Mitsubishi Pajero Pinin 1999 Workshop Manual

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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

ELECTRICAL WIRING

BODY REPAIR MANUAL

ENGINE GROUP

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.

ªGDIº is a trade mark which Mitsubishi Motors

Corporation holds.

Mitsubishi Motors Corporation

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

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

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

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

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

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

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

Engine and Emission Control . . . .

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

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

Automatic Transmission . . . . . . . . .

IKRE00E1

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

EKRE00E1

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

BKRE00E1

PWEE9502-E

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

I603F509D j

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

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

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

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

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

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

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

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

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

Interior and Supplemental

Restraint System (SRS) . . . . . . . .

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

Heater, Air Conditioner and

Ventilation . . . . . . . . . . . . . . . . . . . . .

August 1999

Table of Contents

Chapters

Table of Contents

Troubleshooting

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Summary of Contents for Mitsubishi Pajero Pinin 1999

Page 1 Restraint System (SRS) ..Chassis Electrical ....ªGDIº is a trade mark which Mitsubishi Motors Corporation holds. Heater, Air Conditioner and Ventilation .
Page 2 (3) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B ± Supplemental Restraint System (SRS), before beginning any service or maintenance of any SRS component or any SRS-related component.
Page 3: Table Of Contents
00-1 GENERAL CONTENTS HOW TO USE THIS MANUAL ....Models ........Model Code .
Page 4: How To Use This Manual
00-2 GENERAL ± How to Use This Manual HOW TO USE THIS MANUAL SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS AND SERVICING EXPLANATIONS STANDARD VALUE This manual provides explanations, etc. concerning Indicates the value used as the standard for judging procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection or and servicing of the subject model.
Page 5: Model Indications
00-3 GENERAL ± How to Use This Manual MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. GDI: Indicates the gasoline direct injection. DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an engine.
Page 6: Explanation Of Manual Contents
00-4 GENERAL ± How to Use This Manual EXPLANATION OF MANUAL CONTENTS Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Component Diagram A diagram of the component parts is pro- vided near the front of each section in or- der to give a reader a better understand-...
Page 7 00-5 GENERAL ± How to Use This Manual Indicates the Indicates the Indicates the Indicates the page number. group title. section title. group num- ber. Denotes non-reus- able part. Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the ªStandard Parts- tightening-torque Tableº.
Page 8: How To Use
00-6 GENERAL ± How to Use Troubleshooting/Inspection Service Points HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS Troubleshooting of electronic control systems for which the MUT- II can be used follows the basic outline described below. Furthermore, even in systems for which the MUT- II cannot be used, part of these systems still follow this outline.
Page 9: Diagnosis Function
00-7 GENERAL ± GENERAL ± How to Use Troubleshooting/Inspection Service Points How to Use Troubleshooting/Inspection Service Points 6. INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms even though the results of inspection using the MUT- II show that all diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means of this chart.
Page 10: How To Use The Inspection Procedures
00-8 GENERAL ± How to Use Troubleshooting/Inspection Service Points HOW TO USE THE INSPECTION PROCEDURES The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order, and they first try to discover a problem with a connector or a defective component.
Page 11: Connector Measurement Service Points
00-9 GENERAL ± How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to the LOCK (OFF) position when connecting or disconnecting the connectors and turn the ignition switch ON when measuring, unless otherwise instructed. WHEN INSPECTING WITH CONNECTOR CONNECTED Harness connector (WITH CIRCUIT IN CONDITION OF CONTINUITY) Waterproof Connectors...
Page 12: Connector Inspection
00-10 GENERAL ± How to Use Troubleshooting/Inspection Service Points CONNECTOR INSPECTION Connector disconnected or improperly connected VISUAL INSPECTION Connector is disconnected or improperly connected Connector pins are pulled out Due to harness tension at terminal section Low contact pressure between male and female terminals Low connection pressure due to rusted terminals or foreign matter lodged in terminals Defective connector contact...
Page 13: Inspection Service Points For A Blown Fuse
00-11 GENERAL ± How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE Remove the fuse and measure the resistance between the load side of the fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition of 0 Ω...
Page 14: Vehicle Identification
00-12 GENERAL ± Vehicle Identification VEHICLE IDENTIFICATION VEHICLE INFORMATION CODE PLATE LOCATION Vehicle information code plate is riveted on the toeboard inside the engine compartment. CODE PLATE DESCRIPTION The plate shows model code, engine model, transmission model, and body colour code. Item Contents Contents...
Page 15: Models
4G93-DOHC (1,834 m ) V5M21 <5M/T> WMNJCRA V4AW4 <4A/T> WMRJCLA WMRJCRA MODEL CODE Items Contents Development MITSUBISHI PAJERO PININ Short wheelbase Engine type 1,800 m petrol engine 1 2 3 4 5 6 7 8 9 Sort Wagon Body style 3-door Transmission type...
Page 16: Chassis Number
00-14 GENERAL ± Vehicle Identification CHASSIS NUMBER The chassis number is stamped on the toeboard inside the engine compartment. Items Contents Steering wheel location Left hand drive Right hand drive Body style Standard roof Transmission type 5-speed manual transmission 4-speed automatic transmission Development order PAJERO PININ Short wheelbase Engine...
Page 17: Engine Model Number
00-15 GENERAL ± Vehicle Identification/Major Specifications ENGINE MODEL NUMBER 1. The engine model number is stamped on the cylinder block as shown below. Engine model Engine displacement m 4G93 1,834 2. The engine serial number is stamped near the engine model number.
Page 18 00-16 GENERAL ± Major Specifications Items H66WMNJCLA H66WMNJCRA H66WMRJCLA H66WMRJCRA Vehicle Overall length 1 3,735/3,765* dimensions Overall width 2 1,695 Overall height (unladen) 3 1,695/1,735* /1,705* Wheelbase 4 2,280 Track-front 5 1,435 Track-rear 6 1,445 Overhang-front 7 755/785* Overhang-rear 8 700 Ground clearance 9 200 (unladen)
Page 19: Precautions Before Service
00-17 GENERAL ± Precautions Before Service PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B ± Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
Page 20 00-18 GENERAL ± Precautions Before Service SERVICING THE ELECTRICAL SYSTEM Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (±) cable from the battery in order to avoid damage caused by short-circuiting.
Page 21 00-19 GENERAL ± Precautions Before Service MUT- II MUT- II sub-assembly Refer to the ªMUT- II REFERENCE MANUALº or ªMUT- II OPERATING INSTRUCTIONSº for instructions on handling the MUT- II . ROM pack Connect the MUT- II to the diagnosis connector as shown in the illustration.
Page 22 00-20 GENERAL ± Precautions Before Service Other precautions: Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Avoid contaminating clothes, particularly underpants, with oil. Do not put oily rags in pockets, the use of overalls without pockets will avoid this.
Page 23: Supplemental Restraint System
00-21 GENERAL ± Supplemental Restraint System (SRS) SUPPLEMENTAL RESTRAINT SYSTEM (SRS) or the quarter panels, inner monitor any shocks To improve safety, the SRS is available as optional parts. This system enhances collision safety by coming from the side of the vehicle. The warning restraining the front occupants in case of an lamp on the instrument panel indicates the accident.
Page 24 00-22 GENERAL ± Supplemental Restraint System (SRS) Front passenger's air bag Driver's Seat belts with pre-tensioner Side air bag SRS SERVICE PRECAUTIONS 1. In order to avoid injury to yourself or others NOTE from accidental deployment of the air bag during If any of these components are diagnosed as servicing, read and carefully follow all the faulty, they should only be replaced, in...
Page 25 00-23 GENERAL ± Supplemental Restraint System (SRS) 5. Do not attempt to repair the wiring harness connectors SRS-ECU connector of the SRS. If the connector(s) are diagnosed as defective, replace the wiring harness(es). If the harness(es) are diagnosed as faulty, replace or repair the wiring harness(es) according to the table that follows.
Page 26 00-24 GENERAL ± Supplemental Restraint System (SRS) 6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure. Insert the special tool (probe, MB991222, in the harness set) into the connector from harness side (rear side), and connect the tester to this probe. If any tool than specified is used, damage to the harness and other components will result.
Page 27: Support Locations For Lifting And Jacking
00-25 GENERAL ± Support Locations for Lifting and Jacking SUPPORT LOCATIONS FOR LIFTING AND JACKING Caution Do not support the vehicles at locations other than specified supporting points. Doing so will cause damage, etc. SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS GARAGE JACK Caution Never support any point other than the specified ones, or deformation will result.
Page 28: Support Positions For Asingle-Post Lift Or Double-Post Lift
00-26 GENERAL ± Support Locations for Lifting and Jacking SUPPORT POSITIONS FOR A Caution When service procedures require removing the SINGLE-POST LIFT OR DOUBLE-POST rear suspension, spare tyre and rear bumper, LIFT place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.
Page 29: Support Positions And Support Method For An H-Bar Lift
00-27 GENERAL ± Support Locations for Lifting and Jacking SUPPORT POSITIONS AND SUPPORT METHOD H-bar lift FOR AN H-BAR LIFT Caution H-bar lift When service procedures require removing the rear suspension, fuel tank, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.
Page 30 00-28 GENERAL ± Support Locations for Lifting and Jacking PREPARATION OF ªATTACHMENTSº Block (A) 1. Prepare the blocks (wooden) and nails as shown in the figure. 1,800 Item Dimensions mm Quantity × × Block (A) 1,800 × × Block (B) ×...
Page 31: Standard Part/Tightening-Torque Table
00-29 GENERAL ± Standard Part/Tightening-Torque Table STANDARD PART/TIGHTENING-TORQUE TABLE Each torque value in the table is a standard value The values in the table are not applicable: for tightening under the following conditions. (1) If toothed washers are inserted. (1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
Page 32 NOTES...
Page 33 11A-1 ENGINE <4G9-GDI> CONTENTS GENERAL INFORMATION ....Lash Adjuster Check ......CRANKSHAFT PULLEY .
Page 34: General Information
11A-2 ENGINE <4G9-GDI> ± General Information/Service Specifications GENERAL INFORMATION Items 4G93-GDI Total displacement m 1,834 × × Bore Stroke mm Compression ratio 12.0 Combustion chamber Pentroof + ball-in-piston Camshaft arrangement DOHC Number of valve Intake Exhaust Valve timing Intake Opening BTDC 15 Closing ABDC 56...
Page 35: Sealants
SEALANTS Items Specified sealants Remarks Beam camshaft cap 3M ATD Part No.8660 or equivalent ± Cylinder head Cam position sensor support MITSUBISHI GENUINE PART Semi-drying sealant MD970389 or equivalent Oil pan Thrust case 3M Stud Locking 4170 or equivalent ±...
Page 36: Special Tools
11A-4 ENGINE <4G9-GDI> ± Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT -II sub Measuring the drive belt tension assembly Checking the ignition timing Checking the idle speed Erasing diagnosis code MB991668 Belt tension meter Measuring the drive belt tension (used together with the MUT- II ) MB990767 End yoke holder...
Page 37 11A-5 ENGINE <4G9-GDI> ± Special Tools Tool Number Name MB991653 Cylinder head bolt Cylinder head bolt removal and installation wrench MD998767 Tension pulley Timing belt tension adjustment socket wrench...
Page 38: On-Vehicle Service
11A-6 ENGINE <4G9-GDI> ± On-vehicle Service ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension in the following procedure. Standard value: Vibration frequency Hz 143 ± 185 Tension N 294 ± 490 Deflection (Reference value) mm 9.7 ±...
Page 39 11A-7 ENGINE <4G9-GDI> ± On-vehicle Service <When using a tension gauge> Belt tension gauge Use a belt tension gauge to check that the belt tension is within the standard value. Alternator pulley Crankshaft pulley <Belt deflection check> Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check 98 N that the amount of deflection is within the standard value.
Page 40 11A-8 ENGINE <4G9-GDI> ± On-vehicle Service POWER STEERING OIL PUMP AND AIR CONDITIONER Oil pump pulley COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT Tension pulley 1. Check if the belt tension is within the standard value using one of the methods below. Crankshaft Standard value: pulley...
Page 41: Ignition Timing Check
11A-9 ENGINE <4G9-GDI> ± On-vehicle Service IGNITION TIMING CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT- II to the diagnosis connector. MUT- II 3. Set the timing light to the condenser of the No.1 ignition Condenser coil power supply line (terminal No.3).
Page 42: Idle Speed Check
11A-10 ENGINE <4G9-GDI> ± On-vehicle Service IDLE SPEED CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn off the ignition switch and then connect the MUT- II to the diagnosis connector. 3. Check the basic ignition timing. NOTE Refer to P.11A-9 concerning the check procedure of the basic ignition timing.
Page 43: Compression Pressure Check
11A-11 ENGINE <4G9-GDI> ± On-vehicle Service 6. Check the CO contents and the HC contents at idle. NOTE This measurement should be performed in less than approximately 4 minutes since the engine speed become the idle speed. Standard value CO contents: 0.6% or less HC contents: 200 ppm or less 7.
Page 44: Manifold Vacuum Check
11A-12 ENGINE <4G9-GDI> ± On-vehicle Service 7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 100 kPa 8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 and 7.
Page 45: Lash Adjuster Check
11A-13 ENGINE <4G9-GDI> ± On-vehicle Service LASH ADJUSTER CHECK If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed.
Page 46 11A-14 ENGINE <4G9-GDI> ± On-vehicle Service <LASH ADJUSTER AIR BLEEDING> NOTE (1) If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine.
Page 47 11A-15 ENGINE <4G9-GDI> ± On-vehicle Service 2. Run the engine at idle for 1 ± 3 minutes to let it warm up. Drive pattern for air bleeding 3. With no load on the engine, repeat the drive pattern shown Gradually open the Close the throttle in the illustration at left and check if the abnormal noise throttle valve.
Page 48: Crankshaft Pulley
11A-16 ENGINE <4G9-GDI> ± Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Cover and Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11A-7.) Engine Cover and Under Cover Installation 177 ± 186 Nm (Engine oil) Removal steps 1.
Page 49: Camshaft And Camshaft Oil Seal
11A-17 ENGINE <4G9-GDI> ± Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Intake Hose and Resonance Tank Removal and Intake Manifold Removal and Installation Installation (Refer to GROUP 15 ± Air Cleaner and (Refer to GROUP 15.) Resonance Tank.) Fuel Pump (High Pressure) and Fuel Pressure...
Page 50 11A-18 ENGINE <4G9-GDI> ± Camshaft and Camshaft Oil Seal Lubrication points <Seen from underneath beam camshaft cap> Sealant: MITSUBISHI GENUINE PART Sealant: 3M ATD Part No.8660 or equivalent MD970389 or equivalent (Lip section) (Engine oil) (Engine oil) Sealant: 3M Stud locking 4170 <Seen from above cylinder head>...
Page 51 11A-19 ENGINE <4G9-GDI> ± Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINT MB990767 CAMSHAFT SPROCKET REMOVAL MD998719 INSTALLATION SERVICE POINTS Camshaft sprocket side Screw hole A A CAMSHAFT INSTALLATION 1. Apply engine oil to journals and cams of the camshafts. 2.
Page 52 11A-20 ENGINE <4G9-GDI> ± Camshaft and Camshaft Oil Seal C A CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal as shown in the illustration. MD998713 D A CAMSHAFT SPROCKET INSTALLATION Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque.
Page 53: Oil Pan
48 Nm 19 Nm Bolt Groove hole 7 Nm 24 Nm 7 Nm 7 Nm Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent 7 Nm 39 Nm 18 Nm 93 Nm 12 Nm 93 Nm 42 Nm 98 ± 118 Nm...
Page 54 11A-22 ENGINE <4G9-GDI> ± Oil Pan REMOVAL SERVICE POINTS STEERING GEAR BOX INSTALLATION BOLT REMOVAL Remove the steering gear box installation bolts and lower the steering gear box. LOWER OIL PAN REMOVAL Lower oil pan Place a piece of wood against the lower oil pan, and tap the piece of wood with a hammer to remove the lower oil pan.
Page 55: Crankshaft Oil Seal
11A-23 ENGINE <4G9-GDI> ± Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION 93 ± 103 Nm <M/T> 93 ± 103 Nm <A/T> <M/T> <A/T> Crankshaft Crankshaft (Engine oil: (Engine oil: bolt washer bolt washer surface) surface) Lip section Lip section (Bolt thread) (Bolt thread) Engine oil...
Page 56 11A-24 ENGINE <4G9-GDI> ± Crankshaft Oil Seal REMOVAL SERVICE POINT ADAPTER PLATE<A/T>/FLYWHEEL <M/T>/DRIVE PLATE <A/T>/CRANKSHAFT ADAPTER <A/T> REMOVAL Use the special tool to secure the flywheel or drive plate, and remove the bolts. MD998781 INSTALLATION SERVICE POINTS Crankshaft A A CRANKSHAFT REAR OIL SEAL INSTALLATION rear oil seal Crankshaft 1.
Page 57: Cylinder Head Gasket
11A-25 ENGINE <4G9-GDI> ± Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13A Fuel Pressure Regulator (High Pressure) and Fuel ± On-vehicle Service.) <Pre-removal only> Pump (High Pressure) Removal and Installation Engine Coolant Draining and Supplying (Refer to (Refer to GROUP 13A.) GROUP 14 ±...
Page 58 11A-26 ENGINE <4G9-GDI> ± Cylinder Head Gasket REMOVAL SERVICE POINTS POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pomp and bracket assembly in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord.
Page 59 11A-27 ENGINE <4G9-GDI> ± Cylinder Head Gasket 4. Tighten the bolts by the following procedure. Step Operation Remarks Tighten to 74 Nm. Carry out in the order shown in the illustration. Fully loosen. Carry out in the reverse order of that shown in the illustration.
Page 60: Timing Belt
11A-28 ENGINE <4G9-GDI> ± Timing Belt TIMING BELT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation Crankshaft Pulley Removal and Installation (Refer Air Intake Duct Removal and Installation to P.11A-17.) (Refer to GROUP 15 ± Air Cleaner and Resonance Tank.) 10 ±...
Page 61 11A-29 ENGINE <4G9-GDI> ± Timing Belt REMOVAL SERVICE POINT Timing marks Timing marks TIMING BELT REMOVAL 1. Turn the crankshaft clockwise to align each timing mark. Caution The crankshaft must always be turned clockwise. 2. Loosen the tensioner pulley center bolt and remove the timing belt.
Page 62 11A-30 ENGINE <4G9-GDI> ± Timing Belt B A TIMING BELT INSTALLATION Camshaft sprocket Timing marks Timing marks 1. Align the timing marks of each camshaft sprocket and the crankshaft sprocket. 2. Loosen the tensioner pulley center bolt. 3. Move the crankshaft sprocket half a tooth width in the anti-clockwise direction.
Page 63 11A-31 ENGINE <4G9-GDI> ± Timing Belt 7. Place the belt onto the idler pulley, water pump sprocket, crankshaft sprocket and tensioner pulley in that order. 8. Remove the two paper clips. Idler pulley Tensioner pulley Water pump sprocket Crankshaft sprocket 9.
Page 64 11A-32 ENGINE <4G9-GDI> ± Timing Belt NOTE Even if the 2 mm Allen wrench cannot be easily inserted, then it is satisfactory if the amount of protrusion of the auto tensioner rod is within the standard value. Standard value (A): 3.8 ± 4.5 mm If it is outside the standard value, repeat the operations in steps 1 to 4.
Page 65: Engine Assembly
11A-33 ENGINE <4G9-GDI> ± Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13A Air Cleaner and Resonance Tank Removal and...
Page 66 11A-34 ENGINE <4G9-GDI> ± ENGINE <4G9-GDI> ± Engine Assembly Engine Assembly REMOVAL SERVICE POINTS POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump from the engine with the hose attached. NOTE Place the removed power steering oil pump where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 67 12-1 ENGINE LUBRICATION CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Engine Oil Check .
Page 68: General Information
12-2 ENGINE LUBRICATION ± General Information GENERAL INFORMATION The lubrication method is a fully force-fed, full-flow filtration type. The oil pump is driven by the crankshaft via the timing belt. ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil harmful contaminants which may cause skin cancer.
Page 69: Service Specifications
12-3 ENGINE LUBRICATION ± Service Specifications/Sealant/Lubricants/Special Tools SERVICE SPECIFICATIONS Item Standard value Oil pressure kPa at idle 29 or more at 3,500 r/min 294 ± 686 SEALANT Item Specified sealant Oil pressure switch 3M ATD Part No. 8660 or equivalent LUBRICANTS Items Specifications...
Page 70: On-Vehicle Service
12-4 ENGINE LUBRICATION ± On-vehicle Service ON-VEHICLE SERVICE ENGINE OIL CHECK 1. Pull out the level gauge slowly and check that the oil level is in the illustrated range. 2. Check that the oil is not excessively dirty, that there is no coolant or gasoline mixed in, and that it has sufficient viscosity.
Page 71: Oil Filter Replacement
12-5 ENGINE LUBRICATION ± ENGINE LUBRICATION ± On-vehicle Service On-vehicle Service OIL FILTER REPLACEMENT 1. Start the engine and allow it to warm up until the MB991396 or temperature of the coolant reaches 80 C to 90 C. commercially- 2. Remove the engine oil filler cap. available tool 3.
Page 72 12-6 ENGINE LUBRICATION ± On-vehicle Service 4. Install the oil pressure gauge. NOTE Use a adapter of PT 1/8 thread. 5. Run the engine to warm it. 6. After the engine has been warmed up, check that oil pressure is within the standard value. Standard value: At idle: 29 kPa or more At 3,500 r/min: 294 ±...
Page 73 13A-1 FUEL CONTENTS GASOLINE DIRECT INJECTION (GDI) ........FUEL SUPPLY .
Page 74 13A-2 GASOLINE DIRECT INJECTION (GDI) CONTENTS GENERAL INFORMATION ....Engine Coolant Temperature Sensor Check Throttle Position Sensor Check ... . . SERVICE SPECIFICATIONS .
Page 75: General Information
13A-3 GDI ± General Information GENERAL INFORMATION The Gasoline Direct Injection System consists activities such as fuel injection control, idle of sensors which detect the engine conditions, speed control and ignition timing control. In the engine-ECU which controls the system addition, the engine-ECU is equipped with based on signals from these sensors, and several...
Page 76 13A-4 GDI ± General Information SELF-DIAGNOSIS FUNCTION When an abnormality is detected in one code corresponding to the abnormality is of the sensors or actuators related to output. emission control, the engine warning lamp The RAM data inside the engine-ECU that (check engine lamp) illuminates as a is related to the sensors and actuators can warning to the driver.
Page 77 13A-5 GDI ± General Information Items Specifications Actuators Engine control relay type Contact switch type Fuel pump relay type Contact switch type Injector driver control relay Contact switch type Injector type and number Electromagnetic type, 4 Injector identification mark DIM 100G Throttle valve control servo relay Contact switch type Throttle valve control servo...
Page 78 13A-6 GDI ± General Information GASOLINE DIRECT INJECTION SYSTEM DIAGRAM z 1 Injector driver (In- Engine control relay *1 Oxygen sensor Power supply Fuel pump relay *2 Air flow sensor Ignition switch ± IG jector) Engine- z 2 EGR valve (Step- Injector driver relay *3 Intake air temper- Ignition switch ±...
Page 79: Service Specifications
13A-7 GDI ± Service Specifications/Sealant SERVICE SPECIFICATIONS Item Standard value Adjustment voltage of throttle position sensor 0.4 ± 0.6 (1st channel) V Adjustment voltage of throttle position sensor 4.2 ± 4.8 (2nd channel) V Resistance of throttle position sensor k Ω 3.5 ±...
Page 80: Special Tools
13A-8 GDI ± Special Tools SPECIAL TOOLS Tool Number Name MB991223 Harness set Fuel gauge simple inspection A: Connector pin contact pressure inspection A: MB991219 A: Test harness B: Power circuit inspection B: MB991220 B: LED harness C: Power circuit inspection C: MB991221 C: LED harness D: Commercial tester connection...
Page 81 13A-9 GDI ± Special Tools Tool Number Name MD998464 Test harness Oxygen sensor inspection (4-pin, square) MD998478 Test harness Measurement of voltage during trouble- (3-pin, triangle) shooting Inspection using an analyzer MB991529 Diagnosis code Reading diagnosis code check harness MD998709 Adaptor hose Measurement of fuel pressure MD998742...
Page 82: Troubleshooting
13A-10 GDI ± Troubleshooting TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 ± How to Use Troubleshooting/Inspection Service Points. NOTE If the ECU is replaced, the immobilizer-ECU and ignition key should replaced together with it. Each ECU has an individual information for immobilizer-ECU, and the individual information is registered in the immobilizer-ECU.
Page 83 13A-11 GDI ± Troubleshooting Throttle valve position feedback Throttle valve control servo motor (1st motor) Throttle valve control servo motor (2nd motor) Communication line system with throttle valve controller Engine-ECU NOTE When the electronic-controlled throttle valve system is stopped, the engine warning lamp flashes. METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 ±...
Page 84 13A-12 GDI ± Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE If the diagnosis system detects any sensor malfunction, the vehicle can be driven safely by using a default control logic instead of the faulty sensors. Defective part or What to do when a sensor is defective function Air flow sensor (1) Disables lean-mixture combustion.
Page 85 13A-13 GDI ± Troubleshooting Defective part or What to do when a sensor is defective function Accelerator pedal (1) Disables lean-mixture combustion. position sensor (1st (2) Controls the throttle valve position by using the accelerator pedal position sensor channel) (2nd channel) signal. (3) Disables the electronic-controlled throttle valve system if the accelerator pedal position sensor (2nd channel) signal is also defective.
Page 86 13A-14 GDI ± Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Oxygen sensor system 13A-15 Air flow sensor system 13A-16 Intake air temperature sensor system 13A-17 Throttle position sensor (2nd channel) system 13A-18 Engine coolant temperature sensor system 13A-19 Crank angle sensor system 13A-20...
Page 87 13A-15 GDI ± Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No.11 Oxygen sensor system Probable cause Range of check Malfunction of the oxygen sensor 3 minutes have passed after engine was started. Improper connector contact, open circuit or Engine coolant temperature is approx. 80 ° C or more. short-circuited harness wire Intake air temperature is 20 ±...
Page 88 13A-16 GDI ± Troubleshooting Code No.12 Air flow sensor system Probable cause Range of check Malfunction of the air flow sensor Engine speed is 500 r/min or more. Open circuit or short-circuited harness wire of air Set conditions flow sensor circuit Sensor output frequency is 3.3 Hz or less for 4 seconds.
Page 89 13A-17 GDI ± Troubleshooting Code No.13 Intake air temperature sensor system Probable cause Range of check Malfunction of the intake air temperature sensor After 60 seconds have passed since the engine have started Open circuit or short-circuited harness wire of the Set conditions intake air temperature sensor circuit Sensor resistance is 0.14 k Ω...
Page 90 13A-18 GDI ± Troubleshooting Code No.14 Throttle position sensor system (2nd channel) Probable cause The throttle valve controller determines whether a failure is present or not, and Malfunction of throttle position sensor (2nd channel) sends a signal indicating its result to the engine-ECU. Open circuit or short-circuited harness wire in throttle Range of check position sensor (2nd channel) or poor connector...
Page 91 13A-19 GDI ± Troubleshooting Code No.21 Engine coolant temperature sensor system Probable cause Range of check Malfunction of the engine coolant temperature After 60 seconds have passed since the engine have started sensor Set conditions Open circuit or short-circuited harness wire of the Sensor resistance is 50 Ω...
Page 92 13A-20 GDI ± Troubleshooting Code No.22 Crank angle sensor system Probable cause Range of check Malfunction of the crank angle sensor Engine: During cranking Open circuit or short-circuited harness wire of the Set conditions crank angle sensor circuit Sensor output voltage does not change for 4 seconds (no pulse signal is Malfunction of the engine-ECU being input).
Page 93 13A-21 GDI ± Troubleshooting Code No.23 Camshaft position sensor system Probable cause Range of check Malfunction of the camshaft position sensor While engine is cranking or running Open circuit or short-circuited harness wire of the Set conditions camshaft position sensor circuit Sensor output voltage does not change for 4 seconds (no pulse signal is Malfunction of the engine-ECU being input).
Page 94 13A-22 GDI ± Troubleshooting Code No. 24 Vehicles speed sensor system Probable cause Range of check Malfunction of the vehicle speed sensor Ignition switch: ON Improper connector contact, open circuit Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed after the engine starts.
Page 95 13A-23 GDI ± Troubleshooting Code No.25 Barometric pressure sensor system Probable cause Range of check Malfunction of the barometric pressure sensor After 60 seconds have passed since the engine have started Open circuit or short-circuited harness wire of the Battery voltage is 8 V or more. barometric pressure sensor Set conditions Malfunction of the engine-ECU...
Page 96 13A-24 GDI ± Troubleshooting Code No.31 Detonation sensor system Probable cause Range of check Malfunction of the detonation sensor After 60 seconds have passed since the engine have started Open circuit or short-circuited harness wire of the Set conditions detonation sensor Amount of change in the sensor output voltage (detonation sensor peak Malfunction of the engine-ECU voltage for each half rotation of the crankshaft) is 0.06 V or less for 200...
Page 97 13A-25 GDI ± Troubleshooting Code No.41 Injector system Probable cause Range of check Malfunction of the injector Engine: while cranking, or running Faulty injector driver relay Engine speed: 4,000 r/min or less Faulty injector driver System voltage: 10 V or more Open circuit or short-circuited harness wire in the Fuel shut off, or while forcible activating of injector (actuator test) is in operation.
Page 98 13A-26 GDI ± Troubleshooting From the previous page Measure at engine-ECU connector Check the following connectors: Repair C-17,19. C-17, C-19 Connect the connector. Voltage between terminal 51 and earth (Ignition switch: ON) Check trouble symptom. OK: 4.0 ± 5.0 V Voltage between terminal 1 and earth Replace the injector driver.
Page 99 13A-27 GDI ± Troubleshooting Code No.44 Abnormal combustion Probable cause Range of check Malfunction of the ignition coil While engine is running during lean fuel combustion Malfunction of the spark plug Set conditions Malfunction of the EGR valve Abnormal engine speed due to mis-firing is detected by the crank angle Open circuit or short-circuit in ignition primary sensor circuit...
Page 100 13A-28 GDI ± Troubleshooting Code No.54 Immobilizer system Probable cause Range of check Radio interference of ID codes Ignition switch: ON Incorrect ID code Set conditions Malfunction of harness or connector Improper communication between the engine-ECU and immobilizer-ECU Malfunction of immobilizer-ECU Malfunction of engine-ECU NOTE (1) If the ignition switches are close each other when starting the engine, radio interference may cause...
Page 101 13A-29 GDI ± Troubleshooting Code No.56 Abnormal fuel pressure Probable cause Range of check Malfunction of the fuel pressure sensor Ignition switch: ON Open circuit or short-circuited harness wire of the Set conditions fuel pressure sensor Sensor output voltage is 4.8 V or more for four seconds. Malfunction of the engine-ECU Malfunction of the fuel pump (high pressure) Sensor output voltage is 0.2 V or less for four seconds.
Page 102 13A-30 GDI ± Troubleshooting From the previos page Measure at the fuel pressure sensor Measure at the fuel pressure sensor Check the following connectors: connector A-59. connector A-59. A-36, A-82, C-18, C-19 Connect the connector. (Use test Disconnect the connector, and harness MB991348) measure at the harness side.
Page 103 13A-31 GDI ± GDI ± Troubleshooting Troubleshooting Code No.61 Communication wire with A/T-ECU system Probable cause Range of check Short circuit in ECU communication circuit After 60 seconds have passed since the engine have started Malfunction of the engine-ECU Set conditions Malfunction of the A/T-ECU Torque reduction request signal from A/T-ECU is input continuously for 1.5 seconds or more.
Page 104 13A-32 GDI ± Troubleshooting Code No.66 Brake vacuum sensor system Probable cause Range of check Malfunction of the brake vacuum sensor Ignition switch: ON Improper connector contact, open circuit or Set conditions short-circuited harness wire of the brake vacuum Sensor output voltage is 4.8 V or more. sensor Malfunction of the engine-ECU Sensor output voltage is 0.2 V or less.
Page 105 13A-33 GDI ± Troubleshooting Code No.77 Accelerator pedal position sensor (2nd Probable cause channel) system Range of check Malfunction of the accelerator pedal position sensor Accelerator pedal position sensor (1st channel) system is normal. (2nd channel) Communication between the engine-ECU and throttle valve controller is normal. Open circuit or short-circuited harness wire in the Set conditions accelerator pedal position sensor (2nd channel)
Page 106 13A-34 GDI ± Troubleshooting Code No.78 Accelerator pedal position sensor (1st Probable cause channel) system Range of check Malfunction of the accelerator pedal position sensor Accelerator pedal position sensor (2nd channel) system is normal. (1st channel) Communication between the engine-ECU and throttle valve controller is normal. Open circuit or short-circuited harness wire in the Set conditions accelerator pedal position sensor (1st channel)
Page 107 13A-35 GDI ± Troubleshooting Code No.79 Throttle position sensor (1st channel) system Probable cause The throttle valve controller determines a failure, and sends it result to the engine-ECU. Malfunction of the throttle position sensor (1st channel) Range of check Open circuit or short-circuited harness wire in the Ignition switch: ON throttle position sensor (1st channel), or poor System voltage: 8 V or more...
Page 108 13A-36 GDI ± Troubleshooting Code No.89 Abnormal fuel pressure system Probable cause Range of check Malfunction of the fuel pump (high pressure) Engine: Idling (during stoichio-feedback operation) Malfunction of the intake air temperature sensor Set conditions Malfunction of the barometric pressure sensor Fuel injection correction value remains excessively low for ten seconds or more.
Page 109 13A-37 GDI ± Troubleshooting Code No.92 Throttle valve position feedback system Probable cause The throttle valve controller determines if a failure is present, and sends its result Malfunction of the throttle position sensor (1st channel) to the engine-ECU. Open circuit or short-circuited harness wire in the Range of check throttle position sensor system (1st channel), or poor Ignition switch: ON...
Page 110 13A-38 GDI ± Troubleshooting Code No.95 Malfunction in throttle valve control servo Probable cause motor (1st motor) system Range of check Malfunction of the throttle valve control servo Throttle valve control servo relay: ON Open circuit or short-circuited harness wire in throttle System voltage: 8 V or more valve control servo system, or poor connector contact Set conditions...
Page 111 13A-39 GDI ± Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13A-41 with MUT- II is with MUT- II is Communication with engine-ECU only is not possible. 13A-42 impossible.
Page 112 13A-40 GDI ± Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Symptom Starting Won't start The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine won't start. Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Page 113 13A-41 GDI ± Troubleshooting Items Symptom Driving Shock The feeling of a comparatively large impact or vibration when the engine is accelerated or decelerated. Surge This is repeated surging ahead during constant speed travel or during variable speed travel. Knocking A sharp sound like a hammer striking the cylinder walls during driving and which adversely affects driving.
Page 114 13A-42 GDI ± Troubleshooting INSPECTION PROCEDURE 2 MUT- II communication with engine-ECU is impossible. Probable cause This may be caused by malfunction of engine-ECU power supply circuit and earth Malfunction of engine-ECU power supply circuit circuit. Malfunction of engine-ECU Open circuit between the engine-ECU and diagnosis connector Check the following connectors: Repair...
Page 115 13A-43 GDI ± Troubleshooting INSPECTION PROCEDURE 4 The engine warning lamp remains illuminating and never Probable cause goes out. In cases such as the above, the cause is probably that the engine-ECU is detecting Short-circuit between the engine warning lamp and a problem in a sensor or actuator, or that one of the malfunctions listed at right engine-ECU has occurred.
Page 116 13A-44 GDI ± Troubleshooting From the previous page Check the throttle position sensor (2nd channel) system. (Refer MUT- II Data list to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS 14 Throttle position sensor (2nd channel) (Refer to P.13A-72.) CODE 14.) Clean around the throttle valve. (Refer to P.13A-92.) Inspect engine start ability by cranking the engine while the acceler- ator pedal is slightly depressed.
Page 117 13A-45 GDI ± Troubleshooting INSPECTION PROCEDURE 6 Initial combustion takes place, but does not complete Probable cause (start impossible), too long time to start (poor start) This may be caused by improper spark plug ignition (poor spark), improper mixture Malfunction of the fuel supply system during engine cranking, improper fuel pressure.
Page 118 13A-46 GDI ± Troubleshooting From the previous page Replace the ignition coil. Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx.
Page 119 13A-47 GDI ± Troubleshooting INSPECTION PROCEDURE 7 Unstable idling (rough idle, hunting) Probable cause This malfunction is probably caused by a faulty ignition system, improper air/fuel Malfunction of the ignition system ratio, a faulty electronic-controlled throttle valve system, improper compression Malfunction of the air/fuel ratio control system pressure, etc.
Page 120 13A-48 GDI ± Troubleshooting From the previous page MUT- II Data list Measure fuel high-pressure between the fuel pump (high pressure) 11 Oxygen sensor and injector. (Refer to P.13A-97.) OK: 0 ± 400 mV and 600 ± 1,000 mV alternates when the engine is idling (wait for four minutes after the engine started).
Page 121 13A-49 GDI ± Troubleshooting INSPECTION PROCEDURE 8 Idle speed is high or low (Improper idling) Probable cause The cause is probably that the intake air amount during idling is too great or too Malfunction of the electronic-controlled throttle valve small. system Malfunction of the throttle body MUT- II Self-Diag code...
Page 122 13A-50 GDI ± Troubleshooting INSPECTION PROCEDURE 9 When the engine is cold, it stalls at idling. (Die out) Probable cause The cause is probably an incorrect air/fuel ratio or poor intake air amount when Malfunction of the electronic-control throttle valve the engine is cold.
Page 123 13A-51 GDI ± Troubleshooting INSPECTION PROCEDURE 10 When the engine is hot, it stalls at idling. (Die out) Probable cause The cause is probably an improper air/fuel ratio, faulty electronic-controlled throttle Malfunction of the ignition system valve system, compression pressure. In addition, if the engine stalls suddenly, another Malfunction of air/fuel ratio control system possible cause might be a poor connector contact.
Page 124 13A-52 GDI ± Troubleshooting From the previous page Check the power steering fluid pressure switch system. (Refer MUT- II Data list to P.13A-69, INSPECTION PROCEDURE 31.) 27 Power steering fluid pressure switch (Refer to P.13A-73.) MUT- II Data list Check the A/C switch and A/C relay system. (Refer to P.13A-69, 28 A/C switch (Refer to P.13A-73.) INSPECTION PROCEDURE 32.) MUT- II Data list...
Page 125 13A-53 GDI ± Troubleshooting INSPECTION PROCEDURE 11 The engine stalls when starting the car. (Pass out) Probable cause The cause is probably poor ignition due to a malfunctioning spark plug (weak spark), Malfunction of the ignition system or an incorrect air/fuel ratio when the accelerator is depressed. Malfunction of the EGR valve Air stuck in the air intake system MUT- II Self-Diag code...
Page 126 13A-54 GDI ± Troubleshooting INSPECTION PROCEDURE 12 The engine stalls when decelerating. Probable cause The cause is probably an improper air/fuel ratio due to a faulty EGR system, or Malfunction of the electronic-controlled throttle valve poor intake air volume due to a faulty electronic-controlled throttle valve system. system Malfunction of the EGR valve Have the battery terminals been disconnected recently?
Page 127 13A-55 GDI ± Troubleshooting INSPECTION PROCEDURE 13 Hesitation, sag, stumble, poor acceleration or surge Probable cause The cause is probably a malfunction of the ignition system, electronic-controlled Malfunction of the ignition system throttle valve system, compression pressure, etc. Malfunction of the air/fuel ratio control system Malfunction of the electronic-controlled throttle valve system Improper compression pressure...
Page 128 13A-56 GDI ± Troubleshooting From the previous page Measure high fuel pressure between the fuel pump (high pressure) Repair and injector. (Refer to P.13A-97.) Replace the ignition coil. Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil.
Page 129 13A-57 GDI ± Troubleshooting INSPECTION PROCEDURE 15 The feeling of impact when decelerating Probable cause The cause is probably insufficient intake air due to a faulty electronic-controlled Malfunction of the electronic-controlled throttle valve throttle valve system. system MUT- II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS Is a diagnosis code displayed? CODES.
Page 130 13A-58 GDI ± Troubleshooting INSPECTION PROCEDURE 18 Too high CO and HC concentration when idling Probable cause The cause is probably an incorrect air/fuel ratio Malfunction of air/fuel ratio control system Deterioration of the catalyst MUT- II Self-Diag code Refer to P.13A-14, INSPECTION CHART FOR DIAGNOSIS Is a diagnosis code displayed? CODES.
Page 131 13A-59 GDI ± Troubleshooting From the previous page Check the EGR valve system. (Refer to P.13A-67, INSPECTION MUT- II Data list PROCEDURE 29.) 68 EGR valve (Refer to P.13A-74.) Check purge control solenoid valve system. (Refer to P.13A-68, MUT- II Actuator test INSPECTION PROCEDURE 30.) 08 Purge control solenoid valve (Refer to P.13A-76.) Replace the injector.
Page 132 13A-60 GDI ± Troubleshooting INSPECTION PROCEDURE 20 Fans (radiator fan, A/C condenser fan) are inoperative. Probable cause The engine-ECU sends a duty signal to the fan controller according to engine coolant Malfunction of the fan motor relay temperature, vehicle speed, or A/C switch. Malfunction of the fan motor The fan controller controls radiator fan and condenser fan speeds, based on this Malfunction of the fan controller...
Page 133 13A-61 GDI ± Troubleshooting INSPECTION PROCEDURE 21 GDI ECO indicator lamp does not illuminate. Probable cause If the GDI ECO indicator lamp does not illuminate after turning switch, the causes Burned-out GDI ECO indicator lamp bulb listed in the right column are suspected. Open circuit or short-circuited harness wire in the GDI ECO indicator lamp circuit Malfunction of the engine-ECU...
Page 134 13A-62 GDI ± Troubleshooting INSPECTION PROCEDURE 23 Engine-ECU power supply and earth circuit system Probable cause The cause is probably a malfunction of the engine-ECU or one of the problems Open circuit or short-circuited harness wire in the listed at right. engine-ECU power supply circuit Open circuit or short-circuited harness wire in the engine-ECU earth circuit...
Page 135 13A-63 GDI ± Troubleshooting INSPECTION PROCEDURE 25 Ignition switch-ST system <M/T> Probable cause The ignition switch-ST outputs a HIGH signal to the engine-ECU while the Malfunction of the ignition switch engine is cranking, and the engine-ECU uses this signal to carry out functions Open circuit or short-circuited harness wire such as fuel injection control during starting.
Page 136 13A-64 GDI ± Troubleshooting INSPECTION PROCEDURE 26 Ignition switch-ST and inhibitor switch system <A/T> Probable cause The ignition switch-ST outputs a HIGH signal to the engine-ECU while the Malfunction of the ignition switch engine is cranking, and the engine-ECU uses this signal to carry out functions Malfunction of the inhibitor switch such as fuel injection control during starting.
Page 137 13A-65 GDI ± Troubleshooting INSPECTION PROCEDURE 27 Accelerator pedal position switch system Probable cause The accelerator pedal position switch detects that the accelerator pedal is fully closed, Maladjustment of the accelerator cable and sends a signal to the engine-ECU. The engine-ECU controls idle speed, based Maladjustment of the accelerator pedal position switch on this signal.
Page 138 13A-66 GDI ± Troubleshooting INSPECTION PROCEDURE 28 Fuel pump (low pressure) system Probable cause The engine-ECU turns on the fuel pump relay while the engine is cranking or running, Malfunction of the fuel pump relay and supplies power source to the fuel pump (low pressure). Malfunction of the fuel pump (low pressure) Open circuit or short-circuited harness wire in the fuel pump (low pressure) circuit, or poor connector...
Page 139 13A-67 GDI ± Troubleshooting INSPECTION PROCEDURE 29 EGR valve system Probable cause The engine-ECU controls the EGR valve in order to control the amount of Malfunction of the EGR valve exhaust gas mixed in the intake air. Open circuit or short-circuited harness wire in the EGR valve circuit Malfunction of the engine-ECU Check the EGR valve.
Page 140 13A-68 GDI ± Troubleshooting INSPECTION PROCEDURE 30 Purge control solenoid valve system Probable cause The engine-ECU controls the purge control solenoid valve in order to control Malfunction of the purge control solenoid valve the purge air coming from the canister. Open circuit or short-circuited harness wire in the purge control solenoid valve circuit Malfunction of the engine-ECU...
Page 141: On-Vehicle Service
13A-69 GDI ± Troubleshooting INSPECTION PROCEDURE 31 Power steering fluid pressure switch system Probable cause The power steering fluid pressure switch sends a signal to the engine-ECU according Malfunction of the power steering fluid pressure switch to power steering load. Open circuit or short-circuited harness wire in the Based on this signal, the engine-ECU controls the throttle control servo so that power steering fluid pressure switch circuit, or poor...
Page 142 13A-70 GDI ± Troubleshooting INSPECTION PROCEDURE 33 Stop lamp switch system Probable cause The engine-ECU determines whether the brake pedal is depressed or not, by means Malfunction of the stop lamp switch of the stop lamp switch input signal. Open circuit or short-circuited harness wire in the stop lamp circuit, or poor connector contact Malfunction of the engine-ECU Check the stop lamp switch.
Page 143 13A-71 GDI ± Troubleshooting DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE : Within four minutes after starting the engine : In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than the standard time.
Page 144 13A-72 GDI ± Troubleshooting Item Check items Requirements Normal condition Inspection Refer- procedure ence page Throttle posi- Engine coolant Release the accel- 4,000 ± 4,800 mV Code 13A-18 tion sensor temperature: 80 erator pedal. No.14 ± 95 _ C ± 95 _ C (2nd channel) (2nd channel) Ignition switch:...
Page 145 13A-73 GDI ± Troubleshooting Item Check items Requirements Normal condition Inspection Refer- procedure ence page Barometric Ignition switch: ON Altitude: 0 m 101 kPa Code 13A-23 pressure sen- pressure sen- No 25 No.25 Altitude: 600 m 95 kPa Altitude: 1,200 m 88 kPa Altitude: 1,800 m 81 kPa...
Page 146 13A-74 GDI ± Troubleshooting Item Check items Requirements Normal condition Inspection Refer- procedure ence page Injector drive Engine coolant Idling 0.5 ± 0.7 ms* Code 13A-25 time * temperature: 80 No.41 ± 95 _ C Lamps, electric 2,500 r/min 0.4 ± 0.8 ms cooling fan and all accessories: Transmission:...
Page 147 13A-75 GDI ± Troubleshooting Item Check items Requirements Normal condition Inspection Refer- procedure ence page Fuel pressure Engine coolant After minutes 4 ± 6.9 MPa Code 13A-29 sensor temperature: 80 have passed at No.56 ± 95 _ C idling condition Lamps, electric cooling fan and all accessories:...
Page 148 13A-76 GDI ± Troubleshooting ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. 1 Engine: Idling condition Code No. 13A-25 injector After having becomes different warmed up/Engine warmed up/Engine (becomes unsta- (becomes unsta-...
Page 149 13A-77 GDI ± GDI ± Troubleshooting Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART Engine-ECU Connector Terminal Arrangement Terminal Check item Check requirements (engine condition) Normal condition No.1 injector Engine: Warm up, and then depress the Decreases slightly for accelerator pedal suddenly from the idle speed accelerator pedal suddenly from the idle speed.
Page 150 13A-78 GDI ± Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition Fuel pump relay Ignition switch: ON Engine: stopped System voltage Engine: Idling 0 ± 3 V → → Engine warning lamp Ignition switch: OFF 0 ± 3 V System voltage (after several seconds)
Page 151 13A-79 GDI ± Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition Engine control relay Ignition switch: OFF System voltage Ignition switch: ON 0 ± 3 V Back-up power source Ignition switch: OFF System voltage Air flow sensor Engine: Idling 2.2 ±...
Page 152 13A-80 GDI ± Troubleshooting Terminal Check item Check requirements (engine condition) Normal condition A/C switch Engine: idling A/C switch: OFF 0 ± 3 V A/C switch: ON System voltage (Compressor is operating) Small lamp switch Lighting switch: OFF 0 ± 3 V Lighting switch: ON (Taillamp: ON) System voltage Oxygen sensor heater...
Page 153 13A-81 GDI ± Troubleshooting CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart.
Page 154 13A-82 GDI ± Troubleshooting Engine-ECU Harness Side Connector Terminal Arrangement Terminal No. Check item Standard value, normal condition (check requirements) 6 ± 47 EGR valve (C) 15 ± 20 Ω (at 20 C) 5 ± EGR valve (D) 34 ± 47 EGR valve (A) 32 ±...
Page 155 13A-83 GDI ± Troubleshooting CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS TERMINAL VOLTAGE CHECK CHART Throttle Valve Controller Terminal Arrangement Terminal Check items Requirements Normal value Throttle valve control servo Ignition switch: ON Decreases slightly from → Accelerator pedal: Fully opened system voltage.
Page 156 13A-84 GDI ± Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER Analyzer AIR FLOW SENSOR (AFS) Measurement Method Special 1. Disconnect the air flow sensor connector, and connect patterns pickup the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2.
Page 157 13A-85 GDI ± Troubleshooting Examples of Abnormal Wave Patterns Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency.
Page 158 13A-86 GDI ± Troubleshooting Standard wave pattern 2 engine revolutions (1 camshaft revolution) 75 _ BTDC 5 _ BTDC The time (cycle time) T is reduced when the engine speed increases Crank angle sensor output wave pattern Camshaft posi- tion sensor out- put wave pat- tern Time...
Page 159 13A-87 GDI ± Troubleshooting INJECTORS AND INJECTOR OPEN CIRCUIT CHECK SIGNAL Measurement Method 1. Connect the analyzer special patterns pickup to terminal 1 (No.1 injector) of the engine-ECU connector. 2. Connect the analyzer special patterns pickup to terminal 96 (injector open circuit check signal) of the engine-ECU Analyzer connector.
Page 160 13A-88 GDI ± Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Power transistor control signal Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991658) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to terminal Special 3 of each ignition coil connector in turn.
Page 161 13A-89 GDI ± Troubleshooting Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage Probable cause Rises from approx. 2V to approx. 4.5V at the top-right Normal 2V rectangular wave Open-circuit in ignition primary circuit...
Page 162 13A-90 GDI ± Troubleshooting EGR VALVE (STEPPER MOTOR) Analyzer Measurement Method 1. Disconnect the EGR valve connector, and connect the special tool (test harness: MB991658) in between. 2. Connect the analyzer special patterns pickup to the EGR valve-side connector terminal 1, terminal 3, terminal 4 and terminal 6 respectively.
Page 163 13A-91 GDI ± Troubleshooting Wave Pattern Observation Points Check that the standard wave pattern appears when the EGR control servo is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern Probable cause Induced electromotive force does not appear or is extremely small.
Page 164 13A-92 GDI ± On-vehicle Service ON-VEHICLE SERVICE Fixed SAS Caution (1) Never attempt to tamper the fixed SAS. The fixed SAS is precisely adjusted at factory. (2) Should it be tampered, the full closed position of the throttle valve will be changed. This causes the engine-ECU to learn a wrong position of the throttle valve.
Page 165 13A-93 GDI ± On-vehicle Service 2. Disconnect the throttle valve control servo connector. 3. Turn the ignition switch to ON (but do not start the engine). 4. Check the output voltage of the throttle position sensor (1st channel) when the throttle valve is fully closed by your finger.
Page 166: Accelerator Pedal Position Sensor Adjustment
13A-94 GDI ± On-vehicle Service ACCELERATOR PEDAL POSITION SENSOR Accelerator pedal position sensor ADJUSTMENT Caution Equipment (1) Never attempt to tamper the accelerator pedal position side connector sensor. The sensor position is precisely adjusted at factory. (2) Should it be tampered, follow the procedure below: Accelerator pedal arm 1.
Page 167: Fuel Pressure Test
13A-95 GDI ± On-vehicle Service FUEL PRESSURE TEST High-pressure fuel hose MEASUREMENT OF FUEL LOW PRESSURE BETWEEN FUEL PUMP (LOW PRESSURE) AND FUEL PUMP (HIGH PRESSURE) Fuel pump 1. Release residual pressure from the fuel pipe line to prevent (high pressure) fuel gush out.
Page 168 13A-96 GDI ± On-vehicle Service 5. Connect the MUT- II to the diagnosis connector. 6. Turn the ignition switch to ON. (But do not start the engine.) 7. Select ªItem No.07º from the MUT- II Actuator test to drive the fuel pump (low pressure) at the fuel tank side. Check that there are no fuel leaks from any parts.
Page 169 13A-97 GDI ± GDI ± On-vehicle Service On-vehicle Service 14. Release residual pressure from the fuel pipe line. (Refer to P.13A-99.) 15. Remove the fuel pressure gauge and special tools from the fuel pump (high pressure). Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.
Page 170 13A-98 GDI ± On-vehicle Service 9. Start the engine and run at idle. 10. Measure fuel pressure while the engine is running at idle. Standard value: approximately 4 ± 6.9 MPa 11. Check to see that fuel pressure at idle does not drop even after the engine has been raced several times.
Page 171: Fuel Leak Check
13A-99 GDI ± On-vehicle Service FUEL LEAK CHECK 1. Connect the MUT- II to the diagnosis connector. 2. Disconnect the injector intermediate harness connector. 3. Turn the ignition switch to ON. 4. Select ªItem No.74º from the MUT- II Data list. 5.
Page 172: Fuel Pump Operation Check
13A-100 GDI ± On-vehicle Service 8. If the engine is started, release fuel pressure by the following procedure: (1) Turn off the ignition switch, and then stop the engine. (2) Disconnect one of the ignition coil connectors. (3) Crank the engine for at least two seconds. (4) If the engine is not be started, use the MUT- II to make sure that the fuel pressure is 0.5 MPa or less.
Page 173: Component Location
13A-101 GDI ± On-vehicle Service COMPONENT LOCATION Name Symbol Name Symbol A/C relay Fuel pressure sensor A/C switch Fuel pump relay Ignition coil Accelerator pedal position sensor (1st and 2nd channels) channels) Inhibitor switch <A/T> Air flow sensor (with intake air temperature Injectors sensor and barometric pressure sensor) sensor and barometric pressure sensor)
Page 174: Intake Air Temperature Sensor Check
13A-102 GDI ± On-vehicle Service ENGINE CONTROL RELAY, FUEL PUMP Equipment side connector Engine control relay RELAY, INJECTOR DRIVER RELAY AND THROTTLE VALVE CONTROL SERVO RELAY CONTINUITY CHECK Terminal No. Battery voltage Injector driver relay Not supplied Fuel pump relay Supplied Throttle valve control servo relay...
Page 175: Throttle Position Sensor Check
13A-103 GDI ± On-vehicle Service 2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance. Standard value: 2.1 ± 2.7 k Ω (at 20 C) 0.26 ± 0.36 k Ω (at 80 C) 3. If the resistance deviates from the standard value greatly, replace the sensor.
Page 176: Accelerator Pedal Position Sensor (1St Channel) Check
13A-104 GDI ± On-vehicle Service ACCELERATOR PEDAL POSITION SENSOR Accelerator pedal position sensor (1ST CHANNEL) CHECK 1. Disconnect accelerator pedal position sensor Equipment connector. side connector 2. Measure resistance between terminal No.2 (sensor power supply) and 1 (sensor earth) of the sensor connector. Accelerator Standard value: 3.5 ±...
Page 177: Accelerator Pedal Position Switch Check
13A-105 GDI ± On-vehicle Service ACCELERATOR PEDAL POSITION SWITCH Accelerator pedal position sensor CHECK 1. Disconnect accelerator pedal position sensor Equipment connector. side connector 2. Check continuity between terminal No.4 (accelerator pedal position switch) and 5 (sensor earth) of the connector. Accelerator Normal condition pedal arm...
Page 178: Injector Check
13A-106 GDI ± On-vehicle Service 7. While repeatedly racing the engine, measure the oxygen sensor output voltage. Standard value: Engine Oxygen sensor Remarks output voltage When 0.6 ± 1.0 V If you make the air/fuel ratio racing the rich by racing the engine engine repeatedly, a normal oxy- gen sensor will output a...
Page 179: Throttle Valve Control Servo Check
13A-107 GDI ± On-vehicle Service THROTTLE VALVE CONTROL SERVO CHECK Throttle valve control servo Operation Check 1. Disconnect the air intake hose from the throttle body. Equipment side 2. Turn on the ignition switch. connector 3. Check that the throttle valve opens or closes in response to the accelerator pedal depression.
Page 180: Fuel Pump (High Pressure) And Fuel Pressure Regulator (High Pressure)
13A-108 GDI ± Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) FUEL PUMP (HIGH PRESSURE) AND FUEL PRESSURE REGULATOR (HIGH PRESSURE) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Fuel Discharge Prevention <before removal only> Fuel Leak Check <after installation only> (Refer to (Refer to P.13A-98.) P.13A-98.) Engine Cover Removal and Installation...
Page 181 13A-109 GDI ± Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) Fuel pump (High pressure) removal Fuel pressure regulator (High steps pressure) removal steps F A D Fuel pump (high pressure) air bleeding D Intake manifold assembly removal D Throttle body removal (Refer to (Refer to GROUP 15.) P.13A-113.)
Page 182 13A-110 GDI ± Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure) C A FUEL RETURN PIPE/FUEL PRESSURE HOSE/FUEL FEED PIPE INSTALLATION Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure), fuel pressure regulator (high pressure) or the delivery pipe assembly.
Page 183: Injector
13A-111 GDI ± Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Fuel Pressure Regulator (High Pressure) Removal and Installation (Refer to P.13A-107.) 10 ± 13 10 ± 13 20 ± 25 O-ring O-ring Engine oil Removal steps D A 1. Fuel feed pipe 9.
Page 184 13A-112 GDI ± GDI ± Injector Injector REMOVAL SERVICE POINTS INJECTOR HARNESS CONNECTOR DISCONNECTION Caution Disconnect the battery (±) cable from its terminal before carrying out this operation. DELIVERY PIPE ASSEMBLY/FUEL INJECTOR ASSEMBLY REMOVAL Remove the delivery pipe assembly with the fuel injector assembly still attached.
Page 185 13A-113 GDI ± Injector 4. Align the mating marks on the delivery pipe assembly and the fuel injector, and then install the delivery pipe Fuel injector assembly with the injector assembly still attached. Mat- Delivery pipe marks assembly 5. Install the delivery pipe and fuel injectors to the cylinder head, and then tighten them provisionally.
Page 186: Throttle Body
13A-114 GDI ± Throttle Body THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to GROUP 14 ± On-vehicle Service.) Resonance Tank Removal and Installation (Refer to GROUP 15.) 19 Nm Removal steps 1. Throttle position sensor connector 3.
Page 187 13A-115 GDI ± Throttle Body DISASSEMBLY AND REASSEMBLY Disassembly steps A A 1. Throttle position sensor 2. Throttle body REASSEMBLY SERVICE POINTS A A THROTTLE POSITION SENSOR 1. Position the throttle position sensor on the throttle body along the dotted line as shown in the illustration. 2.
Page 188: Injector Driver
13A-116 GDI ± Injector Driver INJECTOR DRIVER REMOVAL AND INSTALLATION 5 Nm 5 Nm Removal steps 1. Injector driver 2. Bracket REMOVAL SERVICE POINT Lock INJECTOR DRIVER REMOVAL Press the injector driver connector in the place shown in the illustration to disconnect the injector driver connector. Caution 1.
Page 189: Throttle Valve Controller
13A-117 GDI ± Throttle Valve Controller THROTTLE VALVE CONTROLLER Throttle valve controller INSTALLATION SERVICE POINT If the throttle valve controller is replaced, initialize the electronic-controlled throttle valve system. Initialization Turn on the ignition switch, and turn it to LOCK (OFF) position within one second.
Page 190 NOTES...
Page 191 13B-1 FUEL SUPPLY CONTENTS FUEL TANK ....... Fuel Pump Module .
Page 192 13B-2 FUEL SUPPLY ± Fuel Tank FUEL TANK REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Fuel Draining Fuel Supplying. Reduce the Inner Pressure of Fuel Line and Hose Checking for Fuel Leaks (Refer to GROUP 13 ± On-vehicle Service.) Rear Propeller Shaft Installation Center Exhaust Pipe Removal (Refer to GROUP 25.) (Refer to GROUP 15.)
Page 193 13B-3 FUEL SUPPLY ± Fuel Tank INSTALLATION SERVICE POINT A A SUCTION TUBE/HIGH PRESSURE TUBE CONNECTION Caution After the connection, pull the high pressure tube and suction tube gently in the direction of removal to check that they are firmly connected. INSPECTION Fuel pump Fuel hose...
Page 194 13B-4 FUEL SUPPLY ± Fuel Tank DISASSEMBLY AND REASSEMBLY FUEL PUMP MODULE Disassembly steps 1. Fuel gauge unit 9. Stopper 2. Gauge harness 10. Fuel pressure regulator 3. Bracket (low-pressure) and assist pump 4. Cushion assembly A A 11. O-ring 5.
Page 195 14-1 ENGINE COOLING CONTENTS GENERAL INFORMATION ....Engine Coolant Replacement ....Concentration Measurement .
Page 196: General Information
Range of coolant antifreeze concentration of radiator % 30 ± 60 ± Thermostat Valve opening temperature of thermostat C ± Full-opening temperature of thermostat C ± Valve lift (at 95 C) mm 8.5 or more ± LUBRICANT Items Quantity MITSUBISHI GENUINE COOLANT or equivalent...
Page 197: Sealants
Items Specified sealant Remarks Cylinder block drain plug 3M Nut Locking Part No. 4171 or equivalent Drying sealant Water pump Mitsubishi Genuine Parts No. MD970389 or Semi-drying sealant equivalent equivalent Water fitting Water outlet fitting Water by-pass fitting SPECIAL TOOL...
Page 198 14-4 ENGINE COOLING ± Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Radiator fan and condenser fan do not operate. Probable cause <Vehicles with A/C> Radiator fan does not operate. <Vehicles without A/C> The cause could be a malfunction of the fan controller power supply or earth circuit. Malfunction of fusible link The cause could also be a malfunction of the fan controller or the engine-ECU.
Page 199 14-5 ENGINE COOLING ± Troubleshooting <Vehicles without A/C> Fusible link (7) check Replace Fan control relay check (Refer to P.14-11.) (1) NG Check the harness wire between fan control relay and fusible Measure at the fan control relay connector A-42X. link (7), and repair if necessary.
Page 200 14-6 ENGINE COOLING ± Troubleshooting Inspection Procedure 2 Radiator fan and condenser fan do not change speed or Probable cause stop. <Vehicles with A/C> Radiator fan does not change speed or stop. <Vehicles without A/C> The fan controller carries out step-free control of the radiator fan motor and the Malfunction of fan control relay condenser fan motor speeds using signals transmitted from the engine-ECU.
Page 201 14-7 ENGINE COOLING ± Troubleshooting <Vehicles without A/C> Fan control relay check (Refer to P.14-11.) Replace Check the harness wire between fan control relay and engine Repair control relay. Check the harness wire between fan control relay and body earth. Check the harness wire between fan control relay and fan controller.
Page 202: On-Vehicle Service
14-8 ENGINE COOLING ± On-vehicle Service ON-VEHICLE SERVICE ENGINE COOLANT LEAK CHECKING Cap adapter 1. Confirm that the coolant level is up to the filler neck. Install a radiator cap tester, adapter and cap adapter to the filler Adapter neck, and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections.
Page 203: Engine Coolant Replacement
8. Slowly pour the engine coolant into the mouth of the radiator until the radiator is full, and pour also into the reserve tank up to the FULL line. Recommended antifreeze: MITSUBISHI GENUINE COOLANT or equivalent Quantity: 6 Caution Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze.
Page 204: Concentration Measurement
Standard value: 30± 60% (allowable concentration range) RECOMMENDED ANTIFREEZE Antifreeze Allowable concentration MITSUBISHI GENUINE COOLANT 30 ± 60% or equivalent Caution If the concentration of the antifreeze is below 30 %, the anti-corrosion property will be adversely affected. In...
Page 205: Fan Control Relay Continuity Check
14-11 ENGINE COOLING ± On-vehicle Service FAN CONTROL RELAY CONTINUITY CHECK Battery voltage Terminal No. When current is not supplied Fan control relay When current supplied...
Page 206: Thermostat
14-12 ENGINE COOLING ± Thermostat THERMOSTAT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-9.) Engine Cover and Under Cover Removal and Installation Air Cleaner Removal and Installation (Refer to GROUP 15.) 22 ± 25 Nm Removal steps B A 1.
Page 207 14-13 ENGINE COOLING ± Thermostat INSTALLATION SERVICE POINTS Jiggle valve A A THERMOSTAT INSTALLATION Install the thermostat so that the jiggle valve is facing straight Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat. In addition, be careful not to fold Rubber ring over or scratch the rubber ring when inserting.
Page 208: Water Pump
INSTALLATION SERVICE POINT A A WATER PUMP INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without sealant. Specified Sealant: Mitsubishi Genuine Parts No. MD970389 or equivalent...
Page 209: Water Hose And Water Pipe
22 ± 25 Nm 12 ± 15 Nm 22 ± 25 Nm 5, 8, 16 22 ± 25 Nm Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent 22 ± 25 Nm Removal steps B A 1. Radiator lower hose connection D EGR valve 2.
Page 210 2. Apply the specified sealant continuously. Specified sealant: Mitsubishi Genuine Parts No. MD970389 or equivalent 3. Install the water fitting, water bypass fitting and the water outlet fitting while the sealant is wet (within 15 minutes after applying the sealant).
Page 211 14-17 ENGINE COOLING ± Water Hose and Water Pipe INSPECTION WATER PIPE AND HOSE CHECK Check the water pipe and hose for cracks, damage, clog and replace them if necessary.
Page 212: Radiator
14-18 ENGINE COOLING ± Radiator RADIATOR REMOVAL AND INSTALLATION Pre-removal Operations Post-installation Operations Engine Coolant Draining (Refer to P.14-9.) Air Cleaner Installation (Refer to GROUP 15.) Engine Cover and Under Cover Removal Engine cover and Under Cover Installation Air Cleaner Removal (Refer to GROUP 15.) Engine Coolant Supplying (Refer to P.14-9.) A/T Fluid Supplying (Refer to GROUP 23 ±...
Page 213 14-19 ENGINE COOLING ± Radiator REMOVAL SERVICE POINTS RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. A/T OIL COOLER HOSE REMOVAL After removing the hose from the radiator, plug the hose and the radiator nipple to prevent dust or foreign particles from getting in.
Page 214 NOTES...
Page 215 15-1 INTAKE AND EXHAUST CONTENTS SERVICE SPECIFICATION ....EXHAUST MANIFOLD ..... . SPECIAL TOOL .
Page 216 15-2 INTAKE AND EXHAUST ± Service Specification/Special Tool SERVICE SPECIFICATION Items Standard value Limit Distortion of the intake manifold installation surface mm 0.15 or less 0.20 SPECIAL TOOL Tool Number Name MD998770 Oxygen sensor Removal and installation of oxygen sensor wrench...
Page 217 15-3 INTAKE AND EXHAUST ± Air Cleaner AIR CLEANER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation 10 Nm 9 Nm Air cleaner removal steps Resonance tank removal steps 1. Air intake hose 8. Resonance tank 2.
Page 218 15-4 INTAKE AND EXHAUST ± Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Ignition Coil Removal and Installation (Refer to GROUP 14 ± On-vehicle Service.) (Refer to GROUP 16.) Engine Cover and Under Cover Removal and Throttle Body Removal and Installation Installation (Refer to GROUP 13A.)
Page 219 15-5 INTAKE AND EXHAUST ± Intake Manifold REMOVAL SERVICE POINT FUEL PUMP PROTECTOR REMOVAL Lift up the transmission with a jack to create clearance between the engine and the front deck, and remove the fuel pump protector. INSPECTION Check the following points; replace the part if a problem is found.
Page 220 15-6 INTAKE AND EXHAUST ± Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover and Under Cover Removal and Air Cleaner Removal and Installation Installation (Refer to P.15-3.) 18 Nm 29 Nm 13 Nm 29 Nm 98 Nm 12 ±...
Page 221 15-7 INTAKE AND EXHAUST ± INTAKE AND EXHAUST ± Exhaust Pipe and Main Muffler Exhaust Pipe and Main Muffler EXHAUST PIPE AND MAIN MUFFLER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover and Under Cover Removal and Installation 13 Nm 13 Nm 34 Nm 13 Nm...
Page 222 NOTES...
Page 223 16-1 ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM ....IGNITION SYSTEM ....GENERAL INFORMATION .
Page 224: Charging System
16-2 ENGINE ELECTRICAL ± Charging System CHARGING SYSTEM GENERAL INFORMATION The charging system uses the alternator output to keep the battery charged at a constant level under various electrical loads. OPERATION Voltage Rotation of the excited field coil generates AC voltage in the stator.
Page 225 16-3 ENGINE ELECTRICAL ± Charging System ALTERNATOR SPECIFICATIONS Items Specifications Type Battery voltage sensing Rated output V/A 12/100 Voltage regulator Electronic built-in type SERVICE SPECIFICATIONS Items Standard value Limit Alternator output line voltage drop (at 30 A) V ± Max. 0.3 Regulated voltage ambient ±...
Page 226: On-Vehicle Service
16-4 ENGINE ELECTRICAL ± Charging System ON-VEHICLE SERVICE ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST ± Ammeter Alternator Voltmeter Battery ± Terminal B This test determines whether the wiring from the output wire. (Connect the (+) lead of the ammeter to the ªBº terminal, and then connect alternator ªBº...
Page 227: Output Current Test
16-5 ENGINE ELECTRICAL ± ENGINE ELECTRICAL ± Charging System Charging System (6) Reconnect the negative battery cable. (11)If the value displayed on the voltmeter is above (7) Connect a tachometer or the MUT- II . the limit value, there is probably a malfunction in the alternator output wire, so check the wiring (8) Leave the hood open.
Page 228 16-6 ENGINE ELECTRICAL ± Charging System This test determines whether the alternator output (10)Turn the light switch on to turn on headlamps current is normal. and then start the engine. (11)Immediately after setting the headlamps to high (1) Before the test, always be sure to check the beam and turning the heater blower switch to following.
Page 229: Regulated Voltage Test
16-7 ENGINE ELECTRICAL ± Charging System REGULATED VOLTAGE TEST Load Ignition Charging warning switch lamp MB991519 Alternator Alternator relay Yellow Engine- Ammeter Voltmeter Battery ± ±...
Page 230 16-8 ENGINE ELECTRICAL ± Charging System This test determines whether the voltage regulator NOTE is correctly controlling the alternator output voltage. If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between (1) Always be sure to check the following before the alternator ªSº...
Page 231: Waveform Check Using An Analyzer
16-9 ENGINE ELECTRICAL ± Charging System WAVEFORM CHECK USING AN ANALYZER Special Analyzer patterns Alternator pickup MEASUREMENT METHOD Connect the analyzer special patterns pick-up to the alternator B terminal. B terminal STANDARD WAVEFORM Observation Conditions FUNCTION SPECIAL PATTERNS PATTERN HEIGHT VARIABLE VARIABLE knob Adjust while viewing the wave-...
Page 232: Alternator Relay Continuity Check
16-10 ENGINE ELECTRICAL ± Charging System EXAMPLES OF ABNORMAL WAVEFORMS NOTE 1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the analyzer. 2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not operating).
Page 233: Alternator
16-11 ENGINE ELECTRICAL ± Charging System ALTERNATOR REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment Under Cover Installation 20 ± 25 Nm 44 Nm 44 Nm Disassembly steps 1. Drive belt (Power steering, A/C) 4.
Page 234 16-12 ENGINE ELECTRICAL ± Charging System DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Front bracket assembly 8. Stator 2. Alternator pulley 9. Plate B A 3. Rotor A A 10. Regulator assembly 4. Rear bearing 11. Brush 5. Bearing retainer 12. Slinger 6.
Page 235 16-13 ENGINE ELECTRICAL ± Charging System DISASSEMBLY SERVICE POINTS FRONT BRACKET ASSEMBLY REMOVAL Insert a flat tip screwdriver, etc., in the clearance between the front bracket assembly and stator core, to pry open and separate the stator and front bracket. Caution The stator coil could be damaged so do not insert the screwdriver too far.
Page 236 16-14 ENGINE ELECTRICAL ± Charging System REASSEMBLY SERVICE POINTS A A REGULATOR ASSEMBLY INSTALLATION Wire After installing the regulator assembly, insert a wire into the hole provided on the rear bracket while pressing in the brush to fix the brush. NOTE The brush is fixed when a wire is inserted, making rotor installation easier.
Page 237 16-15 ENGINE ELECTRICAL ± Charging System STATOR CHECK 1. Check the continuity between the coil leads, and if there is continuity, replace the stator. 2. Check the continuity between the coil and core, and if there is continuity, replace the stator. RECTIFIER CHECK 1.
Page 238 16-16 ENGINE ELECTRICAL ± Charging System BRUSH CHECK 1. Measure the length of the brush protrusion shown in the illustration, and replace the brush if the measured value is below the limit value. Limit: 2 mm or less Protrusion length 2.
Page 239: Starting System
16-17 ENGINE ELECTRICAL ± Starting System STARTING SYSTEM GENERAL INFORMATION If the ignition switch is turned to the ªSTARTº M-terminal to conduct. Thus, current flows to engage position, current flows in the pull-in and holding coils the starter motor. provided inside magnetic switch, attracting the When the ignition switch is returned to the ªONº...
Page 240: Starter Motor
16-18 ENGINE ELECTRICAL ± Starting System STARTER MOTOR Switch INSPECTION PINION GAP ADJUSTMENT 1. Disconnect field coil wire from M-terminal of magnetic switch. Battery 2. Connect a 12-volt battery between S-terminal and Field coil wire M-terminal. 3. Set switch to ªONº, and pinion will move out. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.
Page 241 16-19 ENGINE ELECTRICAL ± Starting System MAGNETIC SWITCH PULL-IN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12-volt battery between S-terminal and Battery M-terminal. Caution This test must be performed quickly (in less than 10 Field coil wire seconds) to prevent coil from burning.
Page 242 16-20 ENGINE ELECTRICAL ± Starting System MAGNETIC SWITCH RETURN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12-volt battery between M-terminal and body. Battery Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.
Page 243 16-21 ENGINE ELECTRICAL ± Starting System REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover and Under Cover Removal and Installation Front Propeller Shaft Removal and Installation (Refer to GROUP 25.) 26 ± 33 Nm 10 ± 12 Nm 28 Nm 34 Nm 10 ±...
Page 244 16-22 ENGINE ELECTRICAL ± Starting System REMOVAL SERVICE POINTS TRANSMISSION MOUNT CROSSMEMBER REMOVAL 1. Remove the transmission mount crossmember. (Refer to GROUP 32.) 2. Lower the jack holding the engine and transmission assembly to create clearance enough to remove the starter motor installation bolts.
Page 245 16-23 ENGINE ELECTRICAL ± Starting System DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Screw 12. Packing A 2. Magnetic switch 13. Packing B 3. Screw 14. Plate 4. Through bolt 15. Planetary gear 5. Rear bracket 16. Lever A A 17. Snap ring 6.
Page 246 16-24 ENGINE ELECTRICAL ± Starting System DISASSEMBLY SERVICE POINTS S-terminal Magnetic MAGNETIC SWITCH REMOVAL switch M-terminal Disconnect the field coil wire from M-terminal of the magnetic switch. Field coil wire ARMATURE AND BALL REMOVAL When removing the armature, do not lose the ball placed at the end as a bearing.
Page 247 16-25 ENGINE ELECTRICAL ± Starting System REASSEMBLY SERVICE POINTS A A STOP RING/SNAP RING INSTALLATION Using an appropriate tool, pull the stop ring over the snap ring. Stop ring Overrunning clutch Stop ring Snap ring INSPECTION COMMUTATOR 1. Place the armature in a pair of ªVº blocks and check the runout with a dial indicator.
Page 248 16-26 ENGINE ELECTRICAL ± Starting System BRUSH 1. Check the brush for roughness of the surface that contacts the commutator and check the brush length. Limit: Wear limit line 2. In case the contacting surface has been corrected or the brush has been replaced, correct the contacting surface Wear limit line by winding sandpaper around the commutator.
Page 249: Ignition System
16-27 ENGINE ELECTRICAL ± Ignition System IGNITION SYSTEM GENERAL INFORMATION This system is equipped with four ignition coils with The engine-ECU determines which ignition coil built-in power transistors for each of the cylinders. should be controlled by means of the signals from Interruption of the primary current flowing in the the camshaft position sensor and the crank angle primary side of an ignition coil generates a high...
Page 250: Service Specifications
16-28 ENGINE ELECTRICAL ± Ignition System IGNITION COIL SPECIFICATIONS Items Specifications Type Molded 4-coil SPARK PLUG SPECIFICATIONS Items Specifications IZFR6B SERVICE SPECIFICATIONS SPARK PLUG Items Standard value Limit Spark plug gap mm 0.5 ± 0.6 0.75 Spark plug insulation resistance M Ω ±...
Page 251: On-Vehicle Service
16-29 ENGINE ELECTRICAL ± Ignition System ON-VEHICLE SERVICE IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK Check by the following procedure, and replace if there is a malfunction. PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK 1.5 V ± NOTE 1. An analogue-type circuit tester should be used. 2.
Page 252: Spark Plug Check And Cleaning
16-30 ENGINE ELECTRICAL ± Ignition System SPARK PLUG CHECK AND CLEANING CAUTION 1. Do not adjust the gap for iridium plugs. 2. The iridium tips may become damaged when iridium plugs are cleaned. Accordingly, if the plugs are sooty and need to be cleaned, use a plug cleaner in order to protect the terminals, and do not clean for more than 20 seconds.
Page 253: Ignition Coil
16-31 ENGINE ELECTRICAL ± Ignition System IGNITION COIL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation Resonance Tank Removal and Installation (Refer to GROUP 15.) Air Cleaner Assembly and Air Intake Hose Removal and Installation 10 Nm 25 Nm Disassembly steps 1.
Page 254: Crank Angle Sensor
16-32 ENGINE ELECTRICAL ± ENGINE ELECTRICAL ± Ignition System Ignition System CRANK ANGLE SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt Front Lower Cover Removal and Installation (Refer to GROUP 11.) Crank angle sensor 9 Nm CAMSHAFT POSITION SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation...
Page 255: Detonation Sensor
16-33 ENGINE ELECTRICAL ± Ignition System DETONATION SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation 10 ± 12 Nm 20 ± 25 Nm 10 ± 12 Nm Disassembly steps 1. Water pipe clamp A A 2. Detonation sensor REMOVAL SERVICE POINT DETONATION SENSOR REMOVAL INSTALLATION SERVICE POINT...
Page 256 NOTES...
Page 257 17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM ..Vacuum Hose Installation ....CRANKCASE EMISSION CONTROL SERVICE SPECIFICATION .
Page 258 17-2 EXHAUST GAS RECIRCULA TION (EGR) Exhaust Gas Recirculation (EGR) ControL System Check ......SYSTEM .
Page 259: Engine Control System
17-3 ENGINE AND EMISSION CONTROL ± Engine Control System ENGINE CONTROL SYSTEM SERVICE SPECIFICATION Items Standard value Accelerator cable play mm 1 ± 2 ON-VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT 1. Check the accelerator cable play when the accelerator pedal is released.
Page 260: Accelerator Cable And Pedal
17-4 ENGINE AND EMISSION CONTROL ± Engine Control System ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION Post-installation Operation Accelerator Pedal Position Sensor Check and Adjustment (Refer to GROUP 13A ± On-vehicle Service.) Kickdown Cable Adjustment (Refer to GROUP 23 ± On-vehicle Service.) 10 Nm 12 Nm Removal steps...
Page 261: Emission Control System
17-5 ENGINE AND EMISSION CONTROL ± Emission Control System EMISSION CONTROL SYSTEM GENERAL INFORMATION The emission control system consists of the following subsystems: Crankcase emission control system Evaporative emission control system Exhaust emission control system Items Name Specification Crankcase emission Positive crankcase ventilation (PCV) valve Variable flow type control system...
Page 262: Service Specifications
17-6 ENGINE AND EMISSION CONTROL ± Emission Control System SERVICE SPECIFICATIONS Items Standard value Purge control solenoid valve coil resistance (at 20 C) Ω 36 ± 44 EGR valve (stepper motor) coil resistance (at 20 C) Ω 10 ± 20 SPECIAL TOOL Tool Number...
Page 263: Vacuum Circuit Diagram
17-7 ENGINE AND EMISSION CONTROL ± Emission Control System VACUUM CIRCUIT DIAGRAM Intake manifold Throttle body combustion From air chamber cleaner Canister Purge control solenoid valve (ON: OPEN) Vacuum hose colour B: Black R: Red VACUUM HOSE CHECK 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected.
Page 264: Crankcase Emission Control System
17-8 ENGINE AND EMISSION CONTROL ± Emission Control System CRANKCASE EMISSION CONTROL SYSTEM GENERAL INFORMATION The crankcase emission control system prevents The PCV valve lifts the plunger according to the intake manifold vacuum so as to regulate the flow blow-by gases from escaping inside the crankcase into the atmosphere.
Page 265: Positive Crankcase Ventilation System Check
17-9 ENGINE AND EMISSION CONTROL ± Emission Control System POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 1. Remove the ventilation hose from the PCV valve. 2. Remove the PCV valve from the rocker cover. 3. Reinstall the PCV valve at the ventilation hose. 4.
Page 266: Evaporative Emission Control System
17-10 ENGINE AND EMISSION CONTROL ± Emission Control System EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION The evaporative emission control system prevents sent to the combustion chamber. When the engine coolant temperature is low or when fuel vapours generated in the fuel tank from escaping into the atmosphere.
Page 267: Purge Control System Check
17-11 ENGINE AND EMISSION CONTROL ± Emission Control System PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (red stripe) from the throttle body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. Plug 3.
Page 268: Purge Control Solenoid Valve Check
17-12 ENGINE AND EMISSION CONTROL ± Emission Control System PURGE CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (black stripe, red stripe) from the solenoid valve.
Page 269: Exhaust Gas Recirculation (Egr) System
17-13 ENGINE AND EMISSION CONTROL ± Emission Control System EXHAUST GAS RECIRCULATION (EGR) SYSTEM GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers port of the cylinder head to the combustion chamber the nitrogen oxide (NOx) emission level. When the through the intake manifold to decrease the air/fuel air/fuel mixture combustion temperature is high, a mixture combustion temperature, resulting in...
Page 270: Exhaust Gas Recirculation (Egr) Control System Check
17-14 ENGINE AND EMISSION CONTROL ± Emission Control System EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK Refer to GROUP 13A ± Troubleshooting. EGR VALVE (STEPPER MOTOR) CHECK Checking the Operation Sound Throttle body 1. Check that the operation sound of the stepper motor can be heard from the EGR valve when the ignition switch is turned to ON (without starting the engine).
Page 271 17-15 ENGINE AND EMISSION CONTROL ± Emission Control System Operation Check 1. Remove the EGR valve. 2. Connect the special tool (test harness set) to the EGR valve-side connector. 3. Connect terminal No.2 and terminal No.5 to the positive (+) terminal of power supply of approximately 6 V. 4.
Page 272: Egr Valve
17-16 ENGINE AND EMISSION CONTROL ± Emission Control System EGR VALVE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to GROUP 14 ± On-vehicle Service.) Engine Cover Removal and Installation 24 Nm 19 Nm 10 ± 12 Nm 24 Nm 19 Nm Removal steps...
Page 273: Catalytic Converter
17-17 ENGINE AND EMISSION CONTROL ± Emission Control System CATALYTIC CONVERTER GENERAL INFORMATION The three-way catalytic converter, together with the When the mixture is controlled at stoichiometric closed loop air-fuel ratio control based on the oxygen air-fuel ratio, the three-way catalytic converter sensor signal, oxidizes carbon monoxides (CO) and provides the highest purification against the three hydrocarbons (HC) and reduces nitrogen oxides...
Page 274 NOTES...
Page 275 21-1 CLUTCH CONTENTS GENERAL INFORMATION ....CLUTCH PEDAL ......SERVICE SPECIFICATIONS .
Page 276: General Information
Quantity Clutch fluid Brake fluid DOT3 or DOT4 As required Push rod assembly Rubber grease Release cylinder push rod MITSUBISHI genuine grease Part No. 0101011 ON-VEHICLE SERVICE Clutch pedal height Clutch pedal clevis pin play CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1.
Page 277: Bleeding
21-3 CLUTCH ± On-vehicle Service 3. If the clutch pedal height and the clutch pedal clevis pin play are outside the standard value, turn the setting nut Setting nut to adjust them to the standard value. Caution Do not push in the master cylinder push rod at this time, otherwise the clutch will not operate properly.
Page 278: Clutch Pedal
21-4 CLUTCH ± Clutch Pedal CLUTCH PEDAL REMOVAL AND INSTALLATION Post-installation Operation Clutch Pedal Adjustment (Refer to P.21-2.) L.H. drive vehicles R.H. drive vehicles 12 Nm 12 Nm 12 Nm 12 Nm Removal steps 1. Snap pin 5. Stopper <R.H. drive vehicles> 2.
Page 279: Clutch Control
Clutch Pedal Adjustment (Refer to P.21-2.) <L.H. drive vehicles> 13 Nm Release fork Release cylinder push rod 5 Nm Specified grease: MITSUBISHI genuine grease Part No. 0101011 19 Nm 15 Nm 12 Nm 11, 13 20 ± 25 Nm 5 Nm...
Page 280 21-6 CLUTCH ± Clutch Control <R.H. drive vehicles> Release Release fork cylinder push rod Specified grease: MITSUBISHI genuine grease Part No. 0101011 12 Nm 19 Nm 15 Nm 12 Nm 5 Nm 20 ± 25 Nm Clutch master cylinder assembly...
Page 281: Clutch Master Cylinder
21-7 CLUTCH ± Clutch Control DISASSEMBLY AND REASSEMBLY CLUTCH MASTER CYLINDER Caution Do not disassemble piston assembly. 12 Nm Clutch fluid: Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease Disassembly steps 1. Piston stopper ring 8. Reservoir tank <R.H. drive vehicles> 2.
Page 282 NOTES...
Page 283 22-1 MANUAL TRANSMISSION CONTENTS LUBRICANT ....... Transfer Oil Change ......TRANSMISSION CONTROL .
Page 284: Lubricant
22-2 MANUAL TRANSMISSION ± Lubricant/Sealants and Adhesives/On-vehicle Service LUBRICANT Items Specified lubricants Quantity Transmission oil Hypoid gear oil SAE 75W ± 90 or 75W ± 85W conforming to API GL-4 conforming to API GL-4 Transfer oil SEALANTS AND ADHESIVES Items Specified sealant Remarks Contact surface between transmission and...
Page 285: Transfer Oil Check
22-3 MANUAL TRANSMISSION ± On-vehicle Service TRANSFER OIL CHECK 1. Remove the oil filler plug. Oil filler 2. Oil level should be at the lower portion of the oil filler plug hole plug hole. 3. Check that the transfer oil is not noticeably dirty, and it has a suitable viscosity.
Page 286: Transmission Control
22-4 MANUAL TRANSMISSION ± Transmission Control TRANSMISSION CONTROL REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Move the transmission control lever and transfer control Check that the transmission control lever and the lever to the following positions. transfer control lever are moved to each position Transmission control lever: Neutral smoothly and correctly.
Page 287 22-5 MANUAL TRANSMISSION ± Transmission Control SEALANT APPLICATION POINTS A: Sealant: 3M ATD Part No.8660 or equivalent B: Sealant: Sealant: 3M Stud Locking No.4170 or 3M ATD Part No.8660 or equivalent equivalent Sealant: Stud Locking No.4170 or equivalent Both sides of gasket Sealant: 3M ATD Part No.8660 or equivalent...
Page 288 22-6 MANUAL TRANSMISSION ± Transmission Control REMOVAL SERVICE POINT Transmission mount cross- TRANSMISSION CONTROL LEVER ASSEMBLY member instal- REMOVAL lation bolt 1. Support the transfer with a transmission jack, and then remove the transmission mount crossmember installation bolt. 2. Lower the transmission until the transmission control lever assembly installation bolts can be removed.
Page 289 22-7 MANUAL TRANSMISSION ± Transmission Control C A STOPPER BRACKET ASSEMBLY INSTALLATION 1. Eliminate sealant and adhesive adhered to the stopper bracket assembly installation bolts. 2. Use a tap (M8 1.25) to eliminate adhesive adhered to the threaded holes of the stopper bracket assembly installation nuts, and then clean the holes with a compressed air.
Page 290 22-8 MANUAL TRANSMISSION ± Transmission and Transfer Assembly TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Transmission Oil and Transfer Oil Draining and Front Exhaust Pipe and Catalytic Converter Removal Refilling (Refer to P.22-2, 3.) and Installation (Refer to GROUP 17 ± Emission Transmission Control Lever Assembly and Transfer Control.) Control Lever Assembly Removal and Installation...
Page 291: 4Wd Indicator Control Unit
22-9 MANUAL TRANSMISSION ± 4WD Indicator Control Unit 4WD INDICATOR CONTROL UNIT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Seat Assembly (Driver's side) and Rear Seat Cushion Front Floor Console and Rear Floor Console Removal Removal and Installation (Refer to GROUP 52A ± and Installation (Refer to GROUP 52A.) Seat.) Front Scuff Plate (Right) and Quarter Trim (Right)
Page 292 22-10 MANUAL TRANSMISSION ± 4WD Indicator Control Unit NSPECTION 4WD INDICATOR CONTROL UNIT CHECK Measure terminal voltage on each condition. Connect the harness to the control unit. Insert the probe from the back side of the connector and measure the voltage between the terminal No.8 (earth terminal) and each terminal.
Page 293 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B ± Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.
Page 294: Service Specifications
Service Specifications/ 23-2 AUTOMATIC TRANSMISSION ± Lubricants/Sealants and Adhesives SERVICE SPECIFICATIONS Items Standard value Clearance between inner cable stopper and dust cover end surface mm 0.8 ± 1.5 Input shaft speed sensor resistance (at 20 C) Ω Output shaft speed sensor resistance (at 20 C) Ω A/T fluid temperature sensor resistance Ω...
Page 295: Special Tools
23-3 AUTOMATIC TRANSMISSION ± Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT- II sub Checking of the diagnosis code assembly MD998330 Oil pressure gauge Measurement of oil pressure (including (2,942 kPa) MD998331) MD998920 Adapter Connection of oil pressure gauge...
Page 296: Troubleshooting
23-4 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> TROUBLESHOOTING <A/T> STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING Gathering information from custom- Check automatic transmission fluid Replace automatic transmission fluid. Check trouble symptoms. Communication with MUT- II not possible Read the diagnosis code (GROUP Inspection procedure No. 1 in 00 ±...

Page 297 23-5 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> DIAGNOSIS FUNCTION N RANGE LAMP The N range lamp flashes at a frequency of approximately 1 Hz if there is an abnormality in any of the items in the table below which are related to the A/T system. Check the diagnosis code output if the N range lamp is flashing at a frequency of approximately 1 Hz.
Page 298 23-6 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> ROAD TEST State prior to test Test and operation Judgement value Check item Inspection item if there and operation is an abnormality Ignition switch Data list No. 14 APS (Power Code No.13, 14 Ignition switch: supply voltage) APS system (P.23-10) (1) ON...
Page 299 23-7 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> State prior to test Test and operation Judgement value Check item Inspection item if there and operation is an abnormality Selector lever Shift position and Data list No. 27 Solenoid valve Code No.41, 42 No.1 Solenoid valve No.1 position: D...
Page 300 23-8 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> State prior to test Test and operation Judgement value Check item Inspection item if there and operation is an abnormality Selector lever Monitor data list For (1), (2) and (3), Malfunction Upshifting does not occur (P.23-19) position: D No.
Page 301 23-9 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION CHART FOR DIAGNOSIS CODE Code Diagnosis item Reference page Accelerator pedal position sensor system Sensor malfunction, 23-10 (Throttle opening voltage) open circuit, short circuit Accelerator pedal position sensor system Open circuit, 23-10 (Throttle power supply voltage) short circuit A/T fluid temperature sensor system Open circuit...
Page 302 23-10 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No. 13, 14 Accelerator pedal position sensor (APS) Probable cause If the APS output voltage (APS opening voltage) is 4.8 V or higher when the engine Malfunction of the accelerator pedal position sensor is idling, the output voltage is judged to be too high and diagnosis code No.
Page 303 23-11 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> Code No. 22 Wide open throttle switch system Probable cause If the wide open throttle switch does not turn OFF when the accelerator pedal is Malfunction of wide open throttle switch not depressed, there is a short circuit in the wide open throttle switch and diagnosis Malfunction of connector code No.
Page 304 23-12 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> Code No. 38 Vehicle speed sensor system Probable cause If no output pulse is detected from the vehicle speed sensor for 120 seconds or Malfunction of the vehicle speed sensor more continuously while driving at a speed of 60 km/h or more, there is judged Malfunction of harness or connector to be an open circuit in the vehicle speed sensor and diagnosis code No.
Page 305 23-13 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> Code No. 41, 42 Solenoid valve No.1 system Probable cause If the resistance value for a solenoid valve No.1 is too large, it is judged that there Malfunction of solenoid valve No.1 is an open circuit in the solenoid valve No.1 and the diagnosis code No.41 is output. Malfunction of harness or connector If the resistance value for a solenoid valve No.1 is too small, it is judged that there Malfunction of the A/T-ECU...
Page 306 23-14 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> Code No. 55 Abnormal communication with engine-ECU Probable cause If normal communication is not possible for a continuous period of 1 second or Malfunction of harness or connector more when the ignition switch is at the ON position and the battery voltage is 10 Malfunction of the engine-ECU V or more, diagnosis code No.
Page 307 23-15 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection procedure Reference page Communication with the MUT- II is not possible 23-16 Does not move Does not move forward and reverse 23-17 Does not move forward only 23-18 Does not reverse only 23-18...
Page 308 23-16 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with the MUT- II is not possible Probable cause If communication with the MUT- II is not possible, the cause is probably a malfunction Malfunction of self-diagnosis system in the self-diagnosis system or the A/T-ECU is not functioning.
Page 309 23-17 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE 2 Does not move forward and reverse Probable cause When the engine is idling, the vehicle does not move forward and reverse even Malfunction of transmission control cable if the selector lever is shifted from N to D, 2, L or R positionj. In such cases, the Abnormal line pressure cause is probably abnormal line pressure, or a malfunction of the transmission control Malfunction of power train...
Page 310 23-18 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE 3 Does not move forward only Probable cause When the engine is idling, the vehicle does not move forward even if the selector Malfunction of forward clutch lever is shifted from N to D, 2 or L range. In such cases, the cause is probably Malfunction of direct clutch a malfunction of the clutch or brake.
Page 311 23-19 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE 5 Upshifting does not occur Probable cause Upshifting does not occur under conditions when upshifting should occur. Check Malfunction of solenoid valve No. 1, No. 2 → → → shifting from 1 2, 2 3 and 3 4 respectively.
Page 312 23-20 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE 6 Downshifting does not occur Probable cause Downshifting does not occur under conditions when downshifting should occur. Check Malfunction of solenoid No. 1, No. 2 → → → shifting from 2 1, 3 2 and 4 3 respectively.
Page 313 23-21 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE 8 Upshifting occurs spontaneously Probable cause Upshifting occurs in ranges where upshifting should not occur, e. g. upshifting to Malfunction of inhibitor switch 2nd gear in L range, 3rd gear in 2 range or 4th gear in D range when overdrive Malfunction of overdrive switch is disconnected.
Page 314 23-22 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE 10 Large shocks Probable cause → → Shocks accompany shifting from N D, N R and during each upshift and downshift. Malfunction of direct clutch Malfunction of brake No. 3 Malfunction of stop lamp switch Malfunction of inhibitor switch Malfunction of forward clutch Malfunction of valve body...
Page 315 23-23 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE 11 Slippage (vibration) Probable cause Occurs when a clutch or brake does not fully engage due to low hydraulic pressure Malfunction of torque converter or a worn facing. Appears as vibration when the problem is slight. Malfunction of direct clutch Malfunction of forward clutch Malfunction of one-way clutch No.
Page 316 23-24 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE 12 Lockup abnormality Probable cause When lockup does not operate even though in the lockup range, and also when Malfunction of torque converter lockup is operating and the engine is idling but then stalls. Malfunction of valve body Malfunction of A/T-ECU L : Refer to the Transmission Workshop Manual.
Page 317 23-25 AUTOMATIC TRANSMISSION ± AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> Troubleshooting <A/T> INSPECTION PROCEDURE 14 Inhibitor switch system Probable cause If the engine does not start in P or N range, the cause is probably a problem in Malfunction of inhibitor switch the inhibitor switch system.
Page 318 23-26 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> INSPECTION PROCEDURE 16 Stop lamp switch system Probable cause If large shocks occur during squat control, the cause is probably a problem with Malfunction of stop lamp switch the stop lamp switch. Malfunction of harness or connector Malfunction of A/T-ECU MUT- II SERVICE DATA Check the stop lamp switch...
Page 319 23-27 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> SERVICE DATA REFERENCE TABLE Item Inspection item Inspection conditions Normal value Accelerator Engine: Idle Accelerator pedal: Fully 0 ± 5 % pedal position released Selector lever position: N sensor (throttle sensor (throttle opening voltage) Accelerator pedal: Depressed Gradually rises from the above value...
Page 320 23-28 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> Item Inspection item Inspection conditions Normal value Inhibitor switch Ignition switch: ON Selector lever position: P P, R, D Engine: Stopped Engine: Stopped Selector lever position: R P, R, D Selector lever position: N Selector lever position: D P, R, D Selector lever position: 2...
Page 321 23-29 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> REFERENCE FOR FAIL-SAFE/BACKUP FUNCTIONS When malfunctions of the main sensors or actuators are detected by the diagnosis system, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning item Control contents during malfunction Output shaft speed...
Page 322 23-30 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> A/T-ECU TERMINAL VOLTAGE REFERENCE CHART Terminal Inspection item Inspection conditions Standard value Solenoid valve No. 1 When in 1st or 2nd gear System voltage When in 3rd or 4th gear Solenoid valve No. 2 When in 2nd or 3rd gear System voltage When in 1st or 4th gear...
Page 323 23-31 AUTOMATIC TRANSMISSION ± Troubleshooting <A/T> Terminal Inspection item Inspection conditions Standard value Communication with input Engine: Idling Other than 0 V signals from engine-ECU Selector lever position: D Communication with output Engine: Idling Other than 0 V signals to engine-ECU Selector lever position: D Inhibitor switch (2) Selector lever position: 2...
Page 324: Troubleshooting
Troubleshooting <A/T Key Interlock and Shift 23-32 AUTOMATIC TRANSMISSION ± Lock Mechanisms> TROUBLESHOOTING <A/T KEY INTERLOCK AND SHIFT LOCK MECHANISMS> INSPECTION CHART FOR TROUBLE SYMPTOMS Problem Inspection Reference page Procedure No. Selector lever can be moved from P to R without depressing brake pedal 23-32 when ignition key is at positions other than LOCK (OFF).

Page 325 Troubleshooting <A/T Key Interlock and Shift 23-33 AUTOMATIC TRANSMISSION ± Lock Mechanisms> INSPECTION PROCEDURE 3 Selector lever can be moved from P to R with brake pedal Probable cause depressed when ignition key is at LOCK (OFF) position. Lock cam or key interlock cable may be defective. Malfunction of lock cam Malfunction of key interlock cable Check items described in the column ªProbable causeº.
Page 326: On-Vehicle Service
23-34 AUTOMATIC TRANSMISSION ± On-vehicle Service ON-VEHICLE SERVICE ESSENTIAL SERVICE AUTOMATIC TRANSMISSION FLUID CHECK Caution When the transmission has been replaced or overhauled, or driving has been carried out under the severe condition, the A/T fluid cooler line flushing should always be carried out and also, the A/T fluid should always be replaced.
Page 327 23-35 AUTOMATIC TRANSMISSION ± On-vehicle Service AUTOMATIC TRANSMISSION FLUID REPLACEMENT Caution When the transmission has been replaced or overhauled, the A/T fluid cooler line flushing should always be carried out before installing the A/T fluid cooler hose. If you have a A/T fluid changer, use this changer to replace the A/T fluid.
Page 328 23-36 AUTOMATIC TRANSMISSION ± On-vehicle Service 8. Reconnect the hose which was disconnected in step 1 above, and firmly replace the oil level gauge. 9. Start the engine and run it at idle for 1 ± 2 minutes. 10. Move the selector lever through all positions, and then move it to the N position.
Page 329 23-37 AUTOMATIC TRANSMISSION ± On-vehicle Service 4. Repeat the procedure in step 2. NOTE Drain the A/T fluid from the cooler hose 6.0 at least in step 2. Then drain the A/T fluid a little and check the A/T fluid for dirt. If it has been contaminated, repeat the steps 3 and 4.
Page 330 23-38 AUTOMATIC TRANSMISSION ± On-vehicle Service INHIBITOR SWITCH AND CONTROL CABLE ADJUSTMENT Mounting bolt 1. Set the manual control lever to the N position. N position 2. Loosen the inhibitor switch mounting bolt. reference line 3. Turn the inhibitor switch to align the N position reference line on the inhibitor switch with the scratched line on the N position adjusting plate.
Page 331: Transfer Oil Check
23-39 AUTOMATIC TRANSMISSION ± On-vehicle Service HIGH/LOW DETECTION SWITCH CONTINUITY CHECK Check the continuity between the terminal of the black connector installed in the top of transfer case (shown in the illustration) and the transfer case. Transfer lever position Continuity 4HLc Continuity Between 4HLc and 4LLc...
Page 332: A/T Control Component Location
23-40 AUTOMATIC TRANSMISSION ± On-vehicle Service A/T CONTROL COMPONENT LOCATION Name Symbol Name Symbol Accelerator pedal position sensor (APS) Inhibitor switch Input shaft speed sensor A/T-ECU Output shaft speed sensor A/T fluid temperature sensor Overdrive switch Diagnosis connector Solenoid valves Dual-pressure switch Stop lamp switch Engine-ECU...
Page 333: A/T Control Component Check
23-41 AUTOMATIC TRANSMISSION ± On-vehicle Service A/T CONTROL COMPONENT CHECK OVERDRIVE SWITCH CHECK Refer to P.23-51. WIDE OPEN THROTTLE SWITCH CHECK Refer to P23-51. ACCELERATOR PEDAL POSITION SENSOR (APS) CHECK Refer to GROUP 13A ± On-vehicle Service. INHIBITOR SWITCH CHECK Refer to P.23-37.
Page 334 23-42 AUTOMATIC TRANSMISSION ± On-vehicle Service OUTPUT SHAFT SPEED SENSOR CHECK Output shaft speed sensor 1. Disconnect the output shaft speed sensor connector. 2. Measure the resistance between terminals 3 and 4 of the output shaft speed sensor connector. Standard value: 430 43 Ω ...
Page 335 23-43 AUTOMATIC TRANSMISSION ± On-vehicle Service A/T FLUID TEMPERATURE SENSOR CHECK 1. Disconnect the A/T fluid temperature sensor connector. A/T fluid temperature sensor 2. Measure the resistance between terminals 1 and 2 of the A/T fluid temperature sensor connector. Standard value Temperature ( C) Resistance 1,100 Ω...
Page 336: Converter Stall Test
23-44 AUTOMATIC TRANSMISSION ± On-vehicle Service CONVERTER STALL TEST Engine tachometer In this test, the engine maximum speed when the torque converter stalls with the selector lever in the ªDº or ªRº range is measured to check operation of the torque converter, starter and one-way clutch and check holding performance of the transmission clutch (including brake).
Page 337: Hydraulic Pressure Test
23-45 AUTOMATIC TRANSMISSION ± On-vehicle Service HYDRAULIC PRESSURE TEST The hydraulic pressure test is important in determining the causes of transmission failures. Before conducting the test, MD998920 fluid level and condition and throttle cable adjustment, etc. must be checked for defects or abnormalities. When conducting the test, the engine and transmission should be at correct operating temperatures, (engine coolant 80 ±...
Page 338: Hydraulic Circuit
23-46 AUTOMATIC TRANSMISSION ± On-vehicle Service HYDRAULIC CIRCUIT PRND2L 1. Overdrive clutch 16. Cut-back valve 2. Overdrive brake 17. Throttle valve 3. Forward clutch 18. Secondary regulator valve 4. Direct clutch 19. Lockup control valve 5. Brake No. 1 20. Primary regulator valve 6.
Page 339: Selector Lever Operation Check
23-47 AUTOMATIC TRANSMISSION ± On-vehicle Service SELECTOR LEVER OPERATION CHECK 1. Apply the parking brake lever. 2. Move the selector lever from N position to each of D, 2 and L positions to check that the selector lever moves smoothly. 3.
Page 340 23-48 AUTOMATIC TRANSMISSION ± On-vehicle Service 2. If there is a problem on the inspection above, adjust the key interlock cable as follows: (1) Remove the rear floor console. (Refer to GROUP 52A.) 12 Nm Lock cam (2) Move the selector lever to P position. (3) Turn the ignition key to LOCK (OFF) position.
Page 341: Transmission Control Cable Adjustment
23-49 AUTOMATIC TRANSMISSION ± On-vehicle Service 2. If there is a problem on the inspection above, adjust the shift Red marking lock cable as follows: (1) Remove the rear floor console. (Refer to GROUP 52A.) Lock cam Shift lock cable (2) Move the selector lever to P position.
Page 342: Transmission Control
23-50 AUTOMATIC TRANSMISSION ± Transmission Control TRANSMISSION CONTROL REMOVAL AND INSTALLATION Caution Do not strike the SRS-ECU when removing and installing the transmission control cable, key interlock cable, shift lever assembly and the A/T-ECU. Apply sealant to both sides 9, 11 Sealant: Sealant: 3M Stud Locking...
Page 343 23-51 AUTOMATIC TRANSMISSION ± Transmission Control INSTALLATION SERVICE POINT A A TRANSFER LEVER INNER BOOT INSTALLATION Install the transfer lever inner boot as shown in the illustration. Front of vehicle INSPECTION Front of vehicle Slide the connector in the direction of arrow shown in the illustration to remove it from the bracket.
Page 344 23-52 AUTOMATIC TRANSMISSION ± Transmission Control SELECTOR LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 15 Nm 15 Nm 12 Nm Disassembly steps 1. Position indicator socket assembly 10. Adjuster lever 2. Bulb 11. Lock cam 3. Shift knob 12. Pin 4. Push button 13.
Page 345 23-53 AUTOMATIC TRANSMISSION ± Transmission Control DISASSEMBLY SERVICE POINT POSITION INDICATOR SOCKET ASSEMBLY Terminal REMOVAL Use a flat-tipped screwdriver, etc. to remove the terminal of shift knob side from the position indicator socket assembly connector. Screwdriver REASSEMBLY SERVICE POINT 16.0 ± 16.7 mm A A SLEEVE INSTALLATION Sleeve Shift the selector lever to the N position, and then turn the...
Page 346: A/T Key Interlock And Shift Lock Mechanisms
23-54 AUTOMATIC TRANSMISSION ± A/T Key Interlock and Shift Lock Mechanisms A/T KEY INTERLOCK AND SHIFT LOCK MECHANISMS REMOVAL AND INSTALLATION 12 Nm 12 Nm Key interlock cable removal steps Shift lock cable removal steps D Front floor console (Refer to GROUP D Front floor console (Refer to GROUP 52A.) 52A.)
Page 347 23-55 AUTOMATIC TRANSMISSION ± A/T Key Interlock and Shift Lock Mechanisms INSTALLATION SERVICE POINTS Red marking A A SHIFT LOCK CABLE (SELECTOR LEVER SIDE) Lock cam INSTALLATION Shift lock cable 1. Move the selector lever to P position. 2. Move the shift lock cable to position the shift lock cable end above the red marking painted on the lock cam, and then tighten the shift lock cable fixing nut to the specified torque.
Page 348: Transmission Assembly
23-56 AUTOMATIC TRANSMISSION ± Transmission Assembly TRANSMISSION ASSEMBLY REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the transmission on the vehicle body. Pre-removal and Post-installation Operation Transfer Control Lever Assembly Removal and Front Exhaust Pipe and Catalytic Converter Removal...
Page 349 23-57 AUTOMATIC TRANSMISSION ± Transmission Assembly 49 Nm 49 Nm 49 Nm 34 ± 41 Nm 49 Nm 93 Nm 49 Nm 49 Nm 14. Oil cooler hose 18. Transmission mount bushing D Oil pan removal 19. Transmission mount crossmember (Refer to GROUP 11A.) 20.
Page 350 23-58 AUTOMATIC TRANSMISSION ± Transmission Assembly REMOVAL SERVICE POINTS STARTER MOTOR REMOVAL Remove the starter motor with the starter motor harnesses still connected, and secure it inside the engine compartment. DRIVE PLATE CONNECTION BOLTS REMOVAL 1. Remove the connection bolts (6 places) while turning the crankshaft.
Page 351: Transmission Oil Cooler
23-59 AUTOMATIC TRANSMISSION ± Transmission Oil Cooler TRANSMISSION OIL COOLER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Transmission Fluid Draining and Supplying (Refer to P.23-35.) Under Cover Removal and Installation 44 Nm Removal steps 1. Return hose Transmission assembly (Refer to P.23-56.) 2.
Page 352: A/T-Ecu
23-60 AUTOMATIC TRANSMISSION ± A/T-ECU/4WD Indicator Control Unit A/T-ECU REMOVAL AND INSTALLATION Caution Do not strike the G sensor when removing and installing the A/T-ECU. Pre-removal and Post-installation Operation Rear Floor Console Removal and Installation Removal steps 1. Floor console bracket 2.
Page 353 25-1 PROPELLER SHAFT CONTENTS GENERAL INFORMATION ....SPECIAL TOOL ......SERVICE SPECIFICATIONS .
Page 354 25-2 PROPELLER SHAFT ± General Information/Service Specifications/Lubricant/Special Tool GENERAL INFORMATION A two-joint propeller shaft was used for both the front and rear. SERVICE SPECIFICATIONS Items Standard value Limit Propeller shaft runout mm Front ± Rear ± Length of rear propeller shaft mm ±...
Page 355 25-3 PROPELLER SHAFT ± Propeller Shaft PROPELLER SHAFT REMOVAL AND INSTALLATION Caution Do not reuse the rear propeller shaft already shrunk due to a big impact. The rear propeller shaft has impact-absorption mechanism (shrinkage). Pre-removal Operation Post-installation Operation Shift the lever to ª2Hº Transfer Gear Oil Supplying Transfer Gear Oil Draining (M/T: Refer to GROUP 22 ±...
Page 356 25-4 PROPELLER SHAFT ± Propeller Shaft REMOVAL SERVICE POINT FRONT PROPELLER SHAFT ASSEMBLY/REAR PROPELLER SHAFT ASSEMBLY REMOVAL 1. Make mating marks on the differential companion flange and flange yoke, and then remove the propeller shaft assembly. Cover the transmission and transfer not to allow foreign materials to enter.
Page 357 25-5 PROPELLER SHAFT ± Propeller Shaft PROPELLER SHAFT ± Propeller Shaft DISASSEMBLY AND REASSEMBLY Universal joint repair kit Disassembly steps B A 1. Snap ring 4. Flange yoke A A 2. Journal bearing 5. Sleeve yoke 3. Journal 6. Propeller shaft DISASSEMBLY SERVICE POINTS SNAP RING REMOVAL Make mating marks on the flange yoke, sleeve yoke and...
Page 358 25-6 PROPELLER SHAFT ± Propeller Shaft JOURNAL BEARING REMOVAL MB990840 1. Using the special tools, press in the journal bearing to remove the journal bearing on the opposite side. 2. Set the special tools reverse to press in the journal. Then, pull out the journal bearing pressed in step 1.
Page 359 25-7 PROPELLER SHAFT ± Propeller Shaft 3. Install the snap ring on the opposite side and measure the clearance of the snap ring groove with a thickness gauge. Snap ring Standard value: Front propeller shaft (A) 0 ± 0.06 mm Rear propeller shaft (A) 0.02 ±...
Page 360 NOTES...
Page 361 26-1 FRONT AXLE CONTENTS GENERAL INFORMATION ....Solenoid Valve Operation Check ... . . HUB AND KNUCKLE ASSEMBLY .
Page 362: General Information
26-2 FRONT AXLE ± General Information GENERAL INFORMATION The front axle consists of the hub assembly, drive For vehicles with ABS, the ABS rotor for shaft, inner shaft, front differential, detecting the wheel speed has been pressed free-wheeling clutch. in the B.J. joint. The features are: The axle is supported by the ball bearing and The free-wheeling mechanism enables 2WD...
Page 363 26-3 FRONT AXLE ± General Information CONSTRUCTION DIAGRAM Front differential Free-wheeling clutch Differential mount bracket (LH) Differential mount crossmember Drive shaft (RH) Drive shaft (LH) Ball joint Drive shaft Knuckle (LH) Brake disc Differential side B.J. D.O.J. ABS rotor Plastic BJ boot (RH) Differential side Ball bearing...
Page 364: Service Specifications
26-4 FRONT AXLE ± Service Specifications/Lubricants SERVICE SPECIFICATIONS Items Standard value Limit Front axle total backlash mm ± Wheel bearing axial play mm ± Solenoid valve resistance Ω 36 ± 46 ± Hub rotation starting torque Nm ± Setting of D.O.J. boot length mm 80 ±...
Page 365: Sealants And Adhesives
26-5 FRONT AXLE ± Sealants and Adhesives/Special Tools SEALANTS AND ADHESIVES Items Specified sealants and adhesives Remarks Front housing assembly and free- 3M ATD Part No.8661 or equivalent Semi-drying sealant wheeling hosing assembly Front housing assembly and differen- tial carrier Vent plug Differential cover Drive gear and differential case...
Page 366 26-6 FRONT AXLE ± Special Tools Tool Number Name MB991056 Knuckle arm Hub removal MB991355 bridge A: MB991017 A, B: Front hub Hub removal and press-fitting. remover and in- Wheel bearing provisional holding B: MB990998 staller (MB991000, which belongs to MB990998, C: MB991000 should be used as a spacer.) C: Spacer...
Page 367 26-7 FRONT AXLE ± Special Tools Tool Number Name MB990673 Front bearing Bearing removal remover MB990663 Rear axle shaft Bearing installation bearing and retain- er ring installer MB990909 Working base Differential carrier fixing assembly MB990850 End yoke holder Companion flange removal and installation MB990560 Rear axle...
Page 368 26-8 FRONT AXLE ± Special Tools Tool Number Name MB990829 Pinion and side Drive pinion rear bearing inner race bearing installer pressing-in Side bearing inner race pressing-in MB990727 Oil seal installer Drive pinion oil seal pressing-in MB991015 Knuckle oil seal Oil seal pressing-in installer MB990799...
Page 369 26-9 FRONT AXLE ± Special Tools Tool Number Name MB991318 Lower arm bushing Front differential mount insulator <rear> arbour pressing-in MB991183 Bushing arbour MB990843 Drag link bushing remover and installer GENERAL Engine lifter Supporting the engine assembly when the SERVICE differential carrier is removed and installed TOOL MZ203827...
Page 370: On-Vehicle Service
26-10 FRONT AXLE ± On-vehicle Service ON-VEHICLE SERVICE WHEEL BEARING AXIAL PLAY CHECK 1. Remove the disc brake caliper and suspend it with a wire. 2. Remove the brake disc from the front hub. 3. Attach a dial gauge as shown in the illustration, and then measure the axial play while moving the hub in the axial direction.
Page 371: Front Axle Gear Oil Level Check
26-11 FRONT AXLE ± On-vehicle Service FRONT AXLE GEAR OIL LEVEL CHECK Top up the specified gear oil if the gear oil level does not reach the bottom of the filler plug. Specified gear oil: Hypoid gear oil API classification GL-5 or higher, SAE viscosity No.90, 80W NOTE SAE 90 for 10 °...
Page 372: Solenoid Valve Operation Check
26-12 FRONT AXLE ± On-vehicle Service 4. Use the special tools to install a new oil seal. MB990938 MB991115 5. Apply multi-purpose grease to the oil seal lip, and then install the right drive shaft (Refer to P.26-19) and the front housing assembly (Refer to P.26-26).
Page 373 26-13 FRONT AXLE ± On-vehicle Service 4. Connect a hand vacuum pump to solenoid valve B. Apply negative pressure and carry out the following inspections. (9) When battery voltage is not applied to any terminals, the negative pressure is held. Check valve (10)When battery voltage is applied to solenoid valve Vacuum tank...
Page 374: Hub And Knuckle Assembly
26-14 FRONT AXLE ± Hub and Knuckle Assembly HUB AND KNUCKLE ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation Press the Dust Cover with a Finger to Check Whether the Dust Cover is Cracked or Damaged. 108 ± 127 Nm 59 ± 71 Nm 59 ±...
Page 375 26-15 FRONT AXLE ± Hub and Knuckle Assembly TIE ROD END/LOWER ARM REMOVAL MB991113 or MB991406 Caution 1. Only loosen the ball joint nut, but do not remove it. Use the special tool. 2. Suspend the special tool with a cord to prevent it Cord from dropping.
Page 376 26-16 FRONT AXLE ± Hub and Knuckle Assembly DISASSEMBLY AND REASSEMBLY Disassembly steps Reassembly steps 1. Inner oil seal 6. Knuckle A A 4. Wheel bearing 2. Hub 3. Snap ring 3. Snap ring B A 5. Outer oil seal 4.
Page 377 26-17 FRONT AXLE ± Hub and Knuckle Assembly 2. Use the special tool to remove the wheel bearing outer MB990810 inner race from the hub. Caution Be careful not to drop the hub when the outer inner race is pressed out. Outer inner race 3.
Page 378 26-18 FRONT AXLE ± Hub and Knuckle Assembly 3. Use the special tool to measure the hub rotation starting torque. Limit within 1.6 Nm 4. Make sure that the hub rotation starting torque is within the limit, and the hub turns smoothly. MB990326 D A WHEEL BEARING AXIAL PLAY CHECK MB991000...
Page 379: Drive Shaft
26-19 FRONT AXLE ± Drive Shaft DRIVE SHAFT REMOVAL AND INSTALLATION Caution On the vehicles with ABS, when the drive shaft is removed or installed, be careful not to interfere with the ABS rotor installed to the B.J. outer race to prevent the rotor from damage. Pre-removal Operation Post-installation Operation Disengage the Stabilizer Link from the Strut Bar...
Page 380 26-20 FRONT AXLE ± Drive Shaft HUB/KNUCKLE MB991113 or ASSEMBLY/LOWER HUB/KNUCKLE MB991406 ASSEMBLY DISCONNECTION Caution 1. Only loosen the ball joint nut, but do not remove it. Cord Use the special tool. 2. Tie the special tool with a cord not to let it fall off. Ball joint DRIVE SHAFT REMOVAL D.O.J.
Page 381 26-21 Drive Shaft FRONT AXLE ± DISASSEMBLY AND REASSEMBLY Caution The B.J. assembly is non-serviceable and requires replacement if defective. B.J. boot can be replaced. <RH> <LH> Grease: Repair kit grease Grease: Repair kit grease Quantity: <A/T> B.J.: 85 g (40 g for joint, 45 g for boot) D.O.J.: 85 g (50 g for joint, 35 g for boot) <M/T>...
Page 382 26-22 FRONT AXLE ± Drive Shaft A A 7. D.O.J. boot Disassembly steps 8. B.J. boot band (small) B A 1. D.O.J. boot band (small) 9. B.J. boot band (large) B A 2. D.O.J. boot band (large) 10. B.J. boot 3.
Page 383 26-23 FRONT AXLE ± Drive Shaft 3. Position the plastic boot small end so that one drive shaft groove is visible. 4. Turn the adjusting bolt of the special tool so that the MB991561 opening distance (W) meets the standard value. Stopper Standard value (W): 2.9 mm <More than 2.9 mm>...
Page 384 26-24 FRONT AXLE ± Drive Shaft 7. Check that the crimping amount (B) of the B.J. boot band is at the standard value. Standard value (B): 2.4 ± 2.8 mm <If the crimping amount is larger than 2.8 mm> Readjust the value of (W) in step 4 according to the following formula, and then repeat the operation in step 6.
Page 385 26-25 FRONT AXLE ± Drive Shaft 14. Check that the crimping amount (E) of the B.J. boot band is at the standard value. Standard value (E): 2.4 ± 2.8 mm <If the crimping amount is larger than 2.8 mm> Readjust the value of (W) in step 11 according to the following formula, and then repeat the operation in step 13.
Page 386: Main Shaft
26-26 FRONT AXLE ± Main Shaft MAIN SHAFT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Drive Shaft Removal and Installation (Refer to P.26-19.) Free-wheeling Clutch Housing Assembly Removal and Installation (Refer to P.26-45.) Gear Oil Draining and Refilling (Refer to P.26-11.) 17 Nm 88 Nm 98 ±...
Page 387 26-27 FRONT AXLE ± Main Shaft REMOVAL SERVICE POINT BEARING REMOVAL MB990673 Install the special tool as shown in the illustration, and use a press to drive out the bearing from the main shaft. INSTALLATION SERVICE POINTS MB990938 A A OIL SEAL INSTALLATION MB990926 B A BEARING INSTALLATION MB990663...
Page 388: Differential Carrier
26-28 FRONT AXLE ± Differential Carrier DIFFERENTIAL CARRIER REMOVAL AND INSTALLATION Caution To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Pre-removal and Post-installation Operation Drive Shaft Removal and Installation Gear Oil Draining and Refilling (Refer to P.26-11.)
Page 389 26-29 FRONT AXLE ± Differential Carrier REMOVAL SERVICE POINT MZ203827 ENGINE ASSEMBLY SUPPORT Use the special tool to raise the engine assembly until the mount insulators are free from load. DISASSEMBLY 2 19 Disassembly steps 16. Drive pinion front shim (For drive pinion height adjustment) D Inspection before disassembly 17.
Page 390 26-30 FRONT AXLE ± Differential Carrier INSPECTION BEFORE DISASSEMBLY 1. Remove the cover. MB990909 2. Hold the special tool in a vise, and install the differential carrier assembly to the special tool. DRIVE GEAR BACKLASH 1. With the drive pinion locked in place, use a dial gauge to measure the drive gear backlash in four or more places on the drive gear.
Page 391 26-31 FRONT AXLE ± Differential Carrier 2. If the backlash exceeds the limit, adjust the differential gear backlash (Refer to P.26-41). 3. If adjustment is impossible, replace the side gear and pinion gear as a set. DRIVE GEAR TOOTH CONTACT Check the tooth contact of drive gear by following the steps below.
Page 392 26-32 FRONT AXLE ± Differential Carrier Standard tooth contact pattern Problem Solution Narrow tooth side Tooth contact pattern resulting from Drive-side tooth surface (the side excessive pinion height applying power during forward movement) Wide tooth side Coast-side tooth surface (the side applying power during re- verse movement) Increase the thickness of the drive...
Page 393 26-33 FRONT AXLE ± Differential Carrier DISASSEMBLY SERVICE POINTS DIFFERENTIAL CASE ASSEMBLY REMOVAL Remove the differential case assembly with a hammer handle or the like. Caution When taking out the differential case assembly, be careful not to drop and damage the side bearing outer races. NOTE Keep the right and left side bearing outer races and side bearing spacers separate, so that they do not become mixed...
Page 394 26-34 FRONT AXLE ± Differential Carrier DRIVE PINION ASSEMBLY REMOVAL MB990810 1. Make mating marks on the drive pinion and the companion flange. Caution The mating mark must not be on the coupling surface of the companion flange and the front propeller shaft. Companion 2.
Page 395 26-35 FRONT AXLE ± Differential Carrier REASSEMBLY Differential gear set Final drive gear set 78 ± 88 Nm 186 Nm 34 ± 39 Nm* 49 Nm 59 ± 69 Nm 35 Nm Reassembly steps 1. Differential carrier 15. Self-locking nut A A 2.
Page 396 26-36 FRONT AXLE ± Differential Carrier LUBRICATION, SEALANT AND ADHESIVE POINTS (Apply (Apply entire circumfer- ence of the lip entire Sealant: circum- 3M ATD Part No. 8661 or ference equivalent of the lip 2 ± 3 mm Sealant: Adhesive: 3M ATD Part No. 8661 or 3M Stud Locking 4170 or equivalent equivalent...
Page 397 26-37 FRONT AXLE ± Differential Carrier B A DRIVE PINION FRONT BEARING OUTER RACE INSTALLATION MB990938 MB990926 C A DRIVE PINION REAR BEARING OUTER RACE MB990938 INSTALLATION MB990929 D A DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedure. 1.
Page 398 26-38 FRONT AXLE ± Differential Carrier NOTE MB990326 The special tool cannot be turned a full revolution, so turn it several times within the range of movement to run in the bearing, and then measure the rotation torque. 4. Clean the side bearing hub. MB991170 <M/T>...
Page 399 26-39 FRONT AXLE ± Differential Carrier E A DRIVE PINION ROTATION TORQUE ADJUSTMENT Adjust the drive pinion rotation torque by using the following procedure: 1. Insert the drive pinion into the gear carrier, and then install the drive pinion spacer, the drive pinion rear shim, the drive pinion rear bearing inner race, and the companion flange in that order.
Page 400 26-40 FRONT AXLE ± Differential Carrier Drive pinion spacer Identification colour height (A) mm 46.67* White 47.01* ± 57.72* ± 57.08* NOTE : M/T : A/T 5. Remove the companion flange and drive pinion again. Then, after inserting the drive pinion rear bearing inner race into the gear carrier, use the special tool to press-fit the oil seal.
Page 401 26-41 FRONT AXLE ± Differential Carrier F A DIFFERENTIAL GEAR BACKLASH ADJUSTMENT Follow the procedures below to adjust the differential gear backlash. 1. Assemble the side gears, side gear spacers, pinion gears and pinion washers into the differential case. 2. Temporarily install the pinion shaft. NOTE Do not drive in the lock pin yet.
Page 402 26-42 FRONT AXLE ± Differential Carrier 3. Clean the drive gear attaching surface, and then apply the specified adhesive to the threaded holes of the drive gear. Specified sealant: 3M Stud Locking 4170 or equivalent 4. Install the drive gear onto the differential case with the mating marks properly aligned.
Page 403 26-43 FRONT AXLE ± Differential Carrier 3. Measure the thickness of the side bearing spacers on one side, select two pairs of spacers which correspond to that thickness plus one half of the clearance plus 0.05 mm, and then install one pair each to the drive pinion side and the drive gear side.
Page 404 26-44 FRONT AXLE ± Differential Carrier 8. Change the side bearing spacers as illustrated, and then If backlash is too small adjust the drive gear backlash. Thinner Thicker spacer spacer NOTE When increasing the number of side bearing spacers, decrease the same number of the side bearing spacers for opposite side.
Page 405: Free-Wheeling Clutch Assembly
26-45 FRONT AXLE ± Free-wheeling Clutch Assembly FREE-WHEELING CLUTCH ASSEMBLY REMOVAL AND INSTALLATION Caution To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. Pre-removal and Post-installation Operation Gear Oil Draining and Refilling (Refer to P.26-11.) Drive Shaft Removal and Installation...
Page 406 26-46 FRONT AXLE ± Free-wheeling Clutch Assembly INSPECTION FREE-WHEELING ENGAGE SWITCH CONTINUITY CHECK Shaft (switch) position Terminal number Shaft Pushed (ON) Contact point Electrode Released (OFF) DISASSEMBLY AND REASSEMBLY ( Apply to the lip ) Disassembly steps D A 1. Clutch sleeve 8.
Page 407 26-47 FRONT AXLE ± Free-wheeling Clutch Assembly DISASSEMBLY SERVICE POINT BEARING REMOVAL Position the bearing inner race on a support. Then use a press to separate the clutch gear from the bearing. Support REASSEMBLY SERVICE POINTS MB991015 MB990938 A A OIL SEAL INSTALLATION B A BEARING INSTALLATION MB990799 Use the special tool to press-fit the bearing to the shoulder...
Page 408: Solenoid Valve, Vacuum Pipes And Vacuum Tank
26-48 FRONT AXLE ± Solenoid Valve, Vacuum Pipes and Vacuum Tank SOLENOID VALVE, VACUUM PIPES AND VACUUM TANK REMOVAL AND INSTALLATION 17 Nm 1. Vacuum hose Vacuum actuator assembly removal A A 2. Vacuum hose <blue stripe> steps A A 3. Vacuum hose <yellow stripe> A A 9.
Page 409 26-49 FRONT AXLE ± Solenoid Valve, Vacuum Pipes and Vacuum Tank REMOVAL SERVICE POINT Collar Dust cover PIN REMOVAL 1. Remove the one side of the dust cover from the vacuum actuator assembly. 2. Align the pin with the pin hole of the collar, and then drive out the pin with a punch.
Page 410: Front Differential Mount
26-50 FRONT AXLE ± Front Differential Mount FRONT DIFFERENTIAL MOUNT REMOVAL AND INSTALLATION Caution 1. To remove the differential mount crossmember assembly, support the front differential assembly with a jack. 2. To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
Page 411 26-51 FRONT AXLE ± Front Differential Mount DIFFERENTIAL MOUNT INSULATOR MD999547 REPLACEMENT FRONT 1. Use the special tool to drive out the insulator. 2 . Use the special tools and a press to press-fit the insulators MB990947 so that their hollow portion points to the shown direction MB990847 and the insulator protrudes evenly (Distance A is equal MB990981...
Page 412 NOTES...
Page 413 27-1 REAR AXLE CONTENTS Rear Axle Total Backlash Check ....GENERAL INFORMATION ....Gear Oil Level Check .
Page 414: General Information
27-2 REAR AXLE ± General Information GENERAL INFORMATION The rear axle is a banjo-type semi-floating type and For vehicles with ABS, the ABS rotor is provides the following characteristics: press-fitted to the axle shaft. The rear wheel bearing is of an anti-mud order improve stream-crossing...
Page 415: Service Specifications
27-3 REAR AXLE ± General Information/Service Specifications/Lubricants CONSTRUCTION DIAGRAM Brake disc Wheel bearing Vent plug Oil seal Axle housing Differential Axle shaft Axle shaft ABS rotor SERVICE SPECIFICATIONS Items Standard value Limit Rear axle total backlash mm ± Wheel bearing axial play mm ±...
Page 416: Sealants And Adhesives
27-4 REAR AXLE ± Sealants and Adhesives/Special Tools SEALANTS AND ADHESIVES Items Specified sealants and adhesives Specified sealants and adhesives Bearing case 3M ATD Part No. 8661 or equivalent Semi-drying sealant Axle housing (Differential carrier instal- lation surface) Drive gear threaded holes 3M Stud Locking 4170 or equivalent Anaerobic sealant SPECIAL TOOLS...
Page 417 27-5 REAR AXLE ± Special Tools Tool Number Name MB991367 Special spanner Side bearing nut removal and installation MB991385 MB990810 Side bearing puller Side bearing inner race removal Companion flange removal MB990811 Side bearing cup Side bearing inner race removal MB990850 End yoke holder Self-locking nut removal...
Page 418: On-Vehicle Service
27-6 REAR AXLE ± Special Tools/On-vehicle Service Tool Number Name MB990685 Torque wrench Drive pinion turning torque adjustment MB990326 Preload socket MB990802 Bearing installer Drive pinion rear bearing inner race press-fitting Side bearing inner race press-fitting MB990727 Oil seal installer Drive pinion oil seal press-fitting MB991171 Bearing and oil...
Page 419: Gear Oil Level Check
27-7 REAR AXLE ± On-vehicle Service GEAR OIL LEVEL CHECK 1. Remove the filler plug. Gear oil 2. Check that the gear oil level is between the upper limit (the bottom of a filler plug) and the lower limit. 3. If the gear oil level is not between the upper limit and Upper limit 8 mm the lower limit, add the specified gear oil until the gear...
Page 420 27-8 REAR AXLE ± On-vehicle Service 4. Use the special tools to install a new oil seal in position. MB990930 5. Apply multipurpose grease to the lip section of the oil seal. 6. Install the axle shaft assembly. (Refer to P.27-11.) MB990938...
Page 421: Axle Assembly
27-9 REAR AXLE ± Axle Assembly AXLE ASSEMBLY REMOVAL AND INSTALLATION Caution 1. To prevent bushings from breakage , the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. 2.
Page 422 27-10 REAR AXLE ± Axle Assembly REMOVAL SERVICE POINTS REAR PROPELLER SHAFT DISCONNECTION Make mating marks on the companion flange and the flange yoke, and then disconnect the propeller shaft from the companion flange. Caution Use a wire, etc. to suspend the propeller shaft from the body to prevent it from falling.
Page 423: Axle Shaft
27-11 REAR AXLE ± Axle Shaft AXLE SHAFT REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining (Refer to GROUP 35A ± On-vehicle Brake Fluid Filling and Air Bleeding (Refer to Service.) GROUP 35A ± On-vehicle Service.) Parking Brake Lever Stroke Adjustment (Refer to GROUP 36 ±...
Page 424 27-12 REAR AXLE ± Axle Shaft OIL SEAL REMOVAL MB990212 Use the special tools to remove the oil seal. MB990211 INSTALLATION SERVICE POINTS MB990930 A A OIL SEAL INSTALLATION Use the special tools to tap in the oil seal. MB990938 B A PACKING/SHIM INSTALLATION 1.
Page 425 27-13 REAR AXLE ± Axle Shaft (3) If using the shim(s), sandwich the shim(s) between the packings as shown in the illustration. Shims 3. Install the axle shaft assembly. Tighten the nuts in a diagonal order to the specified torque. Tightening torque: 29 Nm Packings DISASSEMBLY AND REASSEMBLY...
Page 426 27-14 REAR AXLE ± Axle Shaft 2. Use a chisel to cut the shaven part of the bearing inner retainer, and then remove the bearing inner retainer. Caution Be careful not to damage the axle shaft. WHEEL BEARING REMOVAL MB991284 Use the special tool to remove the wheel bearing.
Page 427: Differential Carrier
27-15 REAR AXLE ± Differential Carrier DIFFERENTIAL CARRIER REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Differential Gear Oil Draining Brake Fluid Filling and Air Bleeding (Refer to Axle Shaft Removal (Refer to P.27-11.) GROUP 35A ± On-vehicle Service.) Brake Fluid Draining (Refer to GROUP 35A ± Axle Shaft Installation (Refer to P.27-11.) On-vehicle Service.) Differential Gear Oil Filling (Refer to P.27-7.)
Page 428 27-16 REAR AXLE ± Differential Carrier DIFFERENTIAL CARRIER REMOVAL Loosen the differential carrier mounting nuts to the end of each stud bolt, and then strike the lower part of differential carrier with a piece of timber several times to separate the differential carrier from the axle housing.
Page 429 27-17 REAR AXLE ± Differential Carrier DISASSEMBLY Caution Do not disassemble the limited slip differential case assembly (helical gear type), because it is not possible to assemble. <Conventional differential> 22 23 20 21 <Helical LSD> Disassembly steps D Inspection before disassembly 17.
Page 430 27-18 REAR AXLE ± Differential Carrier DISASSEMBLY SERVICE POINTS MB991367 MB991385 SIDE BEARING NUT REMOVAL Use the special tools to remove the side bearing nuts. NOTE Keep the right and left side bearing nuts separate, so that they will not be confused when assembling. DIFFERENTIAL CASE ASSEMBLY REMOVAL Use the handle of hammer to pry up the differential case assembly.
Page 431 27-19 REAR AXLE ± Differential Carrier DRIVE PINION ASSEMBLY/COMPANION FLANGE MB990810 REMOVAL 1. Make the mating marks on the drive pinion and the companion flange in order to position the companion flange correctly when assembling it. Caution Do not make mating mark on the surface that contacts Companion flange with the propeller shaft.
Page 432 27-20 REAR AXLE ± Differential Carrier REASSEMBLY 19 Nm <Conventional differential> 68 ± 78 Nm 19 Nm 78 ± 88 Nm 216 Nm 18 17 <Helical LSD> 19 Nm Differential gear set Final drive gear set 19 Nm Adhesive: 3M Stud Locking 4170 or equivalent Reassembly steps 1.
Page 433 27-21 REAR AXLE ± Differential Carrier REASSEMBLY SERVICE POINTS A A DRIVE PINION REAR BEARING OUTER RACE MB990938 PRESS-FITTING MB990936 Use the special tools to tap in the drive pinion rear bearing outer race. B A DRIVE PINION FRONT BEARING OUTER RACE PRESS-FITTING MB990938 Use the special tools to tap in the drive pinion front bearing...
Page 434 27-22 REAR AXLE ± Differential Carrier 4. Clean the side bearing seat thoroughly. Cutout section MB991170 5. Set the special tool on the side bearing seats, and position the cutout section as shown in the illustration. Then confirm that the special tool contacts with the side bearing seats completely.
Page 435 27-23 REAR AXLE ± Differential Carrier 2. Use the special tool to hold the companion flange, and then tighten the companion flange self-locking nut to the 216 Nm specified torque. MB990850 3. Use the special tool to measure the drive pinion turning MB990326 MB990685 torque (without the oil seal).
Page 436 27-24 REAR AXLE ± REAR AXLE ± Differential Carrier Differential Carrier 6. Install the drive pinion assembly and the companion flange with mating marks properly aligned. Install the new 216 Nm self-locking nut, then use the special tool to hold the MB990850 companion flange, and tighten the self-locking nut to the specified torque.
Page 437 27-25 REAR AXLE ± Differential Carrier 5. If the differential gear backlash exceeds the limit, adjust the backlash by replacing the side gear spacers. 6. If adjustment is not possible, replace the side gears and pinion gears as a set. 7.
Page 438 27-26 REAR AXLE ± Differential Carrier 2. With the drive pinion locked in place, measure the drive gear backlash with a dial indicator on the drive gear. NOTE Measure at four points or more on the circumference of the drive gear. Standard value: 0.08 ±...
Page 439 31-1 WHEEL AND TYRE CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Tyre Inflation Pressure Check .
Page 440: General Information
31-2 WHEEL AND TYRE ± General Information/Service Specifications GENERAL INFORMATION The wheels and tyres of the following specifications have been established. SPECIFICATIONS Items Specification Wheel Type Steel Aluminium* × Size Amount of wheel offset mm Pitch circle diameter (P.C.D.) mm 114.3 Tyre Size...
Page 441 31-3 WHEEL AND TYRE ± Troubleshooting TROUBLESHOOTING Symptom Probable cause Remedy Reference page Rapid wear at Under-inflation Adjust the tyre 31-4. shoulders or lack of rotation pressure. Rapid wear at Over-inflation or centre lack of rotation Cracked treads Under-inflation Adjust the tyre 31-4.
Page 442: On-Vehicle Service
31-4 WHEEL AND TYRE ± On-vehicle Service/Wheel and Tyre ON-VEHICLE SERVICE TYRE INFLATION PRESSURE CHECK NOTE For information on tyre inflation pressure, refer to the label attached near the driver's side door striker. TYRE WEAR CHECK Measure the tread depth of tyres. Limit: 1.6 mm If the remaining tread depth is less than the limit, replace the tyre.
Page 443 32-1 POWER PLANT MOUNT CONTENTS ENGINE MOUNTING ..... . . TRANSMISSION MOUNTING ....
Page 444 32-2 POWER PLANT MOUNT ± Engine Mounting ENGINE MOUNTING REMOVAL AND INSTALLATION Caution Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Crossmember Removal and Installation (Refer to GROUP 33.) 25 Nm*...
Page 445 32-3 POWER PLANT MOUNT ± Transmission Mounting TRANSMISSION MOUNTING REMOVAL AND INSTALLATION Caution Provisionally tighten the parts marked by an asterisk (*), and then fully tighten after loading the full weight of the transmission on the vehicle body. Pre-removal and Post-installation Operation Jack up the Engine and Transmission Assembly until there is no weight on the Engine Mount Bracket Insulator.
Page 446 NOTES...
Page 462 34-1 REAR SUSPENSION CONTENTS GENERAL INFORMATION ....REAR SUSPENSION ASSEMBLY ... SPECIAL TOOLS .
Page 463 34-2 REAR SUSPENSION ± General Information GENERAL INFORMATION The rear suspension is a 5-link coil spring type axle suspension, which assures comfortable ride and outstanding steering stability. COIL SPRING Items Specification × × × × Wire diameter outer diameter free length mm CONSTRUCTION DIAGRAM Bump rubber Coil spring...
Page 464 34-3 REAR SUSPENSION ± Special Tools SPECIAL TOOLS Tool Number Name MB990847 Rear suspension bushing Upper arm rear bushing remover and installer base driving out and press-fitting Lower arm rear bushing driving out and press-fitting MB990947 Lower arm bushing arbor MB990832 Lower arm rear bushing Upper arm rear bushing driving...
Page 465 34-4 REAR SUSPENSION ± Rear Suspension Assembly REAR SUSPENSION ASSEMBLY REMOVAL AND INSTALLATION Caution To prevent bushings from breakage, the parts indicated by * should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. 64 Nm* 81 Nm* 96 Nm*...
Page 466 34-5 REAR SUSPENSION ± Rear Suspension Assembly LATERAL ROD BUSHING REPLACEMENT 1. Use a press to press in and out the bushing. 2. Apply ample amount of soapy water to the outer surface of the bushing and inner surface of the lateral rod pipe, and then press-fit the bushing so that both ends protrude evenly.
Page 467 NOTES...
Page 468 35A-1 SERVICE BRAKES CONTENTS BASIC BRAKE SYSTEM ......... ANTI-SKID BRAKING SYSTEM (ABS) <4WD>...
Page 469 35A-2 BASIC BRAKE SYSTEM CONTENTS GENERAL INFORMATION ....Brake Fluid Level Sensor Check ... . . Disc Brake Pad Check and Replacement .
Page 470 35A-3 BASIC BRAKE SYSTEM ± General Information GENERAL INFORMATION The brake system offers high dependability and durability along with improved braking performance and brake sensitivity. Items Specifications Master cylinder Type Tandem type I.D. mm 22.2 Brake booster Type Vacuum type, single Effective dia.
Page 471 35A-4 BASIC BRAKE SYSTEM ± Service Specifications SERVICE SPECIFICATIONS Items Standard value Limit Brake pedal height mm L.H. drive vehicles 201 ± 204 ± R.H. drive vehicles 201.7 ± 204.7 ± Brake pedal play mm 3 ± 8 ± Brake pedal to floorboard clearance when the brake pedal is depressed mm 105 or more ±...
Page 472 35A-5 BASIC BRAKE SYSTEM ± Lubricants/Sealant/Special Tools LUBRICANTS Items Specified Lubricant Quantity Brake fluid DOT3 or DOT4 As required Vacuum sensor grommet Silicone grease Brake booster seal Piston boot, piston seal Repair kit grease Guide pin, lock pin Piston, wheel cylinder body DOT3 or DOT4 SEALANT Items...
Page 473 35A-6 BASIC BRAKE SYSTEM ± BASIC BRAKE SYSTEM ± On-vehicle Service On-vehicle Service ON-VEHICLE SERVICE BRAKE PEDAL CHECK AND ADJUSTMENT Operating rod BRAKE PEDAL HEIGHT Stop lamp switch 1. Turn up the carpet, etc. under the brake pedal. 2. Measure the brake pedal height as illustrated. Operating rod lock nut Standard value (A):...
Page 474 35A-7 BASIC BRAKE SYSTEM ± On-vehicle Service 2. If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary: Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod Brake pedal height Installation position of the stop lamp switch, etc.
Page 475 35A-8 BASIC BRAKE SYSTEM ± On-vehicle Service 3. With the engine running, step on the brake pedal and No good Good then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition. If the pedal rises, the booster is defective.
Page 476 35A-9 BASIC BRAKE SYSTEM ± On-vehicle Service LOAD SENSING PROPORTIONING VALVE Pressure gauge FUNCTION TEST 1. Connect pressure gauges to the input and output ports of the load sensing proportioning valve. 2. Bleed the system. (Refer to P.35A-10.) 3. Disconnect the spring at the support side. Load sensing pro- portioning valve 4.
Page 477 35A-10 BASIC BRAKE SYSTEM ± On-vehicle Service BLEEDING Caution Specified brake fluid: DOT3 or DOT4 Always use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. MASTER CYLINDER BLEEDING The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier.
Page 478 35A-11 BASIC BRAKE SYSTEM ± On-vehicle Service DISC BRAKE PAD CHECK AND REPLACEMENT NOTE The brake pads have wear indicators that contact the brake disc when the brake pad thickness reaches approximately 2 mm and emit a squealing sound to warn the driver. 1.
Page 479 35A-12 BASIC BRAKE SYSTEM ± On-vehicle Service DISC BRAKE ROTOR CHECK Caution When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation. Before re-finishing or re-processing the brake disc surface, the following conditions should be checked. Inspection items Remarks Scratches, rust, saturated lining materials...
Page 480 35A-13 BASIC BRAKE SYSTEM ± On-vehicle Service BRAKE DISC RUN-OUT CHECK AND CORRECTION 1. Remove the brake assembly, and then hold it with wire. 2. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc.
Page 481 35A-14 BASIC BRAKE SYSTEM ± Brake Pedal BRAKE PEDAL REMOVAL AND INSTALLATION Post-installation Operation Brake Pedal Adjustment (Refer to P.35A-6.) 14 Nm 12 Nm Removal steps 1. Harness connector 7. Split pin <A/T> 2. Stop lamp switch 8. Shift lock cable connection <A/T> 3.
Page 482 35A-15 BASIC BRAKE SYSTEM ± Master Cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER REMOVAL AND INSTALLATION <L.H. drive vehicles with ABS> Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying and Air Bleeding (Refer to P.35A-10.) Brake Pedal Adjustment (Refer to P.35A-6.) 14.7 ±...
Page 483 35A-16 BASIC BRAKE SYSTEM ± Master Cylinder and Brake Booster <L.H. drive vehicles without ABS and R.H. drive vehicles> Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying and Air Bleeding (Refer to P.35A-10.) Brake Pedal Adjustment (Refer to P.35A-6.) Grease: Silicone grease Specified Sealant: 3M ATD Grease: Silicone grease...
Page 484 35A-17 BASIC BRAKE SYSTEM ± Master Cylinder and Brake Booster Master cylinder removal steps A A 6. Vacuum hose 1. Brake pipe connection 2. Brake fluid level sensor connector (With built-in check valve) 3. Bracket <L.H. drive vehicles> 7. Snap pin 4.
Page 485 35A-18 BASIC BRAKE SYSTEM ± Master Cylinder and Brake Booster 2. If the protrusion amount is not within the standard value range, adjust the push rod length by turning the push rod. Use the special tool to turn the push rod while holding the rod spline with angle-nose pliers.
Page 486 35A-19 BASIC BRAKE SYSTEM ± Master Cylinder and Brake Booster MASTER CYLINDER <L.H. drive vehicles without ABS and R.H. drive vehicles> DISASSEMBLY AND REASSEMBLY Brake fluid: DOT3 or DOT4 Master cylinder kit Disassembly steps 1. Reservoir cap 7. Piston guide 2.
Page 487 35A-20 BASIC BRAKE SYSTEM ± Front Disc Brake FRONT DISC BRAKE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying and Air Bleeding (Refer to P.35A-10.) 49 Nm 90 ± 110 Nm Removal steps 1. Brake hose connection 2.
Page 488 35A-21 BASIC BRAKE SYSTEM ± Front Disc Brake 3. Clean the piston and insert it into the cylinder with the special tool. 4. Be careful that the piston boot does not become caught, when lowering the caliper assembly and install the guide pin to the caliper.
Page 489 35A-22 BASIC BRAKE SYSTEM ± Front Disc Brake DISASSEMBLY AND REASSEMBLY 26 Nm Clip kit 26 Nm Pad set Brake caliper kit Shim kit Seal and boot kit Disassembly steps 1. Guide pin lock bolt 8. Piston 2. Guide pin 9.
Page 490 35A-23 BASIC BRAKE SYSTEM ± Front Disc Brake LUBRICATION POINTS Grease: Repair kit grease Piston seal Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off. Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Grease: Repair kit grease...
Page 491 35A-24 BASIC BRAKE SYSTEM ± Front Disc Brake DISASSEMBLY SERVICE POINTS PISTON BOOT/PISTON REMOVAL Use a piece of wood to protect the caliper body outer side, and then apply compressed air through the brake hose connection hole to withdraw the piston and piston boot. Caution If air is blown into the caliper body suddenly, the piston will pop out, causing damage to the caliper body.
Page 492 35A-25 BASIC BRAKE SYSTEM ± Rear Disc Brake REAR DISC BRAKE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying and Air Bleeding (Refer to P.35A-10.) 55 ± 65 Nm 15 Nm Removal steps 1. Brake hose connection A A 2.
Page 493 35A-26 BASIC BRAKE SYSTEM ± Rear Disc Brake 3. Clean the piston and insert it into the cylinder with the special tool. 4. Be careful that the piston boot does not become caught, when lowering the caliper assembly and install the guide pin to the caliper.
Page 494 35A-27 BASIC BRAKE SYSTEM ± Rear Disc Brake DISASSEMBLY AND REASSEMBLY 43 Nm 8 Nm Clip set Grease Brake caliper kit Pad set Shim set Seal and boots kit Disassembly steps A A 1. Guide pin 9. Piston seal A A 2. Lock pin 10.
Page 495 35A-28 BASIC BRAKE SYSTEM ± Rear Disc Brake LUBRICATION POINTS Piston seal Grease: Repair kit grease Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off. Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Grease: Repair kit grease...
Page 496 35A-29 BASIC BRAKE SYSTEM ± Rear Disc Brake DISASSEMBLY SERVICE POINTS PISTON BOOT/PISTON REMOVAL Use a piece of wood to protect the caliper body outer side, and then apply compressed air through the brake hose connection hole to withdraw the piston and piston boot. Caution If air is blown into the caliper body suddenly, the piston will pop out, causing damage to the caliper body.
Page 497 35A-30 BASIC BRAKE SYSTEM ± Rear Disc Brake PAD WEAR CHECK Measure thickness at the thinnest and worn area of the pad. Replace the pad assembly if the pad thickness is less than the limit value. Standard value: 10 mm Limit: 2.0 mm Caution 1.
Page 498 35A-31 BASIC BRAKE SYSTEM ± Load Sensing Proportioning Valve LOAD SENSING PROPORTIONING VALVE REMOVAL AND INSTALLATION Caution Do not disassemble the load sensing proportioning valve. Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-10.) 15 Nm 15 Nm Removal steps...
Page 499 NOTES...
Page 500 35B-1 ANTI-SKID BRAKING SYSTEM (ABS) <4WD> CONTENTS GENERAL INFORMATION ....Brake Fluid Level Sensor Check ......Refer to GROUP 35A SERVICE SPECIFICATIONS .
Page 501 35B-2 FRONT DISC BRAKE Refer to GROUP 35A HYDRAULIC UNIT AND ABS-ECU ..REAR DISC BRAKE ..Refer to GROUP 35A WHEEL SPEED SENSOR ....LOAD SENSING PROPORTIONING G SENSOR .
Page 502 35B-3 ABS <4WD> ± General Information/Service Specifications GENERAL INFORMATION The ABS consists of components such as the wheel identified and the trouble symptoms will be speed sensors, stop lamp switch, hydraulic unit memorized by the diagnosis function. assembly (integrated with the ABS-ECU) and the In addition, reading of diagnosis codes and service ABS warning lamp.
Page 503 35B-4 ABS <4WD> ± Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT- II sub For checking of ABS assembly (Diagnosis code display when using the MUT- II ) MB991529 Diagnosis code For checking of ABS check harness (Diagnosis code display when using the ABS warning lamp) MB991547 ABS check...
Page 504 35B-5 ABS <4WD> ± Troubleshooting TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 ± How to Use Troubleshooting/Inspection Service Points. NOTES WITH REGARD TO DIAGNOSIS 1. The phenomena listed in the following table are not abnormal. Phenomenon Explanation of phenomenon System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment, but this is because the system operation check is being performed,...
Page 505 35B-6 ABS <4WD> ± Troubleshooting ABS WARNING LAMP INSPECTION Check that the ABS warning lamp illuminates as follows. 1. When the ignition key is turned to ªONº, the ABS warning lamp illuminates for approximately 3 seconds and then switches off. 2.
Page 506 35B-7 ABS <4WD> ± Troubleshooting When not using the MUT- II 1. Stop the engine. 2. Use the special tool to earth terminal (1) (diagnosis control terminal) of the diagnosis connector. 3. Turn on the stop lamp switch. (Depress the brake pedal.) 4.
Page 507 35B-8 ABS <4WD> ± Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Diagnosis code No. Inspection item Reference page Front right wheel speed sensor (Open circuit or short circuit) 35B-9 Front left wheel speed sensor (Open circuit or short circuit) 35B-9 Rear right wheel speed sensor (Open circuit or short circuit) 35B-9 Rear left wheel speed sensor (Open circuit or short circuit) 35B-9...
Page 508 35B-9 ABS <4WD> ± Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code Nos.11, 12, 13 and 14 Wheel speed sensor Probable cause (open circuit or short circuit) Code Nos.21, 22, 23 and 24 Wheel speed sensor Code Nos. 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit Malfunction of wheel speed sensor or short-circuit in the (+) wire or (±) wire in any one of the four wheel speed sensors.
Page 509 35B-10 ABS <4WD> ± Troubleshooting Code No.15 Wheel speed sensor (Abnormal output signal) Probable cause This code is output if the output signal of any wheel speed sensor is abnormal Unequal tyre size (other than an open circuit or short circuit). Improper installation of wheel speed sensor Malfunction of wheel speed sensor Malfunction of wiring harness or connector...
Page 510 35B-11 ABS <4WD> ± Troubleshooting Code No.16 ABS-ECU power supply system (abnormal Probable cause voltage drop or rise) This code is output if the ABS-ECU power supply voltage drops below or rises Malfunction of battery above the rated values. Malfunction of wiring harness or connector Furthermore, turning the ignition switch to ACC will erase this code.
Page 511 35B-12 ABS <4WD> ± Troubleshooting Code No.32 G sensor system Probable cause This code is output in the following cases. Malfunction of G sensor G sensor output voltage is less than 0.5 V or more than 4.5 V. (An open or Malfunction of wiring harness or connector short circuit is present in the G sensor circuit.) Malfunction of hydraulic unit and ABS-ECU...
Page 512 35B-13 ABS <4WD> ± Troubleshooting Code No.33 Stop lamp switch system Probable cause This code is output in the following cases. Malfunction of stop lamp switch If the stop lamp switch is continuously on for 15 minutes or more even though Malfunction of wiring harness or connector the ABS system is not operating.
Page 513 35B-14 ABS <4WD> ± ABS <4WD> ± Troubleshooting Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptoms Inspection procedure Reference page Communication between the MUT- II and the whole system is not 35B-14 possible. Communication between the MUT- II and the ABS-ECU is not possible. 35B-15 When the ignition key is turned to ªONº...
Page 514 35B-15 ABS <4WD> ± Troubleshooting Inspection Procedure 2 Communication between MUT- II and the ABS-ECU is not Probable cause possible. The cause may be an open circuit in the ABS-ECU power supply circuit or an open Blown fuse circuit in the diagnosis output circuit. Malfunction of wiring harness or connector Malfunction of hydraulic unit and ABS-ECU Measure at the diagnosis connector C-35 and the ABS-ECU con-...
Page 515 35B-16 ABS <4WD> ± Troubleshooting Inspection Procedure 3 When the ignition key is turned to ªONº (engine stopped), Probable cause the ABS warning lamp does not illuminate. The cause may be an open circuit in the lamp power supply circuit, a blown lamp, Blown fuse a malfunction of the ABS warning lamp relay or an open circuit between the ABS Burn out ABS warning lamp bulb...
Page 516 35B-17 ABS <4WD> ± Troubleshooting Inspection Procedure 4 Even after the engine is started, the ABS warning lamp Probable cause remains illuminated. The cause is probably a short-circuit in the ABS warning lamp illumination circuit. Malfunction of combination meter Malfunction of ABS warning lamp relay Malfunction of wiring harness (short circuit) Malfunction of hydraulic unit and ABS-ECU NOTE...
Page 517 35B-18 ABS <4WD> ± Troubleshooting Inspection Procedure 5 Faulty ABS operation Probable cause This varies depending on the driving conditions and the road surface conditions, Improper installation of wheel speed sensor so problem diagnosis is difficult. However, if a normal diagnosis code is displayed, Malfunction of wiring harness or connector carry out the following inspection.
Page 518 35B-19 ABS <4WD> ± Troubleshooting DATA LIST REFERENCE TABLE The following items can be read by the MUT- II from the ABS-ECU input data. 1. When the system is normal Item No. Check item Checking requirements Normal value Front-right wheel speed sensor Perform a test run Vehicle speeds displayed on the...
Page 519 35B-20 ABS <4WD> ± Troubleshooting CHECK AT ABS-ECU TERMINAL VOLTAGE CHECK CHART 1. Disconnect the ABS-ECU connector. (Refer to P. 35B-27.) 2. Use the special tool to measure the voltage between each terminal and earth (terminal No.23). 3. The terminal layout is shown in the illustration. Earth terminal Check connector MB991547...
Page 520 35B-21 ABS <4WD> ± Troubleshooting RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS 1. Turn the ignition key to the LOCK (OFF) position. 2. Disconnect the ABS-ECU connector. (Refer to P. 35B-27.) 3. Use the special tool to check the resistance and continuity between the terminals indicated in the table below.
Page 521 35B-22 ABS <4WD> ± On-vehicle Service ON-VEHICLE SERVICE WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK 1. Lift up the vehicle and release the parking brake. 2. Disconnect the ABS-ECU connector and then connect the special tool to the harness side connector. (Refer to P.
Page 522 35B-23 ABS <4WD> ± On-vehicle Service Points In Waveform Measurement Symptom Probable causes Remedy Too small or zero waveform Faulty wheel speed sensor Replace sensor amplitude Waveform amplitude fluctuates Axle hub eccentric or with large runout Replace hub excessively (this is no problem if excessively (this is no roblem if the minimum amplitude is 100 mV Faulty ABS-ECU earth...
Page 523 35B-24 ABS <4WD> ± On-vehicle Service HYDRAULIC UNIT CHECK 1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points or place the wheels which are checked on the rollers of the braking force tester. Caution (1) The roller of the braking force tester and the tyre should be dry during testing.
Page 524 35B-25 ABS <4WD> ± On-vehicle Service 6. If the result of inspection is abnormal, correct according to the ªDiagnosis Tableº. Diagnosis Table Operation Judgement Judgement Probable cause Remedy ± Normal ± Abnormal (1) Depress brake pedal Brake force Wheel does not Clogged brake Check and clean to lock wheel.
Page 525 35B-26 ABS <4WD> ± Hydraulic Unit and ABS-ECU HYDRAULIC UNIT AND ABS-ECU REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying and Brake Line Bleeding Air Cleaner Removal (Refer to GROUP 15.) (Refer to GROUP 35A ± On-vehicle Service.) Hydraulic Unit Inspection (Refer to P.35B-24.) Air Cleaner Installation (Refer to GROUP 15.) <L.H.
Page 526 35B-27 ABS <4WD> ± Hydraulic Unit and ABS-ECU <R.H. drive vehicles> 15 Nm Removal steps 1. ABS warning lamp relay 4. Hydraulic unit and ABS-ECU 2. Harness connector 5. Hydraulic unit bracket assembly A A 3. Brake pipe connection REMOVAL SERVICE POINTS Lock lever HARNESS CONNECTOR DISCONNECTION Move the lock lever of the ABS-ECU connector as shown...
Page 527 35B-28 ABS <4WD> ± Hydraulic Unit and ABS-ECU HYDRAULIC UNIT AND ABS-ECU REMOVAL Caution 1. The hydraulic unit assembly is heavy, and so care should be taken when removing it. 2. The hydraulic unit assembly is not to be disassembled; its nuts and bolts should absolutely not be loosened.
Page 528 35B-29 ABS <4WD> ± Wheel Speed Sensor WHEEL SPEED SENSOR REMOVAL AND INSTALLATION Post-installation Operation Wheel Speed Sensor Output Voltage Check (Refer to P.35B-22.) <FRONT> <REAR> 1. Front wheel speed sensor 2. Front ABS rotor (Refer to GROUP NOTE 26 ± Drive Shaft.) The front ABS rotor is integrated with the drive shaft.
Page 529 35B-30 ABS <4WD> ± Wheel Speed Sensor INSPECTION CHECK OF RESISTANCE BETWEEN WHEEL SPEED SENSOR TERMINALS Caution The pole piece can become magnetized because of the magnet built into the wheel speed sensor, with the result that metallic foreign material easily adheres to it. Moreover, the pole piece may not be able to function to correctly sense the wheel rotation speed if it is damaged.
Page 530 35B-31 ABS <4WD> ± G Sensor G SENSOR REMOVAL AND INSTALLATION Caution Do not drop the G sensor or subject it to any shocks. Pre-removal and Post-installation Operation Rear floor console removal and installation (Refer to Group 52A.) 5 Nm G sensor INSPECTION 1.
Page 531 NOTES...
Page 532 36-1 PARKING BRAKES CONTENTS GENERAL INFORMATION ....Parking Brake Switch Check ....Lining Runing-In .
Page 533 36-2 PARKING BRAKES ± General Information/Service Specifications/Lubricants GENERAL INFORMATION The parking brake is of a mechanical control type acting on the rear wheels. A lever is used to apply the parking brake. CONSTRUCTION DIAGRAM Parking brake lever Parking brake cable SERVICE SPECIFICATIONS Items Standard value...
Page 534 36-3 PARKING BRAKES ± On-Vehicle Service ON-VEHICLE SERVICE Parking brake lever PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT 1. Pull the parking brake lever with a force of approx. 196 N and count the number of notches. Standard value: 3 ± 5 notches Adjusting nut 2.
Page 535 36-4 PARKING BRAKES ± On-Vehicle Service PARKING BRAKE SWITCH CHECK Check for continuity between the parking brake switch terminal and the switch mounting bolt. When parking brake lever is pulled Continuity When parking brake lever is released No continuity LINING RUNNING-IN Pull Carry out running-in by the following procedure when replacing the parking brake linings or the rear brake disc rotors, or when...
Page 536 36-5 PARKING BRAKES ± Parking Brake Lever PARKING BRAKE LEVER REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Rear Floor Console Removal Parking Brake Lever Stroke Adjustment (Refer to GROUP 52A.) (Refer to P.36-3.) Rear Floor Console Installation (Refer to GROUP 52A.) Ratchet plate Section A ±...
Page 537 36-6 PARKING BRAKES ± Parking Brake Cable PARKING BRAKE CABLE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Rear Floor Console Removal Parking Brake Lever Stroke Check and Adjustment (Refer to GROUP 52A.) (Refer to P.36-3.) Rear Floor Console Installation (Refer to GROUP 52A.) 55 ±...
Page 538 36-7 PARKING BRAKES ± Parking Brake Cable REMOVAL SERVICE POINTS REAR BRAKE CALIPER ASSEMBLY REMOVAL Remove the rear brake caliper assembly and support it with wire or similar. SHOE HOLD-DOWN CUP REMOVAL Shoe hold-down cup Extend the shoe and lining assembly, and remove the shoe hold-down cup.
Page 539 36-8 PARKING BRAKES ± Parking Brake Drum PARKING BRAKE DRUM REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Drive Shaft Removal (Refer to GROUP 27B.) Drive Shaft Installation (Refer to GROUP 27B.) Parking Brake Lever Stroke Check and Adjustment (Refer to P.36-3.) 55 ±...
Page 540 36-9 PARKING BRAKES ± Parking Brake Drum INSPECTION BRAKE LINING AND BRAKE DRUM CHECK 1. Measure the thickness of the brake lining at several places. Standard value: 2.8 mm Limit: 1.0 mm 2. If the thickness of the brake lining has worn down to the limit value or more, replace the shoe and lining assemblies on both sides of the vehicle.
Page 541 NOTES...
Page 542 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B ± Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.
Page 543: General Information
37A-2 STEERING ± General Information GENERAL INFORMATION A 4-spoke type steering wheel has been mounted. The steering system uses a vane oil pump with The power steering is an integral rack and pinion a fluid flow control system, so that steering effort type that combines the steering gear and linkage varies with engine speed.
Page 544 37A-3 STEERING ± General Information <R.H. drive vehicles> Steering wheel Steering column and shaft Oil pump Oil reservoir Suction hose Return hose Pressure hose Steering gear box and linkage...
Page 545: Service Specifications
37A-4 STEERING ± Service Specifications/Lubricants/Sealant and Adhesive SERVICE SPECIFICATIONS Item Standard value Limit Steering wheel free play mm with engine running ± 30 or less with engine stopped 0 ± 10 ± Steering angle Steering angle Inner wheel Inner wheel 34 40' ±...
Page 546: Special Tools
37A-5 STEERING ± Special Tools SPECIAL TOOLS Tool Number Name MB990635, Steering linkage Tie rod end disconnection MB991113 or puller MB991406 MB990326 Preload socket Ball joint turning torque measurement MB990993 Power steering oil Oil pressure measurement pressure gauge adapter (pump side) MB990994 Power steering oil pressure gauge...
Page 547 37A-6 STEERING ± Special Tools Tool Number Name MB991197 Bar (long type) Gear housing oil seal press fitting MB991199 Oil seal installer MB991213 Oil seal protector Rack assembly installation MB990925 Bearing and oil Oil seal and bearing press fitting seal installer set (Refer to GROUP 26 ±...
Page 548: On-Vehicle Service
37A-7 STEERING ± On-vehicle Service ON-VEHICLE SERVICE STEERING WHEEL FREE PLAY CHECK 1. With the engine running (hydraulic pressure operating), put the front wheels in straight-ahead position. 2. Lightly turn the steering wheel left and right to measure circumferential play on the steering wheel before the wheels start to move.
Page 549: Stationary Steering Effort Check
37A-8 STEERING ± On-vehicle Service 2. After swinging the ball joint stud several times, install the MB990326 nut on the stud. Then, measure ball joint turning torque with the special tool. Standard value: 0.5 ± 2.5 Nm 3. When the torque is over the standard value, replace the tie rod end.
Page 550: Power Steering Fluid Level Check
37A-9 STEERING ± On-vehicle Service POWER STEERING FLUID LEVEL CHECK Fluid level change: Within 5 mm 1. Park the vehicle on a flat, level surface and start the engine. Without the vehicle moving, turn the steering wheel several times until the fluid reaches 50 to 60 C. 2.
Page 551: Oil Pressure Test
37A-10 STEERING ± On-vehicle Service 8. If the level changes more than 5 mm, the air is badly bled. Fluid level change: Within 5 mm So, bleed air again. Caution (1) If the fluid level rises suddenly after the engine is stopped, the bleeding is incomplete.
Page 552: Power Steering Oil Pressure Switch Check
37A-11 STEERING ± On-vehicle Service POWER STEERING OIL PRESSURE SWITCH CHECK Shut-off valve Adapter (MB990993) Pressure 1. Disconnect the pressure hose from the oil pump and gauge connect the special tools. (MB990662) Temperature 2. Bleed air. Without the vehicle moving, turn the steering gauge wheel several times to raise the fluid temperature to 50 to 60 C.
Page 553: Steering Wheel And Shaft
37A-12 STEERING ± Steering Wheel and Shaft STEERING WHEEL AND SHAFT REMOVAL AND INSTALLATION Caution: 1. Before removing the air bag module and clock spring, refer to GROUP 52B ± Service Precautions and Air Bag Module and Clock Spring. 2. Use an earth bolt for one of the steering shaft assembly mounting bolts. The earth bolt has mark ªEº...
Page 554 37A-13 STEERING ± Steering Wheel and Shaft REMOVAL SERVICE POINTS STEERING WHEEL REMOVAL MB990803...
Page 555 37A-14 STEERING ± Steering Wheel and Shaft DISASSEMBLY AND REASSEMBLY <L.H. drive vehicles> <R.H. drive vehicles> 17 Nm AW1122AL BW 581AL Disassembly steps A A 1. Special bolt 4. Shaft assembly A A 2. Steering lock bracket <L.H. drive vehicles> A A 3.
Page 556: Power Steering Gear Box And Linkage
37A-15 STEERING ± Power Steering Gear Box and Linkage POWER STEERING GEAR BOX AND LINKAGE REMOVAL AND INSTALLATION Caution: SRS On vehicles with SRS, before removing steering gear box, refer to GROUP 52B. Also, put the front wheels in straight±ahead position and remove the ignition key. Failure to do so may damage the SRS clock spring and render the SRS air bag inoperative, which results serious driver injury.
Page 557 37A-16 STEERING ± Power Steering Gear Box and Linkage <R.H. drive vehicles> 15 ± 33 Nm 18 Nm 15 Nm 12 Nm 34 Nm 12 Nm 70 Nm Removal steps 1. Steering gear and joint connecting bolt 7. Nut <R.H drive vehicles> 2.
Page 558 37A-17 STEERING ± Power Steering Gear Box and Linkage REMOVAL SERVICE POINTS MB990635, MB991113 or Cord TIE ROD END AND KNUCKLE DISCONNECTION MB991406 Caution (1) In order not to damage the ball joint thread, the tie rod end mounting nut must be only loosened but not removed from the ball joint.
Page 559 37A-18 STEERING ± Power Steering Gear Box and Linkage INSPECTION GEAR BOX PINION TOTAL ROTATION TORQUE CHECK 1. Using the special tool, turn the pinion gear at a speed MB991006 of one rotation per 4 to 6 seconds to measure total rotation torque.
Page 560 37A-19 STEERING ± Power Steering Gear Box and Linkage DISASSEMBLY AND REASSEMBLY <L.H. drive vehicles> Steering gear seal set 25 Nm 59 Nm Flare nut 13 Nm 22 Nm 49 ± 59 Nm 88 Nm Disassembly steps F A 19. Upper oil seal 1.
Page 561 37A-20 STEERING ± Power Steering Gear Box and Linkage <R.H. drive vehicles> Steering gear seal set 25 Nm Flare nut 13 Nm 31 32 22 Nm 30 _ 59 Nm 23 22 88 Nm 49 ± 59 Nm Disassembly steps F A 19.
Page 562 37A-21 STEERING ± Power Steering Gear Box and Linkage Lubrication and Sealing Points Grease: Repair kit grease Fluid: Automatic transmission fluid Fluid: DEXRON or DEXRON II Grease: Repair kit grease Automatic transmission fluid DEXRON or DEXRON II Sealant: 3M ATD Part No. 8661 or equivalent Fluid: Automatic transmission fluid...
Page 563 37A-22 STEERING ± Power Steering Gear Box Box and Linkage DISASSEMBLY SERVICE POINTS RACK SUPPORT COVER REMOVAL MB991621 OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL With a plastic hammer, lightly tap the pinion and valve assembly in its spline to remove the lower oil seal and pinion and valve assembly from the valve housing.
Page 564 37A-23 STEERING ± Power Steering Gear Box Box and Linkage RACK STOPPER/RACK BUSHING ASSEMBLY/ RACK BUSHING/OIL SEAL/O-RING/RACK REMOVAL 1. Remove the rack stopper, rack bushing, oil seal and O-ring together by pulling out the rack gently. 2. Partially bend the oil seal to remove from the rack bushing. Caution Use care not to damage the oil seal press-fitting surface of the rack bushing.
Page 565 37A-24 STEERING ± Power Steering Gear Box Box and Linkage B A OIL SEAL INSTALLATION MB991199 MB991197 Gear housing Oil seal C A RACK ASSEMBLY INSTALLATION Vent hole 1. Apply repair kit grease to the teeth of the rack assembly. Caution Use care not to close the vent hole in the rack with grease.
Page 566 37A-25 STEERING ± Power Steering Gear Box and Linkage Caution Do not use Dia Queen ATF SP II and ATF SP II M as they damage the components of the power steering. 2. Apply the specified fluid to the oil seal inner surface and the O-ring.
Page 567 37A-26 STEERING ± Power Steering Gear Box and Linkage H A LOWER OIL SEAL INSTALLATION Approx. 1 mm MB990941 Using the special tool, press the oil seal into the valve housing. The upper surface of the oil seal must project outwards about seal 1 mm from the housing end surface.
Page 568 37A-27 STEERING ± Power Steering Gear Box and Linkage K A TAB WASHER/TIE ROD INSTALLATION After installing the tie rod to the rack, fold the tab washer end (2 locations) to the tie rod notch. L A BELLOWS BAND INSTALLATION MB991561 1.
Page 569 37A-28 STEERING ± Power Steering Gear Box and Linkage M A TIE ROD END/LOCKING NUT INSTALLATION Edge of bellows Locking nut Screw in the tie rod end until the dimension shown is achieved. assembly groove Then, temporarily tighten with the locking nut. NOTE The locking nut must be tightened securely only after the power steering gear box and linkage are installed to the vehicle and...
Page 570: Power Steering Oil Pump
37A-29 STEERING ± STEERING ± STEERING ± Power Steering Oil Pump Power Steering Oil Pump Power Steering Oil Pump POWER STEERING OIL PUMP REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining (Refer to P.37A-9.) Power Steering Fluid Supplying and Bleeding (Refer to P.37A-9.) Drive Belt Tension Adjusting (Refer to GROUP 11A.)
Page 571 37A-30 STEERING ± Power Steering Oil Pump DISASSEMBLY AND REASSEMBLY Caution Never disassemble the terminal assembly unable to be reassembled. 27 Nm 25 ± 29 Nm 12 Nm 59 Nm NOTE : Automatic transmission fluid DEXRON or DEXRON II Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit Disassembly steps...
Page 572 37A-31 STEERING ± Power Steering Oil Pump REASSEMBLY SERVICE POINTS Inner plug Side plate A A O-RING INSTALLATION × Width mm × 21.0 × 14.8 × 14.8 × × 15.8 Suction connector mounting portion of Terminal assembly oil pump body B A OIL SEAL INSTALLATION MB990938 MB991203...
Page 573: Power Steering Oil Hoses
37A-32 STEERING ± Power Steering Oil Pump/Power Steering Oil Hoses E A VANE INSTALLATION Round Install the vane to the rotor with its round edge outwards edge (towards cam ring). Vane POWER STEERING OIL HOSES REMOVAL AND INSTALLATION Pre±removal and Post±installation Operations Power Steering Fluid Draining and Supplying, and Air Intake Hose, Resonator, Air Duct, Air Cleaner Bleeding (Refer to P.37A±9.)
Page 574 37A-33 STEERING ± Power Steering Oil Hoses <L.H. drive vehicles> 12 Nm 57 Nm 15 Nm 34 Nm 12 Nm 12 Nm <R.H. drive vehicles> 57 Nm 15 Nm 12 Nm 34 Nm 12 Nm Removal steps C A 1. Return hose 6.
Page 575 37A-34 STEERING ± Power Steering Oil Hoses INSTALLATION SERVICE POINTS A A PRESSURE HOSE INSTALLATION Install with the marks on the pressure hose and pressure tube aligned. Mating mark B A SUCTION HOSE INSTALLATION 1. Install with the mark at the end of the hose (oil reservoir Alignment side) and the alignment mark on the oil reservoir aligned.
Page 576 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B ± Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.
Page 577 42-2 DOOR ASSEMBLY ..... . BACK DOOR HANDLE AND LATCH ..DOOR TRIM AND WATERPROOF KEYLESS ENTRY SYSTEM .
Page 578: Hood
42-3 BODY ± Hood HOOD REMOVAL AND INSTALLATION 9 Nm 12 Nm Adjustment of clearance Adjustment of hood height Adjustment of hood step and around hood hood striker linkage Hood latch removal steps Hood removal steps Front grille (Refer to GROUP 51.) 4.
Page 579: Fender
42-4 BODY ± Hood/Fender Clip positions Section A ± A Clip : Clip positions FENDER SEALANT Item Specified sealant Remark Splash shield 3M ATD Part No. 8625 or equivalent Ribbon sealer...
Page 580: Fender
42-5 BODY ± Fender FENDER REMOVAL AND INSTALLATION Caution: SRS Do not strike the front impact sensor when removing or installing the fender. Pre-removal and Post-installation Operation Front Bumper Removal and Installation (Refer to GROUP 51.) Section A ± A Section B ±...
Page 581: Fuel Filler Door
42-6 BODY ± Fender/Fuel Filler Door INSTALLATION SERVICE POINT SIDE TURN SIGNAL LAMP REMOVAL Engage the hook with the fender panel. Hook Fender panel Front of Vehicle FUEL FILLER DOOR REMOVAL AND INSTALLATION Pre±removal and Post±installation Operations Rear Floor Console Removal and Installation (Refer to GROUP 52A.) Quarter Trim, Lower (R.H.) Removal and Installation Front Seat (Driver's side), Rear Seat Removal...
Page 582 42-7 BODY ± Fuel Filler Door REMOVAL SERVICE POINT RIVET REMOVAL Use a drill (é4.0 ± 5.5 mm) to break the rivet by drilling a hole, and then remove the rivet. Rivet Fuel filler door panel assembly Drill INSTALLATION SERVICE POINT Riveter A A RIVET INSTALLATION Use a riveter shown to install rivets as follows:...
Page 583: Window Glass
42-8 BODY ± Window Glass WINDOW GLASS ADHESIVE Items Specified adhesive Windshield 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent Sealant or equivalent Quarter window glass Back door glass SPECIAL TOOLS Tool Number Name MB990480 Window glass Removal and installation of windshield holder...
Page 584 42-9 BODY ± Window Glass HANDLING OF AUTO WINDOW SEALER Keep the sealant in a cool place, not exposed to the direct rays of the sun. Do not place any heavy article on the sealant nor press it, otherwise it will become deformed. Avoid storing the sealant for more than 6 months, because it will lose its sealing effect.
Page 585: Windshield
42-10 BODY ± Window Glass WINDSHIELD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Front Pillar Trim Removal and Installation (Refer to GROUP 52A.) Headlining Removal and Installation (Refer to GROUP 52A.) Section A ± A Section C ± C Section B ± B Primer Primer Primer...
Page 586 42-11 BODY ± Window Glass REMOVAL SERVICE POINTS MB990449 ROOF DRIP MOULDING REMOVAL Use the special tool to lever out the moulding. Caution If the moulding has become warped, it should not be reused. WINDSHIELD REMOVAL 1. In order to protect the body (paint surface), apply cloth tape to all body areas around the installed windshield.
Page 587 42-12 BODY ± Window Glass INSTALLATION SERVICE POINTS A A GLASS STOPPER/CLIP/WINDSHIELD UPPER MOULDING/WINDSHIELD SPACER/WINDSHIELD INSTALLATION 1. When installing new windshield, temporarily position the windshield on the body. Make alignment marks on the windshield and body. 2. Use isopropyl alcohol to degrease the inside of windshield circumference, and also the body flanges.
Page 588 42-13 BODY ± Window Glass 7. Fill a sealant gun with adhesive. Then apply the adhesive evenly around the windshield within 30 minutes after applying the primer. NOTE Cut the tip of the sealant gun nozzle into a V shape to simplify adhesive application.
Page 589: Quarter Window Glass
42-14 BODY ± Window Glass QUARTER WINDOW GLASS REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Quarter Trim, Lower (R.H.) Removal and Installation (Refer to GROUP 52A.) Headlining Removal and Installation (Refer to GROUP 52A.) Section B ± B Section A ± A 3, 7 Primer 12.5...
Page 590 42-15 BODY ± Window Glass REMOVAL SERVICE POINT QUARTER WINDOW GLASS REMOVAL Remove the quarter window glass in the same manner as for the windshild. (Refer to P.42-11.) INSTALLATION SERVICE POINT WINDOW DAM/DUAL LOCK FASTENER/ QUARTER WINDOW GLASS INSTALLATION 1. Use a isopropyl alcohol to decrease the glass and body surfaces where the window dam and dual lock fasteners are installed.
Page 591: Back Door Glass
42-16 BODY ± Window Glass BACK DOOR GLASS REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation High-mounted Stop Lamp Assembly Removal and Installation (Refer to GROUP 52A.) Back Door Trim Removal and Installation (Refer to P.42-34.) Section A ± A Section B ± B 12.5 Primer Primer...
Page 592 42-17 BODY ± Window Glass REMOVAL SERVICE POINT BACK DOOR GLASS REMOVAL Remove the back door glass in the same manner as for the windshield. (Refer to P42-11.) INSTALLATION SERVICE POINT WINDOW DAM/DUAL LOCK FASTENER/GLASS STOPPER/BACK DOOR GLASS INSTALLATION 1. Use a isopropyl alcohol to decrease the glass and body surfaces where the window dam, dual lock fasteners and glass stoppers are installed.
Page 593: Door
42-18 BODY ± Door DOOR SERVICE SPECIFICATIONS Items Standard value Door outside handle play mm 3.7 or more Power window operating current A 5.3 ± 2 (power supply 14.5 V ± 0.3 V at 23 C) Door inside handle play mm 5.3 or more Glass pad and glass Between glass holder and glass rear end (A)
Page 594: On-Vehicle Service
42-19 BODY ± Door ON-VEHICLE SERVICE DOOR FIT ADJUSTMENT MB990900 or 1. If clearance between the door and body is uneven, affix MB991164 protective tape to the fender around the hinge and to the edge of the door. Then use the special tool to loosen the door hinge mounting bolts on the body, and adjust the clearance around the door so that it becomes even.
Page 595: Defective Power Window Adjustment And Replacement
42-20 BODY ± Door DEFECTIVE POWER WINDOW ADJUSTMENT AND REPLACEMENT Runchannel Door If the window glass wrongly, automatically lowers while being sash raised, adjust or replace as follows: 1. Remove the door trim and the waterproof film. (Refer to P.42-23.) 2.
Page 596: Power Window Operation Current Check
42-21 BODY ± Door POWER WINDOW OPERATION CURRENT CHECK 1. Remove the power window fuse and connect a circuit tester as shown. 2. Measure the operation current. When the power window switch is turned to UP, much current flows at the beginning and end of the operation.
Page 597: Door Assembly
42-22 BODY ± BODY ± Door Door DOOR ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation Door Fit Adjustment (Refer to P.42-19.) 4, 5 21 Nm 12 Nm 23 Nm 15 Nm Door assembly removal steps Striker removal steps 1. Harness connector 6.
Page 598: Door Trim And Waterproof Film
42-23 BODY ± BODY ± Door Door Passenger's side Switch Terminal number position 2 (Earth) Released (ON) Depressed (OFF) DOOR TRIM AND WATERPROOF FILM REMOVAL AND INSTALLATION Sealant: 3M ATD Part No. 8625 or equivalent <Vehicles with power windows> <Vehicles without power windows>...
Page 599 42-24 BODY ± Door CLIP AND CLAW POSITIONS View A View B View E View D View C View A View B Section A ± A Delta cover, Delta inner cover, Clip inner, door trim Door trim Door panel Section B ± B View C Section C ±...
Page 600 42-25 BODY ± Door REMOVAL SERVICE POINTS MB990784 POWER WINDOW AND REMOTE-CONTROLLED MIRROR SWITCH ASSEMBLY/POWER WINDOW SWITCH PANEL ASSEMBLY REMOVAL 1. Use the special tool to pry out the power window and remote-controlled mirror switch assembly, first at the front and then at the rear.
Page 601: Door Glass And Regulator
42-26 BODY ± Door B A REGULATOR HANDLE/ESCUTCHEON/CLIP INSTALLATION Horizontal line 1. Install the clip and escutcheon to the regulator handle. 2. Close the front door window glass fully, and then install the regulator handle as shown in the illustration. 30 _ Front of vehicle DOOR GLASS AND REGULATOR...
Page 602 42-27 BODY ± BODY ± Door Door REMOVAL SERVICE POINT POWER WINDOW REGULATOR AND MOTOR ASSEMBLY REMOVAL MB990480 1. Remove the door window glass assembly installation bolts. 2. Lift up the door window glass assembly, and then install the special tool to the window glass as shown in the illustration to prevent the window glass falling.
Page 603 42-28 BODY ± BODY ± Door Door Caution When installing the power window regulator, do not set it in the window glass fully-closed position. If installing the power window regulator in that condition, the window glass safety mechanism will not functions correctly.
Page 604 42-29 BODY ± BODY ± Door Door POWER WINDOW SUB SWITCH CONTINUITY CHECK Switch Terminal No. position DOWN POWER WINDOW RELAY CONTINUITY CHECK Power window relay Battery Terminal No. voltage Not applied Applied...
Page 605: Door Handle And Latch
42-30 BODY ± Door DOOR HANDLE AND LATCH REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Door Trim Removal (Refer to P.42-23.) Door Inside Handle Play Check (Refer to P.42-21.) Door Outside Handle Play Check (Refer to P.42-20.) Door Trim Installation (Refer to P.42-23.) 6 Nm 12 Nm Door handle and door latch...
Page 606 42-31 BODY ± Door B A REAR LOWER SASH INSTALLATION Be sure to install the rear lower sash to the window rear sash (at door) securely. C A DOOR INSIDE HANDLE INSTALLATION Clip Inner cable Outer 1. Install the inside lock cable to the door inside handle as cable end follows: (1) Install the inner cable end in the inside lock cable...
Page 607: Door Opening Weatherstrip
42-32 BODY ± BODY ± Door Door WINDOW GLASS RUNCHANNEL AND DOOR OPENING WHETHERSTRIP REMOVAL AND INSTALLATION Sectional view of clip position Sectional view of clip position Door inner opening weatherstrip Door window glass runchannel removal steps removal steps D Scuff plate (Refer to GROUP 52A.) 3.
Page 608: Back Door
42-33 BODY ± Back Door BACK DOOR SERVICE SPECIFICATION Item Standard value Back door handle play mm 2.0 ± 8.0 SEALANT Item Specified sealant Remark Waterproof film 3M ATD Part No. 8625 or equivalent Ribbon sealer SPECIAL TOOL Tool Number Name MB990784 Ornament remover...
Page 609: Back Door Assembly
42-34 BODY ± Back Door BACK DOOR ASSEMBLY REMOVAL AND INSTALLATION Pre±removal Operation Post±installation Operation High±mounted Stop Lamp Removal High±mounted Stop Lamp Installation (Refer to GROUP 54A.) (Refer to GROUP 54A.) Spare Tyre Carrier Removal (Refer to GROUP 51.) Spare Tyre Carrier Installation (Refer to GROUP 51.) Back Door Fit Adjustment (Refer to P.42-33.) 22 Nm...
Page 610 42-35 BODY ± Back Door INSTALLATION SERVICE POINT A A BACK DOOR OPENING WEATHERSTRIP INSTALLATION Align the marking section on the back door opening weatherstrip with the centre of the body. B A STRIKER INSTALLATION Latch centre Striker centre Install the striker so that the striker centre does not deviate more than 1.5 mm from the latch centre.
Page 611: Film
42-36 BODY ± Back Door BACK DOOR TRIM AND WATERPROOF FILM REMOVAL AND INSTALLATION View A Section A ± A View A Clip Door panel Sealant: : Clip positions 3M ATD Part No. 8625 or equivalent Removal steps 1. Back door trim 2.
Page 612: Back Door Handle And Latch
42-37 BODY ± Back Door BACK DOOR HANDLE AND LATCH REMOVAL AND INSTALLATION Post-installation Operation Back Door Handle Play Check (Refer to P.42-33.) Back door handle and lock key Back door latch removal steps cylinder removal steps Back door trim and waterproof film Back door trim and waterproof film (Refer to P.42-36.) (Refer to P.42-36.)
Page 613: Keyless Entry System
42-38 BODY ± Back Door/Keyless Entry System BACK DOOR LATCH CONTINUITY CHECK Switch Terminal No. position position Back door opend Back door closed DOOR LOCK KEY CYLINDER SWITCH CONTINUITY CHECK <Vehicles with central door locking system> Switch Terminal No. position position LOCK Neutral (OFF)
Page 614: Encrypted Code Registration Method
42-39 BODY ± BODY ± Keyless Entry System Keyless Entry System ENCRYPTED CODE REGISTRATION METHOD Each individual encrypted code is registered inside the transmitter, and so it is necessary to register these codes with the EEPROM inside the ETACS-ECU in the following cases.
Page 615: Hazard Lamp Answerback Adjustment
42-40 BODY ± Keyless Entry System 8. Registration mode will be terminated under the following conditions. When the encrypted codes for four transmitters have been registered; When one minute has passed after registration mode started; When the MUT- II is disconnected (earth is released); When the ignition key is removed;...
Page 616: Keyless Entry System
42-41 BODY ± BODY ± Keyless Entry System Keyless Entry System 3. Adjustment of functions Function Adjustment procedure Keyless entry answerback function When the transmitter lock switch is turned on twice continuously within 2 seconds, the lock answerback function toggles on and off. If the function toggles on, the buzzer sounds once (default condition).
Page 617: Sunroof
42-42 BODY ± BODY ± Sunroof Sunroof SUNROOF SERVICE SPECIFICATION Items Standard value Roof lid glass operating current A (at 20 C) 7 or less TROUBLESHOOTING INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection procedure Reference page The sunroof does not operate when the ignition switch is turned 42-43 to ON.
Page 618 42-43 BODY ± Sunroof INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 The sunroof does not operate when the ignition switch is Probable cause turned to ON. The cause may be a malfunction of a sunroof switch, sunroof-ECU power supply Malfunction of sunroof switch circuit or earth circuit.
Page 619 42-44 BODY ± BODY ± Sunroof Sunroof INSPECTION PROCEDURE 2 The motor does not reverse its direction when a load of 140 Probable cause N or more is applied while the sunroof is closing. The sunroof-ECU monitors the load conditions from the amount of current flowing Malfunction of sunroof-ECU to the motor.
Page 620 42-45 BODY ± Sunroof SUNROOF-ECU TERMINAL VOLTAGE CHART Terminal No. Check Item Check Condition Normal Condition ECU power supply Always System voltage Sensor power supply Ignition switch: ON System voltage Earth Always Sunroof switch (CLOSE, Sunroof switch DOWN input) DOWN input) (close position or down (close position or down position)
Page 621: On-Vehicle Service
42-46 BODY ± Sunroof ON-VEHICLE SERVICE WATER TEST Check if there are any leaks in the sunroof by the following procedure. 1. Fully close the roof lid glass. 2. Adjust the water pressure so that water comes out of the hose to a height of approximately 50 cm when the hose is held vertically facing upwards.
Page 622: Sunroof
42-47 BODY ± Sunroof SUNROOF REMOVAL AND INSTALLATION Post-installation Operation Sunroof Water Test (Refer to P.42-46.) Sunroof Fit Adjustment (Refer to P.42-46.) Section A ± A Claw NOTE : Claw positions 1. Roof lid glass assembly Sunroof motor assembly removal steps Sunroof switch removal steps D Headlining (Refer to GROUP 52A.)
Page 623 42-48 BODY ± Sunroof REMOVAL SERVICE POINTS DRAIN HOSE REMOVAL Tie a cord to the end of the drain hose, and wind tape around it so that there is no unevenness. Then pull the drain hose out from the passenger compartment. Drain hose Cord SUNROOF MOTOR ASSEMBLY REMOVAL...
Page 624 42-49 BODY ± Sunroof B A SUNROOF MOTOR ASSEMBLY INSTALLATION If the fully-closed position of the sunroof motor assembly is incorrect, set the sunroof motor to the fully-closed position by the following procedure, and then install the sunroof motor. 1. Set the sunroof to full tilt-up position by using the close switch.
Page 625 42-50 BODY ± Sunroof DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Roof lid glass assembly 7. Sunshade assembly 2. Weatherstrip 8. Drive unit cover 3. Sunroof motor assembly 9. Mechanish assembly 4. Roof wind deflector panel 10. Drive unit assembly 5. Rail end 11.
Page 626 51-1 EXTERIOR CONTENTS FRONT BUMPER ....REAR WIPER AND WASHER ..REAR BUMPER ..... SERVICE SPECIFICATION .
Page 627: Front Bumper
51-2 EXTERIOR ± Front Bumper FRONT BUMPER REMOVAL AND INSTALLATION NOTE : Clip positions Section B ± B Section A ± A Clip Clip Removal steps 1. Radiator grille 5. Headlamp washer hose connection 2. Splash shield installation clips <Vehicles with headlamp washer> 3.
Page 628 51-3 EXTERIOR ± Front Bumper REMOVAL SERVICE POINT Section A ± A RADIATOR GRILLE REMOVAL Radiator Clip Remove the radiator grille by pushing the tab of the radiator grille grille clips in the direction of the arrows with a flat-tipped screwdriver, while lightly pulling the radiator grille towards you.
Page 629: Rear Bumper
51-4 EXTERIOR ± Rear Bumper REAR BUMPER REMOVAL AND INSTALLATION Removal steps 1. Rear mud guard 6. Bumper center reinforcement 2. Rear splash shield assembly 3. Rear combination lamp or rear fog 7. Bumper side reinforcement lamp connection assembly 4. Rear bumper assembly 5.
Page 630: Exterior Parts
51-5 EXTERIOR ± Rear Bumper/Exterior Parts DISASSEMBLY AND REASSEMBLY 4.9 Nm 4.9 Nm Disassembly steps 1. Bracket <R.H. drive vehicles> 4. Rear fog assembly 2. Bracket <L.H. drive vehicles> <L.H. drive vehicles> 3. Rear combination lamp assembly 5. Rear bumper face <R.H.
Page 631: Exterior Parts
51-6 EXTERIOR ± Exterior Parts EXTERIOR PARTS REMOVAL AND INSTALLATION Section C ± C Section D ± D Section B ± B Section A ± A Section E ± E 5 Nm 5 Nm Body 5 Nm 23 Nm 23 Nm Roof rail removal steps Spare tyre carrier removal steps D Spare tyre cover...
Page 632: Moulding And Garnish
51-7 EXTERIOR ± Exterior Parts/Moulding and Garnish REMOVAL SERVICE POINT Claw (rear) Slit ROOF RACK COVER (FRONT, REAR) REMOVAL 1. Insert the special tool into the slit. NOTE The roof rack assembly has the slit. 2. Insert the special tool as far as possible and remove the claw (front) by prying the roof rack cover toward you.
Page 633: Moulding And Garnish
51-8 EXTERIOR ± Moulding and Garnish MOULDING AND GARNISH REMOVAL AND INSTALLATION Section C ± C Section B ± B Section D ± D Section A ± A Clip Clip Clip Clip Windshield <Vehicles with roof rail> <Vehicles without roof rail> NOTE : Clip positions : Bolt positions...
Page 634 51-9 EXTERIOR ± Moulding and Garnish REMOVAL SERVICE POINT ROOF DRIP MOULDING REMOVAL Use the special tool to lever out the moulding. Caution If the moulding has become warped, it should not be reused. MB990449 SIDE PROTECT MOULDING REMOVAL 1. Attach protection tape all the way along the edges of the Protection tape double-sided tape which is still adhering to the body.
Page 635 51-10 EXTERIOR ± Moulding and Garnish/Windshield Wiper and Washer 4. Remove strip paper from the pressure sensitive double-sided tape. NOTE Affix double-sided tape to the end of strip paper for ease of strip paper removal. (Refer to P.51-8.) 5. Install the side protect moulding. Adhesive tape NOTE Backing paper...
Page 636: Washer
51-11 EXTERIOR ± Windshield Wiper and Washer WINDSHIELD WIPER AND WASHER REMOVAL AND INSTALLATION 13 Nm 13 Nm Section A ± A Claw Section B ± B Section C ± C Clip 1. Washer hose connection Washer tank removal steps 2.
Page 637 51-12 EXTERIOR ± Windshield Wiper and Washer REMOVAL SERVICE POINT WIPER MOTOR REMOVAL 1. Remove the wiper motor mounting bolts. 2. Use a flat-tipped screwdriver to separate the wiper motor crank arm from the linkage assembly, and then remove Linkage assembly the wiper motor.
Page 638 51-13 EXTERIOR ± Windshield Wiper and Washer WASHER MOTOR CHECK 1. With the washer motor installed to the washer tank, fill the washer tank with water. 2. Check that the water squirts out strongly when battery voltage is applied to terminal (2) and terminal (1) is earthed. WASHER FLUID EJECTION POINT CHECK Adjust the ejection angle by moving the nozzle.
Page 639: Service Specifications
51-14 EXTERIOR ± Rear Wiper and Washer REAR WIPER AND WASHER SERVICE SPECIFICATION Items Standard value Park position of rear wiper arm and blade assembly (Distance between wiper blade and back door glass ceramic end line) mm TROUBLESHOOTING The rear wiper and washer is controlled by the Smart Wiring System (SWS). For troublesshooting, refer to GROUP 54B ±...
Page 640 51-15 EXTERIOR ± Rear Wiper and Washer REAR WIPER AND WASHER REMOVAL AND INSTALLATION 8 Nm Wiper motor assembly removal Rear washer hose removal steps steps D Rear seat (Refer to GROUP 52A.) D Back door trim (Refer to GROUP 42.) D Scuff plate and quarter trim (Refer to 1.
Page 641 51-16 EXTERIOR ± Rear Wiper and Washer INSTALLATION SERVICE POINT Back A A WIPER ARM AND BLADE ASSEMBLY door glass INSTALLATION ceramic end line Install so that the wiper blade is positioned at the shown position when the wiper arm stops. Standard value (A): 33 ±...
Page 642: Troubleshooting
51-17 EXTERIOR ± Rear Wiper and Washer/Headlamp Washer WASHER FLUID EJECTION POINT CHECK Adjust the ejection angle by moving the nozzle. Moulding 50 mm 50 mm end line 50 mm Ceramic end line HEADLAMP WASHER TROUBLESHOOTING The headlamp washer is controlled by the Smart Wiring System (SWS). For troublesshooting, refer to GROUP 54B ±...
Page 643 51-18 EXTERIOR ± Headlamp Washer INSPECTION CHECK VALVE CHECK Apply pressure to the inlet of the check valve to check its opening pressure. Opening pressure: 78 kPa HEADLAMP WASHER MOTOR CHECK 1. With the washer motor installed to the washer tank, fill the washer tank with water.
Page 644: Marks
51-19 EXTERIOR ± EXTERIOR ± Marks Marks MARKS REMOVAL AND INSTALLATION A A 5. Vehicle name decal 1. Three diamonds mark A A 6. Three diamonds mark 2. ªGDIº mark A A 7. ªGDIº mark 3. Pininfarina mark 4. Pininfarina logo mark INSTALLATION SERVICE POINT A A INSTALLATION OF MARKS APPLICATION POSITION...
Page 645 51-20 EXTERIOR ± Marks (6) Three diamonds mark Key cylinder Back door end line 165 mm 56 mm (7) GDI mark Window moulding end line 121 mm Back door end line 42 mm INSTALLATION PROCEDURE (1) Clean the mark installation surfaces on the body with unleaded petrol.
Page 646: Outside Door Mirror
51-21 EXTERIOR ± Outside Door Mirror OUTSIDE DOOR MIRROR REMOVAL AND INSTALLATION <Electric remote-con- trolled door mirror> <Manual-controlled door mirror > Section A ± A Clip Door mirror removal steps Electric remote-controlled mirror switch removal steps 1. Delta inner cover 2.
Page 647 51-22 EXTERIOR ± Outside Door Mirror REMOVAL SERVICE POINT Section A ± A Flat-tipped MIRROR REMOVAL screwdriver Mirror Using a hand, push the upper part of mirror to tilt it. Apply a protection tape as shown in the illustration. Insert a flat-tipped screwdriver between a notch behind the mirror and the pivot plate, and then pry off the lower part of mirror from the pivot plate.
Page 648 51-23 EXTERIOR ± Outside EXTERIOR ± Outside Door Mirror Door Mirror INSPECTION ELECTRIC REMOTE-CONTROLLED MIRROR OPERATION CHECK Battery connection terminal Direction of operation DOWN LEFT RIGHT Vehicles with heater mirror ELECTRIC REMOTE-CONTROLLED MIRROR SWITCH CONTINUITY CHECK Switch Switch Terminal No. position position Left mirror...
Page 649 NOTES...
Page 650 52A-1 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS INTERIOR ............SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .
Page 651 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B ± Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.
Page 652: Special Tool
52A-3 INTERIOR ± Special Tool/Instrument Panel SPECIAL TOOL Tool Number Name MB990784 Ornament remover Removal of switch, trim, etc. INSTRUMENT PANEL REMOVAL AND INSTALLATION For installation of the instrument panel, the bolts and screws described below are used. They are indicated by symbols in the illustration.
Page 653 52A-4 INTERIOR ± Instrument Panel Caution: SRS 1. For the passenger side air bag module removal/installation, always observe the service procedures of GROUP 52B ± Air Bag Module. 2. Do not subject the SRS-ECU to any shocks when removing or installing the instrument panel. Pre-removal and Post-installation Operation Steering Column...
Page 654 52A-5 INTERIOR ± Instrument Panel CLIP AND CLAW POSITIONS NOTE : Clip positions : Claw positions Section A ± A Section B ± B Section C ± C Section D ± D Instrument panel Instrument panel Instrument panel Garnish Claw Clip Claw Claw...
Page 655 52A-6 INTERIOR ± Instrument Panel DISASSEMBLY AND REASSEMBLY Section A ± A Claw NOTE : Claw positions Disassembly steps 1. Garnish 8. Center air outlet case 2. Parcel box 9. Instrument panel reinforcement 3. Connector holder 10. Center support panel 4.
Page 656: Floor Console
52A-7 INTERIOR ± Floor Console FLOOR CONSOLE REMOVAL AND INSTALLATION 5 Nm 5 Nm Removal steps 1. Selector nob <M/T> 9. Front floor console 2. Rear floor console 10. Box with lid 3. Transfer lever cover <M/T> 11. Heated seat switch 4.
Page 657 52A-8 INTERIOR ± Floor Console CLIP AND CLAW POSITIONS NOTE : Clip positions : Claw positions Section A ± A Section B ± B Section C ± C Rear floor console Front floor console Rear floor console Claw Claw Clip Claw Section D ±...
Page 658: Trims
52A-9 INTERIOR ± Trims TRIMS REMOVAL AND INSTALLATION 44 Nm 44 Nm 44 Nm 1. Scuff plate 8. Luggage room hook 2. Cowl side trim 9. Front seat belt connection 3. Front door opening trim 10. Quarter trim 4. Assist grip 11.
Page 659 52A-10 INTERIOR ± Trims CLIP AND CLAW POSITIONS NOTE : Clip positions : Claw positions For door trim, refer to GROUP 42. Section A ± A Section C ± C Section D ± D Section B ± B Front pillar trim Front pillar trim Clip Clip...
Page 660: Inside Rear View Mirror
52A-11 INTERIOR ± Inside Rear View Mirror/Headlining INSIDE REAR VIEW MIRROR Button REMOVAL SERVICE POINT Remove by pushing in the direction of the arrow in the illustration. HEADLINING REMOVAL AND INSTALLATION <Front passenger's side only> Removal steps 1. Assist grip Rear pillar trim (Refer to P.52A-9.) 2.
Page 661: Seat
52A-12 INTERIOR ± Seat SEAT FRONT SEAT REMOVAL AND INSTALLATION Caution: SRS Before removal of the seat equipped with the side air bag module, refer to GROUP 52B ± SRS Service Precautions and Air Bag Module. Front floor console box 44 Nm 44 Nm 44 Nm...
Page 662 52A-13 INTERIOR ± Seat INSPECTION HEATED SEAT SWITCH CONTINUITY CHECK Switch Terminal No. position position ± ± Driver's seat switch Passen- ger's seat switch NOTE To inspect the diode, match the polarity of the circuit tester with the (+) (±) polarities in the table. HEATER CHECK Measure the resistance between terminals.
Page 663 52A-14 INTERIOR ± Seat DISASSEMBLY AND REASSEMBLY <Front view of front seat back> <Front view of front seat cushion> Section A±A Section B±B Claw Claw NOTE : Hog ring positions : Claw positions Disassembly steps 10. Front seat cushion pad 11.
Page 664: Rear Seat Belt
52A-15 INTERIOR ± INTERIOR ± Seat Seat REMOVAL SERVICE POINT HEADRESTRAINT GUIDE REMOVAL REAR SEAT REMOVAL AND INSTALLATION 82 Nm 23 Nm 23 Nm 1. Headrestraint 2. Rear seat cushion assembly 3. Rear seat back assembly Rear seat assembly removal steps 4.
Page 665 52A-16 INTERIOR ± Seat DISASSEMBLY AND REASSEMBLY <Back view of rear seat cushion> <Front view of rear seat back> <Front view of rear seat cushion> NOTE : Hog ring positions Disassembly steps 1. Rear seat cushion cover 5. Rear seat back pad 2.
Page 666 52A-17 INTERIOR ± Seat Belt SEAT BELT FRONT SEAT BELT REMOVAL AND INSTALLATION Caution: SRS Before removal of the seat belt pre-tensioner, refer to GROUP 52B ± SRS Service Precautions and Seat Belt with Pre-tensioner. 44 Nm 44 Nm 44 Nm 44 Nm Outer seat belt removal steps Inner seat belt removal...
Page 667 52A-18 INTERIOR ± Seat Belt REAR SEAT BELT REMOVAL AND INSTALLATION 44 Nm 44 Nm 44 Nm 44 Nm Removal steps Rear pillar trim (Refer to P.52A-9.) Quarter trim (Refer to P.52A-9.) Rear seat cushion assembly 3. Outer seat belt (Refer to P.52A-15.) 4.
Page 668 52B-1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS GENERAL INFORMATION ....SRS AIR BAG CONTROL UNIT (SRS-ECU) ....... . SRS SERVICE PRECAUTIONS .
Page 669: General Information
52B-2 SRS ± General Information GENERAL INFORMATION lamp on the instrument panel indicates the To improve safety, the SRS and seat belts with pre-tensioner are available as optional parts. These operational status of the SRS. The clock spring systems enhance collision safety by restraining the is installed in the steering column.
Page 670 52B-3 SRS ± General Information Driver's air bag module Front passenger's air bag module SRS warning lamp Clock spring Driver's air bag Diagnosis connector Seat belts with Front SRS-ECU pre-tensioner passenger's air bag Seat belt pre-tensioner Side air bag SRS-ECU Side air bag module* Side impact sensor*...
Page 671: Srs Service Precautions
52B-4 SRS ± SRS Service Precautions SRS SERVICE PRECAUTIONS NOTE 1. In order to avoid injury to yourself or others from accidental deployment of the air bag during If any of these components are diagnosed as servicing, read and carefully follow all the faulty, they should only be replaced, in precautions and procedures described in this accordance...
Page 672 52B-5 SRS ± SRS Service Precautions SRS-ECU Destination of harness Corrective action Terminal No. → → Repair or replace each wiring 1, 2, 3, 4 Instrument panel wiring harness Front wiring harness Front impact sensor harness. → Instrument panel wiring harness Earth →...
Page 673: Special Tools
52B-6 SRS ± SRS Service Precautions/Special Tools 7. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the front impact sensor, SRS-ECU, air bag module (driver's side and front passenger's side), clock spring, side impact sensors, front seat assemblies (side air bag module), and seat belts with pre-tensioner before drying or baking the vehicle after painting.
Page 674: Test Equipment
52B-7 SRS ± Special Tools/Test Equipment Tool Number Name MR372530 SRS air bag Deployment of driver's side air bag module adapter harness inside the vehicle MB686560 SRS air bag Deployment of front passenger's side air bag adapter harness module inside or outside the vehicle MR203491 SRS air bag Deployment of driver's side air bag module...
Page 675: Troubleshooting
52B-8 SRS ± Troubleshooting TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 ± How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION DIAGNOSIS CODES CHECK Connect the MUT- II to the diagnosis connector (16-pin) under the instrument under cover, then check diagnosis codes.
Page 676 52B-9 SRS ± Troubleshooting Code No. Diagnosis item Reference page Power circuit system (fuse No.6 circuit) 52B-16 Power circuit system (fuse No.8 circuit) 52B-16 SRS warning lamp drive circuit Lamp does not illuminate. 52B-17 system system Lamp does not switch off. 52B-17 SRS warning lamp drive circuit system 52B-17...
Page 677 52B-10 SRS ± Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No.11, 12 or 13 Front impact sensor system Probable cause These diagnostic trouble codes are output if there is abnormal resistance between Malfunction of front impact sensor the input terminals of the front impact sensors. Malfunction of wiring harness of connectors The trouble causes for each diagnosis code No.
Page 678 52B-11 SRS ± Troubleshooting Code No.14, 15, 16, 17, 31, 32, 45, 51, 52, 54, 55, 56, 57, 58, Probable cause 59, 73, 74, 83, 84 System inside SRS-ECU These diagnostic trouble codes are output when a fault is detected in the SRS-ECU. Malfunction of SRS-ECU The defective parts and trouble causes for each diagnosis code No.
Page 679 52B-12 SRS ± Troubleshooting Code No.21, 22, 61, 62 Probable cause Driver's air bag module (squib) system Abnormal resistance is present between input terminals of driver's air bag module Malfunction of clock spring (squib). See table below for what each code tells. Partially open as clock spring is not in neutral position However, once trouble is extinguished, SRS-warning lamp will go out.
Page 680 52B-13 SRS ± Troubleshooting Code No.24, 25, 64, 65 Probable cause Front passenger's air bag module (squib) system Abnormal resistance is present between input terminals of front passenger's air Defective wiring harnesses or connectors bag module (squib). See table below for what each code tells. Malfunction of front passenger's air bag module However, once trouble is extinguished, SRS-warning lamp will go out.
Page 681 52B-14 SRS ± Troubleshooting Code No.26, 27, 66 or 67 Driver's side pre-tensioner (squib) Probable cause system These diagnosis codes are output if there is abnormal resistance between the input Malfunction of wiring harnesses or connectors terminals of the driver's side pre-tensioner (squib). Malfunction of driver's side pre-tensioner (squib) The trouble causes for each diagnosis code No.
Page 682 52B-15 SRS ± Troubleshooting Code No.28, 29, 68 or 69 Front passenger's side Probable cause pre-tensioner (squib) system These diagnosis codes are output if there is abnormal resistance between the input Malfunction of wiring harnesses or connectors terminals of the front passenger's side pre-tensioner (squib). Malfunction of front passenger's side pre-tensioner The trouble causes for each diagnosis code No.
Page 683 52B-16 SRS ± Troubleshooting Code No.34 Connector lock system Probable cause SRS-ECU is poorly connected. Defective connectors However, when vehicle condition returns to normal, this code will be automatically Malfunction of SRS-ECU erased, and the SRS warning lamp will go out. Is SRS-ECU connector C-32 connected properly? Check the following connectors: C-32 Repair...
Page 684 52B-17 SRS ± Troubleshooting Code No.43 SRS warning lamp drive circuit system Probable cause (Lamp does not come on) Open circuit is present for 5 successive seconds or more in SRS warning lamp Defective wiring harnesses or connectors drive circuit. Blown bulb However, once trouble is extinguished, this code, if displayed due to open circuit, Malfunction of SRS-ECU...
Page 685 52B-18 SRS ± Troubleshooting Code No.71, 72, 75, 76 Probable cause Side air bag module (R.H.) (squib) system Abnormal resistance is present between input terminals of SRS-ECU for side air Malfunction of wiring harnesses or connectors bag module (R.H.) (squib). See table below for what each code tells. Malfunction of side air bag module (R.H.) (squib) However, as for code Nos.
Page 686 52B-19 SRS ± Troubleshooting Code No.79 or No.93 Probable cause Side impact sensor (L.H.) communication system These diagnosis code are output if communication between the side impact sensor Malfunction of wiring harnesses or connectors (L.H.) and the SRS±ECU is not possible (code No.79) or abnormal (code No.93). Malfunction of side impact sensor (L.H.) Malfunction of SRS-ECU MUT- II Self-diag code...
Page 687 52B-20 SRS ± Troubleshooting MUT- II Self-diag code SRS check harness Disconnect the side air bag module (L.H.) connector D-32 (MB991613) Insert the probe (MB991222) from the rear of the harness side connector Resistance (3 Ω ) and connect the check harness to the probe. Caution Never insert the probe directly to the terminals from the front of the connector.
Page 688 52B-21 SRS ± Troubleshooting Code No.91 Side impact sensor (L.H.) power supply circuit Probable cause system Power supply voltage of side impact sensor (L.H.) is lower than specified for five Defective wiring harnesses or connectors successive seconds or more. Malfunction of side impact sensor (L.H.) However, once trouble is extinguished, this code will be automatically erased, and Malfunction of SRS-ECU SRS warning lamp will go out.
Page 689 52B-22 SRS ± Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Get an understanding of the trouble symptoms and check according to the inspection procedure chart. Trouble Inspection procedure No(s). Reference page Communication with MUT- II is impossible. 52B-22 SRS warning lamp does not come on. See diagnosis code No.43.
Page 690: Srs Maintenance
52B-23 SRS ± SRS Maintenance SRS MAINTENANCE The SRS must be inspected by an authorized dealer 10 years after the date of vehicle registration. SRS WARNING LAMP CHECK Turn the ignition switch to the ªONº position. Does the SRS warning lamp illuminate for about 7 seconds, turn off and then remain extinguished for at least 5 seconds? If yes, SRS system is functioning properly.
Page 691 52B-24 SRS ± SRS Maintenance AIR BAG MODULES, STEERING WHEEL AND CLOCK <Driver's side> SPRING Inflator case 1. Remove the air bag modules, steering wheel and clock Connector spring. (Refer to P.52B-36.) Caution The removed air bag modules should be stored in a clean, dry place with the cover face up.
Page 692 52B-25 SRS ± SRS Maintenance 11. Check steering wheel for excessive free play. REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION. (Refer to P.52B-41.) Caution The SRS may not activate if any of the above components is not installed properly, which could result in serious injury or death to the vehicle's driver or front passenger.
Page 693 52B-26 SRS ± SRS Maintenance INSTRUMENT PANEL WIRING HARNESS/FRONT WIRING HARNESS/ASSIST WIRING HARNESS/BODY WIRING HARNESS Instrument panel wiring harness Body wiring harness Front wiring harness 1. Check connector for poor connection. 2. Check harnesses for binds, connectors for damage, and terminals for deformation.
Page 694: Post-Collision Diagnosis
52B-27 SRS ± Post-collision Diagnosis POST-COLLISION DIAGNOSIS Whether or not the air bags have deployed, check and service the vehicle after collision as follows: SRS-ECU MEMORY CHECK 1. Connect the MUT- II to the diagnosis connector. (Refer to GROUP 00 ± How to Use Troubleshooting/Inspection Service Points.) Caution Refer to that the ignition switch is LOCK (OFF) when...
Page 695 52B-28 SRS ± Post-collision Diagnosis 2. Check the following parts and replace if there are any malfunctions. Clock spring (Refer to P.52B-36.) Steering wheel, steering column and intermediate joint (1) Check wiring harness (built into steering wheel) and connectors for damage, and terminals for deformation.
Page 696 52B-29 SRS ± Post-collision Diagnosis FRONT IMPACT SENSORS Front side member 1. Check the front side member for deformation or rest. Front impact 2. Check the front impact sensor for dents, cracks, sensor deformation or rust. 3. Check the sensor harnesses for binding, the connectors for damage, and the terminals for deformation.
Page 697: Individual Component Service
52B-30 SRS ± Post-collision Diagnosis/Individual Component Service Front seat back assembly (side air bag module) 1. Check the side air bag module deployment section in the Side air bag module seat for dents and deformation. deployment section 2. Check the harness for binds, the connector for damage and the terminals for deformation.
Page 698: Warning/Caution Labels
52B-31 SRS ± Warning/Caution Labels WARNING/CAUTION LABELS Caution labels on the SRS are attached in the vehicle the SRS. If the label(s) are dirty or damaged, replace as shown. Follow label instructions when servicing with new one(s). Steering wheel Driver's air bag module Clock spring Glove box Sun visor...
Page 699: Front Impact Sensors
52B-32 SRS ± Front Impact Sensors FRONT IMPACT SENSORS Caution 1. Disconnect the battery (±) terminal and wait 3. Do not drop or subject the front impact for 60 seconds or more before starting work. sensor to impact or vibration. Furthermore, disconnected battery...
Page 700 52B-33 SRS ± Front Impact Sensors B A FRONT IMPACT SENSOR INSTALLATION Front side member 1. Securely connect the connector. Label 2. Position the front impact sensor facing toward the front of the vehicle as shown by the arrow on the label, and install it securely.
Page 701: Srs Air Bag Control Unit (Srs-Ecu)
52B-34 SRS ± SRS-ECU SRS AIR BAG CONTROL UNIT (SRS-ECU) Caution 1. Disconnect the negative (±) battery terminal 3. Do not drop or subject the SRS-ECU to and wait for 60 seconds or more before impact or vibration. starting work. Also, the disconnected battery If denting, cracking, deformation, or rust are terminal should be insulated with tape.
Page 702 52B-35 SRS ± SRS-ECU INSTALLATION SERVICE POINTS A A SRS-ECU INSTALLATION Caution Be sure to install the SRS-ECU properly. Otherwise, the SRS air bags do not activate, which results in serious injury or death of vehicle's occupants. B A BRACKET MOUNTING BOLT (EARTH BOLT) INSTALLATION Earth bolt head mark Before installation, Refer to that the bolt is stamped mark...
Page 703: Air Bag Modules And Clock Spring
52B-36 SRS ± Air Bag Modules and Clock Spring AIR BAG MODULES AND CLOCK SPRING Caution 1. Disconnect the negative (±) battery terminal 5. Do not store the air bag modules in a place and wait for 60 seconds or more before more than 93 C.
Page 704 52B-37 SRS ± Air Bag Modules and Clock Spring REMOVAL AND INSTALLATION <Driver's air bag module, clock spring> Pre-removal Operation Put Steering Wheel and Front Wheels in Straight-ahead Position. Remove Ignition Key. Disconnect the Negative (±) Battery Terminal. Column switch 41 Nm 0.69 Nm Section A ±...
Page 705 52B-38 SRS ± Air Bag Modules and Clock Spring <Front passenger's air bag module> Sections A ± A and C ± C Instrument pane Claw Section B ± B Claw Instrument pane NOTE : Claws Removal steps Installation steps A A D Pre-installation inspection 1.
Page 706 52B-39 SRS ± Air Bag Modules and Clock Spring <Front seat back assembly with side air bag module (Vehicles with side air bag)> Side air bag module Removal Installation steps A A D Pre-installation inspection 1. Front seat back assembly 1.
Page 707 52B-40 SRS ± Air Bag Modules and Clock Spring A D PASSENGER'S AIR BAG MODULE REMOVAL Caution The removed air bag module should be stored in a clean, dry place with the deployment surface facing up. A E FRONT SEAT BACK ASSEMBLY REMOVAL Refer to GROUP 52A ±...
Page 708 52B-41 SRS ± Air Bag Modules and Clock Spring Clock Spring Centring Fully turn the clock spring clockwise and then turn it back about 3 times counterclockwise to align the mating marks. Caution Unless the mating marks are properly aligned, the steering wheel gets stuck amid a turn or the flat cable in the clock spring is cut.
Page 709 52B-42 SRS ± Air Bag Modules and Clock Spring Caution If dents, cracks, deformation, or rust are present in the air bag module(s), replace with new one(s). Discard the old one(s) as specified in the service procedure. (Refer to P.52B-48.) CLOCK SPRING CHECK Case If any malfunction is found in the following inspections, replace...
Page 710 52B-43 SRS ± Air Bag Modules and Clock Spring Caution Never measure circuit resistance in the air bag modules (squib) even with the specified tester. Measuring the circuit resistance with a tester causes accidental air bag deployment due to current that flows or static, resulting in serious personal injury.
Page 711: Seat Belt With Pre-Tensioner
52B-44 SRS ± Seat Belt with Pre-tensioner SEAT BELT WITH PRE-TENSIONER Caution 1. Never attempt to disassemble or repair the 4. Do expose seat belt with pre-tensioner to temperatures over 90 _ C. seat belt with pre-tensioner. If faulty, replace 5.
Page 712 52B-45 SRS ± Seat Belt with Pre-tensioner INSTALLATION SERVICE POINTS A A PRE-INSTALLATION INSPECTION When installing a new seat belt with pre-tensioner refer to ªINSPECTIONº. Caution Disposal of the pre-tensioner must be carried out as stated in the procedure. (Refer to P.52B-48.) B A POST-INSTALLATION INSPECTION 1.
Page 713: Side Impact Sensor
52B-46 SRS ± Side Impact Sensor SIDE IMPACT SENSOR Caution 1. Disconnect the negative (±) battery terminal 3. Do not drop or subject the side impact and wait for 60 seconds or more before sensors to impact or vibration. starting work. Also, the disconnected battery If denting, cracking, deformation, or rust are terminal should be insulated with tape.
Page 714 52B-47 SRS ± Side Impact Sensor B A SIDE IMPACT SENSOR INSTALLATION Caution The side impact sensor, unless properly installed, does not operate properly, thereby resulting in serious injury or death of the vehicle's occupants. C A POST-INSTALLATION INSPECTION 1. Turn the ignition switch to ON. 2.
Page 715: Air Bag Module And Seat Belt Pre-Tensioner Disposal Procedures
52B-48 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES Before disposing of a vehicle which is equipped pre-tensioner themselves, the following procedures with air bags or seat belts with pre-tensioner, or must be used to deploy the air bags or operate when disposing of the air bags or seat belt the seat belt pre-tensioners before disposal.
Page 716 52B-49 SRS ± SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures Driver's air bag module (1) Remove the steering column cover, lower. (Refer to GROUP 52A ± Instrument Panel.) (2) Disconnect the clock spring 2-pin connector and Clock spring 2-pin connector...
Page 717 52B-50 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures (1) Remove the glove box. (Refer to GROUP 52A ± Instrument Panel.) (2) Disconnect the front passenger's air bag module 2-pin connector (red) and instrument panel wiring harness connector (2-pin, red).
Page 718 52B-51 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures (7) After deployment of the front passenger's air bag module, discard as specified in the procedure (Refer to P.52B-60). Side air bag module Side air bag module (1) Disconnect the side air bag module wiring harness wiring harness connector (2-pin, yellow) connector (2-pin, yellow) and body wiring harness...
Page 719 52B-52 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures (7) Disconnect the deployment wires as far from the vehicle as possible and connect the wires to the terminals of the battery removed from the vehicle. Deploy the side air bag module. Caution 1) Before deploying the air bag in this manner, first check to be sure that there is no one in...
Page 720 52B-53 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures (5) Using pliers, cut the seat belt pre-tensioner connector Deployment from the harnesses. Connect the deployment Seat belt pre- harnesses tensioner harnesses to each harness that has been cut and insulate the connections with plastic tape.
Page 721 52B-54 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures DEPLOYMENT OUTSIDE THE VEHICLE Caution 1. This should be carried out in a wide, flat area at least 6 m away from obstacles and other people. 2. Do not deploy outside if wind is high. Even in a soft wind, ignite to windward of the air bag modules, front seat back assembly with side air bag module or seat belt pre-tensioner.
Page 722 52B-55 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures (4) Take the SRS air bag adapter harness that is connected to the wires, pass it beneath the old tyre Driver's air bag module wheel assembly, and connect it to the drive's air bag module.
Page 723 52B-56 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures Front passenger's air bag module (1) Remove the front passenger's air bag module from the vehicle. (Refer to P.52B-36.) Caution Once disconnected, both electrodes of the front passenger's air bag module connector short automatically to prevent accidental deployment caused by static etc.
Page 724 52B-57 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures (6) Disconnect the deployment harnesses as far from the front passenger's air bag module as possible and connect the harnesses to the battery removed from the vehicle. Caution 1) Before the deployment, see that no one is near the front passenger's air bag module.
Page 725 52B-58 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures (5) Disconnect the deployment harnesses as far from the front seat back assembly possible and connect the harnesses to the battery removed from the vehicle. Then, deploy. Caution 1) Before the deployment, see that no one is near the front seat back assembly.
Page 726 52B-59 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures Caution Tyre without Pull the seat belt out the outside of the tyre, and wheels then place one tyre without a wheel on top of the existing tyre. (6) Place three old tyres without wheels on top of the tyre secured to the seat belt pre-tensioner.
Page 727: Deployed Air Bag Module Or Operated Seat Belt Pre-Tensioner Disposal Procedures
52B-60 SRS ± Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES After deployment or operation, the air bag module and the seat belt pre-tensioner should be disposed of in the same manner as any other scrap parts, adhering to local laws and/or legislation that may be in force except that the following points should be carefully noted during disposal.
Page 728 54A-1 CHASSIS ELECTRICAL CONTENTS CHASSIS ELECTRICAL ..........SMART WIRING SYSTEM (SWS) .
Page 729 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B ± Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.
Page 730 54A-3 ON-VEHICLE SERVICE ....REAR COMBINATION LAMP, REAR FOG LAMP ........Speedometer Check .
Page 731 54A-4 MULTI-CENTER DISPLAY <MIDDLE MULTI-CENTER DISPLAY <HIGH GRADE> ......GRADE> ......SPECIAL TOOL .
Page 732: Battery
54A-5 CHASSIS ELECTRICAL ± Battery BATTERY SERVICE SPECIFICATION Item Specification Specific gravity of the battery fluid 1.220 ± 1.290 [20 C] ON-VEHICLE SERVICE FLUID LEVEL AND SPECIFIC GRAVITY CHECK Good 1. Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks.
Page 733: Charging
54A-6 CHASSIS ELECTRICAL ± Battery CHARGING 1. When charging a battery while still installed in the vehicle, disconnect the battery cables to prevent damage to electrical parts. 2. The current normally used for charging a battery should be approximately 1/10th of the battery capacity. When performing a quick-charging due to lack of time, etc., the charging current should never exceed the battery capacity as indicated in amperes.
Page 734: Battery Testing Procedure
54A-7 CHASSIS ELECTRICAL ± Battery BATTERY TESTING PROCEDURE TEST STEP (1) Turn headlamps on for 15 seconds. (2) Turn headlamps off for 2 minutes to allow battery voltage to stabilize. (3) Disconnect cables. Charge battery at 5 amps. (see LOAD TEST RATE CHART) Read open circuit voltage.
Page 735: Ignition Switch And Immobilizer System
54A-8 CHASSIS ELECTRICAL ± Ignition Switch and Immobilizer System IGNITION SWITCH AND IMMOBILIZER SYSTEM SPECIAL TOOL Tool Number Name MB991502 MUT- II sub Immobilizer system check assembly (Diagnosis display using the MUT- II ) Registration of the encrypted code MB991223 Harness set Fuel gauge simple check A: Connector pin contact pressure check...
Page 736 54A-9 CHASSIS ELECTRICAL ± Ignition Switch and Immobilizer System INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Transponder communication system Probable cause The encrypted code of the transponder is not sent to the immobilizer-ECU immediately Malfunction of the transponder after the ignition switch is turned to the ON position. Malfunction of the ignition key ring antenna Malfunction of the immobilizer-ECU Does the engine start using the spare...
Page 737 54A-10 CHASSIS ELECTRICAL ± Ignition Switch and Immobilizer System INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Diagnosis code No. 54 has been generated by the Probable cause engine-ECU. There is a problem with communication between the engine-ECU and the Malfunction of harness or connector immobilizer-ECU.
Page 738 54A-11 CHASSIS ELECTRICAL ± Ignition Switch and Immobilizer System Inspection Procedure 3 Engine does not start (cranking but no initial combustion). Probable cause If the fuel injectors are not operating, there might be a problem with the MPI system Malfunction of the MPI system in addition to a malfunction of the immobilizer system.
Page 739 54A-12 CHASSIS ELECTRICAL ± Ignition Switch and Immobilizer System CHECK AT IMMOBILIZER-ECU TERMINAL VOLTAGE CHECK CHART Terminal No. Signal Checking requirements Terminal voltage Immobilizer-ECU power supply Ignition switch: ON System voltage ± ± ± Engine-ECU ± ± Immobilizer-ECU earth Always...
Page 740: Ignition Switch And Immobilizer System
54A-13 CHASSIS ELECTRICAL ± Ignition Switch and Immobilizer System IGNITION SWITCH AND IMMOBILIZER SYSTEM REMOVAL AND INSTALLATION Caution: SRS Before removal of air bag module and clock spring, refer to GROUP 52B ± Service Precautions and Air Bag Module and Clock Spring. Pre-removal and Post-installation Operation Clock Spring and Column Switch Removal and Installation (Refer to GROUP 52B ±...
Page 741 54A-14 CHASSIS ELECTRICAL ± Ignition Switch and Immobilizer System REMOVAL SERVICE POINTS STEERING LOCK CYLINDER REMOVAL 1. Insert the key in the steering lock cylinder and turn it to the ªACCº position. 2. Using a cross-tip (+) screwdriver (small) or a similar tool, push the lock pin of the steering lock cylinder inward and then pull the steering lock cylinder toward you.
Page 742 54A-15 CHASSIS ELECTRICAL ± Ignition Switch and Immobilizer System ENCRYPTED CODE REGISTRATION METHOD AND RESETTING THE CODE TO THE FACTORY SETTING Register the encrypted code in the immobilizer-ECU and then reset the code to the factory setting after parts have been replaced.
Page 743 54A-16 CHASSIS ELECTRICAL ± Ignition Switch and Immobilizer System 4. Use the MUT- II to register the encrypted code. To register the second or subsequent key, leave the MUT- II connected and remove the first registered key. Within 5 seconds insert the key to be registered and turn on the ignition switch.
Page 744 54A-17 CHASSIS ELECTRICAL ± Combination Meters COMBINATION METERS SERVICE SPECIFICATIONS Items Items Standard value Speedometer indication error km/h(mph) 40 (20) 40 ± 48 (20 ± 25) 80 (40) 80 ± 92 (40 ± 47) 120 (60) 120 ± 136 (60 ± 69) 160 (80) 160 ±...
Page 745: Special Tools
54A-18 CHASSIS ELECTRICAL ± Combination Meters SEALANT Items Specified sealant Remark Engine coolant temperature gauge 3M Adhesive nut locking No. 4171 or Drying sealant unit threaded portion equivalent SPECIAL TOOLS Tool Number Name MB991223 Harness set Fuel gauge simple check A: Connector pin contact pressure check A: MB991219 A: Test harness...
Page 746: Troubleshooting
54A-19 CHASSIS ELECTRICAL ± Combination Meters TROUBLESHOOTING INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference procedure page Speedometer does not work. 54A-19 Tachometer does not work. 54A-20 Fuel gauge does not operate. 54A-21 Engine coolant temperature gauge does not operate. 54A-22 GDI ECO indication lamp does not illumination 54A-23...
Page 747 54A-20 CHASSIS ELECTRICAL ± Combination Meters Inspection Procedure 2 Tachometer does not work. Probable cause The ignition signal may not be input from the engine, or there may be a malfunction Malfunction of tachometer in the power supply or earth circuit. Malfunction of harness or connector MUT- II Self-Diag.
Page 748 54A-21 CHASSIS ELECTRICAL ± Combination Meters Inspection Procedure 4 Fuel gauge does not operate. Probable cause If speedometer and tachometer operate normally, the harness from power supply Malfunction of fuel gauge unit to combination meter is normal. Malfunction of fuel gauge Malfunction of harness or connector Do the speedometer and tachometer operate normally? Check the speedometer and tachometer circuit.
Page 749 54A-22 CHASSIS ELECTRICAL ± Combination Meters Inspection Procedure 5 Engine coolant temperature gauge does not operate. Probable cause If speedometer and tachometer operate normally, the harness from power supply Malfunction of engine coolant temperature gauge unit to combination meter is normal. Malfunction of engine coolant temperature gauge Malfunction of harness or connector Do the speedometer and tachometer operate normally?
Page 750 54A-23 CHASSIS ELECTRICAL ± Combination Meters Inspection Procedure 6 GDI ECO indication lamp does not illuminate. Probable cause GDI ECO indication lamp is illuminated by GDI ECO indication lamp-ECU. ECO indication lamp bulb blown When it does not illuminates, GDI ECO indication lamp bulb may be blown, or Malfunction of combination meter combination meter, power supply circuit of GDI ECO indication lamp-ECU or GDI Malfunction of GDI ECO indication lamp...
Page 751: On-Vehicle Service
54A-24 CHASSIS ELECTRICAL ± Combination Meters ON-VEHICLE SERVICE SPEEDOMETER CHECK 1. Adjust the pressure of the tyres to the specified level. (Refer to GROUP 31 ± Service Specifications.) 2. Set the vehicle onto a speedometer tester. 3. Use wheel chocks to hold the front wheels, and apply the parking brake firmly.
Page 752: Fuel Gauge Unit Check
54A-25 CHASSIS ELECTRICAL ± Combination Meters FUEL GAUGE UNIT CHECK <Main> <Sub> Remove the fuel gauge unit from the fuel tank. (Refer to GROUP 13C.) FUEL GAUGE UNIT RESISTANCE 1. Check that resistance value between the fuel gauge terminal and earth terminal is at standard value when fuel gauge unit float is at point F (highest) and point E (lowest).
Page 753: Fuel Level Warning Switch Check
54A-26 CHASSIS ELECTRICAL ± Combination Meters 2. Condition is good if the test lamp goes off when the Thermistor thermistor is immersed in water and comes on when it is taken out of water. Caution Illuminated After finishing this test, wipe the unit dry and install it in the fuel tank.
Page 754: Combination Meters
54A-27 CHASSIS ELECTRICAL ± Combination Meters COMBINATION METERS REMOVAL AND INSTALLATION Section A ± A Instrument panel Clip Clip position Combination meter removal steps Vehicle speed sensor removal 1. Meter hood 3. Vehicle speed sensor 2. Combination meter INSPECTION VEHICLE SPEED SENSOR INSPECTION Vehicle speed 1.
Page 755 54A-28 CHASSIS ELECTRICAL ± Combination Meters FUEL GAUGE RESISTANCE CHECK Fuel gauge 1. Remove the power supply tightening screw. 2. Use an ohmmeter to measure the resistance value between the terminals. Standard value: Power supply ± Earth: 233.3 Ω Power supply ± Fuel gauge: 108.3 Ω Power supply Fuel gauge ±...
Page 756: Outside Thermo Sensor
54A-29 CHASSIS ELECTRICAL ± Outside Thermo Sensor OUTSIDE THERMO SENSOR SERVICE SPECIFICATIONS Items Standard value Internal resistance of outside thermo sensor Ω At 25 Approx. 1,700 OUTSIDE THERMO SENSOR REMOVAL AND INSTALLATION Outside thermo sensor INSPECTION OUTSIDE THERMO SENSOR INTERNAL RESISTANCE Thermometer CHECK Check the internal resistance of the outside thermo sensor...
Page 757: Headlamp, Front Turn-Signal Lamp And Front Fog Lamp
54A-30 CHASSIS ELECTRICAL ± Headlamp, Front Turn-signal Lamp and Front Fog Lamp HEADLAMP, FRONT TURN-SIGNAL LAMP AND FRONT FOG LAMP SERVICE SPECIFICATIONS Items Standard value Limit Headlamp aiming for low Vertical direction 60 mm below horizontal (H) ± beam beam Horizontal direction Position where the 15 sloping section...
Page 758: On-Vehicle Service
54A-31 CHASSIS ELECTRICAL ± Headlamp, Front Turn-signal Lamp and Front Fog Lamp ON-VEHICLE SERVICE HEADLAMP AIMING <USING A BEAM SETTING EQUIPMENT> 1. The headlamps should be aimed with the proper beam setting equipment, and in accordance with the equipment manufacture's instructions. NOTE If there are any regulations pertinent to the aiming of headlamps in the area where the vehicle is to be used,...
Page 759: Headlamp Intensity Measurement
54A-32 CHASSIS ELECTRICAL ± Headlamp, Front Turn-signal Lamp and Front Fog Lamp 4. Check if the beam shining onto the screen is at the standard value. Standard value: Distance of Lamp centre vertical direction (Vertical direction) 60 mm below horizontal (H) (Horizontal direction) Position where the 15 sloping section intersects the vertical line (V)
Page 760: Front Fog Lamp Aiming
54A-33 CHASSIS ELECTRICAL ± CHASSIS ELECTRICAL ± Headlamp, Front Turn-signal Lamp and Front Fog Lamp Headlamp, Front Turn-signal Lamp and Front Fog Lamp FRONT FOG LAMP AIMING 1. Measure the centre of the front fog lamps, as shown in the illustration. 2.
Page 761: Bulb Replacement
54A-34 CHASSIS ELECTRICAL ± Headlamp, Front Turn-signal Lamp and Front Fog Lamp BULB REPLACEMENT <Headlamp Bulb> Spring 1. Disconnect the connector. 2. Remove the socket cover. 3. Remove the bulb mounting spring, and then withdraw the bulb. 4. Install new bulb, and then connect the connector securely. Caution Do not touch the surface of the bulb with hands or dirty gloves.
Page 762: Headlamp, Front Turn-Signal Lamp And Front Fog Lamp
54A-35 CHASSIS ELECTRICAL ± Headlamp, Front Turn-signal Lamp and Front Fog Lamp HEADLAMP, FRONT TURN-SIGNAL LAMP AND FRONT FOG LAMP REMOVAL AND INSTALLATION 5 Nm 5 Nm Section A ± A Claw Instrument panel BX0283AL Fog lamp switch and headlamp Front fog lamp removal steps leveling switch removal steps 8.
Page 763 54A-36 CHASSIS ELECTRICAL ± Headlamp, Front Turn-signal Lamp and Front Fog Lamp REMOVAL SERVICE POINT Section A ± A RADIATOR GRILLE REMOVAL Radiator grille Clip 1. Pull the radiator grille toward you gently, and press the clip tab with a flat-tipped screwdriver toward the arrow to remove the radiator grille.
Page 764: Side Turn-Signal Lamp
Headlamp, Front Turn-signal Lamp and 54A-37 CHASSIS ELECTRICAL ± Front Fog Lamp/Side Turn-signal Lamp FRONT FOG LAMP RELAY CONTINUITY CHECK Battery voltage Terminal No. Not supplied Supplied Front fog lamp relay SIDE TURN-SIGNAL LAMP SPECIAL TOOL Tool Number Name MB990784 Ornament remover Removal of side turn-signal lamp TROUBLESHOOTING...
Page 765: Side Turn-Signal Lamp
Side Turn-signal Lamp/Room Lamp/Rear 54A-38 CHASSIS ELECTRICAL ± Combination Lamp, Rear Fog Lamp SIDE TURN-SIGNAL LAMP Front of vehicle REMOVAL SERVICE POINT SIDE TURN-SIGNAL LAMP REMOVAL Use a special tool to remove the lock from the fender panel, and then remove the side turn-signal lamp. MB990784 ROOM LAMP TROUBLESHOOTING...
Page 766: Rear Combination Lamp, Rear Fog Lamp
54A-39 CHASSIS ELECTRICAL ± Rear Combination Lamp, Rear Fog Lamp REAR COMBINATION LAMP, REAR FOG LAMP REMOVAL AND INSTALLATION <L.H. drive vehicles> Section A ± A Claw Instrument panel BX0283AL Section B ± B Gronmet Body panel 2.5 ± 0.2 Nm Fog lamp switch removal steps Rear fog lamp removal steps 1.
Page 767 54A-40 CHASSIS ELECTRICAL ± Rear Combination Lamp, Rear Fog Lamp REMOVAL AND INSTALLATION <R.H. drive vehicles> Section B ± B Section A ± A Gronmet Claw Instrument panel Body panel BX0283AL 2.5 ± 0.2 Nm Fog lamp switch removal steps 4.
Page 768 54A-41 CHASSIS ELECTRICAL ± Rear Combination Lamp, Rear Fog Lamp INSPECTION FOG LAMP SWITCH CONTINUITY CHECK Terminal No. Relased Pressed INSPECTION REAR FOG LAMP RELAY CONTINUITY CHECK Battery voltage Terminal No. Not supplied Supplied Rear fog lamp relay...
Page 769: High-Mounted Stop Lamp And Licence Plate Lamp
54A-42 CHASSIS ELECTRICAL ± High-mounted Stop Lamp and Licence Plate Lamp HIGH-MOUNTED STOP LAMP AND LICENCE PLATE LAMP REMOVAL AND INSTALLATION Section A ± A High-mounted stop lamp removal Licence plate lamp garnish (Refer to GROUP 42 ± Back Door.) steps 5.
Page 770: Column Switch
54A-43 CHASSIS ELECTRICAL ± Column Switch COLUMN SWITCH REMOVAL AND INSTALLATION Section A ± A Section B ± B Removal steps 1. Column cover, lower 3. Wiper and washer switch 2. Column cover, upper 4. Lighting switch...
Page 771: Rheostat
Rheostat <Vehicles for 54A-44 CHASSIS ELECTRICAL ± Australia and New Zealand> RHEOSTAT SPECIAL TOOL Tool Number Name MB990784 Ornament remover Removal of switch garnish RHEOSTAT REMOVAL AND INSTALLATION Section A ± A Claw Instrument panel Removal steps 1. Switch panel 2.
Page 772: Hazard Warning Lamp Switch
54A-45 CHASSIS ELECTRICAL ± Hazard Warning Lamp Switch HAZARD WARNING LAMP SWITCH SPECIAL TOOL Tool Number Name MB990784 Ornament remover Removal of center panel HAZARD WARNING LAMP SWITCH REMOVAL AND INSTALLATION Section A ± A Instrument panel Clip : shows clips. Removal steps 1.
Page 773: Horn
54A-46 CHASSIS ELECTRICAL ± Horn/Cigarette Lighter HORN Horn relay INSPECTION HORN RELAY CONTINUITY CHECK Battery voltage Terminal No. Not supplied Supplied CIGARETTE LIGHTER REMOVAL AND INSTALLATION Removal steps 1. Plug 3. Bulb 2. Floor console (Refer to GROUP 4. Socket case 52A) 5.
Page 774: Accessory Socket
54A-47 CHASSIS ELECTRICAL ± Cigarette Lighter/Accessory Socket INSPECTION Take out the plug, and check for a worn edge on the Element element spot connection, and for shreds of tobacco or Spot other material on the element. Using a circuit tester, check the continuity of the element. ACCESSORY SOCKET INSPECTION ACCESSORY SOCKET RELAY CONTINUITY CHECK...
Page 775: Radio And Tape Player
54A-48 CHASSIS ELECTRICAL ± Radio and Tape Player RADIO AND TAPE PLAYER TROUBLESHOOTING QUICK-REFERENCE TROUBLESHOOTING CHART Items Problem symptom Relevant chart Noise Noise appears at certain places when travelling. Mixed with noise, only at night. Broadcasts can be heard but FM/MW/LW has a lot of noise. There is noise when starting the engine.
Page 776 54A-49 CHASSIS ELECTRICAL ± Radio and Tape Player CHART A. NOISE A-1 Noise appears at certain places when travelling. Is there a particular structure? Do the following measures eliminate the noise? 1. Change to a different station with a strong signal to boost resistance to interference.
Page 777 54A-50 CHASSIS ELECTRICAL ± Radio and Tape Player A-2 Mixed with noise, only at night. The following factors can be considered as possible to a different station or the appearance of a causes of noise appearing at night. beating sound* may occur. 1.
Page 778 54A-51 CHASSIS ELECTRICAL ± Radio and Tape Player A-3 Broadcasts can be heard but FM/MW/LW has a lot of noise. Noise occurs when the engine is stopped. Noise occurs when the engine in running. Do the following measures eliminate the noise? Inspect the vehicle's noise suppressor.
Page 779 54A-52 CHASSIS ELECTRICAL ± Radio and Tape Player A-4 There is noise when starting the engine. Noise type Conditions Cause Remedy Sounds are in parentheses ( ). FM/MW/LW: Increasing the engine speed Mainly due to the spark Check or replace the Ignition noise causing the popping sound to...
Page 780 54A-53 CHASSIS ELECTRICAL ± Radio and Tape Player A-5 Some noise appears when there is vibration or shocks during travelling. Are connectors properly connected? Ensure proper connection. Static electricity noise: Does noise appear when the radio switch is turned on while the Body static electric from the shock absorber rubber bushings used vehicle is stopped and the radio is struck while tuned away from to prevent vibration, tyres, etc.
Page 781 54A-54 CHASSIS ELECTRICAL ± Radio and Tape Player B. RADIO B-1 No power is supplied when the switch is set to ON. Is dedicated fuse No. 6 blown or is the circuit open? Replace fuse or repair harness. Connect connector securely. Is the connector at the back of the radio connected properly? Disconnect and check the connector at the rear of the radio.
Page 782 54A-55 CHASSIS ELECTRICAL ± Radio and Tape Player B-3 There is noise but no reception for FM/MW/LW or no sound from FM/MW/LW. Is the check being conducted under special electrical field conditions? Example: In an underground garage or inside a building. Is proper performance obtained when the vehicle is moved? Does tuning solve the problem?
Page 783 54A-56 CHASSIS ELECTRICAL ± Radio and Tape Player B-5 Distortion on FM/MW/LW. Occasional Excessive antenna input How much distortion is there? Distortion in the vicinity of the radio sta- tion Constant Remove cords away from cone paper. Are the speaker cords in contact with the cone paper? Repair or replace speakers.
Page 784 54A-57 CHASSIS ELECTRICAL ± Radio and Tape Player B-7 Insufficient memory (preset stations are erased). Is dedicated fuse No. 5 blown or is the circuit open? Replace fuse or repair harness. Repair harness. Disconnect and check the connector at the rear of the radio. Is the memory backup (battery) power being supplied? Repair or replace radio.
Page 785 54A-58 CHASSIS ELECTRICAL ± Radio and Tape Player C-3 No sound from one speaker. Clean the tape player head and check again. Replace the tape player and check again. Repair or replace tape player. It conducts electricity but is Repair harness. Remove the connector on the back of the radio and check shorted out.
Page 786 54A-59 CHASSIS ELECTRICAL ± Radio and Tape Player C-6 Uneven revolution. Tape speed is fast or slow. Does the player play OK if the tape* is changed? Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. Also, tape of C-120 or greater length often get caught in the mechanism and should not be used.
Page 787 54A-60 CHASSIS ELECTRICAL ± Radio and Tape Player C-8 Tape gets caught in mechanism* When the tape is caught in the mechanism, the case may not eject. When this occurs, do not try to force the tape out as this may damage the tape player mechanism. Take the cassette to a service dealer for repair.
Page 788: Radio And Tape Player
54A-61 CHASSIS ELECTRICAL ± Radio and Tape Player RADIO AND TAPE PLAYER REMOVAL AND INSTALLATION Section A ± A Instrument panel Clip : shows clips. Removal steps 1. Center panel 2. Radio and tape player...
Page 789: Cd Autochanger
54A-62 CHASSIS ELECTRICAL ± CD Autochanger CD AUTOCHANGER REMOVAL AND INSTALLATION Removal steps Front seat (LH) 3. CD autochanger assembly 1. Lid 4. Bracket 2. Cover 5. CD autochanger...
Page 790: Speaker
54A-63 CHASSIS ELECTRICAL ± Speaker SPEAKER REMOVAL AND INSTALLATION <Front speaker> <Rear speaker> Front speaker removal steps Rear speaker removal steps 1. Front door trim (Refer to GROUP 3. Quarter trim (Refer to GROUP 42.) 52A.) 2. Speaker 4. Speaker...
Page 791: Antenna
54A-64 CHASSIS ELECTRICAL ± Antenna ANTENNA REMOVAL AND INSTALLATION Removal steps 1. Radio and tape player (Refer to 3. Antenna assembly P.54-61.) 4. Antenna base D Instrument under cover D Instrument panel (Refer to GROUP (Refer to GROUP 52A.) 52A) 2.
Page 792: Rear Window Defogger
54A-65 CHASSIS ELECTRICAL ± Rear Window Defogger REAR WINDOW DEFOGGER Normal characteristic curve Voltage ON-VEHICLE SERVICE PRINTED-HEATER LINE CHECK A (Centre point) approx. 6 V 1. Run engine at 2,000 r/min. Check heater element with battery at full. 2. Turn ON rear window defogger switch. Measure heater Positive Printed Negative...
Page 793 54A-66 CHASSIS ELECTRICAL ± Rear Window Defogger REAR WINDOW DEFOGGER SWITCH REMOVAL AND INSTALLATION Refer to GROUP 55 ± Heater Control. INSPECTION DEFOGGER SWITCH CONTINUITY CHECK <Vehicles with heated-mirrors> Terminal No. Switch position ± <Vehicles with heated-mirrors> NOTE Turn on the defogger switch, and then check that there is <Vehicles without heated-mirrors>...
Page 794 54A-67 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> MULTI-CENTER DISPLAY <MIDDLE GRADE> SPECIAL TOOL Tool Number Name MB990784 Ornament remover Removal of center display hood TROUBLESHOOTING NOTES WITH REGARD TO SERVICE PROCEDURES 1. Before removing the battery The audio system has a large amount of data stored in memory which the user enters over time. When the terminals are disconnected from the battery, the memory which stores this data is affected as shown in the table below.
Page 795 54A-68 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> 2. Diagnosis Function for Audio System Audio system has the following diagnosis function. Function Contents Speaker diagnosis function This function checks if the speakers are all working normally on the audio system or not.
Page 796: Check
54A-69 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> 4. Service Mode For Multi-center Display 1. Enter and terminate the service mode (1) To enter the service mode, turn the ignition switch to ACC. (2) Press the ªHº button twice. (3) Press the ªSETº button and (A) button at the same time. (4) Then the audio unit will enter the service mode.
Page 797 54A-70 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> MAIN UNIT TERMINAL VOLTAGES 1. MULTI-CENTER DISPLAY UNIT Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit circuit...
Page 798 54A-71 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit circuit Input/ M±BUSY (AUDIO) Hi: 4 ± 5 Audio display dose not appear.
Page 799 54A-72 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> 2. AUDIO UNIT CD control connector (DIN cable) Antenna Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit...
Page 800 54A-73 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit circuit Output SPEAKER 0 ± ± The rear left speaker does not sound.
Page 801 54A-74 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> INSPECTION CHART CLASSIFIED BY TROUBLE SYMPTOMS Related Unit Trouble Symptom Inspection Reference Procedure Page Malfunction of multi- No display appears after the ignition key is turned to ACC. 54A-74 center display center display TAPE/CD, UML switches do not work.
Page 802 54A-75 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> INSPECTION PROCEDURE 2 TAPE/CD, UML switches do not work. Measure at multi center display connec- Replace the multi-center display. Check cassette function with LOAD- tor C-54. ING/EJECT Ignition switch: ACC Voltage between terminal (10), (11) and body earth OK: System voltage Replace the audio unit...
Page 803 54A-76 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> INSPECTION PROCEDURE 3 CD switch do not work. Repair Check the connectors: DIN connector between audio unit and CD changer. Check the magazine with LOADING/ Check voltage on connector for CD Repair the fuse and the harness. EJECT function and if lamp light on changer terminal of +B and ACC the panel.
Page 804 54A-77 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> INSPECTION PROCEDURE 5 Abnormal driving data displays. Abnormal average fuel consumption and average speed displays. Abnormal cruising distance displays. 1. When average fuel consumption and average speed displays are abnormal. Check the connector: C-52 Repair Check the harness.
Page 805 54A-78 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> INSPECTION PROCEDURE 6 No illumination for audio buttons light on. Check if the brightness of display Measure at multi-center display con- Replace the multi-center display. changes when the lighting switch is on nector C-52.
Page 806 54A-79 CHASSIS ELECTRICAL ± Multi-center Display <Middle Grade> MULTI-CENTER DISPLAY REMOVAL AND INSTALLATION View A View A Section A ± A Section B ± B Instrument panel Instrument panel Clip Clip : shows tabs. : shows clips. Removal steps 1. Center display hood 3.
Page 807 54A-80 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> MULTI-CENTER DISPLAY <HIGH GRADE> TROUBLESHOOTING NOTES WITH REGARD TO SERVICE PROCEDURES 1. Before removing the battery The multi-center display has a large amount of data stored in memory which the user enters over time.
Page 808 (2) If you find that there is a system abnormality, check according to the Inspection Chart Classified by Trouble Symptoms in the Troubleshooting section. MITSUBISHI MULTI COMMUNICATION SYSTEM DISPLAY PANEL F3 switch F4 switch...
Page 809 54A-82 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> TROUBLE DIAGNOSIS SERVICE FUNCTIONS The Multi-center Display is equipped with the following trouble diagnosis service functions. Function Contents Diagnosis function During normal use, this function constantly monitors the system communication lines, and displays an error if it finds any abnormalities. CD-ROM checking function This function displays a message if it cannot read the CD-ROM or if no CD-ROM is inserted.
Page 810 54A-83 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> (3) If the F1 switch is pressed at the service mode initial screen, service mode will be ended and the screen will change to navigation mode. 2. AUTOMATIC DIAGNOSIS BY MODE (1) If the F3 switch is pressed at the service mode screen, automatic diagnosis by mode will start.
Page 811 54A-84 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> (4) The next mode is the sensor checking mode. Press the F1 switch to start sensor checking. If you would like to proceed to the next checking operation without carrying out sensor checking, press the F6 switch. (5) When sensor checking starts, the gyro output will be checked first while the vehicle is stopped, so make sure that the vehicle is stopped for this check.
Page 812 54A-85 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> (9) The next mode is speaker checking mode. The test sound will be output alternately from each speaker each time the F2 switch is pressed. At the early mass production, sometimes radio sound will be output.
Page 813 54A-86 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> (2) A colored bar will appear on the screen. Press a function switch to change to another screen. The screen will return to the service mode initial screen if the F1 switch is pressed. 4.
Page 814 54A-87 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> (3) Press the F3 switch to display the speaker checking screen. The test sound will be output alternately from each speaker each time the F2 switch is pressed. Press the F1 switch to end speaker checking and return to the audio checking menu screen.
Page 815 54A-88 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> (4) Once the transmission checking is completed, the results of checking will appear on the screen. After checking the results, press the F1 switch to return to the self-diagnosis menu screen. (5) If the F6 switch is pressed at the self-diagnosis menu screen, sensor checking will start.
Page 816 54A-89 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> (8) When sensor checking is completed, the check results will appear on the screen. After checking the results, press the F1 switch to return to the self-diagnosis menu screen. (9) If the F6 switch is pressed at the self-diagnosis menu screen, vehicle signal checking will start.
Page 817 54A-90 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> (4) If the F5 switch is pressed, all past error codes will be cleared, and the screen will return to the diagnosis recording screen. The Clear button will not be displayed at this time. (5) Press the F1 switch to return to the service mode initial screen.
Page 818 54A-91 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> MAIN UNIT TERMINAL VOLTAGES 1. MULTI-CENTER DISPLAY UNIT Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit circuit...
Page 819 54A-92 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit circuit Input R+SYNC (AUDIO) ± Red, white, yellow and magenta do not appear in RGB screen.
Page 820 54A-93 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit circuit 34, 35 ± ± ± ±...
Page 821 54A-94 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> 3. AUDIO UNIT CD control connector (DIN cable) Antenna Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit...
Page 822 54A-95 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit circuit Output SPEAKER 0 ± ± No sound is output from rear left RL (±) System...
Page 823 54A-96 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> Termi- Input/ Signal Symbol Terminal Harness Problem Trouble Symptom Resulting from nal No nal No. Output Output Voltage Voltage Harness Problem Harness Problem Open Short- Circuit circuit ± ± ± ± ± ±...
Page 824 54A-97 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> INSPECTION PROCEDURES FOR EACH TROUBLE SYMPTOM INSPECTION PROCEDURE 1 TAPE/CD, UML switches do not work. No display appears after the ignition key is turned to ACC. Check connectors: C-11, C-53, C-54 Repair and DIN connectors between audio and navigation unit Turn off the ignition key and turn to ACC...
Page 825 54A-98 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> From previous page Disconnect DIN 20-pin connector from Measure at the navigation unit connec- Repair fuse or harness. the navigation unit. tor C-50. Ignition switch: ACC Ignition switch: ACC Measure waveforms of terminal (8), Voltage between terminal (5), (6) (15), (17)
Page 826 54A-99 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> INSPECTION PROCEDURE 2 TAPE/CD, UML switches do not work. (Display appears.) Check connectors: C-11, C-53, C-54 Repair and DIN connectors between audio and navigation unit Does the audio sound turn on or off Measure at audio unit connector C-11.
Page 827 54A-100 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> INSPECTION PROCEDURE 3 No display appears after the ignition key is turned to ACC, but TAPE/CD, UML switches can be operative. Check connectors: C-11, C-53, C-54 Repair and DIN connectors between audio and navigation unit Turn off the ignition key and turn to ACC Measure at the multi-center display...
Page 828 54A-101 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> INSPECTION PROCEDURE 4 CD changer screen displays do not appear when TAPE/CD switches are operated. Check connectors: C-54 and naviga- Repair tion unit DIN connector Does radio reception occur and does Are the results of the hardware switch Replace the audio unit.
Page 829 54A-102 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> INSPECTION PROCEDURE 7 Abnormal driving data displays. Abnormal average fuel consumption (momentary fuel consumption) and average speed displays. Abnormal cruising distance displays. 1. When average fuel consumption (momentary fuel consumption) and average speed displays are abnormal.
Page 830 54A-103 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> INSPECTION PROCEDURE 8 Display moves about. Screen colors do not match correctly. Check connectors: C-50, C-52, C-53, C-54 and DIN connectors Repair between navigation unit and audio unit End (no abnormality) Do red, blue and green colors appear in the monitor color bar service function? Replace the multi-center display unit.
Page 831 54A-104 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> INSPECTION PROCEDURE 10 Compass display does not change when not following a route, or guide does not appear when searching for and following a route. Carry out a sensor check (service function). If no vehicle speed is input, the sensor check does not complete.
Page 832 54A-105 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> ERROR CODE TABLE <ACCORDING TO SCREEN DISPLAY> Error Code Error Details Detection Method (Reference) Refer- ence Page 1011 Ambient temperature sensor not con- Connection checking 54A-105 nected during diagnosis 1021 Fuel gauge not connected during diagnosis Connection checking 54A-106 1031...
Page 833 54A-106 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> Error Code No. 1021 Were the wiring check instructions followed? Repeat the wiring check. Check the harness between C-52 and D-17. Repeat the wiring check. If the same problem occurs, measure at the multi-center display connector C-52. Disconnect connector.
Page 834 54A-107 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> Error Code No. 1092, 1093, 1094, 1095, 1096 Is a CD-ROM for this navigation system inside? Insert the CD-ROM for this navigation system. Is the CD-ROM inserted upside down? Insert the CD-ROM correctly. Is the disc dirty, damaged or iced up? Repair or replace the disc.
Page 835 54A-108 CHASSIS ELECTRICAL ± Multi-Center Display <High Grade> MULTI-CENTER DISPLAY REMOVAL AND INSTALLATION Navigation unit removal steps Multi-center display removal steps 1. Floor console (Refer to GROUP 4. Multi-center display hood 52A ± Floor console) (Refer to P.54A-79.) 2. Radio bracket 5.
Page 836 54B-1 SMART WIRING SYSTEM (SWS) CONTENTS GENERAL INFOMATION ..54B-1 TROUBLESHOOTING ... 54B-6 SPECIAL TOOLS ....54B-5...
Page 837 54B-2 SWS ± General Information GENERAL INFORMATION COMMUNICATION LINE Data lines for multiplex communication are connected between the front-ECU, ETACS-ECU, column switch assembly, multi-center display, power window main switch, and power window motors as illustrated below. ETACS-ECU MUT- II Column switch Power window Power window motor-ECU (column-ECU)
Page 838 54B-3 SWS ± General Information POWER WINDOWS Power Windows Operation Power Window Timer Function A signal line dedicated for transmission of multiplex With the ignition switch in the ON position, the power window relay and power window switch receipt communication data is connected between the power window main switches and the power window permission are turned ON [the power window switch motor-ECU.
Page 839 54B-4 SWS ± General Information REAR WIPER AND WASHER Rear Wiper Operation Rear Washer Operation If the rear wiper switch is turned to the ON position If the rear washer switch is turned to the ON position with the ignition switch at ACC or ON position, the with the ignition switch at ACC or ON position, the rear washer ON signal is sent to the ETACS-ECU, ETACS-ECU cause the rear wiper to operate...
Page 840 54B-5 SWS ± General Information/Special Tools ROOM LAMP With the room lamp switch in the DOOR position, When the ignition key is removed with all the the ETACS-ECU controls the room lamp operation doors closed, the room lamp is illuminated at as follows: an intensity of 65% and turned out approx.
Page 841 54B-6 SWS ± Troubleshooting TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 ± How to Use Troubleshooting/Inspection Service Points. DIAGNOSTIC FUNCTION DIAGNOSIS CODES CHECK Use the MUT- II to check a diagnosis code. (Refer to GROUP 00 ± How to Use Troubleshooting/Inspection Service Points.) NOTE Connect the MUT- II to the 16-pin diagnosis connector (black).
Page 842 54B-7 SWS ± Troubleshooting Input signal Buzzer operation condition Column switch Tail lamp switch Turned the lighting switch from OFF to tail lamp position Headlamp switch Turn the lighting switch from tail lamp position to headlamp position Dimmer switch Turned from OFF to ON Passing switch Turn-signal lamp switch Windshield mist wiper switch...
Page 843 54B-8 SWS ± Troubleshooting DIAGNOSIS CODE INSPECTION PROCEDURES Code No.11 Failure concerning the ETACS-ECU Probable cause The ETACS-ECU monitors its own communication data, and sends a diagnosis Malfunction of ETACS-ECU code when an error takes place consecutive fifteen times in 0.6 second. The diagnosis code will be erased when the ETACS-ECU determines that its own communication data is sent consecutive 15 times in 0.6 second.
Page 844 54B-9 SWS ± Troubleshooting Code No.13 Failure concerning the front-ECU Probable cause This diagnosis code is displayed when the signals that the front-ECU sends to Malfunction of front-ECU the ETACS-ECU are errors consecutive fifteen times in 0.6 second. Malfunction of ETACS-ECU The diagnosis code will be erased when the front-ECU sends normal signals to Malfunction of wiring harness or connector the ETACS-ECU consecutive 15 times in 0.6 second.
Page 845 54B-10 SWS ± Troubleshooting Code No.21 Short circuit in communication lines Probable cause This diagnosis code is displayed when the SWS communication line voltage Malfunction of column switch reaches the LO level for 0.3 second. The diagnosis code is erased when Malfunction of front-ECU voltage in the ETACS-ECU data line reaches the HI level for 0.3 second, or Malfunction of power window main switch...
Page 846 54B-11 SWS ± Troubleshooting TROUBLE SYMPTOM CHART Trouble symptom Inspection Reference procedure page Communication with the MUT- II is impossible. 54B-14 Buzzer Light reminder warning function does not work normally. 54B-15 Multi-center display alarm function does not work normally. 54B-15 Central door Central door locking system does not work normally.
Page 847 54B-12 SWS ± Troubleshooting Trouble symptom Inspection Reference procedure page Rear wiper and Rear wiper does not work at all. 54B-26 washer washer Rear wiper does not stop at the predetermined park position. 54B-26 When the shift lever <M/T> or selector lever <A/T> is moved to R 54B-27 position during the rear wiper operation, the rear wiper does not operate at the continuous mode.
Page 848 54B-13 SWS ± Troubleshooting DEFECTS FOUND BY INPUT SIGNAL CHECK If the input signal check finds a defect, follow the table below to check. Trouble symptom Inspection Reference procedure page Ignition switch (ACC) signal is not sent to the ETACS-ECU. 54B-37 Ignition switch (IG1) signal is not sent to the ETACS-ECU.
Page 849 54B-14 SWS ± Troubleshooting Trouble symptom Inspection Reference procedure page Power window Any switch signal is not sent to the ETACS-ECU. N-16 54B-46 main switch Transmitter Any switch signal is not sent to the ETACS-ECU. N-17 54B-46 Multi-center dis- Any switch signal is not sent to the ETACS-ECU. N-18 54B-47 play...
Page 850 54B-15 SWS ± Troubleshooting Inspection Procedure B-1 Buzzer: Light reminder warning function does not work Probable cause normally. The ETACS-ECU operates the light reminder warning function, based on input Malfunction of driver's door switch signals from the following switched: Malfunction of column switch Ignition switch (IG1) Malfunction of ETACS-ECU Driver's door switch...
Page 851 54B-16 SWS ± Troubleshooting Inspection Procedure C-1 Central door locking system: Central door locking system Probable cause does not work normally. The power supply circuit, the circuit shared by door lock actuators, or the Malfunction of ETACS-ECU ETACS-ECU may be defective. Malfunction of harness wire or connector Measure at ETACS-ECU connector C-82.
Page 852 54B-17 SWS ± Troubleshooting Inspection Procedure C-3 Central door locking system: All the doors do not lock or Probable cause unlock with just the driver's door lock key cylinder key operation or driver's inside lock knob operation. The driver's door lock actuator switch or the ETACS-ECU may be defective. Malfunction of driver's door lock actuator Malfunction of ETACS-ECU Malfunction of harness wire or connector...
Page 853 54B-18 SWS ± Troubleshooting Inspection Procedure D-1 Power window: Power window do not work at all. Probable cause The power window relay or the ETACS-ECU may be defective. Malfunction of power window relay Malfunction of ETACS-ECU Malfunction of harness wire or connector Check the power window relay.
Page 854 54B-19 SWS ± Troubleshooting Inspection Procedure D-3 Power window: Power window sub switch can not operate Probable cause passenger's window. The cause is probably a malfunction of the power window main switch or Malfunction of power window sub switch driver's side power window motor, or an abnormality in the power supply Malfunction of passenger's power window motor circuit.
Page 855 54B-20 SWS ± Troubleshooting Inspection Procedure D-4 Power window: Power window main switch can not Probable cause operate passenger's window. The cause is probably a malfunction of the power window main switch or Malfunction of power window main switch driver's side power window motor, or an abnormality in the power supply Malfunction of passenger's power window motor circuit.
Page 856 54B-21 SWS ± Troubleshooting Inspection Procedure D-6 Power window: When the glass is raised, it then lowers Probable cause automatically. If the sliding resistance is too large when the glass is being raised, it is judged Incorrect window glass adjustment that something is jammed in the window, and the window is lowered by Glass slider is incorrectly installed or warped approximately 150 mm.
Page 857 54B-22 SWS ± Troubleshooting Inspection Procedure E-1 Keyless entry system: Keyless entry system does not Probable cause operate. The cause may be a malfunction of the receiver and transmitter communication Malfunction of transmitter system Malfunction of ETACS-ECU Is the central door locking system operated normally? Check the central door locking system.
Page 858 54B-23 SWS ± Troubleshooting Inspection Procedure F-1 Windshield wiper and washer: Windshield wiper does not Probable cause operate. If the windshield wiper does not work at all, the windshield wiper motor, column Malfunction of windshield wiper motor switch or the front-ECU may be defective. Malfunction of column switch Malfunction of front-ECU Malfunction of harness wire or connector...
Page 859 54B-24 SWS ± Troubleshooting Inspection Procedure F-2 Windshield wiper and washer: Any of the windshield wiper Probable cause switch positions is defective. The windshield wiper motor, column switch or the front-ECU may be defective. Malfunction of windshield wiper motor Malfunction of column switch Malfunction of front-ECU Malfunction of harness wire or connector MUT- II input signal check...
Page 860 54B-25 SWS ± Troubleshooting Inspection Procedure F-4 Windshield wiper and washer: Windshield intermittent Probable cause wiper interval cannot be adjusted. The ETACS-ECU calculates the intermittent wiper interval, and sends a signal to Malfunction of column switch the front-ECU through the SWS communication line. If the signal is defective, Malfunction of front-ECU the front-ECU will ignore the signal and set the intermittent wiper interval to 4 Malfunction of ETACS-ECU...
Page 861 54B-26 SWS ± Troubleshooting Inspection Procedure G-1 Rear wiper and washer: Rear wiper does not work Probable cause normally. The ETACS-ECU operates the rear wiper according to the input signals from the Malfunction of rear wiper motor following switches: Malfunction of column switch Ignition switch (ACC) Malfunction of front-ECU Rear wiper switch...
Page 862 54B-27 SWS ± Troubleshooting Inspection Procedure G-3 Rear wiper and washer: When the shift lever <M/T> or Probable cause selector lever <A/T> is moved to R position during the rear wiper operation, the rear wiper does not operate at the continuous mode.
Page 863 54B-28 SWS ± Troubleshooting Inspection Procedure H-1 Headlamp washer: Headlamp washer does not work. Probable cause The front-ECU operates the headlamp washers if the headlamp washer switch is Malfunction of headlamp washer motor turned to ON while the headlamp relays (low and high) are ON and the ignition Malfunction of column switch switch is at the ACC or ON position.
Page 864 54B-29 SWS ± Troubleshooting Inspection Procedure I-1 Headlamp, tail lamp: Tail lamp do not illuminate. Probable cause The column switch or the front-ECU may be defective. Malfunction of column switch Malfunction of front-ECU Malfunction of harness wire or connector NOTE If only one lamp does not illuminate, the harness wire between the lamp and front-ECU may be defective or the light bulb may be burned out.
Page 865 54B-30 SWS ± Troubleshooting Inspection Procedure I-3 Headlamp, tail lamp: Headlamps (high-beam) do not Probable cause illuminate. The column switch or the front-ECU is suspected to be defective. Malfunction of column switch Malfunction of front-ECU Malfunction of harness wire or connector NOTE If only one of the headlamps (high-beam) does not illuminate, the harness wire between the headlamp and front-ECU may be defective or the headlamp bulb may be burned out.
Page 866 54B-31 SWS ± Troubleshooting Inspection Procedure I-5 Headlamp, tail lamp: The headlamp auto-cut function does Probable cause not work normally. The ETACS-ECU operates the headlamp auto-cut function, based on the signals Malfunction of driver's door switch from the following switch: Malfunction of column switch.
Page 867 54B-32 SWS ± Troubleshooting Inspection Procedure J-1 Flasher timer: Turn-signal lamp do not flash when the Probable cause turn-signal lamp switch is turned on. The ETACS-ECU makes the turn-signal lamps flash, based on the input signals Malfunction of column switch from the following switched: Malfunction of ETACS-ECU Ignition switch (IG1)
Page 868 54B-33 SWS ± Troubleshooting Inspection Procedure J-2 Flasher timer: Hazard warning lamp do not flash when the Probable cause hazard warning lamp switch is turned on. The ETACS-ECU makes the turn-signal lamps flash, base on the input signals Malfunction of hazard warning lamp switch from the hazard warning lamp switch.
Page 869 54B-34 SWS ± Troubleshooting Inspection Procedure K-1 Front fog lamp: Front fog lamps do not illuminate when the Probable cause front fog lamp switch is turned on. If the tail lamps illuminate normally, the front fog lamp switch, the front fog lamp Malfunction of front fog lamp switch relay, the front-ECU or the ETACS-ECU may be defective.
Page 870 54B-35 SWS ± Troubleshooting Inspection Procedure L-1 Rear fog lamp: Rear fog lamps do not illuminate when the Probable cause rear fog lamp switch is turned on. If the headlamps and front fog lamp <vehicles with front fog lamp> illuminate Malfunction of rear fog lamp switch normally, the rear fog lamp switch, the rear fog lamp relay or the ETACS-ECU Malfunction of rear fog lamp relay...
Page 871 54B-36 SWS ± Troubleshooting Inspection Procedure L-2 Rear fog lamp: Rear fog lamp do not go out when the Probable cause headlamps and front fog lamps <vehicles with front fog lamp> are turned off while the fog lamps are on. If the malfunction above occurs, the ETACS-ECU may be defective.
Page 872 54B-37 SWS ± Troubleshooting Inspection Procedure M-2 Room lamp: The room lamp dimming function does not Probable cause work normally. The ETACS-ECU dims the room lamp according to the input signals from the Malfunction of key reminder switch following switches: Malfunction of driver's door switch Ignition switch (IG1) Malfunction of door switches...
Page 873 54B-38 SWS ± Troubleshooting Inspection Procedure N-2 Ignition switch (IG1) signal is not sent to the ETACS-ECU. Probable cause The ignition switch (IG1) input signal is used to operate the following devices. If Malfunction of ETACS-ECU the signal fails, these devices will not work normally. Malfunction of harness wire or connector Light reminder alarm function Power window timer function <vehicles with power window>...
Page 874 54B-39 SWS ± Troubleshooting Inspection Procedure N-4 Hazard warning lamp switch signal is not sent to the Probable cause ETACS-ECU. The hazard warning lamp switch input signal is used to operate the following Malfunction of hazard warning lamp switch devices. If the signal fails, these devices will not work normally. Malfunction of ETACS-ECU Hazard warning lamp Malfunction of harness wire or connector...
Page 875 54B-40 SWS ± Troubleshooting Inspection Procedure N-6 Rear fog lamp switch signal is not sent to the ETACS-ECU. Probable cause The rear fog lamp switch input signal is used to operate the rear fog lamp. If the Malfunction of fog lamp switch signal fails, rear fog lamp will not work normally.
Page 876 54B-41 SWS ± Troubleshooting Inspection Procedure N-8 Inhibitor switch (reverse) signal is not sent to the Probable cause ETACS-ECU. <A/T> The inhibitor switch (reverse) input signal is used to operate the rear wiper. If Malfunction of inhibitor switch the signal is an error, the rear wiper will not operate consecutively twice when Malfunction of ETACS-ECU the rear wiper is on and the selector lever is moved to R position.
Page 877 54B-42 SWS ± Troubleshooting Inspection Procedure N-10 Probable cause Driver's door switch signal is not sent to the ETACS-ECU. Door switches signal is not sent to the ETACS-ECU. <Driver's door switch> Malfunction of driver's or passenger's door switch The driver's door switch is used to operate the following functions. If the signal Malfunction of back door latch fails, these devices will not work normally.
Page 878 54B-43 SWS ± Troubleshooting Inspection Procedure N-11 Passenger's door lock key cylinder switch signal is not Probable cause sent to the ETACS-ECU. The passenger's door lock key cylinder switch is used to operate the central Malfunction of passenger's door lock key cylinder door locking system.
Page 879 54B-44 SWS ± Troubleshooting Inspection Procedure N-13 Driver's door lock actuator switch signal is not sent to the Probable cause ETACS-ECU. The driver's door lock actuator switch is used to operate the following systems Malfunction of driver's door lock actuator or functions.
Page 880 54B-45 SWS ± Troubleshooting Inspection Procedure N-14 Column switch: Probable cause Tail lamp switch signal is not sent to the ETACS-ECU. Headlamp switch signal is not sent to the ETACS-ECU. Dimmer switch signal is not sent to the ETACS-ECU. Passing switch signal is not sent to the ETACS-ECU. Turn-signal lamp switch signal is not sent to the ETACS-ECU.
Page 881 54B-46 SWS ± Troubleshooting Inspection Procedure N-16 Power window main switch: Any switch signal is not sent Probable cause to the ETACS-ECU. If there is a problem with communication between the power window main Malfunction of power window main switch switch and the ETACS-ECU, the input signal check for the power window main Malfunction of ETACS-ECU switch can no longer be carried out.
Page 882 54B-47 SWS ± Troubleshooting Inspection Procedure N-18 Multi-center display: Any switch signal is not sent to the Probable cause ETACS-ECU. The cause is probably a malfunction of the multi-center display or the Malfunction of multi-center display ETACS-ECU. Malfunction of ETACS-ECU Malfunction of harness wire or connector.
Page 883 NOTES...
Page 884 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B ± Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.
Page 885 55-2 Charging ....... . BLOWER MOTOR ASSEMBLY AND INSIDE/OUTSIDE AIR CHANGEOVER Performance Test .
Page 886: General Information
55-3 ± HEATER, AIR CONDITIONER AND VENTILATION General Information GENERAL INFORMATION The heater system uses a two-way-flow full-air-mix refrigerant system has been adopted as a response system that features high performance and low to restrictions on the use of chlorofluorocarbons. operating noise, and includes an independent face In addition, an air purifier which carries out fine air blowing function.
Page 887: Service Specifications
55-4 ± HEATER, AIR CONDITIONER AND VENTILATION Service Specifications/Lubricants/Special Tools SERVICE SPECIFICATIONS Items Standard value Idle speed r/min 600 ± 50 Idle up speed r/min A/C at low load 700 ± 50 A/C at high load 800 ± 50 Resistor (for blower motor) Ω LO: 2.3, ML:1.0, MH: 0.3 Air gap (Magnetic clutch) 0.25 ±...
Page 888: Troubleshooting
55-5 ± HEATER, AIR CONDITIONER AND VENTILATION Troubleshooting TROUBLESHOOTING TROUBLESHOOTING PROCEDURES Trouble symptom Problem cause Remedy Reference page When the ignition Fuse is defective Replace the fuse ± switch is ªONº switch is ªONº, Harness or connector is defective Repair the harness or connector ±...
Page 889 55-6 ± HEATER, AIR CONDITIONER AND VENTILATION Troubleshooting Trouble symptom Problem cause Remedy Reference page Blower fan and Harness or connector is defective Repair the harness or connector ± motor do not stop motor do not stop turning Blower switch is defective Replace the blower switch as- 55-21 sembly...
Page 890 55-7 ± HEATER, AIR CONDITIONER AND VENTILATION Troubleshooting INSPECTION AT THE ENGINE-ECU TERMINAL Terminal Check item Checking requirements Normal condition Fan controller output A/C switch: OFF A/C switch: ON A/C compressor output A/C compressor relay: OFF A/C compressor relay: ON System voltage A/C switch input A/C switch: OFF...
Page 891: On-Vehicle Service
55-8 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service ON-VEHICLE SERVICE Low-pressure High-pressure valve valve REFRIGERANT LEVEL TEST THROUGH PERFORMANCE TEST 1. Park the vehicle to be tested in a place that is not in direct sunlight. 2. Set conditions for outside air temperature as follows: Dry-bulb temperature: 22 or more Charging...
Page 892: Magnetic Clutch Test
55-9 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service MAGNETIC CLUTCH TEST 1. Disconnect the connector (1-pin) to the magnetic clutch. 2. Connect battery (+) voltage directly to the connector for the magnetic clutch. 3. If the magnetic clutch is normal, there will be ªclickº. If the pulley and armature do not make contact (`click'), there is a malfunction.
Page 893 55-10 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service CHARGING 1. With the handles turned back all the way (valve closed), install the adaptor valve to the low-pressure side of the High-pressure Low-pressure gauge manifold. valve valve 2. Connect the charging hose (blue) to the adaptor valve. 3.
Page 894: Charging
55-11 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service 12. Turn the vacuum pump adaptor switch to the R-134a side to start the vacuum pump. Caution Do not operate the compressor for evacuation. 13. Evacuate to a vacuum reading of 100 kPa or higher (takes approx.
Page 895 55-12 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service 24. Fix the engine speed at 1,500 r/min. 25. Tighten the handle of the adaptor valve (valve open) to charge the required volume of refrigerant. Caution If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression.
Page 896 55-13 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service 8. Start the engine. 9. Operate the air conditioner and set at the lowest Charging valve temperature (MAX. COOL). 10. Fix the engine speed at 1,500 r/min. 11. Tighten the handle of the adaptor valve (valve open), and replenish refrigerant while checking the quantity through the sight glass.
Page 897: Performance Test
55-14 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service REFILLING OF OIL IN THE A/C SYSTEM Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too much oil will increase discharge air temperature. When a compressor is installed at the factory, it contains 120 m of refrigerant oil.
Page 898 55-15 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service 7. Set the controls to the A/C as follows: A/C switch: A/C ± ON position Mode selection: Face position Temperature control: Max. cooling position Air selection: Recirculation position Blower switch: HI (Fast) position 8.
Page 899: Refrigerant Leak Repair
55-16 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service REFRIGERANT LEAK REPAIR HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in LOST CHARGE the refrigerant hose lines will greatly reduce the If the system has lost all charge due to a leak: capacity of the entire system.
Page 900: Power Relay Check
55-17 ± ± HEATER, AIR CONDITIONER AND VENTILATION HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service On-vehicle Service POWER RELAY CHECK BLOWER RELAY Battery voltage Terminal No. Power is not supplied Power is supplied Blower relay A/C COMPRESSOR RELAY A/C compressor relay Battery voltage Terminal No.
Page 901: Idle-Up Operation Check
55-18 ± HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service IDLE-UP OPERATION CHECK 1. Before inspection and adjustment, set vehicle in the following condition: Engine coolant temperature: 80 ± 90 _ C Lights, electric cooling fan and accessories: Set to Transmission: Neutral (N or P for vehicles with A/T) Steering wheel: Straightforward 2.
Page 902: Heater Control Assembly And A/Cswitch
Heater Control Assembly and 55-19 ± HEATER, AIR CONDITIONER AND VENTILATION A/C switch HEATER CONTROL ASSEMBLY AND A/C SWITCH REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Center Air Outlet Assembly, Instrument Under Cover Radio, Tape Player Removal and Installation (Refer Removal and Installation (Refer to GROUP 52A ±...
Page 903 Heater Control Assembly and 55-20 ± HEATER, AIR CONDITIONER AND VENTILATION A/C switch INSPECTION BLOWER SWITCH CONTINUITY CHECK Switch position Terminal No. (LO) (ML) (MH) (HI) INSIDE/OUTSIDE AIR CHANGEOVER SWITCH CONTINUITY CHECK Inside/outside air- changeover switch Switch Terminal No. position RECIRC FRESH A/C SWITCH CONTINUITY CHECK...
Page 904 Heater Control Assembly and 55-21 ± HEATER, AIR CONDITIONER AND VENTILATION A/C switch DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Knob assembly 4. Air mix damper cable 2. Bulb harness 5. Heater control panel 3. Air outlet changeover damper cable 6. Blower switch assembly DISASSEMBLY SERVICE POINT AIR OUTLET CHANGEOVER DAMPER CABLE/AIR MIX DAMPER CABLE REMOVAL...
Page 905: Heater Unit, Blower Unit, Resister And Evaporator
Heater Unit, Blower Unit, 55-22 ± HEATER, AIR CONDITIONER AND VENTILATION Resister and Evaporator HEATER UNIT, BLOWER UNIT, RESISTER AND EVAPORATOR REMOVAL AND INSTALLATION Caution: SRS When removing and installing the floor console assembly from vehicles equipped with SRS, do not let it bump against the SRS-ECU or the components.
Page 906 Heater Unit, Blower Unit, 55-23 ± HEATER, AIR CONDITIONER AND VENTILATION Resister and Evaporator 10. Blower unit Glove Box (Refer to GROUP 52A 14. Foot duct ± Instrument Panel.) 19. Heater unit assembly 11. Joint duct 12. Resistor Evaporator and Resister removal 13.
Page 907 Heater Unit, Blower Unit, 55-24 ± HEATER, AIR CONDITIONER AND VENTILATION Resister and Evaporator INSPECTION RESISTOR CHECK Use a circuit tester to measure the resistance between the terminals as indicated below. Check that the measured value is at the standard value. Standard value: Standard value Ω...
Page 908: Blower Motor Assembly And Inside/Outside Air Changeover Damper Motor
HEATER, AIR CONDITIONER Blower Motor Assembly and Inside/Outside 55-25 ± AND VENTILATION Air Changeover Damper Motor BLOWER MOTOR ASSEMBLY AND INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR REMOVAL AND INSTALLATION Blower motor assembly removal Inside/outside air changeover steps damper motor removal steps 1.
Page 909: Compressor And Tension Pulley
HEATER, AIR CONDITIONER Heater Unit, Blower Unit, Resister and ± 55-26 AND VENTILATION Evaporator/Compressor and Tension Pulley INSIDE/OUTSIDE CHANGEOVER DAMPER MOTOR CHECK Battery connection terminal Lever operation Moves to the inside air position Moves to the outside air Inside/outside air change- position over damper motor Caution...
Page 910 55-27 ± HEATER, AIR CONDITIONER AND VENTILATION Compressor and Tension Pulley REMOVAL SERVICE POINTS SUCTION HOSE, DISCHARGE HOSE DISCONNECTION Plug the nipples of the disconnected hose and compressor to prevent from foreign materials from entering. Caution Plug the nipples with material that is not permeable to air as compressor oil and receiver absorb water vapour easily.
Page 911 55-28 ± HEATER, AIR CONDITIONER AND VENTILATION Compressor and Tension Pulley INSPECTION COMPRESSOR MAGNETIC CLUTCH OPERATION INSPECTION Connect the battery (+) terminal to the compressor side terminal, and earth the battery (±) terminal to the body of the compressor. The condition is normal if the sound of the magnetic clutch (click) can be heard.
Page 912 55-29 ± HEATER, AIR CONDITIONER AND VENTILATION Compressor and Tension Pulley REASSEMBLY SERVICE POINTS A A SNAP RING INSTALLATION Rotor Field core Snap ring Install the snap ring so that the tapered surface is at the outer side. Tapered part AV1079AE B A AIR GAP ADJUSTMENT Check whether or not the air gap of the clutch is within the...
Page 913: Condenser And Condenser Fan Motor
Condenser and Condenser 55-30 ± HEATER, AIR CONDITIONER AND VENTILATION Fan Motor CONDENSER AND CONDENSER FAN MOTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Piping connection 12 Nm ring Compressor oil: ZXL 200PG 12 Nm 12 Nm Condenser assembly removal steps 11.
Page 914 Condenser and Condenser 55-31 ± HEATER, AIR CONDITIONER AND VENTILATION Fan Motor REMOVAL SERVICE POINTS DISCHARGE HOSE DISCONNECTION Plug the nipples of the disconnected pipe, hose and condenser assembly to prevent foreign materials from entering. Caution Plug the nipples with material that is not permeable to air as compressor oil and the receiver absorb water vapour easily.
Page 915: Refrigerant Line
55-32 ± HEATER, AIR CONDITIONER AND VENTILATION Refrigerant Line REFRIGERANT LINE REMOVAL AND INSTALLATION <L.H. DRIVE VEHICLES> Pre-removal and Post-installation Operation Discharging and Charging of Refrigerant (Refer to P.55-10.) Engine Cover Removal and Installation (Refer to GROUP 11 ± Engine Assembly.) Air Cleaner Assembly Removal and Installation.
Page 916 55-33 ± HEATER, AIR CONDITIONER AND VENTILATION Refrigerant Line <R.H. DRIVE VEHICLES> Piping connection ring Compressor oil: ZXL 200PG Removal steps 1. Pipe assembly 4. Liquid pipe 2. Suction hose 5. Dual pressure switch 3. Discharge hose REMOVAL SERVICE POINT HOSE/PIPE DISCONNECTION Plug the nipples of the disconnected hose, receiver, evaporator and compressor to prevent foreign materials from entering.
Page 917 55-34 ± HEATER, AIR CONDITIONER AND VENTILATION Ventilators VENTILATORS Caution: SRS When removing and installing the floor console assembly from vehicles equipped with SRS, do not let it bump against the SRS-ECU or the components. Rear heater duct B removal steps Foot distribution duct and rear heater duct A removal steps Front scuff plate, cowl side trim and...
Page 918 55-35 ± HEATER, AIR CONDITIONER AND VENTILATION Ventilators 7. Rear ventilation garnish NOTE 8. Rear ventilation duct A For the front deck garnish, refer to GROUP 51 ± Windshield Wiper and Washer. Rear vent duct removal steps Rear bumper (Refer to GROUP 51.) 9.
Page 919 NOTES...

Mitsubishi Pajero Pinin 1999 Workshop Manual

General

Engine

Engine Lubrication

Gasoline Direct Injection (Gdi)

Engine Cooling

Engine Electrical

Engine and Emission Control

Clutch

Manual Transmission

Automatic Transmission

Front Axle

Rear Axle

Wheel and Tyre

Steering

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Summary of Contents for Mitsubishi Pajero Pinin 1999