Mitsubishi MOTORS Lancer 2004 Workshop Manual

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LANCER /

LANCER WAGON

WORKSHOP MANUAL

FOREWORD

This Workshop manual contains procedures for

service mechanics, including removal, disassembly,

inspection, adjustment, reassembly and installation.

Use the following manuals in combination with this

manual as required.

TECHNICAL INFORMATION MANUAL

WORKSHOP MANUAL

CHASSIS GROUP

BODY REPAIR MANUAL

PARTS CATALOGUE

All information, illustrations and product descriptions

contained in this manual are current as at the time of

publication. We, however, reserve the right to make

changes at any time without prior notice or obligation.

Mitsubishi Motors Corporation

GROUP INDEX

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

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

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

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

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

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

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

Engine and Emission Control . . . . .

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

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

Automatic Transmission. . . . . . . . . .

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

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

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

PYME0302

PYME0302-A

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

PWME0302

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

PBME0302

Rear Suspension . . . . . . . . . . . . . . . .

PBME0302-A

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

B606K005A_

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

Power Steering . . . . . . . . . . . . . . . . .

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

Exterior . . . . . . . . . . . . . . . . . . . . . . . .

Interior and Supplemental

Restraint System (SRS)

Chassis Electrical . . . . . . . . . . . . . . .

Heater, Air Conditioner and

Ventilation

Component Locations. . . . . . . . . . . .

Configration Diagrams . . . . . . . . . . .

May 2004

Circuit Diagrams . . . . . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . .

Table of Contents

Chapters

Table of Contents

Troubleshooting

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Summary of Contents for Mitsubishi MOTORS Lancer 2004

Page 1 Component Locations... . Configration Diagrams ... Mitsubishi Motors Corporation May 2004 Circuit Diagrams ....
Page 2 WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES 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).
Page 3: Table Of Contents
17-1 GROUP 17 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL ..COMPONENT LOCATION (CRANKCASE 17-2 EMISSION CONTROL SYSTEM) ..17-9 POSITIVE CRANKCASE VENTILATION SYSTEM CHECK ....17-9 GENERAL INFORMATION .
Page 4: Engine Control
ENGINE AND EMISSION CONTROL 17-2 ENGINE CONTROL ENGINE CONTROL GENERAL INFORMATION M1171000100277 A cable-type accelerator mechanical suspended-type pedal has been adopted. SERVICE SPECIFICATIONS M1171000300088 Item Standard value Accel cable play mm 1.0 − 2.0 Engine idle speed r/min 750 ± 50 750 ±...
Page 5: Accelerator Cable And Pedal
ENGINE AND EMISSION CONTROL 17-3 ENGINE CONTROL ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION M1171001200341 Post-installation Operation Adjusting the Accelerator Cable (Refer to P.17-2). <L.H. drive vehicles> 5.0 ± 1.0 N·m 12 ± 2 N·m <R.H. drive vehicles> Y1060AU 5.0 ± 1.0 N·m 12 ±...
Page 6 ENGINE AND EMISSION CONTROL 17-4 ENGINE CONTROL Accelerator pedal assembly Accelerator pedal assembly removal steps (Continued) removal steps (Continued) 7. Accelerator control equip bushing 10. Accelerator pedal arm bracket 8. Accelerator pedal arm return spring 11. Accelerator pedal arm 9. Accelerator pedal arm stopper 12.
Page 7: Emission Control Mpi
ENGINE AND EMISSION CONTROL 17-5 EMISSION CONTROL <MPI> EMISSION CONTROL <MPI> • Crankcase emission control system GENERAL INFORMATION • Evaporative emission control system M1173000100370 The emission control system consists of the following • Exhaust emission control system subsystems: Items Name Specification Crankcase emission control Positive crankcase ventilation...
Page 8: Vacuum Hose
ENGINE AND EMISSION CONTROL 17-6 EMISSION CONTROL <MPI> VACUUM HOSE VACUUM HOSE PIPING DIAGRAM M1173000900417 <4G1> Air cleaner Fuel pressure From fuel tank regulator fuel pump EGR valve Canister Oxygen sensor (front) Purge control EGR control Catalytic solenoid valve solenoid valve converter Oxygen sensor (rear) Catalytic...
Page 9: Vacuum Circuit Diagram
ENGINE AND EMISSION CONTROL 17-7 EMISSION CONTROL <MPI> VACUUM CIRCUIT DIAGRAM M1173007100263 <4G1> Intake manifold Throttle body From combustion chamber cleaner Fuel pressure regulator Canister Vacuum hose colour B: Black G: Green control R: Red solenoid Purge Y: Yellow valve L: Blue control valve...
Page 10: Vacuum Hose Check
ENGINE AND EMISSION CONTROL 17-8 EMISSION CONTROL <MPI> VACUUM HOSE CHECK CRANKCASE EMISSION CONTROL M1173007300159 SYSTEM 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly GENERAL INFORMATION (CRANKCASE connected. EMISSION CONTROL SYSTEM) 2.
Page 11: Component Location (Crankcase Emission Control System)
ENGINE AND EMISSION CONTROL 17-9 EMISSION CONTROL <MPI> COMPONENT LOCATION (CRANKCASE POSITIVE CRANKCASE VENTILATION EMISSION CONTROL SYSTEM) (PCV) VALVE CHECK M1173007400208 M1173001200187 <4G1> PCV valve PCV valve AK100010 AK300767 1. Insert a thin rod into the PCV valve from the side <4G6>...
Page 12: Component Location (Evaporative Emission Control System)
ENGINE AND EMISSION CONTROL 17-10 EMISSION CONTROL <MPI> SYSTEM DIAGRAM Throttle body Engine-ECU <4G1-M/T, 4G6>, Engine-A/T-ECU <4G1-A/T> Canister From Manifold absolute pressure fuel (MAP) sensor <4G1> tank Air flow sensor <4G6> Purge Engine coolant control temperature sensor solenoid Control valve relay Intake air temperature sensor...
Page 13: Purge Port Vacuum Check
ENGINE AND EMISSION CONTROL 17-11 EMISSION CONTROL <MPI> 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. Vac- 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum.
Page 14: Fuel Vapour Canister Removal And Installation
ENGINE AND EMISSION CONTROL 17-12 EMISSION CONTROL <MPI> 4. Check airtightness by applying a vacuum with Battery voltage Normal condition voltage applied directly from the battery to the Applied Vacuum leaks purge control solenoid valve and without applying Not applied Vacuum maintained voltage.
Page 15: Exhaust Gas Recirculation
ENGINE AND EMISSION CONTROL 17-13 EMISSION CONTROL <MPI> The EGR flow rate is controlled by the EGR valve so EXHAUST GAS RECIRCULATION as not to decrease the driveability. (EGR) SYSTEM OPERATION GENERAL INFORMATION (EGR SYSTEM) The EGR valve is being closed and does not M1173005200327 recirculate exhaust gases under one of the following The exhaust gas recirculation (EGR) system lowers...
Page 16: Component Location (Egr System)
ENGINE AND EMISSION CONTROL 17-14 EMISSION CONTROL <MPI> <4G6> control Solenoid valve Engine-ECU EGR valve Barometric pressure sensor Air flow sensor Control relay Engine coolant temperature sensor Crank angle sensor Battery AK302349 AB COMPONENT LOCATION (EGR SYSTEM) <4G1> M1173007600224 <4G1> EGR control solenoid valve EGR valve...
Page 17: Egr System Check
ENGINE AND EMISSION CONTROL 17-15 EMISSION CONTROL <MPI> EGR SYSTEM CHECK <4G1> M1173002600348 <4G1> Green stripe Green stripe Three-way terminal EGR valve AK300782 AB EGR valve AK300780 AB <4G6> Green stripe <4G6> Three-way terminal Green stripe EGR valve EGR valve AK300783AB 4.
Page 18: Egr Port Vacuum Check <4G1
ENGINE AND EMISSION CONTROL 17-16 EMISSION CONTROL <MPI> 5. Replace the gasket, and tighten to the specified 1. Disconnect the vacuum hose (White stripe) from torque. the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple. Tightening torque: 2.
Page 19: Egr Control Solenoid Valve Check <4G6
ENGINE AND EMISSION CONTROL 17-17 EMISSION CONTROL <MPI> 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.
Page 20: Exhaust Gas Recirculation (Egr) Valve Removal And Installation
ENGINE AND EMISSION CONTROL 17-18 EMISSION CONTROL <MPI> EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL AND INSTALLATION M1173010500175 Pre-removal and Post-installation Operation Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3). <4G1> 21 ± 4 N·m AC208130 <4G6> 19 ± 3 N·m AC301219 Removal steps (Continued) Removal steps...
Page 21 13-1 GROUP 13 FUEL CONTENTS MULTIPORT FUEL INJECTION (MPI) <4G1> ....MULTIPORT FUEL INJECTION (MPI) <4G6> ....FUEL SUPPLY .
Page 22 NOTES...
Page 23 32-1 GROUP 32 POWER PLANT MOUNT CONTENTS GENERAL INFORMATION ..32-2 TRANSMISSION MOUNTING ..32-5 REMOVAL AND INSTALLATION ..32-5 SERVICE SPECIFICATION ..32-3 ENGINE ROLL STOPPER, SPECIAL TOOL .
Page 24: General Information
32-2 POWER PLANT MOUNT GENERAL INFORMATION GENERAL INFORMATION M1321000100340 • The fore-and-aft, liquid-filled engine mount of The engine mounting system employs the inertial axis four-point suspension method, which is field cylinder type is adopted to reduce engine shake proven. for improved riding comfort. •...
Page 25: Service Specification
32-3 POWER PLANT MOUNT SERVICE SPECIFICATION SERVICE SPECIFICATION M1321000300333 Item Standard value 22 ± 1.5 Protruding length of stabilizer link thread part mm SPECIAL TOOL M1321000600378 Tool Number Name MB991897 Ball joint remover Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113) is also...
Page 26: Engine Mounting
32-4 POWER PLANT MOUNT ENGINE MOUNTING ENGINE MOUNTING REMOVAL AND INSTALLATION M1321001100440 CAUTION *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal Operation Raise the engine and transmission assembly until its weight is not applied to the insulator, and support it securely.
Page 27: Transmission Mounting
32-5 POWER PLANT MOUNT TRANSMISSION MOUNTING TRANSMISSION MOUNTING REMOVAL AND INSTALLATION M1321001400430 CAUTION *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal Operation Post-installation Operation •...
Page 28 32-6 POWER PLANT MOUNT TRANSMISSION MOUNTING INSTALLATION SERVICE POINT Install the transmission mounting stopper so that its arrow points upward. >>A<< TRANSMISSION MOUNTING STOPPER INSTALLATION Engine side Transmission mounting body side bracket Transmission mounting stopper AC200645...
Page 29: Engine Roll Stopper, Centermember
32-7 POWER PLANT MOUNT ENGINE ROLL STOPPER, CENTERMEMBER ENGINE ROLL STOPPER, CENTERMEMBER REMOVAL AND INSTALLATION M1321002300287 CAUTION *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Under Cover Removal and Installation 45 ±...
Page 30: Crossmember
32-8 POWER PLANT MOUNT CROSSMEMBER INSTALLATION SERVICE POINTS >>B<< ENGINE MOUNTING CUSHION >>A<< ENGINE FRONT ROLL STOPPER STOPPER INSTALLATION <4G6> BRACKET INSTALLATION Engine mounting cushion stopper Hole Hole Front of vehicle Front of vehicle AC304315AB AC005918 Install the engine mounting cushion stopper as Install the engine front roll stopper bracket so that its shown.
Page 31 32-9 POWER PLANT MOUNT CROSSMEMBER <L.H. drive vehicles> 12 ± 2 N·m 18 ± 2 N·m 70 ± 10 N·m 57 ± 7 N·m 45 ± 5 N·m* 70 ± 10 N·m 25 ± 4 N·m 21 ± 4 N·m 21 ±...
Page 32 32-10 POWER PLANT MOUNT CROSSMEMBER <R.H. drive vehicles> 57 ± 7 N·m 18 ± 2 N·m 5.0 ± 1.0 N·m 70 ± 10 N·m 45 ± 5 N·m*¹ 25 ± 4 N·m 21 ± 4 N·m 52 ± 7 N·m*¹ 108 ±...
Page 33 32-11 POWER PLANT MOUNT CROSSMEMBER REMOVAL SERVICE POINTS <> CROSSMEMBER ASSEMBLY REMOVAL <<A>> TIE ROD END AND KNUCKLE DISCONNECTION CAUTION • Do not remove the nut from ball joint. Loosen Piece of wood it and use special tool to avoid possible damage to ball joint threads.
Page 34 NOTES...
Page 35 15-1 GROUP 15 INTAKE AND EXHAUST CONTENTS GENERAL INFORMATION ..15-2 REMOVAL AND INSTALLATION <4G6> . . 15-6 INSPECTION......15-7 SERVICE SPECIFICATION .
Page 36: General Information
15-2 INTAKE AND EXHAUST GENERAL INFORMATION GENERAL INFORMATION M1151000100402 The exhaust pipe is divided into three parts. SERVICE SPECIFICATION M1151000300428 Item Standard value Limit Manifold distortion of the installation surface mm 0.15 or less 0.20 SPECIAL TOOL M1151000600399 Tool Number Name MD998770 Oxygen sensor wrench...
Page 37: Air Cleaner
15-3 INTAKE AND EXHAUST AIR CLEANER AIR CLEANER REMOVAL AND INSTALLATION M1151002100486 CAUTION Parts marked by * are made of recycled-paper mixed plastic material, so observe the following precautions. • Avoid any shock or load to these parts when removing and installing them. •...
Page 38 15-4 INTAKE AND EXHAUST AIR CLEANER <4G6> 4.0 ± 1.0 N·m 4.0 ± 1.0 N·m 9.0 ± 1.0 N·m 8.8 ± 1.0 N·m Clamp 12 ± 1 N·m 9.0 ± 1.0 N·m 12 ± 1 N·m AC303619 Removal steps (Continued) Removal steps 6.
Page 39: Inlet Manifold
15-5 INTAKE AND EXHAUST INLET MANIFOLD INLET MANIFOLD REMOVAL AND INSTALLATION <4G1> M1151003000749 Pre-removal Operation Post-installation Operation • Fuel Line Pressure Reduction (Refer to GROUP 13A - • Fuel Delivery Pipe and Fuel Injector Assembly Installation On-vehicle Service P.13A-389). (Refer to GROUP 13A P.13A-398). •...
Page 40: Removal And Installation <4G6
15-6 INTAKE AND EXHAUST INLET MANIFOLD REMOVAL AND INSTALLATION <4G6> M1151003001236 Pre-removal Operation Post-installation Operation • Fuel Line Pressure Reduction (Refer to GROUP 13A - • Fuel Delivery Pipe and Fuel Injector Assembly Installation On-vehicle Service P.13A-389). (Refer to GROUP 13B P.13B-334). •...
Page 41: Inspection
15-7 INTAKE AND EXHAUST EXHAUST MANIFOLD Removal steps (Continued) Battery wiring harness clamp Inlet manifold stay 10. Inlet manifold 11. Inlet manifold gasket 12. Emission vacuum hose & pipe and emission solenoid valve assembly 13. EGR valve 14. EGR valve gasket INSPECTION 2.
Page 42 15-8 INTAKE AND EXHAUST EXHAUST MANIFOLD Removal steps (Continued) Removal steps 6. Exhaust manifold cover 1. Front exhaust pipe connection 7. Exhaust manifold bracket 2. Exhaust pipe gasket 8. Exhaust manifold <<A>> >>A<< 3. Engine control oxygen sensor (front) 9. Exhaust manifold gasket 4.
Page 43: Removal And Installation <4G6
15-9 INTAKE AND EXHAUST EXHAUST MANIFOLD REMOVAL AND INSTALLATION <4G6> M1151003300579 Pre-removal and Post-installation Operation Under cover Removal and Installation 49 ± 5 N·m 29 ± 3 N·m 14 ± 1 N·m 29 ± 3 N·m 49 ± 9 N·m 44 ±...
Page 44: Inspection
15-10 INTAKE AND EXHAUST EXHAUST MANIFOLD REMOVAL SERVICE POINT INSTALLATION SERVICE POINT <<A>> ENGINE CONTROL OXYGEN >>A<< ENGINE CONTROL OXYGEN SENSOR (FRONT) REMOVAL SENSOR (FRONT) INSTALLATION MD998770 MD998770 Engine control Engine control oxygen sensor oxygen sensor (front) (front) AC212566AC AC212566AC Use special tool oxygen sensor wrench (MD998770) Use special tool oxygen sensor wrench (MD998770) to remove the engine control oxygen sensor (front).
Page 45: Exhaust Pipe And Main Muffler
15-11 INTAKE AND EXHAUST EXHAUST PIPE AND MAIN MUFFLER EXHAUST PIPE AND MAIN MUFFLER REMOVAL AND INSTALLATION M1151008700301 <4G1> 13 ± 2 N·m 13 ± 2 N·m 45 ± 5 N·m 45 ± 5 N·m 59 ± 10 N·m 50 ± 10 N·m AC303694AB <4G6>...
Page 46 15-12 INTAKE AND EXHAUST EXHAUST PIPE AND MAIN MUFFLER REMOVAL SERVICE POINT INSTALLATION SERVICE POINT <<A>> ENGINE CONTROL OXYGEN >>A<< ENGINE CONTROL OXYGEN SENSOR (REAR) REMOVAL SENSOR (REAR) INSTALLATION MD998770 MD998770 Engine control Engine control oxygen sensor oxygen sensor (rear) (rear) AC212566AD AC212566AD...
Page 47 14-1 GROUP 14 ENGINE COOLING CONTENTS GENERAL INFORMATION ..14-2 COOLING FAN MOTOR DRIVE CONTROL UNIT CHECK......14-23 FAN CONTROL RELAY CONTINUITY SERVICE SPECIFICATIONS.
Page 48: General Information
14-2 ENGINE COOLING GENERAL INFORMATION GENERAL INFORMATION M1141000100371 The cooling system is designed to keep every part of temperature, the thermostat opens to circulate the the engine at appropriate temperature in whatever coolant through the radiator as well so that the heat condition the engine may be operated.
Page 49: Sealants
14-3 ENGINE COOLING SEALANTS SEALANTS M1141000500324 Item Specified sealant Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent Water pump <4G1>, Thermostat case MITSUBISHI GENUINE Part No.MD970389 or equivalent <4G6>, Cooling water outlet hose fitting <4G6> SPECIAL TOOLS M1141000600246 Tool Number...
Page 50 14-4 ENGINE COOLING SPECIAL TOOLS Tool Number Name MB991955 MUT-III sub assembly Checking the A/T A: MB991824 A: Vehicle (Diagnosis display using the B: MB991827 communication MUT-III) C: MB991910 interface (V.C.I.) D: MB991911 B: MUT-III USB cable MB991824 E: MB991825 C: MUT-III main F: MB991826 harness A (Vehicles...
Page 51: Troubleshooting
14-5 ENGINE COOLING TROUBLESHOOTING Tool Number Name MB991223 Harness set Making voltage and A: MB991219 A: Test harness resistance measurement B: MB991220 B: LED harness during troubleshooting C: MB991221 C: LED harness A: Connector pin contact D: MB991222 adapter pressure inspection D: Probe B: Power circuit inspection C: Power circuit inspection...
Page 52: Inspection Procedure For Trouble Symptoms
14-6 ENGINE COOLING TROUBLESHOOTING INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1: Cooling Fan (L.H.) and Cooling Fan (R.H.) <4G1 (Vehicles with A/C)> or A/C Condenser Fan <4G6> do not Operate Cooling Fan (L.H.) and Cooling Fan (R.H.) or A/C Condenser Fan Drive Circut ENGINE-ECU <M/T>...
Page 53 14-7 ENGINE COOLING TROUBLESHOOTING CIRCUIT OPERATION DIAGNOSIS • The cooling fan motor drive control unit is powered from fusible link (2). STEP 1. Check the cooling fan motor (L.H.). • The engine-ECU <M/T> or engine-A/T-ECU <Vehicles without A/C> <A/T> uses input signals from the A/C switch, the Refer to P.14-25.
Page 54 14-8 ENGINE COOLING TROUBLESHOOTING (1) Disconnect fan control relay connector A-09X STEP 3. Check the cooling fan motor drive (remove the fan control relay) and measure relay control unit connector A-18. box side connector. Connector: A-18 (2) Turn the ignition switch to the "ON" position. A-09X Connector (Relay box side) A-18...
Page 55 14-9 ENGINE COOLING TROUBLESHOOTING Q: Is the connector in good condition? STEP 7. Check the harness wire between fusible Go to Step 10 . YES : link No.2 and fan control relay connector A-09X Repair the connector or replace the relay NO : terminal 4.
Page 56 14-10 ENGINE COOLING TROUBLESHOOTING STEP 12. Check the J/C No.6 C-12 <L.H. drive A-09X Connector vehicles> or C-134 <R.H. drive vehicles>, (Relay box side) intermediate connector A-13 <L.H. drive vehicles> C-111 <R.H. drive vehicles> and fan control relay connector A-09X. Connector: C-12 <L.H.
Page 57 14-11 ENGINE COOLING TROUBLESHOOTING Q: Are these harness wires in good condition? Relay box Connector: A-09X An intermittent malfunction is suspected YES : (Refer to GROUP 00 - How to use troubleshooting P.00-5). Repair the damaged harness wire. Then go NO : Fan control relay to Step 24 .
Page 58 14-12 ENGINE COOLING TROUBLESHOOTING STEP 15. Check the fan control relay connector STEP 17. Check the continuity between cooling A-09X. fan motor drive control unit connector A-18 and body earth. Connector: A-09X Relay box Connector: A-18 Fan control relay A-09X A-18 3 2 1 AC303510AB...
Page 59 14-13 ENGINE COOLING TROUBLESHOOTING STEP 18. Check the cooling fan motor drive STEP 20. Check the cooling fan motor drive control unit connector A-18. control unit connector A-18, intermediate connector A-13 <L.H. drive vehicles> or C-111 Connector: A-18 <R.H. drive vehicles> and engine-ECU connector C-123 <M/T>...
Page 60 14-14 ENGINE COOLING TROUBLESHOOTING Connector: C-123 <M/T>, C-122 <A/T> STEP 21. Check the harness wire between Engine-ECU <M/T> or cooling fan motor drive control unit connector engine-A/T-ECU <A/T> A-18 terminal 2 and engine-ECU connector C-123 terminal 21 <M/T> or engine-A/T-ECU connector C-122 terminal 18 <A/T>.
Page 61 14-15 ENGINE COOLING TROUBLESHOOTING (5) Check for the cooling fan operation. STEP 22. Check the cooling fan motor drive • The cooling fan rotates. (with connector control unit. terminal pin 21 <M/T> or 18 <A/T> Connector: C-123 <M/T>, C-122 <A/T> disconnected) Engine-ECU <M/T>...
Page 62 14-16 ENGINE COOLING TROUBLESHOOTING INSPECTION PROCEDURE 2: Cooling Fan (L.H.) and Cooling Fan (R.H.) <4G1 (Vehicles with A/C)> or A/C Condenser Fan <4G6> do not Change Speed or Stop COOLING FAN (L.H.) AND COOLING FAN TROUBLESHOOTING HINTS • Malfunction of fan control relay (R.H.) OR A/C CONDENSER FAN DRIVE •...
Page 63 14-17 ENGINE COOLING TROUBLESHOOTING STEP 3. Check the harness wire between fan STEP 4. Check the cooling fan motor drive control relay connector A-09X terminal 2 and control unit connector A-18, intermediate cooling fan motor drive control unit connector connector A-13 <L.H. drive vehicles> or C-111 A-18 terminal 3.
Page 64 14-18 ENGINE COOLING TROUBLESHOOTING Connector: C-123 <M/T>, C-122 <A/T> STEP 5. Check the harness wire between cooling Engine-ECU <M/T> or fan motor drive control unit connector A-18 engine-A/T-ECU <A/T> terminal 2 and engine-ECU connector C-123 terminal 21 <M/T> or engine-A/T-ECU connector C-122 terminal 18 <A/T>.
Page 65 14-19 ENGINE COOLING TROUBLESHOOTING (5) Check for the cooling fan operation. STEP 6. Check the cooling fan motor drive • The cooling fan rotates. (with connector control unit. terminal pin 21 <M/T> or 18 <A/T> Connector: C-123 <M/T>, C-122 <A/T> disconnected) Engine-ECU <M/T>...
Page 66 14-20 ENGINE COOLING TROUBLESHOOTING INSPECTION PROCEDURE 3: Cooling Fan (L.H.) does not Operate {When Cooling Fan (R.H.) <4G1> or A/C Condenser Fan <4G6> Operate} <Vehicles with A/C> COOLING FAN (L.H.) AND COOLING FAN STEP 2. Check the cooling fan motor drive (R.H.) OR A/C CONDENSER FAN DRIVE control unit.
Page 67 14-21 ENGINE COOLING TROUBLESHOOTING INSPECTION PROCEDURE 4: Cooling Fan (R.H.) <4G1> or A/C Condenser Fan <4G6> does not Operate {When Cooling Fan (L.H.) Operate} <Vehicles with A/C> COOLING FAN (L.H.) AND COOLING FAN DIAGNOSIS (R.H.) OR A/C CONDENSER FAN DRIVE CIRCUIT STEP 1.
Page 68: On-Vehicle Service
14-22 ENGINE COOLING ON-VEHICLE SERVICE ON-VEHICLE SERVICE ENGINE COOLANT LEAK CHECK 2. Increase the pressure until the indicator of the gauge stops moving. M1141001000300 WARNING Minimum limit: 83 kPa When pressure testing the cooling system, Standard value: 93 − 123 kPa slowly release cooling system pressure to 3.
Page 69: Concentration Measurement
14-23 ENGINE COOLING ON-VEHICLE SERVICE 9. Reinstall the radiator cap. Cylinder block 10.Start the engine and let it warm up until the drain plug thermostat opens. 11.After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine. 12.Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim.
Page 70: Fan Control Relay Continuity Check
14-24 ENGINE COOLING ON-VEHICLE SERVICE FAN CONTROL RELAY CONTINUITY 3. Connect the cooling fan motor drive control unit connector, and disconnect the cooling fan motor CHECK (L.H.) connector. M1141006200280 4. Ensure that the A/C switch is off, and start the engine and run it at idle.
Page 71: Cooling Fan Motor Check
14-25 ENGINE COOLING ON-VEHICLE SERVICE COOLING FAN MOTOR CHECK 1. Remove the cooling fan motor connector. M1141007100060 2. Check to see that the cooling fan motor of the Cooling fan motor drive control unit radiator turns when applying battery power between the connector terminal 1 and 2 of the cooling fan motor.
Page 72: Thermostat
14-26 ENGINE COOLING THERMOSTAT THERMOSTAT REMOVAL AND INSTALLATION M1141002400442 Pre-removal and Post-installation Operation • Engine Coolant Draining and Refilling (Refer to P.14-22). • Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3). • Battery Removal and Installation <4G1> 22 ±...
Page 73: Inspection
14-27 ENGINE COOLING THERMOSTAT Removal steps (Continued) Removal steps Engine control oxygen sensor Water temperature gauge unit connector and connector bracket connector <4G6> <4G1> Water temperature sensor unit Control wiring harness clip <4G6> connector <4G6> Cooling water inlet hose fitting <<A>>...
Page 74 14-28 ENGINE COOLING THERMOSTAT 2. Check that the amount of valve lift is at the standard value when the water is at the full-opening temperature. NOTE: Measure the valve height when the thermostat is fully closed, and use this measurement to compare the valve height when the thermostat is fully open.
Page 75: Water Pump
14-29 ENGINE COOLING WATER PUMP WATER PUMP REMOVAL AND INSTALLATION <4G1> M1141002700421 Pre-removal and Post-installation Operation • Engine Coolant Draining and Refilling (Refer to P.14-22). • Valve Timing Belt Removal and Installation (Refer to GROUP 11A P.11A-33). Bolt specifications 8 × 25 8 ×...
Page 76: Removal And Installation <4G6
14-30 ENGINE COOLING WATER PUMP REMOVAL AND INSTALLATION <4G6> M1141002700432 Pre-removal and Post-installation Operation • Engine Coolant Draining and Refilling (Refer to P.14-22). • Valve Timing Belt and Balancer Timing Belt Removal and Installation (Refer to GROUP 11C P.11C-35). Bolt specifications 22 ±...
Page 77: Water Hose And Water Pipe
14-31 ENGINE COOLING WATER HOSE AND WATER PIPE WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION <4G1> M1141003300415 Pre-removal and Post-installation Operation • Under Cover Removal and Installation • Engine Coolant Draining and Supplying (Refer to P.14-22). • Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3).
Page 78 14-32 ENGINE COOLING WATER HOSE AND WATER PIPE REMOVAL SERVICE POINT >>B<< RADIATOR UPPER HOSE CONNECTION <<A>> RADIATOR UPPER HOSE DISCONNECTION Projection Radiator upper hose Mating marks Mating marks Thermostat case assembly AC200642 AC200641AC 1. Insert radiator upper hose as far as the projection After making mating marks on the radiator upper of the thermostat case assembly.
Page 79: Removal And Installation <4G6
14-33 ENGINE COOLING WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION <4G6> M1141003300426 Pre-removal and Post-installation Operation • Engine Coolant Draining and Supplying (Refer to P.14-22). • Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3). • Thermostat Removal and Installation (Refer to P.14-26). 13 ±...
Page 80: Inspection
14-34 ENGINE COOLING WATER HOSE AND WATER PIPE REMOVAL SERVICE POINT >>B<< THERMOSTAT CASE ASSEMBLY/COOLING WATER OUTLET <<A>> RADIATOR UPPER HOSE HOSE FITTING INSTALLATION DISCONNECTION 1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface.
Page 81: Radiator
14-35 ENGINE COOLING RADIATOR RADIATOR REMOVAL AND INSTALLATION M1141001500468 Pre-removal and Post-installation Operation • Engine Coolant Draining and Supplying (Refer to P.14-22). • Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3). <4G1 (Vehicles without A/C)> 12 ± 2 N·m 12 ±...
Page 82 14-36 ENGINE COOLING RADIATOR 12 ± 2 N·m <4G1 (Vehicles with A/C)> 12 ± 2 N·m AC303473 <4G6> 12 ± 2 N·m 12 ± 2 N·m AC303474 Radiator removal steps Radiator removal steps T/M oil cooler line hose connection Drain plug <A/T>...
Page 83 14-37 ENGINE COOLING RADIATOR Radiator removal steps Cooling fan motor removal steps 12. Cooling fan motor & shroud (Continued) assembly 12. Cooling fan motor & shroud 13. A/C condenser fan motor & shroud assembly assembly <4G6> 15. Cooling fan (L.H.) 14.
Page 84 NOTES...
Page 85 37-1 GROUP 37 POWER STEERING CONTENTS GENERAL INFORMATION ..37-3 DRIVE BELT TENSION CHECK ..37-13 FLUID LEVEL CHECK ....37-13 SERVICE SPECIFICATIONS.
Page 86 37-2 STEERING SHAFT* ....37-21 POWER STEERING OIL PUMP ASSEMBLY..... 37-37 REMOVAL AND INSTALLATION .
Page 87: General Information
37-3 POWER STEERING GENERAL INFORMATION GENERAL INFORMATION M1372000100337 • Integral-type rack and pinion gear with high Power steering has been adopted in all vehicles to make the steering system easier to handle. rigidity and excellent response is used. • A vane type pump with a fluid flow rate control FEATURES system which change steering effort according to the engine speed is used.
Page 88 37-4 POWER STEERING GENERAL INFORMATION CONSTRUCTION DIAGRAM 1300, 1600 - L.H. drive vehicles Steering wheel Oil reservoir Steering column shaft assembly Pressure hose assembly Return hose Suction hose Oil pump assembly Steering gear AC304488AB 1300, 1600 - R.H. drive vehicles Steering wheel Steering column Oil reservoir...
Page 89 37-5 POWER STEERING GENERAL INFORMATION 2000 - L.H. drive vehicles Steering wheel Oil reservoir Steering column shaft assembly Pressure hose Suction hose assembly Return hose Oil pump assembly Steering gear AC304486AB 2000 - R.H. drive vehicles Steering wheel Steering column Oil reservoir shaft assembly Suction hose...
Page 90: Service Specifications
37-6 POWER STEERING SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS M1372000300386 Item Standard value Limit Steering wheel free With engine running − play mm With engine stopped 10 or less − 39°30' ± 1°30' Steering angle Inner wheel Comfort − Sport (L.H. drive vehicles) 33°40' +1°00'/-2°00' −...
Page 91: Lubricants
37-7 POWER STEERING LUBRICANTS LUBRICANTS M1372000400350 Item Specified lubricant Quantity Power steering fluid ATF DEXRON III or DEXRON II Approximately 1.0 L Steering gear Bearing ATF DEXRON III or DEXRON II As required O-ring and seal ring Oil seal Special tool (MB991212, MB991213) Pinion and valve assembly seal ring part...
Page 92: Special Tools
37-8 POWER STEERING SPECIAL TOOLS SPECIAL TOOLS M1372000600354 Tool Number Name MB991897 Ball joint remover Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113) is also available to disconnect knuckle and AC106827 tie rod end ball joint. MB990326 Preload socket Tie rod end ball joint turning torque...
Page 93 37-9 POWER STEERING SPECIAL TOOLS Tool Number Name • Rack support cover removal MB990607 Torque wrench socket <Comfort> • Rack support adjustment <Comfort> • Rack support cover removal MB991621 Piston driver <Sport> • Rack support adjustment <Sport> MB991621 • Lower bearing removal MB990925 Bearing and oil •...
Page 94 37-10 POWER STEERING SPECIAL TOOLS Tool Number Name MB991203 Oil seal and Oil seal and bearing installation bearing installer MB991203 MB991317 Seal ring installer Seal rings installation MB991317 MB990941 Torque tube Lower oil seal installation bearing installer MB990941 MB991561 Boot band crimping Bellows band installation tool MB991561...
Page 95: On-Vehicle Service
37-11 POWER STEERING ON-VEHICLE SERVICE ON-VEHICLE SERVICE STEERING WHEEL FREE PLAY CHECK 1. Place the front wheel on a turning radius gauge and measure the steering angle. M1372001000311 1. With the engine running (hydraulic operation), set Standard value: the front wheels straight ahead. 39°30' ±...
Page 96: Tie Rod End Ball Joint Turning Torque Check
37-12 POWER STEERING ON-VEHICLE SERVICE TIE ROD END BALL JOINT TURNING 4. Move the ball joint stud several times and install the nut on the stud. Using special tool preload TORQUE CHECK socket (MB990326), measure the ball joint turning M1372001500297 torque.
Page 97: Steering Wheel Return To Centre Check
37-13 POWER STEERING ON-VEHICLE SERVICE STEERING WHEEL RETURN TO CENTRE 4. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level CHECK when the engine is stopped, and while it is M1372001800317 Conduct a road test: running.
Page 98: Oil Pump Pressure Test
37-14 POWER STEERING ON-VEHICLE SERVICE OIL PUMP PRESSURE TEST CAUTION M1372002300315 Perform air bleeding only while cranking the engine. If air bleeding is performed while the engine is running, air could enter the fluid. Pressure Shut-off valve gauge Temperature During air bleeding, refill the steering fluid (fully closed) (MB990662) gauge...
Page 99: Power Steering Pressure Switch Check
37-15 POWER STEERING ON-VEHICLE SERVICE 7. If it is not within the standard value, the probable 2. Bleed air, and then turn the steering wheel several cause is a malfunction of the oil line or steering times while the vehicle is not moving so that the gear, so check these parts and repair as temperature of the fluid rises to approximately 50 necessary.
Page 100 37-16 POWER STEERING ON-VEHICLE SERVICE WARNING • If the vehicle continues to be driven after the collision absorbing mechanism has operated, the steering column shaft may be damaged while it is in use. • If there is a slack in the one-way capsule, do not attempt to repair it but replace the steering column shaft assembly.
Page 101: Steering Wheel
37-17 POWER STEERING STEERING WHEEL STEERING WHEEL REMOVAL AND INSTALLATION <COMFORT> M1372011400183 WARNING • Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210). • When removing and installing the steering wheel, do not let it bump against the air bag module.
Page 102 37-18 POWER STEERING STEERING WHEEL REMOVAL SERVICE POINTS 1. By sliding section A of the clock spring connector shown in the illustration in the arrow direction, <<A>> COVER REMOVAL disconnect the connector. Hexagonal bit socket MB990784 AC006294 AB AC100442 Insert special tool ornament remover (MB990784) at the indicated position to remove the cover.
Page 103: Removal And Installation
37-19 POWER STEERING STEERING WHEEL REMOVAL AND INSTALLATION <SPORT> M1372011400194 WARNING • Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210). • When removing and installing the steering wheel, do not let it bump against the air bag module.

Page 104 37-20 POWER STEERING STEERING WHEEL <> STEERING WHEEL AND AIRBAG 1. By sliding section A of the clock spring connector as shown in the illustration in the arrow direction, MODULE ASSEMBLY REMOVAL disconnect the connector. Hexagonal bit Steering socket wheel AC211762 AC AC304700 2.
Page 105: Steering Shaft
37-21 POWER STEERING STEERING SHAFT STEERING SHAFT REMOVAL AND INSTALLATION M1372011500113 WARNING Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210). Pre-removal Operation Post-installation Operation •...
Page 106: Disassembly And Reassembly
37-22 POWER STEERING STEERING SHAFT • When the steering column is replaced, do not release the tilt lever until it has been installed. Do not remove the tilt lever fixing band until Clip the installation has completed. • When installing the steering column, do not Steering column leave it fixed temporarily at only one point shaft...
Page 107 37-23 POWER STEERING STEERING SHAFT DISASSEMBLY SERVICE POINT REASSEMBLY SERVICE POINT <<A>> SPECIAL BOLT REMOVAL >>A<< STEERING LOCK CYLINDER ASSEMBLY/STEERING LOCK Reverse screw tap BRACKET/SPECIAL BOLT Special bolt INSTALLATION Steering lock bracket CAUTION The steering lock bracket and bolts must be replaced with new ones when the steering lock is installed.
Page 108: Power Steering Gear Box And Linkage
37-24 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE POWER STEERING GEAR BOX AND LINKAGE REMOVAL AND INSTALLATION M1372010900237 WARNING Before removing the steering gear, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210). Centre the front wheels. Failure to do so may damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
Page 109 37-25 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE <R.H. drive vehicles> 15 ± 3 N·m 70 ± 10 N·m 57 ± 7 N·m AC304921AC Removal steps (Continued) Removal steps 5. Pressure hose connection 1. Crossmember (Refer to GROUP 32, 6.
Page 110: Inspection
37-26 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE INSTALLATION SERVICE POINT NOTE: When measuring, remove the bellows from the rack housing. Measure the pinion torque through >>A<< JOINT COVER GROMMET the whole stroke of the rack. INSTALLATION If the measured value is not within the standard range, first adjust the rack support cover, and then Joint cover check the total pinion torque again.
Page 111: Disassembly And Reassembly
37-27 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE DISASSEMBLY AND REASSEMBLY M1372011100193 <L.H. drive vehicles> 22 ± 4 N·m Flare nut 13 ± 3 N·m Repair kit grease 59 ± 10 N·m 40 ± 5 N·m 11 8 23 ± 2 N·m -30˚...
Page 112 37-28 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE <R.H. drive vehicles> 22 ± 4 N·m Flare nut 13 ± 3 N·m Repair kit grease 11 8 11 35 17 31 25 ± 4 N·m 29 28 Steering gear seal kit 59 ±...
Page 113 37-29 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE LUBRICATION AND SEALING POINTS Fluid: Fluid: Fluid: ATF DXRON III or ATF DXRON III or ATF DXRON III or DEXRON II DEXRON II DEXRON II Grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent Grease: Repair kit grease Fluid:...
Page 114 37-30 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE DISASSEMBLY SERVICE POINTS <<C>> SEAL RING REMOVAL <<A>> RACK SUPPORT COVER CAUTION REMOVAL When cutting the seal ring, be careful not to damage the pinion and valve assembly or the <Comfort> rack.
Page 115 37-31 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE <<E>> CIRCLIP REMOVAL 2. Partially bend the oil seal and remove it from the rack bushing. CAUTION If the rack stopper is first turned anticlockwise, <<G>> LOWER BEARING REMOVAL the circlip will get caught in the slot in the housing and the rack stopper will not turn.
Page 116 37-32 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE REASSEMBLY SERVICE POINTS >>C<< RACK ASSEMBLY INSTALLATION >>A<< OIL SEAL INSTALLATION CAUTION Do not close the vent hole in the rack with 1. Apply a coating of ATF DEXRON III or DEXRON II grease.
Page 117 37-33 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE >>D<< OIL SEAL/RACK BUSHING >>F<< UPPER OIL SEAL/UPPER INSTALLATION BEARING INSTALLATION MB990938 MB990938 MB990927 Oil seal O-ring MB991203 Rack MB991203 Bearing bushing Oil seal ACX01156 AE ACX01159AC Apply a coating of ATF DEXRON III or DEXRON II to 1.
Page 118 37-34 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE >>H<< LOWER OIL SEAL INSTALLATION CAUTION Approximately 1 mm MB990941 seal MB990607 <Comfort> Housing MB991621 <Sport> AC100273 3. Use the following special tool to tighten the rack support cover to 23 ± 2 N⋅m. ACX01161 •...
Page 119 37-35 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE <When more than 2.9 mm>: Screw in the CAUTION adjusting bolt. When adjusting, set at the highest value of the <When less than 2.9 mm>: Loosen the standard value range. adjusting bolt. NOTE: If the total pinion toque cannot be adjusted CAUTION to the standard value within the specified return...
Page 120: Tie Rod End Ball Joint Dust Cover Replacement
37-36 POWER STEERING POWER STEERING GEAR BOX AND LINKAGE >>N<< TIE ROD END/LOCK NUT TIE ROD END BALL JOINT DUST COVER INSTALLATION REPLACEMENT M1372008200327 If the dust cover is damaged accidentally during service work, replace the dust cover as follows: Edge of bellows Lock nut assembly groove...
Page 121: Power Steering Oil Pump Assembly
37-37 POWER STEERING POWER STEERING OIL PUMP ASSEMBLY POWER STEERING OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION M1372005200298 Pre-removal Operation Post-installation Operation • Power Steering Fluid Draining (Refer to P.37-13). • Power Steering Fluid Supplying and Bleeding (Refer to P.37-13). • Drive Belt Tension Check (1300, 1600: refer to GROUP 11A, On-vehicle Service −...
Page 122: Inspection
37-38 POWER STEERING POWER STEERING OIL PUMP ASSEMBLY <2000> 12 ± 2 N·m 57 ± 7 N·m 49 ± 9 N·m 22 ± 4 N·m 22 ± 4 N·m 49 ± 9 N·m AC200116 AB Removal steps (Continued) Removal steps <<A>>...
Page 123: Disassembly And Reassembly
37-39 POWER STEERING POWER STEERING OIL PUMP ASSEMBLY DISASSEMBLY AND REASSEMBLY M1372005400300 CAUTION Never disassemble the terminal assembly. It cannot be reassembled. <1300, 1600> 12 ± 1 N·m 59 ± 9 N·m 28 ± 1 N·m 28 ± 2 N·m : ATF DEXRON III or DEXRON II AC209709 AC Oil pump seal kit...
Page 124 37-40 POWER STEERING POWER STEERING OIL PUMP ASSEMBLY Disassembly steps (Continued) Disassembly steps (Continued) >>A<< O-ring Suction connector >>A<< Flow control spring O-ring <2000> 28 ± 2 N·m 9.9 ± 2.1 N·m <Sedan, Wagon (Comfort)> 12 ± 1 N·m <Wagon (Sport)> 28 ±...
Page 125: Inspection
37-41 POWER STEERING POWER STEERING OIL PUMP ASSEMBLY REASSEMBLY SERVICE POINTS >>B<< OIL SEAL INSTALLATION >>A<< O-RING INSTALLATION MB990938 Plug assembly Suction connector MB991203 AC000752 Use following special tool to install the oil seal. • MB990938: Bar (Snap-in type) Terminal assembly Side plate •...
Page 126: Power Steering Hoses
37-42 POWER STEERING POWER STEERING HOSES POWER STEERING HOSES REMOVAL AND INSTALLATION M1372005700679 CAUTION • Before removing the clock spring, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210). 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.
Page 127 37-43 POWER STEERING POWER STEERING HOSES Removal steps (Continued) Removal steps (Continued) • Centermember (Refer to GROUP 32, Gasket Engine Roll Stopper Centermember Pressure hose assembly Return tube P.32-7). >>A<< Return hose • Front exhaust pipe (Refer to GROUP <<A>> Return tube 15, Exhaust Pipe and Main Muffler O-ring...
Page 128 37-44 POWER STEERING POWER STEERING HOSES INSTALLATION SERVICE POINTS Removal steps (Continued) • Centermember (Refer to GROUP 32, >>A<< RETURN HOSE INSTALLATION Engine Roll Stopper Centermember <LH DRIVE VEHICLES> P.32-7). • Front exhaust pipe (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-11).
Page 129 36-1 GROUP 36 PARKING BRAKES CONTENTS GENERAL INFORMATION ..36-2 PARKING BRAKE LEVER ..36-5 REMOVAL AND INSTALLATION ..36-5 SERVICE SPECIFICATIONS.
Page 130: General Information
36-2 PARKING BRAKES GENERAL INFORMATION GENERAL INFORMATION M1361000100496 The parking brake is of a mechanical rear-wheel acting type, and its operation utilises a parking brake lever. SPECIFICATIONS Item Specification Type Drum-in disc Clearance adjustment Manual CONSTRUCTION DIAGRAM AC211553 AC104333 Drum-in-disc brake Parking brake lever assembly Parking brake cable AC304152...
Page 131: Lubricants
36-3 PARKING BRAKES LUBRICANTS LUBRICANTS M1361000400293 Item Specified lubricant Rear brake shoe and backing plate contact surface Brake grease SAE J310, NLGI No.1 Rear brake shoe assembly Rear brake shoe slack adjuster ON-VEHICLE SERVICE PARKING BRAKE LEVER STROKE (5) Remove the rear wheel hub plug, and then use a flat-tipped screwdriver to turn the shoe CHECK AND ADJUSTMENT slack adjuster in the direction of the arrow (the...
Page 132: Parking Brake Switch Check
36-4 PARKING BRAKES ON-VEHICLE SERVICE PARKING BRAKE SWITCH CHECK Pull M1361003300381 1. Remove the rear console assembly (Refer to GROUP 52A, Rear Floor Console P.52A-8). 2. Remove the front seat assembly (RH). (Refer to Spring balance GROUP 52A, Front Seat P.52A-24). Approximately 40 mm AC212035 AC...
Page 133: Parking Brake Lever
36-5 PARKING BRAKES PARKING BRAKE LEVER PARKING BRAKE LEVER REMOVAL AND INSTALLATION M1361001300330 Pre-removal Operation Post-installation Operation • Parking Brake Lever Stroke Adjustment (Refer to P.36-3.) Rear Console Assembly and Rear Console Bracket Removal • Rear Console Bracket and Rear Console Assembly (Refer to GROUP 52A, Rear Floor Console P.52A-8.) Installation (Refer to GROUP 52A, Rear Floor Console P.52A-8.)
Page 134: Parking Brake Cable
36-6 PARKING BRAKES PARKING BRAKE CABLE PARKING BRAKE CABLE REMOVAL AND INSTALLATION M1361001900785 Pre-removal Operation Post-installation Operation • Rear Console Assembly and Rear Console Bracket • Parking Brake Lever Stroke Adjustment (Refer to P.36-3). Removal (Refer to GROUP 52A, Rear Floor Console •...
Page 135: Parking Brake Lining And Drum
36-7 PARKING BRAKES PARKING BRAKE LINING AND DRUM PARKING BRAKE LINING AND DRUM REMOVAL AND INSTALLATION M1361002500296 Post-installation Operation • Parking Brake Lever Stroke Check and Adjustment (Refer to P.36-3). • Lining Running-in (Refer to P.36-3). 60 ± 5 N·m 63 ±...
Page 136 36-8 PARKING BRAKES PARKING BRAKE LINING AND DRUM REMOVAL SERVICE POINTS >>B<< REAR BRAKE CHAMBER RETAINER INSTALLATION <<A>> REAR BRAKE ASSEMBLY REMOVAL Rear brake secondary shoe assembly pin Remove the rear brake assembly and support it with wire or something similar. <>...
Page 137: Inspection
36-9 PARKING BRAKES PARKING BRAKE LINING AND DRUM >>D<< SHOE RETURN SPRINGS 1. Measure the thickness of the brake lining at several places. INSTALLATION Standard value: 2.8 mm Limit: 1.0 mm 2. If the thickness of the brake lining is below the Front of the vehicle limit, replace the shoe assemblies on both sides of the vehicle.
Page 138 NOTES...
Page 139 35-1 GROUP 35 SERVICE BRAKES CONTENTS BASIC BRAKE SYSTEM ......ANTI-SKID BRAKING SYSTEM (ABS) ....
Page 140 NOTES...
Page 141 34-1 GROUP 34 REAR SUSPENSION CONTENTS GENERAL INFORMATION ..34-2 REMOVAL AND INSTALLATION ..34-8 INSPECTION......34-9 SERVICE SPECIFICATIONS.
Page 142: General Information
34-2 REAR SUSPENSION GENERAL INFORMATION GENERAL INFORMATION M1341000100353 A trailing arm type multi-link suspension has been adopted as the rear suspension. The shock absorber is a hydraulic, cylindrical double-acting type. CONSTRUCTION DIAGRAM <Comfort> <Sedan> Shock absorber Rear shock absorber damper Upper arm assembly Coil spring Stabilizer bar...
Page 143: Service Specifications
34-3 REAR SUSPENSION SERVICE SPECIFICATIONS SPECIFICATION COIL SPRING Item Sedan Wagon Comfort Sport Comfort Sport Wire diameter mm 78 − 90 78 − 90 78 − 90 78 − 90 Average diameter mm Free length mm SERVICE SPECIFICATIONS M1341000300409 Item Standard value Camber (Difference between right and left within 30') −0°40' ±...
Page 144: Special Tools
34-4 REAR SUSPENSION SPECIAL TOOLS SPECIAL TOOLS M1341000600392 Tool Number Name MB991014 Wheel alignment gauge Wheel alignment attachment measurement <vehicles with aluminium wheels> MB991004 • Pillow ball bushing MB990326 Preload socket rotation starting torque check • Stabilizer link ball joint turning torque MB990326 check MB991447...
Page 145: On-Vehicle Service
34-5 REAR SUSPENSION ON-VEHICLE SERVICE Tool Number Name MB990947 Lower arm bushing arbor Trailing arm bushing removal and press-fitting MB990947 MB991816 Bushing remover and installer base MB990890 Rear suspension bushing base MB990890 A: MB991237 A: Spring compressor Coil spring compressing B: MB991239 body B: Arm set...
Page 146: Control Link Pillow Ball Bushing Axial Play Check
34-6 REAR SUSPENSION ON-VEHICLE SERVICE If camber is not within the standard value, adjust by If toe-in is not within the standard value, adjust by following procedures. following procedures. 1. Disconnect the conjunction of the control link and CAUTION the trailing arm. To prevent bushings from breakage, the control link mounting nut should be temporarily tightened, and then fully tightened to 120 ±...

Page 147: Upper Arm Pillow Ball Bushing Axial Play Check
34-7 REAR SUSPENSION ON-VEHICLE SERVICE UPPER ARM PILLOW BALL BUSHING AXIAL PLAY CHECK <Sport> M1341018400014 1. Raise the vehicle. Front of vehicle Upper arm pillow ball bushing Front of vehicle Lower arm pillow ball bushing AC304398 AD 3. Move the lower arm up and down with your hands to check for an excessive play in the axial direction of the pillow ball bushing.

Page 148: Control Link, Upper Arm And Lower Arm
34-8 REAR SUSPENSION CONTROL LINK, UPPER ARM AND LOWER ARM CONTROL LINK, UPPER ARM AND LOWER ARM REMOVAL AND INSTALLATION M1341004800172 CAUTION : Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the earth in an unladen condition. Post-installation Operation •...
Page 149: Inspection
34-9 REAR SUSPENSION CONTROL LINK, UPPER ARM AND LOWER ARM REMOVAL SERVICE POINTS Tighten the self-locking nut until the stabilizer link thread part protruding length meets the standard <<A>> CONTROL LINK/LOWER ARM value. ASSEMBLY REMOVAL Standard value (A): 6 − 8 mm >>B<<...
Page 150: Lower Arm Bushing And Lower Arm Pillow Ball Bushing Replacement
34-10 REAR SUSPENSION CONTROL LINK, UPPER ARM AND LOWER ARM CONTROL LINK <Sport>/UPPER ARM LOWER ARM BUSHING AND LOWER <Sport>/LOWER ARM PILLOW BALL ARM PILLOW BALL BUSHING BUSHING ROTATION STARTING TORQUE REPLACEMENT M1341011800204 CHECK Lower arm pillow Control link pillow ball bushing <Sport> ball bushing Lower arm bushing Lower arm bushing...
Page 151 34-11 REAR SUSPENSION CONTROL LINK, UPPER ARM AND LOWER ARM LOWER ARM PILLOW BALL BUSHING Use following special tools to drive out and press fit the bushing. REPLACEMENT • MB990957: Lower Arm Bushing Remover and Installer MB990996 • MB990969: Guide •...
Page 152: Trailing Arm Assembly
34-12 REAR SUSPENSION TRAILING ARM ASSEMBLY TRAILING ARM ASSEMBLY REMOVAL AND INSTALLATION M1341002200594 CAUTION : Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the earth in the unladen condition. Pre-removal Operation Post-installation Operation •...
Page 153: Inspection
34-13 REAR SUSPENSION TRAILING ARM ASSEMBLY Removal steps (Continued) <> Lower arm assembly and trailing arm connection 10. Trailing arm and body connection 11. Trailing arm REMOVAL SERVICE POINTS INSTALLATION SERVICE POINT <<A>> LIFTING POINT >>A<< STABILIZER LINK INSTALLATION Trailing arm AC103744 AC006171 AC When removing the trailing arm, move the lifting arm...
Page 154 34-14 REAR SUSPENSION TRAILING ARM ASSEMBLY (2) Make sure that the hollow of the trailing arm bushing is located as shown in the illustration. Press-fitting MB990947 MB990890 16.2 ± 0.5 mm Trailing arm AC006173AB MB991816 2. Set the installation direction and installation AC006172 AF location of the trailing arm bushing.
Page 155: Shock Absorber Assembly
34-15 REAR SUSPENSION SHOCK ABSORBER ASSEMBLY SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION M1341002500261 CAUTION : Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the earth in the unladen condition. Pre-removal and Post-installation Operation •...
Page 156: Inspection
34-16 REAR SUSPENSION SHOCK ABSORBER ASSEMBLY REMOVAL SERVICE POINT >>B<< STABILIZER LINK INSTALLATION <<A>> LOWER ARM BOLT REMOVAL Piece of wood AC103744 Tighten the self-locking nut until the stabilizer link thread part protruding length meets the standard AC107126 AB value. After supporting the lower arm with a jack, remove Standard value (A): 6 −...
Page 157: Disassembly And Reassembly
34-17 REAR SUSPENSION SHOCK ABSORBER ASSEMBLY DISASSEMBLY AND REASSEMBLY M1341005300222 25 ± 5 N·m Sedan, Wagon Wagon (comfort) (sport) AC304156 AB Disassembly steps (Continued) Disassembly steps 9. Rear shock absorber cover <Wagon <<A>> >>E<< 1. Rear suspension coil spring nut (comfort)>...
Page 158 34-18 REAR SUSPENSION SHOCK ABSORBER ASSEMBLY DISASSEMBLY SERVICE POINTS 2. While holding the piston rod, remove the rear suspension coil spring nut (self-locking nut). <<A>> REAR SUSPENSION COIL SPRING NUT (SELF-LOCKING NUT) REMOVAL <> REAR SUSPENSION SHOCK CAUTION ABSORBER DISPOSAL •...
Page 159 34-19 REAR SUSPENSION SHOCK ABSORBER ASSEMBLY >>B<< REAR SUSPENSION COIL SPRING Align the stepped section of the spring upper pad with the upper end of the coil spring, and install the INSTALLATION spring upper pad. CAUTION Do not use an impact wrench to tighten the bolt >>D<<...
Page 160: Stabilizer Bar
34-20 REAR SUSPENSION STABILIZER BAR STABILIZER BAR REMOVAL AND INSTALLATION M1341003000258 Post-installation Operation • Press the dust cover with your finger to check that there are no cracks or damage in the dust cover. 12 ± 2 N·m 39 ± 5 N·m 25 ±...
Page 161: Inspection
34-21 REAR SUSPENSION STABILIZER BAR INSTALLATION SERVICE POINTS STABILIZER LINK BALL JOINT TURNING TORQUE CHECK >>A<< STABILIZER BAR/BUSHING/FIXTURE INSTALLATION MB990326 Approximately Outside of vehicle 9.5 mm Identification colour Bushing (LH) AC001129 Fixture (LH) 1. After shaking the ball joint stud several times, AC102279 install the nut to the stud and use special tool Install the stabilizer bar, the bushings and the fixtures...
Page 162 34-22 REAR SUSPENSION STABILIZER BAR 2. Apply specified grease to the inside of a new dust cover. Specified grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent 3. Wrap plastic tape around the stabilizer link stud, and then install the dust cover to the stabilizer link.
Page 163 33-1 GROUP 33 FRONT SUSPENSION CONTENTS GENERAL INFORMATION ..33-2 STRUT ASSEMBLY ....33-7 REMOVAL AND INSTALLATION ..33-7 SERVICE SPECIFICATIONS.
Page 164: General Information
FRONT SUSPENSION 33-2 GENERAL INFORMATION GENERAL INFORMATION M1332000100407 The front suspension is a McPherson strut with coil spring. The shock absorber is gas-filled hydraulic double-acting type. CONSTRUCTION DIAGRAM <Sport> Strut damper <Comfort> Stabilizer bar Strut damper Coil spring AC304022 Strut cover Strut (shock absorber) Lower arm assembly Front axle No.1...
Page 165: Service Specifications
FRONT SUSPENSION 33-3 SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS M1332000300586 Item Standard value Toe-in At the centre of tyre tread mm 1 ± 2 Toe-angle (per wheel) 0°03' ± 06' Toe-out angle on turns (inner wheel when outer wheel at 20°) 21°42' ± 1°30' Steering angle Inner wheel Comfort...
Page 166: Special Tools
FRONT SUSPENSION 33-4 SPECIAL TOOLS SPECIAL TOOLS M1332000600297 Tool Number Name MB991004 Wheel alignment gauge Wheel alignment attachment measurement <Vehicles with aluminium wheels> MB991004 A: MB991237 A: Spring compressor Coil spring compression B: MB991238 body B: Arm set MB991237 MB991680 Wrench set Strut assembly A: MB991681...
Page 167: On-Vehicle Service
FRONT SUSPENSION 33-5 ON-VEHICLE SERVICE Tool Number Name MB990883 Rear suspension bushing Lower arm bushing (rear) arbor removal and press-fitting MB990883 MB990972 Torsion bar bushing remover base MB990971 MB990887 Ring MB990890 Rear suspension bushing base MB990890 MB991897 Ball joint remover Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage...
Page 168: Lower Arm Ball Joint Axial Play Check
FRONT SUSPENSION 33-6 ON-VEHICLE SERVICE NOTE: The toe will move out as the left NOTE: *: difference between right and left wheels turnbuckle is turned toward the front of the vehicle must be less than 30' and the right turnbuckle is turned toward the rear NOTE: Camber and caster are preset at the factory of the vehicle.
Page 169: Strut Assembly
FRONT SUSPENSION 33-7 STRUT ASSEMBLY STRUT ASSEMBLY REMOVAL AND INSTALLATION M1332001100325 Post-installation Operation • Front Wheel Alignment Adjustment (Refer to P.33-5.) 44 ± 5 N·m 167 ± 9 N·m AC304153 Removal steps (Continued) Removal steps Strut nut (self-locking nut) Front ABS sensor harness bracket Strut assembly Brake hose bracket Knuckle connection...
Page 170: Disassembly And Reassembly
FRONT SUSPENSION 33-8 STRUT ASSEMBLY DISASSEMBLY AND REASSEMBLY M1332001300329 60 ± 10 N·m <Comfort> <Sport> AC300065 AC300065 Disassembly steps (Continued) Disassembly steps Strut cover <Comfort> Strut nut (self-locking nut) <<A>> >>B<< Strut damper <Comfort> Strut insulator Coil spring Strut bearing Spring lower pad >>A<<...
Page 171 FRONT SUSPENSION 33-9 STRUT ASSEMBLY DISASSEMBLY SERVICE POINTS 2. Use following special tools to secure the strut, and then remove the strut nut (self-locking nut). <<A>> STRUT NUT (SELF-LOCKING NUT) • MB991681: Wrench REMOVAL • MB991682: Socket CAUTION • Install special tool arm set (MB991238) evenly, <>...
Page 172: Inspection
FRONT SUSPENSION 33-10 STRUT ASSEMBLY >>B<< STRUT NUT (SELF-LOCKING NUT) 5. Align lower end of the coil spring with the groove in the spring lower seat, and then loosen the INSTALLATION special tools. 1. Ensure that the bearing is seated correctly. CAUTION CAUTION Do not use an impact wrench to tighten the bolt...
Page 173: Lower Arm
FRONT SUSPENSION 33-11 LOWER ARM LOWER ARM REMOVAL AND INSTALLATION M1332001600331 CAUTION : Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the earth in an unladen condition. Post-installation Operation • Check the lower arm ball joint cover for cracks or damage by pushing it with your finger.
Page 174: Inspection
FRONT SUSPENSION 33-12 LOWER ARM REMOVAL SERVICE POINT LOWER ARM BALL JOINT ROTATION STARTING TORQUE CHECK <<A>> LOWER ARM BOLT REMOVAL Piece of wood MB991006 Lower arm bolt (front) AC001091 AB Transmission jack AC006133 AD Lift the transmission with a transmission jack, and 1.
Page 175: Lower Arm Bushing (Rear) Replacement
FRONT SUSPENSION 33-13 LOWER ARM MB990800 MB990883 Lower arm ball joint cover MB990972 Lower arm assembly AC006135 AD 3. Using special tool ball joint remover and installer (MB990800), drive in the lower arm ball joint cover until it is fully seated. MB990887 Lower arm ball joint cover...
Page 176: Stabilizer Bar
FRONT SUSPENSION 33-14 STABILIZER BAR STABILIZER BAR REMOVAL AND INSTALLATION M1332004000468 CAUTION • Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Service Precautions P.52B-5 and Air Bag Module and Clock Spring P.52B-210. Also, put the front wheels in straight-ahead position.
Page 177 FRONT SUSPENSION 33-15 STABILIZER BAR 18 ± 2 N·m 21 ± 4 N·m 25 ± 5 N·m 52 ± 7 N·m* 167 ± 9 N·m 49 ± 10 N·m 108 ± 10 N·m 167 ± 9 N·m AC006139 AD Removal steps (Continued) Removal steps Steering gear and joint Self-locking nut...
Page 178 FRONT SUSPENSION 33-16 STABILIZER BAR REMOVAL SERVICE POINTS <> STABILIZER BAR BRACKET/STABILIZER <<A>> TIE ROD END AND KNUCKLE BUSHING/STABILIZER BAR REMOVAL DISCONNECTION Carry out the following operations to ensure working CAUTION space in order to remove the stabilizer bar brackets, •...
Page 179: Inspection
FRONT SUSPENSION 33-17 STABILIZER BAR Tighten the self-locking nut until the stabilizer link >>B<< SELF-LOCKING NUT thread part protruding length meets the standard INSTALLATION value. Standard value (A): 22 ± 1.5 mm INSPECTION M1332002000279 • Check the stabilizer rubbers and stabilizer bushings for wear and deterioration.
Page 180 NOTES...
Page 181 31-1 GROUP 31 WHEEL AND TYRE CONTENTS GENERAL INFORMATION ..31-2 ON-VEHICLE SERVICE ... 31-7 TYRE INFLATION PRESSURE CHECK . . . 31-7 SERVICE SPECIFICATIONS.
Page 182: General Information
31-2 WHEEL AND TYRE GENERAL INFORMATION GENERAL INFORMATION M1311000100220 The wheels and tyres of the following specifications have been established. SPECIFICATIONS ROAD WHEEL AND TYRE Item Comfort Sport Wheel Type Steel type or Aluminium type* Aluminium type 15 × 6JJ 16 ×...
Page 183: Troubleshooting
31-3 WHEEL AND TYRE TROUBLESHOOTING TROUBLESHOOTING DIAGNOSIS M1311000700385 Symptom Probable cause Remedy Reference page Rapid wear Under-inflation Adjust the tyre For tyre inflation at shoulders or lack of pressure. pressure, refer to rotation the label on the driver's side centre pillar.
Page 184: Wheel Balance Accuracy
31-4 WHEEL AND TYRE TROUBLESHOOTING Symptom Probable cause Remedy Reference page Scalloped Lack of rotation of tyres or worn Rotate the tyres, and <Front> wear or out-of-alignment suspension check the front or Refer to GROUP rear suspension 33, On-vehicle service − Front alignments.
Page 185 31-5 WHEEL AND TYRE TROUBLESHOOTING Clamping cup Hub/shaft assembly Wing nut Spring plate Wheel mounting cone AC305700AB Standard passenger car wheel • If the imbalance is more than 5g, the balancer <Confirming Proper Balance> requires calibration. Contact the balancer 1. After balancing the wheel, loosen the wing nut manufacturer for calibration by their repair and turn the wheel 180°...
Page 186 31-6 WHEEL AND TYRE TROUBLESHOOTING WHEEL BALANCER CALIBRATION CHECKING FLOW CHART Balance wheel. ZERO CALIBRATION CHECK Rotate wheel 1/2 turn. Imbalance = more than 5g (0.18oz) Imbalance = 5g (0.18oz) or less Rebalance wheel. Rotate wheel 1/4 turn. Imbalance = more than 5g (0.18oz) Imbalance = 5g (0.18oz) or less Verify wheel is properly centred.
Page 187: On-Vehicle Service
31-7 WHEEL AND TYRE ON-VEHICLE SERVICE ON-VEHICLE SERVICE TYRE INFLATION PRESSURE CHECK WHEEL RUNOUT CHECK M1311000900312 M1311001100353 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 M1311001000334 Measure the tread depth of the tyres.
Page 188 NOTES...
Page 189 27-1 GROUP 27 REAR AXLE CONTENTS GENERAL INFORMATION ..27-2 ON-VEHICLE SERVICE ... 27-4 WHEEL BEARING AXIAL PLAY CHECK . . 27-4 SERVICE SPECIFICATIONS..27-2 REAR HUB ROTARY-SLIDING RESISTANCE CHECK .
Page 190: General Information
27-2 REAR AXLE GENERAL INFORMATION GENERAL INFORMATION M1271000100304 • ABS rotor for detecting the wheel speeds is The rear axle has the following features: • The wheel bearing is a unit ball bearing press-fitted to the rear hub in vehicles with ABS. (double-row angular contact ball bearing) which incorporates the oil seals and is highly resistant to a thrust load.
Page 191: Special Tools
27-3 REAR AXLE SPECIAL TOOLS SPECIAL TOOLS M1271000600495 Tool Number Name MB990767 End yoke holder Hub fixing B990767 MB991618 Hub bolt remover Hub bolt removal MB991618 MD998801 Remover Removal of ABS rotor MD998812 Installer cap MD998813 Installer 100 MD998815 Installer adapter...
Page 192: On-Vehicle Service
27-4 REAR AXLE ON-VEHICLE SERVICE ON-VEHICLE SERVICE WHEEL BEARING AXIAL PLAY CHECK 3. Wind a rope around the hub bolt and turn the hub by pulling at a 90° angle with a spring balance. M1271000900452 1. Remove the caliper assembly, and suspend the Measure to determine whether or not the caliper assembly with a wire and remove the rotary-sliding resistance of the rear hub is at the...
Page 193: Rear Axle Hub Assembly
27-5 REAR AXLE REAR AXLE HUB ASSEMBLY REAR AXLE HUB ASSEMBLY REMOVAL AND INSTALLATION M1271002000381 CAUTION • Care must be taken not to scratch or damage the teeth of the ABS rotor. The ABS rotor must never be dropped. If the teeth of the ABS rotor are chipped, resulting in a deformation of the ABS rotor, it will not be able to accurately detect the wheel rotation speed, and the system will not function normally.
Page 194: Inspection
27-6 REAR AXLE REAR AXLE HUB ASSEMBLY REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS <<A>> CALIPER ASSEMBLY REMOVAL >>A<< ABS ROTOR INSTALLATION Secure the removed caliper assembly with wire, etc. CAUTION When installing, take care not to deform the ABS <> SELF-LOCKING NUT REMOVAL rotor.
Page 195 26-1 GROUP 26 FRONT AXLE CONTENTS GENERAL INFORMATION ..26-2 FRONT AXLE HUB ASSEMBLY ..26-8 REMOVAL AND INSTALLATION ..26-8 SERVICE SPECIFICATIONS..26-3 INSPECTION.
Page 196: General Information
26-2 FRONT AXLE GENERAL INFORMATION GENERAL INFORMATION M1261000100347 • The dynamic damper has been mounted on the The front axle consists of front hubs, knuckles, wheel bearings and driveshafts, and has the following driveshaft to reduce differential gear noise. • ABS rotor for detecting the wheel speed is features: •...
Page 197: Service Specifications
26-3 FRONT AXLE SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS M1261000300396 Item Standard value Limit Wheel bearing axial play mm − 0.05 Hub starting torque N⋅m − 22 ± 1.5 Protruding length of stabilizer bar mounting bolt mm − 85 ± 3 Setting of TJ boot length mm 1.3L-RH, 1.6L-A/T-RH −...
Page 198: Special Tools
26-4 FRONT AXLE SPECIAL TOOLS SPECIAL TOOLS M1261000600375 Tool Number Name MB990767 End yoke holder Fixing of the hub B990767 MB991618 Hub bolt remover Removal of the hub bolt MB991618 MB991897 Ball joint remover Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113)is also used...
Page 199 26-5 FRONT AXLE SPECIAL TOOLS Tool Number Name MB990685 Torque wrench Measurement of hub starting torque MB990326 Preload socket MB990326 • Removal of the centre bearing MB990810 Side bearing puller bracket • Removal of the wheel bearing inner race (outside) MB990810 MB991460 Plug...
Page 200 26-6 FRONT AXLE SPECIAL TOOLS Tool Type Tool number O D mm MB990926 39.0 MB990925 MB990927 45.0 MB990928 49.5 MB990929 51.0 MB990930 54.0 MB990931 57.0 Installer adapter MB990932 61.0 MB990933 63.5 Brass bar MB990934 67.5 MB990935 71.5 MB990936 75.5 Bar (snap-in type) MB990937 79.0 MB990938...
Page 201: On-Vehicle Service
26-7 FRONT AXLE ON-VEHICLE SERVICE ON-VEHICLE SERVICE WHEEL BEARING AXIAL PLAY CHECK MB991618 M1261000900224 1. Remove the caliper assembly and suspend it with a wire. 2. Remove the brake disc from the front hub. Hub bolt AC302114 3. Use special tool hub bolt remover (MB991618) to remove the hub bolts.
Page 202: Front Axle Hub Assembly
26-8 FRONT AXLE FRONT AXLE HUB ASSEMBLY FRONT AXLE HUB ASSEMBLY REMOVAL AND INSTALLATION M1261001700353 CAUTION • Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be damaged. •...
Page 203 26-9 FRONT AXLE FRONT AXLE HUB ASSEMBLY REMOVAL SERVICE POINTS <<D>> SELF-LOCKING NUT (TIE ROD END CONNECTION) REMOVAL <<A>> CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, etc. CAUTION • Do not remove the nut from ball joint. Loosen <>...
Page 204 26-10 FRONT AXLE FRONT AXLE HUB ASSEMBLY <<E>> DRIVE SHAFT REMOVAL INSTALLATION SERVICE POINT >>A<< STABILIZER <Comfort> RUBBER/SELF-LOCKING NUT (STABILIZER BAR CONNECTION) INSTALLATION MB990767 MB990241 AC100128 <Sport> MB990244 (Three) AC210393 AC MB990767 Install the stabilizer rubber and collar as shown in the figure, and tighten the self-locking nut so that the protruding length of the stabilizer bar mounting bolt MB991354...
Page 205: Inspection
26-11 FRONT AXLE FRONT AXLE HUB ASSEMBLY NOTE: If the meshing of the wheel bearing outer INSPECTION race and the knuckle, or of the wheel bearing M1261001800242 • Check the hub for cracks and spline for wear. inner race and the hub, is loose, replace the •...
Page 206 26-12 FRONT AXLE FRONT AXLE HUB ASSEMBLY DISASSEMBLY SERVICE POINTS 1. Crush the oil seal in two places so that the tabs of the special tool will be caught on the wheel <<A>> HUB REMOVAL bearing inner race (outside). CAUTION When the hub has been removed, always replace CAUTION the wheel bearing with a new part because wheel...
Page 207: Inspection
26-13 FRONT AXLE FRONT AXLE HUB ASSEMBLY REASSEMBLY SERVICE POINTS MB990685 >>A<< WHEEL BEARING INSTALLATION 1. Fill the wheel bearing with multipurpose grease. 2. Apply a thin coating of multipurpose grease to the knuckle and bearing contact surfaces. CAUTION Press the outer race when pressing-in the wheel MB990326 bearing.
Page 208: Drive Shaft Assembly
26-14 FRONT AXLE DRIVE SHAFT ASSEMBLY DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION M1261003500399 CAUTION • Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when removing or installing the drive shaft. Otherwise the ABS rotors will be damaged. •...
Page 209 26-15 FRONT AXLE DRIVE SHAFT ASSEMBLY REMOVAL SERVICE POINTS 2. Turn the bolt and knob as necessary to make the jaws of special tool parallel, tighten the bolt by <<A>> DRIVE SHAFT NUT REMOVAL hand and confirm that the jaws are still parallel. CAUTION NOTE: When adjusting the jaws in parallel, make Do not apply pressure to the wheel bearing by...
Page 210 26-16 FRONT AXLE DRIVE SHAFT ASSEMBLY 4. Use special tool plug (MB991460) to prevent the CAUTION entry of foreign material into the transmission • Do not pull on the drive shaft; doing so will case. damage the TJ; be sure to use the pry bar. •...
Page 211 26-17 FRONT AXLE DRIVE SHAFT ASSEMBLY INSTALLATION SERVICE POINTS >>C<< WASHER/DRIVE SHAFT NUT INSTALLATION >>A<< DRIVE SHAFT INSTALLATION CAUTION When installing the drive shaft, be careful that Washer the spline part of the drive shaft does not damage the oil seal. >>B<<...
Page 212: Disassembly And Reassembly
26-18 FRONT AXLE DRIVE SHAFT ASSEMBLY DISASSEMBLY AND REASSEMBLY M1261003700456 CAUTION • Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly and reassembly. • Never disassemble the BJ assembly except when replacing the BJ boot. 8 11 Grease for TJ Grease for BJ...
Page 213 26-19 FRONT AXLE DRIVE SHAFT ASSEMBLY LUBRICATION POINTS Grease: repair kit grease Amount used: <1.3L-LH, 1.6L-LH, 2.0L-LH>: 120 ± 10 g <1.3L-RH, 1.6L-A/T-RH>: 110 ± 10 g <1.6L-M/T-RH>: 120 ± 10 g <2.0L-RH>: 105 ± 10 g CAUTION The drive shaft joint uses special grease.
Page 214 26-20 FRONT AXLE DRIVE SHAFT ASSEMBLY REASSEMBLY SERVICE POINTS >>C<< TJ CASE INSTALLATION >>A<< DYNAMIC DAMPER/DAMPER CAUTION BAND/TJ BOOT INSTALLATION The drive shaft joint use special grease. Do not mix old and new or different types of grease. CAUTION There should be no grease adhered to the rubber part of the dynamic damper.
Page 215: Inspection
26-21 FRONT AXLE DRIVE SHAFT ASSEMBLY INSPECTION 4. Align the centre groove on the BJ boot small end with the shaft groove. M1261003800130 • Check the drive shaft for damage, bending or corrosion. MB991561 • Check the drive shaft spline part for wear or Stopper damage.
Page 216 26-22 FRONT AXLE DRIVE SHAFT ASSEMBLY CAUTION CAUTION • Secure the drive shaft in an upright position The drive shaft joint uses special grease. Do not and clamp part of the boot band to be crimped mix old and new or different types of grease. securely in the jaws of special tool.
Page 217 26-23 FRONT AXLE DRIVE SHAFT ASSEMBLY Standard value (F): 2.4 − 2.8 mm 16.Check that the boot band is not sticking out past <If the crimping amount is larger than 2.8 mm > the place where it has been installed. If the boot Readjust the value of (W) in step 12 band is sticking out, remove it and then repeat according to the following formula, and then...
Page 218 NOTES...
Page 219 42-1 GROUP 42 BODY CONTENTS HOOD..... WINDOW GLASS... 42-3 42-9 ON-VEHICLE SERVICE.
Page 220 42-2 TROUBLESHOOTING ..TRUNK LID ....42-26 42-43 REMOVAL AND INSTALLATION..42-43 INSPECTION .
Page 221: Hood
42-3 BODY HOOD HOOD ON-VEHICLE SERVICE ADJUSTMENT OF HOOD HEIGHT M1421007400123 ADJUSTMENT OF CLEARANCE AROUND HOOD M1421007200129 Y0215AU Section A – A Hood AC005945 ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD 17 mm STRIKER M1421007300126 Hood bumper X0424CA AC005948AB Rotate the hood bumper by using arrow mark on the hood bumper as a guide to adjust the hood height.
Page 222: Removal And Installation
42-4 BODY HOOD HOOD REMOVAL AND INSTALLATION M1421001600561 Post-installation Operation • Adjustment of Clearance Around Hood (Refer to P.42-3). • Adjustment of Alignment of Hood Stepped Portion and Hood Striker (Refer to P.42-3). • Adjustment of Hood Height (Refer to P.42-3). 21 ±...
Page 223: Fender
42-5 BODY FENDER Clip positions Section A – A Clip Note : Clip positions AC300865 FENDER SPECIAL TOOL M1421000600256 Tool Number Name MB990784 Ornament remover Side turn-signal lamp removal MB990784...
Page 224: Fender
42-6 BODY FENDER FENDER REMOVAL AND INSTALLATION M1421001900302 Pre-removal and Post-installation Operation • Front Bumper Removal and Installation (Refer to GROUP 51, Front Bumper P.51-2.) • Front Deck Garnish Removal and Installation (Refer to GROUP 51, Windshield Wiper and Washer P.51-23.) •...
Page 225 42-7 BODY FENDER REMOVAL SERVICE POINT INSTALLATION SERVICE POINT <<A>> SIDE TURN-SIGNAL LAMP >>A<< SIDE TURN-SIGNAL LAMP REMOVAL INSTALLATION Front of vehicle Hook Side turn-signal light Claw Fender panel Fender panel MB990784 : Front of vehicle AC005719 AC005980 AC005980 Engage the claw with the fender panel, and install Use special tool ornament remover (MB990784) to the side turn-signal lamp.
Page 226: Fuel Filler Lid
42-8 BODY FUEL FILLER LID FUEL FILLER LID REMOVAL AND INSTALLATION M1421002500277 Pre-removal and Post-installation Operation • Rear Seat Removal and Installation (Refer to GROUP 52A, Rear Seat P.52A-28.) • 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-11.) W0570AQ...
Page 227: Strut Tower Bar
42-9 BODY STRUT TOWER BAR STRUT TOWER BAR REMOVAL AND INSTALLATION M1421005600091 44 ± 5 N·m Strut tower bar AC304680AB WINDOW GLASS ADHESIVE M1422000500081 Item Specified adhesive Windshield 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or equivalent Rear window glass 3M ATD Part No.8608 Super Fast Urethane Primer or Quarter window glass...
Page 228: Window Repair
42-10 BODY WINDOW GLASS WINDOW REPAIR M1422005600027 The windshield, rear window glass, quarter window glass and tailgate 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.
Page 229 42-11 BODY WINDOW GLASS WINDOW GLASS INSTALLATION Window glass installation procedure Body side Window glass side Reusing the glass Replace the glass Cleaning of adhesion surface Cleaning of adhesion surface Cleaning of adhesion surface Cut off the residual adhesive until the Completely cut off all of the residual Clean off any dirt adhering to the adhesion thickness is less than 2 mm.
Page 230: Windshield
42-12 BODY WINDOW GLASS WINDSHIELD REMOVAL AND INSTALLATION M1422001000313 Pre-removal and Post-installation Operation • Front Deck Garnish Removal and Installation (Refer to GROUP 51,Windshield Wiper and Washer P.51-23.) • Inside Rear View Mirror Removal and Installation (Refer to GROUP 52A, Inside Rear View Mirror P.52A-23.) •...
Page 231 42-13 BODY WINDOW GLASS Removal steps (Continued) Removal steps >>A<< 3. Window dam Roof drip moulding (Refer to GROUP • >>A<< 4. Glass stopper 51, Moulding P.51-10.) >>A<< 5. Spacer <<A>> >>B<< 1. Windshield >>A<< 6. Windshield spacer >>A<< 2. Windshield moulding REMOVAL SERVICE POINT Glass adhesive knife <<A>>...
Page 232 42-14 BODY WINDOW GLASS Be careful not to remove more adhesive than is 8. When reusing the windshield, remove the necessary. adhesive still adhering to the windshield, and • Be careful also not to damage the paintwork clean with isopropyl alcohol. on the body surface with the knife.
Page 233 42-15 BODY WINDOW GLASS 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.
Page 234: Rear Window Glass
42-16 BODY WINDOW GLASS REAR WINDOW GLASS REMOVAL AND INSTALLATION M1422001600111 Pre-removal and Post-installation Operation • High-mounted Stop Lamp Assembly Removal and Installation <Rear Shelf Mounted Type> (Refer to GROUP 54A, High-Mounted Stop Lamp P.54A-81.) • Rear Pillar Trim and Rear Shelf Trim Removal and Installation (Refer to GROUP 52A, Trims P.52A-11.) •...
Page 235 42-17 BODY WINDOW GLASS Removal steps (Continued) >>A<< 9. Window dam >>A<< 10. Glass stopper REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS <<A>> REAR WINDOW LOWER >>A<< GLASS STOPPER/WINDOW MOULDING REMOVAL DAM/REAR WINDOW UPPER MOULDING/REAR WINDOW GLASS CAUTION INSTALLATION If the drip moulding has become warped, it should not be reused.
Page 236 42-18 BODY WINDOW GLASS Glass stopper and window dam installation position Align the window dam end with Glass end line the ceramic notch. Glass stopper 18 mm Align the glass Mark stopper end with the ceramic notch. Seal line 19 mm Ceramic line Rear window glass...
Page 237: Quarter Window Glass
42-19 BODY WINDOW GLASS QUARTER WINDOW GLASS REMOVAL AND INSTALLATION M1422002500247 Pre-removal and Post-installation Operation • Quarter Trim Upper Removal and Installation (Refer to GROUP 52A, Trims P.52A-11). AC304783 Units: mm Section A – A Section B – B Primer Mark Y1507AU Seal line...
Page 238 42-20 BODY WINDOW GLASS REMOVAL SERVICE POINT MB990480 <<A>> QUARTER WINDOW GLASS REMOVAL AC103605 AD 4. Make mating marks on the quarter window glass and body. 5. Use special tool glass holder (MB990480) to Cloth tape AC103600AD remove the quarter window glass. 1.
Page 239 42-21 BODY WINDOW GLASS INSTALLATION SERVICE POINTS CAUTION Leave the degreased parts for 3 or more minutes >>A<< GASKET/CLIP/DUAL LOCK to dry well, before starting on the next step. Do FASTENER INSTALLATION not touch the degreased parts. 1. Carry out the following procedure to re-install 2.
Page 240: Tailgate Window Glass
42-22 BODY WINDOW GLASS TAILGATE WINDOW GLASS REMOVAL AND INSTALLATION M1422003700170 Pre-removal and Post-installation Operation • Tailgate Trim Removal and Installation (Refer to GROUP 52A, Tailgate Trim P.52A-19). • Tailgate Spoiler Assembly Removal and Installation (Refer to GROUP 51, Tailgate Spoiler P.51-19). •...
Page 241 42-23 BODY WINDOW GLASS Removal steps (Continued) Removal steps >>A<< 5. Dual lock fastener 1. Connecting the harness connector >>A<< 6. Glass stopper <<A>> >>B<< 2. Tailgate window glass >>A<< 7. Window spacer >>A<< 3. Window lower dam >>A<< 4. Window side dam REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS <<A>>...
Page 242 42-24 BODY WINDOW GLASS Window spacer, glass stopper and window dam installation position Seal line 14.5 mm Glass end line Align the glass spacer and with the tailgate window glass mark. AC107207 Position the window side dam Glass spacer 2 mm inside from the tailgate window glass end.
Page 243: Door
42-25 BODY DOOR DOOR SERVICE SPECIFICATIONS M1423000300091 Item Standard value Power window operation current (Power supply voltage 14.5 ± 0.5 V, at 25 °C) A 5 ± 1 2.6 ± 2.5 Door outside handle play mm Front door 1.3 ± 1.3 Rear door 10.4 ±...
Page 244: Troubleshooting
42-26 BODY DOOR Tool Number Name MB991223 Harness set Terminal voltage measurement A: MB991219 A: Test harness A: For checking connector pin contact B: MB991220 B: LED harness pressure C: MB991221 C: LED harness adapter B: For checking power supply circuit D: MB991222 D: Probe C: For checking power supply circuit...
Page 245: On-Vehicle Service
42-27 BODY DOOR ON-VEHICLE SERVICE 3. When the door is stiff to lock and unlock DOOR FIT ADJUSTMENT M1423001100175 CAUTION • Attach protection tape to the fender and door edges where the hinge is installed. • Do not rotate special tool door adjusting MB990939 wrench (MB991164) with a torque of over 98 Temporary...
Page 246: Door Window Glass Adjustment
42-28 BODY DOOR DOOR WINDOW GLASS ADJUSTMENT Door M1423001000327 Runchannel sash 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.
Page 247: Power Window Relay Check
42-29 BODY DOOR 3. If the operation current is outside the standard 2. Release the power window switch from the UP value, refer to GROUP 54B, Troubleshooting position and immediately press it to the DOWN position. The condition of the circuit breaker is P.54B-17, refer to GROUP 54C, Troubleshooting good if the door window glass starts to move P.54C-4.
Page 248: Door Inside Handle Play Adjustment
42-30 BODY DOOR DOOR INSIDE HANDLE PLAY 2. If the door inside handle play is outside the standard value range. ADJUSTMENT 3. Remove the door trim assembly (Refer to GROUP M1423001500292 52A, Door trim P.52A-15). Section A – A 4. Remove the waterproof film (Refer to P.42-39). Inner cable Clip Outer cable end...
Page 249: Door Assembly
42-31 BODY DOOR DOOR ASSEMBLY REMOVAL AND INSTALLATION M1423002200283 Post-installation Operation • Door Fit Adjustment (Refer to P.42-27.) <FRONT DOOR> 27 ± 5 N·m 11 ± 2 N·m 21 ± 4 N·m 9 10 1.5 ± 0.5 N·m 11 ± 2 N·m Y0652AU 27 ±...
Page 250: Inspection
42-32 BODY DOOR INSTALLATION SERVICE POINT INSPECTION M1423006000322 >>A<< STRIKER INSTALLATION DOOR SWITCH CHECK Latch centre Striker centre +1.5 mm -1.5 mm Striker Latch AC305098AB AC211414 Align the centre of the striker and latch within ±1.5 Switch Tester Specified mm, and install. position connection condition...
Page 251 42-33 BODY DOOR <FRONT DOOR> View A Section B - B Section C - C Door trim Door trim NOTE Claw Clip : Clip positions : Claw positions AC305108 <REAR DOOR> View D Section E - E Section F - F Door trim Door trim Clip...
Page 252: Inspection
42-34 BODY DOOR REMOVAL SERVICE POINTS >>B<< WINDOW REGULATOR ASSEMBLY/POWER WINDOW <<A>> WINDOW REGULATOR REGULATOR MOTOR ASSEMBLY ASSEMBLY/POWER WINDOW INSTALLATION REGULATOR MOTOR ASSEMBLY REMOVAL <FRONT DOOR> 1. Remove the door window glass installation bolts. 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.
Page 253 42-35 BODY DOOR How to make the power window switch CAUTION learn the fully closed position when the The anti-trap function does not work until the power window switch completes learning the power window switch is replaced with a fully closed position (It is because the anti-trap new one function is reset).
Page 254: Door Handle And Latch
42-36 BODY DOOR DOOR HANDLE AND LATCH REMOVAL AND INSTALLATION M1423004600328 Pre-removal Operation Post-installation Operation • Door Trim Removal (Refer to GROUP 52A, Door trim • Door Inside Handle Play Check (Refer to P.42-30.) P.52A-15.) • Door Outside Handle Play Check (Refer to P.42-29.) •...
Page 255: Inspection
42-37 BODY DOOR INSTALLATION SERVICE POINTS 2. Install the inside handle rod to the door inside handle. >>A<< DOOR CHECK INSTALLATION 3. Install the door inside handle to the door. INSPECTION M1423004700392 Identification mark FRONT DOOR LOCK ACTUATOR CHECK Front door <Left side> Unlock Lock ACX00541...
Page 256 42-38 BODY DOOR Actuator Switch Check <Driverís side> Actuator Operation Check Lever position Tester Specified Lever Battery connection Lever connection condition position operation 1 − 2 • Connect terminal At the "LOCK" Less than 2 At the The lever position ohms "LOCK"...
Page 257: Window Glass Runchannel And Door Opening Weatherstrip
42-39 BODY DOOR WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP REMOVAL AND INSTALLATION M1423003100290 <FRONT DOOR> : Sectional view of clip position : Sectional view of clip position Section A – A <Front door> Door Sealant: 3M ATD Part No.8633 or equivalent AC304409AB Door window glass runchannel Waterproof film removal steps...
Page 258 42-40 BODY DOOR <REAR DOOR> : Sectional view of clip position : Sectional view of clip position Section A – A Door <Rear door> Section B – B Door Sealant: 3M ATD Part No.8633 or equivalent AC304418AB Door window glass runchannel Waterproof film removal steps removal Door trim assembly (Refer to GROUP...
Page 259: Trunk Lid
42-41 BODY TRUNK LID REMOVAL SERVICE POINT Make a fabricated tool as shown in the illustration to remove the door weatherstrip. <<A>> DOOR OUTER OPENING WEATHERSTRIP REMOVAL INSTALLATION SERVICE POINT >>A<< DOOR OUTER OPENING Fabricated 15 mm WEATHERSTRIP INSTALLATION tool 4 mm The clip colour identifies the left and right weatherstrips so be sure to use the colours so as to...
Page 260: Adjustment Of Clearance Around Trunk Lid
42-42 BODY TRUNK LID After checking the trunk lid release cable for proper 3. If there is a difference in height between the side routing, loosen the trunk lid striker mounting bolts. outer panels and the side edges of the trunk lid Change the position of the trunk lid striker relative to panel assembly, check the trunk lid hinges and, if the trunk lid latch assembly so that trunk lid locking...
Page 261: Removal And Installation
42-43 BODY TRUNK LID TRUNK LID REMOVAL AND INSTALLATION M1421002200180 Section A - A 15 mm Y0637AU Section B - B 14 mm Y0636AU 8.9 ± 1.9 N·m AC301676 Trunk lid striker removal steps Trunk lid weatherstrip removal steps Rear end trim (Refer to GROUP 52A, •...
Page 262 42-44 BODY TRUNK LID Grease application area AC305143 AB REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS <<A>> TRUNK LID TORSION BAR >>A<< TRUNK LID TORSION BAR REMOVAL INSTALLATION Trunk lid torsion bar <RH> Trunk lid torsion bar <LH> Colour mark Trunk lid torsion bar <RH> MB991244 Trunk lid hinge <LH>...
Page 263: Inspection
42-45 BODY TRUNK LID >>B<< TRUNK LID WEATHERSTRIP CAUTION INSTALLATION 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 will interfere with the trunk lid torsion bar <RH>...
Page 264: Tailgate
42-46 BODY TAILGATE TAILGATE SERVICE SPECIFICATIONS M1421000300288 Item Standard value Tailgate handle play 2.3 to 5.9 mm SEALANTS M1424000500098 Item Specified sealant Tailgate waterproof film 3M ATD Part No.8633 or equivalent Tailgate hinge 3M ATD Part No.8531 Heavy drip check sealer, 3M ATD Part No.8646 Automotive joint and seam sealer or equivalent SPECIAL TOOL...
Page 265: Tailgate Handle Play Check
42-47 BODY TAILGATE NOTE: 4. If uneven clearance is present between tailgate and body, reposition the hinge to adjust the Grind here clearance. TAILGATE HANDLE PLAY CHECK M1424002400138 Section A – A Holder AC203660AB When the bolt head interferes with the rear end trim, rasp the interference area with a round file.
Page 266: Tailgate
42-48 BODY TAILGATE TAILGATE REMOVAL AND INSTALLATION M1424001100178 CAUTION • Do not disassemble or throw the tailgate gas spring into fire. • Punch a hole in the gas spring before disposal to release the gas inside. • Ensure the tailgate gas spring piston rod does not come into contact with foreign material. Pre-removal Operation Post-installation Operation •...
Page 267 42-49 BODY TAILGATE Adhesive: 3M ATD Part No.8531 Heavy drip check sealer, 3M ATD Part No.8646 Automotive joint and seam sealer or equivalent AC305322 Tailgate assembly removal steps Tailgate assembly removal steps • Rear end trim (Refer to GROUP 52A, 1.
Page 268: Tailgate Handle And Latch
42-50 BODY TAILGATE TAILGATE HANDLE AND LATCH REMOVAL AND INSTALLATION M1424001700170 Pre-removal Operation • Tailgate Handle Play Check (Refer to P.42-47). 5.0 ± 1.0 N·m Y1518AU 22 ± 4 N·m Y1520AU 9.0 ± 2.0 N·m AC305141 Tailgate latch removal steps Striker removal steps Lower tailgate trim (Refer to GROUP •...
Page 269: Inspection
42-51 BODY KEYLESS ENTRY SYSTEM INSTALLATION SERVICE POINT Lever Battery connection Lever >>A<< STRIKER INSTALLATION position operation • Connect terminal At the The lever "LOCK" No.2 and the moves from the Latch centre Striker centre position negative battery "LOCK" terminal. position to the +1.5 mm •...
Page 270: Special Tools
42-52 BODY KEYLESS ENTRY SYSTEM SPECIAL TOOLS M1428000600280 Tool Number Name MB991502 MUT-II sub-assembly Encrypted code registration B991502 MB991529 Diagnosis code check harness MB991529 MB991955 MUT-III sub-assembly Encrypted code registration A: MB991824 A: Vehicle CAUTION B: MB991827 communication MUT-III main harness B C: MB991910 interface (V.C.I.) (MB991911) should be used.
Page 271: Troubleshooting
42-53 BODY KEYLESS ENTRY SYSTEM TROUBLESHOOTING ENABLING/DISABLING THE M1428000700287 ANSWERBACK FUNCTION The keyless entry system is controlled by the Smart M1428003200214 Wiring System (SWS). For troubleshooting, refer to If the keyless entry system locks or unlocks the GROUP 54B, Troubleshooting P.54B-17 or GROUP doors, the room lamp flashes or illuminates, the...
Page 272 42-54 BODY KEYLESS ENTRY SYSTEM • Enable the hazard answerback function CAUTION when the doors are locked: The Before connecting or disconnecting the MUT-II, ETACS-ECU buzzer will sound once. turn the ignition switch to the "LOCK" (OFF) • Disable the hazard answerback function position.
Page 273: How To Register Secret Code
42-55 BODY KEYLESS ENTRY SYSTEM NOTE: If any operation is not done for at least three 2. If the transmitter ìLOCKî button is pushed minutes after the ETACS-ECU has entered the consecutively twice (within two seconds), the customize mode, the hazard answerback customize ETACS-ECU buzzer will sound, indicating that the mode will be canceled automatically.
Page 274 42-56 BODY KEYLESS ENTRY SYSTEM WHEN THE SPECIAL TOOL DIAGNOSIS 7. If you are using two or more transmitters or have added a second transmitter, the same registration CODE CHECK HARNESS (MB991529) IS procedure should be carried out within one minute USED after registering the code for the first transmitter.
Page 275 42-57 BODY KEYLESS ENTRY SYSTEM NOTE: Once the process is completed six times, CAUTION then it will operate with all doors and tailgate lock Before connecting or disconnecting the V. C. I., and unlock operations once and then go to the turn the ignition switch to the "LOCK"...
Page 276: Transmitter
42-58 BODY KEYLESS ENTRY SYSTEM • When one minute has passed after registration 7. If you are using two or more transmitters or have mode started; added a second transmitter, the same registration • When the V.C.I. is disconnected from the procedure should be carried out within one minute diagnosis connector;...
Page 277: Inspection
42-59 BODY KEYLESS ENTRY SYSTEM DISASSEMBLY SERVICE POINT Install a new battery to the transmitter assembly with its (+) side facing towards the upper cover side. <<A>> BATTERY REMOVAL Battery required for replacement: Coin type CAUTION battery CR1616 Do not allow water or dust to enter the inside of the transmitter assembly when it is open.
Page 278 NOTES...
Page 279 54A-1 GROUP 54A CHASSIS ELECTRICAL CONTENTS BATTERY....IMMOBILIZER SYSTEM 54A-4 TROUBLESHOOTING ..54A-9 DIAGNOSIS CODE CHART..54A-9 SERVICE SPECIFICATIONS.
Page 280 54A-2 COMBINATION METER FOG LAMP ....54A-71 ASSEMBLY ....54A-29 SERVICE SPECIFICATION .
Page 281 54A-3 REAR COMBINATION HORN ....54A-89 REMOVAL AND INSTALLATION..54A-89 LAMP ..... 54A-79 HORN RELAY CONTINUITY CHECK .
Page 282: Battery
CHASSIS ELECTRICAL 54A-4 BATTERY BATTERY SERVICE SPECIFICATIONS M1541000300209 Items Specification Specific gravity of the battery fluid 1.220 − 1.290 (20°C) Dt: Actually measured specific gravity ON-VEHICLE SERVICE t: Actually measured temperature FLUID LEVEL AND SPECIFIC GRAVITY CHARGING CHECK M1541001100509 M1541001000438 CAUTION CAUTION •...
Page 283: Battery Test
CHASSIS ELECTRICAL 54A-5 BATTERY BATTERY TEST STEP 4. Check the open circuit voltage. M1541001200506 (1) Turn headlamps on for 15 seconds. BATTERY TESTING PROCEDURE (2) Turn headlamps off for two minutes to allow battery positive voltage to stabilize. STEP 1. Check the battery cables. (3) Disconnect the battery cables.
Page 284: Ignition Switch
CHASSIS ELECTRICAL 54A-6 IGNITION SWITCH IGNITION SWITCH the engine are not satisfied, the engine will be GENERAL INFORMATION immobilized. If a registered ignition key is lost, all M1543009901274 IGNITION KEY REMINDER BUZZER your ignition keys need to be registered again using MUT-II/III to ensure security (Refer to P.54A-20).
Page 285 CHASSIS ELECTRICAL 54A-7 IGNITION SWITCH Encrypted code registration criteria table The ignition key contains a transponder (small transmitter), which retains an unique encrypted code. Under any of the conditions below, the encrypted code should be registered in the immobilizer-ECU again. The immobilizer-ECU can retain maximum eight different encrypted codes.
Page 286: Special Tools
CHASSIS ELECTRICAL 54A-8 IGNITION SWITCH SPECIAL TOOLS M1543000601641 Tool Number Name MB991502 MUT-II sub • Immobilizer system check assembly • Encrypted code registration B991502 MB991955 MUT-III • Immobilizer system check A: MB991824 sub-assembly • Encrypted code B: MB991827 A: (V. C. I.) Vehicle registration C: MB991910 communication...
Page 287: Troubleshooting
CHASSIS ELECTRICAL 54A-9 IGNITION SWITCH Tool Number Name MB991223 Harness set Making voltage and A: MB991219 A: Test harness resistance measurements B: MB991220 B: LED harness during troubleshooting C: MB991221 C: LED harness A: Connect pin contact D: MB991222 adapter pressure inspection D: Probe B: Power circuit inspection...
Page 288: Diagnostic Trouble Code Procedures
CHASSIS ELECTRICAL 54A-10 IGNITION SWITCH DIAGNOSTIC TROUBLE CODE PROCEDURES Code No.11: Transponder Communication System or Radio Interference of Encrypted Code Ignition Key Ring and Immobilizer-ECU Circuit IMMOBILIZER-ECU HIGH-FREQUENCY CIRCUIT IGNITION KEY IGNITION KEY RING ANTENNA NOTE: Diagnosis code No.11 is always set together with MPI system diagnosis code No.P0513.
Page 289: Symptom Chart
CHASSIS ELECTRICAL 54A-11 IGNITION SWITCH DIAGNOSIS PROCEDURE STEP 4. Connector check: Immobilizer-ECU connector C-202-1. STEP 1. Check for presence of other key near the Connector: C-202-1 key in the ignition. Q: Is there any other key near the key in the ignition? Move the other key well away from key YES : being used.
Page 290: Symptom Procedures
CHASSIS ELECTRICAL 54A-12 IGNITION SWITCH SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: Communication with MUT-II/III is Impossible. Immobilizer-ECU Power Source, Earth and Engine-ECU* 3 or Engine-A/T-ECU * 4 Communication Line Circuit ENGINE CONTROL RELAY ENGINE-ECU ENGINE- A/T-ECU IMMOBILIZER- POWER SOURCE NOTE LH drive vehicles RH drive vehicles Wire colour code B : Black...
Page 291 CHASSIS ELECTRICAL 54A-13 IGNITION SWITCH TROUBLESHOOTING HINTS Q: Is the check result normal? Go to Step 5. YES : • Malfunction of the immobilizer-ECU. Go to Step 3. NO : • Malfunction of the engine-ECU <M/T> or engine-A/T-ECU <A/T>. • The wiring harness or connectors may have STEP 3.
Page 292 CHASSIS ELECTRICAL 54A-14 IGNITION SWITCH STEP 4. Check the harness wires between Connector: C-134, C-137 immobilizer-ECU connector C-202-1 (terminal 1) and engine control relay connector B-16X (terminal 4). Connector: C-202-1 C-137 C-134 Harness side C-134 AC303806 Connector: B-16X C-137 AC303819 Harness side Connector: C-202 AC303796...
Page 293 CHASSIS ELECTRICAL 54A-15 IGNITION SWITCH STEP 5. Resistance measurement at STEP 7. Check the harness wire between immobilizer-ECU connector C-202-1. immobilizer-ECU connector C-202-1 (terminal 4) and earth. Connector: C-202-1 Connector: C-202-1 Harness side Harness side AC303806 AC303806 (1) Disconnect immobilizer-ECU connector C-202-1. NOTE: Connector: C-07 Connector 202-1...
Page 294 CHASSIS ELECTRICAL 54A-16 IGNITION SWITCH Q: Is the harness wire between immobilizer-ECU Q: Are immobilizer-ECU connector C-202-1 and connector C-202-1 (terminal 4) and earth in good engine-ECU connector C-127 <M/T> or condition? engine-A/T-ECU connector C-128 <A/T> in good There is no action to be taken. YES : condition? Go to Step 9.
Page 295 CHASSIS ELECTRICAL 54A-17 IGNITION SWITCH NOTE: Q: Are the harness wires between immobilizer-ECU connector C-202-1 (terminal 3) and engine-ECU Connector: C-13 connector C-127 (terminal 51) <M/T> or <L.H. drive vehicles> engine-A/T-ECU connector C-128 (terminal 111) <A/T> in good condition? Go to Step 10. YES : Repair or replace the damaged NO :...
Page 296 CHASSIS ELECTRICAL 54A-18 IGNITION SWITCH INSPECTION PROCEDURE 2: The Ignition Key cannot be Registered. TECHNICAL DESCRIPTION (COMMENT) STEP 2. Retest the system. The ignition key transponder or the immobilizer-ECU Q: Does registered ignition key function properly? is suspected to be defective. The procedure is complete.
Page 297: Data List Reference Table
CHASSIS ELECTRICAL 54A-19 IGNITION SWITCH STEP 4. Retest the system Q: Is the malfunction eliminated? The procedure is complete. If no YES : malfunction are not found in all steps, an intermittent malfunction is suspected (Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points-How to Cope with Intermittent Malfunction P.00-5).
Page 298: On-Vehicle Service
CHASSIS ELECTRICAL 54A-20 IGNITION SWITCH Registration with the MUT-II ON-VEHICLE SERVICE CAUTION HOW TO REGISTER ENCRYPTED CODE To prevent damage to MUT-II, always turn the M1543008100410 ignition switch to "LOCK" (OFF) position before CAUTION connecting or disconnecting MUT-II. Because registering the encrypted codes is done NOTE: after all previously-registered codes have been Using the key ID register function will cause all...
Page 299 CHASSIS ELECTRICAL 54A-21 IGNITION SWITCH ACX01626 AC000523AC 7. Input the password. Use the "UP" and "DOWN" 4. Select "Immobilizer," press "YES". keys to change the current password digit to a value between 0 and 9. Use the "LEFT" and "RIGHT" keys to move to a different password digit.
Page 300 CHASSIS ELECTRICAL 54A-22 IGNITION SWITCH <Using the MUT-II> Steering shaft MB991502 ACX01563 AC304777 10.The number of keys currently registered will be 1. Connect MUT-II (MB991502) to the 16-pin displayed. To register an additional key, replace diagnosis connector. the ignition key with the next key to be registered 2.
Page 301 CHASSIS ELECTRICAL 54A-23 IGNITION SWITCH 9. The number of keys currently registered will be displayed. To register an additional key, replace the ignition key with the next key to be registered within five seconds and then press the "YES" key. Key ID registration screen will be displayed, then register another key.
Page 302 CHASSIS ELECTRICAL 54A-24 IGNITION SWITCH <Using the MUT-III> IMMOBILIZER POWERTRAIN IMMOBILIZER Check Chart For Simulated Vehicle Self-diagnosis Problem Sy Speed Out Special Data List Resistor Function Voltmeter 16-PIN AC305176 MB991911 5. Choose "Special Function" from "IMMOBILIZER" screen. MB991824 Special Function POWERTRAIN IMMOBILIZER Special Function...
Page 303 CHASSIS ELECTRICAL 54A-25 IGNITION SWITCH 8. If the key ID was registered successfully, <Using the MUT-III> "Progress" indication will turn active (gray). Then the registration process completes. If the key ID failed to be registered, "In-Complete" indication will turn active (gray). 9.
Page 304 CHASSIS ELECTRICAL 54A-26 IGNITION SWITCH Registration of additional key(s) without 5. Enter the vehicles password (secret code) on the "Transponder ID addition" screen, and then click using the MUT-III the check mark icon. If the MUT-III is not available, new key(s) can be registered by operating two keys which have been AC207301 Special Function...
Page 305: Ignition Switch
CHASSIS ELECTRICAL 54A-27 IGNITION SWITCH IGNITION SWITCH REMOVAL AND INSTALLATION M1543002100434 WARNING Before removal of the air bag module, refer to GROUP 52B, SRS Service Precautions and • Air Bag Module and Clock Spring P.52B-5. When removing and installing the steering wheel, do not let it bump against the air bag •...
Page 306 CHASSIS ELECTRICAL 54A-28 IGNITION SWITCH REMOVAL SERVICE POINT Switch Tester Specified <<A>> STEERING LOCK CYLINDER position connection condition REMOVAL "LOCK" (OFF) 1 − 2, 1 − 3, Open circuit 1 − 4, 1− 5, 1 − 6, 2 − 3, Locking pin 2 −...
Page 307: Service Specifications
CHASSIS ELECTRICAL 54A-29 COMBINATION METER ASSEMBLY COMBINATION METER ASSEMBLY SERVICE SPECIFICATIONS M1543000300324 Item Standard value Speedometer indication error km/h (mph) 20 (12) 20 − 24 (12 − 15) 40 (25) 40 − 44 (25 − 28) 80 (50) 80 − 85 (50 − 53) 120 (75) 121 −...
Page 308 CHASSIS ELECTRICAL 54A-30 COMBINATION METER ASSEMBLY Tool Number Name MB991955 MUT-III sub-assembly Reading MPI system A: MB991824 A: (V. C. I.) Vehicle diagnosis code B: MB991827 communication C: MB991910 interface D: MB991911 B: MUT-III USB cable E: MB991825 C: MUT-III Main MB991824 F: MB991826 harness A (Vehicles...
Page 309: Troubleshooting
CHASSIS ELECTRICAL 54A-31 COMBINATION METER ASSEMBLY Tool Number Name MB991223 Harness set Making voltage and A: MB991219 A: Test harness resistance measurements B: MB991220 B: LED harness during troubleshooting C: MB991221 C: LED harness A: Connect pin contact D: MB991222 adapter pressure inspection D: Probe...
Page 310: Symptom Procedures
CHASSIS ELECTRICAL 54A-32 COMBINATION METER ASSEMBLY SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: Speedometer does not work (the other meters work). <M/T> Speedometer Circuit IGNITION SWITCH (IG1) COMBINATION METER CONTROL CIRCUIT DIAGNOSIS CONNECTOR FRONT SIDE ENGINE-ECU VEHICLE SPEED SENSOR NOTE LH drive vehicles RH drive vehicles Wire colour code B : Black...
Page 311 CHASSIS ELECTRICAL 54A-33 COMBINATION METER ASSEMBLY TECHNICAL DESCRIPTION (COMMENT) (2) Use the MUT-II/III to enter simulated vehicle speed. The engine-ECU and its associated components, the combination meter assembly, the wiring harness, or Q: Does the speedometer show that simulated vehicle the connector(s) may be defective.
Page 312 CHASSIS ELECTRICAL 54A-34 COMBINATION METER ASSEMBLY STEP 3. Connector check: Combination meter STEP 4. Check the wiring harness between connector C-04 and diagnosis connector C-11. combination meter connector C-04 (terminal 12) and diagnosis connector C-11 (terminal 14). Connector: C-04 NOTE: <L.H.
Page 313 CHASSIS ELECTRICAL 54A-35 COMBINATION METER ASSEMBLY STEP 5. Retest the system Connector: C-127 Q: Is the speedometer normal? The procedure is complete. (If no YES : . malfunctions are found in all steps, an intermittent malfunction is suspected. Refer C-127 (Y) to GROUP 00, How to Use Harness side Troubleshooting/Inspection Service...
Page 314 CHASSIS ELECTRICAL 54A-36 COMBINATION METER ASSEMBLY Q: Is the wiring harness between combination meter Connector: C-04 connector C-04 (terminal 11) and engine-ECU <R.H. drive vehicles> connector C-127 <RH drive vehicles> (terminal 58) in good condition? Go to Step 9. YES : Repair the wiring harness.
Page 315 CHASSIS ELECTRICAL 54A-37 COMBINATION METER ASSEMBLY INSPECTION PROCEDURE 2: Speedometer does not work (the other meters work). <A/T> Speedometer Circuit IGNITION SWITCH (IG1) CONTROL COMBINATION METER RELAY OUTPUT SHAFT CONTROL CIRCUIT SPEED SENSOR ENGINE- A/T-ECU DIAGNOSIS CONNECOTR FRONT SIDE NOTE LH drive vehicles RH drive vehicles ENGINE-...
Page 316 CHASSIS ELECTRICAL 54A-38 COMBINATION METER ASSEMBLY TECHNICAL DESCRIPTION (COMMENT) (2) Use the MUT-II/III to enter simulated vehicle speed. The engine-ECU and its associated components, the combination meter assembly, the wiring harness, or Q: Does the speedometer show that simulated vehicle the connector(s) may be defective.
Page 317 CHASSIS ELECTRICAL 54A-39 COMBINATION METER ASSEMBLY STEP 3. Connector check: Combination meter STEP 4. Check the wiring harness between connector C-04 and diagnosis connector C-11 combination meter connector C-04 (terminal 12) and diagnosis connector C-11 (terminal 14). Connector: C-04 NOTE: <L.H.
Page 318 CHASSIS ELECTRICAL 54A-40 COMBINATION METER ASSEMBLY STEP 5. Retest the system. Connector: C-04 <L.H. drive vehicles> Q: Is the speedometer normal? The procedure is complete. (If no YES : malfunctions are found in all steps, an intermittent malfunction is suspected. Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points-How to Cope with Intermittent...
Page 319 CHASSIS ELECTRICAL 54A-41 COMBINATION METER ASSEMBLY Go to Step 8. YES : Connector: C-04 Repair or replace the damage NO : <R.H. drive vehicles> component(s). Harness side AC303814 Connector: C-124, C-126 <R.H. drive vehicles> C-126 (GR) C-124 (GR) Harness side C-124 57 56 55 54 53 52 51 50 49 48 47 C-126...
Page 320 CHASSIS ELECTRICAL 54A-42 COMBINATION METER ASSEMBLY STEP 8. Check the wiring harness between Connector: C-124, C-126 <R.H. drive vehicles> combination meter connector C-04 (terminal 11, 12) and engine-A/T-ECU connector C-124 <LH drive vehicles>, C-126 <RH drive vehicles> (terminal 43, 80). Connector: C-03, C-04 C-04 C-126 (GR)
Page 321 CHASSIS ELECTRICAL 54A-43 COMBINATION METER ASSEMBLY NOTE: Q: Is the wiring harness between combination meter connector C-04 (terminal 11, 12) and Connector: C-12 engine-A/T-ECU connector C-124 (terminal 43, 80) <L.H. drive vehicles> in good condition? Go to Step 9. YES : Harness side Repair the wiring harness.
Page 322 CHASSIS ELECTRICAL 54A-44 COMBINATION METER ASSEMBLY INSPECTION PROCEDURE 3: Tachometer does not work (the other meters work). Tachometer Circuit COMBINATION METER CONTROL CIRCUIT NOTE LH drive vehicles RH drive vehicles ENGINE-ECU ENGINE-A/T-ECU Wire colour code B : Black LG : Light green G : Green L : Blue W : White...
Page 323 CHASSIS ELECTRICAL 54A-45 COMBINATION METER ASSEMBLY DIAGNOSIS PROCEDURE Connector: C-04 <R.H. drive vehicles> STEP 1. Check whether the diagnosis code is reset. Q: Is the MPI-related diagnosis code set? Refer to Code No.P0500 <M/T> or 23 <A/T> is set : GROUP 13A −...
Page 324 CHASSIS ELECTRICAL 54A-46 COMBINATION METER ASSEMBLY STEP 4. Check the wiring harness between Connector: C-124 <A/T>, C-127 <M/T> <R.H. drive vehicles> combination meter connector C-04 (terminal 11) and engine-ECU connector C-127 (terminal 58) <M/T> or engine-A/T-ECU connector C-124 (terminal 43) <A/T>. Connector: C-04 C-127 (Y) <L.H.
Page 325 CHASSIS ELECTRICAL 54A-47 COMBINATION METER ASSEMBLY NOTE: Q: Is the wiring harness between combination meter connector C-04 (terminal 11) and engine-ECU Connector: C-12, C-14 <L.H. drive vehicles> connector C-127 (terminal 58) <M/T> or engine-A/T-ECU connector C-124 (terminal 43) <A/T> in good condition? Replace the combination meter assembly.
Page 326 CHASSIS ELECTRICAL 54A-48 COMBINATION METER ASSEMBLY INSPECTION PROCEDURE 4: Fuel gauge does not work (the other meters work). Fuel Gauge Circuit COMBINATION METER CONTROL CIRCUIT FUEL GAUGE UNIT NOTE LH drive vehicles RH drive vehicles LH drive vehicles SEDAN LH drive vehicles WAGON Wire colour code B : Black LG : Light green...
Page 327 CHASSIS ELECTRICAL 54A-49 COMBINATION METER ASSEMBLY DIAGNOSIS PROCEDURE Connector: D-13 <Wagon> STEP 1. Check the fuel gauge circuit. (1) Disconnect D-13 fuel gauge unit connector. D-13 (B) Harness side MB991219 Test lamp (12 V - 3.4 W) AC303917 Fuel gauge Earth Q: Is combination meter connector C-04, fuel gauge unit connector D-13 in good condition?
Page 328 CHASSIS ELECTRICAL 54A-50 COMBINATION METER ASSEMBLY Connector: D-18 Connector: D-13 <Sedan> <Sedan> D-13 (B) Harness side Harness side AC303871 AC303871 Connector: D-13 Connector: D-18 <Wagon> <Wagon> Harness side D-13 (B) Harness side AC303917 AC303917 Prior to the wiring harness inspection, check NOTE: intermediate connector C-22 <LH drive vehicles>, Connector C-22...
Page 329 CHASSIS ELECTRICAL 54A-51 COMBINATION METER ASSEMBLY INSPECTION PROCEDURE 5: Engine Coolant Temperature Gauge does not Work (the other meters work). Engine Coolant Temperature Gauge Circuit COMBINATION METER CONTROL CIRCUIT NOTE LH drive vehicles RH drive vehicles ENGINE COOLANT TEMPERATURE GAUGE UNIT Wire colour code B : Black LG : Light green...
Page 330 CHASSIS ELECTRICAL 54A-52 COMBINATION METER ASSEMBLY STEP 2. Connector check: Combination meter STEP 3. Check the wiring harness between connector C-06 and engine coolant temperature combination meter connector C-06 (terminal 50) gauge unit connector B-112 and engine coolant temperature gauge unit connector B-112 (terminal 1).
Page 331 CHASSIS ELECTRICAL 54A-53 COMBINATION METER ASSEMBLY NOTE: Q: Is the wiring harness between combination meter connector C-06 (terminal 50) and engine coolant Connector: C-13 temperature gauge unit connector B-112 (terminal <L.H. drive vehicles> 1) in good condition? Go to Step 4. YES : Repair or replace the damage NO :...
Page 332 CHASSIS ELECTRICAL 54A-54 COMBINATION METER ASSEMBLY INSPECTION PROCEDURE 6: Combination meter does not work. (the instruments do not work) Combination Meter Power Source Circuit IGNITION BATTERY SWITCH (IG1) RELAY COMBINATION NOTE METER LH drive vehicles RH drive vehicles CONTROL CIRCUIT Wire colour code B : Black LG : Light green...
Page 333 CHASSIS ELECTRICAL 54A-55 COMBINATION METER ASSEMBLY DIAGNOSIS PROCEDURE Q: IS the check result normal? Go to Step 4. YES : Go to Step 2. NO : STEP 1. Voltage measurement at combination meter connector C-04 in order to check the STEP 2.
Page 334 CHASSIS ELECTRICAL 54A-56 COMBINATION METER ASSEMBLY Connector: C-103 STEP 3. Check the wiring harness between <R.H. drive vehicles> combination meter connector C-04 (terminal 7) and battery. Connector: C-04 C-103 (GR) <L.H. drive vehicles> Harness side AC303818 AO Harness side Connector: C-115 <R.H.
Page 335 CHASSIS ELECTRICAL 54A-57 COMBINATION METER ASSEMBLY Q: Is the check result normal? STEP 4. Voltage measurement at combination Go to Step 7. YES : meter connector C-04 to check the battery circuit Go to Step 5. NO : of power supply system to the combination meter.
Page 336 CHASSIS ELECTRICAL 54A-58 COMBINATION METER ASSEMBLY STEP 6. Check the wiring harness between Connector: C-210, C-212 <R.H. drive vehicles> combination meter connector C-04 (terminal 9) and ignition switch (IG1). Front view Connector: C-03, C-04 C-210 C-04 <L.H. drive vehicles> Harness side C-03 C-03 (B) C-212...
Page 337 CHASSIS ELECTRICAL 54A-59 COMBINATION METER ASSEMBLY Q: Is the check result normal? STEP 7. Resistance measurement at combination Repair or replace the connector. YES : meter connector C-04 to check the earth circuit Go to Step 8. NO : to the combination meter. Connector: C-04 STEP 8.
Page 338: On-Vehicle Service
CHASSIS ELECTRICAL 54A-60 COMBINATION METER ASSEMBLY 2. To prevent the front wheel from moving from side STEP 9. Check the wiring harness between to side, attach tension bars to the tie-down hook, combination meter connector C-04 (terminal 1 and secure both ends to anchor plates. and 2) and earth.
Page 339: Fuel Tank Gauge Unit Check
CHASSIS ELECTRICAL 54A-61 COMBINATION METER ASSEMBLY NOTE: For tachometer check, use an external 1. Check that resistance value between the fuel high quality inductive tachometer. gauge terminal and earth terminal is at the standard value when the fuel tank gauge unit float 2.
Page 340 CHASSIS ELECTRICAL 54A-62 COMBINATION METER ASSEMBLY Circuit tester Thermometer 11 ± 1 N·m ACX00779 AI ACX00780AH 3. Put engine coolant temperature gauge unit into 4. After inspection, apply specified sealant at the hot water in specified temperature, and threads of engine coolant temperature gauge unit, ensure that basic resistance is within standard and tighten to the specified torque.
Page 341: Combination Meter Assembly 54A-63
CHASSIS ELECTRICAL 54A-63 COMBINATION METER ASSEMBLY COMBINATION METER ASSEMBLY REMOVAL AND INSTALLATION M1543021300028 AC304803 Removal steps 1. Vehicle speed sensor 2. Meter bezel 3. Instrument panel ornament 4. Combination meter assembly...
Page 342: Inspection
CHASSIS ELECTRICAL 54A-64 COMBINATION METER ASSEMBLY INSPECTION OUTPUT SHAFT SPEED SENSOR CHECK M1543019502407 <A/T> VEHICLE SPEED SENSOR CHECK <M/T> Refer to P.23A-38. COMBINATION METER INTERNAL RESISTANCE CHECK Turn Shaft Resistor 3 – 10 k ¶ AC305188AB 1. Remove the vehicle speed sensor and connect a 3 −...
Page 343: Disassembly And Reassembly
CHASSIS ELECTRICAL 54A-65 COMBINATION METER ASSEMBLY DISASSEMBLY AND REASSEMBLY M1543003100341 <1600 (SPORT), 2000> AC305237 Disassembly steps (Continued) Disassembly steps 4. Bulb 1. Meter glass 5. Combination meter assembly 2. Meter panel 3. Circuit board cover <1300, 1600 (COMFORT)> AC304664 Disassembly steps (Continued) Disassembly steps 4.
Page 344: Headlamp
CHASSIS ELECTRICAL 54A-66 HEADLAMP HEADLAMP SERVICE SPECIFICATIONS M1542000300332 Item Standard value Limit Headlamp aiming Low beam Vertical 0.69° below horizontal (H) ± 0.29° from the direction standard value Horizontal Position at which the stat up point ± 0.5° from the direction of 15°...
Page 345: Luminous Intensity Measurement
CHASSIS ELECTRICAL 54A-67 HEADLAMP NOTE: Height from the floor to the centre of the headlamps (Reference value): 840 mm Distance of Headlamp (3) Measure the distance from the centre line of vertical direction centre the vehicle to the centre of each headlamp. [0.69˚] Transfer the measurement to the screen.
Page 346: Bulb Replacement
CHASSIS ELECTRICAL 54A-68 HEADLAMP Position Lamp Bulb BULB REPLACEMENT M1542001300658 CAUTION Headlamp Bulb Do not touch the bulb surface bare-handed or CAUTION with dirty gloves. If dirt is attached on surface of Do not touch the surface of the bulb with hands the bulb, immediately use alcohol or thinner to or dirty gloves as the bulb may pop after a short remove dirt, and install the bulb after well dried.
Page 347: Headlamp
CHASSIS ELECTRICAL 54A-69 HEADLAMP HEADLAMP REMOVAL AND INSTALLATION M1542001800244 Post-installation Operation Headlamp Aiming Adjustment (Refer to P.54A-66.) AC304719 Removal steps <<A>> Headlamp assembly REMOVAL SERVICE POINT 1. Remove the splash shield, the radiator grill, the front bumper assembly installation clips, the <<A>>...
Page 348: Headlamp Leveling Switch
CHASSIS ELECTRICAL 54A-70 HEADLAMP HEADLAMP LEVELING SWITCH REMOVAL AND INSTALLATION M1542013700040 AC304661AB Removal steps 1. Switch panel 2. Headlamp leveling switch INSPECTION Terminal No. Switch Resistance M1542011200908 position HEAD LAMP LEVELING SWITCH 4 - 6 750 ohms RESISTANCE CHECK 1050 ohms 1410 ohms 1710 ohms 2010 ohms...
Page 349: Fog Lamp
CHASSIS ELECTRICAL 54A-71 FOG LAMP FOG LAMP SERVICE SPECIFICATION M1542000300343 Item Standard value Front fog lamp light axis check Illuminates to within 40 metres SPECIAL TOOL M1542000600894 Tool Number Name MB990784 Ornament remover Removal of instrument panel ornament MB990784 • Run the engine at a speed of 2000 r/min to fully TROUBLESHOOTING charge the battery.
Page 350 CHASSIS ELECTRICAL 54A-72 FOG LAMP CAUTION For the front fog lamp which is not being In the centre measured, disconnect that fog lamp’s connector of front fog lamps if possible so that it does not illuminate while carrying out the adjustment. Furthermore, make sure that the light axis does not get shifted when re-connecting the connector.
Page 351: Fog Lamp
CHASSIS ELECTRICAL 54A-73 FOG LAMP FOG LAMP REMOVAL AND INSTALLATION M1542001500469 4.9 ± 0.7 N·m AC304660 Removal steps (Continued) Removal steps <<A>> Front fog lamp bulb Side under cover • Front fog lamp assembly REMOVAL SERVICE POINT 1. Remove the bulb cover. 2.
Page 352: Fog Lamp Switch
CHASSIS ELECTRICAL 54A-74 FOG LAMP FOG LAMP SWITCH REMOVAL AND INSTALLATION M1542013900033 AC304663AB Removal steps 1. Instrument panel ornament (Refer to GROUP 52A, Instrument panel P.52A-2.) 2. Fog lamp switch (front and rear fog lamp switch) INSPECTION Switch position Tester Specified M1542011200919 connection...
Page 353: Rear Fog Lamp
CHASSIS ELECTRICAL 54A-75 REAR FOG LAMP FRONT FOG LAMP RELAY CHECK Battery voltage Tester Specified connection condition Not supplied 1 − 4 Open circuit • Connect 1 − 4 Less than 2 terminal 2 to ohms the positive battery terminal •...
Page 354: Rear Fog Lamp
CHASSIS ELECTRICAL 54A-76 REAR FOG LAMP REAR FOG LAMP REMOVAL AND INSTALLATION M1542009800077 AC305278AB Removal steps (Continued) Removal steps 4. Socket 1. Bracket 5. Bulb 2. Rear fog lamp assembly 3. Bezel REAR FOG LAMP SWITCH Switch position Tester Specified connection condition REMOVAL AND INSTALATION...
Page 355: Side Turn-Signal Lamp
CHASSIS ELECTRICAL 54A-77 SIDE TURN-SIGNAL LAMP FRONT FOG LAMP RELAY CHECK Battery voltage Tester Specified connection condition Not supplied 1 − 4 Open circuit • Connect 1 − 4 Less than 2 terminal 3 to ohms the positive battery terminal •...
Page 356: Room Lamp
CHASSIS ELECTRICAL 54A-78 ROOM LAMP Clamp the thumb on the fender panel the assemble INSTALLATION SERVICE POINT the side turn signal lamp. Hook Claw Fender panel Fender panel : Front of vehicle AC005719 ROOM LAMP TROUBLESHOOTING M1542000701311 • Not using SWS monitor: GROUP 54B, SWS Dimmer interior lamp control function Troubleshooting P.54B-38.
Page 357: Rear Combination Lamp
CHASSIS ELECTRICAL 54A-79 REAR COMBINATION LAMP REAR COMBINATION LAMP • Not using SWS monitor: GROUP 54B, SWS TROUBLESHOOTING Troubleshooting P.54B-38. M1542000701322 The lamps setup on the rear combination lamp is • Using SWS monitor: GROUP 54C, SWS controlled in the same manner as the lamps of the Troubleshooting P.54C-22.
Page 358: High-Mounted
CHASSIS ELECTRICAL 54A-80 HIGH-MOUNTED STOP LAMP <Wagon> AC304715AB Removal steps (Continued) Removal steps 3. Socket assembly 1. Rear combination lamp assembly 4. Bulb 2. Rear combination lamp body HIGH-MOUNTED STOP LAMP Remove socket from trunk compartment, and ON-VEHICLE SERVICE replace bulb. HIGH-MOUNTED STOP LAMP BULB REPLACEMENT <WITH REAR SHELF>...
Page 359: Removal And Installation
CHASSIS ELECTRICAL 54A-81 HIGH-MOUNTED STOP LAMP HIGH-MOUNTED STOP LAMP REMOVAL AND INSTALLATION M1542005100452 <Sedan> <With rear shelf> 4.9 ± 0.7 N·m AC305293AB Removal steps (Continued) Removal steps High-mounted stop lamp cover Socket assembly (front) Socket High-mounted stop lamp cover Bulb (rear) High-mount stop lamp assembly High-mounted stop lamp body...
Page 360 CHASSIS ELECTRICAL 54A-82 HIGH-MOUNTED STOP LAMP <With rear spoiler> AC304750AB Removal steps Rear spoiler (Refer to GROUP 51, Rear spoiler P.51-18.) High-mounted stop lamp <<A>>...
Page 361 CHASSIS ELECTRICAL 54A-83 HIGH-MOUNTED STOP LAMP <Wagon> AC304722AB Removal steps (Continued) Removal steps Tailgate spoiler (Refer to GROUP Tailgate trim upper (Refer to • 51, Tailgate spoiler P.51-19.) GROUP 52A, Tailgate trim Rear washer nozzle (Refer to P.52A-19.) • GROUP 51, Rear wiper and High-mounted stop lamp connector •...
Page 362: Licence Plate Lamp
CHASSIS ELECTRICAL 54A-84 LICENCE PLATE LAMP LICENCE PLATE LAMP REMOVAL AND INSTALLATION M1542004200199 <Sedan> AC304716AB Removal steps (Continued) Removal steps Socket Licence plate lamp lens Licence plate lamp bulb Packing...
Page 363: Hazard Warning Lamp Switch
CHASSIS ELECTRICAL 54A-85 HAZARD WARNING LAMP SWITCH <Wagon> AC304717AB Removal steps (Continued) Removal steps Socket Licence plate lamp lens Licence plate lamp bulb Packing Harness Licence plate lamp body HAZARD WARNING LAMP SWITCH • Not using SWS monitor: GROUP 54B, SWS TROUBLESHOOTING Troubleshooting P.54B-38.
Page 364: Hazard Warning Lamp Switch
CHASSIS ELECTRICAL 54A-86 HAZARD WARNING LAMP SWITCH HAZARD WARNING LAMP SWITCH REMOVAL AND INSTALLATION M1542006600449 AC304721AB Removal steps (Continued) Removal steps 4. Centre air outlet panel 1. Knob 5. Hazard warning lamp switch 2. Centre panel 3. Meter bezel INSPECTION Switch position Tester Specified M1542011200920...
Page 365: Column Switch
CHASSIS ELECTRICAL 54A-87 COLUMN SWITCH COLUMN SWITCH SPECIAL TOOL M1542000600946 Tool Number Name MB990784 Ornament remover Removal of column cover MB990784 COLUMN SWITCH REMOVAL AND INSTALLATION M1543009100446 Claw AC305305AB Removal steps (Continued) Removal steps 3. Turn-signal and lighting switch 1. Lower column cover 4.
Page 366: Inspection
CHASSIS ELECTRICAL 54A-88 COLUMN SWITCH INSPECTION M1542011200931 TURN-SIGNAL AND LIGHTING SWITCH Switch position Tester condition Specified CHECK condition 3 − 4, 3 − 6, 3 − 7, Open 3 − 8, 3 − 9, 3 − 10, circuit 3 − 11 Headlamp 3 −...
Page 367: Horn
CHASSIS ELECTRICAL 54A-89 HORN HORN REMOVAL AND INSTALLATION M1543007900413 AC304666AB Removal Steps 1. Horn <LO> 2. Horn <HI> HORN RELAY CONTINUITY CHECK Battery voltage Tester Specified M1543019502418 connection condition Not applied 1 − 4 Open circuit • Connect terminal 1 − 4 Less than 2 2 to the positive ohms...
Page 368: Clock
CHASSIS ELECTRICAL 54A-90 CLOCK CLOCK SPECIAL TOOL M1543000601663 Tool Number Name MB990784 Ornament remover Removal of centre panel and centre air outlet panel MB990784 CLOCK REMOVAL AND INSTALLATION M1543005900224 AC304720AB Removal steps (Continued) Removal steps 4. Centre air outlet panel 1.
Page 369: Cigarette Lighter
CHASSIS ELECTRICAL 54A-91 CIGARETTE LIGHTER CIGARETTE LIGHTER • Take out the plug, and check for a worn edge on INSPECTION the element spot connection, and for shreds of M1543005700242 CIGARETTE LIGHTER CHECK tobacco or other material on the element. • Using an ohmmeter, check that the element resistance value is 1.7 ohms.
Page 370: Inspection
CHASSIS ELECTRICAL 54A-92 RHEOSTAT INSPECTION 1. Connect the battery and the test bulb (40 W) as shown in the illumination. M1542006100228 RHEOSTAT RESISTANCE CHECK 2. Operate the rheostat, and if brightness changes smoothly without switching off, rheostat function is normal. 40 W AC305310AB...
Page 371: Speaker
CHASSIS ELECTRICAL 54A-93 SPEAKER SPEAKER REMOVAL AND INSTALLATION M1544002600454 <Front speaker - Sedan/Wagon> <Rear speaker - Wagon> <Rear speaker - Sedan> AC305311AB Rear speaker <Wagon> removal Front speaker removal steps steps Front door trim (Refer to GROUP Quarter trim upper (Refer to 52A, Door trim P.52A-15.) GROUP 52A, Trims P.52A-11.) Front speaker...
Page 372: Antenna
CHASSIS ELECTRICAL 54A-94 ANTENNA ANTENNA REMOVAL AND INSTALLATION M1544002900529 <Sedan> Pre-removal and Post-installation Operation • Front pillar trim, Rear pillar trim, Centre pillar trim lower, Centre pillar trim upper (Refer to GROUP 52A − Trims P.52A-11.) • Headlining Removal and Installation (Refer to GROUP 52A, Headlining P.52A-21.) AC305315AB Removal steps...
Page 373: Rear Window Defogger
CHASSIS ELECTRICAL 54A-95 REAR WINDOW DEFOGGER <Wagon> Pre-removal and Post-installation Operation • Front pillar trim, Centre pillar trim lower, Centre pillar trim upper, Quarter trim lower, Quarter trim upper (Refer to GROUP 52A − Trims P.52A-11.) • Headlining Removal and Installation (Refer to GROUP 52A, Headlining P.52A-21.) AC305316AB Removal steps...
Page 374: On-Vehicle Service
CHASSIS ELECTRICAL 54A-96 REAR WINDOW DEFOGGER ON-VEHICLE SERVICE REAR WINDOW DEFOGGER SWITCH PRINTED HEATER LINES CHECK REMOVAL AND INSTALLATION M1543001800311 M1543006200314 Refer to GROUP 55, Heater Control Assembly and Normal characteristic curve A/C Switch P.55-77. Voltage INSPECTION M1543019502388 DEFOGGER RELAY CHECK A (Centre point) Approximately 6 V Negative...
Page 375 51-1 GROUP 51 EXTERIOR CONTENTS FRONT BUMPER ASSEMBLY ..51-2 TROUBLESHOOTING ....51-22 ON-VEHICLE SERVICE ....51-22 ADHESIVE .
Page 376: Front Bumper Assembly
51-2 EXTERIOR FRONT BUMPER ASSEMBLY FRONT BUMPER ASSEMBLY ADHESIVE M1511000500426 Item Specification Front three-diamond mark Double-sided tape: 20 mm width and 0.8 mm thickness FRONT BUMPER ASSEMBLY REMOVAL AND INSTALLATION M1511001400444 Section A – A Section B – B Section C – C Claw Clip AC304651 AB...
Page 377: Disassembly And Reassembly
51-3 EXTERIOR FRONT BUMPER ASSEMBLY Removal steps (Continued) Removal steps • Fog lamp connector connection 1. Splash shield mounting clip 4. Front bumper beam assembly 2. Radiator grill assembly 5. Front bumper fixing clip 3. Front bumper assembly DISASSEMBLY AND REASSEMBLY M1511001600460 Double-sided tape: Generic products [ 20 mm width and 0.8 mm thickness ]...
Page 378 51-4 EXTERIOR FRONT BUMPER ASSEMBLY DISASSEMBLY SERVICE POINT REASSEMBLY SERVICE POINT <<A>> FRONT BUMPER SIDE PLATE >>A<< FRONT BUMPER SIDE PLATE ASSEMBLY REMOVAL ASSEMBLY Rivet tool Drill Front bumper face Bumper face Rivet Front bumper side plate Front bumper face AC100411AB Section A Use a drill (4.0 mm) to make a hole in the rivet to...
Page 379: Rear Bumper Assembly
51-5 EXTERIOR REAR BUMPER ASSEMBLY REAR BUMPER ASSEMBLY REMOVAL AND INSTALLATION M1511001900397 Pre-removal and Post-installation Operation • Rear Combination Light Removal and Installation. <Sedan> (Refer to GROUP 54A, Rear Combination Lamp P.54A-79.) • Rear End Trim Removal and Installation. (Refer to GROUP 52A, Trims P.52A-11.) •...
Page 380 51-6 EXTERIOR REAR BUMPER ASSEMBLY AC300199 <Wagon> Rear bumper assembly Section A – A Section B – B Section C – C Clip Rear bumper Clip Rear bumper assembly assembly Rear bumper Clip assembly AC305046...
Page 381: Disassembly And Reassembly
51-7 EXTERIOR REAR BUMPER ASSEMBLY DISASSEMBLY AND REASSEMBLY M1511002100349 AC300414 <Sedan> AC304191 AC300200 <Wagon> AC304193 Disassembly steps (Continued) Disassembly steps 5. Rear fog lamp assembly <<A>> >>A<< 1. Rivets 6. Rear fog lamp bezel 2. Rear bumper side plate assembly 7.
Page 382 51-8 EXTERIOR REAR BUMPER ASSEMBLY DISASSEMBLY SERVICE POINT ASSEMBLY SERVICE POINT <<A>> RIVET REMOVAL >>A<< RIVET INSTALLATION Drill Recommended tool Rear bumper face Bumper face Rivet Y0412AU Rear bumper side plate Rear bumper face AC100411AB Section A Use a drill (4.0 mm) to make a hole in the rivet to break it, and then remove the rivet.
Page 383: Mouldings
51-9 EXTERIOR MOULDINGS MOULDINGS SPECIAL TOOL M1511000601136 Tool Number Name Application MB990449 Window moulding remover Removal of drip moulding MB990449 ADHESIVE M1511000500749 Application Specified adhesive Front fender, front and rear door mouldings Double-sided tape [a: 6 mm width 1.2 mm thickness, b: 20 mm width 1.2 mm thickness ]...
Page 384: Mouldings
51-10 EXTERIOR MOULDINGS MOULDINGS REMOVAL AND INSTALLATION M1511004700295 Section A – A Section B – B Section C – C Section D – D 6, 7 2, 3, 4 W0740AU Y0622AU Y0623AU Y0624AU Section E – E <Sedan> AC304339...
Page 385 51-11 EXTERIOR MOULDINGS <Vehicle without roof rail> <Wagon> <Vehicle with roof rail> AC304340 Roof drip moulding removal steps Removal >>B<< 4. Front drip moulding clip C Front deck garnishes (Refer to • >>B<< 5. Rear drip moulding clip P.51-23.) >>A<< 6.
Page 386 51-12 EXTERIOR MOULDINGS INSTALLATION SERVICE POINTS >>B<< REAR DRIP MOULDING CLIP/FRONT DRIP MOULDING CLIP >>A<< DRIP MOULDING CLIP C/DRIP C/FRONT DRIP MOULDING CLIP MOULDING CLIP B/DRIP MOULDING B/FRONT DRIP MOULDING CLIP A CLIP A INSTALLATION INSTALLATION 1. The drip moulding clips A, B and C differ The front drip moulding clips A, B, C and rear drip according to where they are used, so check the moulding clip differ according to where they are...
Page 387 51-13 EXTERIOR MOULDINGS Section A – A Section B – B Section C – C Clip Clip AC400128 AC400117 AC401196 Adhesive tape position AC400840AD Double-sided tape: Generic products [ a: 6 mm width and 1.2 mm thickness, b: 20 mm width and 1.2 mm thickness ] Door moulding removal steps Door moulding removal steps <<A>>...
Page 388 51-14 EXTERIOR MOULDINGS REMOVAL SERVICE POINT <<A>> FRONT FENDER, FRONT AND REAR DOOR MOULDINGS REMOVAL Gently lift and remove the door moulding. If there is any double-sided tape remaining on the door moulding, remove according to the following instructions. <Remove double-sided tape remaining on the body surface>...
Page 389: Side Air Dam
51-15 EXTERIOR SIDE AIR DAM SIDE AIR DAM ADHESIVE M1511000500437 Item Specification Side air dam Double-sided tape 4 mm width and 1.2 mm thickness SIDE AIR DAM REMOVAL AND INSTALLATION M1511005500238 Section A – A Clip Clip Adhesive tape position Double-sided tape: Generic products [ 4 mm width and 1.2 mm thickness ] AC303877...
Page 390 51-16 EXTERIOR SIDE AIR DAM REMOVAL SERVICE POINTS <<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>...
Page 391: Garnishes
51-17 EXTERIOR GARNISHES GARNISHES REMOVAL AND INSTALLATION M1511004100107 Section A – A Delta outer garnish Clip Delta outer garnish AC303863 <Sedan> Section A – A Trunk lid panel Licence plate garnish Clip Licence plate garnish AC303860...
Page 392: Rear Spoiler
51-18 EXTERIOR REAR SPOILER REAR SPOILER REMOVAL AND INSTALLATION M1511006100136 AC303713 Removal steps (Continued) Removal steps 2. Gasket Trunk lid bumper (Refer to GROUP • 3. Rear spoiler 42, Trunk lid P.42-43.) <<A>> 4. High-mounted stop lamp 1. Cap REMOVAL SERVICE POINT CAUTION Ensure that the string is tightly tied.
Page 393: Tailgate Spoiler
51-19 EXTERIOR TAILGATE SPOILER TAILGATE SPOILER REMOVAL AND INSTALLATION M1511019900068 5.2 ± 1.0 N·m AC303721 Tailgate spoiler removal steps Tailgate spoiler removal steps Rear washer hose connection • • Tailgate trim upper (Refer to GROUP 1. Tailgate spoiler assembly 52A, Tailgate trim P.52A-19.) 2.
Page 394: Roof Rail
51-20 EXTERIOR ROOF RAIL ROOF RAIL REMOVAL AND INSTALLATION M1511016600187 AC303725 Section A – A Section B – B Section C – C Claw Claw Claw Claw Claw Section D – D Section E – E Section F – F Claw Claw Claw...
Page 395: Windshield Wiper And Washer
51-21 EXTERIOR WINDSHIELD WIPER AND WASHER WINDSHIELD WIPER AND WASHER Windshield Mist Wiper Operation GENERAL INFORMATION M1511000100514 • If the windshield mist wiper switch is turned to the WINDSHIELD WIPER AND WASHER ON position with the ignition switch at the "ACC" OPERATION or "ON"...
Page 396: Service Specification
51-22 EXTERIOR WINDSHIELD WIPER AND WASHER SERVICE SPECIFICATION M1511000300325 Item Standard value 34 ± 5 Windshield wiper blade park position mm TROUBLESHOOTING ON-VEHICLE SERVICE M1511000700323 M1511000800461 WINDSHIELD INTERMITTENT WIPER The windshield wiper and washer are controlled by the Smart Wiring System (SWS). For INSPECTION troubleshooting, refer to GROUP 54B, 1.
Page 397: Removal And Installation
51-23 EXTERIOR WINDSHIELD WIPER AND WASHER WINDSHIELD WIPER AND WASHER REMOVAL AND INSTALLATION M1511007600350 Section A – A View A 6, 7 Clip A Y0597AU Y0616AU Note Section B – B : Clip A positions : Clip B positions 6, 7 Clip B Y0599AU 27 ±...
Page 398 51-24 EXTERIOR WINDSHIELD WIPER AND WASHER Windshield washer nozzle removal Wiper blade assembly removal steps steps >>B<< 1. Wiper blade assembly • Connection of front washer hose >>A<< 2. Wiper blade 11. Washer nozzle Windshield wiper motor and link Washer tank and washer motor assembly removal steps removal steps 3.
Page 399: Inspection
51-25 EXTERIOR WINDSHIELD WIPER AND WASHER Wiper Motor at Stop Position Operation INSPECTION M1511007700313 1. Connect the battery to the windshield wiper motor FRONT WIPER MOTOR CHECK to rotate the motor in a low speed as shown in the illustration (A) and disconnect the battery during rotation to stop the motor.
Page 400 51-26 EXTERIOR WINDSHIELD WIPER AND WASHER WINDSHIELD WASHER FLUID EJECTION CHECK Move the nozzle to adjust the position so that the spray is in area shown in the area shown in the illustration. UNITS: mm <Right> <Left> Ceramic line terminal Windshield washer Windshield washer nozzle perpendicular...
Page 401 51-27 EXTERIOR WINDSHIELD WIPER AND WASHER WINDSHIELD INTERMITTENT WIPER Switch position Tester Specified VOLUME CHECK connection condition 6 − 11 Windshield mist Less than 2 wiper switch ohms 6 − 10 Windshield intermittent wiper switch 6 − 9 Windshield low-speed wiper switch 6 −...
Page 402: Rear Wiper And Washer
51-28 EXTERIOR REAR WIPER AND WASHER REAR WIPER AND WASHER inhibitor switch "R" turns ON. One second later, GENERAL INFORMATION the ETACS-ECU turns ON the rear wiper drive M1511000100525 REAR WIPER AND WASHER OPERATION signal for three seconds (approximately two cycles).
Page 403: Rear Wiper And Washer
51-29 EXTERIOR REAR WIPER AND WASHER REAR WIPER AND WASHER REMOVAL AND INSTALLATION M1511008500345 2.5 ± 0.4 N·m 9.8 ± 2.0 N·m 7.4 ± 1.4 N·m AC304515 Washer hose removal steps Wiper blade assembly removal steps • Front scuff plate, rear scuff plate, cowl >>A<<...
Page 404: Inspection
51-30 EXTERIOR REAR WIPER AND WASHER INSTALLATION SERVICE POINTS INSPECTION M1511008600193 >>A<< REAR WIPER ARM AND BLADE REAR WIPER MOTOR CHECK ASSEMBLY INSTALLATION End of tailgate glass 1 2 3 4 (A) Operation check AC304536 Before installing the rear wiper arm and blade assembly, operate the rear wiper motor so that the 1 2 3 4 motor stops at the predetermined park position.
Page 405 51-31 EXTERIOR REAR WIPER AND WASHER REAR WASHER MOTOR CHECK For the vertical aiming of washer nozzle, insert the flat-tipped screwdriver into the nozzle and move it to the arrow direction. REAR WIPER AND WASHER SWITCH CHECK AC005900 1. Remove the rear washer tank assembly with the washer hose attached.
Page 406: Headlamp Washer
51-32 EXTERIOR HEADLAMP WASHER HEADLAMP WASHER TROUBLESHOOTING M1511000700356 The headlamp washer is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to GROUP 54B, Troubleshooting P.54B-17 or GROUP 54C, Troubleshooting P.54C-4. HEADLAMP WASHER REMOVAL AND INSTALLATION M1511009700063 4.9 ± 0.7 N·m 4.9 ±...
Page 407: Inspection
51-33 EXTERIOR HEADLAMP WASHER Removal steps (Continued) Headlamp washer motor Headlamp washer gasket • Front bumper (Refer to P.51-2). Headlamp washer actuator assembly 10. O-ring 11. Headlamp washer hose assembly INSPECTION 1. Remove the headlamp washer motor connector. M1511009800082 2. Check to see that the water is vigorously sprayed HEADLAMP WASHER MOTOR CHECK when connecting the positive battery terminal to terminal number 1 and terminal number 2 to the...
Page 408: Mark
51-34 EXTERIOR MARK MARK REMOVAL AND INSTALLATION M1511011800971 AC304202 <Sedan> <Wagon> AC400380 Removal (Continued) Removal >>A<< 2. Rear three-diamond mark >>A<< 1. Front three-diamond mark >>A<< 3. Lancer mark INSTALLATION SERVICE POINT >>A<< MARK APPLICATION 1. Installation position Attach each mark to the position shown in the illustration.
Page 409 51-35 EXTERIOR MARK 2. Three-diamond mark <Sedan> <Wagon> 112 mm 53 ± 1 mm Press line Trunk lid press line Centre line Centre line of vehicle of vehicle AC304163 3. Lancer mark <Sedan> 19 ± 1 mm Rear combination lamp terminal 45 ±...
Page 410: Door Mirror
51-36 EXTERIOR DOOR MIRROR DOOR MIRROR Heated Door Mirror operation GENERAL INFORMATION • The defogger relay switch is activated (ON) by M1511000100536 DOOR MIRROR OPERATION turning on the A/C-ECU built-in defogger switch when the ignition switch is in the "ON" position. Remote Controlled Mirror Operation When the defogger relay is turned ON, power is •...
Page 411: Symptom Procedures
51-37 EXTERIOR DOOR MIRROR SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: All Heated Door Mirrors do not Operate REAR WINDOW DEFOGGER RELAY REAR WINDOW DEFOGGER REMOTE REMOTE CONTROLLED CONTROLLED MIRROR (RH) MIRROR (LH) MIRROR MIRROR HEATER HEATER NOTE LH drive vehicles RH drive vehicles Wire colour code B : Black LG : Light green...
Page 412 51-38 EXTERIOR DOOR MIRROR COMMENTS ON TROUBLE SYMPTOM STEP 2. Connector check: C-212 junction block The heated door mirrors should works for connector approximately 11 minutes when the rear defogger Connector: C-212 switch is turned on. If the mirror heater does not work Junction block (Front view) for the specified period, the defogger relay circuit (heated door mirror power supply circuit) may be...
Page 413 51-39 EXTERIOR DOOR MIRROR INSPECTION PROCEDURE 2: Right or Left Heated Door Mirror does not Operate REAR WINDOW DEFOGGER RELAY REAR WINDOW DEFOGGER REMOTE REMOTE CONTROLLED CONTROLLED MIRROR (RH) MIRROR (LH) MIRROR MIRROR HEATER HEATER NOTE LH drive vehicles RH drive vehicles Wire colour code B : Black LG : Light green...
Page 414 51-40 EXTERIOR DOOR MIRROR COMMENTS ON TROUBLE SYMPTOM Step 3. Check the door mirror assembly (RH). If either of the heated door mirrors does not work, the Check that the heater element of the door mirror door mirror assembly may be defective. assembly (RH) is in good condition (Refer to P.51-47).
Page 415 51-41 EXTERIOR DOOR MIRROR Step 5. Check the wiring harness between E-11 Step 6. Voltage measurement at the E-11 door door mirror assembly (RH) connector terminal mirror assembly (RH) connector. No.4 and body earth. (1) Turn the ignition switch to the ON position. (2) Rear window defogger switch: ON Connector: E-11 Connector: E-11...
Page 416 51-42 EXTERIOR DOOR MIRROR NOTE: Step 7. Connector check: C-212 junction block Connector: C-112 connector Connector: C-212 Junction block (Front view) Harness side AC304819 Prior to the wiring harness inspection, check 23 22 20 19 16 15 intermediate connector C-112 <LHD>, C-30 <RHD> AC304913 and repair if necessary.
Page 417 51-43 EXTERIOR DOOR MIRROR Step 11. Resistance measurement at the E-02 Step 12. Check the wiring harness between E-02 door mirror assembly (LH) connector. door mirror assembly (LH) connector terminal No.4 and body earth. Connector: E-02 Connector: E-02 Harness side Harness side AC304818 AC304818...
Page 418 51-44 EXTERIOR DOOR MIRROR Step 14. Measure the voltage at the E-02 door Step 15. Check the wiring harness between E-02 mirror assembly (LH) connector. door mirror assembly (LH) connector terminal (1) Turn the ignition switch to the ON position. No.1 and C-212 junction block connector (2) Rear window defogger switch: ON terminal No.3.
Page 419: Door Mirror
51-45 EXTERIOR DOOR MIRROR DOOR MIRROR REMOVAL AND INSTALLATION M1511006400308 Section A – A Claw Note : Claw positions AC304733 Remote controlled mirror switch Door mirror removal steps removal steps 1. Cover 7. Instrument panel ornament (Refer to 2. Delta inner cover GROUP 52A, Instrument panel 3.
Page 420 51-46 EXTERIOR DOOR MIRROR REMOVAL SERVICE POINT INSTALLATION SERVICE POINT <<A>> MIRROR REMOVAL >>A<< MIRROR INSTALLATION Section A – A Section A – A Flat-tipped Flat-tipped Mirror Mirror screwdriver screwdriver Pivot plate Pivot plate Protective tape Notch 00007256 00007258 AC000441 AC000442 Push the top of the mirror with your hand to tilt it and While supporting the clip position on the underside of...
Page 421: Inspection
51-47 EXTERIOR DOOR MIRROR ELECTRIC REMOTE CONTROL MIRROR INSPECTION M1511006500286 OPERATION CHECK <VEHICLES WITH ELECTRIC REMOTE CONTROL MIRROR HEATED DOOR MIRROR> OPERATION CHECK <VEHICLES WITHOUT HEATED DOOR MIRROR> 4 5 6 7 AC202548 Check that the mirror moves as described in the AC005969 table when each terminal is connected to the battery.
Page 422 51-48 EXTERIOR DOOR MIRROR DOOR MIRROR CONTROL SWITCH HEATED DOOR MIRROR CHECK CONTINUITY 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. AC005970 Switch position Tester...
Page 423 23-1 GROUP 23 AUTOMATIC TRANSMISSION CONTENTS AUTOMATIC TRANSMISSION (FF) ..... . AUTOMATIC TRANSMISSION OVERHAUL ....
Page 424 NOTES...
Page 425 22-1 GROUP 22 MANUAL TRANSMISSION CONTENTS MANUAL TRANSMISSION (FF) ......MANUAL TRANSMISSION OVERHAUL ....
Page 426 NOTES...
Page 427 21-1 GROUP 21 CLUTCH CONTENTS CLUTCH ......... . . CLUTCH OVERHAUL .
Page 428 NOTES...
Page 429 16-1 GROUP 16 ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM ..IGNITION SYSTEM ..16-2 16-30 GENERAL INFORMATION ..16-2 GENERAL INFORMATION ..16-30 SERVICE SPECIFICATIONS.
Page 430: Charging System
ENGINE ELECTRICAL 16-2 CHARGING SYSTEM CHARGING SYSTEM GENERAL INFORMATION M1161000100522 The charging system uses the alternator output to The average output voltage fluctuates slightly with keep the battery charged at a constant level under the alternator load condition. various electrical loads. When the ignition switch is turned on, current flows in the field coil and initial excitation of the field coil OPERATION...
Page 431: Service Specifications
ENGINE ELECTRICAL 16-3 CHARGING SYSTEM SERVICE SPECIFICATIONS M1161000300258 Item Standard value Limit Alternator output line voltage drop (at 30 A) V maximum 0.3 − Regulated voltage ambient 14.2 − 15.4 −20°C − temperature at voltage regulator V 20°C 13.9 − 14.9 −...
Page 432 ENGINE ELECTRICAL 16-4 CHARGING SYSTEM 2. Turn the ignition switch to the "LOCK" (OFF) Adjust the engine speed by gradually decreasing position. it until the value displayed on the ammeter is 30 A. Take a reading of the value displayed on the 3.
Page 433: Output Current Test
ENGINE ELECTRICAL 16-5 CHARGING SYSTEM OUTPUT CURRENT TEST M1161001000368 Load Ammeter (clamp-type) Voltmeter – Inition switch Charging indicator Brake warning light Alternator Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Battery AK203362 This test determines whether the alternator output CAUTION current is normal. Never use clips but tighten bolts and nuts to 1.
Page 434 ENGINE ELECTRICAL 16-6 CHARGING SYSTEM NOTE: 7. Connect a tachometer or the MUT-II/III (Refer to GROUP 11A − On-vehicle Service − Idle speed For the nominal current output, refer to the • check <4G1> P.11A-11 or GROUP 11C − Alternator Specifications. On-vehicle Service −...
Page 435: Regulated Voltage Test
ENGINE ELECTRICAL 16-7 CHARGING SYSTEM REGULATED VOLTAGE TEST M1161001100354 Load Ammeter (clamp-type) MB991519 Ignition switch Black Alternator Blue Yellow Battery Engine-ECU <M/T> Engine-A/T-ECU <A/T> Voltmeter (digital-type) AK300727 AB This test determines whether the voltage regulator NOTE: The way of disconnecting the alternator correctly controlling the alternator output voltage.
Page 436 ENGINE ELECTRICAL 16-8 CHARGING SYSTEM If the voltage is not within the standard value, 17.Disconnect the negative battery cable. there is a malfunction of the voltage regulator or of 18.Disconnect the ammeter and voltmeter. the alternator. 19.Connect the alternator output wire to the 14.After the test, lower the engine speed to the idle alternator "B"...
Page 437: Waveform Check Using An Oscilloscope
ENGINE ELECTRICAL 16-9 CHARGING SYSTEM WAVEFORM CHECK USING AN OSCILLOSCOPE M1161001200124 Connect the oscilloscope special patterns pick-up to MEASUREMENT METHOD the alternator "B" terminal. Alternator "B" terminal AK100002 STANDARD WAVEFORM Observation Conditions Function Special pattern Pattern height Variable Variable knob Adjust while viewing the waveform.
Page 438 ENGINE ELECTRICAL 16-10 CHARGING SYSTEM 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).
Page 439 ENGINE ELECTRICAL 16-11 CHARGING SYSTEM Abnormal waveform Problem cause Example 3 Broken wire in stator coil AKX00193 Example 4 Short in stator coil AKX00194 Example 5 Open supplementary diode AKX00195 At this time, the charging warning lamp is illuminated.
Page 440: Alternator Assembly
ENGINE ELECTRICAL 16-12 CHARGING SYSTEM ALTERNATOR ASSEMBLY REMOVAL AND INSTALLATION <4G1> M1161001400548 Pre-removal Operation Post-installation Operation • Under Cover Removal • Drive Belt Installation (Refer to GROUP 11A - Crankshaft Pulley P.11A-16). • Drive Belt Removal (Refer to GROUP 11A - Crankshaft Pulley P.11A-16).
Page 441: Removal And Installation <4G6
ENGINE ELECTRICAL 16-13 CHARGING SYSTEM REMOVAL AND INSTALLATION <4G6> M1161001400559 Pre-removal Operation Post-installation Operation • Air Cleaner Assembly Installation (Refer to GROUP 15 • Under Cover Removal P.15-3). • Strut Tower Bar Removal (Refer to GROUP 42 P.42-9). • Drive Belt Installation (Refer to GROUP 11C - Crankshaft •...
Page 442 ENGINE ELECTRICAL 16-14 CHARGING SYSTEM 44 ± 10 N·m 22 ± 4 N·m 23 ± 3 N·m 8.8 ± 1.0 N·m AC303827 Removal steps (Continued) Removal steps <> Alternator assembly Battery wiring harness clamp Water pump pulley Engine oil pressure switch Alternator brace connection Alternator connector...
Page 443: Disassembly And Reassembly
ENGINE ELECTRICAL 16-15 CHARGING SYSTEM DISASSEMBLY AND REASSEMBLY M1161001600166 4.4 ± 1.0 N·m 3.7 ± 0.7 N·m 189 ± 19 N·m 3.7 ± 0.7 N·m AK202845 Disassembly steps (Continued) Disassembly steps <<C>> 8. Stator 1. Front bracket assembly <<A>> 9. Plate 2.
Page 444 ENGINE ELECTRICAL 16-16 CHARGING SYSTEM DISASSEMBLY SERVICE POINTS CAUTION • Use a 180 − 250 W soldering iron, and finish <<A>>FRONT BRACKET ASSEMBLY unsoldering within four seconds. Diodes will REMOVAL be damaged by heat if unsoldering time is too long. •...
Page 445: Inspection
ENGINE ELECTRICAL 16-17 CHARGING SYSTEM >>B<< ROTOR INSTALLATION STATOR Wire AK202779 AK202716 Remove the brush holding wire after the rotor has 1. Check the continuity between coil leads. been installed. If there is no continuity, replace the stator. INSPECTION M1161001700152 ROTOR AK202717 2.
Page 446 ENGINE ELECTRICAL 16-18 CHARGING SYSTEM BRUSH Protrusion length AK202802 AK202808 2. Check the condition of the (−) heat sink by checking continuity between the (−) heat sink and 1. Measure the length of the protrusion of the brush. each of the stator coil lead connecting terminals. Replace the brush if the protrusion length is shorter than the limit.
Page 447: Starting System
ENGINE ELECTRICAL 16-19 STARTING SYSTEM STARTING SYSTEM GENERAL INFORMATION M1162000100202 If the ignition switch is turned to the "START" When the ignition switch is returned to the "ON" position, current flows in the pull-in and holding coils position after starting the engine, the starter clutch is provided inside magnetic switch, attracting the disengaged from the ring gear.
Page 448: Service Specifications
ENGINE ELECTRICAL 16-20 STARTING SYSTEM STARTER MOTOR SPECIFICATIONS Item Type Reduction drive with planetary Reduction drive with planetary gear gear Rated output kW/V 1.2/12 1.4/12 Number of pinion teeth SERVICE SPECIFICATIONS M1162000300068 Item Standard value Limit Pinion gap mm 0.5 − 2.0 −...
Page 449: Starter Motor Assembly
ENGINE ELECTRICAL 16-21 STARTING SYSTEM STARTER MOTOR ASSEMBLY REMOVAL AND INSTALLATION <4G1> M1162001000628 Pre-removal and Post-installation Operation • Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3). • Battery and Battery Tray Removal and Installation <A/T> <M/T> 18 ± 3 N·m 12 ±...
Page 450: Removal And Installation <4G6
ENGINE ELECTRICAL 16-22 STARTING SYSTEM REMOVAL AND INSTALLATION <4G6> M1162001000617 Pre-removal and Post-installation Operation • Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 P.15-3). • Under Cover Removal and Installation 9.0 ± 2.0 N·m 18 ± 3 N·m 30 ±...
Page 451: Starter Motor Assembly Inspection
ENGINE ELECTRICAL 16-23 STARTING SYSTEM STARTER MOTOR ASSEMBLY INSPECTION M1162001100205 PINION GAP ADJUSTMENT <4G1> Switch Starter Wire motor Battery AKX00199 5. If the pinion gap is out of specification, adjust by AK300648 AB adding or removing gasket(s) between the <4G6> magnetic switch and front bracket.
Page 452 ENGINE ELECTRICAL 16-24 STARTING SYSTEM MAGNETIC SWITCH HOLD-IN TEST FREE RUNNING TEST <4G1> <4G1> Carbon-pile rheostat Ammeter Wire Battery Starter Voltmeter Starter motor motor Battery AK300650 AB AK300651AB <4G6> <4G6> Ammeter Carbon-pile rheostat Battery Battery Starter motor Voltmeter Starter Wire motor AKX01244 AKX01246...
Page 453 ENGINE ELECTRICAL 16-25 STARTING SYSTEM MAGNETIC SWITCH RETURN TEST 1. Disconnect the field coil wire from the M-terminal of the magnetic switch. <4G1> CAUTION This test must be performed quickly (in less than Wire 10 seconds) to prevent the coil from burning. 2.
Page 454: Disassembly And Reassembly
ENGINE ELECTRICAL 16-26 STARTING SYSTEM DISASSEMBLY AND REASSEMBLY M1162001200202 AK201881 Disassembly steps (Continued) Disassembly steps 11. Packing B 1. Screw 12. Plate <<A>> 2. Magnetic switch 13. Planetary gear 3. Screw 14. Lever 4. Bolt <> >>A<< 15. Snap ring 5.
Page 455: Inspection
ENGINE ELECTRICAL 16-27 STARTING SYSTEM DISASSEMBLY SERVICE POINTS STARTER MOTOR PARTS CLEANING Never clean in a solvent such starter motor parts <<A>> MAGNETIC SWITCH REMOVAL as the magnetic switch, brush holder, and armature. If they are soaked in a solvent, their insulation could be impaired.
Page 456 ENGINE ELECTRICAL 16-28 STARTING SYSTEM OVERRUNNING CLUTCH Free Lock AK202715 2. Measure the diameter of the commutator. AK202710 Standard value: 29.4 mm 1. Make sure that the pinion cannot be turned Limit: 28.8 mm counterclockwise and can be turned clockwise freely.
Page 457 ENGINE ELECTRICAL 16-29 STARTING SYSTEM MAGNETIC SWITCH Growler M terminal AK202733 AK202891 2. Set the armature in a growler. 1. Coil open circuit test CAUTION • Check that there is continuity between the M Clean the surface of the armature thoroughly terminal and body A.
Page 458: Ignition System
ENGINE ELECTRICAL 16-30 IGNITION SYSTEM IGNITION SYSTEM GENERAL INFORMATION M1163000100294 This system is equipped with two ignition coils (A and The engine-ECU <M/T> or engine-A/T-ECU <A/T> B) with built-in power transistors for the No. 1 and turns the two power transistors inside the ignition No.
Page 459: Service Specifications
ENGINE ELECTRICAL 16-31 IGNITION SYSTEM IGNITION COIL SPECIFICATION Item Specification Type Molded 2-coil SPARK PLUG SPECIFICATIONS Items 4G66 BKR6E-11 IGR6A11 DENSO K20PR-U11 − CHAMPION RC8YC4 − SERVICE SPECIFICATIONS M1163000300180 IGNITION COIL Item Standard value Secondary coil resistance kΩ 8.5 − 11.5 SPARK PLUG Items Standard value...
Page 460: On-Vehicle Service
ENGINE ELECTRICAL 16-32 IGNITION SYSTEM ON-VEHICLE SERVICE RESISTIVE CORD CHECK M1163001400124 IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK M1163001200324 Check by the following procedure, and replace if there is a malfunction. SECONDARY COIL RESISTANCE CHECK AKX00382 Measure the resistance of the all spark plug cables. 1.
Page 461: Spark Plug Check And Cleaning <4G6
ENGINE ELECTRICAL 16-33 IGNITION SYSTEM SPARK PLUG CHECK AND CLEANING CRANK ANGLE SENSOR CHECK M1163004500272 <4G6> Check the crank angle sensor circuit if self-diagnosis M1163004300353 code No. P0335 is shown. CAUTION (Refer to GROUP 13A − Troubleshooting − When pulling off the spark plug cable from the Inspection chart for diagnosis code <4G1>...
Page 462 ENGINE ELECTRICAL 16-34 IGNITION SYSTEM STANDARD WAVEFORM Observation Conditions Function Secondary Pattern height High (or Low) Pattern selector Raster Engine revolutions Curb idle speed Spark line (point A) Ignition voltage (point D) Secondary ignition voltage wave pattern Wave dampling reduction section (point B) Dwell section Point C Time...
Page 463 ENGINE ELECTRICAL 16-35 IGNITION SYSTEM NO. 2 cylinder NO. 1 cylinder NO. 4 cylinder ignition noise NO. 3 cylinder ignition noise Secondary ignition voltage wave pattern Time Newtral section AKX01275 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).
Page 464 ENGINE ELECTRICAL 16-36 IGNITION SYSTEM EXAMPLES OF ABNORMAL Example 3 • Wave characteristics WAVEFORMS 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 •...
Page 465: Ignition Coil Relay Check
ENGINE ELECTRICAL 16-37 IGNITION SYSTEM IGNITION COIL RELAY CHECK Battery Terminal No.to Continuity test M1163006500018 voltage be connected to results tester Not applied 1 − 4 Open circuit Ignition coil relay Connect 1 − 4 Less than 2 ohms terminal No.2 and battery (+) terminal.
Page 466: Ignition Coil
ENGINE ELECTRICAL 16-38 IGNITION SYSTEM IGNITION COIL REMOVAL AND INSTALLATION <4G1> M1163004000404 10 ± 2 N·m 10 ± 2 N·m 25 ± 5 N·m AC303965AB Removal steps (Continued) Removal steps Ignition coil Ignition coil connector Spark plug Spark plug cable Accelerator cable support clamp <RHD>...
Page 467: Removal And Installation <4G6
ENGINE ELECTRICAL 16-39 IGNITION SYSTEM REMOVAL AND INSTALLATION <4G6> M1163004000415 10 ± 2 N·m 3.0 ± 0.5 N·m 25 ± 4 N·m AC301786 Removal steps (Continued) Removal steps Ignition coil Rocker cover centre cover Spark plug Ignition coil connector Spark plug cable...
Page 468: Camshaft Position Sensor
ENGINE ELECTRICAL 16-40 IGNITION SYSTEM CAMSHAFT POSITION SENSOR REMOVAL AND INSTALLATION M1163003400443 <4G1> 8.8 ± 1.0 N·m AC303970AB <4G6> 8.8 ± 1.0 N·m Removal steps (Continued) Removal steps Camshaft position sensor Camshaft position sensor O-ring connector...
Page 469: Crankshaft Position Sensor
ENGINE ELECTRICAL 16-41 IGNITION SYSTEM CRANKSHAFT POSITION SENSOR REMOVAL AND INSTALLATION <4G1> M1163003500439 Pre-removal and Post-installation Operation • Valve Timing Belt Removal and Installation (Refer to GROUP 11A P.11A-33). 11 ± 1 N·m 8.8 ± 1.0 N·m AC208380AB Removal steps Engine crank angle sensor Crank angle sensor connector bracket...
Page 470: Removal And Installation <4G6
ENGINE ELECTRICAL 16-42 IGNITION SYSTEM REMOVAL AND INSTALLATION <4G6> M1163003500440 Pre-removal and Post-installation Operation • Valve Timing Belt Removal and Installation (Refer to GROUP 11C P.11C-35). 3.0 ± 0.5 N·m 22 ± 4 N·m 8.8 ± 1.0 N·m 22 ± 4 N·m 8.8 ±...
Page 471: Detonation Sensor
ENGINE ELECTRICAL 16-43 IGNITION SYSTEM DETONATION SENSOR REMOVAL AND INSTALLATION M1163002800556 CAUTION Do not drop or hit the detonation sensor against other components. Internal damage may result, and the detonation sensor will need to be replaced. <4G1> Cylinder block (Intake side) 23 ±...
Page 472 ENGINE ELECTRICAL 16-44 IGNITION SYSTEM REMOVAL SERVICE POINT INSTALLATION SERVICE POINT <<A>> ENGINE CONTROL DETONATION >>A<< ENGINE DETONATION SENSOR SENSOR REMOVAL INSTALLATION Engine control Engine control detonation detonation sensor sensor MD998773 MD998773 AC100807 AC100807 Use special tool detonation sensor wrench Use special tool detonation sensor wrench (MD998773) to remove the engine control detonation (MD998773) to tighten the engine control detonation...
Page 473 12-1 GROUP 12 ENGINE LUBRICATION CONTENTS GENERAL INFORMATION ..12-2 SPECIAL TOOLS ....12-3 SERVICE SPECIFICATION ..12-2 ON-VEHICLE SERVICE .
Page 474: General Information
12-2 ENGINE LUBRICATION GENERAL INFORMATION GENERAL INFORMATION M1121000100357 • Avoid contaminating clothes, particularly The lubrication method is a fully force-fed, full-flow filtration type. The engine oil pump is a trochoid type underpants, with oil. • Do not put oily rags in pockets, the use of overalls which is driven by the crankshaft <4G1>.The engine oil pump is a gear type which is driven by the without pockets will avoid this.
Page 475: Sealant
12-3 ENGINE LUBRICATION SEALANT SEALANT M1121000500258 Item Specified sealant Remark Oil pressure switch 3M ATD Part No. 8660 or equivalent Semi-drying sealant SPECIAL TOOLS M1121000600415 Tool Number Name MB991396 Oil filter wrench Removal and installation of engine oil filter (When using the engine oil filter of MD360935) B991396...
Page 476: On-Vehicle Service
12-4 ENGINE LUBRICATION ON-VEHICLE SERVICE ON-VEHICLE SERVICE ENGINE OIL CHECK 4. Install a new engine oil pan drain plug gasket so that it faces in the direction shown in the M1121000900342 illustration, and then tighten the engine oil pan <4G1> drain plug to the specified torque.
Page 477: Oil Pressure Check
12-5 ENGINE LUBRICATION ON-VEHICLE SERVICE Number Special tool Tightening torque MD348631 Oil filter wrench Approximately 3/4 MB991396 <4G1>, turn (16 ± 4 N⋅m) <4G1> (MB991828) or MB991828 equivalent <4G1>, MD365876 MB991610 <4G1> <4G6> or commercially- MD360935 Oil filter wrench Approximately 1 turn available tool (14 ±...
Page 478 12-6 ENGINE LUBRICATION ON-VEHICLE SERVICE CAUTION MD998054 AKX00295AD AKX00294 8. Apply the specified sealant to the thread of oil Since sealant is applied to the thread of oil pressure switch. pressure switch, take care not to damage the oil Specified sealant: 3M ATD Part No. 8660 or pressure switch when removing it.
Page 479 11-1 GROUP 11 ENGINE CONTENTS ENGINE MECHANICAL <4G1> ......ENGINE OVERHAUL <4G1> ......ENGINE MECHANICAL <4G6>...
Page 480 NOTES...
Page 481 00-1 GROUP 00 GENERAL CONTENTS GENERAL ......... . GENERAL <ELECTRICAL>...
Page 482 NOTES...
Page 483 80-1 GROUP 80 CONFIGURATION DIAGRAMS CONTENTS OVERALL CONFIGURATION DASH PANEL ....80-16 DIAGRAM..... . 80-2 DASH PANEL <LHD>...
Page 484: Overall Configuration Diagram
80-2 CONFIGURATION DIAGRAMS OVERALL CONFIGURATION DIAGRAM OVERALL CONFIGURATION DIAGRAM OVERALL WIRING DIAGRAM <SEDAN (LHD) > M1801000100569 Front wiring Control wiring Instrument panel Roof wiring Floor wiring harness (RH) harness wiring harness harness harness (RH) Rear bumper wiring harness Rear door wiring harness Front bumper wiring harness...
Page 485: Overall Wiring Diagram
80-3 CONFIGURATION DIAGRAMS OVERALL CONFIGURATION DIAGRAM OVERALL WIRING DIAGRAM <SEDAN (RHD) > M1801000100581 Front wiring Control wiring Instrument panel Roof wiring Floor wiring harness (RH) harness harness wiring harness harness (RH) Rear bumper wiring harness Rear door wiring harness Front bumper wiring harness Front door Battery wiring...

Page 486: Overall Wiring Diagram
80-4 CONFIGURATION DIAGRAMS OVERALL CONFIGURATION DIAGRAM OVERALL WIRING DIAGRAM <WAGON (LHD) > M1801000100592 Tailgate wiring Front wiring Control wiring Instrument panel Roof wiring Floor wiring harness (RH) harness harness harness wiring harness harness (RH) Rear bumper wiring harness Rear door wiring harness Front bumper wiring harness...

Page 487: Overall Wiring Diagram
80-5 CONFIGURATION DIAGRAMS OVERALL CONFIGURATION DIAGRAM OVERALL WIRING DIAGRAM <WAGON (RHD) > M1801000100600 Tailgate wiring Front wiring Control wiring Instrument panel Roof wiring Floor wiring harness (RH) harness harness wiring harness harness harness (RH) Rear bumper wiring harness Rear door wiring harness Front bumper wiring harness...

Page 488: Engine Compartment
80-6 CONFIGURATION DIAGRAMS ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT <LHD> M1801000301298 Connector A-01 symbol A-02 A-32 A-03 A-04X A-31 A-05X A-09X A-10X A-11X A-12 Front wiring A-13 A-29 harness (RH) A-28 A-14 A-27 A-15 Connector colour code B : Black A-26 BR : Brown G : Green...
Page 489: Engine Compartment
80-7 CONFIGURATION DIAGRAMS ENGINE COMPARTMENT ENGINE COMPARTMENT <RHD> M1801000301306 Connector A-01 A-02 symbol A-32 A-03 A-04X A-31 A-05X A-09X A-10X A-11X A-30 Front wiring harness (RH) A-12 A-29 A-14 A-27 A-15 A-26 Connector colour code B : Black BR : Brown G : Green A-16 GR : Gray...

Page 490: Engine And Transmission
80-8 CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION <4G1-MPI (LHD) > M1801000400689 Connector B-01 B-02 B-03 B-04 B-05 B-06 B-07 B-09 symbol thru Control wiring harness B-10X B-15X B-16X B-17X B-26 B-18 Earth cable Battery wiring harness Connector colour code...
Page 491 80-9 CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION <4G1-MPI (LHD) > (CONTINUED) Connector B-101 B-102 B-103 B-104 B-105 symbol B-118 -101 thru -118 B-107 B-117 B-108 Control wiring harness Earth cable Battery wiring harness Connector colour code B : Black B-116 BR : Brown G : Green...
Page 492: Engine And Transmission <4G1-Mpi (Rhd)
80-10 CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION <4G1-MPI (RHD) > M1801000400690 Connector B-09 B-02 B-03 B-04 B-05 B-06 B-07 B-01 symbol thru B-10X B-14X Control wiring B-15X harness B-16X B-17X B-26 B-18 Earth cable Battery wiring harness Connector colour code B-25 B : Black...
Page 493 80-11 CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION <4G1-MPI (RHD) > (CONTINUED) Connector B-101 B-102 B-103 B-104 B-105 B-118 symbol -101 thru -118 B-107 B-117 Control wiring B-108 harness Earth cable Battery wiring harness Connector colour code B : Black BR : Brown B-116 G : Green...
Page 494: Engine And Transmission <4G6-Mpi (Lhd)
80-12 CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION <4G6-MPI (LHD) > M1801000400708 Connector B-01 B-02 B-05 B-06 B-07 B-08 B-03 B-04 symbol Earth B-09 cable thru Control wiring harness B-10X B-16X B-17X B-26 B-18 Battery wiring harness Connector colour code B-25 B : Black...
Page 495 80-13 CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION <4G6-MPI (LHD) > (CONTINUED) Connector B-105 B-101 B-103 B-104 B-106 symbol -101 B-118 Earth cable thru -118 B-112 B-117 B-116 Battery wiring harness Connector colour code B : Black Control wiring BR : Brown harness G : Green...
Page 496: Engine And Transmission <4G6-Mpi (Rhd)
80-14 CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION <4G6-MPI (RHD) > M1801000400719 Connector B-02 B-03 B-04 B-05 B-06 B-07 B-01 symbol Earth B-08 cable B-09 thru B-10X B-14X B-16X B-17X Control wiring harness B-18 B-26 Connector colour Battery wiring code harness B : Black...
Page 497 80-15 CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION <4G6-MPI (RHD) > (CONTINUED) Connector B-105 B-101 B-103 B-104 B-106 symbol -101 Earth cable thru -118 B-117 B-118 B-112 B-116 Battery wiring harness Control wiring Connector colour harness code B : Black BR : Brown G : Green GR : Gray...
Page 498: Dash Panel
80-16 CONFIGURATION DIAGRAMS DASH PANEL DASH PANEL DASH PANEL <LHD> M1801000601040 Connector C-01 C-02 C-03 C-04 C-05 C-06 C-08 C-09 symbol Instrument panel wiring harness C-10 thru C-36 C-35 C-11 C-34 C-33 C-12 C-32 C-31 Control wiring harness C-29 Connector colour code C-13 B : Black...
Page 499 80-17 CONFIGURATION DIAGRAMS DASH PANEL DASH PANEL <LHD> (CONTINUED) Connector C-101 C-102 C-103 C-104 C-106 C-107 symbol Antenna feeder -101 cable thru -140 C-108 C-140 A/C wiring harness C-109 C-139 Instrument panel C-110 Control wiring wiring harness harness C-112 Connector colour C-133 code B : Black...
Page 500 80-18 CONFIGURATION DIAGRAMS DASH PANEL DASH PANEL <LHD> (CONTINUED) JUNCTION BLOCK Connector symbol (Front view) (Rear view) -201 C-208 C-209 C-210 C-211 C-225 thru -227 C-224 C-212 STEERING COLUMN C-223 C-213 C-222 Clock spring C-214 C-221 C-215 C-207 C-220 C-219 C-218 C-217 C-227...
Page 501: Dash Panel
80-19 CONFIGURATION DIAGRAMS DASH PANEL DASH PANEL <RHD> M1801000601051 Connector C-09 C-08 C-04 C-07 C-06 C-05 C-02 C-01 symbol Instrument panel wiring harness thru C-36 C-32 C-10 C-34 C-33 C-11 C-31 Control wiring harness C-30 C-37 C-28 Connector colour code B : Black BR : Brown C-16...

Page 502 80-20 CONFIGURATION DIAGRAMS DASH PANEL DASH PANEL <RHD> (CONTINUED) Connector C-108 C-107 C-106 C-105 C-103 C-102 C-101 symbol Antenna -101 feeder thru cable -140 C-139 A/C wiring harness C-109 Instrument panel wiring harness C-140 C-110 C-111 C-138 Control wiring C-113 harness Connector colour C-115...
Page 503 80-21 CONFIGURATION DIAGRAMS DASH PANEL DASH PANEL <RHD> (CONTINUED) JUNCTION BLOCK Connector symbol (Front view) (Rear view) -201 C-208 C-209 C-210 C-211 C-225 thru -227 C-224 C-212 STEERING COLUMN C-223 C-213 C-222 C-214 Clock spring C-221 C-216 C-207 C-220 C-219 C-218 C-217 C-227...
Page 504: Floor And Roof
80-22 CONFIGURATION DIAGRAMS FLOOR AND ROOF FLOOR AND ROOF FLOOR AND ROOF <SEDAN (LHD) > M1801000900844 Connector D-01 D-02 D-03 D-04 D-05 D-06 D-07 D-08 D-13 symbol <Vehicles with curtain air bag> D-04 D-36 D-06 D-37 D-35 D-14 D-34 Antenna feeder cable Antenna feeder cable...

Page 505: Floor And Roof
80-23 CONFIGURATION DIAGRAMS FLOOR AND ROOF FLOOR AND ROOF <SEDAN (RHD) > M1801000900855 Connector D-01 D-02 D-03 D-08 D-13 D-04 D-05 D-06 D-07 <Vehicles with curtain air bag> symbol Antenna feeder cable D-04 D-36 D-06 D-37 D-35 Roof wiring harness D-14 D-34 Roof wiring...

Page 506: Floor And Roof
80-24 CONFIGURATION DIAGRAMS FLOOR AND ROOF FLOOR AND ROOF <WAGON (LHD) > M1801000900866 Connector D-02 D-03 D-01 D-04 D-05 D-07 D-08 D-09 D-10 D-11 D-12 symbol <Vehicles with curtain air bag> Antenna D-13 feeder D-35 D-04 D-36 D-06 D-37 cable D-34 Roof wiring harness...

Page 507: Floor And Roof
80-25 CONFIGURATION DIAGRAMS FLOOR AND ROOF FLOOR AND ROOF <WAGON (RHD) > M1801000900877 Connector D-01 D-02 D-03 D-04 D-05 D-07 D-08 D-09 D-10 D-11 D-12 symbol <Vehicles with curtain air bag> D-13 D-04 D-36 D-06 D-37 D-35 Antenna feeder cable Roof wiring harness D-14...

Page 508: Door
80-26 CONFIGURATION DIAGRAMS DOOR DOOR DOOR <LHD> M1801001400585 Connector symbol Driver's side Passenger's side E-01 E-10 E-02 E-11 Front Front E-06 E-05 E-04 E-03 E-16 E-15 E-14 E-13 E-12 Connector colour Rear Rear code B : Black BR : Brown G : Green GR : Gray L : Blue...
Page 509: Door
80-27 CONFIGURATION DIAGRAMS DOOR DOOR <RHD> M1801001400596 Connector symbol Driver's side Passenger's side E-10 E-01 E-11 E-02 Front Front E-16 E-15 E-05 E-13 E-12 E-06 E-20 E-04 E-03 Connector colour Rear Rear code B : Black BR : Brown G : Green GR : Gray L : Blue None : Milk white...

Page 510: Trunk (Luggage Compartment)
80-28 CONFIGURATION DIAGRAMS TRUNK (LUGGAGE COMPARTMENT) TRUNK (LUGGAGE COMPARTMENT) TRUNK (LUGGAGE COMPARTMENT) <SEDAN (LHD) > M1801001500355 Connector symbol F-01 F-03 F-04 F-05 F-06 Defogger earth F-08 Antenna feeder cable Floor wiring F-22 harness (RH) F-10 F-11 Floor wiring harness (LH) Connector colour code B : Black...

Page 511: Trunk (Luggage Compartment)
80-29 CONFIGURATION DIAGRAMS TRUNK (LUGGAGE COMPARTMENT) TRUNK (LUGGAGE COMPARTMENT) <SEDAN (RHD) > M1801001500366 Connector symbol F-04 F-03 F-05 F-07 F-08 F-22 Antenna feeder cable Defogger earth F-06 F-10 Floor wiring harness (RH) F-01 F-11 Floor wiring harness (LH) F-14 Connector colour code Rear bumper B : Black...

Page 512: Tailgate
80-30 CONFIGURATION DIAGRAMS TAILGATE TAILGATE TAILGATE <WAGON (LHD) > M1801001900223 Connector symbol F-01 F-06 F-02 F-03 F-10 F-22 Antenna feeder cable F-07 F-08 Floor wiring harness (RH) Defogger Floor wiring earth harness (LH) F-09 F-21 F-11 Tailgate wiring harness F-12 Connector colour code B : Black...
Page 513: Tailgate
80-31 CONFIGURATION DIAGRAMS TAILGATE TAILGATE <WAGON (RHD) > M1801001900234 Connector symbol F-22 F-01 F-06 F-03 F-10 F-07 Antenna feeder cable Floor wiring harness (RH) F-08 Defogger Floor wiring F-09 earth harness (LH) F-21 F-11 Tailgate wiring harness F-12 Rear bumper wiring harness F-13 Connector colour...

Page 514 NOTES...
Page 515 70-1 GROUP 70 COMPONENT LOCATIONS CONTENTS ECU ......70-2 SOLENOID VALVE....70-11 RELAY .
Page 516: Ecu
70-2 COMPONENT LOCATIONS M1701000500140 Name Symbol Name Symbol A/C-ECU Cooling fan motor drive control unit ABS-ECU Front-ECU Column switch (incorporating Immobilizer-ECU Column-ECU) Engine-A/T-ECU <A/T> Power window main switch (incorporating ECU) Engine-ECU <M/T> Power window sub switch (incorporating ECU) ETACS-ECU SRS-ECU <LHD>...
Page 517 70-3 COMPONENT LOCATIONS AC304537 NOTE: *: also equipped on the rear doors. <LHD> Cooling fan motor drive control unit ABS-ECU Hydraulic unit Radiator fan AC100209 AC AC300571 <RHD> Column switch (incorporating ABS-ECU column-ECU) Hydraulic unit AC206790 AC301746 Front-ECU Battery A/C-ECU AC301728 AC301732...
Page 518 70-4 COMPONENT LOCATIONS Junction Engine-ECU <M/T> or block engine-A/T-ECU <A/T> ETACS-ECU AC100229 AI AC301739 Immobilizer-ECU Power window sub switch (incorporating ECU) AC301733 AB AC301749AB Power window main switch (incorporating ECU) SRS-ECU AC301747 AB AC301748 AB...
Page 519: Relay
70-5 COMPONENT LOCATIONS RELAY RELAY M1701000400369 Name Symbol Name Symbol A/C compressor relay Heated seat relay A/T control relay Horn relay Accessory socket relay Ignition coil relay Blower relay Power window relay Engine control relay Radiator fan relay Front fog lamp relay Rear fog lamp relay Fuel pump relay (1) Rear window defogger relay...
Page 520: Sensor
70-6 COMPONENT LOCATIONS SENSOR SENSOR M1701000600567 Name Symbol Name Symbol Air cleaner air flow sensor <4G6> Output shaft speed sensor <A/T> Air thermo sensor Side impact sensor (Front) Camshaft position sensor Side impact sensor (Rear) Engine control detonation sensor Throttle body throttle sensor Engine control oxygen sensor (Front) Vehicle speed sensor <M/T>...
Page 521 70-7 COMPONENT LOCATIONS SENSOR <4G1> Engine crank angle sensor connector Engine crank angle sensor Timing belt front Timing belt front lower cover upper cover AC208762 <4G6> Crankshaft Engine crank Engine crank angle sprocket angle sensor sensor connector Heat protector AC302008 <4G1>...
Page 522 70-8 COMPONENT LOCATIONS SENSOR <4G1> <4G1> Engine control oxygen sensor Heat protector (Front) connector Camshaft position sensor Engine control Rocker cover oxygen sensor (Front) AC206644 AD AC301754 <4G6> <4G6> Heat protector Engine control Rocker cover oxygen sensor (Front) connector Camshaft position sensor Engine control oxygen sensor (Front)
Page 523 70-9 COMPONENT LOCATIONS SENSOR <A/T> Air cleaner bracket Output shaft Centre speed sensor pillar Side impact sensor (Front) Input shaft speed sensor AC206775 AD AC300517 AD Blower assembly Side impact sensor (Rear) Rear Air thermo seat belt sensor AC301755 AC300534 AC Wheel speed sensor (Front) Wheel speed sensor...
Page 524: Fusible Link And Fuse
70-10 COMPONENT LOCATIONS FUSIBLE LINK AND FUSE FUSIBLE LINK AND FUSE M1701000100476 Name Symbol Name Symbol Fuses No.1 to 20 Fusible links No.1 to 5 (Passenger compartment) (Engine compartment) Fuses No.6 to 25 Fusible link No.26 (Engine compartment) (Battery positive terminal) AC301758AD Battery Fusible link No.26...
Page 525: Earth Cable
70-11 COMPONENT LOCATIONS EARTH CABLE EARTH CABLE M1701001000308 <4G1> Timing belt front upper cover AC206557 <4G6> Throttle body AC302485 AC303148 SOLENOID VALVE M1701000800516 Name Symbol Name Symbol A/T control solenoid valve assembly Emission solenoid valve (Purge control system) <4G6> Emission solenoid valve (EGR system) B Hydraulic unit (incorporating solenoid valve) Emission solenoid valve (Purge control...
Page 526 70-12 COMPONENT LOCATIONS SOLENOID VALVE <LHD> <RHD> AC302007 <LHD> <4G6> Hydraulic unit Emission solenoid valve (incorporating (Purge control system) solenoid valve) Emission solenoid valve (EGR system) Intake manifold AC100230 AC302484 <4G1> Idle speed <RHD> control servo Hydraulic unit (incorporating solenoid valve) Air cleaner Emission solenoid valve cover...
Page 527: Diode
70-13 COMPONENT LOCATIONS DIODE Transmission assembly A/T control solenoid valve assembly connector A/T control solenoid valve assembly Inhibitor switch AC208684 DIODE M1701000900223 <WAGON> Diode AC300441 AC301240...
Page 528: Earth
70-14 COMPONENT LOCATIONS EARTH EARTH M1701000300362 <SEDAN-L.H. drive vehicles> AC301175 <SEDAN-R.H. drive vehicles> AC301176 AC301751 NOTE: Same earth numbers are used in the circuit diagram.
Page 529 70-15 COMPONENT LOCATIONS EARTH <WAGON-L.H. drive vehicles> AC301177 <WAGON-R.H. drive vehicles> AC301178 AC301756 NOTE: Same earth numbers are used in the circuit diagram.
Page 530 70-16 COMPONENT LOCATIONS EARTH Glove box AC301742 AC300427 <LHD> Diagnosis connector AC301741AB AC301737 AB <RHD> <LHD> Windshield wiper arm Junction AC100195 block AC300429 3 16 Steering column <RHD> <RHD> shaft assembly AC212109 AC AC206768 AD...
Page 531 70-17 COMPONENT LOCATIONS EARTH <SEDAN> Rear seatback hook (RH) Rocker cover AC301208 AC301743 11 12 <WAGON> Rear Relay box speaker (RH) AC212111 AC300437 Rear wiper motor Air cleaner assembly AC301745 AC212112 SRS-ECU Heat protector AC301744 AC301750 AB...
Page 532: Inspection Connector And Spare Connector
70-18 COMPONENT LOCATIONS INSPECTION CONNECTOR AND SPARE CONNECTOR <SEDAN> Rear seatback hook (LH) SRS-ECU AC301210 AC300436 AC <WAGON> <LHD> Junction block Rear speaker (LH) AC300440 AC208871AC INSPECTION CONNECTOR AND SPARE CONNECTOR M1701000200343 Name Symbol Name Symbol Diagnosis connector Spare connector (for front fog lamp relay) Engine speed detection connector Spare connector (for front fog lamp...
Page 533 70-19 COMPONENT LOCATIONS INSPECTION CONNECTOR AND SPARE CONNECTOR Front-ECU Spare connector Spare connector (for front fog lamp (for audio) relay) Engine speed detection connector AC212306 AC301735 AB Spare connector (for front fog lamp) Diagnosis connector Heat protector AC100188 AH AC301740 Spare connector (for front fog lamp switch)
Page 534 NOTES...
Page 535 55-1 GROUP 55 HEATER, AIR CONDITIONER AND VENTILATION CONTENTS SERVICE SPECIFICATIONS..55-3 DIAGNOSIS TROUBLESHOOTING FLOW ......55-5 SYMPTOM CHART .
Page 536 55-2 ON-VEHICLE SERVICE... 55-69 BLOWERMOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION SIGHT GLASS REFRIGERANT DAMPER CONTROL MOTOR ..55-85 LEVEL TEST......55-69 MAGNETIC CLUTCH TEST .
Page 537 55-3 HEATER, AIR CONDITIONER AND VENTILATION SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS M1552000300292 Item Standard value 750 ± 100 Idle speed r/min 850 ± 100 Idle-up speed r/min Resistor (for blower motor) Ω 2.54 1.24 0.3 − 0.5 Air gap (magnetic clutch) mm LUBRICANTS M1552000400299 Item...
Page 538 55-4 HEATER, AIR CONDITIONER AND VENTILATION SPECIAL TOOLS SPECIAL TOOLS M1552000600312 Tool Tool number Name Application MB991367 Special spanner Armature mounting nut of compressor removal and installation B991367 MB991386 MB991223 Harness set Continuity check and voltage A:MB991219 A: Test harness measurement at harness wire or B:MB991220 B: LED harness...
Page 539 55-5 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW SYMPTOM CHART M1552009600364 M1552009900611 Refer to GROUP 00, How to Use NOTE: Refer to GROUP 14, Troubleshooting P.14-5 Troubleshooting/Inspection Service Points P.00-5. for the condenser fan. Symptom Inspection Reference Procedure Page When the ignition switch is "ON"...
Page 540 55-6 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING INSPECTION PROCEDURE 2: Inside/Outside Air Selection is not possible. Outside/Inside Air Selection Damper Control Motor Circuit IGNITION SWITCH (IG2) OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR A/C-ECU <LHD> <RHD> HEATER CONTROL PANEL Wire colour code B : Black LG : Light green G : Green...
Page 541 55-7 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING DIAGNOSIS STEP 3. Voltage measurement at the C-107 outside/inside air selection damper control motor connector. STEP 1. Check the defogger and A/C operations. Connector: C-107 Q: Do the defogger and A/C work normally? <L.H.D.>...
Page 542 55-8 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 4. Check the wiring harness between C-107 Connector: C-106 outside/inside air selection damper control motor <L.H.D.> C-106 connector terminal No.7 and the ignition switch (IG2). Connector: C-107 <L.H.D.> AC303804 Connector: C-106 Harness side <R.H.D.>...
Page 543 55-9 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 5. Connector check: C-139 A/C-ECU Connectors: C-209, C-210 connector <R.H.D.> Junction block (front view) Connector: C-139 <L.H.D.> C-210 C-209 Harness side C-139 (B) C-209 Harness side AC303802 Connector: C-139 <R.H.D.> C-210 Harness side Harness side C-139 (B) AC303823...
Page 544 55-10 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 6. Check the wiring harness between C-107 STEP 7. Check the wiring harness between C-107 outside/inside air selection damper control motor outside/inside air selection damper control motor connector (terminals 6 and 4) and C-139 A/C-ECU connector (terminals 6 and 4) and C-139 A/C-ECU connector (terminals 2 and 3).
Page 545 55-11 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING INSPECTION PROCEDURE 3: When the A/C is Operating, Temperature Inside the Passenger Compartment does not Decrease (Cool Air is not Emitted). <L.H.D.> A/C-ECU System Circuit ENGINE-ECU ENGINE-A/T-ECU DUAL PRESSURE SWITCH A/C-ECU HEATER CONTROL PANEL RESISTOR AIR THERMO SENSOR...
Page 546 55-12 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING COMMENTS ON TROUBLE SYMPTOM STEP 4. Connector check: B-114 A/C compressor If cool air is not distributed when the A/C switch is on, connector and C-123 engine-ECU connector the air thermo sensor or the A/C compressor relay <M/T>...
Page 547 55-13 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 5. Voltage measurement at the B-114 A/C Connector C-123 compressor connector. (Harness side) Connector: B-114 <4G1-L.H.D.> Harness side AC305159 (3) Disconnect engine-ECU connector C-123, and B-114 (B) earth terminal 8. <M/T> AC303782 Connector C-122 Connector: B-114 (Harness side)
Page 548 55-14 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 6. Connector check: C-139 A/C-ECU STEP 8. Connector check: C-109 resistor connector connector Connector: C-109 Connector: C-139 <L.H.D.> <L.H.D.> Harness side C-139 (B) Harness side AC303802 AC303804 Q: Is the check result normal? Q: Is the check result normal? Go to Step 7.
Page 549 55-15 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 10. Connector check: A-31 dual pressure STEP 13. Check the wiring harness between switch connector C-106 air thermo sensor connector (terminals 4 and 5) and C-139 A/C-ECU connector (terminals Connector: A-31 16 and 13). <L.H.D.>...
Page 550 55-16 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 14. Check the wiring harness between A-31 STEP 15. Connector check: C-125 engine-ECU dual pressure switch connector terminal No.1 connector <M/T> or C-126 engine-A/T-ECU and C-139 A/C-ECU connector terminal No.4. connector <A/T> Connectors: C-125 <M/T>, C-126 <A/T>...
Page 551 55-17 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING NOTE: STEP 16. Check the wiring harness between Connector: C-15 C-125 engine-ECU connector <M/T> terminal <L.H.D.> No.45 or C-126 engine-A/T-ECU connector <A/T> terminal No.83 and A-31 dual pressure switch connector terminal No.2. Connector: A-31 <L.H.D.>...
Page 552 55-18 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 17. Connector check: C-123 engine-ECU STEP 18. Check the wiring harness between connector <M/T> or C-124 engine-A/T-ECU C-123 engine-ECU connectors terminal No.24 connector <A/T> <M/T> or C-124 engine-A/T-ECU connectors terminal No.61 <A/T> and C-139 A/C-ECU Connectors: C-123 <M/T>, C-124 <A/T>...
Page 553 55-19 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING NOTE: STEP 20. Check the refrigerant temperature Connector: C-15 switch. <L.H.D.> Refer to P.55-95. Q: Is the refrigerant temperature switch operating properly? Go to Step 21. YES : Replace the refrigerant temperature switch. NO : C-15 (L) STEP 21.
Page 554 55-20 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING INSPECTION PROCEDURE 4: When the A/C is Operating, Temperature Inside the Passenger Compartment does not Decrease (Cool Air is not Emitted). <R.H.D.> A/C-ECU System Circuit ENGINE-ECU ENGINE-A/T-ECU DUAL PRESSURE SWITCH A/C-ECU HEATER CONTROL PANEL RESISTOR AIR THERMO SENSOR...
Page 555 55-21 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING COMMENTS ON TROUBLE SYMPTOM STEP 4. Connector check: B-114 A/C compressor If cool air is not distributed when the A/C switch is on, connector and C-123 engine-ECU connector the air thermo sensor or the A/C compressor relay <M/T>...
Page 556 55-22 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 5. Voltage measurement at the B-114 A/C Connector C-123 compressor connector. (Harness side) Connector: B-114 <4G1-R.H.D.> Harness side AC305159 (3) Disconnect engine-ECU connector C-123, and B-114 (B) earth terminal 8. <M/T> AC303786 Connector C-122 Connector: B-114 (Harness side)
Page 557 55-23 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 6. Connector check: C-139 A/C-ECU STEP 8. Connector check: C-109 resistor connector connector Connector: C-109 Connector: C-139 <R.H.D.> <R.H.D.> Harness side Harness side C-139 (B) AC303818 AC303816 Q: Is the check result normal? Q: Is the check result normal? Go to Step 7.
Page 558 55-24 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 10. Connector check: A-31 dual pressure STEP 13. Check the wiring harness between switch connector C-106 air thermo sensor connector (terminals 4 and 5) and C-139 A/C-ECU connector (terminals 4 Connector: A-31 and 6).
Page 559 55-25 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 14. Check the wiring harness between A-31 STEP 15. Connector check: C-125 engine-ECU dual pressure switch connector terminal No.1 connector <M/T> or C-126 engine-A/T-ECU and C-139 A/C-ECU connector terminal No.1. connector <A/T> Connector: A-31 Connectors: C-125 <M/T>, C-126 <A/T>...
Page 560 55-26 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING NOTE: STEP 16. Check the wiring harness between Connector: C-28 C-125 engine-ECU connector <M/T> terminal <RHD> No.45 or C-126 engine-A/T-ECU connector <A/T> terminal No.83 and A-31 dual pressure switch connector terminal No.2. Connector: A-31 <R.H.D.>...
Page 561 55-27 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 17. Connector check: C-123 engine-ECU STEP 18. Check the wiring harness between connector <M/T> or C-124 engine-A/T-ECU C-123 engine-ECU connectors terminal No.24 connector <A/T> <M/T> or C-124 engine-A/T-ECU connectors terminal No.61 <A/T> and C-139 A/C-ECU Connectors: C-123 <M/T>, C-124 <A/T>...
Page 562 55-28 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 19. Check the magnetic clutch operation. STEP 21. Check the air thermo sensor. Refer to P.55-93. Refer to P.55-90. Q: Can the sound of the magnetic clutch (click) be Q: Is the air thermo sensor in good condition? Go to Step 22.
Page 563 55-29 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING INSPECTION PROCEDURE 5: Blower Fan and Motor do not Turn. Blower Motor Circuit IGNITION FUSIBLE LINK SWITCH (IG2) <RHD> <LHD> BLOWER RELAY BLOWER SWITCH <LHD> <RHD> <LHD> <RHD> BLOWER MOTOR Wire colour code B : Black LG : Light green G : Green...
Page 564 55-30 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING COMMENTS ON TROUBLE SYMPTOM STEP 3. Resistance measurement at the C-110 If the blower fan and motor does not turn when the blower motor connector. blower switch is operated, the blower switch may be Connector: C-110 defective.
Page 565 55-31 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 4. Check the wiring harness between C-110 STEP 5. Voltage measurement at C-110 blower blower motor connector terminal No.2 and body motor connector. earth. Connector: C-110 <L.H.D.> Connector: C-110 <L.H.D.> Harness side Harness side AC303804 AC303804...
Page 566 55-32 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 6. Connector check: C-214 blower relay STEP 8. Voltage measurement at C-214 blower connector relay connector. Connector: C-214 Connector: C-214 <L.H.D.> <L.H.D.> Junction block (front view) Junction block (front view) Junction block side Junction block side AC303808 AC303808...
Page 567 55-33 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING Q: Is the check result normal? STEP 9. Check the wiring harness between C-214 The trouble can be an intermittent YES : blower relay connector terminal No.3 and the malfunction (Refer to GROUP 00, How to ignition switch (IG2).
Page 568 55-34 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 11. Check the wiring harness between STEP 12. Check the wiring harness between C-214 blower relay connector terminal No.1 and C-214 blower relay connector terminal No.1 and earth. earth. Connectors: C-212, C-214 Connectors: C-212, C-214 <L.H.D.>...
Page 569 55-35 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 13. Voltage measurement at C-214 blower STEP 14. Check the wiring harness between relay connector. C-214 blower relay connector terminal No.5 and fusible link (1). Connector: C-214 <L.H.D.> Connectors: C-211, C-214 Junction block (front view) <L.H.D.>...
Page 570 55-36 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING Q: Is the check result normal? STEP 15. Check the wiring harness between The trouble can be an intermittent YES : C-214 blower relay connector terminal No.5 and malfunction (Refer to GROUP 00, How to fusible link (1).
Page 571 55-37 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 18. Check the wiring harness between Connectors: C-210, C-214 C-140 blower switch connector terminal No.2 and <R.H.D.> C-214 blower relay connector terminal No.4. Junction block (front view) Connector: C-140 C-210 <L.H.D.> Harness side C-214 AC303802 Harness side...
Page 572 55-38 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING Q: Is the check result normal? STEP 19. Check the wiring harness between The trouble can be an intermittent YES : C-110 blower motor connector terminal No.1 and malfunction (Refer to GROUP 00, How to C-140 blower switch connector terminal No.6.
Page 573 55-39 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING INSPECTION PROCEDURE 6: Blower Air Amount cannot be Changed. Blower Switch and Resistor Circuit BLOWER RELAY BLOWER SWITCH RESISTOR <LHD> <RHD> BLOWER MOTOR Wire colour code B : Black LG : Light green G : Green L : Blue W : White...
Page 574 55-40 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 2. Connector check: C-140 blower switch STEP 3. Check the blower switch continuity. connector and C-109 resistor connector Refer to P.55-79. Q: Is the blower switch continuity in good condition? Connector: C-109 Go to Step 4.
Page 575 55-41 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING Q: Is the check result normal? Connector: C-140 Go to Step 7. YES : <L.H.D.> Repair the connector. NO : STEP 7. Check the wiring harness between C-110 Harness side blower motor connector (terminal 1) and C-109 resistor connector (terminal 2).
Page 576 55-42 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING INSPECTION PROCEDURE 7: Rear Window Defogger Function does not Operate. Rear Window Defogger Circuit IGNITION SWITCH (IG2) FUSIBLE LINK <RHD> <LHD> REAR WINDOW DEFOGGER RELAY <LHD> <RHD> <RHD> REAR WINDOW REAR WINDOW <LHD> DEFOGGER DEFOGGER A/C-ECU OR...
Page 577 55-43 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING COMMENTS ON TROUBLE SYMPTOM STEP 2. Connector check: F-22 rear window If the rear window defogger does not operate when defogger connector the rear window defogger switch is turned on, the Connector: F-22 rear window defogger relay system may be <WAGON - L.H.D.>...
Page 578 55-44 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING (2) Turn the ignition switch to the "ON" position. STEP 3. Voltage measurement at F-22 rear (3) Turn the rear window defogger switch to the "ON window defogger connector. " position. Connector: F-22 SEDAN <L.H.D.>...
Page 579 55-45 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 4. Connector check: C-213 rear window STEP 6. Voltage measurement at C-213 rear defogger relay connector window defogger relay connector. Connector: C-213 Connector: C-213 <L.H.D.> <L.H.D.> Junction block (front view) Junction block (front view) Junction block side Junction block side AC303808...
Page 580 55-46 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 7. Check the wiring harness between C-213 STEP 8. Check the wiring harness between C-213 rear window defogger relay connector terminal rear window defogger relay connector terminal No.5 and the fusible link (1). No.5 and the fusible link (1).
Page 581 55-47 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING Prior to the wiring harness inspection, check STEP 10. Check the wiring harness between intermediate connector C-121 and C-138 and C-213 rear window defogger relay connector junction block connector C-211, and repair if terminal No.3 and ignition switch (IG2).
Page 582 55-48 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING NOTE: Prior to the wiring harness inspection, check Connectors: C-213, C-216 junction block connector C-210, and repair if <R.H.D.> necessary. Junction block (front view) • Check the rear window defogger relay power supply line for open circuit. Q: Is the check result normal? The trouble can be an intermittent YES :...
Page 583 55-49 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING Connector: F-22 STEP 12. Connector check: C-139 A/C-ECU <WAGON - R.H.D.> connector or heater control unit connector Harness side Connector: C-139 <L.H.D.> Harness side C-139 (B) AC303956 Connector: F-22 <SEDAN - R.H.D.> AC303802 Connector: C-139 Harness side <R.H.D.>...
Page 584 55-50 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 13. Check the wiring harness between Connectors: C-212, C-213 C-213 rear window defogger relay connector <R.H.D.> Junction block (front view) terminal No.1 and C-139 A/C-ECU connector or heater control unit connector terminal No.1 <L.H.D.>...
Page 585 55-51 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING Q: Is the check result normal? STEP 14. Connector check: F-06 rear window Go to Step 15. YES : defogger connector Repair the connector. NO : Connector: F-06 <WAGON - L.H.D.> STEP 15. Resistance measurement at F-06 rear Harness side window defogger connector.
Page 586 55-52 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING Q: Is the check result normal? STEP 16. Check the wiring harness between F-06 The trouble can be an intermittent YES : rear window defogger connector terminal No.1 malfunction (Refer to GROUP 00, How to and earth.
Page 587 55-53 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING INSPECTION PROCEDURE 9: Malfunction of the A/C-ECU Power Supply System. <L.H.D.> A/C-ECU Power Supply Circuit IGNITION SWITCH (IG2) A/C-ECU HEATER CONTROL PANEL Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow...
Page 588 55-54 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING DIAGNOSIS STEP 3. Check the wiring harness between C-139 A/C-ECU connector terminal No.10 and the ignition switch (IG2). STEP 1. Connector check: C-139 A/C-ECU connector Connector: C-139 <L.H.D.> Connector: C-139 <L.H.D.> Harness side C-139 (B) Harness side C-139 (B)
Page 589 55-55 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 4. Resistance measurement resistance at STEP 5. Check the wiring harness between C-139 C-139 A/C-ECU connector. A/C-ECU connector terminal No.12 and the earth. Connector: C-139 Connector: C-139 <L.H.D.> <L.H.D.> Harness side Harness side C-139 (B) C-139 (B) AC303802...
Page 590 55-56 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING INSPECTION PROCEDURE 10: Malfunction of the A/C-ECU Power Supply System. <R.H.D.> A/C-ECU Power Supply Circuit IGNITION SWITCH (IG2) A/C-ECU HEATER CONTROL PANEL Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow...
Page 591 55-57 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING DIAGNOSIS STEP 3. Check the wiring harness between C-139 A/C-ECU connector terminal No.7 and the ignition switch (IG2). STEP 1. Connector check: C-139 A/C-ECU connector Connector: C-139 <R.H.D.> Connector: C-139 <R.H.D.> Harness side C-139 (B) Harness side C-139 (B)
Page 592 55-58 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING Q: Is the check result normal? STEP 5. Check the wiring harness between C-139 The trouble can be an intermittent YES : A/C-ECU connector terminal No.3 and the earth. malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5).
Page 593 55-59 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING INSPECTION PROCEDURE 11: A/C Compressor power supply system. A/C Compressor Circuit IGNITION BATTERY SWITCH (IG2) RELAY COMPRESSOR RELAY REFRIGERANT TEMPERATURE SWITCH ENGINE-ECU ENGINE-A/T-ECU MAGNETIC CLUTCH NOTE : M/T : A/T Wire colour code B : Black LG : Light green G : Green...
Page 594 55-60 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING COMMENTS ON TROUBLE SYMPTOM STEP 3. Voltage measurement at B-17X A/C If the power is not supplied to the A/C compressor, compressor relay connector. the A/C compressor circuit system may be Connector: B-17X defective..
Page 595 55-61 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 4. Check the wiring harness between B-17X Connectors: C-209, C-210 A/C compressor relay connector terminal No.2 <L.H.D.> and the ignition switch (IG2). Junction block (front view) Connector: B-17X C-210 Relay box side C-209 Front of vehicle...
Page 596 55-62 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 5. Check the wiring harness between B-17X Connectors: C-209, C-210 A/C compressor relay connector terminal No.2 <R.H.D.> Junction block (front view) and the ignition switch (IG2). Connector: B-17X C-210 C-209 Relay box side C-209 Front of Harness side...
Page 597 55-63 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 6. Voltage measurement at B-17X A/C STEP 7. Check the wiring harness between B-17X compressor relay connector. A/C compressor relay connector terminal No.1 and the battery. Connector: B-17X Connector: B-17X Relay box side Relay box side Front of vehicle...
Page 598 55-64 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 8. Connector check: B-114 A/C compressor STEP 9. Check the wiring harness between B-17X connector A/C compressor relay connector terminal No.4 and B-114 A/C compressor connector terminal Connector: B-114 No.1. <4G1-L.H.D.> Connector: B-17X Harness side Relay box side B-114 (B)
Page 599 55-65 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 10. Connector check: C-123 engine-ECU Connector: B-114 connector <M/T> or C-122 engine-A/T-ECU <4G1-R.H.D.> connector <A/T> Connectors: C-122 <A/T>, C-123 <M/T> Harness side <L.H.D.> B-114 (B) AC303786 Connector: B-114 <4G6-R.H.D.> C-122 (GR) Harness side C-123 (Y) Harness side C-122...
Page 600 55-66 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING STEP 11. Check the wiring harness between STEP 12. Check the wiring harness between C-123 engine-ECU connector terminal No.8 and C-122 engine A/T-ECU connector terminal No.20 B-17X A/C compressor relay connector terminal and B-17X A/C compressor relay connector No.3.
Page 601 55-67 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING CHECK AT ECU TERMINAL <L.H.D.> M1552010300527 <C-139> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AC300861AC Terminal No. Check item Checking requirement Normal condition Rear defogger switch Defogger switch: ON Defogger switch: OFF System voltage...
Page 602 55-68 HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING CHECK AT ECU TERMINAL <R.H.D.> M1552010300538 <C-139> AC304990 AB Terminal No. Check item Checking requirement Normal condition Output to the engine-A/T-ECU A/C stopped (A/C1) • A/C switch: ON System voltage • Blower switch: ON Output to the engine-A/T-ECU When the A/C is under low load System voltage (A/C2)
Page 603: On-Vehicle Service
55-69 HEATER, AIR CONDITIONER AND VENTILATION ON-VEHICLE SERVICE ON-VEHICLE SERVICE SIGHT GLASS REFRIGERANT LEVEL 3. If the magnetic clutch is normal, there will be a "click." If the pulley and armature do not make TEST contact ("click"), there is a malfunction. M1552008400378 1.
Page 604: Charging
55-70 HEATER, AIR CONDITIONER AND VENTILATION ON-VEHICLE SERVICE CHARGING 5. Close the high and low-pressure valves of the gauge manifold. M1552001200362 CAUTION Be sure to connect the power plug of the vacuum pump to the vacuum pump adapter, and then High-pressure Low-pressure connect the power plug of the adapter to a 100-V...
Page 605 55-71 HEATER, AIR CONDITIONER AND VENTILATION ON-VEHICLE SERVICE CAUTION CAUTION Do not operate the compressor in the vacuum If the service can is inverted, liquid refrigerant condition; damage may occur. may be drawn into the compressor damaging it by liquid compression. Keep the service can 13.Loosen the valve of the adapter valve fully (valve upright to ensure that refrigerant is charged in closed), and turn off the vacuum pump adapter...
Page 606: Correcting Low Refrigerant Level In Case The Service Can In Used
55-72 HEATER, AIR CONDITIONER AND VENTILATION ON-VEHICLE SERVICE 25.After charging with refrigerant, turn the handle of 7. Install the quick joint (for low-pressure) to the the adaptor valve back all the way (valve closed). low-pressure service valve. 26.Tighten the charging valve handle (valve closed). NOTE: The low-pressure service valve should be Remove the quick joint (for low-pressure) from the connected to the suction hose.
Page 607: Performance Test
55-73 HEATER, AIR CONDITIONER AND VENTILATION ON-VEHICLE SERVICE PERFORMANCE TEST NOTE: The high-pressure service valve is on the A/C pipe and the low-pressure service valve is on M1552001400355 1. The vehicles to be tested should be in a place that the suction hose.
Page 608: Refrigerant Leak Repair Procedure
55-74 HEATER, AIR CONDITIONER AND VENTILATION ON-VEHICLE SERVICE REFRIGERANT LEAK REPAIR Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so that they are PROCEDURE at least 80 mm from the exhaust manifold. It is good M1552001500277 practice to inspect all flexible hose lines at least once LOST CHARGE...
Page 609: Power Relay Check
55-75 HEATER, AIR CONDITIONER AND VENTILATION ON-VEHICLE SERVICE POWER RELAY CHECK A/C COMPRESSOR RELAY CONTINUITY M1552008800309 CHECK BLOWER RELAY CONTINUITY CHECK A/C compressor relay Blower relay 1 2 3 Front of vehicle AC305307 AC305308 Battery voltage Tester Specified Battery voltage Tester Specified connection condition...
Page 610: Idle-Up Operation Check
55-76 HEATER, AIR CONDITIONER AND VENTILATION ON-VEHICLE SERVICE • Lamps, electric cooling fan and accessories: Set FAN CONTROL RELAY CONTINUITY to OFF CHECK • Transmission: Neutral ("N" or "P" for vehicles with A/T) • Steering wheel: Straightforward 2. Check whether or not the idle speed is the standard value.
Page 611: Heater Control Assembly And A/Cswitch
55-77 HEATER, AIR CONDITIONER AND VENTILATION HEATER CONTROL ASSEMBLY AND A/C SWITCH HEATER CONTROL ASSEMBLY AND A/C SWITCH REMOVAL AND INSTALLATION M1552002400347 AC304650 Removal steps (Continued) Removal steps Centre panel >>B<< Air mixing door control cable Manual air conditioner control panel connection assembly >>A<<...
Page 612 55-78 HEATER, AIR CONDITIONER AND VENTILATION HEATER CONTROL ASSEMBLY AND A/C SWITCH INSTALLATION SERVICE POINT >>B<< AIR MIX DOOR CABLE >>A<< BLOWER VENT CHANGEOVER CONNECTION DAMPER CABLE <R.H.D.> MAX. COOL position <R.H.D.> Mode locator MAX HOT position FACE Mode selection position damper link Mode locator...
Page 613: Inspection
55-79 HEATER, AIR CONDITIONER AND VENTILATION HEATER CONTROL ASSEMBLY AND A/C SWITCH INSPECTION Switch Tester connection Specified M1552014300927 position condition BLOWER SWITCH CONTINUITY CHECK 1 − 2, 2 − 4, 2 − 5, 2 − 6 Open circuit 0 (OFF) 1 −...
Page 614 55-80 HEATER, AIR CONDITIONER AND VENTILATION HEATER CONTROL ASSEMBLY AND A/C SWITCH DISASSEMBLY SERVICE POINT Insert a flat-tipped screwdriver into the clip through the inside of the control base and prize out the clip <<A>> BLOW VENT CHANGEOVER claw to disconnect the cables. DAMPER CABLE AND AIR MIX DAMPER CABLE REMOVAL (-) flat-tipped...
Page 615: Heater Unit, Heater Core, Blower Assembly And Evaporator Unit
55-81 HEATER, AIR CONDITIONER AND VENTILATION HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT REMOVAL AND INSTALLATION M1552011600457 Pre-removal and Post-installation Operation • Refrigerant draining and Refilling (Refer to Charging P.55-70 and Discharging P.55-72).
Page 616: Heater Unit
55-82 HEATER, AIR CONDITIONER AND VENTILATION HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT REMOVAL SERVICE POINT <<A>> FLEXIBLE SUCTION HOSE AND LIQUID PIPE B DISCONNECTION CAUTION As the compressor oil and receiver are highly moisture absorbent, use a non-porous material to plug the hose and nipples.
Page 617: Disassembly And Assembly
55-83 HEATER, AIR CONDITIONER AND VENTILATION HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT DISASSEMBLY AND ASSEMBLY <R.H.D.> M1551005400235 -Pipe coupling O ring A/C compressor oil: SUN PAG 56 AC304863 Disassembly steps (Continued) Disassembly steps Evaporator Foot duct (RH) Air thermo sensor clip Heater core Air thermo sensor...

Page 618: Blower Assembly
55-84 HEATER, AIR CONDITIONER AND VENTILATION HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT BLOWER ASSEMBLY DISASSEMBLY AND REASSEMBLY M1551005500179 AC3054131AB Disassembly steps (Continued) Disassembly steps Blower motor Joint duct Air filter Resister Blower case Outside/inside air selection damper control motor Hose...
Page 619: Blowermotor, Resistor And Outside/Inside Air Selection Damper Control Motor
55-85 HEATER, AIR CONDITIONER AND VENTILATION BLOWERMOTOR, RESISTOR AND OUTSIDE/ INSIDE AIR SELECTION DAMPER CONTROL MOTOR BLOWERMOTOR, RESISTOR AND OUTSIDE/ INSIDE AIR SELECTION DAMPER CONTROL MOTOR REMOVAL AND INSTALLATION M1551002800320 AC304885AB Outside/inside air selection Blower motor removal step damper control motor removal Front passenger's side under cover •...
Page 620: Inspection
55-86 HEATER, AIR CONDITIONER AND VENTILATION BLOWERMOTOR, RESISTOR AND OUTSIDE/ INSIDE AIR SELECTION DAMPER CONTROL MOTOR REMOVAL SERVICE POINT Use an ohmmeter to measure the resistance between the terminals. Check that the measured <<A>> BLOWER MOTOR REMOVAL value is at the standard value. NOTE: Standard value: Measurement terminal...
Page 621 55-87 HEATER, AIR CONDITIONER AND VENTILATION BLOWERMOTOR, RESISTOR AND OUTSIDE/ INSIDE AIR SELECTION DAMPER CONTROL MOTOR OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR CHECK CAUTION Inside air Outside air AC100625 Cut off the battery voltage when the damper is in the inside/outside air position. Lever position Battery Lever connection...
Page 622: Evaporator Assembly
55-88 HEATER, AIR CONDITIONER AND VENTILATION EVAPORATOR ASSEMBLY EVAPORATOR ASSEMBLY REMOVAL AND INSTALLATION <L.H.D.> M1552003600355 Pre-removal and Post-installation Operation • Refrigerant draining and Refilling (Refer to Charging P.55-70 and Discharging P.55-72). • Air cleaner assembly <1300,1600> or Air cleaner and air cleaner air flow sensor assembly <2000>...
Page 623: Removal And Installation
55-89 HEATER, AIR CONDITIONER AND VENTILATION EVAPORATOR ASSEMBLY REMOVAL AND INSTALLATION <R.H.D.> M1552003600366 Pre-removal and Post-installation Operation • Refrigerant draining and Refilling (Refer to Charging P.55-70 and Discharging P.55-72). • Air cleaner assembly <1300,1600> or Air cleaner and air cleaner air flow sensor assembly <2000> Removal and Installation (Refer to GROUP 15, Air cleaner P.15-3).

Page 624: Inspection
55-90 HEATER, AIR CONDITIONER AND VENTILATION EVAPORATOR ASSEMBLY REMOVAL SERVICE POINT INSPECTION M1552014300938 <<A>> FLEXIBLE SUCTION HOSE AND AIR THERMO SENSOR INSPECTION 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.
Page 625: Tension Pulley
55-91 HEATER, AIR CONDITIONER AND VENTILATION COMPRESSOR ASSEMBLY AND TENSION PULLEY COMPRESSOR ASSEMBLY AND TENSION PULLEY REMOVAL AND INSTALLATION M1552004100472 Pre-removal Operation Post-installation Operation • Refrigerant Discharging (Refer to P.55-72). • Drive Belt Tension Adjustment (1300, 1600: Refer to GROUP 11A, On-vehicles Service − Drive Belt Tension Check P.11A-7, 2000: Refer to GROUP 11C, On-vehicles Service −...
Page 626 55-92 HEATER, AIR CONDITIONER AND VENTILATION COMPRESSOR ASSEMBLY AND TENSION PULLEY REMOVAL SERVICE POINTS <<C>> DRIVE BELT REMOVAL <2000> The following operations will be needed due to the <<A>> FLEXIBLE SUCTION HOSE AND serpentine drive system with the alternator drive belt FLEXIBLE DISCHARGE HOSE auto tensioner.
Page 627: Inspection
55-93 HEATER, AIR CONDITIONER AND VENTILATION COMPRESSOR ASSEMBLY AND TENSION PULLEY INSTALLATION SERVICE POINT INSPECTION M1552014300949 >>A<< A/C COMPRESSOR COMPRESSOR MAGNETIC CLUTCH INSTALLATION OPERATION CHECK If a new compressor is installed, first adjust the amount of oil according to the procedures described Magnetic clutch connector below, and then install the compressor.
Page 628: Disassembly And Reassembly
55-94 HEATER, AIR CONDITIONER AND VENTILATION COMPRESSOR ASSEMBLY AND TENSION PULLEY DISASSEMBLY AND REASSEMBLY M1552004600660 16 ± 1 N·m AC100630 Magnetic clutch disassembly Cooling temperature switch Armature disassembly steps >>B<< Snap ring Snap ring Rotor Refrigerant temperature switch Snap ring O ring >>A<<...
Page 629: Inspection
55-95 HEATER, AIR CONDITIONER AND VENTILATION COMPRESSOR ASSEMBLY AND TENSION PULLEY >>B<< SNAP RING INSTALLATION INSPECTION M1552014300950 REFRIGERANT TEMPERATURE SWITCH Snap ring Clutch coil Rotor CAUTION Do not heat more than necessary. Tapered part AC001412 Thermometer Using snap ring pliers, fit the snap ring so that the snap ringís tapered part is on the outside.
Page 630: Fan Motor
55-96 HEATER, AIR CONDITIONER AND VENTILATION CONDENSER AND CONDENSER FAN MOTOR CONDENSER AND CONDENSER FAN MOTOR REMOVAL AND INSTALLATION M1552006700384 Pre-removal and Post-installation Operation • Refrigerant draining and Refilling (Refer to Charging P.55-70 and Discharging P.55-72). • Air cleaner cover and air flow sensor assembly Removal and Installation (Refer to GROUP 15, Air cleaner P.15-3).
Page 631: Inspection
55-97 HEATER, AIR CONDITIONER AND VENTILATION CONDENSER AND CONDENSER FAN MOTOR REMOVAL SERVICE POINT INSPECTION M1552014300961 <<A>> FLEXIBLE SUCTION HOSE AND CONDENSER FAN MOTOR CHECK 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.
Page 632: Refrigerant Line
55-98 HEATER, AIR CONDITIONER AND VENTILATION REFRIGERANT LINE REFRIGERANT LINE REMOVAL AND INSTALLATION <L.H.D.> M1552006400402 Pre-removal and Post-installation Operation • Refrigerant Draining and Refilling (Refer to P.55-70.) • Air Cleaner Removal and Installation (Refer to GROUP 15, Air cleaner P.15-3.) •...
Page 633: Removal And Installation
55-99 HEATER, AIR CONDITIONER AND VENTILATION REFRIGERANT LINE REMOVAL SERVICE POINT INSTALLATION SERVICE POINT <<A>> HOSE/PIPE DISCONNECTION >>A<< SUCTION HOSE INSTALLATION When replacing the suction hose, refill them with a CAUTION specified amount of compressor oil, and then install As the compressor oil and receiver are highly them.

Page 634 55-100 HEATER, AIR CONDITIONER AND VENTILATION REFRIGERANT LINE REMOVAL SERVICE POINT INSTALLATION SERVICE POINT <<A>> HOSE/PIPE DISCONNECTION >>A<< SUCTION HOSE INSTALLATION When replacing the suction hose, refill them with a CAUTION specified amount of compressor oil, and then install As the compressor oil and receiver are highly them.
Page 635: Ducts
55-101 HEATER, AIR CONDITIONER AND VENTILATION DUCTS DUCTS REMOVAL AND INSTALLATION M1553001000101 Cross-section A-A Clip Instrument panel AC304890 Foot duct Removal steps Air Outlet Removal steps Rear heater duct A (RH) upper side Centre Air Outlet Panel • Under cover (Refer to GROUP Centre Air Outlet 52A, Instrument panel P.52A-2.) Side Air Outlet...
Page 636: Ventilators
55-102 HEATER, AIR CONDITIONER AND VENTILATION VENTILATORS VENTILATORS REMOVAL AND INSTALLATION M1553001600318 Cross-Section A-A Cross-Section B-B Claw Claw AC304949 AC304951 Rear ventilation duct removal steps • Rear bumper assembly (Refer to GROUP 51, Rear bumper P.51-5.) Rear ventilation duct...
Page 637 52-1 GROUP 52 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM(SRS) CONTENTS INTERIOR ......... . SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .
Page 638 NOTES...

This manual is also suitable for:

Lancer wagon 2004

Mitsubishi MOTORS Lancer 2004 Workshop Manual

Emission Control

Mount

Exhaust

General Information

Special Tool

Service Specification

Air Cleaner

Inlet Manifold

Exhaust Manifold

Exhaust Pipe and Main Muffler

14-1 Group 14 Engine Cooling

37-1 Group 37 Power Steering

36-1 Group 36 Parking Brakes

Service Specifications

General Information

Lubricants

On-Vehicle Service

Parking Brake Lever

Parking Brake Cable

Parking Brake Lining and Drum

34-1 Group 34 Rear Suspension

Suspension

31-1 Group 31 Wheel and Tyre

Service Specifications

General Information

Troubleshooting

On-Vehicle Service

Wheel and Tyre

27-1 Group 27 Rear Axle

26-1 Group 26 Front Axle

42-1 Group 42 Body

Hood

Fender

Fuel Filler Lid

Window Glass

Strut Tower Bar

Door

Trunk Lid

Tailgate

Keyless Entry System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Mitsubishi MOTORS Lancer 2004