOOTING
35B-125
INSPECTION PROCEDURE 5: In the Inspection with the M.U.T.-II/III Data List, the Parking Brake Switch is not Turned ON or Turned OFF.
Parking Brake Switch Circuit ABS-ECU
PARKING BRAKE SWITCH
OPERATION
The ABS-ECU monitors the parking brake switch to optimise the ABS control.
PROBABLE CAUSES
The most likely causes for this case are: Damaged wiring harness or connector Malfunction of the parking brake switch Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)

The cause may be an open or a short circuit between the parking brake switch and the ABS-ECU.
35B-126
DIAGNOSIS

TROUBLESHOOTING
(3) Set M.U.T.-II/III to data reading mode for following item. Item No.29: Parking brake switch OK: Checking requirement Pull the parking brake lever Release the parking brake lever Display ON OFF
Q: Is the parking brake switch input normal? YES : This malfunction is intermittent. Refer to
MB991502
AC311157AB
GROUP 00, How to Use Troubleshooting/Inspection Service Points How to Cope With Intermittent Malfunction P.00-5. NO : Go to Step 2. STEP 2. Check the parking brake switch circuit. Resistance measurement at ABS-ECU connector B-118.
Connector: B-118
16-PIN
B-118 (B)
MB991911 MB991824 Connector B-118 (harness side)

12 34 11 10
9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
MB991827
AC311153AB
AC311168AF
(1) Disconnect ABS-ECU connector B-118 and measure at the harness side.

TROUBLESHOOTING
35B-127
(2) Check for continuity between terminal 1 and earth with pulling or releasing the parking brake lever. OK: If the parking brake lever is pulled, there should be no continuity, and if the parking brake lever is released, there should be continuity (less than 2 ohms).
Q: Does continuity exist when the parking brake lever is released, and dose continuity not exist when the parking brake lever is pulled? YES : Go to Step 3. NO : Go to Step 4.

Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1
C-122 (L)
AC311160AC AC311127AB
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
Connector: D-28
D-28 (B)
Harness side
1
AC311162AC
Parking brake switch connector D-28 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
35B-128
Connector: D-28

TROUBLESHOOTING

Q: Does the parking brake switch turn ON/OFF normally in the inspection by M.U.T.-II/III data list? YES : The procedure is complete. NO : Return to Step 1.
D-28 (B)
Harness side
1
AC311162AC
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
The wire between parking brake switch connector D-28 (terminal 1) and ABS-ECU connector B-118 (terminal 1)
Q: Is the harness wire damaged? YES : Repair or replace it and then go to Step 6. NO : Replace the parking brake switch (Refer to
GROUP 36, Parking Brake Lever P.36-4). Then go to Step 6.

TROUBLESHOOTING
35B-129
INSPECTION PROCEDURE 6: The Neutral Position Learning of the Steering Wheel Sensor is not Detected.
ST-1
ST-2
ST-N
CIRCUIT OPERATION
The ABS system detects the neutral position learning of the steering wheel sensor by the signal from the stop lamp.

The diagnosis is difficult because it depends on driving condition and road surface, if the diagnosis code has not been set, carry out the following checks (refer to TROUBLESHOOTING HINTS).
35B-130
PROBABLE CAUSES

TROUBLESHOOTING
The most likely causes for this case are: Damaged wiring harness or connector Malfunction of the stop lamp switch system Tyres are not all the same diameter Malfunction of suspension Malfunction of the steering wheel sensor installation Malfunction of the brake modulator hydraulic unit (integrated with ABS-ECU)
DIAGNOSIS
STEP 1. Check the front tyres.
Q: Are the tyre diameters different? YES : Replace the appropriate tyre and then go to
MB991502
AC311157AB
Step 13.
NO : Go to Step 2.
STEP 2. Check the front suspension.

Q: Is the front suspension abnormal? YES : Repair the front suspension and then go to
16-PIN
Step 13.
NO : Go to Step 3.
MB991911 MB991824
MB991827
AC311153AB

TROUBLESHOOTING
35B-131
(3) Set M.U.T.-II/III to data reading mode for following item. Item No.37: Steering wheel sensor neutral position learning OK: Checking requirement After driving straight at vehicle speed over than 10 km/h Before driving with ignition switch ON Display ON OFF

0.8 - 2.1 V Time

AC211894 AB
Q: Is the steering wheel sensor straight ahead position learning input normal? YES : Go to Step 5. NO : Confirm the steering wheel sensor is
correctly installed. Then go to Step 4. STEP 4. Check for steering wheel sensor output voltage.
Connector: C-230
P.35B-150). and then go to Step 13. STEP 5. Check the stop lamp.
Q: Does the stop lamp turn on and off normally? YES : Go to Step 9. NO : Go to Step 6.
STEP 6. Check the stop lamp switch installation condition.

1 5 4 3 2
Q: Is the stop lamp switch installed correctly? YES : Check the stop lamp switch (Refer to
GROUP 35A, Brake pedal P.35A-15). Then go to Step 7. NO : Repair the installation of the stop lamp switch (Refer to GROUP 35A, On-vehicle Service Brake pedal Check and Adjustment P.35A-5). Then go to Step 13.
AC311195AD
(1) Connect steering wheel sensor connector C-230.
35B-132

TROUBLESHOOTING

Connector: C-129
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
Fuse: No.10
No.10
AC311160AG
AC208825AN
Intermediate connectors C-129
Connector: C-102
Connector: C-102
2 4
1 3
2 4
1 3
AC311161AI AC311161AI
Stop lamp switch connector C-102 Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
The wire between relay box in engine compartment (fuse No.10) and stop lamp switch connector C-102 (terminal 2) The wire between stop lamp switch connector C-102 (terminal 1) and stop lamps

TROUBLESHOOTING
35B-133
STEP 9. Check the stop lamp switch circuit. Voltage measurement at ABS-ECU connector B-118.
Connector: B-118

Connector: B-118
B-118 (B) Harness side B-118 (B)

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Connectors: C-105, C-124 Connector B-118 (harness side)

12 34 11 10
9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
C-124
33 32 31 30 29 28 27 26 25 24 23
C-105
AC311168AG
(1) Disconnect ABS-ECU connector B-118 and measure at the harness side. (2) Depress the brake pedal to turn on the stop lamp switch. (3) Measure the voltage between terminal 19 and earth. OK: System voltage
Connector C-105
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 28 2930 31 32 33
Connector C-124
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
AC311207AB
Joint connector C-105 Intermediate connector C-124
Connector: C-102
2 4
1 3
AC311161AI
Stop lamp switch connector C-102
35B-134

TROUBLESHOOTING
Check the connectors for loose, corroded or damaged terminals, or terminals pushed back in the connector.
Connector: B-118

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13

Connector: C-102
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
2 4
1 3
AC311161AI
Connector: B-118
(integrated with ABS-ECU) (Refer to P.35B-143). Then go to Step 13. NO : Repair it and then go to Step 13. STEP 13. Retest the system.

12 34 11 10
9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13
Q: Is the neutral position learning of the steering wheel sensor detected by the ABS system? YES : The procedure is complete. NO : Return to Step 1.
33 32 31 30 29 28 27 26 25 24 23
AC311127AB
The wire between stop lamp switch connector C-102 (terminal 1) and ABS-ECU connector B-118 (terminal 19)
INSPECTION PROCEDURE 7: Faulty ABS Operation
COMMENT ON TROUBLE SYMPTOM (COMMENT)

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.
Malfunction of the brake modulator hydraulic unit
DIAGNOSIS
Check the brake modulator hydraulic unit (Refer to P.35B-140). If the brake modulator 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:

TROUBLESHOOTING
35B-135

The following items can be read by the M.U.T.-II/III from the ABS-ECU input data. M.U.T.-II/III Item Check item Checking requirements display No. FR SNSR FL SNSR RR SNSR RL SNSR BATT. VOLTAGE PARKING SW GS (STRAIGHT) STOP LAMP SW ST-N MEMORY GS (LATERAL) ST-N 11 12 13 14 21 29 32 36 37 Front-right wheel speed Drive the vehicle sensor Front-left wheel speed sensor Rear-right wheel speed sensor Rear-left wheel speed sensor ABS-ECU power supply Ignition switch: ON voltage Parking brake switch Longitudinal G-sensor Stop lamp switch Pull the parking brake lever. Release the parking brake lever. When vehicle stops. When vehicle is driven. Depress the brake pedal. Release the brake pedal. Steering wheel sensor After driving straight at vehicle speed neutral position learning over 10 km/h. Before driving with ignition switch ON. 71 74 Lateral G-sensor Steering wheel sensor (ST-N) When vehicle stops. When vehicle is driven. Ignition switch: ON Steering: Neutral position and fully turned Steering: Except for the above ST-1 ST-2 ST ANGLE 75 76 86 Steering wheel sensor (ST-1) Steering wheel sensor (ST-2) Steering degree Ignition switch: ON Steering wheel sensor neutral position learning is finished (service data item No.37 displays ON). Steering: Turn 90 + 90 to the right. Steering: Neutral OFF Steering: Turn 90 - 90 to the left. Ignition switch: ON Steering: Turn slowly. 10 16 V ON OFF 2.4 2.6 V 1.0 4.0 V ON OFF ON OFF 2.4 2.6 V 1.0 4.0 V ON
M1352011500702
Normal valve Vehicle speeds displayed on the speedometer and M.U.T.-II/III are identical.
OFF Display ON and OFF alternately
35B-136

TROUBLESHOOTING
M1352011600709
ACTUATOR TEST REFERENCE TABLE

The M.U.T.-II/III 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.
No. Item 01 02 03 04 Solenoid valve for front-left wheel Solenoid valve for front-right wheel Solenoid valve for rear-left wheel Solenoid valve for rear-right wheel Solenoid valves and pump motors in the hydraulic unit (simple inspection mode)
ACTUATOR TEST SPECIFICATIONS

Activation pattern
Start of activation Solenoid valve A B C 0.05 s ON OFF 1s 2s
End of activation
0.01 s
Pump motor
NOTE A: Hydraulic pressure increases B: Hydraulic pressure holds C: Hydraulic pressure decreases
AC100172 AG
CHECK AT ABS-ECU
M1352011800695
Use the following steps to remove the connector cover of the ABS-ECU and then measure the terminal voltage.
AC211694AB
Lock lever
AC211555AB
2. Push up and unlock the hooks of the ABS-ECU connector as shown in the illustration, then remove the connector cover.
1. Move the lock lever of the ABS-ECU connector as shown in the illustration, and then disconnect the ABS-ECU as connector.

TROUBLESHOOTING
35B-137
TERMINAL VOLTAGE CHECK CHART
AC211716
1. Measure the voltages between terminals (12) (earth terminal) and each respective terminal. 2. The terminal layout is shown in the illustration. Terminal No. 1 2 Check item
NOTE: Do not measure terminal voltage for approximately three seconds after the ignition switch is turned "ON." The ABS-ECU performs the initial check during that period. Normal condition 1 V or less System voltage Serial communication with M.U.T.-II/III 1 V or less 0.8 2.1 V 2.7 4.4 V Approximately 0 V System voltage System voltage Approximately 0 V System voltage 2.4 2.6 V (horizontal position) 0V Variation in the voltage value 0.8 2.1 V and 2.7 4.4 V System voltage 1 V or less 0V 2.4 2.6 V (horizontal position)
Checking requirements Release the parking brake lever.
Parking brake switch Pull the parking brake lever. M.U.T.-II/III When the M.U.T.-II/III is connected
When the M.U.T.-II/III is not connected 4 Steering wheel sensor (ST-N) Ignition Steering wheel: Neutral switch: "ON" position and fully turned. Steering wheel: Except for the above 5 10 11 14 Diagnosis changeover input ABS-ECU power supply When the M.U.T.-II/III is connected When the M.U.T.-II/III is not connected Ignition switch: "ON" Ignition switch: "START" or "ACC"
Solenoid valve power Always supply Lateral G-sensor input Longitudinal G-sensor earth Steering wheel sensor (ST-2) Ignition switch: "ON"
15 17
Always Ignition Steering wheel: Turned switch: "ON"
19 24 25
Stop lamp monitor input Lateral G-sensor earth Longitudinal G-sensor input
Ignition Stop lamp switch: "ON" switch: "ON" Stop lamp switch: "OFF" Always Ignition switch: "ON"
35B-138
Terminal No. 26 Check item Steering wheel sensor (ST-1)

ON-VEHICLE SERVICE
Checking requirements Ignition Steering wheel: Turned switch: "ON"
Normal condition Variation in the voltage value 0.8 2.1 V and 2.7 4.4 V 1 V or less 7 V or more System voltage
27 33
ABS-ECU warning Ignition When the lamp off lamp transistor output switch: "ON" When the lamp is illuminated Motor power supply Always
RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS
AC211717
1. Turn the ignition switch to the "LOCK" (OFF) position and disconnect the ABS-ECU connectors before checking resistance and continuity. ABS-ECU terminal No. 67 89 22 31 29 30 12 body earth 34 body earth Signal
2. Check the resistance and continuity between the terminals indicated in the table below. 3. The terminal layout is shown in the illustration. Normal condition 1.24 1.64 k 1.24 1.64 k 1.24 1.64 k 1.24 1.64 k Less than 2 ohms Less than 2 ohms
Rear-left wheel speed sensor Rear-right wheel speed sensor Front-left wheel speed sensor Front-right wheel speed sensor Earth Earth
ON-VEHICLE SERVICE
WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT
Lift up the vehicle and release the parking brake.
M1352001600612
1. Move the lock lever of the ABS-ECU connector as shown, and then disconnect the ABS-ECU connector.
Lock lever
AC211555AB
AC211694AB
2. Push up and unlock the hooks of the ABS-ECU connector as shown in the illustration, then remove the connector cover.

ON-VEHICLE SERVICE
35B-139
Faulty wheel speed sensor NOTE: Check the connection of the wheel speed sensor harness and connector before using the oscilloscope.
When turned by hand

AC211695AB
3. Manually turn the wheel to be measured 1/2 to 1 turn/second. Measure the output voltage with a voltmeter or oscilloscope. NOTE: The output waveform is low when the wheel speed is low. Similarly, it will be higher as the wheel speed increases. Waveform may also be observed by driving the vehicle. Terminal No. Front left 22 31 Front right 29 30 Rear left 6 7 Rear right 8 9
When idling (5 6 km/h), with 1st gear
[10.0 ms/DIV IV/DIV]
Output voltage: Minimal voltmeter reading: 42 mV Maximum voltmeter reading: 300 mV Minimal oscilloscope reading: 120 mV Maximum oscilloscope reading: 600 mV Probable causes of low output voltage Wheel speed sensor pole piece-to-wheel speed rotor clearance too large POINTS IN WAVEFORM MEASUREMENT Symptom Probable causes Too small or zero waveform amplitude
AC000949 AF
4. To observe the waveform with an oscilloscope: Front Wheels: Shift into low gear and drive the wheels. Rear Wheels: Turn the wheels manually at a constant speed.
Remedy Replace wheel speed sensor
Faulty wheel speed sensor or excessive gap between it and the wheel speed rotor
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) Noisy or disturbed waveform Open circuit in harness Incorrectly mounted wheel speed sensor
Replace hub assembly Repair harness wires
Open circuit in wheel speed sensor Replace wheel speed sensor Repair harness wire Mount wheel speed sensor correctly
Wheel speed rotor with missing or Replace wheel speed rotor damaged teeth NOTE: The wheel speed 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.
35B-140
HYDRAULIC UNIT CHECK

ON-VEHICLE SERVICE
M1352001700642
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. 3. Turn the ignition switch to the "LOCK" (OFF) position.
CAUTION To prevent damage to the M.U.T.-II/III, always turn the ignition switch to the "LOOK" (OFF) position before connecting or disconnecting the M.U.T.-II/III.
16-PIN
M.U.T.-II
AC207179AB
16-PIN
MB991911 MB991824
MB991827
AC210056AC
4. Connect the M.U.T.-II/III as shown in the illustration. 5. After checking that the shift lever is in neutral, start the engine. 6. Use the M.U.T.-II/III to force-drive the actuator. For the M.U.T.-II/III, follow the steps below. (1) Select "Interactive Diagnosis" from the start-up screen. (2) Select "System select." (3) Choose "ABS" from the "CHASSIS" tab. (4) Select "Actuator Test" from "ABS" screen

ON-VEHICLE SERVICE
35B-141
(5) Choose an appropriate item for hydraulic unit check. NOTE: The ABS system will switch to the M.U.T.-II/III mode and the ABS warning lamp will illuminate.
Depressed Pedal operation Released Increase in pressure Solenoid valve position Steady pressure Reduction in pressure Checking the brake force Lock
NOTE: When the ABS has been interrupted by the fail-safe function, the M.U.T.-II/III actuator testing cannot be used.
M.U.T.-II/III actuator test (Item No.01, 02, 03, 04) start
2 seconds 1 seconds
Drag force when the pedal is free
3 seconds Approx. 0.05 second

AC000954AH
7. 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 reading taken in step 2. The result should be as shown in the diagram above. Front wheel 785 981 N Rear wheel 588 784 N
35B-142

ON-VEHICLE SERVICE
8. If the result of inspection is abnormal, repair according to the Diagnosis Table below. Diagnosis Table
M.U.T.-II/III Display Operation Inspection result Judgment Probable cause Remedy
01 FR VALVE 02 FL VALVE 03 RR VALVE 04 RL VALVE
Depress brake pedal to lock wheel. Using the M.U.T.-II/III, 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 Abnorm Clogged brake lock when brake al line other than pedal is hydraulic unit depressed. Clogged hydraulic circuit in hydraulic unit Brake force is not released Incorrect hydraulic unit brake tube connection Hydraulic unit solenoid valve not functioning correctly
Check and clean brake line Replace hydraulic unit assembly Connect correctly
Replace hydraulic unit assembly
9. After inspection, disconnect the M.U.T.-II/III immediately after turning the ignition switch to the "LOCK" (OFF) position.
IN THE EVENT OF A DISCHARGED BATTERY

M1352003500600
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.
WARNING

HYDRAULIC UNIT
35B-143
HYDRAULIC UNIT
M1352008600549
NOTE: The ABS-ECU is integrated in the hydraulic unit.
<LH DRIVE VEHICLES>

Pre-removal Operation Brake Fluid Draining Post-installation Operation Brake Fluid Filling Bake Line Bleeding (Refer to P.35A-7). Hydraulic Unit Check (Refer to P.35B-140).
2
15 2 Nm
2 1 2
2
25 6 Nm
25 6 Nm
AC100173 AC
<<A>>
Removal steps 1. ABS-ECU harness connector >>A<< 2. Brake tube connection
<>
Removal steps (Continued) 3. Brake modulator hydraulic unit (hydraulic unit and ABS-ECU) 4. Brake hydraulic unit bracket
NOTE: The ABS-ECU is integrated in the hydraulic unit.
35B-144
<RH DRIVE VEHICLES>

HYDRAULIC UNIT
Pre-removal Operation Brake Fluid Draining Air Intake Hose and Air Cleaner Removal
Post-installation Operation Brake Fluid Filling Bake Line Bleeding (Refer to P.35A-7). Hydraulic Unit Check (Refer to P.35B-140). Air Intake Hose and Air Cleaner Installation
2
15 2 Nm
3 1 2
25 6 Nm
2 4
25 6 Nm
AC311045AB
<<A>>
Removal steps 1. ABS-ECU harness connector >>A<< 2. Brake tube connection
<>
Removal steps (Continued) 3. Brake modulator hydraulic unit (hydraulic unit and ABS-ECU) 4. Brake hydraulic unit bracket

HYDRAULIC UNIT
35B-145
REMOVAL SERVICE POINTS <<A>> ABS-ECU HARNESS CONNECTOR DISCONNECTION
INSTALLATION SERVICE POINT >>A<< BRAKE TUBE CONNECTION

2 3 4 5 1
6
Lock lever
AC211555AB AC100240AB
Move the lock lever of the ABS-ECU connector as shown in the illustration, and then disconnect the harness connector.
<> BRAKE MODULATOR HYDRAULIC UNIT (HYDRAULIC UNIT AND ABS-ECU) REMOVAL
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 tubes to the hydraulic unit assembly 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)
WARNING
35B-146

ABS SENSOR
ABS SENSOR
M1352020700061
Post-installation Operation Wheel Speed Sensor Output Voltage Measurement (Refer to P.35B-138).
<Front>
1
<Rear>
AC211696AB
<<A>>
1. 2.
Front wheel speed sensor removal steps Front wheel speed sensor Front wheel speed rotor (Refer to GROUP 26, Drive Shaft Assembly P.26-11).
<<A>>
>>A<<
3. 4.
Rear wheel speed sensor removal steps Rear wheel speed sensor Rear wheel speed rotor (Refer to GROUP 27, Drive Shaft Assembly P.27-36).
NOTE: The wheel speed rotors are integrated with the drive shaft and cannot be disassembled.

ABS SENSOR
35B-147
REMOVAL SERVICE POINT <<A>> FRONT WHEEL SPEED SENSOR/REAR WHEEL SPEED SENSOR REMOVAL
CAUTION
NOTE: The projection can become magnetized due to the magnet inside the wheel speed 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.
<Front> <Rear>
<Front>
<Rear>
AC100242 AB
AC211699AB
Be careful when handling the projection at the tip of the wheel speed sensor and the toothed edge of the wheel speed rotor so as not to damage them by contacting other parts.
2. Measure the resistance between the wheel speed sensor terminals. Standard value: 1.24 1.64 k 3. If the internal resistance of the wheel speed sensor is not within the standard value, replace it with a new wheel speed sensor.
INSTALLATION SERVICE POINT >>A<< REAR WHEEL SPEED SENSOR INSTALLATION

Rear wheel speed sensor
ACX01120 AB
Parking brake cable

AC211698AB
Install the rear wheel speed sensor, crossing with the parking brake cable as shown.
INSPECTION
M1352020800057
WHEEL SPEED SENSOR CHECK

1. Check whether any metallic foreign material has adhered to the projection at the wheel speed sensor tip. Remove any foreign material. Also check whether the pole piece is damaged. Replace it with a new one if it is damaged.
4. Remove all connections from the speed sensor. The circuit should be open between terminals (1) and (2) and the body of the wheel speed sensor. If the circuit is not open, replace with a new wheel speed sensor. 5. Check the wheel speed sensor cable for breakage, damage or disconnection. Replace with a new one if a problem is found. NOTE: When checking for cable damage, remove the cable clamp part from the body and then gently bend and pull the cable near the clamp.
35B-148

G-SENSOR
TOOTHED WHEEL SPEED ROTOR CHECK
Check whether the wheel speed rotor teeth are broken or deformed. Replace the EBJ assembly of the driveshaft, respectively, if the teeth are damaged or deformed.
AC000965
G-SENSOR
M1352010100369
CAUTION Do not drop or apply a shock on the G-sensor.

Pre-removal and Post-installation Operation Rear Console Assembly Removal and Installation (Refer to GROUP 52A, Rear Floor Console Assembly P.52A-8).
Parking brake lever
2
Rear of the vehicle
Y2056AU
AC211700 AB
>>B<< >>A<<
1. 2.
Lateral G-sensor Longitudinal G-sensor

G-SENSOR
35B-149
INSTALLATION SERVICE POINTS >>A<< LONGITUDINAL G-SENSOR INSTALLATION

The arrow mark on the G-sensor must point to front of the vehicle.
>>B<< LATERAL G-SENSOR INSTALLATION

The arrow mark on the G-sensor must point to the parking brake lever.
1. Disconnect the G-sensor connector and connect special tool test harness set (MB991348), between terminals of the disconnected connector. 2. With the ignition switch turned to the "ON" position, 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 points straight down. Read output voltage between terminals number 2 and number 3. Standard Value: 3.4 3.6 V 4. If the voltage deviates from the standard value, and nothing is wrong with the power supply wire and earth wire, replace the G-sensor.
INSPECTION
M1352018000098
LATERAL/LONGITUDINAL G-SENSOR CHECK
Label
MB991348
Connector: D-37/D-38 (Harness side)
Label
AC103662AG
35B-150


M1352009500039
CAUTION Before removing the steering wheel and air bag module assembly, be sure to refer to GROUP 52B, Service Precautions (P.52B-3) and Drivers, Front Passengers Air Bag Module and Clock Spring (P.52B-110).
Make sure no oil adheres to the steering wheel sensor because a photointerruptors are mounted on the steering wheel sensor.
Pre-removal and Post-installation Operation Steering Wheel Removal and Installation (Refer to GROUP 37, Steering Wheel P.37-13). Column Cover, Clock Spring and Column Switch Assembly Removal and Installation (Refer to GROUP 37, Steering Shaft P.37-15).
Steering wheel sensor
AC311019AB
36-1
GROUP 36
PARKING BRAKES
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .
PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . PARKING BRAKE SWITCH CHECK . . . . . LINING RUNNING-IN . . . . . . . . . . . . . . . . .
36-2 36-2
PARKING BRAKE LEVER . . . . . . . . .

36-4
36-4
PARKING BRAKE CABLE. . . . . . . . . 36-2 36-3

36-3 36-3 36-3 REMOVAL AND INSTALLATION . . . . . . . .
36-5
36-5
PARKING BRAKE LINING AND DRUM

36-6
36-6 36-7
36-2
PARKING BRAKES
GENERAL INFORMATION
GENERAL INFORMATION
M1361000100418
The parking brake is of a mechanical control type acting on the rear wheels. A lever is used to apply the parking brake.
AC211553AB
M1361000300490
Item
Standard value
Limit Minimum 1.0 169.0
Parking brake lever stroke (Operation force: Approximately 5 7 notches 200 N) Rear brake lining thickness mm Rear drum inside diameter mm 2.8 168.0
LUBRICANTS
M1361000400367
Item Backing plate Shoe and lining assembly Adjuster
Specified lubricant Brake grease SAE J310, NLGI No.1
PARKING BRAKES
ON-VEHICLE SERVICE
36-3
ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT
M1361000900447
1. Pull the parking brake lever with a force of approximately 200 N and count the number of notches. Standard value: 5 7 notches 2. If the parking brake lever stroke is not the standard value, adjust as described below. (1) Remove the rear floor console assembly (Refer to GROUP 52A, Rear Floor Console P.52A-8).
Cable rod Adjusting nut
AC006198AB
3. Check for continuity between the parking brake switch terminal and the switch mounting bolt. When parking brake lever is pulled Less than 2 ohms When parking brake lever is released Open circuit
LINING RUNNING-IN
M1361001100336
Pull
AC006190
(2) Loosen the adjusting nut to move it to the cable rod end so that the cable will be free. (3) Depress the brake pedal repeatedly until the lever has no change in its stroke. NOTE: Depressing the brake pedal repeatedly adjusts shoe clearance correctly.
Spring balance
Approximately 40 mm
AC212035AB
CAUTION If the parking brake lever stroke is below the standard value and the braking is too firm, the rear brakes may drag. (4) Turn the adjusting nut to adjust the parking brake lever stroke to the standard value. After adjusting, check that there is no space between the adjusting nut and the parking brake lever. Check that the adjusting nut is secured with the nut holder. (5) After adjusting the parking brake lever stroke, jack up the rear end of the vehicle, and then release the parking brake and turn the rear wheels to check that the rear brakes are not dragging.
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.
CAUTION Carry out running-in a place with good visibility, and pay careful attention to safety. 1. Adjust the parking brake stroke to the standard value. Standard value (Operation force: Approximately 200 N): 5 - 7 notches
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 meters. 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 BRAKE SWITCH CHECK

M1361003300488
1. Remove the rear floor console assembly (Refer to GROUP 52A, Rear Floor Console P.52A-8). 2. Remove the front seat assembly (RH) (Refer to GROUP 52A, Front Seat P.52A-18).
36-4
PARKING BRAKES
PARKING BRAKE LEVER
PARKING BRAKE LEVER

M1361001300426
Pre-removal Operation Rear Floor Console Assembly and Rear Console Bracket Removal (Refer to GROUP 52A, Rear Floor Console P.52A-8).
Post-installation Operation Parking Brake Lever Stroke Adjustment (Refer to P.36-3). Rear Floor Console Assembly and Rear Console Bracket Installation (Refer to GROUP 52A, Rear Floor Console P.52A-8).
4 1 3
5 2
AC212036 AB
Ratchet pawl
Section A - A
Section B - B
A
Ratchet plate
B A
ABC
B
AC212037AB
1. 2. 3.
Removal steps Adjusting nut Parking brake switch connector Parking brake cable connection
4. 5.
Removal steps (Continued) Parking brake lever assembly Parking brake switch
PARKING BRAKES
PARKING BRAKE CABLE
36-5
PARKING BRAKE CABLE

M1361001900644
CAUTION During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly.
Pre-removal Operation Rear Floor Console Assembly and Rear Console Bracket Removal (Refer to GROUP 52A, Rear Floor Console P.52A-8). Rear Seat Cushion Assembly Removal (Refer to GROUP 52A, Rear Seat P.52A-20). Post-installation Operation Parking Brake Lever Stroke adjustment (Refer to P.36-3). Rear Seat Cushion Installation (Refer to GROUP 52A, Rear Seat P.52A-20). Rear Floor Console Assembly and Rear Console Bracket Installation (Refer to GROUP 52A, Rear Floor Console P.52A-8).
1
Removal steps Shoe and lining assembly (Refer to P.36-6). 1.
AC212038 AB
Removal steps (Continued) Parking brake cable connection (Refer to P.36-4). Parking brake cable
36-6
PARKING BRAKES

M1361002500401
CAUTION During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly.
118 19 Nm 54 5 Nm
14
12 11 3
10
13
7 11 9 8 4 5 2
5 11
Specified grease: Brake grease SAE J310, NLGI No.1
AC212051 AB
<<A>>
1. 2. >>B<< 3. 4. >>A<< 5. 6. 7. 8.
Removal steps Rear disc brake caliper assembly Rear brake disc Rear brake shoe return spring Rear brake shoe auto adjuster spring Rear brake shoe slack adjuster Parking brake operating lever strut Rear brake shoe-to-strut spring Rear brake shoe spring cup
Removal steps (Continued) Rear brake shoe hold-down spring Parking brake cable clip Rear brake shoe assembly Rear hub assembly (Refer to GROUP 27, Rear Hub Assembly P.27-32). 13. Rear brake backing plate 14. Rear brake pin 9. 10. 11. 12.
PARKING BRAKES
36-7
REMOVAL SERVICE POINT <<A>> REAR DISC BRAKE CALIPER ASSEMBLY REMOVAL
CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly. Remove the rear brake caliper assembly and support it with a wire or similar material.
Install the rear brake shoe return springs in the order shown in the illustration. NOTE: The figure shows the left wheel; for the right wheel, the position is symmetrical.
INSPECTION
M1361002600334
BRAKE LINING AND BRAKE DRUM CHECK
INSTALLATION SERVICE POINTS >>A<< REAR BRAKE SHOE SLACK ADJUSTER INSTALLATION
AC212066
Shoe adjusting bolt
1. Measure the thickness of the brake lining at several places. Standard value: 2.8 mm Limit: 1.0 mm
AC212064 AB
Install the rear brake adjuster so that the shoe adjusting bolt of left hand wheel is attached towards the rear of the vehicle, and the shoe adjusting bolt of right hand wheel is towards the front of the vehicle.
2. If the thickness of the brake lining has worn down to the limit value or more, replace the rear brake shoe assemblies on both sides of the vehicle.
>>B<< REAR BRAKE SHOE RETURN SPRING INSTALLATION
Rear of vehicle
AC212064AB
Paint
2
AC212065 AB
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 of the brake disc has worn down to the limit value or more, or if it is excessively worn on one side, replace the brake disc.
NOTES
55-1
GROUP 55
HEATER, AIR CONDITIONER AND VENTILATION

CONTENTS
SERVICE SPECIFICATIONS. . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . .
DIAGNOSIS TROUBLESHOOTING FLOW DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . DIAGNOSIS CODE CHART . . . . . . . . . . . . DIAGNOSTIC TROUBLE CODE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . TROUBLE SYMPTOM CHART. . . . . . . . . . SYMPTOM PROCEDURES . . . . . . . . . . . . DATA LIST REFERENCE TABLE . . . . . . . ACTUATOR TEST TABLE . . . . . . . . . . . . . CHECK AT ENGINE-A/T ECU TERMINALS CHECK AT A/C-ECU TERMINALS. . . . . . .
55-3 55-3 55-3 55-5

55-5 55-5 55-5 55-6 55-29 55-29 55-100 55-101 55-101 55-102
COMPRESSOR NOISE CHECK . . . . . . . . . POWER RELAY CHECK. . . . . . . . . . . . . . . IDLE-UP OPERATION CHECK. . . . . . . . . . CLEAN AIR FILTER REPLACEMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . .
55-106 55-107 55-107 55-108
HEATER CONTROL ASSEMBLY AND A/C SWITCH . . . . . . . . . . . . . . . . . . . . 55-108

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT . . . . . . . . . . . . . 55-109
REMOVAL AND INSTALLATION . . . . . . . . HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . . 55-109 55-110
DISASSEMBLY AND REASSEMBLY <LHD> 55-110 DISASSEMBLY AND REASSEMBLY <RHD> 55-111 BLOWER ASSEMBLY. . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . 55-112 55-112
ON-VEHICLE SERVICE. . . . . . . . . . .
MAGNETIC CLUTCH TEST . . . . . . . . . . . . COMPRESSOR DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . DUAL PRESSURE SWITCH CHECK . . . . . CHARGING AND DISCHARGING . . . . . . . REFILLING OF OIL IN THE A/C SYSTEM . PERFORMANCE TEST . . . . . . . . . . . . . . . REFRIGERANT LEAK REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . .
55-104
55-104 55-104 55-104 55-104 55-104 55-104 55-105
MODE SELECTION DAMPER CONTROL MOTOR, AIR MIXING DAMPER CONTROL MOTOR, OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR AND BLOWER MOTOR . . . . 55-113
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-113 55-114
Continued on next page
55-2
SENSORS . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
55-116
55-116 55-117
DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
55-124 55-125
EVAPORATOR ASSEMBLY . . . . . . .
REMOVAL AND INSTALLATION <LHD> . . REMOVAL AND INSTALLATION <RHD> . INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
55-118
55-118 55-119 55-120
CONDENSER AND CONDENSER FAN MOTOR. . . . . . . . . . . . . . . . . . . . 55-126

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-126 55-127
REFRIGERANT LINE . . . . . . . . . . . . . 55-128

REMOVAL AND INSTALLATION <LHD> . . REMOVAL AND INSTALLATION <RHD> . . 55-128 55-129
OUTSIDE THERMO SENSOR . . . . . .

INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
55-121
55-121
COMPRESSOR ASSEMBLY AND TENSION PULLEY. . . . . . . . . . . . . . .

DUCTS . . . . . . . . . . . . . . . . . . . . . . . . 55-130 55-122

55-122 55-123 REMOVAL AND INSTALLATION . . . . . . . . 55-130
VENTILATORS . . . . . . . . . . . . . . . . . . 55-131

55-3
M1552000300515
Item Idle speed r/min Idle-up speed r/min Air gap (magnetic clutch) mm Resistance value for mode selection damper control motor and potentiometer k A/C refrigerant temperature switch operating temperature C Being turned off Being turned on Standard value 850 50 850 50 0.3 0.5 Approximately 0.65 5.35 150 120
Resistance value for air mixing damper control motor and potentiometer k Approximately 0.65 5.35
LUBRICANTS
M1552000400396
Item Each connection of refrigerant line Refrigerant
Specified lubricant SUN PAG 56 R134a (HFC-134a)
Quantity 120 mL As required 480 520 g
Compressor refrigerant unit lubricant SUN PAG 56
SPECIAL TOOLS
M1552000600505
Tool
Number MB991367
Name Special spanner
Use Armature mounting nut of compressor removal and installation
B991367
MB991386
Pin
MB991502
M.U.T.-II sub-assembly
Automatic A/C check
B991502
55-4
Tool
A

SPECIAL TOOLS
Number MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826
Name M.U.T.-III sub-assembly A: Vehicle Communication Interface (V. C. I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A (Vehicles with CAN communication system) D: M.U.T.-III main harness B (Vehicles without CAN communication system) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
Use Automatic A/C check
MB991824
MB991827
DO NOT USE
MB991910
MB991911
MB991825
MB991826 MB991955
MB991223 Harness set a. MB991219 a. Check harness b. MB991220 b. LED harness c. MB991221 c. LED harness adapter d. MB991222 d. Probe
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
DO NOT USE
MB991223BA

TROUBLESHOOTING
55-5
Tool
Number MB992006
Name Extra fine probe
Use Continuity check and voltage measurement at harness wire or connector
MB992006
TROUBLESHOOTING
M1554004700102
DIAGNOSIS FUNCTION
M1554004800176
How to read diagnosis code

Connect the M.U.T.-II/III to the 16-pin diagnosis connector to read diagnosis code (Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points P.00-5).
How to erase diagnosis code

DIAGNOSIS CODE CHART

M1554004900537
Code No. 11 12 13 14 15 16 21 22 31 32 41 42
Diagnostic item Interior temperature senor system (open circuit) Interior temperature sensor system (short circuit) Outside thermo sensor system (open circuit) Outside thermo sensor system (short circuit) Heater water temperature sensor system (open circuit) Heater water temperature sensor system (short circuit) Air thermo sensor system (open circuit) Air thermo sensor system (short circuit) Air mixing damper control motor and potentiometer sensor system Mode selection damper control motor and potentiometer sensor system Air mixing damper control motor and potentiometer activating system
Reference page P.55-6 P.55-8 P.55-11 P.55-14 P.55-17 P.55-20 P.55-23
Mode selection damper control motor and potentiometer activating P.55-26 system
55-6

TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE PROCEDURES
Code No.11, 12: Interior Temperature Sensor System
Interior Temperature Sensor Circuit A/C-ECU
INTERIOR TEMPERATURE SENSOR
Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple

This code is set when the interior temperature sensor circuit is open (Code No.11) or is short (Code No.12).
DIAGNOSIS PROCEDURE
STEP 1. Check the interior temperature sensor. Refer to P.55-117.
Q: Is the check result normal? YES : Go to Step 2. NO : Replace the interior temperature sensor.
PROBABLE CAUSES
Malfunction of the interior temperature sensor Damaged the wiring harness or connectors Malfunction of the automatic A/C control panel (A/C-ECU)

TROUBLESHOOTING
55-7
STEP 2. Connector check: C-36 A/C-ECU connector and C-142 interior temperature sensor connector
Connector: C-36, C-142 <LHD>
STEP 3. Check the wiring harness between C-36 A/C-ECU connector (terminals 1 and 20) and C-142 interior temperature sensor connector (terminals 2 and 1).
C-142 (B) C-36 (B) C-142 (B) C-36 (B) Harness side C-36
Harness side C-36
C-142 C-142
AC504641AC AC504641AC
Connector: C-36 <RHD> Harness side Connector: C-36 <RHD> Harness side
C-36 (B) C-36 (B)

AC504618AJ AC504618AJ
Connector: C-142 <RHD> Connector: C-142 <RHD> Harness side Harness side C-142 (B) C-142 (B)
AC504625AD AC504625AD
Q: Is the check result normal? YES : Go to Step 3. NO : Repair the connector.
Check the sensor signal line and earth line for open or short circuit.
Q: Is the check result normal? YES : Replace the automatic A/C control panel
(A/C-ECU)
NO : Repair the wiring harness.
55-8

TROUBLESHOOTING
Code No.13, 14: Outside Thermo Sensor System
Outside Thermo Sensor Circuit A/C-ECU
OUTSIDE THERMO SENSOR

This code is set when the outside thermo sensor circuit is open (Code No.13) or is short (Code No.14).
DIAGNOSIS PROCEDURE
STEP 1. Check the outside thermo sensor. Refer to P.55-121.
Q: Is the check result normal? YES : Go to Step 2. NO : Replace the outside thermo sensor.
PROBABLE CAUSES
Malfunction of the outside thermo sensor Damaged the wiring harness and connectors Malfunction of the automatic A/C control panel (A/C-ECU)

TROUBLESHOOTING
55-9
STEP 2. Connector check: A-44 outside thermo sensor connector and C-36 A/C-ECU connector
Connector: A-44
STEP 3. Check the wiring harness between A-44 outside thermo sensor connector (terminals 1 and 2) and C-36 A/C-ECU connector (terminals 20 and 7).
Connector: A-44
Harness side Harness side A-44 (BR) A-44 (BR)

AC504656AB
Connector: C-36 <LHD> Connector: C-36 <LHD>
AC504656AB
Harness side
C-36 (B)
AC504622AB
Harness side
C-36 (B)
AC504622AB
C-36 (B) C-36 (B)

AC504618AJ
AC504618AJ
55-10
NOTE:
Connector: C-129 <RHD>

TROUBLESHOOTING
AC504618AK
Connector: C-145 <LHD>
AC504622AE
Prior to the wiring harness inspection, check intermediate connector C-145 <LH drive vehicles> or C-129 <RH drive vehicles>, and repair if necessary. Check the sensor signal line and earth line for open or short circuit.
(A/C-ECU)

TROUBLESHOOTING
55-11
Code No.15, 16: Heater Water Temperature Sensor System
Heater Water Temperature Sensor Circuit HEATER WATER TEMPERATURE SENSOR
A/C-ECU

This code is set when the heater water temperature sensor circuit is open (Code No.15) or is short (Code No.16).
DIAGNOSIS PROCEDURE
STEP 1. Check the heater water temperature sensor. Refer to P.55-117.
Q: Is the check result normal? YES : Go to Step 2. NO : Replace the heater water temperature
PROBABLE CAUSES
Malfunction of the heater water temperature sensor Damaged the wiring harness or connectors Malfunction of the automatic A/C control panel (A/C-ECU)
sensor.
55-12

TROUBLESHOOTING
STEP 2. Connector check: C-36 A/C-ECU connector and C-32 heater water temperature connector
STEP 3. Check the wiring harness between C-36 A/C-ECU connector (terminals 4 and 20) and C-32 heater water temperature sensor connector (terminals 2 and 1).
AC504617AJ AC504617AJ
Connector: C-32, C-36 <RHD> Connector: C-32, C-36 <RHD>
C-32 C-36 (B) C-32 C-36 (B)
Harness side C-32
Harness side C-32
C-36 C-36
AC504624AE
Connector: C-36 <LHD> Connector: C-36 <LHD>
AC504624AE
Harness side
C-36 (B)
AC504622AB
Harness side
C-36 (B)
AC504622AB

TROUBLESHOOTING
55-13
NOTE:
AC504617AF
AC504618AF
Prior to the wiring harness inspection, check intermediate connector C-10, and repair if necessary. Check the sensor signal line and earth line for open or short circuit.
(A/C-ECU)
55-14

TROUBLESHOOTING
Code No.21, 22: Air Thermo Sensor System
<LHD>
Air Thermo Sensor Circuit AIR THERMO SENSOR
A/C-ECU
<RHD>
Air Thermo Sensor Circuit HEATER WATER TEMPERATURE SENSOR AIR THERMO SENSOR
A/C-ECU

TROUBLESHOOTING
55-15

This code is set when the air thermo sensor circuit is open (Code No.21) or is short (Code No.22).
STEP 2. Connector check: C-36 A/C-ECU connector and C-35 air thermo sensor connector
PROBABLE CAUSES
Malfunction of the air thermo sensor Damaged the wiring harness or connectors Malfunction of the automatic A/C control panel (A/C-ECU)
Harness side
DIAGNOSIS PROCEDURE
AC504617AD
STEP 1. Check the air thermo sensor. Refer to P.55-120.

Q: Is the check result normal? YES : Go to Step 2. NO : Replace the air thermo sensor.
Connectors: C-35, C-36 <RHD>
C-35
C-36 (B)
Harness side C-35
C-36
AC504624AC
Harness side
C-36 (B)
AC504622AB
55-16

TROUBLESHOOTING
STEP 3. Check the wiring harness between C-36 A/C-ECU connector (terminals 8 and 20) and C-35 air thermo sensor connector (terminals 1 and 2).
NOTE:
Harness side
AC504617AF

AC504617AD
C-35
C-36 (B) Connector: C-32 <RHD>
AC504618AF
Harness side C-35
Harness side
C-36
AC504618AL
AC504624AC
Prior to the wiring harness inspection, check intermediate connector C-10 and heater water temperature sensor connector C-32 <RH drive vehicles>, and repair if necessary. Check the sensor signal line and earth line for open or short circuit.
(A/C-ECU)
Harness side C-36 (B)
AC504622AB

TROUBLESHOOTING
55-17
Code No.31: Air Mixing Damper Control Motor Potentiometer System
<LHD>
Air Mixing Damper Control Motor Potentiometer Circuit AIR MIXING DAMPER CONTROL MOTOR AND POTENTIOMETER
A/C-ECU
<RHD>
Air Mixing Damper Control Motor Potentiometer Circuit AIR MIXING DAMPER CONTROL MOTOR AND POTENTIOMETER
A/C-ECU
55-18

TROUBLESHOOTING

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.
STEP 2. Connector check: C-36 A/C-ECU connector and C-144 air mixing damper control motor and potentiometer connector
PROBABLE CAUSES
Malfunction of the air mixing damper control motor and potentiometer Damaged the wiring harness or connectors Malfunction of the automatic A/C control panel (A/C-ECU)
Harness side
C-36 (B)
AC504622AB
DIAGNOSIS PROCEDURE
STEP 1. Check the air mixing damper control motor and potentiometer. Refer to P.55-114.
Q: Is the check result normal? YES : Go to Step 2. NO : Replace the air mixing damper control
motor and potentiometer.
C-144
C-36 (B)
Harness side C-36
C-144
AC504624AI
Harness side
AC504617AL

TROUBLESHOOTING
55-19
STEP 3. Check the wiring harness between C-36 A/C-ECU connector (terminals 10, 5 and 20) and C-144 air mixing damper control motor and potentiometer connector (terminals 2, 5 and 6).
Connectors: C-10, C-144 <LHD>
C-144
C-10
C-10 Harness side C-36 (B)

AC504622AB
Connectors: C-10, C-32, C-36, C-144 <RHD> C-32
Harness side C-144
C-10 C-144 C-36 (B)
AC504701AC
C-10
Harness side C-32
NOTE: Prior to the wiring harness inspection, check intermediate connector C-10, and heater water temperature sensor connector C-32 <RH drive vehicles>, and repair if necessary. Check the potentiometer power supply, earth and signal line for open or short circuit.
Harness side C-36
Harness side C-144
(A/C-ECU).
AC504624AQ
55-20

TROUBLESHOOTING
Code No.32: Mode Selection Damper Control Motor Potentiometer System
<LHD>
Mode Selection Damper Control Motor Potentiometer Circuit MODE SELECTION DAMPER CONTROL MOTOR AND POTENTIOMETER
A/C-ECU
<RHD>
Mode Selection Damper Control Motor Potentiometer Circuit MODE SELECTION DAMPER CONTROL MOTOR AND POTENTIOMETER
HEATER WATER TEMPERATURE SENSOR
A/C-ECU

TROUBLESHOOTING
55-21

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.
STEP 2. Connector check: C-36 A/C-ECU connector and C-143 mode selection damper control motor and potentiometer connector
PROBABLE CAUSES
Malfunction of the mode selection damper control motor and potentiometer Malfunction of the automatic A/C control panel (A/C-ECU) Damaged the wiring harness or connectors
Harness side
C-36 (B)
AC504622AB
DIAGNOSIS PROCEDURE
STEP 1. Check the mode selection damper control motor and potentiometer. Refer to P.55-114.
Q: Is the check result normal? YES : Go to Step 2. NO : Replace the mode selection damper control
C-143
C-36 (B)
Harness side C-36
C-143
AC504624AK
Harness side
AC504617AM
55-22

TROUBLESHOOTING
STEP 3. Check the wiring harness between C-36 A/C-ECU connector (terminals 10, 6 and 20) and C-143 mode selection damper control motor and potentiometer connector (terminals 2, 5 and 6).
C-143
C-10
Harness side
C-10 C-36 (B)

AC504622AB
Connectors: C-10, C-32, C-36, C-143 <RHD> C-143
Harness side C-143
C-10
C-32
AC504701AD
C-36 (B)
C-10
Harness side C-32
NOTE: Prior to the wiring harness inspection, check intermediate connector C-10 and heater water temperature sensor connector C-32 <RH drive vehicles>, and repair if necessary. Check the potentiometer power supply, earth and signal line for open or short circuit.
Q: Is the check result normal? YES : Malfunction of the automatic A/C control
Harness side C-36
Harness side C-143
panel (A/C-ECU)
AC504624AR

TROUBLESHOOTING
55-23
Code No.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 Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple

This code is set when the air mixing damper cannot be rotated to the preset opening angle.
DIAGNOSIS PROCEDURE
STEP 1. Check the air mixing damper control motor and potentiometer. Refer to P.55-114.
Q: Is the check result normal? YES : Go to Step 2. NO : Replace the air mixing damper control
PROBABLE CAUSES
Malfunction of the air mixing damper control motor and potentiometer Malfunction of the automatic A/C control panel (A/C-ECU) Damaged the wiring harness or connectors
55-24

TROUBLESHOOTING Q: Is the check result normal? YES : Go to Step 3. NO : Repair the connector.
STEP 2. Connector check: C-37 A/C-ECU connector and C-144 air mixing damper control motor and potentiometer connector
Harness side
C-37 (B)
AC504622AC
C-144
C-37 (B)
Harness side C-37
C-144
AC504624AM
Harness side
AC504617AL

TROUBLESHOOTING
55-25
STEP 3. Check the wiring harness between C-37 A/C-ECU connector (terminals 22 and 25) and C-144 air mixing damper control motor and potentiometer connector (terminals 3 and 1).
C-144
C-10
Harness side C-10 C-37 (B)

AC504622AC
Connectors: C-10, C-37, C-144 <RHD>
Harness side C-144
C-10 C-144 C-37 (B)
AC504701AC
C-10
NOTE: Prior to the wiring harness inspection, check intermediate connector C-10, and repair if necessary. Check the motor activating lines for open or short circuit.
Q: Is the check result normal? YES : Malfunction of the automatic A/C control
panel (A/C-ECU)
Harness side C-37 Harness side C-144
AC504624AN
55-26

TROUBLESHOOTING
Code No.42: Mode Selection Damper Control Motor and Potentiometer Activating System
Mode Selection Damper Control Motor and Potentiometer Circuit MODE SELECTION DAMPER CONTROL MOTOR AND POTENTIOMETER
A/C-ECU MOTOR DRIVE 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 : Grey R : Red P : Pink V : Violet PU : Purple

This code is set when the mode selection damper cannot be rotated to the preset opening angle.
DIAGNOSIS PROCEDURE
STEP 1. Check the mode selection damper control motor and potentiometer. Refer to P.55-114.
Q: Is the check result normal? YES : Go to Step 2. NO : Replace the mode selection damper control
PROBABLE CAUSES
Malfunction of the mode selection damper control motor and potentiometer Malfunction of the automatic A/C control panel (A/C-ECU) Damaged the wiring harness or connectors

TROUBLESHOOTING
55-27
STEP 2. Connector check: C-37 A/C-ECU connector and C-143 mode selection damper control motor and potentiometer connector
Harness side
C-37 (B)
AC504622AC
Connectors: C-37, C-143 <RHD> C-143
C-37 (B)
Harness side C-37
C-143
AC504624AO
Harness side
AC504617AM
55-28

TROUBLESHOOTING
STEP 3. Check the wiring harness between C-37 A/C-ECU connector (terminals 21 and 24) and C-143 mode selection damper control motor and potentiometer connector (terminals 3 and 1).
C-143
C-10
Harness side C-10 C-37 (B)

AC504622AC
Connectors: C-10, C-37, C-143 <RHD> C-143
Harness side C-143
C-10 C-37 (B)
AC504701AD
C-10
(A/C-ECU).
Harness side C-37 Harness side C-143
AC504624AP

TROUBLESHOOTING
55-29
TROUBLE SYMPTOM CHART

M1554005000571
Symptom Communication with the M.U.T.-II/III is not possible.
Inspection Reference page procedure number 1 P.55-29 P.55-32
When the A/C is operating, temperature inside the 2 passenger compartment does not decrease (cool air is not emitted). A/C outlet air temperature cannot be set. The blower does not work. The blower air volume cannot be changed. When sunlight intensity changes, blower air temperature does not change. The outside/inside air changeover is impossible. Rear window defogger function does not operate. Malfunction of the A/C-ECU power supply system. A/C compressor power supply system. Condenser fan does not operate. 3 4 5 6 7 8 9 10 11
P.55-41 P.55-42 P.55-54 P.55-56 P.55-58 P.55-63 P.55-73 P.55-79 P.55-86
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with the M.U.T.-II/III is not Possible.
Diagnosis Connector Circuit A/C-ECU
<LHD> <RHD>
DIAGNOSIS CONNECTOR
FRONT SIDE
55-30

TROUBLESHOOTING

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 M.U.T.-II/III, the diagnosis line between the A/C-ECU and the diagnosis connector may be defective.
STEP 3. Connector check: C-36 A/C-ECU connector and C-14 diagnosis connector
PROBABLE CAUSES
Damaged the wiring harness or connectors Malfunction of the automatic A/C control panel (A/C-ECU)
C-36 (B) C-14
DIAGNOSIS PROCEDURE
STEP 1. Check the communication with other systems.
Q: Is the communication with the other systems possible using the M.U.T.-II/III? YES : Go to Step 2. NO : Check the diagnosis line using the
Harness side C-14
C-36
M.U.T.-II/III, and repair if necessary.

AC504641AD
STEP 2. Check operations of the A/C, rear window defogger and outside/inside air selection damper control motor.
Q: Does the A/C, rear window defogger or outside/inside air selection damper control motor operate? YES : Go to Step 3. NO : Refer to Inspection procedure 9
Harness side
"Malfunction of the A/C-ECU power supply system P.55-73."
C-14 (B)
AC504625AE
Connector: C-36 <RHD> Harness side
C-36 (B)
AC504618AJ

TROUBLESHOOTING
55-31
STEP 4. Check the wiring harness between C-36 A/C-ECU connector (terminal 17 and 18) and C-14 diagnosis connector (terminal 11 and 1).
NOTE:
AC504618AM
C-36 (B) C-14 Connector: C-23 <LHD>
Harness side C-14 C-23 (B) C-36

AC504622AG
AC504641AD
Prior to the wiring harness inspection, check joint connector C-23 <LH drive vehicles> or C-21 <RH drive vehicles> , and repair if necessary. Check the communication lines for open or short circuit.
Harness side
(A/C-ECU).
C-14 (B)
AC504625AE
C-36 (B)
AC504618AJ
55-32

TROUBLESHOOTING
Inspection Procedure 2: When the A/C is Operating, Temperature Inside the Passenger Compartment does not Decrease (Cool Air is not Emitted).
A/C-ECU System Circuit ENGINE-ECU
LOWPRESSURE SIDE
DUAL PRESSURE SWITCH
HIGHPRESSURE SIDE
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 : Grey R : Red P : Pink V : Violet PU: Purple
BLOWER LINER CONTROLLER AIR THERMO SENSOR

TROUBLESHOOTING
55-33

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.
STEP 4. Connector check: A-36 A/C compressor connector and C-121 engine-ECU connector
Connector: A-36
PROBABLE CAUSES
Improper amount of refrigerant Malfunction of the air thermo sensor Malfunction of the dual pressure switch 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-ECU
Harness side
A-36 (B) Connector: C-121 <LHD>
AC504616AB
Harness side
DIAGNOSIS PROCEDURE
STEP 1. Check the rear window defogger and outside/inside air selection damper control motor operation.
Q: Do the rear window defogger and outside/inside air selection damper control motor work normally? YES : Go to Step 2. NO : Refer to Inspection procedure 9
C-121 (GR)
AC504617AB
"Malfunction of the A/C-ECU power supply system P.55-73 ." 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 "The blower
C-121 (GR)
AC504618AB
does not work P.55-42." 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.
55-34

TROUBLESHOOTING
STEP 5. Voltage measurement at the A-36 A/C compressor connector.

Connector: A-36
Connector A-36 (Harness side)

Harness side
AC301541GC
A-36 (B)
AC504616AB
Connector: C-121 <LHD> Harness side
(4) Measure the voltage between terminal 1 and body earth. OK: System voltage
Q: Is the check result normal? YES : Go to Step 6. NO : Refer to Inspection procedure 10 "A/C
Compressor power supply system P.55-79."

C-121 (GR)
AC504617AB
C-121 (GR)
AC504618AB

AC504619AB
(2) Disconnect engine-ECU connector C-121, and earth terminal 20.

TROUBLESHOOTING
55-35
STEP 6. Connector check: C-36 A/C-ECU connector and C-34 blower liner controller connector
STEP 7. Check the wiring harness between C-34 blower liner controller connector terminal No.5 and C-36 A/C-ECU connector terminal No.2.
Harness side
Harness side
AC504617AC
AC504617AC
C-36 (B) C-34 C-34
C-36 (B)
Harness side C-34
Harness side C-34
C-36
C-36
AC504624AB
AC504624AB
Harness side
C-36 (B)
AC504622AB
Harness side
C-36 (B)
AC504622AB
Q: Is the check result normal? YES : Go to Step 8. NO : Repair the wiring harness.
55-36

TROUBLESHOOTING
STEP 8. Connector check: A-25 dual pressure switch connector

Connector: A-25 A-25 (BR) Harness side
STEP 11. Check the wiring harness between C-35 air thermo sensor connector (terminals 4 and 5) and C-36 A/C-ECU connector (terminals 8 and 10).
Harness side
AC504616AC
AC504617AD
STEP 9. Check the dual pressure switch operation. Refer to P.55-104.

Q: Is the dual pressure switch operating properly? YES : Go to Step 10. NO : Replace the dual pressure switch.
C-35 C-36 (B)
STEP 10. Connector check: C-35 air thermo sensor connector

Harness side C-35
Harness side
C-36
AC504624AC AC504617AD
Harness side
Harness side
C-36 (B)
AC504622AB
AC504618AD

TROUBLESHOOTING
55-37
NOTE:
STEP 12. Check the wiring harness between A-25 dual pressure switch connector terminal No.1 and C-37 A/C-ECU connector terminal No.34.
AC504617AF

AC504616AC
Harness side
AC504618AF
Prior to the wiring harness inspection, check intermediate connector C-10, and repair if necessary. Check the air thermo sensor output and earth line for open or short circuit.
C-37 (B)
AC504622AC
C-37 (B)
AC504618AE
55-38
NOTE:

TROUBLESHOOTING

Connector: C-117 <LHD> Harness side C-117 (GR)
AC504617AE
Connector: C-111 <RHD> Connector: C-117 Harness side
AC504617AG
AC504625AB
Prior to the wiring harness inspection, check intermediate connector C-111, and repair if necessary. Check the dual pressure switch output line for open or short circuit.
C-117 (GR)
AC504618AY

TROUBLESHOOTING
55-39
STEP 14. Check the wiring harness between C-117 engine-ECU connector terminal No.83 and A-25 dual pressure switch connector terminal No.2.
Connector: C-117, C-122 <RHD>
C-117 (GR)
C-122
C-117 Harness side
AC504616AC
C-122
C-117 (GR)
AC504624AS
NOTE:
Connector: C-111 <RHD> C-111 C-111
C-117 Harness side Connector: C-124 <LHD>

AC504701AE
AC504625AB
AC504622AD
Prior to the wiring harness inspection, check intermediate connector C-111 and C-124 <LH drive vehicles> or C-122 <RH drive vehicles>, and repair if necessary. Check the communication line for open or short circuit.
55-40

TROUBLESHOOTING

STEP 16. Check the wiring harness between C-119 engine-ECU connectors terminal No.65 and C-37 A/C-ECU connector terminal No.32.
C-119 (GR) Harness side
C-37 (B)
AC504617AH AC504622AC
Connector: C-119 <RHD> Harness side Connector: C-37 <RHD> Harness side C-119 (GR) C-37 (B)
AC504618AI
AC504618AE
C-119 (GR)
AC504617AH
C-119 (GR)
AC504618AI

TROUBLESHOOTING
55-41
NOTE:
STEP 17. Check the magnetic clutch operation. Refer to P.55-123.

Q: Can the sound of the magnetic clutch (click) be heard? YES : Go to Step 18. NO : Replace the compressor magnet clutch.
C-122 (L)
AC504618AH
STEP 18. Check the refrigerant temperature switch. Refer to P.55-125.

Q: Is the refrigerant temperature switch operating properly? YES : Go to Step 19. NO : Replace the refrigerant temperature switch.
STEP 19. Check the air thermo sensor. Refer to P.55-120.

Q: Is the air thermo sensor in good condition? YES : Go to Step 20. NO : Replace the air thermo sensor.
AC504622AD
Prior to the wiring harness inspection, check intermediate connector C-124 <LH drive vehicles> or C-122 <RH drive vehicles>, and repair if necessary. Check the communication line for open or short circuit.
STEP 20. Check the refrigerant level. Refer to P.55-104.

Q: Is the refrigerant level correct? YES : Go to Step 21. NO : Correct the refrigerant level (Refer to
P.55-104). STEP 21. Replace the A/C-ECU. Check that the air conditioner works normally.
Q: Is the check result normal? YES : The procedure is complete. NO : Replace the engine-ECU.
Inspection Procedure 3: A/C Outlet Air Temperature cannot be set.

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.
DIAGNOSIS PROCEDURE
M.U.T.-II/III diagnosis code
Q: Is the diagnosis code set? YES : Refer to diagnosis code chart P.55-5. NO : Replace the automatic A/C control panel
PROBABLE CAUSE
Malfunction of the A/C-ECU
(A/C-ECU).
55-42

TROUBLESHOOTING
Inspection Procedure 4: The Blower does not work.
Blower Circuit FUSIBLE LINK 1 IGNITION SWITCH (IG2)
BLOWER RELAY
BLOWER MOTOR (BLOWER LINEAR CONTROLLER)
<RHD>
<LHD>
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 : Grey R : Red P : Pink V : Violet PU : Purple

If the blower motor does not operate, the blower motor circuit system may be defective.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III actuator test Carry out the actuator test. (Refer to P.55-101) Item 01, 02, 03, 04: Blower motor
Q: Does the blower motor work normally? YES : Replace the automatic A/C control panel
PROBABLE CAUSES
Malfunction of the blower motor (blower linear controller). Malfunction of the automatic A/C control panel (A/C-ECU) Damaged the wiring harness or connectors
(A/C-ECU).
NO : Go to Step 2.

TROUBLESHOOTING
55-43
STEP 2. Voltage measurement at the C-34 blower linear controller connector.

STEP 3. Check the blower relay. Refer to GROUP 55A, On-vehicle Service Power relay check P.55-107.
Q: Is the blower relay in good condition? YES : Go to Step 4. NO : Replace the blower relay.
Harness side
STEP 4. Voltage measurement at C-216 blower relay connector.

AC504617AC
Connector: C-34 <RHD> Harness side Junction block side
AC504692AB
AC504618AC
Connector: C-216 <RHD> Junction block (Front view)
(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the ON position.
Junction block side

AC504694AB
(1) Remove the relay, and measure at the junction block side. (2) Turn the ignition switch to the ON position.
AC301541JY
Connector C-216 (Junction block side)
AC301541JZ
(3) Voltage between terminal 1 and body earth. OK: System voltage
55-44

TROUBLESHOOTING
Connector: C-211, C-216 <RHD> Junction block (Front view)
STEP 5. Connector check: C-216 blower relay connector

Connector: C-216 <LHD> Junction block (Front view)
C-211
Junction block side C-216
AC504692AB
Harness side C-211
Connector: C-216 <RHD> Junction block (Front view) Junction block side C-216
Junction block side

AC504635AC
AC504694AB
NOTE: Prior to the wiring harness inspection, check junction block connector C-211, 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
STEP 6. Check the wiring harness between C-216 blower relay connector terminal No.1 and the ignition switch (IG2).
malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness.
Junction block (Front view) C-211
C-216
Harness side C-211
AC504633AC

TROUBLESHOOTING
55-45
STEP 7. Measure the voltage at C-216 blower relay connector.


Junction block side
Junction block side
AC504692AB
AC504692AB
Junction block side
Junction block side
AC504694AB
AC504694AB
(1) Remove the relay, and measure at the junction block side.
AC301541KA
55-46

TROUBLESHOOTING
STEP 9. Check the wiring harness between C-216 blower relay connector terminal No.5 and fusible link (1).
Connectors: C-212, C-216 <LHD> Junction block (Front view)
NOTE:
Harness side
C-212 (B)
AC504622AH
Connector: C-126 <RHD> C-216 Harness side Harness side C-212
AC504618AN
AC504633AD
Connectors: C-212, C-216 <RHD> Junction block (Front view) C-212 (B)
Prior to the wiring harness inspection, check intermediate connectors C-126 and junction block connector C-212, and repair if necessary. Check the blower relay power supply line for open circuit.
C-216 Harness side C-212
AC504635AD

TROUBLESHOOTING
55-47
STEP 10. Resistance measurement at C-216 blower relay connector.


Junction block side
Junction block side
AC504692AB
AC504692AB
Junction block side
Junction block side
AC504694AB
AC504694AB
AC301541KB
(2) Measure the resistance between terminal 3 and body earth OK: 2 or less
55-48

TROUBLESHOOTING
STEP 12. Check the wiring harness between C-216 blower relay connector terminal No.3 and body earth.
C-36 (B)
AC504618AJ
C-214 C-216 Harness side C-214
NOTE: Prior to the wiring harness inspection, check junction block connector C-214 and joint connector C-36 <RH drive vehicles>, and repair if necessary. Check the blower relay earth wires for open circuit.
AC504633AE
Connector: C-214, C-216 <RHD> Junction block (Front view)
AC504635AE

TROUBLESHOOTING
55-49
STEP 13. Connector check: C-216 blower relay connector and C-34 blower linear controller connector
Harness side
AC504617AC
AC504618AC
Junction block side
AC504692AB
Junction block side
AC504694AB
55-50

TROUBLESHOOTING
STEP 14. Check the wiring harness between C-216 blower relay connector terminal No.4 and C-34 blower linear controller connector terminal No.6.
Harness side
Junction block (Front view) C-211 Connector: C-34 <RHD> Harness side C-216
AC504617AC
Harness side C-211
AC504618AC
AC504633AC
NOTE: Prior to the wiring harness inspection, check junction block connector C-211, and repair if necessary. Check the blower linear controller power supply line for open circuit.
Connector: C-211, C-216 <RHD> Junction block (Front view) C-211
C-216
Harness side C-211
AC504635AC

TROUBLESHOOTING
55-51
STEP 15. Resistance measurement at the C-34 blower linear controller connector.
STEP 16. Connector check: C-34 blower liner controller

Harness side
Harness side
AC504617AC
AC504617AC
AC504618AC
AC504618AC
AC301541KC
(2) Continuity between terminal 3 and body earth OK: 2 or less

55-52

TROUBLESHOOTING
STEP 17. Check the wiring harness between C-34 blower linear controller connector terminal No.3 and body earth.
STEP 18. Connector check: C-36 A/C-ECU connector and C-34 blower linear controller connector
Harness side
Harness side
AC504617AC
AC504617AC
C-36 (B) C-34

AC504618AC
Check the blower linear controller earth line for open circuit.
Harness side C-34
C-36
AC504624AB
Harness side
C-36 (B)
AC504622AB

TROUBLESHOOTING
55-53
STEP 19. Check the wiring harness between C-36 A/C-ECU connector terminal No.2 and C-34 blower linear controller connector terminal No.5.
Q: Is the check result normal? YES : Replace the A/C control panel (A/C-ECU) or
the blower motor (blower linear controller).

Harness side
AC504617AC
C-36 (B) C-34
Harness side C-34
C-36
AC504624AB
Harness side
C-36 (B)
AC504622AB
Check the communication line for open or short circuit.
55-54

TROUBLESHOOTING
Inspection Procedure 5: The Blower Air Volume cannot be changed.
Blower Motor Circuit BLOWER RELAY
BLOWER MOTOR (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 : Grey R : Red P : Pink V : Violet PU : Purple

If the blower air volume can not be changed when the blower switch is operated, the circuit between blower motor (blower linear controller) and A/C-ECU may be defective.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III actuator test Carry out the actuator test. Items 01, 02, 03, 04: Blower motor
POSSIBLE CAUSES
Blower motor (blower linear controller) Damaged the wiring harness or connectors Malfunction of the automatic A/C control panel (A/C-ECU)
(A/C-ECU)
NO : Go to Step 2.

TROUBLESHOOTING
55-55
STEP 2. Connector check: C-36 A/C-ECU connector and C-34 blower linear controller connector
STEP 3. Check the wiring harness between C-36 A/C-ECU connector terminal No.2 and C-34 blower linear controller connector terminal No.5.
Harness side
Harness side
AC504617AC
AC504617AC
C-36 (B) C-34 C-34
C-36 (B)
Harness side C-34
Harness side C-34
C-36
C-36
AC504624AB
AC504624AB
Harness side
C-36 (B)
AC504622AB
Harness side
C-36 (B)
AC504622AB
Check the communication line for open or short circuit.

(A/C-ECU) or the blower motor (blower linear controller). NO : Repair the wiring harness.
55-56

TROUBLESHOOTING
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.
STEP 2. M.U.T.-II/III 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
PROBABLE CAUSES
Malfunction of the photo sensor Damaged the wiring harness or connectors Malfunction of the A/C-ECU
to P.55-5. STEP 3. M.U.T.-II/III data list Item 25: Photo sensor OK: Check that the volume of insolation takes inverse proportion with the M.U.T.-II/III displayed voltage.
DIAGNOSIS PROCEDURE
STEP 1. Check the rear window defogger and outside/inside air selection damper control motor operation.
Q: Do the rear window defogger and outside/inside air selection damper control motor work normally? YES : Go to Step 2. NO : Refer to Inspection procedure 9
(A/C-ECU).
NO : Go to Step 4.

TROUBLESHOOTING
55-57
STEP 4. Connector check: C-36 A/C-ECU connector and C-141 photo sensor connector.
STEP 5. Check the wiring harness between C-141 photo sensor connector (terminal 1, 2) and C-36 A/C-ECU connector (terminal 19, 9).
C-141 C-141 C-36 (B) C-36 (B) Harness side C-36 Harness side C-36
C-141 C-141
AC504641AE AC504641AE
C-36 (B) C-36 (B)

AC504618AJ AC504618AJ
Connector: C-141 <RHD> Connector: C-141 <RHD>
AC504625AG AC504625AG
Q: Is the check result normal? YES : Go to Step 5. NO : Repair or replace the connector.
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.
55-58

TROUBLESHOOTING
Inspection Procedure 7: The outside/inside air changeover is impossible.
Outside/Inside Air Selection Damper Control Motor Circuit A/C-ECU

MOTOR DRIVE CIRCUIT
IGNITION SWITCH (IG2)
OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR

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.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III actuator test Carry out the actuator test. (Refer to P.55-101) Item 13, 14: outside/inside air selection damper control motor
PROBABLE CAUSES
Malfunction of the outside/inside air selection damper control motor Damaged the wiring harness or connectors Malfunction of the automatic A/C control panel (A/C-ECU)
(A/C-ECU)
NO : Go to Step 2.

TROUBLESHOOTING
55-59
STEP 2. Measure the voltage at C-07 outside/inside air selection damper control motor connector.
STEP 3. Connector check: C-07 outside/inside air selection damper control motor connector
AC504617AK AC504617AK
Connector: C-07 <RHD> Connector: C-07 <RHD> Harness side Harness side
AC504618AO AC504618AO
(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the ON position.
AC301541KD
55-60

TROUBLESHOOTING
STEP 4. Check the wiring harness between C-07 outside/inside air selection damper control motor connector terminal No.7 and the ignition switch (IG2).
NOTE:
Connector: C-101 <LHD> C-101 (L)
C-07
AC504622AI
C-10 Connector: C-101 <RHD>
C-07 Harness side C-101 (L)
C-10 Connectors: C-210, C-211 <LHD> Junction block (Front view)

AC504701AB
AC504625AF
Connectors: C-07, C-10 <RHD> C-07
C-211
C-210
C-10 Harness side C-210 C-07 Harness side C-211
C-10
AC504633AF
AC504624AF

TROUBLESHOOTING
Connectors: C-210, C-211 <RHD> Junction block (Front view) C-211
55-61
STEP 6. Connector check: C-37 A/C-ECU connector and C-07 outside/inside air selection damper control motor connector
C-210
Harness side
Harness side C-210

AC504617AK
Connectors: C-07, C-37 <RHD> C-211 C-07
AC504635AF
C-37 (B)
Prior to the wiring harness inspection, check intermediate connector C-10, joint connector C-101 and junction block connectors C-210 and C-211, and repair if necessary. Check the motor power supply line for open circuit.
Harness side C-07
malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness. STEP 5. Check the outside/inside air selection damper control motor Refer to P.55-114.
Q: Is the check result normal? YES : Go to Step 6. NO : Replace the outside/inside air selection
C-37
AC504624AG
damper control motor.
Harness side
C-37 (B)
AC504622AC
55-62

TROUBLESHOOTING
STEP 7. Check the wiring harness between C-37 A/C-ECU connector (terminals 23 and 26) and C-07 outside/inside air selection damper control motor connector (terminals 6 and 4).
Harness side
C-07
C-37 (B)
AC504622AC
C-10
C-07 Harness side
(A/C-ECU).
C-10
AC504701AB
Connectors: C-07, C-10, C-37 <RHD> C-07
C-10 C-37 (B)
C-07 Harness side
C-10
C-37 Harness side
AC504624AH

TROUBLESHOOTING
55-63
Inspection Procedure 8: Rear Window Defogger function does not operate.
Rear Window Defogger Circuit IGNITION SWITCH (IG2) FUSIBLE LINK 1
REAR WINDOW DEFOGGER RELAY
REAR WINDOW DEFOGGER A/C-ECU
CIRCUIT OPERATION
If the rear window defogger does not operate when the rear window defogger switch is turned on, the rear window defogger relay system may be defective.
DIAGNOSIS PROCEDURE
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
PROBABLE CAUSES
Malfunction of the A/C-ECU Malfunction of the rear window defogger relay Damaged the wiring harness or connectors Malfunction of the rear window defogger
55-64

TROUBLESHOOTING
STEP 2. Voltage measurement at F-16 rear window defogger connector.

Connector: F-16 <LHD>
STEP 3. Check the rear window defogger relay continuity. Refer to P.55-107.
Q: Is the rear window defogger relay in good condition? YES : Go to Step 4. NO : Replace the rear window defogger relay.
Harness side
STEP 4. Voltage measurement at C-215 rear window defogger relay connector.

AC504707AB
Connector: F-16 <RHD>
Harness side
Junction block side
AC504692AC
AC504709AB
(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the rear window defogger switch to the "ON" position.
Junction block side
Connector F-16 (Harness side)
AC504694AC
AC301541KE
AC301541KF

TROUBLESHOOTING
55-65
STEP 5. Connector check: C-215 rear window defogger relay connector

STEP 6. Check the wiring harness between C-215 rear window defogger relay connector terminal No.5 and the fusible link (1).
Junction block side
C-212 (B)
AC504692AC
C-215
Connector: C-215 <RHD> Junction block (Front view) Harness side C-212
Junction block side

AC504694AC
AC504633AG
Connectors: C-212, C-215 <RHD> Junction block (Front view) C-212 (B)
C-215
Harness side C-212
AC504635AG
55-66
NOTE:

TROUBLESHOOTING
STEP 7. Voltage measurement at C-215 rear window defogger relay connector.

Harness side
Junction block side

AC504622AH
AC504692AC
Junction block side

AC504618AN
Prior to the wiring harness inspection, check intermediate connectors C-126 and junction block connector C-212, and repair if necessary. Check the rear window defogger relay power supply line for open or short circuit.
AC504694AC
(1) Remove the relay, and measure at the junction block side. (2) Turn the ignition switch to the "ON" position.
AC301541KG

TROUBLESHOOTING
55-67
STEP 8. Connector check: C-215 rear window defogger relay connector

Junction block side
C-215
AC504692AC
Harness side C-211
Junction block side C-215 Junction block side

AC504635AH
AC504694AC
NOTE: Prior to the wiring harness inspection, check junction block connector C-211, and repair if necessary. Check the rear window defogger power supply line for open circuit.
STEP 9. Check the wiring harness between C-215 rear window defogger relay connector No.1 and ignition switch (IG2).
Connectors: C-211, C-215 <LHD> Junction block (Front view) C-211
C-215
Harness side C-211
AC504633AH
55-68

TROUBLESHOOTING
STEP 10. Connector check: C-215 rear window defogger relay connector and C-36 A/C-ECU connector
STEP 11. Check the wiring harness between rear window defogger relay connector C-215 No.3 and A/C-ECU connector C-36 No.16.
Harness side
C-36 (B)
AC504622AB
Harness side
C-36 (B)
AC504622AB
C-36 (B)
C-36 (B)
AC504618AJ
AC504618AJ

AC504692AC
C-215
Harness side C-214
Junction block side

AC504694AC AC504633AI

TROUBLESHOOTING
Connectors: C-214, C-215 <RHD> Junction block (Front view)
55-69
STEP 12. Connector check: C-215 rear window defogger relay connector and F-16 rear window defogger connector

AC504692AC
Junction block side
Connector: C-215 <RHD> Junction block (Front view) Junction block side C-215 Junction block side
AC504635AI
NOTE: Prior to the wiring harness inspection, check junction block connector C-214, and repair if necessary. Check the rear window defogger relay line for open or short circuit.
AC504694AC
Harness side
AC504707AB
Connector: F-16 <RHD>
Harness side
AC504709AB
55-70

TROUBLESHOOTING
STEP 13. Check the wiring harness between C-215 rear window defogger relay connector terminal No.4 and F-16 rear window defogger connector terminal No.1.
Harness side
AC504707AB
Connector: F-16 <RHD> C-215 Harness side C-217 Junction block side C-215
AC504709AB
C-217
AC504633AK
NOTE: Prior to the wiring harness inspection, check junction block connector C-217, and repair if necessary. Check the rear window defogger power supply line for open or short circuit.
Connectors: C-215, C-217 <RHD> Junction block (Front view)
(A/C-ECU).
C-215
C-217
C-217
AC504635AK

TROUBLESHOOTING
55-71
STEP 14. Resistance measurement at F-06 rear window defogger connector.

Connector: F-06 <LHD> F-06 (B) Harness side
STEP 15. Connector check: F-06 rear window defogger connector

AC504707AC
AC504707AC
Connector: F-06 <RHD> F-06 (B) Harness side
AC504709AC
AC504709AC
Connector F-06 (Harness side)
AC301541KH
(2) Continuity between terminal 1 and body earth. OK: 2 ohm or less
55-72

TROUBLESHOOTING
STEP 16. Check the wiring harness between F-06 rear window defogger connector terminal No.1 and earth.
STEP 17. Check the rear window defogger. Refer to P.54A-80.

Q: Does the rear window defogger work normally? YES : The trouble can be an intermittent
malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5). NO : Repair the rear window defogger.
AC504707AC
AC504709AC
Check the rear window defogger earth line for open or short circuit.
malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5). NO : Repair or replace the wiring harness.

TROUBLESHOOTING
55-73
Inspection Procedure 9: Malfunction of the A/C-ECU power supply system.
A/C-ECU Power Supply Circuit IGNITION SWITCH (IG2)
BATTERY
RELAY BOX
A/C-ECU BATTERY BACK-UP
<LHD>
<RHD>
CIRCUIT OPERATION
The A/C-ECU power system may be defective if the A/C, defogger, and outside/inside air selection damper motor all do not operate normally.
PROBABLE CAUSES
Damaged the wiring harness or connectors Malfunction of the A/C-ECU
55-74

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Voltage measurement at A/C-ECU connector C-37.

C-37 (B) C-37 (B)

AC504622AC AC504622AC
Connector: C-37 <RHD> Harness side C-37 (B) C-37 (B)

AC504618AE
AC504618AE
(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the "ON" position.
STEP 3. Check the wiring harness between C-37 A/C-ECU connector terminal No.28 and the ignition switch (IG2).
Harness side
AC301541JV
C-37 (B)
AC504622AC
C-37 (B)
AC504618AE

TROUBLESHOOTING
55-75
NOTE:
Connectors: C-211, C-214 <LHD> Junction block (Front view) C-211
STEP 4. Resistance measurement at C-37 A/C-ECU connector.

Harness side C-214 C-37 (B) Harness side C-211 Connector: C-37 <RHD> Harness side C-214
AC504622AC
C-37 (B)
AC504633AB
AC504618AE

C-214
Harness side C-211

AC301541JW
C-214
(2) Continuity between terminal 27 and body earth. OK: 2 ohm or less
AC504635AB
Prior to the wiring harness inspection, check junction block connectors C-214 and C-211, and repair if necessary. Check the A/C-ECU power supply line for open or short circuit.
55-76

TROUBLESHOOTING

NOTE:
Connector: C-06 <LHD> C-06 (GR)
Harness side
C-37 (B)
AC504622AC
AC504617AI
Connector: C-37 <RHD> Harness side C-06 (GR)
C-37 (B)
AC504625AC
AC504618AE
Prior to the wiring harness inspection, check joint connector C-06 <LH drive vehicles>, and repair if necessary. Check the A/C-ECU earth line for open or short circuit.
STEP 6. Check the wiring harness between C-37 A/C-ECU connector terminal No.27 and the earth.
(A/C-ECU).
Harness side
C-37 (B)
AC504622AC
C-37 (B)
AC504618AE

TROUBLESHOOTING
55-77
STEP 7. Voltage measurement at C-36 A/C-ECU connector.


Harness side
C-36 (B)
AC504622AB
Harness side
C-36 (B)
AC504622AB
C-36 (B)
C-36 (B)
AC504618AJ
AC504618AJ
STEP 9. Check the wiring harness between C-36 A/C-ECU connector terminal No.3 and battery.
AC301541JX
(2) Measure the voltage between terminal 3 and earth. OK: System voltage
Harness side
C-36 (B)
AC504622AB
(A/C-ECU). NO : Go to Step 8.
C-36 (B)
AC504618AJ
55-78
NOTE:

TROUBLESHOOTING Q: Is the check result normal? YES : The trouble can be an intermittent
C-05 (GR)
C-129
C-05
C-129
AC504641AB
Connectors: C-05, C-129 <RHD> C-05 (GR)
C-129
C-05
C-129
AC504624AD
Prior to the wiring harness inspection, check intermediate connector C-129 and joint connector C-05, and repair if necessary. Check the A/C-ECU power supply (battery back-up) line for open or short circuit.

TROUBLESHOOTING
55-79
Inspection Procedure 10: A/C Compressor power supply system.
A/C Compressor Circuit IGNITION SWITCH (IG2)
BATTERY
RELAY BOX
A/C COMPRESSOR RELAY
A/C COMPRESSOR
A/C REFRIGERANT TEMPERATURE SWITCH
ENGINE-ECU
MAGNETIC CLUTCH

If the power is not supplied to the A/C compressor, the A/C compressor circuit system may be defective.
POSSIBLE CAUSES
Malfunction of the A/C compressor relay Damaged the wiring harness or connectors
55-80

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-13X A/C compressor relay connector
Connector: B-13X
STEP 3. Voltage measurement at B-13X A/C compressor relay connector.

Connector: B-13X
Relay box side

2 1 3
Relay box side

2 4 1 3
Front of vehicle
AC504760AB
Front of vehicle
AC504760AB
(1) Remove the relay, and measure at the relay box side. (2) Turn the ignition switch to the "ON" position.
Connector B-13X (Relay box side)
STEP 2. Check the A/C compressor relay continuity. Refer to P.55-107.

Q: Is the A/C compressor relay in good condition? YES : Go to Step 3. NO : Replace the A/C compressor relay.
Front of vehicle
AC301541KI

TROUBLESHOOTING
55-81
STEP 4. Check the wiring harness between B-13X A/C compressor relay connector terminal No.2 and the ignition switch (IG2).
Connector: B-13X
Relay box side

2 4 1 3
C-122 (L)
AC504618AH
Front of vehicle
AC504760AB
NOTE:
Connector: C-101, C-124 <LHD> C-101 (L) C-210 C-211
C-124 C-101 Harness side
Harness side C-210
C-211
C-124
AC504633AF
AC504641AF
C-101 (L)
AC504625AF
55-82

TROUBLESHOOTING
STEP 5. Voltage measurement at B-13X A/C compressor relay connector.

Connector: B-13X
Relay box side C-210

2 4 1 3
Harness side C-210
Front of vehicle
AC504760AB
C-211
Connector B-13X (Relay box side)
AC504635AF
Prior to the wiring harness inspection, check intermediate connector C-124 <LH drive vehicles>, C-122 <RH drive vehicles>, joint connector C-101, junction block connectors C-210 and C-211, and repair if necessary. Check the A/C compressor relay power supply line for open circuit.
Front of vehicle
AC301541KJ

TROUBLESHOOTING
55-83
STEP 6. Check the wiring harness between B-13X A/C compressor relay connector terminal No.1 and the battery.
Connector: B-13X
STEP 7. Connector check: A-36 A/C compressor connector

Connector: A-36
Relay box side

2 4 1 3
Harness side
Front of vehicle
AC504760AB
A-36 (B)
AC504616AB
NOTE:
Connector: A-29 <LHD>
A-29 (B)
AC504656AC
AC504618AP
Prior to the wiring harness inspection, check intermediate connector A-29 <LHD> or C-31 <RHD>, and repair if necessary. Check the A/C compressor relay power supply line for open circuit.
55-84

TROUBLESHOOTING Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness.
STEP 8. Check the wiring harness between B-13X A/C compressor relay connector terminal No.4 and A-36 A/C compressor connector terminal No.1.
Connector: A-36

Harness side
C-121 (GR) A-36 (B) Connector: B-13X Connector: C-121 <RHD> Relay box side
2 4 1 3
AC504616AB
AC504617AB
Harness side
C-121 (GR)
Front of vehicle
AC504760AB
NOTE:
AC504618AB
A-13 (B)
AC504656AD
AC504618AP
Prior to the wiring harness inspection, check intermediate connector A-13 <LHD> or C-31 <RHD>, and repair if necessary. Check the A/C compressor power supply line for open circuit.

TROUBLESHOOTING
55-85
STEP 11. Check the wiring harness between C-121 engine-ECU connector terminal No.20 and B-13X A/C compressor relay connector terminal No.3.
Connector: B-13X
Relay box side

2 4 1 3
Front of vehicle
AC504760AB
C-121 (GR)
AC504617AB
C-121 (GR)
AC504618AB
Check the A/C compressor relay earth line for open or short circuit.
55-86

TROUBLESHOOTING
Inspection Procedure 11: Condenser Fan does not Operate.
Condenser Fan Motor Circuit BATTERY IGNITION SWITCH (IG2)
RELAY BOX
CONDENSER FAN RELAY (HI)
CONDENSER FAN RELAY (LO)
NOTE : LH drive vehicles : RH drive vehicles
CONDENSER FAN MOTOR
ENGINE-ECU

TROUBLESHOOTING
55-87
CIRCUIT OPERATION
If the condenser fan motor does not operate, the condenser fan relay circuit system or the earth system of the condenser fan motor is suspected.
DIAGNOSIS PROCEDURE
STEP 1. Connector check: A-34 condenser fan motor connector and C-121 engine-ECU connector
PROBABLE CAUSES
Malfunction of the condenser fan relay (HI) Malfunction of the condenser fan relay (LO) Malfunction of the condenser fan motor Malfunction of the engine-ECU Damaged the wiring harness or connectors
Harness side
A-34 (B)
AC310431AG
Connector: A-34 <RHD>
Harness side A-34 (B)
AC310433 AF
C-121 (GR)
AC504617AB
C-121 (GR)
AC504618AB
55-88

TROUBLESHOOTING
STEP 2. Voltage measurement at A-34 condenser fan motor connector.


C-121 (GR) Harness side
A-34 (B)
AC504617AB AC310431AG
C-121 (GR) Harness side A-34 (B)

AC504618AB AC310433 AF
(1) Remove the relay, and measure at the relay box side.
Connector: C-121 (Harness side)
AC504964AB

Connector: A-34 (Harness side)
AC310507AI

TROUBLESHOOTING
55-89
STEP 3. Connector check: A-07X condenser fan relay (HI) connector

Connector: A-07X
STEP 5. Voltage measurement at A-07X condenser fan relay (HI) connector.

Connector: A-07X
Relay box side
Relay box side
AC311017AB
AC311017AB
(1) Remove the relay, and measure at the relay box side. (2) Turn the ignition switch to the "ON" position.
Connector: A-07X (Relay box side)
STEP 4. Check the condenser fan relay (HI) continuity. Refer to P.55-107.
Q: Is the condenser fan relay (HI) in good condition? YES : Go to Step 5. NO : Replace the condenser fan relay (HI).
2 4
1 3
AC310507AJ
55-90

TROUBLESHOOTING
STEP 6. Check the wiring harness between A-07X condenser fan relay (HI) connector terminal No.2 and the ignition switch (IG2).
Connector: A-07X
AC310454 AV
Relay box side Connectors: C-210, C-211 <LHD> Junction block (front view)
AC311017AB
NOTE:
Connectors: C-101, C-129 <LHD> C-101 (L) C-210
C-211
C-129
Harness side C-210

6 5 4 3 2 1 14 13 12 11 10 9 8 7
C-101 Harness side C-211

2 1 6 5 4 3
C-129
AC310449AF
AC310447AG
C-101 (L)
AC310456 AQ

TROUBLESHOOTING
Connectors: C-210, C-211 <RHD> Junction block (front view)
55-91
C-211
STEP 7. Voltage measurement at A-07X condenser fan relay (HI) connector.

Connector: A-07X
C-210
Relay box side Harness side C-210

6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC311017AB
2
AC310459AF
Harness side C-211

2 1 6 5 4 3
1 3
Prior to the wiring harness inspection, check intermediate connector C-129, joint connector C-101, junction block connectors C-210 and C-211, and repair if necessary. Check the condenser fan relay (HI) power supply line for open circuit.
AC310507AK
55-92

TROUBLESHOOTING
STEP 8. Check the wiring harness between A-07X condenser fan relay (HI) connector terminal No.4 and the battery.
Connector: A-07X
STEP 9. Check the wiring harness between A-07X condenser fan relay (HI) connector terminal No.3 and C-121 engine-ECU connector terminal No.30.
Connector: A-07X
Relay box side
Relay box side
AC311017AB
AC311017AB
Check the condenser fan relay (HI) power supply line for open circuit.
C-121 (GR)
AC504617AB
C-121 (GR)
C-31
C-31
Harness side C-121
AC504624AT

TROUBLESHOOTING
55-93
NOTE:
STEP 11. Voltage measurement at A-34 condenser fan motor connector.

A-29 (B)
1 2 3 4 5 6 7 8
Harness side
A-34 (B)
AC310542 AB
Prior to the wiring harness inspection, check intermediate connector A-29 <LHD> or C-31 <RHD>, and repair if necessary. Check the condenser fan relay (HI) earth line for open or short circuit.
AC310431AG
STEP 10. Check the wiring harness between A-07X condenser fan relay (HI) connector terminal No.1 and A-34 condenser fan motor connector terminal No.1.
Connector: A-07X
AC310433 AF
Relay box side
AC311017AB
Check the condenser fan motor power supply line for open circuit.
55-94

TROUBLESHOOTING

Harness side
STEP 12. Connector check: A-06X condenser fan relay (LO) connector
Connector: A-06X
C-121 (GR)
Relay box side

AC504617AB
AC311017AC
C-121 (GR)
STEP 13. Check the condenser fan relay (LO) continuity. Refer to P.55-107.
AC504618AB
Connector: C-121 (Harness side)
Q: Is the condenser fan relay (LO) in good condition? YES : Go to Step 14. NO : Replace the condenser fan relay (LO).
STEP 14. Voltage measurement at A-06X condenser fan relay (LO) connector.
Connector: A-06X
AC504964AB

Relay box side
AC311017AC
AC310507AL

TROUBLESHOOTING
55-95

STEP 15. Check the wiring harness between A-06X condenser fan relay (LO) connector terminal No.2 and C-129 intermediate connector terminal No.2.
Connector: A-06X
2 4
1 3
AC310507AM
Relay box side
AC311017AC
AC310446AI
AC310454AJ
Check the condenser fan relay (LO) power supply line for open circuit.
55-96

TROUBLESHOOTING
STEP 16. Voltage measurement at A-06X condenser fan relay (LO) connector.
Connector: A-06X
STEP 17. Check the wiring harness between A-06X condenser fan relay (LO) connector terminal No.4 and the battery.
Connector: A-06X
Relay box side Relay box side

AC311017AC
2 4 1 3
AC311017AC
Check the condenser fan relay (HI) power supply line for open circuit.
AC310507AN

TROUBLESHOOTING
55-97
STEP 18. Check the wiring harness between A-06X condenser fan relay (LO) connector terminal No.3 and C-121 engine-ECU connector terminal No.31.
Connector: A-06X
NOTE:
A-29 (B)
1 2 3 4 5 6 7 8
AC310542 AB
Relay box side
AC311017AC
Prior to the wiring harness inspection, check intermediate connector A-29 <LHD> or C-31 <RHD>, and repair if necessary. Check the condenser fan relay (HI) earth line for open or short circuit.
C-121 (GR)
AC504617AB
C-121 (GR)
C-31
C-31
Harness side C-121
AC504624AT
55-98

TROUBLESHOOTING
STEP 19. Check the wiring harness between A-06X condenser fan relay (LO) connector terminal No.1 and A-34 condenser fan motor connector terminal No.2.
Connector: A-06X
STEP 20. Connector check: A-35 condenser fan motor connector

Harness side
Relay box side
A-35 (GR)
AC310431AH
AC311017AC
Harness side Harness side A-35 (GR)

AC310433 AG
A-34 (B)
AC310431AG
AC310433 AF
Check the condenser fan motor power supply line for open circuit.

TROUBLESHOOTING
55-99
STEP 21. Resistance measurement at A-35 condenser fan motor connector.

STEP 22. Check the wiring harness between A-35 condenser fan motor connector terminal No.1 and earth.

AC310431AH
A-35 (GR)
AC310431AH
Connector: A-35 <RHD> Connector: A-35 <RHD>

AC310433 AG
A-35 (GR)
AC310433 AG
Check the condenser fan motor earth line for open circuit.
AC310506AO AC310506
(2) Measure the resistance value between terminal 1 and earth. OK: 2 ohms or less
Q: Is the check result normal? YES : Replace the engine-ECU. NO : Go to Step 22.
55-100

TROUBLESHOOTING
M1554005100341

Item No. 11 Check items Interior temperature sensor Inspection conditions Turn the ignition switch to the ON position. Turn the ignition switch to the ON position. Turn the ignition switch to the ON position. Normal condition Room temperature is the same as M.U.T.-II/III displayed temperature. Outside temperature is the same as M.U.T.-II/III displayed temperature. Heater core wall surface temperature is the same as M.U.T.-II/III displayed temperature. Evaporator outlet temperate is the same as M.U.T.-II/III displayed temperature The volume of insolation takes inverse proportion with the M.U.T.-II/III displayed voltage.
13
Outside thermo sensor
15
Heater water temperature sensor
21
Air thermo sensor
Turn the ignition switch to the ON position. Turn the ignition switch to the ON position. Change the volume of insolation.
25
Photo sensor
31
Air mixing damper control motor and potentiometer
Turn the ignition switch to Opening angle: approximately the ON position. 100% Door position: MAX HOT Turn the ignition switch to Opening angle: approximately the ON position. 0% Door position: MAX COOL
32
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
42
A/C pressure sensor
Turn the ignition switch to the ON position.
A/C refrigerant pressure is the same as M.U.T.-II/III displayed pressure.

TROUBLESHOOTING
55-101
ACTUATOR TEST TABLE

M1554005200315
Item No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 38 39
Check items Blower motor
Drive content Stop Low speed Middle speed High speed
Air mixing damper control motor
Open angle: Approximately 0% (MAX COOL) Opening angle: approximately 50% Open angle: Approximately 100% (MAX HOT)
Mode selection damper control motor FACE FOOT DEF Compressor output Outside/inside air selection damper control motor Idle-up OFF ON Outside air Inside air OFF (A/C high pressure) ON (A/C low pressure)
CHECK AT ENGINE-A/T ECU TERMINALS

M1554005400289
<C-121>
<C-119>
41 42 43 44 45 46 47 4849 50 51 52 53 54 55 5657 58 59 60 61 62 63 64 65 66 67 68
<C-117>
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 8687 88 89 90 91 92 93 94 95 96 97 98 99 100
AC504605AB
Terminal No. 20 30
Check items Output to A/C compressor Condenser fan motor relay (HI)
Check conditions A/C compressor relay: OFF A/C compressor relay: ON Fan inactive state (Engine coolant temperature: 90C or less Fan high-speed rotation state (Engine coolant temperature: 105C or less
Normal conditions System voltage 0V System voltage 1 V or less System voltage 1 V or less
31
Condenser fan motor relay (LOW)
Fan inactive state (Engine coolant temperature: 90C or less) Fan low-speed rotation state (Engine coolant temperature: 95 100C or less)
83 65
Input from A/C-ECU (A/C1) Input from A/C-ECU (A/C2)
When the A/C is in operation (When the air System voltage thermo sensor detects 3C or more). When the A/C is under low load System voltage
55-102

TROUBLESHOOTING
M1554005400290
CHECK AT A/C-ECU TERMINALS
<C-36>
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
<C-37>
21 2223 24 25 26 27 28 29 30 31 32 33 34 35 36
AC300196 AC
Terminal Check items No.
Check conditions
Normal conditions
1 2 3 4 5 6 7 8 9 10 11 16 17
Interior temperature sensor Output to blower pulse controller Back-up power supply Input from heater water temperature sensor Input from air mixing damper control motor potentiometer Input from mode selection damper control motor potentiometer Input from the air thermo sensor Photo sensor (-) Potentiometer power supply Input from the A/C pressure sensor Rear defogger Diagnosis set
Sensor temperature: 25C (4k) When the blower is operating. Always Sensor temperature: 25C (4k) When the damper flaps is moving to the MAX HOT position. When the damper is moved to the DEF position. Sensor temperature: 25C (4k) Brightness is 0 lux Brightness is 100,000 lux or more Always 2.6 MPa When the rear defogger is stopped Ignition switch: ON
2.1 2.7V 0 2.5V (Effective alternating voltage) System voltage 2.1 2.7V 4.1 4.6 V 4.1 4.6 V 2.1 2.7 V 2.1 2.7 V 4.9 5.1 V Approximately 0 V 5V 3.9 V System voltage A voltmeter needle fluctuates between 0 and 12 V. Approximately 5 V 0V 0V 10 V Faint voltage (0.5 V) 10 V Faint voltage (0.5 V)
Input from the outside thermo sensor Sensor temperature: 25C (4k)
12 15 -
When the rear defogger is operating. 2.0 V or less
18 19 20 21
Input from diagnosis Photo sensor (+) Sensors and potentiometers earth Air outlet changeover damper motor (FACE)
Ignition switch: ON Always Always When the damper is moved to the FACE position. When the damper is moved to the DEF position.
22
Air mix damper motor (MAX COOL)
When the damper flaps is moving to the MAX COOL position. When the damper flaps is moving to the MAX HOT position.

TROUBLESHOOTING Terminal Check items No. Check conditions
55-103
Normal conditions
23
Outside/inside air selection damper control motor (outside)
When the damper is moved to the inside air recirculation position When the damper is moved to the outside air inside air intake position
10 V (When the motor is stopped) 2.0 V or less Faint voltage (0.5 V) 10 V Faint voltage (0.5 V) 10 V 2.0 V or less 10 V (When the motor is stopped) Continuity exists. System voltage Continuity exists. System voltage System voltage System voltage 0V
24
Mode selection damper control motor When the damper is moved to the and potentiometer (DEF) FACE position. When the damper is moved to the DEF position.
25
Air mixing damper control motor and potentiometer (MAX HOT)
When the damper flaps is moving to the MAX COOL position. When the damper flaps is moving to the MAX HOT position.
26
outside/inside air selection damper control motor (inside)
When the damper is moved to the inside air recirculation position When the damper is moved to the outside air inside air intake position
27 28 29 30 31 32 33 34
Earth IG2 power supply Illumination earth ILL power supply Input from the engine-A/T-ECU (A/C2) Input from the compressor relay Input from the engine-A/T-ECU (A/C1) ACC power supply
Always Ignition switch: ON Always Lighting switch: ON When the A/C is under low load Compressor: ON When the A/C is stopped
When the A/C is operating (When the System voltage compressor is operating) Ignition switch: ACC System voltage
35 36
55-104

ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
MAGNETIC CLUTCH TEST
M1552008500483
1. Disconnect the magnetic clutch connector to the magnetic clutch.

Magnetic clutch connector
1. Remove the dual pressure switch connector and connect the high/low pressure side terminals located on the harness side as shown in the illustration. 2. Install a gauge manifold to the high-pressure side service valve of the refrigerant line (Refer to P.55-128, P.55-129). 3. When the high/low pressure sides of the dual pressure switch are at operation pressure (ON) the resistance should less than two ohms between the terminals. If open circuit, replace the switch.
CHARGING AND DISCHARGING

AC005671AC
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.
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.
M1552022200044
REFILLING OF OIL IN THE A/C SYSTEM

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. Compressor oil: SUN PAG 56 Quantity Evaporator: 60 mL Condenser: 15 mL Flexible suction hose: 10 mL Receiver: 10 mL
M1552020000066
COMPRESSOR DRIVE BELT ADJUSTMENT

M1552001000409
Refer to GROUP 11A, On-vehicle Service Drive Belt Tension Check P.11A-7.
DUAL PRESSURE SWITCH CHECK

M1552010400375
High/Low Pressure Side
Low-pressure side High-pressure side 210 25 2060 200 230 20 2650 200 ON OFF (kPa)
AC001368 AD
PERFORMANCE TEST
M1552001400429
1. The vehicles to be tested should be in a place that is not in direct sunlight.
ON OFF

ON-VEHICLE SERVICE
55-105
Low-pressure valve
High-pressure valve
Gauge manifold Charging hose (red) Charging hose (blue) A Adaptor valve (for lowpressure)
Lowpressure service valve
Sleeve Adaptor valve (for highpressure)
Highpressure service valve
NOTE: The high-pressure service valve is on the A/C pipe and the low-pressure service valve is on the suction hose. 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. Keep engine speed to idling speed with A/C clutch engaged. 9. Engine should be warmed up with doors and all windows opened.
Thermometer
AC001388 AB
2. Close the high and low-pressure valve of the gauge manifold. 3. Connect the charging hose (blue) to the low-pressure 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).
AC304576 AB
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 Discharge air temperature C Compressor high pressure kPa Compressor low pressure kPa 20 8.0 11.0 740 840 150 190 25 12.0 16.0 950 1,050 190 240 30 17.0 21.0 1,160 1,300 240 300 35 22.5 27.5 1,360 1,550 300 375
REFRIGERANT LEAK REPAIR PROCEDURE

M1552001500385
LOST CHARGE
If the system has lost all charge due to a leak: 1. Evacuate the system (Refer to P.55-104).
2. Charge the system with approximately 480 520 g of refrigerant. 3. Check for leaks. 4. Discharge the system. 5. Repair leaks.
55-106

ON-VEHICLE SERVICE
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.
On standard plumbing fittings with O-rings, these O-rings are not reusable.
COMPRESSOR NOISE CHECK

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.
M1552008700379
LOW CHARGE
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. 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.
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 P.55-104). 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.

ON-VEHICLE SERVICE
55-107
POWER RELAY CHECK

M1552008800428
BLOWER RELAY CONTINUITY CHECK

Blower relay
A/C COMPRESSOR RELAY, CONDENSER FAN RELAY (LO) AND (HI) CONTINUITY CHECK
A/C compressor relay Condenser fan relay (HI)
Condenser fan relay (LO)
1 2 3 4 5
5 4 1 3
1
X
2 4
1 4 2 3
AC310514AB
Front of vehicle
AC310515AB
Battery voltage Tester connection Not applied 45 Connect 45 terminal 3 to the positive battery terminal Connect terminal 1 to the negative battery terminal
Battery voltage Tester connection Not applied 14 Connect 14 terminal 2 to the positive battery terminal Connect terminal 3 to the negative battery terminal
IDLE-UP OPERATION CHECK

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 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 P.13A-396. Standard value: 850 50 r/min
M1552001600683
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 up 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.
55-108

HEATER CONTROL ASSEMBLY AND A/C SWITCH
CLEAN AIR FILTER REPLACEMENT PROCEDURE

M1552020100096
1. Remove the glove box (Refer to GROUP 52A, Instrument Panel P.52A-2).
Clean air filter
AC309643AC
2. Remove the two screws as shown, and replace the clean air filter. 3. Install the glove box.
HEATER CONTROL ASSEMBLY AND A/C SWITCH

M1552002400659
3 2 4 5 5 1
4 2
AC504841AB
1. 2.
Removal steps Centre lower case (Refer to GROUP 52A, Instrument panel assembly P.52A-2) Knob
3. 4.
Removal steps (Continued) Automatic A/C control panel (A/C-ECU) Bracket

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
55-109

M1552011600521
Pre-removal and Post-installation Operation Refrigerant draining and Refilling (Refer to Charging and Discharging P.55-104). Engine coolant Draining and Refilling (Refer to GROUP 14, On vehicles service P.14-15). Instrument Panel Removal and Installation (Refer to GROUP 52A, Instrument Panel P.52A-2). Air cleaner cover and air flow sensor assembly Removal and Installation (Refer to GROUP 15, Air cleaner P.15-5). Rear console assembly Removal and Installation (Refer to GROUP 52A, Rear console assembly P.52A-8). Front floor console assembly Removal and Installation (Refer to GROUP 52A, Front floor console assembly P.52A-7). Front seat assembly Removal and Installation (Refer to GROUP 52A, Front seat assembly P.52A-18).
-Pipe coupling
2 5 7 9
12 2 Nm
6, 7
O-ring
A/C compressor oil: SUN PAG 56
3 6 1 8N
44 10 Nm
44 10 Nm
AC304861AC
1. 2. 3.
Removal steps Front deck crossmember Centre duct Intake duct Foot duct (RH), Rear heater duct A (RH) upper side (Refer to P.55-130).
<<A>> <<A>>
4. 5. 6. 7. 8. 9.
Removal steps (Continued) Blower assembly Heater hose connection Flexible suction hose connection Liquid pipe B connection O-ring Heater unit
55-110

REMOVAL SERVICE POINT <<A>> FLEXIBLE SUCTION HOSE/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.
HEATER UNIT
DISASSEMBLY AND REASSEMBLY <LHD>
M1551005400503
-Pipe coupling
3 12 6, 9 11 4 16 10 13 14 9 15
AC504612 AB
O-ring
5 6 7N 8
1. 2. 3. 4. 5. 6. 7.
Disassembly steps Foot duct (LH) Air mixing damper control motor and potentiometer Mode selection damper control motor and potentiometer Heater core Expansion valve Joint O-ring
8. 9. 10. 11. 12. 13. 14. 15. 16.
Disassembly steps (Continued) Evaporator cover Evaporator Air thermo sensor clip Air thermo sensor Heater water temperature sensor Aspirator Aspirator hose Harness Heater case

55-111
DISASSEMBLY AND REASSEMBLY <RHD>

M1551005400514
-Pipe coupling
1 17 2 15 16
13
O-ring
14 10 4 11 7
9 8 12 6 3
AC504713AB
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Disassembly steps Foot duct (RH) Foot duct (LH) Evaporator cover Heater core Expansion valve Evaporator O-ring Air thermo sensor clip Air thermo sensor Aspirator
Disassembly steps (Continued) 11. Aspirator hose 12. Harness 13. Air mixing damper control motor and potentiometer 14. Mode selection damper control motor and potentiometer 15. Heater water temperature sensor clip 16. Heater water temperature sensor 17. Heater case
55-112

BLOWER ASSEMBLY
M1551005500287
1 5
AC504715AB
1. 2.
Disassembly steps Joint duct Outside/inside air selection damper control motor
3. 4. 5.
Disassembly steps (Continued) Blower motor Air filter Blower case
MODE SELECTION DAMPER CONTROL MOTOR, AIR MIXING DAMPER CONTROL MOTOR, OUTSIDE/INSIDE
55-113
MODE SELECTION DAMPER CONTROL MOTOR, AIR MIXING DAMPER CONTROL MOTOR, OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR AND BLOWER MOTOR
M1554019900016
4
AC504716AB
<<A>>
1. 2.
<<A>>
3.
4.
REMOVAL SERVICE POINT Blower motor removal step Front passenger's side under cover <<A>> BLOWER MOTOR AND MODE Blower motor Air mixing damper control motor SELECTION DANPER CONTROL MOTOR and potentiometer removal step AND POTENTIOMETER REMOVAL Air mixing damper control motor NOTE: and potentiometer Mode selection damper control motor and potentiometer removal step Mode selection damper control motor and potentiometer Outside/inside air selection damper control motor removal step Glove box (Refer to GROUP 52A, Instrument Panel P.52A-2). AC304916 Engine-ECU (Refer to GROUP Use of commercially available offset screw driver is 13A, Engine-ECU P.13A-416). Outside/inside air selection damper recommended. control motor
55-114
INSPECTION

MODE SELECTION DAMPER CONTROL MOTOR, AIR MIXING DAMPER CONTROL MOTOR,
M1551006300491
CHECK THE AIR MIXING DAMPER CONTROL MOTOR AND POTENTIOMETER

<L.H. drive vehicles> MAX. COOL position MAX HOT position
MODE SELECTION DAMPER CONTROL MOTOR AND POTENTIOMETER CHECK

FACE position DEF position
1 2 3 4 5 6 1 2 3 4 5 6
AC301517AG
AC301519AG
<R.H. drive vehicles> DEF position 1 2

3 4 5 6
<R.H. drive vehicles>

1 2 3 4 5 6
FACE position MAX. COOL position

AC504718AB
MAX HOT position
AC504717AB
CHECK THE AIR MIXING DAMPER CONTROL MOTOR Battery Battery Lever operation connection connection (+) terminal (-) terminal 1 3 3 1 Rotate to the HOT position. Rotate to the COOL position.
MODE SELECTION DAMPER CONTROL MOTOR CHECK Battery Battery Lever operation connection connection (+) terminal (-) terminal 1 3 3 1 Rotate to the DEF position. Rotate to the FACE position.
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 k
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 k
MODE SELECTION DAMPER CONTROL MOTOR, AIR MIXING DAMPER CONTROL MOTOR, OUTSIDE/INSIDE
55-115
OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR CHECK

CAUTION
BLOWER MOTOR CHECK

Execute actuator test item No.01 to 04 by using M.U.T.-II/III with the vehicle body, and check that the blower motor works normally. (Refer to P.55-101).
Inside air
Outside air
AC100625AE
Cut off the battery voltage when the damper is in the outside/inside air position. Lever position Battery connection At the inside position Connect terminal 7 to the positive battery terminal Connect terminal 4 to the negative battery terminal Connect terminal 7 to the positive battery terminal Connect terminal 6 to the negative battery terminal Lever operation 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
55-116

SENSORS
SENSORS
M1554001900196
2 1
AC504729AB
1.
Interior temperature sensor removal steps Interior temperature sensor
2. <<A>> 3.
Heater water temperature sensor removal steps Foot duct <front passenger's side> (Refer to GROUP 55, Ventilator P.55-131). Heater water temperature sensor Photo sensor removal steps Photo sensor

SENSORS
55-117
REMOVAL SERVICE POINT <<A>> PHOTO SENSOR REMOVAL

Photo sensor connector
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

String Resistance 20 (k ) 15
AC504803AB
10 5 0 20 40 60 -10 0 Temperature (C) 80

AC503134 AB
1. Remove the photo sensor together with the defroster nozzle. 2. Suspend the connector with a string to avoid the connector drops behind the instrument panel.
INSPECTION
M1552014302150
INTERIOR TEMPERATURE SENSOR CHECK

Resistance 20 (k ) 15 10 5 0 20 40 60 -10 0 Temperature (C) 80
AC503134 AB
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.
PHOTO SENSOR CHECK

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.
55-118

EVAPORATOR ASSEMBLY
EVAPORATOR ASSEMBLY
REMOVAL AND INSTALLATION <LHD>
M1552003600496
Pre-removal and Post-installation Operation Refrigerant draining and Refilling (Refer to Charging and discharging P.55-104). Air cleaner and air cleaner air flow sensor assembly Removal and Installation (Refer to GROUP 15, Air cleaner P.15-5).
-Pipe coupling
2
12 2 Nm
1, 2, 4, 7
O-ring
10 9 7
4 3 8 8
6 5
AC504937AB
<<A>> <<A>>
1. 2. 3. 4. 5. 6. 7. 8.
Removal steps Flexible suction hose connection Liquid pipe B connection Expansion valve Joint Glove box (Refer to GROUP 52A, Instrument Panel P.52A-2). Engine-ECU (Refer to GROUP 13A, Engine-ECU P.13A-416). Joint duct Foot duct (RH), Rear heater duct A (RH) upper side (Refer to P.55-130). Evaporator cover Evaporator O-ring
Removal steps (Continued) 9. Air thermo sensor clip 10. Air thermo sensor


EVAPORATOR ASSEMBLY
55-119
REMOVAL AND INSTALLATION <RHD>

M1552003600504
Pre-removal and Post-installation Operation Refrigerant draining and Refilling (Refer to Charging and discharging P.55-104). Air cleaner and air cleaner air flow sensor assembly Removal and Installation (Refer to GROUP 15, Air cleaner P.15-5).
-Pipe coupling
1, 2, 6
O-ring
2
12 2 Nm
3 7 1 7 8 9
6 5
4
<<A>> <<A>> 1. 2. 3. 4. Removal steps Flexible suction hose connection Liquid pipe B connection Expansion valve Glove box (Refer to GROUP 52A, Instrument Panel P.52A-2). Engine-ECU (Refer to GROUP 13A, Engine-ECU P.13A-416). Joint duct 5. 6. 7. 8. 9.
AC304886AC
<>
Removal steps (Continued) Foot duct (RH), Rear heater duct A (RH) upper side (Refer to P.55-130). Evaporator cover Evaporator O-ring Air thermo sensor clip Air thermo sensor
55-120

EVAPORATOR ASSEMBLY

INSPECTION
M1552014302161
AIR THERMO SENSOR INSPECTION
<> EVAPORATOR REMOVAL

Resistance 25 (k ) Dashboard pad 20 15 10 5 0 -10 0 10 20 30 40 Temperature (C)
AC103376 AB
Blower unit
AC305312 AB
CAUTION Do not cut the upper side of the pad. 1. When removing the evaporator, cut and fold back the dashboard pad as in the diagram (The thickness of the pad interferes with the removal of the evaporator). 2. Remove the evaporator.
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.

55-121

INSPECTION
M1552014302138
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.
Outside thermo sensor

AC212287AF
Resistance 50 (k ) 40 30 20 10 0 -30 -20 0 20 40 60 Temperature (C) AC103489AB
55-122

COMPRESSOR ASSEMBLY AND TENSION PULLEY

M1552004100535
Pre-removal Operation Refrigerant Discharging (Refer to P.55-104).
Post-installation Operation Drive Belt Tension Adjustment (Refer to GROUP 11A, On-vehicles Service Drive Belt Tension Check P.11A-7). Refrigerant Charging (Refer to P.55-104).
-Pipe coupling
6 5 3N 3N 2
1, 2
1 4
25 4 Nm
AC310766AB
<<A>> <<A>>
1. 2. 3.
Removal steps <> Flexible suction hose connection Flexible discharge hose connection <<C>> O-ring
>>A<<
4. 5. 6.
Removal steps (Continued) Drive belt A/C compressor A/C compressor bracket
REMOVAL SERVICE POINTS <<A>> FLEXIBLE SUCTION HOSE/FLEXIBLE DISCHARGE HOSE 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 hoses and compressor nipples.
<> DRIVE BELT REMOVAL

The following operations will be needed due to the serpentine drive system with the alternator drive belt auto tensioner.

Alternator drive belt auto tensioner
55-123
1. Measure the amount (X mL) of oil within the removed compressor. 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 mLX 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
Hole B
Hole A
AC107640AD
Alternator drive belt auto tensioner
L-shaped hexagon wrench
AC107641AC
1. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the alternator drive belt auto tensioner, and turn the alternator drive belt auto tensioner anti-clockwise until it hits the stopper.
INSPECTION
M1552014301834
COMPRESSOR MAGNETIC CLUTCH OPERATION CHECK

Magnetic clutch connector
CAUTION To reuse the alternator drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the alternator drive belt using chalk.
2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the alternator drive belt.
<<C>> A/C COMPRESSOR REMOVAL

Take care not to spill any compressor oil when removing the compressor.
AC005671AK
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.
Connect the compressor connector terminal to the battery positive (+) terminal and earth the batterys negative () terminal to the compressor unit. At that time, the magnetic clutch should make a definite operating sound.
55-124

M1552004600808
9 8 7 6 11 5 10
N
3N 2
4
16 1 Nm
AC100630 AB
1. 2. 3. >>D<<
Cooling temperature switch disassembly steps Snap ring Refrigerant temperature switch O-ring Magnetic clutch disassembly Air gap adjustment
<<A>>
>>C<< >>B<< >>A<<
4. 5. 6. 7. 8. 9. 10. 11.
Magnetic clutch disassembly Self-locking nut Armature Snap ring Rotor Snap ring Field core Shim A/C compressor
DISASSEMBLY SERVICE POINT <<A>> SELF-LOCKING NUT REMOVAL

MB991386
Use the special tools to remove the self-locking nut. Special spanner (MB991367) Pin (MB991386)
MB991367
AC100633AB

55-125
REASSEMBLY SERVICE POINTS >>A<< FIELD CORE

Field core projection
>>D<< AIR GAP ADJUSTMENT

Thickness gauge
Compressor unit pin hole

AC100634 AB
AC100637AB
Line up the pin hole on the compressor unit with the field core projection and attach.
>>B<< SNAP RING INSTALLATION

Snap ring Rotor Clutch coil
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
INSPECTION
M1552014301340
REFRIGERANT TEMPERATURE SWITCH

CAUTION Do not heat more than necessary.
Tapered part
AC001412 AB
Using snap ring pliers, fit the snap ring so that the snap rings tapered part is on the outside.
Thermometer
>>C<< SELF-LOCKING NUT INSTALLATION

MB991386
Engine oil
AC100787 AB
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.
120C Continuity
AC100633AB
150C
No continuity Oil temperature
Use the special tools to install the self-locking nut. Special spanner (MB991367) Pin (MB991386)
AC100810 AD
2. When the oil temperature reaches the standard value, check that voltage is supplied between the terminals.
55-126
Standard value: Item Less than 2 ohms No continuity

CONDENSER AND CONDENSER FAN MOTOR
Temperature Slightly below 150C 150C or more
NOTE: When the oil temperature is 150C or more and there is no continuity, the resistance will not be 2 or lower until the oil temperature reduces to 120C or less.

M1552006700674
Pre-removal and Post-installation Operation Refrigerant Draining and Refilling (Refer to P.55-104). Front Bumper Removal and Installation (Refer to GROUP 51 P.51-2).
4.9 0.9 Nm -Pipe coupling 12 2 Nm
6
N 10
5, 6
10 N
2 3 4 1
7
N 10
AC211410AC
<<A>>
1. 2. 3. 4.
Fan shroud assembly removal steps Fan shroud assembly Fan Fan motor Fan shroud
<> <>
>>A<<
Condenser removal steps 5. Flexible discharge hose connection 6. Liquid pipe A connection 7. Condenser 8. Clamp 9. Receiver 10. O ring

55-127
M1552014301351
REMOVAL SERVICE POINT <<A>> FAN SHROUD ASSEMBLY REMOVAL
INSPECTION CONDENSER FAN MOTOR CHECK

A-34
1 2
1 2
A-35
AC211409AC
AC211409AC
1. Remove the intercooler mounting bolts/nuts and pull the intercooler forward. 2. Move the fan motor/shroud assembly upward for removal.
BATTERY CONNECTION
CONDENSER FAN MOTOR OPERATION Condenser fan motor LO operation
<> FLEXIBLE DISCHARGE HOSE/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 material, plug the dismantled hose and condenser assembly nipples.
Connect connector A-34 terminal 2 to the positive battery terminal Connect connector A-35 terminal 2 to the negative battery terminal Connect connector A-34 terminal 1 to the positive battery terminal Connect connector A-35 terminal 2 to the negative battery terminal
Condenser fan motor HI operation
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 cm3 (0.5 floz)
55-128

REFRIGERANT LINE
REFRIGERANT LINE
REMOVAL AND INSTALLATION <LHD>
M1552006401063
Pre-removal and Post-installation Operation Refrigerant Draining and Refilling (Refer to P.55-104). Air Cleaner Removal and Installation (Refer to GROUP 15, Air cleaner P.15-5). Radiator Grille Removal and Installation (Refer to GROUP 51, Front bumper P.51-2).
13 1 Nm High-pressure side service valve
8N 1 8 N
Low-pressure side service valve 12 2 Nm
2
4.9 0.9 Nm
7 8 N
4
12 2 Nm
5 8N
25 4 Nm
8N 3
-Pipe coupling
1, 2, 3, 5, 6
O-ring O-ring
AC304553AE
<<A>> <<A>> <<A>> <<A>> <<A>> >>A<<
1. 2. 3. 4. 5. 6. 7. 8.
Removal steps Dual pressure switch Liquid pipe A Flexible discharge hose Expansion valve cover Flexible suction hose Liquid pipe B Expansion valve cover O-ring
REMOVAL SERVICE POINT <<A>> HOSE/PIPE 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 other foreign bodies, plug the condenser, compressor, and expansion valve nipples.

REFRIGERANT LINE
55-129
INSTALLATION SERVICE POINT >>A<< FLEXIBLE 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
REMOVAL AND INSTALLATION <RHD>

M1552006401074
Pre-removal and Post-installation Operation Refrigerant Draining and Refilling (Refer to P.55-104). Air Cleaner Removal and Installation (Refer to GROUP 15, Air cleaner P.15-5). Radiator Grille Removal and Installation (Refer to GROUP 51, Front bumper P.51-2).
8N
High-pressure Side Service Valve
13 1 Nm
6
Low-pressure side service valve
1
4.9 0.9 Nm
8N 5
12 2 Nm
2 7 8N 8N 4
12 2 Nm
25 4 Nm
8N
-Pipe coupling
1, 2, 3, 5, 6
O-ring O-ring
AC304554 AB
<<A>> <<A>> <<A>>
1. 2. 3. 4.
Removal steps Dual pressure switch Liquid pipe A Flexible discharge hose Expansion valve cover
<<A>> <<A>>
>>A<<
5. 6. 7. 8.
Removal steps (Continued) Flexible suction hose Liquid pipe B Expansion valve cover O-ring
55-130

DUCTS
REMOVAL SERVICE POINT <<A>> HOSE/PIPE 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 other foreign bodies, plug the condenser, compressor, and expansion valve nipples.
INSTALLATION SERVICE POINT >>A<< FLEXIBLE 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
DUCTS
M1553001000134
Cross-section A-A
Clip
4 5
Instrument panel
3 2
4 6
A A
1 3
10 7 11 13 12 8
AC304890 AB
1. 2. 3.
Air Outlet Removal steps Centre Air Outlet Panel Centre Air Outlet Side Air Outlet
4.
Defroster nozzle and Distribution duct Removal steps Instrument Panel (Refer to 52A, Instrument Panel P.52A-2). Side defroster duct

VENTILATORS Defroster nozzle and Distribution duct Removal steps (Continued) Defroster nozzle Distribution duct Foot duct Removal steps Console cover and Glove box (Refer to GROUP 52A, Instrument panel P.52A-2). Foot duct (RH) Rear heater duct A (RH) upper side Under cover (Refer to GROUP 52A, Instrument panel P.52A-2). 9. 10. 11. 12. 13.
55-131
5. 6. 7. 8.
Foot duct Removal steps Foot duct (LH) Rear heater duct Removal steps Front floor console (Refer to GROUP 52A, Front floor console assembly P.52A-7). Front seat (Refer to GROUP 52A Front seat assembly P.52A-18). Floor carpet and Floor pads Rear heater duct A (LH) Left -hand rear heater duct B Right-hand rear heater duct B Rear heater duct A (RH) lower side
VENTILATORS
M1553001600523
1
Cross-Section A A Claw Cross-Section B B A A A A
Claw
B B
AC211528 AD
1
Rear ventilation duct removal steps Rear bumper assembly (Refer to GROUP 51, Rear bumper P.51-5). Rear ventilation duct
1.
NOTES
31-1
GROUP 31
WHEEL AND TYRE

CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . TROUBLESHOOTING . . . . . . . . . . . .
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . WHEEL BALANCE ACCURACY . . . . . . . .
31-2 31-2 31-3

31-3 31-4
ON-VEHICLE SERVICE . . . . . . . . . . .
TYRE INFLATION PRESSURE CHECK . . . TYRE WEAR CHECK . . . . . . . . . . . . . . . . . WHEEL RUNOUT CHECK . . . . . . . . . . . . .
31-7
31-7 31-7 31-7
WHEEL AND TYRE . . . . . . . . . . . . . .

INSTALLATION SERVICE POINT . . . . . . .
31-7
31-7
31-2
WHEEL AND TYRE

GENERAL INFORMATION
GENERAL INFORMATION
M1311000100134
The wheels and tyres of the following specifications have been established. Item Wheel Type Size
SPECIFICATIONS
ROAD WHEEL AND TYRE Specification Aluminium type 17 8JJ 38 114.3 235/45R17 93W Specification
Amount of wheel offset mm Pitch circle diameter (PCD) mm Tyre SPARE WHEEL AND TYRE Item Spare wheel Type Size Amount of wheel offset mm Pitch circle diameter (PCD) mm Spare tyre Size Size
Steel type 17 4T 30 114.3 T125/70D17 98M
NOTE: PCD indicates the pitch circle diameter of the wheel installation holes.
M1311000300473
Item Tread depth of tyre mm Wheel runout (Radial runout) mm Wheel runout (Lateral runout) mm
Limit Minimum 1.6 1.0 or less 1.0 or less
WHEEL AND TYRE

TROUBLESHOOTING
31-3
TROUBLESHOOTING
DIAGNOSIS
M1311000700523
Symptom Rapid wear at shoulders
Probable cause Under-inflation or lack of rotation
Remedy Adjust the tyre pressure.
Reference page For tyre inflation pressure, refer to the label on the driver's side centre pillar.
ACX00923AB
ACX00924 AB
Rapid wear at centre
Over-inflation or lack of rotation
ACX00925AB
ACX00926AB
Cracked treads
Under-inflation
Adjust the tyre pressure.
For tyre inflation pressure, refer to the label on the driver's side centre pillar.
ACX00927AB
Wear on one side
Excessive camber
Check the camber.
ACX00928 AB
Refer to GROUP 33, On-vehicle service Front wheel alignment check and adjustment P.33-4.
ACX00929 AB
Feathered edge
Incorrect toe-in
Adjust the toe-in.
ACX00930AB
ACX00931AB
Bald spots
Unbalanced wheel
Balance the wheels.
P.31-4
ACX00932AB
ACX00933 AB
31-4
Symptom Scalloped wear
WHEEL AND TYRE

TROUBLESHOOTING
Probable cause
Remedy
Reference page Refer to GROUP 33, On-vehicle service Front wheel alignment check and adjustment P.33-4.
Lack of rotation of tyres or worn Rotate the tyres, and or out-of-alignment suspension check the front suspension alignment.
ACX00934
WHEEL BALANCE ACCURACY

M1311001700582
PURPOSE
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 P.31-6).
PROCEDURE <BALANCING TIPS>

Clamping cup Wing nut
Hub/shaft assembly
Spring plate Wheel mounting cone
AC000041AB
Standard passenger car wheel
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.
<CONFIRMING PROPER BALANCE>

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.
WHEEL AND TYRE

TROUBLESHOOTING
31-5
<WHEEL BALANCER CALIBRATION CHECKS>

1. Mount an undamaged original-equipment alloy rim and tyre assembly (wheel) onto your off-the-car wheel balancer. Balance the wheel. 2. <<Zero Calibration Check>> Loosen the balancer wing nut, rotate the wheel a half-turn (180), and retighten the nut. Recheck the balance. If the imbalance is 5 g 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 5 g, 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 5 g 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 5 g, the balancer requires calibration. Contact the balancer manufacturer for calibration by their repair representative.
4. <<Static Balance Check>> Attach a 5 g weight to the outer rim. Recheck the balancer. The balancer should detect 5 2 g of imbalance 170 to 190 away from the 5 g 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. <<Dynamic Balance Check>> Attach a 5 g weight to the inner rim at 180 opposite the 5 g weight that was added in Step 4. Recheck the balance. The balancer should detect 5 2 g of imbalance 170 to 190 away from both the inner and outer 5 g 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.
31-6
WHEEL BALANCER CALIBRATION CHECKING FLOW CHART
WHEEL AND TYRE

TROUBLESHOOTING
Balance wheel.
Rotate wheel 1/2 turn.
ZERO CALIBRATION CHECK
Imbalance = 5 g or less
Imbalance = more than 5 g
Rebalance wheel. Rotate wheel 1/4 turn.
Imbalance = 5 g or less
Imbalance = more than 5 g
Verify wheel is properly centred. Verify cones, cup, and wing nut are clean, undamaged, and appropriate for wheel. Make necessary corrections, then recheck wheel balance.
STATIC BALANCE Attach a 5 g weight to the outer rim. CHECK Is the imbalance 5 2 g at 170 190 away from the 5 g weight?
YES
NO
Attach a 5 g weight to the inner rim at 180 opposite the weight on the outer rim. Is the imbalance 5 2 g at 170 190 away from both 5 g weights?
DYNAMIC BALANCE CHECK
YES
NO
Balancer does not require calibration.
Balancer requires calibration. Contact balancer manufacturer.

AC502720AB
WHEEL AND TYRE

ON-VEHICLE SERVICE
31-7
ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK
M1311000900419
WHEEL RUNOUT CHECK

M1311001100461
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

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.
M1311001000442
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: Radial runout; 1.0 mm or less Lateral runout; 1.0 mm or less If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TYRE

INSTALLATION SERVICE POINT
Tighten the wheel nuts to the specified torque.
M1311001300379
Tightening torque: 98 10 Nm
NOTES
33-1
GROUP 33
FRONT SUSPENSION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .
FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . LOWER ARM BALL JOINT AXIAL PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . BALL JOINT DUST COVER CHECK . . . . .
33-2 33-3 33-3 33-4

33-4 33-5 33-5
DISASSEMBLY AND ASSEMBLY . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
33-7 33-9
LOWER ARM . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . BALL JOINT DUST COVER REPLACEMENT LOWER ARM PILLOW BALL BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
33-10
33-10 33-11 33-12 33-12
STABILIZER BAR* . . . . . . . . . . . . . . .
33-14
33-14 33-16
STRUT ASSEMBLY. . . . . . . . . . . . . .
33-6
33-6 33-6
CROSSMEMBER BAR . . . . . . . . . . . .
33-17
33-17
WARNING
33-2
FRONT SUSPENSION
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1332000100311
A MacPherson strut independent suspension-type suspension is used for the front suspension. Aggressive use of special components that include Mitsubishi Motors own inverted struts and forged aluminium parts reduces weight to create a suspension that gives superior performance made with competition use in mind.
Coil spring Strut insulator Stabilizer link (pillow ball bushing)
Stabilizer bar
Lower arm bushing (pillow ball bushing) Strut (inverted strut)
Lower arm assembly (forged aluminium) Front axle No.1 crossmember Front axle crossmember bar
AC211383AC
SPECIFICATIONS
COIL SPRING Item Wire diameter mm Average diameter mm Free length mm Specification 14 155 286
FRONT SUSPENSION
33-3
M1332000300735
Item Toe-in mm Steering angle Inner wheel Outer wheel (reference) Camber (selectable from 2 options) Caster Kingpin inclination Lower arm ball joint starting torque Nm Lower arm pillow ball bushing starting torque Nm Stabilizer link ball joint turning torque Nm NOTE: *: Default factory setting Specification 02 3145' 130' 2715' 100' 030'* or 200 030 (Left/right deviation within 30') 355' 030' (Left/right deviation within 30') 1345' 130' 0.5 3.4 0.5 3.0 1.7 3.2
SPECIAL TOOLS
M1332000600532
Tool
Number A: MB991237 B: MB991238
Name A: Spring compressor body B: Arm set
Use Coil spring compression
A B
MB991237
A B
MB991680 A: MB991681 B: MB991682
Wrench set A: Wrench B: Socket
Strut assembly disassembly and reassembly
MB991680
MB991006
Preload socket
Lower arm ball joint starting torque measurement
MB991006
MB990326
Preload socket
Lower arm ball bushing starting torque measurement
MB990326
MB990800
Ball joint dust cover installer
Lower arm ball joint dust cover press-in
MB990800
33-4
FRONT SUSPENSION
ON-VEHICLE SERVICE
Name Bar
Use Lower arm pillow ball bushing removal and press-fitting
MB990883
MB991816
Bushing remover & installer base
MB991576
Base
MB991576
MB991897 or MB992011
Ball joint remover
AC106827
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.
ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT
M1331000900875
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: 0 2 mm
Lock nut Clip
1. Adjust the toe-in by undoing the clip and lock 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 lock nut to the specified torque. Tightening torque: 52 2 Nm 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. Standard value: Inner wheel Outer wheel (for reference) 3145' 130' 2715'
AC006074 AD
FRONT SUSPENSION
ON-VEHICLE SERVICE
33-5
CAMBER, CASTER AND KINGPIN INCLINATION

Standard value: Item Specification Camber (Selectable from 100' 030'*1 or 2 options) 200' 030'*1 Caster Kingpin inclination 355' 030'*1 1345' 130'
Select the camber by the installation direction of the arrow of the connecting bolt of the strut assembly and the knuckle. 100' 030': Install the bolt turning the arrow in the direction of inside the vehicle. 200' 030': Install the bolt turning the arrow in the direction of outside the vehicle.
LOWER ARM BALL JOINT AXIAL PLAY CHECK

M1332010900051
NOTE: . 1. *1: Difference between right and left wheels must be less than 30' 2. Caster and kingpin inclination are preset at the factory and cannot be adjusted.
SELECTION THE CAMBER

<Camber: 100'> <Camber: 200'>
1. Raise the vehicle. 2. Remove the stabilizer bar from the lower arm assembly. 3. Move the lower arm up and down with your hands to check for excessive play in the axial direction of the ball joint. If there is excessive play, replace the lower arm assembly.
BALL JOINT DUST COVER CHECK

M1332008600398
AC505096 AE
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.
33-6
FRONT SUSPENSION
STRUT ASSEMBLY
STRUT ASSEMBLY
M1332001100422
Post-installation Operation Front Wheel Alignment Check and Adjustment (Refer to P.33-4).
44 5 Nm
2 1 5
3
167 9 Nm
AC310743 AB
1. 2. 3. 4. 5.
Removal steps Front wheel speed sensor harness bracket Brake hose bracket Knuckle connection Strut mounting nut Strut assembly
INSPECTION
Check for oil leaks from the strut assembly. Check the strut assembly for damage or deformation.
M1332001200300
FRONT SUSPENSION
STRUT ASSEMBLY
33-7
DISASSEMBLY AND ASSEMBLY

M1332001300620
1 3 7
60 10 Nm
2 3 4 5 6
9
AC310745AB
1. <<A>>>>A<<2. 3. 4. 5.
Disassembly steps Strut cover Strut nut Strut insulator Spring upper seat Strut damper
<>
6. 7. 8. 9.
Disassembly steps (Continued) Strut cover Coil spring Spring lower pad Front suspension strut
33-8
DISASSEMBLY SERVICE POINTS <<A>> STRUT NUT REMOVAL
FRONT SUSPENSION
STRUT ASSEMBLY
CAUTION Do not tighten the bolt of special tool spring compressor body (MB991237) too tight. Special tool spring compressor body (MB991237) will be broken if the allowable tightening torque of 74 Nm is exceed. 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.
Do not use an impact wrench to remove the strut nut. Vibration of the impact wrench will cause special tools (MB991237 and MB991238) to slip and cause personal injury. Vibration of the impact wrench will cause the valve inside the strut to drop out.
WARNING
MB991682 MB991681
AC006091 AB
MB991238
MB991237
2. Use following special tools to secure the strut, and then remove the self-locking nut. Wrench (MB991681) Socket (MB991682)
AC001085AB
<> FRONT SUSPENSION STRUT REMOVAL

Wear goggles when drilling to protect your eyes from flying metal debris.
WARNING
1. Use following special tools to compress the coil spring. Spring compressor body (MB991237) Arm set (MB991238)
AC001087
The gas must be discharged from the front suspension strut assembly before discarding it. Place the strut 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.
FRONT SUSPENSION
STRUT ASSEMBLY
33-9
ASSEMBLY SERVICE POINTS >>A<< STRUT NUT INSTALLATION

1. Ensure that the bearing is seated correctly.
CAUTION Do not use an impact wrench to tighten the strut nut, otherwise the strut nut will be damaged. Vibration of the impact wrench will cause the valve inside the strut to dropout.
MB991238
MB991237
MB991682
MB991681
AC001085AB
2. Install following special tools to the strut assembly same as its removal. Spring compressor body (MB991237) Arm set (MB991238)
AC211766AB
CAUTION Do not use an impact wrench to tighten the bolt of special tool spring compressor body (MB991237), otherwise the special tool will break.
3. While the coil spring is being compressed by the special tools, temporarily tighten the strut nut.
6. Using following special tools, tighten the strut nut to 60 10 Nm. Wrench (MB991681) Socket (MB991682)
Rod
AC211769
7. After tightening the strut nut, fill the multi purpose grease to the bearing part of strut insulator.
INSPECTION
AC310747AB
4. Align the hole in the strut spring lower seat with the hole in the upper spring seat. NOTE: Using a rod as shown facilitates the alignment. 5. Correctly align both ends of the coil spring with the grooves in the spring seat, and then loosen the special tools.
Check the strut bearing for wear or rust. Check the rubber parts for damage or deterioration. Check the coil spring for deformation, deterioration or damage. Check the front suspension strut for deformation.
M1332001400229
33-10
FRONT SUSPENSION
LOWER ARM
LOWER ARM
M1332001600405
CAUTION During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe off quickly.
*: 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 P.33-4).
5
39 5 Nm 39 5 Nm
1 4 5
186 10 Nm*
2 3
167 9 Nm 108 10 Nm
AC310744AB
<<A>>
1. 2. 3.
Removal steps Stabilizer link nut Lower arm and knuckle connection Lower arm and crossmember connection
4. 5.
Removal steps (Continued) Stabilizer bar bracket Lower arm assembly
FRONT SUSPENSION
LOWER ARM
33-11
REMOVAL SERVICE POINT <<A>> LOWER ARM AND CROSSMEMBER DISCONNECTION

Piece of wood
2. When the measured value exceeds the standard value, replace the lower arm assembly. 3. When the measured value is lower than the standard value, check that the lower arm ball joint turns smoothly without excessive play. If there is no excessive play, the ball joint can be reused.
PILLOW BALL BUSHING STARTING TORQUE CHECK
Garage jack
Mounting bolt
AC006133AE
Pillow ball joint
As for the L.H. lower arm assembly, withdraw the lower arm bolt (front) with the transmission lift up by using a transmission jack.
INSPECTION
M1332001700491
LOWER ARM BALL JOINT STARTING TORQUE CHECK
Pillow ball bushing
MB990326
Ball joint
AC504614AB
MB991006
1. Insert the bolt to the lower arm pillow ball bushing. In the opposite direction, insert the washer then install the nut. After rotating the inner sleeve (contained washer) several times, measure the starting torque of the lower arm pillow ball bushing using special tool preload socket (MB990326). Standard value: 0.5 3.0 Nm 2. When the measured value exceeds the standard value, replace the pillow ball bushing. 3. When the measured value is lower than the standard value, check that the lower arm pillow ball bushing turns smoothly without excessive play. If there is no excessive play, the pillow ball bushing can be reused.
Ball joint
AC504613AB
1. After shaking the lower arm ball joint stud several times, use special tool preload socket (MB991006) to measure the starting torque of the ball joint. Standard value: 0.5 3.4 Nm
33-12
FRONT SUSPENSION
LOWER ARM
LOWER ARM 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 lower arm. 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.
Replace the bushing as follows:
MB990651 MB991576
BALL JOINT DUST COVER REPLACEMENT

If the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Remove the dust cover. 2. Apply multipurpose grease to the lip and inside of the dust cover.
M1332008200312
Lower arm assembly
MB990800
MB991816
Dust cover
AC504563 AB
AC006135 AB
1. Use following special tools to drive out the bushing. Bar (MB990651) Base (MB991576) Bushing remover & installer base (MB991816)
Marking 60
3. Using special tool ball joint remover and installer (MB990800), press the dust cover until it contacts the lower arm assembly. 4. Press the dust cover with your finger to check that there are no cracks or damage in the dust cover.
LOWER ARM PILLOW BALL BUSHING REPLACEMENT

M1332008100564
Pillow ball bushing
AC504565 AB
2. Set the bushing to the lower arm assembly so that the bushing marking and the opening are as shown in the illustration.
AC504566AB
FRONT SUSPENSION
LOWER ARM
33-13
3. Use special tools to press in the bushing until its outer tube is flush with the lower arm assembly surface.
MB990651 MB991576
Lower arm assembly
Outer tube
MB991816
AC504564 AB
33-14
FRONT SUSPENSION
STABILIZER BAR
STABILIZER BAR
M1332004000662
CAUTION Before removing the steering wheel and air bag module assembly, refer to GROUP 52B Service Precautions (P.52B-3) and Drivers, Front Passengers Air Bag Module(s) and Clock Spring (P.52B-110). 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.
During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe off quickly. *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition.
Pre-removal Operation Steering Wheel - Drivers Air Bag Module Assembly Removal (Refer to GROUP 37, Steering Wheel P.37-13). Clock Spring Removal (Refer to GROUP 52B, Drivers, Front Passengers Air Bag Module(s) and Clock Spring P.52B-110). Front Axle Crossmember Bar Removal (Refer to P.33-17). Front Axle No.1 Crossmember Assembly Removal (Refer to GROUP 32, Crossmember P.32-10). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Post-installation Operation Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Front Axle No.1 Crossmember Assembly Installation (Refer to GROUP 32, Crossmember P.32-10). Front Axle Crossmember Bar Installation (Refer to P.33-17). Clock Spring Installation (Refer to GROUP 52B, Drivers, Front Passengers Air Bag Module(s) and Clock Spring P.52B-110). Steering Wheel - Drivers Air Bag Module Assembly Installation (Refer to GROUP 37, Steering Wheel P.37-13). Check the Dust Cover for Cracks or Damage by Pushing it with Finger. Checking Steering Wheel Position with Wheels Straight Ahead Front Wheel Alignment Check and Adjustment (Refer to P.33-4).
FRONT SUSPENSION
STABILIZER BAR
33-15
6
18 2 Nm
21 4 Nm
10
8 9
39 5 Nm
4 3 1
N
25 5 Nm
39 5 Nm
7
52 7 Nm*
167 9 Nm
49 10 Nm
AC310741AB
108 10 Nm
1. 2. 3. <<A>> 4. 5.
Removal steps Stabilizer link Stabilizer bar bracket Lower arm and knuckle connection Tie rod end knuckle connection Steering shaft cover
6. 7. <> <> <> >>A<< >>A<< >>A<< 8. 9. 10.
Removal steps (Continued) Steering gear and joint connection bolt Rear roll stopper connection bolt Stabilizer bracket Stabilizer bushing Stabilizer bar
33-16
FRONT SUSPENSION
STABILIZER BAR
REMOVAL SERVICE POINTS <<A>> 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 or MB992011) to avoid possible damage to ball joint threads. Hang special tool ball joint remover (MB991897 or MB992011) with a cord to prevent it from falling.
Cord
Piece of wood
Transmission jack
AC102600 AD
1. Use a transmission jack to hold the crossmember, remove the crossmember mounting nuts and bolts.
Nut
MB991897 or MB992011 Bolt Ball joint

AC208247AJ
CAUTION Be careful not to lower the crossmember excessively. The power steering return hose bracket may deform if the crossmember is lowered too much.
2. Lower the crossmember until the fixture, the bushing and the stabilizer bar can be removed.
1. Install special tool ball joint remover (MB991897 or MB992011) as shown in the figure.
Bolt Parallel
INSTALLATION SERVICE POINTS >>A<< STABILIZER BAR/STABILIZER BUSHING/STABILIZER BRACKET/INSTALLATION

Outside of vehicle Identification mark
Knob
Good
Bad
AC106821AB
2. Turn the bolt and knob as necessary to make the jaws of special tool ball joint remover (MB991897 or MB992011) 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.
Stabilizer bushing (LH)
Stabilizer bracket (LH)

AC006141AJ
Align the stabilizer bar identification mark with the right end of the bushing (LH).
INSPECTION
Check the stabilizer bushings for wear and deterioration. Check the stabilizer bar for deterioration or damage. Check all bolts for condition and straightness.
M1332002000321
<> STABILIZER BRACKET/STABILIZER BUSHING/STABILIZER BAR REMOVAL

Carry out the following operations to ensure working space in order to remove the fixture, the bushing and the stabilizer bar.
FRONT SUSPENSION
CROSSMEMBER BAR
33-17
STABILIZER LINK BALL JOINT TURNING TORQUE CHECK

MB990326
Standard value: 1.7 3.2 Nm 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.
STABILIZER LINK BALL JOINT DUST COVER CHECK

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.
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.
CROSSMEMBER BAR
M1332016100086
49 10 Nm Front axle crossmember bar

AC310742 AB
NOTES
34-1
GROUP 34
REAR SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .
REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . BALL JOINT DUST COVER INSPECTION
34-2 34-3 34-3 34-4

34-4 34-4
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . TRAILING ARM BALL JOINT DUST COVER REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
34-10 34-11 34-11
LOWER ARM ASSEMBLY AND ASSIST LINK . . . . . . . . . . . . . . . . . . . . . . . . . . 34-12

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . ASSIST LINK BALL JOINT DUST COVER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-12 34-14 34-15
REAR SUSPENSION ASSEMBLY . .

34-5
34-5
SHOCK ABSORBER ASSEMBLY . . .

REMOVAL AND INSTALLATION . . . . . . . . DISASSEMBLY AND ASSEMBLY . . . . . . .
34-16
34-16 34-17
UPPER ARM ASSEMBLY . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . UPPER ARM BALL JOINT DUST COVER REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
34-7
34-7 34-8 34-8
STABILIZER BAR. . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . STABILIZER BAR LINK BALL JOINT DUST COVER REPLACEMENT . . . . . . . . . . . . . .
34-20
34-20 34-21 34-22
TRAILING ARM . . . . . . . . . . . . . . . . .
34-10
34-2
REAR SUSPENSION
GENERAL INFORMATION
GENERAL INFORMATION
M1341000100706
A trailing arm type multi-link suspension is used for the rear suspension. In contrast to the trailing arm multi-link system used on the Lancer, the Lancer Evolution uses a newly developed multi-link system built on a double wishbone base to achieve superior handling stability. Optimum design of the suspension
points and use of aluminium parts for the suspension arms and crossmember reduces weight. In addition, use of ball joints on the suspension arms reduce friction and creates a suspension system that exhibits superior stroke characteristics that respond well under all driving conditions.
Coil spring Shock absorber Upper arm assembly (forged aluminium) Stabilizer bar link Assist link (forged aluminium) Crossmember (forged aluminium) Differential support member Differential support arm Stabilizer bar
Assist link control bar Trailing arm assembly (forged aluminium ) Lower arm assembly (forged aluminium)
AC211385AC
SPECIFICATION COIL SPRING

Item Wire diameter mm Average diameter mm Free length mm Standard 12 88 287 Option 12 88 277
REAR SUSPENSION
34-3
M1341000300722
Item Toe-in mm Camber Thrust angle Upper arm ball joint starting torque Nm Trailing arm ball joint starting torque Nm Assist link ball joint starting torque Nm Assist link slide bushing starting torque Nm Lower arm pillow ball bushing starting torque Nm Stabilizer bar link ball joint turning torque Nm Standard value 32 100' 030' (Difference between right and left within 30') 000' 009' 0.5 2.5 0.5 2.5 0.5 2.5 0.5 2.0 0.5 3.0 1.7 3.1
SPECIAL TOOLS
M1341000600626
Tool
Number MB991897 or MB992011
Name Ball joint remover
Use Ball joint and Knuckle disconnection NOTE: Steering linkage puller (MB990635 or MB991113) is also available to disconnect ball joint and Knuckle. Ball joints and side bushing starting torque measurement Pillow ball bushing turning torque measurement Ball joint dust cover press-fitting
AC106827
MB990326
Preload socket
MB990326
MB990800
Ball joint dust cover installer
MB990800
A: MB991237 B: MB991239
A B
MB991237
A: Spring compressor body B: Arm set
Coil spring removal and installation
34-4
REAR SUSPENSION
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT
The rear suspension, wheels and tires should be serviced to normal condition prior to measurement of wheel alignment. 1. Measure the wheel alignment with the vehicle parked on a level surface.
M1341011000725
If camber and/or toe-in is not within the standard value, adjust by following procedures.
Camber adjusting bolt
TOE-IN
Standard value: 3 2 mm If toe-in is not within the standard value, adjust by following procedures. 1. Be sure to adjust the camber before making toe adjustment.
Lower arm
AC310762 AB
Assist link
1. Carry out camber adjustment by turning the camber adjusting bolt (lower arm to rear crossmember mounting bolt). Left wheel: Turning clockwise (+) camber Right wheel: Turning clockwise () camber NOTE: The scale has gradations of approximately 14 2. After adjusting the camber, the toe should be adjusted.
Toe adjusting bolt

AC310761AB
BALL JOINT DUST COVER INSPECTION

Check the toe control arm assembly and the stabilizer bar link assembly ball joint dust cover as follows. 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 toe suspension arms or the stabilizer bar link assembly. NOTE: Cracks or damage to the dust cover may cause damage to the ball joint.
M1341012800326
2. Carry out adjustment by turning the toe adjusting bolt (assist link mounting bolt which is located on the inner side of the body). Left wheel: Turning clockwise (+) toe-in Right wheel: Turning clockwise () toe-in NOTE: The scale has gradations of approximately 3.3 mm (single side toe angle equivalent to 19).
CAMBER
Standard value: 100 030 (difference between right and left wheel: less than 30)
REAR SUSPENSION
REAR SUSPENSION ASSEMBLY
34-5

M1341001000199
CAUTION During maintenance, take care not to contact the parts or tools to the caliper, because the paint of caliper will be scratched. And contact the parts or tools to the caliper, wipe out quickly.
*:To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
Pre-removal Operation Centre Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Post-installation Operation Centre Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Parking Brake Lever Stroke Check (Refer to GROUP36-On-vehicle Service Parking Brake Lever Stroke Check and Adjustment P.36-3). Wheel Alignment Check And Adjustment (Refer to P.34-4).
3
44 5 Nm
4N 1
32 2 Nm 49 5 Nm 64 4 Nm* 24 4 Nm
3 10 9 15 7 12 11
147 9 Nm*
6 13 14
N
13
88 5 Nm 54 5 Nm
120 10 Nm 88 5 Nm
13
AC310772AB
93 15 Nm*
<<A>>
1. 2. 3. 4. 5. 6. 7. 8.
Removal steps Fuel filler cap Protector Bolt Shock absorber mounting nut Brake caliper assembly Rear ABS sensor Brake disc Parking brake cable end
<> >>B<< 9. 10. 11. 12. <<C>> >>A<< 13. 14.
Removal steps (Continued) Propeller shaft connection Upper arm mounting bolt Trailing arm mounting bolt Assist link mounting bolt Crossmember mounting bolt Differential support assembly mounting nut 15. Rear suspension assembly
34-6
REAR SUSPENSION
REMOVAL SERVICE POINTS <<A>> BRAKE CALIPER ASSEMBLY REMOVAL

CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly. Remove the brake caliper assembly and support with wire.
Tighten the bolt by following the order shown in the illustration. The sort and size of each bolt is different, so tighten by following the table below. NOTE: In order to maintain accuracy and for ease of installing, the attachment hall diameter of the crossmember is different on forward/rearward. Follow the tightening order of the mounting bolts. No. Sort of bolt Size of bolt (Screw diameter Length) mm 12 152
<> PROPELLER SHAFT DISCONNECTION

1. Mark the mating mark on the companion flange of the differential carrier and the flange yoke of the propeller shaft. 2. Remove the propeller shaft mounting bolt and nut.
1,2,3 4 5
Flange bolt (with washer) 12 105 Bolt (with spring washer and washer)
Flange bolt (with washer) 12 70
>>B<< PROPELLER SHAFT CONNECTION

CAUTION If there is oil or grease on the thread of the mounting bolt or nut, they will loosen. So after wiping off oil or grease from the threads, tighten the mounting bolt. Install the differential carrier and propeller shaft by aligning the mating marks.
<<C>> CROSSMEMBER MOUNTING BOLT REMOVAL

Support the differential case with a garage jack or transmission jack, then remove the crossmember mounting bolt.
INSTALLATION SERVICE POINTS >>A<< CROSSMEMBER MOUNTING BOLT INSTALLATION

3 3
4 5 5
4 2
AC211967AB
REAR SUSPENSION
UPPER ARM ASSEMBLY
34-7
UPPER ARM ASSEMBLY

M1341003600335
CAUTION During maintenance, take care not to contact the parts or tools to the caliper, because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
: To prevent bushings from breakage, the parts indicated by *1 should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
Post-installation Operation Press the dust cover with your finger to check that there are no cracks or damage in the dust cover. Wheel Alignment Check and Adjustment (Refer to P.34-4).
*1
3 6 5
64 4 Nm*
7
24 4 Nm
3
39 5 Nm
4
49 5 Nm
4
81 6 Nm
N
AC310782AB
<<A>>
1. 2. 3. 4. 5.
Removal steps Fuel filler cap*2 Protector*2 Bolt*2 Upper arm assembly and knuckle connection Upper arm assembly mounting bolt
6. 7.
Removal steps (Continued) Upper arm stopper Upper arm assembly
NOTE: Install/remove the parts with the mark "*2" when installing/removing the LH side upper arm assembly.
34-8
REAR SUSPENSION
UPPER ARM ASSEMBLY
REMOVAL SERVICE POINT <<A>> UPPER ARM BALL JOINT AND KNUCKLE DISCONNECTION
Cord
INSPECTION
M1341015500186
UPPER ARM BALL JOINT STARTING TORQUE CHECK
MB990326
ACX00716 AB
Ball joint Bolt MB991897 or MB992011

AC106820 AE
1. After shaking the upper arm ball joint stud several times, use special tool preload socket (MB990326) to measure the starting torque of the ball joint. Standard value: 0.5 2.5 Nm 2. When the measured value exceeds the standard value, replace the upper arm assembly. 3. When the measured value is lower than the standard value, check that the ball joint turns smoothly without excessive play. If there is no excessive play, the ball joint can be reused.
Nut
1. Install the special tool ball joint remover (MB991897 or MB992011) as shown in the figure.
Bolt Parallel
UPPER ARM 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 upper arm assembly. 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.
Knob
Good
Bad
AC106821AB
2. Turn the bolt and knob as necessary to make the jaws of the special tool ball joint remover (MB991897 or MB992011) 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 upper arm assembly and the knuckle.
UPPER ARM BALL JOINT DUST COVER REPLACEMENT

Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Remove the dust cover.
M1341010900413
REAR SUSPENSION
UPPER ARM ASSEMBLY
34-9
MB990800
3. Using the special tool ball joint remover and installer (MB990800), punch the dust cover until it contacts the snap ring. 4. Press the dust cover with your finger to check that there are no cracks or damage in the dust cover.
AC212031AB
2. Fill the multipurpose grease in the dust cover and lubricate the lip. (Amount of filling grease in the dust cover: approximately 7 g).
34-10
REAR SUSPENSION
TRAILING ARM
TRAILING ARM
M1341002200743
*: To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
81 6 Nm
1 3
147 9 Nm*
4 5 4
AC310784 AB
<<A>>
1. 2.
Removal steps Parking brake cable bolt Trailing arm assembly and knuckle connection
3. 4. 5.
Removal steps (Continued) Trailing arm assembly mounting bolt Trailing arm bushing stopper Trailing arm assembly
REAR SUSPENSION
TRAILING ARM
34-11
M1341002300289
REMOVAL SERVICE POINT <<A>> TRAILING ARM ASSEMBLY AND KNUCKLE DISCONNECTION
Cord
INSPECTION BALL JOINT STARTING TORQUE CHECK
MB990326
ACX00716 AB

AC106820 AE
1. After shaking the ball joint stud several times, use special tool preload socket (MB990326) to measure the starting torque of the ball joint. Standard value: 0.5 2.5 Nm 2. When the measured value exceeds the standard value, replace the trailing arm assembly. 3. When the measured value is lower than the standard value, check that the ball joint turns smoothly without excessive play. If there is no excessive play, the ball joint can be reused.
Nut
1. Install the special tool ball joint remover (MB991897 or MB992011) as shown in the figure.
Bolt Parallel
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 trailing 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.
Knob
Good
Bad
AC106821AB
2. Turn the bolt and knob as necessary to make the jaws of the special tool ball joint remover (MB991897 or MB992011) 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 trailing arm assembly and the knuckle.
TRAILING ARM BALL JOINT DUST COVER REPLACEMENT

Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Remove the dust cover.
M1341010900424
MB990800
AC212031AB
34-12
REAR SUSPENSION
LOWER ARM ASSEMBLY AND ASSIST LINK
2. Fill the multipurpose grease in the dust cover and lubricate the lip (Amount of filling grease in the dust cover: approximately 7 g).
3. Using special tool ball joint remover and installer (MB990800), punch the dust cover until it contacts the snap ring. 4. Press the dust cover with your finger to check that there are no cracks or damage in the dust cover.

M1341017100065
*: To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
93 15 Nm*
6 4
81 6 Nm
2
N
93 15 Nm*
3
N N
88 10 Nm*
88 10 Nm*
1
AC310785AB
1. <<A>> 2. >>A<< 3.
Lower arm assembly removal steps Lower arm assembly to shock absorber connecting bolt Lower arm assembly mounting bolt Lower arm assembly
<> <<C>>
4. 5. 6.
Assist link removal steps Assist link and knuckle connection Assist link mounting bolt Assist link assembly
REAR SUSPENSION
34-13
REMOVAL SERVICE POINTS <<A>> LOWER ARM ASSEMBLY MOUNTING BOLT REMOVAL
Mating marks
2. Turn the bolt and knob as necessary to make the jaws of special tool ball joint remover (MB991897 or MB992011) 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 assist link assembly and the knuckle.
<<C>> ASSIST LINK MOUNTING BOLT REMOVAL

AC310794 AB
Make mating marks on the lower arm and the decentering cam bolt, then remove the lower arm and the decentering cam bolt.
Mating marks
<> ASSIST LINK AND KNUCKLE DISCONNECTION

Cord Eccentric cam bolt
AC310795 AB
Make mating marks on the assist link and the decentering cam bolt, then remove the toe control arm and the decentering cam bolt.
INSTALLATION SERVICE POINT >>A<< LOWER ARM ASSEMBLY INSTALLATION

With red marking: RH side lower arm assembly

AC106820 AE
Nut
With countersunk 10mm: LH side lower arm assembly
1. Install special tool ball joint remover (MB991897 or MB992011) as shown in the figure.
Bolt Parallel
AC310797AB
Check the identification mark, install the lower arm assembly.
Knob
Good
Bad
AC106821AB
34-14
INSPECTION
REAR SUSPENSION
M1341017200051
ASSIST LINK BALL JOINT STARTING TORQUE CHECK
3. When the measured value is lower than the standard value, check that the assist link slide bushing turns smoothly without excessive play. If there is no excessive play, the slide bushing can be reused.
MB990326
ASSIST 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 trailing arm assembly. 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.
ACX00716 AB
1. After shaking the assist link ball joint stud several times, measure the starting torque of the assist link ball joint by using special tool preload socket (MB990326). Standard value: 0.5 2.5 Nm 2. When the measured value exceeds the standard value, replace the assist link. 3. When the measured value is lower than the standard value, check that the assist link ball joint turns smoothly without excessive play. If there is no excessive play, the ball joint can be reused.
LOWER ARM PILLOW BALL BUSHING STARTING TORQUE CHECK
ASSIST LINK SLIDE BUSHING STARTING TORQUE CHECK

Pillow ball bushing
MB990326 MB990326
AC212117AB AC310798AB
1. After inserting the bolt to the assist link slide bush and attaching the washer in the opposite direction, install the nut. After rotating the inner sleeve (include the washer) several times, measure the starting torque of the assist link slide bushing by using special tool preload socket (MB990326). Standard value: 0.5 2.0 Nm 2. When the measured value exceeds the standard value, replace the assist link.
1. Insert the bolt to the lower arm pillow ball bushing, in the opposite direction, insert the washer then install the nut. After rotating the inner sleeve (contained washer) several times, measure the starting torque of the lower arm below ball bushing using special tool preload socket (MB990326). Standard value: 0.5 3.0 Nm 2. When the measured value exceeds the standard value, replace the lower arm assembly.
REAR SUSPENSION
34-15
3. When the measured value is lower than the standard value, check that the lower arm pillow ball bushing turns smoothly without excessive play. If there is no excessive play, the pillow ball bushing can be reused.
ASSIST LINK BALL JOINT DUST COVER REPLACEMENT

M1341017300058
MB990800
Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Remove the dust cover. 2. Fill the multipurpose grease in the dust cover and lubricate the lip (Amount of filling grease in the dust cover: approximately 7 g). 3. Using special tool ball joint remover and installer (MB990800), punch the dust cover until it contacts the snap ring. 4. Press the dust cover with your finger to check that there are no cracks or damage in the dust cover.
AC212031AB
34-16
REAR SUSPENSION
SHOCK ABSORBER ASSEMBLY

M1341002500391
: To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
Pre-removal and Post-installation Operation Trunk Room Side Trim Removal and Installation (Refer to GROUP 52A, Trims P.52A-10).
*
1N
44 5 Nm
2
N
88 10 Nm*
AC310799AB
1.
Removal steps Coil spring nut
2. 3.
Removal steps (Continued) Coil spring bolt Shock absorber assembly
REAR SUSPENSION
34-17
DISASSEMBLY AND ASSEMBLY

M1341005300363
25 5 Nm
1N
2 3 9 4 7 5 11 6
8
10
12
AC310801AB
<<A>> >>D<< 1. 2. 3. >>C<< 4. >>B<< 5. 6.
Disassembly steps Coil spring nut Coil spring washer Coil spring bushing Shock absorber insulator Spring upper pad Coil spring bushing
7. 8. 9. 10. >>A<< 11 12
Disassembly steps (Continued) Coil spring collar Shock absorber cup Shock absorber cover Shock absorber damper Coil spring Shock absorber assembly
34-18
REAR SUSPENSION
DISASSEMBLY SERVICE POINT <<A>> COIL SPRING NUT REMOVAL

CAUTION Install special tools spring compressor body (MB991237) and arm set (MB991239) evenly, and so that the maximum length will be attained within the installation range. Do not use an impact wrench, as it will cause the bolt of special tool spring compressor body (MB991237) to be seized.
ASSEMBLY SERVICE POINTS >>A<< COIL SPRING INSTALLATION

CAUTION Do not use an impact wrench, as it will cause the bolt of the special tool spring compressor body (MB991237) to be seized.
MB991237
MB991237
MB991239
AC001070 AB
MB991239
AC001070 AB
1. Use special tools spring compressor body (MB991237) and arm set (MB991239) to compress the coil spring, and install it to the spring seat of the shock absorber.
1. Use special tools spring compressor body (MB991237) and arm set (MB991239) to compress the coil spring.
To prevent the piston rod lock nut inside the shock absorber from loosening, do not use an impact wrench when the coil spring nut is loosened.
WARNING
Spring seat stepped section

AC006176AB
Piston rod
2. Align the end of the coil spring with the stepped section of the spring seat of the shock absorber.
>>B<< SPRING UPPER PAD INSTALLATION

AC310802 AB
2. Holding the piston rod, remove the coil spring nut.
Spring upper pad stepped section
AC310803AB
Align the stepped section of the spring upper pad with the end of the coil spring, and install the spring upper pad.
REAR SUSPENSION
34-19
>>C<< SHOCK ABSORBER INSULATOR INSTALLATION
Install the shock absorber insulator so that the lower bushing inner pipe of the shock absorber and the line between the shock absorber insulator mounting bolts are straight when looking from above.
Lower bushing inner pipe
>>D<< COIL SPRING NUT INSTALLATION

CAUTION To prevent the piston rod lock nut inside the shock absorber from loosening, do not use an impact wrench when the coil spring nut is tightened. 1. Provisionally tighten the coil spring nut.
Shock absorber insulator mounting bolt
Spring upper pad stepped section
MB991237
Spring seat stepped section
Lower bushing inner pipe
MB991239
AC001070 AB
AC310805AB
2. After removing special tools spring compressor body (MB991237) and arm set (MB991239), tighten the coil spring nut to 25 5 Nm.
34-20
REAR SUSPENSION
STABILIZER BAR
STABILIZER BAR
M1341003000322
CAUTION During maintenance, take care not to contact the parts or tools to the caliper, because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly.
Post-installation Operation Press the dust cover with your finger to check that there are no cracks or damage in the dust cover.
2
39 5 Nm
3 4
39 5 Nm
3
24 4 Nm 39 5 Nm
2
1. 2. 3. Removal steps Stabilizer nut Stabilizer bar link Stabilizer bar bracket >>A<< >>A<< 4. 5.
AC310809AB
Removal steps (Continued) Stabilizer bushing Stabilizer bar
>>A<<
REAR SUSPENSION
STABILIZER BAR
34-21
M1341001400368
INSTALLATION SERVICE POINT >>A<< STABILIZER BAR/STABILIZER BUSHING/STABILIZER BAR BRACKET INSTALLATION
INSPECTION STABILIZER BAR LINK BALL JOINT TURNING TORQUE CHECK

MB990326
AC212145AB
Approx. 10mm
1. After shaking the stabilizer bar link ball joint stud several times, install the stabilizer nut to the stud and use special tool preload socket (MB990326) to measure the turning torque of the stabilizer bar link ball joint. Standard value: 1.7 3.1 Nm 2. When the measured value exceeds the standard value, replace the stabilizer bar 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 reuse that ball joint.
B A
AC310811AB
Align the stabilizer bar until the identification colour of the stabilizer bar is out of the dimension shown as the illustration from the stabilizer bush to the vehicle centre. After tightening the stabilizer bracket mounting bolt A, tighten mounting bolt B.
STABILIZER BAR 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 bar link. NOTE: Cracks or damage of the dust cover may cause damage of the ball joint. When it is damaged during service work, replace the dust cover.
34-22
STABILIZER BAR LINK BALL JOINT DUST COVER REPLACEMENT
REAR SUSPENSION
STABILIZER BAR
Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows:
M1341010900338
2. Apply multipurpose grease to the inside of the dust cover. 3. Wrap plastic tape around the stabilizer bar link stud, and then install the dust cover to the stabilizer bar link.
Clip ring end (possible on opposite direction)
90
Clip ring
AC006188AB
AC310812 AB
1. Remove the clip ring and the dust cover.
4. Secure the dust cover by the clip ring. Then install the clip ring end in order to position it 90 degrees from the axis of the link. 5. Check the dust cover for cracks or damage by pushing it with your finger.
AC212251AB
21A-1
GROUP 21A
CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .
CLUTCH PEDAL CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . CLUTCH BLEEDING . . . . . . . . . . . . . . . . .
21A-2 21A-2 21A-2 21A-3

21A-3 21A-4
CLUTCH SWITCH CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
21A-4
CLUTCH PEDAL. . . . . . . . . . . . . . . . .
21A-5
21A-5
CLUTCH CONTROL . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
21A-7
21A-7 21A-8 21A-9 21A-10
21A-2
CLUTCH
GENERAL INFORMATION
GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control. The clutch shares a brake fluid reservoir with the brake system.
M1211000100223
M1211000300357
Item Clutch pedal height mm Clutch pedal height mm Clutch pedal clevis pin play mm Clutch pedal free play mm Distance between the clutch pedal and the clutch pedal stopper when the clutch pedal is released mm LH drive vehicles LH drive vehicles RH drive vehicles
Standard value 203.8 2 198.7 2 13 4 13 114.3 or more 95 or more
Distance between the clutch pedal and the dash pad when the RH drive vehicles clutch pedal is released mm
LUBRICANTS
M1211000400194
Item Clutch fluid Pushrod assembly Boot Release cylinder push rod
Specified lubricant Brake Fluid DOT 3 or DOT 4 Rubber grease Rubber grease MITSUBISHI genuine grease Part No.0101011
Quantity As required As required As required As required
CLUTCH
ON-VEHICLE SERVICE
21A-3
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND ADJUSTMENT
M1211000900401
Clutch pedal height <LH drive vehicles>
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.
A Clutch pedal free play Clutch pedal stopper <RH drive vehicles>
A C
AC100355 AC
Carpet Dash pad

AC310574 AB
<LH drive vehicles>
1. Measure the clutch pedal height. Standard value (A): 203.8 2 mm <LH drive vehicles>, 198.7 2 mm <RH drive vehicles>
Clutch pedal clevis pin play
Clutch pedal stopper <RH drive vehicles>
B
AC100355 AB
2. Measure the clutch pedal clevis pin play. Standard value (B): 1 3 mm
Setting nut
Dash pad
AC310575AD
Clutch pedal 13 2 Nm
AC100356 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 or dash pad when the clutch is disengaged are within the standard value ranges. Standard value (C): 4 13 mm Standard value (D): 114.3 mm or more <LH drive vehicles>, 95 mm or more <RH drive vehicles>
21A-4
CLUTCH
ON-VEHICLE SERVICE
5. If the clutch pedal free play and the distance between the clutch pedal and the clutch pedal stopper or dash pad 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.
4. Check that the brake fluid reservoir level stays between "MAX" and "MIN" marks throughout the clutch bleeding process.
CLUTCH SWITCH CHECK AND ADJUSTMENT

M1211001100185
1. Adjust the clutch pedal.
CLUTCH BLEEDING
M1211001400216
CAUTION Use the specified brake fluid. Do not mix brake fluids. Specified fluid: Brake fluid DOT 3 or DOT 4
AC310580
2. Connect an ohmmeter to the clutch switch connector, and then check for continuity when the clutch pedal is fully depressed and when it is released outward. Tester connection
AC211514 AB
Pedal position Specified condition Fully depressed Open circuit Released Less than 2 ohms
1-2
1. Connect a hose with a bottle to the bleeder screw. 2. Open the bleed nipple.
CAUTION For bleeding, never "pump" the clutch pedal. This may cause an oil leak at the clutch cylinder.
3. 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.
3. If the continuity is incorrect, replace the clutch switch.
CLUTCH
CLUTCH PEDAL
21A-5
CLUTCH PEDAL
M1211001600340
Post-installation Operation Clutch Pedal Adjustment (Refer to P.21A-3).

<LH drive vehicles>
15 16 6 4
12 2 Nm
7 5
<RH drive vehicles>
10
9
12 2 Nm
14 8 11
12 2 Nm
2 15 16 8 6
1
N
13 12
12 2 Nm
5 4
12 2 Nm
10
9
12 2 Nm
7 13 14 12
AC310323AC
1. 2. 3. 4. 5.
Removal steps Instrument panel under cover (Refer to GROUP 52A, Instrument panel P.52A-2). Clutch pedal position switch Clutch pedal position switch harness Clip Stopper Snap pin
>>A<<
Removal steps (Continued) 6. Clevis pin 7. Clutch master cylinder mounting nut 8. Clutch pedal assembly mounting bolt 9. Clutch switch 10. Nut 11. Stopper 12. Pedal pad
21A-6
13. 14. 15. 16. Removal steps (Continued) Pedal stopper Clutch pedal assembly Turn over spring Bushing
CLUTCH
CLUTCH PEDAL
INSTALLATION SERVICE POINT >>A<< CLUTCH SWITCH INSTALLATION

Clutch switch
Clutch pedal
0.5 1.5 mm
AC309757AB
Install the clutch switch at the specified dimension when the clutch pedal is released.
CLUTCH
CLUTCH CONTROL
21A-7
CLUTCH CONTROL
M1211001900396
Pre-removal Operation Clutch Fluid Draining Strut Tower Bar Removal (Refer to GROUP42, Strut Tower Bar P.42-9 ).
Post-installation Operation Strut Tower Bar Removal (Refer to GROUP42, Strut Tower Bar P.42-9 ). Clutch Fluid Supplying Clutch Line Bleeding (Refer to P.21A-4). Clutch Pedal Adjustment (Refer to P.21A-3).
<LH drive vehicles>

Release fork 15 2 Nm
10 11
Release cylinder push rod
Specified grease: MITSUBISHI genuine grease PART No. 0101011 or equivalent
4 10
18 3 Nm 30 4 Nm 12 2 Nm
2
12 2 Nm
9 11
AC211515 AD
1. 2. 3. 4. 5. 6. 7. 8.
Clutch master cylinder removal steps Clevis pin assembly Eye bolt Gasket Reservoir hose Clevis pin and pushrod assembly connecting part Clutch master cylinder 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
21A-8
<RH drive vehicles>
Release fork
CLUTCH
CLUTCH CONTROL
Release cylinder push rod
12 2 Nm
Specified grease: MITSUBISHI genuine grease PART No. 0101011 or equivalent
4 6
15 2 Nm
18 3 Nm
6, 8
9 7
AC310343 AB
1. 2. 3. 4. 5. 6. 7.
Clutch master cylinder removal steps Clevis pin assembly Clutch pipe connection Reservoir hose Clutch master cylinder Sealer Clutch release cylinder removal steps Clutch pipe Clutch release cylinder
8. 9.
Clutch line removal steps Clutch pipe Clutch hose

M1211002000169
INSPECTION
Check the master cylinder or clutch hose for fluid leakage. Check the clutch hose or tube for cracks or clogging.
CLUTCH
CLUTCH CONTROL
21A-9

M1211002100315
CLUTCH MASTER CYLINDER
CAUTION Do not disassemble the piston assembly.
6
13 2 Nm
7 4 5 2N 8
<LH drive vehicles>
3
N
1 5 8
<RH drive vehicles>
2 1 4 2
3 4
Piston repair kit Clutch fluid: Brake fluid DOT3 OR DOT4 Grease: Rubber grease
AC310349AD
>>A<<
1. 2. 3. 4.
Disassembly steps Piston stopper ring Piston assembly Pushrod assembly Boot
5. 6. 7. 8.
Disassembly steps (Continued) Spring pin Reservoir tank Seal Master cylinder body
21A-10
CLUTCH
CLUTCH CONTROL
REASSEMBLY SERVICE POINT >>A<< PUSHROD ASSEMBLY INSTALLATION
Set the length of the pushrod assembly to the dimension shown to make the adjustment of the clutch pedal easier.
INSPECTION
Check inside the cylinder body for rust and scars. Check the piston for rust and scars. Check the pipe connection for clogging.
M1211002200163
103 0.5 mm
AC001144 AG
22A-1
GROUP 22A
MANUAL TRANSMISSION (FF)

CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . TROUBLESHOOTING <ACD> . . . . .
TROUBLESHOOTING STRATEGY . . . . . . DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . INSPECTION CHART FOR DIAGNOSIS CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS TROUBLE CODE PROCEDURES. . . . . . . . . . . . . . . . . . . . . .
22A-3 22A-3 22A-3 22A-4 22A-7

22A-7 22A-7 22A-8 22A-9
TROUBLESHOOTING <M/T>. . . . . . . 22A-148

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 22A-148 TROUBLESHOOTING STRATEGY . . . . . . 22A-148 SYMPTOM CHART . . . . . . . . . . . . . . . . . . . 22A-148 SYMPTOM PROCEDURES . . . . . . . . . . . . 22A-149
ON-VEHICLE SERVICE . . . . . . . . . . . 22A-151

TRANSMISSION OIL CHECK . . . . . . . . . . . 22A-151 TRANSMISSION OIL REPLACEMENT. . . . 22A-152 TRANSFER OIL CHECK . . . . . . . . . . . . . . . 22A-152 TRANSFER OIL REPLACEMENT . . . . . . . 22A-152 FLUID CHECK. . . . . . . . . . . . . . . . . . . . . . . 22A-152 BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 22A-153 ACD OPERATION CHECK . . . . . . . . . . . . . 22A-153 HYDRAULIC PRESSURE CHECK . . . . . . . 22A-154 WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT. . . . . . . . . . . . 22A-154 OIL TEMPERATURE SENSOR CHECK . . . 22A-156
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 22A-118 SYMPTOM PROCEDURES . . . . . . . . . . . . 22A-119 DATA LIST REFERENCE TABLE . . . . . . . 22A-142 ACTUATOR TEST JUDGEMENT VALUE . 22A-145 CHECK AT 4WD-ECU TERMINALS. . . . . . 22A-146
WARNING
22A-2
TRANSMISSION CONTROL . . . . . . . 22A-157
REMOVAL AND INSTALLATION . . . . . . . . 22A-157 SELECT CABLE (SHIFT LEVER SIDE) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 22A-159
4WD-ECU . . . . . . . . . . . . . . . . . . . . . . 22A-167
SENSOR, SWITCH AND RELAY* . . . 22A-168

REMOVAL AND INSTALLATION . . . . . . . . 22A-168 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 22A-169
TRANSFER ASSEMBLY* . . . . . . . . . 22A-160

TRANSMISSION ASSEMBLY . . . . . . 22A-163

AIR DUCT . . . . . . . . . . . . . . . . . . . . . . 22A-170


GENERAL INFORMATION
22A-3
M1221000100848
GENERAL INFORMATION
Item Transmission model Transmission type Gear ratio 1st 2nd 3rd 4th 5th 6th Reverse Final deceleration ratio Speedometer gear ratio Front differential Transfer Deceleration ratio Limited slip differential Specification W6MAA 6-speed forward, 1-speed reverse constant mesh 2.909 1.944 1.434 1.100 0.868 0.693 2.707 4.583 Not applicable Helical gear LSD 3.307 Hydraulic multi plate clutch <ACD>
M1221000300132
Item Hydraulic unit generation oil pressure MPa Oil temperature sensor resistance k At 20C At 110C
Standard value 1.0 1.6 2.31 2.59 0.145 0.146
LUBRICANTS
M1221000400430
Item Transmission oil Transfer oil Fluid
Specified lubricant Dia Queen LSD gear oil DIA QUEEN ATF SP III
Quantity L 0.6 1.0
DIA QUEEN SUPER MULTI GEAR 75W-85W (GL-4) or exact equivalent 2.2
22A-4

SPECIAL TOOLS
SPECIAL TOOLS
M1221000600832
Tool
A
Number MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826
Name
Use
MB991824
MB991827
DO NOT USE
MB991910
M.U.T.-III sub-assembly Checking the ACD (Diagnosis A: Vehicle communication display by using the M.U.T.-III) interface (V. C. I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A (Vehicles with CAN communication system) D: M.U.T.-III main harness B (Vehicles without CAN communication system) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
MB991911
MB991825
MB991826 MB991955
MB991502
M.U.T.-II Sub assembly
Diagnosis code checking
B991502
MB991529
Diagnosis code checking harness
MB991529

SPECIAL TOOLS
22A-5
Use Check at the ECU terminals A: Connector pin contact inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection
Tool
A
Number MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Name Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe
DO NOT USE
MB991223 AZ
MB992006
Extra fine probe
MB992006
MB991348
Test harness set
G-sensor check
MB991348
MD998330 (including MD998331)

AC103525
Oil pressure gauge (3.0 MPa)
Hydraulic pressure measurement
MB991705
Adapter
MB991705
22A-6

SPECIAL TOOLS
Name Engine hanger balancer
Use 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.
B991454
MB991895
Engine hanger
MB991895
Slide bracket (HI) E F 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

TROUBLESHOOTING <ACD>
22A-7
TROUBLESHOOTING STRATEGY
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points P.00-5. NOTE: Before starting the troubleshooting procedure, make sure that the following items have been checked okay. Is the appropriate steering wheel installed at the centre of the steering column shaft correctly? Are the tyre, wheel size, specifications, air pressure, balance, and wear state normal? Is the wheel alignment normal? Has the engine, suspension, etc. been remodeled in such a way that it will affect the ACD and AYC systems?
M1221007000604
If a malfunction occurs in the ACD, all of the ACD mode indicator lamps (tarmac, gravel, and snow) will illuminate. If all of the ACD mode indicator lamps (tarmac, gravel, and snow) are illuminating, check for diagnosis code.
METHOD OF READING THE DIAGNOSIS CODE

Use the M.U.T.-II/III to read the diagnosis code. (Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points P.00-5).
DIAGNOSIS FUNCTION
M1221007700012
METHOD OF ERASING THE DIAGNOSIS CODE

Use the M.U.T.-II/III to erase the diagnosis code. (Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points P.00-5).
ACD MODE INDICATOR LAMP SYSTEM
ACD mode indicator lamp
AC311095AB
22A-8

INSPECTION CHART FOR DIAGNOSIS CODES

M1221007800019
Diagnosis code No. 12 13 21 22 23 24 25 26 31 32 33 34 41 42 45 46 47 51 52 56 57 61 62 63 65 71
Diagnosis items Power supply voltage (valve power supply) system Fail-safe relay system (inside 4WD-ECU) Wheel speed sensor system <FR> Wheel speed sensor system <FL> Wheel speed sensor system <RR> Wheel speed sensor system <RL> Wrong-diameter tyre Wheel speed sensor system Steering wheel sensor system <ST-1, ST-2, ST-N> Steering wheel sensor system <ST-N> Steering wheel sensor system <ST-1, ST-2> TPS system Pressure sensor system faulty output signal open circuit or short circuit short circuit fixed short circuit or output fixed open circuit or short circuit short circuit open circuit or short circuit open earth abnormal power supply Longitudinal G-sensor system Lateral G-sensor system Stop lamp switch system ACD mode switch system Parking brake switch system ABS monitor system Proportional valve system <AYC> open circuit or short circuit abnormal sensor open circuit or short circuit abnormal sensor open circuit stuck open circuit or short circuit open circuit or short circuit open circuit or short circuit open circuit or short circuit open circuit or short circuit open circuit or short circuit
Reference page P.22A-9 P.22A-14 P.22A-14 P.22A-14 P.22A-14 P.22A-14 P.22A-18 P.22A-19 P.22A-20 P.22A-29 P.22A-29 P.22A-33 P.22A-37 P.22A-37 P.22A-41 P.22A-46 P.22A-49 P.22A-53 P.22A-62 P.22A-68 P.22A-77 P.22A-83 P.22A-88
short circuit or not returned P.22A-94 to original position open circuit or defective ABS open circuit or short circuit P.22A-99 Refer to GROUP 27 Diagnostic Trouble Code Chart P.27-9 Refer to GROUP 27 Diagnostic Trouble Code Chart P.27-9
72
Directional control valve system <Right>
open circuit or short circuit

22A-9
Reference page Refer to GROUP 27 Diagnostic Trouble Code Chart P.27-9 P.22A-105 P.22A-109 P.22A-113 Refer to GROUP 27 Diagnostic Trouble Code Chart P.27-9
Diagnosis code No. 73
Diagnosis items Directional control valve system <Left> open circuit or short circuit
74 81 82 84
Proportional valve system <ACD> Electric pump relay system
open circuit or short circuit open circuit or short circuit electric pump malfunction or pressure sensor defect
AYC control error
85
ACD control error
NOTE: Code No.85 is not a code number set due to malfunction, but a code number output when control for the 4WD-ECU to protect the ACD is stopped in excessive driving. ACD control can be recovered by turning the ignition switch ON to OFF to ON.
DIAGNOSIS TROUBLE CODE PROCEDURES
Code No.12 Power supply voltage (valve power supply) system
Power supply circuit <LH drive vehicles> IGNITION SWITCH (IG2)
4WD-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
22A-10

Power supply circuit <RH drive vehicles> IGNITION SWITCH (IG2)
4WD-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
OPERATION
The 4WD-ECU (terminal 13) is energized through the fuse by the ignition switch (IG2).
Or code No.12 is set when the battery voltage drops.
PROBABLE CAUSES
Damaged harness wires and connectors Malfunction of the battery Malfunction of the 4WD-ECU

The power supply circuit opens or short-circuits if the power supply voltage of the 4WD-ECU is below 9 V or above 18 V.

22A-11
DIAGNOSIS
STEP 1. Check the battery. Refer to GROUP 54A, Battery On-vehicle Service Battery Test P.54A-5.
Q: Is the battery damaged? YES : Charge or replace the battery. NO : Go to Step 2.
STEP 3. Measure the voltage at 4WD-ECU connector C-25. (1) Turn the ignition switch to the ON position.
Connector: C-25 4WD-ECU <LH drive vehicles>
C-25 (Y)
STEP 2. M.U.T.-II/III data list Item 10: Battery voltage (Refer to Data List Reference Table P.22A-142).
Rear console assembly <RH drive vehicles>
4WD-ECU C-25 (Y)
Harness side
AC311002AB
(2) Measure the voltage between 4WD-ECU connector C-25 terminal No.13 and earth. OK: System voltage
22A-12

Connector: C-138 <RH drive vehicles>
STEP 4. Connectors check: C-25 4WD-ECU connector, C-124 intermediate connector, C-210 J/B connector <LH drive vehicles> or C-25 4WD-ECU connector, C-138 intermediate connector, C-214 J/B connector <RH drive vehicles>.
C-138
AC311016AB
C-25 (Y) Rear console assembly <RH drive vehicles>
Connector: C-214 Junction block (front view) <RH drive vehicles>
C-214 Junction block side
4WD-ECU C-25 (Y)
AC310458AO
Check for the contact with terminals.

Harness side
AC311002AB
Connector: C-124 <LH drive vehicles>
C-124
AC311015AB
Connector: C-210 <LH drive vehicles> Junction block (front view)
C-210
Junction block side
AC310448AS

22A-13
STEP 5. Check the harness between 4WD-ECU connector C-25 terminal No.13 and J/B connector C-210 terminal No.8 <LH drive vehicles> or J/B connector C-214 terminal No.16 <RH drive vehicles>.
STEP 6. M.U.T.-II/III data list Item 10: Battery voltage (Refer to Data List Reference Table P.22A-142).
00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the 4WD-ECU.
STEP 7. Connector check: C-25 4WD-ECU connector.

C-25 (Y) 4WD-ECU C-25 (Y) <RH drive vehicles> Rear console assembly
Harness side
AC311002AB
4WD-ECU C-25 (Y)
Connector: C-210 <LH drive vehicles> Junction block (front view) Harness side C-210
AC311002AB
Junction block side

AC310448AS
Connector: C-214 Junction block (front view) <RH drive vehicles>
C-214 Junction block side
AC310458AO
Check the power supply line for short or open circuit.

22A-14

Code No.13 Fail-safe relay system (inside 4WD-ECU)
OPERATION
The power supplied from the ignition switch will be distributed to each section inside the ECU through the fail-safe relay (incorporated in the ECU).
PROBABLE CAUSES
Malfunction of the 4WD-ECU
DIAGNOSIS
Replace the 4WD-ECU.
Q: Is the malfunction eliminated? YES : The inspection is complete. NO : If no malfunction is not found an intermittent

Code No.13 will be set as the open circuit or short circuit of the fail-safe relay when the voltage is above 6 V during fail-safe relay OFF or when the voltage is below 6 V during ON.
malfunction is suspected. (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5).
Code No.21, 22, 23, 24 Wheel speed sensor system
ABS-ECU signal line system circuit ABS-ECU
4WD-ECU
SB : Sky blue
OPERATION
The ABS-ECU detects the speed of each wheel according to the pulse signals from each wheel speed sensor. The 4WD-ECU receives the wheel speed sensor signals through the ABS-ECU.

A diagnosis code corresponding to the open circuit or short circuit of the wheel speed sensor is set when one wheel speed sensor has detected a vehicle speed of above 15 km/h, but any one of the remaining three wheel speed sensors could not detect the vehicle speed.

22A-15
PROBABLE CAUSES
Malfunction of the wheel speed sensor Damaged harness wires and connectors Malfunction of the ABS-ECU Malfunction of the 4WD-ECU
DIAGNOSIS
Q: Are ABS diagnosis codes 11, 12, 13, 14, 21, 22, 23, 24 set? YES : Refer to GROUP 35B Check Chart for
Diagnosis Codes P.35B-9. NO : Go to Step 2. STEP 2. M.U.T.-II/III data list Item 01: Wheel speed sensor <FR> Item 02: Wheel speed sensor <FL> Item 03: Wheel speed sensor <RR> Item 04: Wheel speed sensor <RL> Check the above data list (Refer to data list reference table P.22A-142).
4WD-ECU C-25 (Y)
Harness side
AC311002AB
(2) Measure the voltage between the following terminals of 4WD-ECU connector C-25 and earth while turning the relevant tyre of the terminal being measured one-half to one turn per second. Terminal No.9 <FR> Terminal No.6 <FL> Terminal No.7 <RR> Terminal No.8 <RL> OK: 0 5 V flushing
22A-16

TROUBLESHOOTING <ACD> Q: Is the check result normal? YES : Go to Step 5. NO : Repair the defective connector.
STEP 4. Connectors check: B-118 ABS-ECU connector, C-25 4WD-ECU connector.

Connector: B-118 <LH drive vehicles> B-118 (B)
<RH drive vehicles> B-118 (GR)
B-118
Harness side
AC311020 AB
4WD-ECU C-25 (Y)
Harness side
AC311002AB

22A-17
STEP 5. Check the harness between ABS-ECU connector B-118 (terminal No.9, 6, 7, 8) and 4WD-ECU connector C-25 (terminal No.18, 32, 21, 20).
Check the output line for short or open circuit.

STEP 6. M.U.T.-II/III data list Item 01: Wheel speed sensor <FR> Item 02: Wheel speed sensor <FL> Item 03: Wheel speed sensor <RR> Item 04: Wheel speed sensor <RL> Check the above data list (Refer to data list reference table P.22A-142).
<RH drive vehicles> B-118 (GR)

Connector: C-25 4WD-ECU <LH drive vehicles> B-118 C-25 (Y) Rear console assembly Harness side
AC311020 AB
<RH drive vehicles>
Connector: C-25 4WD-ECU <LH drive vehicles> C-25 (Y) C-25 (Y) Rear console assembly <RH drive vehicles> Harness side
AC311002AB
4WD-ECU

4WD-ECU C-25 (Y)
Harness side
AC311002AB
22A-18
Code No.25 Wrong-diameter tyre

ABS SIGNAL LINE SYSTEM CIRCUIT

Refer to P.22A-14.

OPERATION
The 4WD-ECU receives each wheel speed sensor signal through the ABS-ECU to detect the tyre conditions.
Diagnosis Codes P.35B-9. NO : Go to Step 3. STEP 3. M.U.T.-II/III diagnosis code

Q: Are ACD diagnosis codes 21, 22, 23, 24 set? YES : Refer to diagnosis code 21, 22, 23, 24

Code No.25 is set as wrong-diameter tyre when one of the four vehicle speeds is outside the range of specified values in respect to the average of the four vehicle speed sensors, when the vehicle speed is above 20 km/h with the steering wheel in the straight ahead position. However the warning lamp does not light up.
Wheel Speed Sensor System P.22A-14.

NO : Go to Step 4.
PROBABLE CAUSES
Malfunction of the tyre Malfunction of the wheel speed sensor Damaged harness wires and connectors Malfunction of the ABS-ECU Malfunction of the 4WD-ECU
DIAGNOSIS
STEP 1. Check the tyre. Check the tyre pressure, size and brand.
Q: Is the check result normal? YES : Go to Step 2. NO : Adjust or replace the tyre.

22A-19
Code No.26 Wheel speed sensor system (faulty output signal)
ABS SIGNAL LINE SYSTEM CIRCUIT

Refer to P.22A-14.

OPERATION
The 4WD-ECU receives each wheel speed sensor signal through the ABS-ECU to detect the conditions of the wheel speed sensors.
Diagnosis Codes P.35B-9. NO : Go to Step 3. STEP 3. M.U.T.-II/III diagnosis code

Q: Are ACD diagnosis codes 21, 22, 23, 24 set? YES : Refer to diagnosis code 21, 22, 23, 24

Code No.26 is set as output signal error of the wheel speed sensor when one wheel speed is outside the specified range at the vehicle speed of above 20 km/h. However, warning lamp will light up.
Wheel Speed Sensor System P.22A-14.

NO : Go to Step 4.
PROBABLE CAUSES
Malfunction of the tyre Malfunction of the wheel speed sensor Damaged harness wires and connectors Malfunction of the ABS-ECU Malfunction of the 4WD-ECU
DIAGNOSIS
STEP 1. Check the tyre. Check the tyre pressure, size and brand.
Q: Is the check result normal? YES : Go to Step 2. NO : Adjust or replace the tyre.
22A-20

Code No.31 Steering wheel sensor system <ST-1, ST-2, ST-N>
Steering wheel sensor system circuit <LH drive vehicles> IGNITION SWITCH (IG2) 4WD-ECU

Steering wheel sensor system circuit <RH drive vehicles> IGNITION SWITCH (IG2) 4WD-ECU
22A-21
OPERATION
The steering wheel sensor detects the neutral position and steering angle of the steering wheel by the photointerruptor (ST-1, ST-2 or ST-N), and sends them to the 4WD-ECU.
PROBABLE CAUSES
Malfunction of the steering wheel sensor Damaged harness wires and connectors Malfunction of the 4WD-ECU

Code No.31 is set when open circuit or short circuit of the steering wheel sensor output line (ST-1, ST-2, or ST-N) occurs.
DIAGNOSIS
Q: Are ABS diagnosis codes 81, 82, 83 set? YES : Go to Step 8. NO : Go to Step 2.
22A-22

STEP 2. M.U.T.-II/III data list Item 21: Steering wheel sensor voltage <ST-1> Item 22: Steering wheel sensor voltage <ST-2> Item 23: Steering wheel sensor voltage <ST-N> Check the above data list (Refer to data list reference table P.22A-142).

C-26 (Y)
Rear console assembly
<RH drive vehicles>
Connector: C-26 4WD-ECU <LH drive vehicles> C-26 (Y) 4WD-ECU
C-26 (Y)
Harness side Rear console assembly

AC311002AC
<RH drive vehicles>

4WD-ECU C-26 (Y)
Harness side
AC311002AC
(2) Measure the voltage between the following terminals of 4WD-ECU connector C-26 and earth while turning the steering wheel. Terminal No.33 <ST-1> Terminal No.34 <ST-2> Terminal No.44 <ST-N> OK: Approximately 1.5 3.5 V flushing

22A-23
STEP 6. Connectors check: C-26 4WD-ECU connector, C-122 intermediate connector <LH drive vehicles> or C-26 4WD-ECU connector, C-138 intermediate connector <RH drive vehicles>.
STEP 7. Check the harness between 4WD-ECU connector C-26 (terminal No.33, 34, 44) and intermediate connector C-122 (terminal No.12, 1, 2) <LH drive vehicles> or intermediate connector C-138 (terminal No.5, 2, 1) <RH drive vehicles>.
C-26 (Y)
Rear console assembly <RH drive vehicles>
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y) C-26 (Y)
4WD-ECU
Harness side
AC311002AC
Harness side
AC311002AC
C-122
C-122
AC311015AC
AC311015AC
C-138
AC311016AB
C-138
AC311016AB

Check the output line for open circuit.

22A-24

STEP 9. Measure the voltage at steering wheel sensor connector C-230.

C-230
<RH drive vehicles>
C-230 Harness side

AC311035AB
(1) Disconnect the steering wheel sensor connector C-230, and measure the voltage between terminal No.2 and earth at the wiring harness side. (2) Turn the ignition switch to the ON position. OK: System voltage

22A-25
<LH drive vehicles>
STEP 10. Connectors check: C-101 J/C (2), C-210 J/B connector, C-230 steering wheel sensor connector.
Connector: C-101 <LH drive vehicles> C-101 (L)
Connector: C-230
C-230
<RH drive vehicles>
AC311015AE
Connector: C-101 <RH drive vehicles> C-230 Harness side C-101 (L)
AC311035AB

AC311037AB
C-210
Junction block side
AC310448AS
Connector: C-210 Junction block (front view) <RH drive vehicles> C-210
Junction block side
AC310458AP
22A-26

STEP 11. Check the harness between J/B connector C-210 terminal No.13 and steering wheel sensor connector C-230 terminal No.2.
STEP 12. Measure the resistance at steering wheel sensor connector C-230.
C-230 C-210 Junction block side <RH drive vehicles>

AC310448AS
Connector: C-210 Junction block (front view) <RH drive vehicles> C-210
C-230 Junction block side Harness side

AC311035AB
AC310458AP
Connector: C-230
<LH drive vehicles>
(1) Disconnect the steering wheel sensor connector C-230, and measure the resistance between terminal No.3 and earth at the wiring harness side. OK: 2 or less
C-230
<RH drive vehicles>
C-230 Harness side

AC311035AB

Q: Is the check result normal? YES : The inspection is complete. NO : Repair the wiring harness.

22A-27
STEP 13. Connectors check: C-06 J/C (3), C-230 steering wheel sensor connector.
Connector: C-06 <LH drive vehicles> C-06 (GR)
STEP 14. Check the harness between steering wheel sensor connector C-230 terminal No.3 and body earth.
C-230
AC311039AB
<RH drive vehicles>
Connector: C-06 <RH drive vehicles> C-06 (GR)
C-230 Harness side

AC311037AC
Connector: C-230
AC311035AB
<LH drive vehicles>
Check the earth line for open circuit.

Q: Is the check result normal? YES : The inspection is complete. NO : Repair the wiring harness.
C-230
<RH drive vehicles>
C-230 Harness side

AC311035AB

22A-28

STEP 15. Connectors check: C-230 steering wheel sensor connector, C-122 intermediate connector <LH drive vehicles> or C-138 intermediate connector <RH drive vehicles>.
STEP 16. Check the harness between steering wheel sensor connector C-230 (terminal No.5, 4, 1) and intermediate connector C-122 (terminal No.12, 1, 2) <LH drive vehicles> or intermediate connector C-138 (terminal No.5, 2, 1) <RH drive vehicles>.
C-230 C-230 <RH drive vehicles> <RH drive vehicles>
C-230 Harness side

AC311035AB
C-230 Harness side

AC311035AB
C-122 C-122
AC311015AC
AC311015AC
C-138
AC311016AB

C-138
AC311016AB
Check the output line for short or open circuit.

Q: Is the check result normal? YES : Replace the steering wheel sensor. NO : Repair the wiring harness.

22A-29
Code No.32, 33 Steering wheel sensor system <ST-N>
STEERING WHEEL SENSOR SYSTEM CIRCUIT

Refer to P.22A-20.
OPERATION
Refer to P.22A-20.

Code No.32 is set when the steering wheel sensor ST-N has been detected at the neutral position in a state where the steering wheel has been determined to have changed above 40 from steering wheel sensor ST-1 and ST-2. Code No.33 is set when the steering wheel sensor ST-N has been detected at the neutral position in a state where the steering wheel has been determined to have changed above 400 from steering wheel sensor ST-1 and ST-2.
C-26 (Y) Rear console assembly
<RH drive vehicles>
4WD-ECU C-26 (Y)
PROBABLE CAUSES
Harness side
AC311002AC
DIAGNOSIS
STEP 1. M.U.T.-II/III data list Item 52: Steering wheel sensor <ST-N> (Refer to data list reference table P.22A-142).
(2) Measure the voltage between 4WD-ECU connector C-26 terminal 44 and earth while turning the steering wheel. OK: Approximately 1.5 3.5 V flushing
22A-30


STEP 4. M.U.T.-II/III data list Item 52: Steering wheel sensor <ST-N> (Refer to data list reference table P.22A-142).
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y)
Harness side
AC311002AC


22A-31
<LH drive vehicles>
STEP 5. Connectors check: C-26 4WD-ECU connector, C-122 intermediate connector, C-230 steering wheel sensor connector <LH drive vehicles> or C-26 4WD-ECU connector, C-138 intermediate connector, C-230 steering wheel sensor connector <RH drive vehicles>.
Connector: C-230
C-230
<RH drive vehicles>
C-26 (Y)
<RH drive vehicles> C-230 Harness side 4WD-ECU

AC311035AB
C-26 (Y)

Harness side
AC311002AC
C-122
AC311015AC
C-138
AC311016AB
22A-32

STEP 6. Check the harness between 4WD-ECU connector C-26 terminal No.44 and steering wheel sensor connector C-230 terminal No.1.
STEP 7. Replace the steering wheel sensor and then recheck the diagnosis code. (1) Replace the steering wheel sensor. (2) Test drive the vehicle. (3) Check the diagnosis code.
Q: Is the diagnosis code set? YES : Go to Step 4. NO : The inspection is complete.
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y)
Harness side
AC311002AC
Connector: C-230
<LH drive vehicles>
C-230
<RH drive vehicles>
C-230 Harness side

AC311035AB


22A-33
Code No.34 Steering wheel sensor system <ST-1, ST-2>
STEERING WHEEL SENSOR SYSTEM CIRCUIT

Refer to P.22A-20.
OPERATION
Refer to P.22A-20.

Code No.34 is set when no change in the steering wheel sensor signal at a vehicle speed of above 15 km/h is detected for a total of more than 15 minutes <ST-1, ST-2>, and turning is detected during this time.
C-26 (Y) Rear console assembly
<RH drive vehicles>
PROBABLE CAUSES
C-26 (Y) 4WD-ECU
DIAGNOSIS
STEP 1. M.U.T.-II/III data list Item 53: Steering wheel sensor <ST-1> Item 54: Steering wheel sensor <ST-2> Check the above data list (Refer to data list reference table P.22A-142).
Harness side
AC311002AC
(2) Measure the voltage between the following terminals of 4WD-ECU connector C-26 and earth while turning the steering wheel. Terminal No.33 <ST-1> Terminal No.34 <ST-2> OK: Approximately 1.5 3.5 V flushing
22A-34


STEP 4. M.U.T.-II/III data list Item 53: Steering wheel sensor <ST-1> Item 54: Steering wheel sensor <ST-2> Check the above data list (Refer to data list reference table P.22A-142).
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y)
Harness side
AC311002AC


22A-35
<LH drive vehicles>
STEP 5. Connectors check: C-26 4WD-ECU connector, C-122 intermediate connector, C-230 steering wheel sensor connector <LH drive vehicles> or C-26 4WD-ECU connector, C-138 intermediate connector, C-230 steering wheel sensor connector <RH drive vehicles>.
Connector: C-230
C-230
<RH drive vehicles>
C-26 (Y)
<RH drive vehicles> C-230 Harness side 4WD-ECU

AC311035AB
C-26 (Y)

Harness side
AC311002AC
C-122
AC311015AC
C-138
AC311016AB
22A-36

STEP 6. Check the harness between 4WD-ECU connector C-26 (terminal No.33, 34) and steering wheel sensor connector C-230 (terminal No.5, 4).
STEP 7. Replace the steering wheel sensor and then recheck the diagnosis code. (1) Replace the steering wheel sensor. (2) Test drive the vehicle. (3) Check the diagnosis code.
Q: Is the diagnosis code set? YES : Go to Step 4. NO : The inspection is complete.
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y)
Harness side
AC311002AC
Connector: C-230
<LH drive vehicles>
C-230
<RH drive vehicles>
C-230 Harness side

AC311035AB


22A-37
Code No.41, 42 Throttle position sensor system
Throttle position sensor system circuit THROTTLE POSITION SENSOR
<LH DRIVE VEHICLES> OR <RH DRIVE VEHICLES>
4WD-ECU
SB : Sky blue
OPERATION
The 4WD-ECU receives a change in the output voltage from the throttle position sensor to determine the accelerator pedal opening angle.
DIAGNOSIS
Q: Is MPI diagnosis code P0120 set? YES : Refer to GROUP 13A Inspection Chart for

Code No.41 is set as excessively small output when the TPS output is below 0.2 V In the idling state. Code No.42 is set as excessively large output when the TPS output is more than 4.8 V for more than 2 minutes continuously below a vehicle speed of 10 km/h.
Diagnosis Codes P.13A-60.

NO : Go to Step 2.
STEP 2. M.U.T.-II/III data list Item 13: Throttle position sensor voltage (Refer to data list reference table P.22A-142).
PROBABLE CAUSES
Malfunction of the throttle position sensor Damaged harness wires and connectors Malfunction of the 4WD-ECU
22A-38


C-26 (Y) C-26 (Y) Rear console assembly
<RH drive vehicles>
<RH drive vehicles>
4WD-ECU 4WD-ECU C-26 (Y) C-26 (Y)

AC311002AC AC311002AC

(2) Measure the voltage between 4WD-ECU connector C-26 terminal No.39 and earth. OK: Accelerator pedal fully released: 0.535 0.735 V Accelerator pedal fully depressed: 4.5 5.0 V
STEP 5. M.U.T.-II/III data list Item 13: Throttle position sensor voltage (Refer to data list reference table P.22A-142).
STEP 6. Check throttle position sensor. Check throttle position sensor (Refer to P.13A-404).
Q: Is the check result normal? YES : Go to Step 7. NO : Repair or replace throttle position sensor.

22A-39
STEP 7. Connectors check: B-03 throttle position sensor connector, C-26 4WD-ECU connector, C-105 J/C (6).
<RH drive vehicles> B-03 (B)
B-03 Sensor side
AC311020 AC
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y)
Harness side
AC311002AC
22A-40

TROUBLESHOOTING <ACD> Q: Is the check result normal? YES : Go to Step 5. NO : Repair the wiring harness.
STEP 8. Check the harness between throttle position sensor connector B-03 terminal No.2 and 4WD-ECU connector C-26 terminal No.39.
<RH drive vehicles> B-03 (B)
B-03 Sensor side
AC311020 AC
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y)
Harness side
AC311002AC

22A-41
Code No.45 Pressure sensor system (open circuit or short circuit)
Pressure sensor system circuit <LH drive vehicles> 4WD-ECU
PRESSURE SENSOR
22A-42

Pressure sensor system circuit <RH drive vehicles> 4WD-ECU
PRESSURE SENSOR
OPERATION
The 4WD-ECU receives accumulator pressure information from the pressure sensor to control the electric pump.
DIAGNOSIS
STEP 1. M.U.T.-II/III data list Item 18: Pressure sensor (Refer to data list reference table P.22A-142).

Code No.45 is set when the output signal from the pressure sensor is below 0.2 V.
PROBABLE CAUSES
Malfunction of the pressure sensor Damaged harness wires and connectors Malfunction of the 4WD-ECU

22A-43

C-26 (Y)
Rear console assembly C-26 (Y) Rear console assembly
<RH drive vehicles>
<RH drive vehicles>
4WD-ECU C-26 (Y) 4WD-ECU C-26 (Y) Harness side

AC311002AC
(2) Measure the voltage between 4WD-ECU connector C-26 terminal No.32 and earth. OK: 0.5 1.5 V
Harness side
AC311002AC

STEP 4. M.U.T.-II/III data list Item 18: Pressure sensor (Refer to data list reference table P.22A-142).
22A-44

STEP 5. Connectors check: C-26 4WD-ECU connector, C-122, C-134, F-21 intermediate connector, F-26 pressure sensor connector.
C-134 (B)
C-26 (Y)
AC311015AG
<RH drive vehicles>
4WD-ECU C-26 (Y) C-134 (GR) Connector: F-21, F-26 Harness side F-21
AC311002AC AC311016AD
Connector: C-122 <LH drive vehicles> F-26 F-26 (B) F-21 (B) C-122 Sensor side
AC311042AB

AC311015AC
C-122 (L)
AC311016AE

22A-45
STEP 6. Check the harness between 4WD-ECU connector C-26 (terminal No.43, 32) and pressure sensor connector F-26 (terminal No.1, 2).
Q: Is the check result normal? YES : Replace the pressure sensor. NO : Repair the wiring harness.
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y)
Harness side
AC311002AC
Connector: F-26
F-26 F-26 (B) Sensor side

AC311042AC
Check the power supply line, output line for short or open circuit.
22A-46

Code No.46 Pressure sensor system (open earth)
PRESSURE SENSOR SYSTEM CIRCUIT

Refer to P.22A-41.
STEP 2. Connector check: F-26 pressure sensor connector.

Connector: F-26
OPERATION
Refer to P.22A-41.

Code No.46 is set when the output signal from the pressure sensor is above 2.0 V.
AC311042AC
PROBABLE CAUSES

Q: Is the check result normal? YES : Replace the pressure sensor. NO : Repair the defective connector.
DIAGNOSIS
STEP 1. Measure the voltage at pressure sensor connector F-26.
Connector: F-26

AC311042AC
Disconnect the pressure sensor connector, and measure the resistance between terminal 3 and body earth at the harness side. OK: 2 or less

22A-47
STEP 3. Connectors check: C-25 4WD-ECU connector, C-122, C-134, F-21 intermediate connector, F-26 pressure sensor connector <LH drive vehicles> or C-25 4WD-ECU connector, C-134, C-138, F-21 intermediate connector, F-26 pressure sensor connector <RH drive vehicles>.
C-134 (GR)
AC311016AD
Connector: C-138 <RH drive vehicles> C-25 (Y) Rear console assembly <RH drive vehicles>
C-138 4WD-ECU C-25 (Y) Connector: F-21, F-26 F-21 Harness side
AC311002AB AC311016AB
F-26 F-26 (B) F-21 (B) Sensor side

AC311042AB

C-122
AC311015AC
C-134 (B)
AC311015AG
22A-48

TROUBLESHOOTING <ACD> Q: Is the check result normal? YES : Replace the 4WD-ECU. NO : Repair the wiring harness.
STEP 4. Check the harness between 4WD-ECU connector C-25 terminal No.10 and pressure sensor connector F-26 terminal No.3.
4WD-ECU C-25 (Y)
Harness side
AC311002AB
Connector: F-26

AC311042AC
Check the power supply line, output line, earth line for short or open circuit.

22A-49
Code No.47 Pressure sensor system (abnormal power supply)
PRESSURE SENSOR SYSTEM CIRCUIT

Refer to P.22A-41.
OPERATION
Refer to P.22A-41.

Code No.47 is set when the pressure sensor power supply voltage is above 4.0V during pressure sensor power OFF or less than 4.0V during pressure sensor power ON.
C-26 (Y)
PROBABLE CAUSES
<RH drive vehicles>
DIAGNOSIS
C-26 (Y)
4WD-ECU
STEP 1. M.U.T.-II/III data list Item 19: Pressure sensor power supply (Refer to data list reference table P.22A-142).
Harness side
AC311002AC
(2) Measure the voltage between 4WD-ECU connector C-26 terminal No.43 and earth. OK: 5 V
22A-50


STEP 4. M.U.T.-II/III data list Item 19: Pressure sensor power supply (Refer to data list reference table P.22A-142).
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y)
Harness side
AC311002AC


22A-51
STEP 5. Connectors check: C-26 4WD-ECU connector, C-122, C-134, F-21 intermediate connector, F-26 pressure sensor connector.
C-134 (B)
C-26 (Y)
AC311015AG
<RH drive vehicles>
4WD-ECU C-26 (Y) C-134 (GR) Connector: F-21, F-26 Harness side F-21
AC311002AC AC311016AD
Connector: C-122 <LH drive vehicles> F-26 F-26 (B) F-21 (B) C-122 Sensor side
AC311042AB

AC311015AC
C-122 (L)
AC311016AE
22A-52

TROUBLESHOOTING <ACD> Q: Is the check result normal? YES : Replace the pressure sensor. NO : Repair the wiring harness.
STEP 6. Check the harness between 4WD-ECU connector C-26 terminal No.43 and pressure sensor connector F-26 terminal No.1.
C-26 (Y)
<RH drive vehicles>
4WD-ECU C-26 (Y)
Harness side
AC311002AC
Connector: F-26

AC311042AC

1 Mitsubishi Lancer Evo IX.

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1 Mitsubishi Lancer Evo IX.

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15-1

INTAKE AND EXHAUST

15-2 15-2 15-2 15-2

REMOVAL AND INSTALLATION . . . . . . . .

EXHAUST MANIFOLD AND TURBOCHARGER . . . . . . . . . . . . . . .

EXHAUST PIPE AND MAIN MUFFLER 15-13

INTAKE AND EXHAUST

SUPERCHARGING PRESSURE CONTROL

Standard value 96 121

Approximately 100 29 35 Approximately 59 0.15 or less 0.20

Name Oxygen sensor wrench

Use Removal and installation of oxygen sensor

Plug Vacuum terminal

Waste gate actuator

INTAKE AND EXHAUST

Idling (after warm-up)

WASTE GATE ACTUATOR CHECK

SUPERCHARGING PRESSURE CONTROL SYSTEM CHECK

Vacuum terminal Boost hose

1. Connect a manual pump (pressure-application type) to nipple.

Waste gate actuator

INTAKE AND EXHAUST

WASTE GATE SOLENOID VALVE CHECK

AIR BY-PASS VALVE CHECK

INLET MANIFOLD VACUUM CHECK

COIL RESISTANCE CHECK

INTAKE AND EXHAUST

9.0 1.0 Nm 9.0 1.0 Nm

INTAKE AND EXHAUST

6.0 1.0 Nm 6.0 1.0 Nm

8. 9. 10. 11. 12. 13.

INTAKE AND EXHAUST

1. 2. 3. 4. 5. >>A<< 6. >>A<< 7. <<A>> 8.

INTAKE AND EXHAUST

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

INTAKE AND EXHAUST

INSTALLATION SERVICE POINT >>A<< O-RING/ FUEL HIGH-PRESSURE HOSE INSTALLATION

Check the following points; replace the part if a problem is found.

Inlet Manifold Check

INTAKE AND EXHAUST

EXHAUST MANIFOLD AND TURBOCHARGER

INTAKE AND EXHAUST

REMOVAL SERVICE POINTS <<A>> OXYGEN SENSOR (FRONT) REMOVAL

INSTALLATION SERVICE POINTS >>A<< TURBOCHARGER ASSEMBLY INSTALLATION

<<B>> TURBOCHARGER OIL FEED PIPE REMOVAL

INTAKE AND EXHAUST

>>B<< AIR OUTLET FITTING GASKET INSTALLATION

Check the following points; replace the part if a problem is found.

Exhaust Manifold Check

>>C<< TURBOCHARGER OIL RETURN PIPE GASKET INSTALLATION

Turbocharger Assembly Check

Turbocharger oil return pipe gasket protrusion

>>D<< OXYGEN SENSOR (FRONT) INSTALLATION

INTAKE AND EXHAUST

EXHAUST PIPE AND MAIN MUFFLER

CAMSHAFT POSITION SENSOR .

CRANK ANGLE SENSOR . . . . . . .

STARTER MOTOR ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . .

Limit maximum 0.3 70 % of normal output current

Name M.U.T.-II sub assembly

Use Checking the idle speed

MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826

Checking the idle speed

Alternator test harness