Airtrek Workshop Manual

GROUP INDEX
OUTLANDER
WORKSHOP MANUAL
FOREWORD
General . . . . . . . . . . . . . . . . . . . . . . .
00
Engine . . . . . . . . . . . . . . . . . . . . . . . .
11
Engine Lubrication . . . . . . . . . . . . . .
12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Engine Cooling . . . . . . . . . . . . . . . . .
14
Intake and Exhaust . . . . . . . . . . . . . .
15
This Workshop manual contains procedures for service mechanics, including removal, disassembly, in- Engine Electrical. . . . . . . . . . . . . . . .
spection, adjustment, reassembly and installation.
Use the following manuals in combination with this Engine and Emission Control . . . . .
manual as required.
16
17
Clutch. . . . . . . . . . . . . . . . . . . . . . . . .
21
Manual Transmission . . . . . . . . . . . .
22
Propeller Shaft . . . . . . . . . . . . . . . . .
25
Front Axle . . . . . . . . . . . . . . . . . . . . .
26
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
27
Wheel and Tyre . . . . . . . . . . . . . . . . .
31
Power Plant Mount . . . . . . . . . . . . . .
32
All information, illustrations and product descriptions Front Suspension . . . . . . . . . . . . . . .

contained in this manual are current as at the time of
publication. We, however, reserve the right to make Rear Suspension . . . . . . . . . . . . . . .
changes at any time without prior notice or obligation.
33
Service Brakes . . . . . . . . . . . . . . . . .
35
Parking Brakes . . . . . . . . . . . . . . . . .
36
Steering . . . . . . . . . . . . . . . . . . . . . . .
37
Body. . . . . . . . . . . . . . . . . . . . . . . . . .
42
Exterior . . . . . . . . . . . . . . . . . . . . . . .
Interior and Supplemental
..........
Restraint System (SRS)
Chassis Electrical . . . . . . . . . . . . . . .
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . .
51
TECHNICAL INFORMATION MANUAL

INZE03E1
WORKSHOP MANUAL
BODY REPAIR MANUAL
BNZE03E1
PARTS CATALOGUE
B606R503A_
Mitsubishi Motors Europe B.V.
May 2003
34
52
54
55
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL

RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
(1)
Improper service or maintenance of any component of the SRS or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative).
(2) The SRS components and seat belt with pretensioner should not be subjected to heat, so
remove the SRS-ECU, drivers and front passengers air bag modules, clock spring, side air bag
modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.
SRS-ECU, air bag module and clock spring 93C or more
Seat belt with pre-tensioner: 90C or more
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this Manual, and especially its GROUP
52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of
any component of the SRS or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
11B-1
GROUP 11B
00
11
ENGINE OVERHAUL
12
13
14
CONTENTS
HOW TO USE THIS MANUAL. . . . . .
11B
GENERAL INFORMATION . . . . . . . .
11B
GENERAL SPECIFICATIONS . . . . . .
11B
SERVICE SPECIFICATIONS. . . . . . .
11B
EXHAUST MANIFOLD REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . .
15
11B
WATER PUMP AND WATER HOSE . 11B

WATER PUMP AND WATER HOSE
REMOVAL AND INSTALLATION . . . . . . . .
16
17
21
11B
ROCKER ARMS AND CAMSHAFT . . 11B
22
25
11B
ROCKER ARMS AND CAMSHAFT

11B
26
TORQUE SPECIFICATIONS . . . . . . .
11B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11B
27
SEALANTS . . . . . . . . . . . . . . . . . . . .
11B
CYLINDER HEAD AND VALVES. . . . 11B
31
SPECIAL TOOLS. . . . . . . . . . . . . . . .
11B
REWORK DIMENSIONS . . . . . . . . . .
ALTERNATOR AND IGNITION

SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR AND IGNITION SYSTEM
TIMING BELT. . . . . . . . . . . . . . . . . . .
11B
11B
TIMING BELT INSPECTION. . . . . . . . . . . .
11B
FUEL AND EMISSION PARTS . . . . . 11B
INTAKE MANIFOLD REMOVAL AND

INSTALLATION. . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD. . . . . . . . . . . .
32
CYLINDER HEAD AND VALVES

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11B
33
OIL PAN AND OIL PUMP. . . . . . . . . . 11B
11B
INTAKE MANIFOLD . . . . . . . . . . . . .
11B
11B
TIMING BELT REMOVAL AND

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

AND INSTALLATION . . . . . . . . . . . . . . . . .

35
OIL PAN AND OIL PUMP REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . .
11B
OIL PAN AND OIL PUMP INSPECTION. . .
11B
36
PISTON AND CONNECTING ROD . . 11B
37
PISTON AND CONNECTING ROD

11B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11B
42
51
52
11B
11B
34
CRANKSHAFT AND CYLINDER BLOCK

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B
11B

11B
11B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11B
54
55
ENGINE OVERHAUL
11B-2
HOW TO USE THIS MANUAL

M1113025100155

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

Key service points, service standards, and instructions for
using special tools are collated as service points and explained in detail.
<<A>>: Outward-pointing brackets denote removal service points

or disassembly service points.
>>A<<: Inward-pointing brackets denote installation service points
or reassembly service points.
Lubricant and Sealant Symbols

Every location where a lubricant or sealant must be applied
or added is indicated using a relevant symbol in the component part drawing and/or on the page after the component
part drawing.
. . . . . . . . . . Grease
. . . . . . . . . . Sealant or form-in-place gasket (FIPG)
. . . . . . . . . . Brake fluid
. . . . . . . . . . Engine oil or gear oil
Inspection
Only those inspection procedures which use special tools or measuring appliances are described. You must perform general visual inspection and part cleaning whenever necessary although their procedures are not described in this manual.
AK202851
ENGINE OVERHAUL
11B-3
Page number
Section title
ENGINE OVERHAUL
11-54

REMOVAL AND INSTALLATION
3
Apply engine oil
to all moving
parts before
installtion.
Denotes non-reusable part.

1
11 1 Nm
16
11 1 Nm
15
132 5 Nm
9.0 1.0 Nm
Tightening torque
14
13
12
11
10
25 2 Nm + 90 to 100
AK204351AB
Removal steps
1. Drive plate bolt
2. Adapter plate
3. Drive plate
4. Crankshaft bushing
5. Rear plate
6. Bellhousing cover
>>E<< 7. Oil seal case
>>D<< 8. Oil seal
>>C<< 9. Bearing cap bolt
10. Bearing cap
>>B<< 11. Crankshaft bearing, lower
>>A<< 12. Crankshaft
INSTALLATION SERVICE POINTS

>>A<< THRUST BEARING INSTALLATION
Grooves
AK100786AB
The alphabetical character in this category of

heading matches that of the relevant removal
steps, installation steps, disassembly steps, or
reassembly steps.
Procedures and cautions for removal, installation, disassembly, and reassembly are explained under this category of heading.
AK300250
ENGINE OVERHAUL
11B-4
GENERAL INFORMATION
GENERAL INFORMATION
M1113000100233
VEHICLE AND ENGINE MODELS

Vehicle name
Vehicle
model
Engine model
Displacement Specification
mL
Outlander
CU2W
4G63-7
1,997
Double overhead camshaft, 16-valve
GENERAL SPECIFICATIONS
M1113000200478
Items
Specification
Bore stroke mm
85 88
Displacement mL
1,997
Combustion chamber
Pentroof type
Number of cylinders
Valve mechanism
Type
Double overhead camshaft
Number of intake valves
Number of exhaust
valves
Lash adjusters
Hydraulic
Rocker arms
Roller cam followers
Compresssion ratio
10.0
Fuel injection system
Electronically controlled multi-point injection (MPI)

system
Ignition system
Electronically controlled two-coil system
Generator
Alternator (with built-in IC regulator)
Starter motor
Gear reduction drive type
SERVICE SPECIFICATIONS
M1113000300419
Items
Standard value
Limit
Auto-tensioner rod extension length

(with timing belt installed) mm
3.8 - 4.5
Auto-tensioner rod extension length (when free) mm
12.0
Auto-tensioner rod retraction length

(when pressed with force of 98 to 196 N) mm
Less than 1
34.91
34.41
Less than 0.05
0.2
TIMING BELT
ROCKER ARMS AND CAMSHAFTS

Cam height mm
Cylinder head gasket surface warp mm
ENGINE OVERHAUL
11B-5
Items
Standard value
Limit
Cylinder head gasket surface grinding limit

(including cylinder block grinding amount) mm
0.2
Cylinder head overall height mm
131.9 - 132.1
Cylinder head bolt nominal length mm
99.4
Valve margin mm
Intake valves
1.0
0.5
Exhaust valves
1.5
1.0
Valve stem diameter mm
6.6
Valve face angle
45.5
Intake valves
0.02 - 0.05
0.10
Exhaust valves
0.05 - 0.09
0.15
Intake valves
109.5
109.0
Exhaust valves
109.7
109.2
Intake valves
49.2
49.7
Exhaust valves
48.4
48.9
Valve spring free height mm
48.3
47.3
Valve spring load/height N/mm
294/40
Valve spring squareness
1.5or less
Valve face-to-seat contact width mm
0.9 - 1.3
Valve guide inside diameter mm
6.6
Valve guide press-in height mm
19.2 - 19.8
Drive gear
0.08 - 0.14
Driven gear
0.06 - 0.12
85.0
Valve stem-to-guide clearance mm

Valve height mm
Valve stem projection mm
OIL PAN AND OIL PUMP

Oil pump gear side clearance mm
PISTONS AND CONNECTING RODS

Piston outside diameter mm
Piston ring side clearance in ring
groove mm
No. 1
0.02 - 0.06
0.1
No. 2
0.02 - 0.06
0.1
Piston ring end gap mm
No. 1
0.20 - 0.30
0.8
No. 2
0.30 - 0.45
0.8
Oil ring
0.10 - 0.40
1.0
Piston pin outside diameter mm
22.0
Piston pin press-in load (at ambient temperature) N
7,350 - 17,100
Oil clearance at crankshaft pins mm
0.03 - 0.05
0.1
Connecting rod big end thrust clearance mm
0.10 - 0.25
0.4
Crankshaft end play mm
0.05 - 0.25
0.4
Crankshaft journal diameter mm
57.0
Crankshaft pin diameter mm
45.0
Oil clearance at crankshaft journals mm
0.03 - 0.04
0.1
Cylinder block gasket surface warp mm
0.05
0.1
ENGINE OVERHAUL
11B-6
REWOK DIMENSIONS
Items
Standard value
Limit
Cylinder block gasket surface grinding limit

(including cylinder head grinding amount) mm
0.2
Cylinder block overall height mm
284
Cylinder bore diameter mm
85
Taper of cylinder mm
0.01 or less
Cylinder-to-piston clearance mm
0.02 - 0.04
Crankshaft bearing cap bolt nominal length mm
71.1
REWOK DIMENSIONS
M1113024300178
Items
Standard value

Diameter of oversize valve seat ring hole in cylinder head
mm
Intake
Exhaust
Diameter of oversize valve guide hole in cylinder head mm
0.03 oversize
35.30 - 35.33
0.06 oversize
35.60 - 35.63
0.03 oversize
33.30 - 33.33
0.06 oversize
33.60 - 33.63
0.05 oversize
12.05 - 12.07
0.25 oversize
12.25 - 12.27
0.50 oversize
12.50 - 12.52
TORQUE SPECIFICATIONS
M1113023400503
Items
Tightening torque Nm
ALTERNATOR AND IGNITION COIL

Oil level gauge guide bolts
13 1
Idler pulley bolt
79 5
Auto-tensioner assembly bolts (M8)
22 4
Auto-tensioner assembly bolts (M10)
44 10
Water pump pulley bolt
8.8 1.0
Alternator brace bolt (flange bolt)
23 3
Alternator brace bolt (washer assembled bolt)
22 4
Alternator nuts
44 10
Crankshaft pulley bolt
25 4
Center cover bolts
3.0 0.5
Ignition coil bolts
10 2
Spark plugs
25 5
TIMING BELT
Timing belt cover bolts (flange bolts)
11 1
Timing belt cover bolts (washer-assembled bolts)
9.0 1.0
ENGINE OVERHAUL
11B-7
Items
Power steering pump bracket bolts
49 9
Tensioner pulley bolt
48 5
Tensioner arm bolt
21 4
Auto-tensioner bolts
23 3
Idler pulley bolt
35 6
Crank angle sensor bolts
8.8 1.0
Oil pump sprocket nut
54 4
Crankshaft bolt
167
Tensioner B bolt
19 3
Counterbalance shaft sprocket bolt
45 3
Rocker cover bolts
3.5 0.5
Engine support bracket bolts
49 5
Camshaft sprocket bolt
88 10
FUEL SYSTEM
Vacuum hose and pipe clamp bolt
11 1
Throttle body bolts
19 3
EGR valve bolts
20 2
Fuel pressure regulator bolts
9.0 2.0
Delivery pipe and injector assembly bolts
11 1
Solenoid valve assembly bolts
9.0 1.0
INTAKE MANIFOLD
Intake manifold stay bolts
31 3
Intake manifold bolts (M8)
20 2
Intake manifold bolts and nuts (M10)
36 6
Engine hanger bolt
19 3
EXHAUST MANIFOLD
Oxygen sensor
44 5
Exhaust manifold cover bolts
14 1
Exhaust manifold bracket bolt (Cylinder block side)
35 6
Exhaust manifold bracket bolt (Exhaust manifold side)
44 5
Exhaust manifold nuts (M8)
29 3
Exhaust manifold nuts (M10)
49 5

Coolant temperature sensor
29 10
Coolant temperature gauge unit
10.8 1.0
Water inlet fitting bolts
13 2
Water outlet fitting bolts
13 2
Thermostat housing bolts
23 4
Water inlet pipe bolts
13 2
Water pump bolts
14 1
11B-8
ENGINE OVERHAUL
Items
Knock sensor
23 2
ROCKER ARMS AND CAMSHAFTS

Camshaft position sensor bolts
8.8 1.0
Cover bolts
10 2
Camshaft position sensing cylinder bolt
22 4
Camshaft position sensor support bolts
14 1
Bearing cap bolts
20 1
Oil delivery body bolts
11 1

Cylinder head bolts
78 2 loosen completely 20 2
90 + 90
OIL PUMP CASE AND OIL PAN

Drain plug
39 5
Transmission stay bolts
22 4
Oil pan upper section bolts
9.0 3.0
Oil pan lower section bolts
9.0 3.0
Oil screen bolts
19 3
Oil pressure switch
19 3
Relief plug
44 5
Oil filter bracket bolts
19 3
Plug cap
23 3
Flange bolts
36 3
Oil pump case bolts
23 3
Oil pump cover bolts
17 1
Oil pump cover screws
10 2
PISTONS AND CONNECTING RODS

Connecting rod cap nuts
20 2 90 to 94

Flywheel bolts
132 5
Rear plate bolts
11 1
Bell housing cover bolts
9.0 1.0
Rear oil seal case bolts
11 1
Beam bearing cap bolts
25 2 90 to 100
ENGINE OVERHAUL
11B-9
SEALANTS
SEALANTS
M1113000500402
Items
Specified sealants
Engine support bracket bolts
Mitsubishi Genuine Part No.MD970389

or equivalent
Semicircular packing
3M ATD No.8660 or equivalent
Rocker cover
Mitsubishi Genuine Part No. MD970389

or equivalent
Engine coolant temperature sensor
3M Nut Locking Part No.4171 or

equivalent
Engine coolant temperature e gauge unit
Water outlet fitting*

Thermostat housing*

or equivalent
Cylinder head (camshaft bearing cap fitting section)
Camshaft position sensor support*

or equivalent
Oil pressure switch
Oil pan*

or equivalent
Rear oil seal case*

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

Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper or
wire brush. Make sure that the FIPG application surface is flat and smooth. Also make sure that the surface is free from oils, greases and foreign
substances. Do not fail to remove old FIPG that may
remain in the fastener fitting holes.
APPLICATION OF FIPG
Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet (in less
than 15 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during installation. Avoid operating the engine or letting oils or
water come in contact with the sealed area before a
time sufficient for FIPG to harden (approximately one
hour) has passed. FIPG application method may
vary from location to location. Follow the instruction
for each particular case described later in this manual.
ENGINE OVERHAUL
11B-10
SPECIAL TOOLS
SPECIAL TOOLS
M1113000600465
Tool
Number
Name
Use
MD998781
Flywheel stopper
Retention of flywheel
MD998778
Crankshaft sprocket
puller
Removal of crankshaft sprocket

and crankshaft sprocket B
MD998785
Sprocket stopper
Retention of counterbalancer
shaft sprocket
MD998767
Tension pulley socket Manipulation of tensioner pulley

wrench
during adjustment of timing belt
tension
MD998738
Set screw
Retention of tentioner arm and

auto-tensioner during timing belt
installation
MD998713
Camshaft oil seal

installer
Installation of camshaft oil seal
MD998442
Air bleed wire
Air bleeding of lash adjuster
D998781
D998767
D998738
D998713
ENGINE OVERHAUL
11B-11
SPECIAL TOOLS
Tool
Number
Name
Use
MB991654
Cylinder head bolt

wrench
Removal and installation of

cylinder head bolts
MD998772
Valve spring
compressor
Compression of valve spring
MD998735
Valve spring
compressor
Compression of valve spring
MD998737
Valve stem seal

installer
Installation of valve stem seal
MD998162
Plug wrench
Removal and installation of front

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

case plug cap
MD998371
Silent shaft bearing

puller
Removal of counterbalancer shaft

front bearing
MD998372

puller
Removal of counterbalancer shaft

front and rear bearings
B991654
ENGINE OVERHAUL
11B-12
SPECIAL TOOLS
Tool
Number
Name
Use
MB991603

installer stopper
Guide and stopper for removal

and press-fitting of
counterbalancer shaft rear
bearing
MD998705

installer
Press-fitting of counterbalancer
shaft front and rear bearings
MD998375
Crankshaft front oil

seal installer
Installation of crankshaft front oil

seal
MD998285
Crankshaft front oil

seal guide
Guide for installation of

crankshaft front oil seal
MD998780
Piston pin setting tool Removal and press-fitting of

piston pin
MD998776
Crankshaft rear oil

seal installer
Installation of crankshaft rear oil

seal
MB990938
Handle
Installation of crankshaft rear oil

seal
D998285
D998776
B990938
ENGINE OVERHAUL
11B-13

M1113001000392
12
3.0 0.5 Nm
N2
10 2 Nm
13
14
15
13 1 Nm
25 5 Nm
3
10
44 10 Nm
N4
9
22 4 Nm
8
7
44 10 Nm
23 3 Nm
8.8 1.0 Nm
25 4 Nm
11
79 5 Nm
6N
22 4 Nm
1.
2.
3.
4.
5.
6.
7.
8.
Removal steps
Oil level gauge
O-ring
Oil level gauge guide
O-ring
Idler pulley
Cap
Auto-tensioner assembly
Water pump pulley
AK204441AB
Removal steps&RQWLQXHG

9. Alternator brace
10. Alternator
11. Crankshaft pulley
12. Center cover
13. Spark plug cable
14. Ignition coil
15. Spark plug
ENGINE OVERHAUL
11B-14
TIMING BELT
TIMING BELT
M1113001900500
21
11 1 Nm
3.5 0.5 Nm
24
25
22
28
20
48 5 Nm
N 23
21 4 Nm
12
11 1 Nm
26 N
7
23 3 Nm
27 N
32
11 1 Nm
11 1 Nm
11
167 Nm
33
29
49 5 Nm
9.0 1.0 Nm
31
45 3 Nm
16 17
19 3 Nm
14
30
34
19
88 10 Nm
18
13
8
8.8 1.0 Nm
49 9 Nm
15
10
35 6 Nm
AK204445 AB
54 5 Nm
<<A>>
<>
<<C>>
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Power steering pump bracket
>>M<< 4. Timing belt
>>L<< 5. Tensioner pulley
6. Tensioner arm
>>K<< 7. Auto-tensioner
8. Idler pulley
9. Crank angle sensor
>>J<< 10. Oil pump sprocket
>>I<< 11. Crankshaft bolt

12. Crankshaft sprocket
13. Crankshaft sensing blade
14. Tensioner B
<<E>> >>H<< 15. Timing belt B
<<F>> >>G<< 16. Counterbalancer shaft sprocket
>>F<< 17. Spacer
<<G>> >>E<< 18. Crankshaft sprocket B
19. Crankshaft key
20. Breather hose
21. Positive crankcase ventilation (PCV)
hose
<<D>> >>I<<
>>I<<
ENGINE OVERHAUL
TIMING BELT
>>D<<
>>D<<
>>C<<
>>B<<
<<H>> >>A<<

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

<<A>> TIMING BELT REMOVAL
11B-15
CAUTION
Never remove the timing belt with any piston at
the top dead center (TDC). If a piston is at TDC,
the exhaust valves of the cylinder are pushed by
the exhaust cams, compressing the valve
springs. If the belt is removed under this condition, the sprocket will be turned in the reverse
direction by the force of the springs, incurring
risk of injury.
2. Set the timing mark of the exhaust camshaft
sprocket to a point about one tooth before the
TDC of the No.1 cylinder piston on compression
stroke.
3. Loosen the lock nut of the tensioner pulley, then
remove the timing belt.
<> OIL PUMP SPROCKET REMOVAL
Crosspoint
screwdriver
AK202756AB
1. If the timing belt is to be reused, make an arrow

mark with something like chalk on the back of the
belt indicating the direction of rotation so it may be
reinstalled in the same direction.
Timing mark
AK202825 AB
1. Remove the plug on the left side of cylinder block.

2. Insert a crosspoint screwdriver (shank diameter 8
mm) to prevent the counterbalancer shaft from
rotating.
3. Remove the flange bolt.
4. Remove the oil pump sprocket.
<<C>> CRANKSHAFT BOLT REMOVAL
AK202757 AB
MD998781
AK202738 AB
1. Hold the drive plate with the special tool Fly wheel
stopper(MD998781).
2. Remove the crankshaft bolt.
ENGINE OVERHAUL
11B-16
TIMING BELT
<<D>> CRANKSHAFT SPROCKET REMOVAL
1. Use the special tool Sprocket stopper

(MD998785) to prevent the counterbalancer shaft
sprocket from rotating.
2. Remove the counterbalancer shaft mounting bolt.
MD998778
<<G>> CRANKSHAFT SPROCKET B REMOVAL
MD998778
AK202741 AB
Use the special tool Crankshaft sprocket puller

(MD998778) if the sprocket is stuck and hard to
remove.
AK202740AB
<<E>> TIMING BELT B REMOVAL
Use the special tool Crankshaft sprocket puller

(MD998778) if the sprocket is stuck and hard to
remove.
<<H>> CAMSHAFT SPROCKET BOLT REMOVAL
AK202758AB
If the timing belt is to be reused, make an arrow mark

with something like chalk on the back of the timing
belt indicating the direction of rotation so it may be
reinstalled in the same direction.
AK202858AB
<<F>> COUNTERBALANCER SHAFT SPROCKET

REMOVAL
MD998785
AK202739AB
Remove the camshaft sprocket bolt while preventing

the camshaft from rotation using a wrench fitted on
the hexagonal portion of the camshaft.
ENGINE OVERHAUL
11B-17
TIMING BELT

>>A<< CAMSHAFT SPROCKET BOLT INSTALLATION
>>C<< SEMICIRCULAR PACKING INSTALLATION

1. Remove thoroughly the old sealant and FIPG
remaining on the semicircular packing, cylinder
head, and rocker cover.
AK202858AB
AK202860AB
2. Apply sealant to the surface indicated in the

drawing of the semicircular packing.
Specified sealant:
3. Install the semicircular packing on the cylinder
head.
10 mm
AK202859
Tighten the camshaft sprocket bolt to 88 10 Nm

while preventing the camshaft from rotation using a
wrench fitted on the hexagonal portion of the camshaft.
>>B<< ENGINE SUPPORT BRACKET
INSTALLATION
10 mm
Semicircular
packing
Cylinder head
AK202861 AB
4. Apply sealant to the area indicated in the drawing

of the semicircular packing and cylinder head.
Specified sealant:
>>D<< ROCKER COVER/ROCKER COVER
GASKET A INSTALLATION
Timing belt side
AK202743AB
1. Remove thoroughly the old sealant remaining on

the indicated bolt and in its hole.
2. Coat the bolt with sealant, then install and tighten
it.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
AK202862 AB
1. Apply beads of FIPG on the surfaces of the rocker

cover indicated in the drawing.
ENGINE OVERHAUL
11B-18
TIMING BELT
Specified sealant:
equivalent
2. Install the rocker cover gasket A on the rocker
cover before the FIPG hardens.
>>F<< SPACER INSTALLATION

Spacer
Oil
seal
Timing belt side
Chamfer
Counterbalancer
shaft
AK202820 AB
CAUTION
AK202863 AB
3. Apply beads of FIPG to the surfaces of the rocker

cover indicated in the drawing.
Specified sealant:
equivalent
4. Install the rocker cover on the cylinder head
before the FIPG hardens.
If the spacer is opposite in direction to that

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

INSTALLATION
MD998785
Sprocket "B"
Crankshaft
AK202739AB
Degrease
Front case
AK101651AC
Clean and then degrease the crankshaft sprocket B

and the sprocket fitting surface of the crankshaft.
NOTE: Degreasing is necessary to prevent lack of
frictional coefficient between the mating surfaces.
1. Use the special tool Sprocket stopper

(MD998785) as shown in the drawing to prevent
the counterbalancer shaft sprocket from rotating.
2. Tighten the sprocket mounting bolt to 45 3 Nm.
ENGINE OVERHAUL
11B-19
TIMING BELT
>>H<< TIMING BELT B INSTALLATION
Timing
marks
5. Make sure that the timing marks on the oil pump

case and those of the sprockets are all aligned
with each other.
5 7 mm
Timing
marks
AK202920 AB
1. Align the timing marks on the crankshaft sprocket

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

Timing
belt B
AK202919 AB
6. Push a central point of the timing belt B tension

section lightly with an index to see if it deflects 5 7 mm.
>>I<< CRANKSHAFT BOLT/CRANKSHAFT
SPROCKET/CRANKSHAFT SENSING BLADE
INSTALLATION
Crankshaft sensing blade
Crankshaft bolt
Crankshaft
Clean
Tensioner B
center
Mounting bolt center
AK202921 AB
3. Make sure that the tensioner B center is

positioned as shown in the drawing relative to the
mounting bolt center.
Washer
Chamfer
Degrease
Crankshaft sprocket
AK202838 AB
1. Clean and then degrease the crankshaft sprocket,

sprocket fitting surface of the crankshaft, and
crankshaft sensing blade. Install the crankshaft
sprocket and crankshaft sensing blade on the
crankshaft.
2. Clean the bolt hole in the crankshaft, and then
washer.
3. Apply a necessary minimum amount of oil to the
threads and seating surface of the crankshaft bolt.
AK202922AB
4. Lift the tensioner B with fingers to move it in the

direction of the arrow until the tension section of
the timing belt becomes taut. While keeping the
tensioner B in this position, tighten its bolt.
NOTE: When the bolt is tightened, prevent the
tensioner B shaft from turning. If the shaft turns,
the belt will be overtightened.
MD998781
AK202738 AB
ENGINE OVERHAUL
11B-20
TIMING BELT
4. Hold the drive plate using the special tool Fly

wheel stopper(MD998781).
5. Tighten the crankshaft bolt to a torque of 167 Nm.
>>J<< OIL PUMP SPROCKET INSTALLATION
AK202767
2. Install the auto-tensioner in position. Leave the

wire installed until the auto-tensioner is
completely installed.
Crosspoint screwdriver
AK202732 AB
>>L<< TENSIONER PULLEY INSTALLATION
1. Prevent the counterbalancer shaft from rotating in

the same method as in the removal procedure.
2. Install the oil pump sprocket.
3. Install the oil pump sprocket.
4. Tighten the flange nut to 54 5 Nm.
>>K<< AUTO-TENSIONER INSTALLATION
Tensioner
pulley holes
A
AK202759AB
Install the tensioner pulley with its holes aligned as

shown in the drawing.
>>M<< TIMING BELT INSTALLATION
Timing marks
AK202768 AB
1. If the auto-tensioner rod remains in its fully

extended position, reset it to the retracted position
as follows:
(1) Clamp the auto-tensioner in a vise at right
angles to the jaws.
(2) Push in the rod little by little with the vise until
the set hole A in the rod is aligned with the set
hole B in the cylinder.
(3) Insert a piece of wire (1.4 mm diameter) into
the set holes.
(4) Remove the auto-tensioner from the vise.
AK202903 AB
1. Bring the timing mark on the exhaust camshaft

sprocket to a point one sprocket tooth away from
the timing mark on the rocker cover in the
counterclockwise direction.
NOTE: If the timing marks were aligned, the
exhaust camshaft would be turned counterclockwise by one sprocket tooth and stay there by the
force of the valve springs.
ENGINE OVERHAUL
TIMING BELT
Timing marks
AK202904 AB
2. Align the timing mark on the intake camshaft

sprocket with that on the rocker cover.
NOTE: The intake camshaft will be turned slightly
clockwise from where the timing marks are
aligned by the force of the valve springs and stay
there.
11B-21
(2) Insert a crosspoint screwdriver with a shank

diameter of 8 mm through the plug hole. If it
can be inserted 60 mm or more, the sprocket
is in the correct phase. If the insertion depth is
up to 20 - 25 mm, the screwdriver is blocked
by the counterbalancer shaft. Then turn the oil
pump sprocket one turn and realign the timing
marks. Then check that the screwdriver can be
inserted 60 mm or more. Keep the screwdriver
inserted until installation of timing belt is
finished.
Timing marks
AK202761 AB
(3) Turn the oil pump sprocket counterclockwise

by one sprocket tooth.
AK202760
3. Bring the timing mark on the crankshaft sprocket

to a point one sprocket tooth away from the
mating timing mark in the counterclockwise
direction like in the operation with the exhaust
camshaft sprocket.
AK202771
5. Install the timing belt on the exhaust camshaft

sprocket, and hold it in place with a paper clip at
the point indicated in the drawing.
Plug
Crosspoint
screwdriver
AK202752 AB
4. Align the timing mark on the oil pump sprocket

with that on the cylinder block.
(1) Remove the plug from the cylinder block.
AK202772
ENGINE OVERHAUL
11B-22
TIMING BELT
6. Turn the intake camshaft sprocket

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

NOTE: Turning slightly the intake camshaft
sprocket counterclockwise will facilitate installation of the belt on the tensioner pulley.
Crankshaft
sprocket
Timing marks
AK202763AB
AK202847 AB
7. Turn the exhaust camshaft sprocket clockwise to

align the timing marks, and make sure that the
intake camshaft sprocket timing marks are also
aligned.
10.Turn slightly the crankshaft sprocket clockwise to

take up the slack in the idler pulley portion of the
timing belt.
11.Check that each of the timing marks on the
crankshaft, oil pump, and exhaust camshaft
sprockets is one sprocket tooth away from its
mating timing mark in the counterclockwise
direction.
MD998767
Crankshaft
sprocket
Oil pump
sprocket
AK202762AB
8. Install the timing belt on the idler pulley, oil pump

sprocket, and crankshaft sprocket, in this order.
NOTE: There should be no slack in the installed
portion of the belt.
Camshaft
sprocket
Tensioner
pulley
AK202773 AB
AK202764 AB
12.Turn the tensioner pulley counterclockwise using

the special tool Tension pulley socket wrench
(MD998767) to give tension to the belt and hold
the tensioner in position by temporarily tightening
the tensioner lock bolt.
NOTE: Take up the slack in the belt portion
between the intake and exhaust camshaft sprockets.
13.Turn the crankshaft clockwise to make the timing
mark align with the No.1 cylinder top dead center
mark.
ENGINE OVERHAUL
11B-23
TIMING BELT
20.Check that the wire (inserted in the auto-tensioner

when it was installed) can be moved freely. If the
wire can be pulled freely, the belt tensioner is
adjusted properly. Remove the wire. At that time,
check that the auto-tensioner rod extends by the
specified amount.
Standard value: 3.8 - 4.5 mm
MD998738
CAUTION
AK202774 AB
14.Install the special tool Set screw (MD998738) and

turn down the tool until the wire (inserted in the
auto-tensioner when it was installed) can be
moved freely.
Be sure to check the tightening torque of the

crankshaft bolt anytime the crankshaft has been
turned counterclockwise. If the torque lower than
specification, tighten the bolt to the specified
torque.
21.If the wire cannot be pulled out freely, perform the
steps 14. through 18. again to make the belt
tension proper.
INSPECTION
M1113002000362
TIMING BELT
Check closely the entire timing belt.
Replace it if any of the following conditions is found.
MD998767
AK202775 AB
CAUTION
Prevent the timing belt from slipping as it
becomes loose following rotation of the intake
and exhaust camshafts.
15.Loosen the tensioner pulley lock bolt.
16.Turn the torque wrench attached to the special
tool Tension pulley socket wrench (MD998767)
counterclockwise until the slack in the timing belt
is taken up.
17.Turn the torque wrench clockwise from the
position of step 16. until the torque wrench
reading becomes 3.5 Nm, then tighten the
tensioner pulley lock bolt.
AK202794
1. Hardened back side rubber

Back side surface is glossy, lacking in elasticity,
and so hard that no impression is left when
pressed with fingernail.
Cracks
Peeling of canvas
Cracks
Cracks in sides
Extension
amount
Cracks in tooth roots

AK202829 AB
18.Remove the special tool that was installed in step

14.
19.Turn the crankshaft clockwise two turns, then let it
alone for approx. 15 minutes.
2.
3.
4.
5.
Cracks in back rubber surface

Cracks in canvas
Cracks in tooth roots
Cracks in belt sides
AK202793 AB
ENGINE OVERHAUL
11B-24
TIMING BELT
AUTO-TENSIONER
Rounded edge
12 mm
Abnormal wear
(Fluffy strand)
AK202795 AB
6. Abnormally worn belt sides;

NOTE: belt sides are normal if they have knifecut surfaces.
Canvas lost and
rubber exposed
Missing
Tooth
AK202796 AB
7. Badly worn teeth

Initial stage: Canvas is worn (canvas fiber is fluffy;
teeth look whitish due to worn-out rubber; canvas
texture is unclear)
Second stage: Canvas is lost and rubber is exposed
(tooth width narrows down)
8. Missing tooth
AK202765 AB
1. Check the auto-tensioner for leaks from the

sealed sections.
Replace it if leaky.
2. Check the rod end for wear and other damage.
Replace the auto-tensioner if the rod is badly
worn or damaged.
3. Measure the extension length of the rod.
If it is not within the standard value range, replace
the auto-tensioner.
Standard value: 12 mm
98 to 196 N
Movement
AK202766 AB
4. Press the rod with a force of 98 to 196 N and

measure the amount of retraction. If the
measurement exceeds the standard value,
replace the auto-tensioner.
Standard value: 1 mm maximum
ENGINE OVERHAUL
11B-25
FUEL AND EMISSION PARTS

M1113002200355
7
8
11 1 Nm
9.0 1.0 Nm
18
10 N
9.0 2.0 Nm
17
2
11 1 Nm
15 N
16
19 3 Nm
14
13 N
5
11
12
4
20 2 Nm
6
11 1 Nm
11 1 Nm
AK204439AB
>>C<<
>>B<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
Removal steps
Vacuum hose and pipe
Vacuum pipe
Throttle body assembly
Throttle body gasket
EGR valve
EGR gasket
Vacuum hose
Fuel hose
Fuel pressure regulator
>>A<<

10. O-ring
11. Delivery pipe and injector
12. Insulator
13. Insulator
14. Injector
15. O-ring
16. Grommet
17. Delivery pipe
18. Solenoid valve assembly
11B-26
ENGINE OVERHAUL

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

smoothly. If it does not, the O-ring may be
jamming, so remove the fuel pressure regulator
and check the O-ring for damage. If the O-ring is
intact, insert it into the delivery pipe and check it
for smooth rotation again.
>>C<< THROTTLE BODY GASKET
INSTALLATION
Tab
AK202905 AB
Install the throttle body gasket with its tab located as

ENGINE OVERHAUL
11B-27
INTAKE MANIFOLD
INTAKE MANIFOLD
M1113002700286
36 6 Nm
19 3 Nm
4
3
36 6 Nm
20 2 Nm
31 3 Nm
AK204438 AB
Removal steps
>>A<< 1. Intake manifold stay

2. Intake manifold
3. Intake manifold gasket
4. Engine hanger

>>A<< INTAKE MANIFOLD STAY INSTALLATION
Intake manifold
stay
AK202865 AB
Tighten the bolts to the specified torque 31 3 Nm

on both ends after making sure that the stay is in
close contact with the bosses on the intake manifold
and cylinder block.
ENGINE OVERHAUL
11B-28
EXHAUST MANIFOLD
EXHAUST MANIFOLD
M1113004900383
14 1 Nm
44 5 Nm
29 3 Nm
14 1 Nm
6
4
49 5 Nm
35 6 Nm
44 5 Nm
AK204437 AB
Removal steps
1. Oxygen sensor
2. Exhaust manifold cover
3. Exhaust manifold bracket

4. Engine hanger
5. Exhaust manifold
6. Exhaust manifold gasket
ENGINE OVERHAUL
11B-29

M1113017900220
13 2 Nm
9
13 2 Nm
13 2 Nm
6
1
23 4 Nm
11
10
5
4
10.8 1.0 Nm
3
29 10 Nm
14
23 2 Nm
13
12
14 1 Nm
AK204436AB
>>E<<
>>D<<
>>C<<
>>B<<
>>A<<
>>A<<
>>A<<
Removal sequence
1. Water hose
2. Water hose
3. Coolant temperature sensor
4. Coolant temperature gauge unit
5. Water inlet fitting
6. Thermostat
7. Water outlet fitting
8. Thermostat housing
9. O-ring
10. Water inlet pipe
11. O-ring
12. Water pump
13. Water pump gasket
14. Knock sensor

>>A<< O-RING/WATER INLET PIPE INSTALLATION
CAUTION
Never allow any oil or grease to touch the Orings.
Clamp the water inlet pipe only after installation of the thermostat case.
Replace the O-rings at both ends of the water inlet
pipe with new ones. Insert the O-rings into the water
pump and thermostat housing after wetting their
peripheries with water.
11B-30
ENGINE OVERHAUL
>>B<< THERMOSTAT HOUSING INSTALLATION
>>D<< COOLANT TEMPERATURE GAUGE UNIT

INSTALLATION
AK202918AB
1. Remove all old FIPG remaining on the thermostat

housing and cylinder head.
2. Apply a 2.7 0.3 mm diameter bead of FIPG on
the indicated surface of the thermostat housing.
Specified sealant:
equivalent
>>C<< WATER OUTLET FITTING INSTALLATION
AK202800AB
1. Remove all old sealant remaining on the threaded

hole in the coolant temperature gauge unit and
the thermostat housing.
NOTE: A new coolant temperature gauge unit is
coated with sealant. It does not require coating
with sealant before installation.
2. Apply sealant to the indicated threads of the
coolant temperature gauge unit.
Specified sealant:
3M Nut Locking Part No.4171 or equivalent
>>E<< COOLANT TEMPERATURE SENSOR
INSTALLATION
AK202755AB
1. Remove all old FIPG remaining on the water

outlet fitting and thermostat housing.
2. Apply a 2.7 0.3 mm diameter bead of FIPG to
the indicated surface of the water outlet fitting.
Specified sealant:
equivalent
AK202799AB
CAUTION
When using a tool, avoid letting it touch the connector portion which is made of plastic.
1. Remove all old sealant remaining on the threads
of the coolant temperature sensor and in the
threaded hole in the thermostat housing.
2. Apply sealant to the coolant temperature sensors
threads indicated in the drawing.
Specified sealant:
3M ATD Part No.8660 or equivalent
ENGINE OVERHAUL
11B-31

M1113005400455
10 2 Nm
N4
11
14
13
20 1 Nm
6
9
12
14 1 Nm
2N
1
10
22 4 Nm
15
8.8 1.0 Nm
11 1 Nm
18
N7
16
17
Apply engine oil

to all moving
parts before
installation.
AK202894 AB
>>F<<
>>E<<
>>D<<
>>C<<
>>C<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
Removal steps
Camshaft position sensor
O-ring
Cover
Gasket
Camshaft position sensing cylinder
Camshaft position sensor support
Camshaft oil seal
Bearing cap, rear right
Bearing cap, rear left
>>C<<
>>C<<
>>C<<
>>C<<
>>C<<
>>B<<
<<A>> >>A<<

10. Bearing cap, front
11. Bearing cap No.5
15. Camshaft
16. Rocker arm
17. Lash adjuster
18. Oil delivery body
ENGINE OVERHAUL
11B-32
SERVICE POINTS FOR REMOVAL
1. Set each camshaft with its dowel pin at the top.
<<A>> LASH ADJUSTER REMOVAL
CAUTION
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
311B, the instruction under LASH ADJUSTER
in the INSPECTION section.)

>>A<< LASH ADJUSTER INSTALLATION
CAUTION
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
311B, the instruction under LASH ADJUSTER
in the INSPECTION section.)
Install the lash adjuster into the rocker arm, being
careful not to spill the diesel fuel it contains.
>>B<< CAMSHAFT INSTALLATION
Timing belt side
Cap number
Intake/exhaust
identification
letter
AK202870 AB
2. The bearing caps No. 2 to 5 are identical in shape

for both intake and exhaust camshafts. Check the
identification mark on each cap before installation.
Identification mark (stamped on front and
Nos. 2 - 5 bearing caps)
I: intake camshaft
E: exhaust camshaft
3. Remove completely sealant remaining on the
bearing caps and cylinder head.
Slit
Exhaust camshaft
AK202869 AB
AK202871AB
CAUTION
Do not confuse the intake camshaft with the
exhaust camshaft.
The exhaust camshaft has a 4 mm wide slit at
the rear end.
>>C<< BEARING CAP INSTALLATION
Dowel pin
AK203979 AC
4. Apply sealant to the surfaces indicated in the

drawing.
Specified sealant:
5. Install each bearing cap and tighten its bolts in
two or three passes.
6. Finally tighten the bolts to 20 1 Nm.
7. Check that the rocker arms are correctly installed.
NOTE: Wipe off any squeezed out sealant completely.
ENGINE OVERHAUL
11B-33
>>D<< CAMSHAFT OIL SEAL INSTALLATION

MD998713
1. Turn the exhaust camshaft to the No.1 cylinder top

dead center position.
NOTE: The camshaft will slightly turn counterclockwise by the force of the exhaust valve spring.
2. Install the camshaft position sensing cylinder with
the smaller vane located as shown in the drawing.
INSPECTION
M1113005500388
CAMSHAFT
AK202872 AB
Use the special tool Camshaft oil seal installer

(MD998713) to drive each oil seal into position in the
cylinder head.
>>E<< CAMSHAFT POSITION SENSOR
SUPPORT INSTALLATION
AK202797AB
Measure the cam height (nose-to-heel diameter).

If any cam is worn beyond the limit, replace the camshaft.
Standard value: 34.91 mm
Limit: 34.41 mm
AK202754AB
1. Remove completely the FIPG remaining on the

camshaft position sensor support and cylinder
head.
2. Apply a 3 1 mm diameter bead of FIPG to the
indicated surface of the camshaft position sensor
support.
Specified sealant:
equivalent
LASH ADJUSTERS
CAUTION
The lash adjuster is a precision-engineered
component. Do not allow dust or other foreign
matter to enter it.
Do not disassemble lash adjusters.
Use only non-contaminated diesel fuel to
clean the lash adjuster.
For rough
cleaning
For finish
cleaning
For diesel
fuel filling
>>F<< CAMSHAFT POSITION SENSING

CYLINDER INSTALLATION
Smaller vane
A
AK202836 AB
Cam position
sensor
AK202844 AB
1. Prepare three containers and approximately five

liters of diesel fuel. Pour into each container the
diesel fuel in an amount enough for a lash
adjuster placed in the container in its upright
position to completely submerge.
ENGINE OVERHAUL
11B-34
CAUTION
The hole in the side of the lash adjuster must be
directed toward the inside of container A. Never
direct it against any person.
4. Take the lash adjuster out of the container, then
move the plunger by pushing the steel ball gently
to discharge the diesel fuel from the pressure
chamber.
AK202837
2. Place the lash adjuster in container A and wash

its outside surface.
NOTE: Use a nylon brush if there are hard-toremove deposits.
Diesel fuel
MD998442
AK202839 AB
CAUTION
Diesel fuel
MD998442
AK202839 AB
CAUTION
The steel ball spring of the lash adjuster is
extremely weak. The lash adjusters functionality
may be badly affected if the special tool is
inserted too strongly.
3. While gently pushing the internal steel ball using
the special tool Air bleed wire (MD998442), move
the plunger in and out 5 - 10 times to eliminate
stiffness in the plunger and expel contaminated
oil.
NOTE: The plunger must be free from jamming
and any other abnormalities. If a defect is found in
plunger operation, replace the lash adjuster.
The steel ball spring of the lash adjuster is

extremely weak. The lash adjusters functionality
may be badly affected if the special tool is
inserted too strongly.
5. Soak the lash adjuster in the diesel fuel in
container B. Move the plunger in and out 5 - 10
times by gently pushing the internal steel ball
using the special tool Air bleed wire (MD998442)
until the plunger moves smoothly to wash the lash
adjusters pressure chamber.
MD998442
Diesel fuel
AK202840 AB
CAUTION
MD998442
Diesel fuel
AK202840 AB
The hole in the side of the lash adjuster must be

directed toward the inside of container B. Never
direct it against any person.
6. Take the lash adjuster out of the container, then
move the plunger by pushing the steel ball gently
to discharge the diesel fuel from the pressure
chamber.
ENGINE OVERHAUL
11B-35
8. Place the lash adjuster upright with the plunger at

the top. Push the plunger firmly until it makes a full
stroke, then return the plunger slowly and release
the hold of the steel ball to allow the pressure
chamber to be filled with diesel fuel.
MD998442
Diesel fuel
AK202841 AB
CAUTION
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could
enter the pressure chamber when the chamber is
filled with diesel fuel.
7. Soak the lash adjuster in the diesel fuel in
container C. Gently push the internal steel ball
using the special tool Air bleed wire (MD998442).
MD998442
Diesel fuel
AK202842 AB
AK202843
9. Take the lash adjuster out of the container, place it

upright with the plunger at the top, and push the
plunger firmly. The plunger must not move at all.
NOTE: If the lash adjuster contracts, perform the
operations 7. through 9. again. Replace the lash
adjuster if it still contracts even after the pressure
chamber has completely been filled with diesel
fuel (air has been bled).
10.Keep the serviced lash adjusters in their upright
positions to prevent diesel fuel from spilling out.
Protect them from dust or other foreign matter.
Install the lash adjusters onto the engine as soon
as possible.
ENGINE OVERHAUL
11B-36

M1113006900389
78 2 Nm loosen completely
20 2 Nm 90 + 90
1
2
4
5
6
12 N
13
16 N
8
9
10
14 N
15
17 N
20
19 N
11
18 N
7
3N
Apply engine oil

to all moving
parts before
installation.
AK202895 AB
Removal steps
<<A>> >>D<< 1. Cylinder head bolt

<> >>C<<
>>B<<
2.
3.
4.
5.
6.
Cylinder head assembly

Cylinder head gasket
Retainer lock
Valve spring retainer
Valve spring
<> >>C<<
>>B<<
>>A<<

7. Intake valve
8. Retainer lock
9. Valve spring retainer
10. Valve spring
11. Exhaust valve
12. Valve stem seal
13. Valve spring seat
ENGINE OVERHAUL
11B-37

>>A<< 14. Valve stem seal

15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head

>>A<< VALVE STEM SEAL INSTALLATION
MD998737

<<A>> CYLINDER HEAD BOLT REMOVAL
AK202874 AB
CAUTION
MB991654
AK202723 AB
Use the special tool Cylinder head bolt wrench

(MB991654) to loosen the cylinder head bolts.
<> RETAINER LOCK REMOVAL
MD998772
The special tool must always be used when

installing the valve stem seal. Improper installation could result in oil leaks past the valve guide.
1. Install the valve spring seat.
2. Install the valve.
3. Apply a thin coat of engine oil to a new valve stem
seal.
4. Use the special tool Valve stem seal installer
(MD998737) to install the stem seal on the valve
guide. Use the stem of the valve to guide the stem
seal.
Intake valve stem seal
Colour: Gray
AK202742 AB
Exhaust valve stem seal

Colour: Grayish green
AK202875 AB
NOTE: Do not confuse the stem seals for intake

valves with those for exhaust valves.
MD998735
>>B<< VALVE SPRING INSTALLATION
Painted
end
AK202873 AB
Compress the valve spring using the special tool

Valve spring compressor (MD998772), then remove
the retainer lock.
NOTE: Store removed valves, springs and other
parts, after putting to each of them a tag that identifies its cylinder No. or installation location.
Spring
retainer
Stem
seal
Spring
seat
AK202551AB
Install each valve spring with the painted end toward

the rocker arm.
ENGINE OVERHAUL
11B-38
>>C<< RETAINER LOCK INSTALLATION

MD998772
2. Apply engine oil to the threads and washer of the

bolt.
NOTE: Use the special tool Cylinder head bolt
wrench (MB991654) to tighten the bolts.
Timing belt side
10
AK202742 AB
MD998735
7
AK202806 AB
3. Tighten the bolts to 78 2 Nm in the indicated

sequence.
4. Loosen all the bolts completely.
5. Tighten the bolts again to a torque of 20 2 Nm
in the indicated sequence.
AK202873 AB
Compress the valve spring using the special tool

Valve spring compressor (MD998772), then install
the retainer lock.
90
>>D<< CYLINDER HEAD BOLT INSTALLATION

90
Paint marks
AK202720 AB
CAUTION
Nominal length
AK202750 AB
MB991654
If the tightening angle is smaller than 90,

proper fastening performance could not be
assured. Be sure to respect that angle.
If the bolt is tightened to an angle greater than
the specified angle, loosen the bolt completely and then retighten it beginning with
the first step.
6. Make paint marks on each bolts head and on the
cylinder head.
7. Turn the bolts 90 in the tightening direction and in
the indicated sequence.
8. Give another 90 turn in the tightening direction to
each bolt, making sure that the paint mark on the
bolt head and that on the cylinder head are on the
same line.
AK202723 AB
1. When reusing a cylinder head bolt, check that its

nominal length (shank length) is not greater than
the limit. If the limit is exceeded, replace the bolt.
Limit: 99.4 mm
INSPECTION
M1113007000378
CYLINDER HEAD
1. Before cleaning the cylinder head, check it for
traces of water and gas leakage and for cracks
and any other damage.
ENGINE OVERHAUL
11B-39
2. Thoroughly remove oils, scale, sealants, carbon

and other contamination. Clean the oil passages,
then check using compressed air that they are not
blocked.
Standard values:
Intake 1.0 mm
Exhaust 1.5 mm
Limits:
Intake 0.5 mm
Exhaust 1.0 mm
AK202724
Total length
CAUTION
The thickness of the metal that can be removed
by grinding from both the cylinder head and the
mating cylinder block is limited to 0.2 mm in
total.
3. Check the cylinder head gasket surface for warp
using a straightedge and thickness gauge.
If the surface is warped beyond the limit, grind the
surface for rectification.
Gasket surface warp
Standard value: Less than 0.05 mm
Limit: 0.2 mm
Grinding limit: 0.2 mm
Cylinder head height (standard value for new
part):
131.9 - 132.1 mm
VALVES
1. Check the valve face for correct contact with the
seat. Reface the valve if the contact is partial or
one sided.
AK202876 AB
3. Measure the total length of the valve.

Replace the valve if the length is less than the
limit.
Standard values:
Intake 109.50 mm
Exhaust 109.70 mm
Limits:
Intake 109.00 mm
Exhaust 109.20 mm
VALVE SPRINGS
Out of square
Free height
AK202706 AB
Contact
(Should be at
center of face)
Margin
AK202729 AB
2. Measure the margin.

Replace the valve if its margin is smaller than the
limit.
1. Measure the free height of the spring.

Replace the spring if its height is smaller than the
limit.
Limit: 46.0 mm
2. Measure the squareness of the spring.
Replace the spring if it is out of square beyond the
limit.
Standard value: 1.5 or smaller
Limit: 4
ENGINE OVERHAUL
11B-40
VALVE GUIDE
With the valve installed in position and its face

pressed against the valve seat, measure the valve
stem projection (distance between the the valve stem
end and spring seating surface). If the measurement
exceeds the limit, replace the valve seat.
Standard values:
Intake 49.20 mm
Exhaust 48.40 mm
valve
guide
Stem diameter
Guide inside diameter
AK202709 AB
Measure the valve guide inside diameter and valve

stem diameter to calculate the clearance between
the valve guide and valve stem.
If the limit is exceeded, replace the valve guide or
valve, or both.
Standard values:
Intake 0.02 - 0.05 mm
Exhaust 0.05 - 0.09 mm
Limits:
Intake 49.70 mm
Exhaust 48.90 mm
VALVE SEAT RECONDITIONING

1. Before reconditioning the valve seat, check the
clearance between the valve guide and valve
stem and, if necessary, replace the valve guide.
0.9 1.3 mm
0.9 1.3mm
65
65
Limits:
Intake 0.10 mm
Exhaust 0.15 mm
25
15
VALVE SEATS
44
Valve stem
end
Valve stem
projection
Spring
seating
surface
AK202814 AB
AK202850 AB
2. Resurface the valve seat to the indicated width

and angles.
3. After resurfacing, lap the valve and valve seat
using lapping compound.
ENGINE OVERHAUL
11B-41
VALVE SEAT REPLACEMENT
4. Resurface the valve seat. See the VALVE SEAT

RECONDITIONING section.
0.5 1 mm
VALVE GUIDE REPLACEMENT

1. Force out the valve guide toward the cylinder
block using a press.
Cut
CAUTION
0.5 1 mm
AK202707 AB
1. Cut inside of the valve seat to be replaced until its

wall becomes thin enough for removal, then
remove the valve seat.
Do not use a replacement valve guide of the

same size as the removed one.
2. Machine the valve guide hole in the cylinder head
to the size matched to the selected oversize valve
guide.
Valve guide hole diameters
0.05 oversize: 12.05 - 12.07 mm
0.25 oversize: 12.25 - 12.27 mm
0.50 oversize: 12.50 - 12.52 mm
Valve seat
height
Oversize hole diameter

AK202708 AB
2. Rebore the valve seat hole in the cylinder head to

a diameter matched to the diameter of the
selected oversize valve seat.
Intake valve seat hole diameters:
0.3 oversize: 35.30 - 35.33 mm
0.6 oversize: 35.60 - 35.63 mm
Exhaust valve seat hole diameters:
0.3 oversize: 33.30 - 33.33 mm
0.6 oversize: 33.60 - 33.63 mm
3. Before fitting the valve seat, cool it in liquid
nitrogen to prevent damage to its hole in the
cylinder head due to interference.
19.2 19.8 mm
AK202877 AB
3. Press-fit the valve guide until it remains protruded

above the cylinder head by the amount indicated
in the drawing.
NOTE: .
1. Press the valve guide from above the cylinder
head.
2. The valve guides for the intake valves are different in length from those for the exhaust
valves (45.5 mm for intake valves; 50.5 mm for
exhaust valves)
4. After installing the valve guide, insert a new valve
in it to check for smooth movement.
ENGINE OVERHAUL
11B-42

M1113008100301
19 3 Nm
10
Apply engine oil

to all moving
parts before
installtion.
32
31
28
30
21
23 3 Nm
10 2 Nm
23 3 Nm
29
22
20
23 24
16
19 3 Nm
19 3 Nm
26
15
17 1 Nm
25
19
14
13
27
17 18
9.0 3.0 Nm
36 3 Nm
11
3
23 3 Nm
23 3 Nm
12
39 5 Nm
2
44 5 Nm
9.0 3.0 Nm
39 5 Nm
9.0 3.0 Nm
22 4 Nm
1
9.0 3.0 Nm
AK202676 AB
9.0 3.0 Nm
>>O<<
>>N<<
<<A>>
<>
<<C>>
>>M<<
>>L<<
>>L<<
Removal steps
1. Drain plug
2. Drain plug gasket
3. Oil filter
4. Transmission stay <4WD>
5. Oil pan <2WD>
6. Oil pan lower section <4WD>
7. Oil pan upper section <4WD>
8. Oil screen
9. Gasket
10.Oil pressure switch
>>K<<
<<D>>
>>J<<
<<E>>
>>I<<
>>H<<

11.Relief plug
12.Gasket
13.Relief spring
14.Relief plunger
15.Oil filter bracket
16.Gasket
17.Plug
18.O-ring
19.Flange bolt
20.Front case
ENGINE OVERHAUL
11B-43
>>G<<
>>G<<
>>F<<
>>E<<
>>D<<
<<F>> >>C<<
<<G>> >>B<<
<<G>> >>A<<

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

<<A>> OIL PAN REMOVAL <2WD>
<<C>> OIL PAN UPPER SECTION REMOVAL

<4WD>
A
AK202692 AB
Screw bolts into the bolt holes A shown in the drawing (holes at both ends) to remove the oil pan.
CAUTION
Do not use a scraper or the special tool to
remove the oil pan.
MD998727
<<D>> PLUG REMOVAL

MD998162
AK202574 AB
1. Remove the oil pan bolts.

2. Insert the special tool Oil pen remover
(MD998727) into the joint between the cylinder
block and oil pan by tapping the tool with a
hammer.
3. Remove the oil pan by tapping an edge of the
special tool Oil pen remover (MD998727) with a
hammer to move it sideways.
<> OIL PAN LOWER SECTION REMOVAL
<4WD>
Remove the oil pan by tapping it through a piece of
wood applied to a side with a plastic hammer.
MD998783
AK202585 AB
Fit the teeth of the special tool in notches of the plug

as shown in the drawing and support the tool with the
special tool to loosen the plug.
Plug wrench (MD998162)
Plug wrench retainer (MD998783)
<<E>> FLANGE BOLT REMOVAL
CAUTION
Do not use a scraper or the special tool to
remove the oil pan.
Plug
Crosspoint
screwdriver
AK202586 AB
1. Remove the plug on the left side of the cylinder

block. Insert a cross point screwdriver (shank
diameter 8 mm) into the plug hole more than 60
mm to prevent the left counterbalancer shaft from
rotating.
ENGINE OVERHAUL
11B-44
2. When removing the rear bearing of the left

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

AK202642
2. Loosen and remove the flange bolt.
>>A<< LEFT COUNTERBALANCER SHAFT REAR

BEARING INSTALLATION
MB991603
<<F>> COUNTERBALANCER SHAFT FRONT

BEARING REMOVAL
MD998705
AK202548 AB
Front
bearing
1. Install the special tool Silent shaft bearing installer

stopper (MB991603) on the cylinder block.
MD998371
AK202633 AB
CAUTION
Remove the front bearing first. Otherwise, the
special tool cannot be used.
Use the special tool Silent shaft bearing puller
(MD998371) to remove the counterbalancer shaft
front bearing from the cylinder block.
<<G>> COUNTERBALANCER SHAFT REAR
BEARING REMOVAL
1. Use the special tool Silent shaft bearing puller
(MD998371) to remove the counterbalancer shaft
rear bearings from the cylinder block.
MB991603
MD998372
AK202634 AB
MB991603
MD998705
Rear bearing
AK202635 AB
2. Set the rear bearing on the special tool Silent

shaft bearing installer (MD998705).
NOTE: The left counterbalancer shaft rear bearing has no oil hole.
3. Force the rear bearing into the cylinder block by
sticking the special tool.
ENGINE OVERHAUL
11B-45
>>B<< RIGHT COUNTERBALANCER SHAFT

REAR BEARING INSTALLATION
MD998705
Guide pin
AK202581 AB
AK202579 AB
1. Install the guide pin on the cylinder block.
>>C<< COUNTERBALANCER SHAFT FRONT

BEARING INSTALLATION
Rear bearing (Right)

Ratchet ball
Oil
hole
Tool element for

rear bearing
installation
AK202582 AB
AK202549 AB
2. Set the bearing on the special tool Silent shaft

bearing installer (MD998705) with its oil hole on
the ratchet ball.
1. Detach from the special tool Silent shaft bearing

installer (MD998705) its element for rear bearing
installation.
MD998705
Guide pin
Guide pin
AK202579 AB
AK202580 AB
3. Insert the special tool Silent shaft bearing installer

(MD998705) while passing the guide pin through
its hole and force the bearing into position by
striking the tool.
2. Install the guide pin on the cylinder block.

Front bearing
Ratchet ball
Oil
hole
AK202549 AC
3. Set the bearing on the special tool Silent shaft

bearing installer (MD998705) with its oil hole on
the ratchet ball.
ENGINE OVERHAUL
11B-46
>>E<< COUNTERBALANCER SHAFT OIL SEAL

INSTALLATION
MD998705
Socket wrench
Oil seal
Front case
Guide pin
AK202580 AB
4. Insert the special tool Silent shaft bearing installer

(MD998705) into the cylinder block while passing
the guide pin through its hole and force the
bearing into position by striking the tool.
AK202646 AB
Use an appropriate socket wrench to install the counterbalancer shaft oil seal.
>>F<< CRANKSHAFT OIL SEAL INSTALLATION
MD998375
Oil seal
Front case
AK202583AB
>>D<< OIL PUMP OIL SEAL INSTALLATION
Oil seal
Socket
wrench
AK202645 AB
Use the special tool Crankshaft front oil seal installer

(MD998375) to install the crankshaft oil seal.
>>G<< OIL PUMP DRIVEN GEAR/OIL PUMP
DRIVE GEAR INSTALLATION
Front case
Alignment
marks
AK202639 AB
Use an appropriate socket wrench to install the oil

pump oil seal.
AK202660 AB
Apply engine oil generously to the gears and line up

the alignment marks.
ENGINE OVERHAUL
11B-47
>>H<< FRONT CASE INSTALLATION

Counterbalancer
shaft, left
MD998285
1. Insert a correspond screwdriver (shank diameter

8 mm) into the hole in the left side of the cylinder
block to prevent the counterbalancer shaft from
rotating.
Counterbalancer
shaft, right
AK202577 AB
1. Install the special tool crankshaft front oil seal

guide (MD998258) on the front end of crankshaft
and apply a thin coat of engine oil to the outer
surface of the special tool. Be sure to use the
special tool when the front case is fitted with an oil
seal.
2. Install the front case on the cylinder block with a
new front case gasket in between and temporarily
tighten all the flange bolts except those that are
used for tightening the filter bracket.
3. Install the oil filter bracket on the front case with
the oil filter bracket gasket in between and
temporarily tighten the washer-assembled bolts.
AK202642
2. Tighten the flange bolts.

>>J<< PLUG INSTALLATION
1. Install a new O-ring on the front case.
MD998162
MD998783
AK202585 AB
2. Use the special tool to tighten the plug to the

specified torque.
Plug wrench (MD998162)
Plug wrench retainer (MD998783)
MD998285
AK202656 AB
4. Tighten all the bolts to the specified torques.
>>K<< OIL PRESSURE SWITCH INSTALLATION
>>I<< FLANGE BOLT INSTALLATION
AK202625AB
Crosspoint
screwdriver
CAUTION
AK202641 AB
Be careful not to block the oil passage with sealant.

1. Apply sealant to the threaded portion.
Specified Sealant:
ENGINE OVERHAUL
11B-48
Specified sealant:
equivalent
NOTE: In the grooved areas on the oil pan flange,
apply FIPG bead along the center of the groove.
MD998054
M6 16
AK204037AD
2. Tighten the oil pressure switch together with the

cylinder block by the specified torque using of the
special tool Oil pressure switch wrench
MD998054.
Tightening torque: 19 3 Nm
>>L<< OIL PAN UPPER SECTION/OIL PAN
LOWER SECTION INSTALLATION <4WD>
CAUTION
Do not apply FIPG over remaining old FIPG.
Doing so could result in oil leakage.
1. Clean the gasket surfaces of the cylinder block
and oil pan.
Timing belt side
AK202685 AB
3. Install the shorter bolts in the locations indicated

in the drawing.
CAUTION
4. Thoroughly remove old FIPG from the gasket
surfaces of the oil pan upper and lower sections.
Timing belt side
Bolt hole
area
Grooved
area
Bolt hole
area
Grooved area
AK202688 AB
CAUTION
Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could
result in leakage.
2. Apply a 4 mm diameter bead of FIPG to the flange
surface all around the oil pan.
AK202686 AB
CAUTION
result in leakage.
ENGINE OVERHAUL
11B-49

Specified sealant:
equivalent
Timing belt side

M6 8
Timing belt side

9
Specified sealant:
equivalent
12
1
11
3
2
AK202693 AB
10
AK202687 AB
6. Install the oil pan lower section by tightening the

bolts in the indicated sequence.
>>M<< OIL PAN INSTALLATION <2WD>
3. Install the shorter bolts in the locations indicated

in the drawing.
>>N<< OIL FILTER INSTALLATION
Bracket side
CAUTION
1. Thoroughly remove old FIPG from the gasket
surfaces of the cylinder block and oil pan.
Engine oil
Timing belt side

AK202556 AB
Bolt hole
area
Grooved
area
AK202694 AB
CAUTION
result in leakage.
1. Clean the installation surface of the filter bracket.

2. Apply engine oil to the o-ring of the oil filter.
3. Install the oil filter to the bracket and tighten it to
the specified torque.
4. If no torque wrench can be used for tightening,
use the following procedure:
(1) Screw in the oil filter until its o-ring contacts
the oil filter bracket.
(2) Tighten the oil filter 3/4 turn.
ENGINE OVERHAUL
11B-50
>>O<< DRAIN PLUG GASKET INSTALLATION

Drain plug
AK202835AB
Oil pan
Gasket
Oil pan
side
2. Check the journals for seizure, damage and

defective contact with bearings.
If any of these faults is found, replace the
counterbalance shaft, bearings and/or oil pump
case assembly.
OIL PUMP
AK202603AB
CAUTION
Installing the gasket with the wrong side facing
the oil pan will result in oil leakage.
Replace the drain plug gasket with a new one. Install
it with the side indicated in the drawing toward the oil
pan.
INSPECTION
M1113008200212
COUNTERBALANCE SHAFTS
1. Check that the oil holes are not blocked.
Clean if necessary.
AK202831
1. Install the drive and driven gears in the oil pump

case.
2. Measure the gear side clearance using a straight
edge and thickness gauge.
Standard values:
Drive gear 0.08 - 0.14 mm
Driven gear 0.06 - 0.12 mm
ENGINE OVERHAUL
11B-51

M1113008400528
6
7
8
Apply engine oil to

all moving parts
before
installation.
10
4
9
12
11
3
2
1
20 2 Nm + 90 to 94
AK202896 AB
>>G<<
<<A>> >>F<<
>>E<<
>>D<<
>>C<<
1.
2.
3.
4.
5.
6.
Removal steps
Connecting rod cap nut
Connecting rod cap
Connecting rod bearing
Piston and connecting rod assembly
Connecting rod bearing
Piston ring No. 1
>>C<< 7. Piston ring No. 2

>>B<< 8. Oil ring
<> >>A<< 9. Piston pin
10. Piston
11. Connecting rod
12. Bolt
ENGINE OVERHAUL
11B-52

<<A>> CONNECTING ROD CAP REMOVAL
Push rod
Cylinder
number
Front mark
Front
mark
Guide C
AK202812 AB
Mark the cylinder number on the side of the connecting rod big end as a guide for reassembly.
Base
<> PISTON PIN REMOVAL

Push
rod
Guide A: 17.9 mm
Guide B
AK202781 AB
Guide A: 18.9 mm
GuidE C
Guide A: 20.9 mm
Base
1. Insert the tool element, Push rod, into the piston

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

Guide A: 21.9 mm
>>A<< PISTON PIN INSTALLATION

Timing belt side
Crankshaft
bore size mark
AK202783 AB
No.4
No.3
No.2
No.1
The special tool Piston pin setting tool (MD998780),

consists of the elements shown in the drawing.
AK202923 AB
1. When replacing a piston, check the cylinder bore

size mark stamped at the indicated location on the
cylinder block and select an appropriate
replacement piston using the following table.
Cylinder bore size mark
Piston size mark
II
No mark
III
ENGINE OVERHAUL
11B-53
NOTE: The piston size mark is located on the piston top surface.
3 mm + L
Guide B
Guide A
AK202789 AB
Connecting rod
Piston
8. Screw the tool element, Guide B, into the tool

element, Guide A until the gap between both the
elements is equal to the dimension L (obtained in
step 3.) plus 3 mm.
Piston pin
Push rod
Piston pin
AK202784 AB
2. Measure the following dimensions:

A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width
3. Obtain dimension L from the measurements using
the following formula.
L = [(A-C) - (B-D)] 2
4. Insert the tool element, Push rod, into the piston
pin and attach the element, Guide A, to the push
rod end.
5. Assemble the connecting rod with the piston with
their front marks facing in the same direction.
6. Apply engine oil to the outside surface of the
piston pin.
7. Insert the assembly of piston pin, Push rod, and
Guide A (put together in step 4.) into the piston
holes from the front mark side.
Front
mark
Front mark
Guide A
Base
Guide B
AK202782 AB
9. Place the piston and connecting rod assembly

onto the element, Piston setting base, with the
front marks facing up.
10.Install the piston pin using a press. If the required
press force is less than the standard value,
replace the piston and piston pin assembly or the
connecting rod, or both.
Standard value: 7,350 - 17,100 N
ENGINE OVERHAUL
11B-54
>>B<< OIL RING INSTALLATION
>>C<< PISTON RING NO. 2/PISTON RING NO. 1

INSTALLATION
Lower
side
rail
end gap
Upper
side
rail
end gap
Piston ring
expander
Spacer end gap
AK202879 AB
AK202786 AB
1. Fit the oil ring spacer into the piston ring groove.
Install the upper side rail, then the lower side rail.
NOTE: .
1. Locate the side rail and spacer end gaps as
2. New spacers and side rails are an identified by
color marks as follows:
Size
Color mark
Standard
Non mark
0.50 mm oversize
Blue
1.00 mm oversize
Yellow
Identification mark
Size marks
No. 1
No. 2
AK202807 AB
CAUTION
Use of ring expander to expand the side rail end
gap can break the side rail, unlike other piston
rings.
Side rail end
Using a piston ring expander, install the piston rings

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

(blue paint on periphery)
No. 2 ring No mark
(green paint on periphery)
AK202785 AB
2. To install each side rail, first fit one end of the rail
into the piston groove, then press the remaining
portion progressively into position by finger as
3. Make sure that the installed side rails move
smoothly in either direction.
0.50 mm oversize
50
1.00 mm oversize
100
>>D<< PISTON AND CONNECTING ROD

ASSEMBLY INSTALLATION
1. Apply engine oil generously to the pistons outside
surface, piston rings, and oil ring.
ENGINE OVERHAUL
11B-55

Side rail
No. 1
No. 2
2. Crankshaft pin diameter marks are stamped in the

indicated locations.
Side rail
AK202730 AB
2. Align the end gaps of the piston rings and oil ring
(side rails and spacer) as shown in the drawing.
3. Insert the piston and connecting rod assembly
from the top of cylinder with the front mark on the
crown toward the camshaft sprocket.
AK202719AB
3. Connecting rod bearing identification mark is

stamped in the indicated location on each
bearing.
Crankshaft pin
Connecting rod
bearing
Identification Diameter mm
mark
Identification
mark
44.995 - 45.000 1
II
44.985 - 44.995 2
III
AK202798
CAUTION
Do not strike the assembly with a large force.
Doing so could break the piston rings.
When striking the assembly into cylinder, do
not allow it to interfere with the oil jet.
4. Use a piston ring band to hold the piston rings
compressed when inserting the piston and
connecting rod assembly into the cylinder.
44.980 - 44.985 3
<Bearing selection example>
If the crankshaft pin diameter mark is I, select a
bearing marked 1.
If the crankshaft pin diameter mark is illegible,
measure the pin diameter and select a bearing
with the mark corresponding to the measurement.
4. Install the upper and lower halves of the selected
bearing on the connecting rod big end and cap,
respectively.
>>F<< CONNECTING ROD CAP INSTALLATION
>>E<< CONNECTING ROD BEARING

INSTALLATION
1. When replacing the connecting rod bearing,
select a bearing of the size appropriate for the
crankshaft pin diameter in accordance with the
crankshaft pin and connecting rod bearing
matching table shown below.
Locations of crankshaft pin diameter
marks
No. 1
No. 4
Cylinder
number
Bearing
locating
notches
No. 2
No. 3
AK202909 AB
AK202813 AB
1. Install the bearing cap on the connecting rod while

aligning the marks made during disassembly. If
the connecting rod is new and has no alignment
mark, assemble it with the cap such that the both
bearing locating notches are on the same side as
ENGINE OVERHAUL
11B-56
CAUTION
If the tightening angle is less than 90, adequate tightness could not be assured.
If the tightening angle exceeds 94, loosen the
nut completely and then perform the tightening procedure again beginning with the first
step.
7. Turn the nut 90 to 94 to bring the mark on the
nut into alignment with that on the bolt.
AK202821
2. Make sure that the thrust clearance of the

connecting rod big end is proper.
Limit: 0.4 mm
>>G<< CONNECTING ROD CAP NUT
INSTALLATION
1. The connecting rod cap bolts and nuts are
tightened using the torque-to-yield method. For
this reason, each bolt to be reused must be
checked for elongation before installation.
Whether or not the bolt has been elongated can
be determined by running a nut with fingers
through all the threads of the bolt. If the nut does
not turn smoothly over all the threads, the bolt has
been elongated and must be replaced.
2. Apply engine oil to the threads and bearing
surface of each nut before installation.
3. Finger-tighten the nuts on the bolts, then tighten
the nuts alternately and repeatedly to install the
cap properly.
4. Tighten the nuts to a torque of 20 2 Nm.
90 to 94
INSPECTION
M1113008500365
PISTON RING
AK202787
1. Measure the clearance between each piston ring

and its groove. If the limit is exceeded, replace the
ring or piston, or both.
Standard values:
No. 1 ring: 0.03 - 0.07 mm
No. 2 ring: 0.02 - 0.06 mm
Limits: 0.1 mm
Force ring down
with piston
Paint marks
Paint marks
Piston ring
Nut
Bolt
AK202721 AB
5. Make a paint mark on the head of each nut.

6. Make a paint mark on the bolt at a point 90to 94
away from the paint mark made on the nut in the
tightening direction.
End gap
AK202788 AB
2. Install a piston ring or oil ring side rail into the

cylinder bore and force it down with the head of a
piston until the ring is at right angles to the
cylinder wall. Measure the end gap with a
thickness gauge.
NOTE: If the end gap is excessive, replace the
piston ring.
Standard values:
No. 1 ring: 0.25 - 0.35 mm
No. 2 ring: 0.40 - 0.55 mm
Oil ring: 0.10 - 0.40 mm
ENGINE OVERHAUL
11B-57
Limits:
No. 1 ring: 0.8 mm
No. 2 ring: 0.8 mm
Oil ring: 1.0 mm
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC
GAUGE METHOD)
1. Wipe off oil from the crankshaft pin and
connecting rod bearing.
2. Cut a piece of plastic gauge whose length is
equivalent to the width of the bearing and place it
on the crankshaft pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten
the nuts to the specified torque20 2 Nm + 90 to
94.
4. Remove the nuts, then remove the connecting rod
cap carefully.
AK202848
5. Measure the largest width of the crushed plastic

gauge using the ruler printed on the bag of the
plastic gauge.
Limit: 0.1 mm
ENGINE OVERHAUL
11B-58

M1113008700507
CAUTION
On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown
in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in
damage.
3
Apply engine oil
to all moving
parts before
installtion.
2
1
11 1 Nm
16
11 1 Nm
15
132 5 Nm
9.0 1.0 Nm
14
13
12
11
10
25 2 Nm + 90 to 100
AK204351AB
>>E<<
>>D<<
1.
2.
3.
4.
5.
6.
7.
8.
Removal steps
Flywheel bolt
Adapter plate
Flywheel
Adapter plate
Crankshaft bushing
Rear plate
Bell housing cover
Oil seal case
>>C<< 9. Oil seal

>>C<< 10. Bearing cap bolt
>>B<< 11. Beam bearing cap
12. Crankshaft bearing, lower
>>B<< 13. Crankshaft

>>A<< 14. Crankshaft bearing, upper
15. Thrust bearing
16. Cylinder block
ENGINE OVERHAUL
11B-59

>>A<< THRUST BEARING INSTALLATION
If the crankshaft journal diameter mark is 0 and

the cylinder block bearing bore mark is 1, then
select a bearing with a 2 mark as the No. 1, 2, 4
or 5 bearing and a bearing with a 1 mark as the
No. 3 bearing.
If the crankshaft journal diameter mark is illegible,
measure the journal diameter and select a
bearing with the mark corresponding to the
measurement.
Groove
Timing belt side
AK202769 AB
Diameter identification marks of

bearing bores in cylinder block
Install the two thrust bearings in the No. 3 bearing

bore in the cylinder block. Each thrust bearing must
be installed with the grooved end toward the crankshaft web.
NOTE: Applying engine oil to the bearings will help
facilitate holding them in position.
No. 4
No. 5
No. 3
No. 1 No. 2
>>B<< CRANKSHAFT BEARING INSTALLATION
Cylinder
bore size
mark
Location of crankshaft journal

diameter marks
No. 2
No. 1
No. 3
AK202777 AB
No. 4
No. 5
AK202908 AB
1. Location of crankshaft journal diameter marks

<Bearing selection example>
Crankshaft journal diameter
Identification mark Journal diameter
measurement mm
0
56.994 - 57.000
56.988 - 56.994
56.982 - 56.988
2. The diameter identification marks of the bearing

bores in the cylinder block are stamped in the
location shown in the drawing.
Cylinder block
bearing bore
marking
No. 1, 2, 4 and 5
bearing
No. 3 bearing
Crankshaft bearing marking
ENGINE OVERHAUL
11B-60
Crankshaft bearing size mark location

size mark
10
Size mark
AK202753 AB
3. The size mark of each crankshaft bearing is

indicated by ink in the location shown in the
drawing.
Groove
Arrow
AK202737 AB
4. Tighten the bolts to 25 2 Nm in the indicated

sequence.
5. Make a paint mark on the head of the bolt.
6. Make a paint mark on the bearing cap at a point
90 to 100 away from the paint mark made on the
bolt head in the tightening direction.
Paint mark
Paint mark
Upper bearing half

Lower bearing half
90 to 100
AK202770 AB
4. Install bearing halves with oil grooves in the

cylinder block bearing bores.
5. Install bearing halves with no oil grooves in the
beam bearing cap.
>>C<< BEAM BEARING CAP/BEARING CAP
BOLT INSTALLATION
1. Install the beam bearing cap on the cylinder block
with the arrow pointing to the timing belt.
AK202722 AB
CAUTION
If the tightening angle is less than 90, adequate tightness could not be assured.
If the tightening angle exceeds 100, loosen
the bolt completely and then perform the
tightening again beginning with the first step.
7. Turn clockwise the bolts 90 to 100 in the
indicated tightening sequence to bring the mark
on each bolt head into alignment with that on the
bearing cap.
Nominal length
AK202805 AB
2. Measure the nominal length of each bearing cap

bolt before installation. If the measurement
exceeds the limit, replace the bolt.
Limit: 71.1 mm
3. Apply engine oil to the threads and bearing
surface of the bolt.
AK202823
8. After installing the beam bearing cap, measure

the end play of the crankshaft. If the end play
exceeds the limit, replace the crankshaft bearings.
ENGINE OVERHAUL
11B-61
Limit: 0.4 mm
>>D<< REAR OIL SEAL INSTALLATION
MB990938
Measure the crankshaft oil clearance using a plastic

gauge as follows:
1. Wipe off oil from the crankshaft journal surface
and the crankshaft bearing inner surface.
2. Install the crankshaft.
Plastic gauge
MD998776
AK202827 AB
Use the special tools to press-fit the rear oil seal in

the rear oil seal case.
Handle (MB990938)
Crankshaft rear oil seal installer (MD998776)
>>E<< REAR OIL SEAL CASE INSTALLATION
1. Remove completely old FIPG remaining on the
rear oil seal case and cylinder block.
AK202826 AB
3. Cut a piece of plastic gauge whose length is

equivalent to the width of the bearing and place it
on the crankshaft journal in parallel with its axis.
4. Install the crankshaft bearing cap carefully and
tighten the bolts to the specified torque of 25 2
Nm + 90 to 100.
5. Remove the bolts, then remove the crankshaft
bearing cap carefully.
AK202824AB
2. Apply a bead of FIPG to the surface of the rear oil

seal case as shown in the drawing.
Specified sealant:
equivalent
3. Install the oil seal into the cylinder block after
applying an appropriate amount of engine oil to
the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts
to 11 1 Nm.
INSPECTION
M1113008800366
CRANKSHAFT OIL CLEARANCE

(PLASTIC GAUGE METHOD)
This plastic gauge method is recommended as a
simplest way of measuring the crankshaft oil clearance.
Plastic gauge
AK202822 AB
6. Measure the largest width of the crushed plastic

gauge using the ruler printed on the bag of the
plastic gauge.
Limit: 0.1 mm
CYLINDER BLOCK
1. Visually check the cylinder block for scratches,
rust, and any other corrosion. Also check it for
cracks using a flaw detecting penetrant.
If any defect is evident, replace the cylinder block.
11B-62
ENGINE OVERHAUL
BORING CYLINDERS
1. Select an oversize of the pistons to be used based
on the largest of the cylinder bores.
AK202833
2. Use a straightedge and thickness gauge to check

the cylinder block top surface for warp.
Make sure that the surface is free from remaining
gasket material and other foreign matter.
Limit: 0.1 mm
3. Check cylinder walls for scratches and seizure.
If defects are evident, rebore to oversize or
replace the cylinder block.
11.65 mm
Piston diameter
AK202880 AB
2. Oversize pistons are available in two oversizes:

0.50 mm and 1.00 mm. Bore each cylinder to a
size that provides the standard clearance when
combined with the selected piston. The reference
position for piston diameter measurement is as
3. Based on the piston diameter measurement,
calculate the boring finish dimension.
Boring finish dimension = [Piston diameter] +
[0.02 - 0.04 mm (clearance between piston and
cylinder)] - [0.02 mm (honing margin)]
CAUTION
12 mm
AK202731 AB
4. Use a cylinder gauge to measure the cylinder

bore diameter and taper.
If the cylinder is worn badly, rebore it to an
oversize and replace the piston and piston rings
with ones matched with the new bore size.
Taper: 0.01 mm
To prevent deformation of cylinder block that

would result from the heat generated by boring,
bore the cylinders in the following sequence: No.
2 No. 4 No. 1 No. 3.
4. Bore all the cylinders to the calculated boring
finish dimension.
5. Hone the bored cylinders to the final finish
dimension (piston diameter + clearance between
piston and cylinder).
6. Check the clearance between the piston and
cylinder.
16-1
GROUP 16
00
11
ENGINE
ELECTRICAL
12
13
14
15
16
CONTENTS
17
CHARGING SYSTEM . . . . . . . .
16
GENERAL INFORMATION . . . . . .
16
16
22
SERVICE SPECIFICATIONS. . . . .
16
SERVICE SPECIFICATIONS . . . . .
16
25
SPECIAL TOOL . . . . . . . . . . . . . . .
16
SPECIAL TOOL . . . . . . . . . . . . . . .
16
26
ON-VEHICLE SERVICE. . . . . . . . .
16
ON-VEHICLE SERVICE . . . . . . . . .
16
IGNITION SYSTEM . . . . . . . . .
16
21
27
31
ALTERNATOR OUTPUT LINE VOLTAGE

DROP TEST . . . . . . . . . . . . . . . . . . . . .
16
IGNITION COIL (WITH BUILT-IN POWER

TRANSISTOR) CHECK . . . . . . . . . . . . .
16
OUTPUT CURRENT TEST . . . . . . . . . .
16
RESISTIVE CORD CHECK . . . . . . . . . .
16
REGULATED VOLTAGE TEST. . . . . . .
16
SPARK PLUG CHECK AND CLEANING
16
CAMSHAFT POSITION SENSOR CHECK
16
CRANK ANGLE SENSOR CHECK . . . .
16
DETONATION SENSOR CHECK . . . . .
16
IGNITION SECONDARY VOLTAGE

WAVEFORM CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . .
16
36
IGNITION COIL. . . . . . . . . . . . . . . .
16
37
REMOVAL AND INSTALLATION. . . . . .
16
42
CAMSHAFT POSITION SENSOR .
16
51
16
52
16
54

OSCILLOSCOPE. . . . . . . . . . . . . . . . . .
ALTERNATOR ASSEMBLY . . . . .
16
16
REMOVAL AND INSTALLATION . . . . .
16
DISASSEMBLY AND REASSEMBLY . .
16
INSPECTION . . . . . . . . . . . . . . . . . . . . .
16
STARTING SYSTEM . . . . . . . . .
16
16
16
STARTER MOTOR ASSEMBLY . .
16
16
INSPECTION . . . . . . . . . . . . . . . . . . . . .
16
16
INSPECTION . . . . . . . . . . . . . . . . . . . . .
16
CRANKSHAFT POSITION SENSOR

16
DETONATION SENSOR . . . . . . . .
16
16
32
33
34
35
55
ENGINE ELECTRICAL
16-2
CHARGING SYSTEM
CHARGING SYSTEM
GENERAL INFORMATION
M1161000100287
The charging system uses the alternator output to

keep the battery charged at a constant level under
various electrical loads.
OPERATION
The average output voltage fluctuates slightly with

the alternator load condition.
When the ignition switch is turned on, current flows in
the field coil and initial excitation of the field coil
occurs.
When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field
current increases and it falls as the field current
decreases. When the battery voltage (alternator "S"
terminal voltage) reaches a regulated voltage of
approximately 14.4 V, the field current is cut off.
When the battery voltage drops below the regulated
voltage, the voltage regulator regulates the output
voltage to a constant level by controlling the field
current.
In addition, when the field current is constant, the
alternator output voltage rises as the engine speed
increases.
Voltage
Approximately
14.4 V
Time
AKX00183 AC
Rotation of the excited field coil generates AC

voltage in the stator.
This alternating current is rectified through diodes to
DC voltage having a waveform shown in the
illustration.
SYSTEM DIAGRAM
Alternator
B
Stator coil
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
G
S
L
Field coil
+
FR
Voltage regulator
Ignition switch
Charge warning light
Battery
AK100054 AF
ALTERNATOR SPECIFICATIONS
Item
Specification
Type
Battery voltage sensing
Rated output V/A
12/90
Voltage regulator
Electronic built-in type
ENGINE ELECTRICAL
16-3
CHARGING SYSTEM
M1161000300258
Item
Standard value
Limit
Alternator output line voltage drop (at 30 A) V
maximum 0.3
Regulated voltage ambient

-20C
temperature at voltage regulator V 20C
14.2 - 15.4
13.9 - 14.9
60C
13.4 - 14.6
80C
13.1 - 14.5
70 % of normal output current
Output current
SPECIAL TOOL
M1161000600163
Tool
Number
Name
Use
MB991519
Alternator test harness
Checking the alternator

("S" terminal voltage)
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST
M1161000900249
Ammeter (clamp-type)
Alternator
Voltmeter (digital-type)
"B" terninal
Battery
AK203361AD
This test determines whether the wiring from the

alternator "B" terminal to the battery (+) terminal
(including the fusible line) is in a good condition or
not.
1. Always be sure to check the following before the
test.
Alternator installation
Drive belt tension
(Refer to 311A, GROUP 11A - On-Vehicle

Service.)
Fusible link
Abnormal noise from the alternator while the
engine is running
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
16-4
ENGINE ELECTRICAL
CHARGING SYSTEM
4. Connect a clamp-type DC test ammeter with a

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

it until the value displayed on the ammeter is 30 A.
Take a reading of the value displayed on the
voltmeter at this time.
Limit: maximum 0.3 V
NOTE: When the alternator output is high and the
value displayed on the ammeter does not
decrease until 30 A, set the value to 40 A. Read
the value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is
maximum 0.4 V.
11.If the value displayed on the voltmeter is above
the limit value, there is probably a malfunction in
the alternator output wire, so check the wiring
between the alternator "B" terminal and the
battery (+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the
harness has become discolored due to
overheating, repair and then test again.
12.After the test, run the engine at idle.
13.Turn off all lamps and the ignition switch.
14.Remove the tachometer or the MUT-II.
15.Disconnect the negative battery cable.
16.Disconnect the ammeter and voltmeter.
17.Connect the negative battery cable.
ENGINE ELECTRICAL
16-5
CHARGING SYSTEM
OUTPUT CURRENT TEST

M1161001000238
Load
Ammeter
(clamp-type)
Voltmeter
Inition switch
Charging indicator
B
FR
L
Brake warning light
S
G
Battery
Alternator
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
AK203362 AH
This test determines whether the alternator output

current is normal.
1. Before the test, always be sure to check the
following.
Battery (Refer to 354A, GROUP 54A - Battery
- On-Vehicle Service.)
NOTE: The battery should be slightly discharged.
The load needed by a fully-charged battery is
insufficient for an accurate test.
Drive belt tension
Service.)
Fusible link
engine is running.
position.
CAUTION
Never use clips but tighten bolts and nuts to
connect the line. Otherwise loose connections
(e.g. using clips) will lead to a serious accident
because of high current.
output wire.
wire.
5. Connect a voltmeter with a range of 0 - 20 V
between the alternator "B" terminal and the earth
[Connect the (+) lead of the voltmeter to the "B"
terminal, and then connect the (-) lead of the
voltmeter to the earth].
6. Connect the negative battery cable.
speed check).
16-6
ENGINE ELECTRICAL
CHARGING SYSTEM
8. Leave the hood open.

9. Check that the reading on the voltmeter is equal to
the battery voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "B" terminal and the battery (+)
terminal.
10.Turn the light switch on to turn on headlamps and
then start the engine.
11.Immediately after setting the headlamps to high
beam and turning the heater blower switch to the
high revolution position, increase the engine
speed to 2,500 r/min and read the maximum
current output value displayed on the ammeter.
Limit: 70 % of normal current output
NOTE: .
For the nominal current output, refer to the
Alternator Specifications.
Because the current from the battery will soon
drop after the engine is started, the above step
should be carried out as quickly as possible in
order to obtain the maximum current output
value.
The current output value will depend on the
electrical load and the temperature of the
alternator body.
If the electrical load is small while testing, the
specified level of current may not be output
even though the alternator is normal. In such
cases, increase the electrical load by leaving
the headlamps turned on for some time to
discharge the battery or by using the lighting
system in another vehicle, and then test again.
The specified level of current also may not be
output if the temperature of the alternator body
or the ambient temperature is too high. In such
cases, cool the alternator and then test again.
12.The reading on the ammeter should be above the
limit value. If the reading is below the limit value
and the alternator output wire is normal, remove
the alternator from the engine and check the
alternator.
13.Run the engine at idle after the test.
14.Turn the ignition switch to the "LOCK" (OFF)
position.
ENGINE ELECTRICAL
16-7
CHARGING SYSTEM
REGULATED VOLTAGE TEST

M1161001100246
Load
Ammeter (clamp-type)
Ignition switch
MB991519
Black
B
FR
L
S
G
Alternator
Blue
Battery
Engine-ECU
<M/T> or
Engine-A/TECU <A/T>
Red
Yellow
Voltmeter (digital-type)
AK202360AH
This test determines whether the voltage regulator

correctly controlling the alternator output voltage.
1. Always be sure to check the following before the
test.
Check that the battery installed in the vehicle is
fully charged.
(Refer to 354A, GROUP 54A - Battery - OnVehicle Service.)
Drive belt tension
Service.)
Fusible link
engine is running
position.
4. Use the special tool Alternator test harness
(MB991519) to connect a digital voltmeter
between the alternator "S" terminal and earth
[Connect the (+) lead of the voltmeter to the "S"
terminal, and then connect the (-) lead of the
voltmeter to a secure earth or to the battery (-)
terminal].
output wire.

wire.
6. Reconnect the negative battery cable.
speed check).
8. Turn the ignition switch to the "ON" position and
check that the reading on the voltmeter is equal to
the battery voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "S" terminal and the battery (+)
terminal.
9. Turn all lamps and accessories off.
10.Start the engine.
11.Increase the engine speed to 2,500 r/min.
12.Read the value displayed on the voltmeter when
the alternator output current alternator becomes
10 A or less.
13.If the voltage reading conforms to the value in the
voltage regulation, then the voltage regulator is
operating normally.
If the voltage is not within the standard value,
there is a malfunction of the voltage regulator or of
the alternator.
ENGINE ELECTRICAL
16-8
CHARGING SYSTEM
14.After the test, lower the engine speed to the idle

speed.
15.Turn the ignition switch to the "LOCK" (OFF)
position.

19.Connect the alternator output wire to the
alternator "B" terminal.
20.Remove the special tool, and return the connector
to the original condition.
Voltage Regulation Table

Standard value:
Inspection terminal
Terminal "S"
Voltage regulator ambient

temperature C
Voltage V
-20
14.2 - 15.4
20
13.9 - 14.9
60
13.4 - 14.6
80
13.1 - 14.5
WAVEFORM CHECK USING AN OSCILLOSCOPE

M1161001200124
MEASUREMENT METHOD
Alternator
CH1
"B" terminal
AK100002 AC
Connect the oscilloscope special patterns pick-up to

the alternator "B" terminal.
STANDARD WAVEFORM
Observation Conditions
Function
Special pattern
Pattern height
Variable
Variable knob
Adjust while viewing the waveform.
Pattern selector
Raster
Engine speed
Curb idle speed
ENGINE ELECTRICAL
16-9
CHARGING SYSTEM
(V)
0.4
0.2
Voltage at
alternator
"B" terminal
0
0.2
0.4
Time
AKX00189AG
NOTE:
when the voltage waveform reaches an excessively

high value (approximately 2 V or higher at idle), it
often indicates an open circuit due to a brown fuse
between alternator "B" terminal and battery, but not a
defective alternator.
AKX00190
The voltage waveform of the alternator "B" terminal

can undulate as shown in the illustration. This
waveform is produced when the regulator operates
according to fluctuations in the alternator load
(current), and is normal for the alternator. In addition,
EXAMPLE OF ABNORMAL WAVEFORMS

NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
16-10
ENGINE ELECTRICAL
CHARGING SYSTEM
Abnormal waveform
Problem cause
Example 1
Open diode
AKX00191
Example 2
Short in diode
AKX00192
Example 3
Broken wire in
stator coil
AKX00193
Example 4
Short in stator
coil
AKX00194
Example 5
Open
supplementary
diode
AKX00195
At this time, the charging warning lamp is illuminated.
ENGINE ELECTRICAL
16-11
CHARGING SYSTEM
ALTERNATOR ASSEMBLY
M1161001400504
Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Drive Belt Removal (Refer to GROUP 11A, Crankshaft
Pulley 311A).
Post-installation Operation
Drive Belt Installation (Refer to GROUP 11A, Crankshaft
Pulley 311A).
Drive Belt Tension Adjustment (Refer to GROUP 11A, Onvehicle Service 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
3
5
1
7
11 1 Nm
13 1 Nm
44 10 Nm
12 2 Nm
N2
22 4 Nm
(Engine oil)
23 3 Nm
6
8.8 1.0 Nm
AC301643 AB
1.
2.
3.
4.
Removal steps
Oil level gauge and guide
O-ring
Detonation sensor harness
connector and clamp
Power steering oil pressure hose
clamp
<<A>>
<>
5.
6.
7.
8.
9.

Harness connector
Water pump pulley
Alternator connector
Alternator brace
Alternator assembly
ENGINE ELECTRICAL
16-12
CHARGING SYSTEM
REMOVAL SERVICE POINT

<<A>> HARNESS CONNECTOR
DISCONNECTION
<> ALTERNATOR ASSEMBLY REMOVAL

Remove the alternator assembly from above the
vehicle.
Lock lever
AC200022AE
Move the lock lever of the ABS-ECU connector as

shown in the illustration, and then disconnect the
harness connector.
ENGINE ELECTRICAL
16-13
CHARGING SYSTEM
DISASSEMBLY AND REASSEMBLY

M1161001600155
1
4
5
7
10
12
9
8
14
13
11
AK202845 AB
<<A>>
<>
>>B<<
1.
2.
3.
4.
5.
6.
7.
Disassembly steps
Front bracket assembly
Alternator pulley
Rotor
Rear bearing
Bearing retainer
Front bearing
Front bracket
<<C>>
<<C>> >>A<<
Disassembly steps&RQWLQXHG

8. Stator
9. Plate
10. Regulator assembly
11. Brush
12. Rubber packing
13. Rectifier
14. Rear bracket
ENGINE ELECTRICAL
16-14
CHARGING SYSTEM
DISASSEMBLY SERVICE POINTS

<<A>> FRONT BRACKET ASSEMBLY REMOVAL
<<C>> STATOR / REGULATOR ASSEMBLY

REMOVAL
Rectifier
assembly
Solder
Solder
AK202778 AB
AK202718
CAUTION
CAUTION
Do not insert the screwdriver blades too deep.
Doing so could damage the stator coil.
Insert the blades of screwdrivers between the front
bracket assembly and stator core, and pry and
separate them with the screwdrivers.
<> ALTERNATOR PULLEY REMOVAL
Use a 180 - 250 W soldering iron, and finish

unsoldering within four seconds. Diodes will
be damaged by heat if unsoldering time is too
long.
Avoid applying undue force to the diode
leads.
1. Unsolder the stator leads from the main diode of
the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the
regulator assembly, undo the soldered points on
the rectifier assembly.
REASSEMBLY SERVICE POINTS

>>A<< REGULATOR ASSEMBLY INSTALLATION
AK202714
Wire
CAUTION
Perform operation carefully not to damage the
rotor.
Clamp the rotor in a vise with the pulley facing up to
remove the pulley.
AK202779 AB
Rear bracket
Brush
Wire
AK202830 AB
After installing the regulator assembly, insert a piece

of wire through the hole in the rear bracket while
pressing the brush to keep the brush against
movement.
ENGINE ELECTRICAL
16-15
CHARGING SYSTEM
NOTE: Holding the brush with the wire facilities

installation of the rotor.
STATOR
>>B<< ROTOR INSTALLATION
Wire
AK202716
AK202779 AB
Remove the brush holding wire after the rotor has

been installed.
1. Check the continuity between coil leads.

If there is no continuity, replace the stator.
INSPECTION
M1161001700129
ROTOR
AK202717
2. Check the continuity between coil and core.

If there is no continuity, replace the stator.
AK202735
RECTIFIER ASSEBMLY
1. Measure the resistance between the two slip rings

of the rotor coil to check the continuity between
them.
Replace the rotor if the resistance is not within the
standard value range.
Standard value: 3 - 5 W
2. Check the continuity between the slip rings and
core.
AK202803
1. Check the condition of the (+) heat sink by

checking continuity between the (+) heat sink and
each of the stator coil lead connecting terminals.
If continuity is present for both terminals, the
diode is shorted. Replace the rectifier assembly.
AK202736
3. If continuity is present, replace the rotor.
ENGINE ELECTRICAL
16-16
STARTING SYSTEM
BRUSH
Protrusion
length
AK202802
2. Check the condition of the (-) heat sink by

checking continuity between the (-) heat sink and
each of the stator coil lead connecting terminals.
If continuity is present in both directions, the diode
is shorted. Replace the rectifier assembly.
AK202808 AB
1. Measure the length of the protrusion of the brush.

Replace the brush if the protrusion length is
shorter than the limit.
Limit: 2 mm minimum
2. Unsolder the lead of the brush. The brush will
come out, becoming ready for removal.
Solder
AK202804
3. Check the condition of the diode trio by testing

continuity of each of the three diodes using a
circuit tester connected to both sides of the diode.
Connect in a polarity and then reverse the polarity
for each test.
If continuity exists or no continuity exists for both
polarities, the diode is defective. Replace the
rectifier assembly if any of the diodes is defective.
AK202834 AB
3. Install a new brush by pushing it into the holder as

shown in the drawing and soldering the lead.
STARTING SYSTEM
GENERAL INFORMATION
M1162000100183
If the ignition switch is turned to the "START"

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

position after starting the engine, the starter clutch is
disengaged from the ring gear.
An overrunning clutch is provided between the pinion
and the armature shaft, to prevent damage to the
starter.
ENGINE ELECTRICAL
16-17
STARTING SYSTEM
SYSTEM DIAGRAM
Holding coil
Plunger
Pull-in coil
Lever
B
Ignition switch
Overrunning clutch
M
S
Pinion gear
Armature
Battery
Brush
Yoke
AK202970 AB
STARTER MOTOR SPECIFICATIONS

Item
Specification
Type
Reduction drive with planetary gear
Rated output kW/V
1.4/12
Number of pinion teeth
M1162000300057
Item
Standard value
Limit
Pinion gap mm
0.5 - 2.0
Commutator run-out mm
0.05
0.1
Commutator diameter mm
29.4
28.8
Undercut depth mm
0.5
0.2
ENGINE ELECTRICAL
16-18
STARTING SYSTEM
STARTER MOTOR ASSEMBLY

M1162001000587
Pre-removal and Post-installation Operation

Resonator and Air Intake Duct Removal and Installation
(Refer to GROUP 15, Air Cleaner 314).
Under Cover Removal and Installation (Refer to GROUP
51, Under Cover 311A).
18 3 Nm
9.0 2.0 Nm
3
30 3 Nm
1
49 9 Nm
2
5
AC301550 AB
1.
2.
3.
Removal steps
Starter cover
Starter connector
Clutch release cylinder connecting
bolts

<<A>> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from above the vehicle.
<<A>>
4.
5.
6.

Clutch hose clamp
Starter assembly
Starter cover bracket
ENGINE ELECTRICAL
16-19
STARTING SYSTEM
STARTER MOTOR ASSEMBLY INSPECTION

M1162001100186
PINION GAP ADJUSTMENT
MAGNETIC SWITCH PULL-IN TEST
Switch
S
S
M
battery
Starter
motor
Battery
Starter
motor
Wire
AKX01242 AE
AKX01238 AF
1. Disconnect the field coil wire from the M-terminal

of the magnetic switch.
2. Connect a 12-volt battery between the S-terminal
and M-terminal.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move
out.
Wire

CAUTION
and M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it
doesnt, replace the magnetic switch.
MAGNETIC SWITCH HOLD-IN TEST
Stopper
S
M
Battery
Pinion
Pinion gap
Starter
motor
AKX00198 AC
4. Check the pinion-to-stopper clearance (pinion

gap) with a feeler gauge.
Wire
AKX01244AE

CAUTION
AKX00199
5. If the pinion gap is out of specification, adjust by

adding or removing gasket(s) between the
magnetic switch and front bracket.

and body.
3. Manually pull out the pinion as far as the pinion
stopper position.
4. If the pinion remains out, everything is in order. If
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
ENGINE ELECTRICAL
16-20
STARTING SYSTEM
FREE RUNNING TEST

Ammeter
A
S
M
MAGNETIC SWITCH RETURN TEST
Carbon-pile
rheostat
S
M
Battery
Starter
motor
Battery
V
Voltmeter
Starter
motor
AKX01246 AE
1. Place the starter motor in a vise equipped with

soft jaws and connect a fully-charged 12-volt
battery to the starter motor as follows:
2. Connect a test ammeter (100-ampere scale) and
carbon pile rheostat in series between the positive
battery terminal and starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the
starter motor.
4. Rotate the rheostat to full-resistance position.
5. Connect the battery cable from the negative
battery terminal to the starter motor body.
6. Adjust the rheostat until the battery positive
voltage shown on the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns
smoothly and freely.
Current: maximum 90 Amps
Wire
AKX01248 AE

CAUTION
2. Connect a 12-volt battery between the M-terminal
and body.
WARNING
Be careful not to get your fingers caught
when pulling out the pinion.
3. Pull the pinion out and release. If the pinion
quickly returns to its original position, everything is
operating properly. If it doesnt, replace the
magnetic switch.
ENGINE ELECTRICAL
16-21
STARTING SYSTEM

M1162001200183
12
16 14
13
11
15
21
2
20
19
17 18
22
4
8
7
9
10
<<A>>
Disassembly steps
1. Cover
2. Screw
3. Magnetic switch
4. Screw
5. Bolt
6. Rear bracket
7. Brush holder
8. Rear bearing
9. Armature
10. Yoke assembly
11. Ball
AK202910 AB
<> >>A<<
<> >>A<<

12. Packing A
13. Packing B
14. Plate
15. Planetary gear
16. Lever
17. Snap ring
18. Stop ring
19. Overrunning clutch
20. Internal gear
21. Planetary gear shaft
22. Front bracket
ENGINE ELECTRICAL
16-22
STARTING SYSTEM
STARTER MOTOR PARTS CLEANING
<<A>> MAGNETIC SWITCH REMOVAL
Never clean in a solvent such starter motor parts

as the magnetic switch, brush holder, and
armature. If they are soaked in a solvent, their
insulation could be impaired. When these parts
require cleaning, wipe off contamination with
cloth.
1. Never soak the drive unit in a solvent. If it is
washed in a solvent, the grease having been
packed in the overrunning clutch at the factory will
be washed out. Wipe the drive unit with cloth if it
requires cleaning.
B terminal
M terminal
S terminal
Field coil
lead
AK202890 AB
CAUTION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the
magnetic switch.
>>A<< STOP RING/SNAP RING INSTALLATION
<> SNAP RING/STOP RING REMOVAL

Socket wrench
Stop ring
Stop ring
Overrunning
clutch
Stop ring
Pinion Gear
Overrunning
clutch
Snap ring
AK202911 AB
Use a suitable puller to pull the stop ring until it gets

over the snap ring.
AK202790 AB
1. Apply a long socket wrench of an appropriate size

to the stop ring and strike the wrench to drive out
the stop ring toward the pinion gear side.
Snap ring
pliers
INSPECTION
M1162001300135
COMMUTATOR
Snap ring
Pinion gear
Overrunnning
clutch
AK202712
AK202791 AB
2. Remove the snap ring with snap ring pliers, then

remove the stop ring and overrunning clutch.
1. Support the armature with a pair of V block and

turn it to measure the runout of the surface not
rubbed by the brushes using a dial gauge.
Standard value: 0.05 mm or less
Limit: 0.1 mm
ENGINE ELECTRICAL
16-23
STARTING SYSTEM
Push the brush into the brush holder to make sure

that the spring is working on the brush.
If the spring is not working, replace the brush holder.
OVERRUNNING CLUTCH
Free
AK202715
2. Measure the diameter of the commutator.

Limit: 28.8 mm
Lock
AK202710 AB
Segment
1. Make sure that the pinion cannot be turned

counterclockwise and can be turned clockwise
freely.
2. Check the pinion for abnormal ware and damage.
Undercut
Mica
BRUSHES
AK202711 AB
3. Measure the depth of the undercut between

segments.
Limit: 0.2 mm
BRUSH HOLDER
Brush
height
AK202846 AB
AK202897
1. Check the commutator contacting surface of each

brush for abnormal roughness. Also check the
height of the brush. Replace the brush holder if
the height is lower than the limit.
Limit: 7.0 mm
2. When the contact surface of the brush is rectified
or the brush holder is replaced, recondition the
contact surface with sandpaper wrapped around
the commutator.
ENGINE ELECTRICAL
16-24
STARTING SYSTEM
ARMATURE COIL
1. Check the armature coil for short circuit as
follows:
MAGNETIC SWITCH
A
Growler
M terminal
AK202891 AB
AK202733 AB
2. Set the armature in a growler.
CAUTION
Clean the surface of the armature thoroughly
before performing the test.
3. While holding a thin strip of iron against the
armature in parallel with its axis, turn the armature
slowly. The armature is normal if the iron strip is
not attracted to the armature or it does not vibrate.
1. Coil open circuit test

Check that there is continuity between the M
terminal and body A.
If there is no continuity, replace the magnetic
switch.
B terminal
M terminal
AK202892 AB
AK202734
4. Check the insulation between commutator

segments and armature coils. The armature coils
are properly insulated if no continuity is present.
2. Contact fusion check

Check that there is no continuity between the B
terminal and M terminal.
If there is continuity, replace the magnetic switch.
B terminal
M terminal
AK202893 AB
AK202713
5. Check continuity between a segment and another.

There is no open circuit in the tested coil if there is
continuity.
3. Switch contact check

Push the indicated end of the magnetic switch
with a strong force to close the internal contacts.
Without releasing the switch end, check that
there is continuity between the B terminal and M
terminal.
If there is no continuity, replace the magnetic
switch.
ENGINE ELECTRICAL
16-25
IGNITION SYSTEM
IGNITION SYSTEM
GENERAL INFORMATION
M1163000100249
This system is equipped with two ignition coils (A and

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

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

Intake air temperatur
sensor
Ignition
switch
Engine coolant
temperature sensor
Camshaft position
sensor
Crank angle sensor
Barometric pressure
sonsor
Ignition coil B
Ignition coil A
Engine-ECU
<M/T> or
Engine-A/TECU <A/T>
Battery
Spark plug
Detonatoin sensor
Cylinder No.
Ignition switch-ST
AK101074 AF
ENGINE ELECTRICAL
16-26
IGNITION SYSTEM
IGNITION COIL SPECIFICATION

Item
Specification
Type
Molded 2-coil
SPARK PLUG SPECIFICATIONS

Item
Specification
NGK
IGR6A11
M1163000300157
IGNITION COIL
Item
Standard value
Secondary coil resistance kW
8.5 - 11.5
SPARK PLUG
Item
Standard value
Limit
Spark plug gap mm
1.0 - 1.1
1.3
Item
Standard value
Limit
Resistance kW
Maximum 19
RESISTIVE CORD
SPECIAL TOOL
M1163000600200
Tool
Number
Name
Use
MD998773
Detonation sensor
wrench
Detonation sensor
removal and installation
ON-VEHICLE SERVICE
IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK
M1163001200272
Check by the following procedure, and replace if

there is a malfunction.
ENGINE ELECTRICAL
16-27
IGNITION SYSTEM
SECONDARY COIL RESISTANCE CHECK
RESISTIVE CORD CHECK

M1163001400113
AKX01264
Measure the resistance between the high-voltage

terminals of the ignition coil.
Standard value: 8.5 - 11.5 kW
PRIMARY COIL AND POWER

TRANSISTOR CONTINUITY CHECK
Measure the resistance of the all spark plug cables.

1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Maximum 19 kW
SPARK PLUG CHECK AND CLEANING

M1163004300290
NOTE: .
CAUTION
1.5 V
AKX00382
When pulling off the spark plug cable from the

plug always hold the cable cap, not the cable.
1. Remove the spark plug cables.
2. Remove the spark plugs.
CAUTION
1 2 3
AKX01265AD
An analogue-type circuit tester should be used.

Connect the negative (-) prove of the circuit tester
to terminal No. 1.
Do not attempt to adjust the gap of the iridium

plug.
Always use a plug cleaner and finish cleaning
within 20 seconds. Do not use wire brushes.
Otherwise, the iridium and platinum tip may
be damaged.
CAUTION
10 seconds) to prevent coil from burning and
power transistor from breakage.
1.5 V power supply
between 2 - 3
Continuity between 1 2
When current is flowing
Continuity
When current is not

flowing
No continuity
Iridium tip
Platinum tip
AKX01327AD
3. Check the plug gap and replace if the limit is

exceeded.
Limit: 1.3 mm
CAUTION
Be careful not to allow foreign matter in
cylinders.
4. Clean the engine plug holes.
5. Install the spark plugs.
ENGINE ELECTRICAL
16-28
IGNITION SYSTEM
CAMSHAFT POSITION SENSOR CHECK

M1163004400167
Check the camshaft position sensor circuit if selfdiagnosis code, No. P340 is shown.
(Refer to 313A, GROUP 13A - Troubleshooting
- Inspection procedure for diagnosis code.)
CRANK ANGLE SENSOR CHECK

M1163004500205
Check the crank angle sensor circuit if self-diagnosis

code, No. P335 is shown.
(Refer to 313A GROUP 13A - Troubleshooting
DETONATION SENSOR CHECK

M1163002900036
Check the detonation sensor circuit if self-diagnosis

code, No. P0325 is shown.
(Refer to 313A, GROUP 13A - Troubleshooting
IGNITION SECONDARY VOLTAGE

OSCILLOSCOPE
M1163001700170
MEASUREMENT METHOD
1. Clamp the secondary pickup around the spark
plug cable.
NOTE: .
The peak ignition voltage will be reversed
when the spark plug cables No. 2 and No. 4,
or No. 1 and No. 3 cylinders are clamped.
Because of the two-cylinder simultaneous
ignition system, the waveforms for two
cylinders in each group appear during
waveform observation (No. 1 cylinder - No. 4
cylinder, No. 2 cylinder - No. 3 cylinder).
However, waveform observation is only
applicable for the cylinder with the spark plug
cable clamped by the secondary pickup.
Identifying which cylinder waveform is
displayed can be difficult. For reference,
remember that the waveform of the cylinder
attached to the secondary pickup will be
displayed as stable.
2. Clamp the spark plug cable with the trigger
pickup.
NOTE: Clamp the trigger pickup to the same
spark plug cable clamped by the secondary
pickup.
STANDARD WAVEFORM
Observation Conditions
Function
Secondary
Pattern height
High (or Low)
Pattern selector
Raster
Engine revolutions
Curb idle speed
ENGINE ELECTRICAL
16-29
IGNITION SYSTEM
Spark line (point A)
kV
Ignition voltage
(point D)
Secondary
ignition voltage
wave pattern
Wave dampling reduction section (point B)
Dwell section
0
Point C
Time
AKX00278AD
Observation Conditions (The only change from above condition is the pattern selector.)
Pattern selector
Display
kV
NO. 1 cylinder
NO. 3 cylinder
ignition noise
Secondary ignition
voltage wave pattern
NO. 2 cylinder
ignition noise
Time
0
2
NO. 4 cylinder
Newtral section
AKX01275 AC
ENGINE ELECTRICAL
16-30
IGNITION SYSTEM
WAVEFORM OBSERVATION POINTS

Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal
waveform examples, 1, 2, 3 and 4).
Spark line
Plug gap Condition of Compression

force
electrode
Concentration Ignition
of air mixture timing
Spark plug
cable
Length
Long
Small
Normal
Low
Rich
Advanced
Leak
Short
Large
Large wear
High
Lean
Retarded
High
resistance
High
Large
Large wear
High
Lean
Retarded
High
resistance
Low
Small
Normal
Low
Rich
Advanced
Leak
Large
Plug is fouled -
Height
Slope
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations
Coil and condenser
3 or more
Normal
Except above
Abnormal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations
Coil
5 - 6 or higher
Normal
Except above
Abnormal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition
voltage
Plug gap
Condition of Compression
electrode
force
Concentration Ignition
of air mixture timing
Spark plug
cable
High
Large
Large wear
High
Lean
Retarded
High
resistance
Low
Small
Normal
Low
Rich
Advanced
Leak
EXAMPLES OF ABNORMAL WAVEFORMS
AKX00280
Example 1
Wave characteristics
Spark line is high and short.
Cause of problem
Spark plug gap is too large.
AKX00281
Example 2
Spark line is low and long, and is sloping.
Also, the second half of the spark line is distorted.
This could be a result of misfiring.
Cause of problem
Spark plug gap is too small.
ENGINE ELECTRICAL
16-31
IGNITION SYSTEM
AKX00282
Example 3
Spark line is low and long, and is sloping.
However, there is almost no spark line
distortion.
Cause of problem
Spark plug gap is fouled.
AKX00283
Example 4
Spark line is high and short.
Difficult to distinguish between this and abnormal
waveform example 1.
Cause of problem
Spark plug cable is nearly falling off (Causing a
dual ignition).
AKX00284
Example 5
No waves in wave damping section.
Cause of problem
Layer short in ignition coil.
ENGINE ELECTRICAL
16-32
IGNITION SYSTEM
IGNITION COIL
M1163004000374
10 2 Nm
3.0 0.5 Nm
1
4
4
3
2
5
25 4 Nm
AC301786 AB
1.
2.
3.
Removal steps
Rocker cover centre cover
Ignition coil connector
Spark plug cable
4.
5.

Ignition coil
Spark plug
ENGINE ELECTRICAL
16-33
IGNITION SYSTEM
CAMSHAFT POSITION SENSOR

M1163003400410
3N
8.8 1.0 Nm
AC301556 AB
1.
Removal steps
connector connection
2.
3.

O-ring
ENGINE ELECTRICAL
16-34
IGNITION SYSTEM
CRANKSHAFT POSITION SENSOR

M1163003500398
3.0 0.5 Nm
22 4 Nm
6
1
8.8 1.0 Nm
22 4 Nm
4
3
7
8.8 1.0 Nm
49 9 Nm
49 9 Nm
AC301612
1.
<<A>>
2.
3.
4.
Removal steps
Power steering pressure switch
connector
A/C compressor connector
A/C compressor connector clamp
Power steering oil pump assembly

<<A>> POWER STEERING OIL PUMP ASSEMBLY
REMOVAL
Remove the power steering oil pump assembly from
the bracket with the hose attached.
NOTE: Place the removed power steering oil pump
assembly in a place where it will not be a hindrance
when removing and installing and secure it with a
cord or wire.
5.
6.
7.
8.

Power steering oil pump bracket
Crankshaft position sensor
Crankshaft position sensor
connector bracket
ENGINE ELECTRICAL
16-35
IGNITION SYSTEM
DETONATION SENSOR
M1163002800493
CAUTION
Do not drop or hit the detonation sensor against other components. Internal damage may result, and
the detonation sensor will need to be replaced.
<Intake side>
2
23 2 Nm
1.
<<A>>
>>A<<
2.
AC301657AB
Removal steps
Detonation sensor connector
connection
Detonation sensor
INSTALLATION SERVICE POINT
<<A>> DETONATION SENSOR REMOVAL
>>A<< DETONATION SENSOR INSTALLATION
Detonation
sensor
MD998773
Detonation
sensor
MD998773
AC100807 AC
Use special tool detonation sensor wrench

(MD998773) to remove the detonation sensor.
AC100807 AC
Use special tool detonation sensor wrench

(MD998773) to tighten the detonation sensor to the
specified torque.
127(6
21B-1
GROUP 21B
00
11
CLUTCH
OVERHAUL
12
13
14
15
16
CONTENTS
17
21B
CLUTCH . . . . . . . . . . . . . . . . . . . . . . .
21B
CLUTCH REMOVAL AND INSTALLATION
21B
21
21B
CLUTCH INSPECTION . . . . . . . . . . . . . . . .
21B
22
21B
CLUTCH RELEASE CYLINDER . . . .
21B
25
TORQUE SPECIFICATIONS . . . . . . .
21B
CLUTCH RELEASE CYLINDER

DISASSEMBLY AND REASSEMBLY . . . . .
21B
26
21B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
21B
27
LUBRICANTS . . . . . . . . . . . . . . . . . .
31
32
33
34
35
36
37
42
51
52
54
55
CLUTCH OVERHAUL
21B-2

M1212002400041

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

Key service points, service standards, and instructions
for using special tools are collated as service points and
explained in detail.
<<A>>: Outward-pointing brackets denote removal service points

or disassembly service points.
>>A<<: Inward-pointing brackets denote installation service points
or reassembly service points.
Lubricant and Sealant Symbols

Every location where a lubricant or sealant must be applied or added is indicated using a relevant symbol in the
component part drawing and/or on the page after the
component part drawing.
. . . . . . . . . . Grease
. . . . . . . . . . Sealant or form-in-place gasket (FIPG)
. . . . . . . . . . Brake fluid
. . . . . . . . . . Gear oil
Inspection
If an inspection reveals a defect or fault, effect a repair and, if necessary, replace relevant parts.
AK300001
CLUTCH OVERHAUL
21B-3
Group title
Section title
Page number
MANUAL TRANSMISSION
OVERHAUL CONTROL HOUSING
22-43
CONTROL HOUSING
Denotes non-reusable part.
10
12
13
14
5
4
9
8
11
15
Tightening torque
2
1
22.3 0.3 Nm
Disassembly steps
1. Spring washer
2. Stopper bracket
<<A>> >>E<< 3. Lock pin
4. Interlock plate
5. Control finger
Procedures and cautions for removal, installation, disassembly, and reassembly are explained under this category of heading.
AK204399AB
Disassembly steps
>>D<< 6. Spring pin
7. Stopper body
8. Spring
9. Spacer
10. Control shaft
<<A>> LOCK PIN REMOVAL
Drive out the lock pin from the direction shown.
Lock pin
Control
finger
AK204273 AB
The alphabetical character in this category of

heading matches that of the relevant removal
steps, installation steps, disassembly steps,
or installation steps.
AK300002
CLUTCH OVERHAUL
21B-4
M1212000200148
Item
Specification
Clutch operating method
Hydraulic type
Clutch disc type
Single dry disc type
Clutch disc size OD ID mm
230 155
Clutch cover type
Diaphragm spring type
Clutch cover setting load N
4,320
M1212000300112
Item
Limit
Diaphragm spring end height difference
0.5 mm
Clutch disc facing rivet sink
Minimum 0.3 mm
M1212001800110
Part
Nm
Clutch fluid line bracket bolt
18 3
Clutch tube flare nut
15 1
Union bolt
22 2
Clutch release cylinder mounting bolt
18 3
Clutch cover mounting bolt
18 3
Fulcrum
35 6
Air bleeder
17 1
LUBRICANTS
M1212000400120
Item
Specified lubricant
Release fork and release bearing contact surface
MITSUBISHI genuine grease Part

Number 0101011 or equivalent
Release fork and fulcrum contact surface

Release fork and release cylinder pushrod contact surface
Clutch disc splines
Piston and piston cup
Release cylinder inner surface
Brake fluid DOT3 or DOT4
CLUTCH OVERHAUL
21B-5
CLUTCH
CLUTCH
M1212001000125
18 3 Nm
2
3
35 6 Nm
17
11
16
14
12
4
15
13
22 2 Nm
7
6
9
15 1 Nm
18 3 Nm
18 3 Nm
10
AK204191AB
1.
2.
3.
4.
5.
6.
7.
8.
9.
Removal steps
Clutch fluid line bracket
Insulator
Washer
Clutch tube
Union bolt
Union
Gasket
Valve plate <W5M42>
Compression spring <W5M42>
>>B<<
>>B<<
<<A>>
>>A<<
10.
11.
12.
13.
14.
15.
16.
17.

Clutch release cylinder
Clutch cover
Clutch disc
Return clip
Clutch release bearing
Release fork
Release fork boot
Fulcrum
CLUTCH OVERHAUL
21B-6
CLUTCH

<<A>> RELEASE FORK REMOVAL
1. Apply Mitsubishi genuine grease part number

0101011 or equivalent to the illustrated positions
of the release fork.
2. Install the release fork to the fulcrum.
>>B<< CLUTCH DISC AND CLUTCH COVER
INSTALLATION
Fulcrum
Flywheel
Clutch disc
Clip
Clutch disc
guide
Release fork
AK204409AB
Move the release fork in the direction shown to

remove the clip from the fulcrum.
Clutch cover

>>A<< RELEASE FORK INSTALLATION
Apply grease
AK204214 AB
1. Apply Mitsubishi genuine grease part number

0101011 or equivalent to the clutch disc splines
and rub it in the splines with a brush.
2. Using the clutch disc guide to position the clutch
disc on the flywheel.
3. Install the clutch cover onto the flywheel.
INSPECTION
M1212001100100
Apply grease
Apply grease
AK204410AB
CLUTCH COVER
1. Check the diaphragm spring end for wear and
uneven height. Replace if wear is evident or
height difference exceeds the limit.
Limit: 0.5 mm
2. Check the pressure plate surface for wear, cracks
and discoloration.
3. Check the rivets of the strap plate for looseness. If
loose, replace the clutch cover.
CLUTCH OVERHAUL
CLUTCH
CLUTCH DISC
CAUTION
Dont clean the clutch disc in a cleaning solvent.
1. Check the facing for loose rivets, uneven contact,
evidence of seizure, or deposited oils and
greases. If defective, replace the clutch disc.
NOTE: If contaminated with grease or oil, determine the source of the contaminant and repair it.
21B-7
3. Check the torsion spring for play and damage. If

defective, replace the clutch disc.
4. Place the clutch disc on the input shaft and check
for sliding condition and play in the rotating
direction. If poor sliding condition is evident,
clean, reassemble, and recheck.
If excessive play is evident, replace the clutch disc
and/or input shaft.
CLUTCH RELEASE BEARING
Rivet sink
Torsion spring
AK300248AB
2. Measure the rivet sink. Replace the clutch disc if it

is below the limit.
Minimum limit: 0.3 mm
CAUTION
Release bearing is packed with grease. Therefore, do not wash it in a cleaning solvent.
1. Check for seizure, damage, noise or binding/
rough rotation.
2. Check for wear on the surface which contacts with
the diaphragm spring.
3. Check for wear on the surface which contacts with
the release fork. If abnormally worn, replace.
RELEASE FORK
If the surface which contacts with the bearing is
abnormally worn, replace.
CLUTCH OVERHAUL
21B-8

M1212001500119
6
9
17 1 Nm
AK204216AB
<<A>>
>>A<<
1.
2.
3.
4.
5.
Disassembly steps
Push rod
Boot
Piston assembly
Piston cup
Piston
6.
7.
8.
9.

Conical spring
Cap
Air bleeder
Release cylinder
CLUTCH OVERHAUL
21B-9
DISASSEMBLY SERVICE POINT
REASSEMBLY SERVICE POINT
<<A>> PISTON ASSEMBLY REMOVAL
>>A<< PISTON ASSEMBLY INSTALLATION
AKX00765
AK204411AB
1. Cover with a shop towel to prevent the piston from

popping out.
CAUTION
Apply compressed air slowly to prevent brake
fluid from splashing.
2. Apply the compressed air into the tube mounting
hole to remove the piston assembly.
AK204412AB
1. Apply brake fluid DOT3 or DOT4 to the piston cup

and inner surface of the release cylinder.
2. Insert the piston assembly into the release
cylinder.
INSPECTION
M1212001600116
PISTON CUP
Check the lip of piston cup for scratch. If it is
scratched, check the inner surface of the release cylinder for scratches.
RELEASE CYLINDER
Check the inner surface of the release cylinder for
scratches or abnormal wear, replace if necessary.
127(6
22B-1
GROUP 22B
00
11
MANUAL
TRANSAXLE
(TRANSMISSION)
OVERHAUL
12
13
14
15
16
17
21
22
CONTENTS
22B
22B
25
OUTPUT SHAFT. . . . . . . . . . . . . . . . . 22B

OUTPUT SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B
OUTPUT SHAFT INSPECTION . . . . . . . . .
22B
31
REVERSE IDLER GEAR . . . . . . . . . . 22B
32
22B
SNAP RING, SPACER AND THRUST

PLATE FOR ADJUSTMENT . . . . . . .
22B
TORQUE SPECIFICATION . . . . . . . .
22B
SPEEDOMETER GEAR . . . . . . . . . . . 22B
22B
SPEEDOMETER GEAR DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B
22B
SELECT LEVER . . . . . . . . . . . . . . . . . 22B
SEALANTS . . . . . . . . . . . . . . . . . . . .
LUBRICANTS . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . .
22B
TRANSMISSION . . . . . . . . . . . . . . . .
22B
TRANSMISSION DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B
TRANSMISSION INSPECTION . . . . . . . . .
22B
INPUT SHAFT . . . . . . . . . . . . . . . . . .
22B
INPUT SHAFT DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B
INPUT SHAFT INSPECTION . . . . . . . . . . .
22B
26
REVERSE IDLER GEAR DISASSEMBLY

AND REASSEMBLY . . . . . . . . . . . . . . . . . .
22B
27
33
34
35
36
SELECT LEVER DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
37
22B
42
CONTROL HOUSING . . . . . . . . . . . . . 22B
51
CONTROL HOUSING DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B
52
CLUTCH HOUSING . . . . . . . . . . . . . . 22B
54
CLUTCH HOUSING DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B
Continued on next page
55
22B-2
TRANSMISSION CASE. . . . . . . . . . .
TRANSMISSION CASE DISASSEMBLY
AND REASSEMBLY. . . . . . . . . . . . . . . . . . .
DIFFERENTIAL . . . . . . . . . . . . . . . . .
DIFFERENTIAL DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .
22B
22B
22B
22B
CENTER DIFFERENTIAL . . . . . . . . . 22B

CENTER DIFFERENTIAL DISASSEMBLY
AND REASSEMBLY . . . . . . . . . . . . . . . . . .
22B
TRANSFER . . . . . . . . . . . . . . . . . . . . 22B
TRANSFER DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
22B
MANUAL TRANSAXLE (TRANSMISSION) OVERHAUL

GENERAL INFORMATION
22B-3
GENERAL INFORMATION
M1222000100090
MANUAL TRANSMISSION MODELS

Transmission model
Combined engine
Vehicle model
F5M42-2-Y4B2
4G63-D4-MPI
CU2W
W5M42-1-Z4B2
4G63-D4-MPI
CU2W
22B-4

GENERAL INFORMATION
SECTIONAL VIEW
<F5M42>
AK204419

GENERAL INFORMATION
22B-5
<W5M42>
AK204420
22B-6
M1222000200127
TRANSMISSION MODEL TABLE

Transmission
Speedomerter
model
gear ratio
Final gear
ratio
Vehicle model
Engine model
Transfer
gear ratio
F5M42-2-Y4B2
36/27
4.625
CU2W
4G63-D4-MPI
W5M42-1-Z4B2
36/27
4.687
CU2W
4G63-D4-MPI
0.3018
GEAR RATIO TABLE

F5M42
1st
3.583
2nd
1.947
3rd
1.379
4th
1.030
5th
0.820
Reverse
3.363
W5M42
M1222000300102
Item
Standard value
Minimum limit
Differential case preload
0.05 - 0.11 mm
Input shaft front bearing end play
0 - 0.12 mm
Input shaft 5th speed gear end play
0 - 0.09 mm
Input shaft rear bearing end play
0 - 0.12 mm
Synchronizer ring back surface to gear clearance
0.5 mm
Output shaft roller bearing inner race end play
0 - 0.12 mm
Output shaft 3rd speed gear end play
0 - 0.09 mm
Output shaft ball bearing end play
0 - 0.09 mm
Differential pinion backlash <F5M42>
0 - 0.15 mm
Center differential pinion backlash <W5M42>
0.025 - 0.150 mm
SNAP RING, SPACER AND THRUST PLATE FOR

ADJUSTMENT
M1222012000120
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT FRONT BEARING END PLAY)
Thickness mm
Identification symbol
Thickness mm
2.24
None
2.38
Brown
2.31
Blue

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
22B-7
SNAP RING (FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY AND OUTPUT SHAFT
FRONT BEARING END PLAY)
Thickness mm
Thickness mm
1.43
Green (2)
1.59
Yellow (2)
1.51
White (2)
THRUST PLATE (FOR ADJUSTMENT OF INPUT SHAFT 5TH SPEED GEAR END PLAY)
Thickness mm
Thickness mm
2.82
2.98
2.86
3.02
2.90
3.06
2.94
3.10
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT 3RD SPEED GEAR END PLAY)
Thickness mm
Thickness mm
2.81
Green
2.97
Orange
2.85
White
3.01
Red
2.89
Yellow
3.05
Pink
2.93
Black
3.09
Blue
SNAP RING (FOR ADJUSTMENT OF OUTPUT SHAFT REAR BEARING END PLAY)
Thickness mm
Thickness mm
2.31
Black (2)
2.55
Yellow
2.35
None
2.59
Black
2.39
Blue
2.63
Orange
2.43
Brown
2.67
Blue
2.47
Green
2.71
Brown
2.51
White
SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD) <F5M42>

Thickness mm
Thickness mm
0.71
71
1.01
01
0.74
74
1.04
04
0.77
77
1.07
07
0.80
80
1.10
0.83
83
1.13
0.86
86
1.16
0.89
89
1.19
0.92
92
1.22
0.95
95
1.25
0.98
98
22B-8
SPACER (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE PRELOAD) <W5M42>

Thickness mm
Thickness mm
0.74
74
1.04
04
0.77
77
1.07
07
0.80
80
1.10
0.83
83
1.13
0.86
86
1.16
0.89
89
1.19
0.92
92
1.22
0.95
95
1.25
0.98
98
1.28
1.01
01
1.31
SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE BACKLASH) <F5M42>

Thickness mm
Thickness mm
0.72 - 0.79
0.98 - 1.02
0.80 - 0.84
1.02 - 1.06
0.85 - 0.90
1.07 - 1.11
0.90 - 0.94
1.12 - 1.16
0.94 - 0.98
1.16 - 1.20
SPACER (FOR ADJUSTMENT OF CENTER DIFFERENTIAL CASE BACKLASH) <W5M42>

Thickness mm
Thickness mm
0.75 - 0.82
1.05 - 1.12
0.83 - 0.92
1.09 - 1.16
0.93 - 1.00
1.15 - 1.22
1.01 - 1.08
M1222012100105
Part
Nm
Roll stopper bracket mounting bolt
70 10
Shift cable bracket mounting bolt
18 3
Select lever mounting bolt
18 3
Speedometer gear mounting bolt
3.9 1.0
Backup light switch
32 2
Poppet spring
32 2
Harness bracket bolt
18 3
Harness bracket bolt
3.9 1.0
Interlock plate bolt
30 3
Control housing mounting bolt
18 3
Under cover mounting bolt
6.9 0.9

SEALANTS AND ADHESIVES
Part
Nm
Reverse idler gear shaft mounting bolt
48 6
Clutch housing-transaxle case mounting bolt
44 5
Front bearing retainer mounting bolt
18 3
Transfer - clutch housing mounting bolt <W5M42>
69 10
Select lever mounting nut
11 1
Stopper bracket mounting bolt
22.3 0.3
Clutch release bearing retainer mounting bolt
9.8 0.2
Differential drive gear mounting bolt
132 5
22B-9
SEALANTS AND ADHESIVES

M1222000500106
Item
Specified sealant
Clutch housing-transaxle case mating surface
MITSUBISHI Genuine sealant part No. MD997740 or

equivalent
Under cover-transaxle case mating surface

Control housing-transaxle case mating surface
Air breather
3M SUPER WEATHERSTRIP No.8001 or equivalent
Differential drive gear bolt
3M STUD Locking No.4170 or equivalent
FORM-IN-PLACE GASKET (FIPG)

This transmission has several areas where the formin-place gasket (FIPG) is used for sealing. To ensure
that the FIPG fully serves its purpose, it is necessary
to observe some precautions when applying it. Bead
size, continuity and location are of paramount importance.
Too thin a bead could cause leaks. Too thick a bead,
on the other hand, could be squeezed out of location,
causing blocking or narrowing of fluid passages. To
prevent leaks or blocking of passages, therefore, it is
absolutely necessary to apply the FIPG evenly without a break, while observing the correct bead size.
FIPG hardens as it reacts with the moisture in the
atmospheric air, and it is usually used for sealing
metallic flange areas.
Disassembly
Parts sealed with a FIPG can be easily removed
without need for the use of a special method. In
some cases, however, the FIPG in joints may have to
be broken by tapping parts with a mallet or similar
tool.
Surface Preparation
Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper.
Make sure that the FIPG application surface is flat
and smooth. Also make sure that the surface is free
from oils, greases and foreign substances. Do not fail
to remove old FIPG that may remain in the fastener
fitting holes.
FIPG Application
Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet (in less
than 10 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during installation. Avoid operating the transmission or letting oils
or water come in contact with the sealed area before
a time sufficient for FIPG to harden (approximately
one hour) has passed.
FIPG application method may vary from location to
location. Follow the instruction for each particular
case described later in this manual.
22B-10
LUBRICANTS
LUBRICANTS
M1222000400079
TRANSMISSION
Item
Specified lubricant
Each O-ring
Hypoid gear oil SAE 75W-90 or 75W-85W conforming to

API classification GL-4
Each oil seal

Select lever shoe
MITSUBISHI genuine grease part No.0101011 or

equivalent
TRANSFER
Item
Specified lubricant
Each O-ring
Hypoid gear oil API classification GL-5 SAE 90
Each oil seal
SPECIAL TOOLS
M1222000600125
Tool
Number
Name
Application
MB990935
Installer adapter
Installation of differential case

taper roller bearing outer race
<F5M42> and center differential
case rear taper roller bearing
outer race <W5M42>
MB990938
Handle
Use with Installer adapter
MB990927
Installer adapter
Installation of sealing cap
MD998801
Bearing remover
Installation and removal of

gears, bearings and sleeves
MD998812
Installer cap
Use with Installer and Installer

adapter
B990938

SPECIAL TOOLS
Tool
22B-11
Number
Name
Application
MD998813
Installer-100
Use with Installer cap and

Installer adapter
MD998816
Installer adapter (30) Installation of input shaft front

bearing
MD998825
Installer adapter (52) Installation of 1st-2nd speed

synchronizer hub, 3rd-4th
speed synchronizer hub and 1st
speed gear sleeve
MD998824
Installer adapter (50) Installation of 4th speed gear

sleeve, 5th speed gear and
thrust plate stopper
MD998818
Installer adapter (38) Installation of input shaft rear

bearing, roller bearing inner
race, reverse gear sleeve and
output shaft rear ball bearing
MD998917
Bearing remover
Installation and removal of

gears, bearing and sleeves
MD998814
Installer-200
Use with Installer cap and

Installer adapter
MD998822
Installer adapter (46) Installation of 2nd speed gear

sleeve and 3rd speed gear
22B-12
Tool

SPECIAL TOOLS
Number
Name
Application
MD998819
Installer adapter (40) Installation of 5th-reverse

speed synchronizer hub, 4th
speed gear and 5th speed gear
sleeve
MD999566
Claw
Removal of taper roller bearing

outer race
MD998772
Valve spring
compressor
Removal of output shaft front

roller bearing outer race
MD998346
Bearing outer race

remover
Removal of output shaft front

MB990934
Installer adapter
Installation of output shaft front

MB991550
Bearing outer race

installer
Installation of center differential

case front taper roller bearing
outer race <W5M42>
MB990926
Installer adapter
Installation of clutch housing

input shaft oil seal
MD998325
Differential oil seal

installer
Installation of differential oil seal

SPECIAL TOOLS
Tool
22B-13
Number
Name
Application
MD998823
Installer adapter (48) Installation of differential case

taper roller bearing <F5M42>
and center differential case rear
taper roller bearing <W5M42>
MB990930
Installer adapter
MD998830
Installer adapter (66) Installation of center differential

case front taper roller
<W5M42>
MB990937
Installer adapter
Installation of transfer oil seal

<W5M42>
MD998800
Oil seal adapter

<W5M42>
MB990887
Ring

<W5M42>
MB990891
Bushing remover
installer base
Using with ring
MB990936
Installer adapter

<W5M42>
Removal of center differential

case front taper roller bearing
bearing <W5M42>
22B-14
TRANSMISSION
TRANSMISSION
M1222001000126
<F5M42>
18 3 Nm
32 2 Nm
3.9 1.0 Nm
3.9 1.0 Nm
7
11
70 10 Nm
18 3 Nm
10
1
70 10 Nm
AK203151AC
>>J<<
>>I<<
1.
2.
3.
4.
5.
6.
7.
Disassembly steps
Roll stopper bracket, front
Roll stopper bracket, rear
Shift cable bracket
Select lever
Speedometer gear
Backup light switch
Gasket
8.
9.
10.
11.

Poppet spring
Gasket
Harness bracket
Harness bracket
22B-15
TRANSMISSION
14
Apply gear oil to all
moving parts before
installation.
18 3 Nm
30 3 Nm
15
12
44 5 Nm
22
20
13
21
23
18
17
19
24
48 6 Nm
25
16
6.9 0.9 Nm
AK204218AB
>>H<<
>>G<<
12.
13.
14.
15.
16.
17.
18.
19.
Disassembly steps
Gasket
Control housing
Neutral return spring
Under cover
Reverse idler gear shaft bolt
Gasket
Reverse idler gear assembly
<<A>>
<>
>>F<<
>>E<<
>>D<<
>>D<<
20.
21.
22.
23.
24.
25.

Sealing cap
Transaxle case
Outer race
Spacer
Magnet holder
Magnet
22B-16
TRANSMISSION
moving parts before
installation.
30
29
27
28
26
32
38
31
34
33
39
36
37
18 3 Nm
35
AK204219AB
>>C<<
<<C>>
<<C>>
<<C>>
>>C<<
>>C<<
>>B<<
>>B<<
>>B<<
26.
27.
28.
29.
30.
31.
32.
33.
Disassembly steps
Spring pin
1st-2nd speed shift rail
1st-2nd speed shift fork
Spring pin
Spring pin
3rd-4th speed shift rail
3rd-4th speed shift fork
5th speed-reverse shift rail
<<C>>
>>B<<
<<D>>
<<D>>
>>A<<
>>A<<
34.
35.
36.
37.
38.
39.

5th speed-reverse shift fork
Front bearing retainer
Input shaft
Output shaft
Differential
Clutch housing
22B-17
TRANSMISSION
<W5M42>
18 3 Nm
32 2 Nm
3.9 1.0 Nm
9
11
3.9 1.0 Nm
14
10
18 3 Nm
13
8
70 10 Nm
12
2
70 10 Nm
3
69 10 Nm
AK204184AB
>>J<<
>>I<<
1.
2.
3.
4.
5.
6.
7.
8.
Disassembly steps
Transfer
O-ring
Roll stopper bracket, front
Roll stopper bracket, rear
Roll stopper bracket, adaptor
Shift cable bracket
Select lever
Speedometer gear
9.
10.
11.
12.
13.
14.

Backup light switch
Gasket
Poppet spring
Gasket
Harness bracket
Harness bracket
22B-18
TRANSMISSION
17
18 3 Nm
moving parts before
installation.
30 3 Nm
18
15
25
23
16
44 5 Nm
24
26
21
20
22
27
48 6 Nm
28
19
6.9 0.9 Nm
AK204187AB
>>H<<
>>G<<
15.
16.
17.
18.
19.
20.
21.
22.
Disassembly steps
Gasket
Control housing
Neutral return spring
Under cover
Reverse idler gear shaft bolt
Gasket
Reverse idler gear assembly
<<A>>
<>
>>F<<
>>E<<
>>D<<
>>D<<
23.
24.
25.
26.
27.
28.

Sealing cap
Transaxle case
Outer race
Spacer
Magnet holder
Magnet
22B-19
TRANSMISSION
33

moving parts before
installation.
32
30
31
29
35
41
34
37
36
42
39
40
18 3 Nm
38
AK204189AB
>>C<<
<<C>>
<<C>>
>>C<<
>>C<<
>>B<<
>>B<<
29.
30.
31.
32.
33.
34.
35.
Disassembly steps
Spring pin
1st-2nd speed shift rail
1st-2nd speed shift fork
Spring pin
Spring pin
3rd-4th speed shift fork
<<C>>
<<C>>
>>B<<
>>B<<
<<D>>
<<D>>
>>A<<
>>A<<
36.
37.
38.
39.
40.
41.
42.

5th speed-reverse shift rail
5th speed-reverse shift fork
Front bearing retainer
Input shaft
Output shaft
Differential
Clutch housing
22B-20
TRANSMISSION

<<A>> SEALING CAP REMOVAL
Sealing cap
<<C>> 3RD-4TH SPEED SHIFT RAIL/3RD-4TH

SPEED SHIFT FORK/5TH SPEED-REVERSE
SHIFT RAIL/5TH SPEED-REVERSE SHIFT FORK
REMOVAL
1. Shift the 3rd-4th speed shift fork and 5th speedreverse shift fork in the direction shown.
3rd-4th
speed
shift fork
AK204301 AB
1. Drive a screwdriver into the center of the sealing

cap.
2. Bend the screwdriver back to remove the sealing
cap.
<> TRANSAXLE CASE REMOVAL
1. Remove all sixteen bolts securing the transaxle
case to the clutch housing.
5th speed
reverse
shift fork
AK204222 AB
2. Pull up on the 3rd-4th speed shift rail and 5th

speed-reverse shift rail and take them out of the
hole in the clutch housing.
3rd-4th speed
shift rail
Snap ring
5th speedreverse
shift rail
AK204223 AB
AK204226 AB
2. Use snap ring pliers to expand the indicated snap

ring. The snap ring will release the grooved ball
bearing, and the output shaft assembly will fall
under its own weight.
CAUTION
Do not use a scraper or chisel to remove the
transaxle case.
3. Remove the transaxle case from the clutch
housing by gently prying on opposite sides at the
same time.
3. Slide the 3rd-4th speed shift rail and 5th speedreverse shift rail in the direction shown and
remove them together with the shift forks.
<<D>> INPUT SHAFT AND OUTPUT SHAFT
REMOVAL
Input shaft
Output shaft
AK204224 AB
Remove the input and output shafts together.

TRANSMISSION
22B-21
ADJUSTMENT BEFORE REASSEMBLY
SPACER SELECTION FOR DIFFERENTIAL CASE

PRELOAD ADJUSTMENT
>>A<< OUTPUT SHAFT/INPUT SHAFT INSTALLATION

Input shaft
Solders
Output shaft
AK204224 AB
AK204227 AB
1. Put solders (1.6 mm diameter, about 10 mm long)

in the illustrated positions of the transaxle case.
2. Install the taper bearing outer race and differential
assembly into the transaxle case.
NOTE: If necessary, replace the differential case
and taper bearing before carrying out these
adjustments.
3. Install the clutch housing and tighten the bolts to
4. Remove the clutch housing, and then remove the
differential assembly.
5. Remove the outer race and take out crushed
solders.
Install the input and output shafts together.

>>B<< 5TH SPEED-REVERSE SHIFT FORK/5TH
SPEED-REVERSE SHIFT RAIL/3RD-4TH SPEED
SHIFT FORK/3RD-4TH SPEED SHIFT RAIL
INSTALLATION
3rd-4th speed
synchronizer
sleeve
5th speedreverse
synchronizer
sleeve
AK204229AB
1. Shift the 3rd-4th speed synchronizer sleeve and

5th speed-reverse synchronizer sleeve in the
direction shown.
AKX00953
6. Measure the thickness of the crushed solder with

a micrometer and select a spacer that will provide
the standard preload value.
Standard value: 0.05 - 0.11 mm preload
5th speedreverse
shift fork
3rd-4th speed
shift fork
5th speedreverse
shift rail
AK204230 AB
2. Assemble the 3rd-4th speed shift rail and fork,

and the 5th speed-reverse shift rail and fork.
22B-22
TRANSMISSION
Installer adapter (MB990935)

Handle (MB990938)
5th speedreverse
shift rail
3rd-4th speed
shift rail
>>E<< TRANSAXLE CASE INSTALLATION
CAUTION
Squeeze sealant evenly onto the transaxle housing. Do not leave gaps or excess amounts, otherwise oil leaks are likely.
AK204223 AC
3. While fitting each shift fork in the groove of

synchronizer sleeve, slide the shift rails in the
direction shown and install.
4. Insert the 3rd-4th speed shift rail and 5th speedreverse shift rail into the rail hole in the clutch
housing.
>>C<< SPRING PIN INSTALLATION
1. Align the pin holes in the shift rail and shift fork.
Shift fork
Shift rail
2.5 mm
AK204232AB
1. Apply a 2 mm diameter bead of sealant

(Mitsubishi Genuine Part number MD997740 or
equivalent) as illustrated onto the transaxle case.
NOTE: Be sure to install the transaxle case onto
the transaxle housing while the sealant is still wet
(within 15 minutes).
Spring pin
AK204302 AC
2. Insert the new spring pin. Push it in as shown so

that the slit and center axis of the rail are aligned.
Snap ring
>>D<< SPACER AND OUTER RACE

INSTALLATION
1. Install the spacer selected in the section
"ADJUSTMENT BEFORE REASSEMBLY."
MB990938
MB990935
AK204231 AB
2. Using special tools, press the outer race into the

transaxle case.
AK204226 AB
2. Align the transaxle case and expand the snap

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

TRANSMISSION
>>F<< SEALING CAP INSTALLATION

MB990938
22B-23
2. Install the under cover to the transaxle case and

tighten the bolts to specified torque.
Tightening torque: 6.9 0.9 Nm
away from oil for approximately one hour.
MB990927
>>H<< CONTROL HOUSING INSTALLATION
CAUTION
AK204234 AB
Squeeze sealant onto the case. Do not leave

gaps or excess amounts, otherwise oil leaks are
likely.
1. Using special tools, press install the sealing cap

onto the case.
Handle (MB990938)
Sealing cap
AK204236AB
AK204233 AB
2. Evenly press the sealing cap so it is fully seated

and not at an angle.
>>G<< UNDER COVER INSTALLATION
CAUTION
Squeeze sealant onto the case. Do not leave
gaps or excess amounts, otherwise oil leaks are
likely.
1. Apply a 0.2 mm diameter bead of sealant

equivalent) as llustrated onto the control housing.
NOTE: Be sure to install the housig to the case
quickly while the sealant is still wet (within 15 minutes).
2. Install the control housing to the transaxle case
and tighten the bolts to specified torque.
away from the oil for approximately one hour.
>>I<< SPEEDOMETER GEAR INSTALLATION
O-ring
AK204235AB
1. Apply a 2 mm diameter bead of sealant

equivalent) as illustrated onto the under cover.
NOTE: Be sure to install the under cover to the
case quickly while the sealant is still wet (within 15
minutes).
AK204237 AB
1. Apply gear oil (Hypoid gear oil SAE 75W-90 or

75W-85W conforming to API classification GL-4)
to the O-ring of the speedometer gear. Install into
the transaxle housing.
2. Tighten the bolt to specified torque.
22B-24

TRANSMISSION
>>J<< SELECT LEVER INSTALLATION
INSPECTION
M1222001100101
Control shaft
BACKUP LIGHT SWITCH
Select lever
shoe
AK204238 AB
1. Apply grease (Mitsubishi Genuine Part number

0101011 or equivalent) to the control shaft sliding
portion of the select lever shoe.
2. Install the select lever and tighten the bolts to
specified torque.
AKX00952
Check for continuity between terminals.

SWITCH CONDITION
CONTINUITY
Pressed
Open
Released
Conductive
22B-25
INPUT SHAFT
INPUT SHAFT
M1222001600117
9
moving parts before
installation.
11
10
12
14
15
13
16
19
18
20
4
6
7
16
17
AK204391AB
<<A>>
<>
<<C>>
<<D>>
>>M<<
>>L<<
>>K<<
>>J<<
>>I<<
>>H<<
>>E<<
>>D<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Disassembly steps
Snap ring
Ball bearing
Thrust plate stopper
Thrust plate
5th speed gear
4th speed gear
Needle roller bearing
4th speed gear sleeve
Synchronizer ring
Synchronizer spring
>>G<<
>>F<<
>>E<<
>>D<<
<<E>>
>>C<<
>>B<<
>>A<<
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Synchronizer sleeve
3rd-4th speed synchronizer hub
Synchronizer ring
Synchronizer spring
3rd speed gear
Snap ring
Ball bearing
Oil seal
Input shaft
22B-26
INPUT SHAFT
<<D>>4TH SPEED GEAR SLEEVE REMOVAL
<<A>> BALL BEARING REMOVAL
MD998801
MD998801
AK204241 AB
AK204239 AB
1. Using special tool Bearing remover (MD998801),

support the ball bearing, and then set them on the
press.
2. Push down on the input shaft with the press and
remove the ball bearing.

support the 3rd speed gear, and then set them on
the press.
remove the 4th speed gear sleeve.
<<E>> BALL BEARING REMOVAL
<> THRUST PLATE STOPPER REMOVAL

MD998801
AK204242 AB
AK204293AB
Using a screwdriver, pry up at the position shown in

the illustration and remove the thrust plate stopper.
<<C>>5TH SPEED GEAR REMOVAL

press.
MD998801
>>A<< OIL SEAL INSTALLATION
Oil seal
3.5 mm
AK204240 AB

support the 5th speed gear, and then set them on
the press.
remove the 5th speed gear.
AK204243 AC
Install the oil seal into the end of the input shaft as
shown.
22B-27
INPUT SHAFT
>>B<< BALL BEARING INSTALLATION

MD998812
MD998813
MD998801
MD998816
Install the synchronizer spring onto the synchronizer

ring as shown.
>>E<< SYNCHRONIZER RING INSTALLATION
CAUTION
There are 3rd speed and 4th speed synchronizer
rings, if the wrong one is installed it will effect
the shift feeling.
Notch
AK204244AC

support the 2nd speed gear portion of the input
shaft, and then set them on the press.
2. Using special tools, press install the ball bearing
with the press.
Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (30) (MD998816)
>>C<< SNAP RING INSTALLATION
AK204312 AB
1. Ascertain whether or not there are identification

notches on the synchronizer ring.
Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring
2. Install the synchronizer ring so that it completely
fits over the machined cone of the gear.
>>F<< 3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Installation
direction
Snap ring
AK204245 AB
1. Install the thickest snap ring that can be fitted in

the snap ring groove of input shaft.
2. Make sure that the ball bearing end play meets
the standard value.
Standard value: 0 - 0.12 mm
Groove
>>D<< SYNCHRONIZER SPRING INSTALLATION
SYNCHRONIZER
Synchrnizer
SPRING
spring
AK204263AB
AK204295 AB

2. Make sure that the synchronizer ring has been
perfectly matched to the 3rd speed gear cone.
3. Check the installation direction of the 3rd-4th
speed synchronizer hub, and put it on the input
shaft.
22B-28
INPUT SHAFT
MD998812
MD998813
MD998801
MD998825
2. Install the synchronizer sleeve so that the areas

with teeth that have raised tips (three areas total)
are aligned with the areas on the synchronizer
hub that have deep grooves between the teeth
(three areas total).
>>H<< 4TH SPEED GEAR SLEEVE
INSTALLATION
AK204246 AC
4. Using special tools, press install the 3rd-4th

speed synchronizer hub with the press.
5. Make sure that the synchronizer ring can rotate
freely.
>>G<< SYNCHRONIZER SLEEVE INSTALLATION
Identification
groove
Installation
direction
MD998812
MD998813
MD998801
MD998824
AK204247 AC

2. Using special tools, install the 4th speed gear
sleeve with the press.
>>I<< 5TH SPEED GEAR INSTALLATION
AK204296AC
1. Check the installation direction of the

synchronizer sleeve, and install it onto the 3rd-4th
speed synchronizer hub.
MD998812
MD998813
MD998801
MD998824
Projecting portion
AK204248 AB
Deep grooves
AK204199AB

2. Using special tools, install the 5th speed gear onto
the input shaft with the press.
22B-29
INPUT SHAFT
>>J<< THRUST PLATE INSTALLATION

Surface stamped
with identification
mark
2. Using special tools, install the ball bearing onto

the input shaft with the press.
>>M<< SNAP RING INSTALLATION
Thrust plate
AK204249AB
1. Install the thickest thrust plates that can be fitted

in the groove of the input shaft. Install the thrust
plate so the surface stamped with the
identification mark is facing up.
2. Make sure that the 5th speed gear end play meets
the standard value.
>>K<< THRUST PLATE STOPPER INSTALLATION
Snap ring
AK204251 AB

the groove of the input shaft.
the standard value.
MD998812
INSPECTION
MD998813
INPUT SHAFT
M1222001700095
MD998824
AK204294 AB
Install the thrust plate stopper by pressing special

tools, by hand. Make sure that it is not tilted.
>>L<< BALL BEARING INSTALLATION
MD998812
MD998818
AK204201AB
1. Check the outside diameter of the needle bearing

mounting portion for damage, abnormal wear and
seizure.
2. Check the splines for damage and wear.
3. Check that the helical gear teeth surfaces are not
damaged or worn.
MD998801
AK204250 AC

NEEDLE ROLLER BEARING

1. Combine the needle roller bearing with the input
shaft or bearing sleeve and gear, and check that it
rotates smoothly without noise or play.
2. Check the needle roller bearing cage for
deformation.
22B-30
INPUT SHAFT
SYNCHRONIZER RING
SYNCHRONIZER SLEEVE AND HUB

Sleeve
Hub
AK204298AB
1. Check the clutch gear teeth for damage and

broken.
2. Check internal surface for damage, wear and
broken threads.
Gear
A
Synchronizer
ring
AK204217 AB
1. Combine the synchronizer sleeve and hub, and

check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or
broken.
SPEED GEARS
AK204307 AB
3. Force the synchronizer ring toward the clutch gear

and check clearance "A". If "A" is less than the
limit, replace the synchronizer ring.
AK204299AB
1. Check that the helical and clutch gear tooth

surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are not
roughened, damaged or worn.
3. Check that the gear inside diameter and front and
rear surfaces are not damaged and worn.
22B-31
OUTPUT SHAFT
OUTPUT SHAFT
M1222002200112
20
22
24

moving parts before
installation.
26
19
27
29
18
21
23
25
1
28
30
32
33
31
13
3 2
36
12
34
15
35
17
14 10 11
16
6
4
13
AK204392AB
<<A>>
<>
>>Q<<
>>P<<
>>O<<
<<C>>
>>M<<
>>L<<
>>F<<
>>N<<
>>M<<
>>L<<
<<D>>
>>K<<
>>J<<
>>I<<
>>H<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Disassembly steps
Snap ring
Ball bearing
Reverse gear sleeve
Reverse gear
Synchronizer ring
Synchronizer spring
Synchronizer sleeve
5th speed-reverse synchronizer
hub
Synchronizer ring
Synchronizer spring
5th speed gear
5th speed gear sleeve
4th speed gear
Snap ring
3rd speed gear
<<E>>
>>G<<
>>D<<
>>F<<
>>E<<
>>D<<
<<F>>
>>C<<
>>B<<
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

2nd speed gear
2nd speed gear sleeve
Inner synchronizer ring
Synchronizer cone
Outer synchronizer ring
Synchronizer spring
Synchronizer sleeve
1st-2nd speed synchronizer hub
Outer synchronizer ring
Synchronizer spring
Inner synchronizer ring
Synchronizer cone
1st speed gear
1st speed gear sleeve
Snap ring
22B-32
<<G>>
>>A<<
OUTPUT SHAFT
35. Roller bearing inner race
36. Output shaft

<<A>> BALL BEARING REMOVAL
MD998917
<<C>> 5TH SPEED-REVERSE SYNCHRONIZER

HUB REMOVAL
Synchronizer hub
MD998801
Ball bearing
AK204254 AB
AK204252 AC

press.
2. Push down on the output shaft with the press, and
<> REVERSE GEAR BEARING SLEEVE
REMOVAL
MD998801

support the 4th speed gear, and then set them on
the press.
2. Push down on the output shaft with the press and
remove the 5th speed-reverse synchronizer hub.
<<D>> 3RD SPEED GEAR REMOVAL
MD998917
3rd speed gear
Reverse gear
bearing sleeve
AK204255 AB
AK204253 AB

support the reverse gear, and then set them on
the press.
remove the reverse gear bearing sleeve.

support the 2nd speed gear, and then set them on
the press.
remove the 3rd speed gear.
<<E>> 2ND SPEED GEAR SLEEVE REMOVAL
2nd speed gear sleeve

MD998917
AK204256 AC

support the 1st speed gear, and then set them on
the press.
22B-33
OUTPUT SHAFT

remove the 2nd speed gear sleeve.
<<F>> 1ST SPEED GEAR SLEEVE REMOVAL

>>A<< ROLLER BEARING INNER RACE INSTALLATION
MD998801
1st speed gear sleeve
MD998812
MD998818
Roller bearing
inner race
MD998801
AK204260 AB
AK204257 AC

support the 1st speed gear sleeve, and then set
them on the press.
remove the 1st speed gear sleeve.
<<G>> ROLLER BEARING INNER RACE
REMOVAL
MD998917

support the output shaft gear, and then set them
on the press.
2. Using special tools, install the roller bearing inner
race with the press.
>>B<< SNAP RING INSTALLATION
Roller bearing
inner race
Snap ring
AK204258 AB

support the roller bearing inner race, and then set
them on the press.
remove the roller bearing inner race.
AK204261 AB

the groove of output shaft.
2. Make sure that the roller bearing inner race end
play meets the standard value.
>>C<<1ST SPEED GEAR SLEEVE INSTALLATION
1. Set the output shaft on the press support stand.
22B-34

OUTPUT SHAFT
MD998812
MD998812
MD998814
1st speed
gear sleeve
MD998825
MD998814
1st-2nd speed
synchronizer
hub
AK204265 AC
AK204262 AC
2. Using special tools, install the 1st speed gear

sleeve with the press.
>>D<< SYNCHRONIZER SPRING INSTALLATION
MD998825
3. Using special tools, install the 1st-2nd speed

synchronizer hub with the press.
4. Make sure that the outer synchronizer ring on the
1st speed gear side can rotate freely.
>>F<< SYNCHRONIZER SLEEVE INSTALLATION
Identification
groove
Installation
direction
Synchronizer spring
AK204316AB
Install the synchronizer spring onto the outer synchronizer ring

as shown.
>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB
INSTALLATION
AK204296AC
1. Check that the synchronizer sleeve is in the

correct direction for installation, and install it on
the 1st-2nd speed synchronizer hub.
Projecting portion
Installation direction
Deep grooves
AK204305 AC
2. Check that the 1st-2nd speed synchronizer hub is

in the correct installation direction, and put it on
the output shaft.
AK204199AB
2. Install the synchronizer sleeve so that the areas

with teeth that have raised tips (three areas total)
are aligned with the areas on the synchronizer
hub that have deep grooves between the teeth
(three areas total).
22B-35
OUTPUT SHAFT
>>G<< 2ND SPEED GEAR SLEEVE

INSTALLATION
>>I<< SNAP RING INSTALLATION
MD998812
MD998813
MD998822
Snap ring
AK204268AB
AK204266 AC
2. Using special tools, install the 2nd speed sleeve

onto the output shaft with the press.
>>H<< 3RD SPEED GEAR INSTALLATION
1. Check that the 2nd speed gear and the outer
synchronizer ring have been properly installed.
Also, make sure the claws on the synchronizer
cone (four places) are correctly fitted into the
holes in the 2nd speed gear (four places).

2. Make sure that the 3rd speed gear end play meets
the standard value.
>>J<< 4TH SPEED GEAR INSTALLATION
MD998812
MD998813
4th speed gear
MD998819
MD998812
MD998814
3rd speed gear
MD998822
AK204267 AB
2. Using special tools, install the 3rd speed gear

3. Make sure that the 2nd speed gear and the outer
synchronizer ring can rotate freely.
AK204269 AB
2. Using special tools, install the 4th speed gear onto

the output shaft with the press.
>>K<< 5TH SPEED GEAR SLEEVE
INSTALLATION
MD998812
5th speed
gear sleeve
MD998813
MD998819
AK204300 AB
Using special tools, install the 5th speed gear sleeve

22B-36
OUTPUT SHAFT
>>L<< SYNCHRONIZER SPRING INSTALLATION
AK204306 AB
SYNCHRONIZER
Synchrnizer
SPRING
spring
AK204263AB
3. Check that the 5th speed-reverse synchronizer

hub is oriented correctly for installation, and fit it
on the output shaft.
Install the synchronizer spring onto the synchronizer

ring as shown.
MD998812
MD998813
MD998819
>>M<< SYNCHRONIZER RING INSTALLATION

Synchronizer hub
CAUTION
There is a 5th speed synchronizer ring and a
reverse synchronizer ring. Be careful not to confuse the two when installing, as a mistake can
effect the shift feeling.
AK204228 AB
4. Using special tools, press install the 5th speedreverse synchronizer hub with the press.
5. Make sure that the synchronizer ring on the 5th
speed gear side can rotate freely.
Notch
AK204393AB
1. Check for the presence of identification notches

on the synchronizer ring.
No notches: 5th speed synchronizer ring
Three notches: Reverse synchronizer ring
2. Install the synchronizer ring so that it fits
completely over the machined cone of the gear.
>>N<< 5TH SPEED-REVERSE SYNCHRONIZER
HUB INSTALLATION
2. Make sure that the synchronizer ring is fitted
correctly on the cone of the 5th speed gear.
>>O<< REVERSE GEAR SLEEVE INSTALLATION

1. Make sure the synchronizer ring, reverse gear
and needle roller bearing have been correctly
installed.
MD998812
MD998818
Reverse
gear
Reverse gear
sleeve
AK204270 AB
2. Using special tools, press fit the reverse gear

sleeve. Make sure that the reverse gear and the
synchronizer ring can rotate freely during the
pressing process.

OUTPUT SHAFT

>>P<< BALL BEARING INSTALLATION
1. Check the installation direction of the ball bearing.
22B-37
1. Check the splines for damage and wear.

2. Check that the helical gear teeth surfaces are not
damaged or worn.
NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the
bearing sleeve and gear, and check that it rotates
smoothly without noise or play.
2. Check the needle roller bearing cage for
deformation.
MD998812
MD998818
Ball bearing
SYNCHRONIZER RING
AK204271 AC
2. Using special tools, install the ball bearing with

the press.
>>Q<< SNAP RING INSTALLATION
AK204298AB
1. Check if the clutch gear teeth are damaged or

broken.
2. Check internal surface for damage, wear and
broken threads.
Snap ring
Gear
A
Synchronizer
ring
AK204272 AC

the standard value.
INSPECTION
M1222002300090
OUTPUT SHAFT
AK204310AB
AK204307 AB
3. Force the synchronizer ring toward the clutch gear

and check clearance "A". If "A" is less than the
limit, replace the synchronizer ring.
22B-38
OUTPUT SHAFT
OUTER SYNCHRONIZER RING/INNER

SYNCHRONIZER RING/SYNCHRONIZER CONE
<FOR 1ST SPEED>
CAUTION
1. Check that the clutch gear tooth surfaces and

cone surfaces are not damaged or broken.
A
Gear
When replacing, replace the outer ring, inner ring

and cone as a set.
Outer ring
Cone
Inner ring
AK203130AD
AK204309AB
1. Check that the clutch gear tooth surfaces and

cone surfaces are not damaged or broken.
2. Install the outer ring, inner ring and cone, force

them toward the gear, and check clearance "A". If
"A" is less than the limit, replace them as a set.
SYNCHRONIZER SLEEVE AND HUB
Gear
Sleeve
A
Outer ring
Cone
Inner ring
Hub
AK204259 AB
2. Install the outer ring, inner ring and cone, force

them toward the gear, and check clearance "A". If
"A" is less than the limit, replace them as a set.
OUTER SYNCHRONIZER RING/INNER
SYNCHRONIZER RING/SYNCHRONIZER CONE
<FOR 2ND SPEED>
AK204217 AB
1. Combine the synchronizer sleeve and hub, and

check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
SYNCHRONIZER SPRING
CAUTION
When replacing, replace the outer ring, inner ring
and cone as a set.
AK204314AB
Check that the spring is not sagging, deformed or

broken.
AK204395AB

OUTPUT SHAFT
SPEED GEARS
22B-39
1. Check that the helical and clutch gear tooth

surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are
not roughened, damaged or worn.
3. Check that the gear inside diameter and front and
rear surfaces are not damaged and worn.
AK204299AB
22B-40
REVERSE IDLER GEAR
REVERSE IDLER GEAR

M1222012500084

moving parts before
installation.
1
7
2
3
5
6
4
AK204396AB
1.
2.
3.
4.
Disassembly steps
Snap ring
Cone spring
Thrust washer
Steel ball
5.
6.
7.

Reverse idler gear
Reverse idler gear shaft
22B-41
SPEEDOMETER GEAR
SPEEDOMETER GEAR
M1222003400089

moving parts before
installation.
AK204397AB
1.
2.
Disassembly steps
E-clip
Speedometer driven gear
3.
4.

O-ring
Sleeve
22B-42
SELECT LEVER
SELECT LEVER
M1222012800074
6
5
8
2
9
11 1 Nm
3
4
10
AK204398AB
>>A<<
>>A<<
>>A<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Disassembly steps
Dust cover
Nut
Spring washer
Washer
Select lever bushing
Select lever shoe
Select lever
Select lever bushing
Dust cover
Select lever shaft

>>A<< DUST COVER AND SELECT LEVER
BUSHING INSTALLATION
Select lever
bushing
Dust cover
AK204311 AB
Make sure the dust cover and select lever bushing

installation direction is correct, and the distinguished
parts are correctly assembled as shown.
22B-43
CONTROL HOUSING
CONTROL HOUSING
M1222013100090
10
12
13
14
5
4
9
8
11
15
22.3 0.3 Nm
AK204399AB
<<A>>
>>E<<
>>D<<
>>C<<
>>B<<
>>A<<
1.
2.
3
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Disassembly steps
Spring washer
Stopper bracket
Lock pin
Interlock plate
Control finger
Spring pin
Stopper body
Spring
Spacer
Control shaft
Air breather
Control shaft boot
Oil seal
Needle bearing
Control housing

<<A>> LOCK PIN REMOVAL
Lock pin
Control finger
AK204273 AB
Drive out the lock pin from the direction shown.
22B-44

CONTROL HOUSING
>>C<< AIR BREATHER INSTALLATION
>>A<< NEEDLE BEARING INSTALLATION

Control housing
Needle bearing
Model number
stamped side
0 0.5 mm
AK204274AB
AK204176AC
Press fit the needle bearing into the control housing

side as shown.
Make sure that the side with the model number
stamped on it faces the end of the control housing as
shown.
1. Apply sealant (3M SUPER WEATHERSTRIP No.

8001 or equivalent) to the inserting portion of air
breather.
Emboss
mark
>>B<< OIL SEAL INSTALLATION
AK204220 AB
2. Install the air breather so that the embossed mark

is in the direction shown in the figure.
AK204303AB
Apply gear oil (Hypoid gear oil SAE 75W-90 or 75W85W conforming to API classification GL-4) to the oil
seal lip area.
>>D<< SPRING PIN INSTALLATION
Control shaft
Stopper body
Slit
Spring pin
AK204177AB
Drive in the spring pin so that the slit is in the direction shown in the figure.

CONTROL HOUSING
>>E<<LOCK PIN INSTALLATION
22B-45
Drive the lock pin in from the direction shown in the

figure.
AK204273 AC
22B-46
CLUTCH HOUSING
CLUTCH HOUSING
M1222003700109
2
1
9.8 2.0 Nm
AK204400AB
<<A>>
<>
>>E<<
>>D<<
>>C<<
>>B<<
>>A<<
1.
2.
3
4.
5.
6.
7.
Disassembly steps
Clutch release bearing retainer
Oil seal
Oil seal
Outer race
Outer race
Bushing
Clutch housing

<<A>> OUTER RACE REMOVAL
MD999566
AK204276 AB
Using special tool Claw (MD999566), remove the

outer race from the clutch housing.
22B-47
CLUTCH HOUSING
<> OUTER RACE REMOVAL

MD998772
>>B<< OUTER RACE INSTALLATION
MD998346
Model number
stamped side
AK204277AB
1.
2.
Set special tools as indicated in the figure.

Valve spring compressor (MD998772)
Bearing outer race remover (MD998346)
Turn the nut on special tool Bearing outer race
remover (MD998346) to pull up on the tool and
take out the outer race.
AK204279 AB
1. Check the installation direction of the outer race.

Install the outer race so the side with the model
number stamping can be seen.
MB990938
MB990934
>>A<< BUSHING INSTALLATION
Seam of bushing
AK204280 AB
Air vent
2. Using special tools, press fit the outer race into

the clutch housing.
Handle (MB990938)
AK204278 AB
>>C<< OUTER RACE INSTALLATION

1. Check the installation direction of the outer race.
1. Press fit the bushing so the seam is away from

the air vent.
MB990938
1 mm
MB990935 <F5M42>
MB991550 <W5M42>
AK204281 AC
AK204291 AC
2. Be sure the bushing is fully seated as shown. It

must be 1 mm below the housing surface.
2. Using special tools, press fit the outer race into

the clutch housing.
Handle (MB990938)
Bearing outer race installer (MB991550)
22B-48

CLUTCH HOUSING
>>D<<OIL SEAL INSTALLATION
>>E<< OIL SEAL INSTALLATION
AK204284AB
AK204282AB

75W-85W conforming to API classification GL-4)
to the oil seal lip.
1. Apply transmission oil (Hypoid gear oil SAE 75W90 or 75W-85W conforming to API classification
GL-4) to the oil seal lip.
MB990938
MD998325
MB990926
AK204283 AB
2. Using special tool Differential oil seal installer

(MD998325), press fit the oil seal into the clutch
housing.
AK204285 AB
2. Using special tools, press fit the oil seal into the
clutch housing.
Handle (MB990938)
22B-49
TRANSMISSION CASE
TRANSMISSION CASE
M1222013400079
1
2
6
AK204407AB
>>C<<
>>B<<
1.
2.
3.
Disassembly steps
Oil seal
Needle bearing
Oil guide
>>A<<
4.
5.
6.

Snap ring
Bushing
Transaxle
22B-50
TRANSMISSION CASE

>>A<< BUSHING INSTALLATION
Model number
stamped side
Seam of bushing
AK204287 AB
Air vent
AK204292 AB
1. Press fit the bushing so the seam is away from

the air vent.
2. Press fit the needle bearing until it is flush with the

case.
>>C<<OIL SEAL INSTALLATION
3 mm
AK204304 AC
2. Be sure the bushing is fully seated as shown. It

must be 3 mm below the housing surface.
>>B<< NEEDLE BEARING INSTALLATION
1. Check the installation direction of the needle
bearing.
AK204286AB

75W-85W conforming to API classification GL-4).
MD998325
AK204288 AB
2. Using special tool Differential oil seal installer

(MD998325), press fit the oil seal into the
transaxle case.

DIFFERENTIAL
22B-51
DIFFERENTIAL
M1222002500094
<F5M42>

moving parts before
installation.
3
8
6
5
4
132 5 Nm
8
1
7
5
2
6
AK204408AB
<<A>>
>>D<<
>>C<<
>>B<<
>>A<<
>>A<<
1.
2.
3.
4.
5.
Disassembly steps
Differential drive gear
Taper roller bearing
Lock pin
Pinion shaft
Pinion
>>A<<
>>A<<
>>A<<
6.
7.
8.
9.

Washer
Side gear
Spacer
Differential case
22B-52

DIFFERENTIAL

<<A>> TAPER ROLLER BEARING REMOVAL
MD998801
AKX00770
3. Insert the pinion shaft.

AK204289 AB

support the taper roller bearing, and then set them
on the press.
2. Push down on the differential case with the press
and remove the bearing.

>>A<< SPACER/SIDE GEAR/WASHER/PINION/
PINION SHAFT INSTALLATION
AKX00768
1. After a spacer has been mounted on the back

surface of the side gear, install the side gear in the
differential case.
NOTE: When a new side gear is to be installed,
mount a medium thickness spacer.
2. Set the washer on the back of each pinion, and
put both pinions simultaneously in mesh with the
side gears. While rotating them, install them in
position.
AKX00766
4. Measure the backlash between the side gear and

pinion.
5. If the backlash is out of specification, select a
spacer that should get the back lash with in the
standard value and re-measure the backlash.
NOTE: Repeat until the backlash on both sides
are equal.
>>B<<LOCK PIN INSTALLATION
Differential case
Lock pin
Pinion shaft
AK204290 AB
Install the lock pin so that it will be oriented in the

direction shown.
22B-53
DIFFERENTIAL
>>C<< TAPER ROLLER BEARING INSTALLATION
MD998812
MD998823
1. Apply sealant (3M AAD Part Number 8730 or

8731 or equivalent) to the entire threaded portion
of the bolt.
Taper roller
bearing
7
6
AK204319 AC
Using special tools, install the taper roller bearing

with the press.
>>D<< DIFFERENTIAL DRIVE GEAR
INSTALLATION
AK204320AB
4
AK204221 AC
2. Tighten to the specified torque in the illustrated

sequence.
22B-54
CENTER DIFFERENTIAL
CENTER DIFFERENTIAL
M1222002800040
<W5M42>
1
moving parts before
installation.
11
12
12
132 5 Nm
17
9
14
10
12
13
12
11
15
16
9
AK204225AB
<<A>>
>>D<<
>>C<<
>>B<<
>>C<<
>>C<<
>>C<<
>>C<<
>>C<<
>>C<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
Disassembly steps
Center differential drive gear
Center differential flange
Snap ring
Front output shaft
Spacer
Side gear
Lock pin
Pinion shaft
<>
>>C<<
>>C<<
>>C<<
>>C<<
>>C<<
>>A<<
10.
11.
12.
13.
14.
15.
16.
17.

Pinion shaft holder
Pinions
Washers
Side gear
Spacer
Speed meter drive gear
Differential case

CENTER DIFFERENTIAL

<<A>> TAPER ROLLER BEARING REMOVAL
22B-55

with the press.
>>B<< TAPER ROLLER BEARING INSTALLATION
MD998917
MD998823
MD998812
AK204264AB
1. Support the taper roller bearing with special tool

bearing remover (MD998917), and then set them
on the press.
to remove the bearing.
<> TAPER ROLLER BEARING REMOVAL
MD998917
MB990930
AK204308AB

with the press.
>>C<< SPACER, SIDE GEAR, WASHER, PINION
AND PINION SHAFT, PINION SHAFT HOLDER,
LOCK PIN, FRONT OUTPUT SHAFT, SNAP RING,
CENTER DIFFERENTIAL FLANGE,
INSTALLATION
AK204275AB
1. Support the taper roller bearing with special tools,

and then set them on the press.
Bearing remover (MD998917)
to remove the bearing.

>>A<< TAPER ROLLER BEARING INSTALLATION
MD998830
MD998812
AK204297AB
AK204315
1. Mount a spacer on the back surface of the side

gear, and then install the side gear in the
differential case.
use a medium thickness spacer (0.93 to 1.00
mm).
2. Place the washers on the back of the pinions, and
simultaneously mesh the four pieces with the side
gears. Place them into position while rotating
them. Then, install the pinion shaft holder.
3. Insert the pinion shaft.
22B-56

CENTER DIFFERENTIAL
Differential case
Lock pin
Pinion shaft

9. If the backlash is out of the standard value, select
a spacer and re-measure the backlash.
NOTE: Adjust until the backlash on both sides are
equal.
>>D<< CENTER DIFFERENTIAL DRIVE GEAR
INSTALLATION
AK204317AC
4. Install the lock pin so that it will be oriented in the

direction shown.
5. Install the front output shaft on the side gear, and
install the snap ring.
6. Mount a spacer on the back surface of the side
gear, and then install the side gear in the
differential case.
use a medium thickness spacer.
7. Install the center differential flange by aligning the
matching marks, and temporarily tighten the four
machine screws.
AK204320AB
1. Apply sealant (3M STUD Locking No.4170 or

equivalent) to the entire threaded portion of the
bolt.
1
10
8
6
7
4
9
AK204318AB
AK204389
8. Measure the backlash between the side gear and

pinion.
2. Tighten to the specified torque in the illustrated

sequence.
22B-57
TRANSFER
TRANSFER
M1222004000062
4
1
2
5
6
11
8
9

moving parts before
installation.
10
23 3 Nm
>>E<<
>>D<<
>>A<<
>>A<<
>>A<<
>>C<<
>>B<<
>>A<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Disassembly steps
Dust seal guide
Oil seal
Oil seal
O-ring
O-ring
O-ring
Oil seal
Oil seal
O-ring
Transfer cover
Transfer

>>A<< O-RING INSTALLATION
Install a O-ring to the transfer, and apply gear oil
(Hypoid gear oil API classification GL-5 SAE 90) to
the O-ring.
AK204413AB

1. Apply gear oil (Hypoid gear oil API classification
GL-5 SAE 90).
MB990938
MB990937
AK204414AB
transfer cover.
Handle (MB990938)
22B-58
TRANSFER
>>C<< OIL SEAL INSTALLATION

GL-5 SAE 90).
MD998800
transfer.
Ring (MB990887)
Bushing remover installer base (MB990891)
>>E<< OIL SEAL INSTALLATION
GL-5 SAE 90).
MB990936
AK204415AB
2. Using special tool oil seal installer (MD998800),

press fit the oil seal into the transfer cover.
>>D<< OIL SEAL INSTALLATION
GL-5 SAE 90).
MB990891
MB990887
AK204416 AB
AK204417AB
2. Using special tool installer adapter (MB990936),

press fit the oil seal into the transfer.
12-1
GROUP 12
00
11
ENGINE
LUBRICATION
12
13
14
15
16
CONTENTS
17
12
SPECIAL TOOLS . . . . . . . . . . . . . . . .
12
SERVICE SPECIFICATION . . . . . . . .
12
ON-VEHICLE SERVICE . . . . . . . . . . .
12
ENGINE OIL CHECK . . . . . . . . . . . . . . . . .
12
ENGINE OIL REPLACEMENT . . . . . . . . . .
12
ENGINE OIL FILTER REPLACEMENT. . . .
12
OIL PRESSURE CHECK . . . . . . . . . . . . . .
12
LUBRICANT. . . . . . . . . . . . . . . . . . . .
12
SEALANT. . . . . . . . . . . . . . . . . . . . . .
12
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
ENGINE LUBRICATION
12-2
GENERAL INFORMATION
GENERAL INFORMATION
M1121000100346
The lubrication method is a fully force-fed, full-flow

filtration type. The oil pump is a gear type which is
driven by the crankshaft via the timing belt.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them. Other precautions:
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.
Avoid contaminating clothes, particularly

underpants, with oil.
Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
Do not wear heavily soiled clothing and oilimpregnated foot-wear. Overalls must be cleaned
regularly and kept separate from personal
clothing.
Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
Obtain First Aid treatment immediately for open
cuts and wounds.
Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
If skin disorders develop, obtain medical advice
without delay.
SERVICE SPECIFICATION
M1121000300135
Item
Oil pressure kPa
Standard value
at idle
29 or more
at 3,500 r/min
294 - 686
LUBRICANT
M1121000400400
Item
Specification
Engine oil ACEA classification
A1, A2 or A3
Engine oil API classification
SG or higher
Engine oil quantity L
Oil filter
0.3
Total
4.3
ENGINE LUBRICATION
12-3
SEALANT
SEALANT
M1121000500140
Item
Specified sealant
Remark
Oil pressure switch
3M ATD Part No. 1215, 3M ATD

Part No. 1141E, 3M ATD Part No.
1212D or equivalent
SPECIAL TOOLS
M1121000600363
Tool
Number
Name
Use
MB991610
Oil filter wrench
Removal and installation

of engine oil filter (When
using the oil filter of
MD356000)
MD998054
Oil pressure switch

wrench
Removal and installation

of oil pressure switch
MB991610
ON-VEHICLE SERVICE
ENGINE OIL CHECK
M1121000900320
1. Pull out the level gauge slowly and check that the
oil level is in the illustrated range.
2. Check that the oil is not excessively dirty, that
there is no coolant or petrol mixed in, and that it
has sufficient viscosity.
Drain plug
Drain plug
gasket
Oil pan side
ENGINE OIL REPLACEMENT
Oil pan
M1121001000386
1. Start the engine and allow it to warm up until the

temperature of the coolant reaches 80 C to 90
C.
2. Remove the engine oil filler cap.
CAUTION
Use care as oil could be hot.
3. Remove the drain plug to drain oil.
AC300837AB
4. Install a new drain plug gasket so that it faces in

the direction shown in the illustration, and then
tighten the drain plug to the specified torque.
NOTE: Install the drain plug gasket so it faces in
the direction shown in the illustration.
ENGINE LUBRICATION
12-4
ON-VEHICLE SERVICE
MB991610 or
commerciallyavailable tool
AC000093 AH
AC301513
5. Refill with specified quantity of oil.

Specified Engine Oil (ACEA and API
classification): ACEA A1, A2 or A3/API SG or
higher
Total quantity (Includes volume inside oil
filter): 4.3 L
6. Install the engine oil filler cap.
7. Check oil level.
5. Use the respective tool in the following table to

remove the engine oil filter.
6. Clean the filter bracket side mounting surface.
ENGINE OIL FILTER REPLACEMENT

M1121001100350
1. Start the engine and allow it to warm up until the

temperature of the coolant reaches 80 C to 90
C.
2. Remove the engine oil filler cap.
CAUTION
Use care as oil could be hot.
3. Remove the drain plug to drain oil.
4. Remove the under cover.
O-ring
AC103250 AD
7. Apply a small amount of engine oil to the O-ring of

the new oil filter.
8. Once the O-ring of the oil filter is touching the
flange, use the respective tool in the following
table to tighten to the specified torque.
9. Install the drain plug and refill the engine oil (Refer
to 312).
10.Race the engine 2-3 times, and check to be sure
that no engine oil leaks from installation section of
the oil filter.
Number
Special tool
Tightening torque
MD356000
Oil filter wrench (MB991610)

or equivalent
Approximately 3/4 turn (14 2 Nm)
MD136466,
MD322508
Commercially- available tool Approximately 3/4 turn (17 3 Nm)
OIL PRESSURE CHECK

M1121002300294
Cylinder block
Oil pressure switch
AK000197AF
ENGINE LUBRICATION
12-5
ON-VEHICLE SERVICE
1. Check engine oil quantity.

2. Remove the oil pressure switch terminal.
CAUTION
MD998054
AKX00295AD
AKX00294 AD
Since sealant is applied to the thread of oil

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

pressure switch.
Specified sealant: 3M ATD Part No. 1215 or
equivalent
CAUTION
MD998054
AKX00294 AD
Do not start the engine within one hour after the

oil pressure switch has been installed.
9. Use the special tool to tighten the oil pressure
switch to the specified torque.
10.Install the oil pressure switch terminal.
127(6
11A-1
GROUP 11A
00
11
ENGINE
MECHANICAL
12
13
14
15
16
CONTENTS
17
11A
11A
SEALANTS . . . . . . . . . . . . . . . . . . . .
11A
SPECIAL TOOLS. . . . . . . . . . . . . . . .
11A
ON-VEHICLE SERVICE. . . . . . . . . . .
CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
11A
22
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A
25
REMOVAL AND INSTALLATION <2WD>. .
11A
11A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11A
27
CRANKSHAFT OIL SEAL . . . . . . . . . 11A
31
11A
DRIVE BELT TENSION CHECK. . . . . . . . .
11A
AUTO-TENSIONER CHECK . . . . . . . . . . .
11A
IGNITION TIMING CHECK . . . . . . . . . . . . .
11A
IDLE SPEED CHECK . . . . . . . . . . . . . . . . .
11A
IDLE MIXTURE CHECK . . . . . . . . . . . . . . .
11A
COMPRESSION PRESSURE CHECK. . . .
11A
MANIFOLD VACUUM CHECK . . . . . . . . . .
11A
LASH ADJUSTER CHECK . . . . . . . . . . . . .
11A
11A
CYLINDER HEAD GASKET . . . . . . . . 11A

11A
TIMING BELT . . . . . . . . . . . . . . . . . . . 11A
11A
26
32
33
34
35
11A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11A
36
ENGINE ASSEMBLY . . . . . . . . . . . . . 11A
37
CRANKSHAFT PULLEY . . . . . . . . . . 11A

21
11A
42
51
52
54
55
ENGINE MECHANICAL
11A-2
GENERAL INFORMATION
GENERAL INFORMATION
M1111000100356
Item
4G63
Total displacement mL
1,997
Bore Stroke mm
85 88
Compression ratio
10.0
Compression chamber
Pentroof
Camshaft arrangement
DOHC
Number of valve
Valve timing
Intake
Exhaust
Intake opening
BTDC 17
Intake closing
ABDC 51
Exhaust opening
BBDC 57
Exhaust closing
ATDC 13
Fuel system
Electronically controlled multipoint fuel injection
Rocker arm
Roller type
Auto-lash adjuster
Equipped
M1112000300234
Item
Standard value
Limit
Vibration frequency Hz
(Reference)
110 - 144
Tension N (Reference)
245 - 412
Basic ignition timing
5 BTDC 2
Ignition timing
Approximately
10 BTDC
Idle speed r/min
750 100
CO contents %
0.5 or less
HC contents ppm
100 or less
Compression pressure kPa-r/min
1,370 - 250
930 - 250
Compression pressure difference of all cylinders kPa
Maximum 98
Intake manifold vacuum kPa
Minimum 60
Cylinder head bolt nominal length mm
99.4
Drive belt tension
Balancer timing belt tension (When

adjusted)
Deflection mm
5-7

replaced)
Deflection mm
5-7
ENGINE MECHANICAL
11A-3
SEALANTS
Item
Standard value
Limit
5 - 10
Timing belt tensioner adjuster rod protrusion amount mm
3.8 - 4.5
Timing belt tensioner adjuster rod movement mm
Within 1

checked)
Deflection mm
SEALANTS
M1112000500238
Item
Specified Sealant
Remark
Cylinder head
MITSUBISHI GENUINE PART MD970389 or

equivalent
Semi-drying
sealant
Camshaft position sensor support

Rocker cover
Camshaft end seal
Rocker cover gasket
MITSUBISHI GENUINE PART MD970389 or

equivalent
Engine oil pan <2WD>

Engine upper oil pan <4WD>
Engine lower oil pan <4WD>
SPECIAL TOOLS
M1112000600279
Tool
Number
Name
Use
MB991502
MUT-II sub assembly
Drive belt tension check

Checking the ignition timing
Checking the idle speed
MB991668
Belt tension meter set
Drive belt tension check (used

together with MUT-II)
MD998772
Valve spring compressor
Compressing valve spring
MD998737
Valve stem seal installer
Valve stem seal installation
B991502
B991668
MD998772
ENGINE MECHANICAL
11A-4
SPECIAL TOOLS
Tool
Number
Name
Use
MD998713
Camshaft oil seal installer
Camshaft oil seal installation
MD998727
Oil pan remover
Oil pan removal <2WD>
MD998781
Flywheel stopper
Supporting the flywheel
MB990938
Installer bar
Crankshaft rear oil seal

installation
MD998776

installer
MD998285
Crankshaft front oil seal

guide
MD998375

installer
MB991654
Cylinder head bolt wrench

(12)
D998713
D998727
D998781
B990938
D998776

installation
D998285
B991654

cylinder head bolt
ENGINE MECHANICAL
11A-5
SPECIAL TOOLS
Tool
Number
Name
Use
MD998738
Adjusting bolt
Supporting the timing belt

tensioner arm and timing belt
tensioner adjuster
MB991367
Special spanner
Holding the crankshaft camshaft

drive sprocket
MB991385
Pin
MD998767
Tensioner wrench
D998738
B991367
B991385
D998767
Valve timing belt tension

adjustment
ENGINE MECHANICAL
11A-6
ON-VEHICLE SERVICE
Tool
Number
Name
Use
MB991454
Engine hanger balancer
MB991527
Hanger
When the engine hanger is used:

Supporting the engine assembly
during removal and installation of
the transmission assembly
NOTE: Special tool MB991454 is
a part of engine hanger
attachment set MB991453.
MB991895
Engine hanger
B991454
B991527
Z203830
MB991928
A: MB991929
B: MB991930
E C: MB991931
D: MB991932
E: MB991933
F: MB991934
Slide bracket (HI)
F
A
D
B
Engine hanger
A: Joint (50) 2
B: Joint (90) 2
C: Joint (140) 2
D: Foot (standard) 4
E: Foot (short) 2
F: Chain and hook
assembly
C
B991928
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003100399
CAUTION
Check the drive belt tension after turning the
crankshaft clockwise one turn or more.
Indicator mark
AC107639AB
1. Make sure that the indicator mark is within the

area marked with A in the illustration.
2. If the mark is out of the area, replace the drive

belt. (Refer to 311A.)
NOTE: The drive belt tension check is not
necessary as auto-tensioner is adopted.
ENGINE MECHANICAL
11A-7
ON-VEHICLE SERVICE
AUTO-TENSIONER CHECK
M1111003000154
CAUTION
OPERATION CHECK
1. Turn OFF the engine from the idle state then
check to see that the drive belt is not protruding
from the pulley width of the auto-tensioner.
2. Remove the drive belt.(Refer to 311A.)
16-pin
MUT-II
AC107640AB
3. Securely insert the spindle handle or ratchet

handle with a 12.7 mm insertion angle into the jig
hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.
4. If there are any problems in the procedure 1 or 3,
replace the auto-tensioner.(Refer to 311A.)
5. Install the drive belt.(Refer to 311A.)
FUNCTION CHECK
You can verify if the auto-tensioner is defective or not
by checking the drive belt tension.
When using MUT-II
1. Check the drive belt tension. (Refer to 311A.)
2. Measure the drive belt tension vibration frequency
by the following procedures:
MB991668
AC211862 AB
To prevent damage to MUT-II, always turn the

ignition switch to the "LOCK" (OFF) position
before connecting or disconnecting MUT-II.
(1) Connect special tool belt tension meter set
(MB991668) to the MUT-II.
(2) Connect the MUT-II to the diagnosis
connector.
(3) Turn the ignition switch to ON position, and
select "BELT TENSION" on the menu screen.
ENGINE MECHANICAL
11A-8
ON-VEHICLE SERVICE
CAUTION
The temperature of the surface of the belt
should be as close to normal temperature as
possible.
Do not allow any contaminants such as water
or oil to get onto the microphone.
If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual
values.
If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not
correspond to actual values.
Do not take the measurement while the
vehicles engine is running.
Power steering
oil pump pulley
Power steering
oil pump pulley
Water pump
pulley
AC102807AB
2. Use a belt tension gauge in the middle of the belt

between the pulleys (at the place indicated by the
arrow) to measure that the belt tension is within
the standard value.
Standard value: 245 - 412 N
3. If not within the standard value, replace the autotensioner.(Refer to 311A.)
IGNITION TIMING CHECK
15
MB991668
Water pump
pulley
10 20 mm
Belt tension gauge
M1111001700425
15
AC102022
Y0195AU
MUT-II
Gentry tap with
your finger
AC102806 AB
(4) Hold special tool belt tension meter set

(MB991668) to the middle of the drive belt
between the pulleys (at the place indicated by
arrow), approximately 10 - 20 mm away from
the rear surface of the belt so that it is
perpendicular to the belt (within an angle of
15 degree).
(5) Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and
measure that the vibration frequency of the
belt is within the standard value.
Standard value: 110 - 144 Hz
3. If not within the standard value, replace the autotensioner. (Refer to 311A.)
When using a tension gauge
1. Check the drive belt tension. (Refer to 311A.)
AK000871 AC
1. Before inspection, set the vehicle to the preinspection condition.

position and then connect the MUT-II to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Use the MUT-II to measure engine idle speed and
check that it is within the standard value.
Standard value: 750 100 r/min
6. Select No. 17 of the MUT-II Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5 BTDC 2
8. If the basic ignition timing is outside the standard
value, inspect the MPI system (Refer to 313A,
GROUP 13A - Troubleshooting - Inspection chart
for diagnosis code).
ENGINE MECHANICAL
11A-9
ON-VEHICLE SERVICE
CAUTION
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this
condition may damage the engine.
9. Press the MUT-II clear key (Select a forced driving
cancel mode) to release the Actuator test.
10.Check that ignition timing is at the standard value.
Standard value: approximately 10 BTDC
NOTE: .
The ignition timing may fluctuate within 7
BTDC. This is normal.
In higher altitude, the ignition timing is more
advanced than the standard value by
approximately 5.
11.Remove the timing light.
12.Turn off the ignition switch and then remove the
MUT-II.

NOTE: .
The idle speed is controlled automatically by
the idle speed control system.
When using the MUT-II, select item No. 22 and
take a reading of the idle speed.
8. If the idle speed is outside the standard value,
inspect the MPI system (Refer to 313A,
GROUP 13A - Troubleshooting - Inspection chart
for diagnosis code).
IDLE MIXTURE CHECK

M1111002100255
AC102022
Y0195AU
MUT-II
IDLE SPEED CHECK

M1111003500472
AC102022
Y0195AU
AK000871 AC
MUT-II
AK000871 AC

2. Turn the ignition switch to "LOCK" (OFF) position.
3. Connect the MUT-II to the diagnosis connector or
connect a tachometer to the engine speed
detection connector.

3. Connect the MUT-II to the diagnosis connector or
connect a tachometer to the engine speed
detection connector.
Engine speed
ditection connector
AK000899 AC
Engine speed
ditection connector
AK000899 AC

6. Check that ignition timing is at the standard value.
7. Check the idle speed.

6. Check that ignition timing is at the standard value.
7. Run the engine at 2,500 r/min for 2 minutes.
8. Set the CO, HC tester.
9. Check the CO contents and the HC contents at
idle.
Standard value
CO contents: 0.5 % or less
HC contents: 100 ppm or less
10.If there is a deviation from the standard value,
check the following items:
ENGINE MECHANICAL
11A-10
ON-VEHICLE SERVICE
Diagnosis output
Fuel pressure
Injector
Ignition coil, spark plug cable, spark plug
EGR control system
Evaporative emission control system
Compression pressure
NOTE: Replace the three way catalyst when the
CO and HC contents are not within the standard
value, even though the result of the inspection is
normal on all items.
COMPRESSION PRESSURE CHECK

M1111002600465
Crank angle
sensor
connector
AK201364AC

2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
NOTE: Doing this will prevent the engine-ECU<M/
T> or engine-A/T-ECU<A/T> from carrying out
ignition and fuel injection.
8. Measure the compression pressure for all the

cylinders, and check that the pressure differences
of the cylinders are below the limit.
Limit: Maximum 98 kPa
9. If there is a cylinder with compression or a
compression difference that is outside the limit,
pour a small amount of engine oil through the
spark plug hole, and repeat the operations in
steps from (6) to (8).
(1) If the compression increases after oil is added,
the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
surface.
(2) If the compression dose not rise after oil is
added, the cause is a burnt or defective valve
seat, or pressure is leaking from the gasket.
10.Connect the crank angle sensor connector.
11.Install the spark plugs and spark plug cables.
12.Use the MUT-II to erase the diagnosis codes.
NOTE: This will erase the diagnosis code
resulting from the crank angle sensor connector
being disconnected.
MANIFOLD VACUUM CHECK

M1111002700417
AC102022
Y0195AU
MUT-II
CAUTION
Keep away from the spark plug hole when
cranking.
If compression is measured with water, oil,
fuel, etc., that has come from cracks inside
the cylinder, these materials will become
heated and will gush out from the spark plug
hole, which is dangerous.
5. Cover the spark plug hole with a shop towel etc.,
and after the engine has been cranked, check that
no foreign material is adhering to the shop towel.
6. Set compression gauge to one of the spark plug
holes.
7. Crank the engine with the throttle valve fully open
and measure the compression pressure.
Standard value (at engine speed of 250 r/
min):
1,370 kPa
Limit (at engine speed of 250 r/min):
Minimum 930 kPa
AK000871 AC

3. Connect a tachometer or connect the MUT-II to
the diagnosis connector.
Vacuum
gauge
Fuel pressure
regulator
AK201369AB
ENGINE MECHANICAL
11A-11
ON-VEHICLE SERVICE
4. Attach a three-way joint to the vacuum hose

between the fuel pressure regurator and the air
intake plenum, and connect a vacuum gauge.
5. Start the engine and check that idle speed is
within the standard valve.
6. Check the intake manifold vacuum.
Limit: Minimum 60 kPa
7. Turn off the ignition switch.
8. Remove the vacuum gauge and the three-way
joint, and then connect the vacuum hose.
9. Remove the engine tachometer or the MUT-II.
LASH ADJUSTER CHECK

M1111002900336
If an abnormal noise (knocking) that seems to be

coming from the lash adjuster is heard after starting
the engine and dose not stop, carry out the following
check.
NOTE: .
The abnormal noise which is caused by a
problem with the lash adjusters is generated after
the engine is started, and will vary according to
the engine speed. However, this noise is not
related to the actual engine load.
Because of this, if the noise dose not occur
immediately after the engine is started, if it dose
not change in accordance with the engine speed,
or if it changes in accordance with the engine
load, the source of the noise is not the lash
adjusters.
If there is a problem with the lash adjusters, the
noise will almost never disappear, even if the
engine has been run at idle to let it warm up.
The only case where the noise might disappear is if
the oil in the engine has not been looked after
properly and oil sludge has caused the lash
adjusters to stick.
2. Check that the noise occurs immediately after the
engine is started, and that the noise changes in
accordance with changes in the engine speed.
If the noise dose not occur immediately after the
engine is started, or if it dose not change in
accordance with the engine speed, the problem is
not being caused by the lash adjusters, so check
for some other cause of the problem. Moreover, if
the noise dose not change in accordance with the
engine speed, the cause of the problem is
probably not with the engine (In these cases, the
lash adjusters are normal).
3. While the engine is idling, check that the noise

level does not change when the engine load is
varied (for example, by shifting from N to D).
If the noise level changes, the cause of the noise
is probably parts striking because of worn
crankshaft bearings or connecting rod bearings
(In such cases, the lash adjusters are normal).
4. After the engine has warmed up, run it at idle and
check if any noise can be heard.
If the noise has become smaller or disappeared,
oil sludge could make the lash adjusters stick.
Clean the lash adjusters (Refer to GROUP 11D Rocker Arms and Camshaft - Rocker Arms and
Camshaft Inspection 311B). If not improved,
go to step 5.
5. Bleed air from the lash adjusters (Refer to 311A
).
6. If the noise has not disappeared even after the air
bleeding, clean the lash adjusters (Refer to
GROUP 11D - Rocker Arms and Camshaft Rocker Arms and Camshaft Inspection 311B).
<LASH ADJUSTER AIR BLEEDING>

NOTE: .
If the vehicle is parked on a slope fir a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high
pressure chamber when starting the engine.
After parking the vehicle for long periods, the oil
drains out of the oil passage, and it takes time for
the oil to be supplied to the lash adjuster, so air
can get into the high-pressure chamber.
If either of the above situations occur, the
abnormal noise can be eliminated by bleeding
the air from inside the lash adjusters.
Good
Max
Min.
AKX00328 AE
1. Check the engine oil and replenish or replace the

oil if necessary.
ENGINE MECHANICAL
11A-12
ON-VEHICLE SERVICE
NOTE: .
If there is an only small amount of oil, air will
be drawn in through the oil screen and will get
into the oil passage.
If the amount of oil is greater than normal, then
the oil will being mixed by the crankshaft and a
large amount of air may get mixed into the oil.
If the oil is degenerated, air and oil will not
separate easily in oil, and the amount of air
mixed into the oil will increase.
High-pressure chamber
AK100001AC
If the air which has been mixed in with the oil

due to any of the above reasons gets into the
high pressure chamber of the lash adjuster,
the air inside the high pressure chamber will
be compressed when the valve is open and
the lash adjuster will over-compress, resulting
in abnormal noise when the valve close. This
is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air
inside the lash adjusters is then released, the
operation of the lash adjusters will return to
normal.
Drive pattern for air breeding

Gradually open
Close the throttle valve
the throttle valve
Approximately
3,000 r/min
Idle speed
15 s
15 s
Once
AKX00330AE
2. Run the engine at idle for 1 - 3 minutes to let it

warm up.
3. With no load on the engine, repeat the drive
pattern shown in the illustration above and check
if the abnormal noise disappears (The noise
should normally disappear after 10 - 30
repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is
probably not due to air inside the lash adjusters).
4. After the noise has disappeared, repeat the drive
pattern shown in the illustration above a further 5
times.
5. Run the engine at idle for 1 - 3 minutes and check
that the noise has disappeared.
ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-13
CRANKSHAFT PULLEY
M1112001600409
351).
Drive Belt Tension Check (Refer to 311A).
Cover 351).
2
1
25 4 Nm
AC300537AB
<<A>>
1.
2.
Removal steps
Drive belt
Crank shaft damper pulley
ENGINE MECHANICAL
11A-14
CRANKSHAFT PULLEY
CAUTION
<<A>> DRIVE BELT REMOVAL

The following operations will be needed due to the
serpentine drive system with the drive belt autotensioner.
To reuse the drive belt, draw an arrow indicating

the rotating direction (clockwise) on the back of
the belt using chalk.
Auto-tensioner
Auto-tensioner
Hole B
L-shaped
hexagon
wrench
Hole A
AC107641AB
AC107640AC

hole of the auto-tensioner, and turn the autotensioner anti-clockwise until it hits the stopper.
2. Align hole A with hole B, insert an L-shaped

hexagon wrench, etc. to fix and then remove the
drive belt.
ENGINE MECHANICAL
11A-15
CAMSHAFT AND VALVE STEM SEAL

M1112006600211
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Air Cleaner and Air Cleaner Bracket Removal (Refer to
GROUP 15, Air Cleaner 315).
Battery and Battery Tray Removal
Valve Timing Belt Removal (Refer to 311A).
Valve Timing Belt Installation (Refer to 311A).
Battery and Battery Tray Installation
Air Cleaner and Air Cleaner Bracket installation (Refer to
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
11 1 Nm
3.0 0.5 Nm
11 1 Nm
4
6
3.5 0.5 Nm
5
8
9.0 2.0 Nm
1
8.8 1.0 Nm
11 1 Nm
9
N
11
12
11 1 Nm
N 10
AC300538 AB
1.
2.
3.
4.
Removal steps
Accelerator cable connection
Crank angle sensor connector
Control wiring harness connection
Spark plug cables and ignition coils
(Refer to GROUP 16, Ignition Coil
316).
>>N<<
>>M<<

5. Rocker cover PCV hose
6. Rocker cover breather hose
7. Control wiring harness connection
8. Rocker cover
9. Camshaft end seal
10. Spark plug hole gaskets
ENGINE MECHANICAL
11A-16
<<A>>
>>L<<
>>K<<

11. Rocker cover gasket
12. Radiator upper hose connection
22
20
24
25
23
20 1 Nm
Apply engine oil to all

moving parts before
installation.
21
26
19
17
N 18
11 1 Nm
89 9 Nm
13
30
29
25 4 Nm
22 4 Nm
15
31*
32*
33*
N 34*
16
27
28
10 2 Nm
14 N
14 1 Nm
31*
32*
33*
35* N
AC300539 AB
<>
>>J<<
>>I<<
>>H<<
>>G<<
>>F<<
>>F<<
>>F<<
>>F<<
>>F<<
Removal steps
13. Camshaft position sensor support
cover
cover gasket
15. Camshaft position sensing cylinder
17. Camshaft sprockets
18. Camshaft oil seals
19. Camshaft bearing caps, front
20. Camshaft bearing caps, rear
21. Camshaft bearing caps, No.2
>>F<<
>>E<<
>>E<<
>>D<<
<<C>>
>>C<<
>>B<<
>>A<<
>>A<<
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

Camshaft bearing caps, No.4
Inlet camshaft
Exhaust camshaft
Rocker arms
Rocker arm lash adjusters
Oil delivery body
Spark plugs
Valve spring retainer locks
Valve spring retainers
Valve springs
Inlet valve stem seals
Exhaust valve stem seals
ENGINE MECHANICAL
11A-17
LUBRICATION AND SEALING POINTS

<The bottom view of the rocker cover>
10 mm
10 mm
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

Rocker
cover
<View A>
10 mm
10 mm
Cylinder
head
A
10 mm
Sealant:
MITSUBISHI GENUINE
PART MD970389 or
equivalent
Sealant: 3M ATD Part No.8660

or equivalent
A
A
3 mm
Sealant: MITSUBISHI GENUINE

PART MD970389 or equivalent
(Lip section)
Engine oil
AC300541
<Top view of cylinder head>
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent
ENGINE MECHANICAL
11A-18
<<C>> VALVE SPRING RETAINER LOCKS

REMOVAL
<<A>> RADIATOR UPPER HOSE

DISCONNECTION
CAUTION
When removing valve spring retainer locks, leave
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the
cylinder if the piston is not properly in the TDC
position.
Mating marks
MD998772
AC200641AC
Make mating marks on the radiator hose and the

hose clamp. Disconnect the radiator hose.
<> CAMSHAFT SPROCKETS REMOVAL
AC201799 AB
Use special tool valve spring compressor

(MD998772) to compress the valve spring, remove
the valve spring retainer locks.

>>A<< EXHAUST VALVE STEM SEALS/INLET
VALVE STEM SEALS INSTALLATION
Gray
Gray green
Inlet side
Exhaust side
AC201457AB
1. Hold the hexagon part of the camshaft with a

wrench.
2. Loosen the camshaft sprocket mounting bolts and
remove the camshaft sprocket.
AC201542AB
1. Check the valve stem seal colour to identify the

inlet side or exhaust side.
2. Apply a small amount of engine oil to the valve
stem seals.
ENGINE MECHANICAL
11A-19
CAUTION
Valve stem seals cannot be reused.
The special tool valve stem seal installer
(MD998737) must be used to install the valve
stem seal. Improper installation could result
in oil leaking past the valve guide.
MD998737
Valve
Valve stem
seal
Valve guide
AC107414 AC
3. Use special tool to fill a new valve stem seal in the

valve guide using the valve stem area as a guide.
>>D<< ROCKER ARM LASH ADJUSTERS

INSTALLATION
CAUTION
If the rocker arm lash adjuster is reused, always
clean and check it before installation. (Refer to
GROUP 11B, Rocker Arms and Camshaft Inspection).
>>E<< EXHAUST CAMSHAFT/INLET CAMSHAFT
INSTALLATION
1. Remove sealant remained on the cylinder head.
2. Apply engine oil to the cam and the journal of the
camshaft.
CAUTION
Engine front
>>B<< VALVE SPRINGS INSTALLATION
Slit
Rocker arm side

Exhaust camshaft
AC201458AB
Do not install wrong camshaft at the side of inlet

or exhaust. The exhaust camshaft has a slit at the
rear surface.
3. Install the camshaft to the cylinder head.
Identification
colour
AC201453AB
Install the valve springs with its identification colour

painted end facing the locker arm.
>>C<< VALVE SPRING RETAINER LOCKS
INSTALLATION
>>F<< CAMSHAFT BEARING CAPS, NO. 4/

CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT
BEARING CAPS, NO. 5/CAMSHAFT BEARING
CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/
CAMSHAFT BEARING CAPS, FRONT
INSTALLATION
Approximately 3
MD998772
Dowel pin
AC201799 AB
Use special tool valve spring compressor

(MD998772) to compress the valve spring in the
same manner as removal.
Inlet side
Exhaust side
AC201459AB
1. Set the dowel pin of the camshaft to the position

as shown in the illustration.
ENGINE MECHANICAL
11A-20
E4
Engine front
Bearing
cap No.
Identification of
inlet side and
exhaust side
AC201460AB
2. Since the shape of camshaft bearing caps No.2 5 is identical, check the identification marks so
that the bearing cap No., inlet side, or exhaust
side cannot be mistaken to install to the direction
as shown in the illustration.
Identification mark (engraved on the front
and bearing caps No.2 - 5)
I: Inlet side
E: Exhaust side
5. Check the identification marks on the camshaft

bearing caps, front so that inlet side and exhaust
side cannot be mistaken in the same way as that
of bearing caps No.2 - 5.
CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
adhesion surface during that time.
6. Tighten the bearing cap mounting bolts increasing
the pressure in 2 to 3 times and finally tighten to
7. Ensure that the rocker arms are installed properly.
NOTE: Remove an excess of sealant completely.
>>G<< CAMSHAFT OIL SEALS INSTALLATION
Engine front
MD998713
AC201461AB
3. Apply sealant to the positions (6 areas) of the

upper side of the cylinder head as shown in the
illustration.
Specified sealant: MITSUBISHI GENUINE
NOTE: Install the camshaft bearing caps, rear
and camshaft bearing caps, front within 15
minutes after applying liquid gasket.
Engine front
Front
marking
AC201462AB
4. Position the camshaft bearing caps, rear in the

direction as shown in the illustration for
installation.
AC102323 AB
1. Apply engine oil to the entire inner diameter of the

oil seal lip.
2. Use special tool camshaft oil seal installer
(MD998713) to press-fit the oil seals.
>>H<< CAMSHAFT SPROCKETS INSTALLATION
AC201457AB
1. Hold the hexagon part of the camshaft with a

wrench in the same manner as removal.
2. Tighten the camshaft sprocket mounting bolts to
ENGINE MECHANICAL
>>I<< CAMSHAFT POSITION SENSOR SUPPORT

INSTALLATION
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.
11A-21
2. Install the vane (small) of the camshaft position

sensing cylinder at an angle of approximately 45
degrees to the position of the dowel pin of the
exhaust camshaft.
3. Tighten the camshaft position sensing cylinder
mounting bolts to the specified torque.
>>K<< RADIATOR UPPER HOSE CONNECTION
Projection
3 mm
AC201463 AB
2. Apply the sealant to the camshaft position sensor

support flange in a continuous bead as shown in
the illustration.
NOTE: Install the camshaft position sensor
support within 15 minutes after applying liquid
gasket.
3. Install the camshaft position sensor support to the
cylinder head.
CAUTION
4. Tighten the camshaft position sensor support
mounting bolts to the specified torque.
Water outlet fitting
Mating marks
AC200642 AE
1. Insert each hose as far as the projection of the

water outlet fitting.
2. Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
>>L<< ROCKER COVER GASKET INSTALLATION
1. Remove sealant remained on the rocker cover.
>>J<< CAMSHAFT POSITION SENSING

CYLINDER INSTALLATION
Approximately 45
Dowel pin
Vane (small)
Vane (large)
AC201464AB
1. Set the dowel pin of the exhaust camshaft to the

position (No.1 cylinder at compression TDC) as
shown in the illustration.
NOTE: Use the force of the exhaust valve spring
to rotate anti-clockwise.
AC201465AB
2. Apply sealant to the positions (4 areas) of the

lower side of the rocker cover as shown in the
illustration.
NOTE: Install the rocker cover gasket within 15
3. Install the rocker cover gasket to the rocker cover.
ENGINE MECHANICAL
11A-22
>>M<< CAMSHAFT END SEAL INSTALLATION

>>N<< ROCKER COVER INSTALLATION
Engine front
AC201469AB
1. Apply sealant to the positions of the rocker cover

gasket (6 areas) as shown in the illustration.
NOTE: Install the rocker cover within 15 minutes
after applying liquid gasket.
2. Install the rocker cover to the cylinder head.
10 mm
10 mm
Cylinder head
AC201468 AB
Apply sealant to the positions of the camshaft end

seal as shown in the illustration and install to the
cylinder head.
Specified sealant: 3M ATD Part No.8660 or
equivalent
NOTE: Install the camshaft end seal within 15
CAUTION
3. Tighten the rocker cover mounting bolts to the
specified torque.
ENGINE MECHANICAL
11A-23
OIL PAN
OIL PAN
REMOVAL AND INSTALLATION <2WD>
M1112002800592
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Front Exhaust Pipe Installation (Refer to GROUP 15,
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Cover 351).
5
N
35 6 Nm
39 5 Nm
9.0 3.0 Nm
2
26 5 Nm
9.0 1.0 Nm
9.0 3.0 Nm
1.
2.
3.
Removal steps
Exhaust manifold bracket
Flywheel housing front lower cover
Engine oil pan drain plug
AC300542 AB
>>B<< 4.
<<A>> >>A<< 5.

Engine oil pan drain plug gasket
Engine oil pan
ENGINE MECHANICAL
11A-24
OIL PAN
3. Assemble the engine oil pan to the cylinder block.
<<A>> ENGINE OIL PAN REMOVAL

1. Remove the engine oil pan mounting bolts.
CAUTION
Perform this slowly to avoid deformation of the
engine oil pan flange.
CAUTION
sealant surface during that time.
MD998727
MD998727
M6 8 mm
AC102698 AB
4. Tighten the engine oil pan mounting bolts to the

specified torque. Be careful when installing, as the
oil pan mounting bolts (indicated in the illustration)
have different lengths from the other bolts.
>>A<< ENGINE OIL PAN INSTALLATION

1. Remove sealant from the engine oil pan and
cylinder block surfaces.
>>B<< ENGINE OIL PAN DRAIN PLUG GASKET

INSTALLATION
AC102324 AB
2. Remove the engine oil pan using special tool oil

pan remover (MD998727).
Engine
oil pan
side
4 mm
Groove portion Bolt hole portion
AC102133AB
2. Apply a bead of the sealant to the cylinder block

mating surface of the engine oil pan as shown.
NOTE: Install the engine oil pan within 15 minutes
after applying sealant.
AC102325 AE
Replace the gasket with a new gasket. Install the

new gasket in the direction shown in the illustration.
ENGINE MECHANICAL
11A-25
OIL PAN

M1112002800600
351).
Centre Member Removal (Refer to GROUP 32, Engine
Roll Stopper and Centre Member 332).
Centre Member Installation (Refer to GROUP 32, Engine
Roll Stopper and Centre Member 332).
Cover 351).
9.0 3.0 Nm
9.0 3.0 Nm
39 5 Nm
44 10 Nm
9.0 1.0 Nm
22 4 Nm
5
9.0 3.0 Nm
9.0 3.0 Nm
AC300543 AB
>>D<<
1.
>>C<<
2.
3.
4.
Removal steps
Transmission housing front lower
cover stay
Flywheel housing front lower cover
Engine oil pan drain plug
Engine oil pan drain plug gasket
<<A>>
<>
>>B<<
>>A<<
5.
6.

Engine lower oil pan
Engine upper oil pan
ENGINE MECHANICAL
11A-26
OIL PAN
<<A>> ENGINE LOWER OIL PAN REMOVAL

1. Remove the engine lower oil pan mounting bolts.
>>A<< ENGINE UPPER OIL PAN INSTALLATION

1. Remove sealant from the engine upper oil pan
and cylinder block surfaces.
CAUTION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.
4 mm
Bolt hole
portion
Groove
portion
Engine lower oil pan

AC102931AB
2. Apply a piece of wood to the lower oil pan and

strike it with a hammer to remove the engine lower
oil pan.
<> ENGINE UPPER OIL PAN REMOVAL
1. Remove the engine upper oil pan mounting bolts.
CAUTION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.
AC102242AB
2. Apply a bead of the sealant to the mating surface

of the engine upper oil pan as shown.
NOTE: Install the engine upper oil pan within 15
minutes after applying sealant.
3. Assemble the engine upper oil pan to the cylinder
block.
CAUTION
B
B
A
A
B
AC102946AB
2. Screw in the bolt into bolt hole A in the location

shown. Then lift the upper oil pan and remove it.
B
B
A
A
AC102929AB
4. Insert the bolts to the engine upper oil pan as

shown, and tighten them to the specified torque.
ENGINE MECHANICAL
11A-27
OIL PAN
Name
Symbol
Flange bolt A
B
Quantity
Size mm
(D L)
Name
M6 16
Flange bolt A
16
M6 18
NOTE: D: Nominal diameter, L: Nominal length

>>B<< ENGINE LOWER OIL PAN INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan.
Symbol
Quantity
Size mm
(D L)
M6 75
11
M6 10
NOTE: D: Nominal diameter, L: Nominal length

>>C<< ENGINE OIL PAN DRAIN PLUG GASKET
INSTALLATION
Engine lower
oil pan side
4 mm
AC102325 AF
Bolt hole
portion
Groove
portion
AC102243AB
2. Apply a bead of the sealant to the mating surface

of the engine lower oil pan as shown.
NOTE: Install the engine lower oil pan within 15
minutes after applying sealant.
3. Assemble the engine lower oil pan to the engine
upper oil pan.
CAUTION
B-1
B-11
M1112002900210
B-7
B-6
A-3
B-8
B-9
B-12
B-2
>>D<< TRANSMISSION HOUSING FRONT

LOWER COVER STAY INSTALLATION
Install the transmission housing front lower cover
stay in the following order.
1. Tighten the engine side four mounting bolts to the
specified torque.
2. Tighten the transmission side two mounting bolts
to the specified torque.
INSPECTION
B-10
B-4
B-5
Replace the gasket with a new one. Install the new

gasket in the direction shown in the illustration.
AC102930AB
4. Insert the bolts to the engine lower oil pan as

shown, and tighten them to the specified torque in
the order shown.
Check the oil pan for cracks.

Check the oil pan sealant-coated surface for
damage and deformation.
ENGINE MECHANICAL
11A-28
CRANKSHAFT OIL SEAL
CRANKSHAFT OIL SEAL

M1112003100273
132 5 Nm
4
5
7
8
9
3
N
Lip section
Lip section
Engine oil
AC300544 AB
>>D<<
1.
>>C<<
2.
3.
Crankshaft front oil seal removal

steps
Valve timing belt, balancer timing
belt (Refer to 311A).
Crankshaft balancer shaft drive
sprocket
Crankshaft key
<<A>>
<>
>>B<<
>>A<<
4.
5.
6.
7.
8.
9.
Crankshaft rear oil seal removal

steps
Transmission assembly
Flywheel bolts
Flywheel adapter plate
Flywheel assembly
Flywheel adapter plate
Crankshaft bush
ENGINE MECHANICAL
11A-29
CRANKSHAFT OIL SEAL

<<A>> TRANSMISSION ASSEMBLY REMOVAL
CAUTION
2. Use the following special tools to press-fit the oil

seal.
Installer bar (MB990938)
Crankshaft rear oil seal installer (MD998776)
>>B<< FLYWHEEL BOLTS INSTALLATION
Engine front
MD998781
Flywheel
assembly
Flywheel bolt
AC300897 AB
Do not remove the flywheel bolt shown by the

arrow. If this bolt is removed, the flywheel
assembly will become out of balance and
damaged.
Refer to GROUP 22A, Transmission Assembly
322A.
<> FLYWHEEL BOLTS REMOVAL
AC211914AC
1. Use special tool flywheel stopper (MD998781) to

secure the flywheel in the same manner as
removal.
2. Tighten the flywheel bolts to the specified torque.
>>C<< CRANKSHAFT FRONT OIL SEAL
INSTALLATION
MD998781
Crankshaft
MD998375
(Engine oil)
AC211914AC
1. Use special tool flywheel stopper (MD998781) to

secure the flywheel.
2. Remove the flywheel bolts.

>>A<< CRANKSHAFT REAR OIL SEAL
INSTALLATION
Oil seal
MB990938
(Engine oil)
MD998776
Crankshaft
AC102328 AB
1. Apply a small amount of engine oil to the entire

inner diameter of the oil seal lip.
MD998285
(Oil applied to the
circumference)
Oil seal
AC102329 AC
1. Apply a small amount of engine oil to the entire

inner diameter of the oil seal lip.
2. Apply a small amount of engine oil to the outer
diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft.
3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal.
ENGINE MECHANICAL
11A-30
CYLINDER HEAD GASKET
>>D<< CRANKSHAFT BALANCER SHAFT DRIVE

SPROCKET INSTALLATION
: Clean
: Clean and degrease
Crankshaft
Front case
Crankshaft
balancershaft
drive sprocket
Engine front
AC211222 AB
1. Clean or degrease the front case, the crankshaft

and the crankshaft balancer shaft drive sprocket
as shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket
in the direction shown in the illustration.

M1112004000655
Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service - Fuel Pump Connector Disconnection
(How to Reduce Pressurized Fuel Lines) 313A.]
351).
Battery Removal
Rocker Cover Centre Cover Removal (Refer to 311A
).
Valve Timing Belt Removal (Refer to 311A).
Valve Timing Belt Installation (Refer to 311A).
Rocker Cover Centre Cover Installation (Refer to 311A
).
Battery Installation
Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Check and
Adjustment 317).
Cover 351).
Fuel Leak Check
ENGINE MECHANICAL
11A-31
9
10
5.0 1.0 Nm
16
12
7
17
6
14
5.0 1.0 Nm
4
18
15
9.0 2.0 Nm
13 11
20
2
13 1 Nm
(Engine oil)
19
AC300545 AB
Removal steps
Power steering fluid pressure
switch connector
3. Crank angle sensor connector
4. Ignition coil connectors
5. Detonation sensor connector
6. Purge control solenoid valve
connector
7. EGR control solenoid valve
connector
8. Injector connectors
9. Throttle position sensor connector
10. Idle speed control servo connector
11. Camshaft position sensor
connector
1.
2.

12. Oxygen sensor connector
13. Engine coolant temperature sensor
connector
14. Engine coolant temperature gauge
unit connector
15. Capacitor connector
16. Accelerator cable connection
17. Brake booster vacuum hose
connection
18. Engine oil level gauge and guide
assembly
19. O-ring
20. Canister vacuum hose connection
ENGINE MECHANICAL
11A-32
24
25
26
<Cold engine>
78 2 Nm 0 Nm 20 2 Nm +90 +90
5.0 1.0 Nm
27 N
(Engine oil)
28
(Engine oil)
29
22
11 1 Nm
21
30 N
31 3 Nm
23
AC300546 AB
21.
22.
23.
24.
Removal steps
Detonation sensor connection
Battery wiring harness connection
Inlet manifold stay
Exhaust manifold (Refer to GROUP
15, Exhaust Manifold 315).
Water outlet fitting and thermostat
case assembly (Refer to GROUP
14, Water Hose and Water Pipe
314).
Rocker cover (Refer to 311A).
Heater water hose connection
>>C<<
<<A>>
>>C<<
>>B<<
>>A<<
25.
26.
27.
28.
29.
30.

Fuel return line hose connection
Fuel high-pressure hose
connection
O-ring
Cylinder head bolts
Cylinder head assembly
Cylinder head gasket
ENGINE MECHANICAL
11A-33

<<A>> CYLINDER HEAD BOLTS REMOVAL
Identification
mark "63"
MB991654
Exhaust side
AC107217AC
2. Assemble to the cylinder block so the cylinder

head gasket identification mark "63" is at the top
surface and on the exhaust side.
Engine front
>>B<< CYLINDER HEAD BOLTS INSTALLATION

3
10
2
(Engine oil)
AC201623 AB
Using special tool cylinder head bolt wrench

(MB991654), loosen the cylinder head bolts in two or
three steps in the order of the numbers shown in the
illustration.
NOTE: If the cylinder head bolts cannot be pulled out
due to the washer being trapped in the valve spring,
raise the bolt slightly, then remove it while holding it
by using a magnet.

>>A<< CYLINDER HEAD GASKET INSTALLATION
CAUTION
Do not allow any foreign materials to get into the
coolant passages, oil passages and cylinder.
1. Remove the gasket from the cylinder head and
cylinder block.
A
AC102537AB
1. Check that the nominal length of each cylinder

head bolt meets the limit. If it exceeds the limit,
replace the bolt with a new one.
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.
ENGINE MECHANICAL
11A-34
CAUTION
The bolt is not tightened sufficiently if the bolt is
tightened less than 90 degree angle.
(5) Tighten the bolt an additional 90 degree angle
as shown. Then check to see that the paint
mark on the head of the cylinder head bolts
and the paint mark on the cylinder head are
aligned.
(6) If tightening the bolt 90 degree angle results in
moving the paint mark on the bolt past the
paint mark on the cylinder head, remove the
bolt and start over from step 1.
MB991654
Engine front
>>C<< O-RING/FUEL HIGH-PRESSURE HOSE

INSTALLATION
10
Do not let any engine oil get into the delivery

pipe.
1. Apply a small amount of new engine oil to the Oring.
2. Turning the fuel high-pressure hose to the right
and left, install it to the delivery pipe, while being
careful not to damage the O-ring. After installing,
check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage.
After this, re-insert it to the delivery pipe and
4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
AC201625 AB
3. Use special tool cylinder head bolt wrench

(MB991654) to tighten the cylinder head bolts as
follows:
(1) Tighten the cylinder head bolts to 78 2 Nm
in the order shown.
(2) Loosen the bolts fully in the reverse order of
that shown.
(3) Tighten the cylinder head bolts to 20 2 Nm
in the order shown.
Step (4)
90
Paint marking
Step (5)
90
Paint marking
AC102331AB
(4) Apply a paint mark to the heads of the cylinder

head bolts and cylinder head, then tighten 90
degree angle as shown.
CAUTION
ENGINE MECHANICAL
11A-35
TIMING BELT
TIMING BELT
M1112004300656
351).
Crankshaft Shaft Damper Pulley Removal (Refer to
311A).
Crankshaft Shaft Damper Pulley Installation (Refer to
311A).
Cover 351).
10
9
2
48 5 Nm
11 1 Nm
21 4 Nm
3
8.8 1.0 Nm
23 3 Nm
11
1
6
44 10 Nm
5
4
22 4 Nm
>>H<<
1.
2.
3.
4.
5.
6.
7.
7
11 1 Nm
79 5 Nm
9.0 1.0 Nm
Removal steps
Control wiring harness connection
Timing belt upper cover
Water pump pulley
Idler pulley
End cap
Auto-tensioner
Timing belt lower cover
AC300547 AB

Engine front mounting bracket
(Refer to GROUP 32, Engine
Mount 332).
Valve timing belt tension

adjustment
8. Valve timing belt
9. Timing belt tensioner pulley
10. Timing belt tensioner arm
11. Timing belt tensioner adjuster
>>G<<
<<A>>
>>F<<
>>E<<
>>D<<
ENGINE MECHANICAL
11A-36
TIMING BELT
12
22 4 Nm
16
35 6 Nm
21
20
22 4 Nm
13
19 3 Nm
14
(Engine oil)
49 9 Nm
15
18
19
49 9 Nm
17
8.8 1.0 Nm
167 Nm
AC300548 AB
<>
Removal steps
12. Power steering fluid pressure
switch connector
13. Power steering oil pump assembly
14. A/C compressor connector
15. Power steering oil pump bracket
16. Timing belt idler pulley
17. Crank angle sensor
<<C>>
<<D>>
>>C<<
>>C<<
>>B<<
18.
19.
>>A<<
>>A<<
20.
21.

Crankshaft camshaft drive sprocket
Crankshaft angle sensing blade
Balancer timing belt tension
adjustment
Balancer timing belt tensioner
Balancer timing belt

<<A>> VALVE TIMING BELT REMOVAL
CAUTION
Never turn the crankshaft anti-clockwise.
MD998738
Timing mark
Timing belt
under cover
AC102492 AB
AC102487
1. Turn the crankshaft clockwise, align each timing

mark to set No.1 cylinder to TDC of its
compression stroke.
2. Remove the timing belt under cover rubber plug

and then set the special tool adjusting bolt
(MD998738).
ENGINE MECHANICAL
11A-37
TIMING BELT
CAUTION
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
screwed in all at once, the timing belt tensioner
adjuster rod will not easily retract and the special
tool may bend.
Timing belt
tensioner arm
MD998738
AC107289 AB
<> POWER STEERING OIL PUMP ASSEMBLY

REMOVAL
With the hose installed, remove the power steering
oil pump assembly from the bracket.
NOTE: Secure the removed power steering oil pump
assembly with cord or rope at a position where they
will not interfere with the removal of the balancer
timing belt.
<<C>> CRANKSHAFT CAMSHAFT DRIVE
SPROCKET REMOVAL
Crankshaft
camshaft
drive
sprocket
MB991385
3. Screw in the special tool until it comes in contact

with the timing belt tensioner arm.
MB991367
AC102332 AB
AC102775AB
4. Gradually screw in the special tool. Then align the

timing belt tensioner adjuster rod set hole A with
the timing belt tensioner adjustor cylinder set hole
B.
Timing belt
tensioner pulley
mounting bolt
1. Use the following special tools to support the

crankshaft camshaft drive sprocket.
Special spanner (MB991367)
Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft camshaft drive sprocket.
<<D>> BALANCER TIMING BELT REMOVAL
CAUTION
To reuse the balancer timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk.

>>A<< BALANCER TIMING BELT/BALANCER
TIMING BELT TENSIONER INSTALLATION
Wire
Balancershaft sprocket
Belt tension side
AC107185 AB
Timing mark
Timing mark
5. Insert a wire, etc.in the set hole.
CAUTION
To reuse the valve timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk.
6. After removal of adjusting bolt special tool, loosen
the timing belt tensioner pulley mounting bolt and
remove the valve timing belt.
Crankshaft
balancershaft
drive sprocket
AC102689 AB
1. Ensure that the crankshaft balancershaft drive

sprocket timing marks and balancershaft sprocket
timing marks are aligned.
ENGINE MECHANICAL
11A-38
TIMING BELT
2. Install the balancer timing belt on the crankshaft

balancershaft drive sprocket and balancershaft
sprocket. There should be no slack on the tension
side.
Centre of the
mounting bolt
1. With your fingers, lift the balancer timing belt

tensioner in the direction of the arrow. Apply
pressure of 3.0 0.4 Nm to the balancer timing
belt. Tighten the assembling bolt to the specified
torque. Then, fix the balancer timing belt
tensioner.
Balancershaft sprocket
Timing mark
Centre of
the pulley
Timing mark
AC102690 AB
3. Assemble and temporarily fix the centre of the

pulley of the balancer timing belt tensioner so that
it is at the top left from the centre of the mounting
bolt, and the pulley flange is at the front-side of
the engine.
4. Adjust the balancer timing belt tension.
>>B<< BALANCER TIMING BELT TENSION
ADJUSTMENT
CAUTION
When tightening the mounting bolt, ensure that
the tensioner does not rotate with the bolt.
Allowing it to rotate with the bolt can cause
excessive tension of the belt.
AC102691
Crankshaft
balancershaft
drive sprocket
AC102689AC
2. Turn the crankshaft clockwise two turns to set

No.1 cylinder to TDC of its compression stroke
and check that the sprocket timing marks are
aligned.
ENGINE MECHANICAL
11A-39
TIMING BELT
Approximately 100 N
Deflection
AC102693 AB
3. Apply a pressure of approximately 100N at the

centre (arrow area) between the sprocket as
shown, then inspect whether the belt deflection is
within the standard value.
Standard value:
At adjustment: 5 - 7 mm
At replacement: 5 - 7 mm
4. If not within the standard value, adjust the belt
tension again.
>>C<< CRANKSHAFT ANGLE SENSING BLADE/
CRANKSHAFT CAMSHAFT DRIVE SPROCKET
INSTALLATION
: Clean
: Clean and degrease
: Apply engine oil
2. Install the crankshaft angle sensing blade and

crankshaft camshaft drive sprocket in the direction
shown.
3. Place the larger chamfer side of the crank shaft
pulley washer in the direction shown and then
assemble on the crankshaft pulley centre bolt.
4. Apply some engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
Crankshaft
camshaft
drive
sprocket
MB991367
AC102332 AB
5. Use the following special tool as during removal to

support the crankshaft camshaft drive sprocket.
Pin (MB991385)
6. Tighten the crankshaft pulley centre bolts to the
specified torque.
Tightening torque: 167 Nm
>>D<< TIMING BELT TENSIONER ADJUSTER
INSTALLATION
1. Install according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.
Crankshaft pulley
center bolt
Crankshaft camshaft
drive sprocket
CAUTION
Crankshaft
If the compression is too fast, the procedure may

damage the rod.
A
Crankshaft
pulley washer
Engine front
MB991385
Crankshaft angle
sensing blade
AC211535AB
1. Clean or degrease the crankshaft, the crankshaft

angle sensing blade, the crankshaft camshaft
drive sprocket and crankshaft pulley washer as
shown.
NOTE: Also clean the degreased surfaces.
AC102334 AB
(1) Slowly compress the timing belt tensioner

adjuster rod using a press or vice, then align
the set hole A of the rod with set hole B of the
timing belt tensioner adjuster cylinder.
ENGINE MECHANICAL
11A-40
TIMING BELT
>>F<< VALVE TIMING BELT INSTALLATION

Wire
Timing mark
AC102335 AB
(2) Insert a wire or pin into the aligned set hole.

NOTE: When replacing the timing belt
tensioner adjuster with new parts, the timing
belt tensioner adjuster is set with a pin.
2. Assemble the timing belt tensioner adjuster to the
engine, then tighten the assembling bolt to the
specified torque. Do not remove the wire or pin
until the tension of the valve timing belt is
adjusted.
Camshaft sprocket
Crankshaft
camshaft
drive sprocket
Timing mark
Timing mark
>>E<< TIMING BELT TENSIONER PULLEY

INSTALLATION
Engine oil
pump sprocket
AC102486 AC
1. Align the timing marks on the camshaft sprocket,

crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Bolt
Balancershaft
Timing belt tensioner

pulley hole
Plug
AC102336AB
Temporarily tighten the timing belt tensioner pulley as

shown.
Cylinder
block
AC102337 AE
2. Adjust the timing mark of the engine oil pump

sprocket. Unplug the cylinder block plug. Insert a
bolt (M6 sectional width 10 mm, minor diameter
45 mm) from the plug hole and then check. If the
bolt comes in contact with the balancer shaft turn
the sprocket one rotation. Re-adjust the timing
mark and then check to see that the bolt fits. Do
not remove the bolt until the valve timing belt is
assembled.
ENGINE MECHANICAL
TIMING BELT
3. Install the valve timing belt as follows:

Inlet side
camshaft sprocket
11A-41
Timing mark
Timing mark
Exhaust side
camshaft sprocket
AC201802 AB
Timing belt
tensioner
pulley
Crankshaft
camshaft
drive
sprocket
Timing belt
idler pulley
(3) Use two wrenches to align the timing mark on

the rocker cover with that on the camshaft
sprocket. Pass the valve timing belt around the
inlet-side camshaft sprocket.
Engine
oil pump
sprocket
AC102488 AC
(1) Pass the valve timing belt around the

crankshaft camshaft drive sprocket, the engine
oil pump sprocket and the timing belt idler
pulley in that order.
Paper clip
AC201803AB
(4) Hold the valve timing belt with paper clips.

(5) Pass the valve timing belt around the timing
belt tensioner pulley.
CAUTION
Paper clip
Incorporate the valve timing belt. Then apply

reverse rotation (anti-clockwise rotation)
pressure to the cam shaft sprocket. Re-check to
see that each timing mark is aligned while the
tension side of the belt is tight.
(6) Remove the two paper clips.
AC201801AB
(2) Pass the valve timing belt around the exhaustside camshaft sprocket, and hold the valve
timing belt with paper clip.
MD998767
AC102694 AB
4. Turn the timing belt tensioner in the direction

shown using special tool tensioner wrench
(MD998767) to apply tension to the valve timing
belt. Then pre-tighten the timing belt tensioner
pulley.
5. Check that the timing marks are aligned.
ENGINE MECHANICAL
11A-42
TIMING BELT
Bolt
Balancershaft
CAUTION
When tightening the mounting bolt, ensure that
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.
Plug
Cylinder
block
AC102337 AE
6. Remove the bolt inserted in Step 2 above, then

assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified
torque.
8. Adjust the valve timing belt tension.
>>G<< VALVE TIMING BELT TENSION
ADJUSTMENT
MD998767
AC102695AB
6. With special tool tensioner wrench (MD998767)

and torque wrench, apply tension torque 3.5 Nm,
and tighten the timing belt tensioner pulley
mounting bolt to the specified torque.
MD998738
Wire
Timing belt
under cover
AC102492 AB
1. Set special tool adjusting bolt (MD998738) when

removing the valve timing belt.
CAUTION
Always screw in special tool by hand, since use
of a spanner or other tools may damage the wire
or pin inserted in the timing belt tensioner
adjuster.
2. Gradually screw in special tool until the wire or pin
inserted in the timing belt tensioner adjuster lightly
moves.
3. Turn the crankshaft 1/4 turn anti-clockwise.
4. Turn the crankshaft in the clockwise direction until
you align each timing mark to set No.1 cylinder to
TDC of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting
bolt.
AC102776 AB
7. Remove wire or pin inserted to timing belt

tensioner.
MD998738
Timing belt
under cover
AC102492 AB
8. Remove the special tool adjusting bolt

(MD998738), and install the rubber plug to the
timing belt under cover.
9. Rotate the crankshaft clockwise two turns, and
leave it for about 15 minutes.
ENGINE MECHANICAL
11A-43
TIMING BELT
CAUTION
Always check the tightening torque of the crank
shaft pulley centre bolt when turning the crack
shaft pulley centre bolt anti-clockwise. Retighten if it is loose.
Wire
Timing mark
AC102776 AB
10.Insert wire or pin removed in Step 7 again, and

ensure that it can be pulled out easily. When wire
or pin can be easily removed, appropriate tension
is applied on timing belt. In this case, remove wire
or pin.
Camshaft
sprocket
Crankshaft
camshaft
drive sprocket
Timing belt
tensioner
adjuster
Timing mark
Timing mark
AC102338AB
If the projection of timing belt tensioner adjuster

rod is within the standard value, appropriate
tension is applied.
Standard value (A): 3.8 - 4.5 mm
11.If wire or pin cannot be easily pulled out, repeat
Step 1 through Step 9 to reach proper valve timing
belt tension.
Engine
oil pump
sprocket
AC201411AB
12.Check again that the timing marks on sprockets

are aligned.
>>H<< END CAP INSTALLATION
CAUTION
Always replace the end cap with new parts since
there may be fall-off or sealing defect if the end
cap is re-used.
INSPECTION
M1112004400352
TIMING BELT TENSIONER ADJUSTER

CHECK
1. Check for oil leak from seal, and replace it if leak
is detected.
2. Check for wear or damage at the top of the rod.
Replace it, if required.
ENGINE MECHANICAL
11A-44
TIMING BELT
98 196 N
Movement
BALANCER TIMING BELT TENSION

CHECK
Check the balancer timing belt tension as follows:
B
Approximately 100 N
Rod
Timing belt
tensioner
adjuster
AC102339 AB
3. Hold the timing belt tensioner adjuster by hand,

and press the top end of the rod onto the metal
(e.g. cylinder block) under a pressure of 98 - 196
N to measure the movement of the rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
4. If the measured value is out of the standard value,
replace the timing belt tensioner adjuster.
Deflection
AC102693 AB
1. Apply a pressure of approximately 100 N at the

centre (arrow area) between the sprocket as
shown then inspect whether the deflection is
within the standard value.
Standard value: 5 - 10 mm
2. If not within the standard value, adjust the belt
tension. (Refer to 311A).
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-45
ENGINE ASSEMBLY
M1112001000720
CAUTION
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Hood Removal (Refer to GROUP 42, Hood 342).
351).
Battery and Battery Tray Removal
Rocker Cover Centre Cover Removal (Refer to 311A
).
Radiator Assembly Removal (Refer to GROUP 14,
Radiator 314).
Starter Assembly Removal (Refer to GROUP 16, Starter
Motor Assembly 316).
Starter Assembly Installation (Refer to GROUP 16,
Starter Motor Assembly 316).
Radiator Assembly Installation (Refer to GROUP 14,
Radiator 314).
Battery and Battery Tray Installation
Rocker Cover Centre Cover Installation (Refer to 311A
).
Adjustment 317).
Cover 351).
Hood Installation (Refer to GROUP 42, Hood 342).
Fuel Leak Check
ENGINE MECHANICAL
11A-46
ENGINE ASSEMBLY
9
5.0 1.0 Nm
10
17
12
7
5
6
14
5.0 1.0 Nm
15
11
9.0 2.0 Nm
13
2
1
9.0 2.0 Nm
18
5.0 1.0 Nm
16
9.0 2.0 Nm
5.0 1.0 Nm
1.
2.
3.
4.
5.
6.
7.
8.
9.
Removal steps
Power steering fluid pressure
switch connector
Crank angle sensor connector
Ignition coil connectors
Purge control solenoid valve
connector
EGR control solenoid valve
connector
Injector connectors
Throttle position sensor connector
10.
11.
12.
13.
14.
<<A>>
15.
16.
17.
18.
AC300549 AB

Idle speed control servo connector
connector
Oxygen sensor connector
connector
Engine coolant temperature gauge
unit connector
Capacitor connector
Battery wiring harness connection
Drive belt
ENGINE MECHANICAL
11A-47
ENGINE ASSEMBLY
23
24
19
25
5.0 1.0 Nm
26 N
(Engine oil)
12 2 Nm
20
44 10 Nm*
22 4 Nm
27
22
22 4 Nm
45 5 Nm*
29
28
21
AC300550 AB
<>
<>
Removal steps
19. Brake booster vacuum hose
connection
20. Canister vacuum hose connection
21. A/C compressor and clutch
assembly
22. Power steering oil pump assembly
23. Heater water hoses connection
24. Fuel return line hose connection
>>E<<
<<C>>
<<D>>
<<E>>
>>E<<
>>D<<
>>C<<
>>B<<
>>A<<

25. Fuel high-pressure hose
connection
26. O-ring
Transmission assembly
27. Self-locking nuts
28. Engine front mounting bracket
29. Engine assembly
ENGINE MECHANICAL
11A-48
ENGINE ASSEMBLY
<<C>> TRANSMISSION ASSEMBLY REMOVAL
<<A>> DRIVE BELT REMOVAL

Auto-tensioner
AC300950AB
Hole B
Hole A
AC107640AC

CAUTION
1. Pre-tighten the 2 bolts on the car to assemble the

radiator support upper insulator to set the special
tools engine hanger MB991895 or engine hanger
MB991928.
2. Remove the transmission assembly (Refer to
GROUP 22A, Transmission Assembly 322A).
<<D>> ENGINE FRONT MOUNTING BRACKET
REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.
MB991895
MB991527
Auto-tensioner
L-shaped
hexagon
wrench
MB991454
AC107631AB
AC107641AB

drive belt.
<> A/C COMPRESSOR AND CLUTCH
ASSEMBLY/POWER STEERING OIL PUMP
ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly, and power steering oil pump
assembly from the bracket.
NOTE: Secure the removed A/C compressor and
clutch assembly, and power steering oil pump
assembly with cord or rope at a position where they
will not interfere with the removal of the engine
assembly.
(1) <Special tool engine hanger (MB991895) is

used>
Remove special tool MB991895.
MB991928
MB991527
MB991454
AC211405 AB

used>
Remove special tool MB991928.
ENGINE MECHANICAL
11A-49
ENGINE ASSEMBLY
2. Support the engine assembly with a garage jack.

3. Remove the chain block.
4. Use the following special tool as during removal to
support the engine.
MB991454
MB991527
MB991895
MB991527
AC107632 AB
3. Hold the engine assembly with a chain block, etc.

4. Place a garage jack against the engine oil pan
with a piece of wood in between so that the weight
of the engine assembly is no longer being applied
to the engine front mounting bracket.
5. Loosen the engine front mounting bracket
mounting nuts and bolt, and remove the engine
front mounting bracket.
MB991454
AC107631AB

used>
Set special tool MB991895. (Refer to
GROUP 22A, Transmission Assembly
322A).
<<E>> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and wiring
harness connectors and so on are disconnected
from the engine, lift the chain block slowly to remove
the engine assembly upward from the engine
compartment.
MB991928
MB991527

>>A<< ENGINE ASSEMBLY INSTALLATION
MB991454
AC211405 AB

used>
Set special tool MB991928 (Refer to
GROUP 22A, Transmission Assembly
322A).
MB991454
MB991527
>>C<< SELF-LOCKING NUTS INSTALLATION
CAUTION
Install the engine assembly, being careful not to
pinch the cables, hoses or wiring harness
connectors.
Do not tighten the self-locking nuts while the

engine is hot.
Tighten the self-locking nuts to the specified torque
while the engine is cold.
>>B<< ENGINE FRONT MOUNTING BRACKET

INSTALLATION
1. Place a garage jack against the engine oil pan
with a piece of wood in between, and install the
engine front mounting bracket while adjusting the
position of the engine.
>>D<< TRANSMISSION ASSEMBLY

INSTALLATION
1. Install the transmission assembly (Refer to
GROUP 22A, Transmission Assembly 322A).
AC107632 AB
ENGINE MECHANICAL
11A-50
ENGINE ASSEMBLY
>>E<< O-RING/FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
AC300950AB
2. Remove from the car the 2 bolts, to assemble the

radiator support upper insulator.
Do not let any engine oil get into the delivery

pipe.
1. Apply a small amount of new engine oil to the Oring.
2. Turning the fuel high-pressure hose to the right
and left, install it to the delivery pipe, while being
careful not to damage the O-ring. After installing,
3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage.
After this, re-insert it to the delivery pipe and
4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
11-1
GROUP 11
ENGINE
00
11
12
13
CONTENTS
14
15
16
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
17
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
127(6
22A-1
GROUP 22A
00
11
MANUAL
TRANSMISSION
12
13
14
15
16
CONTENTS
17
LUBRICANT. . . . . . . . . . . . . . . . . . . .
22A
22A
SPECIAL TOOLS. . . . . . . . . . . . . . . .
22A
22A
TRANSMISSION OIL LEVEL CHECK . . . .
22A
TRANSMISSION OIL REPLACEMENT . . .
22A
TRANSFER OIL CHECK . . . . . . . . . . . . . .
22A
TRANSFER OIL REPLACEMENT . . . . . . .
22A
TRANSMISSION CONTROL . . . . . . .
22A
22A
SHIFT LEVER ASSEMBLY . . . . . . . . . . . . .
22A
22A
TRANSFER ASSEMBLY . . . . . . . . . .
22A
22A
TRANSMISSION ASSEMBLY . . . . . . 22A

22A
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
MANUAL TRANSMISSION
22A-2
GENERAL INFORMATION
GENERAL INFORMATION
M1221000100633
The manual transmission come in two models, namely, F5M42 and W5M42.
Item
Specification
Transmission model
F5M42 (2WD)
Engine model
4G63-DOHC-MPI
Transmission type
5-speed forward, 1-speed reverse constant mesh
Transmission gear ratio
W5M42 (4WD)
1st
3.583
3.583
2nd
1.947
1.947
3rd
1.379
1.379
4th
1.030
1.030
5th
0.820
0.820
Reverse
3.363
3.363
Final reduction ration (Differential gear ratio)
4.625
4.687
Speedometer gear ratio
31/36
31/36
LUBRICANT
M1221000400151
Item
Specified lubricant
Quantity L
Transmission oil
Gear oil SAE 75W-90 or 75W-85W conforming to API GL-4
2.2 <2WD>
2.3 <4WD>
Transfer oil
Hypoid gear oil API classification GL-5 SAE90
0.53
MANUAL TRANSMISSION
22A-3
SPECIAL TOOLS
SPECIAL TOOLS
M1221000600627
Tool
Number
Name
Use
MB991453
Engine hanger
assembly
MB991454
Engine hanger
balancer
When the engine hanger is used:

Supporting the engine assembly
during removal and installation of the
transmission assembly
NOTE: Special tool MB991454 is a
part of engine hanger attachment set
MB991453.
MB991527
Engine hanger
MB991895
Engine hanger
B991453
B991454
B991527
MB991895
MB991928
A: MB991929
B: MB991930
E C: MB991931
D: MB991932
E: MB991933
F: MB991934
Slide bracket (HI)
F
A
D
B
C
B991928
Engine hanger
A: Joint (50) 2
B: Joint (90) 2
C: Joint (140) 2
D: Foot (standard) 4
E: Foot (short) 2
F: Chain and hook
assembly
MANUAL TRANSMISSION
22A-4
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
TRANSMISSION OIL LEVEL CHECK
TRANSFER OIL CHECK
M1221000900446
M1221001100089
Filler plug hole
Filler plug hole
Transmission oil
Filler plug
Filler plug
Transfer oil
AC210553 AB
AC210553AC
1. Remove the filler plug.

2. Check that the oil level is up to the lower edge of
the filler plug hole.
3. Check that the oil is not noticeably dirty.
4. Tighten the filler plug to the specified torque.

2. Check that the oil level is up to the lower edge of
the filler plug hole.
3. Check that the oil is not noticeably dirty.
TRANSMISSION OIL REPLACEMENT
TRANSFER OIL REPLACEMENT
M1221001000350
M1221001200064
Filler plug
Filler plug
Drain plug
AC210554 AB

2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque.
4. Fill with gear oil API classification GL-4 SAE 75W85W or 75W-90 until the level comes to the lower
portion of filler plug hole.
Quantity: 2.2 L <2WD>
Quantity: 2.3 L <4WD>
Drain plug
AC210555 AB

2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque.
4. Fill with hypoid gear oil API classification GL-5
SAE90 until the level comes to the lower portion of
filler plug hole.
Quantity: 0.53 L
MANUAL TRANSMISSION
22A-5
TRANSMISSION CONTROL
M1221003800523
WARNING
Be careful not to subject the SRS-ECU to any shocks during removal and installation of the
shift cable and select cable assembly.
Air Cleaner Assembly Removal and Installation (Refer to
Battery and Battery Tray Removal and Installation.
11
9
12 2 Nm
10
N
6.0 1.5 Nm
2
6
12 2 Nm
12
AC210284AB
1.
2.
3.
>>B<<
4.
5.
<<A>> >>A<<
<<A>> >>A<<
6.
7.
8.
9.
Gearshift cable and select cable

assembly removal steps
Gearshift lever knob
Front floor console (Refer to
GROUP 52A 352A).
Snap pin
Select cable connection (Gearshift
lever side)
Gearshift cable clip
Gearshift cable connection
(Gearshift lever side)
SRS-ECU (Refer to GROUP 52B
352B).
Console side cover bracket
Snap pin
Gearshift link clip
Select cable connection
(Transmission side)
<<A>> >>A<<
>>A<<
>>B<<
Gearshift cable and select cable

10. Gearshift cable connection
(Transmission side)
11. Gearshift cable and select cable
assembly
Gearshift lever assembly
removal steps
1. Gearshift lever knob

GROUP 52A 352A).
2. Snap pin
3. Select cable connection (Gearshift
lever side)
4. Gearshift cable clip
5. Gearshift cable connection
(Gearshift lever side)
12. Gearshift lever assembly
MANUAL TRANSMISSION
22A-6
CAUTION
<<A>> GEARSHIFT LINK CLIP/SELECT CABLE

CONNECTION (TRANSMISSION SIDE)/GEAR
SHIFT CABLE CONNECTION (TRANSMISSION
SIDE) REMOVAL
New gearshift
link clip
Gearshift cable,
Select cable
Claws
Cable bracket
Shift cable, Select cable

Gearshift link clip
AC210556 AB
Push up the claws of the gearshift link clip using a

screwdriver, etc., and then remove the gearshift link
clip from the bracket together with the cables.

>>A<< GEARSHIFT CABLE AND SELECT CABLE
ASSEMBLY/GEARSHIFT CABLE CONNECTION
(TRANSMISSION SIDE)/SELECT CABLE
CONECTION (TRANSMISSION SIDE)/GEARSHIFT
LINK CLIP INSTALLATION
Select lever
AC210558 AB
Insert thoroughly the gearshift link clip, shift

cable and select cable until they click in place.
3. After installing the new gearshift link clip to the
cable bracket of the transmission, install the shift
cable and select cable to the cable bracket.
NOTE: The clip is reversible.
4. Move the shift lever to all positions and check that
the operation is smooth.
>>B<< GEAR SHIFT CABLE CLIP INSTALLATION
Neutral position
AC210557AB
1. Set the transmission side shift lever and the

passenger compartment side shift lever to the
neutral position.
2. Install the painted part of the shift cable end
(transmission side) and painted part of the select
cable (transmission side) facing the snap pin.
9.5 mm
5 - 8 mm
AC210559AB
1. Make sure that there is no excessive play at the

shift cable end gearshift cable clip. If there is
excessive play or the gearshift cable clip is
disengaged from the shift cable end, check the
clip opening gap. If the gap is more than 9.5 mm,
squeeze the gearshift cable clip until the relaxed
gap reaches 5 to 8 mm.
MANUAL TRANSMISSION
22A-7
3. Install the shift cable to the shift lever.
AC210560 AB
2. Engage the gearshift cable clip with the shift cable

hook securely, and push the gearshift cable clip
with your thumbs until it clicks in place.
SHIFT LEVER ASSEMBLY

M1221004000177
9
14 2 Nm
4 3
2
6
5
10 1 Nm
12
11
10
AC210285 AB
1.
2.
3.
4.
5.
6.
7.
Disassembly steps
Gearshift link bolt
Gearshift select lever
Gearshift link bushing
Gearshift lever spring
Gearshift link collar
Bolt
Gearshift lever retainer

8. Gearshift lever
9. Gearshift link bushing
10. Gearshift lever bracket distance
piece
11. Gearshift link bushing
12. Gearshift lever bracket
MANUAL TRANSMISSION
22A-8
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
M1221003200037
CAUTION
*: Indicates parts which should be temporarily tightened, and then fully tightened after installing the
engine into the vehicle.
Front Under Cover Removal and Installation (Refer to GROUP 51, Front Bumper 351).
Side Under Cover Removal and Installation (Refer to GROUP 51, Front Bumper 351).
Engine Coolant Draining and Supplying (Refer to GROUP 14, On-vehicle Service 314).
Transfer Oil Draining and Supplying (Refer to 322A).
Drive Shaft, Output Shaft Removal and Installation (Refer to GROUP 26 326).
Front Exhaust Pipe Removal and Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315).
Propeller Shaft Removal and Installation (Refer to GROUP 25 325).
10
3
69 10 Nm
9.0 2.0 Nm
8N
30 3 Nm
69 10 Nm
52 7 Nm
5
N
9.0 2.0 Nm
2
1
52 7 Nm
30 3 Nm
6
69 10 Nm
69 10 Nm
1.
2.
3.
4.
5.
Removal steps
Water feed tube assembly
Gasket
Water return tube assembly
Gasket
Rear roll stopper connection bolt
<<A>>
AC210286 AB

6. Centre member assembly
7. Transfer assembly
8. O-ring
9. Water feed hose
10. Water return hose
MANUAL TRANSMISSION
TRANSFER ASSEMBLY

<<A>> TRANSFER ASSEMBLY REMOVAL
Engine and
Transmission
assembly
Transfer assembly
AC207772 AC
With the engine mount and transmission assembly

towards the front of the vehicle, and remove the
transfer assembly from between the engine block
and crossmember.
22A-9
MANUAL TRANSMISSION
22A-10
TRANSMISSION ASSEMBLY
M1221002700222
CAUTION
*: Indicates parts which should be temporarily tightened, and then fully tightened after installing the
engine into the vehicle.
Air Cleaner assembly, Air Cleaner Bracket Removal and Installation (Refer to GROUP 15, Air Cleaner 315).
Battery and Battery Tray Removal and Installation.
Front Under Cover Removal and Installation (Refer to GROUP 51, Front Bumper 351).
Side Under Cover Removal and Installation (Refer to GROUP 51, Front Bumper 351).
Transfer Oil Draining and Supplying <4WD> (Refer to 322A).
Drive Shaft Removal and Installation (Refer to GROUP 26 326).
Output Shaft Removal and Installation <4WD> (Refer to GROUP 26 326).
Front Exhaust Pipe Removal and Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler 315).
Propeller Shaft Removal and Installation <4WD> (Refer to GROUP 25 325).
18 3 Nm
18 3 Nm
5
18 3 Nm
1
2
3
7
70 10 Nm
<2WD>
70 10 Nm
<4WD>
7
70 10 Nm
AC210287AB
1.
2.
3.
4.
5.
Removal steps
Transmission harness clamp
Back-up lamp switch connector
Vehicle speed sensor connector
Clutch release cylinder and clutch
oil pipe
Snap pin
6.
7.

Cable bracket and cable assembly
<Transmission side>
Transfer assembly (Refer to
322A).
Rear roll mount bracket
MANUAL TRANSMISSION
22A-11
8.
<<A>>

Rear roll mount adapter bracket
<4WD>
Engine and transmission
assembly supporting
47 7 Nm*
48 5 Nm
48 5 Nm
82 7 Nm*
9
48 5 Nm
9
48 5 Nm
11
12
10
11
48 5 Nm
15
13
<4WD>
16
44 10 Nm
14
<2WD>
22 4 Nm
9.0 1.0 Nm
14
26 5 Nm
9.0 1.0 Nm
AC210288 AB
Removal steps
Transmission assembly upper part
coupling bolts
Starter coupling bolts (Refer to

GROUP 16 316.)
10. Transmission mount assembly
11. Transmission mount stopper
12. Transmission mount bracket
9.
<<A>>
>>B<<
<>
<<C>>
>>A<<

Engine assembly supporting
Clutch release bearing connection
Transmission stay <4WD>
Bell housing cover
Transmission assembly lower part
coupling bolts
16. Transmission assembly
13.
14.
15.
MANUAL TRANSMISSION
22A-12

<<A>> ENGINE AND TRANSMISSION ASSEMBLY
SUPPORTING/TRANSMISSION MOUNT
ASSEMBLY REMOVAL
Front Side
Slide
Bracket
(HI)
Joint (90)
(MB991930)
Engine and transmission assembly
Foot (Standard)
Joint (50)
(MB991932)
(MB991929)
Foot (Standard)
(MB991932)
AC212277AB
Garage jack
AC210384 AB
While supporting the engine and transmission

assembly with a garage jack, remove the
transmission mount assembly.
2. <Engine hanger (special tool MB991928) is used>

(1) Assemble the engine hanger (special tool
MB991928). Set following parts to the base
hanger.
Slide bracket (HI)
Foot (standard) (MB991932)
Joint (90) (MB991930)
Joint (50) (MB991929)
<> ENGINE ASSEMBLY SUPPORT
AC210400 AB
AC210400 AB
MB991895
MB991928
Slide Bracket (HI)
MB991929
MB991527
MB991934
MB991932
MB991454
MB991454
AC210388 AB
1. <Engine hanger (special tool MB991895) is used>

(1) Set special tool MB991895 to the strut
mounting nuts and the radiator support upper
insulator mounting bolts, which are located in
the engine compartment, as shown.
(2) Set special tools MB991454 to hold the
engine/transmission assembly.
MB991930
MB991932
MB991527
AC210392 AB
(2) Set the engine hanger (special tool

MB991928) to the strut mounting nuts and the
radiator support upper insulator mounting
bolts, which are located in the engine
compartment, as shown.
NOTE: Adjust the engine hanger balance by
sliding the slide bracket (HI).
(3) Set special tools MB991454 to hold the
engine/transmission assembly.
MANUAL TRANSMISSION
22A-13
<<C>> CLUTCH RELEASE BEARING

SEPARATION
CAUTION
B
A
Release Fork
CAUTION
Be sure to push the release fork in the direction
A before inserting a screwdriver.
3. Separate the release bearing from the wedge
collar by prying with the screwdriver (turning the
screwdriver grip 90).
NOTE: The release fork is forced to move fully in
the direction B by the return spring as soon as it is
separated from the wedge collar.
Service Hole
Wedge Collar
Release Bearing
AC210561AB
If it is hard to turn the screwdriver (to pry off the

release bearing), remove the screwdriver once
and repeat the below procedure after pushing the
release fork fully in the direction a two or three
times. Forcibly prying can cause the release
bearing to be damaged.
1. Remove the cover from the service hole in the
clutch housing.
2. While pushing the release fork by hand in the
direction A, insert a flap-tip screwdriver between
the release bearing and the wedge collar.
>>A<< TRANSMISSION STAY INSTALLATION

Install the transmission stay as below.
1. Tighten the engine-side bolts to the specified
torque.
2. Tighten the transmission-side bolts to the
specified torque.
>>B<< TRANSMISSION MOUNT STOPPER
INSTALLATION
Engine side
Arrow
Transmission
mount stopper
Transmission
mount bracket
AC210408 AB
Install the transmission mount stopper so that the

arrow points as shown in the illustration.
127(6
54A-1
GROUP 54A
00
11
CHASSIS
ELECTRICAL
12
13
14
15
CONTENTS
BATTERY. . . . . . . . . . . . . . . . . .
FLUID LEVEL AND SPECIFIC GRAVITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING . . . . . . . . . . . . . . . . . . . . . .
BATTERY TEST . . . . . . . . . . . . . . . . . .
54A
54A
54A
54A
54A
54A
IGNITION SWITCH* . . . . . . . . . .
54A
SPECIAL TOOLS. . . . . . . . . . . . . .
54A
INTRODUCTION . . . . . . . . . . . . . .
54A
TROUBLESHOOTING . . . . . . . . . .
54A
54A
HOW TO REGISTER ENCRYPTED

CODE. . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSPONDER LOCK CHECK . . . . . .
54A
54A
16
IGNITION SWITCH . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . .
COMBINATION METER
ASSEMBLY . . . . . . . . . . . . . . .
54A
54A
54A
17
21
22
54A
25
26
54A
SEALANT . . . . . . . . . . . . . . . . . . . .
54A
SPECIAL TOOLS . . . . . . . . . . . . . .
54A
32
54A
33
54A
54A
54A
54A
54A
27
SPEEDOMETER CHECK . . . . . . . . . . .
TACHOMETER CHECK. . . . . . . . . . . . .
FUEL GAUGE UNIT CHECK <2WD> . .
FUEL GAUGE UNIT CHECK <4WD> . .
ENGINE COOLANT TEMPERATURE
GAUGE UNIT CHECK . . . . . . . . . . . . . .
54A
31
34
35
36
37
42
51
:$51,1*65(*$5',1*6(59,&,1*2)6833/(0(17$/5(675$,176<67(0656(48,33('9(+,&/(6
WARNING
(1)
Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from
rendering the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRSrelated component.
NOTE
The SRS includes the following components: front impact sensors, SRS-ECU, SRS warning lamp, air bag module, clock spring
and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS
service or maintenance) are indicated in the table of contents by an asterisk (*).
52
54
55
54A-2
COMBINATION METER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . .
DISASSEMBLY AND ASSEMBLY . . . . .
REAR FOG LAMP . . . . . . . . . . . . .

54A
54A
54A

INSPECTION . . . . . . . . . . . . . . . . . . . . .
54A
54A
54A
SIDE TURN SIGNAL LAMP . . .
54A
SPECIAL TOOL . . . . . . . . . . . . . . .
54A
SIDE TURN SIGNAL LAMP. . . . . .
54A
54A
HEADLAMP . . . . . . . . . . . . . . .
54A
SERVICE SPECIFICATIONS . . . .
54A
TROUBLESHOOTING . . . . . . . . .
54A
ON-VEHICLE SERVICE . . . . . . . .
54A
54A
ROOM LAMP . . . . . . . . . . . . . .
54A
54A
54A
54A
REAR COMBINATION LAMP .
54A
REAR COMBINATION LAMP

DIAGNOSIS . . . . . . . . . . . . . . . . . .
54A
SPECIAL TOOL . . . . . . . . . . . . . . .
54A
REAR COMBINATION LAMP . . . .
54A
54A
HEADLAMP AIMING . . . . . . . . . . . . . . . .
LUMINOUS INTENSITY
MEASUREMENT. . . . . . . . . . . . . . . . . . .
BULB REPLACEMENT . . . . . . . . . . . . . .
HEADLAMP. . . . . . . . . . . . . . . . . .
HEADLAMP LEVELING SWITCH

INSPECTION. . . . . . . . . . . . . . . . . . . . . .
54A
54A
54A
54A
54A
FOG LAMP . . . . . . . . . . . . . . . .
54A
54A
SPECIAL TOOL . . . . . . . . . . . . . .
54A
54A
54A
54A
FOG LAMP AIMING . . . . . . . . . . . . . . . .
HIGH MOUNTED STOP LAMP

HIGH MOUNTED STOP LAMP . . .
LICENCE PLATE LAMP. . . . . .

LICENCE PLATE LAMP . . . . . . . .
FOG LAMP . . . . . . . . . . . . . . . . . .
FOG LAMP SWITCH. . . . . . . . . . .

INSPECTION. . . . . . . . . . . . . . . . . . . . . .
REAR FOG LAMP . . . . . . . . . .
54A
54A
54A
54A
54A
54A
54A
SPECIAL TOOL . . . . . . . . . . . . . .
54A
54A
54A
54A
54A
54A
54A
HAZARD WARNING LAMP

SWITCH . . . . . . . . . . . . . . . . . .
54A
54A
SPECIAL TOOL . . . . . . . . . . . . . . .
54A
HAZARD WARNING LAMP

SWITCH . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . .
54A
54A
54A
54A-3
COLUMN SWITCH. . . . . . . . . . . . . . . 54A
SPECIAL TOOL . . . . . . . . . . . . . . .
COLUMN SWITCH. . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . .
54A
54A
54A
54A
HORN . . . . . . . . . . . . . . . . . . . . . 54A
RHEOSTAT . . . . . . . . . . . . . . .
RHEOSTAT. . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . .
SPEAKER. . . . . . . . . . . . . . . . .
SPEAKER . . . . . . . . . . . . . . . . . . . .
HORN . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . .
54A
54A
54A
CLOCK. . . . . . . . . . . . . . . . . . . . 54A
SPECIAL TOOL . . . . . . . . . . . . . . .
54A
CLOCK. . . . . . . . . . . . . . . . . . . . . .
54A
54A
CIGARETTE LIGHTER . . . . . . . 54A

INSPECTION . . . . . . . . . . . . . . . . .
54A
ACCESSORY SOCKET. . . . . . . 54A

SPECIAL TOOL . . . . . . . . . . . . . . .
54A
ACCESSORY SOCKET. . . . . . . . .
54A
54A
54A

INSPECTION . . . . . . . . . . . . . . . . . . . . .
ANTENNA . . . . . . . . . . . . . . . .
ANTENNA. . . . . . . . . . . . . . . . . . . .
REAR WINDOW DEFOGGER .
54A
54A
54A
54A
54A
54A
54A
54A
54A
54A
54A
54A
54A
54A
54A
PRINTED HEATER LINES CHECK . . . .
REAR WINDOW DEFOGGER

SWITCH . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . .
54A
54A
54A
CHASSIS ELECTRICAL
54A-4
BATTERY
BATTERY
M1541000300179
Items
Specification
Specific gravity of the battery fluid
1.220 - 1.290 (20C)
ON-VEHICLE SERVICE
CHARGING
M1541001100468
FLUID LEVEL AND SPECIFIC GRAVITY

CHECK
M1541001000416
Inspect whether or not the battery fluid is between

the UPPER LEVEL and LOWER LEVEL marks.
CAUTION
If the battery fluid is below the LOWER
LEVEL, the battery could explode in using.
If the battery fluid is over the UPPER LEVEL,
leakage could result.
Therometer
Hydrometer
Battery fluid
AC211242AB
1. Use a hydrometer and thermometer to check the

specific gravity of the battery fluid.
Standard value: 1.220 - 1.290 (20C)
2. The specific gravity of the battery fluid varies with
the temperature, so use the following formula to
calculate the specific gravity for 20C. Use the
calculated value to determine whether or not the
specific gravity is satisfactory.
D20 = (t-20) X 0.0007 + Dt
D20: Specific gravity of the battery fluid
calculated for 20C
Dt: Actually measured specific gravity
t: Actually measured temperature
Battery type
Capacity (5-hour rate)
75D23L
53 A
3. Determine when charging is finished.

When the specific gravity of the battery
electrolyte is constantly within 1.250 - 1.290 for a
continuous period of one hour or more.
CAUTION
The battery plus should be removed during
charging.
The battery electrolyte level may rise and
overflow from the battery during charging.
Explosions may occur if the battery is
brought close to naked flames during
charging.
After charging is complete, replace the
battery plus, pour water over the battery to
rinse away any sulphuric acid, and let the
battery stand to dry.
Do not let the battery electrolyte temperature
rise above approximately 45C (approximately
55C during rapid charging).
1. Remove the battery from the vehicle.
2. The normal charging current is a value in
amperes which is 1/10th of the battery capacity. If
the battery needs to be charged rapidly because
of reasons such as time limitations, the maximum
charging current for rapid charging is the battery
capacity expressed as an ampere value.
Normal charging current Rapid charging

current
5.3 A
53 A
When the voltage per cell during charging is 2.5 V constantly for a continuous period of one hour
more.
CHASSIS ELECTRICAL
54A-5
BATTERY
BATTERY TEST
STEP 4. Check the open circuit voltage.

(1) Turn headlamps on for 15 seconds.
(2) Turn headlamps off for two minutes to allow
battery positive voltage to stabilize.
(3) Disconnect the battery cables.
(4) Read open circuit voltage.
M1541001200465
BATTERY TESTING PROCEDURE

STEP 1. Check the battery cables.
Remove the negative cable, then the positive cable.
Check for dirty or corroded connections.
Q: Is open circuit voltage 12.4 volts or more?

YES : Go to Step 6.
NO : Go to Step 5.
Q: Are the battery cables dirty or have corroded

connections?
YES : Clean the battery cables. Then go to Step 2.
NO : Go to Step 2.
STEP 5. Charge battery.

Q: Charging the battery?
YES : Go to Step 6.
NO : Charge the battery at 5 amps for 15 hours.
STEP 2. Check the battery post.

Check for loose battery post.
Q: Are the battery post faulty?
YES : Replace the battery. Then go to Step 4.
NO : Go to Step 3.
Then re-test, go to Step 4.

STEP 6. Check the load test.
(1) Connect a load tester to the battery.
(2) Load the battery at the recommended discharge
rate (See LOAD TEST RATE CHART) for 15
seconds.
(3) Read voltage after 15 seconds, then remove
load.
(4) Compare the measured value with the minimum
voltage. (See LOAD TEST CHART.)
STEP 3. Check the battery case and cover.

(1) Remove the hold-downs and shields.
(2) Check for broken/cracked case or cover.
Q: Is the battery case or cover faulty?
YES : Replace the battery. Then go to Step 4.
NO : Go to Step 4.
Q: Is the voltage higher than minimum voltage?

NO : Replace the battery. Then go to Step 4.
YES : The battery is normal.
LOAD TEST CHART

Temperature C
21 and
above
16
10
-1
-7
-12
-18
Minimum voltage
9.5
9.4
9.3
9.1
8.9
8.7
8.5
9.6
LOAD TEST RATE CHART

Battery type
75D23L
Charging time when fully discharged h (5amp. rated current charging)
11
Load test (Amps)
275
CHASSIS ELECTRICAL
54A-6
IGNITION SWITCH
IGNITION SWITCH
SPECIAL TOOLS
M1543000601492
Tool
Number
Name
Use
MB991502
MUT-II sub
assembly
Immobilizer system check

Encrypted code
registration
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Making voltage and

resistance measurements
during troubleshooting
A: Connect pin contact
pressure inspection
B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester
connection
B991502
D
MB991223 AC
INTRODUCTION
IMMOBILIZER SYSTEM
M1543009901230
IGNITION KEY REMINDER BUZZER

The ignition key reminder buzzer will sound under
the following condition, and warn the driver to
remove the ignition key.
The drivers door is opened when the ignition
switch is at "LOCK" (OFF) or "ACC" position
without removing the ignition key.
However, the lamp reminder buzzer will take
precedence over this function.
DOOR LOCK PREVENTION FUNCTION

If the key is left in the ignition switch while the drivers
door opened or the assistant door opened, all door
are automatically unlock to prevent locking the
ignition key in the vehicle after door is locked.
The immobilizer system consists of the ignition key,

the immobilizer-ECU with key ring antenna, and the
engine-ECU. The ignition key has a built-in
transponder. Only the registered ignition key permits
the engine to start, therefore, the engine can never
be started by means of a forged key or by connecting
the ignition wiring directly. The system is significantly
safe and reliable against theft. In addition, the driver
has only to turn the ignition switch to the "ON"
position to activate the immobilizer system. If the
requirements for starting the engine are not satisfied,
the engine will be immobilized. If a registered ignition
key is lost, all your ignition keys need to be
registered again using MUT-II to ensure security
(Refer to 354A). An additional ignition key can be
registered as follows (only if no ignition keys are
lost):
Using MUT-II (Refer to 354A).
CHASSIS ELECTRICAL
54A-7
IGNITION SWITCH
OPERATION
1. When the ignition switch is turned to "ON"
position, the engine-ECU sends a requirement for
the encrypted code to the immobilizer-ECU (at
this time, the engine is remobilized).
2. When the immobilizer-ECU receives the
requirement from the engine-ECU, the
immobilizer-ECU supplies power to the
transponder inside the ignition key via the
antenna. The energized transponder sends the
encrypted code back to the immobilizer-ECU via
the antenna.
3. The immobilizer-ECU judges the encrypted code

with its code logic in itself. If they are identical, the
immobilizer-ECU sends the encrypted code to the
engine-ECU.
4. If the engine-ECU can not receive the encrypted
code, the engine will be immobilized.
Immobilizer-ECU
with an antenna
Ignition key
Power
(Wireress)
Control signal
Engine-ECU
Injector
CPU
CPU
Encrypted
code
Ignition
Memory
Transponder
Encrypted code
(Wireless)
MUT-II
Steering lock
AC206892 AD
TROUBLESHOOTING
IMMOBILIZER SYSTEM DIAGNOSIS
IGNITION KEY REMINDER BUZZER AND

DOOR LOCK PREVENTION FUNCTION
DIAGNOSIS
DIAGNOSIS CODE CHART
M1543000700935
The ignition key reminder buzzers are controlled by

the Smart Wiring System (SWS). For
troubleshooting, refer to respective Groups below.
Not using SWS monitor: GROUP 54B, SWS
Diagnosis 354B.
Using SWS monitor: GROUP 54C, SWS
Diagnosis 354C.
Diagnosis code No. Diagnosis item
M1543007100376
CAUTION
During diagnosis, a diagnosis code associated
with other system may be set when the ignition
switch is turned on with connector(s)
disconnected. On completion, confirm all
systems for diagnosis code code(s). If diagnosis
code code(s) are set, erase them all.
Use the following chart to develop proper diagnostic
strategy.
Reference page
11
Transponder communication system or radio interference

of encrypted code
354A.
12
Encrypted codes are not the same or are not registered
354A.
CHASSIS ELECTRICAL
54A-8
IGNITION SWITCH
DIAGNOSTIC TROUBLE CODE

PROCEDURES
Code No.11: Transponder Communication System or Radio Interference of Encrypted Code
Ignition Key Ring and Immobilizer-ECU Circuit

IMMOBILIZER-ECU
HIGH FREQUENCY
CIRCUIT
C-304-1
IGNITION
KEY RING
ANTENNA
TRANSPONDER
IGNITION KEY
AC300911AB
DIAGNOSIS CODE SET CONDITION

Diagnosis code No.11 may be output if other
ignition keys are in the vicinity of the vehicle as it
is being started.
The transponders encrypted code is not sent to
the immobilizer-ECU immediately after the
ignition switch is turned to "ON" position.
NOTE: Diagnosis code No.11 is always output
together with MPI system diagnosis code No.P1610.
TROUBLESHOOTING HINTS
Radio interference of the encrypted code
Malfunction of the transponder
Malfunction of the immobilizer-ECU.
DIAGNOSIS PROCEDURE
STEP 1. Check for presence of other key near the
key in the ignition.
Q: Is there any other key near the key in the ignition?
YES : Move the other key well away from key
being used. Retest the system.

NO : Go to Step 2.
STEP 2. Check that the engine start using the

spare ignition key which encrypted code has
been registered.
Q: Does the engine start using the spare ignition key
for which the encrypted code has been registered?
YES : Replace the ignition key that does not work.
Then register the password (secret code)

and encrypted code 354A. Retest the
system.
NO : Go to Step 3.
STEP 3. Check the diagnosis code.
Q: Which diagnosis code is set, code No.11 or 12? the
encrypted code has been registered?
Code No.12 is set : Refer to354A.
Code No.11 is set : Go to Step 4.
CHASSIS ELECTRICAL
54A-9
IGNITION SWITCH
STEP 4. Connector check: Immobilizer-ECU

connector C-304-1.
Connector: C-304-1
C-304-1
Harness side
AC211664AB
Q: Are immobilizer-ECU connector C-304-1 in good

condition?
YES : Replace immobilizer-ECU and Then
register the password (secret cod) and

encrypted code. Retest the system.
NO : Repair or replace the damage
component(s).
Code No.12: Encrypted Codes are Not identical or not Registered

DIAGNOSIS CODE SET CONDITION
The encrypted code sent by the transponder is not
the same encrypted code which is registered in the
immobilizer-ECU.
NOTE: Diagnosis code No.12 is always output
together with MPI system diagnosis code No.P1610.
The encrypted code in the ignition key has not
been properly registered
Malfunction of immobilizer-ECU.
DIAGNOSIS PROCEDURE
Was the encrypted code registered?
YES : Replace the immobilizer-ECU and then re-
register the encrypted code (Refer to 354A

).
NO : Register the encrypted code (Refer to
354A).
SYMPTOM CHART
M1543007200986
Symptom
Inspection
procedure No.
Reference page
Communication with MUT-II is impossible
354A
The ignition key cannot be registered
354A
Engine cranks but does not start
354A
CHASSIS ELECTRICAL
54A-10
IGNITION SWITCH
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Communication with MUT-II is Impossible.
ENGINE
CONTROL RELAY
POWER
SOURCE
IMMOBILIZERECU
ENGINE-ECU
Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
SB : Sky blue
AC301596AB
TECHNICAL DESCRIPTION (COMMENT)

This malfunction may be caused by a defective
immobilizer-ECU, engine-ECU, or a defect in the
communication line between the immobilizerECU and engine-ECU. If this malfunction
appears when the MPI system and MUT-II can
communicate each other, MPI system diagnosis
code No.P1610 will reset.
If the MPI system is normal, the engine control
relay can be determined as normal. In addition, if
the MPI system and MUT-II can communicate
each other, the circuits between the diagnosis
connector and the engine-ECU can determined
as normal.
NOTE: If this malfunction appears, MPI system

diagnosis code No.P1610 will be output.
Malfunction of the immobilizer-ECU
Malfunction of the engine-ECU
The wiring harness or connectors may have
loose, corroded, or damaged terminals, or
terminals pushed back in the connector
CHASSIS ELECTRICAL
54A-11
IGNITION SWITCH
DIAGNOSIS PROCEDURE
STEP 1. Check if MUT-II can communicate with
the MPI system and if an MPI system diagnosis
code other than P1610 is set.
Q: Can MUT-II communicate with the MPI system? Is
an MPI system diagnosis code other than P1610
set?
YES : Go to Step 2.
NO : Refer to GROUP 13A, MPI Diagnosis
STEP 3. Connector check: Immobilizer-ECU

connector C-304-1 and engine control relay
connector B-17X
Connector: B-17X
Relay box side
313A.
STEP 2. Measure the voltage at immobilizer-ECU
connector C-304-1.
AC211667AB
Connector: C-304-1
Connector: C-304-1
C-304-1
C-304-1
Harness side
Harness side
AC211664AB
AC211664AB
(1) Disconnect immobilizer-ECU connector C-304-1.

(2) Turn the ignition switch to the "ON" position.
C-304-1 Harness connector:
Component side
component(s). Confirm that MUT-II

communicates normally.
AC212142 AB
(3) Measure the voltage between terminal 1 and

earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 5.
NO : Go to Step 3.
Q: Are immobilizer-ECU connector C-304-1 and

engine control relay connector B-17X in good
condition?
YES : Go to Step 4.
NO : Repair or replace the damaged
CHASSIS ELECTRICAL
54A-12
IGNITION SWITCH
STEP 4. Check the harness wires between

immobilizer-ECU connector C-304-1 (terminal 1)
and engine control relay connector B-17X
(terminal 1).
NOTE:
Connectors: C-17, C-106
Connector: B-17X
C-106(GR)
Relay box side
C-17(GR)
C-17
AC211667AB
Connector: C-304-1
C-106
C-304-1
Harness side
AC212135AB
AC211664AB
Connector: C-304
Harness side
C-304
AC212136AB
Prior to the wiring harness inspection, check

intermediate connector C-106, joint connector C-17
and key reminder switch connector C-304, and repair
if necessary.
Q: Are the harness wires between immobilizer-ECU
connector C-304-1 (terminal 1) and engine control
relay connector B-17X (terminal 1) in good
condition?
YES : There is no action to be taken.
NO : Replace damaged component(s). Confirm
that MUT-II communicates normally.
CHASSIS ELECTRICAL
54A-13
IGNITION SWITCH
STEP 5. Measure the resistance at immobilizerECU connector C-304-1.

Connector: C-304-1
STEP 7. Check the harness wire between

and earth.
Connector: C-304-1
C-304-1
C-304-1
Harness side
Harness side
AC211664AB
AC211664AB
(1) Disconnect immobilizer-ECU connector C-304-1.

NOTE:
C-304-1 Harness connector:
Component side
Connector: C-304
Harness side
C-304
AC212143AB
AC212136AB
(2) Measure the resistance between terminal 4 and

earth.
OK: 2 ohms or less
Prior to the wiring harness inspection, check key

reminder switch connector C-304, and repair if
necessary.

YES : Go to Step 8.
NO : Go to Step 6.
Q: Is the harness wire between immobilizer-ECU

connector C-304-1 (terminal 4) and earth in good
condition?
STEP 6. Connector check: immobilizer-ECU

connector C-304-1
Connector: C-304-1
C-304-1
Harness side
AC211664AB
Q: Is immobilizer-ECU connector C-304-1 in good

condition?
YES : Go to Step 7.


CHASSIS ELECTRICAL
54A-14
IGNITION SWITCH
STEP 8. Connector check: immobilizer-ECU

connector C-304-1 and engine-ECU connector C136
Connector: C-136
STEP 9. Check the harness wires between

and engine-ECU connector C-136 (terminal 51).
Connector: C-136
Harness side
C-136
Harness side
C-136
AC300688AB
Connector: C-304-1
AC300688AB
Connector: C-304-1
C-304-1
C-304-1
Harness side
Harness side
AC211664AB
Q: Are immobilizer-ECU connector C-304-1 and

engine-ECU connector C-136 in good condition?
YES : Go to Step 9.
AC211664AB
NOTE:
Connector: C-104

C-104
AC300232 AB
Connector: C-304
Harness side
C-304
AC212136AB
Prior to the wiring harness inspection, check key

reminder switch connector C-304, intermediate
connector C-104, and repair if necessary.
CHASSIS ELECTRICAL
IGNITION SWITCH
Q: Are the harness wires between immobilizer-ECU
connector C-304-1 (terminal 3) and engine-ECU
connector C-136 (terminal 51) in good condition?
YES : Go to Step 10.

STEP 10. Replace the immobilizer-ECU or
engine-ECU.
Replace the immobilizer-ECU.
54A-15
STEP 11. Recheck for malfunction.

Q: Is a malfunction eliminated?
YES : The procedure is complete. (If no
malfunctions are found in all steps, an

intermittent malfunction is suspected. Refer
to GROUP 00, How to Use Troubleshooting/
Inspection Service Points - How to Cope
with Intermittent Malfunction 300).
NO : Replace the engine-ECU.
Q: Did the communication with MUT-II become

possible after replacing the immobilizer-ECU?
YES : Register the password (secret code) and
encrypted code 354A. Confirm that

MUT-II communicates normally
NO : Go to Step 11.
INSPECTION PROCEDURE 2: The Ignition Key cannot be Registered.

The ignition key transponder or the immobilizer-ECU
is suspected to be defective.
Malfunction of the ignition key
Malfunction of immobilizer-ECU
DIAGNOSIS PROCEDURE
STEP 1. Check for diagnosis code.
STEP 2. Retest the system.

Q: Does registered ignition key function properly?

with Intermittent Malfunction 300).
NO : Replace the immobilizer-ECU.
Q: Does diagnosis code No.11 reset?

YES : Refer to 354A.
NO : Replace the ignition key that cannot be
registered. Then re-register the encrypted

code. (Refer to 354A). Verify that the
ignition key can be registered, then Go to
Step 2.
INSPECTION PROCEDURE 3: Engine does not Start (Cranking but no Initial Combustion).
If the fuel injectors are not operating, there might be
a problem with the MPI system in addition to a
malfunction of the immobilizer system. It is normal for
this to occur if an attempt is made to start the engine
using a key that has not been properly registered.
Malfunction of MPI system
Malfunction of immobilizer-ECU
DIAGNOSIS PROCEDURE
STEP 1. Check the system voltage.
Measure the system voltage during cranking.
Q: Is the voltage 8 volts or more?
YES : Go to Step 2.
NO : Check the battery. Refer to 354A. The
engine should start.
CHASSIS ELECTRICAL
54A-16
IGNITION SWITCH
STEP 2. Check the immobilizer system diagnosis

code and MPI system diagnosis code.
Q: Which diagnosis code resets, the immobilizer
system diagnosis code or the MPI system
diagnosis code?
Immobilizer system diagnosis code is set : Refer
STEP 3. Check the starting system.

Q: Does the engine start?
YES : Go to Step 4.
NO : Refer to GROUP 13A, Diagnosis -
Symptom Chart 313A. If the

malfunction is not resolved, replace the
immobilizer-ECU. Then register the
password (secret code) and encrypted
code. (Refer to 354A.) The engine
should start.
to 354A.
MPI system diagnosis code is set : Refer to
GROUP 13A, Diagnosis 313A.

No diagnosis code is set : Go to Step 3.
STEP 4. Retest the system

Q: Is the malfunction eliminated?
malfunction are not found in all steps, an

Inspection Service Points-How to Cope with
Intermittent Malfunction 300.)
NO : Replace the immobilizer-ECU.
DATA LIST REFERENCE TABLE

M1543007300295
Item No.
Inspection item
Inspection
requirement
Normal condition
01
Key has been registered
Number of registered ignition keys
CHECK AT IMMOBILIZER-ECU
M1543007600434
TERMINAL VOLTAGE CHECK
AC212297AB
Terminal No.
Signal
Inspection condition
Terminal voltage
Immobilizer-ECU power supply
Ignition switch: "LOCK"

(OFF)
0V
Ignition switch: "ON"
System voltage
Engine-ECU
Immobilizer-ECU earth
Always
0V
CHASSIS ELECTRICAL
54A-17
IGNITION SWITCH
ON-VEHICLE SERVICE
Registration with the MUT-II
HOW TO REGISTER ENCRYPTED CODE

ignition switch to "LOCK" (OFF) position before
connecting or disconnecting MUT-II.
NOTE: .
Using the key ID register function will cause all
key IDs that have been previously registered in
the immobilizer-ECU to be erased. All keys need
to be registered. Those which have been
registered before should be on hand before using
this function.
If registering more than one key, do not
disconnect MUT-II halfway through the
registration process.
After registering key IDs, check that the engine
can be started using all of the keys that have
been registered. If the engine will not start, refer
to Immobilizer System Diagnosis 354A.
M1543008100391
CAUTION
Because registering the encrypted codes is done
after all previously-registered codes have been
erased, you should keep all of the ignition keys
that have already been registered accessible.
If the ignition key, Immobilizer-ECU, engine-ECU is
replaced or an ignition key is added, encrypted
codes of all the ignition keys must be registered. (A
maximum of eight different ignition key can be
registered.) Moreover, when the immobilizer-ECU
has been replaced, you will need to use MUT-II to
register the immobilizer-ECU and input the vehicle
secret code and to register the password (secret
code) that the owner specifies into the immobilizerECU.
If an attempt is made to start the engine with an
unregistered ignition key, cranking occurs, but fuel
supply is cut off to disable the engine. In
approximately.
NOTE: Engine-ECU has an encrypted code for
immobilizer-ECU, and the encrypted code is
registered in the immobilizer-ECU and ignition key.
CAUTION
16-PIN
POINTS TO NOTE DURING OPERATION

If none of the functions can be used, check the
diagnosis codes, and after carrying out any
necessary repairs, repeat the operation.
If an incorrect password is input ten times in a row,
the immobilizer-ECU judges that an unauthorized
operation is being attempted. Start-prevention mode
will be set, and engine operation will stop and all
special functions will be disabled. If the ignition
switch is turned to "ON" position, "Unauthorized
operation, startprevention mode" will be cancelled.
MB991502
AC300380 AB
1. Connect MUT-II to diagnosis connector (16- pin).

2. Turn the ignition switch to "ON" position.
KEY ID (ENCRYPTED CODE)

REGISTRATION
All ignition keys can be registered with MUT-II.
Additional ignition keys can be registered with MUTII.
AC000522AD
3. At "System Select," press "YES"
CHASSIS ELECTRICAL
54A-18
IGNITION SWITCH
AC000523AC
4. Select "Immobilizer," press "YES".
AC000530AC
ACX01626 AC
7. Input the password. Use the "UP" and "DOWN"

keys to change the current password digit to a
value between 0 and 9. Use the "LEFT" and
"RIGHT" keys to move to a different password
digit. Press the "YES" key to accept the password.
If an incorrect password is input five times in a
row, this screen is displayed and the immobilizerECU switches to unauthorized operation, startprevention mode.
NOTE: Four separate digits must be input to
make up the password.
5. Select "Special Func", press "YES".

If diagnosis code No.11 exists, "Cant execute" will
be displayed. Check for diagnosis code
No.11(Refer to 354A.)
ACX01561 AD
8. Press the "YES" key to start key ID registration.
AC000518 AC
ACX01562 AC
ACX01558 AG
6. Select "key ID register", press "YES".
9. This will be displayed when the key ID registration

is successful. If an error occurs during key ID
registration, the message "Cant execute" will be
displayed. If the key has already been registered,
"Key ID has been registered" will be displayed.
CHASSIS ELECTRICAL
54A-19
IGNITION SWITCH
16-PIN
MB991502
ACX01563 AC
AC300380 AB
10.The number of keys currently registered will be

displayed. To register an additional key, replace
the ignition key with the next key to be registered
within five seconds and then press the "YES" key.
Key ID registration screen will be displayed, then
register another key.
If key ID registration is complete, press the "NO"
key.
NOTE: A maximum of eight different keys can be
registered.
11.This completes the registration operation. Turn
the ignition switch "LOCK" (OFF) and leave it off
for approximately ten seconds.
12.Check that the engine can be started with each of
the ignition keys.
13.Check that the immobilizer system diagnosis
code and MPI system diagnosis code did not set.
14.Turn the ignition switch to "LOCK" (OFF) position.
15.Disconnect MUT-II.
1. Connect MUT-II (MB991502) to the 16-pin

AC000522AD
3. At "System Select," press "YES"
Registration of additional keys with the MUT-II

Additional key(s) can be registered with the MUT-II
while keeping all existing key data.
CAUTION
ignition switch to "LOCK" (OFF) position before
connecting or disconnecting MUT-II.
NOTE: To register additional keys with the MUT-II,
no registered keys must be lost.
AC000523AC
AC000530AC
5. Select "Special Func", press "YES".

If diagnosis code No.11 exists, "Cant execute" will
be displayed. Check for diagnosis code
No.11(Refer to 354A.)
CHASSIS ELECTRICAL
54A-20
IGNITION SWITCH
AC101476 AB
AC000518 AC
AC101478 AB
6. Select "Add key ID reg", press "YES".
9. The number of keys currently registered will be

displayed. To register an additional key, replace
the ignition key with the next key to be registered
within five seconds and then press the "YES" key.
Key ID registration screen will be displayed, then
register another key.
NOTE: A maximum of eight different keys can be
registered.
If key ID registration is complete, press the "NO" key.
10.This completes the registration operation. Turn
the ignition switch "LOCK" (OFF) and leave it off
for approximately ten seconds.
11.Check that the engine can be started with each of
the ignition keys.
12.Check that the immobilizer system diagnosis
code and MPI system diagnosis code did not set.
13.Turn the ignition switch to "LOCK" (OFF) position.
14.Disconnect MUT-II.
TRANSPONDER LOCK CHECK

M1543024100090
AC101477 AB
7. Press the "YES" key to start key ID registration.

8. This will be displayed when the add key ID
registration is successful. If an error occurs during
key ID registration, the message "Cant execute"
will be displayed. If the key has already been
registered, "Key ID has been registered" will be
displayed.
Follow the procedure below to judge if the ignition

key can be overwritten (i.e. the ignition key is correct)
or not.
16-PIN
MB991502
AC300380 AB
1. Connect MUT-II to the 16-pin diagnosis connector.

CHASSIS ELECTRICAL
54A-21
IGNITION SWITCH
AC000522AD
3. At "System Select," press "YES."
AC106459 AD
5. Select "Data list" press "YES".
AC000523AC
AC106460 AB
6. Confirm "TP LOCK CHECK."

TP Lock Check Ignition Key:
Judgment Of
Ignition Key
UNLOCK
Can be
overwritten
Correct
LOCK
Can not be
overwritten
Incorrect
CHASSIS ELECTRICAL
54A-22
IGNITION SWITCH
IGNITION SWITCH
M1543002100401
WARNING
Before removal of the air bag module, refer to GROUP 52B, SRS Service Precautions and
Air Bag Module and Clock Spring 352B.

When removing and installing the steering wheel, do not let it bump against the air bag
module.
Section A A
Claw
4
3
2.5 0.5 Nm
A
A
2
5
1
7
6
1.5 0.5 Nm
NOTE
: Claw position
2.5 0.5 Nm
8
9
4
AC300001 AB
AC300451
Removal steps
1. Instrument lower panel (Refer to
GROUP 52A, Instrument panel 352A
)
2. Steering wheel (Refer to GROUP 37A,
Steering wheel 337)

3. Column cover upper
4. Column cover lower
CHASSIS ELECTRICAL
54A-23
IGNITION SWITCH
5. Clock spring and column switch
assembly (Refer to GROUP 52B, Air
bag modules and clock spring 352B
)
6. Steering lock cylinder
Ignition switch connector
7. Ignition switch
Key reminder switch connector
<<A>>

<<A>> STEERING LOCK CYLINDER REMOVAL

8. Key reminder switch and bulb
assembly
9. Immobilizer-ECU
Switch
position
Tester
connection
Specified
condition
"LOCK" (OFF)
1 - 2, 1 - 3,
1 - 4, 1- 5,
1 - 6, 2 - 3,
2 - 4, 2- 5,
2 - 6, 3 - 4,
3- 5, 3 - 6,
4- 5, 4 - 6,
5-6
Open circuit
"ACC"
1-6
Less than 2
ohms
"ON"
1 - 2, 1 - 4,
1 - 6, 2 - 4,
2 - 6, 4 - 6
Less than 2
ohms
"START"
1 - 2, 1 - 5,
2-5
Less than 2
ohms
Lock pin
AC200314 AB
1. Insert the key in the steering lock cylinder and turn

it to the "ACC" position.
2. Using a small Phillips head screwdriver, pull the
steering lock cylinder toward you.
INSPECTION
M1544009700195
IGNITION SWITCH CONTINUITY CHECK
KEY REMINDER SWITCH CONTINUITY

CHECK
1 2 3
4 5 6
1
2
3 4 5 6 7
AC200316 AB
Disconnect ignition switch connector C-303 without

removing the ignition switch. Then check the
continuity.
AC200315 AB
Disconnect key reminder switch connector C-304

without removing the ignition switch and key
reminder switch. Then check the continuity.
Status of
ignition key
Tester
connection
Specified
condition
Removed
4-6
Less than 2
ohms
Inserted
4-6
Open circuit
CHASSIS ELECTRICAL
54A-24
COMBINATION METER ASSEMBLY

M1543000300294
Item
Standard value
Speedometer indication error km/h
Tachometer indication error r/min
Fuel gauge unit

resistance W
2WD
20
20 - 24
40
40 - 44
80
80 - 86
120
122 - 128
160
163 - 170
200
204 - 212
700
700 100
2,000
2,000 100
3,000
3,000 150
4,000
4,000 200
5,000
5,000 250
6,250
6,250 150
Float position F (highest) 3.0 0.6

Float position E (lowest) 110 2.5
4WD
Fuel pump and

gauge unit
Fuel gauge unit

Fuel gauge unit float

height mm
2WD
4WD
Float position F (A)
35.4 2
Float position E (B)
186.7 2
Fuel pump and

gauge unit
Float position F (At)
36.7 2
149.6 2
Fuel gauge unit
Float position F (A)
23.4 2
194.2 2
Engine coolant temperature gauge unit resistance W
SEALANT
M1543024600017
Item
Specified sealant
Engine coolant temperature gauge unit
3M 1215 or equivalent
104 + 13.5 (at 70C)
CHASSIS ELECTRICAL
54A-25
SPECIAL TOOLS
M1543000601500
Tool
Number
Name
Use
MB990784
Ornament remover
Removal of instrument panel

drivers side garnish and
meter bezel.
MB991502
MUT-II sub assembly
Reading MPI system

diagnosis code
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Making voltage and

resistance measurements
A: Connect pin contact
pressure inspection
connection
MB990784
B991502
D
MB991223 AC
TROUBLESHOOTING
SYMPTOM CHART
M1543007200997
Symptom
Inspection
procedure No.
Reference page
Speedometer does not work (the other meters work).
354A
Tachometer does not work (the other meters work).
354A
Fuel gauge does not work (the other meters work).
354A
Engine coolant temperature gauge does not work (the other

meters work).
354A
Combination meters does not work (the instruments do not

work).
354A
CHASSIS ELECTRICAL
54A-26
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Speedometer does not work (the other meters work.)
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONTROL
CIRCUIT
VEHICLE SPEED
SENSOR
DIAGNOSIS
CONNECTOR
FRONT SIDE
ENGINE-ECU
Wire colour code

SB : Sky blue
AC301597AB

The engine-ECU and its associated components, the
combination meter assembly, the wiring harness, or
the connector(s) may be defective.
Malfunction of the engine-ECU
Malfunction of the combination meter assembly
terminals pushed back in the connector.
CHASSIS ELECTRICAL
54A-27
DIAGNOSIS PROCEDURE
STEP 3. Check the wiring harness between

combination meter connector C-04 (terminal 46)
and diagnosis connector C-24 (terminal 14).
NOTE:
STEP 1. Check the speedometer.
Connectors: C-02, C-04, C-24

C-04
C-02
16-PIN
MB991502
AC300380 AB
C-24(B)
(1) Connect the MUT-II to the diagnosis connector.

(2) Use the MUT-II to enter simulated vehicle speed.
Q: Does the speedometer show that simulated vehicle
speed?
YES : Go to Step 5
NO : Go to Step 2
C-02
C-04 harness side
C-24
STEP 2. Connector check: Combination meter

connector C-04 and diagnosis connector C-24
AC210823 AB
Prior to the wiring harness inspection, joint connector

C-02, and repair if necessary.
C-04
Q: Is the wiring harness between combination meter

connector C-04 (terminal 46) and diagnosis
YES : Go to Step 4
component(s).
C-24(B)
C-04 harness side
Q: Is the speedometer normal?


Intermittent Malfunction 300).
NO : Replace the combination meter assembly.
C-24
AC210822 AB
Q: Is combination meter connector C-04 and

diagnosis connector C-24 in good condition?
YES : Go to Step 3
component(s).
STEP 5. Read diagnosis code by using the MUTII.

Q: Is the MPI-related diagnosis code set?
YES : Refer to GROUP 13A - Troubleshooting
313A.
NO : Go to Step 6
CHASSIS ELECTRICAL
54A-28
STEP6. Connector check: Joint connector C-02

and engine-ECU connector C-137
Connector: C-02
STEP 7. Check the wiring harness between joint

connector C-02 (terminal 25) and engine-ECU
connector C-137 (terminal 86).
Connector: C-02
C-02
C-02
AC210824 AB
AC210824 AB
Connector: C-137
C-137
Harness side
Connector: C-137
Harness side
AC300691AB
C-137
Q: Is joint connector C-02 and engine-ECU connector

C-137 in good condition?
YES : Go to Step 7
AC300691AB
NOTE:
component(s).
C-105
C-16 (L)
C-16
C-105
AC300692 AB

intermediate connectors C-105, joint connectors C16 and repair if necessary.
CHASSIS ELECTRICAL
54A-29

Q: Is the wiring harness between joint connector C-02
(terminal 25) and engine-ECU connector C-137
(terminal 86) in good condition?
YES : Go to Step 8
component(s).
STEP 9. Pulse check

Use the MUT-II or a voltmeter to check that the
vehicle speed signal is received.
System switch
Check conditions
Vehicle speed signal
When the vehicle speed

has reached 10 km/h or
more
OK: The MUT-II sounds or the voltmeter

needle fluctuates.
Q: Is the speedometer normal?


NO : Go to Step 9.

YES : Replace the combination meter assembly.
INSPECTION PROCEDURE 2: Tachometer does not work (the other meters work.)
COMBINATION
METER
CONTROL
CIRCUIT
ENGINE-ECU
Wire colour code

SB : Sky blue
AC301769AB

Ignition signal may not be received from the engineECU, or the combination meter assembly, the wiring
harness, or the connector(s) may be defective.
Malfunction of the combination meter assembly
CHASSIS ELECTRICAL
54A-30
DIAGNOSIS PROCEDURE
STEP 1. Using MUT-Il, read MPI diagnosis code.
Q: Is the MPI-related diagnosis code set?
Code No.P0300 is set : Refer to GROUP 13A -

and engine-ECU connector C-136 (terminal 58)
Connector: C-04
C-04
Troubleshooting 313A.
NO : Go to Step 2
Harness side

connector C-04 and engine-ECU connector C-136
Connector: C-04
AC210827AB
C-04
Harness side
Connector: C-136
Harness side
AC210827AB
Connector: C-136
Harness side
C-136
AC300688AB
NOTE:
Connector: C-105
C-136
AC300688AB
Q: Is combination meter connector C-04 and engineECU connector C-136 in good condition?
YES : Go to Step 3
component(s).
Q: Is the tachometer normal?
YES : Intermittent Malfunction. Refer to GROUP
00, How to Use Troubleshooting/Inspection

Service Points-How to Cope with
NO : Go to Step 4
C-105
AC210826 AB

intermediate connector C-105, and repair if
necessary.
connector C-04 (terminal 47) and engine-ECU
YES : Replace the combination meter assembly.
component(s).
CHASSIS ELECTRICAL
54A-31
INSPECTION PROCEDURE 3: Fuel gauge does not work (the other meters work.)
Fuel Gauge Circuit

COMBINATION
METER
CONTROL
CIRCUIT
FUEL
GAUGE UNIT (SUB)
FUEL
GAUGE UNIT
FUEL PUMP
AND GAUGE UNIT (MAIN)
Wire colour code

B : Black LG : Light green G : Green L : Blue
W : White Y : Yellow SB : Sky blue BR : Brown
O : Orange GR : Gray R : Red P : Pink V : Violet
AC301770 AB

If only the fuel gauge does not operate, fuel gauge
unit <2WD>, the fuel pump and gauge unit <4WD>,
the combination meter, wiring harness or
connector(s) may be defective.
Malfunction of the fuel gauge unit.
Malfunction of the combination meter.
54A-32
CHASSIS ELECTRICAL
DIAGNOSIS PROCEDURE
STEP 1. Check the fuel gauge circuit.
(1) Disconnect D-15 <2WD> fuel gauge unit
connector or D-16 <4WD> fuel pump and gauge
unit (main) connector.

connector C-04, fuel gauge unit connector D-15
<2WD> or fuel pump and gauge unit (main)
connector D-16 <4WD>
Connector: C-04
C-04
Harness side
MB991219
Test lamp
(12 V - 3.4 W)
Harness side
D-15 <2WD>
3 2 1
Harness side
D-16 <4WD>
AC103414
AC
AC211647
(2) Connect a test lamp (12 V - 3.4 W) via test

harness (MB991219) between the wiring harness
connector terminals 1 and 2.
Q: Does the test lamp illuminate?
YES : Go to Step 8.
NO : Go to Step 2.
AC210827AB
3 2 1
5 4
Connectors: D-15<2WD>, D-16<4WD>

D-15<2WD>
harness side
3 2 1
D-15 (B)
D-16 (GR)
D-16<4WD>
harness side
3 2 1
5 4
AC211648 AB
Q: Is combination meter connector C-04, fuel gauge

unit connector D-15 <2WD> or fuel pump and
gauge unit (main) connector D-16 <4WD> in good
condition?
YES : Go to Step 3.
component(s).
CHASSIS ELECTRICAL
54A-33

and fuel gauge unit connector D-15 (terminal 1)
<2WD> or fuel pump and gauge unit (main)
connector D-16 (terminal 2) <4WD>.
NOTE:
Connectors: D-12, D-24

C-04
D-12
D-24
C-117
D-12
harness side
C-04 harness side
D-24
C-117
AC301594 AB
AC211650AB

D-15<2WD>
harness side
3 2 1
D-15 (B)
D-16 (GR)
D-16<4WD>
harness side
Prior to the wiring harness inspection, check fuel

gauge unit (sub) connector D-12, intermediate
connector C-117, D-24, and repair if necessary.
connector C-04 (terminal 43) and fuel gauge unit
connector D-15 (terminal 1) <2WD> or fuel pump
and gauge unit (main) connector D-16 (terminal 2)
<4WD> in good condition?
YES : Go to Step 4.
component(s). Then go to Step 4.
3 2 1
5 4

AC211648 AB
Q: Is the fuel gauge normal?


NO : Go to Step 5.
CHASSIS ELECTRICAL
54A-34
STEP 5. Connector check: Fuel gauge unit

connector D-15 <2WD> or fuel pump and gauge
unit (main) D-16 <4WD>
D-15<2WD>
harness side
3 2 1
D-15 (B)
D-16 (GR)
D-16<4WD>
harness side
3 2 1
5 4
AC211648 AB
Q: Is fuel gauge unit connector D-15 <2WD> or fuel

pump and gauge unit (main) D-16 <4WD> in good
condition?
YES : Go to Step 6.
component(s).
STEP 6. Check the wiring harness between fuel
gauge unit connector D-15 (terminal 2) <2WD>
and fuel pump and gauge unit connector D-16
(terminal 1) <4WD> and earth.
D-15<2WD>
harness side
3 2 1
D-15 (B)
D-16 (GR)
D-16<4WD>
harness side
3 2 1
5 4
AC211648 AB
NOTE:
Q: Is the wiring harness between fuel gauge unit

connector D-15 (terminal 2) <2WD> and fuel pump
and gauge unit connector D-16 (terminal 1) <4WD>
and earth in good condition?
YES : Go to Step 7.
component(s).

NO : Carry out the troubleshooting again.
STEP 8. Check the fuel gauge circuit.
(1) Disconnect D-15 <2WD> fuel gauge unit
connector or D-16 <4WD> fuel pump and gauge
unit (main) connector.
MB991219
Test lamp
(12 V - 3.4 W)
Component side
D-15 <2WD>
3 2 1
Component side
D-16 <4WD>
3 2 1
5 4
AC103414
AC211647
AB
(2) Connect a test lamp (12 V - 3.4 W) via special

tool test harness (MB991219) between the wiring
harness connector terminals 1 and 2.
Q: Does the fuel gauge in the combination meter
fluctuate about half of it full scale?
YES : Replace the fuel gauge unit.
NO : Go to Step 9.
Connector: D-24

D-24
AC301595 AB

intermediate connectors D-24, and repair if
necessary.

NO : Replace combination meter.
CHASSIS ELECTRICAL
54A-35
INSPECTION PROCEDURE 4: Engine Coolant Temperature Gauge does not Work. (the other meters
work.)
COMBINATION
METER
CONTROL
CIRCUIT
ENGINE COOLANT
TEMPERATURE
GAUGE UNIT
Wire colour code

SB : Sky blue
AC301771AB

If only the engine coolant temperature gauge does
not operate, the combination meter, the wiring
harness or its connector may be defective.
Malfunction of the engine coolant temperature
gauge unit
Malfunction of the combination meter.
DIAGNOSIS PROCEDURE
STEP 1. Check the engine coolant temperature
gauge circuit.
(1) Disconnect the B-109 engine coolant
temperature gauge unit connector.
Test lamp
(12 V 3.4 W - 7.0 W)
Connector
Earth
AC102026AD
(2) Connect a test lamp (12 V - 3.4 W to 12 V - 7.0

W) to the wiring harness side connector.
(3) Ignition switch: ON
Q: Does the test lamp illuminate?
YES : Go to Step 5.
NO : Go to Step 2.
CHASSIS ELECTRICAL
54A-36

connector C-04 and engine coolant temperature
gauge unit connector B-109
Connector: C-04

and engine coolant temperature gauge unit
connector B-109 (terminal 1).
Connector: C-04
C-04
C-04
Harness side
Harness side
AC210827AB
AC210827AB
Connector: B-109
Connector: B-109
Harness side
Harness side
B-109(B)
B-109(B)
AC211653AC
AC211653AC
Q: Is combination meter connector C-04 and engine

coolant temperature gauge unit connector B-109 in
good condition?
YES : Go to Step 3.
NOTE:
Connector: C-104
component(s).
Q: Is the engine coolant temperature gauge normal?

NO : Go to Step 4.
C-104(B)
AC211655 AB

intermediate connectors C-104, and repair if
necessary.
connector C-04 (terminal 44) and engine coolant
temperature gauge unit connector B-109 (terminal
1) in good condition?
YES : Go to Step 6.
component(s).
CHASSIS ELECTRICAL
STEP 5. Check the engine coolant temperature

gauge circuit.
(1) Disconnect the B-109 engine coolant
temperature gauge unit connector.
Test lamp
(12 V 3.4 W - 7.0 W)
Connector
Earth
AC102026AD
(2) Connect a test lamp (12 V - 3.4 W to 12 V - 7.0

W) to the wiring harness side connector.
Q: Does the engine coolant temperature gauge in the
combination meter fluctuate about half of it full
scale?
YES : Replace the engine coolant temperature
gauge unit.
NO : Go to Step 6.
54A-37
STEP 6. Retest the system

Q: Is the engine coolant temperature gauge normal?

NO : Replace the combination meter.
CHASSIS ELECTRICAL
54A-38
INSPECTION PROCEDURE 5: Combination meter does not work. (the instruments do not work)
FUSIBLE
LINK 1
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONTROL CIRCUIT
Wire colour code

SB : Sky blue
AC301772 AB

The cause is thought to be malfunction of the power,
earth circuitry or combination meter.
Malfunction of the combination meter
Damaged wiring harness or connectors
CHASSIS ELECTRICAL
54A-39
DIAGNOSIS PROCEDURE

connector C-04 for damage.
STEP 1. Measure the voltage at combination

meter connector C-04 in order to check the
battery circuit of power supply system to the
combination meter.
Connector: C-04
C-04
Harness side
Connector: C-04
C-04
Harness side
AC210827AB
AC210827AB
(1) Disconnect the combination meter connector C04 and measure the voltage at combination meter
connector C-04 harness side.
C-04 Harness side
AC211656AC

earth.
OK: System voltage
Q: IS the check result normal?
YES : Go to Step 4.
NO : Go to Step 2.
Q: Is combination meter connector C-04 in good

condition?
YES : Go to Step 3.
NO : Repair or replace the connector. Check to
see that all meters operate.
CHASSIS ELECTRICAL
54A-40

and fusible link (1).
NOTE: .
Fusible link (1)
C-02
Fusible link (1)
C-116
AC200715 AE
C-02
Connector: C-04
C-04
C-116
Harness side
AC211668AB
AC210827AB

C-202
C-204(B)
C-202 harness side
C-204 harness side
AC211670 AB

intermediate connectors C-116, junction block
connectors C-202 and C-204 and joint connector C02, and repair if necessary.
.
CHASSIS ELECTRICAL
54A-41

Q: Are the wiring harness between combination meter
connector C-04 (terminal 34) and fusible link (1) in
good condition?
NO : Repair or replace the wiring harness. Check
to see that all meters operate.

meter connector C-04 to check the battery circuit
of power supply system to the combination
meter.
Connector: C-04
STEP 5. Connector check: combination meter

connector C-04
Connector: C-04
C-04
Harness side
AC210827AB
C-04
Harness side

condition?
YES : Go to Step 6.
NO : Repair or replace the connector. Check to
see that all meters operate.
AC210827AB
(1) Measure at combination meter connector C-04

without disconnecting the connector.
(2) Turn the ignition switch to ON position.
C-04 Harness connector:
Component side
AC211674AB

earth.
OK: System voltage
YES : Go to Step 7.
NO : Go to Step 5.
CHASSIS ELECTRICAL
54A-42

and ignition switch (IG1).
Connector: C-04
STEP 7. Measure the resistance at combination

meter connector C-04 to check the earth circuit
to the combination meter.
Connector: C-04
C-04
C-04
Harness side
Harness side
AC210827AB
AC210827AB
(1) Disconnect the combination meter connector C04 and measure the resistance at combination
meter connector C-04.
NOTE:
C-203
C-04 Harness connector
C-205
C-203 harness side

AC211676AB
C-205 harness side
AC211675AB

Junction block connectors C-203 and C-205, and
repair if necessary.
connector C-04 (terminal 42) and ignition switch
(IG1) in good condition?

earth.
OK: 2 ohms or less
earth.
OK: 2 ohms or less
YES : Repair or replace the connector.
NO : Go to Step 8.
CHASSIS ELECTRICAL
54A-43

connector C-04 for damage.
ON-VEHICLE SERVICE
SPEEDOMETER CHECK
Connector: C-04
M1543000900393
Adjust the pressure of tyres to the specified level.

(Refer to GROUP 31, On-vehicle Service 331.)
C-04
Harness side
CAUTION
Do not operate the clutch suddenly. Do not
increase/decrease speed rapidly while testing.
CAUTION
<4WD>
AC210827AB

condition?
YES : Go to Step 9.

Free roler

combination meter connector C-04 (terminal 40
and 41) and earth.
AC107077AC
Set a free-roller on the rear tyre for 4WD.

<2WD>
Connector: C-04
C-04
Harness side
Wheel chocks
AC107078 AC
AC210827AB

connector C-04 (terminal 40 and 41) and earth in
good condition?
YES : This procedure is complete.
1. Set the vehicle onto a speedometer tester and

use wheel chocks to hold the rear wheels.
Tension bar
Front
Anchor plate
AC001288 AB
2. To prevent the front wheel from moving from side

to side, attach tension bars to the tie-down hook,
and secure both ends to anchor plates.
3. To prevent the vehicle from moving, attach a chain
or wire to the rear retraction hook, and make sure
the end of the chain or wire is secured.
CHASSIS ELECTRICAL
54A-44
4. Check if the speedometer indicator range is within

the standard values.
Standard value:
4,000 r/min: 200 r/min

5,000 r/min: 250 r/min
6,250 r/min: 150 r/min
FUEL GAUGE UNIT CHECK <2WD>
Standard indicator
km/h
Allowance range
km/h
20
20 - 24
40
40 - 44
Remove the fuel pump module and the remove the

fuel gauge unit. (Refer to GROUP 13B, Fuel Tank
313B.)
80
80 - 86
FUEL GAUGE UNIT RESISTANCE
120
122 - 128
160
163 - 170
200
204 - 212
M1543001200427
Fuel gauge
Earth
5. If not to the standard value, inspect for proper tyre

size. If not correct, replace the tyres with original
size tyres and retest. If correct, replace the
speedometer. If still not to standard value, replace
the vehicle speed sensor.
TACHOMETER CHECK
Position F
M1543001000401
Tachometer
Engine speed
detection
connector
Position E
Paper clip
AC210843 AB
AC203782 AC
1. Attach an external high quality tachometer to the

engine speed detection connector on the harness
side (such as with a paper clip).
NOTE: For tachometer check, use an external
high quality inductive tachometer.
2. Compare the readings of the vehicle tachometer
and the external tachometer at every engine
speed, and check if the variations are within the
standard values.
Standard values:
700 r/min: 100 r/min
2,000 r/min: 100 r/min
3,000 r/min: 150 r/min
1. Check that resistance value between the fuel

gauge terminal and earth terminal is at the
standard value when the fuel gauge unit float is
between position "F" (highest) and position "E"
(lowest).
Standard value:
Float position "F": 3 0.6 W
Float position "E": 110 2.5 W
2. Check that resistance value changes smoothly
when the float moves slowly between position "F"
(highest) and position "E" (lowest).
3. If all checks are correct, go to fuel gauge unit float
height check. If any check is not correct, replace
the fuel gauge unit.
CHASSIS ELECTRICAL
54A-45
FUEL GAUGE UNIT FLOAT HEIGHT
Position F
B
Position E
AC210842AB
1. Move the float and measure height A at position

"F" (highest) and B at position "E" (lowest) with
the float arm touching stopper.
Standard value:
Position F (A): 35.4 mm 2 mm
Position E (B): 186.7 mm 2 mm
1. Check that resistance value between the fuel

gauge terminal and earth terminal is at the
standard value when the fuel gauge unit float is
between position "F" (highest) and position "E"
(lowest).
Standard value:
Float position "F": 1.5 0.5 W
Float position "E": 55 1.5 W
2. Check that resistance value changes smoothly
when the float moves slowly between position "F"
(highest) and position "E" (lowest).
FUEL GAUGE UNIT FLOAT HEIGHT

<Fuel pump and gauge unit>
A
B Position F
FUEL GAUGE UNIT CHECK <4WD>

M1543001200438
Remove the fuel pump module and the remove the

fuel gauge unit. (Refer to GROUP 13B, Fuel Tank
313B.)
FUEL GAUGE UNIT RESISTANCE
Position E
<Fuel gauge unit>
Position F
<Fuel pump and

gauge unit>
Earth
Fuel gauge
Earth
<Fuel gauge unit>
Fuel gauge
Position E
AC211661 AC
Position F
Position F
Position E
Position E
AC211660 AC
1. Move the float and measure height A at position

"F" (highest) and B at position "E" (lowest) with
the float arm touching stopper.
Standard value <Fuel pump and gauge unit>:
Float position A: 36.7 mm
Float position B: 149.6 2 mm
Standard value <Fuel gauge unit>:
Float position A: 23.4 2 mm
Float position B: 194.2 2mm
CHASSIS ELECTRICAL
54A-46

GAUGE UNIT CHECK
M1543001500376
1. Drain the engine coolant. (Refer to GROUP 14On-vehicle Service 314.)

2. Remove the engine coolant temperature gauge
unit.
11 1 Nm
Circuit tester
ACX00780AH
4. After inspection, apply specified sealant at

threads of engine coolant temperature gauge unit,
and tighten to the specified torque.
Semi-drying sealant: 3M 1215 or equivalent
5. Add engine coolant. (Refer to GROUP 14 - Onvehicle Service 314.)
Thermometer
ACX00779 AI
3. Put engine coolant temperature gauge unit into

the hot water in specified temperature, and ensure
that basic resistance is within standard value.
Standard value: 104 13.5 W (at 70C)
Reference value
Temperature (C)
Resistance W
50
230
60
155
80
73

M1543021300017
1.5 0.5 Nm
2
3
1.5 0.5 Nm
AC211662 AB
CHASSIS ELECTRICAL
54A-47

Removal steps
1. Instrument panel drivers side garnish (Refer
to GROUP 52A - Instrument panel 352A.)
2. Meter bezel (Refer to GROUP 52A Instrument panel 352A.)
3. Combination meter assembly
DISASSEMBLY AND ASSEMBLY

M1543003100329
1.5 0.5 Nm
1
AC211663 AB
Disassembly steps
1. Meter glass
2. Meter panel
3. Circuit board cover

4. Bulb
5. Combination meter assembly
CHASSIS ELECTRICAL
54A-48
HEADLAMP
HEADLAMP
M1542000300280
Item
Headlamp
aiming
Standard value
Limit
Vertical
direction
42 mm (0.24) below horizontal (H)
51 mm ( 0.29) from the standard

value
Horizontal
direction
Position at which the stat up point of

15 is crossed with vertical line (V)
87 mm ( 0.5) from the standard

value
TROUBLESHOOTING
M1542000701203
Features the headlamp automatic shutdown function

to avoid battery drain when the headlamps are left
on. The main features are as follows:
Extinguishes automatically in three minutes if the
ignition switch is turned off with the lighting switch
on.
Extinguishes in one second if the drivers door is
opened within that 3-minute period.
If the headlamps are turned on with the ignition
switch off, the headlamps and tail lamps will
extinguish in three minutes after the drivers door
is opened or closed.
The headlamps are controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to
respective Groups below.
Diagnosis 354B.
Diagnosis 354C.
7. Place the vehicle on a level floor, perpendicular to

a flat screen 10 m away from the bulb centremarks on the headlamp lens.
8. Rock vehicle sideways to allow vehicle to assume
its normal position.
9. Bounce the front suspension through three (3)
oscillations by applying the body weight to hood or
bumper.
(1)
Headlamp centre
Screen
(3)
(2)
Vehicle centre line

(3)
10 m
ON-VEHICLE SERVICE
HEADLAMP AIMING
M1542000900497
PRE-AIMING INSTRUCTIONS
1. Inspect for badly rusted or faulty headlamp
assemblies.
2. These conditions must be corrected before a
satisfactory adjustment can be made.
3. Inspect tyre inflation, and adjust if it is necessary.
4. If the fuel tank is not full, place a weight in luggage
room of the vehicle to simulate weight of a full
tank (0.8 kg per litre).
5. There should be no other load in the vehicle other
than driver or substituted weight of approximately
75 kg placed in drivers position.
6. Thoroughly clean the headlamp lenses.
Headlamp
centre
AC300909AB
10.Four lines of adhesive tape (or equivalent

markings) are required on screen or wall:
(1) Position a vertical tape or mark so that it is
aligned with the vehicle centre line.
(2) Measure the distance from the centre-marks
on the headlamp lens to the floor. Transfer the
measurement to the screen. Horizontal tape or
mark on the screen is for reference of vertical
adjustment.
NOTE: Height from the floor to the centre of
the headlamps (Reference value): 840 mm
CHASSIS ELECTRICAL
54A-49
HEADLAMP
(3) Measure the distance from the centre line of

the vehicle to the centre of each headlamp.
Transfer the measurement to the screen.
Vertical tape or mark on the screen with
reference to the centre line of each headlamp
bulb.
(V)
Distance of
vertical direction Headlamp centre
[42 mm (0.24)]
(H)
15
HEADLAMP ADJUSTMENT
High intensity
zone
CAUTION
Do not cover a headlamp for more than three
minutes to prevent the plastic headlamp lens
deformation.
When adjusting one headlamp beam, make
sure that another headlamp is off by
disconnecting the connector from it. When
reconnecting the connector, make sure that
the headlamp beam is not disturbed
accidentally.
1. The low-beam headlamp should project on the
screen upper edge of the beam (cut-off).
ACX01800AD
Standard value:
(Vertical direction) 42 mm (0.24) below
horizontal (H)
(Horizontal direction) Position at which the
stat up point of 15 is crossed with vertical
line (V)
Limit:
Vertical direction; 51 mm ( 0.29) from the
standard value
Horizontal direction; 87 mm ( 0.5) from
the standard value
LUMINOUS INTENSITY MEASUREMENT

M1542001000419
Vertical
direction
Vertical direction
AC300115 AB
2. If not the case, turn the adjusting screws to

achieve the specified low-beam cut-off location on
the aiming screen.
1. Set the headlamps to high-beam

2. Using a photometer, and following its
manufacturers instruction manual, measure the
headlamp centre intensity and check to be sure
that the limit value is satisfied.
Limit: 30,000 cd or more {When a screen is
set 25m ahead of the vehicle}
NOTE: When measuring the intensity, maintain an
engine speed of 2,000 r/min., with the battery fully
charged.
There may be special local regulations pertaining to
headlamp intensity. Be sure to make any
adjustments necessary to satisfy such regulations.
If an illuminometer is used to make the
measurements, convert its values to photometer
values by using the following formula.
I =E x r2:
I = intensity (cd)
E = illumination (lux)
r = distance (m) from headlamps to illuminometer
CHASSIS ELECTRICAL
54A-50
HEADLAMP
BULB REPLACEMENT
Position Lamp Bulb

M1542001300595
Headlamp Bulb
CAUTION
Do not touch the surface of the bulb with hands
or dirty gloves as the bulb may pop after a short
time. If the surface does become dirty, clean it
with alcohol or thinner, and let it dry thoroughly
before installing.
1. Disconnect the headlamp connector.
Socket cover
CAUTION
As a principal, the position lamps can be
removed as individual part. If not, remove the
position lamp from the headlamp and position
lamp assembly, and then remove the position
lamp from the headlamp. Then replace the
bulb.
Do not touch the bulb surface bare-handed or
with dirty gloves. If dirt is attached on surface
of the bulb, immediately use alcohol or
thinner to remove dirt, and install the bulb
after well dried.
AC300097 AB
2. Remove the socket cover, and then remove the

bulb.
Position lamp socket
AC300089 AB
1. Screw out the position lamp socket.

2. Disconnect the connector.
Front Turn-Signal Lamp bulb

CAUTION
Do not touch the bulb surface bare-handed or
with dirty gloves. If dirt is attached on surface of
the bulb, immediately use alcohol or thinner to
remove dirt, and install the bulb after well dried.
Front turn-signal
lamp socket
AC300098 AB
Disconnect the connector, and screw out the front

turn-signal lamp socket.
CHASSIS ELECTRICAL
HEADLAMP
54A-51
HEADLAMP
M1542001800211
Headlamp Aiming Adjustment (Refer to 354A.)
1
4.9 0.7 Nm
<<A>>
1.
2.
AC300070 AB
Removal steps
Radiator grill
Headlamp assembly

<<A>> HEADLAMP ASSEMBLY REMOVAL
AC201812 AD
1. Remove half of the front bumper assembling clips

and bolts.
NOTE: The Figure illustrates the procedures to
remove the headlamp assembly (LH).
2. Slide the front bumper down to remove the

headlamp assembly.
CHASSIS ELECTRICAL
54A-52
HEADLAMP
HEADLAMP LEVELING SWITCH

M1542013700039
AC210845AE
Removal steps
1. Instrument lower panel (Refer to GROUP
52A-Instrument panel assembly 352A
.)
2. Headlamp leveling switch
INSPECTION
M1542011200867
HEAD LAMP LEVELING SWITCH

RESISTANCE CHECK
AC212497AB
Terminal No.
Switch
position
Resistance
4-6
750 ohms
1050 ohms
1410 ohms
1710 ohms
2010 ohms
0, 1, 2, 3, 4
2830 ohms
5-6
CHASSIS ELECTRICAL
54A-53
FOG LAMP
FOG LAMP
M1542000300291
Item
Standard value
Fog lamp aiming (vertical direction)
Within 45 mm (0.86) to 75 mm (1.44) below the vertical centre

line ahead of fog lamp.
SPECIAL TOOL
M1542000600708
Tool
Number
Name
Use
MB990784
Ornament remover Removal of instrument panel

drivers side garnish, meter bezel
and fog lamp switch
MB990784
TROUBLESHOOTING
M1542000701214
When the front fog lamp switch is turned to ON with

the tail lamp or the headlamp on (the tail lamp switch
or the headlamp switch is ON), the fog lamp relay
turns on, and the fog lamps will illuminate.
If the tail lamps or the headlamps are turned off with
the lighting switch OFF while the fog lamps are on,
the front fog lamps turn off at the same time to
prevent unattended operation.
If the tail lamps are turned off by the headlamp
automatic shutdown function, the fog lamps turn off
at the same time. However, if the tail lamps illuminate
again, the fog lamps do not.
The front fog lamps are controlled by the Smart
Wiring System (SWS). For troubleshooting, refer to
Diagnosis 354B.
Diagnosis 354C.
3. Inspect tyre inflation, and adjust if necessary.

4. If fuel tank is not full, place a weight in the trunk of
the vehicle to simulate weight of a full tank (0.8 kg
per litre).
5. There should be no other load in the vehicle other
than driver or substituted weight of approximately
75 kilograms placed in drivers position.
6. Thoroughly clean the fog lamp lenses.
7. Place the vehicle on a level floor, perpendicular to
a flat screen 3 meters away from the bulb centremarks on the fog lamp lens.
8. Rock the vehicle sideways to allow the vehicle to
assume its normal position.
9. Bounce the front suspension through three (3)
oscillations by applying the body weight to the
hood or bumper.
55 mm
55 mm
33 mm
ON-VEHICLE SERVICE
Fog lamp
centre
FOG LAMP AIMING
33 mm
M1542001100416
PRE-AIMING INSTRUCTIONS
1. Inspect for badly rusted or faulty fog lamp
assemblies.
2. These conditions must be corrected before a
satisfactory adjustment can be made.
AC300907AB
10.Measure the centre of the fog lamps as shown in

the illustration.
CHASSIS ELECTRICAL
54A-54
FOG LAMP
FOG LAMP ADJUSTMENT
(1)
Screen
Fog lamp centre

(3)
(2)
Vehicle centre line
Vertical centre line

ahead of fog lamp
H
Cut off line
45 mm
(3)
75 mm
3m
B
AC212529 AB
11.Four lines of adhesive tape (or equivalent

markings) are required on screen or wall:
(1) Position a vertical tape or mark so that it is
aligned with the vehicle centre line.
(2) Measure the distance from the centre of the
fog lamp lens to the floor. Transfer the
measurement to the screen. Horizontal tape or
mark on the screen is for reference of vertical
adjustment.
(3) Measure the distance from the centre line of
the vehicle to the centre of each fog lamp.
Transfer the measurement to the screen.
Vertical tape or mark on the screen is for
reference to the centre line of each fog lamp.
A: Upper most level of cut off line

B: Lower most level of cut off line
AC212531AC
1. Check if the beam shining onto the screen is at

the standard value.
Standard value:
Fog lamp cut off line (Vertical direction):
Within 45 mm (0.86) to 75 mm (1.44) below
the vertical centre line ahead of fog lamp.
Vertical adjustment
AC300910 AB
2. If it is not within the standard value range, adjust

by turning the adjusting screw.
NOTE: The horizontal direction is non-adjustable. If
deviation of the lamp beam axis exceeds the
standard value, check that the mounting location or
some other points are not faulty.
CHASSIS ELECTRICAL
54A-55
FOG LAMP
FOG LAMP
M1542001500447
4.9 0.7 Nm
3
2
1
1.
Removal steps
Fog lamp assembly

<<A>> FOG LAMP BULB REMOVAL
CAUTION
Use the specified genuine part when
replacing the bulb.
Do not touch the glass portion of bulb with
bare hand or dirty gloves. Should the glass
portion be spoiled, remove the soil as soon as
possible using alcohol or thinner and let it dry
before mounting.
AC201732 AC
Turn the fog lamp bulb left to remove it.
<<A>>
AC212438 AB
2.
3.

Fog lamp
Fog lamp bulb
CHASSIS ELECTRICAL
54A-56
FOG LAMP
FOG LAMP SWITCH

M1542013900022
1.5 0.5 Nm
Vehicles with
front fog lamp
Vehicles without
front fog lamp
5
3
AC212463 AC

3. Fog lamp switch bracket
4. Fog lamp switch (front and rear fog lamp
switch)
5. Fog lamp switch (rear fog lamp switch)
Removal steps
1. Instrument panel drivers side garnish
(Refer to GROUP 52A, Instrument panel
352A.)
2. Meter bezel (Refer to GROUP 52A,
Instrument panel 352A.)
INSPECTION
M1542011200760
FRONT FOG LAMP SWITCH CONTINUITY CHECK

Switch position Tester
connection
Pressed
Specified
condition
1 - 2 (without Less than 2

rear fog lamp) ohms
5 - 6 (with rear
fog lamp)
Released
AC201409 AB
1-2
Open circuit
CHASSIS ELECTRICAL
54A-57
REAR FOG LAMP
FRONT FOG LAMP RELAY CHECK
Front fog lamp relay
Battery voltage
Tester
connection
Specified
condition
Not supplied
1-4
Open circuit
Connect
1-4
terminal 3 to
the positive
battery terminal
Connect
terminal 2 to
the negative
battery terminal
Less than 2
ohms
1
4
2
AC212478 AB
REAR FOG LAMP

TROUBLESHOOTING
M1542000701225
If the rear fog lamp switch is turned ON when the

headlamp or the front fog lamp is turned ON, the rear
fog lamp is switched ON and OFF alternatively.
If the headlamp and the front fog lamp, the rear fog
lamp is turned OFF at the same time.
The fog lamps are controlled by the Smart Wiring

System (SWS). For Troubleshooting, refer to
Diagnosis 354B.
Diagnosis 354C.
SPECIAL TOOL
M1542000600719
Tool
MB990784
Number
Name
Use
MB990784

drivers side garnish, meter bezel
and fog lamp switch
CHASSIS ELECTRICAL
54A-58
REAR FOG LAMP
REAR FOG LAMP

M1542009800066
1.5 0.5 N m
Vehicles with
front fog lamp
Vehicles without
front fog lamp
5
3
6
9
AC300487AB
1.
2.
3.
4.
5.
Rear fog lamp switch removal

steps
Instrument panel drivers side
garnish (Refer to GROUP 52A,
Meter bezel (Refer to GROUP 52A,
Fog lamp switch bracket
Fog lamp switch (front fog lamp
switch and rear fog lamp switch)
Fog lamp switch (rear fog lamp
switch)
6.
7.
8.
9.
Rear fog lamp removal steps

Rear bumper (Refer to GROUP 51,
Rear bumper 351.)
Rear fog lamp assembly
Rear fog lamp body and lens
Socket
Bulb
INSPECTION
M1542007700030
REAR FOG LAMP SWITCH CONTINUITY

CHECK
AC201409 AB

connection
Specified
condition
Pressed
1-2
Less than 2
ohms
Released
1-2
Open circuit
CHASSIS ELECTRICAL
54A-59
SIDE TURN SIGNAL LAMP
REAR FOG LAMP RELAY CHECK
Battery voltage
Tester
connection
Specified
condition
Not supplied
1-4
Open circuit
Connect
1-4
terminal 3 to
the positive
battery terminal
Connect
terminal 2 to
the negative
battery terminal
Less than 2
ohms
Junction block
Rear fog lamp relay
1 2
3 4
4
2
AC210598 AB

SPECIAL TOOL
M1542000600720
Tool
MB990784
Number
Name
Use
MB990784
Ornament remover Removal of side turn-signal lamp
CHASSIS ELECTRICAL
54A-60

M1542003300137
4
3
AC203309 AD
<<A>> >>A<< 1.
2.
3.
4.
Removal steps
Side turn-signal lamp assembly
Side turn-signal lamp
Bulb
Socket
<<A>> SIDE TURN-SIGNAL LAMP REMOVAL
>>A<< SIDE TURN-SIGNAL LAMP INSTALLATION

Hook
Fender
panel
Side turn-signal lamp
Claw
MB990784
Vehicle front
AC200034 AC
Use a special tool ornament remover (MB990784),

etc. to remove the side turning-signal lamp by
pushing the fender forward, bending the hook, and
then unclamping the thumb.
Vehicle front
AC200035AC
Clamp the thumb on the fender panel the assemble

the side turn signal lamp.
CHASSIS ELECTRICAL
ROOM LAMP
54A-61
ROOM LAMP
TROUBLESHOOTING
M1542000701236
Room lamp delay shutdown function

The room lamp off is delayed by ETACS-ECU. The
lamps off delay time vary according to the conditions.
The control details are as follows. The lamp delay off
Yes/NO and delay time can be set with the settings
(adjustment function). for adjustment methods and
adjustment details (post-adjustment operations).
ADJUSTMENT PROCEDURE
Not using SWS monitor: GROUP 54B, 354B
.
Using SWS monitor: GROUP 54C, 354B
.
The room lamp lights up if the ignition switch is at
the "LOCK" (OFF) position and either of the
doors are opened (either of the door switches:
ON). At this time, if all doors are closed (all door
switches: OFF) then the lamp will gradually dim
down to lamps off in about 15 seconds.
NOTE: When the lamps are dimmed and the ignition
switch is turned ON or if the door is locked, then
the dimming operations stop and the lamps are
turned OFF.
When the ignition switch is at the ON position and
one of the doors are opened (one of the door
switches: ON) then the room lamp will light up. At
this time, if all doors are closed (all door switches:
OFF) then the lamps will dim out.
When the ignition key is pulled out the room lamp
lights up and then will dim out in 15 seconds. The
lamp will dim out if the ignition key is inserted
again and the door is locked while the timer is
activated.
The room lamp is controlled by the Smart Wiring

Diagnosis 354B.
Diagnosis 354C.
Interior lamp automatic cut function <vehicles
with keyless entry system>
The interior lamp automatic cut function, dims out the
room lamp and other interior lamps by activating the
keep relay built-in the ETACS-ECU when the ignition
switch is OFF and the multi-purpose fuse loaded
signals built-in the ETACS-ECU is ON and 30
minutes passes. The lamps lights back up if the
ignition switch is turned to the ON position or either
of the doors is opened (either of the door switches:
ON). The function Yes/No feature can be changed
with the settings (adjustment function). for
adjustment methods and adjustment details (postadjustment operations).
ADJUSTMENT PROCEDURE
Not using SWS monitor: GROUP 54B, 354B
.
Using SWS monitor: GROUP 54C, 354B
.
The head lamp are controlled by the Smart Wiring
Diagnosis 354B.
Diagnosis 354C.
CHASSIS ELECTRICAL
54A-62

REAR COMBINATION LAMP DIAGNOSIS
M1542000701247
The lamps setup on the rear combination lamp is

controlled in the same manner as the lamps of the
headlamp assembly. For details go to the reference.
For troubleshooting, refer to respective Groups
below.

Diagnosis 354B.
Diagnosis 354C.
SPECIAL TOOL
M1542000600731
Tool
Number
Name
Use
MB990784
Ornament remover Removal of ventilation cap and

rear combination lamp assembly
MB990784

M1542003900418
Section A - A
Clip
1
A
4.9 0.7 Nm
3
A
AC210600 AE
Removal steps
Ventilation cap (Refer to GROUP
52A, Trims 352A.)
Rear combination lamp connector
connection

1. Rear combination lamp
2. Harness assembly
3. Bulb
CHASSIS ELECTRICAL
54A-63

M1542005100429
2.5 0.3 Nm
5.1 0.2 Nm
5.1 0.2 Nm
AC100674 AF
Removal steps
Tailgate upper trim (Refer to
GROUP 52A, Tailgate trim 352A
.)
High-mounted stop lamp connector
connection
1.
2.

Spoiler
High-mounted stop lamp
CHASSIS ELECTRICAL
54A-64
LICENCE PLATE LAMP
LICENCE PLATE LAMP

LICENCE PLATE LAMP
M1542004200166
1
(L.H.side)
(R.H.side)
AC300488AB
1.
2.
3.
Removal steps
Licence plate lamp lens
Packing
Licence plate lamp body
4.
5.

Licence plate lamp bulb
Socket assembly
CHASSIS ELECTRICAL
54A-65
HAZARD WARNING LAMP SWITCH

TROUBLESHOOTING
M1542000701258
FLASHER TIMER FUNCTION

The hazard warning lamps (flasher timer function)
are controlled by the Smart Wiring System (SWS).
For troubleshooting, refer to respective Groups
below.

Diagnosis 354B.
Diagnosis 354C.
SPECIAL TOOL
M1542000600742
Tool
Number
Name
Use
MB990784
Ornament remover Removal of centre lower panel

assembly
MB990784

M1542006600416
AC300490
1.5 0.5 Nm
2
Removal steps
1. Centre lower panel assembly (Refer to
GROUP 52A, Instrument panel 352A.)
2. Hazard warning lamp switch
AC301773AB
CHASSIS ELECTRICAL
54A-66
COLUMN SWITCH
INSPECTION
M1542011200771

CONTINUITY CHECK

connection
Specified
condition
Released
1-2
Open circuit
Pressed
1-2
Less than 2
ohms
AC102590 AB
COLUMN SWITCH
SPECIAL TOOL
M1542000600753
Tool
MB990784
Number
Name
Use
MB990784
Ornament remover Removal of column cover
CHASSIS ELECTRICAL
54A-67
COLUMN SWITCH
COLUMN SWITCH
M1543009100413
Section A - A
2
Claw
Column
cover
A
A
Note
: Claw position
3
1
Removal steps
1. Instrument panel (Refer to GROUP 52A,
2. Column cover upper
AC100538 AC

3. Column cover lower
4. Turn-signal and lighting switch
5. Windshield wiper and washer switch
CHASSIS ELECTRICAL
54A-68
COLUMN SWITCH
INSPECTION
M1542011200782
TURN-SIGNAL AND LIGHTING SWITCH

CHECK
Turn-signal and lighting switch
AC103138 AC
Switch position Tester condition
Specified
condition
OFF
3 - 4, 3 - 6, 3 - 7,
3 - 8, 3 - 9, 3 - 10,
3 - 11
Open
circuit
Headlamp
washer switch
3-4
Less than
2 ohms
Headlamp
switch
3-6
Less than
2 ohms
Switch position Tester condition
Specified
condition
Tail lamp switch
3-7
Less than
2 ohms
Passing switch
3-8
Less than
2 ohms
Dimmer switch
3-9
Less than
2 ohms
Turn-signal lamp 3 - 10
switch (RH)
Less than
2 ohms
Turn-signal lamp 3 - 11
switch (LH)
Less than
2 ohms
NOTE: Integrated column ECU does not allow

windshield wiper switch continuity test. For
inspection and diagnosis, refer to the respective
Group
below.
.

Diagnosis 354B.
Diagnosis 354C.
CHASSIS ELECTRICAL
HORN
54A-69
HORN
HORN
M1543007900394
21 4 Nm
1
21 4 Nm
2
Removal Steps
1. Horn <LO>
2. Horn <HI>
AC203808 AC
CHASSIS ELECTRICAL
54A-70
CLOCK
INSPECTION
M1543006500047
HORN RELAY CONTINUITY CHECK
Battery voltage
Tester
connection
Specified
condition
Not applied
1-4
Open circuit
Connect terminal 1 - 4
2 to the positive
battery terminal
Connect terminal
3 to the negative
battery terminal
Less than 2
ohms
Horn relay
AC210599 AF
CLOCK
SPECIAL TOOL
M1543000601511
Tool
MB990784
Number
Name
Use
MB990784

garnish, meter bezel and
instrumental panel centre clock
panel
CHASSIS ELECTRICAL
54A-71
CIGARETTE LIGHTER
CLOCK
M1543005900183
1.5 0.5 Nm
4
3
1.5 0.5 Nm
AC100537 AC
Removal steps
1. Instrument panel drivers side garnish (Refer
to GROUP 52A, Instrument panel 352A.)
2. Meter bezel (Refer to GROUP 52A,

3. Instrument panel clock garnish (Refer to
GROUP 52A, Instrument panel 352A.)
4. Clock
CIGARETTE LIGHTER
INSPECTION
M1543005700231
CIGARETTE LAMPER CHECK

Element
Spot
ACX01832 AD
Take out the plug, and check for a worn edge on

the element spot connection, and for shreds of
tobacco or other material on the element.
Using an ohmmeter, check that the element
resistance value is 1.7 ohms.
CHASSIS ELECTRICAL
54A-72
ACCESSORY SOCKET
ACCESSORY SOCKET
SPECIAL TOOL
M1543000601522
Tool
Number
Name
Use
MB990784
Ornament remover Removal of quarter trim lower
MB990784
ACCESSORY SOCKET
M1543008900223
1
2
Removal Steps
Quarter trim lower (LH) (Refer to GROUP
52A, Trim352A.)
AC300489 AC
Removal Steps&RQWLQXHG

1. Socket case
2. Accessory socket
CHASSIS ELECTRICAL
54A-73
ACCESSORY SOCKET
INSPECTION
M1543009000182
ACCESSORY SOCKET RELAY

CONTINUITY CHECK
Accessory socket relay
AC210599 AB
Battery voltage
Tester
Specified
connection condition
Not applied
1-4
Open circuit
Connect terminal
2 to the positive
battery terminal
Connect terminal
3 to the negative
battery terminal
1-4
Less than 2
ohms
CHASSIS ELECTRICAL
54A-74
RHEOSTAT
RHEOSTAT
RHEOSTAT
M1542006000287
AC210844AB
Removal steps
1. Instrument lower panel (Refer to GROUP
52A-Instrument panel assembly 352A
.)
2. Rheostat
INSPECTION
M1542006100217
RHEOSTAT RESISTANCE CHECK
40W
AC212513AB
1. Connect the battery and the test bulb (40 W) as

shown in the illumination.
2. Operate the rheostat, and if brightness changes

smoothly without switching off, rheostat function is
normal.
CHASSIS ELECTRICAL
54A-75
SPEAKER
SPEAKER
SPEAKER
M1544002600421
5
6
1.5 0.5 Nm
4
3
2
1.5 0.5 Nm
AC102825 AD
1.
2.
Front door speaker removal

steps
Front door speaker garnish
Front door speaker
3.
4.
5.
6.
Rear door speaker removal

steps
Rear door speaker garnish
Rear door speaker
Tweeter removal steps
Delta cover (Refer to GROUP 51,
Door Mirror 351.)
Tweeter
CHASSIS ELECTRICAL
54A-76
ANTENNA
ANTENNA
ANTENNA
M1544002900499

Front pillar trim, Quarter trim upper, Quarter trim lower,
Centre pillar trim lower, Centre pillar trim upper (Refer to
GROUP 52A - Trim 352A.)
Assist Grip, Headlining (Refer to GROUP 52A Headlining 352A.)
Instrument Panel Removal and Installation (Refer to
GROUP 52A, Instrument Panel 352A).
1
3
3.0 1.0 Nm
AC300925 AB
Removal steps
1. Rod assembly
2. Antenna nut

3. Base
4. Antenna feeder assembly
CHASSIS ELECTRICAL
54A-77

GENERAL INFORMATION
M1543000100290
Rear Defogger operation

The defogger relay turns ON if the defogger switch
built-in the A/C-ECU is turned ON when the ignition
switch is in the "ON" position. When the defogger
relay turns ON, power is supplied to the defogger
and the defogger is activated. The defogger comes
with a timer function that causes the defogger switch
to automatically turn OFF in about 11 minutes
(manual A/C) or about 20 minutes (automatic A/C)
after the defogger switch is turned ON.
3. If 12 volts is indicated at A, there is a break in the

negative terminals from A. Move test bar slowly to
negative terminal to detect where voltage
changes suddenly (0volts).
4. If 0 volts is indicated at A, there is a break in the
positive terminals from A. Defect where the
voltage changes suddenly (12 volts) in the same
method described above.
REAR WINDOW DEFOGGER SWITCH

M1543006200295
TROUBLESHOOTING
M1543000700957
The rear window defogger is controlled by the A/CECU. For troubleshooting, refer to GROUP 55ATroubleshooting 355A or GROUP 55BTroubleshooting 355B.
Refer to GROUP 55A, Heater Control Assembly and

Blower Switch Assembly 355A.
INSPECTION
M1543019502225
DEFOGGER RELAY CHECK
ON-VEHICLE SERVICE
PRINTED HEATER LINES CHECK
M1543001800292
Normal characterstic curve

Voltage
A (Center point)
Approximately 6 V
Positive
terminal
Junction block
Defogger relay
Negative
terminal
Print heater line
OFF
ON
Abnormal characterstic curve

1
Voltage
Open circuit point

AC212486 AB
Positive
terminal
Print heater line
Battery voltage
Tester
connection
Specified
condition
Not supplied
4-5
Open circuit
Connect terminal
1 to the positive
battery terminal
Connect terminal
3 to the negative
battery terminal
4-5
Less than 2
ohms
Negative
terminal
ACX00813 AC
1. Run engine at 2,000 r/min. Check heater element

with battery at full.
2. Turn "ON" rear window defogger switch. Measure
heater element voltage with circuit tester at rear
window glass centre A. Condition is good if it
indicates about six volts.
127(6
13A-1
GROUP 13A
MULTIPORT FUEL
INJECTION (MFI)
00
11
12
13
14
15
CONTENTS
16
17
13A
ENGINE CONTROL RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A
13A
FUEL PUMP RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A
22
SEALANT. . . . . . . . . . . . . . . . . . . . . .
13A
INTAKE AIR TEMPERATURE SENSOR

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A
25
SPECIAL TOOLS. . . . . . . . . . . . . . . .
13A

SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13A
26
TROUBLESHOOTING . . . . . . . . . . . .
13A
THROTTLE POSITION SENSOR CHECK . 13A
27
ON-VEHICLE SERVICE. . . . . . . . . . . 13A

THROTTLE BODY (THROTTLE VALVE
AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13A
THROTTLE POSITION SENSOR
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13A
BASIC IDLE SPEED ADJUSTMENT . . . . . 13A
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13A
FUEL PUMP CONNECTOR
DISCONNECTION (HOW TO REDUCE
PRESSURIZED FUEL LINES) . . . . . . . . . . 13A
FUEL PUMP OPERATION CHECK . . . . . . 13A
COMPONENT LOCATION . . . . . . . . . . . . . 13A
OXYGEN SENSOR CHECK . . . . . . . . . . . . 13A
21
INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A
31
IDLE SPEED CONTROL (ISC) SERVO

(STEPPER MOTOR) CHECK . . . . . . . . . . . 13A
32
INJECTOR . . . . . . . . . . . . . . . . . . . . . 13A
33
REMOVAL AND INSTALLATION . . . . . . . . 13A
34
THROTTLE BODY ASSEMBLY . . . . . 13A
35
36
THROTTLE BODY ASSEMBLY

DISASSEMBLY AND REASSEMBLY . . . . . 13A
ENGINE ECU . . . . . . . . . . . . . . . . . . . 13A

37
42
51
52
54
55
MULTIPORT FUEL INJECTION (MFI)
13A-2
GENERAL INFORMATION
GENERAL INFORMATION
M1131000100701
The Multipoint Fuel Injection System consists of sensors which detect the engine conditions, the engineECU which controls the system based on signals
from these sensors, and actuators which operate
under the control of the engine-ECU. The engineFUEL INJECTION CONTROL
The injector drive times and injection timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continuallychanging engine operation conditions.
A single injector is mounted at the intake port of each
cylinder. Fuel is sent under pressure from the fuel
tank by the fuel pump, with the pressure being regulated by the fuel pressure regulator. The fuel thus
regulated is distributed to each of the injectors.
Fuel injection is normally carried out once for each
cylinder for every two rotations of the crankshaft. The
firing order is 1-3-4-2. This is called sequential fuel
injection. The engine-ECU provides a richer air/fuel
mixture by carrying out "open-loop" control when the
IDLE AIR CONTROL
The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle
valve in accordance with changes in idling conditions
and engine load during idling. The engine-ECU
drives the idle speed control motor to keep the
engine running at the pre-set idle target speed in
accordance with the engine coolant temperature and
ECU carries out activities such as fuel injection control, idle speed control and ignition timing control. In
addition, the engine-ECU is equipped with several
diagnosis modes which simplify troubleshooting
when a problem develops.
engine is cold or operating under high load conditions in order to maintain engine performance. In
addition, when the engine is warm or operating under
normal conditions, the engine-ECU controls the
air/fuel mixture by using the oxygen sensor signal to
carry out "closed-loop" control in order to obtain the
theoretical air/fuel mixture ratio that provides the
maximum cleaning performance from the three way
catalyst.
air conditioner load. In addition, when the air conditioner switch is turned off and on while the engine is
idling, the idle speed control motor operates to adjust
the throttle valve bypass air amount in accordance
with the engine load conditions in order to avoid fluctuations in the engine speed.
IGNITION TIMING CONTROL

The power transistor located in the ignition primary
circuit turns ON and OFF to control the primary current flow to the ignition coil. This controls the ignition
timing in order to provide the optimum ignition timing
with respect to the engine operating conditions. The
ignition timing is determined by the engine-ECU from
the engine speed, intake air volume, engine coolant
temperature and atmospheric pressure.
SELF-DIAGNOSIS FUNCTION
When an abnormality is detected in one of the
sensors or actuators related to emission control,
the engine warning lamp (check engine lamp)
illuminates as a warning to the driver.
When an abnormality is detected in one of the
sensors or actuators, a diagnosis code corresponding to the abnormality is output.
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control
The RAM data inside the engine-ECU that is

related to the sensors and actuators can be read
by means of the MUT-II. In addition, the actuators
can be force-driven under certain circumstances.
Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running.

GENERAL INFORMATION
2. A/C Relay Control

Turns the compressor clutch of the A/C ON and OFF.
3. Fan Motor Control
The revolutions of the radiator fan and condenser fan
are controlled in response to the engine coolant
temperature and vehicle speed.
4. Purge Control Solenoid Valve Control
(Refer to 317, GROUP 17 - Engine And Emission

Control - Evaporative Emission Control System).
5. EGR Control Solenoid Valve Control
[Refer to 317, GROUP 17 - Engine And Emission Control - Exhaust Gas Recirculation (EGR)
System].
Items
Throttle body
Specifications
Throttle bore mm
60
Throttle position sensor
Variable resistor type
Idle speed control servo
Stepper motor type
Engine-ECU
Identification No.
E6T38971
Sensors
Air flow sensor
Karman vortex type
Barometric pressure Sensor
Semiconductor type
Intake air temperature sensor
Thermistor type
Engine coolant temperature
Thermistor type
Oxygen sensor
Zirconia type
Inhibitor switch
Contact switch type
Hall element type
Crank angle sensor
Hall element type
Detonation sensor
Piezoelectric type
Power steering fluid pressure switch
Contact switch type
Engine control relay type
Contact switch type
Fuel pump relay type
Contact switch type
Injector type and number
Electromagnetic type, 4
Injector identification mark
HDA 250E
Duty cycle type solenoid valve
Actuators
Fuel pressure Regulator pressure kPa

regulator
13A-3
329
13A-4
GENERAL INFORMATION
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM

1
2
3
4
Oxygen sensor (front)

Oxygen sensor (rear)
Air flow sensor
Intake air temperature
sensor
5 Throttle position sensor
6 Camshaft position
sensor
7 Crank angle sensor
8 Barometric pressure
sensor
9 Engine coolant
temperature sensor
10 Detonation sensor
Power supply
Ignition switch-IG
Ignition switch-ST
A/C switch
A/C load signal
A/C pressure
sensor
Power steering
fluid pressure switch
Alternator FR
terminal
Vehicle speed
sensor
Engine control relay

Fuel pump relay
A/C compressor relay
Ignition coil
Fan controller
Engine warning lamp
Diagnosis output
Alternator G terminal
Oxygen sensor heater
Tachometer
4 Intake air temperature sensor

2 Idle speed control servo
3 Air flow sensor
(Stepper motor)
8 Barometric
5 Throttle position
pressure sensor
sensor
6 Camshaft position sensor
Air
Fuel pressure
regulator
To
fuel tank
1 Injector
2 Idle speed control
servo (Stepper motor)
3 EGR control solenoid
valve
4 Purge control solenoid
valve
Engine-ECU
From
fuel pump
EGR valve
Canister
1 Oxygen sensor
(front)
1 Injector
Catalytic
converter
9 Engine coolant
temperature sensor
3 EGR control
solenoid valve
10 Detonation sensor
7 Crank angle sensor
2 Oxygen sensor (rear)
Catalytic
converter
4 Purge control
solenoid valve
AK204338 AB
13A-5
M1131000300459
Items
Specifications
Basic idle speed r/min
700 50
Throttle position sensor adjusting voltage mV
535 - 735
Throttle position sensor resistance kW
3.5 - 6.5
Idle speed control servo coil resistance (at 20C) W
28 - 33
Intake air temperature sensor -20C

resistance kW
0C
13 - 17
Engine coolant temperature

sensor resistance kW
5.3 - 6.7
20C
2.3 - 3.0
40C
1.0 - 1.5
60C
0.56 - 0.76
80C
0.30 - 0.42
-20C
14 - 17
0C
5.1 - 6.5
20C
2.1 - 2.7
40C
0.9 - 1.3
60C
0.48 - 0.68
80C
0.26 - 0.36
Oxygen sensor output voltage (at racing) V
0.6 - 1.0
Oxygen sensor heater

resistance (at 20C) W
front
4.5 - 8.0
rear
11 - 18
Fuel pressure kPa
Vacuum hose disconnection
330 - 350 at curb idle
Vacuum hose connection
Approximately. 270 at curb idle
Injector coil resistance (at 20C) W
10.5 - 13.5
SEALANT
M1131000500237
Item
Specified sealant
Remark

Threaded portion
3M Nut Locking Part No. 4171 or equivalent
Drying sealant
13A-6
SPECIAL TOOLS
SPECIAL TOOLS
M1131000600342
Tool
Number
Name
Use
MB991502
MUT-II sub
assembly
Reading diagnosis code

MPI system inspection
MB991348
Test harness set
Measurement of voltage during

troubleshooting
Inspection using an oscilloscope
MB991709
Test harness

troubleshooting
Adjusting of idle speed control servo
MD998478
Test harness (3pin, triangle)

Troubleshooting
MB991536
Check harness
for throttle
position sensor
adjustment

Troubleshooting
Adjusting of throttle position sensor
MD998464
Test harness (4pin, square)

Troubleshooting
Inspection of oxygen sensor (front)
MB991658
Test harness

Troubleshooting
Inspection of oxygen sensor (rear)
B991502
MB991348
MB991536
MB991658

SPECIAL TOOLS
Tool
13A-7
Number
Name
Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Check at the ECU terminals

A: Connector pin contact inspection
D: Commercial tester connection
MD998709
Adaptor hose
Measurement of fuel pressure
MD998742
Hose adaptor
MB991637
Fuel pressure
gauge set
MB991223
MB991637
13A-8
TROUBLESHOOTING
Tool
Number
Name
Use
MD998706
Injector test set
Checking the spray condition of

injectors
MB991607
Injector test
harness
MD998741
Injector test
adaptor
MB991608
Clip
MD998706
MB991607
MD998741
MB991608
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1131150000342
Refer to 300, GROUP 00 - How to Use Troubleshooting/Inspection Service Points.

NOTE: If the engine-ECU is replaced, the steering
lock cylinder and ignition key should be replaced
together with it.
DIAGNOSIS FUNCTION
M1131155500074
ENGINE WARNING LAMP (CHECK

ENGINE LAMP)
Engine warning lamp

(check engine lamp)
AK300251AB
If an abnormality occurs in any of the following items

related to the Multipoint Fuel Injection (MPI) system,
the engine warning lamp will illuminate.
If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.

TROUBLESHOOTING
ENGINE WARNING LAMP INSPECTION ITEMS

Code No.
Diagnosis item
Engine-ECU
P0100
Air flow sensor system
P0105
Barometric pressure sensor system
P0110
Intake air temperature sensor system
P0115
Engine coolant temperature sensor system
P0120
Throttle position sensor system
P0125*
Feedback system monitor
P0130
Oxygen sensor (front) system <Sensor 1>
P0135
Oxygen sensor heater (front) system <Sensor 1>
P0136
Oxygen sensor (rear) system <Sensor 2>
P0141
Oxygen sensor heater (rear) system <Sensor 2>
P0170
Abnormal fuel system
P0201
No. 1 injector system
P0202
P0203
P0204
P0300
Random cylinder mis-fire detection system
P0301*
No. 1 cylinder mis-fire detection system
P0302*
P0303*
P0304*
P0325
Detonation sensor system
P0335
Crank angle sensor system
P0340
Camshaft position sensor system
P0403
EGR control solenoid valve system
P0420
Catalyst deterioration system
P0443
Purge control solenoid valve system
P0500
Vehicle speed sensor system
P0505
Idle speed control system
P0551*
Power steering fluid pressure switch system
P1603*
Battery back-up line system
P1610
Immobilizer system
13A-9
13A-10
TROUBLESHOOTING
NOTE: .
If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between MUT-II and the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is
next turned on and the same malfunction is re-detected.However, for items marked with a "*" in the diagnosis code number column, the engine warning lamp illuminates only on the first detection of the malfunction.
After the engine warning lamp illuminates, it will be switched off under the following conditions.
When the engine-ECU monitored the power train malfunction three times* met set condition requirements, it detected no malfunction.
*: In this case, "one time" indicates from engine start to stop.
For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
Sensor 1 indicates, the sensor mounted at a position closest to the engine, and sensor 2 indicates the
sensor mounted at the position second closest to the engine.
METHOD OF READING AND ERASING

DIAGNOSIS CODES
INSPECTION USING MUT-II DATA LIST

AND ACTUATOR TESTING
Refer to 300, GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
1. Carry out inspection by means of the data list and

the actuator test function, if there is an
abnormality, check and repair the chassis harness
and components.
2. After repairing, re-check using the MUT-II and
check that the abnormal input and output have
returned to normal as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II, and then start the engine
again and carry out a road test to confirm that the
problem has disappeared.
DIAGNOSIS USING DIAGNOSIS 2 CODES

1. Switch the diagnosis mode of the engine control
unit to DIAGNOSIS 2 mode using the MUT-II.
2. Carry out a road test.
3. Take a reading of the diagnosis code and repair
the problem location.
4. Turn the ignition switch to OFF and then back to
ON again.
NOTE: By turning the ignition switch to OFF, the
ENGINE-ECU will switch the diagnosis mode
from DIAGNOSIS 2 mode to DIAGNOSIS 1
mode.
5. Erase the diagnosis codes.
FREEZE FRAME DATA

When the engine-ECU detects a malfunction and
stores a diagnosis code, it also stores a current status of the engine. This function is called "Freeze
frame data". By analysing this "Freeze frame" data
with the MUT-II, an effective troubleshooting can be
performed.
The display items of freeze frame data are shown
below.
DISPLAY ITEM LIST

Item No.
Data
Unit
21
22
Engine speed
r/min
24
Vehicle speed
km/h
80
Long-term fuel compensation (long-term fuel trim)
82
Short-term fuel compensation (short-term fuel trim)
13A-11
TROUBLESHOOTING
Item No.
Data
88
Fuel control condition
87
Unit
Open loop
OL
Closed loop
CL
Open loop owing to drive condition
OL-DRV.
Open loop owing to system malfunction
OL-SYS.
Closed loop based on one oxygen sensor
CL- H02S
Calculation load value
Diagnosis code during data recording
NOTE: If malfunctions have been detected in multiple systems, store one malfunction only, which has
been detected first.
READINESS TEST STATUS

The engine-ECU monitors the following main diagnosis items, judges if these items are in good condition
or not, and the stores its history. this history can be
read out by using MUT-II. (If the ECU has judged a
item before, the MUT-II displays "Complete").
In addition, if diagnosis codes are erased or the battery cable is disconnected, this history will also be
erased (the memory will be reset).
Catalyst: P0420
Oxygen sensor: P0130
Oxygen sensor heater: P0135, P0141
FAIL-SAFE FUNCTION REFERENCE TABLE

When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by
means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item
Control contents during malfunction
Air flow sensor
1. Uses the throttle position sensor signal and engine speed signal (crank angle
sensor signal) to take reading of the basic injector drive time and basic ignition
timing from the pre-set mapping.
2. Fixes the idle speed control servo in the appointed position so idle control is not
performed.

sensor
Controls as if the intake air temperature is 25C.
Barometric pressure
sensor
Controls as if the barometric pressure is 101 kPa.
Throttle position sensor No increase in fuel injection amount during acceleration due to the throttle position
sensor signal.
Engine coolant
temperature sensor
Controls as if the engine coolant temperature is 80C.
Camshaft position
sensor
Injectors fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the
ignition switch is turned to the "ON" position, the No. 1 cylinder top dead centre is
not detected at all)
Air/fuel ratio feedback control (closed loop control) is not performed.
Performs the feedback control (closed loop control) of the air/fuel ratio by using
only the signal of the oxygen (front) installed on the front of the catalytic converter.
Detonation sensor
Fixes the ignition timing as that for regular gasoline.
13A-12
TROUBLESHOOTING
Malfunctioning item
Control contents during malfunction
Ignition coil
(incorporating power
transistor)
Cuts off the fuel supply to cylinders with an abnormal ignition.
Alternator FR terminal
Does not control the output of the alternator according to an electrical load. (works
as a normal alternator)
Misfiring
If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be
shut down.
INSPECTION CHART FOR DIAGNOSIS CODE

M1131151000624
Code No.
Diagnosis item
Reference page
P0100
Air flow sensor system
313A
P0105
Barometric pressure sensor system
313A
P0110
Intake air temperature sensor system
313A
P0115
Engine coolant temperature sensor system
313A
P0120
Throttle position sensor system
313A
P0125*
Feedback system monitor
313A
P0130
Oxygen sensor (front) system <Sensor 1>
313A
P0135
Oxygen sensor heater (front) system <Sensor 1>
313A
P0136
Oxygen sensor (rear) system <Sensor 2>
313A
P0141
Oxygen sensor heater (rear) system <Sensor 2>
313A
P0170
Abnormal fuel system
313A
P0201
No.1 Injector system
313A
P0202
313A
P0203
313A
P0204
313A
P0300
Random cylinder mis-fire detection system
313A
P0301*
No.1 cylinder mis-fire detection system
313A
P0302*
313A
P0303*
313A
P0304*
313A
P0325
Detonation sensor system
313A
P0335
Crank angle sensor system
313A
P0340
Camshaft position sensor system
313A
P0403
EGR control solenoid valve system
313A
P0420
Catalyst deterioration system
313A
P0443
Purge control solenoid valve system
313A
P0500
Vehicle speed sensor system
313A
P0505
Idle speed control system
313A
P0551*
Power steering fluid pressure switch system
313A

TROUBLESHOOTING
13A-13
Code No.
Diagnosis item
Reference page
P0622
Alternator FR terminal system
313A
P1603*
Battery back-up line system
313A
P1610
Immobilizer system
313A
NOTE: .
Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit.
Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the engine
is started and the same malfunction is re-detected. However, for items marked with "*", the diagnosis
code is recorded on the first detection of the malfunction.
Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates the sensor mounted at the position second closest to the engine.
13A-14
TROUBLESHOOTING
INSPECTION PROCEDURE FOR

DIAGNOSIS CODES
Code No. P0100 Air Flow Sensor System
Air flow sensor circuit
Battery
W-B
W-B
3
4
B-17X
4
B-08
Air flow sensor
1 2 3 4 5 6 7
G-W
20
J/C (1)
C-16
G-B
W-R
C-135
17
G-W
19
40
90
C-137
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
C-134
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300252 AB

TROUBLESHOOTING
OPERATION
Power is supplied to the air flow sensor (terminal
No. 4) from the engine control relay (terminal No.
1) and earthed to the engine-ECU (terminal No.
40) from the air flow sensor (terminal No. 5).
A power voltage of 5 V is applied to the air flow
sensor output terminal (terminal No. 3) from the
engine-ECU (terminal No. 90).
An air flow sensor filter reset signal is inputted to
the air flow sensor (terminal No. 7) from the
FUNCTION
Air flow sensor outputs a pulse signal proportional to the intake air flow rate.
The engine-ECU determines the basic injection
timing of the injector using the pulse signal output
from the air flow sensor and the engine speed
signal.
When the throttle position sensor output is low,
the engine-ECU causes the power transistor in
the unit to be ON to send an air flow sensor filter
reset signal to the air flow sensor. In response to
the reset signal, the air flow sensor resets the filter circuit to improve the ability of the air flow sensor to measure the air flow rate in the area where
the intake air flow rate is low.
TROUBLE JUDGMENT
Check Condition
Engine speed is 500 r/min or more.
Judgment Criterion
Sensor output frequency of 3.3 Hz or less for 2
seconds.
PROBABLE CAUSE
Failed air flow sensor
Open/short circuit in air flow sensor circuit or
loose connector contact
Failed engine-ECU
13A-15
DIAGNOSIS PROCEDURE
STEP 1. MUT-II data list
Refer to Data list reference table 313A.
a. Item 12: Air flow sensor
YES : Intermittent malfunction (Refer to GROUP
00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-08 air flow sensor
connector
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
Harness side connector
AK300253 AB

YES : Go to Step 3 .
NO : Repair.
STEP 3. Measure voltage at B-08 air flow sensor

connector.
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Disconnect connector, and measure at harness

side.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: 4.9 - 5.1 V
NO : Go to Step 4 .
13A-16
TROUBLESHOOTING
STEP 4. Measure voltage at C-137 engine-ECU

connector.
CONNECTOR: C-137
STEP 5. Connector check: C-137 engine-ECU

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Measure engine-ECU terminal voltage.

Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 6 .
AK300254 AB
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

YES : Check and repair harness between B-08
(terminal No. 3) air flow sensor connector

and C-137 (terminal No. 90) engine-ECU
connector.
Check output line for open circuit.
NO : Repair.
13A-17
TROUBLESHOOTING

connector.
CONNECTOR: C-137
STEP 7. Check harness between B-08 (terminal

No. 3) air flow sensor connector and C-137
(terminal No. 90) engine-ECU connector.
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300253 AB
CONNECTOR: C-137

AK300254 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Check output line for short circuit.

NO : Repair.

00 - How to Use
300).
NO : Replace engine-ECU.
13A-18
TROUBLESHOOTING

connector.
STEP 10. Connector check: B-17X engine control

relay connector
CONNECTOR: B-17X
Connector: B-08
Relay boxs
triangle marks
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 10 .
B-17X
Harness side
connector
AK300255 AB
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB


and B-17X (terminal No.1) engine control
relay connector.
Check power supply line for
open/short circuit.
NO : Repair.
STEP 11. Check at B-08 air flow sensor
connector.
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Disconnect and measure at harness side.

Resistance between terminal No. 5 and earth.
OK: 2 W or less
13A-19
TROUBLESHOOTING

connector
CONNECTOR: C-135

Connector: B-08
C-135
B-08 (B)
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300253 AB
CONNECTOR: C-135

AK300256 AB

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
NOTE: Before checking harness, check intermediate

Check earthing line for open circuit and damage.
NO : Repair.
13A-20
TROUBLESHOOTING

connector.
Connector: B-08

Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness.
Ignition switch: ON
OK: 7 - 8 V
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-134

C-134

connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
CONNECTOR: C-134

AK300257 AB
Check reset signal line for short circuit.

C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

YES : Replace air flow sensor.
NO : Repair.
13A-21
TROUBLESHOOTING

connector.
Connector: B-08

Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Transmission: Neutral
OK:
0 - 1 V (Engine: Idling)
6 - 9 V (Engine: 3,000 r/min)
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-134

C-134

connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

CONNECTOR: C-134
AK300257 AB
Check reset signal line for open circuit and damage.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

NO : Repair.
13A-22
TROUBLESHOOTING
STEP 20. Measure output waveform at B-08 air

flow sensor connector (Use oscilloscope).
Connector: B-08

No. 4) air flow sensor connector and B-17X
(terminal No. 1) engine control relay connector.
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Engine: Idling
OK: Waveforms should be displayed on
inspection procedure using an oscilloscope
(Refer to 313A) and noise should not be
displayed in the waveform.
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

AK300255 AB
Check power supply line for damage.
STEP 21. Replace air flow sensor.

After replacing the air flow sensor, re-check the
trouble symptoms.
NO : Check end.

NO : Repair.

connector
CONNECTOR: C-134

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300255 AB
AK300257 AB

NO : Repair.

NO : Repair.
13A-23
TROUBLESHOOTING

STEP 26.Connector check: C-135 engine-ECU

connector
CONNECTOR: C-135
Connector: B-08
B-08 (B)
C-135
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-137
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
Connector: B-08
C-137
B-08 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
7 6 5 4 3 2 1
AK300253 AB
AK300254 AB
Check output line for damage.

NO : Repair.

YES : Check intermediate connector C-16, and
repair if necessary. If intermediate

connector is normal, check and repair
harness between B-08 (terminal No. 5) air
flow sensor connector and C-135 (terminal
No. 40) engine-ECU connector.
Check earthing line for damage.
No : Repair.
13A-24
TROUBLESHOOTING
Code No. P0105: Barometric Pressure Sensor System
Barometric pressure sensor circuit
B-08
Barometric pressure sensor
(Incorporated in air flow sensor)
1 2 3 4 5 6 7
2
B-W
20
Y-B
J/C (1)
C-16
G-W
17
B-W
81
85
40
C-135
C-137
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code

AK300258 AB
OPERATION
A power voltage of 5 V is applied to the barometric pressure sensor power terminal (terminal No.
1) of the air flow sensor connector from the
engine-ECU (terminal No. 81) and earthed to the
engine-ECU (terminal No. 40) from the air flow
sensor (terminal No. 5).
The sensor signal is inputted to the engine-ECU
(terminal No. 85) from the barometric pressure
sensor output terminal (terminal No. 2) of the air
flow sensor connector.
FUNCTION
The barometric pressure sensor converts the barometric pressure into a voltage signal and inputs
the signal to the engine-ECU.
In response to the signal, the engine-ECU corrects the fuel injection amount, etc.
TROUBLE JUDGMENT
Check Condition
2 seconds later after the ignition switch has been
in "ON" position or the engine has started up.
The battery voltage is 8 V or more.
Judgment Criterion
The sensor output voltage is 4.5 V or more (Barometric pressure of above 114 kPa or equivalent)
for 2 seconds.
Or
The sensor output voltage is 0.2 V or less (Barometric pressure of below 53kpa or equivalent) for
2 seconds.
13A-25
TROUBLESHOOTING
PROBABLE CAUSE
Failed barometric pressure sensor
Open/short circuit in barometric pressure sensor
circuit or loose connector contact
Failed engine-ECU

connector.
Connector: B-08
DIAGNOSIS PROCEDURE
a. Item 25: Barometric pressure sensor
00 - How to Use
300).
NO : Go to Step 2 .
connector
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 4 .
Connector: B-08

connector.
CONNECTOR: C-137
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 6 .
13A-26
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300254 AB
AK300253 AB


connector.
Check power supply line for open
circuit.
NO : Repair.
13A-27
TROUBLESHOOTING


connector.
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-137
AK300253 AB

side.
OK: 2 W or less
C-137

connector
CONNECTOR: C-135
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Check power supply line for short circuit.

NO : Repair.

a. Item No. 25: Barometric pressure sensor
00 - How to Use
300).
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-28
TROUBLESHOOTING


connector.
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

Check earthing line for open circuit or damage.
NO : Repair.
AK300253 AB
Use special tool test harness (MB991709) to connect only terminal No. 1, No. 2 and No. 5, and
then measure at pick-up harness.
Ignition switch: ON
OK: 4.9 - 5.1 V

TROUBLESHOOTING

connector
CONNECTOR: C-137
13A-29

connector.
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-08
Ignition switch: ON
OK: 0.5 V or less
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB


connector.
NO : Repair.
AK300253 AB
13A-30
TROUBLESHOOTING

connector
CONNECTOR: C-135

connector.
Connector: B-08
B-08 (B)
C-135
7 6 5 4 3 2 1

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
Connector: B-08
AK300253 AB
Ignition switch: ON
OK:
Altitude 0m: 3.8 - 4.2 V
Altitude 600m: 3.5 - 3.9 V
Altitude 1,200m: 3.3 - 3.7 V
Altitude 1,800m: 3.0 - 3.4 V
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB


NO : Repair.

connector
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-31
TROUBLESHOOTING


connector.
CONNECTOR: C-137
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK:
Altitude 0m: 3.8 - 4.2 V
Altitude 600m: 3.5 - 3.9 V
Altitude 1,200m: 3.3 - 3.7 V
Altitude 1,800m: 3.0 - 3.4 V
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Check output line for short circuit and damage.

YES : Replace air flow sensor.
NO : Repair.

13A-32
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300254 AB
AK300253 AB


connector.
Check output line for open circuit and
damage.
NO : Repair.
13A-33
TROUBLESHOOTING
Code No. P0110: Intake Air Temperature Sensor System
Intake air temperature sensor circuit
B-08
(Incorporated in air flow sensor)
1 2 3 4 5 6 7
B-W
20
J/C (1)
C-16
Y-L
17
B-W
72
40
C-137
C-135
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
5V
Engine-ECU
Wire colour code

AK300259 AB
OPERATION
A power voltage of 5 V is applied to the intake air
temperature sensor output terminal (terminal No.
6) of the air flow sensor connector from the
engine-ECU (terminal No. 72)
The power voltage is earthed to the engine-ECU
(terminal No. 40) from the air flow sensor (terminal No. 5).
FUNCTION
The intake air temperature sensor converts the
intake air temperature into a voltage and inputs
the voltage signal to the engine-ECU.
In response to the signal, the engine-ECU corrects the fuel injection amount, etc.
The intake air temperature sensor is a kind of
resistor, which has characteristics to reduce its
resistance as the intake air temperature rises.
Therefore, the sensor output voltage varies with
the intake air temperature, and becomes lower as
the intake air temperature rises.
TROUBLE JUDGMENT
Check Condition
in "ON" position or the engine has started up.
Judgment Criterion
The sensor output voltage is 4.6 V or more
(intake air temperature of below -45C or equivalent) for 2 seconds.
Or
The sensor output voltage is 0.2 V or loss (intake
air temperature above 125C or equivalent) for 2
seconds.
PROBABLE CAUSE
Failed intake air temperature sensor
Open/short circuit in intake air temperature sensor circuit or loose connector contact
Failed engine-ECU
13A-34
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector.

a. Item 13: Intake air temperature sensor
OK: At ambient temperature (atmospheric
temperature) or equivalent.
00 - How to Use
300).
NO : Go to Step 2 .
connector
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

side.
OK: 2 W or less
NO : Go to Step 5 .
Connector: B-08

connector
B-08 (B)
CONNECTOR: C-135
7 6 5 4 3 2 1
AK300253 AB

NO : Repair.
C-135
STEP 3. Check intake air temperature sensor

itself.
Check intake air temperature sensor itself (Refer
to 313A).
NO : Replace air flow sensor.
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.

TROUBLESHOOTING

Connector: B-08
13A-35

OK: At ambient temperature (atmospheric
temperature) or equivalent.
00 - How to Use
300).
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-135

connector.
Connector: B-08
C-135
B-08 (B)
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
AK300253 AB

side.
Ignition switch: ON
OK: 4.5 - 4.9 V
NO : Go to Step 9 .
13A-36
TROUBLESHOOTING

connector.
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK300253 AB

Disconnect B-08 air flow sensor connector.
Ignition switch: ON
OK: 4.5 - 4.9 V

AK300254 AB
AK300253 AB


connector.
NO : Repair.
13A-37
TROUBLESHOOTING

connector
CONNECTOR: C-137

Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300253 AB
CONNECTOR: C-137

AK300254 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-38
TROUBLESHOOTING

connector.
Connector: B-08

Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Use special tool test harness (MB991709) to connect only terminal No. 5 and No. 6, and then
measure at pick-up harness.
Ignition switch: ON
OK:
Ambient temperature at -20C: 3.8 - 4.4 V
Ambient temperature at 0C: 3.2 - 3.8 V
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

connector
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

NO : Repair.

TROUBLESHOOTING

connector
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

YES : Check intermediate connector C-16 and

NO : Repair.
13A-39
13A-40
TROUBLESHOOTING
Code No. P0115: Engine Coolant Temperature Sensor System
Engine coolant temperature sensor circuit
B-108
(MU802406)
1 2
BR
Y-G
92
83
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
5V
Wire colour code

AK300260 AB
OPERATION
A power voltage of 5 V is applied to the engine
coolant temperature sensor output terminal (terminal No. 1) from the engine-ECU (terminal No.
83).
(terminal No. 92) from the engine coolant temperature sensor (terminal No. 2).
FUNCTION
The engine coolant temperature sensor converts
the engine coolant temperature into a voltage signal, and inputs the voltage to the engine-ECU.
In response to the signal, the engine-ECU controls the fuel infection amount and the fast idle
speed when the engine is cold state.
The engine coolant temperature sensor is a kind

of resistor, which has characteristics to reduce its
resistance as the engine coolant temperature
rises. Therefore, the sensor output voltage varies
with the engine coolant temperature, and
becomes lower as the engine coolant temperature rises.
TROUBLE JUDGMENT
Check Condition
in "ON" position or just after the engine has
started up.
Judgment Criterion
The sensor output voltage is 4.6 V or more (water
temperature of below -45C or equivalent) for 2
seconds.
Or
The sensor output voltage of 0.1 V or less (water
temperature of above 140C or equivalent) for 2
seconds.
13A-41
TROUBLESHOOTING
Check Condition
After the engine has started up.
STEP 3. Measure resistance at B-108 engine

coolant temperature sensor connector.
Judging Conditions
The sensor output voltage rises 1.6 V or more
(engine coolant temperature below 40C or
equivalent) from 1.6 V or less (engine coolant
temperature above 40C or equivalent).
Connector: B-108
2 1
Harness side
connector
PROBABLE CAUSE
Failed engine coolant temperature sensor
Open/short circuit in engine coolant temperature
sensor circuit or loose connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
a. Item 21: Engine coolant temperature sensor
OK:
Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
Engine hot state: At 80 - 120C
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-108 engine coolant
temperature sensor connector
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

NO : Repair.
B-108 (B)
AK300261 AB
Disconnect connector, and measure at sensor

side.
Resistance between terminal No. 1 and No. 2.
OK:
Engine coolant temperature at -20C: 14 - 17
kW
Engine coolant temperature at 0C: 5.1 - 6.5
kW
kW
kW
Engine coolant temperature at 60C: 0.48 0.68 kW
Engine coolant temperature at 80C: 0.26 0.36 kW
NO : Replace engine coolant temperature
sensor.
13A-42
TROUBLESHOOTING
STEP 4. Measure voltage at B-108 engine coolant

temperature sensor connector.
Connector: B-108

connector.
CONNECTOR: C-137
2 1
Harness side
connector
B-108 (B)
C-137
AK300261 AB

side.
Ignition switch: ON
OK: 4.5 - 4.9 V
NO : Go to Step 5 .
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

Disconnect B-108 engine coolant temperature
sensor.
Ignition switch: ON
OK: 4.5 - 4.9 V
NO : Go to Step 7 .
13A-43
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

(terminal No. 1) engine coolant temperature

sensor connector and C-137 (terminal No.
83) engine-ECU connector.
NO : Repair.
AK300254 AB

NO : Repair.
13A-44
TROUBLESHOOTING

No. 1) engine coolant temperature sensor
connector and C-137 (terminal No. 83) engineECU connector.
STEP 10. Measure voltage at B-108 engine

Connector: B-108
2 1
Connector: B-108
Harness side
connector
2 1
Harness side
connector
B-108 (B)
AK300261 AB
B-108 (B)
AK300261 AB
CONNECTOR: C-137
Disconnect connector and measure at harness

side.
OK: 2 W or less

connector
C-137

CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

OK:
Engine hot state: At 80 - 120 C
00 - How to Use
300).
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
NO : Repair.
13A-45
TROUBLESHOOTING

STEP 13. Measure voltage at B-108 engine

Connector: B-108
2 1
Connector: B-108
Harness side
connector
2 1
Harness side
connector
B-108 (B)
AK300261 AB
B-108 (B)
AK300261 AB
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Ignition switch: ON
OK:
Engine coolant temperature at -20C: 3.9 - 4.5
V
Engine coolant temperature at 0C: 3.2 - 3.8 V
V
V
V
V
13A-46
TROUBLESHOOTING

connector
CONNECTOR: C-137

Connector: B-108
2 1
Harness side
connector
C-137
B-108 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300261 AB
CONNECTOR: C-137
AK300254 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

TROUBLESHOOTING

connector
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

YES : Check harness between B-108 (terminal

connector and C-137 (terminal No. 92)
engine-ECU connector.
NO : Repair.
13A-47
13A-48
TROUBLESHOOTING
Code No. P0120: Throttle Position Sensor System

Throttle position sensor circuit
B-06
(MU802724)
1 2 3 4
Y-B
81
BR
84
92
C-137
Engine-ECU
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
Wire colour code

AK300262 AB
OPERATION
A power voltage of 5 V is applied to the throttle
position sensor (terminal No. 1) from the engineECU (terminal No. 81).
(terminal No. 92) from the throttle position sensor
(terminal No. 4).
(terminal No. 84) from the throttle position sensor
output terminal (terminal No. 2).
FUNCTION
The throttle position sensor converts the opening
of the throttle valve into a voltage and inputs the
voltage signal to the engine-ECU.
In response to the signal, the engine-ECU checks
the opening of the throttle valve.
TROUBLE JUDGMENT
Check Condition
Ignition switch: ON
Or
Excluding 2 seconds after the ignition switch has
been in "ON" position or just after the engine has
started up.
Judgment Criteria
The sensor output voltage is 0.2 V or less for 2
seconds.
Or
When the engine speed is 1,000 r/min or less and
the charging efficiency is 40% or less, the throttle
position sensor output voltage is 4.4 V or more for
2 seconds.
13A-49
TROUBLESHOOTING
PROBABLE CAUSE
Failed throttle position sensor
Open/short circuit in throttle position sensor circuit or loose connector contact
Failed engine-ECU
STEP 4. Measure voltage at B-06 throttle position

sensor connector.
Connector: B-06
B-06 (B)
DIAGNOSIS PROCEDURE
a. Item 14: Throttle position sensor
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-06 throttle position
sensor connector
4 3 2 1
AK300263 AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 5 .
Connector: B-06
B-06 (B)

connector.
CONNECTOR: C-137
4 3 2 1
AK300263 AB

NO : Repair.
STEP 3. Check throttle position sensor itself.

Check throttle position sensor itself (Refer to
313A).
NO : Replace throttle position sensor.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 7 .
13A-50
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-06
B-06 (B)
4 3 2 1
AK300254 AB
AK300263 AB

(terminal No. 1) throttle position sensor

circuit.
NO : Repair.
13A-51
TROUBLESHOOTING

No. 1) throttle position sensor connector and C137 (terminal No. 81) engine-ECU connector.
STEP 10. Measure resistance at B-06 throttle

position sensor connector.
Connector: B-06
Connector: B-06
B-06 (B)
B-06 (B)
4 3 2 1
4 3 2 1
AK300263 AB
CONNECTOR: C-137
AK300263 AB

side.
OK: 2 W or less
C-137

connector
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Check power supply line for short circuit.

NO : Repair.

00 - How to Use
300).
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-52
TROUBLESHOOTING

No. 4) throttle position sensor connector and C137 (terminal No. 92) engine-ECU connector.
STEP 13. Measure voltage at B-06 throttle

Connector: B-06
Connector: B-06
B-06 (B)
B-06 (B)
4 3 2 1
4 3 2 1
AK300263 AB
CONNECTOR: C-137
Ignition switch: ON
OK: 4.9 - 5.1 V
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
AK300263 AB
13A-53
TROUBLESHOOTING

connector
CONNECTOR: C-137

Connector: B-06
B-06 (B)
C-137
4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-06
4 3 2 1
Ignition switch: ON
OK: 0.5 V or less
B-06 (B)
AK300263 AB


NO : Repair.
AK300263 AB
13A-54
TROUBLESHOOTING

connector
CONNECTOR: C-137

Connector: B-06
B-06 (B)
C-137
4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-06
B-06 (B)
AK300263 AB
Ignition switch: ON
OK:
Accelerator pedal fully released: 0.535 - 0.735
V
Accelerator pedal fully depressed: 4.5 - 5.0 V
4 3 2 1
AK300263 AB


NO : Repair.
STEP 18. Adjust throttle position sensor

Adjust throttle position sensor (Refer to 313A
).
Q: Is the adjusted value normal?
NO : Adjust throttle position sensor.
13A-55
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK:
Accelerator pedal fully released: 0.535 - 0.735
V
Accelerator pedal fully depressed: 4.5 - 5.0 V
Connector: B-06
B-06 (B)
4 3 2 1
AK300254 AB
AK300263 AB


Check output line for short circuit and
damage.
NO : Repair.

13A-56
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-06
B-06 (B)
4 3 2 1
AK300254 AB
AK300263 AB


damage.
NO : Repair.
Code No. P0125: Feedback system monitor

OPERATION
Refer to P0201 injector circuit 313A.
Refer to P0130 Oxygen sensor (front) circuit
313A.
FUNCTION
The engine-ECU effects air-fuel ratio feedback
control in accordance with the signals from the
heater oxygen sensor (front).
If the heated oxygen sensor (front) has deteriorated, corrections will be made by the heated oxygen sensor (rear).
diagnosis code P0125 becomes stored in memory if a failure is detected in the above air/fuel
ratio feedback control system.
TROUBLE JUDGMENT
Check Conditions
The engine coolant temperature approximately.
82C or more.
13A-57
TROUBLESHOOTING
Within the range of air-fuel ratio feedback operation.

Not in low speed operation.
Judgment Criteria
The oxygen sensor output voltage is not deviated
from 0.5 V for 30 seconds.
PROBABLE CAUSE
Failed oxygen sensor (front)
Harness damage in oxygen sensor (front) circuit
or loose connector contact
Failed oxygen sensor (rear)
NOTE: When the oxygen sensor (front) begins to
deteriorate, the oxygen sensor output voltage will
deviate from the voltage when the sensor was new
(normally 0.5 volt at stoichiometric ratio). This deviation will be corrected by the oxygen sensor (rear).If
the oxygen sensor (rear) responds poorly because it
has deteriorated, it will improperly correct the oxygen
sensor (front). Thus, even when closed loop control
is being effected, the fluctuation of the oxygen sensor (front) output voltage decreases, without intersecting with 0.5 volt. As a result, there is a possibility
of diagnosis code P0125 becoming registered.
Failed fuel system
Failed exhaust system
Failed engine-ECU
STEP 3.Check for intake of air from intake hose

and inlet manifold.
NO : Repair.
STEP 4.Check for leakage of exhaust emission

from exhaust manifold.
NO : Repair.
STEP 5.Check throttle body (throttle valve

portion) for contamination.
NO : Clean throttle body (throttle valve portion)
(Refer to 313A).
STEP 6. Connector check: B-112 oxygen sensor
(front) connector, C-137 engine-ECU connector
Connector: B-112
B-112 (B)
DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Is any other diagnosis code than P0170 output?
YES : Inspection chart for diagnosis code (Refer
to 313A).
NO : Go to Step 2 .
2 1
4 3
CONNECTOR: C-137
STEP 2.MUT-II data list

b. Item 21: Engine coolant temperature sensor
c. Item 25: Barometric pressure sensor
d. Item 69: Oxygen sensor (rear)
Q: Are the check results normal?
NO : Perform the diagnosis code classified check
procedure for the sensor that has shown an

abnormal data valve (Refer to Inspection
Chart for Diagnosis Codes 313A).
AK300264 AB
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-58
TROUBLESHOOTING
STEP 7. Check oxygen sensor (front) itself.

Check oxygen sensor (front) itself (Refer to
313A).
STEP 9. Connector check: Injector connector

Connector: B-01, B-02, B-04, B-05

NO : Replace oxygen sensor (front).
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
STEP 8. Check harness between B-112 oxygen

sensor (front) connector and C-137 engine-ECU
connector.
Connector: B-112
B-112 (B)
2 1
a.
b.
c.
d.
AK300265 AB
B-01 (No.1 injector connector)


NO : Repair.
2 1
4 3
AK300264 AB
CONNECTOR: C-137
STEP 10. Check injector itself.

Check Injector itself (Refer to 313A).
NO : Replace injector.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-59
TROUBLESHOOTING

relay connector and B-134 engine-ECU
connector.
CONNECTOR: B-17X
Relay boxs
triangle marks
STEP 12. Check harness between B-17X engine

control relay connector and injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
B-17X
Harness side
connector
Harness side
connector
AK300255 AB
AK300255 AB
Connector: B-01, B-02, B-04, B-05

CONNECTOR: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
2 1
AK300265 AB
a. Check harness between B-17X (terminal No. 1)

engine control relay connector and B-01 (terminal
No. 1) No. 1 injector connector.
b. Check harness between B-17X (terminal No. 1)
c. Check harness between B-17X (terminal No. 1)
d. Check harness between B-17X (terminal No. 1)
NO : Repair
13A-60
TROUBLESHOOTING
STEP 13. Check harness between injector

connector and C-134 engine-ECU connector.

YES : Repair.
NO : Replace engine-ECU
Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
2 1
AK300265 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
a. Check harness between B-01 (terminal No. 2)

No. 1injector connector and C-134 (terminal No.
b. Check harness between B-02 (terminal No. 2)
No. 2 injector connector and C-134 (terminal No.
c. Check harness between B-04 (terminal No. 2)
d. Check harness between B-05 (terminal No. 2)
NO : Repair
STEP 14. Measure fuel pressure.

Measure fuel pressure (Refer to 313A).
13A-61
TROUBLESHOOTING
Code No. P0130: Oxygen Sensor (Front) System <sensor 1>
Oxygen sensor (front) circuit
B-112
(MU802605)
1 2
3 4
From Engine control relay
To engine-ECU
B
2
B
W
92
J/C (2)
C-17
76
B
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code

AK300266 AB
OPERATION
(terminal No. 76) from the oxygen sensor output
terminal (terminal No. 4).
The oxygen sensor (terminal No. 2) is earthed
with engine-ECU (terminal No. 92).
FUNCTION
The oxygen sensor converts the concentration of
oxygen in the exhaust emission into a voltage
and inputs the signal to the engine-ECU.
When the air-fuel ratio is richer than the theoretical air-fuel ratio, the oxygen sensor outputs a voltage of about 1 V. When it is leaner than the
theoretical air-fuel ratio, it outputs a voltage of
about 0 V.
In response to the signal, the engine-ECU controls the fuel infection amount so that the air-fuel
ratio can be equivalent to the theoretical air-fuel
ratio.
TROUBLE JUDGMENT
Check Condition
Above 3 minutes later after the engine has
started up.
The engine coolant temperature approximately
82C or more.
The engine speed is 1,200 r/min or more.
The volumetric efficiency 25% or more.
The monitoring time is 5 seconds.
Judgment Criteria
When the oxygen sensor (front) output voltage is
0.2 V or less and a power voltage of 5 V is
applied to the oxygen sensor (front) in the
engine-ECU, the sensor output voltage is 4.5 V or
more.
Check Condition
The engine speed is 3,000 r/min or less.
During the air-fuel ratio feedback control
13A-62
TROUBLESHOOTING
Judgment Criteria
When the oxygen sensor (front) output frequency
is 6 or less for 10 seconds on the average.
STEP 3. Measure voltage at B-112 oxygen sensor

(front) connector.
Connector: B-112
PROBABLE CAUSE
Failed oxygen sensor
Open/short circuit in oxygen sensor (front) circuit
Failed engine-ECU

B-112 (B)
2 1
4 3
DIAGNOSIS PROCEDURE
a. Item 11: Oxygen sensor (front)
00 - How to Use
300).
NO : Go to Step 2 .
(front) connector
AK300264 AB

side.
OK: 2 W or less
NO : Go to Step 4 .

connector
CONNECTOR: C-137
Connector: B-112
B-112 (B)
C-137
2 1
4 3

NO : Repair.
AK300264 AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-63
TROUBLESHOOTING

No. 2) oxygen sensor (front) connector and C-137
Connector: B-112
B-112 (B)
2 1
4 3

00 - How to Use
300).
STEP 7. Measure at B-112 oxygen sensor (front)
connector.
AK300264 AB
Connector: B-112
CONNECTOR: C-137

B-112 (B)
2 1
4 3
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
AK300264 AB
Use special tool test harness (MD998464) to connect connector, and measure at pick-up harness.
Engine: After warm-up
Ignition switch: ON
OK: 0.5 V or less
NO : Go to Step 8 .
13A-64
TROUBLESHOOTING

connector
CONNECTOR: C-137

(front) connector.
Connector: B-112
B-112 (B)
2 1
4 3
C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB

(terminal No. 2) oxygen sensor (front)

NO : Repair.
AK300264 AB
Use special tool test harness (MD998464) to connect connector, and measure at pick-up harness.
OK:
600 - 1,000 mV when 200 mV or lower abrupt
racing is done a few seconds after abrupt
deceleration from 4,000 r/min.
STEP 10. Check oxygen sensor itself

Check oxygen sensor (front) itself (Refer to
313A).
NO : Replace oxygen (front) sensor.
13A-65
TROUBLESHOOTING

connector

connector.
CONNECTOR: C-137
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB


NO : Repair.
AK300254 AB

OK:

13A-66
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB


NO : Repair.
AK300254 AB

NO : Repair.
13A-67
TROUBLESHOOTING
Code No. P0135: Oxygen Sensor Heater (Front) System <Sensor 1>
Oxygen sensor (front) heater circuit
Battery
W-B
W-B
B-17X

B-112
(MU8026053)
Engine
control
relay
1
1 2
3 4
2
1
To engine-ECU
Y-R
60
C-136
51 52 53 54 55 56
57 58 59 60 61 62
Engine-ECU
Wire colour code

AK300267 AB
OPERATION
Power is supplied to the heater power terminal
(terminal No. 1) of the oxygen sensor (front) connector from the engine control relay (terminal No.
1).
The heater (terminal No. 3) of the oxygen sensor
(front) connector is controlled by the power transistor in the engine-ECU (terminal No. 60).
FUNCTION
The power supply to the oxygen sensor heater
(front) is controlled by the ON/OFF control of the
power transistor in the engine-ECU.
Heating the oxygen sensor heater (front) enables
the oxygen sensor to provide good response
even when the exhaust emission temperature is
low.
13A-68
TROUBLESHOOTING
TROUBLE JUDGMENT
Check Conditions
The engine coolant temperature is approximately.
20C or higher.
The oxygen sensor heater (front) is in "ON" position.
The engine speed is 50 r/min or more.
The battery voltage is 11 - 16 V.
Judgment Criteria
The heater current of oxygen sensor heater
(front) is below 0.2 A or above 3.5 A for 1 second.
PROBABLE CAUSE
Failed oxygen sensor heater
Open/short circuit in oxygen sensor (front) circuit
Failed engine-ECU
STEP 2. Measure resistance at B-112 oxygen

sensor (front) connector.
Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB

side.
OK: 4.5 - 8.0 W
NO : Replace oxygen sensor (front).
DIAGNOSIS PROCEDURE
(front) connector

(front) connector.
Connector: B-112
Connector: B-112
B-112 (B)
B-112 (B)
2 1
4 3

NO : Repair.
AK300264 AB
2 1
4 3
AK300264 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13A-69
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
CONNECTOR: C-136
B-17X
Relay boxs
triangle marks

connector.
C-136
Harness side
connector
AK300255 AB
56 55 54 53 52 51
62 61 60 59 58 57
Connector: B-112
B-112 (B)

Ignition switch: ON
OK: System voltage
2 1
4 3
AK300268 AB
AK300264 AB

(terminal No. 1) oxygen sensor connector

and B-17X (terminal No. 1) engine control
relay connector.
open/short circuit.
NO : Repair.

NO : Go to Step 6 .

connector
CONNECTOR: C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.
13A-70
TROUBLESHOOTING


connector
CONNECTOR: C-136
Connector: B-112
B-112 (B)
C-136
2 1
4 3
AK300264 AB
56 55 54 53 52 51
62 61 60 59 58 57
CONNECTOR: C-136

AK300268 AB

NO : Repair.
C-136

No. 1) oxygen sensor (front) connector and B17X (terminal No. 1) engine control relay
connector.
56 55 54 53 52 51
62 61 60 59 58 57
Connector: B-112
AK300268 AB
Check earthing line for open/short circuit.
B-112 (B)

YES : Replace engine-ECU.
NO : Repair.
2 1
4 3
AK300264 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB

NO : Repair.

TROUBLESHOOTING

Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB
CONNECTOR: C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.
13A-71
STEP 11. Check the trouble symptoms.

Q: Does trouble symptom persist?
NO : Intermittent malfunction (Refer to GROUP
00 - How to Use
300).
13A-72
TROUBLESHOOTING
Code No. P0136: Oxygen Sensor (Rear) System <Sensor 2>
Oxygen sensor (rear) circuit
C-18
(MU801688)
1 2
3 4
From engine control relay
To engine-ECU
J/C (2)
C-17
92
75
B
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code

AK300269 AB
OPERATION
(terminal No. 75) from the oxygen sensor (rear)
The oxygen sensor (rear) (terminal No. 3) is
earthed with engine-ECU (terminal No. 92).
FUNCTION
The oxygen sensor (rear) converts the concentration of oxygen in the exhaust emission into a voltage signal and inputs the voltage signal to the
engine-ECU.
When the air-fuel ratio is richer than the theoretical air-fuel ratio, the oxygen sensor (rear) outputs
a voltage of about 1 V. When it is leaner than the
theoretical air-fuel ratio, it outputs a voltage of
about 0 V.
In response to the signal, the engine-ECU controls the fuel infection amount so that the air-fuel
ratio can be equivalent to the theoretical air-fuel
ratio.
TROUBLE JUDGMENT
Check Conditions
Above 3 minutes later after the engine has
started up.
82C or higher.
The engine speed is 1,200 r/min or more.
The volumetric efficiency is 25% or more.
The monitoring time is 5 seconds.
Judgment Criteria
When the oxygen sensor (rear) output voltage is
0.2 V or less and a power voltage of 5 V is
applied to the oxygen sensor (rear) in the engineECU, the sensor output voltage is 4.5 V or more.
PROBABLE CAUSE
Failed oxygen sensor
Open/short circuit in oxygen sensor (rear) circuit
Failed engine-ECU
13A-73
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 3. Measure voltage at C-18 oxygen sensor

(rear) connector.

a. Item 59: Oxygen sensor (rear)
Connector: C-18
1 2
3 4

00 - How to Use
300).
NO : Go to Step 2 .
Harness side
connector
C-18
STEP 2. Connector check: C-18 oxygen sensor

(rear) connector
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB

side.
OK: 2 W or less
NO : Go to Step 4 .

connector
AK300270 AB
CONNECTOR: C-137

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-74
TROUBLESHOOTING
STEP 5. Check harness between C-18 (terminal

No. 3) oxygen sensor (rear) connector and C-137

a. Item 59: Oxygen sensor (rear)
Connector: C-18
1 2
3 4
Harness side
connector
00 - How to Use
300).
C-18

(rear) connector.
Connector: C-18
1 2
3 4
Harness side
connector
AK300270 AB
C-18
CONNECTOR: C-137
C-137
AK300270 AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Ignition switch: ON
OK: 0.5 V or less
NO : Go to Step 8 .
13A-75
TROUBLESHOOTING

connector
CONNECTOR: C-137

(rear) connector.
Connector: C-18
1 2
3 4
Harness side
connector
C-18
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB

YES : Check and repair harness between C-18

connector.
NO : Repair.
AK300270 AB
OK:
STEP 10. Check oxygen sensor (rear) itself.

Check oxygen sensor (rear) itself (Refer to
313A).
NO : Replace oxygen (rear) sensor.
13A-76
TROUBLESHOOTING

connector

connector.
CONNECTOR: C-137
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB


connector.
NO : Repair.
AK300254 AB

OK:

13A-77
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB

(terminal No. 4) oxygen sensor (rear)

NO : Repair.
AK300254 AB

NO : Repair.
13A-78
TROUBLESHOOTING
Code No. P0141: Oxygen Sensor Heater (Rear) System <Sensor 2>
Oxygen sensor (rear) heater circuit
Battery
W-B
W-B
B-17X

C-18
(MU801688)
Engine
control
relay
1
1 2
3 4
2
2
R
To engine-ECU
2
J/C (2)
C-17
Y-R
54
C-136
51 52 53 54 55 56
57 58 59 60 61 62
Engine-ECU
Wire colour code
AK300271 AB
OPERATION
Power is supplied to the heater power terminal
(terminal No. 2) of the oxygen sensor (rear) connector from the engine control relay (terminal No.
1).
The heater (terminal No. 1) of the oxygen sensor
(rear) connector is controlled by the power transistor in the engine-ECU (terminal No. 54).
FUNCTION
The power supply to the oxygen sensor heater
(rear) is controlled by the ON/OFF control of the
power transistor in the engine-ECU.
Heating the oxygen sensor heater (rear) enables
the oxygen sensor to provide good response
even when the exhaust emission temperature is
low.
13A-79
TROUBLESHOOTING
TROUBLE JUDGMENT
Judgment Criteria
20 C or higher.
The oxygen sensor heater (rear) is in "ON" position.
The engine speed is 50 r/min or more.
Judgment Criteria
The heater current of front oxygen sensor heater
(rear) is below 0.2 A or above 3.5 A for 1 second.
STEP 2. Measure resistance at C-18 oxygen

sensor (rear) connector.
Connector: C-18
1 2
3 4
Harness side
connector
C-18
PROBABLE CAUSE
Failed oxygen sensor heater (rear)
Open/short circuit in oxygen sensor (rear) circuit
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-18 oxygen sensor
(rear) connector
Connector: C-18
1 2
3 4
Harness side
connector
AK300270 AB

side.
OK: 11 - 18 W
NO : Replace oxygen (rear) sensor.

(rear) connector.
Connector: C-18
C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB

NO : Repair.
AK300270 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13A-80
TROUBLESHOOTING

relay connector
CONNECTOR: C-137

connector.
CONNECTOR: C-136
C-136
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
56 55 54 53 52 51
62 61 60 59 58 57

AK300254 AB
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300268 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 6 .

connector
CONNECTOR: C-136
AK300270 AB


harness between C-18 (terminal No. 2)
oxygen sensor (rear) connector and B-17X
(terminal No. 1) engine control relay
connector.
open/short circuit.
NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.
13A-81
TROUBLESHOOTING

No. 1) oxygen sensor connector and C-136

connector
CONNECTOR: C-136
Connector: C-18
1 2
3 4
Harness side
connector
C-136
C-18

56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB
AK300270 AB
CONNECTOR: C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.

NO : Repair.
13A-82
TROUBLESHOOTING

No. 2) oxygen sensor connector and B-17X
Connector: C-18

No. 1) oxygen sensor connector and C-136
Connector: C-18
1 2
3 4
1 2
3 4
Harness side
connector
C-18
Harness side
connector
C-18
AK300270 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
AK300270 AB
CONNECTOR: C-136
B-17X
Harness side
connector
C-136
AK300255 AB

NO : Repair.
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.

00 - How to Use
300).

TROUBLESHOOTING
13A-83
Code No. P0170: Abnormal Fuel System

OPERATION
FUNCTION
If the fuel system goes out of order, the fuel correction value will become larger.
The engine-ECU checks whether the fuel correction value is within the standard limits.
TROUBLE JUDGMENT
Check Conditions
In learning air-fuel ratio
Judgment Criteria
The compensation value of fuel injection amount
is too low for 2 seconds or more.
Or
The compensation value of fuel injection amount
is too high for 2 seconds or more.
PROBABLE CAUSE
Failed fuel supply system
Failed intake air temperature sensor
Failed purge control solenoid valve
Failed engine-ECU
DIAGNOSIS PROCEDURE
Q: Is any other diagnosis code than P0170 output?
to 313A).
NO : Go to Step 2 .

b. Item 13: Intake air temperature sensor
c. Item 21: Engine coolant temperature sensor
d. Item 22: Barometric pressure sensor

abnormal data value (Refer to Inspection
STEP 3. Check for intake of air from intake hose
and inlet manifold.
NO : Repair.
STEP 4. Check for leakage of exhaust emission

NO : Repair.
STEP 5. Check throttle body (throttle valve

(Refer to 313A).
a. Item 11: Oxygen sensor (front).
NO : Check oxygen sensor (front) system (Refer
to313A, Code No. P0130).
13A-84
TROUBLESHOOTING
STEP 7. Connector Check: Injector connector

Connector: B-01, B-02, B-04, B-05

connector
CONNECTOR: B-17X
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
2 1
a.
b.
c.
d.
AK300265 AB
B-01 (No.1 injector connector).

Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
CONNECTOR: C-134

NO : Replace.
STEP 8. Check injector itself.

C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Replace.
13A-85
TROUBLESHOOTING

Connector: B-01, B-02, B-04, B-05
Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
AK300265 AB
CONNECTOR: B-17X
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
2 1
Relay boxs
triangle marks

2 1
AK300265 AB
CONNECTOR: C-134
B-17X
Harness side
connector
C-134
AK300255 AB

NO : Replace.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Replace.
STEP 12. Check purge control solenoid valve

itself.
Check purge control solenoid valve itself (Refer to
GROUP 17 - Emission Control System - Evaporative Emission Control System 317).
NO : Replace purge control solenoid valve.
13A-86

TROUBLESHOOTING

NO : Repair.
13A-87
TROUBLESHOOTING
Code No. P0201: No. 1 Injector System
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
R
R
Injector
No. 1
B-01
R
1
1 2
Injector
No. 2
Injector
No. 4
B-04
B-05
1 2
1 2
1 2
Y-R
Injector
No. 3
B-02
Y-G
14
15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300272 AB
13A-88

TROUBLESHOOTING
OPERATION
Power is supplied to the injector (terminal No. 1)
from the engine control relay (terminal No. 1).
The engine-ECU (terminal No. 1) makes the
power transistor in the unit be in "ON" position,
and that makes currents go on the injector (terminal No. 2).
FUNCTION
The engine-ECU controls the power supply interval of the injector.
The fuel injection amount of the injector depends
on the power supply interval.
TROUBLE JUDGMENT
Check Conditions
The engine speed is 50 - 1,000 r/min.
The throttle position sensor output voltage is 1.15
V or less.
Injector not in forced drive (actuator test) mode
Judgment Criterion
No surge voltage of the injector coil is detected
for 2 seconds.
PROBABLE CAUSE
Failed No. 1 injector
Open/short circuit in injector circuit or loose connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. MUT-II actuator test
Refer to Actuator test reference table list 313A
.
a. Item 01: No. 1 injector
OK: Idling state varies.
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-01 No. 1 injector

connector
Connector: B-01
B-01 (GR)
2 1
AK300265 AC

NO : Repair.
STEP 3. Measure resistance at B-01 No. 1 injector

connector.
Connector: B-01
B-01 (GR)
2 1
AK300265 AC
Disconnect connector, and measure at injector

side.
OK: 10.5 - 13.5 W
NO : Replace No. 1 injector.
13A-89
TROUBLESHOOTING
STEP 4. Measure voltage at B-01 No. 1 injector

connector.

relay connector
CONNECTOR: B-17X
Connector: B-01
Relay boxs
triangle marks
B-17X
B-01 (GR)
2
2 1
AK300265 AC

side.
Ignition switch: ON
OK: System voltage
Harness side
connector
AK300255 AB
Connector: B-01
B-01 (GR)

NO : Go to Step 5 .
2 1
AK300265 AC

YES : Check and repair harness between B-17X

connector and B-01 (terminal No. 1) No. 1
injector connector.
open/short circuit.
NO : Repair.
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

NO : Repair.
AK300255 AB
13A-90
TROUBLESHOOTING
STEP 7. Check harness between B-17X (terminal

No. 1) engine control relay connector and B-01
(terminal No. 1) No. 1 injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

No. 2) No.1 injector connector and C-134
Connector: B-01
B-17X
B-01 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AC
CONNECTOR: C-134
Connector: B-01
B-01 (GR)
C-134
2 1
AK300265 AC

NO : Repair.

AK300257 AB

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
Check output line for open/short circuit and damage.

NO : Repair.

TROUBLESHOOTING
STEP 10. Measure signal waveform at C-134

engine-ECU connector (Use oscilloscope).
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Engine: Idling
OK: Waveforms should be display on
Inspection procedure using an oscilloscope
(Refer to 313A).
00 - How to Use
300).
13A-91
13A-92
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
R
R
Injector
No. 1
B-01
R
1
1 2
Injector
No. 2
Injector
No. 4
B-04
B-05
1 2
1 2
1 2
Y-R
Injector
No. 3
B-02
Y-G
14
15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300272 AB
13A-93
TROUBLESHOOTING
OPERATION
FUNCTION
TROUBLE JUDGMENT
Check Conditions
The engine speed is 50 - 1,000 r/mim.
The throttle position sensor output voltage 1.15 V
or less.
Judgment Criteria
for 2 seconds.
PROBABLE CAUSE
Open/short circuit in No. 2 injector circuit or loose
connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
.
00 - How to Use
300).
NO : Go to Step 2 .

connector
Connector: B-02
B-02 (GR)
2 1
AK300265 AD

NO : Repair.
STEP 3. Measure at resistance B-02 No. 2 injector

connector.
Connector: B-02
B-02 (GR)
2 1
AK300265 AD

side.
OK: 10.5 - 13.5 W
13A-94
TROUBLESHOOTING

connector.

relay connector
CONNECTOR: B-17X
Connector: B-02
Relay boxs
triangle marks
B-17X
B-02 (GR)
2
2 1
AK300265 AD

side.
Ignition switch: ON
OK: System voltage
Harness side
connector
AK300255 AB
Connector: B-02
B-02 (GR)

NO : Go to Step 5 .
2 1
AK300265 AD


injector connector.
open/short circuit and damage.
NO : Repair.
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

NO : Repair.
AK300255 AB
13A-95
TROUBLESHOOTING

CONNECTOR: B-17X
Relay boxs
triangle marks

No. 2) No. 2 injector connector and C-134
Connector: B-02
B-17X
B-02 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AD
CONNECTOR: C-134
Connector: B-02
B-02 (GR)
C-134
2 1
AK300265 AD

NO : Repair.

AK300257 AB

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.
13A-96
TROUBLESHOOTING

CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Engine: Idling
OK: Waveform should be display on Inspection procedure using an oscilloscope (Refer
to 313A).
00 - How to Use
300).
13A-97
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
R
R
Injector
No. 1
B-01
R
1
1 2
Injector
No. 2
Injector
No. 4
B-04
B-05
1 2
1 2
1 2
Y-R
Injector
No. 3
B-02
Y-G
14
15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300272 AB
13A-98

TROUBLESHOOTING
OPERATION
FUNCTION
TROUBLE JUDGMENT
Check Conditions
The throttle position sensor output voltage is 1.15
V or less.
Judgment Criteria
for 2 seconds.
PROBABLE CAUSE
connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
.
00 - How to Use
300).
NO : Go to Step 2 .

connector
Connector: B-04
B-04 (GR)
2 1
AK300265 AE

NO : Repair.

connector.
Connector: B-04
B-04 (GR)
2 1
AK300265 AE

side.
OK: 10.5 - 13.5 W
13A-99
TROUBLESHOOTING

connector.

relay connector
CONNECTOR: B-17X
Connector: B-04
Relay boxs
triangle marks
B-17X
B-04 (GR)
2
2 1
AK300265 AE

side.
Ignition switch: ON
OK: System voltage
Harness side
connector
AK300255 AB
Connector: B-04
B-04 (GR)

NO : Go to Step 5 .
2 1
AK300265 AE


injector connector.
open/short circuit.
NO : Repair.
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

NO : Repair.
AK300255 AB
13A-100
TROUBLESHOOTING

CONNECTOR: B-17X
Relay boxs
triangle marks

Connector: B-04
B-17X
B-04 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AE
CONNECTOR: C-134
Connector: B-04
B-04 (GR)
C-134
2 1
AK300265 AE

NO : Repair.

AK300257 AB

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

TROUBLESHOOTING

CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Engine: Idling
to 313A).
00 - How to Use
300).
13A-101
13A-102
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
R
R
Injector
No. 1
B-01
R
1
1 2
Injector
No. 2
Injector
No. 4
B-04
B-05
1 2
1 2
1 2
Y-R
Injector
No. 3
B-02
Y-G
14
15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300272 AB
13A-103
TROUBLESHOOTING
OPERATION
FUNCTION
TROUBLE JUDGMENT
Check Conditions
The throttle position sensor output 1.15 V or less.
Judgment Criterion
for 2 seconds
PROBABLE CAUSE
connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
.
00 - How to Use
300).
NO : Go to Step 2 .

connector
Connector: B-05
B-05 (GR)
2 1
AK300265 AF

NO : Repair.

connector.
Connector: B-05
B-05 (GR)
2 1
AK300265 AF

side.
OK: 10.5 - 13.5 W
13A-104
TROUBLESHOOTING

connector.

relay connector
CONNECTOR: B-17X
Connector: B-05
Relay boxs
triangle marks
B-17X
B-05 (GR)
2
2 1
AK300265 AF

side.
Ignition switch: ON
OK: System voltage
Harness side
connector
AK300255 AB
Connector: B-05
B-05 (GR)

NO : Go to Step 5 .
2 1
AK300265 AF


injector connector.
open/short circuit and damage.
NO : Repair.
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

YES : Go to Step 7.
NO : Repair.
AK300255 AB
13A-105
TROUBLESHOOTING

CONNECTOR: B-17X
Relay boxs
triangle marks

Connector: B-05
B-17X
B-05 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AF
CONNECTOR: C-134
Connector: B-05
B-05 (GR)
C-134
2 1
AK300265 AF

NO : Repair.

AK300257 AB

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.
13A-106
TROUBLESHOOTING

CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Engine: Idling
to 313A).
00 - How to Use
300).
Code No. P0300: Random cylinder mis-fire detected

OPERATION
FUNCTION
If a misfire occurs while the engine is running, the
engine speed changes for an instant.
The engine-ECU checks for such changes in
engine speed.
TROUBLE JUDGMENT
Check Conditions
5 seconds later after the engine has started up.
The engine coolant temperature is -10C or
higher.
The intake air temperature is -10C or higher.
The barometric pressure is 72 kPa or more.

The volumetric efficiency is 30 - 60%.
The adaptive learning has been completed with
the vane that generates the crankshaft position
signals.
During the engine operation except the shift
change or low speed driving and rapid acceleration and deceleration, also intermittent operation
of air compressor (A/C: within the 3 seconds after
changing to ON from OFF or to OFF from ON).
The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms.
Judgment Criteria
The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified
number (of 7.3 % on more than the two cylinders)
with the engine speed of 200 r/min.
Or
13A-107
TROUBLESHOOTING
The number of misfiring (that is 1.5 times the

emission standard limit) is beyond the specified
number (of 2 % on more than the two cylinders)
PROBABLE CAUSE
Ignition system related part(s) failed
Failed crank angle sensor
Incorrect air-fuel ratio
Low compression pressure
Failed coolant temperature sensor
Skipping of timing belt teeth.
EGR system and EGR valve failed
Failed engine-ECU
STEP 3.Check ignition coil spark.

Q: Is the check resuit normal?
NO : Check ignition circuit system (Refer to
Inspection procedure 29 313A).

STEP 4.Connector check: Injector connector
Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
DIAGNOSIS PROCEDURE
M

Item 22: Crank angle sensor
OK: Keep the engine speed constant to
make the pulse width of output waveform
constant.
NO : Check crank angle sensor system (Refer to
Code No. P0335 313A).

b. Item 81: Long-term fuel compensation
c. Item 82: Short-term fuel compensation

abnormal data valve (Refer to, Inspection
2 1
a.
b.
c.
d.
AK300265 AB


NO : Repair.
STEP 5.Check injector itself.

13A-108
TROUBLESHOOTING
STEP 6.Connector check: B-17X engine control

connector
CONNECTOR: B-17X
Relay boxs
triangle marks

CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
B-17X
Harness side
connector
Harness side
connector
AK300255 AB
AK300255 AB
Connector: B-01, B-02, B-04, B-05

CONNECTOR: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
2 1
AK300265 AB

NO : Repair.

TROUBLESHOOTING

Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
13A-109

Measure fuel pressure (Refer to fuel pressure
test 313A)
NO : Repair.
STEP 10. Check for intake of air from intake hose

and inlet manifold.
M
2 1
AK300265 AB

NO : Repair.
CONNECTOR: C-134
STEP 11. Check for skipped timing belt teeth.

NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
STEP 12. Exhaust gas recirculation system

check.
Exhaust gas recirculation system check [Refer to
GROUP 17 - Exhaust gas recirculation (EGR)
system 317].
YES : Replace engine-ECU
NO : Repair.
13A-110

TROUBLESHOOTING
Code No. P0301: No. 1 cylinder mis-fire detection system

OPERATION
FUNCTION
engine speed.
TROUBLE JUDGMENT
Check Conditions
higher.
The volumetric efficiency is 30 - 60 %.
signals.
Judgment Criterion
Or
with the engine speed of 1,000 r/min.
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE
NO : Check ignition Circuit System (Refer to
Inspection procedure 29 313A)

STEP 2.Connector check: B-01 No.1 injector
connector
Connector: B-01
B-01 (GR)
2 1
AK300265 AC

NO : Repair.
STEP 3.Check No.1 injector itself.

NO : Replace No.1 injector.
13A-111
TROUBLESHOOTING

connector
CONNECTOR: B-17X
Relay boxs
triangle marks
STEP 5.Check harness between B-17X (terminal

(terminal No. 1) No.1 injector connector.
CONNECTOR: B-17X
B-17X
Relay boxs
triangle marks
Harness side
connector
AK300255 AB
CONNECTOR: C-134
B-17X
Harness side
connector
AK300255 AB
Connector: B-01
B-01 (GR)
C-134
2 1
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
AK300265 AC

NO : Repair.
13A-112
TROUBLESHOOTING
STEP 6. Check harness between B-01(terminal

(terminal No. 1) engine-ECU connector

test 313A).
NO : Repair.
Connector: B-01
B-01 (GR)
2 1
AK300265 AC
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

OPERATION
FUNCTION
engine speed.
TROUBLE JUDGMENT
Check Conditions
higher.

The volumetric efficiency is 30 - 60 %.
signals.
13A-113
TROUBLESHOOTING
Judgment Criterion
Or
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE


connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
CONNECTOR: C-134

STEP 2.Check connector: B-02 No.2 injector
connector
Connector: B-02
C-134
B-02 (GR)
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

M
2 1

NO : Repair.
AK300257 AB
AK300265 AD

NO : Repair.
13A-114
TROUBLESHOOTING

No. 1) engine control relay connector and B02(terminal No. 1) No.2 injector connector.

CONNECTOR: B-17X
Relay boxs
triangle marks
Connector: B-02
B-17X
B-02 (GR)
3
M
Harness side
connector
2 1
AK300255 AB
AK300265 AD
CONNECTOR: C-134
Connector: B-02
B-02 (GR)
C-134
2 1
AK300265 AD
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

AK300257 AB

NO : Repair.

test 313A)
NO : Repair.

OPERATION
FUNCTION
engine speed.
TROUBLE JUDGMENT
Check Conditions
higher.
13A-115
TROUBLESHOOTING

signals.
Judgment Criterion
Or


relay connector, B-134 engine-ECU connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
CONNECTOR: C-134
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

connector
Connector: B-04
B-04 (GR)
2 1

NO : Repair.
AK300265 AE
AK300257 AB

NO : Repair.
13A-116
TROUBLESHOOTING


CONNECTOR: B-17X
Relay boxs
triangle marks
Connector: B-04
B-17X
B-04 (GR)
3
M
Harness side
connector
2 1
AK300255 AB
AK300265 AE
CONNECTOR: C-134
Connector: B-04
B-04 (GR)
C-134
2 1
AK300265 AE
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

AK300257 AB

NO : Repair.

test 313A)
NO : Repair.

OPERATION
FUNCTION
engine speed.
TROUBLE JUDGMENT
Check Conditions
higher.
13A-117
TROUBLESHOOTING

signals.
Judgment Criterion
Or


connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
CONNECTOR: C-134
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE
C-134
STEP 1.Check the ignition coil spark.

NO : Check ignition Circuit System (Refer to
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

connector
Connector: B-05
B-05 (GR)
2 1

NO : Repair.
AK300265 AF

NO : Repair.
13A-118
TROUBLESHOOTING

CONNECTOR: B-17X
Relay boxs
triangle marks

Connector: B-05
B-17X
B-05 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AF
CONNECTOR: C-134
Connector: B-05
B-05 (GR)
C-134
2 1
AK300265 AF

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

test 313A)
NO : Repair.
13A-119
TROUBLESHOOTING
Code No. P0325: Detonation Sensor System
Detonation sensor circuit
C-137
Engine-ECU
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
78
W
B-103
(MU802661)
B
2
1 2
Detonation sensor
Wire colour code

B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet
O: Orange GR: Gray
AK300273 AB
OPERATION
(terminal No. 78) from the detonation sensor (terminal No. 1).
FUNCTION
The detonation sensor detects the vibration of the
cylinder block caused by detonation waves, and
inputs a signal to the engine-ECU.
In response to the signal, the engine-ECU provides controls to retard the ignition timing when
the detonation occurs.
TROUBLE JUDGMENT
Check Condition
Judgment Criteria
The change amount of the detonation sensor output voltage (the detonation sensor peak voltage
in every one third a turn of the crankshaft) is
below 0.08 V in 200 consecutive times.
13A-120
TROUBLESHOOTING
PROBABLE CAUSE
Failed detonation sensor
Open/short circuit in detonation sensor circuit or
Failed engine-ECU
STEP 2. Measure resistance at B-103 detonation

sensor connector.
Connector: B-103
2 1
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-103 detonation
sensor connector
Harness side
connector
B-103 (GR)
Connector: B-103
2 1
Harness side
connector
B-103 (GR)
Detonation sensor
Alternator
AK300274 AB

side.
OK: 2 W or less
Detonation sensor
Alternator
AK300274 AB

NO : Repair.

NO : Check and repair harness between B-103
(terminal No. 2) detonation sensor

connector and body earth.
Check earthing line for open circuit
and damage.
13A-121
TROUBLESHOOTING

connector
CONNECTOR: C-137

No. 1) detonation sensor connector and C-137
(terminal No.78) engine-ECU connector.
Connector: B-103
2 1
Harness side
connector
B-103 (GR)
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Detonation sensor
Alternator
AK300274 AB
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

00 - How to Use
300).
13A-122

TROUBLESHOOTING
STEP 6. Replace detonation sensor.

After replacing the detonation sensor, re-check
the trouble symptoms.
NO : Check end.
13A-123
TROUBLESHOOTING
Code No. P0335: Crank Angle Sensor System

Crank angle sensor circuit
Battery
W-B
W-B
3
4
B-17X
1
R
B-29
(MU802603)
1 2
3
Crank angle sensor
1
B-W
18
J/C(1)
C-16
G-R
17
B-W
40
89
C-137
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
5V
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code
O: Orange GR: Gray
AK300275 AB
13A-124

TROUBLESHOOTING
OPERATION
Power is supplied to the crank angle sensor (terminal No. 3) from the engine control relay (terminal No. 1) and is earthed to the engine-ECU
(terminal No. 40) from the crank angle sensor
(terminal No. 1).
A power voltage of 5 V is applied to the crank
angle sensor output terminal (terminal No. 2)
from the engine-ECU (terminal No. 89).
FUNCTION
The crank angle sensor detects the crank angle
(position) and inputs a pulse signal to the engineECU.
In response to the signal, the engine-ECU controls the injector, etc.
DIAGNOSIS PROCEDURE
a. Item 22: Crank angle sensor
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-29 crank angle
sensor connector
Connector: B-29
TROUBLE JUDGMENT
Check Condition
Engine in cranking state.
Judgment Criterion
The sensor output voltage remains unchanged
(no pulse signal is inputted) for 2 seconds.
2 1
3
Harness side
connector
B-29 (B)
PROBABLE CAUSE
Open/short circuit in crank angle sensor circuit or
Failed engine-ECU
Crank angle sensor

AK300276 AB

NO : Repair.
13A-125
TROUBLESHOOTING
STEP 3. Measure voltage at B-29 crank angle

sensor connector.

connector.
Connector: B-29
CONNECTOR: C-137
2 1
3
Harness side
connector
B-29 (B)
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-29
2 1
3
Harness side
connector
Crank angle sensor

AK300276 AB
B-29 (B)

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 4 .
Crank angle sensor

AK300276 AB

Disconnect B-29 crank angle sensor connector.
Ignition switch: ON
OK: 4.9 - 5.1 V

NO : Go to Step 6 .
13A-126
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-29
2 1
3
Harness side
connector
AK300254 AB
B-29 (B)
Crank angle sensor

AK300276 AB

(terminal No. 2) crank angle sensor

NO : Repair.
13A-127
TROUBLESHOOTING

No. 2) crank angle sensor connector and C-137

Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
00 - How to Use
300).
STEP 9. Measure voltage at B-29 crank angle
sensor connector.
Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
Crank angle sensor

AK300276 AB
CONNECTOR: C-137
Crank angle sensor

C-137
AK300276 AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

side.
Ignition switch: ON
OK: System voltage
13A-128
TROUBLESHOOTING

relay connector
Connector: B-29
CONNECTOR: B-17X
Relay boxs
triangle marks
Harness side
connector
STEP 11. Measure resistance at B-29 crank angle

sensor connector.
B-17X
2 1
3
Harness side
connector
B-29 (B)
AK300255 AB
Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
Crank angle sensor

AK300276 AB

side.
OK: 2 W or less
Crank angle sensor
AK300276 AB


connector
CONNECTOR: C-135
(terminal No. 3) crank angle sensor

connector and B-17X (terminal No. 1)
engine control relay connector.
open/short circuit.
NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-129
TROUBLESHOOTING

STEP 14. Measure output waveform at B-29 crank

angle sensor connector (Use oscilloscope).
Connector: B-29
Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
2 1
3
Harness side
connector
B-29 (B)
Crank angle sensor

Crank angle sensor
AK300276 AB
AK300276 AB
CONNECTOR: C-135
C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
Engine: Idling
(Refer to 313A), its maximum value
should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in
waveform.
13A-130
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
Connector: B-29
B-17X
Harness side
connector

No. 3) crank angle sensor connector and B-17X
2 1
3
Harness side
connector
B-29 (B)
AK300255 AB

NO : Repair.
Crank angle sensor

AK300276 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB

NO : Repair.
13A-131
TROUBLESHOOTING
STEP 17. Connector check: C-135 and C-137

engine-ECU connectors
CONNECTOR: C-135, C-137

Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
C-135
C-137
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
C-135 Harness side connector
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300277 AB

NO : Repair.
Crank angle sensor

AK300276 AB
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-132
TROUBLESHOOTING

STEP 20. Check the crankshaft sensing blade.
Connector: B-29

NO : Replace the crankshaft sensing blade.
2 1
3
Harness side
connector
STEP 21: MUT-II data list

B-29 (B)

00 - How to Use
300).
NO : Replace crank angle sensor.
Crank angle sensor

AK300276 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-133
TROUBLESHOOTING
Code No. P0340: Camshaft Position Sensor System
Camshaft position sensor circuit
Battery
W-B
W-B
3
4
B-17X
R
3
B-106
(MU802337)
1 2 3
1
B-W
19
J/C (1)
C-16
L-Y
17
B-W
40
88
C-135
C-137
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code

AK300278 AB
OPERATION
Power is supplied to the camshaft position sensor
(terminal No. 3) from the engine control relay (terminal No. 1) and is earthed to the engine-ECU
(terminal No. 40) from the camshaft position sensor (terminal No. 1).
A power voltage of 5 V is applied to the camshaft

position sensor output terminal (terminal No. 2)
from the engine-ECU (terminal No. 88).
FUNCTION
The camshaft position sensor detects the top
dead center on the compression stroke of the No.
1 cylinder and inputs a pulse signal to the engineECU.
13A-134
TROUBLESHOOTING
TROUBLE JUDGMENT
STEP 2. Measure voltage at B-106 camshaft

Check Condition
After the engine has started up.
Connector: B-106
Judgment Criterion
PROBABLE CAUSE
Failed camshaft position sensor
Open/short circuit in camshaft position sensor circuit or loose connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-106 camshaft
position sensor connector
Connector: B-106
3 2 1
Harness side
connector
B-106 (B)
AK300279 AB

NO : Repair.
3 2 1
Harness side
connector
B-106 (B)
AK300279 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 3 .

TROUBLESHOOTING

relay connector
STEP 4. Measure voltage at B-106 camshaft

Connector: B-106
CONNECTOR: B-17X
Relay boxs
triangle marks
13A-135
B-17X
3 2 1
Harness side
connector
B-106 (B)
Harness side
connector
AK300255 AB
Connector: B-106
3 2 1
Harness side
connector
AK300279 AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 5 .
B-106 (B)
AK300279 AB

(terminal No. 3) camshaft position sensor

open/short circuit.
NO : Repair.
13A-136
TROUBLESHOOTING

connector.
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-106
Connector: B-106
3 2 1
3 2 1
Harness side
connector
Harness side
connector
B-106 (B)
B-106 (B)
AK300279 AB

Disconnect B-106 camshaft position sensor connector.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 7 .
AK300254 AB
AK300279 AB

(terminal No. 2) camshaft position sensor

NO : Repair.
13A-137
TROUBLESHOOTING

connector
CONNECTOR: C-137

No. 2) camshaft position sensor connector and
C-135 (terminal No. 56) engine-ECU connector.
Connector: B-106
3 2 1
Harness side
connector
C-137
B-106 (B)
AK300279 AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
CONNECTOR: C-135

AK300254 AB

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.

00 - How to Use
300).
13A-138
TROUBLESHOOTING
STEP 10. Measure resistance at B-106 camshaft

Connector: B-106

Connector: B-106
3 2 1
3 2 1
Harness side
connector
Harness side
connector
B-106 (B)
B-106 (B)
AK300279 AB

side.
OK: 2 W or less
AK300279 AB
CONNECTOR: C-135

C-135

connector
CONNECTOR: C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
C-135

NO : Repair.
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.

13A-139
TROUBLESHOOTING
STEP 13. Measure output waveform at B-106

camshaft position sensor connector (Use
oscilloscope).
Connector: B-106

B-17X (terminal No. 1) engine control relay
connector.
Connector: B-106
3 2 1
3 2 1
Harness side
connector
Harness side
connector
B-106 (B)
B-106 (B)
AK300279 AB
Engine: Idling
(Refer to 313A), its maximum value
should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in
waveform.
B-17X
Harness side
connector

NO : Repair.
Relay boxs
triangle marks
B-17X
Harness side
connector

NO : Repair.
CONNECTOR: B-17X
CONNECTOR: B-17X
AK300255 AB

relay connector.
Relay boxs
triangle marks
AK300279 AB
AK300255 AB
13A-140
TROUBLESHOOTING
STEP 16. Connector check: C-135 and C-137

engine-ECU connectors

Connector: B-106
3 2 1
Harness side
connector
C-135
C-137
B-106 (B)
AK300279 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

C-137
AK300277 AB

NO : Repair.
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

TROUBLESHOOTING

Connector: B-106
13A-141
STEP 19. Check camshaft position sensing

cylinder.
NO : Replace camshaft position sensing cylinder.
3 2 1
Harness side
connector

YES : Replace camshaft position sensor.
B-106 (B)
AK300279 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
00 - How to Use
300).
13A-142
TROUBLESHOOTING
Code No. P0403: EGR Control Solenoid Valve System
EGR control solenoid valve circuit
Battery
W-B
W-B
4
B-17X
1
1
B-102
1 2

2
76
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

O: Orange GR: Gray
AK300280 AB
OPERATION
Power is supplied to the EGR control solenoid
valve (terminal No. 1) from the engine control
relay (terminal No. 1).

power transistor in the unit be in "ON", and that
makes currents go on the EGR control solenoid
valve (terminal No. 2).
13A-143
TROUBLESHOOTING
FUNCTION
In response to the signal from the engine-ECU,
the EGR control solenoid valve controls the operation of the EGR valve.
STEP 3. Measure resistance at B-102 EGR

control solenoid valve connector.
Connector: B-102
2 1
Harness side
connector
TROUBLE JUDGMENT
Check Conditions
Except the engine stalling
B-102 (BR)
Judgment Criteria
If the off surge voltage from the motor coil is not
generated when the EGR valve control motor is
driven.
PROBABLE CAUSE
Failed EGR control solenoid valve
Open/short circuit in EGR control solenoid valve
Failed engine-ECU
DIAGNOSIS PROCEDURE
Refer to Actuator test reference table 313A.
a. Item 10: EGR control solenoid valve
OK: Operating sound can be heard and the
valve vibrates.
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-102 EGR control
solenoid valve connector
Connector: B-102
2 1
Harness side
connector
B-102 (BR)
AK300281 AB

NO : Repair.
AK300281 AB
Disconnect connector, and measure at solenoid

valve side.
OK: 29 - 35 W (at 20C)
NO : Replace EGR control solenoid valve.
STEP 4. Measure voltage at B-102 EGR control

solenoid valve connector.
Connector: B-102
2 1
Harness side
connector
B-102 (BR)
AK300281 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13A-144
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

connector.
CONNECTOR: C-134
B-17X
C-134
Harness side
connector
AK300255 AB
Connector: B-102
2 1
Harness side
connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
B-102 (BR)
AK300281 AB

(terminal No. 1) EGR control solenoid valve

open/short circuit.
NO : Repair.

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 7 .
13A-145
TROUBLESHOOTING

connector

connector
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Connector: B-102
2 1
Harness side
connector
B-102 (BR)
AK300281 AB

(terminal No. 2) EGR control solenoid valve

Check output line for open/short
circuit.
NO : Repair.
AK300257 AB

NO : Repair.
13A-146
TROUBLESHOOTING

No. 2) EGR control solenoid valve connector and
Connector: B-102
2 1

No. 1) EGR control solenoid valve connector and
B-17X (terminal No. 1) engine control relay
connector.
Connector: B-102
2 1
Harness side
connector
Harness side
connector
B-102 (BR)
B-102 (BR)
AK300281 AB
AK300281 AB
CONNECTOR: C-134
CONNECTOR: B-17X
Relay boxs
triangle marks
C-134
B-17X
Harness side
connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
AK300255 AB

NO : Repair.

Refer to actuator test reference table list 313A
.
Item 10: EGR control solenoid valve
valve vibrates.
00 - How to Use
300).

TROUBLESHOOTING
13A-147
Code No. P0420: Catalyst malfunction

FUNCTION
The signal from the heated oxygen sensor (rear)
differs from the heated oxygen sensor (front).
That is because the catalytic converter purifies
exhaust gas. When the catalytic converter has
deteriorated, the signal from the heated oxygen
sensor (front) becomes similar to the heated oxygen sensor (rear).
The engine-ECU compares the output of the front
and rear heated oxygen sensor signals.

b. Item 59: Oxygen sensor (rear)

abnormal data valve (Refer to Inspection
TROUBLE JUDGMENT
Check Conditions
Engine speed: 3,000 r/min or less.
During the driving.
During the air-fuel ratio feedback control.
Judgment Criterion
When the output frequency ratio of the oxygen
sensor (rear) vs. The oxygen sensor (front) is 0.8
or more on the average for 12 seconds.
PROBABLE CAUSE
Catalytic converter deteriorated
Failed oxygen sensor (rear)
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1.Check for leakage of exhaust emission
NO : Repair.

OK: 0 - 0.4 and 0.6 - 1.0 volt should alternate
15 times or more within 10 seconds (engine
speed at 2,000 r/min).
NO : Replace the oxygen sensor (front).
STEP 4.Replace the oxygen sensor (rear).

After replacing the oxygen sensor (rear), recheck the trouble symptoms.
NO : Check end.
STEP 5.Replace the catalytic converter.

After replacing the catalytic converter, re-check
YES : Replacing engine-ECU.
NO : Check end.
13A-148
TROUBLESHOOTING
Code No. P0443: Purge Control Solenoid Valve System

Purge control solenoid valve circuit
Battery
W-B
W-B
4
B-17X
1
B-101
(MU802779)
1 2
1
BR
9
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

O: Orange GR: Gray
AK300282 AB
OPERATION
Power is supplied to the purge control solenoid
valve (terminal No. 2) from the engine control

and that makes currents go on the purge control
solenoid valve (terminal No. 1).
13A-149
TROUBLESHOOTING
FUNCTION
In response to a signal from the engine-ECU, the
purge control solenoid valve controls the flow rate
of the purge air to be introduced into the surge
tank.
STEP 3: Measure resistance at B-101 purge

control solenoid valve connector.
Connector: B-101
2 1
Harness side
connector
TROUBLE JUDGMENT
Check Conditions
Ignition switch: ON
Judgment Criteria
The surge voltage (system voltage + 2 V) of solenoid coil is not detected when the purge control
solenoid valve is turned in OFF position from ON.
B-101 (B)
AK300283AB
Disconnect connector, and measure at solenoid

valve side.
OK: 30 - 34 W (at 20C)
PROBABLE CAUSE
Failed purge control solenoid valve
Open/short circuit in purge control solenoid value
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 4. Measure voltage at B-101 purge control

solenoid valve connector.

Item 08: Purge control solenoid valve
valve vibrates
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-101 purge control
solenoid valve connector
Connector: B-101
2 1
Harness side
connector
B-101 (B)
AK300283AB

NO : Repair.
Connector: B-101
2 1
Harness side
connector
B-101 (B)
AK300283AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13A-150
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

connector.
CONNECTOR: C-134
B-17X
C-134
Harness side
connector
AK300255 AB
Connector: B-101
2 1
Harness side
connector
B-101 (B)
AK300283AB

(terminal No. 2) purge control solenoid valve

Check power line for open/short
circuit.
NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 7 .
13A-151
TROUBLESHOOTING

connector

connector
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Connector: B-101
2 1
Harness side
connector
B-101 (B)
AK300283AB

(terminal No. 1) purge control solenoid valve

Check output line for open and short
circuit.
NO : Repair.
AK300257 AB

NO : Repair.
13A-152
TROUBLESHOOTING

No. 1) purge control solenoid valve connector
connector.
Connector: B-101

No. 2) purge control solenoid valve connector
and B-17X (terminal No. 1) engine control relay
connector.
Connector: B-101
2 1
2 1
Harness side
connector
Harness side
connector
B-101 (B)
B-101 (B)
AK300283AB
AK300283AB
CONNECTOR: B-17X
CONNECTOR: C-134
Relay boxs
triangle marks
C-134
B-17X
Harness side
connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
AK300255 AB
Check power line for damage.

NO : Repair.

NO : Repair.

Item 08: purge control solenoid valve
valve vibrates
00 - How to Use
300).
13A-153
TROUBLESHOOTING
Code No. P0500: Vehicle speed sensor system
Vehicle speed sensor circuit
Ignition switch
Engine-ECU
C-137
C-303
1 2 3
4 5 6
LOCK
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
ST
ACC
IG1 IG2
2
L-B
86
C-203
6
W-L
2 J/B
7.5A
C-202
11
3
J/C (1)
C-16
Meter and gauge
B-W
2
C-106
3
W-L
B-W
3
1
B-115
1 2 3
Vehicle speed sensor
2
B
8
J/C (2)
C-17
B
Wire colour code

O: Orange GR: Gray
AK300284 AB
OPERATION
A power voltage of 5 V is applied to the vehicle
speed sensor (terminal No. 3) from the engineECU (terminal No. 86).
FUNCTION
The vehicle speed sensor converts the vehicle
speed to the voltage, and then input it into the
engine-ECU
13A-154

TROUBLESHOOTING
TROUBLE JUDGMENT
Check Conditions
Engine speed: 2,000 r/min or more.
Under the high load operation (The volumetric
efficiency is 40 - 75 %).
Judgment Criterion
PROBABLE CAUSE
Failed Vehicle speed sensor
Open/short circuit in vehicle speed sensor circuit
Failed engine-ECU

a. Item 24: Vehicle speed sensor
00 - How to Use Troubleshooting/Inspection

Service Points 300).
STEP 3.Check connector: C-137 engine-ECU
connector
CONNECTOR: C-137
DIAGNOSIS PROCEDURE
STEP 1.Check the speedometer
NO : Check the speedometer (Refer to GROUP
54A -Combination Meter Assembly and

Vehicle speed sensor - On-vehicle Service
354A).
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

TROUBLESHOOTING
STEP 4.Check harness between C-137 (terminal

No. 86) engine-ECU connector and B-115
(terminal No. 3) Vehicle speed sensor connector.
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
CONNECTOR: B-115
3 2 1
Harness side
connector
AK300285AB

Check output line for open circuit and damage.
NO : Repair.
STEP 5.Check the trouble symptoms.

YES : Replacing engine-ECU.
00 - How to Use Troubleshooting/Inspection

C-137
B-115 (B)
13A-155
13A-156
TROUBLESHOOTING
Code No. P0505: Idle Speed Control Servo System
Idle speed control servo circuit

Battery
W-B
W-B
3
B-17X
1
R
2
B-105
1 2 3
4 5 6
L-Y
Y-L
17
G-Y
18
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code
AK300286 AB
13A-157
TROUBLESHOOTING
OPERATION
The power is supplied to the idle speed control
servo (terminal No. 2 and No. 5) from the engine
control relay (terminal No. 1).
The engine-ECU (terminal No. 4, No. 5, No. 17
and No. 18) makes power transistor in the unit be
in "ON" position in order, and that makes currents
go on the idle speed control servo (terminal No.
1, No. 3, No. 4 and No. 6).
Judgment Criteria
The actual idle speed is higher than the target
idle speed by 100 r/min or more for 10 seconds.
FUNCTION
The idle speed control servo opens and closes
the servo valve in response to a signal from the
engine-ECU to control the intake air flow rate during idling.
DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT
Check conditions
The vehicle speed has reached 1.5 km/h or more
at least once.
During the closed-loop idle speed control.
Judgment Criteria
Check conditions
The vehicle speed has reached 1.5 km/h or more
at least once.
The highest ambient temperature at the last drive
is 45 C or less.
82C or higher.
Judgment Criteria
Check conditions
82C or higher.
The power steering switch is in OFF position.
The charging efficiency is 40 % or less.
PROBABLE CAUSE
Failed idle speed control servo
Open/short circuit in idle speed control servo circuit or loose connector contact
Failed engine-ECU
STEP 1. MUT-II Data List

a. Item 45: Idle speed control position
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-105 idle speed
control servo connector
Connector: B-105
3
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB

NO : Repair.
STEP 3. Check idle speed control servo itself.

Check idle speed control servo itself (Refer to
313A).
NO : Replace idle speed control servo.
13A-158
TROUBLESHOOTING
STEP 4. Measure voltage at B-105 idle speed

control servo connector.
Connector: B-105
STEP 5. Check connector: B-17X engine control

relay connector
CONNECTOR: B-17X
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB

side.
Ignition switch: ON
Voltage between terminal No. 2 and earth, also
between terminal No. 5 and earth.
OK: System voltage
NO : Go to Step 5 .
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
Connector: B-105
3
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB

(terminal No. 2 or No. 5) idle speed control

servo connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
13A-159
TROUBLESHOOTING

connector.
CONNECTOR: C-134

open/short circuit.
connector
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
Connector: B-105
AK300257 AB
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB

side.
Ignition switch: ON
Voltage between terminal No. 4 and earth,
between terminal No. 5 and earth, between terminal No. 17 and earth, also voltage between terminal No. 18 and earth.
OK: System voltage
idle speed control servo and C-134 engineECU.

1. Harness between idle speed control
servo terminal No. 1 and engineECU connector terminal No. 4

NO : Repair.
13A-160
TROUBLESHOOTING
STEP 8. Check harness between B-105 idle

speed control servo and C-134 engine-ECU.
Connector: B-105
3
2 1

No. 2 or No. 5) idle speed control servo
connector and B-17X (terminal No. 1) engine
control relay connector.
Connector: B-105
6 5 4
Harness side
connector
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB
B-105 (B)
CONNECTOR: C-134
AK300287 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
Harness side
connector
AK300255 AB

AK300257 AB
1. Harness between idle speed control servo terminal No. 1 and engine-ECU connector terminal
No. 4
No. 17
No. 5
No. 18
NO : Repair.
B-17X

NO : Repair.

a. Item 45: Idle speed control position
00 - How to Use
300).

TROUBLESHOOTING
13A-161
Code No. P0551: Power Steering Fluid Pressure Switch System
C-135
Engine-ECU
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
37
B-28
(MU801211)
1
Wire colour code

AK300288 AB
CONDITION
The battery voltage is applied to the power steering fluid pressure switch (terminal No. 1) from the
FUNCTION
It is detected whether a load is applied on the
power steering fluid pump by steering or not, and
the signal is inputted to the engine-ECU. When
the power steering fluid pressure switch "ON" signal (a large load on the power steering fluid
pump) is inputted, the engine-ECU provides the
idle-up control.
TROUBLE JUDGMENT
Check Conditions
The engine coolant temperature is approximately

30C or higher.
Repeat, 10 times or more, the *1 running and
stop also *2 running.
*1 running: engine speed of 2,500 r/min or more
(Vehicle speed of 50 km/h or more).
*2 running: Vehicle speed of 1.5 km/h or less.
Judgment Criteria
The power steering pressure switch remains in
ON position.
PROBABLE CAUSE
Failed power steering fluid pressure switch
Open/short circuit in power steering fluid pressure switch circuit or loose connector contact
Failed engine-ECU
13A-162
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector.
STEP 1. Connector check: B-28 power steering

fluid pressure switch connector
CONNECTOR: C-135
CONNECTOR: B-28
C-135
B-28 (B)
1
Harness side
connector
AK300289 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

NO : Repair.
AK300256 AB
STEP 2. Measure voltage at B-28 power steering

fluid pressure switch connector.

NO : Go to Step 5 .
CONNECTOR: B-28
B-28 (B)
1
Harness side
connector
AK300289 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 3 .

Ignition switch: ON
OK: System voltage
13A-163
TROUBLESHOOTING

connector
CONNECTOR: C-135

connector
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
CONNECTOR: B-28
B-28 (B)
1
Harness side
connector
AK300256 AB
AK300289 AB

(terminal No. 1) power steering fluid

pressure switch connector and C-135
NO : Repair.
13A-164
TROUBLESHOOTING

No. 1) power steering fluid pressure switch

connector.
CONNECTOR: C-135
CONNECTOR: B-28
B-28 (B)
C-135
1
Harness side
connector
AK300289 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

CONNECTOR: C-135
AK300256 AB
C-135

Engine: Idling
OK:
System voltage (Steering wheel: Stationary)
1 V or less (Steering wheel: Turned)
NO : Go to Step 9 .
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.

connector
CONNECTOR: C-135

a. Item 27: Power steering fluid pressure switch
C-135

00 - How to Use
300).
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-165
TROUBLESHOOTING

No. 1) power steering fluid pressure switch

connector
CONNECTOR: C-135
CONNECTOR: B-28
B-28 (B)
C-135
1
Harness side
connector
AK300289 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

CONNECTOR: C-135
AK300256 AB

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

YES : Replace power steering fluid pressure
switch.
NO : Repair.
13A-166
TROUBLESHOOTING
Code No. P0622: Alternator FR Terminal System
Alternator circuit
C-135
Engine-ECU
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
41
Y-B
B-19
1
Y-B
B-30
(MU802046)
1 2 3 4
IC Voltage
regulator
Alternator
Wire colour code

O: Orange GR: Gray
AK300290 AB
OPERATION
The energized state of the alternator field coil is
inputted from the alternator (terminal No. 4) to the
FUNCTION
A signal of the power supply duty ratio for the
alternator field coil is inputted to the engine-ECU.
In response to the signal, the engine-ECU
detects the alternator output current and controls
the idling speed according to the output current
(electric load).
TROUBLE JUDGMENT
Check Condition
Judgment Criterion
Input voltage from alternator FR terminal is the
system voltage or more for 20 seconds.
PROBABLE CAUSE
Alternator FR terminal circuit open circuited
Failed engine-ECU
13A-167
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector
STEP 1. Connector check: B-19 intermediate

connector
CONNECTOR: B-19
CONNECTOR: B-19
B-19 (B)
B-19 (B)
Female side
connector
3 2 1
6 5 4
Female side
connector
3 2 1
6 5 4
AK300294 AB

NO : Repair.
STEP 2. Measure voltage at B-19 intermediate

connector.
AK300294 AB

NO : Repair.

No. 1) intermediate connector and C-135
CONNECTOR: B-19
CONNECTOR: B-19
B-19 (B)
B-19 (B)
1 2 3
4 5 6
1 2 3
4 5 6
Male side
connector
Male side
connector
AK300295 AB
Disconnect connector, and measure at male connector side.

Ignition switch: ON
OK: System voltage
AK300295 AB
CONNECTOR: C-135

NO : Go to Step 3 .
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-168

TROUBLESHOOTING

00 - How to Use
300).
connector.
B-19 (B)
3 2 1
6 5 4
B-30 (GR)
4 3 2 1
AK300296 AB

NO : Repair.

No. 4) alternator connector and B-19 (terminal
No. 1) intermediate connector.
AK300294 AB
Ignition switch: ON
OK: System voltage
NO : Go to Step 7 .
CONNECTOR: B-30
Harness side
connector
CONNECTOR: B-19
Female side
connector
STEP 7. Connector check: B-30 alternator

connector
CONNECTOR: B-30
B-30 (GR)
4 3 2 1
Harness side
connector
AK300296 AB
CONNECTOR: B-19
B-19 (B)
3 2 1
6 5 4
Female side
connector
AK300294 AB

YES : Replace alternator.
NO : Repair.

TROUBLESHOOTING

connector.
CONNECTOR: B-19
13A-169

No. 4) alternator connector and B-19 (terminal
No. 1) intermediate connector pin No. 1.
CONNECTOR: B-30
B-19 (B)
B-30 (GR)
3 2 1
6 5 4
Female side
connector
4 3 2 1
AK300294 AB
Engine: Idle after warm-up
Radiator fan: Inactive
OK: Switching the headlamps to ON from
OFF causes the voltage to fall.
Harness side
connector
CONNECTOR: B-19
B-19 (B)
3 2 1
6 5 4
Female side
connector

connector
CONNECTOR: B-30
B-30 (GR)
4 3 2 1
Harness side
connector

NO : Repair.
AK300296 AB
AK300296 AB

NO : Repair.
AK300294 AB
13A-170
TROUBLESHOOTING

No. 1) intermediate connector and C-135
CONNECTOR: B-19
Q: Same symptoms regenerated?

NO : Intermittent malfunction (Refer to Group 00
- How to Use troubleshooting/Inspection

B-19 (B)
1 2 3
4 5 6
Male side
connector
AK300295 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
STEP 13. Check trouble symptom.

TROUBLESHOOTING
13A-171
Code No. P1603: Battery Backup Line System
Battery backup circuit

Battey
9
20A
Relay box
W-B
A-14
5
W-B
80
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Battery
backup
Engine-ECU
Wire colour code

O: Orange GR: Gray
AK300297 AB
OPERATION
Power is directly supplied to the engine-ECU (terminal No. 80) from the battery.
TROUBLE JUDGMENT
FUNCTION
The engine-ECU is check the open circuit of battery backup line.
Judgment Criterion
The battery backup line voltage 6 V or less.
Check Condition
Ignition switch: ON
PROBABLE CAUSE
Open/short circuit in battery backup line circuit or
Failed engine-ECU
13A-172
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector
STEP 1 MUT-II self-diag code

Temporarily place the ignition switch in "LOCK"
(OFF) position, and 10 seconds after that, place it
in "ON" position again.
CONNECTOR: C-137
Q: Is the diagnosis code P1603 set?

00 - How to use Troubleshooting/Inspection

connector.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
CONNECTOR: C-137
AK300254 AB

NO : Repair.
C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
00 - How to Use
Troubleshooting/Inspection Service
Points300).

AK300254 AB

side.
Ignition switch: ON
OK: System voltage
NO : Check intermediate connector A-14, and

harness between battery and C-137
open/short circuit.

TROUBLESHOOTING
13A-173
Code No. P1610: Immobilizer System
Immobilizer-ECU circuit
Signal
transmission
circuit
C-304-1
Immobilizer-ECU
1
2
3 4 5 6 7
C-304
(MU801547)
V
11
C-104
V
51
C-136
51 52 53 54 55 56
57 58 59 60 61 62
Engine-ECU
Wire colour code

AK300298 AB
OPERATION
The signals are sent and received between
engine-ECU (terminal No. 51) and immobilizerECU (terminal No. 7).
FUNCTION
Engine-ECU sends or receives the control signals to or from immobilizer-ECU to certify the
ignition key.
NOTE: .
If the registered ignition keys are close each
other when starting the engine, radio interference may cause this code to be displayed.
This code may be displayed when registering
the key encrypted code.
TROUBLE JUDGMENT
Check Condition
Ignition switch: ON
Judgment Criterion
Improper communication problems between the
engine-ECU and the immobilizer-ECU are
detected.
PROBABLE CAUSE
Open/short circuit in immobilizer system circuit or
Failed immobilizer-ECU
Failed engine-ECU
13A-174
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-304 immobilizerECU connector and C-136 engine-ECU connector

No. 3) immobilizer-ECU connector and C-136
Connector: C-304
Harness side
connector
Connector: C-304
Harness side
connector
1
2
76543
1
2
76543
C-304
C-304
AK203418 AC
AK203418 AC
CONNECTOR: C-136
CONNECTOR: C-136
C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AB
AK300268 AB

NO : Repair.

NO : Repair.

00 - How to Use
300).
STEP 4. After replacing the immobilizer-ECU, recheck the trouble symptoms.
NO : Check end.

TROUBLESHOOTING
13A-175
INSPECTION CHART FOR TROUBLE SYMPTOMS

M1131151500522
Items
Trouble symptom
Inspection
procedure
No.
Communication
with MUT-II is
impossible
Communication with all system is not possible
Communication with engine-ECU only is not possible
Engine warning
lamp
The engine warning lamp does not illuminate right after the ignition switch 3
is turned the "ON" position
The engine warning lamp remains illuminating and never goes out
Starting
Starting impossible
(No initial combustion)
The starter is impossible to operate. 5
Starting impossible
(Starter operative but no initial
combustion)
The starter is operative and cranks

the engine, but none of initial
combustion is in the cylinders and
the engine is not started.
Starting impossible
The initial combustion occurs, but
(Initial combustion but no complete the engine stalls soon due to the
combustion)
incomplete combustion.
Improper idling
Engine stalls
Improper starting
(Long time to start)
It is long cranking to start the engine.
Unstable idling
(Rough idling, hunting)
The engine speed is not constant

8
and changeable during the idling.
Usually, the judgment can be based
on the movement of the tachometer
pointer, also on the vibration
transmitted to the steering wheel, sift
lever, vehicle body and so on.
Improper idling speed
The proper idling speed is not

satisfied.
Engine stalled during idling

(Die out)
The engine stalls during the idling in

no relation to the vehicle movement.
The engine stalls when starting the The engine stalls during the
car
operation, or when the accelerator
(Pass out)
pedal is depressed from the idling.
The engine stalls when
decelerating
The engine stalls at the deceleration. 10
13A-176
TROUBLESHOOTING
Items
Trouble symptom
Inspection
procedure
No.
Driving
Engine does not revolve up
The engine speed is not higher when 11

the accelerator pedal is depressed.
Hesitation, sag
The response of vehicle speed

12
(engine speed) is delayed when the
accelerator pedal is depressed, or
the vehicle speed (engine speed) is
temporarily dropped during the
acceleration. These phenomena are
called "hesitation" and the serious
hesitation is called "sag".
Poor acceleration
The engine cannot obtain the

acceleration corresponding to the
degree of throttle opening although
the engine is smooth at the constant
speed.
Stumble
The engine speed increase is

delayed when the accelerator pedal
is initially depressed at the starting.
Surge
The vehicle body is repeated to

vibrate jollity in the forward and
backward directions at the constant
speed or acceleration.
The feeling of impact or vibration

when accelerating
The large impact feeling occurs at

the acceleration.
13
The feeling of impact or vibration

when decelerating
The large impact feeling occurs at

the deceleration.
14
Knocking
Sharp sound like a hammer striking

on the cylinder walls during the
driving can be heard and wrongly
affects the driving.
15
Ignition timing offset
The basic ignition timing is deviated

from the datum value.
16
Stopping
Run on (Dieseling)
The engine continues to run after the 17

ignition switch is in "LOCK (OFF)"
position.
Exhaust gas
Odor, white smoke, black smoke,

high-concentration CO/HC during
idling
The exhaust gas is extremely rank

odor, white smoke or black smoke.
The concentration of CO & HC is
high during the idling.
18
Charging
performance
Battery rundown
The battery is soon rundown or the

charging ability of battery is small.
19

TROUBLESHOOTING
13A-177
Items
Trouble symptom
Cooling
performance
Overheating
The temperature of engine cooling

water is extremely high.
20
Abnormal rotation of fan Motor
The fan motor is abnormally rotated

when the ignition switch is in "ON"
position in no relation to the engine
cooling water temperature.
21
Poor A/C Performance
The temperature of air cooling from

A/C is not efficient or very far from
the target temperature.
22
A/C performance
Inspection
procedure
No.
PROBLEM SYMPTOMS TABLE

Inspection Trouble symptom
procedure
No.
Reference
page
Communication with all system is not possible
313A
Communication with engine-ECU only is not possible
313A
The engine warning lamp does not illuminate right after the ignition switch is
turned the "ON" position
313A
The engine warning lamp remains illuminating and never goes out
313A
Starting impossible (No initial combustion)
313A
Starting impossible (Starter operative but no initial combustion)
313A
Starting impossible (Initial combustion but no complete combustion)
313A
Starting impossible (Long time to start)

8
Unstable idling (Rough idling, hunting)
313A
Improper idling speed (Too high or too low)

Engine stalls during idling (Die out)
9
The engine stalls when starting the car (pass out)
313A
10
The engine stalls when decelerating
313A
11
Engine does not revolve up
313A
12
Hesitation, sag
313A
Poor acceleration
Stumble
Surge
13
The feeling of impact or vibration when accelerating
313A
14
The feeling of impact or vibration when decelerating
313A
15
Knocking
313A
16
Ignition timing offset
313A
17
Run on (Dieseling)
313A
18
Odor, white smoke, black smoke, high-concentration CO/HC during idling
313A
19
Battery rundown
313A
20
Overheating
313A
13A-178
TROUBLESHOOTING
Inspection Trouble symptom

procedure
No.
Reference
page
21
Abnormal rotation of fan motor
313A
22
Poor A/C performance
313A
23
Engine-ECU power supply, engine control relay, ignition switch-IG1 system
313A
24
Fuel pump system
313A
25
Fan control relay system
313A
26
A/C switch system
313A
27
A/C compressor relay system
313A
28
A/C load signal system
313A
29
A/C pressure sensor system
313A
30
Ignition circuit system
313A
13A-179
TROUBLESHOOTING
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with All System is not Possible

Data link connector circuit
Fusible link (1)
C-116
15
R
C-204
1
15
15A
J/B
12
C-205
W-B
C-24
16
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Data link connector

5
4
B
Wire colour code

AK300300 AB
OPERATION
Battery voltage is applied to diagnosis connector
(terminal No.16).
Diagnosis connector (terminals No. 4 and 5) are
earthed to the vehicle body.
COMMENT ON TROUBLE SYMPTOM

Failure is possibly caused by failed power supply
circuit or failed earthing circuit of diagnosis connector.
PROBABLE CAUSE
Failed diagnosis connector
Open/short circuit in diagnosis connector circuit
Failed MUT-II
13A-180
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 3: Measure voltage at C-24 diagnosis

connector.
STEP 1: Check connector: C-24 diagnosis

connector
Connector: C-24
Connector: C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)

AK203424 AE

AK203424 AE

NO : Repair.
STEP 2: Measure resistance at C-24 diagnosis

connector.
Connector: C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)
Disconnect connector, and measure at the harness side.

OK: System voltage
NO : Check intermediate connectors C-116, C-204
and C-205, and repair if necessary. If

connectors are normal, check and repair
diagnosis connector and battery.
open/short circuit.
STEP 4: Replace MUT-II
After replacing the MUT-II, re-check the trouble
symptoms.
C-24 (B)

AK203424 AE

side.
Resistance between terminal No. 4 and earth,
also between terminal No. 5 and earth.
OK: 2 W or less
NO : Check and repair harness between C-24
(terminal No. 4) diagnosis connector and

body earth, also between C-24 (terminal No.
5) diagnosis connector and body earth.
and damage.

NO : Check end

TROUBLESHOOTING
STEP 5: Check harness between C-24 (terminal

No. 6) diagnosis connector and battery.
Connector: C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)

AK203424 AE

connectors C116, C-204 and C-205, and repair if
necessary.
(terminal No. 4 and No. 5) diagnosis

NO : Repair.
13A-181
13A-182
TROUBLESHOOTING
Inspection Procedure 2: Communication with Engine-ECU only is not Possible.
Data link connector circuit
C-136
Engine-ECU
51 52 53 54 55 56
57 58 59 60 61 62
62
O-W
C-105
5
O-W
32
J/C (3)
C-02
29
O-L
C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Data link connector
Wire colour code

AK300301 AB
OPERATION
There is data communication between diagnosis
connector output terminal (terminal No. 7) and
DIAGNOSIS PROCEDURE

Failure is possibly caused by failed power supply
circuit or failed earthing circuit of engine-ECU.
Q: Is lamp illuminating for few seconds?

NO : Check engine-ECU power supply, engine
PROBABLE CAUSE
Open/short circuit in engine-ECU power circuit
Between engine-ECU and diagnosis connector
for short circuit
Failed engine-ECU
STEP 1: Check engine warning lamp.

Ignition switch: OFF ON
control relay and ignition switch IG1 system

(Refer to Inspection Procedure 23 313A
).
13A-183
TROUBLESHOOTING
STEP 2: Connector check: C-136 engine-ECU

connector
CONNECTOR: C-136

No. 7) diagnosis connector and C-136 (terminal
Connector: C-24
C-136
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)

AK203424 AE
56 55 54 53 52 51
62 61 60 59 58 57
CONNECTOR: C-136

AK300268 AB

NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB
NOTE: Before Checking harness, check intermediate connectors C-105 and C-02, and repair if necessary.
Check communication line for open/short circuit
and damage.
NO : Repair.
STEP 4: Check the trouble symptom.

00 - How to Use
300).
13A-184
TROUBLESHOOTING
Inspection Procedure 3: The Engine Warning Lamp Does not Illuminate Right after the Ignition Switch
is Turned The "ON" Position
Malfunction indicator lamp (Engine warning lamp) circuit
Ignition switch
C-303
LOCK
1 2 3
4 5 6
ST
ACC
IG1
IG2
2
L-B
C-203
6
2
7.5A
J/B
25
C-205
C-04
B-W
42
31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G
Malfunction indicator lamp

(Engine warning lamp)
C-05
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122
G
14
R-W
7
C-105
R-W
36
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Engine-ECU
Wire colour code

AK300302 AB
OPERATION
Battery voltage is applied to engine warning lamp
of combination meter connector (terminal No. 42)
from ignition switch.
Engine-ECU (terminal No. 36) makes power transistor in unit be in "ON" position, and that makes
currents go on engine warning lamp of combination meter connector (terminal No. 14).
13A-185
TROUBLESHOOTING
COMMENTS ON TROUBLE SYMPTOM

Engine-ECU turns on engine warning lamp for 5
seconds to check for burnt-out bulb immediately
after ignition switch is turned to ON.
If engine warning lamp is not lit just after turning
ignition switch to "ON" position, failure is possibly
caused by burn-out bulb, open/short circuit or
other faults.
STEP 3: Connector check: C-04 combination

meter connector
CONNECTOR: C-04
C-04
PROBABLE CAUSE
Engine warming lamp bulb burnt out
Failed ignition switch
Open/short circuit in engine warning lamp circuit
for or loose connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G
STEP 1: Check engine start-up.

Q: Is engine started?

).
STEP 2: Check engine warning lamp for burntout bulb.
AK300303AB

NO : Repair
STEP 4: Measure voltage at C-04 combination

meter connector.
CONNECTOR: C-04
C-04

NO : Replace engine warning lamp.
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

AK300303AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13A-186
TROUBLESHOOTING
STEP 5: Connector check: C-303 ignition switch

connector
CONNECTOR: C-303

connector
CONNECTOR: C-135
C-303
3 2 1
6 5 4
C-135
Harness side
connector
AK300304 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-04
C-04
AK300256 AB

NO : Repair.
STEP 7: Measure voltage at C-135 engine-ECU

connector.
CONNECTOR: C-135
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

AK300303AB

YES : Check intermediate connectors C-203 and
C-205, and repair if necessary. If

intermediate connectors are normal, check
and repair harness between C-04 (terminal
No. 42) combination meter connector and
C-303 (terminal No. 2) ignition switch
connector.
open/short circuit.
NO : Repair
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .
13A-187
TROUBLESHOOTING
STEP 8: Check connector: C-05 combination

meter connector

connector
CONNECTOR: C-303
CONNECTOR: C-05
C-05 (L)
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

NO : Repair.
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G

AK300305 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB


combination meter connector and C-135
circuit.
NO : Repair
13A-188
TROUBLESHOOTING

No. 42) combination connector and C-303
(terminal No. 2) ignition switch connector.

connector
CONNECTOR: C-05
CONNECTOR: C-04
C-05 (L)
C-04
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G
AK300305 AB

AK300303AB
CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

connectors C-203 and C-205, and repair if necessary.
NO : Repair.

NO : Repair.

TROUBLESHOOTING

No. 14) combination connector and C-135
CONNECTOR: C-05
C-05 (L)
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G

AK300305 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-189
STEP 13: Check the trouble symptoms.

00 - How to Use
300).
13A-190
TROUBLESHOOTING
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and never goes out
Malfunction indicator lamp (Engine warning lamp) circuit
Ignition switch
C-303
LOCK
1 2 3
4 5 6
ST
ACC
IG1
IG2
2
L-B
C-203
6
2
7.5A
J/B
25
C-205
C-04
B-W
42
31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G
Malfunction indicator lamp

(Engine warning lamp)
C-05
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122
G
14
R-W
7
C-105
R-W
36
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Engine-ECU
Wire colour code

AK300302 AB
OPERATION
Battery voltage is applied to engine warning lamp
(terminal No. 42) from ignition switch.
Engine-ECU (terminal No. 36) makes power transistor in unit be in "ON" position, and that makes
currents go on engine warning lamp (terminal No.
14).
13A-191
TROUBLESHOOTING

Engine-ECU has detected failed sensor or failed
actuator. Or failure is possibly caused by short
circuit or other faults.

connector.
CONNECTOR: C-135
PROBABLE CAUSE
Short circuit in between engine warning lamp and
engine-ECU circuit.
Failed engine-ECU
DIAGNOSIS PROCEDURE
C-135
STEP 1: MUT-II self-diag code

Q: Diagnosis code set?
to 313A.)
NO : Go to Step 2 .
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

connector
CONNECTOR: C-05
C-05 (L)
CONNECTOR: C-135
C-135
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300305 AB

AK300256 AB

NO : Repair

Ignition switch: ON
OK: System voltage
NO : Check intermediate connector C-105, and

combination meter connector and C-135
13A-192

TROUBLESHOOTING
STEP 4: Check the trouble symptoms.

00 - How to Use
300).
Inspection Procedure 5: Starting impossible (No Initial Combustion)

Failure is possibly caused by failed starter itself
or failed related circuit.

connector
CONNECTOR: C-137
PROBABLE CAUSE
Failed battery
Failed starter motor
Open/short circuit in starter associated circuit or
DIAGNOSIS PROCEDURE
STEP 1: Check battery voltage.
Measure battery voltage at cranking.
OK: 8 V or higher
NO : Check battery (Refer to GROUP 54A -
Battery - On-vehicle Service - Battery Test

354A).
Item 18: Cranking signal
OK:
ON (Ignition switch: ST)
OFF (Ignition switch: ON)
NO : Go to Step 3 .
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-193
TROUBLESHOOTING

connector.
STEP 6: Check ignition switch.

CONNECTOR: C-137
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
AK300254 AB

Ignition switch: ST
OK: System voltage
NO : Go to Step 5 .
CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

connector

CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

NO : Repair.
Check ignition switch (Refer to GROUP 54A Ignition Switch - Ignition Switch 354A).
B-19, and repair if necessary. If intermediate

connector are normal, check and repair
inhibitor switch connector and C-303
open/short circuit.
NO : Replace ignition switch.
13A-194
TROUBLESHOOTING

connector and B-26 starter connector
STEP 8: Check connector: B-26 starter connector

CONNECTOR: B-26
CONNECTOR: C-303
B-26 (B)
C-303
3 2 1
6 5 4
1
Harness side
connector
Harness side
connector
AK300306 AB
AK300304 AB

NO : Repair.
CONNECTOR: B-26
STEP 9: Measure voltage at B-26 starter

connector.
B-26 (B)
CONNECTOR: B-26
1
Harness side
connector
AK300306 AB

B-19, and repair if necessary. If intermediate

ignition switch connector and B-26 (terminal
No. 1) starter connector.
NO : Repair.
B-26 (B)
1
Harness side
connector
AK300306 AB

Ignition switch: ST
OK: System voltage
13A-195
TROUBLESHOOTING

connector
CONNECTOR: C-303
STEP 11: Connector check: B-25 starter

connector
CONNECTOR: B-25
C-303
3 2 1
6 5 4
B-25
1
Harness side
connector
AK300304 AB
AK300307 AB

NO : Repair.
CONNECTOR: B-26
STEP 12: Measure voltage at B-25 starter

connector.
B-26 (B)
CONNECTOR: B-25
1
Harness side
connector
Harness side
connector
AK300306 AB

YES : Check intermediate connectors B-19 and C-
106, and repair if necessary. If intermediate

ignition switch connector and B-26 (terminal
No. 1) starter connector.
damage.
NO : Repair.
B-25
1
Harness side
connector
AK300307 AB

OK: System voltage
(terminal No. 1) starter connector and

battery.
open/short circuit.
13A-196
TROUBLESHOOTING

No. 5) ignition switch connector and B-26
(terminal No. 1) starter connector.
STEP 14: Check harness between B-25 (terminal

No. 1) starter connector and battery.
CONNECTOR: B-25
CONNECTOR: C-303
C-303
3 2 1
6 5 4
B-25
1
Harness side
connector
Harness side
connector
AK300304 AB
AK300307 AB

YES : Replace starter.
NO : Repair.
CONNECTOR: B-26
B-26 (B)
1
Harness side
connector
AK300306 AB

connectors B-19 and C-106, and repair if necessary.
NO : Repair.
Inspection Procedure 6: Starting impossible (Starter Operative but No Initial Combustion)

Failure is possibly caused by failed ignition circuit, failed fuel feed or other faults.
PROBABLE CAUSE
Failed battery
Timing belt broken
Failed idle speed control
Throttle valve fouled around
Failed ignition system
Failed fuel system
Failed immobilizer system
Failed engine-ECU
DIAGNOSIS PROCEDURE
OK: 8 V or higher
YES : Go to STEP 2 .
NO : Check battery (Refer to GROUP 54 -
Battery - On-vehicle Service - Battery test

354A).
13A-197
TROUBLESHOOTING
STEP 2: Check engine warning lamp for burnt out

bulb.

).
YES : Inspection chart for diagnosis codes (Refer
to 313A)
NO : Go to Step 4 .
STEP 8: MUT-II DATA LIST

Item 18: Cranking signal
OK:
ON (Ignition switch: ST)
OFF (Ignition switch: ON)
NO : Go to Step 9 .

connector
CONNECTOR: C-137
STEP 4: MUT-II actuator test

Item 07: Fuel pump
OK: Operating sound of fuel pump can be
heard.
C-137

NO : Check fuel pump system (Refer to
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Inspection Procedure 24 313A)

STEP 5. Check timing belt for breakage.
Engine: Cranking
OK: Camshaft rotates.

AK300254 AB
CONNECTOR: C-303

NO : Replace timing belt.
STEP 6. Check the engine start ability.

With depressing the accelerator pedal slightly,
and start the engine.
Q: Is the start ability good?
NO : Go to Step 8 .
STEP 7: Check idling speed control for operating

sound.
Check idle speed control servo for operating
sound (Refer to 313A).
YES : Clean throttle body (throttle valve portion)
(Refer to 313A).
NO : Check idle speed control servo system
(Refer to code No. P0505 313A).
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

YES : Check intermediate connectors B-19 and C-

ignition switch connector and C-137
circuit.
NO : Repair.
13A-198

TROUBLESHOOTING
STEP 10: MUT-II DATA LIST

STEP 12: Connector check: B-110 and B-111

ignition coil connectors
Connector: B-110, B-111

NO : Check crank angle sensor system (Refer to
Code No. P0335 313A).
B-111 (GR)
3 2 1
Harness side
connector
STEP 11: Check injector for operating sound.

Check injector for operating sound (Refer to
313A).
Q: Can operating sound be heard?
NO : Check the injector system of the defective
cylinder.
(Refer to Code No. P0201: No. 1 injector
system 313A.)
system 313A.)
system 313A.)
system 313A.)
B-110 (GR)
AK300308 AB

NO : Repair.
STEP 13: Measure voltage at each of B-110 and

B-111 ignition coil connectors.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

Ignition switch: ON
OK: System voltage
13A-199
TROUBLESHOOTING

connector
STEP 15: Check ignition coil spark.

CONNECTOR: C-303
CONNECTOR: C-303
C-303
3 2 1
6 5 4
C-303
3 2 1
6 5 4
Harness side
connector
Harness side
connector
AK300304 AB
AK300304 AB

B-111 (GR)
3 2 1
Harness side
connector
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
B-110 (GR)
AK300308 AB
AK300308 AB

YES : Check intermediate connectors A-14, C-
116, C-203 and C-205, and repair if

necessary. Check and repair harness
between C-303 (terminal No. 2) ignition
switch connector and (terminal No. 1)
affected cylinders ignition coil connector.
open/short circuit.
NO : Repair.

NO : Check intermediate connectors A-14, C-116,
C-203 and C-205, and repair if necessary.

Check and repair harness between C-303
(terminal No. 2) ignition switch connector
and (terminal No. 1) affected cylinders
ignition coil connector.
STEP 16: Replace engine-ECU
After replacing the engine-ECU, re-check the
trouble symptoms.
YES : Check for foreign matters (water, kerosene,
etc.) in fuel and replace if necessary.

NO : Check end.
Inspection Procedure 7: Starting Impossible (Initial Combustion But no Complete Combustion),

Improper Starting (Long time to Start)
Failure is possibly caused by poor ignition, incorrect air-fuel ratio at cranking, improper fuel pressure or other faults.
PROBABLE CAUSE
Failed battery
Failed fuel system
Air-fuel ratio control

Failed idle speed control system
Failed intake system
Failed exhaust gas cleaning system
Throttle valve fouled around
Timing belt not in place
Compression pressure improper
Failed engine-ECU
13A-200

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1: Check battery condition.
Q: Have the battery terminal been disconnected?
YES : After warm-up engine, idle for about 10
minutes.
NO : Go to Step 2 .

OK: 8 V or higher
Battery - On-vehicle Service - Battery Test

354A).
YES : Inspection chart for diagnosis codes (Refer
to 313A)
NO : Go to Step 4 .

b. Item 21: Engine coolant temperature sensor
c. Item 25: Barometric pressure sensor

STEP 5: Check start ability.
With depressing the accelerator pedal slightly,
and start the engine.
Q: Is the start ability good?
NO : Go to Step 7 .
STEP 6: Check idle speed control servo for

operating sound.
YES : Clean throttle body (throttle valve portion)
(Refer to 313A).
(Refer to Code No. P0505 313A).

STEP 7: MUT-II actuator test
Item 07: Fuel pump
OK: Operating sound of fuel pump can be
heard.
Inspection Procedure 24 313A).

STEP 8: Check air intake from intake hose and
inlet manifold.
NO : Repair.

Check injector for operating sound at engine
cranking (Refer to 313A).
cylinder.
(Refer to Code No. P0201: No.1 injector system
313A.)
313A.)
313A.)
313A.)
STEP 10. Check timing marks of timing belt.
NO : Align timing marks.
13A-201
TROUBLESHOOTING

connector.
CONNECTOR: C-134
STEP 13: Connector check: B110 and B-111

B-111 (GR)
3 2 1
Harness side
connector
C-134
B-110 (GR)
AK300308 AB
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.
AK300257 AB

Ignition switch: ON
OK: 0.5 V or less
STEP 14: Check ignition coil spark.

STEP 15: Check spark plug.


NO : Replace spark plug.

connector
CONNECTOR: C-134
STEP 16: Check spark plug cable itself.

Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).
NO : Replace spark plug cable.
C-134
STEP 17: Check ignition coil itself.

Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

(terminal No. 13 and No. 26) engine-ECU

and damage.
NO : Repair.

NO : Replace ignition coil.
13A-202
TROUBLESHOOTING
STEP 18: Check harness between terminal No. 2

of each cylinders ignition coil connector and
vehicle body earth.
B-111 (GR)
3 2 1
Harness side
connector
STEP 19: Check spray condition of injector.

Check each injector for spray condition (Refer to
313A).
STEP 20: Check compression pressure.

Check compression pressure (Refer to GROUP
11A - On-vehicle Service 311A).
B-110 (GR)
AK300308 AB

NO : Repair.
CONNECTOR: C-134
C-134
STEP 21: Check EGR control solenoid valve

itself.
Check EGR control solenoid valve itself [Refer to
GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317
].
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

YES : Check and repair harness between terminal
No. 3 of each cylinders ignition coil

connector and C-134 engine-ECU
connector.
Check signal line for open/short
circuit and damage.
NO : Repair.
STEP 22: Check EGR valve itself.

Check EGR valve itself [Refer to GROUP 17 Emission Control System - Exhaust Gas Recirculation (EGR) System 317].
NO : Replace EGR valve.
STEP 23: Replace engine-ECU.

After replacing the engine-ECU, re-check the
trouble symptoms.

NO : Check end.
Inspection Procedure 8: Unstable idling (Rough idling, hunting), Improper idling speed (Too high or
too low), Engine stalls during idling (Die out)
Probable causes can be widely found in ignition
system, air-fuel ratio control system, idle speed
control system, fuel system, etc. A sudden
engine stall is possibly caused by poor connector
contact.
PROBABLE CAUSE
Failed fuel system
Failed air-fuel ratio control system
Failed intake/exhaust system

TROUBLESHOOTING
Failed emission gas cleaning system

Throttle valve body fouled
Timing belt out of place
Compression pressure improper
Failed engine-ECU
DIAGNOSIS PROCEDURE
13A-203
STEP 5: Check idle speed control servo for

operating sound.

STEP 1: Check battery condition.
Q: Has the battery terminal been disconnected?
YES : After warm-up engine, idle for about 10
minutes.
NO : Go to Step 2 .

to 313A).
NO : Go to Step 3 .
c. Item 14: Throttle position sensor
d. Item 21: Engine coolant temperature sensor
e. Item 25: Barometric pressure sensor

a. Item 27: Power steering fluid pressure switch
NO : Check power steering fluid pressure switch
system (Refer to Code No. P0551 313A

).
STEP 6: Check throttle body (throttle valve

(Refer to 313A).
STEP 7: Check air intake from intake hose and
inlet manifold.
NO : Repair.

313A).
cylinder.
system 313A.)
system 313A.)
system 313A.)
system 313A.)
STEP 9: Check timing marks of timing belt.

to Code No. P0130 313A).
13A-204
TROUBLESHOOTING

connector.

connector.
CONNECTOR: C-134
CONNECTOR: C-135
C-134
C-135
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300257 AB

Ignition switch: ON
OK: 0.5 V or less

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

(terminal No. 13 and No. 26) engine-ECU

and damage.
NO : Repair.
AK300256 AB

Engine: Idling after warm-up
Radiator fan: Not operating
OFF causes the voltage to increase by 0.2 3.5 V.

13A-205
TROUBLESHOOTING

connector and B-30 alternator connector
CONNECTOR: C-135

No. 33) engine-ECU connector and B-30 (terminal
No. 1) alternator connector.
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
AK300256 AB
CONNECTOR: B-30
CONNECTOR: B-30
B-30 (GR)
B-30 (GR)
4 3 2 1
Harness side
connector

NO : Repair.
4 3 2 1
AK300296 AB
Harness side
connector
AK300296 AB

connector B-19, and repair if necessary.
NO : Repair.
13A-206
TROUBLESHOOTING

connector.
CONNECTOR: C-135

connector and B-30 alternator connector
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

Radiator fan: Not operating
OFF causes the voltage to fall.

AK300256 AB
CONNECTOR: B-30
B-30 (GR)
4 3 2 1
Harness side
connector

NO : Repair.
AK300296 AB
13A-207
TROUBLESHOOTING

No. 54) engine-ECU connector and B-30 (terminal

connector.
CONNECTOR: C-134
CONNECTOR: C-135
C-134
C-135
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300257 AB
AK300256 AB
CONNECTOR: B-30
B-30 (GR)
4 3 2 1
Harness side
connector
AK300296 AB

connector B-19, and repair if necessary.
NO : Repair.

Engine: Idling
A/C switch: ON (A/C compressor ON)
OK:
1 V or less (with outside air temperature sensor ambient temperature at 18C or higher
and A/C set for maximum air flow at minimum temperature)
System voltage (with A/C set for minimum air
flow at room temperature)

NO : Check A/C load signal system (Refer to

STEP 21. Connector check: B-110 and B-111

B-111 (GR)
3 2 1
Harness side
connector
00 - How to Use
300).
B-110 (GR)
AK300308 AB

NO : Repair.
13A-208

TROUBLESHOOTING
STEP 22. Check ignition coil spark.

STEP 26. Check harness between terminal No. 2

of ignition coil connector of each cylinder and
body earth.
STEP 23. Check spark plug.

STEP 24. Check individual spark plug cable

).
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
Q: Q: Is the check result normal?

STEP 25. Check ignition coil itself.

C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Check earthing line for open/short circuit and

damage.
No. 3 of ignition coil connector of each

cylinder and C-134 engine-ECU
Check signal line for open/short and
damage.
NO : Repair.
STEP 27. Check injector for spray condition.
313A).
STEP 28. Check compression pressure.

NO : Repair.

TROUBLESHOOTING

itself.
Check purge control solenoid valve itself (Refer to
GROUP 17 - Emission Control System - Evaporative Emission Control System 317)
STEP 30. Check EGR control solenoid valve

itself.
].
13A-209

itself.
].

Item 07: Fuel pump
OK: Operating sounds of fuel pump can be
heard.
inspection Procedure 24 313A).

STEP 33. Replace engine-ECU.
After engine-ECU is replaced, re-check for trouble symptom.
Q: Does trouble system persist?

NO : Check end.
Inspection Procedure 9: The Engine Stalls when Starting the Car (Pass Out)
Engine stall on starting is possibly caused by misfire due to failed spark plug, improper air-fuel
ratio at accelerator pedal depression or other
faults.
PROBABLE CAUSE
Failed intake system
Failed emission gas cleaning system
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 2. Check EGR control solenoid valve itself.

].
STEP 3. Check EGR valve itself.

13A-210
TROUBLESHOOTING
STEP 4. Check air intake from intake hose and

inlet manifold.
NO : Repair.


ignition connectors.
B-111 (GR)

3 2 1
Harness side
connector

body earth.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
B-110 (GR)

NO : Repair.
AK300308 AB
CONNECTOR: C-134

NO : Go to Step 7 .
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
STEP 8.Check spark plug cable itself.

).
AK300257 AB


cylinder and C-134 engine-ECU.
circuit and damage.
NO : Repair.
13A-211
TROUBLESHOOTING
Inspection Procedure 10. The Engine Stalls when Decelerating

Engine stall on deceleration is possibly caused
by insufficient air intake, improper air-fuel ratio
due to failed exhaust gas recirculation system or
other faults.
PROBABLE CAUSE
Failed emission control system
Throttle valve fouled
Failed engine-ECU
DIAGNOSIS PROCEDURE


(Refer to 313A).
to 313A).
NO : Go to Step 2 .


B-111 (GR)
3 2 1
Harness side
connector

NO : Check throttle position sensor system
B-110 (GR)

Item 45: Idle speed control servo position
OK: Idle speed control servo drops to 0 - 2
Steps at deceleration (engine at 1,000 r/min
or higher).

].
AK300308 AB

NO : Repair.

NO : Go to Step 9 .

13A-212

TROUBLESHOOTING
STEP 10. Check spark plug cable itself.

).

body earth.

B-111 (GR)
3 2 1
Harness side
connector

B-110 (GR)

AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB


circuit and damage.
NO : Repair.
Inspection Procedure 11: Engine does not Revole Up

Failure is possibly caused by failed fuel system,
ignition system or other faults.
DIAGNOSIS PROCEDURE
PROBABLE CAUSE
Failed fuel system
Timing belt out of place
Failed engine-ECU

to 313A).
NO : Go to Step 2 .
13A-213
TROUBLESHOOTING

NO : Align match marks.
STEP 8. Check harness between terminal No. 2 of

ignition coil connector of each cylinder and body
earth.

B-111 (GR)
3 2 1
Harness side
connector
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
B-110 (GR)
AK300308 AB

NO : Repair
C-134

NO : Go to Step 5 .
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB


).



circuit and damage.
NO : Repair
NO : Repair
13A-214

TROUBLESHOOTING
Inspection Procedure 12: Hesitation, sag,poor acceleration, stumble, surge

Failure is possibly caused by failed ignition system, improper air-fuel ratio, improper compression pressure or other faults.
PROBABLE CAUSE
Failed air-fuel ratio control system
Failed fuel system
Failed intake and exhaust system
Throttle valve fouled
Improper compression pressure
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 2. Check injector for operating sound.
313A).
cylinder.
(Refer to code No. P0201: No. 1 injector system
313A).
313A).
313A).
313A).

a. Idem 13: Intake air temperature sensor
b. Item 14: Throttle position sensor
Procedure for the sensor that has shown an

itself.
Check purge control solenoid valve itself (Refer
to GROUP 17 - Emission Control System Evaporative Emission Control System 317).

].

Check EGR itself [Refer to GROUP 17 - Emission Control System - Exhaust Gas Recirculation
(EGR) System 317].

NO : Check oxygen sensor system (Refer to
Code No. P0130 313A).
13A-215
TROUBLESHOOTING

B-111 (GR)
3 2 1
Harness side
connector

body earth.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
B-110 (GR)
AK300308 AB
AK300308 AB

NO : Repair
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

).



cylinder and C-134 engine-ECU
circuit and damage.
NO : Repair.
(Refer to 313A).
NO : Repair.
13A-216
TROUBLESHOOTING

NO : Repair.
Inspection Procedure 13. The Feeling of Impact or Vibration when Accelerating

Failure is possibly caused by failed ignition leak
with rise in spark plug-required voltage at acceleration.
PROBABLE CAUSE
Failed engine-ECU

NO : Go to Step 4 .

DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 2. Check connector: B-110 and B-111

B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

NO : Repair.

).


TROUBLESHOOTING
13A-217
STEP 7. Check harness between terminal No. 2 of

ignition coil connector of each cylinder and body
earth.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

3 of ignition coil connector of each cylinder

and C-134 engine-ECU
circuit and damage.
NO : Repair.
Inspection Procedure 14: The feeling of impact or vibration when decelerating

Failure is possibly caused by insufficient air
intake due to failed idle speed control system.
PROBABLE CAUSE
Throttle valve body fouled
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
13A-218

TROUBLESHOOTING
STEP 2. Check idle speed control servo for

operating sound.

NO : Check throttle position sensor system

STEP 4. Check throttle body (throttle valve)
contamination.
(Refer to 313A).
Inspection Procedure 15: Knocking

Failure is possibly caused by failed detonation
control, improper thermal value of spark plug or
other faults.
PROBABLE CAUSE
Defective detonation sensor
Failed detonation control system
Defective spark plug
Failed engine-ECU

B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
AK300308 AB

NO : Repair.

YES : Check detonation sensor (Refer to Code
No. P0325 313A).

NO : Go to Step 4 .

13A-219
TROUBLESHOOTING

16 -Ignition System - On-vehicle Service 316
).
STEP 7. Check harness between ignition coil

connector terminal No. 2 of each cylinder and
body earth.

B-111 (GR)
3 2 1
Harness side
connector

B-110 (GR)
AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

YES : Check and repair harness between ignition
coil connector terminal No. 3 of each

cylinder and C-134 engine-ECU connector.
Check signal line for open circuit,
short circuit and damage.
NO : Repair.
Inspection Procedure 16: Ignition Timing Offset

Failure is possibly caused by failed crank angle
sensor, failed camshaft position sensor, improper
installed timing belt or other faults.
PROBABLE CAUSE
Failed camshaft position sensor
Improperly installed timing belt
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
13A-220
TROUBLESHOOTING
STEP 2. Measure output waveforms of crank

angle sensor and camshaft position sensor (Use
oscilloscope).
Connector: B-29

NO : Go to Step 4 .
2 1
3
Harness side
connector
B-29 (B)

00 - How to Use
300).
STEP 4. Check crank angle sensor and camshaft
position sensor mounted conditions.
NO : Repair.

Crank angle sensor

AK300276 AB
STEP 6. Check crank angle sensor vane.
Connector: B-106
3 2 1
Harness side
connector

NO : Replace crank angle sensor vane.
STEP 7. Check camshaft position sensing

cylinder.
B-106 (B)
AK300279 AB
Crank Angle Sensor

Use special tool test harness (MB998478) to connect B-29 crank angle sensor connector, and
measure at pick-up harness.
Engine: Idling
Camshaft Position Sensor
Use special tool test harness (MD991709) to connect B-106 camshaft position sensor connector,
and measure at pick-up harness.
Engine: Idling
OK: Output waveform timings of both sensors are the same as the check procedure
(Refer to 313A) using an oscilloscope.

NO : Replace camshaft position sensing cylinder.
STEP 8. Replace crank angle sensor.

After replacing the crank angle sensor, re-check
NO : Check end.

TROUBLESHOOTING
13A-221
STEP 9. Replace camshaft position sensor.

After replacing the camshaft position sensor, recheck the trouble symptoms.
00 - How to Use
300).
Inspection Procedure 17: Run on (Dieseling)

Failure is possibly caused by leakage from injector.
PROBABLE CAUSE
Failed injector
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Check injector for spray condition.
313A).
Inspection Procedure 18: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC during
Idling
Failure is possibly caused by improper air-fuel
ratio, deteriorated catalyst, failed ignition system,
failed fuel system, failed compression pressure or
other faults.
PROBABLE CAUSE
Incorrect air/fuel ratio
Failed fuel system
Failed intake and exhaust system
Failed compression pressure
Failed catalytic converter
Failed engine-ECU
STEP 2. Check injector for operating sound.

313A).
cylinder.
(Refer to 313A, Code P0201: No. 1 injector
System)
System)
System)
(Refer to 313A, Code P0204: No. 4
injector System)
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 3. Check ignition timing.

Check ignition timing. (Refer to GROUP 11A On-vehicle Service 311A).
NO : Check for offset ignition timing (Refer to
13A-222

TROUBLESHOOTING


itself.
].


Procedure for the sensor that has shown an

STEP 5. Check air intake from intake hose and
inlet manifold.
NO : Repair.
STEP 6. Check for emission leakage from

exhaust manifold.
NO : Repair.

(Refer to 313A).


NO : Repair.
STEP 13. Check positive crankcase ventilation

valve itself.
Check positive crankcase ventilation valve itself
(Refer to GROUP 17 - Emission Control System
- crankcase Emission Control System 317).
NO : Replace positive crankcase ventilation
valve.



to Code No. P0130 313A).

STEP 9. Check Purge control solenoid valve
itself.
Check purge control solenoid valve itself (Refer
to GROUP 17 - Emission Control System Evaporative Emission Control System 317).

).

TROUBLESHOOTING
13A-223

STEP 18. Check injector for spraying condition.

313A).



STEP 19. Replace catalytic converter.

After replacing the catalytic converter, re-check

NO : Repair.

NO : Check end
Inspection Procedure 19: Battery Rundown

Failure is possibly caused by failed alternator,
failed generation control circuit or other faults.
STEP 2. Connector check: B-19 intermediate

connector
CONNECTOR: B-19
PROBABLE CAUSE
Failed battery
Alternator G terminal short-circuited
Failed alternator
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Check battery voltage.
Measure battery voltage during cranking.
OK: 8 V or more

354A).
B-19 (B)
3 2 1
6 5 4
Female side
connector

NO : Repair.
AK300294 AB
13A-224

TROUBLESHOOTING

connector.
STEP 4. Connector check: C-303 ignition switch

connector
CONNECTOR: C-303
CONNECTOR: B-19
B-19 (B)
C-303
3 2 1
6 5 4
1 2 3
4 5 6
Male side
connector
Harness side
connector
Disconnect connector, and measure at male connector side.

Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
AK300304 AB
AK300295 AB
CONNECTOR: B-19
B-19 (B)
1 2 3
4 5 6
Male side
connector
AK300295 AB

YES : Check intermediate connectors C-04, C-05,
C-105, C-203 and C-205, and repair if

necessary. If intermediate connectors are
normal, check and repair harness between
B-19 (terminal No. 5) intermediate
ignition switch connector.
open/short circuit.
NO : Repair.
13A-225
TROUBLESHOOTING

connector.
CONNECTOR: B-19

No. 4) intermediate connector and B-30 (terminal
CONNECTOR: B-19
B-19 (B)
B-19 (B)
3 2 1
6 5 4
Female side
connector
3 2 1
6 5 4
AK300294 AB
Disconnect connector, and measure at female

connector side.
Ignition switch: ON
OK: System voltage
Female side
connector
AK300294 AB
CONNECTOR: B-30

NO : Go to Step 6 .
B-30 (GR)

connector
Harness side
connector
4 3 2 1
CONNECTOR: B-30
4 3 2 1
Harness side
connector

NO : Repair.

NO : Repair.
B-30 (GR)
AK300296 AB
AK300296 AB
13A-226

TROUBLESHOOTING

No. 5) intermediate connector and B-30 (terminal
CONNECTOR: B-19

No. 3) alternator connector and C-303 (terminal
No. 2) ignition switch connector.
CONNECTOR: B-30
B-19 (B)
B-30 (GR)
3 2 1
6 5 4
Female side
connector
4 3 2 1
AK300294 AB
Harness side
connector
AK300296 AB
CONNECTOR: C-303
CONNECTOR: B-30
B-30 (GR)
C-303
3 2 1
6 5 4
4 3 2 1
Harness side
connector
Harness side
connector
Check power supply line for open/short circuit.

NO : Repair.
AK300304 AB
AK300296 AB

connectors C-04, C-05, C-105, C-203 and C-205 and
NO : Repair.

connector
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-227
TROUBLESHOOTING

connector.

connector.
CONNECTOR: C-135
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
CONNECTOR: B-19
B-19 (B)
1 2 3
4 5 6
Male side
connector
AK300295 AB

side.
Ignition switch: ON
OK: System voltage
(terminal No. 4) intermediate connector and

C-135 (terminal No. 33) engine-ECU
connector.
AK300256 AB

Radiator fan: Inactive
OFF causes the voltage to increase by 0.2 3.5 V.

NO : Check alternator.

00 - How to Use
300).
13A-228

TROUBLESHOOTING
Inspection Procedure 20: Overheating

Failure is possibly caused by failed engine cooling system, failed fan controller, failed engine
coolant temperature sensor or other faults.
PROBABLE CAUSE
Insufficient or deteriorated engine coolant
Failed fan controller
Failed engine coolant temperature sensor
Failed thermostat
Failed water pump
Failed radiator core
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 2. Check engine coolant
NOTE: If engine coolant level falls too early, check
for leaky spots, and repair if necessary.
Check engine coolant (Refer to GROUP 14 - Onvehicle Service 314).
NO : Replace or add engine coolant.

Item 21: Fan controller
OK: Fan motor rotating
NO : Check fan control relay system (Refer to

Item 21: Engine coolant temperature sensor
OK:
Engine hot state: At 80 - 120C
NO : Check engine coolant temperature sensor
system (Refer to Code No. P0115 313A

).
STEP 5. Check thermostat.
Check thermostat (Refer to GROUP 14 - Thermostat 314).
NO : Replace thermostat.
STEP 6. Check water pump.

Check water pump.
YES : Replace radiator.
NO : Replace water pump.

TROUBLESHOOTING
13A-229
Inspection Procedure 21: Abnormal Rotation of Fan Motor
Fan controller (Radiator fan, A/C condensor fan) Circuit
5V
A-20
(MU802322)
1 2 3
Fan controller
2
L-W
7
A-14
L-W
21
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300309 AB
OPERATION
The control (duty) signal is inputted to the fan
controller (terminal No. 2) from the engine-ECU
(terminal No. 21).
FUNCTION
The engine-ECU inputs a duty signal suitable for
the engine coolant temperature, vehicle speed
and A/C switch position to the fan controller. In
response to the signal, the fan controller controls
the rotating speeds of the radiator fan and A/C
condenser fan (The fan speed becomes higher
as the average voltage of the terminal comes
nearer to 5V).
PROBABLE CAUSE
Open/short circuit in fan controller circuit or loose
connector contact
Failed engine-ECU
13A-230
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector

00 - How to Use
300).
CONNECTOR: C-134

connector.
C-134
CONNECTOR: C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

C-134
AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
STEP 2. Check at C-134 engine-ECU connector.

CONNECTOR: C-134
AK300257 AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

YES : Replace fan controller.
NO : Go to Step 5 .
STEP 5. Connector check: A-20 fan controller

connector
Connector: A-20
AK300257 AB

side.
Ignition switch: ON
Short-circuit terminal No. 21 to earth.
OK: Fan motor stops rotating.
NO : Go to Step 4 .
A-20 (GR)
3 2 1
Harness side
connector

NO : Repair.
AK203423 AC

TROUBLESHOOTING
13A-231
STEP 6. Check harness between A-20 (terminal

No. 2) fan controller connector and C-134
Connector: A-20
A-20 (GR)
3 2 1
Harness side
connector
AK203423 AC
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

connector A-14, and repair if necessary.
YES : Replace fan controller.
NO : Repair.
Inspection Procedure 22: Poor A/C Performance

Failure is possibly caused by short /overcharged
A/C refrigerant, failed A/C control system, failed
fan control system or other faults.
PROBABLE CAUSE
Short or overcharged A/C refrigerant
Failed A/C compressor relay
Failed A/C-ECU
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
13A-232

TROUBLESHOOTING
STEP 2. A/C compressor magnet clutch

operation check.
Engine: Idling
A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more
Maximum Hot when temperature in cabin is 25C
or less
OK:
Magnet clutch active (when A/C is ON)
Magnet clutch inactive (when A/C is OFF)

Item 49: A/C relay
a. Engine: Running at idle
b. A/C set temperature:
25C or more.
Maximum Hot when temperature in cabin is
25C or less.
OK:
ON (when A/C is ON)
OFF (when A/C is OFF)

NO : Go to Step 3 .

YES : Check A/C system (Refer to GROUP 55A -
Troubleshooting 355A).
NO : Check A/C compressor relay (Refer to

Item 28: A/C switch
a. Engine: Idling
25C or more
25C or less
OK:
ON (when A/C is ON)
NO : Check A/C switch (Refer to Inspection
Procedure 26 313A).
inspection procedure 27 313A).

STEP 5. Check charged amount of A/C
refrigerant.
Check charged amount of A/C refrigerant (Refer
to GROUP 55A - On-vehicle Service 355A).
NO : Adjust charged amount of A/C refrigerant.

OK: Fan motor rotates.
YES : Check A/C load signal system (Refer to

NO : Check fan control relay system (Refer to
Inspection Procedure 25313A).
13A-233
TROUBLESHOOTING
Inspection Procedure 23: Engine-ECU Power Supply, Engine Control Relay, Ignition Switch-IG1
System
Power supply and ignition switch-IG circuit
Battery
9
20A
Relay box
Ignition switch
123
456
ACC
ST
W-B
C-303
LOCK
R
IG1
A-14
5
IG2
W-B
L-B
6
W-B
W-B
4
B-17X
8
7.5A
J/B
3
1
C-202
Engine
control
relay
L-B
R
C-106
10
J/C (2)
C-17
W-B
Y-G
9
L-B
10
R
12
25
38
80
82
Battery
backup
Power
source
C-134
C-135
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Engine-ECU
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Wire colour code

AK300310
AB
13A-234

TROUBLESHOOTING
OPERATION
The battery voltage is applied to the engine control relay (terminal No. 3 and 4).
power transistor in the unit be in "ON" position
and makes currents go on the engine control
relay coil, and that makes the relay be in "ON"
position.
When the engine control relay is in "ON" position,
the battery voltage is supplied to the engineECU, the sensor and the actuator from the
engine control relay (terminal No. 1).
FUNCTION
When the ignition switch ON signal is input to the
engine-ECU, the engine-ECU places the engine
control relay in the ON position. Accordingly, the
battery voltage is supplied to the engine-ECU,
sensor and actuator.
PROBABLE CAUSE
Failed engine control relay
Open/short circuit in engine control relay circuit or
Failed engine-ECU
DIAGNOSIS PROCEDURE

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB

NO : Repair.
STEP 3. Check engine control relay.

Check engine control relay (Refer to 313A).
NO : Replace engine control relay.
STEP 4. Measure voltage at B-17X engine control

relay connector.
CONNECTOR: B-17X
STEP 1. Check battery voltage.

Measure battery voltage during cranking.
OK: 8 V or more

354A).
Relay boxs
triangle marks
Harness side
connector
B-17X
AK300255 AB
Remove relay, and measure at relay box side.

OK: System voltage

harness between B-17X (terminal No. 4)
engine control relay connector and battery.
open/short circuit.
13A-235
TROUBLESHOOTING

connector.

connector.
CONNECTOR: C-137
CONNECTOR: C-134
C-134
C-137
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300257 AB

Ignition switch: ON
OK: System voltage
YES : Check and repair C-134 engine-ECU
AK300254 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .
connector.
NO : Go to Step 6 .

connector

connector
CONNECTOR: C-137
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

AK300254 AB

NO : Repair.

NO : Repair.
13A-236
TROUBLESHOOTING
STEP 9. Check ignition switch.

Check ignition switch (Refer to GROUP 54A Ignition Switch - Ignition Switch 354A).
NO : Replace ignition switch.

No. 2) ignition switch connector and C-137
CONNECTOR: C-303

connector
CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
C-303
CONNECTOR: C-137
3 2 1
6 5 4
Harness side
connector
AK300304 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

connectors C-106, C-202 and C-203, and repair if
necessary.
Check output line for open/short circuit.
YES : Check and repair ignition switch IG1 power
supply line harness and connector.

Check power supply line for short
circuit.
NO : Repair.
13A-237
TROUBLESHOOTING

connector.
CONNECTOR: C-135

connector.
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

Ignition switch: ON
OK: 1 V or less
CONNECTOR: B-17X
Relay boxs
triangle marks
Harness side
connector
AK300256 AB
B-17X

AK300255 AB

Ignition switch: OFF
OK: System voltage
NO : Check and repair harness between B-17X

Check earthing line for open/short
circuit.
13A-238
TROUBLESHOOTING

connector, C-303 ignition switch connector
CONNECTOR: C-135

CONNECTOR: C-303
C-303
C-135
3 2 1
6 5 4
Harness side
connector
AK300304 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-137

AK300256 AB
CONNECTOR: C-303
C-137
C-303
3 2 1
6 5 4
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Harness side
connector
AK300304 AB

AK300254 AB

NO : Repair.

connectors C-106, C-202 and C-203 and repair if
necessary.
NO : Repair.

00 - How to Use
300).
13A-239
TROUBLESHOOTING
STEP 17. Check harness between B-17X

(terminal No. 1) engine control relay connector
and C-134 (terminal No. 12 and No. 25) engineECU connector.
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
STEP 18. Check engine control relay output

power supply harness and connector for short
circuit.
NO : Repair.

(terminal No. 3 and No. 4) engine control relay
connector and battery.
CONNECTOR: B-17X
Harness side
connector
AK300255 AB
Relay boxs
triangle marks
B-17X
CONNECTOR: C-134
2
Harness side
connector
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
AK300255 AB

NO : Repair.
13A-240
TROUBLESHOOTING

connector.
CONNECTOR: B-17X
B-17X
Relay boxs
triangle marks
Harness side
connector
AK300255 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-241
TROUBLESHOOTING
Inspection Procedure 24: Fuel Pump System
Fuel pump circuit

Battery
C-303
123
456
24
15A
L-B
C-202
2
4
C-213
1 2
3 4
1 2
3 4
OFF
Fuel
pump
relay (1)
C-215
C-203
6
ON
Ignition switch
ACC
IG2
C-116
41
C-215
ST
IG1
Reray box
LOCK
ON
OFF
Fuel
pump
relay (2)
C-213
C-209 1
C-205 11
8
7.5A
J/B
C-205
14
B-L
D-24 6
G
B-L
5
Fuel pump
D-16
(MU802058)
1 2 3
4 5
B
D-24 4
G
B
22
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

AK300311 AB
13A-242
TROUBLESHOOTING
OPERATION
The battery voltage is applied to the fuel pump
relay (1) (terminal No. 3) form the ignition switch
and is earthed to the vehicle body from the fuel
pump relay (1) (terminal No. 2).
relay (1) (terminal No. 4) and to the fuel pump
relay (2) (terminal No. 1) from the fuel pump relay
(1) (terminal No. 1).
relay (2) (terminal No. 3) from the ignition switch.
power transistor in the unit be in "ON" position
and makes currents go on the fuel pump relay (2)
coil, and that makes the relay be in "ON" position.
When the fuel pump relay (2) is in "ON" position,
the battery voltage is supplied to the fuel pump
(low pressure) from the fuel pump relay (2) (terminal No. 4).
FUNCTION
When the ignition switch ON signal is input to the
engine-ECU, the engine-ECU places the fuel
pump relay in the "ON" position. Accordingly, the
battery voltage is supplied to the fuel pump.
PROBABLE CAUSE
Failed fuel pump relay
Failed fuel pump
Open/short circuit in fuel pump drive circuit or
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-215 fuel pump relay
(1) connector and C-213 fuel pump relay (2)
connector
Junction blocks
triangle marks
C-215
C-213
2 1
4 3
Harness side
connector
AK300312 AB

NO : Repair.
STEP 2. Check fuel pump relay.

Fuel pump relay, continuity check (Refer to
313A).
NO : Replace fuel pump relay.
STEP 3. Measure resistance at C-215 fuel pump

relay (1) connector.
CONNECTOR: C-215
Junction blocks
triangle marks
C-215
2 1
4 3
Harness side
connector
AK300313 AB
Remove relay, and measure at junction block

side.
OK: 2 W or less
NO : Check intermediate connector C-205, and

fuel pump relay (1) connector and body
earth.
and damage.
13A-243
TROUBLESHOOTING
STEP 4. Measure voltage at C-215 fuel pump

CONNECTOR: C-215
Junction blocks
triangle marks

connector
CONNECTOR: C-303
C-215
2 1
4 3
Harness side
connector
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
AK300313 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
CONNECTOR: C-215
Junction blocks
triangle marks
C-215
2 1
4 3
Harness side
connector
AK300313 AB


fuel pump relay (1) connector and C-303
circuit and damage.
NO : Repair.
13A-244

TROUBLESHOOTING

CONNECTOR: C-215
Junction blocks
triangle marks

connector
CONNECTOR: C-303
C-215
2 1
4 3
Harness side
connector
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
AK300313 AB

side.
OK: System voltage
NO : Check intermediate connectors C-116 and

No. 4) fuel pump relay (1) connector and
battery.
open/short circuit.
CONNECTOR: C-213
C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
AK300321 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .
CONNECTOR: C-213
C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
AK300321 AB


ignition switch connector and C-213
(terminal No. 3) fuel pump relay (2)
connector.
open/short circuit.
NO : Repair.
13A-245
TROUBLESHOOTING

connector

connector.
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
AK300257 AB
CONNECTOR: C-213
C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
AK300321 AB

side.
Ignition switch: ON
OK: System voltage
NO : Check intermediate connectors C-106 and

No. 2) fuel pump relay (2) connector and C134 (terminal No. 22) engine-ECU
connector.
Check earthing line for open/short
circuit.
13A-246

TROUBLESHOOTING
STEP 11. Connector check: D-16 fuel pump

connector
Connector: D-16

No. 4) fuel pump relay (2) connector and D-16
(terminal No. 5) fuel pump connector.
CONNECTOR: C-213
D-16 (GR)
3 2 1
5 4
Harness side
connector
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
C-213
AK203431AC
AK300321 AB

NO : Repair.
Connector: D-16
STEP 12. Measure voltage at D-16 fuel pump

connector.
D-16 (GR)
Connector: D-16
3 2 1
5 4
Harness side
connector
D-16 (GR)
3 2 1
5 4
Harness side
connector
AK203431AC

side.
Ignition switch: ON
Using a jumper wire, connect C-134 (terminal No.
22) engine-ECU connector and earth.
OK: System voltage
AK203431AC

connectors D-209 and D-24, and repair if necessary.
NO : Repair.
13A-247
TROUBLESHOOTING
STEP 14. Measure resistance at D-16 fuel pump

connector.
Connector: D-16

(terminal No. 3) fuel pump relay (1) connector.
CONNECTOR: C-303
D-16 (GR)
3 2 1
5 4
Harness side
connector
C-303
3 2 1
6 5 4
AK203431AC

side.
OK: 2 W or less
NO : Check intermediate connector D-24, and

harness between D-16 (terminal No. 4) fuel
pump connector and body earth.
and damage.
connector
CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
CONNECTOR: C-215
C-215
2 1
4 3
Harness side
connector
AK300313 AB
NOTE: Before checking harness,check intermediate

NO : Repair.
STEP 17. Check harness between battery and C215 (terminal No. 4) fuel pump relay (1)
connector.
CONNECTOR: C-215
Harness side
connector
AK300304 AB
Junction blocks
triangle marks
Junction blocks
triangle marks
C-215
2 1
4 3
Harness side
connector

NO : Repair.
AK300313 AB

NO : Repair.
13A-248
TROUBLESHOOTING

No. 1) fuel pump relay (1) connector and C-213
Junction blocks
triangle marks

No. 3) fuel pump relay (2) connector and C-134
CONNECTOR: C-213
Junction blocks
triangle marks
C-215
C-213
2 1
4 3
Harness side
connector
2 1
4 3
Harness side
connector
C-213
AK300312 AB
AK300321 AB
CONNECTOR: C-134

NO : Repair.

C-134
CONNECTOR: C-303
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

C-303
AK300257 AB
3 2 1
6 5 4
Harness side
connector
AK300304 AB
CONNECTOR: C-213
C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
AK300321 AB

NO : Repair.

NO : Repair.

TROUBLESHOOTING

No. 3) fuel pump relay (2) connector and D-16
(terminal No.5) fuel pump connector.
CONNECTOR: C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
C-213
AK300321 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

connectors D-24 and C-205, and repair if necessary.
YES : Replace fuel pump.
NO : Repair.
13A-249
13A-250
TROUBLESHOOTING
Inspection Procedure 25: Fan Control Relay System
Fan control relay Circuit

Battery
W
9
20A
W-B
A-14
5
W-B
W-B
3
4
B-17X
1
Engine control system
R
To engine-ECU
Fusible link (2)
J/C (2)
C-17
R
A-14
11
L-W
R
4
A-10X
Fan control relay
4
2
3
B
L
3
A-20
(MU802322)
1 2 3
Smoothing
circuit
Fan controller
Wire colour code

O: Orange GR: Gray

AK300323 AB

TROUBLESHOOTING
OPERATION
The battery voltage is applied to the fan control
relay (terminal No. 1) from the engine control
relay (terminal No. 1) and is earthed to the vehicle body from the fan control relay (terminal No.
3).
The battery voltage is applied to the fan control
When the fan control relay is in "ON" position, the
battery voltage is supplied to the fan controller
(terminal No. 3) from the fan control relay (terminal No. 2).
FUNCTION
When the engine control relay is in "ON" position,
the fan control relay is also simultaneously
placed in "ON" position. Accordingly, the battery
voltage is supplied to the fan controller.
PROBABLE CAUSE
Failed fan control relay
Failed radiator fan motor
Failed condenser fan motor
Open/short circuit in fan control relay circuit or
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: A-10X fan control
relay connector
CONNECTOR: A-10X
STEP 2. Check fan control relay.

Check fan control relay (Refer to GROUP 14 On-vehicle Service 314).
NO : Replace fan control relay.
STEP 3. Measure resistance at A-10X fan control

relay connector.
CONNECTOR: A-10X
A-10X
1
4
Harness side
connector
Remove relay and measure at relay box side.

OK: 2 W or less
NO : Check and repair harness between A-10X
(terminal No. 3) fan control relay connector

and body earth.
and damage.
CONNECTOR: A-10X
A-10X
4
Harness side
connector

NO : Repair.
AK300324 AB
STEP 4. Measure voltage at A-10X fan control

relay connector.
A-10X
13A-251
AK300324 AB
1
4
Harness side
connector
AK300324 AB
Remove relay and measure at relay box side.

Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13A-252
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
STEP 6. Measure voltage at A-10X fan control

relay connector.
CONNECTOR: A-10X
B-17X
A-10X
Harness side
connector
AK300255 AB
A-10X
4
Harness side
connector
1
4
Harness side
connector
AK300324 AB

Voltage between terminal No. 4 and earth
OK: System voltage
CONNECTOR: A-10X
AK300324 AB

YES : Check intermediate connectors A-14 and C-

engine control relay connector and A-10X
(terminal No. 1) fan control relay connector.
open/short circuit.
NO : Repair.

NO : Check and repair harness between battery
and A-10X (terminal No. 4) fan control relay

connector.
open/short circuit.
STEP 7. Connector check: A-20 fan controller
connector
Connector: A-20
A-20 (GR)
3 2 1
Harness side
connector

NO : Repair.
AK203423 AC
13A-253
TROUBLESHOOTING
STEP 8. Measure voltage at A-20 fan controller

connector.

relay connector
CONNECTOR: B-17X
Connector: A-20
Relay boxs
triangle marks
B-17X
A-20 (GR)
3 2 1
Harness side
connector
AK203423 AC

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 9 .
STEP 9. Check harness between A-10X (terminal

No. 2) fan control relay connector and A-20
(terminal No. 3) fan controller connector.
Harness side
connector
AK300255 AB

NO : Repair.

and A-10X (terminal No. 1) fan control relay
connector.
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
CONNECTOR: A-10X
A-10X
1
4
Harness side
connector
Harness side
connector
AK300255 AB
CONNECTOR: A-10X
AK300324 AB
A-10X
Connector: A-20
3
1
4
Harness side
connector
A-20 (GR)
3 2 1
Harness side
connector
AK300324 AB

connectors A-14 and C-17, and repair if necessary.
AK203423 AC

NO : Repair.

YES : Check and repair harness between A-10X
(terminal No. 3) fan control relay connector

and body earth.
NO : Repair.
13A-254
TROUBLESHOOTING

connector
CONNECTOR: C-134

C-134
00 - How to Use
300).
connector.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
CONNECTOR: C-134

AK300257 AB

NO : Repair.
C-134
STEP 13. Fan motor drive test.

CONNECTOR: C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Disconnect C-134 engine-ECU connector.

Ignition switch: ON

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
13A-255
TROUBLESHOOTING
STEP 16. Check harness between A-10X

(terminal No. 4) fan control relay connector and
battery.
CONNECTOR: A-10X

No. 2) fan controller connector and C-134
Connector: A-20
A-10X
A-20 (GR)
3
1
4
Harness side
connector
AK300324 AB
3 2 1
Harness side
connector
AK203423 AC
CONNECTOR: C-134

NO : Repair.
STEP 17. Check harness between A-10X

(terminal No. 2) fan control relay connector and
A-20 (terminal No. 3) fan controller connector.
C-134
CONNECTOR: A-10X
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
A-10X

AK300257 AB
1
4
Harness side
connector
AK300324 AB

YES : Replace fan motor and fan controller.
NO : Repair.
Connector: A-20
A-20 (GR)
3 2 1
Harness side
connector

AK203423 AC

YES : Replace fan motor and fan controller.
NO : Repair.
13A-256
TROUBLESHOOTING
Inspection Procedure 26: A/C Switch System
A/C Switch circuit
C-06
A/C-ECU
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
4 <Manual A/C>
34 <Auto A/C>
G-B
C-104
7
G-B
45
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Engine-ECU
Wire colour code

AK300325 AB
OPERATION
The battery voltage is applied to the engine-ECU
(terminal No. 45) from the A/C-ECU (terminal No.
4) <Manual A/C> or A/C-ECU (terminal No. 34)
<Auto A/C>.
FUNCTION
When the A/C switch is in "ON" position, A/C
switch ON signal is inputted to the engine-ECU
from the A/C-ECU. In response to the signal, the
engine-ECU controls the A/C compressor relay.
PROBABLE CAUSE
Failed A/C
Failed A/C system
Open/short circuit in A/C circuit or loose connector contact
Failed engine-ECU
13A-257
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
connector.
CONNECTOR: C-135
STEP 2. Measure voltage at C-06 A/C-ECU

connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C>.
Connector: C-06
<Manual A/C>
C-06 (B)
C-135
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

Engine: Running at idle
25C or more
or less
OK:
System voltage (when A/C is ON)
0.5 V or less (when A/C is OFF)
NO : Go to Step 2 .
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
AK300327AB

Engine: Idling
25C or more
or less
Voltage between terminal No. 4 and earth <Manual A/C>
Voltage between terminal No. 34 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 3 .
13A-258
TROUBLESHOOTING
STEP 3. Connector check: C-06 A/C-ECU

connector <Auto A/C> C-135 engine-ECU
connector
Connector: C-06
<Manual A/C>
STEP 4. Check harness between C-06 A/C-ECU

connector <Auto A/C> and C-135 (terminal No.
Connector: C-06
<Manual A/C>
C-06 (B)
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
AK300327AB
CONNECTOR: C-135
C-26 (B)
Harness side
connector
AK300327AB
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
AK300256 AB

NO : Repair.
13A-259
TROUBLESHOOTING

connector <Auto A/C> and C-135 engine-ECU
connector

connector
CONNECTOR: C-135
Connector: C-06
<Manual A/C>
C-06 (B)
C-135
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
AK300326 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
Connector: C-26
<Auto A/C>
AK300256 AB

NO : Repair.
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
AK300327AB
CONNECTOR: C-135
C-135

Item 28: A/C switch
a. Engine: Idling
25C or more.
25C or less.
OK:
ON (when A/C is ON)
00 - How to Use
300).
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB


harness between C-06 (terminal No. 4) or
C-26 (terminal No. 34) A/C-ECU connector
connector.
NO : Repair.
13A-260
TROUBLESHOOTING
Inspection Procedure 27: A/C Compressor Relay System
A/C compressor relay Circuit

Ignition switch
C-303
1 2 3
4 5 6
LOCK
ST
IG1
ACC
IG2
4
L-R
Battery
C-203
2
5 J/B
7.5A
10
10A
C-205
16
Relay box
L-R
B-R
C-106
11
A-14
9
B-R
L-R
3
4
B-18X
A/C-ECU
B-W
1
8
Engine-ECU
A/C compressor
assembly
B-27
(MU802653)
A/C refrigerant
temperature
switch
Magnetic
clutch
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

O: Orange GR: Gray

AK300328 AB
13A-261
TROUBLESHOOTING
OPERATION
The battery voltage is applied to the A/C compressor relay (terminal No. 4).
The battery voltage is applied to the A/C compressor relay (terminal No. 3) from the ignition
switch. The engine-ECU (terminal No. 8) makes
the power transistor in the unit be in "ON" position and makes currents go on the A/C compressor relay coil, and that makes the relay be in "ON"
position.
When the A/C compressor is in "ON" position, the
battery voltage is supplied to the A/C compressor
(terminal No. 1) from the A/C compressor relay
(terminal No. 1).
FUNCTION
When the A/C switch "ON" signal is input to the
engine-ECU, the engine-ECU places the A/C
compressor relay in the "ON" position. Accordingly, the battery voltage supplied to the A/C compressor operates the magnet clutch.
PROBABLE CAUSE
Failed A/C compressor relay
Failed A/C compressor magnet clutch
Open/short circuit in A/C compressor relay circuit
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-18X A/C
compressor relay connector
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X
Harness side
connector

NO : Repair.
AK300329 AB
STEP 2. A/C compressor relay check.

Check A/C compressor relay (Refer to GROUP
NO : Replace A/C compressor relay.
STEP 3. Measure voltage at B-18X A/C

compressor relay connector.
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X
Harness side
connector
AK300329 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13A-262
TROUBLESHOOTING

connector
STEP 5. Measure voltage at B-18X A/C

CONNECTOR: B-18X
CONNECTOR: C-303
Relay boxs
triangle marks
B-18X
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
Harness side
connector
Harness side
connector
AK300329 AB

OK: System voltage
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X

AK300329 AB

YES : Check intermediate connectors C-106, C-
202 <Auto A/C>, C-203 and C-205 <Manual

A/C>, and repair if necessary. If
and repair harness between B-18X
(terminal No. 3) A/C compressor relay
ignition switch connector.
open/short circuit.
NO : Repair.

A/C compressor relay connector and
battery.
open/short circuit.
STEP 6. Connector check: B-27 A/C compressor
connector
CONNECTOR: B-27
B-27 (B)
1
Harness side
connector

NO : Repair.
AK300330 AB
13A-263
TROUBLESHOOTING
STEP 7. Measure voltage at B-27 A/C compressor

connector.

connector.
CONNECTOR: C-134
CONNECTOR: B-27
B-27 (B)
C-134
1
Harness side
connector
AK300330 AB
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X

AK300257 AB
Harness side
connector

Ignition switch: ON
OK: System voltage
AK300329 AB

side.
Remove B-18X (terminal No. 1 and No. 4) A/C
compressor relay and short-circuit of harness
side connector.
Ignition switch: ON
OK: System voltage

NO : Go to Step 9 .

connector
CONNECTOR: C-134

(terminal No. 1) A/C compressor connector

and B-18X (terminal No. 1) A/C compressor
relay connector.
circuit.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13A-264
TROUBLESHOOTING

(terminal No. 2) A/C compressor relay connector
connector.
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X

Item 49: A/C relay
a. Engine: Idling
25C or more
25C or less
OK:
ON (when A/C is ON)
Harness side
connector
AK300329 AB
CONNECTOR: C-134
00 - How to Use
300).
connector
C-134
CONNECTOR: C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

C-134
AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13A-265
TROUBLESHOOTING

connector.

No. 4) ignition switch connector and B-18X
(terminal No. 3) A/C compressor relay connector.
CONNECTOR: C-303
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X
C-303
2
3 2 1
6 5 4
Harness side
connector
AK300304 AB
Harness side
connector
AK300329 AB
CONNECTOR: B-18X
CONNECTOR: C-134
Relay boxs
triangle marks
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

connector
CONNECTOR: C-303
Harness side
connector
3 2 1
6 5 4
AK300329 AB

connectors C-106, C-202 <Auto A/C>, C-203 and C205 <Manual A/C>, and repair if necessary.
NO : Repair.
STEP 16. Check harness between battery and B18X (terminal No. 4) A/C compressor relay
connector.
CONNECTOR: B-18X
Relay boxs
triangle marks
C-303
B-18X
Harness side
connector
Harness side
connector
AK300304 AB

NO : Repair.
B-18X
AK300329 AB

NO : Repair.
13A-266
TROUBLESHOOTING

and B-27 (terminal No. 1) A/C compressor relay
connector.
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X
Harness side
connector
AK300329 AB
CONNECTOR: B-27
B-27 (B)
1
Harness side
connector
AK300330 AB

YES : Replace A/C compressor magnet clutch.
NO : Repair.

TROUBLESHOOTING
13A-267
Inspection Procedure 28: A/C Load Signal System
A/C load signal circuit
C-06
A/C-ECU
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
5 <Manual A/C>
32 <Auto A/C>
L-W
C-106
6
L-W
24
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

AK300338 AB
OPERATION
The A/C load signal is inputted to the engineECU (terminal No. 24) from the A/C-ECU (terminal No. 5). <Manual A/C> or (terminal No. 32)
<Auto A/C>
FUNCTION
The magnitude of the A/C compressor load is
detected and input to the engine-ECU. The
engine-ECU provides A/C idle up control according to the A/C compressor load condition.
PROBABLE CAUSE
Failed A/C-ECU
Open/short circuit in A/C load signal circuit or
Failed engine-ECU
13A-268
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector

connector.
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

AK300257 AB

Engine: Idling
A/C switch: ON (A/C compressor in driven state)
Voltage between terminal No. 24 and earth
OK:
1 V or less (when the temperate around the
atmospheric air temperature sensor is 18C
or more, and the A/C is set to the lowest temperature and the maximum air flow rate)
System voltage (when the A/C is set to the
temperature in the cabin and the minimum
air flow rate)

NO : Go to Step 4 .

NO : Repair.

00 - How to Use
300).
connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13A-269
TROUBLESHOOTING
STEP 5. Measure voltage at C-06 A/C-ECU

connector <Auto A/C>.
Connector: C-06
<Manual A/C>
STEP 6. Connector Check: C-06 A/C-ECU

connector <Auto A/C>
Connector: C-06
<Manual A/C>
C-06 (B)
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
AK300327AB
Measure A/C-ECU terminal voltage.

Engine: Idling
25C or more
or less
Voltage between terminal No. 5 and earth <Manual A/C>
Voltage between terminal No. 32 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 6 .
C-26 (B)
Harness side
connector

NO : Repair.
AK300327AB
13A-270
TROUBLESHOOTING

No. 5) or C-26 (terminal No. 32) A/C-ECU
Connector: C-06
<Manual A/C>
STEP 8. Check connector: C-06 A/C-ECU

connector <Auto A/C>
Connector: C-06
<Manual A/C>
C-06 (B)
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
C-26 (B)
Harness side
connector
AK300326 AB
AK300327AB
AK300327AB
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
AK300257 AB

NO : Repair.


harness between C-06 (terminal No. 5) or
C-26 (terminal No. 32) A/C-ECU connector
connector.
NO : Repair.
13A-271
TROUBLESHOOTING
Inspection Procedure 29: A/C Pressure Sensor System
A/C Pressure sensor circuit
A-02
(MU802509)
A/C Pressure sensor
1 2 3
3
1
BR
G-Y
G-R
C-116
5
17
A-14
17
BR
G-R
C-105
21
C-104
4
G-Y
81
A/C-ECU
G-R
BR
92
42
C-135
C-137
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code

AK300339 AB
OPERATION
A power voltage of 5 V is applied to the A/C pressure sensor power terminal (terminal No. 3) from
the engine-ECU (terminal No. 81) and is earthed
to the engine-ECU (terminal No. 92) from the A/C
pressure sensor (terminal No. 1).
(terminal No. 42) from the A/C pressure sensor
FUNCTION
The A/C pressure sensor detects the A/C refrigerant pressure and inputs the pressure signal to
the engine-ECU. The engine-ECU uses the signal for ON/OFF control of the magnet clutch of
the A/C compressor.
PROBABLE CAUSE
Failed A/C pressure sensor
Open/short circuit in A/C pressure sensor circuit
Failed engine-ECU
13A-272
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 3. Measure voltage at A-02 A/C pressure

sensor connector.
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
Harness side
connector
3 2 1
Harness side
connector
AK300340AB

a. Item 3A: A/C pressure sensor
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: A-02 A/C pressure
sensor connector
AK300340AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 4 .

connector.
CONNECTOR: C-137
Connector: A-02
A-02 (B)
C-137
3 2 1
Harness side
connector
AK300340AB

NO : Repair.
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 5 .
13A-273
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
AK300254 AB

NO : Repair.
Connector: A-02
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

YES : Check intermediate connector A-14, and

harness between A-02 (terminal No. 3) A/C
pressure sensor connector and C-137
Check power line for open circuit.
NO : Repair.
13A-274
TROUBLESHOOTING

No. 3) A/C pressure sensor connector and C-137
STEP 9. Measure resistance at A-02 A/C pressure

sensor connector.
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
Harness side
connector
3 2 1
Harness side
connector
AK300340AB
CONNECTOR: C-137
AK300340AB

side.
Resistance between terminal No. 1 and earth
OK: 2 W or less
C-137

connector
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Check power line for short circuit.
NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

a. Item 3A: A/C pressure sensor
00 - How to Use
300).
AK300254 AB

NO : Repair.
13A-275
TROUBLESHOOTING


sensor connector.
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
Harness side
connector
3 2 1
Harness side
connector
AK300340AB
CONNECTOR: C-137
AK300340AB
Ignition switch: ON
OK: 4.9 - 5.1 V
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Check earthing line for open circuit or damage.
NO : Repair.
13A-276
TROUBLESHOOTING

connector

sensor connector.
Connector: A-02
CONNECTOR: C-137
A-02 (B)
3 2 1
Harness side
connector
C-137
AK300340AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: A-02
Ignition switch: ON
OK: 0.5 or less
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

YES : Check intermediate connector A-14, and

harness between A-02 (terminal No. 3) A/C
pressure sensor connector and C-137
Check power line for damage.
NO : Repair.
13A-277
TROUBLESHOOTING

connector

sensor connector.
Connector: A-02
CONNECTOR: C-137
A-02 (B)
3 2 1
Harness side
connector
C-137
AK300340AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: A-02
A/C switch: ON
OK:
1.8 - 2.0 V (A/C refrigerant pressure: 1 kPa)
A-02 (B)
3 2 1
Harness side
connector
AK300340AB


connector
CONNECTOR: C-135

and repair harness between A-02 (terminal
No. 1) A/C pressure sensor connector and
connector.
NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-278
TROUBLESHOOTING

(terminal No. 42) engine-A/T-ECU connector.

connector.
CONNECTOR: C-135
Connector: A-02
A-02 (B)
C-135
3 2 1
Harness side
connector
AK300340AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-135

AK300256 AB
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

A/C switch: ON
OK:


AK300256 AB

Check output line for short circuit and damage.
YES : Replace A/C pressure sensor.
NO : Repair.
13A-279
TROUBLESHOOTING

connector
CONNECTOR: C-135

connector
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
AK300256 AB

NO : Repair.
Connector: A-02
A-02 (B)
3 2 1
Harness side
connector
AK300340AB


and repair harness between A-02 (terminal
No. 2) A/C pressure sensor connector and
connector.
Check power line for open circuit and
damage.
NO : Repair.
13A-280
TROUBLESHOOTING
Inspection Procedure 30: Ignition Circuit System
Ignition circuit
Ignition switch
C-303
1 2 3
4 5 6
LOCK
ST
IG1
ACC
IG2
L-B
C-203
6
1
10A
J/B
10
C-205
C-116
26
A-14
16
W
Ignition coil 1
B-110
Ignition coil 2
B-111
1 2 3
1 2 3
3
Spark
plug
B-107
Capacitor
B
W-L
B-L
B
10
23
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300341 AB
13A-281
TROUBLESHOOTING
OPERATION
The battery voltage is applied to the ignition coil
(terminal No. 1) from the ignition switch and is
earthed to the vehicle body from the ignition coil
(terminal No. 2).
A power voltage of 12 V is applied to the ignition
coil output terminal (terminal No. 3) from the
engine-ECU (terminal No. 10 and No. 23).
FUNCTION
When the engine-ECU makes the power transistor in the unit be in "OFF" position, the battery
voltage in the unit is applied to the power transistor unit, and that makes the power transistor unit
be in "ON" position. The engine-ECU makes the
power transistor in the unit be in "ON", and that
makes the power transistor unit be in "OFF" position.
In response to the signal from the engine-ECU,
the power transistor unit is in "ON" position. The
primary current is going to the ignition coil. When
the power transistor unit is in "OFF" position, the
primary current is interrupted and high voltage is
generated in the secondary coil.
PROBABLE CAUSE
Failed ignition coil
Failed spark plug
Failed spark plug cable
Open/short circuit in ignition primary circuit or
Failed engine-ECU
DIAGNOSIS PROCEDURE
).


B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

NO : Repair.

STEP 5. Measure voltage at B-111 and B-110

ignition coil connectors.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 6 .
13A-282
TROUBLESHOOTING

connector
CONNECTOR: C-303
STEP 7. Measure voltage at B-111 and B-110

C-303
B-111 (GR)
3 2 1
Harness side
connector
3 2 1
6 5 4
Harness side
connector
B-110 (GR)
AK300304 AB
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

YES : Check intermediate connectors A-14, C-
203, C-205 and C-116, and repair if

necessary. If intermediate connectors are
normal, check and repair harness between
C-303 (terminal No. 2) ignition switch
connector and B-111 (terminal No. 1)
ignition coil connector, also between C-303
(terminal No. 2) ignition switch connector
and B-110 (terminal No. 1) ignition coil
connector.
open/short circuit.
NO : Repair.
AK300308 AB

side.
Engine: Cranking
OK: 0.5 - 4.0 V
NO : Go to Step 8 .
13A-283
TROUBLESHOOTING

connector.

connector
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
B-111 (GR)
AK300257 AB

3 2 1
Harness side
connector
B-110 (GR)
B-110 (GR)
AK300308 AB
AK300308 AB

Disconnect B-111 and B-110 ignition coil connectors.
Engine: Cranking
OK: 0.5 - 4.0 V
B-111 (GR)
3 2 1
Harness side
connector

(terminal No. 3) ignition coil connector and

connector, also between B-110 (terminal
No. 3) ignition coil connector and C-134
NO : Repair.
13A-284
TROUBLESHOOTING

connector
CONNECTOR: C-134

No. 3) ignition coil connector and C-134 (terminal
No. 23) engine-ECU connector, also between B110 (terminal No. 3) ignition coil connector and
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

NO : Repair.

00 - How to Use
300).
13A-285
TROUBLESHOOTING
STEP 13. Measure resistance at B-111 and B-110

B-111 (GR)
3 2 1
Harness side
connector

No. 2) ignition switch connector and B-111
(terminal No. 1) ignition coil connector, also
between C-303 (terminal No. 2) ignition switch
connector and B-110 (terminal No. 1) ignition coil
connector.
CONNECTOR: C-303
B-110 (GR)
AK300308 AB

side.
OK: 2 W or less
(terminal No. 2) ignition coil connector and

body earth, also between B-110 (terminal
No. 2) ignition coil connector and body
earth.
and damage.
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

connectors A-14, C-116, C-203 and C-205, and
NO : Repair.
13A-286
TROUBLESHOOTING

No. 3) ignition coil connector and C-134 (terminal
No. 23) engine-ECU connector, also between B110 (terminal No. 3) ignition coil connector and C134 (terminal No. 10) engine-ECU connector.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13A-287
TROUBLESHOOTING
Data List Reference Table

M1131152000735
Item Inspection
No. item
11
Oxygen
Engine: After
sensor (front) warm-up (leaner
by deceleration,
richer by
acceleration)
Engine: After
warm-up (using
oxygen sensor,
check air-fuel
ratio as well as
control status by
engine-ECU.
12
13
14
16
Air flow
sensor *1
Intake air
temperature
sensor
Throttle
position
sensor
Normal
condition
Inspection
procedure
No.
Reference
page
Excessive
deceleration from
4,000 r/min
200 mV or less
Code No.
P0130
313A
At excessive
acceleration
600 - 1,000 mV
Idle operation
400 mV or less
600 - 1,000
mV (altered)
Code No.
P0110
313A
Code No.
P0120
313A
Procedure
No. 23
313A
2,500 r/min
Engine coolant Idle operation

temperature:
2,500 r/min
80 - 95C
Lamps, electric Acceleration
cooling fan and
all
accessories:
OFF
Transmission:
Neutral
Ignition switch:
ON or engine
running
Ignition switch:
ON
16 - 24 Hz
72 - 112 Hz
According to
acceleration,
frequency is
amplified.
Intake air
temperature:
-20C
-20C
Intake air
temperature: 0C
0 C
Intake air
temperature: 20C
20C
Intake air
temperature: 40C
40C
Intake air
temperature: 80C
80 C
Set to Idle position
535 - 735 mV
Release accelerator
pedal gradually
Increased
according to
accelerator pedal
stroke
Release accelerator
pedal fully
4,500 - 5,000
mV
Power supply Ignition switch: ON

voltage
System voltage
13A-288
TROUBLESHOOTING
Item Inspection
No. item
Normal
condition
Inspection
procedure
No.
Reference
page
18
Cranking
signal
(ignition
switch-ST)
Ignition switch:
ON
Engine: Stopped
OFF
313A
Engine: Cranking
ON
Procedure
No. 23
Engine
coolant
temperature
sensor
Ignition switch:
ON or engine
running
Coolant temperature: -20C

-20C
Code No.
P0115
313A
Code No.
P0335
313A
Code No.
P0105
313A
Code No.
P0551
313A
Procedure
No. 26
313A
21
Coolant temperature: 0C
0 C
20C
40C
80C
22
Crank angle
sensor
Engine:
Cranking
Tachometer:
Connected
Compare engine
Matched
speed on tachometer
with the value
displayed on MUT-II
Engine: Idle
operation
Coolant temperature: 1,100 - 1,300

-20C
r/min
0 C
r/min
20C
r/min
Coolant temperature: 940 - 1,140 r/min
40C
Coolant temperature: 650 - 850 r/min
80C
25
27
28
Barometric
pressure
sensor
Ignition switch:
ON
Altitude: 0m
101 kPa
Altitude: 600m
95 kPa
Altitude: 1,200m
88 kPa
Altitude: 1,800m
81 kPa
Power
Engine: Idle
steering fluid operation
pressure
switch
Steering wheel: Not

operated
OFF
Steering wheel:
Operated
ON
A/C switch
AC switch: OFF
OFF
AC
A/C
switch: compressor
ON
is not driven
OFF
Engine: Idle
A/C
compressor
is driven
ON
13A-289
TROUBLESHOOTING
Item Inspection
No. item
Normal
condition
Inspection
procedure
No.
Reference
page
37
Engine coolant
temperature:
80 - 95C
Lamps, electric
cooling fan and
all
accessories:
OFF
Idel operation
13 - 33 %
2,500 r/min
12 - 32 %
Excessive
acceleration
According to
acceleration,
volumetric
efficiency is
increased.
A/C in MAX COOL

state (under high
load)
2,200 mV or
more
Procedure
No. 29
313A
Procedure
No. 30
313A
3A
41
Volumetric
efficiency
A/C pressure
sensor
Injectors *2
After engine
warm-up, idle
operation
A/C switch: ON
A/C in MAX HOT

1,800 mV or less
state (under low load)
Engine: Cranking Coolant temperature: 5.6 - 8.4 ms

0C (all cylinders in
simultaneous
injecting operation)
Coolant temperature: 5.6 - 8.4 ms
20C
Coolant temperature: 5.6 - 8.4 ms
80C
Injectors*3
44
Ignition
advance
Engine coolant
temperature:
80 - 95C
Lamps, electric
cooling fan and
all
accessories:
OFF
Transmission:
Neutral
Idle operation
2.0 - 3.2 ms
2,500 r/min
2.2 - 3.4 ms
Excessive
acceleration
Increased
Engine: After
Idle operation
warm-up
2,500 r/m
Install timing
light (for use to
measure
actual ignition
timing)
2 - 18BTDC
18 - 38BTDC
13A-290
TROUBLESHOOTING
Item Inspection
No. item
Normal
condition
Inspection
procedure
No.
Reference
page
45
ISC (stepper
motor) servo
position*4
Engine coolant A/C switch: OFF

temperature:
A/C switch: OFF
80 - 95C
ON
Lighting,
electric cooling
fan and
accessories:
OFF
Transmission:
Neutral
Engine: Idle
operation
(When A/C
switch is ON,
A/C
compressor
must be ON)
2 - 25 steps
A/C relay
Engine: After
warm-up, idle
operation after
warm-up
Procedure
No. 27
313A
0 mV or less
600 - 1,000 mV
(altered)
Code No.
P0136
313A
0.9 - 4.9 gm/s
49
A/C switch: OFF
OFF
A/C
A/C
switch: compressor
ON
is not driven
OFF
A/C
compressor
is driven
59
Oxygen
Engine: After
sensor (rear) warm-up
12
*5
Air flow
sensor
Increased 10 70 steps
At excessive
acceleration
Engine coolant Idle operation

temperature:
2,500 r/min
80 - 95C
Lamps, electric Acceleration
cooling fan and
all
accessories:
OFF
Transmission:
Neutral
ON
7.2 - 13.2 gm/s

According to
acceleration,
frequency is
amplified.
13A-291
TROUBLESHOOTING
Item Inspection
No. item
Normal
condition
Inspection
procedure
No.
Reference
page
13
*5
Ignition switch:
ON or engine
running
Intake air
temperature:
-20C
-20C
Code No.
P0110
313A
Intake air
temperature: 0C
0 C
Intake air
temperature: 20C
20C
Intake air
temperature: 40C
40C
Intake air
temperature: 80C
80 C
Code No.
P0115
313A
21
*5
Intake air
temperature
sensor
Engine
coolant
temperature
sensor
Ignition switch:
ON or engine
running
Coolant temperature: -20C

-20C
0C
20C
40C
80C
22
*5
Crank angle
sensor
Engine:
Cranking
Tachometer:
Connected
Compare engine
Matched
speed on tachometer
with the value
displayed on MUT-II
Engine: Idle
operation

-20C
r/min
r/min
0C
r/min
20C
Coolant temperature: 940 - 1,140 r/min
40C
Coolant temperature: 650 - 850 r/min
80C
24
*5
Vehicle
Drive 40 km/h
speed sensor
Approximately 40 Code No.

km/h
P0500
313A
44
*5
Ignition
advance
2 - 18 deg
Engine: After
Idle operation
warm-up
2,500 r/m
Install timing
light (for use to
measure
actual ignition
timing)
18 - 38 deg
13A-292
Item Inspection
No. item
TROUBLESHOOTING
Normal
condition
Inspection
procedure
No.
Reference
page
81
*5
Long-term
Engine: After warm-up, 2,500 r/min
fuel
without any load (during closed loop)
compensatio
n
-12.5 - 12.5 %
Code No.
P0170
313A
82
*5
Shot-term
Engine: After warm-up, 2,500 r/min
fuel
without any load (during closed loop)
compensatio
n
-25 - 25 %
Code No.
P0170
313A
87
*5
Calculation
losd value
Engine: After
warm-up
Idle operation
13 - 33 %
2,500 r/m
12 - 32 %
88
*5
Fuel control
condition
Engine: After
warm-up
2,500 r/m
Closed loop
Acceleration
Open loop-drive
condition
8A
*5
Throttle
position
sensor
(Throttle
opening
angle)
Ignition switch:
ON
Set to Idle position
0 - 10 %
313A
Release accelerator
pedal gradually
Increased
according to
accelerator pedal
stroke
Code No.
P0120
Release accelerator
pedal fully
80 - 100 %
Excessive
deceleration from
4,000 r/min
0.2 V or less
0.6 - 1 V
(altered)
Code No.
P0130
313A
Idle operation
2,500 r/min
0.4 V or less
0.6 - 1 V
(altered)
At excessive
acceleration
0 V or less 0.6 Code No.

- 1 V (altered)
P0136
313A
A1
*5
Oxygen
Engine: After
sensor (front) warm-up (leaner
by deceleration,
richer by
acceleration)
Engine: After
warm-up (using
oxygen sensor,
check air-fuel
ratio as well as
control status by
engine-A/ECU.
A1
*5
Oxygen
Engine: After
sensor (rear) warm-up
CAUTION
When shifting the select lever to D range, the brakes should be applied so that the vehicle does not
move forward
NOTE: *1: On the new vehicle (mileage: 500 km or less), air flow sensor output frequency may be higher by
approx. 10%.
NOTE: *2: Injector drive time ranges shown are when power voltage is 11 V and the cranking speed is 250
r/min. or less.
NOTE: *3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approx. 10%.
NOTE: *4: On the new vehicle (mileage: 500 km or less), the number of steps of stepper motor may be larger
by approx. 30 steps.
NOTE: *5: When service data in check mode is selected, the data is not displayed.
13A-293
TROUBLESHOOTING
Actuator Test Reference Table

M1131152500439
Item Inspection
No. item
Drive content
Inspection conditions
Normal
condition
Code No.
/Inspection
procedure
No.
Reference
page
01
Cut off No. 1

injector
Engine: After warm-up,

idle operation (Cut off
injectors sequentially to
check for a cylinder that
does not change engine in
idle status.
Engine is
changed
(becomes
unstable or
stalled)
Code No.
P0201
313A
Code No.
P0202
313A
Code No.
P0203
313A
Code No.
P0204
313A
Procedure
No. 24
313A
Injector
02
Cut off No. 2

injector
03
Cut off No. 3

injector
04
Cut off No. 4

injector
07
Fuel pump
Drive fuel
pump to
circulate fuel
Ignition
Hold return Pulse is felt
switch: "ON" hose with
fingers to
feel pulse of
fuel flowing
Check for
pump
operating
noise near
fuel tank
Operating
noise audible
08
Purge
control
solenoid
valve
Switch solenoid Ignition switch: "OFF"

valve from OFF
to ON
When the valve Code No.

is actuated,
P0443
operating noise
is audible
313A
10
EGR control
solenoid
valve
Switch solenoid Ignition switch: "ON"

valve from OFF
to ON
When the valve Code No.

is actuated,
P0403
operating noise
is audible.
313A
17
Basic ignition Switch engine- Engine: Idle operation

timing
ECU to ignition Install timing light
timing adjusting
mode
5 BTDC
21
Fan
controller
Fan motor is
rotated
Procedure
No. 21
313A
Actuate fan
motor

A/C switch: ON
13A-294
TROUBLESHOOTING
CHECK AT THE ECU TERMINALS
NOTE: .
1. Make the voltage measurement with the
engine-ECU connector connected.
2. You may find it convenient to pull out the
engine-ECU to make it easier to reach the
connector terminals.
3. The checks can be carried out off the order
given in the chart.
M1131153500175
TERMINAL VOLTAGE CHECK CHART

Needle-nosed wire probe
CAUTION
Short-circuiting the positive (+) probe between a
connector terminal and earth could damage the
vehicle wiring, the sensor, engine-ECU or all of
them. Be careful to prevent this!
3. If voltmeter shows any division from standard
value, check the corresponding sensor, actuator
and related electrical wiring, then repair or
replace.
4. After repair or replacement, recheck with the
voltmeter to confirm that the repair has corrected
the problem.
AK201749AB
1. Connect a needle-nosed wire probe to a voltmeter

probe.
2. Insert the needle-nosed wire probe into each of
the engine-ECU connector terminals from the wire
side, and measure the voltage while referring to
the check chart.
Engine-ECU Connector Terminal Arrangement

Engine-ECU Connector
C-134
C-135
C-136
C-137
1 2 3 4 5 6 7 8 9 10 11 12 13 31 32 33 34 35 36 37 38 51 52 53 54 55 56 71 72 73 74 75 76 77 78 79 80 81
14 15 16 17 18 19 20 21 22 23 24 25 26 39 40 41 42 43 44 45 46 57 58 59 60 61 62 82 83 84 85 86 87 88 89 90 9192
AK300342 AB
Terminal
No.
Check item
Check condition (Engine condition)
Normal condition
No. 1 injector
14
No. 2 injector
While engine is idling after having warmed

up, suddenly depress the accelerator pedal.
From 11 - 14 V,
momentarily drops slightly
No. 3 injector
15
No. 4 injector
Stepper motor coil

<A1>
17
Stepper motor coil

<A2>
Stepper motor coil

<B1>
18
Stepper motor coil

<B2>
EGR control
solenoid Valve
Engine: Soon after the warmed up engine System voltage 1 V or

is star
less (Changes repeatedly)
A/C switch: OFF ON (A/C compressor
is operating)
System Voltage
While engine is idling, suddenly depress the

accelerator pedal.
From system voltage,

momentarily drops
13A-295
TROUBLESHOOTING
Terminal
No.
Check item
Normal condition
A/C relay
Engine: Idle speed

A/C switch: OFF ON (A/C compressor
is operating)
System voltage or
Momentarily 6V or more
1 V or less
Purge control
solenoid valve
System voltage
Running at 3,500 r/min while engine is

warming up after having been started.
1 V or less
10
Ignition coil - No. 1,

No. 4
Engine r/min: 3,000 r/min
0.3 - 3.0 V
23
Ignition coil - No. 2,

No. 3
12
Power supply
System voltage
25
19
21
22
Air flow sensor reset Engine: Idle speed

Signal
6-9V
Fan controller
Radiator and condenser fan is not operating
0 - 0.3 V
Radiator and condenser fan is operating
0.7 V or more
Ignition switch: ON
System voltage
Engine: Idle speed
1 V or less
Fuel pump relay
24
A/C load signal
33
Alternator G terminal
36
Engine warming
lamp
Ignition switch: "LOCK" (OFF) "ON"
37
Power steering fluid

pressure switch
Engine: Idling after

warming up
0-1V
Refer to GROUP 55 - Troubleshooting (Inspection at the Automatic

compressor - ECU Terminal)
Engine: Warm, idle (radiator fan: OFF)
Headlamp: OFF ON
Stop lamp: OFF ON
Rear defogger switch: OFF ON
Voltage increases by 0.2 3.5 V
1 V or less System
voltage (After several
seconds have elapsed)
When steering wheel System voltage

is Stationary
When steering wheel 1 V or less
is turned
38
Control relay (Power Ignition switch: "LOCK" (OFF)

supply)
Engine: Warm, idle (radiator fan: OFF)
Headlamp: OFF ON
Stop lamp: OFF ON
Rear defogger switch: OFF ON
41
Alternator FR
terminal
42
A/C pressure sensor Engine: Idling

A/C switch: ON
When A/C is "MAX,

COOL" condition
(when the load by
A/C is high)
System voltage
1 V or less
Voltage decreases
2.2 V or more
When A/C is "MAX,

1.8 V or less
HOT" condition (when
the load by A/C is
low)
13A-296

TROUBLESHOOTING
Terminal
No.
Check item
Normal condition
45
A/C switch
Engine: Idle speed
0.5 V or less
Turn the A/C switch

OFF
Turn the A/C switch

System voltage
ON (A/C compressor
is operating)
54
Oxygen sensor
heater (rear)
Engine: Idling after warming up
1 V or less
Engine r/min:Racing
System voltage
58
Tachometer signal
0.3 - 3.0 V
60
Oxygen sensor
heater (front)
Engine: Idling after warming up
1 V or less
Engine r/min:5,000 r/min
System voltage
71
Ignition switch - ST
Engine: Cranking
8 V or more
72
Intake air
temperature sensor
When intake air

3.8 - 4.4 V
temperature is -20C
When intake air
temperature is 0C
3.2 - 3.8 V
When intake air

temperature is 20C
2.3 - 2.9 V
When intake air

temperature is 40C
1.5 - 2.1 V
When intake air

temperature is 60C
0.8 - 1.4 V
When intake air

temperature is 80C
0.4 - 1.0 V
75
Oxygen sensor
(rear)
Engine: Idling after warmed up (Check using 0 0.6 V (Changes

a digital type voltmeter)
repeatedly)
76
Oxygen sensor
(front)
Engine: Running at 2,500 r/min after warmed 0 0.8 V (Changes

up (Check using a digital type voltmeter)
repeatedly)
80
Backup power
supply
Ignition switch: "LOCK" (OFF)
System voltage
81
Sensor impressed
voltage
4.9 - 5.1 V
82
Ignition switch - IG
System voltage
83
Engine coolant
temperature sensor
When engine coolant 3.9 - 4.5 V

temperature is -20C
temperature is 0C
temperature is 20C
temperature is 40C
temperature is 60C
temperature is 80C
13A-297
TROUBLESHOOTING
Terminal
No.
Check item
Normal condition
84
Throttle position
sensor
Set throttle valve to

idle Position
0.535 - 0.735 V
Fully open throttle

valve
4.4 - 5.3 V
Altitude: 0 m
3.8 - 4.2 V
Altitude: 600 m
3.5 - 3.9 V
Altitude: 1,200 m
3.3 - 3.7 V
Altitude: 1,800 m
3.0 - 3.4 V
85
Barometric pressure Ignition switch: "ON"

sensor
86
Vehicle speed
sensor

Move the vehicle forword slowly
0 5 V Changes
repeatedly
88
Camshaft position
sensor
Engine: Cranking
0.4 - 3.0 V
Engine: Idling
1.5 - 3.0 V
Crank angle sensor
Engine: Cranking
0.4 - 4.0 V
Engine: Idling speed
1.5 - 2.5 V
Engine: Idle speed
2.2 - 3.2 V
89
90
Air flow sensor
CHECK CHART FOR RESISTANCE AND

CONTINUITY BETWEEN TERMINALS
2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity
between the terminals of the engine-ECU
harness-side connector while referring to the
check chart.
NOTE: .
1. When measuring resistance and checking
continuity, a harness for checking contact pin
pressure should be used instead of inserting a
test probe.
2. Checking need not be carried out in the order
given in the chart.
CAUTION
If the terminals that should be checked are mistaken, or if connector terminals are not correctly
shorted to earth, damage may be caused to the
vehicle wiring, sensors, engine-ECU and/or ohmmeter. Be careful to prevent this!
4. If the ohmmeter shows any deviation from the
standard value, check the corresponding sensor,
actuator and related electrical wiring, and the
repair or replace.
5. After repair or replacement, recheck with the
ohmmeter to confirm that the repair or
replacement has corrected the problem.
13A-298
TROUBLESHOOTING
Engine-ECU Harness Side Connector Terminal Arrangement

Engine-ECU Harness Side Connector
C-137
C-136
C-135
C-134
8180 79 78 77 76 75 74 73 72 71 56 55 54 53 52 51 38 37 36 35 34 33 32 31 13 12 11 10 9 8 7 6 5 4 3 2 1
92 91 90 89 88 87 86 85 84 83 82 62 61 60 59 58 57 46 45 44 43 42 41 40 39 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300343 AB
Terminal
No.
Inspection item
Normal condition (Check condition)
1 - 12
No. 1 injector
13 - 16 W (At 20C)
12 - 14
No. 2 injector
2 - 12
No. 3 injector
12 - 15
No. 4 injector
4 - 12
Stepper motor coil (A1)
12 - 17
Stepper motor coil (A2)
5 - 12
Stepper motor coil (B1)
12 - 18
Stepper motor coil (B2)
6 - 12
29 - 35 W (At 20C)
9 - 12
29 - 35 W (At 20C)
12 - 54
Oxygen sensor heater(rear)
11 - 18 W (At 20C)
12 - 60
Oxygen sensor heater(front)
4.5 - 8.0 W (At 20C)
26 - 33 W (At 20C)
13 - Body ECU earth

earth
Continuity (0 W)
26 - Body
earth
81 - 83
14 - 17 kW (When coolant temperature is -20C)

5.1 - 6.5 kW (When coolant temperature is 0C)
72 - 81
13 - 17 kW (When intake air temperature is -20C)

5.3 - 6.7 kW (When intake air temperature is 0C)
INSPECTION PROCEDURE USING

OSCILLOSCOPE
M1131154500479
The output signals of the sensors and the conditions

of the actuation signals of the actuators can be
inspected visually by observing the waveforms on
the oscilloscope.
13A-299
TROUBLESHOOTING
AIR FLOW SENSOR
2. Connect the oscilloscope special patterns pickup

to air flow sensor connector terminal No. 3.
Measurement Method
Oscilloscope
1 2 3 4 5 6 7
Special
patterns
pickup
Alternate Method (Test harness not available)

to engine-ECU terminal No. 90.
Standard Wave Pattern
Observation conditions
Function
Special patterns
AK000786 AE
1. Disconnect the air flow sensor connector, and

connect the special tool Test harness (MB991709)
in between (All terminals should be connected).
Pattern height
Low
Pattern selector
Display
Engine speed
Idle
Standard wave pattern

(V)
10
The time (cycle time) T is reduced when

the amount of intake air inereases.
T
T1
T2
Times T1 and T2 are equal.
Time
AK202334 AB
Observation conditions (from conditions above engine is increased by racing.)

(V)
10
Time
AK202335 AB
Wave Pattern Observation Points

Check that cycle time T becomes shorter and the frequency increases when the engine speed is
increased.
13A-300

TROUBLESHOOTING
Examples of Abnormal Wave Patterns
CAMSHAFT POSITION SENSOR AND

CRANK ANGLE SENSOR
Measurement Method
Camshaft position Oscilloscope
sensor connector
1 2 3
Special patterns
pick-up
AKX01597
Example 1
Cause of problem
Sensor interface malfunction
Wave pattern characteristics
Rectangular wave pattern is output even when
Example 2
Cause of problem
Damaged rectifier or vortex generation column
Unstable wave pattern with non-uniform frequency. However, when an ignition leak
occurs during acceleration, the wave pattern
will be distorted temporarily, even if the air
flow sensor is normal.
1 2
3
Crank angle
sensor connector
AK000840AC
1. Disconnect the camshaft position sensor

connector and connect the special tool Test
harness (MB991709) in between (All terminals
should be connected).
2. Connect the oscilloscope special pattern pickup to
camshaft position sensor terminal No. 2.
3. Disconnect the crank angle sensor connector and
connect the special tool Test harness
(MD998478) in between.
to crank angle sensor terminal No. 2.
to engine-ECU terminal No. 88 (When checking
the camshaft position sensor signal wave
pattern).
the crank angle sensor signal wave pattern).
13A-301
TROUBLESHOOTING

Observation condition
Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine speed
Idle
2 engine revolutions
(1 camshaft revolution)

(V)
The time (cycle time)

T is reduced when the
engine speed increases
75 BTDC
5 BTDC
Crank angle
sensor output
wave pattern
0
Camshaft position
sensor output
wave pattern
Time
0
TDC: Top dead centre
No.1 TDC

Check that cycle time T becomes shorter when the
engine speed increases.
No.3 TDC
No.4 TDC
No.2 TDC
AK202336 AB

Rectangular wave pattern is output even when
AKX01602
AKX01597
Example 1
Cause of problem
Sensor interface malfunction
Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern is displaced to the left or right.
13A-302
TROUBLESHOOTING
INJECTOR
Measurement Method
Oscilloscope
1 2
Special
patterns
pickup
AK101807AC
1. Disconnect the injector connector, and then

connect the special tool Test harness set
(MB991348) in between (All terminals should be
connected).
to terminal No. 2 of the injector connector.

to engine- ECU terminal No. 1 (When checking
the No. 1 cylinder).
to engine-ECU terminal No. 2 (When checking the
No. 3 cylinder).
Function
Special patterns
Pattern height
Variable
Variable knob
Adjust while viewing the

wave pattern
Pattern selector
Display
Engine speed
Idle

Point A.
(V)
Solenoid back
electromotive
force
(Approx.710V)
50
Point B
Injector drive
time
Time
Power
voltage
0 Drive signal: ON
Drive signal: OFF

AK202347AB
13A-303
TROUBLESHOOTING

Point A: Height of solenoid back electromotive force
Contrast with standard wave
pattern
Probable
cause
Solenoid coil back electromotive

force is low or doesnt appear at
all.
Short in the
injector solenoid
1. Disconnect the ISC servo connector, and connect

the special tool Test harness (MB991709) in
between.
to the ISC servo-side connector terminal No. 1,
No. 3, No. 4 and No. 6 respectively.
to engine-ECU terminal No. 4, connection
terminal No. 5, connection terminal No. 17, and
connection terminal No. 18 respectively.
Point B: Injector drive time

Function
Special patterns
When idling
When racing
AKX01605AE
The injector drive time will be synchronized with the

MUT-II tester display.
When the engine is suddenly raced, the drive
time will be greatly extended at first, but the drive
time will soon match the engine speed.
Pattern height
High
Pattern selector
Display
Engine condition
When the engine coolant

temperature is 20C or
below, turn the ignition
switch from LOCK (OFF)
position to ON (without
starting the engine).

(STEPPER MOTOR)
While the engine is

idling, turn the A/C
switch to ON.
Measurement Method
Immediately after
starting the warm
engine.
Oscilloscope
1 2 3
4 5 6
Special
patterns
pickup
AK300344AB
13A-304
TROUBLESHOOTING
(V)
30
Stepper
motor
control
signal
wave
pattern
The wave pattern

appears for an
instant, but soon
disappears.
Point B
Coilreverse electromotive
force (Approx.3x10V)
Point A
Induced electromotive force
from the motor turning
20
10
Time
AK201857 AB
Wave pattern Observation Points

Check that the standard wave pattern appears when
the stepper motor is operating.
Point A: Presence or absence of induced electromotive force from the motor turning (Refer to the abnormal wave pattern).
pattern
Probable
cause
Induced electromotive force does

not appear or is extremely small.
Motor is
malfunctioning
Example 1
Cause of problem
Motor is malfunctioning. (Motor is not operating.)
Induced electromotive force from the motor turning does not appear.
Open
circuit
side
Point B: Height of coil reverse electromotive force

pattern
Probable
cause
Coil reverse electromotive force

does not appear or is extremely
small.
Short in the
coil
Examples of Abnormal Wave Pattern
AKX01608AE
Normal
side
AKX01609AF
Example 2
Cause of problem
Open circuit in the line between the stepper
motor and the engine-ECU.
Current is not supplied to the motor coil on the
open circuit side (Voltage does not drop to 0
V).
Furthermore, the induced electromotive force
waveform at the normal side is slightly different from the normal waveform.
13A-305
TROUBLESHOOTING
IGNITION COIL AND POWER TRANSISTOR

Measurement Method
Oscilloscope
1 2 3
Special
patterns
pickup
1. Disconnect the ignition coil connector, and

connect the special tool Test harness set
(MB991348) in between (All terminals should be
connected).
Crank angle
sensor output
wave pattern

to engine-ECU terminal No. 10 (No. 1 - No. 4),
connection terminal No. 23 (No. 2 - No.3)
respectively.
AK300345 AB

to terminal No. 3 of each ignition coil connector in
turn.
Observation condition
Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine r/min
Approximately. 1,200
r/min
(V)
6
4
T
5 BTDC
Compression top dead center
75 BTDC
2
0
4
Power transistor
control signal
wave pattern
T1
Ignition period
2
0
OFF
ON
Dwell section
T : Revolution time corresponding to a crank angle of 180

T1 : Time computed by the engine-ECU
: Spark advance angle

Point: Condition of wave pattern build-up section and
maximum voltage (Refer to abnormal wave pattern
examples 1 and 2).
AK204435 AC
Condition of wave pattern

build-up section and
maximum voltage
Probable cause
Rises from approximately. 2 V

to approximately 4.5 V at the
top-right
Normal
2 V rectangular wave
Open-circuit in
ignition primary
circuit
Rectangular wave at power

voltage
Power transistor
malfunction
13A-306
ON-VEHICLE SERVICE
Normal wave pattern

VB
Normal wave pattern
2V
AKX01613AD
AKX01612AD
Example 1
Wave pattern during engine cranking
Cause of problem
Open-circuit in ignition primary circuit
Top-right part of the build-up section cannot be
seen, and voltage value is approximately 2 V
too low.
Example 2
Wave pattern during engine cranking
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor
is ON.
ON-VEHICLE SERVICE
THROTTLE BODY (THROTTLE VALVE
AREA) CLEANING
M1131001000332
1. Remove the air intake hose from the throttle body.

2. Spray cleaning fluid on a clean cloth.
5. Adjust the basic idle speed (Refer to 313A).
THROTTLE POSITION SENSOR

ADJUSTMENT
M1131001100414
CAUTION
Do not spray the cleaning fluid directly to the
throttle valve.
Make sure the cleaning fluid does not enter
the motor from the bypass line. Also make
sure it does not enter the sensor through the
shaft.
Be careful not to rub off the molybden applied
around the throttle valve shaft.
Throttle position
sensor
2 3 4
Equipment side connector
AK300346 AB
1. Connect the MUT-II to the diagnosis connector.

When not using the MUT-II, proceed as follows.
15 mm
15 mm
Throttle position
sensor
Areas on throttle valve to
apply molybdenum disulfide
AK000833AD
3. Wipe off the dirt around the throttle valve with the
cloth sprayed with cleaning fluid.
4. Attach the air intake hose.
MB991536
AK201752AB

ON-VEHICLE SERVICE
(1) Disconnect the throttle position sensor

connector and connect the special tool Test
harness (MB991536) between the
disconnected connector taking care not to
confuse the terminal to be connected.
(2) Connect digital voltmeter between the terminal
No. 2 (special tools yellow clip on the sensor
output) and the terminal No. 4 (special tools
red clip on the sensor earth) of the throttle
2. Turn the ignition switch to "ON" position (but do
not start the engine).
3. Check the output voltage of the throttle position
sensor.
Standard value: 535 - 735 mV
AK300347AB
4. If not within the standard value, loosen the throttle

position sensor mounting bolts. Then rotate the
sensor body to adjust.
6. Remove the MUT-II. If the MUT-II is not used,
remove the special tool, and then connect the
throttle position sensor connector.
7. If a diagnosis code is displayed, erase the
diagnosis code by using the MUT-II or disconnect
the negative battery cable from the battery
terminal and then leave it for at least 10 seconds.
After that, reconnect the battery cable, and then
let the engine run at idle for approximately 10
minutes.
13A-307
BASIC IDLE SPEED ADJUSTMENT

M1131001800468
CAUTION
The standard idling speed has been adjusted
by the speed adjusting screw (SAS) by the
manufacturer, and there should usually be no
need for readjustment.
If the adjustment has been changed by mistake, the idle speed may become too high or
the idle speed may drop too low when loads
from components such as the A/C are placed
on the engine. If this occurs, adjust by the following procedure.
The adjustment, if made, should be made
after first confirming that the spark plugs, the
injectors, the idle speed control servo, the
compression pressure, etc., are all normal.
1. Before inspection and adjustment, set the vehicle
to the pre-inspection condition.
2. Connect the MUT-II to the diagnosis connector
(16-pin).
NOTE: When the MUT-II is connected, the diagnosis control terminal should be earthed.
3. Start the engine and run at idle.
4. Select the item No. 30 of the MUT-II Actuator test.
NOTE: This holds the ISC servo at the basic step
to adjust the basic idle speed.
5. Check the idle speed.
NOTE: .
The engine speed may be 20 to 100 r/min
lower than indicated above for a new vehicle
[driven approximately 500 km or less], but no
adjustment is necessary.
If the engine stalls or the engine speed is low
even though the vehicle has been driven
approximately 500 km or more, it is probable
that deposits are adhered to the throttle valve,
so clean it (Refer to 313A).
AK300348
6. If not within the standard value range, turn the

speed adjusting screw (SAS) to make the
necessary adjustment.
13A-308
ON-VEHICLE SERVICE
NOTE: If the idling speed is higher than the standard value range even when the SAS is fully
closed, check whether or not there is any indication that the fixed SAS has been moved. If there is
an indication that it has been moved, adjust the
fixed SAS.
7. Press the MUT-II clear key, and release the ISC
servo from the Actuator test mode.
NOTE: Unless the ISC servo is released, the
Actuator test mode will continue 27 minutes.
9. Disconnect the MUT-II.
10.Start the engine again and let it run at idle speed
for about 10 minutes; check that the idling
condition is normal.
FUEL PRESSURE TEST

M1131001900368
1. Release residual pressure from the fuel pipe line

to prevent fuel gush out (Refer to 313A).
<When using the fuel pressure gauge set (special tool)>

a. Remove the union joint and bolt from the special
tool Adaptor hose (MD998709) and attach the
special tool Hose adaptor (MD998742) to the
adaptor hose.
b. Via a gasket, install the special tool Fuel pressure
gauge set (MB991637) into the special tool that
has already assembled as described in (a)
above.
<When using the fuel pressure gauge>
a. Remove the union joint and bolt from special tool
Adaptor hose (MD998709) and attach the special
tool Hose adaptor (MD998742) to the adaptor
hose.
b. Via a suitable O-ring or gasket, install the fuel
pressure gauge to the special tool that has
already assembled as described in (a) above.
Fuel pressure
gauge set
CAUTION
Cover the hose connection with rags to prevent
splash of fuel that could be caused by some
residual pressure in the fuel pipe line.
O-ring or gasket
MD 998709
Delivery
pipe
MD 998742
High-pressure
fuel hose
AKX01457AF
4. Install the assembled fuel pressure measurement

tools between the fuel rail and fuel high-pressure
hose.
CAUTION
AK300349AB
2. Disconnect the high-pressure fuel hose at the

delivery pipe side.
MB 991637
Gasket
MD 998709
Delivery
pipe
MD 998742
High-pressure
fuel hose
AKX01458AG
3. Assemble the fuel pressure measurement tools as

follows.
To prevent damage to the MUT-ll, always turn the

before connecting or disconnecting the MUT-ll.
6. Turn the ignition switch to "ON" position (But do
7. Select "Item No. 07" from the MUT-II Actuator test
to drive the fuel pump. Check that there are no
fuel leaks from any parts.
8. Finish the actuator test or turn the ignition switch
to "LOCK" (OFF) position.
9. Start the engine and run at idle.
10.Measure fuel pressure while the engine is running
at idle.
Standard value: Approximately. 270 kPa at
cerb idle

ON-VEHICLE SERVICE
AK300349AB
11.Disconnect the vacuum hose from the fuel

pressure regulator and measure fuel pressure
with the hose end closed by a finger.
Symptom
Probable cause
Fuel pressure too low

Fuel pressure drops after racing
No fuel pressure in fuel return
hose
Fuel pressure too high
13A-309
Standard value: 330 - 350 kPa at cerb idle

12.Check to see that fuel pressure at idle does not
drop even after the engine has been raced several
times.
13.Racing the engine repeatedly, hold the fuel return
hose lightly with fingers to feel that fuel pressure
is present in the return hose.
NOTE: If the fuel flow rate is low, there will be no
fuel pressure in the return hose.
14.If any of fuel pressure measured in steps 10 to 13
is out of specification, troubleshoot and repair
according to the table below.
Remedy
Clogged fuel filter
Replace fuel filter
Fuel leaking to return side due to Replace fuel pressure regulator

poor fuel regulator valve seating or
settled spring
Low fuel pump delivery pressure
Replace fuel pump
Binding valve in fuel pressure

regulator
Replace fuel pressure regulator
Clogged fuel return hose or pipe
Clean or replace hose or pipe
Same fuel pressure when vacuum Damaged vacuum hose or

hose is connected and when
Clogged nipple
disconnected
15.Stop the engine and check change of fuel
pressure gauge reading. Normal if the reading
does not drop within 2 minutes. If it does, observe
the rate of drop and troubleshoot and repair
according to the table below.
Symptom
Probable cause
Replace vacuum hose or clean

nipple
Remedy
Fuel pressure drops gradually after Leaky injector

engine is stopped
Leaky fuel regulator valve seat
Replace injector
Fuel pressure drops sharply

immediately after engine is
stopped
Replace fuel pump
Check valve in fuel pump is held

open
16.Release residual pressure from the fuel pipe line

(Refer to 313A).
CAUTION
Cover the hose connection with rags to prevent
splash of fuel that could be caused by some
residual pressure in the fuel pipe line.
17.Remove the fuel pressure gauge and special tool
from the delivery pipe.
Replace fuel pressure regulator
18.Replace the O-ring at the end of the fuel high

pressure hose with a new one. Furthermore,
apply engine oil to the new O-ring before
replacement.
19.Fit the fuel high pressure hose over the delivery
pipe and tighten the bolt to specified toque.
20.Check for any fuel leaks by following the
procedure in step 7.
21.Disconnect the MUT-II.
13A-310
ON-VEHICLE SERVICE
FUEL PUMP CONNECTOR

DISCONNECTION (HOW TO REDUCE
PRESSURIZED FUEL LINES)
M1131000900558
(2) Remove the rear seat assembly (Refer to

GROUP 52A,Rear Seat Assembly Removal
and Installation 352A).
Service hole cover
WARNING
When removing the fuel pipe, etc., release
fuel pressure to prevent fuel spray.
1. Remove the rear seat assembly (Refer to GROUP
52A - Rear Seat Assembly 352A).
Service hole cover
AC102784 AB
(3) Remove the service hole cover.
AC102784 AB
2. Remove the service hole cover.

Fuel pump assembly <2WD>
or fuel tank pump and gauge assembly <4WD>
AC101011AE
connector
(4) Disconnect the fuel pump assembly <2WD> or

the fuel tank pump and gauge assembly
<4WD> connector.
Fuel pump assembly <2WD> or
fuel tank pump and gauge assembly <4WD>
connector
AC101011AD
3. Disconnect the fuel pump assembly connector

<2WD> or fuel tank pump and gauge assembly
connector <4WD>.
4. After starting the engine and letting it run until it
stops naturally, turn the ignition switch to the
"LOCK" (OFF) position.
5. Connect the fuel pump assembly connector
<2WD> or fuel tank pump and gauge assembly
connector <4WD>.
6. Install the service hole cover and rear seat
assembly (Refer to GROUP 52A - Rear Seat
Assembly 352A).
FUEL PUMP OPERATION CHECK

M1131002000584
1. Check the operating of the fuel pump by MUT-II to

force-drive the fuel pump.
2. If the fuel pump will not operate, check by using
the following procedure. If normal, check the fuel
pump drive circuit.
(1) Turn the ignition switch to the "LOCK" (OFF)
position.
2
4
3
5
AC101012 AD
(5) When the fuel pump drive connector is

attached directly to the battery, check if the
sound of the fuel pump operation can be
heard. If no operating sound is heard, replace
the fuel tank pump (Refer to GROUP 13A,
Fuel Pump Module Disassembly and
Assembly 352A).
NOTE: As the fuel pump is an in-tank type, the
fuel pump sound is hard to hear. Remove the
fuel tank filler tube cap and check from the tank
inlet.
(6) Check for fuel pressure by pinching the fuel
hose with fingertips.

ON-VEHICLE SERVICE
(7) Connect the fuel pump assembly <2WD> or

the fuel tank pump and gauge assembly
<4WD> connector.
13A-311
(8) Install the service hole cover and rear seat

assembly (Refer to GROUP 52A, Rear Seat
Assembly Removal and Installation P.52A-25).
COMPONENT LOCATION
M1131002100622
Name
Symbol
Name
Symbol
Air flow sensor

(with intake air temperature sensor and
barometric pressure sensor)
Engine-ECU
Engine warming lamp

(check engine lamp)
A/C relay
Fuel pump relay (1) and (2)
A/C switch
A/C pressure sensor
Ignition coil
Injector
Crank angle sensor
Detonation sensor
Diagnosis connector
Power steering fluid pressure switch
Vehicle speed sensor
H
P
AK300351AB
13A-312
ON-VEHICLE SERVICE
ENGINE CONTROL RELAY CONTINUITY

CHECK
INTAKE AIR TEMPERATURE SENSOR

CHECK
M1131050000185
Relay boxs
triangle marks
M1131002800364
Intake air
temperature
sensor
Equipment side
connector
1 2 3 4 5 6 7

AK300352 AB
Tester
Battery Voltage
Connectio
n Terminal
Normal
State
2-3
No Voltage
Continuity
1-4
No Voltage
No continuity
Voltage (Connect
Continuity
positive (+) terminal of
battery to terminal No. 3
and negative (-)
terminal of battery to
terminal No. 2.)
AK300354 AB
1. Disconnect the air flow sensor connector.

2. Measure resistance between terminals No. 5 and
No. 6.
Standard value:
13 - 17 kW (at -20C)
5.3 - 6.7 kW (at 0C)
2.3 - 3.0 kW (at 20C)
1.0 - 1.5 kW (at 40C)
0.56 - 0.76 kW (at 60C)
0.30 - 0.42 kW (at 80C)
3. Remove the air flow sensor
FUEL PUMP RELAY CONTINUITY CHECK

sensor
M1131033000193
Junction blocks
triangle marks
Fuel pump
relay (1)
Fuel pump
relay (2)
1
3
2
4
AKX01621AD
Equipment side
connector
AK300353 AB
Tester
Battery Voltage
Connectio
n Terminal
Normal
State
2-3
No Voltage
Continuity
1-4
No Voltage
No continuity
Voltage (Connect
Continuity
positive (+) terminal of
battery to terminal No. 3
and negative (-)
terminal of battery to
terminal No. 2.)
4. Measure resistance while heating the sensor

using a hair drier.
Normal condition:
Temperature (C)
Resistance (kW)
Higher
Smaller
5. If the value deviates from the standard value or

the resistance remains unchanged, replace the air
flow sensor assembly.
6. Install the air flow sensor and tighten it to the
specified torque.
Tightening torque: 8.8 1 Nm
13A-313
ON-VEHICLE SERVICE

SENSOR CHECK
M1131003100335
CAUTION
Be careful not to touch the connector (resin section) with the tool when removing and installing.
1 2
4. Apply sealant to threaded portion.

Specified sealant:
3M NUT Locking Part No. 4171 or equivalent
5. Install the engine coolant temperature sensor and
tighten it to the specified torque.
THROTTLE POSITION SENSOR CHECK

M1131003200398
Throttle position
sensor
AK300355
1. Remove the engine coolant temperature sensor.
2 3 4
AKX01622
2. With temperature sensing portion of engine

coolant temperature sensor immersed in hot
water, check resistance.
Standard value:
14 - 17 kW (at -20C)
5.1 - 6.5 kW (at 0C)
2.1 - 2.7 kW (at 20C)
0.9 - 1.3 kW (at 40C)
0.48 - 0.68 kW (at 60C)
0.26 - 0.36 kW (at 80C)
3. If the resistance deviates from the standard value
greatly, replace the sensor.
AK300346 AB
1. Disconnect the throttle position sensor connector.

2. Measure the resistance between the throttle
position sensor side connector terminal No. 1 and
terminal No. 4.
3. Measure the resistance between the throttle
position sensor side connector terminal No. 2 and
terminal No. 4.
Normal condition:
Throttle valve slowly
Changes smoothly in
open until fully open from proportion to the opening
the idle position
angle of the throttle valve
4. If the resistance is outside the standard value, or if
it doesnt change smoothly, replace the throttle
position sensor.
NOTE: For the throttle position sensor adjustment
procedure, refer to 313A.
OXYGEN SENSOR CHECK

M1131005000497
AKX01623AD
1 2
3 4
AK300356 AB
13A-314
ON-VEHICLE SERVICE
1. Disconnect the oxygen sensor connector and

connect the special tool Test harness
(MD998464) to the connector on the oxygen
sensor side.
2. Make sure that there is continuity (4.5 - 8.0 W at
20C) between terminal No. 1 (red clip of special
tool) and No. 3 (blue clip of special tool) on the
oxygen sensor connector.
3. If there is no continuity, replace the oxygen
sensor.
4. Warm up the engine until engine coolant is 80C
or higher.
5. Perform a tracing for 5 minutes or more with the
engine speed of 4,500 r/min.
Oxygen
sensor
equipment
side connector
Black
White
MD998464
AKX01624 AF
6. Connect a digital voltage meter between terminal

No. 2 (black clip of special tool) and No. 4 (white
clip of special tool).
7. While repeatedly racing the engine, measure the
oxygen sensor output voltage.
Standard value:
Engine
Oxygen
Remarks
sensor
output
voltage
When
racing the
engine
0.6 - 1.0 V
If you make the air-fuel

ratio rich by racing the
engine repeatedly, a
normal oxygen sensor
will output a voltage of
0.6 - 1.0 V.
CAUTION
Be very careful when connecting the jumper
wire; incorrect connection can damage the
oxygen sensor.
Be careful the heater is broken when voltage
of beyond 8V is applied to the oxygen sensor
heater.
NOTE: If the sufficiently high temperature (of
approximate 400C or more) is not reached
although the oxygen sensor is normal, the output
voltage would be possibly low although the rich
air-fuel ratio. Therefore, if the output voltage is
low, use a jumper wire to connect the terminal
No.1 (red clip of special tool) and the terminal No.
3 (blue clip of special tool) of the oxygen sensor
with a (+) terminal and (-) terminal of 8 V power
supply respectively, then check again.
8. If the sensor is defective, replace the oxygen
sensor.
NOTE: For removal and installation of the oxygen
sensor, refer to GROUP 15 - Exhaust Manifold.
315.
2 1
4 3
Equipment side
connector
Oxygen sensor
connector (rear)
AK300357 AB
1. Disconnect the oxygen sensor connector and

connect the special tool Test harness (MB991658)
to the connector on the oxygen sensor side.
2. Make sure that there is continuity (11 - 18 W at
20C) between terminal No. 1 and No. 2 on the
oxygen sensor connector.
3. If there is no continuity, replace the oxygen
sensor.
4. Warm up the engine until engine coolant is 80C
or higher.
5. Perform a tracing for 5 minutes or more with the
engine speed of 4,500 r/min.
13A-315
ON-VEHICLE SERVICE
INJECTOR CHECK
M1131005200327
Oxygen sensor
Check the Operation Sound

Injector
1 2
Equipment side
connector
MB991658
AK000121 AC
6. Connect a digital voltage meter between terminal

No. 3 and No. 4.
7. While repeatedly racing the engine, measure the
oxygen sensor output voltage.
Standard value:
Engine
Oxygen
Remarks
sensor
output
voltage
When
racing the
engine
0.6 - 1.0 V
If you make the air-fuel

ratio rich by racing the
engine repeatedly, a
normal oxygen sensor
will output a voltage of
0.6 - 1.0 V.
CAUTION
Be very careful when connecting the jumper
wire; incorrect connection can damage the
oxygen sensor.
Be careful the heater is broken when voltage
of beyond 8V is applied to the oxygen sensor
heater.
NOTE: If the sufficiently high temperature (of
approximate 400C or more) is not reached
although the oxygen sensor is normal, the output
voltage would be possibly low although the rich
air-fuel ratio. Therefore, if the output voltage is
low, use a jumper wire to connect the terminal
No.2 and the terminal No. 1 of the oxygen sensor
with a (+) terminal and (-) terminal of 8 V power
supply respectively, then check again.
8. If the sensor is defective, replace the oxygen
sensor.
NOTE: For removal and installation of the oxygen
sensor, refer to GROUP 15 - Exhaust Pipe and
Main Muffler 315.
AK300358 AB
1. Use a stethoscope to listen to the operation sound

(clicking) of the injectors while the engine is idling
or cranking.
CAUTION
Beware that the operation sounds of other injectors can be heard even if the injector that is being
inspected might not be operating.
2. Verify that the operation sound increases with the
engine speed.
NOTE: If the operating sound cannot be heard,
inspect the injector actuation circuit.
Measurement of Resistance between Terminals

1. Disconnect the injector connector.
2. Measure the resistance between terminals.
Standard value: 10.5 - 13.5 W (at 20C)
3. Connect the injector connector.
Check the Injection Condition

1. Following the steps below, bleed out the residual
pressure within the fuel pipe line to prevent flow of
the fuel (Refer to 313A).
2. Remove the injector.
3. Assemble the following special tools as shown in
Fig.
Injector test set (MD998706)
Injector test harness (MB991607)
Injector test adaptor (MD998741)
Clip (MB991608)
13A-316
ON-VEHICLE SERVICE
High-pressure fuel hose

MD998741
Return hose
MB991607
Pressure regulator
Clip (MB991608) MD998706
Injector
Battery
AK101794 AD

5. Turn the ignition switch to "ON" position (But do
6. Select "Item No. 07" from the MUT-II Actuator test
to drive the fuel pump.

(STEPPER MOTOR) CHECK
M1131005400417
Check the Operation Sound
Mainhose
1 2
4 5
Equipment side
connector
Return hose
Injector
Idle speed
control servo
AK300359 AB
Battery
AK101795 AC
7. Activate the injector and check the atomized

spray condition of the fuel.
The condition can be considered satisfactory
unless it is extremely poor.
8. Stop the actuation of the injector, and check for
leakage from the injectors nozzle.
Standard value: 1 drop or less per minute
9. Activate the injector without activating the fuel
pump; then, when the spray emission of fuel from
the injector stops, disconnect the special tool and
restore it to its original condition.
10.Disconnect the MUT-II.
1. Check that the engine coolant temperature is

20C or below.
NOTE: Disconnecting the engine coolant temperature sensor connector and connecting the harness-side of the connector to another engine
coolant temperature sensor that is at 20C or
below is also okay.
2. Check that the operation sound of the stepper
motor can be heard after the ignition is turned to
the "ON" position (but without starting the engine).
3. If the operation sound cannot be heard, check the
stepper motors activation circuit.
If the circuit is normal, it is probable that there is a
malfunction of the stepper motor or of the engineECU.

ON-VEHICLE SERVICE
Check the Coil Resistance
13A-317
Operation Check
1 2 3
4 5 6
AKX01626
1 2 3
4 5 6
AKX01561AE
1. Disconnect the idle speed control servo

connector.
2. Measure the resistance between terminal No. 2
and either terminal No. 1 or terminal No. 3 of the
connector at the idle speed control servo side.
Standard value: 28 - 33 W (at 20C)
3. Measure the resistance between terminal No. 5
and either terminal No. 6 or terminal No. 4 of the
connector at the idle speed control servo side.
1. Remove the throttle body.

2. Remove the stepper motor.
3. Connect the special tool Test harness
(MB991709) to the idle speed control servo
connector.
4. Connect the positive (+) terminal of a power
supply (approximately 6 V) to the terminals No. 2
and No. 5.
5. With the idle speed control servo as shown in the
illustration, connect the negative (-) terminal of
the power supply to each clip as described in the
following steps, and check whether or not a
vibrating feeling (a feeling of very slight vibration
of the stepper motor) is generated as a result of
the activation of the stepper motor.
(1) Connect the negative (-) terminal of the power
supply to the terminal No. 1 and terminal No.
4.
4.
6.
6.
4.
(6) Repeat the tests in sequence from (5) to (1).
6. If vibration is detected during the test, the stepper
motor can be considered to be normal.
13A-318
INJECTOR
INJECTOR
M1131007100649
Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
315).
Fuel Leakage Inspection.
Fuel Discharge Prevention (Refer to 313A).
Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
315).
11 1 Nm
8.9 1.9 Nm
9
5
8
7N
6
5.0 1.0 Nm
19
15 N
16
18
17
10
N
6,10
7,11
11
18
12
13
19
16
N 15
14
Engine Oil
AC300484 AB
1.
2.
3.
4.
5.
>>A<<
>>A<<
<<A>>
>>A<<
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18
19.
Removal steps
PCV hose connection
Injector connector
Emission control equipment hose
connector
connection
O-ring
Fuel return hose connection
Fuel hose
Delivery pipe pressure regulator
O-ring
Fuel delivery pipe and fuel injector
assembly
Insulators
Fuel injector assembly
O-ring
Fuel injector sheets
Insulators
Fuel injectors
Fuel delivery pipe

<<A>> FUEL DELIVERY PIPE AND FUEL INJECTOR ASSEMBLY REMOVAL
CAUTION
Do not drop the injector.
Remove the fuel delivery pipe with the fuel injector
assembly attached to it.

>>A<< FUEL INJECTOR ASSEMBLY/DELIVERY
PIPE PRESSURE REGULATOR/FUEL HIGHPRESSURE HOSE INSTALLATION
CAUTION
Do not let the engine oil get into the delivery pipe
will be damaged.
1. Apply a drop of new engine oil to the O-ring.
13A-319
2. Turn the fuel injector assembly. To the right and

left to install to the fuel delivery pipe. Repeat for
delivery pipe pressure regulator and fuel highpressure hose. Be careful not to damage the Oring. After installing, check that the item turns
smoothly.
3. If it dose not turn smoothly, the O-ring may be
trapped, remove the item, re-install it into the fuel
delivery pipe and check again.
4. Tighten the delivery pipe pressure regulator and

fuel high-pressure hose to the specified torque.
Tightening torque:
8.9 1.9 Nm <Delivery pipe pressure regulator>
5.0 1.0 Nm <Fuel high-pressure hose>

M1131007700544
315).
315).
Engine Coolant Supplying (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314).
Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Adjustment 317).
7
2
5.0 1.0 Nm
19 3 Nm
N8
3
4
5
1.
2.
3.
4.
5.
Removal steps
Water return hose connection
Water feed hose connection
6.
>>A<<
7.
8.
AC300416AB

Emission vacuum hose
connection
Throttle body assembly
Throttle body gasket
13A-320

>>A<< THROTTLE BODY GASKET INSTALLATION
Install the throttle body gasket as shown in the illustration.
CAUTION
Poor idling etc. may result if the throttle body
gasket is installed incorrectly.
Up
Towards front
of vehicle
AC200313AB
THROTTLE BODY ASSEMBLY DISASSEMBLY AND REASSEMBLY

M1131009700409
5
6
2.0 0.5 Nm
2.0 0.5 Nm
1
2
3
4
AK203824 AB
<<A>>
<>
>>A<<
1.
2.
3.
4.
Removal steps
O-ring
Throttle body

5. Speed adjusting screw
6. O-ring
13A-321
NOTE: .
The speed adjusting screw is correctly adjusted
at the factory and should not be removed.
If the speed adjusting screw should happen to
have been removed, carry out speed adjusting
screw adjutment.

<<A>> THROTTLE POSITION SENSOR DISASSEBLY
1. Do not disassemble the sensor and motor.
2. Do not clean the sensor and motor by dipping
them into cleaning solvent. Clean them with shop
towel.
<> THROTTLE BODY DISASSEMBLY
1. Do not disassemble the throttle body.
2. Check if the vacuum port or passage is clogged.
Use compressed air to clean the vacuum
passage.

>>A<< THROTTLE POSITION SENSOR (TPS)
INSTALLATION
AK203835AB
1. Install the throttle position sensor to the throttle

body as shown in the illustration.
2. Turn the throttle position sensor 90 degrees
counterclockwise to set it, and tighten the screws.
Throttle position
sensor power
Earth
Throttle position
sensor output
AK200203 AB
3. Connect an ohmmeter between terminals 2

(output) and 4 (earth), or between terminals 1
(power) and 2 (output).
Then, make sure that the resistance changes
smoothly when the throttle valve is slowly moved
to the fully open position.
13A-322
ENGINE ECU
ENGINE ECU
M1131033800036

Cowl Side Trim (RH) Removal and Installation (Refer to
GROUP 52A, Instrument Panel Assembly 352A).
3
5.0 1.0 Nm
5.0 1.0 Nm
AC300630AB
1.
REMOVAL STEPS
Engine-ECU connector
2.
3.
REMOVAL STEPS&RQWLQXHG

Engine-ECU
Engine-ECU bracket
13-1
GROUP 13
FUEL
00
11
12
13
CONTENTS
14
15
16
MULTIPORT FUEL INJECTION (MFI) . . . . . . . . . . . . . . . . . . . . 13A
17
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
127(6
13B-1
GROUP 13B
00
11
FUEL SUPPLY
12
13
14
CONTENTS
13B
SEALANT. . . . . . . . . . . . . . . . . . . . . .
13B
13B
FUEL PUMP OPERATION CHECK . . . . . .
13B
FUEL GAUGE UNIT CHECK . . . . . . . . . . .
13B
FUEL PUMP ASSEMBLY <2WD>, FUEL TANK

PUMP AND GAUGE ASSEMBLY <4WD>
REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
13B
FUEL GAUGE UNIT REPLACEMENT . . . .
13B
15
FUEL TANK GAUGE UNIT REPLACEMENT

<2WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13B
FUEL TANK GAUGE UNIT REPLACEMENT

<4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13B
FUEL TANK . . . . . . . . . . . . . . . . . . . .
13B
13B
FUEL PUMP ASSEMBLY <2WD>, FUEL

TANK PUMP AND GAUGE ASSEMBLY
<4WD> DISASSEMBLY AND REASSEMBLY 13B
FUEL TANK GAUGE UNIT DISASSEMBLY
AND REASSEMBLY . . . . . . . . . . . . . . . . . .
13B
16
17
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
FUEL SUPPLY
13B-2
GENERAL INFORMATION
GENERAL INFORMATION
M1135000100350
The fuel tank is located under the floor of the rear

seats to provide increased protection and a more
luggage space.
A fuel tank safety valve assembly has been
adopted to prevent fuel from leaking out in case
of a collision.
A fuel pump assembly <2WD>, fuel pump and

gauge assembly <4WD> including fuel pump, fuel
filter, reservoir and fuel gauge unit, has been
adopted to lighten weight and improve serviceability.
SEALANT
M1135005200017
Item
Specified sealant
Service hole cover and floor pan <2WD>
3M 8513 Grommets windshield sealer (Black)
ON-VEHICLE SERVICE
FUEL PUMP OPERATION CHECK
M1135001000118
Refer to GROUP 13A - On-vehicle Service, Fuel

Pump Operation Check 313A.
FUEL GAUGE UNIT CHECK
2. Remove the service hole cover mounting screws

and remove the service hole cover.
connector
M1135003100296
Refer to GROUP 54A - Combination Meter, On-vehicle Service, Fuel Gauge Unit Check 354A
<2WD>, 354A <4WD>.
Fuel suction
tube <4WD>

<4WD> REPLACEMENT
M1135004900240
1. Remove the rear seat cushion assembly (Refer to

GROUP 52A - Rear seat assembly 352A).
Service hole cover
Fuel return hose
Fuel high-pressure
hose
AC102778AB
AC102784 AB
3. Disconnect the fuel pump assembly <2WD> or

fuel tank pump and gauge assembly <4WD>
connector, fuel return hose, fuel high-pressure
hose and fuel suction tube <4WD>.
FUEL SUPPLY
13B-3
ON-VEHICLE SERVICE
CAUTION
CAUTION
Fuel tank pump and

gauge assembly
Corresponding side
Fuel high-pressure hose or
fuel pump suction tube <4WD>
Service hole
Float
3 mm
AC107193 AC
For 4WD: Pay attention not to damage the float

when removing and installing fuel tank pump and
gauge assembly through the service hole.
4. Remove the mounting nuts and fuel pump bracket
plate, and remove the fuel pump assembly
<2WD>, fuel tank pump and gauge assembly
<4WD> from the service hole.
5. Install the fuel pump assembly <2WD>, fuel tank
pump and gauge assembly <4WD> to the fuel
tank through the service hole.
Quick connector
AC300047AC
After connecting the fuel high-pressure hose or

fuel pump suction tube <4WD>, slightly pull it to
ensure that it is installed securely. Also confirm
that there is a play approximately 3 mm.
connector
Fuel suction
tube <4WD>
Fuel pump braket plate
2.5 0.4 Nm
AC107194AC
6. Install the fuel pump bracket plate to the fuel tank

and tighten the mounting nuts to the specified
torque.
Fuel return hose
Fuel high-pressure
hose
AC102778AB
7. Connect the fuel pump assembly <2WD> or fuel

tank pump and gauge assembly <4WD>
connector, fuel return hose, fuel high-pressure
hose and fuel suction tube <4WD>.
Service hole cover
AC102784 AB
FUEL SUPPLY
13B-4
ON-VEHICLE SERVICE
8. Tighten the service hole cover mounting screws

and install the service hole cover.
9. Install the rear seat cushion assembly. (Refer to
GROUP 52A - Rear seat assembly 352A).
CAUTION
Fuel tank gauge unit
FUEL GAUGE UNIT REPLACEMENT

Gauge unit
FUEL TANK GAUGE UNIT

REPLACEMENT <2WD>
M1135001400279

GROUP 52A - Rear Seat Assembly 352A).
Flat-tipped screwdriver
Service hole
AC107188AD
Pay attention not to damage the gauge unit and

the float of the fuel tank gauge unit when withdrawing it from the service hole.
4. Remove the fuel tank gauge unit mounting nuts
and remove the fuel tank gauge unit from service
hole.
CAUTION
Service hole cover
AC107600AC
2. Pry off the service hole cover using a flat-tipped

screwdriver, etc.
Gauge unit
Service hole
AC107188AE

the float of the fuel tank gauge unit when inserting it from the service hole.
harness connector
AC107601AC
2.5 0.4 Nm
3. Disconnect the fuel tank gauge unit harness

connector.
AC107602 AC
5. Install the fuel tank gauge unit to the fuel tank

through the service hole, and tighten the mounting
nuts to the specified torque.
FUEL SUPPLY
13B-5
ON-VEHICLE SERVICE

harness connector
Service hole cover
AC107603AC
AC107601AC
6. Connect the fuel tank gauge unit harness

connector.
2. Remove the service hole cover mounting screws

and remove the service hole cover.
Fuel pump suction tube
Service hole cover

Fuel tank gauge

unit harness
connector
Floor pan
AC100961AD
7. Apply the specified sealant to the contact surfaces

of the service hole cover and the floor pan, and
install the service hole cover.
Specified sealant: 3M 8513 Grommets
Windshield Sealer (Black)
8. Install the rear seat cushion assembly (Refer to
AC107189AC
3. Disconnect the fuel tank gauge unit harness

connector and fuel pump suction tube.
CAUTION
Gauge unit
FUEL TANK GAUGE UNIT

REPLACEMENT <4WD>
Service hole
M1135001400280

Float
AC107190AD

the float of the fuel tank gauge unit when withdrawing it from the service hole.
4. Remove the fuel tank gauge unit mounting nuts
and remove the fuel tank gauge unit from service
hole.
FUEL SUPPLY
13B-6
ON-VEHICLE SERVICE
CAUTION
CAUTION
Main pipe nozzle or
fuel main pipe
Gauge unit

fuel pump suction tube

Service hole
Float
3 mm
Quick connector
AC107190 AE

the float of the fuel tank gauge unit when inserting it from the service hole.
2.5 0.4 Nm
AC300047AB

fuel pump suction tube, slightly pull it to ensure
that it is installed securely. Also confirm that
there is a play approximately 3 mm.
Fuel pump suction tube
AC107618AC
5. Install the fuel tank gauge unit to the fuel tank

through the service hole, and tighten the mounting
nuts to the specified torque.
Fuel tank gauge

unit harness
connector
AC107189AC
6. Connect the fuel tank pump gauge unit harness

connector and fuel suction tube.
Service hole cover
AC107603AC
7. Tighten the service hole cover mounting screws

and install the service hole cover.
8. Install the rear seat cushion assembly (Refer to
FUEL SUPPLY
13B-7
FUEL TANK
FUEL TANK
M1135001900401
Draining Fuel
Fuel Pump Connector Disconnection (How to Reduce
Fuel Pressure) (Refer to GROUP 13A - On-vehicle Service 313A).
Centre Exhaust Pipe Removal (Refer to GROUP 15,
Propeller Shaft Removal <4WD> (Refer to GROUP 25,
Propeller Shaft 325).
Propeller Shaft Installation <4WD> (Refer to GROUP 25,
Propeller Shaft 325).
Centre Exhaust Pipe Installation (Refer to GROUP 15,
Refilling Fuel
Checking for Fuel Leaks
<2WD>
2.5 0.4 Nm
21
11
12
2.5 0.4 Nm
15
17
13
5
13
15 13
22
18 N
2.5 0.4 Nm
2.5 0.4 Nm
20 N
19
20 N
13
14 13
19
24
25
23
26 4 Nm
26 4 Nm
7
AC212356 AB
FUEL SUPPLY
13B-8
FUEL TANK
<4WD>
2.5 0.4 Nm
21
16
11
12
8
2.5 0.4 Nm
13
17
2.5 0.4 Nm
15
13
15
13
22
N 18
2.5 0.4 Nm
20 N
19
14
13
13
20 N
4
19
24
10
25
23
26 4 Nm
<<A>>
<<A>>
Fuel tank assembly removal

steps
1. Fuel filler hose connection <Fuel
filler neck side>
2. Fuel filler neck breather hose
connection <Fuel filler neck side>
3. Main pipe connection
4. Return pipe
5. Fuel vapour pipe
6. Parking brake cable clamp
connection <RH side>
7. Wiring harness clamp connection
8. Fuel tank gauge unit assembly, fuel
pump assembly <2WD>, fuel tank
pomp and gauge assembly <4WD>
connector connection
Rear differential support member

installation nuts and bolts <4WD>
(Refer to GROUP 27B - Rear
Differential Carrier Assembly
327B).
9. Fuel tank assembly <2WD>
10. Fuel tank assembly <4WD>
AC212516AB
>>A<<
>>A<<
<>
<>
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Fuel tank assembly removal

steps&RQWLQXHG
Fuel return hose
Fuel tank hose
Fuel tank vapour hose 2way valve
Fuel vapour pipe
Fuel pump suction tube <4WD>
Gasket
Fuel tank safety valve
Gasket
Fuel pump bracket plate
Fuel pump assembly <2WD>, fuel
tank pump and gauge assembly
<4WD>
Fuel filler hose
Fuel filler neck breather hose
Fuel tank
FUEL SUPPLY
13B-9
FUEL TANK
<FUEL FILLER NECK>
30
27
28
29
1
26
AC300410AB
Fuel filler neck removal steps

Fuel filler hose connection <Fuel
filler neck side>
2. Fuel filler neck breather hose
connection <Fuel filler neck side>
26. Fuel filler neck protector
1.
27.
28.
29.
30.
Fuel filler neck removal steps

Fuel tank cap
Fuel filler neck
Fuel filler neck valve
Gasket
FUEL SUPPLY
13B-10
FUEL TANK
CAUTION
<<A>> REAR DIFFERENTIAL SUPPORT MEMBER INSTALLATION NUTS AND BOLTS <4WD>/
FUEL TANK ASSEMBLY <4WD> REMOVAL
Fuel tank assembly
Rear differential
carrier assembly
Support the fuel tank assembly securely so that

it does not fall off from the transmission jack.
3. Tilt the fuel tank assembly to disconnect the
connectors.
Towards front
of vehicle
Rear differential
carrier assembly
Tilt
Towards front
of vehicle
AC300033AB
1. Remove the rear differential support member

installation nuts and bolts, and then tilt the rear
differential carrier assembly (Refer to GROUP
27A - Rear Differential Carrier Assembly 327B
).
Lower
Fuel tank assembly
AC300043AB
4. Remove the fuel tank assembly to the direction

shown, being careful not to strike it against the
rear differential carrier assembly.
<> FUEL TANK GAUGE UNIT/FUEL PUMP
ASSEMBLY <2WD>, FUEL TANK PUMP AND
GAUGE ASSEMBLY <4WD> REMOVAL
CAUTION
When withdrawing the fuel tank gauge unit, fuel
tank pump and gauge assembly from the fuel
tank, be careful not damage the module unit and
the float.
Fuel tank assembly
Transaxle jack
AC107196 AD
2. Raise and support the fuel tank assembly with a

transmission jack, and remove the mounting nuts
and bolts.
Towards front
of vehicle
Fuel tank assembly
Rear differential
carrier assembly

>>A<< FUEL PUMP SUCTION TUBE <4WD>/FUEL
HIGH-PRESSURE HOSE INSTALLATION
CAUTION
Corresponding side
fuel pump suction tube <4WD>
Tilt
3 mm
AC300040 AB
Quick connector
AC300047AC

fuel pump suction tube <4WD>, slightly pull it to
ensure that it is installed securely. Also confirm
that there is a play approximately 3 mm.
FUEL SUPPLY
13B-11
FUEL TANK

<4WD> DISASSEMBLY AND
REASSEMBLY
M1135004600294
<2WD>
2
10
1N
N5
6
N5
4
9
11
AC300077AB
1.
2.
>>A<<
3.
4.
5.
Disassembly steps
Gasket
Fuel tank pump connector
connection
Fuel pump bracket
Fuel pump hose
O-ring
>>A<<
6.
7.
8.
9.
10.
11.

Fuel pump tube
Fuel pump bracket
Fuel tank pump
Fuel tank pump cushion
Fuel tank grommet
Fuel tank filter assembly
FUEL SUPPLY
13B-12
FUEL TANK
<4WD>
4
N 13
2
1N
3
8
11
9
N
6
12
10
14
AC300470AB
Disassembly steps
Gasket
Fuel tank gauge unit connector
connection
3. Fuel tank gauge unit
4. Fuel tank pump connector
connection
5. Fuel pump bracket
6. Fuel pump hose
7. Fuel tank assist pump
8. O-ring
9. Fuel tank tube
10. Fuel pump bracket
1.
2.
>>A<<
>>A<<
11.
12.
13.
14.

Fuel tank pump
Fuel tank pump cushion
Fuel tank grommet
Fuel tank filter assembly

>>A<< FUEL TANK GROMMET/O-RING INSTALLATION
Apply gasoline on the grommet and the O-ring before
mounting them to prevent damage or twisting.
FUEL SUPPLY
13B-13
FUEL TANK
FUEL TANK GAUGE UNIT DISASSEMBLY AND REASSEMBLY

M1135051100057
<2WD>
<4WD>
3
3
AC102461 AD
1.
Disassembly steps
Gasket
2.
3.

Fuel in tank filter <4WD>
127(6
54-1
GROUP 54
CHASSIS
ELECTRICAL
00
11
12
13
14
15
CONTENTS
16
17
CHASSIS ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54A
21
22
SMART WIRING SYSTEM (SWS) NOT USING SWS

MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54B
25
SMART WIRING SYSTEM (SWS) USING SWS MONITOR . . . . 54C
27
26
31
32
33
34
35
36
37
42
51
52
54
55
127(6
54B-1
GROUP 54B
SMART WIRING
SYSTEM (SWS) NOT
USING SWS
MONITOR
00
11
12
13
14
15
16
17
21
22
CONTENTS
54B
CHECK AT ECU TERMINAL . . . . . . . 54B
SPECIAL TOOLS. . . . . . . . . . . . . . . .
54B
ON-VEHICLE SERVICE . . . . . . . . . . . 54B
54B
CONFIGURATION FUNCTION
<Vehicles with keyless entry system> . . . . . 54B
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR
54B-2
GENERAL INFORMATION
GENERAL INFORMATION
M1549000100403
The exclusive signal lines for transmitting the multidistribution data are connected as follows between
the ETACS-ECU, column switch (incorporated inside
the column-ECU), front-ECU, power window main
switch (incorporated inside the power window-ECU),
and power window sub switches (incorporated inside
the power window-ECU) for internal communication.
Power window
sub switch
(Rear RH)
ETACS-ECU
Power window
main switch
Column switch
Power window
sub switch
(Front)
Power window
sub switch
(Rear LH)
Front-ECU
: Bidirectional communication
: Unidirectional communication
Buzzer
When the ignition key is removed and then the

drivers door is opened with turning ON the tail lamp
or the head lamp, the buzzer sounds continuously to
alert the driver that the lamp is still ON.
However, if the tail lamp or the headlamp is turned off
by the headlamp auto-turn off function, the buzzer
does not sound.
Lamp reminder function

ON
Tail lamp or
headlamp
Key
reminder
switch
OFF
ON
(Key removed)
OFF
(Key inserted)
Driver's
door
switch
Buzzer
output
AC212517AG
ON (Open)
OFF (Closed)
ON (Tone alarn
sounds)
OFF (Tone alarm
does not sound)
AC101512
Central door locking

Central door locking control function
t: 0.25 seconds
Lock switch
Unlock switch
ON
OFF
ON
OFF
ON
Lock relay
output
OFF
Unlock relay
output
ON
OFF
t
t
AC101496 AD
When the front doors is locked (when the lock switch

turns ON after turning OFF the unlock switch in the
drivers door lock actuator), ETACS-ECU turns ON
the lock relay output for 0.25 second, and locks all
doors (including the tailgate).
When the front doors is unlocked (when the unlock
switch turns ON after turning OFF the lock switch on
the drivers door lock actuator), ETACS-ECU turns
ON the unlock relay output for 0.25 second, and
unlocks all doors (including the tailgate).
54B-3
GENERAL INFORMATION
Key reminder function
Key reminder
switch
(Key inserted)ON
(Key removed)OFF
Driver's door
switch
Driver's door actuator
switch
(Open)ON
(Close)OFF
LOCK
UNLOCK
t
Lock relay
ON
OFF
T2
T2
T2
T2
ON
Unlock relay
OFF
T1
T1
T1
t: 0.3 seconds
T1: 0.25 seconds
T2: 1 second
When the drivers door is opened with the ignition key

inserted to the ignition cylinder and the door is locked
(when the lock switch turns ON after turning OFF the
unlock switch in the drivers door lock actuator), after
approximately 0.3 second, ETACS-ECU turns ON
the unlock relay output for 0.25 second to discourage
the door lock operation so that the ignition key left in
the ignition cylinder is prevented.
If the discouraging the door lock operation fails, the
current supply will be retried. (The unlock relay
output is turned ON for 0.25 second up to five times
with one second interval.)
NOTE: The broken line in the graph indicates the
current supply retry state if the discouraging door
lock operation fails.
T1
T1
T1
T1
T1
AC101499 AB
Door unlock function with the impact detection

If the vehicle crashed with the ignition switch ON or
30 seconds after turning the ignition switch to LOCK
(OFF), and the impact sensor detects an impact
greater than the specified value, the impact sensor
sends the signal to ETACS-ECU. Then, within the 0.1
second, ETACS-ECU energizes the unlock relay for
one second for releasing the door lock to prevent
passengers to kept inside the vehicle after the crash.
NOTE: The fail safe disables the operation under the
following conditions. (Diagnosis code No. 31 or 32 is
output at this time.) Turn ON the ignition switch again
after turning the ignition switch to LOCK (OFF) to
return from the fail safe state.
.
No. 31: When the ignition switch is ON, and the
sensor shows under the short circuit detect
voltage for 2.5 second
No. 32: When the ignition switch is ON, and the
sensor shows over the closed circuit detect
voltage for 0.4 second
54B-4
GENERAL INFORMATION
Keyless entry system

Keyless entry hazard lamp answer back function
(the initial condition: with function of lock/
unlock)
LOCK
Keyless entry
transmitter
OFF
Lock relay output
UNLOCK
ON
Unlock relay output

Hazard
warning light
OFF
ON
OFF
Illuminate
Extinguish
AC101500 AB
The hazard answer back function that allows

checking the lock/unlock state of the door easily even
in the daytime is installed. When the lock signal from
the keyless entry transmitter is received into ETACSECU, all doors (including the tailgate) are locked, and
the turn signal lamp blinks twice. When the unlock
signal is received, all doors (including the tailgate)
are unlocked, and the turn signal lamp blinks once.
NOTE: The answer back blink time can be adjusted
by the adjusting function.
Timed locking mechanism
After unlocking the doors with the keyless entry
transmitter, if no doors are opened, if the ignition key
is not inserted or if the locking function is not
operated, the ETACS-ECU automatically locks the
doors in 30 seconds.
Windshield wiper and washer

Intermittent control (the initial condition: with function)
18
Intermittent wiper volume

"FAST" position
18
Intermittent time:
TI(sec.)
Intermittent time:
TI(sec.)
0
Intermittent wiper volume

"SLOW" position
100
FAST
SLOW
Intermittent wiper volume position
Vehicle speed (km/h)

AC300134 AB
ETACS-ECU calculates the intermittent time TI from

the vehicle speed calculated from the windshield
intermittent wiper volume of the column switch and
the vehicle speed signals (engine-ECU), and sends it
to the front ECU as SWS data.
NOTE: The vehicle speed sensing function can be

invalidated by the adjusting function.
TI: Intermittent time

ON
Windshield wiper auto stop signal
OFF
ON
Windshield wiper drive signal
OFF
TI
TI
TI
AC300135 AC
The front ECU determines the intermittent time TI

from the input SWS data, and turns ON the
windshield wiper drive signal. When the wiper comes
to the stop position, the windshield wiper auto-stop
signal is turned OFF, and the windshield wiper drive
signal turns OFF.
When the intermittent time TI is elapsed after being

turned ON the windshield wiper drive signal, the
windshield wiper drive signal is turned ON again, and
the above-mentioned operation is repeated.
54B-5
GENERAL INFORMATION
Mist wiper control

ON
Windshield wiper "MIST" switch
OFF
ON
Windshield wiper auto stop signal
OFF
ON
Windshield wiper drive signal
OFF
Windshield wiper speed switching relay
(HI) ON
TI
TI
(LO) OFF
Windshield wiper switch "OFF" position
Windshield wiper intermittent operation
TI: Intermittent time
AC300283 AC
When the windshield wiper mist switch of the column

switch is turned ON while the ignition switch is ACC
or ON, the column switch turns ON the windshield
wiper drive signal. At the same time, the wiper speed
switch relay turns to ON (HI). When the windshield
mist wiper switch is ON, the windshield wiper
operates at the high speed.
Low speed wiper and high speed wiper control
ON
Windshield wiper "LO" switch
OFF
ON
Windshield wiper "HI" switch
OFF
Windshield wiper
auto stop signal
ON
Windshield wiper
drive signal
ON
OFF
OFF
Windshield wiper speed (HI) ON

switching relay
(LO) OFF
Windshield wiper low speed operation
Windshield wiper hight speed operation

AC300284AC
When the windshield low speed wiper switch of the

column switch is turned ON while the ignition switch
is ACC or ON, the column switch turns ON the
windshield wiper drive signal. Also, the wiper speed
switching relay turns to OFF (LO), and the windshield
wiper operates at the low speed.
When the windshield high speed wiper switch is

turned ON, the windshield wiper drive signal turns
ON. Also, the wiper speed switching relay turns ON
(HI), and the windshield wiper operates at the high
speed.
54B-6

GENERAL INFORMATION
Rear wiper and washer

Rear wiper control [the initial condition: 8 seconds (without successive operations)]
ON
Rear wiper switch
OFF
Transmission range switch "R" position
ON
OFF
t
T2
T1
T2
T2
T1
ON
Rear wiper drive signal
OFF
T3
T4
T4
T3
T4
t: 1.0 second
T1: 7.4 seconds
T2: 8.0 seconds
T3: 3.0 seconds
T4: 0.6 second
T4
T4
AC301877AB
1. When the rear wiper switch on the column switch

is turned ON with the ignition switch at the ACC
or ON position, ETACS-ECU turns ON the rear
wiper drive signal for 3 seconds (approximately 2
operations) and performs the intermittent action
at 8-second intervals.
When the transmission range is moved to R (reverse)
position during the rear wiper operation, the
inhibitor switch R (reverse) position turns ON one
second after that, ETACS-ECU sends the rear
wiper drive signal for 3 seconds (approximately 2
operations), and operates the intermittent action
in 8 seconds interval.
2. By the special operation of the rear wiper switch

on the column switch (successive 2-time
operations), the rear wiper operates continuously
regardless of the set intermittent time.
NOTE: The rear wiper intermittent time can be
adjusted or canceled for continuous operation by the
adjusting function.
Headlamp
Headlamp automatic-shutdown function (the initial condition: with function)
Ignition switch (IG)
ON
OFF
Driver's seat
door switch
(Opend) ON
(Closed) OFF
Headlamp
Lighting switch
Tail lamp
OFF
Tail lamp output
Headlamp output
ON
OFF
ON
OFF
3 minutes
1 second
AC300449 AB
Even when the lighting switch (tail lamp switch or

head lamp) is ON, the headlamp (including the tail
lamps) turns off automatically with any of the
following conditions to prevent the battery discharge
caused by unattended operation.
54B-7
GENERAL INFORMATION
If the ignition switch is turned OFF with the

lighting switch ON, the lamp turns off
automatically after 3 minutes. If the drivers door
is opened during the 3 minutes, the lamp turns off
after one second. (One seconds before turning
off, the lamp reminder buzzer sounds.)
After the head lamp auto cut function, when the
lighting switch is turned OFF and then ON or, the
ignition switch is turned ON, the head lamp lights
again.
NOTE: For vehicles with the keyless entry system,
this function can be invalidated by the adjusting
function.
Flasher timer function
Hazard warning lamp
Hazard lamp
switch
Turn signal
lamp output
RH
Turn signal
lamp output
LH
Turn signal lamp

Ignition
switch (IG)
When the turn signal lamp switch is ON (LH or RH)

with the ignition switch is ON, the turn signal lamp
output (flash signal) is turned ON.
If the lamp bulb of the front or rear turn signal lamp
has burned out, the flashing speed becomes faster to
alert the driver that the lamp bulb has burned out.
ON
ON
OFF
ON
OFF
ON
OFF
AC101509AC
OFF
Turn signal lamp ON

switch RH
OFF
Turn signal lamp ON
switch LH
OFF
Turn signal lamp ON
output RH
OFF
Turn signal lamp ON
output LH
OFF
AC101508 AC
When the hazard lamp switch input signal turning

from OFF to ON is detected, the flashing states turns
over by the signal. (When the hazard lamp is not
blinking, it blinks. If it is blinking, it turns off.)
NOTE: .
1. The push-return switch is adopted for the hazard
lamp switch.
2. Even if the lamp bulb has burned out, the flashing
speed of the hazard lamp is not changed.
Fog lamp
Front Fog Lamp Control Function <Vehicles with Front Fog Lamp>
Headlamp
Lighting switch
Tail lamp
OFF
Front fog lamp switch

Headlamp automatic shutdown
output
Fog lamp output
ON
OFF
(Switched off) ON
(Illuminated) OFF
(Illuminated) ON
(Extinguished) OFF
AC212278 AF
When the fog lamp switch is turned to ON with the

tail lamp or the headlamp lit (the taillamp switch or
the headlamp switch is ON), the fog lamp relay turns
ON, and the fog lamps lamp.
If the tail lamp or the headlamp is turned off with the
lighting switch OFF while the fog lamps lit, the fog
lamps turn off the same time to prevent unattended
operation.
If the tail lamp is turned off by the headlamp autoturn off function, the fog lamps turn off at the same
time. However, if the tail lamps lamp again, the fog
lamps do not.
54B-8
GENERAL INFORMATION
Rear Fog Lamp Control Function <Vehicles with Rear Fog Lamp>
Headlamp
Lighting switch
Tail lamp
OFF
Illuminated
Front fog lamps
Extinguished
ON
Rear fog lamp switch
OFF
ON
Rear fog lamps
OFF
AC212279 AB
If the rear fog lamp switch is turned ON when the

headlamp or the front fog lamp is turned ON, the rear
fog lamp is switched ON and OFF alternatively.
If the headlamp and the front fog lamp are turned

OFF, the rear fog lamp is turned OFF at the same
time.
Interior lamp
Dimmer interior lamp control function (the initial
condition: 15 seconds)
<Vehicles with keyless entry system>
ON
Ignition switch
ACC
OFF
Key removed
(Any one open) ON
Door switch
Driver's door
lock actuator switch
(lock switch)
(All closed) OFF

(Any one open) ON
(All closed) OFF
LOCK
Lock/unlock signal
by keyless entry
OFF
UNLOCK
100 %
65 %
Room lamp brightness

0%
15 seconds
15 seconds
15 seconds
AC300453 AD
54B-9
GENERAL INFORMATION
When the interior lamp switch is on the door position,

By removing the ignition key with all doors and the
ETACS-ECU controls the interior lamp lights as
tailgate closed, the lamp turns ON 100%, and
follows.
turns off after 15 seconds.
1. When the ignition switch is OFF:
By inserting the ignition key again or operating the
By opening any door or tailgate lamps, the lamp
door lock with the lamp lit, the lamps turns off.
turns ON (100%), and dims (65%) when the door
4. Keyless entry room lamp answer back <Vehicles
or tailgate is closed, then and turns off after 15
with keyless entry system>:
seconds.
The room lamp blinks two times while locking the
However, when the ignition switch is turned ON or
door for easy checking the keyless entry function.
the door lock is operated, the lamps turn off at
When the door is unlocked, the lamp lights on for
that time.
15 seconds (100%), and turns off.
2. When the ignition switch is ON:
NOTE: For the vehicles with the keyless entry
By opening any door or tailgate lamps, the lamp
system, the delayed interior lamp turning off duration
(100%) turns ON and OFF when the door or tail
and the operation times of the keyless entry interior
gate is closed.
lamp answer back can be changed by the adjusting
3. When all doors and the tailgate are closed, and
function.
the ignition key is removed <Vehicles with keyless
entry system>:
Interior lamp automatic-shutdown function <Vehicles with Keyless Entry System> (the initial
condition: with function)
ON
Ignition switch
ACC
OFF
Door switch
(Any one open) ON

(All closed) OFF
Interior lamp
(Illuminated) ON
(Extinguished) OFF
T
T: 30 minutes
t: Within 30 minutes
When the interior lamp such as the room lamp [all

interior lamps connecting to the room lamp fuse (the
front room lamp, the map lamp, the rear room lamp,
and the ignition key cylinder illumination lamps)] is lit,
but either one of the conditions is met, the interior
lamp is turned off automatically for preventing the
battery discharge caused by the unattended
operation or the door-ajar.
After 30 minutes with the interior lamp lit while the
ignition switch is OFF, the lamp turns off
automatically.
After 30 minutes with any door opened while the
ignition switch is OFF, the lamp turns off
automatically.
t
AC212552 AB
After auto-turn off function, the interior lamp turns

ON when any of the following condition is met.
Open and close doors.
Operate the keyless entry transmitter.
Turn the ignition switch to ACC or ON.
NOTE: .
1. The interior lamp automatic-shutdown function
can be disabled or enabled by the adjusting
function.
2. After relighting, the lamp turns off after 30
minutes, when the interior lamp automaticshutdown function is met.
54B-10

GENERAL INFORMATION
Ignition key cylinder illumination lamp control function

Ignition switch (IG)
Key reminder switch
Driver's seat door switch
Ignition key cylinder

illumination lamp output
ON
OFF
(Key removed) ON
(Key inserted) OFF
(Opened) ON
(Closed) OFF
(Illuminated) ON
(Extinguished) OFF
T: 30 seconds
The ignition key cylinder illumination lamp lights for

30 seconds when the drivers door is opened/closed
with the ignition switch OFF. Also when the ignition
key is removed from the ignition key cylinder, the
lamp lights for 30 seconds. In any cases, the ignition
key cylinder illumination lamp turns ON when the
ignition switch is turned to ON.
T
AC212553AB

SPECIAL TOOLS
54B-11
SPECIAL TOOLS
M1549000300504
Tool
Number
Name
Use
MB991502
MUT-II sub assembly
Check the SWS (The MUT-II

displays diagnosis codes and
input signals)
MB991529
Diagnosis code check Input signal check by using a

harness
voltmeter
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Check harness
B: LED harness
C: LED harness
adapter
D: Probe
B991502
MB991529
D
MB991223 AC
Continuity check and voltage

measurement at harness wire or
connector
A: For checking connector pin
contact pressure
B: For checking power supply
circuit
C: For checking power supply
circuit
D: For connecting a locally
sourced tester
54B-12

TROUBLESHOOTING
TROUBLESHOOTING
PRIOR TO TROUBLESHOOTING
M1549014700312
Before carrying out troubleshooting, check the

following two items.
Make sure that the ETACS-ECU, the junction
block (J/B), the front-ECU and the engine
compartment relay box are connected securely.
Check that the system fuses and fusible links are
not burned out.
STANDARD FLOW OF DIAGNOSTIC

TROUBLESHOOTING
M1549000500478
Refer to GROUP 00 - How to Use Troubleshooting/

Inspection Service Points 300.
DIAGNOSTIC FUNCTION
M1549028900063
How to read diagnosis code

Use the MUT-II to read diagnosis code (Refer to
GROUP 00 - How to Use Troubleshooting/
Inspection Service Points 300.)
NOTE: Connect the MUT-II to the 16-pin diagnosis

connector (black).
NOTE: A diagnosis code can not be read when the
ETACS-ECU is defective or the power supply voltage
has risen. In this case, refer to inspection procedure
A-1 "Communication with the MUT-II is not possible
354B."
How to check input signals

1. Use the MUT-II or a voltmeter to check input
signals (Refer to GROUP 00 - How to Use
Troubleshooting/Inspection Service Points 300
.)
2. The input signals below can be checked by
connecting the MUT-II or a voltmeter to the
NOTE: If a fault is found at the input signal check,
refer to trouble symptom chart 354B.
Switches which are applicable to input signal check, and their check conditions
Input signals
Requirements for sounding buzzer
Ignition switch (ACC)
When turned from the LOCK (OFF) position to the

ACC position
Ignition switch (IG1)
When turned from ACC to ON
Back-up lamp switch
When the ignition switch is turned ON and the shift

lever is moved to the R position.
Key reminder switch <Vehicles with keyless entry

system>
When the inserted ignition key is pulled out
Hazard warning lamp switch
When the switch is turned from off to on

Drivers door switch
When the drivers door is opened
All of the door switches
A door is opened when all the doors are closed
Drivers door lock actuator
When the drivers key cylinder or inside lock knob is

unlocked or locked
Passengers door lock key cylinder switch
Turn the key to the lock or unlock position
When the vehicle speed has reached 10 km/h or

more
54B-13
Input signals
Column switch

Tail lamp switch
When the lighting switch is moved from the automatic

lamp position to the tail lamp position.
Headlamp switch
When the lighting switch is moved from the tail lamp

position to the automatic lamp position.
Dimmer switch
Passing lamp switch

Turn-signal lamp switch (LH)
Turn-signal lamp switch (RH)
Wind shield mist wiper switch
Headlamp washer switch
Windshield intermittent wiper
switch
Windshield low-speed wiper
switch
Windshield high-speed wiper
switch
Windshield intermittent wiper
volume
When the windshield intermittent wiper volume is

rotated from "FAST" to "SLOW" (a pulse is sent
around the volume middle position)
Windshield washer switch
Rear wiper switch

Rear washer switch
Keyless entry
transmitter
Switches
Interior lamp loaded signal

When a load is applied through multi-purpose fuse
No.18

M1549000700234
Code No.
Diagnosis Details
Reference
page
11
Trouble related to the ETACS-ECU
354B
12
Trouble related to the column switch or improper connection to the

ETACS-ECU
354B
13
Trouble related to the front-ECU or improper connection to the ETACS- 354B

ECU
21
Short circuit in SWS communication line
354B
31
Open circuit in the signal line between the SRS-ECU and the ETACSECU (impact detection signal)
354B
32
Short circuit in the signal line between the SRS-ECU and the ETACSECU (impact detection signal)
54B-14

DIAGNOSTIC TROUBLE CODE PROCEDURES
Diagnosis code 11: Trouble related to the ETACS-ECU

DIAGNOSIS CODE SET CONDITIONS
The ETACS-ECU monitors the data, which the ECU
itself sends. If errors occur consecutively 15 times
(for 0.6 seconds), a diagnosis code will be set. Then,
if the data does not contain any errors consecutively
15 times (for 0.6 seconds), the ECU will stop sending
the diagnosis code.
Possible causes
Malfunction of the ETACS-ECU
DIAGNOSTIC PROCEDURE
Check whether the diagnosis code is reset.
(1) Erase the diagnosis code.
(2) Again check that diagnosis code No.11 is set.
Q: Is diagnosis code No.11 set?
YES : Replace the ETACS-ECU.
NO : The trouble can be an intermittent
malfunction (Refer to GROUP 00 - How to

Cope with Intermittent Malfunction 300).

54B-15
Diagnosis code 12: Trouble related to the column switch or improper connection with the ETACS-ECU
CAUTION
Whenever the ECU is replaced, ensure that the
power supply circuit, the earthing circuit and the
communication circuit are normal.
Column Switch Power Supply and SWS Communication Circuit
IGNITION
SWITCH (IG1)
FUSIBLE
LINK 1
COLUMN-ECU
ETACS-ECU
COLUMN
SWITCH
DIAGNOSIS
CONNECTOR
FRONT SIDE

If the column switch ignores the data request signal
sent by the ETACS-ECU (three times or more for one
second), this diagnosis code will be set. Then, when
the column switch observes the request signal for
one second, the ECU will stop sending the diagnosis
code.
Possible causes
Malfunction of the column switch
Damaged harness wires and connectors
Wire colour code

B : Black
LG : Light green
G : Green
L: Blue
W : White
Y: Yellow
SB : Sky blue
BR : Brown
O : Orange
GR : Gray
R : Red
P : Pink
V : Violet
Step 1. Use the MUT-II to confirm a diagnosis
code.
(2) On completion, check that diagnosis code No.12
is not reset.
YES : Go to Step 5.
NO : Go to Step 2.
54B-16

Step 2. Connector check: C-310 column switch

connector
Connector: C-310
Step 3. Measure the voltage at C-310 column

switch connector.
Connector: C-310
Harness side
Harness side
5 4 3 2 1
10 9 8 7 6
5 4 3 2 1
10 9 8 7 6
AC301399 AC

YES : Go to Step 3.
NO : Repair the defective connector.
AC301399 AC
(1) Remove the column switch, and measure at the

wiring harness side.
Connector C-310
(Harness side)
5 4 3 2 1
10 9 8 7 6
AC301541BD
(2) Voltage between C-310 column switch connector

terminal No.1 and body earth
OK: System voltage
YES : Replace the column switch.
NO : Go to Step 4.
Step 4. Check the wiring harness between C-310

column switch connector terminal No.1 and the
battery.
Connector: C-310
Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC
54B-17

YES : The trouble can be an intermittent
NOTE:

NO : Repair the wiring harness.
C-02
Step 5. Measure the resistance at the C-310

column switch connector.
Connector: C-310
C-116
C-02
Harness side
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
2324 25 2627 28 2930 3132 33
5 4 3 2 1
10 9 8 7 6
C-116
1 2
5 6 7
3 4
AC301399 AC
8 9
10 1112 1314
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
1617 18 19 20 21
(1) Remove the column switch, and measure at the

AC301396 AM
Connector C-310
(Harness side)

Junction block (Front view)
C-204(B)
C-202
5 4 3 2 1
10 9 8 7 6
AC301541BE
(2) Resistance between C-310 column switch

connector terminal No.4 and body earth
OK: 2 W or less
Harness side
C-202
6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-204
1
AC210475 AL
Prior to the wiring harness inspection, check junction

block connectors C-202, C-204, intermediate
connector C-116 and joint connector C-02, and
Check the power supply line for open circuit.

YES : Go to Step 7.
NO : Go to Step 6.
54B-18

column switch connector terminal No.4 and the
body earth.
Connector: C-310
Step 8. Check the wiring harness from C-219

ETACS-ECU connector terminal Nos. 59 and 68 to
C-310 column switch connector terminal Nos. 3
and 2.
Connector: C-219
Junction block (Rear view)
Harness side
Harness side
5 4 3 2 1
10 9 8 7 6
C-219(GR)
AC301399 AC
Check the earth wires for open circuit.

59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
Connector: C-310

Harness side
Step 7. Connector check: C-219 ETACS-ECU

connector
5 4 3 2 1
10 9 8 7 6
Connector: C-219
AC301399 AC
NOTE:
Connector: C-02
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 8.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
AC301395 AC
Prior to the wiring harness inspection, check joint

Check the communication lines for open circuit.
YES : Go to Step 9.

Step 9. Check whether the diagnosis code is

reset.
Replace the column switch, and then check that the
diagnosis code is not reset.
(1) Replace the column switch.
is not reset.
NO : The procedure is complete.
54B-19
54B-20
Diagnosis code 13: Trouble related to the front-ECU or improper connection with the ETACS-ECU
CAUTION
Front-ECU Power Supply and SWS Communication Circuit
IGNITION
SWITCH (IG2)
RELAY BOX
(FUSE 22 )
FRONT-ECU
POWER
SOURCE
DIAGNOSIS
CONNECTOR
ETACS-ECU
FRONT SIDE
Wire colour code


If the front-ECU has sent abnormal signal to the
ETACS-ECU for consecutively 15 communication
cycles (0.6 second), the diagnosis code will be set. If
the front-ECU has sent normal signal to the ETACS-
SB : Sky blue
ECU for consecutively 15 communication cycles (0.6

second), the ETACS-ECU will stop sending the
diagnosis code.
54B-21
Possible causes
Malfunction of the front-ECU
Step 3. Measure the voltage at A-11X front-ECU

connector.
Connector: A-11X
code.
is not reset.
YES : Go to Step 5.
NO : Go to Step 2.
Relay box side
Step 2. Connector check: A-11X front-ECU

connector
11 10 9 8 7 6 5 4 3 2 1
Connector: A-11X
AC301483 AD
(1) Remove the front-ECU, and measure at the relay

box side.
Connector A-11X
(Relay box side)
11 10 9 8 7 6 5 4 3 2 1
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC301541AF
AC301483 AD

YES : Go to Step 3.
(2) Voltage between A-11X front-ECU connector

OK: System voltage
YES : Replace the front-ECU.
NO : Go to Step 4.
54B-22
Step 4. Check the wiring harness between A-11X

front-ECU connector terminal No.5 and the
battery.

connector
Connector: A-12X
Connector: A-11X
Relay box side

Relay box side
3130 29 2827 26 25 24 2322 21
11 10 9 8 7 6 5 4 3 2 1
AC301483 AE
AC301483 AD



YES : Go to Step 6.
54B-23
Step 6. Measure the resistance at A-12X frontECU connector.

Connector: A-12X

front-ECU connector terminal No.21 and the body
earth.
Connector: A-12X
Relay box side

Relay box side
3130 29 2827 26 25 24 2322 21
3130 29 2827 26 25 24 2322 21
AC301483 AE

box side.
AC301483 AE


Connector A-12X
(Relay box side)
31 30 29 2827 26 25 24 2322 21

connector
AC301541AG
Connector: C-219
(2) Resistance between A-12X front-ECU connector

OK: 2 W or less
YES : Go to Step 8.
NO : Go to Step 7.
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 9.
54B-24

ETACS-ECU connector terminal No.59 and A-12X
front-ECU connector terminal No.30.
NOTE:
Connector: A-12X
C-02
C-116
C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
2324 25 2627 28 2930 3132 33
C-116
Relay box side
1 2
3130 29 2827 26 25 24 2322 21
5 6 7
3 4
8 9
10 1112 1314
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
1617 18 19 20 21
AC301396 AM
AC301483 AE
Connector: C-219

Harness side
C-219(GR)

connector C-02 and intermediate connector C-116,
and repair if necessary.
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

reset.
Replace the column switch, and then check that the
is not reset.

54B-25
Diagnosis code 21: Short circuit in SWS communication line
CAUTION
communication circuit is normal.
SWS Communication Line
FRONT-ECU
COLUMN-ECU
COLUMN
SWITCH
ETACS-ECU
CPU
POWER
WINDOW
MAIN SWITCH
Wire colour code


If the SWS communication line voltage is kept at low
level for 0.3 second, the diagnosis code will be set. If
the ETACS-ECU data line voltage is kept at high level
for 0.3 second, or the ETACS-ECU has received
normal signal from the other ECUs or switches, the
ETACS-ECU will stop sending the diagnosis code.
While this code is set, the other codes will not be set.
SB : Sky blue
Possible causes
Malfunction of the power window main switch
54B-26
Connector: E-05

connector, C-203 column switch connector, C219 ETACS-ECU connector and E-05 power
window main switch connector
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Connector: A-11X
AC301418 AC

YES : Go to Step 2.
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC301483 AD
Connector: C-203
Harness side
2
1
6 5 4 3
AC210474 AC
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
54B-27
Step 2. Check the wiring harness from each of A12X front-ECU connector terminal No.30, C-310
column switch connector terminal No.3 and E-05
power window main switch connector terminal
No.4 to C-219 ETACS-ECU connector terminal
No.59.

C-218
Connector: A-11X
C-219(GR)
Harness side
C-218
1 2 3 4 5
C-219
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
Relay box side

AC210477AD
11 10 9 8 7 6 5 4 3 2 1
Connector: E-05
AC301483 AD
Harness side
Connector: C-203
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC
Harness side
2
1
6 5 4 3
AC210474 AC
54B-28
NOTE:

column switch connector terminal No.2 and C219 ETACS-ECU connector terminal No.68.
Connector: C-219
C-02
Harness side
C-116
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
C-02
AC210476 AE
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
2324 25 2627 28 2930 3132 33
Connector: C-310
C-116
1 2
5 6 7
3 4
8 9
10 1112 1314
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
1617 18 19 20 21
Harness side
AC301396 AM

connector C-02, intermediate connectors C-116 and
C-218, and repair if necessary.
YES : Go to Step 3.
5 4 3 2 1
10 9 8 7 6
AC301399 AC

YES : Go to Step 4.

reset.
When A-11X front-ECU connector is disconnected,
check that diagnosis code No.21 is not reset.
However, diagnosis code No.13 will be set at this
time.
YES : Replace the front-ECU.
NO : Go to Step 5.

reset.
When E-05 power window main switch connector is
disconnected, check that diagnosis code No.21 is not
reset.
YES : Replace the power window main switch.
NO : Go to Step 6.

54B-29
Step 6. Check that the hazard warning lamps

illuminate.
When the ignition switch is turned to the LOCK
(OFF) position, check if the hazard warning lamps
illuminate.
YES : Refer to diagnosis code No.12 "Column
switch fault or improper connection 354B

."
NO : Refer to inspection procedure A-2 "Check
the ETACS-ECU battery power supply
circuit 354B."
Diagnosis code 31: Open circuit in signal line between the SRS-ECU and the ETACS-ECU (impact
detection signal)
Diagnosis code 32: Short circuit in signal line between the SRS-ECU and the ETACS-ECU (impact
detection signal)
CAUTION
input signal circuit is normal.
ETACS-ECU
SRS-ECU
IMPACT-DEPENDENT
DOOR UNLOCK
SIGNAL PROCESSING
CIRCUIT
Wire colour code

B : Black LG : Light green
G : Green L : Blue
W : White Y : Yellow
SB : Sky blue BR : Brown
O : Orange GR : Gray
R : Red P : Pink V : Violet

If the voltage in the signal line between the SRSECU and the ETACS-ECU has exceeded 4.6 V for 40
milliseconds or more, the ETACS-ECU will set
diagnosis code No.31 as an open circuit. If the signal
line voltage has reached 1.5 V or less for at least 2.5
seconds, the ETACS-ECU will set diagnosis code
No.32 as a short circuit. If the ignition switch is turned

off, the ETACS-ECU will stop sending the diagnosis
code.
Possible causes
Malfunction of the SRS-ECU
54B-30
Step 3. Measure the resistance at the C-115 SRSECU connector.

code.
Check that the SRS-ECU sets a diagnosis code.
YES : Go to Step 2.
NO : Refer to GROUP 52B - Troubleshooting
313A.
Step 2. Connector check: C-115 SRS-ECU
connector and C-220 ETACS-ECU connector
Connector: C-115
Connector: C-115
Harness side
2 1
4 3
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
C-115(Y)
AC301397AH
(1) Disconnect the connector, and measure at the

Harness side
Connector C-115
(Harness side)
2 1
4 3
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
2 1
4 3
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
C-115(Y)
AC301397AH
Connector: C-220
AC301541 AQ
(2) Resistance between C-115 SRS-ECU connector

OK: 2 W or less
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210476 AF

YES : Go to Step 3.

YES : Go to Step 5.
NO : Go to Step 4.

SRS-ECU connector terminal No.15 and body
earth.
Connector: C-115
Harness side
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
C-115(Y)
AC301397AH


54B-31
TROUBLE SYMPTOM CHART

ETACS-ECU connector terminal No.29 and C-115
SRS-ECU connector terminal No.14.
Connector C-115
(Harness side)
2 1
4 3
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413

reset.
Replace the ETACS-ECU, and then check that the
(1) Replace the ETACS-ECU.
(3) Check that diagnosis code No.31 or 32 is not
reset.
Q: Is diagnosis code No.31 or 32 set?
YES : Replace the SRS-ECU.
AC301541 AQ
Connector: C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210476 AF

YES : Go to Step 6.

M1549000800576
Symptom
Inspection
procedure
number
Reference
page
Communication with the MUT-II is not possible.
A-1
354B
When the ignition switch is at the LOCK (OFF) position, the functions do A-2
not work normally.
354B
Check the battery power supply circuit to the ETACS-ECU.
<Function system>
Symptom
Inspection
procedure
number
Reference
page
Alarm Function
Lamp reminder buzzer function does not

work normally.
B-1
354B
Central door locking system does not work. C-1
354B
A door can not be locked or unlocked by

the central door locking system.
354B
C-2
54B-32

Symptom
Power window
Windshield wiper and

washer
Inspection
procedure
number
Reference
page
Power windows do not work at all.
D-1
354B
Drivers power window does not work by

means of the power window main switch.
D-2
354B
Relevant power window(s) do not work by

means of the front and rear passengers
power window sub switches.
D-3
354B
Front and/or rear passengers power

window(s) do not work by means of the
power window main switch.
D-4
354B
Power window anti-trap function does not

work normally.
D-5
354B
Power windows lowers automatically while D-6

it is rising.
354B
Keyless entry system does not work.
E-1
354B
Keyless entry hazard warning lamp

answerback function or the room lamp
answerback function does not work
normally.
E-2
354B
Encrypted code cannot be registered.
E-3
354B
The timer lock function does not work after E-4

the doors have been unlocked by the
keyless entry system.
354B
The windshield wipers do not work at all.
F-1
354B
The windshield wipers do not work when

F-2
the wiper switch is at "INT", "Washer" or
"Mist" position. However, the wipers work
at low speed when the switch is at "Lo" and
"Hi" position.
354B
The windshield wipers do not stop at the

specified park position.
F-3
354B
The windshield wipers do not work

normally.
F-4
354B
The intermittent wiper interval cannot be

adjusted by operating the windshield
intermittent wiper volume control.
F-5
354B
The intermittent wiper interval is not

changed according to the vehicle speed.
F-6
354B
The windshield washer does not work.
F-7
354B

Symptom
54B-33
Inspection
procedure
number
Reference
page
Rear wiper does no not work at all.
G-1
354B
The rear wiper does not stop at the

G-2
354B
When the shift lever is moved to "R"

position during the rear wiper operation,
the rear wiper does not operate at the
continuous mode.
G-3
354B
The rear washer does not work.
G-4
354B
Headlamp washer
The headlamp washer does not work.
H-1
354B

illumination lamp
The ignition key cylinder illumination lamp

does not illuminate/extinguish normally.
I-1
354B
Headlamp and tail lamp
The tail lamps do not illuminate normally.
J-1
354B
The low-beam headlamps do not illuminate J-2

normally.
354B
The high-beam headlamps do not

illuminate normally.
J-3
354B
The high-beam and low-beam headlamps

do not illuminate when the passing switch
is operated.
J-4
354B
The headlamp automatic shutdown

function does not work normally.
J-5
354B
Any of tail lamps, position lamps or licence J-6

plate lamp does not illuminate.
354B
The headlamp(s) do not illuminate.

<including high-beam indicator>
J-7
354B
The turn-signal lamps do not illuminate.
K-1
354B
The hazard warning lamps do not

illuminate.
K-2
354B
Any of the turn-signal lamps does not

illuminate.
K-3
354B
The front fog lamps do not illuminate

normally.
L-1
354B
The rear front fog lamps do not illuminate

normally.
L-2
354B
Either of the front fog lamps does not

L-3
354B
Any of the rear fog lamps does not

illuminate.
L-4
354B
Flasher timer
Fog lamp
54B-34

CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK
Symptom
Interior lamp
Inspection
procedure
number
Reference
page
The front or rear room lamp does not

M-1
illuminate or extinguish normally. <Vehicles
without keyless entry system>
354B

M-2
354B
Interior lamp automatic shutoff function

does not work normally. <Vehicles with
keyless entry system>
M-3
354B
The door-ajar warning lamp does not

illuminate/extinguish normally.
M-4
354B

M1549024200125
<Pulse check>
If a problem is found in the Service Data inspection, observe the table below.
Symptom
Inspection
procedure
number
Reference
page
The ignition switch (ACC) signal is not received.
N-1
354B
The ignition switch (IG1) signal is not received.
N-2
354B
The back-up lamp switch signal is not received.
N-3
354B
The drivers door switch signal is not received.
N-4
354B
Column switch (lighting and turnsignal lamp switch)
N-5
354B
The tail lamp switch signal is not

received.
The headlamp switch signal is not
received.
The dimmer switch signal is not
received.
The passing switch signal is not
received.
The turn-signal lamp switch (LH)
signal is not received.
The turn-signal lamp switch (RH)
The headlamp washer switch signal
is not received.

Symptom
Column switch (windshield wiper/

washer and rear wiper washer
switch)
54B-35
Inspection
procedure
number
Reference
page
N-6
354B
N-7
354B
When the power window main switch N-8

is operated, the switch signals are
not received.
354B
The windshield mist wiper switch

The windshield intermittent wiper
switch signal is not received.
The windshield low-speed wiper
The windshield high-speed wiper
The windshield washer switch signal
is not received.
The rear wiper switch signal is not
received.
The rear washer switch signal is not
received.
volume signal is not received.
Power window main switch
The key reminder switch signal is not received.
N-9
354B
The hazard warning lamp switch signal is not received.
N-10
354B
All the door switch signals are not received.
N-11
354B
The drivers door lock actuator switch signal is not received.
N-12
354B
The vehicle speed signal is not received.
N-13
354B
Each switch signal of the keyless entry transmitter is not received.
N-14
354B
The front fog lamp switch signal is not received.
N-15
354B
The rear fog lamp switch signal is not received.
N-16
354B
The interior lamp loaded signal is not detected.
N-17
354B
The passengers door lock key cylinder switch signal is not detected.
N-18
354B
54B-36

OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION
OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL

INSPECTION PROCEDURES
M1549020300175
If troubles have occurred in the functions which use the SWS simultaneously, observe the table below to
check input signals.
(This table shows only the input signals which will cause troubles in at least two functions simultaneously).
Function
N-1
N-2
N-4
N-5
N-6
N-9
N-11
N-12
N-13
N-17
Control of central door

locking
Door locking released due to impact detection.
Keyless entry hazard

warning lamp answerback
Power window control
Control of windshield wiper

washer
Rear wiper washer control

illumination lamp function
Headlamp control
Tail lamp control
Headlamp automatic
shutdown function
Fog lamp control
Turn-signal lamp control
Dome lamp control
Interior lamp automatic

shutdown function
Door-ajar indicator lamp

SYMPTOM PROCEDURES
54B-37
SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-1: No communication with MUT-II
CAUTION
MUT-II Communication and ETACS-ECU Earth Circuit
ETACSECU
DIAGNOSIS
CONNECTOR
Wire colour code

It is suspected that the power supply circuit to the
ETACS-ECU is defective, or the wiring harness
between the diagnosis connector and the ETACSECU or their connector(s) is damaged.
NOTE: If the wiring harness between the ETACSECU and body earth is defective, also check C-217
ETACS-ECU connector terminal No.3, and repair if
necessary.
Possible causes
FRONT SIDE
DIAGNOSIS
CONNECTOR
FRONT SIDE
Step 1. Check that the MUT-II communicates with
the other systems.
Use the MUT-II to confirm that it communicates with
the engine-ECU.
YES : Go to Step 2.
NO : Diagnose the engine control system by
referring to 313A.
54B-38

SYMPTOM PROCEDURES
Step 2. Check that the MUT-II can communicate

with the system.
When the ignition switch is turned ON, check if the
MUT-II can communicate with the system.

ETACS-ECU connector.
Connector: C-219

YES : Refer to inspection procedure A-2 "Check

circuit" 354B.
NO : Go to Step 3.
Harness side
C-219(GR)

connector
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

junction block side.
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 4.
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
Connector C-219
(Harness side)
AC301541AY
(2) Resistance between C-219 ETACS-ECU

OK: 2 W or less
YES : Go to Step 6.
NO : Go to Step 5.

ETACS-ECU connector terminal No.56 and body
earth.
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE


54B-39
SYMPTOM PROCEDURES
Step 6. Connector check: C-24 diagnosis

connector
Connector: C-24

C-24 diagnosis connector terminal Nos. 9 and 1.
Connector: C-24
Harness side
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Harness side
C-24(B)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC301395 AF
C-24(B)
AC301395 AF

YES : Go to Step 7.
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 8.
Step 8. Retest the system.

Check whether the communication with the MUT-II is
possible.

NO : Replace the ETACS-ECU.
54B-40
SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-2: When the ignition switch is at the LOCK (OFF) position, the functions
do not work normally. Check the battery power supply circuit to the ETACS-ECU.
CAUTION
power supply circuit and the earthing circuit are
normal.
FUSIBLE
LINK 1
ETACS-ECU
Wire colour code

G : Green L : Blue

If this circuit is defective and the ignition switch is at
the LOCK (OFF) position, the ETACS-ECU does not
work. In this case, the functions below will be
suspended.
Ignition key cylinder illumination lamp
Headlamp automatic shutdown function
However, when the ignition switch is at the ON
position, the functions below will work.
Reading diagnosis code and checking input
signal by MUT-II.
Hazard warning lamp
Room lamps
Possible causes
connector
Connector: C-217
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 2.
54B-41
SYMPTOM PROCEDURES
Step 2. Measure the voltage at the C-217 ETACSECU connector.

Connector: C-217

ETACS-ECU connector terminal No.20 and
fusible link (1).
Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
(1) Remove the ETACS-ECU, and measure at the

AC210476 AC
NOTE:
Connector: C-116
Connector C-217
(Junction block side)
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG
AC301541AS
(2) Voltage between C-217 ETACS-ECU connector

terminal No.20 and body earth.
OK: System voltage
Connector: C-204
C-204(B)

YES : Go to Step 4.
NO : Go to Step 3.
Harness side
1
AC210474 AD

intermediate connector C-116 and junction block

54B-42

SYMPTOM PROCEDURES

Connector: C-217

earth.
Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

AC210476 AC
NOTE:
Connector: C-205
Connector C-217
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC301541AT
(2) Continuity between C-217 ETACS-ECU

connector terminal No.3 and body earth.
OK: 2W or less
YES : Go to Step 6.
NO : Go to Step 5.
AC210474 AE

block connector C-205, and repair if necessary.

Check that the battery power supply circuit to the
ETACS-ECU is normal.


SYMPTOM PROCEDURES
54B-43
TONE ALARM
INSPECTION PROCEDURE B-1: Lamp reminder buzzer function does not work normally.
CAUTION
input and output signal circuits are normal.
Lamp Reminder Tone Alarm Function
ETACS-ECU
INPUT SIGNAL
DRIVER'S DOOR SWITCH
HEADLAMP SWITCH
IGNITION SWITCH (IG1)
TAIL LAMP SWITCH

The ETACS-ECU operates this function in
accordance with the input signals below.
Drivers door switch
Tail lamp switch
Headlamp switch
If this function does not work normally, these input
signal circuit(s) or the ETACS-ECU may be defective.
Possible causes
Malfunction of the drivers door switch
Step 1. Check the power supply circuit.
illuminate.
YES : Go to Step 2.

circuit 354B."
54B-44

SYMPTOM PROCEDURES
Step 2. Pulse check

Check the input signals below, which are related to
the lamp reminder buzzer function.
System switch
Check conditions
When turned from ACC

to ON
Drivers door switch
When the drivers door is

opened
Tail lamp switch
When the lighting switch

is turned to the TAIL
position
Headlamp switch

is turned to the
HEADLAMP position

needle fluctuates.
All the signals are received normally. : Go to Step
3.
The ignition switch (IG1) signal is not received. :
Refer to inspection procedure N-2 "The

ignition switch (IG1) signal is not received
354B."
The drivers door switch signal is not received. :

drivers door switch signal is not received
354B."
The tail lamp switch signal is not received. : Refer
to inspection procedure N-5 "The column
switch (lighting and turn-signal lamp switch)
signal is not received 354B."
The headlamp switch signal is not received. :

column switch (lighting and turn-signal lamp
switch) signal is not received 354B."

The lamp reminder buzzer function should work
normally.


SYMPTOM PROCEDURES
CENTRAL DOOR LOCKING SYSTEM
INSPECTION PROCEDURE C-1: Central Door Locking System does not Work.
CAUTION
Central Door Lock Power Supply Circuit

FUSIBLE
LINK 1
ETACS-ECU
DOOR
UNLOCK
RELAY
DOOR
LOCK
RELAY
FRONT
DOOR LOCK
ACTUATOR (LH)
Wire colour code

SB : Sky blue
54B-45
54B-46

SYMPTOM PROCEDURES

If the central door locking system does not work at
all, the front door lock actuator (LH) or the ETACSECU may be defective.
POSSIBLE CAUSES
Malfunction of the front door lock actuator (LH)
DIAGNOSIS PROCEDURE
illuminate.
YES : Go to Step 2.

circuit" 354B.
Step 2. Pulse check
Check the input signal from the drivers door lock
actuator switch.
System switch
Check conditions
Drivers door lock

actuator switch
When the drivers key

cylinder or inside lock
knob is unlocked or
locked
Step 3. Connector check: E-11 front door lock

actuator (LH) connector
Connector: E-11
E-11(B)
Harness side
3 2 1
6 5 4
AC301418 AD

YES : Go to Step 4.
Step 4. Check the front door lock actuator (LH)

Check that the front door lock actuator (LH) works
normally. Refer to GROUP 42 - Door 342.
YES : Go to Step 5.
NO : Replace the front door lock actuator (LH).

connector
Connector: C-217
OK: The MUT-II sound or the voltmeter

needle fluctuate.
YES : Go to Step 3.
NO : Refer to inspection procedure N-12 "The
Junction block
(Rear view)
drivers door lock actuator signal is not

received 354B."
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB

YES : Go to Step 6.
54B-47
SYMPTOM PROCEDURES

ETACS-ECU connector terminal No. 2 and fusible
link (1).
NOTE:
Connector: C-116
Connector: C-217
Junction block
(Rear view)
C-116
1 2
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
5 6 7
3 4
8 9
10 11 12 13 14
15
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301396 AB
Connector: C-204
AC210477 AB
C-204(B)
Fusible link: No.1
Harness side
1
AC210474 AD
AC301515 AB

Check the power supply line for open or short
circuit.
YES : Go to Step 7.

Check that the central door locking system works
normally.

54B-48

SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-2: A Door or a Tailgate can not be Locked or Unlocked by the Central
Door Locking System.
Central Door Lock Circuit
ETACS-ECU
DOOR
LOCK
RELAY
DOOR
UNLOCK
RELAY
FRONT
DOOR LOCK
ACTUATOR (LH)
FRONT
DOOR LOCK
ACTUATOR
(RH)
REAR
DOOR LOCK
ACTUATOR
(LH)
REAR
DOOR LOCK
ACTUATOR
(RH)
Wire colour code

TAILGATE
LOCK
ACTUATOR
SB : Sky blue
54B-49
SYMPTOM PROCEDURES

If a door or the tailgate can not be locked or unlocked
by the central door locking system, the door lock
actuator or the tailgate lock actuator may be
defective.
POSSIBLE CAUSES
Malfunction of the door lock actuator
Malfunction of the tailgate lock actuator
Step 3. Check the front door lock actuator (LH)

YES : Go to Step 4.
Step 4. Connector check: C-217, C-220 ETACSECU connector
DIAGNOSIS PROCEDURE
Step 1. Confirm which door lock actuator is

defective.
C-217
Q: Which door fails to lock correctly?

Drivers door : Go to Step 2.
Front passengers door : Go to Step 6.
Rear right door : Go to Step 10.
Rear left door : Go to Step 14.
Tailgate : Go to Step 18.

Connector: E-11
Junction block
(rear view)
C-220
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
E-11(B)
Harness side
AC210477 AF
3 2 1
6 5 4
AC301418 AD

YES : Go to Step 3.

YES : Go to Step 5.
54B-50
SYMPTOM PROCEDURES

ETACS-ECU connector terminal No. 12 and C-220
ETACS-ECU connector No. 22 to E-11 front door
lock actuator (LH) connector terminal Nos. 6 and
4.
NOTE:
Connector: C-118
C-217
C-118
Junction block
(rear view)
C-220
1 2 3 4 5 6 7 8 9 10 11
C-217
Junction block side
12 13 14 15 16 17 18 19 20 21 22
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
23 24 25 26 27
28 29 30 31 32
C-220
Harness side
AC301396 AE
Connector: C-205
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210477 AF
Connector: E-11
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE
E-11(B)

Check the input and output lines for open circuit.
Harness side
3 2 1
6 5 4
AC301418 AD


54B-51
SYMPTOM PROCEDURES

actuator (RH) connector
Connector: E-25

E-25 front door lock actuator (RH) connector
terminal Nos. 4 and 6.
Connector: C-217
E-25
Harness side
E-25(B)
3 2 1
6 5 4
AC301412 AF
Junction block
(Rear view)

YES : Go to Step 7.
Step 7. Check the front door lock actuator (RH).

Check that the front door lock actuator (RH) works
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

YES : Go to Step 8.
NO : Replace the front door lock actuator (RH).

connector
AC210477 AB
Connector: E-25
Connector: C-217
E-25
Harness side
E-25(B)
3 2 1
6 5 4
Junction block
(Rear view)
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB

YES : Go to Step 9.
AC301412 AF
54B-52

SYMPTOM PROCEDURES
NOTE:
Step 11. Check the rear door lock actuator (RH).

Check that the rear door lock actuator (RH) is in
good condition. Refer to GROUP 42 - Door 342.
Connector: C-15

NO : Replace the rear door lock actuator (RH).
2
1
3 4
5 6
10 11 12
7 8 9
13 14 15 16 17 18 19

connector
C-15(GR)
AC301397AD
Connector: C-217
Connector: C-205
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Junction block
(Rear view)
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE

C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1


AC210477 AB
Step 10. Connector check: E-28 rear door lock

Connector: E-28
E-28(B)
E-28
Harness side
3 2 1
6 5 4
AC301414 AE


54B-53
SYMPTOM PROCEDURES

E-28 rear door lock actuator (RH) connector
NOTE:
Connector: C-209
Connector: C-217
Harness side
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210474 AG
Junction block
(Rear view)
D-02
C-217
Junction block side
D-31
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
D-02
1
2 3
4 5 6 7 8
AC210477 AB
D-31
Connector: E-28
E-28(B)
E-28
Harness side
1 2
3 4
5 6 7 8 9 10
11 12 13 14 15 16
AC301409 AD
3 2 1
6 5 4
AC301414 AE
Prior to the wiring harness inspection, check D-02,

D-31 intermediate connectors and C-209 junction
block connector, and repair if necessary.

54B-54
SYMPTOM PROCEDURES

Connector: E-08

E-08 rear door lock actuator (LH) connector
Connector: C-217
E-08(B)
E-08
Harness side
3 2 1
6 5 4
AC301416 AE
Junction block
(Rear view)

Step 15. Check the rear door lock actuator (LH).

Check that the rear door lock actuator (LH) is in good
condition. Refer to GROUP 42 - Door 342.
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

NO : Replace the rear door lock actuator (LH).

connector
AC210477 AB
Connector: E-08
Connector: C-217
E-08(B)
E-08
Harness side
Junction block
(Rear view)
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB

3 2 1
6 5 4
AC301416 AE
54B-55
SYMPTOM PROCEDURES
NOTE:
Step 19. Check the tailgate lock actuator.

Check that the tailgate lock actuator is in good
condition. Refer to GROUP 42 - Tailgate 342.
Connector: C-209

NO : Replace the tailgate lock actuator.
Harness side
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210474 AG

connector
Connector: C-217
Connector: D-26
D-26
1
2 3
4 5 6 7 8
Junction block
(Rear view)
AC301410 AB
Prior to the wiring harness inspection, check D-26

intermediate connectors and C-209 junction block
connector, and repair if necessary.
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1


AC210477 AB
Step 18. Connector check: F-06 tailgate lock

actuator connector
Connector: F-06
F-06
Harness side
F-06(B)
3 2 1
6 5 4
AC301665 AE


54B-56
SYMPTOM PROCEDURES

F-06 tailgate lock actuator connector terminal
Nos. 2 and 3.
NOTE:
Connector: C-209
Connector: C-217
Harness side
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210474 AG

intermediate connector F-05 and junction block
Junction block
(Rear view)

C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB
Connectors: F-05, F-06
F-06(B)
F-05
F-05
1 2
3 4
5 6 7 8 9 10
F-06
Harness side
3 2 1
6 5 4
AC301666 AG


SYMPTOM PROCEDURES
54B-57
INSPECTION PROCEDURE C-3: The central door locking system can not be operated by means of the
front passengers door lock key cylinder.
CAUTION
Central Door Lock (Front Passenger's Door Lock Key Cyilinder Switch) Circuit
FUSIBLE
LINK 1
ETACS-ECU
DOOR
UNLOCK
RELAY
FRONT DOOR
LOCK ACTUATOR (LH)
DOOR
LOCK
RELAY
INPUT SIGNAL
FRONT
PASSENGER'S
DOOR LOCK KEY
CYLINDER SWITCH
DOOR LOCK ACTUATOR AND

TAILGATE LOCK ACTUATOR

If the central door locking system does not work by
means of the front passengers door lock key
cylinder, the front passengers door lock key cylinder
or the ETACS-ECU may be defective.
Possible causes
Malfunction of the front passengers door lock key
cylinder
Step 1. Check the operation of the central door
locking system.
normally by means of the drivers door lock key
cylinder and inside lock knob.
YES : Go to Step 2.
NO : Refer to inspection procedure C-1 "Central
door locking system does not work at all

354B."
54B-58
SYMPTOM PROCEDURES
Step 2. Pulse check

Check the input signal from the front passengers
door lock key cylinder switch.
System switch
Check conditions
Front passengers door

lock key cylinder switch
Turn the key to the lock

or unlock position

needle fluctuates.

normally by means of the front passenger's door lock
key cylinder.


YES : Go to Step 3.
front passenger's door lock key cylinder

switch signal is not received 354B."
INSPECTION PROCEDURE C-4: The Ignition Key Reminder Function does not Work Normally.
CAUTION
Ignition Key Reminder Function Circuit

FUSIBLE
LINK 1
ETACS-ECU
INPUT SIGNAL
DOOR
UNLOCK
RELAY
FRONT DOOR
LOCK ACTUATOR (LH)
DOOR
LOCK
RELAY
DRIVER'S DOOR
LOCK ACTUCTOR
SWITCH
DRIVER'S DOOR
SWITCH
KEY REMINDER
SWITCH


If the key reminder function does not work normally,
the input signal circuits below or the ETACS-ECU
may be defective.
Key reminder switch
Driver's door switch
Driver's door lock actuator
POSSIBLE CAUSES
Malfunction of the key reminder switch
Malfunction of the driver's door switch
Malfunction of the driver's door lock actuator

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
illuminate.
YES : Go to Step 2.

circuit" 354B.
54B-59
Step 2. Pulse check

Check the input signals below which are related to
the key reminder function.
System switch
Check conditions
Drivers door switch

opened
Key reminder switch
When the inserted

ignition key is pulled out
Drivers door lock

actuator switch

knob is unlocked or
locked

needle fluctuates.
3.

354B."
The key reminder switch signal is not received. :
Refer to inspection procedure N-9 "The key

reminder switch signal is not received
354B."
The drivers door lock actuator switch signal is not
received. : Refer to inspection procedure N-12
"The drivers door lock actuator signal is not

received 354B.
Q: Does the ignition key reminder function work
normally?

INSPECTION PROCEDURE C-5: The impact detection door unlock function does not function.
CAUTION
If the impact detection door unlock function does not
work normally, the input signal circuit from the impact
detection sensor, the SRS-ECU or the ETACS-ECU
may be defective.
Possible causes
54B-60

SYMPTOM PROCEDURES
Use the MUT-II to confirm a diagnosis code.
Check whether the ETACS-ECU sets diagnosis code
No.31 or 32.
Q: Is the diagnosis code set?
YES : Refer to 354B.

SYMPTOM PROCEDURES
54B-61
POWER WINDOWS
INSPECTION PROCEDURE D-1: Power windows do not work at all.
CAUTION
Power Window Relay Circuit
FUSIBLE
LINK 5
ETACS-ECU
Wire colour code

B : Black
LG : Light green
G : Green
L: Blue
W : White
Y: Yellow
SB : Sky blue
BR : Brown
O : Orange
GR : Gray
R : Red
P : Pink
V : Violet
POWER WINDOW
RELAY
POWER
WINDOW
SUB
SWITCH
(FRONT: RH)
CPU

If the power windows do not work at all, the power
window relay, the power window main switch or the
ETACS-ECU may be defective.
POWER
WINDOW
SUB
SWITCH
(REAR: LH)
POWER
WINDOW
SUB
SWITCH
(REAR: RH)
POWER WINDOW
MAIN SWITCH
Possible causes
Malfunction of the power window relay
54B-62
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 1. Pulse check
Check the input signal from the ignition switch.
System switch
Check conditions
When turned from ACC to

ON

needle fluctuates.
YES : Go to Step 2.
NO : Refer to inspection procedure A-2 "When
the ignition switch is at the LOCK (OFF)

position, the functions do not work normally.
Check the battery power supply circuit to the
ETACS-ECU 354B."
Step 2. Connector check: C-208 power window
relay connector

YES : Go to Step 4.
NO : Replace the power window relay.
Step 4. Connector check: E-05 power window

main switch connector
Connector: E-05
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF

YES : Go to Step 5.
NO : Repair the connector.
Connector: C-208
Junction block (front view)
C-208
Junction block side
3 2 1
4
5
AC210475 AD

YES : Go to Step 3.
Step 3. Check the power window relay.

Refer to GROUP 42 - Door - On-vehicle Service
342.
54B-63
SYMPTOM PROCEDURES
Step 5. Measure the voltage at the E-05 power

window main switch connector.
Connector: E-05

power window relay connector terminal No.4 and
E-05 power window main switch connector
terminal No.6.
C-203
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF
C-208

(2) Turn the ignition switch to the ON position.
C-203
Harness side
2
1
6 5 4 3
C-208
Junction block side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Connector E-05
(Harness side)
3 2 1
4
5
AC210475 AB
AC301469 AB
(3) Voltage between terminal 6 and body earth

OK: System voltage
Connectors: E-05, E-12

YES : Go to Step 9.
NO : Go to Step 6.
E-05
E-12
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC
54B-64
SYMPTOM PROCEDURES
NOTE:
Step 7. Measure the voltage at C-208 power

window relay connector.
Connector: C-118
Connector: C-208
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
C-208
Junction block side
3 2 1
4
5
AC301396 AE

intermediate connectors C-118, E-12 and junction
malfunction (Refer to GROUP 00, How to

NO : Repair the harness wire, and then go to
Step 7.
AC210475 AD

3 2 1
4
5
Connector C-208
AC301459AB

OK: System voltage
YES : Go to Step 9.
NO : Go to Step 8.
54B-65
SYMPTOM PROCEDURES

fusible link (5).
Connector: C-116

C-203
C-208
C-116
1 2
C-203
Harness side
2
1
6 5 4 3
C-208
Junction block side
5 6 7
3 4
8 9
10 11 12 13 14
15
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301396 AB
3 2 1
4
5

AC210475 AB


Fusible link: No.5
AC301515 AC
NOTE: Prior to the wiring harness inspection, check

54B-66
SYMPTOM PROCEDURES
Step 9. Measure the resistance at C-208 power

Connector: C-208

body earth.
C-205
C-208
C-205
Harness side
C-208
Junction block side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
3 2 1
4
5
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-208
Junction block side
AC210475 AD


junction block connector C-205, and repair if
necessary.

AC301460AB
(2) Resistance between terminal 3 and body earth

OK: 2W or less
NO : Go to Step 10.
AC210475 AC

3 2 1
4
5
Connector C-208
3 2 1
4
5
54B-67
SYMPTOM PROCEDURES

connector
Connector: C-217

connector
Connector: C-219
Junction block
(Rear view)
Junction block
(Rear view)
C-219
Harness side
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
59 58 57 56 55 5453 52 51
68 67 66 65 64 63 62 61 60
74 73 72
71 70 69
AC210477 AB

AC210477 AC

54B-68
SYMPTOM PROCEDURES

ETACS-ECU connector terminal No.59 and E-05
No.4.
NOTE:
Connectors : C-02, C-118
C-02
Connector: C-219
C-118
Junction block
(Rear view)
C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
C-219
Harness side
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
59 58 57 56 55 5453 52 51
68 67 66 65 64 63 62 61 60
74 73 72
71 70 69
AC210477 AC
28 29 30 31 32
AC301396 AG

intermediate connectors C-118, E-12 and joint
E-05

After the power window main switch is replaced,
check that all the power windows work.
(1) Replace the power window main switch.
(2) Check that the all the power windows work.
E-12

E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC


SYMPTOM PROCEDURES
54B-69
INSPECTION PROCEDURE D-2: Drivers power window does not work by means of the power window
main switch.
Power Window (front: LH) Circuit
FUSIBLE
LINK 5
POWER
WINDOW
RELAY
ETACS-ECU
POWER
WINDOW
MAIN SWITCH
FRONT
(LH)
POWER WINDOW
MOTOR
(FRONT: LH)
Wire colour code

SB : Sky blue
54B-70

SYMPTOM PROCEDURES

If the drivers power window does not work by means
of the power window main switch, the power window
main switch or the drivers door power window motor
may be defective.
Possible causes
Malfunction of the power window motor (front,
LH)
DIAGNOSIS PROCEDURE
STEP 3. Measure the resistance at the E-05

power window main switch connector.
Connector: E-05
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF
STEP 1. Check the power window main switch.

Check that all of the front passengers and rear door
power windows can operate by means of the power
window main switch.
YES : Go to Step 2.
NO : Refer to Inspection Procedure D-1 "Power
windows do not work at all 354B."

STEP 2. Connector check: E-05 power window

6 5 4
3 2 1
14 13 12 11 10 9 8 7
Connector E-05
(Harness Side)
AC301468 AB

OK: 2W or less
Connector: E-05

YES : Go to Step 5.
NO : Go to Step 4.
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF

YES : Go to Step 3.

SYMPTOM PROCEDURES
STEP 4. Check the wiring harness between E-05

No.2 and body earth.
54B-71


E-05
Connector: E-05
E-12
E-05
Harness side
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301418 AF

AC301419 AC
NOTE:
Connector: C-118
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Connector E-05
(Harness side)
AC301469 AB

OK: System voltage
YES : Go to Step 8.
NO : Go to Step 6.
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301396 AE

intermediate connectors C-118 and E-12, and repair
if necessary.
54B-72

SYMPTOM PROCEDURES

relay connector
Connector: C-208

terminal No.6.
C-203
C-208
C-208
Junction block side
C-203
Harness side
2
1
6 5 4 3
3 2 1
4
5
C-208
Junction block side
3 2 1
4
5
AC210475 AD

YES : Go to Step 7.
AC210475 AB
E-05
E-12
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC
54B-73
SYMPTOM PROCEDURES
NOTE:
STEP 9. Check the wiring harness from E-13

power window motor (front LH) connector
terminal Nos. 1 and 3 to E-05 power window main
switch connector terminal Nos. 7 and 1.
Connector: C-118
Connectors: E-05, E-12, E-13
E-13(GR)
E-05
E-12
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
28 29 30 31 32
E-13
Harness side
E-12
AC301396 AE


NO : Repair the harness wire, and then go to
Step 7.
motor (front LH) connector
Connector: E-13
E-13(GR)
E-13
Harness side
3 2 1
6 5 4
AC301419 AD

intermediate connector E-12, and repair if necessary.
Check the input and output lines for open or short
circuit.

check that the drivers door power window can be
operated by the power window main switch.
(2) Check that the drivers power window works by
3 2 1
6 5 4
AC301418 AB

YES : Go to Step 9.
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16

NO : Replace the power window motor assembly
(front LH).
54B-74

SYMPTOM PROCEDURES
INSPECTION PROCEDURE D-3:Relevant power window(s) do not work by means of the front and rear
passengers power window sub switches.
Power Window (front: RH) Circuit

FUSIBLE
LINK 5
POWER
WINDOW
RELAY
ETACSECU
POWER
WINDOW
SUB SWITCH
(FRONT: RH)
CPU
POWER WINDOW
MOTOR
(FRONT: RH)
Wire colour code

SB : Sky blue
54B-75
SYMPTOM PROCEDURES
Power Window (rear) Circuit
FUSIBLE
LINK 5
POWER
WINDOW
RELAY
ETACS-ECU
POWER
WINDOW
SUB SWITCH
(REAR: RH)
POWER
WINDOW
SUB SWITCH
(REAR: LH)
CPU
CPU
POWER
WINDOW
MOTOR
(REAR: RH)
POWER
WINDOW
MOTOR
(REAR: LH)
Wire colour code


If the front passengers or rear power window does
not work by means of the respective power window
sub switch, the power window sub switch or the
power window motor may be defective.
SB : Sky blue
Possible causes
Malfunction of the power window sub switch
(front, RH), power window sub switch (rear, RH)
or power window sub switch (rear, LH)
Malfunction of the power window motor (front,
RH), power window motor (rear, RH) or power
window motor (rear, LH)
54B-76

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 4. Measure the resistance at E-17 power

window sub switch (front RH) connector.
Step 1. Check the power window main switch.

Check that the power window lock switch is turned
off.
YES : Go to Step 2.
NO : Turn off the power window lock switch.
Connector: E-17
E-17
Harness side
3 2
1
8 7 6 5 4
Step 2. Determine a trouble spot.

Q: Which power window does not work?
AC301412 AB


sub switch (front RH) connector
Connector: E-17
3 2
1
8 7 6 5 4
E-17
Harness side
3 2
1
8 7 6 5 4
Connector E-17
(Harness side)
AC301474 AB

OK: 2W or less
AC301412 AB

YES : Go to Step 4.

YES : Go to Step 6.
NO : Go to Step 5.

SYMPTOM PROCEDURES
Step 5. Check the wiring harness from E-17

power window sub switch (front RH) connector
terminal No.1 to body earth.
54B-77


Step 6. Measure the voltage at E-17 power
E-17
Connector: E-17
E-24
E-17
Harness side
3 2
1
8 7 6 5 4
E-17
Harness side
3 2
1
8 7 6 5 4
AC301412 AB

E-24
1 2
3
4 5 6 7 8
AC301413 AC
3 2
1
8 7 6 5 4
NOTE:
Connector: C-15
Connector E-17
(Harness Side)
AC301470 AB

OK: System voltage
YES : Go to Step 9.
NO : Go to Step 7.
C-15(GR)
C-15
2
1
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
AC301398 AC

intermediate connector C-15, E-24, and repair if
necessary.
54B-78

SYMPTOM PROCEDURES

relay connector
Connector: C-208

power window sub switch (front LH) connector
terminal No.4 to C-208 power window relay
connector terminal No.4.
E-17
E-24
E-17
Harness side
C-208
Junction block side
3 2
1
8 7 6 5 4
3 2 1
4
5
E-24
1 2
3
4 5 6 7 8
AC210475 AD

YES : Go to Step 8.
AC301413 AC

C-203
C-208
C-203
Harness side
2
1
6 5 4 3
C-208
Junction block side
3 2 1
4
5
AC210475 AB
54B-79
SYMPTOM PROCEDURES
NOTE:

power window motor (front RH) connector
terminal Nos. 1 and 3 to E-17 power window sub
switch (front LH) connector terminal Nos. 5 and
7.
Connector: C-15
E-23(GR)
E-17
C-15(GR)
E-24
C-15
2
1
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
E-17
Harness side
3 2
1
8 7 6 5 4
AC301398 AC


motor (front RH) connector
Connector: E-23
E-23
Harness side
3 2 1
6 5 4
E-23(GR)
AC301412 AC

E-23
Harness side
E-24
1 2
3
4 5 6 7 8
3 2 1
6 5 4
AC301413 AB

circuit.

After the power window sub switch (front RH) is
replaced, check that the front passengers door
power window can be operated by the power window
sub switch (front RH).
(1) Replace the power window sub switch (front RH).
(2) Check that the front passengers door power
window can be operated by the power window

(front RH).
54B-80
SYMPTOM PROCEDURES

sub switch (rear RH) connector
Connector: E-21

power window sub switch (rear RH) connector
E-21
E-21
Harness side
3 2
1
8 7 6 5 4
E-27
AC301414 AC

E-21
Harness side
3 2
1
8 7 6 5 4

window sub switch (rear RH) connector.
E-27
Connector: E-21
1 2
3
4 5 6 7 8
AC301415 AC
E-21
Harness side
NOTE:
Connector: D-02
3 2
1
8 7 6 5 4
D-02
AC301414 AC

1
2 3
4 5 6 7 8
AC301408 AH

intermediate connectors E-27 and D-02, and repair if
necessary.
3 2
1
8 7 6 5 4
Connector E-21
(Harness side)
AC301472 AB

OK: 2W or less
NO : Go to Step 14.



SYMPTOM PROCEDURES

Connector: E-21
54B-81

relay connector
Connector: C-208
E-21
Harness side
3 2
1
8 7 6 5 4
AC301414 AC

C-208
Junction block side
3 2 1
4
5
3 2
1
8 7 6 5 4
AC210475 AD
Connector E-21
(Harness Side)
AC301462 AC

OK: System voltage
NO : Go to Step 16.

54B-82
SYMPTOM PROCEDURES

terminal No.4 to C-208 power window connector
terminal No.4.
NOTE:
Connector: C-13
E-21
C-13(L)
E-27
C-13
E-21
Harness side
1
2 3
4 5 6 7 8 9
10 11 12 13 14 15
3 2
1
8 7 6 5 4
E-27
AC301398 AB
3
1 2
4 5 6 7 8
Connector: D-02
AC301415 AC
D-02
1
2 3
4 5 6 7 8

C-203
AC301408 AH

intermediate connectors C-13, D-02, E-27 and
necessary.
C-208
C-203
Harness side

2
1
6 5 4 3

C-208
Junction block side
3 2 1
4
5
AC210475 AB

SYMPTOM PROCEDURES

motor (rear RH) connector
Connector: E-20
E-20(GR)
E-20
Harness side
54B-83

After the power window sub switch (rear RH) is
replaced, check that the rear right door power
window can be operated by the power window sub
switch (rear RH).
(1) Replace the power window sub switch (rear RH).
(2) Check that the rear right door power window can
be operated by the power window sub switch
(rear RH).
3 2 1
6 5 4
AC301414 AB


power window motor (rear RH) connector
switch (rear RH) connector terminal Nos. 7 and 5.

(rear RH).
sub switch (rear LH) connector
Connector: E-01
E-20(GR)
E-21
E-01
Harness side
3 2
1
8 7 6 5 4
AC301416 AB
E-27

E-20
Harness side
3 2 1
6 5 4
E-27
E-21
Harness side
1 2
3
4 5 6 7 8
3 2
1
8 7 6 5 4
AC301415 AB

circuit.
54B-84
SYMPTOM PROCEDURES

window sub switch (rear LH) connector.
Connector: E-01

power window sub switch (rear LH) connector
E-01
E-01
Harness side
3 2
1
8 7 6 5 4
E-09
AC301416 AB

E-01
Harness side
3 2
1
8 7 6 5 4
E-09
3 2
1
8 7 6 5 4
Connector E-01
(Harness Side)
3
1 2
4 5 6 7 8

OK: 2W or less
NO : Go to Step 23.
AC301417 AC
AC301461AB
NOTE:
Connector: D-26
D-26
1
2 3
4 5 6 7 8
AC301410 AB

necessary.


SYMPTOM PROCEDURES

Connector: E-01
54B-85
Step 25. C-208 power window relay connector

Connector: C-208
E-01
Harness side
3 2
1
8 7 6 5 4
AC301416 AB

C-208
Junction block side
3 2 1
4
5
3 2
1
8 7 6 5 4
AC210475 AD
Connector E-01
(Harness side)
AC301462 AB

OK: System voltage
NO : Go to Step 25.

54B-86
SYMPTOM PROCEDURES

terminal No.4 to C-208 power window relay
NOTE:
Connector: C-117
E-01
E-09
C-117
E-01
Harness side
1 2 3
111213
4 5 6 7 8 9 10
14 1516 17 1819 20 2122 2324 25
3 2
1
8 7 6 5 4
26 27 28 29
32 33 34
35
30 31
36 37
38
E-09
AC301396 AC
1 2
3
4 5 6 7 8
Connector: D-26
AC301417 AC
D-26
1
2 3
4 5 6 7 8

C-203
AC301410 AB

necessary.
C-208
C-203
Harness side

2
1
6 5 4 3

C-208
Junction block side
3 2 1
4
5
AC210475 AB
54B-87
SYMPTOM PROCEDURES

motor (rear LH) connector
Connector: E-03

power window motor (rear LH) connector
switch (rear LH) connector terminal Nos. 7 and 5.
E-03(GR)
E-03
Harness side
E-01
E-03(GR)
3 2 1
6 5 4
E-09
AC301416 AC

E-01
Harness side
3 2
1
8 7 6 5 4
E-03
Harness side
E-09
3
1 2
4 5 6 7 8
3 2 1
6 5 4
AC301417 AB

circuit.

After the power window sub switch (rear LH) is
replaced, check that the rear left door power window
can be operated by the power window sub switch
(rear LH).
(1) Replace the power window sub switch (rear LH).
(2) Check that the rear left door power window can
(rear LH).

(rear LH).
54B-88
SYMPTOM PROCEDURES
INSPECTION PROCEDURE D-4: Front and/or rear passengers power window(s) do not work by
Power Window Circuit
REAR
(RH)
FRONT
(RH)
LOCK
SWITCH
CPU
REAR
(LH)
POWER WINDOW
MAIN SWITCH
CPU
POWER WINDOW
SUB SWITCH
(FRONT: RH)
CPU
POWER WINDOW
SUB SWITCH
(REAR: LH)
CPU
POWER WINDOW
SUB SWITCH
(REAR: RH)
Wire colour code

SB : Sky blue
54B-89
SYMPTOM PROCEDURES

If the passengers and/or rear power window does
not work by means of the power window main switch,
the power window main switch or the respective
power window sub switch(es) may be defective.
Possible causes
(front, RH), power window sub switch (rear, RH)
or power window sub switch (rear, LH)

Q: Which power window does not work when the
power window main switch is operated?

main switch connector and E-17 power window
Connector: E-05
DIAGNOSIS PROCEDURE
Step 1. Check the power window main switch.
Check that the drivers power window works by
YES : Go to Step 2.
NO : Refer to inspection procedure D-2 "Drivers
power window does not work by means of

the power window main switch 354B."
Step 2. Check the power window sub switch.
Check that each power window works by means of
the respective power window sub switch when the
power window lock switch is turned off.
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF
Connector: E-17
E-17
Harness side
3 2
1
8 7 6 5 4

YES : Go to Step 3.
NO : Refer to inspection procedure D-3 "Relevant
power window(s) do not work by means of

the front and rear passengers power
window sub switches 354B."
AC301412 AB

YES : Go to Step 5.
54B-90
SYMPTOM PROCEDURES
Step 5. Check the wiring harness between E-05

No.11 and E-17 power window sub switch (front
LH) connector terminal No.6.
NOTE:
Connector: C-15
E-05
C-15(GR)
E-12
C-15
2
1
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
AC301398 AC
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
Connector: C-118
AC301419 AC
E-17
E-24
E-17
Harness side
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
3 2
1
8 7 6 5 4
23 24 25 26 27
28 29 30 31 32
E-24
AC301396 AE
1 2
3
4 5 6 7 8
AC301413 AC

intermediate connectors C-15, C-118, E-12 and E24, and repair if necessary.
YES : Go to Step 6.
54B-91
SYMPTOM PROCEDURES

After the power window sub switch (front LH) is
sub switch.
(1) Replace the power window sub switch (front LH).
(2) Check that the front passengers power window
works by means of the power window main
switch.

No.11 and E-21 power window sub switch (rear
RH) connector terminal No.6.
E-05


NO : Replace the power window main switch.
E-12
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Connector: E-05
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
E-05
Harness side
AC301419 AC
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF
E-21
Connector: E-21
E-27
E-21
Harness side
E-21
Harness side
3 2
1
8 7 6 5 4
AC301414 AC

YES : Go to Step 8.
3 2
1
8 7 6 5 4
E-27
3
1 2
4 5 6 7 8
AC301415 AC
54B-92
SYMPTOM PROCEDURES
NOTE:
Connector: D-02
Connector: C-13
D-02
1
2 3
4 5 6 7 8
AC301408 AH
C-13(L)
C-13

intermediate connectors C-13, C-118, D-02, E-12
and E-27, and repair if necessary.
YES : Go to Step 9.
1
2 3
4 5 6 7 8 9
10 11 12 13 14 15
AC301398 AB
Connector: C-118

switch.
(2) Check that the rear right power window works by

C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301396 AE
54B-93
SYMPTOM PROCEDURES

Connector: E-05

No.11 and E-01 power window sub switch (rear
LH) connector terminal No.6.
E-05
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
AC301418 AF
Connector: E-01
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-01
Harness side
E-12
3 2
1
8 7 6 5 4
AC301416 AB

1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC
E-01
E-09
E-01
Harness side
3 2
1
8 7 6 5 4
E-09
1 2
3
4 5 6 7 8
AC301417 AC
54B-94
SYMPTOM PROCEDURES
NOTE:

can be operated by the power window sub switch.
(2) Check that the rear left power window works by
C-118

C-117

C-117
1 2 3
4 5 6 7 8 9 10
111213
14 1516 17 1819 20 2122 2324 25

26 27 28 29
32 33 34
35
30 31
36 37
38
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301396 AD
Connector: D-26
D-26
1
2 3
4 5 6 7 8
AC301410 AB


SYMPTOM PROCEDURES
54B-95
NSPECTION PROCEDURE D-5: The window glass lowers automatically while it is rising.
If the sliding resistance is too great when the window
is being raised or the window glass encounters an
object, the window glass will lower by approximately
150 mm.
Possible causes
Improper adjusted door window glass
Incorrectly installed or warped glass slider
Malfunction of the power window motor
Malfunction of the window regulator
DIAGNOSIS PROCEDURE
Step 2. Check the power window operating

current.
Check that the power window operating current is
normal (Refer to GROUP 42 - Door - On-vehicle
Service 342).
YES : Adjust the door window glass (Refer to
GROUP 42 - Door - On-vehicle service

342), and then go to Step 3.
NO : Replace the defective power window motor
assembly which operating current are
abnormal.
Step 1. Check the power window anti-trap

function.
Check that the power window anti-trap function
works. Refer to GROUP 42 - Door - On-vehicle
Service 342.
Step 3. Check that the door window glasses are

installed correctly.
Check that the door window glasses are installed
correctly. Refer to GROUP 42 - Door - On-vehicle
Service 342.

YES : Go to Step 2.

YES : Go to Step 4.
NO : Adjust the door window glass (Refer to
window anti-trap function does not work

normally 354B."

342).
Check that the power window does not lower
automatically while it is being raised.

of the defective window.
54B-96
SYMPTOM PROCEDURES
INSPECTION PROCEDURE D-6: Power window anti-trap function does not work normally.
Power Window (front) Circuit
POWER
WINDOW MAIN
SWITCH
POWER WINDOW
SUB SWITCH
(FRONT: RH)
CPU
HALL IC
HALL IC
CPU
HALL IC
POWER
WINDOW MOTOR
(FRONT: LH)
Wire colour code
HALL IC
POWER
WINDOW MOTOR
(FRONT: RH)
SB : Sky blue

SYMPTOM PROCEDURES
54B-97
POWER WINDOW
SUB SWITCH
(REAR: LH)
POWER WINDOW
SUB SWITCH
(REAR: RH)
CPU
HALL IC
HALL IC
CPU
HALL IC
POWER
WINDOW MOTOR
(REAR: RH)
POWER
WINDOW MOTOR
(REAR: LH)
Wire colour code

The revolution detection sensor, which is
incorporated in the power window motor, may be
defective.
Possible causes
HALL IC
SB : Sky blue
DIAGNOSIS PROCEDURE
Step 1. Check the power window operating
current.
Service 342).

abnormal.
54B-98

SYMPTOM PROCEDURES
Step 2. Confirm the power window learning

function.
Check that the power window switch has learned the
fully closed position of the windows (Refer to
GROUP 42 - Door 342).

Nos. 8, 9, 10 and 12 to E-13 power window motor
(front RH) connector terminal Nos. 5, 4, 6 and 2.

YES : Go to Step 3.
NO : Make the power window switch learn the
fully closed position of the windows (Refer

to GROUP 42 - Door 342).
E-13(GR)
E-05
E-12

Q: Which door does the power window anti-trap
function fail on?

E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-13
Harness side
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
3 2 1
6 5 4

AC301419 AD

Check the input and output lines to the revolution
detection sensor for open or short circuit.
E-13(GR)
E-05

YES : Go to Step 6.
E-05
Harness side

check that the drivers power window anti-trap
function works.
(2) Check that the drivers power window anti-trap
function works.
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-13
Harness side
3 2 1
6 5 4
AC301419 AE

YES : Go to Step 5.


(front LH).
54B-99
SYMPTOM PROCEDURES

Connector: E-23

Connector: E-23
E-23
Harness side
E-23
Harness side
E-23(GR)
3 2 1
6 5 4
E-23(GR)
3 2 1
6 5 4
AC301412 AC
AC301412 AC

YES : Go to Step 8.
NOTE:
Connector: C-15

window motor (front RH) connector.
Connector: E-23
E-23
Harness side
E-23(GR)
3 2 1
6 5 4
C-15(GR)
C-15
AC301412 AC

AC301398 AC
3 2 1
6 5 4
Connector E-23
(Harness side)

intermediate connector C-15, and repair if necessary.
AC301471AC
(2) Resistance between E-23 power window motor

(front RH) connector terminal No.5 and body
earth.
OK: 2W or less
NO : Go to Step 9.
1
2
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19

54B-100

SYMPTOM PROCEDURES

Connector: E-17
E-17
Harness side
3 2
1
8 7 6 5 4

replaced, check that the front passengers anti-trap
function can be operated by the power window sub
switch.
anti-trap function works.
AC301412 AB


terminal Nos. 2, 8 and 3 to E-23 power window
motor (front LH) connector terminal Nos. 6, 4 and
2.
E-24
E-17
Harness side
E-23
Harness side

Connector: E-20
E-20(GR)
E-20
Harness side
E-23(GR)
E-17
3 2
1
8 7 6 5 4

(front LH).
E-24
1 2
3
4 5 6 7 8
3 2 1
6 5 4
AC301413 AB

3 2 1
6 5 4
AC301414 AB


SYMPTOM PROCEDURES

window motor (rear RH) connector.
Connector: E-20
54B-101

Connector: E-20
E-20(GR)
E-20(GR)
E-20
Harness side
E-20
Harness side
3 2 1
6 5 4
3 2 1
6 5 4
AC301414 AB

AC301414 AB
NOTE:
Connector: D-02
D-02
3 2 1
6 5 4
Connector E-20
(Harness side)
1
2 3
4 5 6 7 8

(rear RH) connector terminal No.5 and body
earth.
OK: 2W or less
NO : Go to Step 15.
AC301408 AH
AC301471AB

intermediate connector D-02, and repair if necessary.

Connector: E-21
E-21
Harness side
3 2
1
8 7 6 5 4
AC301414 AC

54B-102
SYMPTOM PROCEDURES

motor (rear RH) connector terminal Nos. 6, 4 and
2.

Connector: E-03

E-03(GR)
E-20(GR)
E-21
E-03
Harness side
3 2 1
6 5 4
AC301416 AC
E-27

E-20
Harness side

window motor (rear LH) connector.
3 2 1
6 5 4
E-27
E-21
Harness side
1 2
3
4 5 6 7 8
Connector: E-03
3 2
1
8 7 6 5 4
E-03(GR)
AC301415 AB


replaced, check that the rear right door anti-trap
switch.
(2) Check that the rear right power window anti-trap
function works.

(rear RH).
E-03
Harness side
3 2 1
6 5 4
AC301416 AC

3 2 1
6 5 4
Connector E-03
(Harness side)
AC301463 AB

(rear LH) connector terminal No.5 and body
earth.
OK: 2W or less
NO : Go to Step 21.
54B-103
SYMPTOM PROCEDURES

Connector: E-03

motor (rear LH) connector terminal Nos. 6, 4 and
2.
E-03(GR)
E-03
Harness side
E-01
E-03(GR)
3 2 1
6 5 4
E-09
AC301416 AC
NOTE:
Connector: D-26
E-01
Harness side
D-26
3 2
1
8 7 6 5 4
1
2 3
4 5 6 7 8
E-03
Harness side
AC301410 AB


E-09
1 2
3
4 5 6 7 8
3 2 1
6 5 4
AC301417 AB


replaced, check that the rear left door anti-trap
switch.
(2) Check that the rear left power window anti-trap
function works.
Connector: E-01
E-01
Harness side
3 2
1
8 7 6 5 4
AC301416 AB



(rear LH).
54B-104

SYMPTOM PROCEDURES
KEYLESS ENTRY SYSTEM
INSPECTION PROCEDURE E-1: Keyless Entry System does not Work.
CAUTION
Keyless Entry System Function Circuit

ETACS-ECU
KEYLESS ENTRY
RECEIVER
INPUT SIGNAL
ALL OF THE DOOR SWITCHES
DRIVER'S DOOR LOCK ACTUATOR SWITCH
KEYLESS ENTRY TRANSMITTER SWITCH
KEY REMINDER SWITCH

If the keyless entry system does not work normally,
the input signal circuits to the components below or
the ETACS-ECU may be defective.
Key reminder switch
Keyless entry transmitter
POSSIBLE CAUSES
Malfunction of the door switches
Malfunction of the keyless entry transmitter
Malfunction of the drivers door lock actuator
DIAGNOSIS PROCEDURE
illuminate.
YES : Go to Step 2.

circuit" 354B.

SYMPTOM PROCEDURES
Step 2. Pulse check

the keyless entry system.
System switch
Check conditions
Key reminder switch
When the inserted

A door is opened when

all the doors are closed
Drivers door lock

actuator switch

knob is unlocked or
locked
54B-105

Check the keyless entry system works normally.

Keyless entry transmitter When the switch is

switch
turned from off to on
needle fluctuates.
3.

354B."
All the door switch signals are not received. :
Refer to inspection procedure N-11 "All the

door switch signals are not received 354B
."

received 354B.
The keyless entry transmitter switch signal is not
"Each switch signal of the keyless entry

transmitter is not received 354B."
INSPECTION PROCEDURE E-2: Keyless Entry Hazard Warning Lamp Answerback Function or the
Room Lamp Answerback Function does not Work Normally.
CAUTION
If the hazard warning lamp and the room lamp work
normally, the ETACS-ECU may be defective.
Alternatively, it is possible that the keyless entry

hazard warning lamp answerback function was
disabled by the adjustment function.
POSSIBLE CAUSES
Defective turn-signal lamp
Malfunction of the room lamp
54B-106

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 3. Check the operation of the room lamps.

Check that the room lamps illuminate normally.
Step 1. Check the adjustment function.

Check that the keyless entry hazard warning lamp
answerback function has been enabled by using the
adjustment function.
YES : Go to Step 2.
NO : Enable the keyless entry hazard warning
lamp answerback function by using the

adjustment function. (Refer to 354B.)
Step 2. Check the operation of the hazard
warning lamp.
Check that the hazard warning lamps illuminate
normally.

YES : Go to Step 4.
NO : Refer to inspection procedure M-2 "The
front or rear room lamp does not illuminate/

extinguish 354B."
answerback function or the room lamp answerback
function work normally.


YES : Go to Step 3.
NO : Refer to inspection procedure K-2 "The
hazard warning lamps do not illuminate

354B".
INSPECTION PROCEDURE E-3: Encrypted Code cannot be Registered.
CAUTION
Encrypted Transmitter Code Register Mode

ETACS-ECU
INPUT SIGNAL
KEY REMINDER SWITCH

If the encrypted code registration mode is not
entered, the key reminder switch, the hazard warning
lamp switch or the ETACS-ECU may be defective.
If the registration is not possible although the

registration mode is entered, the keyless entry
transmitter or the ETACS-ECU may be defective.

SYMPTOM PROCEDURES
54B-107
POSSIBLE CAUSES
Step 2. Pulse check

the encrypted code of the keyless entry transmitter.
System switch
Check conditions
DIAGNOSIS PROCEDURE
Key reminder switch
When the inserted

Step 1. Check the encrypted code registration

mode.
Check that the encrypted code registration mode is
entered.
Hazard warning lamp

switch
When the switch is


YES : Go to Step 3.
NO : Go to Step 2.

switch
needle fluctuates.
3.

354B."
The hazard warning lamp switch signal is not
"The hazard warning lamp switch signal is

not received 354B."

transmitter is not received 354B."
Check that the encrypted code can be registered.

54B-108

SYMPTOM PROCEDURES
INSPECTION PROCEDURE E-4: The Timer Lock Function does not Work after the Doors have been
Unlocked by the Keyless Entry System.
CAUTION
If the keyless entry timer lock does not work
normally, the input signal circuit(s) to the keyless
entry transmitter or the ETACS-ECU may be
defective.
POSSIBLE CAUSES
DIAGNOSIS PROCEDURE
Step 1. Check the operation of the keyless entry
system.
Check that the keyless entry system works normally.
YES : Go to Step 2.
NO : Refer to inspection procedure E-1 "Keyless
entry system does not work 354B."

Check that the timer lock works normally.


SYMPTOM PROCEDURES
WINDSHIELD WIPER AND WASHER
INSPECTION PROCEDURE F-1: The windshield wipers does not work at all.
CAUTION
Windshield Wiper Power Supply Circuit
IGNITION
SWITCH (ACC)
FRONT-ECU
WIPER SPEED
SWITCHING
RELAY
WINDSHIELD
WIPER MOTOR
CIRCUIT
BREAKER
Wire colour code

SB : Sky blue
54B-109
54B-110

SYMPTOM PROCEDURES

The windshield wiper motor, the column switch or the
front-ECU may be defective.
Possible causes
Malfunction of the windshield wiper motor
Step 3. Connector check: B-07 windshield wiper

motor connector
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD
Step 1. Check the diagnosis code.

(OFF) position, check that the ETACS-ECU does not
set the diagnosis code.

YES : Go to Step 4.

YES : Refer to diagnosis code chart 354B.
NO : Go to Step 2.
Step 4. Check the windshield wiper motor

assembly.
Refer to GROUP 51 - Windshield wiper 351.
Step 2. Pulse check

the windshield wiper.
System switch
Check conditions
When turned from the

LOCK (OFF) position to
the ACC position.
Windshield mist wiper

switch
When the switch is

turned from off to on.

needle fluctuates.
All the signals are received normally : Go to Step
3.
The ignition switch (ACC) signal is not received. :

ignition switch (ACC) signal is not received
354B."
Windshield mist wiper switch signal is not
received. : Refer to inspection procedure N-6 "The
column switch (windshield wiper washer

and rear wiper washer switch) signal is not
received 354B."

YES : Go to Step 5
NO : Replace the windshield wiper motor
assembly.
54B-111
SYMPTOM PROCEDURES
Step 5. Measure the resistance at the B-07

windshield wiper motor connector.
Connector:
B-07
B-07(GR)
B-07
Harness side
Step 6. Check the wiring harness between B-07

windshield wiper motor connector terminal No.5
and body earth.
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
3 2 1
5 4
AC301521AD

AC301521AD
NOTE:
Connector: C-17
3 2 1
5 4
Connector B-07
(Harness side)
AC301635 AB
(2) Continuity between B-07 windshield wiper motor

OK: 2W or less
YES : Go to Step 7.
NO : Go to Step 6.
C-17(GR)
C-17
Harness side
5 4
3 2 1
13 12 11 10 9 8 7 6
AC301398 AE
Prior to the wiring harness inspection, check the

junction connector C-17 and repair if necessary.

54B-112
SYMPTOM PROCEDURES

connector
Connector: A-12X
Step 8. Measure the voltage at the A-12X frontECU connector.

Connector: A-12X
Relay box side
Relay box side
3130 29 2827 26 25 24 2322 21
3130 29 2827 26 25 24 2322 21
AC301483 AE

YES : Go to Step 8.
AC301483 AE

box side.
(2) Ignition switch: ACC
31 30 29 2827 26 25 24 2322 21
Connector A-12X
(Relay box side)
AC301473 AB
(3) Check the voltage between the A-12X front-ECU

OK: System voltage
NO : Go to Step 9.
54B-113
SYMPTOM PROCEDURES

ignition switch (ACC).
NOTE:
Connector: C-116
Connector: A-12X
C-116
1 2
Relay box side

3130 29 2827 26 25 24 2322 21
5 6 7
3 4
8 9
10 11 12 13 14
15
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301396 AB
AC301483 AE

C-203
C-202
C-202 Harness side

6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-203 Harness side

2
1
6 5 4 3
AC210475 AM

junction block connectors C-202, C-203 and
intermediate connector C-116 and repair if
necessary.
Check the power supply line to the ignition switch
(ACC) for open circuit.
54B-114
SYMPTOM PROCEDURES



column switch connector terminal No.8 and A12X front-ECU connector terminal No.26.
Connector: C-310

connector
Connector: C-310
C-310
Harness side
5 4 3 2 1
10 9 8 7 6
C-310
Harness side
5 4 3 2 1
10 9 8 7 6
AC301400 AB
NOTE:
Connector: C-116
AC301400 AB

C-116
1 2
5 6 7
3 4
8 9
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
1617 18 1920 21
AC301396 AB

necessary.
Check the wiper backup circuit.

SYMPTOM PROCEDURES
54B-115

The windshield wiper should now work normally at
all.

NO : Replace the front-ECU.
INSPECTION PROCEDURE F-2: The windshield wipers does not work when the wiper switch is at
"INT", "WASHER" or "MIST" position. However, the wipers work at low speed when the switch is at
"LO" and "HI" position.
CAUTION
Windshield Wiper Motor Drive Circuit

FRONT-ECU
WIPER SPEED
SWITCHING
RELAY
INPUT SIGNAL
WINDSHIELD WIPER HI SPEED SWITCH
WINDSHIELD WIPER INTERMIT SWITCH
WINDSHIELD WIPER LO SPEED SWITCH
WINDSHIELD WIPER MIST SWITCH
WINDSHIELD
WIPER MOTOR
CIRCUIT
BREAKER

The system may be at fail-safe mode as the SWS
communication line is defective. If the front-ECU
does not receive the ignition switch (ACC) signal due
to an open circuit in the SWS communication lines or
other reasons when the ignition switch is at the ACC
position, the system will enter the fail-safe mode.
Wire colour code

Possible causes
54B-116

SYMPTOM PROCEDURES
NO : Go to Step 2.
Step 2. Pulse check

System switch
Check conditions

the ACC position.

switch
When the switch is


needle fluctuates.
3.

354B."

received 354B."
The windshield wiper should now work normally.

54B-117
SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-3: The windshield wipers do not stop at the specified park position
CAUTION
Windshield Wiper Automatic Stop Relay Circuit
IGNITION
SWITCH (ACC)
FRONT-ECU
WIPER
AUTOMATIC
STOP RELAY
WINDSHIELD
WIPER MOTOR
Wire colour code


The windshield wiper motor or the front-ECU may be
defective.
Possible causes
SB : Sky blue
motor connector
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD

YES : Go to Step 2.
54B-118
SYMPTOM PROCEDURES

assembly.
YES : Go to Step 3
assembly.
Step 3. Measure the voltage at the B-07
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD

3 2 1
5 4
Connector B-07
(Harness side)
AC301636 AB
(3) Check the voltage between the B-07 windshield

wiper motor connector terminal No.2 and body
earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.

and ignition switch (ACC).
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD
54B-119
SYMPTOM PROCEDURES

NOTE:
Connector: C-104

connector
C-104(B)
Connector: A-12X
C-104
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301398 AF
Relay box side

3130 29 2827 26 25 24 2322 21
C-203
C-202
AC301483 AE

YES : Go to Step 6.
C-202 Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-203 Harness side

2
1
6 5 4 3
AC210475 AM

junction connectors C-202, C-203 and the
necessary.
Check the power supply line to ignition switch
54B-120
SYMPTOM PROCEDURES

and A-12X front-ECU connector terminal No.29.
NOTE:
Connector: A-14
Connector: A-12X
A-14(GR)
A-14
1 2 3 4 5 6 7
8 9
10 11
15
14
12 13
16 17
Relay box side

3130 29 2827 26 25 24 2322 21
AC210456 AD
AC301483 AE
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD

intermediate connector A-14 and repair if necessary.
Check the input signal lines.
YES : Go to Step 7.

Check that the windshield wipers stop at the


SYMPTOM PROCEDURES
54B-121
INSPECTION PROCEDURE F-4: The windshield wipers does not work normally.
CAUTION

FRONT-ECU
WIPER SPEED
SWITCHING
RELAY
INPUT SIGNAL
WINDSHIELD
WIPER MOTOR
CIRCUIT
BREAKER

Wire colour code

Possible causes
54B-122

SYMPTOM PROCEDURES
Step 1. Pulse check

System switch
Check conditions

the ACC position.

switch
When the switch is

Windshield intermittent
wiper switch
When the switch is

Windshield low-speed
wiper switch
When the switch is

Windshield high-speed
wiper switch
When the switch is

Step 2. Check the operation of the windshield

wipers.
Check that the windshield wipers work at high speed
and the mist mode.
YES : Go to Step 3.
NO : Go to Step 9.

motor connector
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4

needle fluctuates.
2.

354B."

received 354B."
Windshield intermittent wiper switch signal is not

received 354B."
Windshield low-speed wiper switch signal is not

received 354B."
Windshield high-speed wiper switch signal is not

received 354B."
AC301521AD

YES : Go to Step 4.
54B-123
SYMPTOM PROCEDURES

Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4

Check that the windshield wipers work normally by
moving the switch to each position.

NO : Replace the windshield wiper motor.
connector
AC301521AD

(3) Windshield wiper switch: LO
Connector: A-12X
3 2 1
5 4
Connector B-07
(Harness side)
AC301637 AB

earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 6.
Relay box side

3130 29 2827 26 25 24 2322 21
AC301483 AE

YES : Go to Step 7.
54B-124
SYMPTOM PROCEDURES

and body earth.
Connector:
B-07
B-07(GR)
B-07
Harness side

motor connector
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
3 2 1
5 4
AC301521AD
AC301521AD
NOTE:
Connector: A-14


Connector:
B-07
B-07(GR)
A-14(GR)
B-07
Harness side
3 2 1
5 4
A-14
AC301521AD
1 2 3 4 5 6 7
8 9
10 11
14
15
12 13
16 17

(3) Windshield wiper switch: HI
AC210456 AD

intermediate connector A-14, and repair if necessary.
Check the power supply line to front-ECU for
open circuit.
YES : Go to Step 8.


3 2 1
5 4
Connector B-07
(Harness side)
AC301638 AB

earth.
OK: System voltage
NO : Go to Step 12.
54B-125
SYMPTOM PROCEDURES



and body earth.
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4

connector
Connector: A-12X
AC301521AD
NOTE:
Connector: A-14
A-14(GR)
Relay box side

3130 29 2827 26 25 24 2322 21
AC301483 AE
A-14
1 2 3 4 5 6 7
8 9
10 11
14
15
12 13
16 17

AC210456 AD

Check the power supply line to front-ECU for
open circuit.


54B-126

SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-5: The intermittent wiper interval can not be adjusted by operating the
windshield intermittent wiper volume control.
CAUTION
Windshield Wiper Intermittent Volume Input Signal

ETACS-ECU
INPUT SIGNAL
WINDSHIELD WIPER
INTERMITTENT VOLUME

The column switch or the front-ECU may be
defective.
Possible causes
DIAGNOSIS PROCEDURE
Step 1. Pulse check
the windshield intermittent wiper function.
System switch
Check conditions
When turned from LOCK

(OFF) position to the
ACC position
Windshield intermittent
wiper volume
When the windshield

intermittent wiper volume
is rotated from "FAST" to
"SLOW" (a pulse is sent
around the volume
middle position)

needle fluctuates.
2.

354B."
The windshield wiper volume signal is not
windshield wiper volume signal is not

received 354B."

SYMPTOM PROCEDURES
54B-127

Check that the windshield intermittent wiper interval
can be adjusted by operating the windshield
OK: The intermittent wiper interval is
changed as the intermittent wiper volume is
rotated.

NO : Replace the front-ECU
INSPECTION PROCEDURE F-6: The intermittent wiper interval is not changed according to the
vehicle speed.
CAUTION
Vehicle Speed Input Signal

ETACS-ECU
INPUT SIGNAL
VEHICLE SPEED
W3Z04E06AA

The ETACS-ECU calculates the intermittent wiper
interval according to the vehicle speed signal which
is sent by the engine-ECU.
If the intermittent wiper interval does not depend on
the vehicle speed, the input circuit of the vehicle
speed signal and the ETACS-ECU may be defective.
Possible causes
Malfunction of the vehicle speed signal (engineECU)
DIAGNOSIS PROCEDURE
YES : Go to Step 2.
NO : Refer to Inspection Procedure F-5 "The
intermittent wiper interval can not be

intermittent wiper volume control 354B
."
54B-128

SYMPTOM PROCEDURES
Step 2. Pulse check

the vehicle speed-dependent intermittent wiper.
System switch
Check conditions
When turned from LOCK

(OFF) position to the
ACC position

(engine-ECU)

more

needle fluctuates.
Step 3. Check the SWS monitor customized

function.
Use the SWS monitor customize function to confirm
that "SPEED SEN WIP" is set to "W.FUNCTION".
CAUTION
The SWS monitor must be used in order to
confirm and change that setting. Use the SWS
monitor to confirm and/or change the
customized function.
YES : Go to Step 4.
NO : Use the SWS monitor customize function to
set the "SPEED SEN WIP" to

"W.FUNCTION" (Refer to GROUP 54C Customize adjustment 354B).
3.

354B."
The vehicle speed signal (engine-ECU) is not
"The vehicle speed signal is not received

354B."

Check that the intermittent wiper interval depends on
the vehicle speed.


SYMPTOM PROCEDURES
54B-129
INSPECTION PROCEDURE F-7: The windshield washer does not work.
CAUTION
Windshield Washer Motor Circuit
IGNITION
SWITCH (ACC)
FRONT-ECU
WINDSHIELD
WASHER
RELAY
INPUT SIGNAL
WINDSHIELD WASHER
WINDSHIELD
WASHER MOTOR
Wire colour code


The windshield washer motor, the column switch or
the front-ECU may be defective.
Possible causes
Malfunction of the windshield washer motor
DIAGNOSIS PROCEDURE
wipers.
Check that the windshield wipers work normally.
YES : Go to Step 2.
windshield wipers does not work at all

354B."
54B-130

SYMPTOM PROCEDURES
Step 2. Pulse check

System switch
Check conditions

the ACC position.
Windshield washer
switch
When the switch is

Step 5. Measure the resistance at the A-26

windshield washer motor connector.
Connector: A-26
A-26
Harness side
1
2

needle fluctuates.
3.
AC210453 AF


354B."
Windshield washer switch signal is not received. :
1
2

received 354B."
Connector A-26
(Harness side)
AC301475 AB
Step 3. Connector check: A-26 windshield

washer motor connector
Connector: A-26
(2) Continuity between A-26 windshield washer

motor connector terminal No.1 and body earth
OK: 2W or less
YES : Go to Step 7.
NO : Go to Step 6.
A-26
Harness side
Step 6. Check the wiring harness between A-26

windshield washer motor connector terminal
1
2
AC210453 AF

YES : Go to Step 4.
Step 4. Check the windshield washer motor

assembly.
Refer to GROUP 51 - Windshield washer 351.
YES : Go to Step 5
NO : Replace the windshield washer motor.
Connector: A-26
A-26
Harness side
1
2
AC210453 AF


54B-131
SYMPTOM PROCEDURES

connector
Connector: A-12X

No.2 and A-12X front-ECU connector terminal
No.31.
Connector: A-12X
Relay box side

3130 29 2827 26 25 24 2322 21
Relay box side

3130 29 2827 26 25 24 2322 21
AC301483 AE

YES : Go to Step 8.
AC301483 AE
Connector: A-26
A-26
Harness side
1
2
AC210453 AF

YES : Go to Step 9.

The windshield washer should now work normally.

54B-132

SYMPTOM PROCEDURES
REAR WIPER AND WASHER
INSPECTION PROCEDURE G-1: The rear wiper does not work at all.
CAUTION
Rear Wiper Drive Circuit
IGNITION
SWITCH (ACC)
ETACS-ECU
REAR
WIPER RELAY
INPUT SIGNAL
REAR WIPER SWITCH
REAR
WIPER MOTOR
Wire colour code


If the rear wiper does not work normally, the input
signal circuits to the components below, the rear
wiper motor or the ETACS-ECU may be defective.
Rear wiper switch
SB : Sky blue
Possible causes
Malfunction of the rear wiper motor
54B-133
SYMPTOM PROCEDURES
code.
Check that the ETACS-ECU sets a diagnosis code.
Q: Is diagnosis code set?
NO : Go to Step 2.
Step 2. Pulse check

the rear wiper.
System switch
Check conditions

the ACC position
Column switch (rear

wiper switch)
When the switch is


needle fluctuates.
Step 4. Check the rear wiper motor.

Refer to GROUP 51 - Rear wiper and washer 351
.
YES : Go to Step 5.
NO : Replace the rear wiper motor.
Step 5. Measure the resistance at the F-02 rear

wiper motor connector.
Connector: F-02
F-02
Harness side
4 3 2 1
AC301665 AB


3.

354B."
The column switch (rear wiper switch) signal is not

received 354B."
Step 3. Connector check: F-02 rear wiper motor
connector
Connector: F-02
F-02
Harness side
4 3 2 1
AC301665 AB

YES : Go to Step 4.
4 3 2 1
Connector F-02
(Harness side)
AC301641AB
(2) Resistance between F-02 rear wiper motor

OK: 2 W or less
YES : Go to Step 7.
NO : Go to Step 6.
54B-134
SYMPTOM PROCEDURES
Step 6. Check the wiring harness between F-02

rear wiper motor connector terminal No.1 and
body earth.
Connector: F-02

ETACS-ECU connector terminal No.16 and F-02
rear wiper motor connector terminal No.2.
Connector: C-217
F-02
Harness side
4 3 2 1
Junction block
(Rear view)
AC301665 AB
Check the earth line for open or short circuit.


C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

connector
AC210477 AB
Connector: C-217
Connector: F-02
F-02
Harness side
4 3 2 1
Junction block
(Rear view)
AC301665 AB
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB

YES : Go to Step 8.

SYMPTOM PROCEDURES
NOTE:
54B-135

Check that the rear wiper works normally.
Connector: C-209


C-209 Harness side

7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210475 AO
Connector: F-05
F-05
1 2
3 4
5 6 7 8 9 10
AC301666 AB

connectors C-209 and repair if necessary.
Check the output line.
Q: 1Is the check result normal?
YES : Go to Step 9.
54B-136
SYMPTOM PROCEDURES
INSPECTION PROCEDURE G-2: The rear wiper does not stop at the specified park position.
CAUTION
Rear Wiper Auto-stop Signal Input
IGNITION
SWITCH (ACC)
ETACSECU
REAR
WIPER
RELAY
REAR WIPER
MOTOR
Wire colour code


If the rear wiper does not stop normally within the
predetermined range, the rear wiper motor or the
SB : Sky blue
Possible causes

SYMPTOM PROCEDURES

connector
Connector: F-02
54B-137
Step 3. Measure the voltage at the F-02 rear wiper

motor connector.
Connector: F-02
F-02
Harness side
F-02
Harness side
4 3 2 1
4 3 2 1
AC301665 AB
AC301665 AB

YES : Go to Step 2.

.

4 3 2 1

YES : Go to Step 3.
Connector F-02
(Harness side)
AC301642 AB
(3) Check the voltage between F-02 rear wiper motor

OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.
Step 4. Check the wiring harness between

ignition switch (ACC) and F-02 rear wiper motor
Connector: F-02
F-02
Harness side
4 3 2 1
AC301665 AB
54B-138
SYMPTOM PROCEDURES
NOTE:

C-203

connector
C-209
Connector: C-217
C-203 Harness side

2
1
6 5 4 3
Junction block
(Rear view)
C-209 Harness side

7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210475 AN
Connector: F-05
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB

YES : Go to Step 6.
F-05
1 2
3 4
5 6 7 8 9 10
AC301666 AB

connectors C-203, C-209 and repair if necessary.
circuit.
54B-139
SYMPTOM PROCEDURES

NOTE:
Connector: C-209
Connector: C-217
Junction block
(Rear view)
C-209 Harness side
7 6 5
15 1413
C-217
Junction block side
12
4 3 2 1
11 10 9 8
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210475 AO
Connector: F-05
AC210477 AB
Connector: F-02
F-02
Harness side
4 3 2 1
AC301665 AB
F-05
1 2
3 4
5 6 7 8 9 10
AC301666 AB

circuit.
YES : Go to Step 7.
54B-140

SYMPTOM PROCEDURES

Check that the rear wiper auto stop function works
normally.

INSPECTION PROCEDURE G-3: When the shift lever is moved to "R" position during the rear wiper
operation, the rear wiper does not operate at the continuous mode.
CAUTION
"R" Position During Rear Wiper Operation Circuit

IGNITION
SWITCH (ACC)
ETACS-ECU
REAR
WIPER
RELAY
INPUT SIGNAL
BACK-UP LAMP SWITCH
("R" POSITION)
REAR WIPER SWITCH
REAR WIPER
MOTOR

If the rear wiper does not operate consecutively
when the selector lever is moved to the R position
during the rear wiper operation, the input signal
circuit to the back-up lamp switch ("R" position) or
Possible causes
Malfunction of the back-up lamp switch

Step 1. Confirm the operation of the rear wiper.
Check that the rear wiper work normally.
YES : Go to Step 2.
NO : Refer to Inspection Procedure G-1 "The rear
wiper does not work at all 354B."

SYMPTOM PROCEDURES
Step 2. Pulse check

Check the input signal, which are related to the R
(reverse) gear-linked rear wiper operation.
System switch
Check conditions
Back-up lamp switch
When the ignition switch

is turned ON and the
shift lever is moved to
the R position.

needle fluctuates.
YES : Go to Step 3.
back-up lamp switch signal is not received

354B."
54B-141

Check that the rear wiper operates consecutively
when the shift lever is moved to the R position during
the rear wiper operation.

54B-142

SYMPTOM PROCEDURES
INSPECTION PROCEDURE G-4: The rear washer does not work.
CAUTION
Rear Washer Drive Circuit

IGNITION
SWITCH (ACC)
ETACS-ECU
REAR
WASHER
RELAY
INPUT SIGNAL
REAR WASH. SW
REAR
WASHER
MOTOR
Wire colour code


If the rear washer does not work normally, the input
signal circuits to the rear washer switch, rear washer
motor or the ETACS-ECU may be defective.
Possible causes
Malfunction of the rear washer motor

YES : Go to Step 2.
wiper does not work at all 354B."

SYMPTOM PROCEDURES
Step 2. Pulse check

the rear washer.
Ignition switch: ACC
System switch
Check conditions
Column switch (rear

washer switch)
When the switch is


needle fluctuates.
YES : Go to Step 3.

received 354B."
54B-143
Step 5. Measure the resistance at the A-27 rear

washer motor connector.
Connector: A-27
A-27
Harness side
1
2
A-27(G)
AC210453 AG

Step 3. Connector check: A-27 rear washer motor

connector
1
2
Connector: A-27
Connector A-27
(Harness side)
A-27
Harness side
AC301639 AB
1
2
(2) Resistance between A-27 rear washer motor

OK: 2 W or less
A-27(G)
AC210453 AG

YES : Go to Step 4.
Step 4. Check the rear washer motor.

.
YES : Go to Step 5.
NO : Replace the rear washer motor.

YES : Go to Step 7.
NO : Go to Step 6.

rear washer motor connector terminal No.1 and
body earth.
Connector: A-27
A-27
Harness side
1
2
A-27(G)
AC210453 AG


54B-144
SYMPTOM PROCEDURES

connector
Connector: C-220

ETACS-ECU connector terminal No.23 and A-27
rear washer motor connector terminal No.2.
Connector: A-27
A-27
Harness side
Junction block
(Rear view)
1
2
A-27(G)
AC210453 AG
Connector: C-220
C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210477 AE

YES : Go to Step 8.
Junction block
(Rear view)
C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210477 AE

SYMPTOM PROCEDURES
NOTE:
54B-145

Check that the rear washer works normally.
Connector: C-116


C-116
1 2
5 6 7
3 4
8 9
10 11 12 13 14
15
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301396 AB

necessary.
Check the output signal line.
YES : Go to Step 9.
54B-146

SYMPTOM PROCEDURES
HEADLAMP WASHER
INSPECTION PROCEDURE H-1: The headlamp washer does not work.
CAUTION
Headlamp Washer Motor Circuit
FUSIBLE
LINK 5
FRONT-ECU
HEADLAMP
WASHER
INPUT SIGNAL
HEADLAMP WASHER
HEADLAMP
WASHER MOTOR
Wire colour code


The headlamp washer motor, the column switch or
POSSIBLE CAUSES
Malfunction of the headlamp washer motor
DIAGNOSIS PROCEDURE
NO : Go to Step 2.

SYMPTOM PROCEDURES
Step 2. Pulse check

System switch
Check conditions

the ACC position.
Headlamp washer switch When the switch is


headlamp washer motor connector.
Connector : A-25
A-25
Harness side
2 1

needle fluctuates.
3.
54B-147
A-25(B)
AC210453 AI


354B."
Headlamp washer switch signal is not received. :

column switch (headlamp washer switch)
Step 3. Connector check: A-25 headlamp washer
motor connector
Connector : A-25
2 1
Connector A-25
(harness side)
AC301725 AB
(2) Continuity between A-25 headlamp washer motor

OK: 2W or less
YES : Go to Step 7.
NO : Go to Step 6.
A-25
Harness side

headlamp washer motor connector terminal No.2
and body earth.
2 1
A-25(B)
AC210453 AI

YES : Go to Step 4.
Step 4. Check the headlamp washer motor

assembly.
Refer to GROUP 51 - Headlamp washer 351.
YES : Go to Step 5
NO : Replace the headlamp washer motor.
Connector : A-25
A-25
Harness side
2 1
A-25(B)
AC210453 AI


54B-148
SYMPTOM PROCEDURES

connector
Connector: A-11X

Connector: A-11X
Relay box side
Relay box side
11 10 9 8 7 6 5 4 3 2 1
11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

YES : Go to Step 8.
AC301483 AD
(1) Remove the front-ECU, and measure at the

11 10 9 8 7 6 5 4 3 2 1
Connector A-11X
(Relay box side)
AC301726 AB

OK: System voltage
NO : Go to Step 9.
54B-149
SYMPTOM PROCEDURES

fusible link (5).
Connector: A-11X

Connector: A-11X
Relay box side
Relay box side
11 10 9 8 7 6 5 4 3 2 1
11 10 9 8 7 6 5 4 3 2 1
AC301483 AD
Check the power supply line from the fusible link

(5) for open circuit.
AC301483 AD
Connector : A-25


A-25
Harness side
2 1
A-25(B)
AC210453 AI
Check the output line to headlamp washer motor

for open circuit.

The headlamp washer should now work normally.

54B-150

SYMPTOM PROCEDURES
IGNITION KEY HOLE ILLUMINATION

LAMP
INSPECTION PROCEDURE I-1: The ignition key cylinder illumination lamp does not illuminate/
extinguish normally.
CAUTION
Ignition Key Cylinder Illumination Lamp Circuit
ETACS-ECU
FUSIBLE
LINK 1
KEY
REMINDER SWITCH
KEY CYLINDER
ILLUMINATION LAMP
Wire colour code


<Vehicles without keyless entry system>
Drivers door switch
Key reminder switch
Drivers door switch
signal circuit(s), the ignition key cylinder illumination
lamp or the ETACS-ECU may be defective.
Possible causes
SB : Sky blue
Malfunction of the ignition key cylinder

illumination lamp
Step 1. Check the operation of the room lamp.
Check that the room lamps illuminate and extinguish
normally.
YES : Go to Step 2.

extinguish <vehicles without keyless entry
system>354B ." Or refer to inspection
procedure M-2 "The front or rear room lamp
does not illuminate/extinguish <vehicles
with keyless entry system>354B ."

SYMPTOM PROCEDURES
Step 2. Pulse check

the ignition key cylinder illumination lamp.
System switch
Check conditions

to ON
Key reminder switch*
When the inserted

Drivers door switch

opened
NOTE: *: Vehicles with keyless entry system

needle fluctuates.
3.

354B."

354B."
54B-151
Step 3. Connector check: C-304 key reminder

switch connector
Connector: C-304
Harness side
2
1
7 6 5 4 3
AC301399 AB

YES : Go to Step 4.
Step 4. Check the bulb of the ignition key

cylinder illumination lamp.
Check the bulb of the ignition key cylinder
illumination lamp.
YES : Go to Step 5.
NO : Replace the bulb of the ignition key cylinder
illumination lamp.

354B."

connector
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 6.
54B-152
SYMPTOM PROCEDURES

C-304 ignition key cylinder illumination lamp
connector terminal Nos. 1 and 2.
Connector: C-219


Harness side
C-219(GR)

Check that the ignition key cylinder illumination lamp
illuminates/extinguishes normally.
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
Connector: C-304
Harness side
2
1
7 6 5 4 3
AC301399 AB

YES : Go to Step 7.

SYMPTOM PROCEDURES
54B-153
HEADLAMP AND TAIL LAMP
INSPECTION PROCEDURE J-1: The tail lamps do not illuminate normally.
CAUTION
Tail Lamp Relay Circuit
BATTERY
FRONT-ECU
INPUT SIGNAL
TAIL LAMP
RELAY
HEADLAMP AUTOMATIC
SHUTDOWN
TAIL LAMP SWITCH
RELAY
BOX
LICENSE PLATE LAMP

POSITION LAMP (LH)
REAR COMBINATION
LAMP (LH)
POSITION LAMP (RH)

REAR COMBINATION
LAMP (RH)

If all the tail lamps do not illuminate, the tail lamp
switch input circuit or the front-ECU may be
defective.
Possible causes
Wire colour code

NO : Go to Step 2.
54B-154
SYMPTOM PROCEDURES
Step 2. Pulse check

Check the input signal from the tail lamp switch.
System switch
Check conditions

to ON
Tail lamp switch

position

connector.
Connector: A-11X

needle fluctuates.
3.

354B."
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

connector

box side.
Connector: A-11X
Connector A-11X
(Relay box side)
11 10 9 8 7 6 5 4 3 2 1
AC301541 AD

OK: System voltage
Relay box side

YES : Go to Step 6.
NO : Go to Step 5.
11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

YES : Go to Step 4.

battery.


SYMPTOM PROCEDURES
54B-155

Check that the tail lamps illuminate normally.

INSPECTION PROCEDURE J-2: The low-beam headlamps do not illuminate normally.
CAUTION
Headlamp Relay (Low-Beam) Circuit
BATTERY
FRONT-ECU
INPUT SIGNAL
HEADLAMP
RELAY: LO
HEADLAMP AUTOMATIC
SHUTDOWN
HEADLAMP SWITCH
RELAY
BOX
HEADLAMP (LH)
HEADLAMP (RH)

If the low-beam headlamps do not illuminate, the
headlamp switch input circuit or the front-ECU may
be defective.
Possible causes
Wire colour code

NO : Go to Step 2.
54B-156
SYMPTOM PROCEDURES
Step 2. Pulse check

Check the input signal from the headlamp switch.
System switch
Check conditions

to ON
Headlamp switch

is turned to the
HEADLAMP position

connector.
Connector: A-11X

needle fluctuates.
3.

354B."
Relay box side

11 10 9 8 7 6 5 4 3 2 1

AC301483 AD

connector

box side.
Connector: A-11X
Connector A-11X
(Relay box side)
11 10 9 8 7 6 5 4 3 2 1
AC301541 AE

terminal Nos. 8, 9 and body earth
OK: System voltage
Relay box side

YES : Go to Step 6.
NO : Go to Step 5.
11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

YES : Go to Step 4.

SYMPTOM PROCEDURES

front-ECU connector terminal Nos. 8, 9 and the
battery.
54B-157

Check that the low-beam headlamps illuminate
normally.
Connector: A-11X

Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC301483 AD


54B-158
SYMPTOM PROCEDURES
INSPECTION PROCEDURE J-3: The high-beam headlamps do not illuminate normally.
CAUTION
Headlamp Relay (High-Beam) Circuit
BATTERY
FRONT-ECU
INPUT SIGNAL
HEADLAMP
RELAY: HI
HEADLAMP AUTOMATIC
SHUTDOWN
HEADLAMP SWITCH
RELAY
BOX
COMBINATION METER
HEADLAMP (LH)
HEADLAMP (RH)

If the high-beam headlamps do not illuminate, the
dimmer switch input circuit or the front-ECU may be
defective.
Possible causes
Step 1. Check that the headlamps operate.
Check that the low-beam headlamps illuminate and
YES : Go to Step 2.
NO : Refer to inspection procedure J-2 "The low-
beam headlamps do not illuminate normally

354B."
Wire colour code

Step 2. Pulse check

Check the input signal from the dimmer switch.
System switch
Check conditions
Dimmer switch
When the dimmer switch

is turned from off to on

needle fluctuates.
YES : Go to Step 3.

Check that the high-beam headlamps illuminate
normally.


SYMPTOM PROCEDURES
54B-159
INSPECTION PROCEDURE J-4: The high-beam and low-beam headlamps do not illuminate when the
passing switch is operated.
CAUTION
If the low-beam and high-beam headlamps are
normal, the passing switch input signal circuit or the
Possible causes
Step 2. Pulse check

Check the input signal from the passing switch.
System switch
Check conditions
Passing lamp switch
When the passing switch

is turned from off to on

needle fluctuates.
YES : Go to Step 3.

Check that the low-beam and high-beam headlamps
work normally.
YES : Go to Step 2.
NO : Repair the headlamps. Refer to trouble
symptom chart 354B.

When the passing switch is turned on, check if the
headlamps illuminate normally.

INSPECTION PROCEDURE J-5: The headlamp automatic shutdown function does not work normally.
CAUTION
Headlamp Automatic Shutdown Function
ETACS-ECU
INPUT SIGNAL
HEADLAMP SWITCH
TAIL LAMP SWITCH


Drivers door switch
Tail lamp switch
54B-160

SYMPTOM PROCEDURES
Headlamp switch
signal circuit(s), the front-ECU or the ETACS-ECU
may be defective. Note that this function can be
disabled/enabled by the adjustment function (default
setting; enabled).
Possible causes
Check that the headlamp automatic shutdown
function has been enabled by using the adjustment
function.
YES : Go to Step 2.
NO : Enable the headlamp automatic shutdown
function by using the adjustment function.

Refer to 354B.
work normally.
YES : Go to Step 3.
NO : Repair the headlamps. Refer to trouble
symptom chart 354B.
Step 3. Pulse check

the headlamp automatic shutdown function.
System switch
Check conditions

to ON
Drivers door switch

opened
Tail lamp switch

position

needle fluctuates.
4.

354B."

354B."
headlamp automatic shutdown function works
normally.
(2) Check that the headlamp automatic shutdown
function works normally.

54B-161
SYMPTOM PROCEDURES
INSPECTION PROCEDURE J-6: Any of tail lamps, position lamps or licence plate lamp does not
illuminate.
CAUTION
Tail Lamps, Position Lamps and License Plate Lamps Circuit
TAIL LAMP
RELAY
FRONT-ECU
RELAY
BOX
HEADLAMP
ASSEMBLY
(POSITION)
(LH)
(RH)
REAR
COMBINATION
LAMP (TAIL: LH)
LICENCE
PLATE LAMP
(LH)
(RH)
Wire colour code


If the tail lamps, the position lamps or the licence
plate lamps do not illuminate, the wiring harness
connector(s), the bulb or the fuse may be defective or
burned out.
REAR
COMBINATION
LAMP (TAIL: RH)
SB : Sky blue
Possible causes
Burned-out bulb
54B-162
SYMPTOM PROCEDURES
Step 1. Connector check: D-14 <right tail lamp>

or D-19 <left tail lamp> rear combination lamp
connector, A-29 <right position lamp> or A-16
<left position lamp> headlamp assembly
connector, F-08 <right licence plate lamp> or F10 <left licence plate lamp> licence plate lamp
connector
F-10(GR)
F-08(GR)
Connector: A-16
Harness side
F-08
F-10
2 1
2 1
Harness side
3 2 1
6 5 4
A-16(B)
AC210455 AD
AC301666 AD
Connector: A-29

YES : Go to Step 2.
Harness side
3 2 1
6 5 4
Step 2. Check the bulbs of the tail lamps, the

position lamp or the licence plate lamp.
Check the bulb of the lamp which does not illuminate.
A-29(B)
AC210453 AC

YES : Go to Step 3.
NO : Replace the bulb of the lamp which does not
illuminate.
D-14
D-19
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
AC301411AB

SYMPTOM PROCEDURES
Step 3. Measure the resistance at the D-14 <right

tail lamp> or D-19 <left tail lamp> rear
combination lamp connector, the A-29 <right
position lamp> or A-16 <left position lamp>
headlamp assembly connector, the F-08 <right
licence plate lamp> or F-10 <left licence plate
lamp> licence plate lamp connector.
54B-163
F-10(GR)
Connector: A-16
F-08(GR)
Harness side
Harness side
3 2 1
6 5 4
A-16(B)
F-08
F-10
2 1
2 1
AC210455 AD
Connector: A-29
AC301666 AD

(2) Check the resistance between the lamp
Harness side
3 2 1
6 5 4
A-29(B)
AC210453 AC
Connector A-16, A-29

(Harness side)
D-14
D-19
3 2 1
6 5 4
AC301541AI
Resistance between A-16 <position LH>

headlamp assembly connector terminal No.1
and body earth
Resistance between A-29 <position RH>
and body earth
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
Connector D-14, D-19

(Harness side)
1
2
6 5 4 3
AC301411AB
AC301541BG
54B-164
SYMPTOM PROCEDURES
Resistance between D-14 <right tail lamp> rear

combination lamp connector terminal No.3
and body earth
Resistance between D-19 <left tail lamp> rear
and body earth
Connector F-08, F-10

(Harness side)
2 1
AC301541BM
Resistance between F-08 <licence plate lamp,

RH> licence plate lamp connector terminal
No.1 and body earth
Resistance between F-10 <licence plate
lamp, LH> licence plate lamp connector
OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
54B-165
SYMPTOM PROCEDURES
Step 4. Check the wiring harness from D-14

<right tail lamp> or D-19 <left tail lamp> rear
combination lamp connector terminal No.3, A-29
<right position lamp> or A-16 <left position
lamp> headlamp connector terminal No.1 or F-08
<right licence plate lamp> or F-10 <right licence
plate lamp> licence plate lamp connector
Connectors: F-08, F-09, F-10
F-10(GR)
Connector: A-16
F-08(GR)
F-09(GR)
F-09
Harness side
3 2 1
6 5 4
A-16(B)
AC210455 AD
1 2
3 4
Harness side
F-08
2 1
F-10
2 1
Connector: A-29
AC301666 AD

intermediate connector F-09 <licence plate lamp>,
Harness side
3 2 1
6 5 4
A-29(B)
AC210453 AC
D-14
D-19
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
AC301411AB

YES : Go to Step 7.
54B-166
SYMPTOM PROCEDURES

connector
Connector: A-11X
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

YES : Go to Step 6.
54B-167
SYMPTOM PROCEDURES

lamp> headlamp assembly connector terminal
No.2, F-08 <right licence plate lamp> or F-10 <left
licence plate lamp> licence plate lamp connector
terminal No.2 to A-11X front-ECU connector
terminal No.4.
D-14
D-19
Connector: A-11X
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
AC301411AB

Relay box side
11 10 9 8 7 6 5 4 3 2 1
F-10(GR)
AC301483 AD
F-08(GR)
Connector: A-16
F-09(GR)
F-09
Harness side
3 2 1
6 5 4
A-16(B)
1 2
3 4
Harness side
F-08
2 1
F-10
AC210455 AD
Connector: A-29
2 1
AC301666 AD
Harness side
3 2 1
6 5 4
A-29(B)
AC210453 AC
54B-168
SYMPTOM PROCEDURES
NOTE:
Connector: D-31
1 2
3 4
5 6 7 8 9 10
1112 13 14 15 16
C-01
C-117
AC301408 AE
C-116
C-01
C-116
1 2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
5 6 7
3 4
10 11 12 13 14
15
8 9
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
C-117
1 2 3
4 5 6 7 8 9 10
111213
14 1516 17 18 19 20 2122 232425

26 2728 29
32 33 34
35
30 31
36 37
38
AC301396 AN


connector C-01 <right tail lamp>, intermediate
connector C-116 <tail lamp and licence plate lamp>,
C-117 <left tail lamp and licence plate lamp>, D-31
<right tail lamp>, F-09 <licence plate lamp>, junction
block connector C-202 <right tail lamp> and C-209
<right tail lamp>, and repair if necessary.
Check the output lines for open circuit.
YES : Go to Step 7.

Check that the tail lamps, the position lamps and the
licence plate lamps illuminate normally.
The lamps illuminate normally at both high and low
beams. : The trouble can be an intermittent
C-202

When the tail lamps do not illuminate : Replace
the rear combination lamp socket assembly.
C-209
When the position lamps do not illuminate :
Replace the position lamp socket.

When the licence plate lamps do not illuminate :
Harness side
C-202
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Replace the licence plate lamp socket.

C-209
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210475 AJ

SYMPTOM PROCEDURES
54B-169
INSPECTION PROCEDURE J-7: The headlamp(s) do not illuminate. <including high-beam indicator>
CAUTION
Headlamps (High-Beam Indicator Lamp) Circuit
FRONT-ECU
HEADLAMP
RELAY: LO
HEADLAMP
RELAY: HI
RELAY BOX
HEADLAMP
(LH)
(RH)
COMBINATION
METER
Wire colour code


If any of the headlamps or the high-beam indicator
does not illuminate, the wiring harness connector(s),
the bulb or the fuse may be defective or burned out.
SB : Sky blue
Possible causes
Malfunction of the headlamp bulbs
Malfunction of the high-beam indicator bulb
54B-170
SYMPTOM PROCEDURES
Step 1. Connector check: A-30 <headlamp RH>,
A-15 <headlamp LH> headlamp assembly
connector or C-05 <high-beam indicator>
combination meter connector
Step 2. Check the bulb(s) of the headlamps or the

high-beam indicator lamp.
Check the bulb(s) of the defective lamp.
YES : Go to Step 3.
NO : Replace the bulb(s) of the defective lamp.
Connector: A-15
A-15(B)
Harness side
Step 3. Measure the resistance at A-30

<headlamp RH>, A-15 <headlamp LH> headlamp
assembly connector or C-05 <high-beam
indicator> combination meter connector.
Connector: A-15
1
3 Y 2
A-15(B)
AC210455 AC
Harness side
Connector: A-30
1
3 Y 2
AC210455 AC
A-30(B)
Connector: A-30
Harness side
1
3 Y 2
AC210453 AD
Connector: C-05
A-30(B)
C-05(L)
Harness side
1
3 Y 2
AC210453 AD
Harness side
(front view)
Connector: C-05
C-05(L)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE

YES : Go to Step 2.
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE

54B-171
SYMPTOM PROCEDURES


(Harness side)
Step 4. Check the wiring harness from A-30

<right headlamp> or A-15 <left headlamp>
headlamp connector terminal No.2, or C-05
<high-beam indicator lamp> combination meter
connector terminal No.8 to body earth.
Connector: A-15
1
3 Y 2
A-15(B)
Harness side
AC301541AH
Resistance between A-30 <right headlamp>

and body earth
Resistance between A-15 <left headlamp>
and body earth
1
3 Y 2
AC210455 AC
Connector: A-30
Connector C-05
(Harness side)
A-30(B)
Harness side
1
3 Y 2
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC210453 AD
Connector: C-05
AC301541 AO
Resistance between C-05 <high-beam

indicator lamp> combination meter connector
OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE

YES : Go to Step 7.
54B-172
SYMPTOM PROCEDURES

connector
Connector: A-11X
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

YES : Go to Step 6.

SYMPTOM PROCEDURES

<right headlamp>, A-15 <left headlamp>
headlamp connector terminal No.1 <low-beam>,
No.3 <high-beam>, C-05 combination meter
connector terminal No.9 <high-beam indicator>
to A-11X front-ECU connector terminal No.6
<low-beam> or No.10 <high-beam>.
54B-173
Connector: A-11X
Connector: A-15
A-15(B)
Harness side
Relay box side
1
3 Y 2
11 10 9 8 7 6 5 4 3 2 1
AC210455 AC
Connector: A-30
AC301483 AD

intermediate connector C-116 <high-beam
indicator>, and repair if necessary.
A-30(B)
Harness side
1
3 Y 2
AC210453 AD

C-05(L)

YES : Go to Step 7.

Check that the headlamps and the high-beam
indicator lamp illuminate/extinguish normally.
C-116
When the high-beam indicator lamp does not

illuminate : Replace the combination meter.
C-116
1 2
5 6 7
3 4
10 11 12 13 14
15
8 9
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
Harness side
C-05
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12

When the headlamps do not illuminate : Replace
the headlamp socket.
AC301396 AJ
54B-174
SYMPTOM PROCEDURES
FLASHER TIMER
INSPECTION PROCEDURE K-1: The turn-signal lamps do not illuminate.
CAUTION
Turn-Signal Lamp Power Supply Circuit
BATTERY
RELAY
BOX
ETACS-ECU
TURN-SIGNAL
LAMP RELAY: RH
TURN-SIGNAL
LAMP RELAY: LH
FRONT TURN SIGNAL

LAMP (LH)
SIDE TURN SIGNAL
LAMP (LH)
REAR
COMBINATION
LAMP
FRONT TURN SIGNAL

LAMP (RH)
SIDE TURN SIGNAL
LAMP (RH)
COMBINATION
METER
Wire colour code


If all the turn-signal lamps do not illuminate, the
ignition switch (IG1), the turn-signal lamp switch
input circuit or the ETACS-ECU may be defective.
Possible causes
SB : Sky blue
operate.
normally.
YES : Go to Step 6.
NO : Go to Step 2.

SYMPTOM PROCEDURES

connector
Connector: C-217
54B-175

ETACS-ECU connector terminal No.11 and the
battery.
Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
AC210476 AC

YES : Go to Step 3.
NOTE:
Connector: C-116

Connector: C-217
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG
Junction block side
Connector: C-202
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC210474 AB
Connector C-217

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC301541AU

OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.


54B-176

SYMPTOM PROCEDURES

Check that the turn-signal lamps illuminate normally.

Check that the turn-signal lamps illuminate.



Step 6. Pulse check
the turn-signal lamp illumination.
System switch
Check conditions
Turn-signal lamp switch

(RH)
When the turn-signal

lamp switch (RH) is
Turn-signal lamp switch

(LH)
When the turn-signal

lamp switch (LH) is

needle fluctuates.
7.
The turn-signal lamp switch (RH) signal is not

The turn-signal lamp switch (LH) signal is not



SYMPTOM PROCEDURES
54B-177
INSPECTION PROCEDURE K-2: The hazard warning lamps do not illuminate.
CAUTION
Hazard Warning Lamp Circuit
BATTERY
RELAY
BOX
ETACS-ECU
INPUT SIGNAL
TURN-SIGNAL
LAMP RELAY: RH
TURN-SIGNAL
LAMP RELAY: LH
COMBINATION METER
FRONT TURN SIGNAL
LAMP (LH)
REAR COMBINATION
LAMP (LH)
SIDE TURN SIGNAL
LAMP (LH)
HAZARD
WARNING
LAMP SWITCH
COMBINATION METER
FRONT TURN SIGNAL
LAMP (RH)
REAR COMBINATION
LAMP (RH)
SIDE TURN SIGNAL
LAMP (RH)
Wire colour code


If the hazard warning lamps do not illuminate, the
hazard warning lamp input signal circuit or the
Possible causes
Malfunction of the hazard warning lamp switch
SB : Sky blue
Step 1. Check that the turn-signal lamps operate.
YES : Go to Step 2.
NO : Refer to inspection procedure K-1 "The turn
signal lamps do not illuminate 354B."
54B-178

SYMPTOM PROCEDURES

When the ignition switch is at the LOCK (OFF)
position, check that the functions below work
normally.
Central door locking system
Dome lamp (excluding interior lamp automatic
shutdown function)
YES : Go to Step 3.

circuit 354B."
Step 3. Pulse check

Check the input signal from the hazard warning lamp
switch.
System switch
Check conditions
Hazard warning lamp

switch
When the hazard

warning lamp switch is

needle fluctuates.
The signal is received normally. : Go to Step 4.

not received 354B."
Check that the hazard warning lamps illuminate.


SYMPTOM PROCEDURES
54B-179
INSPECTION PROCEDURE K-3: Any of the turn-signal lamps does not illuminate.
CAUTION
Turn-Signal Lamps Circuit
ETACS-ECU
SIDE TURN
SIGNAL
LAMP
(LH)
HEADLAMP
ASSEMBLY
(FRONT TURN:
LH)
REAR
COMBINATION
LAMP (LH)
COMBINATION
METER
(LH) (RH)
Wire colour code

SB : Sky blue
54B-180

SYMPTOM PROCEDURES
ETACS-ECU
REAR
COMBINATION
LAMP (RH)

If any of the turn-signal lamp does not illuminate
normally, wiring harness connector(s) or the bulb
may be defective.
HEADLAMP
ASSEMBLY
(FRONT TURN:
RH)
SIDE TURN
SIGNAL
LAMP (RH)
Possible causes
Defective turn-signal lamp bulb
54B-181
SYMPTOM PROCEDURES
Connectors: A-04, A-16
A-04(GR)
Step 1. Connector check: A-29 <front RH> or A-16

<front LH> front turn-signal lamp connector, A-01
<side RH> or A-04 <side LH> side turn-signal
lamp connector, D-14 <rear RH> or D-19 <rear
LH> rear combination lamp connector, C-05
<turn-signal indicator lamp> and C-04 <turnsignal indicator lamp (LH)> combination meter
connector
A-16(B)

A-01(GR)
Harness side
A-04
A-16
2 1
3 2 1
6 5 4
A-29(B)
AC210456 AB

C-05(L)
C-04
Harness side
A-29
A-01
2 1
3 2 1
6 5 4
AC210454 AB
Harness side
C-05
C-04
41 4039 38 3736 35 3433 32 31
52 51 50 49 48 47 46 4544 43 42
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AH
54B-182
SYMPTOM PROCEDURES
Step 2. Check the bulb(s) of the turn-signal lamps

or the turn-signal indicator lamps.
D-14
D-19
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
AC301411AB

YES : Go to Step 2.

YES : Go to Step 3.
54B-183
SYMPTOM PROCEDURES
Step 3. Measure the resistance at the A-29 <front

RH> or A-16 <front LH> front turn-signal lamp
connector, the A-01 <side RH> or A-04 <side LH>
side turn-signal lamp connector, the D-14 <rear
RH> or D-19 <rear LH> rear combination lamp
connector, the C-05 <turn-signal indicator lamp>
and C-04 <turn-signal indicator lamp (LH)>
combination meter connector.

C-05(L)
C-04

A-01(GR)
Harness side
C-05
C-04
41 4039 38 3736 35 3433 32 31
52 51 50 49 48 47 46 4544 43 42
A-29(B)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AH
Harness side
A-29
A-01
2 1
D-14
3 2 1
6 5 4
D-19
AC210454 AB
A-04(GR)
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
A-16(B)
AC301411AB

(2) Measure the resistance between the defective
lamp connector terminal and body earth.
Harness side
A-04
A-16
2 1
3 2 1
6 5 4
AC210456 AB
54B-184
SYMPTOM PROCEDURES
Connector C-05
(Harness side)

(Harness side)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
3 2 1
6 5 4
AC301541AI
Resistance between A-29 <front RH>

and body earth
Resistance between A-16 <front LH>
and body earth

(Harness side)
2 1
AC301541AB
Resistance between A-01 <side RH> side

turn-signal lamp connector terminal No.1 and
body earth
Resistance between A-04 <side LH> side
body earth

(Harness side)
2
1
6 5 4 3
AC301541BG
Resistance between D-14 <rear RH> rear

and body earth
Resistance between D-19 <rear LH> rear
and body earth
AC301541 AP
Resistance between C-05 <turn-signal

indicator lamp> combination meter terminal
No.12 and body earth
OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
54B-185
SYMPTOM PROCEDURES

<front RH> or A-16 <front LH> front turn-signal
lamp connector terminal No.2, A-01 <side RH> or
A-04 <side LH> side turn-signal lamp connector
terminal No.1, D-14 <rear RH> or D-19 <rear LH>
rear combination lamp connector terminal No.3,
or C-05 <turn-signal indicator lamp> combination
meter connector terminal No.12 to body earth.

C-05(L)
C-04

A-01(GR)
Harness side
C-05
C-04
41 4039 38 3736 35 3433 32 31
52 51 50 49 48 47 46 4544 43 42
A-29(B)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AH
Harness side
A-29
A-01
2 1
D-14
3 2 1
6 5 4
D-19
AC210454 AB
A-04(GR)
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
A-16(B)
AC301411AB
Harness side
A-04
A-16
2 1
3 2 1
6 5 4
AC210456 AB
54B-186

SYMPTOM PROCEDURES
NOTE:

connector
Connector: C-14
Connector: C-217
1 2
3 4
5 6 7 8 9 10
AC301397 AC

intermediate connector C-14 <side RH>, and repair if
necessary.

Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 6.
54B-187
SYMPTOM PROCEDURES
Step 6. Check the wiring harness from the A-29

lamp connector terminal No.3, the A-01 <side
RH> or A-04 <side LH> side turn-signal lamp
connector terminal No.2, the D-14 <rear RH> or
D-19 <rear LH> rear combination lamp connector
terminal No.6, the C-05 <turn-signal indicator
lamp RH> combination meter connector terminal
No.10 or C-04 <turn-signal indicator lamp LH>
combination lamp connector terminal No.31 to C217 ETACS-ECU connector terminal No.9 <RH>
or 14 <LH>.
A-04(GR)
A-16(B)

A-01(GR)
Harness side
A-04
A-16
2 1
3 2 1
6 5 4
AC210456 AB
A-29(B)
C-05(L)
C-04
Harness side
A-29
A-01
2 1
3 2 1
6 5 4
C-116
C-116
AC210454 AB
Harness side
C-04
C-05
41 4039 38 3736 35 3433 32 31

52 51 50 49 48 47 46 4544 43 42
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AI
54B-188
SYMPTOM PROCEDURES
NOTE:
Connector: C-217
Connector: C-14
1 2
3 4
5 6 7 8 9 10
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
AC301397 AC

D-14
D-19
C-202
C-205
C-209
Harness side
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
C-205
C-202
6 5 4
3 2 1
14 13 12 11 10 9 8 7
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-209
AC301411AB
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210475 AH
Connector: D-31
3 4
1 2
5 6 7 8 9 10
1112 13 14 15 16
AC301408 AE

intermediate connector C-14 <side RH>, C-116
<front or side LH> or D-31 <rear RH> and junction
block connector C-202 <front and side>, C-209
<rear> or C-205 <turn-signal indicator lamp>, and
YES : Go to Step 7.

SYMPTOM PROCEDURES

Check that the turn-signal lamps and the indicator
lamps illuminate normally.

The front turn-signal lamps do not illuminate. :
Replace the socket.

The side turn-signal lamps do not illuminate. :
Replace the socket.

The rear turn-signal lamps do not illuminate. :
Replace the socket assembly.

The turn-signal indicator lamps do not illuminate. :
Replace the combination meter.
54B-189
54B-190

SYMPTOM PROCEDURES
FOG LAMP
INSPECTION PROCEDURE L-1: The front fog lamps do not illuminate normally.
CAUTION
Front Fog Lamp Circuit
BATTERY
RELAY
BOX
FRONT FOG
LAMP RELAY
FRONT-ECU
FRONT
FOG LAMP
(LH)
FRONT
FOG LAMP
(RH)
COMBINATION
METER
Wire colour code

OPERATION
Tail lamp switch
Headlamp switch
SB : Sky blue
If the front fog lamps do not illuminate normally,

these input signal circuit(s) or the ETACS-ECU may
be defective.
Possible causes
Malfunction of the front fog lamp switch

SYMPTOM PROCEDURES
Step 1. Check that the tail lamps and headlamps
operate.
Check that the tail lamps and headlamps illuminate
normally.
54B-191
Step 3. Connector check: A-05X front fog lamp

relay connector.
Connector: A-05X

YES : Go to Step 2.
NO : Check the tail lamps and the headlamps
(Refer to trouble symptom chart 354B).

Step 2. Pulse check
the front fog lamps.
System switch
Check conditions

to ON
Tail lamp switch

position
Headlamp switch

is turned to the
HEADLAMP position
When the front fog lamp

switch is turned from off
to on

needle fluctuates.
3.

354B."

The front fog lamp switch signal is not received. :

front fog lamp switch signal is not received
354B."
Relay box side

2
Front of
vehicle
AC301483AC

YES : Go to Step 4.
Step 4. Check the front fog lamp relay.

Refer to GROUP 54A - Front fog lamp 354A.
YES : Go to Step 5.
NO : Replace the front fog lamp relay.
54B-192
SYMPTOM PROCEDURES
Step 5. Measure the voltage at the A-05X front fog

lamp relay connector.
Connector: A-05X

front fog lamp relay connector (terminal Nos. 1
and 2) and the battery.
Connector: A-05X
Relay box side

2
Relay box side
Front of
vehicle
Front of
vehicle
AC301483AC
(1) Remove the front fog lamp relay, and measure at

the relay box side.
AC301483AC


Connector A-05X
(Relay box side)
AC301541AC
(2) Check the voltage between the front fog lamp

relay connector and body earth.
Voltage between A-05X front fog lamp relay
Voltage between A-05X front fog lamp relay
OK: System voltage
YES : Go to Step 7.
NO : Go to Step 6.
54B-193
SYMPTOM PROCEDURES

connector
Connector: A-11X

front fog lamp relay connector terminal No.3 and
A-11X front-ECU connector terminal No.11.
Connectors: A-05X, A-11X
A-11X
A-05X
Relay box side
Relay box side

A-05X
11 10 9 8 7 6 5 4 3 2 1
A-11X
11 10 9 8 7 6 5 4 3 2 1
Front of
vehicle
AC301483 AD
AC301483 AB

YES : Go to Step 8.

YES : Go to Step 9.

Check that the front fog lamps illuminate normally.

54B-194

SYMPTOM PROCEDURES
INSPECTION PROCEDURE L-2: The rear fog lamps do not illuminate normally.
CAUTION
Rear Fog Lamp Circuit
FUSIBLE
LINK 1
REAR
FOG
LAMP
RELAY
COMBINATION
METER
REAR FOG
LAMP
ETACS-ECU
Wire colour code

OPERATION
Tail lamp switch
Headlamp switch
If the rear fog lamps do not illuminate normally, these
input signal circuit(s) or the ETACS-ECU may be
defective.
Possible causes
Malfunction of the fog lamp switch
SB : Sky blue
operate.
normally.
YES : Go to Step 2.
(Refer to trouble symptom chart 354B).
54B-195
SYMPTOM PROCEDURES
Step 2. Pulse check

the rear fog lamps.
System switch
Check conditions

to ON
Tail lamp switch

position
Headlamp switch

is turned to the
HEADLAMP position
When the rear fog lamp
to on

needle fluctuates.
3.

354B."

The rear fog lamp switch signal is not received. :

rear fog lamp switch signal is not received
354B."
Step 2. Connector check: C-212 rear fog lamp

relay connector
Connector: C-212
Junction block side

2 1
4 3
AC210474 AI

YES : Go to Step 3.
Step 3. Check the rear fog lamp relay.

Refer to GROUP 54A - Rear fog lamp 354A.
YES : Go to Step 4.
NO : Replace the rear fog lamp relay.
54B-196
SYMPTOM PROCEDURES
Step 4. Measure the voltage at the C-212 rear fog

Connector: C-212

rear fog lamp relay connector (terminal Nos. 3
Connectors: C-201, C-204, C-205, C-212
C-204
C-201
Junction block side
C-205
2 1
4 3
AC210474 AI
Junction block side

C-212
C-212
(1) Remove the rear fog lamp relay, and measure at

the relay box side.
2 1
4 3
Harness side
C-201
C-204
Connector C-212
(Relay box side)
5 4 3
2 1
13121110 9 8 7 6
2 1
4 3
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210475 AE
AC301541 AR
(2) Check the voltage between the rear fog lamp

Voltage between C-212 rear fog lamp relay
OK: System voltage
YES : Go to Step 6.
NO : Go to Step 5.
NOTE:
Connector: C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301395 AH

necessary.

54B-197
SYMPTOM PROCEDURES

connector
Connector: C-219

rear fog lamp relay connector terminal No.2 and
C-219 ETACS-ECU connector terminal No.74.
C-201
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 7.
C-212
Harness side
Junction block side
C-201
C-212
5 4 3
2 1
13121110 9 8 7 6
2 1
4 3
AC210475 AF
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

necessary.
YES : Go to Step 8.

Check that the rear fog lamps illuminate normally.

54B-198

SYMPTOM PROCEDURES
INSPECTION PROCEDURE L-3: The front fog lamp(s) do not illuminate.
CAUTION
BATTERY
RELAY
BOX
FRONT FOG
LAMP RELAY
FRONT-ECU
FRONT
FOG LAMP
(LH)
FRONT
FOG LAMP
(RH)
COMBINATION
METER
Wire colour code


If any of the front fog lamps do not illuminate, the
wiring harness connector(s), the bulb or the fuse may
be defective or burned out.
SB : Sky blue
Possible causes
Burned-out front fog lamp bulb

SYMPTOM PROCEDURES
Step 1. Connector check: A-24 <RH> or A-19
<LH> front fog lamp connector, or C-05 <front fog
lamp indicator lamp> combination meter
connector
Connector: A-19
Harness side
A-19(B)
2 1
AC210455 AE
Connector: A-24
Harness side
2 1
A-24(B)
AC210453 AB
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE

YES : Go to Step 2.
54B-199
Step 2. Check the bulbs of the front fog lamps or

the front fog lamp indicator lamp.
YES : Go to Step 3.
54B-200
SYMPTOM PROCEDURES
Step 3. Measure the resistance at A-24 <RH> or

A-19 <LH> front fog lamp connector, or C-05
<front fog lamp indicator lamp> combination
meter connector.
Resistance between A-19 <LH> front fog

lamp connector terminal No.2 and body earth
Connector C-05
(Harness side)
Connector: A-19
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
Harness side
A-19(B)
AC301541 AP
2 1
AC210455 AE
Connector: A-24
Resistance between C-05 <front fog lamp

OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
Harness side
2 1
A-24(B)
AC210453 AB
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE


(Harness side)
2 1
AC301541 AJ
Resistance between A-24 <RH> front fog


SYMPTOM PROCEDURES
Step 4. Check the wiring harness from A-24 <RH>

or A-19 <LH> front fog lamp connector terminal
No.2 or C-05 <front fog lamp indicator lamp>
combination meter connector terminal No.12 to
body earth.
54B-201
Step 5. Connector check: A-05X fog lamp relay

connector
Connector: A-05X
Connector: A-19
Harness side
A-19(B)
2 1
AC210455 AE
Relay box side
Connector: A-24
Front of
vehicle
Harness side
AC301483AC
2 1
A-24(B)
AC210453 AB
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE



YES : Go to Step 6.
54B-202
SYMPTOM PROCEDURES

combination meter connector terminal No.7 to A05X fog lamp relay connector terminal No.4.

C-05(L)
Connector: A-05X
C-116
C-116
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
Harness side
C-05
Relay box side
2
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
Front of
vehicle
AC301483AC
AC301396 AJ

intermediate connector C-116 <front fog lamp
indicator lamp>, and repair if necessary.
YES : Go to Step 7.
Connector: A-19

Check that the fog lamp and the front fog lamp
indicator lamp illuminate normally.
Harness side
A-19(B)
2 1
AC210455 AE
Connector: A-24


The fog lamps do not illuminate. : Replace the fog
lamp(s).
The front fog lamp indicator lamp does not
illuminate. : Replace the combination meter.
Harness side
2 1
A-24(B)
AC210453 AB

SYMPTOM PROCEDURES
54B-203
INSPECTION PROCEDURE L-4: Any of the rear fog lamps does not illuminate.
CAUTION
FUSIBLE
LINK 1
REAR
FOG
LAMP
RELAY
COMBINATION
METER
REAR FOG
LAMP
ETACS-ECU
Wire colour code


If any of the rear fog lamps do not illuminate, the
SB : Sky blue
Possible causes
Burned-out rear fog lamp bulb
54B-204
SYMPTOM PROCEDURES
Step 1. Connector check: F-12 rear fog lamp
connector or C-05 <rear fog lamp indicator lamp>
Connector: C-05

fog lamp connector or C-05 <fog lamp indicator
lamp> combination meter connector.
Connector: C-05
C-05(L)
C-05(L)
Harness side
(front view)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE
Connector: F-12
Harness side
Connector: F-12
2 1
Harness side
2 1
F-12(B)
F-12(B)
AC301665 AD
AC301665 AD

YES : Go to Step 2.
Step 2. Check the bulbs of the rear fog lamps or

the rear fog lamp indicator lamp.
YES : Go to Step 3.

54B-205
SYMPTOM PROCEDURES

Connector F-12
(Harness side)
Step 4. Check the wiring harness from F-12 rear

fog lamp connector terminal No.1, C-05 <rear fog
Connector: C-05
C-05(L)
2 1
Harness side
(front view)
AC301541BN
Resistance between F-12 rear fog lamp relay

11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE
Connector C-05
(Harness side)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301541 AP
Resistance between C-05 <rear fog lamp

OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
F-12(B)
F-09(GR)
Harness side
F-09
1 2
3 4
F-12
2 1
AC301666 AF

intermediate connector F-09 <rear fog lamp>, and

54B-206

SYMPTOM PROCEDURES

relay connector
Connector: C-212

connector terminal No.5 to C-212 rear fog lamp
relay connector terminal No.1.
Connector: C-05
C-05(L)
Junction block side

Harness side
(front view)
2 1
4 3
AC210474 AI
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12

YES : Go to Step 6.
AC301395 AE

C-201
C-212
Harness side
Junction block side
C-201
C-212
5 4 3
2 1
13121110 9 8 7 6
2 1
4 3
AC210475 AF

SYMPTOM PROCEDURES
C-05(L)
54B-207

Check that the rear fog lamp and the rear fog lamp

The rear fog lamps do not illuminate. : Replace the
rear fog lamp(s).
C-117
The rear fog lamp indicator lamp does not

C-117
1 2 3
4 5 6 7 8 9 10
111213
14 1516 17 18 19 20 2122 232425

26 2728 29
32 33 34
35
30 31
36 37
38
Harness side
C-05
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AK
F-12(B)
F-09(GR)
Harness side
F-09
1 2
3 4
F-12
2 1
AC301666 AF

intermediate connector C-117 <rear fog lamp>, F-09
<rear fog lamp> and junction block connector C-201
<rear fog lamp and rear fog lamp indicator lamp>,
YES : Go to Step 7.
54B-208
SYMPTOM PROCEDURES
ROOM LAMP
INSPECTION PROCEDURE M-1: The front or rear room lamp does not illuminate or extinguish
normally. <Vehicles without keyless entry system>
CAUTION
Room Lamp Circuit
ETACS-ECU
REAR
ROOM
LAMP
FRONT
ROOM
LAMP
Wire colour code


SB : Sky blue

Possible causes

SYMPTOM PROCEDURES
illuminate.
54B-209
Step 3. Connector check: D-05 front room lamp

connector, D-11 rear room lamp connector
Connector: D-05
Harness side

YES : Go to Step 2.
1
2

circuit 354B."
AC301408 AB
Step 2. Pulse check

the front and rear room lamps.
System switch
Check conditions

to ON

Drivers door lock

actuator switch

unlocked or locked

needle fluctuates.
3.

354B."

."
"The drivers door lock actuator switch

Connector: D-11
D-11(GR)
Harness side
2 1
AC301410 AD

YES : Go to Step 4.
Step 4. Check the bulbs of the front or rear room

lamps.
Check that the front or rear room lamp bulbs are not
burned out.
YES : Go to Step 5.
NO : Replace the front or rear room lamp bulb.

connector
Connector: C-217
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 6.
54B-210

SYMPTOM PROCEDURES

D-05 front room lamp connector terminal Nos. 2
and 1.
Connector: C-217

D-11 rear room lamp connector terminal Nos. 2
and 1.
Connector: C-217
Junction block side
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
Connector: D-05
AC210476 AC
Connector: D-11
D-11(GR)
Harness side
Harness side
1
2
2 1
AC301408 AB
NOTE:
AC301410 AD
NOTE:
Connector: C-210
Connector: C-210
Harness side
Harness side
3 2 1
3 2 1
AC210474 AH
AC210474 AH



YES : Go to Step 7.

YES : Go to Step 8.

Check that the front or rear room lamp illuminates
and extinguishes normally.

54B-211
SYMPTOM PROCEDURES
INSPECTION PROCEDURE M-2: The front and rear room lamp do not illuminate or extinguish
normally. <Vehicles with keyless entry system>
CAUTION
Room Lamp Circuit
ETACS-ECU
REAR
ROOM
LAMP
FRONT
ROOM
LAMP
Wire colour code


Key reminder switch
SB : Sky blue

signal circuit(s), the interior lamp automatic
shutdown function or the ETACS-ECU may be
defective. The delay-off setting of this function can be
changed by the adjustment function (default setting;
15 seconds).
Possible causes
54B-212

SYMPTOM PROCEDURES
Check that the room lamp delay-off time has been
set to other than "0 second" by the adjustment
function.
YES : Go to Step 2.
NO : Use the adjustment function to set the room
lamp delay-off time to other than "0 second."

Refer to 354B.
illuminate.
YES : Go to Step 3.

circuit" 354B.
Step 3. Pulse check

the front and rear room lamps.
System switch
Check conditions

to ON

Drivers door lock

actuator switch

unlocked or locked
Interior lamp loaded

signal
When a load is applied

through multi-purpose
fuse No.18

needle fluctuates.
4.

354B."

."

Interior lamp loaded signal is not detected. : Refer
to inspection procedure N-17 "Interior lamp
loaded signal is not detected 354B."
54B-213
SYMPTOM PROCEDURES

Connector: D-05
Harness side

and 1.
Connector: C-217
1
2
Junction block side
AC301408 AB
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
Connector: D-11
AC210476 AC
D-11(GR)
Connector: D-05
Harness side
2 1
Harness side
1
2
AC301410 AD

YES : Go to Step 5.
Step 5. Check the bulbs of the front or rear room

lamps.
Check that the front or rear room lamp bulbs are not
burned out.
YES : Go to Step 6.
AC301408 AB
NOTE:
Connector: C-210
Harness side
3 2 1
AC210474 AH

connector
Connector: C-217

YES : Go to Step 8.
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 7.
54B-214
SYMPTOM PROCEDURES

and 1.
Connector: C-217

YES : Go to Step 9.

Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
Connector: D-11
D-11(GR)
Harness side
2 1
AC301410 AD
NOTE:
Connector: C-210
Harness side
3 2 1
AC210474 AH



SYMPTOM PROCEDURES
54B-215
INSPECTION PROCEDURE M-3: Interior lamp automatic shutoff function does not work normally.
CAUTION
Interior Lamp Automatic Shut-off Function Circuit
FUSIBLE
LINK 1
ETACS-ECU
INPUT SIGNAL
ALL DOOR
SWITCH
FRONT DOOR
SWITCH
IGNITION
SWITCH (ACC)
IGNITION
SWITCH (IG1)
INTERIOR LAMP
LOADED SIGNAL
KEEP RELAY
LOAD
DETERMINATION
CIRCUIT
INTERIOR
LAMP CUT
BACK-UP
CIRCUIT
COMBINATION
METER

The ETACS-ECU operates the interior lamp
automatic shutdown function in accordance with the
input signals below.
Drivers door switch
Note that this function can be disabled/enabled by
the adjustment function (default setting; enabled).
FRONT ROOM LAMP

REAR ROOM LAMP
Possible causes
Check that the interior lamp automatic shutdown
function.
YES : Go to Step 2.
NO : Enable the interior lamp automatic
shutdown function by using the adjustment

function. Refer to 354B.
54B-216

SYMPTOM PROCEDURES

illuminate.
YES : Go to Step 3.

circuit 354B."
Step 3. Pulse check

the front and rear dome lamps.
System switch
Check conditions

the ACC position

to ON
Drivers door switch
Drivers door is opened

while all the other doors
are closed.


signal

fuse No.18

needle fluctuates.
4.

354B."

354B."

354B."

."
Interior lamp loaded signal is not detected : Refer
to inspection procedure N-17 "Interior lamp
loaded signal is not detected 354B."


SYMPTOM PROCEDURES
54B-217
INSPECTION PROCEDURE M-4: The door-ajar warning lamp does not illuminate/extinguish normally.
CAUTION
Door Ajar Indicator Lamp Circuit
ETACS-ECU
INPUT SIGNAL
COMBINATION
METER
ALL DOOR SWITCH

FRONT DOOR SWITCH
Wire colour code

SB : Sky blue

If the door-ajar warning lamp does not work normally,
the input signal circuits from all the door switches or
Step 2. Pulse check

the door-ajar warning lamp.
System switch
Check conditions
Possible causes
All the door switches are defective.
Drivers door switch
Drivers door is opened

while all the other doors
are closed.

Q: Does the room lamp illuminate/extinguish?
YES : Go to Step 2.

system>354B." Or refer to inspection
with keyless entry system>354B ."

needle fluctuates.
3.

354B."

."
54B-218
SYMPTOM PROCEDURES
Step 3. Connector check: C-05 combination

meter connector
Connector: C-05
C-05(L)

C-05 combination meter connector terminal Nos.
21 and 22.
Connector: C-05
C-05(L)
Harness side
(front view)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12

YES : Go to Step 4.
AC301395 AE
Connector: C-219
Step 4. Check the door-ajar warning lamp bulb.

Check the door-ajar warning lamp bulb.
YES : Go to Step 5.
NO : Replace the door-ajar warning lamp bulb.
Harness side
C-219(GR)

connector
AC210476 AE

YES : Go to Step 7.
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 6.

door-ajar warning lamp illuminates/extinguishes
normally.
(2) Check that the door-ajar warning lamp

54B-219
INPUT SIGNAL PROCEDURES
INSPECTION PROCEDURE N-1: The ignition switch (ACC) signal is not received.
CAUTION
Ignition Switch (ACC) Input Circuit
IGNITION
SWITCH (ACC)
ETACS-ECU
Wire colour code


Input signal from the ignition switch (ACC) is used to
operate the functions below. If the signal is abnormal,
these functions will not work normally.
Interior lamp automatic shutdown function
SB : Sky blue
connector
Connector: C-217
Possible causes
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 2.
54B-220


Connector: C-217

Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

(2) Ignition switch: ACC position
AC210476 AC
NOTE:
Connector: C-203
Connector C-217
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
2
1
6 5 4 3
AC210474 AC
AC301541AV

OK: System voltage
YES : Go to Step 4.
NO : Go to Step 3.


Check that the ignition switch (ACC) signal is
received normally.

54B-221
INSPECTION PROCEDURE N-2: The ignition switch (IG1) signal is not received.
CAUTION
Ignition Switch (IG1) Input Circuit
IGNITION
SWITCH (IG1)
ETACS-ECU
Wire colour code


Input signal from the ignition switch (IG1) is used to
Turn signal lamp
Room lamps
Possible causes
SB : Sky blue
connector
Connector: C-217
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 2.
54B-222


Connector: C-217

ignition switch (IG1).
Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

(2) Ignition switch: ON position
AC210476 AC
NOTE:
Connector: C-203
Connector C-217
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
2
1
6 5 4 3
AC210474 AC
AC301541AW

OK: System voltage
YES : Go to Step 4.
NO : Go to Step 3.


Check that the ignition switch (IG1) signal is received
normally.


54B-223
INSPECTION PROCEDURE N-3: The back-up lamp switch signal is not received.
CAUTION
Back-up Lamp Switch Input Circuit
IGNITION
SWITCH (IG1)
BACK-UP
LAMP SWITCH
ETACS-ECU
Wire colour code


Input signal from the back-up lamp switch is used to
operate the rear wiper. If the signal is abnormal, the
rear wiper will not work normally.
SB : Sky blue
Possible causes
54B-224

Step 1. Connector check: B-114 back-up lamp

switch connector and C-220 ETACS-ECU
connector
Connector: C-220
Connector: B-114
Harness side
Harness side
2 1
B-114(B)
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210476 AF
AC301521 AB
Connector: C-220

(3) Shift position: R position
Connector C-220
(Harness side)
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210476 AF
AC301541BA

YES : Go to Step 2.
Step 2. Check the back-up lamp switch

Check the back-up lamp switch (Refer to GROUP
22B - Transmission 322B).
YES : Go to Step 3.
NO : Replace the inhibitor switch.

OK: System voltage
NO : Go to Step 4.
54B-225
Step 4. Measure the voltage at the B-114 back-up

lamp switch connector.
Connector: B-114

back-up lamp switch connector terminal No.1
and C-220 ETACS-ECU connector terminal No.39.
Connector: B-114
Harness side
:
Harness side
2 1
2 1
:
B-114(B)
AC301521 AB

B-114(B)
AC301521 AB
Connector: C-220
Connector B-114
(Harness side)
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
2 1
AC210476 AF
AC301541AK
(3) Voltage between B-114 back-up lamp switch

OK: System voltage
YES : Go to Step 5.
NO : Go to Step 6.
NOTE:
Connector: C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
AC301395 AC
Connector: C-105
1 2 3 4
5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
AC301397AF

Check the input line for open circuit.
YES : Go to Step 7.
54B-226

and the ignition switch (IG1).
Connector: B-114
Harness side
2 1
AC301521 AB
NOTE:
Connector: C-106
C-106(GR)
AC301397AG

C-203
C-202
Harness side
C-202
6 5 4
3 2 1
14 13 12 11 10 9 8 7

Check that the back-up lamp switch signal is
received normally.
B-114(B)
2
1
3 4
5 6
10 11 12
7 8 9
13 14 15 16 17 18 19

C-203
2
1
6 5 4 3
AC210475 AG

intermediate connector C-106, junction block
connectors C-202 and C-203, and repair if
necessary.
(IG1) for open circuit.

54B-227
INSPECTION PROCEDURE N-4: The drivers door switch signal is not received.
CAUTION
Driver's Door Switch Input Circuit
ETACS-ECU
FRONT DOOR
SWITCH (LH)
Wire colour code


Input signal from the drivers door switch is used to
Room lamps
Possible causes
SB : Sky blue
Step 2. Connector check: D-28 front door switch

(LH) connector
Connector: D-28
Harness side
3 2 1
AC301410 AF

YES : Go to Step 3.
Step 1. Check the installation condition.

Check that the front door switch (LH) is installed on
the body correctly.
Step 3. Check the front door switch (LH).

Refer to GROUP 42 - Door 342.

YES : Go to Step 2.
NO : Correct the installation condition.

YES : Go to Step 4.
NO : Replace the front door switch (LH).
54B-228


connector
Connector: C-217
Step 5. Check the wiring harness between D-28

front door switch (LH) connector terminal No.3
Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
AC210476 AC

YES : Go to Step 5.
Connector: D-28
Harness side
3 2 1
AC301410 AF
NOTE:
Connector: C-209
Harness side
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210474 AG

YES : Go to Step 6.

Check that the drivers door switch signal is received
normally.


54B-229
INSPECTION PROCEDURE N-5: The column switch (lighting, turn-signal lamp and headlamp washer
switch) signal is not received.
CAUTION
Lighting Switch Input Circuit
COLUMN SWITCH
COLUMN-ECU
LO
HI
PASS
LH
OFF
DIMMER
PASSING SWITCH
RH
TURN-SIGNAL
LAMP SWITCH

Input signal from the column switch (lighting, turnsignal lamp and headlamp washer switch) is used to
Fog lamp
Turn signal lamp
Headlamp washer
Possible causes
OFF
HEAD
HEAD
OFF TAIL
TAIL
LIGHTING
SWITCH
Step 2. Check the column switch (lighting switch

and switch body).
Refer to GROUP 54A - Column switch 354A.
YES : Go to Step 3.
NO : Replace the column switch.

code.
YES : Refer to diagnosis code chart 300.
NO : Go to Step 4.
Step 1. Check the column switch connector.
Check that the wiper and washer switch connector,
the lighting switch connector and the switch body
connector are in good condition.
YES : Go to Step 2.

Replace the column switch, and check if the column
switch (lighting, turn-signal lamp and headlamp
washer switch) sends signal.
(2) Check if the column switch (lighting and turnsignal switch) sends signal.
YES : The procedure is complete.
54B-230

INSPECTION PROCEDURE N-6: The column switch (windshield wiper washer and rear wiper washer
CAUTION
Windshield Wiper and Washer Switch Input Circuit
COLUMN SWITCH
COLUMN-ECU
UPPER
SIDE
WINDSHIELD
WIPER SWITCH
WINDSHIELD
WASHER
SWITCH

Input signal from the column switch (wiper switch) is
used to operate the functions below. If the signal is
abnormal, these functions will not work normally.
Possible causes
code.
YES : Refer to diagnosis code chart 300.
NO : Go to Step 2.
REAR
WIPER
SWITCH
REAR
WASHER
SWITCH

Replace the column switch, and check if the column
switch (windshield wiper washer and rear wiper
washer switch) sends signal.
(2) Check if the column switch (windshield wiper/
washer and rear wiper washer switch) sends
signal.
54B-231
INSPECTION PROCEDURE N-7: The windshield intermittent wiper volume signal is not received.
CAUTION
Windshield Intermittent Wiper Interval Adjusting Knob Input Circuit
ETACSECU
COLUMN
SWITCH
WINDSHIELD
INTERMITTENT
WIPER INTERVAL
ADJUSTING KNOB
UPPER
SIDE
Wire colour code


The intermittent wiper interval is calculated in
accordance with the input signal from the windshield
intermittent wiper volume. If this signal is abnormal,
the wiper interval can not be adjusted.
Possible causes
SB : Sky blue
connector
Connector: C-310
Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC

YES : Go to Step 2.
54B-232

Connector: C-310

Connector: C-219
Harness side
Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC

column switch side.
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE
Connector: C-310
Connector C-310
(Harness side)
5 4 3 2 1
10 9 8 7 6
Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC
AC301541BC

OK: The resistance should rise from 0 to
1 kW when the windshield intermittent
wiper volume is rotated from "Fast" to
"Slow".
YES : Go to Step 3.

connector
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 4.

YES : Go to Step 5.

Check that the windshield intermittent wiper volume
is sending a correct signal.


54B-233
INSPECTION PROCEDURE N-8: When the power window main switch is operated, the switch signals
are not received.
CAUTION
Power Window Main Switch Input Circuit
FUSIBLE
LINK 5
ETACS-ECU
POWER
WINDOW RELAY
FRONT SIDE
DIAGNOSIS
CONNECTOR
POWER WINDOW
MAIN SWITCH
Wire colour code

SB : Sky blue
54B-234

Input signal from the power window main switch is
used in order to check the power window main switch
and confirm how the system is communicating with
the ETACS-ECU. If the communication line is
defective, the power windows will not work normally.

No.4.
Connector: C-219
Possible causes
Harness side
C-219(GR)
Step 1. Check the operation by using the power

window main switch.
Check if each window can be operated by means of
the power window main switch.
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
Q: Can each power window be operated by means of

the power window main switch?
YES : Go to Step 2.
NO : Go to Step 5.
E-05

connector and E-05 power window main switch
connector
E-12
E-05
Harness side
Connector: C-219
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
Connector: E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC

YES : Go to Step 3.
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC

NOTE:
54B-235

Connector: E-05
C-02
C-118
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC
C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
C-118

YES : Go to Step 6.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32

Connector: E-05
AC301396 AG

YES : Go to Step 4.
Step 4. Replace the power window main switch,

and then retest the system.
Replace the power window main switch, and check
that the power window main switch signal is
received.
(2) Check that the power window main switch signal
is received.
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC
(1) Remove the power window main switch, and

measure at the wiring harness side.
Connector E-05
(Harness side)
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301541BH
(2) Voltage between E-05 power window main switch

OK: System voltage
YES : Go to Step 9.
NO : Go to Step 7.
54B-236


relay connector
Connector: C-208

terminal No.6.
C-203
Junction block side

3 2 1
4
5
AC210474 AF
C-208

YES : Go to Step 8.
Harness side
Junction block side
C-203
C-208
3 2 1
4
5
2
1
6 5 4 3
AC210475 AI
E-05
E-12
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC
54B-237
NOTE:

Connector: C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
E-05
AC301395 AH
E-12

E-05
Harness side

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

E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
Step 9. Measure the resistance at the E-05 power

AC301419 AC
Connector: E-05
NOTE:
Connector: C-118
Harness side
1 2 3 4 5 6 7 8 9 10 11
6 5 4
3 2 1
14 13 12 11 10 9 8 7
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301418 AC

AC301395 AH

if necessary.
Connector E-05
(Harness side)


6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301541BI
(2) Resistance between E-05 power window main

switch connector terminal No.2 and body earth
OK: 2W or less
NO : Go to Step 10.
54B-238


Check that each switch signal is received by
operating the power window main switch.

INSPECTION PROCEDURE N-9: The key reminder switch signal is not received.
CAUTION
Key Reminder Switch Input Circuit
ETACSECU
KEY
REMINDER
SWITCH
WHEN REMOVING
KEY: ON
Wire colour code


Input signal from the key reminder switch is used to
SB : Sky blue
Room lamps
Possible causes

54B-239
Step 3. Measure the resistance at the C-304 key

reminder switch connector.

switch connector
Connector: C-304
Connector: C-304
Harness side
2
1
7 6 5 4 3
Harness side
2
1
7 6 5 4 3
AC301399 AB

YES : Go to Step 2.
Step 2. Check the key reminder switch.

Refer to GROUP 54A - Ignition switch 354A.
AC301399 AB

Connector C-304
(Harness side)
2
1
7 6 5 4 3

YES : Go to Step 3.
NO : Replace the key reminder switch.
AC301541 BB
(2) Resistance between C-304 key reminder switch

OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.

key reminder switch connector terminal No.4 and
the body earth.
Connector: C-304
Harness side
2
1
7 6 5 4 3
AC301399 AB


54B-240


connector
Connector: C-220

Connector: C-220
Harness side
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210476 AF
AC210476 AF

YES : Go to Step 6.
Connector: C-304
Harness side
2
1
7 6 5 4 3
AC301399 AB

YES : Go to Step 7.

Check that the key reminder switch signal is received
normally.

54B-241
INSPECTION PROCEDURE N-10: The hazard warning lamp switch signal is not received.
CAUTION
Hazard Warning Lamp Switch Input Circuit
ETACSECU
HAZARD
WARNING
LAMP SWITCH
Wire colour code


Input signal from the hazard warning lamp switch is
Keyless entry system (encrypted code
registration)
Hazard warning lamp
Possible causes
SB : Sky blue
Step 1. Connector check: C-22 hazard warning
lamp switch connector
Connector: C-22
Harness side
4 3 2 1
AC301395 AI

YES : Go to Step 2.
Step 2. Check the hazard warning lamp switch.

Refer to GROUP 54A - Hazard warning lamp switch
354A.
YES : Go to Step 3.
NO : Replace the hazard warning lamp switch.
54B-242
Step 3. Measure the resistance at the C-22 hazard

warning lamp switch connector.

connector
Connector: C-219
Connector: C-22
Harness side
Harness side
4 3 2 1
C-219(GR)
AC301395 AI

Connector C-22
(Harness side)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 6.

hazard warning lamp switch connector terminal
No.1.
4 3 2 1
Connector: C-22
AC301541 AZ
(2) Resistance between C-22 hazard warning lamp

OK: 2 W or less
Harness side
4 3 2 1

YES : Go to Step 5.
NO : Go to Step 4.
AC301395 AI

No.2 and the body earth.
Connector: C-219
Connector: C-22
Harness side
C-219(GR)
Harness side
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
4 3 2 1

AC301395 AI



YES : Go to Step 7.

54B-243

Check that the hazard warning lamp switch signal is
received normally.

INSPECTION PROCEDURE N-11: All the door switch signals are not received.
CAUTION
All Door Switches Input Circuit
ETACS-ECU
FRONT DOOR
SWITCH
(RH)
REAR DOOR
SWITCH
(RH)
TAILGATE REAR DOOR

SWITCH
SWITCH
(LH)
Wire colour code


Input signals from all the door switches are used to
operate the functions below. If the signal(s) are
Room lamps
FRONT DOOR
SWITCH
(LH)
SB : Sky blue
Possible causes
54B-244

Connectors: D-10, D-20, D-28
Step 1. Pulse check

Check the input signal from the drivers door switch.
System switch
Check conditions
Drivers door switch

opened

needle fluctuates.
D-01
D-20
D-28

YES : Go to Step 2.

354B."
Step 2. Connector check: D-28 <front, LH>, D-42
<front, RH>, D-10 <rear, RH> or D-20 <rear, LH>
door switch connectors or F-07 <tailgate>
tailgate switch connector, and C-217 ETACS-ECU
connector
Harness side
D-01
D-20
D-28
3 2 1
3 2 1
3 2 1
AC301411AC
Connector: D-42
Connector: C-217
Harness side
3 2 1
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC301408 AF
AC210476 AC
Connector: F-07
Harness side
1
F-07(B)
AC301665 AC

YES : Go to Step 3.

Check that the door switch is installed on the body
correctly.
YES : Go to Step 4.
54B-245
Step 4. Check the door switch.

Connector: D-42

YES : Go to Step 5.
NO : Replace the door switch.
Harness side
3 2 1
Step 5. Check the wiring harness from terminal

No.2 of the D-28 <front, LH>, D-42 <front, RH>, D10 <rear, RH> or D-20 <rear LH> door switch
connector or terminal No.1 of the F-07 <tailgate>
tailgate switch connector to terminal No.7 of the
C-217 ETACS-ECU connector.
AC301408 AF
Connector: C-217
F-05
F-07(B)
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
Harness side
F-05
F-07
1 2
3 4
5 6 7 8 9 10
D-01
D-20
AC301666 AC
D-28
Harness side
D-01
D-20
D-28
3 2 1
3 2 1
3 2 1
AC301411AC
54B-246
NOTE:

Check that all the drivers door switch signals are
received normally.
Connector: C-13

C-13(L)
1
2 3
4 5 6 7 8 9
10 11 12 13 14 15
AC301397AB

C-205
C-209
Harness side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-209
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210475 AK

intermediate connector F-05 <tailgate> or C-13
<RH> and junction block connector C-205 <RH> or
C-209 <LH and tailgate>, and repair if necessary.
YES : Go to Step 6.
NO : Repair the wiring harness between each of
the door switches and the ETACS-ECU.


54B-247
INSPECTION PROCEDURE N-12: The drivers door lock actuator switch signal is not received.
CAUTION
Door Lock Actuator Input Circuit
ETACS-ECU
DOOR LOCK
ACTUATOR
(FRONT: LH)

Input signal from the drivers door lock actuator is
Room lamps
Possible causes
Connector: E-11
E-11(B)
Harness side
3 2 1
6 5 4
AC301418 AD

YES : Go to Step 2.
54B-248
Step 2. Check the front door lock actuator (LH).

YES : Go to Step 3.

front door lock actuator (LH) connector terminal
No.1 and body earth
Connector: E-11
Step 3. Measure the resistance at the E-11 front

door lock actuator (LH) connector.
E-11(B)
Harness side
Connector: E-11
3 2 1
6 5 4
AC301418 AD
E-11(B)
NOTE:
Harness side
Connector: C-118
3 2 1
6 5 4
AC301418 AD

Connector E-11
(Harness side)
23 24 25 26 27
28 29 30 31 32
AC301395 AH

necessary.
3 2 1
6 5 4
AC301541BK
(2) Resistance between E-11 front door lock actuator

(LH) connector terminal No.1 and body earth
OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22


connector
Connector: C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210476 AF

YES : Go to Step 6.

Step 6. Check the wiring harness from E-11 front

door lock actuator (LH) connector terminal Nos. 2
and 3 to C-220 ETACS-ECU connector terminal
Nos. 36 and 35.
Connector: C-220

Check that the drivers door lock actuator switch
signal is received normally.

Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210476 AF
Connector: E-11
E-11(B)
Harness side
3 2 1
6 5 4
AC301418 AD
NOTE:
Connector: C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
54B-249
28 29 30 31 32
AC301395 AH

necessary.
YES : Go to Step 7.
54B-250

INSPECTION PROCEDURE N-13: The vehicle speed signal is not received.
CAUTION
Vehicle Speed Sensor Input Circuit
ETACS-ECU
VEHICLE
SPEED SENSOR
Wire colour code

G : Green L : Blue

Vehicle speed signal is used to operate the
windshield wiper (vehicle speed-dependent wiper
function). If this signal is abnormal, the windshield
wipers do not work normally.
Possible causes
Malfunction of the vehicles speed sensor
Step 1. Check the speedometer.
Check that the speedometer works normally.
YES : Go to Step 2.
NO : Diagnose the combination meter (Refer to
GROUP 54A - Combination meter 354A

).
54B-251
Step 2. Connector check: B-115 vehicles speed

sensor connector
Connector: B-115

vehicles speed sensor connector terminal No.2
and the body earth.
Connector: B-115
Harness side
B-115(B)
Harness side
3 2 1
B-115(B)
3 2 1
AC301521AC

YES : Go to Step 3.

vehicles speed sensor connector.
AC301521AC
NOTE:
Connector: C-17
4 5
1 2 3
6 7 8 9 10 1112 13
Connector: B-115
Harness side
B-115(B)
3 2 1
AC301521AC

C-17(GR)
AC301397AE


connector
Connector B-115
(Harness side)
Connector: C-219
3 2 1
AC301541 AL
(2) Resistance between B-115 vehicles speed

sensor connector terminal No.2 and body earth
OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 6.
54B-252

NOTE:
Connector: C-02
Connector: B-115
Harness side
B-115(B)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
3 2 1
AC301395 AC

AC301521AC
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
C-105
C-16(L)
AC210476 AE
C-16
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
C-105
1 2 3 4
5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
AC301398 AD

connector C-02, C-16 and intermediate connector C105, and repair if necessary.
YES : Go to Step 7.

Check that the vehicle speed signal is received
normally.


54B-253
INSPECTION PROCEDURE N-14: Each switch signal of the keyless entry transmitter is not received.
CAUTION
Transmitter Input Circuit
ETACS-ECU
KEYLESS ENTRY
RECEIVER

Input signal from the keyless entry transmitter is
used to operate the keyless entry system. If the
signal is abnormal, the keyless entry system will not
work normally.
Possible causes
Defective battery of the keyless entry transmitter
Step 1. Pulse check
Check whether the ETACS-ECU receives signal from
a transmitter or not. For this check, you should use
the 2-button-type transmitter (integrated with a key),
which cover screw is silver and has already been
registered.
NOTE: For how to register the keyless entry
transmitter encrypted code, refer to GROUP 42 On-vehicle Service 342.
System switch
Check conditions

"LOCK/UNLOCK" switch turned from off to on
needle fluctuates.
YES : Go to Step 2.
NO : Go to Step 4.
KEYLESS ENTRY
TRANSMITTER
Step 2. Check the transmitter battery.

Refer to GROUP 42 - Keyless entry system 342.
YES : Go to Step 3.
NO : Replace the keyless entry transmitter
battery.
Step 3. Register the encrypted code, and then
retest the system.
(1) Register the keyless entry transmitter again.
(2) Check that each signal is received from the
keyless entry transmitter.

NO : Replace the keyless entry transmitter.
Check that each signal is received from the keyless
entry transmitter.

54B-254

INSPECTION PROCEDURE N-15: The front fog lamp switch signal is not received.
CAUTION
Front Fog Lamp Switch Input Circuit
ETACSECU
FOG LAMP
SWITCH
NOTE
: WITHOUT REAR FOG LAMP
: WITH REAR FOG LAMP
Wire colour code


Input signal from the front fog lamp switch is used to
operate the front fog lamps. If the signal is abnormal,
the front fog lamps will not illuminate and extinguish
normally.
Possible causes
SB : Sky blue
Step 1. Connector check: C-03 fog lamp switch
connector
Connector: C-03
Harness side
6 5 4 3 2 1
AC301395 AD

YES : Go to Step 2.
Step 2. Check the front fog lamp switch.

Refer to GROUP 54A - Front fog lamp 354A.
YES : Go to Step 3.
NO : Replace the fog lamp switch.

Step 3. Measure the resistance at the C-03 fog

Connector: C-03
54B-255
Step 4. Check the wiring harness from C-03 fog

lamp switch connector terminal No.2 <without
rear fog lamp> or 6 <with rear fog lamp> to body
earth.
Connector: C-03
Harness side
6 5 4 3 2 1
Harness side
AC301395 AD
6 5 4 3 2 1
(1) Remove the fog lamp switch, and measure at the

AC301395 AD

Connector C-03
(Harness side)


6 5 4 3 2 1
*2
*1
Note
*1: Without rear fog lamp
*2: With rear fog lamp

connector
AC301541 AM
(2) Resistance between C-03 fog lamp switch

connector terminal No.2 <without rear fog lamp>
or 6 <with rear fog lamp> and body earth
OK: 2W or less
YES : Go to Step 5.
NO : Go to Step 4.
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 6.
54B-256

ETACS-ECU connector No.54 to C-03 fog lamp
switch connector terminal No.1 <without rear fog
lamp> or 5 <with rear fog lamp>.
Connector: C-03


Harness side
6 5 4 3 2 1
AC301395 AD
Connector: C-219
Harness side
C-219(GR)

Check that the front fog lamp switch signal is
received normally.
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 7.
54B-257
INSPECTION PROCEDURE N-16: The rear fog lamp switch signal is not received.
CAUTION
Rear Fog Lamp Switch Input Circuit
ETACSECU
FOG LAMP
SWITCH
Wire colour code


Input signal from the rear fog lamp switch is used to
operate the rear fog lamps. If the signal is abnormal,
the rear fog lamps will not illuminate and extinguish
normally.
Possible causes
SB : Sky blue
connector
Connector: C-03
Harness side
6 5 4 3 2 1
AC301395 AD

YES : Go to Step 2.
Step 2. Check the rear fog lamp switch.

YES : Go to Step 3.
54B-258



connector
Connector: C-219
Connector: C-03
Harness side
Harness side
6 5 4 3 2 1
C-219(GR)
AC301395 AD

Connector C-03
(Harness side)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 6.

fog lamp switch connector terminal No.1.
6 5 4 3 2 1
Connector: C-03
AC301541 AN
(2) Continuity between C-03 fog lamp switch

OK: 2W or less
YES : Go to Step 5.
NO : Go to Step 4.
Harness side
6 5 4 3 2 1
AC301395 AD
Connector: C-219

fog lamp switch connector terminal No.2 and
body earth.
Harness side
Connector: C-03
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
Harness side
6 5 4 3 2 1
AC301395 AD



YES : Go to Step 7.


Check that the rear fog lamp switch signal is received
normally.

54B-259
54B-260
INSPECTION PROCEDURE N-17: Interior lamp loaded signal is not detected.
CAUTION
IGNITION
SWITCH (ACC)
FUSIBLE
LINK 1
IGNITION
SWITCH (IG1)
RELAY
BOX
ETACS-ECU
KEEP RELAY
INTERIOR LAMP CUT
BACK-UP CIRCUIT
POWER
SOURCE
LOAD
DETERMINATION
CIRCUIT
COMBINATION
METER
FRONT LAMP
REAR LAMP
Wire colour code


The interior lamp automatic shutdown function
operates in accordance with the interior lamp loaded
signal. If this signal is abnormal, the functions below
will not work normally.
SB : Sky blue
Room lamps
Possible causes
Damaged wiring harness or connector(s)

54B-261

illuminate.
Connector: C-217

YES : Go to Step 2.

circuit 354B."
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

connector
Connector: C-217

Connector C-217
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
AC301541AW

YES : Go to Step 3.

OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.
54B-262


Connector: C-217

Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
NOTE:
Connector: C-203
AC210476 AC

(2) Turn the ignition switch to the ACC position.
Connector C-217
Harness side
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2
1
6 5 4 3
AC210474 AC


AC301541AX

OK: System voltage
YES : Go to Step 7.
NO : Go to Step 6.


Connector: C-217
54B-263

Check that the interior lamp loaded signal is received
normally.

Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
NOTE:
Connector: C-116
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG
Connector: C-202
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC210474 AB

block connector C-202 or intermediate connector C116, and repair if necessary.

54B-264
INSPECTION PROCEDURE N-18: The passengers door lock key cylinder switch signal is not
detected.
CAUTION
Door Lock Key Cylinder Switch Input Circuit
ETACS-ECU
DOOR LOCK
KEY CYLINDER
SWITCH (RH)
Wire colour code


Input signal from the front passengers door lock key
cylinder switch is used to operate the central door
locking function. If the signal is abnormal, the central
door locking function will not work normally.
Possible causes
cylinder switch
SB : Sky blue
Step 1. Connector check: E-18 door lock key
cylinder switch (RH) connector
Connector: E-18
Harness side
E-18(B)
3 2 1
AC301412 AD

YES : Go to Step 2.
54B-265
Step 2. Check the door lock key cylinder switch

(RH).
YES : Go to Step 3.
NO : Replace the door lock key cylinder switch

door lock key cylinder switch (RH) connector
terminal No. 2 and body earth.
Connector: E-18
Harness side
(RH).
E-18(B)
3 2 1
Step 3. Measure the resistance at the E-18 door

lock key cylinder switch (RH) connector.
Connector: E-18
AC301412 AD
Harness side
E-18(B)
NOTE:
Connector: C-15
3 2 1
AC301412 AD

2
1
3 4
5 6
10 11 12
7 8 9
13 14 15 16 17 18 19
C-15(GR)
AC301397AD

Connector E-18
(Harness side)

YES : Intermittent malfunction. (Refer to GROUP
3 2 1
AC301541BL
(2) Resistance between E-18 door lock key cylinder

switch (RH) connector terminal No. 2 and body
earth
OK: 2 W or less
00 - How to Cope with Intermittent

Malfunction 300).)
connector
Connector: C-220

YES : Go to Step 5.
NO : Go to Step 4.
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210476 AF

YES : Go to Step 6.
54B-266

Step 6. Check the wiring harness from E-18 door

lock key cylinder switch (RH) connector terminal
Nos. 1 and 3 to C-220 ETACS-ECU connector
Connector: C-220

Check that the passengers door lock key cylinder
switch signal is received normally.
YES : Intermittent malfunction. (Refer to GROUP

Malfunction 300).)
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210476 AF
Connector: E-18
Harness side
E-18(B)
3 2 1
AC301412 AD
NOTE:
Connector: C-15
2
1
3 4
5 6
7 8 9
10 11 12
13 14 15 16 17 18 19
C-15(GR)
AC301397AD

YES : Go to Step 7.

CHECK AT ECU TERMINAL
54B-267

M1549001200599
ETACS-ECU
AC005554AF
NOTE: Terminal numbers 1 to 20 can not be measured as the ETACS-ECU is mounted on the junction block
directly. The values are for reference only.
Terminal Check items
No.
Check conditions
Normal conditions
Output to the power window relay
When the power windows are

operative
System voltage
Power supply to the central door

locking system (battery positive
voltage)
Always
System voltage
Earth (for ECU)
Always
0V
System voltage
Output to room lamp
When the room lamp is on
2 V or less
Power supply to interior lamp

(battery positive voltage)
Always (when the interior lamp off

function is off)
System voltage
Input from all the door switches
One of the door switches: ON (door 0 V

open)
Power supply from ignition switch

(IG1)
Ignition switch: ON
Output to right turn-signal lamps
When right turn-signal lamps are on System voltage
10
Input from drivers door switch
Drivers door switch: ON (door

open)
0V
11
Power supply to hazard warning

lamp (battery positive voltage)
Always
System voltage
12
Output to central door locking (for

locking the doors)
When the door lock actuators lock

the doors
System voltage
13

unlocking the doors other than the
drivers door)
When the door lock actuators

unlock the doors
System voltage
14
Output to left turn-signal lamps
When the left turn-signal lamps are System voltage

on
15
16
Output to rear wiper
When rear wiper is operating
System voltage
17
Input of rear wiper automatic stop

signal
System voltage
18

(ACC)
System voltage
System voltage
54B-268


No.
Check conditions
Normal conditions
19
20
Battery power supply (for ECU)
Always
System voltage
21
Input from rear fog lamp switch
Rear fog lamp switch: ON
0V
22

unlocking the drivers door)

unlock the doors
System voltage
23
Rear washer output
When rear washer is operating
System voltage
24 to 28 -
29
Input of collision signal
30
Input to key reminder switch
Key reminder switch: ON (ignition

key removed)
0V
31 to 34 -
35
Input to drivers door lock actuator

(lock switch)
Drivers door lock: Locked
0V
36

(unlock switch)
Drivers door lock: Unlocked
0V
37, 38
39
Input to inhibitor switch ("R"

position)
Selector lever: R
Ignition switch: ON
System voltage
40 to 44 -
51
When diagnosis code is set (the

MUT-II is connected or the
diagnosis connector No.1 is
earthed)
0 to 12 V (pulse signal)
When input check signal is sent
0 V, 12 V (input signal
is fluctuating)
Setting diagnosis code or sending

input check signal
52
53
Output to door-ajar indicator lamp
When door-ajar indicator lamp is on 0 V
54
Input from front fog lamp switch
Front fog lamp switch: ON
0V
55
Input from hazard warning lamp

switch
Hazard warning lamp switch: ON
0V
56
Earth (for sensor)
Always
0V
57, 58
59
SWS communication line
Always
60 to 62 -
63
Input of vehicle speed signal
When the vehicle is being driven
64, 65
66
Input from windshield intermittent

wiper volume
Turn the ignition switch to the ACC

position, and move the wiper
volume from "Fast" to "Slow."
0 to 2.5 V
67
Input from diagnosis control
When MUT-II is connected
0V
68
Input of SWS request signal
Always
69
Output to ignition key cylinder

illumination lamp
When ignition key cylinder

illumination is on
2 V or less

54B-269

No.
Check conditions
Normal conditions
70
71

function is off)
System voltage
72
73
Output to seat belt warning lamp
When seat belt warning lamp is on
0V
74
Output to rear fog lamp
When rear fog lamp is on
System voltage
Column switch
AC005555AB
Termin
al No.
Check items
Check conditions
Normal conditions
System voltage
Always
System voltage
Always
Always
Earth
Always
0V
Output to windshield intermittent

wiper volume

0 to 2.5 V
Move the wiper volume from "Fast"
to "Slow."
Back-up output to windshield wiper Windshield low-speed wiper switch 0 V

switch
or windshield high-speed wiper
switch: ON

(IG1)
10
Back-up output to headlamp switch Headlamp switch: ON
Ignition switch: ON
System voltage
0V
54B-270

Front-ECU
1 2 3 4 5 6 7 8 9 10 11
2122 23242526 272829 30 31

AC103263 AB
NOTE: Measurement is not possible as the front-ECU is mounted on the relay box directly. The values are for
reference only.
No.
Check conditions
Normal conditions
Output to headlamp washer
When headlamp washer is

operating
System voltage
Battery power supply (for headlamp Always

washer)
System voltage
Output to tail lamps
When the tail lamps are on
System voltage
Always
System voltage
Output to low-beam headlamps
When low-beam headlamps are on System voltage
Battery power supply (for tail lamps) Always
System voltage
8, 9
Battery power supply (for

headlamps)
Always
System voltage
10
Output to high-beam headlamps
When high-beam headlamps are on System voltage
11
Output to front fog lamps
When front fog lamps are on
System voltage
21
Earth
Always
0V
22
Power supply to the ignition switch

(IG2)
Ignition switch: ON
System voltage
23
24
Output to windshield wiper (high

speed operation)
When windshield wipers are

operating at high speed
System voltage
25
Output to windshield wiper (low

speed operation)

operating at low speed
System voltage
26
Back-up input from windshield

wiper switch
Windshield low-speed wiper switch 0 V

switch: ON
27
Back-up input from headlamp

switch
Headlamp switch: ON
0V
28

(ACC)
System voltage
29
Input of windshield wiper automatic When windshield wipers are

stop signal
operating
System voltage
30
Always
31
Output to windshield washer
When windshield washer is

operating
System voltage

54B-271
1 2 3
4 5 6
7 8 9 10 11 12 13 14
AC103264 AE

No.
Check conditions
Normal conditions
Output to power window motor
Earth
Always
0V
SWS communication line (to

ETACS-ECU)
Always
Power supply
Power window relay: ON
System voltage
Input from power window motor

(pulse sensor earth)
0V

(pulse sensor signal)

operating
10


operating
11
SWS communication line (power

window sub switch)
12

(power supply to pulse sensor)

operating
5V
13, 14
54B-272

Power window sub switch
1
2 3
4 5 6 7 8
AC103265 AE

No.
Check conditions
Normal conditions
Earth
Always
0V
Power supply
System voltage

ON-VEHICLE SERVICE
54B-273
ON-VEHICLE SERVICE
CONFIGURATION FUNCTION
M1549002500429
Ignition switch: "LOCK" (OFF) position

Drivers door switch: OFF (drivers door
closed)
ii. When the windshield washer switch is ON for
more than ten seconds, the buzzer in the
ETACS-ECU sounds for three seconds, and
the configuration mode will be set.
2. Conditions for exiting the configuration mode
Diagnosis control: OFF (Disconnect the MUTII or the earth of No.1 pin of the 16-pin
diagnosis connector disconnected.)
Key reminder switch: ON (Remove the ignition
key)
Ignition switch: Turning to any position other
than "LOCK" (OFF) position
Drivers door switch: ON (drivers door
opened)
When three minutes pass without
configurations performed
When the other warning buzzer output is
generated
3. Configurations of various functions
According to the configuration mode entry conditions

of the input switch, the following functions can be
adjusted. The data on configuration will be
memorized even if the battery is removed.
Keyless entry system hazard answerback
function
Vehicle speed-dependent wiper function
Headlamp automatic-shutdown function
Delayed lamp-off time of the room lamp
Interior lamp automatic-shutdown function
Initialization of all functions (Returns to initial
settings)
1. Conditions for entering the configuration mode
i. Set each switch to the following state.
Hazard lamp switch: OFF
Diagnosis control: ON (Connect the MUTII or earth No.1 pin of the 16-pin diagnosis
connector.)
Key reminder switch: OFF (Insert the
ignition key)
Function
Configuration procedure
Keyless entry system hazard
answerback function
When the lock button of the transmitter is pressed twice continuously within
two seconds, the hazard answerback function during the lock state will be
switched between available or unavailable.
Function available: Buzzer sounds once. (Initial state)
Function not available: Buzzer sounds twice.
When the unlock button of the transmitter is pressed twice continuously
within two seconds, the hazard answerback function during the unlock
state will be switched between available or unavailable.
Vehicle speed-dependent
wiper function
When the windshield wiper mist switch is turned ON for more than two
seconds, the vehicle speed-dependent wiper function is switched between
available or unavailable.
Headlamp automaticshutdown function
When the passing switch is turned ON for more than two seconds with the
head lamp switch ON and the turn signal lamp switch turned to RH, the
headlamp automatic-shutdown function is switched between available or
unavailable.
Function available: (when the tail lamp illuminates with the ignition
switch turned to the "LOCK" (OFF) position, it is not automatically turned
off): Buzzer sounds three times. (Initial state)
54B-274

ON-VEHICLE SERVICE
Function
Configuration procedure
Delayed lamp-off time of the

interior lamp
When the turn signal lamp switch is set in the order of RH to LH to RH to

LH within three seconds from the LH position, the delayed lamp-off time
switches (Returns to a after e, and repeats from a in order.)
a. 30 seconds: Buzzer sounds once.
b. 10 seconds: Buzzer sounds twice.
c. 0 seconds (No delay time): Buzzer sounds three times.
d. 15 seconds: Buzzer sounds four times. (Initial state)
e. 7.5 seconds: Buzzer sounds five times.
Interior lamp automaticshutdown function
When the hazard lamp switch is turned ON for more than two seconds, the
interior lamp automatic-shutdown function switches in the following order.
(a and b switches alternately)
a. Function available: Buzzer sounds once. (Initial state)
b. Function not available: Buzzer sounds twice.
Initialization of all functions
When the windshield washer switch is ON for more than 20 seconds

continuously, the buzzer sounds twice, and all functions will be initialized.
(Settings are returned to their initial states.) The configuration mode entry
buzzer sounds after 10 seconds, however to initialize all functions, the ON
state should be continued for 20 seconds. When the windshield washer
switch is ON for more than 20 seconds continuously without the
configuration mode set, the configuration mode will be set after 10 seconds
without the initialization of all functions.
54C-1
GROUP 54C
00
11
SMART WIRING
SYSTEM (SWS)
USING SWS
MONITOR
12
13
14
15
16
17
21
22
CONTENTS
25
54C
SPECIAL TOOLS. . . . . . . . . . . . . . . .
54C
CHECK AT ECU TERMINAL . . . . . . . 54C
54C
26
27
31
32
33
34
35
36
37
42
51
52
54
55
SMART WIRING SYSTEM (SWS) USING SWS MONITOR
54C-2
GENERAL INFORMATION
GENERAL INFORMATION
M1549000100414
For the general information regarding the SWS, refer

to GROUP 54B - General Information 354B.
SPECIAL TOOLS
M1549000300526
Tool
Number
Name
Use
MB991502
MUT-II sub-assembly
Check the SWS (The MUT-II

displays diagnosis codes and
pulse check)
MB991862
A: MB991806
B: MB991812
C: MB991822
SWS monitor kit

A: SWS monitor
cartridge
B: SWS monitor
harness (for columnECU)
C: Probe harness
SWS communication line check

(ECU check and service data)
MB991529
Diagnosis code check Input signal check by using a

harness
voltmeter
B991502
B991813
MB991529

SPECIAL TOOLS
Tool
A
54C-3
Number
Name
Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe

connector
contact pressure
circuit
circuit
sourced tester
MB991854
SWS monitor harness SWS communication line check

(for 13-pin connector) (ECU check and service data)
MB991896
Adapter harness for

door communication
D
MB991223AB
MB991854
MB991896
Door communication line check

(service data)
54C-4

TROUBLESHOOTING
TROUBLESHOOTING
PRIOR TO TROUBLESHOOTING
M1549014700323
Before carrying out troubleshooting, check the

following two items.
Make sure that the ETACS-ECU, the junction

block (J/B), the front-ECU and the engine
compartment relay box are connected securely.
Check that the system fuses and fusible links are
not burned out.
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

M1549000500489
1. Gather information about the problem

from the customer.
2. Verify that the condition described

by the customer exists.
Check that the ETACS-ECU is applicable for the
3. Confirming version number and destination
NG
If the ECU is not applicable for them,

replace it with correct one.
OK
4. ECU check on the SWS monitor
vehicle specifications.
NG
Check the power supply circuit for the ECU

communication lines and repair if necessary.
OK
5. Check the data list by using the SWS monitor.
NG
6. Check of input signal circuit system
OK
7. Check of output signal circuit system

AC211883 AB
1. Gather information about the problem from the

customer.
2. Verify that the condition described by the
customer exists.
NOTE: If an error occurs in the SWS
communication line, the ECU isolated from the
communication line performs a fail-safe or backup
operation, so the problem may not match the one
shown in the Trouble Symptom Chart. However,
the cause of the failure can be tracked down by
performing the following troubleshooting with the
SWS monitor.
3. Confirming version number and destination
Check whether the SWS version number (0) and
destination (EU W/O DRL) meet the vehicle
specifications. If they are different, replace the
ETACS-ECU with a correct one.
4. ECU check on the SWS monitor

Check whether the communication status of the
input- or output-signal-side ECU associated with
the defective function is normal.
If "OK " is displayed for all related ECUs, they
communicate with each other normally and the
input or output signal circuit system may be
defective. Therefore, check SWS monitor service
data.
If "NG" is displayed for any of the related ECUs,
something may be wrong with the ECU for which
"NG" appears, its power supply or earthing
system, or a wiring harness or connector
between the SWS monitor and the ECU. Check
the wiring harness and connectors associated
with the ECU and examine the ECU itself.
5. Check the data list by using the SWS monitor.
54C-5
TROUBLESHOOTING
6.
7.
Select the defective function from the functionspecific diagnostic menu, and check the service
data that appears for each function item. This
allows you to check whether the transmission data
is normal or not. You can judge which circuit is the
cause of the trouble, input circuit or output circuit.
NOTE: In addition to the function-specific
diagnostic menu, a service data menu is available
for SWS monitor service data to check all items
for each ECU.
The switch condition does not meet the service
data display: Input signal system related to
defective functions
The switch condition meets the service data
display: Output signal system related to defective
functions
Check of input signal circuit system
Check relevant switch, sensor, input signal-side
ECU and their wiring harness and connector.
Check of output signal circuit system
Check an output signal-side ECU, electrical load
components and their wiring harness and
connector.
How to connect the SWS communication line

<Special tool SWS monitor harness (for 13-pin
connector) MB991854>
Diagnosis
connector
(13-pin)
Diagnosis
connector
(16-pin)
MB991502
MB991854
AC200084AG
Connect special tool SWS monitor harness (for 13pin connector) to the diagnosis connector (13-pin
connector) MB991854.
How to establish communication between

doors
MB991822
MB991812
HOW TO CONNECT THE SWS MONITOR

M1549014800342
MB991896
CAUTION
Always turn the ignition switch to the "LOCK"
(OFF) position before connecting or
disconnecting the SWS monitor and the MUT-II.
How to connect the SWS communication line
<Special tool SWS monitor harness (for columnECU) MB991812>
Column switch
connector
MB991812
Column switch
connector at
harness side
AC103262AE
1. Remove the steering column cover.

2. Remove the steering column switch connector.
3. Connect special tool SWS monitor harness (for
column-ECU) MB991812.
AC103783AC
1. Connect special tool SWS monitor harness (for

column-ECU) MB991812 to special tool adapter
harness for door communication MB991896.
2. Connect special tool Probe harness MB991822 to
special tool adapter harness for door
communication MB991896 assembled in step 1.
3. Confirm that all the harnesses are connected.
Then insert the probe of special probe harness
MB991822 to each female connector terminal on
special tool adapter harness for door
communication MB991896 by backprobing.
NOTE: For the connectors and their terminal
numbers on the door communication line for the
probe to insert, refer to the reference table.
54C-6

TROUBLESHOOTING
Reference table of connectors and their terminal numbers on door communication line
Insert the probe of the probe harness to each female
connector terminal on the door communication line
by backprobing.
Connector name
Connector number
Intermediate connector
Instrument panel wiring

harness and floor wiring
harness (RH) combination
C-13 (Floor wiring harness

(RH) side)

C-15 (Front door wiring
harness and front door wiring harness (RH) side)
harness and floor wiring
harness (LH) combination
Terminal
No.
4
17
C-117 (Instrument panel wiring 10

harness side)

C-118 (Front door wiring
harness and front door wiring harness (LH) side)
26
Floor wiring harness (RH) and D-02 (Floor wiring harness

rear door wiring harness (RH) (RH) side)
combination
Floor wiring harness (LH) and D-26 (Floor wiring harness

rear door wiring harness (LH) (LH) side)
combination
Rear door wiring harness (LH) E-09 (Rear door wiring

and rear door sub wiring
harness (LH) side)
Front door wiring harness

E-12 (Front door wiring
(LH) and front door sub wiring harness (LH) side)
Front door wiring harness

E-24 (Front door wiring
(RH) and front door sub wiring harness (RH) side)
Rear door wiring harness

E-27 (Rear door wiring
(RH) and rear door sub wiring harness (RH) side)
E-05
11
Power window sub switch (front, RH)
E-17
Power window sub switch (rear RH)
E-21
Power window sub switch (rear LH)
E-01
54C-7
TROUBLESHOOTING
Connector: D-02
D-02
1
2 3
4 5 6 7 8
C-13(L)
C-15(GR)
AC301408 AH
Connector: D-26
C-13
C-15
1
2 3
4 5 6 7 8 9
10 11 12 13 14 15
2
1
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
D-26
1
2 3
4 5 6 7 8
AC301398 AZ
AC301410 AB

E-01
Harness side
E-01
3 2
1
8 7 6 5 4
C-118
E-09
C-117
3
1 2
4 5 6 7 8
C-117
1 2 3
E-09
AC301416 AG
4 5 6 7 8 9 10
111213
14 1516 17 1819 20 2122 2324 25

26 27 28 29
32 33 34
35
30 31
36 37
38
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301396 AD
54C-8
TROUBLESHOOTING
E-17
Harness side
3 2
1
8 7 6 5 4
E-05
E-17
E-24
E-24
3
1 2
4 5 6 7 8
E-12
AC301412 AH
E-05
Harness side

E-21
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
3 2
1
8 7 6 5 4
E-21
E-12
E-27
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
E-27
3
1 2
4 5 6 7 8
AC301414 AI
AC301419 AC
ECU CHECK
M1549014900305
Use the MUT-II and the SWS monitor to check ECUs

(Refer to MUT-II reference manual).
1. The following ECUs can be checked by using the
MUT-II and the SWS monitor.
NOTE: If a malfunction is found by the "ECU
CHECK", proceed "Symptom Procedure" (Refer to
354C).
SWS monitor-compatible ECUs and their conditions

Item
No.
ECUs to be checked
Display on MUT-II Normal

conditions
ECU conditions
80
Column switch (columnECU)
COLUMN ECU
OK*1
All of the column switch, power

supply, earth and interconnecting
communication line are normal
83
ETACS-ECU
ETACS ECU
OK
All of the ETACS-ECU switch,

power supply, earth and
interconnecting communication line
are normal
84
Front-ECU
FRONT ECU
OK*2
All of the front-ECU, power supply,

earth and interconnecting
communication line are normal
85
Power window main

switch (power window
module)
P/W MODULE
OK*2 (when All of the power window main

switch, power supply, earth and
the ignition
switch is ON) interconnecting communication line
are normal
Other SWS-related ECUs
Other ECUs
NG
ECUs are not used
54C-9
TROUBLESHOOTING
NOTE: .
*1: If "NG" is displayed beside the ETACS-ECU while the ignition switch is off, "NG" is also displayed
beside the column-ECU.
*2: If "NG" is displayed beside the ETACS-ECU, "NG" is also displayed beside the front-ECU and the
power window main switch (power window module).
DATA LIST CHECK

M1549015000327
1. Use the MUT-II and the SWS monitor to check

"DATA LIST." This "DATA LIST" check is
applicable for signals, which are transmitted and
received through the SWS communication line
and the communication lines routed from one
door to another. For the input signals which are
not applicable for the SWS monitor check, refer to
pulse check procedure 354C.
NOTE: If a problem is found in the "DATA LIST"

check, refer to the Problems during Input Signal
Check <Service data, function diagnosis or pulse
check> (Refer to 354C).
2. The following input signals can be checked by
using the MUT-II and the SWS monitor.

Column switch (column-ECU)
Item No. Check items Display on
MUT-II
Check conditions
Normal condition
00
lighting switch: HEAD
ON
lighting switch: Other than HEAD
OFF
01
02
03
05
06
07
08
09
10
Headlamp
switch
HEADLAMP
SW
Tail lamp
switch
TAIL LAMP SW Lighting switch: TAIL
Dimmer
switch
DIMMER SW
Passing lamp PASSING SW

switch
ON
Lighting itch: OFF
OFF
Dimmer switch: ON
ON
Dimmer switch: OFF
OFF
Passing lamp which: ON
ON
Passing lamp which: OFF
OFF
Windshield
intermittent
wiper switch
INT WIPER SW Wiper switch: INT
Windshield
low-speed
wiper switch
LO WIPER SW Wiper switch: LO
Windshield
high-speed
wiper switch
HI WIPER SW
Wind shield
mist wiper
switch
MIST WIPER
SW
Windshield
washer
switch
FRONT WASH. Windshield washer switch: ON

SW
Windshield washer switch: OFF
ON
Turn-signal
lamp switch
(RH)
TURN SIG. RH Turn-signal lamp switch: RH
ON
Wiper switch: Other than INT
ON
OFF
ON
Wiper switch: Other than LO
OFF
Wiper switch: HI
ON
Wiper switch: Other than HI
OFF
Wiper switch: Mist
ON
Wiper switch: Other than mist
OFF
Turn-signal lamp switch: Other than RH
OFF
OFF
54C-10
TROUBLESHOOTING

MUT-II
11
13
14
15
Check conditions
Turn-signal
lamp switch
(LH)
TURN SIG. LH Turn-signal lamp switch: LH
Rear wiper
switch
REAR WIPER
SW
Rear washer REAR WASH.

switch
SW
Normal condition
ON
Turn-signal lamp switch: Other than LH
OFF
Rear wiper switch: INT
ON
Rear wiper switch: Other than INT
OFF
Rear wiper switch: Washer
ON
Rear wiper switch: Other than washer
OFF
With or
INT WIP KNOB Vehicles with intermittent wiper control
without
Vehicles without intermittent wiper control
windshield
intermittent
wiper control
EQUIP
Headlamp
washer
switch
Headlamp washer switch: ON
ON
Headlamp washer switch: OFF
OFF

MUT-II
Check conditions
Normal
conditions
30
Ignition switch: ON or START
ON
Ignition switch: LOCK (OFF) or ACC
OFF
Ignition switch: ACC or ON
ON
Ignition switch: LOCK (OFF) or START
OFF
16
HD WASHER
SW
NONE
ETACS-ECU
31
32
Ignition
switch (IG1)
IG SW(IG1)
Ignition
IG SW(ACC)
switch (ACC)
Drivers door DR DOOR SW Driver's door switch ON (The drivers door

switch
is open).
ON
Driver's door switch OFF (The driver's door OFF

is closed).
33
35
36
Reception of P/W SW
power
ACCEPT
window
switch
Headlamp
automatic
shutdown
function
Request of
fog lamp
illumination
Ignition switch: from ON or START to LOCK from PERMIT to

(OFF) or ACC
PROHIBIT (after
approximately 30
seconds)
HD AUTO-CUT 1. Lighting switch: Other than OFF

2. Ignition switch: from ON or START to
LOCK (OFF) or ACC
3. Driver's door switch: ON (driver's door
open)
F.FOG LAMP
PERMIT
OFF to ON (after
approximately one
second)
When requirements for the headlamp

automatic shutdown are not satisfied
OFF
1. Lighting switch: "TAIL" or "HEAD"

2. Fog lamp switch: ON
ON
Other than the conditions above
OFF
54C-11
TROUBLESHOOTING

MUT-II
Check conditions
Normal
conditions
37
Windshield
INT WIPE
intermittent
TIME
wiper interval
1. Ignition switch: ACC or ON

2. Operate the intermittent wiper control,
and change the wiper interval
The MUT-II
displays
intermittent wiper
interval in
response to the
intermittent wiper
control positions
41
Back-up
lamp switch
INHIBITOR SW Back-up lamp switch: ON
Buzzer
BUZZER
ON
Back-up lamp switch: OFF
OFF
1. Ignition switch: LOCK (OFF)

2. Tail lamp or headlamp switch: ON
3. Drivers door switch: ON (drivers door
open)
ON
When requirements for sounding each

warning buzzer are not satisfied
OFF

MUT-II
Check conditions
Normal
conditions
70
lighting switch: Other than OFF (excluding

when high-beam is on) or the wiper switch
is at position other than OFF
Normal response

Lighting switch: OFF
lightingr switch: OFF
SLEEP
RESPONSE
Lamping switch: HEAD

Headlamps: at high beam
HI BEAM
RESPONSE
No response
43
Front-ECU
Response by Front ECU

the frontresponse
ECU
NOTE: For item number 70, the MUT-II also displays "NG" under the "ECU Check" when it displays "No
response" under the front-ECU check.
54C-12
TROUBLESHOOTING
Power window main switch (power window module)

MUT-II
71
Response
from power
window
module
Check conditions
P/W ECU ACK Ignition switch: ON or START
Normal
conditions
NORMAL ACK
1. Ignition switch: ON or START

INPUT CHECK
2. Operate any switch of the power window (only momentarily
main switch.
when switch is
operated)
NO ACK
NOTE: For item number 71, the MUT-II also displays "NG" under the "ECU CHECK" when it displays "NO
ACK" under the "P/W ECU ACK" check.
Communication between doors
MUT-II
C0
C1
C2
C4
C5
C6
C8
Check conditions
Front
passengers
power
window UP
switch
PASS DOR UP Front passengers power window switch:

UP
Front
passengers
power
window
DOWN
switch
PASS DOR
DOWN
Front
PASS DOR
passengers AUTO
power
window
AUTO switch
Rear right
power
window UP
switch
REAR RH UP
Rear right
power
window
DOWN
switch
REAR RH
DOWN
Normal
conditions
ON
Front passengers power window switch:

Other than "UP"
OFF

DOWN
ON

Other than "DOWN"
OFF

AUTO
ON

Other than "AUTO"
OFF
Rear right power window switch: UP
ON
Rear right power window switch: Other than OFF

"UP"
Rear right power window switch: DOWN
ON

"DOWN"
Rear right
REAR RH
power
AUTO
window
AUTO switch
Rear right power window switch: AUTO
Rear left
power
window UP
switch
Rear left power window switch: UP
ON
Rear left power window switch: Other than

"UP"
OFF
REAR LH UP
ON

"AUTO"
54C-13
TROUBLESHOOTING

MUT-II
Check conditions
Normal
conditions
C9
Rear left power window switch: DOWN
ON

"DOWN"
OFF
Rear left power window switch: AUTO
ON

"AUTO"
OFF
CA
CB
CD
CE
CF
Rear left
power
window
DOWN
switch
REAR LH
DOWN
Rear left
REAR LH
power
AUTO
window
AUTO switch
Power
window lock
switch
P/W LOCK SW Power window lock switch: ON
Multi-stop
MLT-MODE
STOP
ON
Power window lock switch: OFF
OFF
1. When multimode is working

2. Either function of keyless entry
transmitter: ON
ON (only
momentarily when
switch is operated)
Other than the conditions above
OFF
Reception of P/W SW
power
RECEPT
window
switch
PERMIT
Ignition
switch (IG1)
ON
Ignition switch: LOCK (OFF) or ACC
OFF
IG1
Ignition switch: from ON or START to LOCK from PERMIT to

(OFF) or ACC
PROHIBIT (after
approximately 30
seconds)
NOTE: Service data of door communication will be sent from the power window main switch to the door
communication line. Therefore, the display will remain "OFF" unless the probe is inserted.
54C-14

TROUBLESHOOTING
FUNCTION DIAGNOSIS
The table below shows the service data and their
normal condition, which are displayed during the
"FUNCTION DIAG." The row "Normal conditions"
shows values, which are shown when each operation
is made.
Wiper
Item
Input signals
Item No. Display on MUT-II
Normal conditions
F.WIPER INT
(intermittent)
Windshield
intermittent wiper
switch
05
INT WIPER SW
ON
06
Windshield lowspeed wiper switch
LO WIPER SW
OFF
Windshield high07
speed wiper switch
HI WIPER SW
OFF
Wind shield mist

wiper switch
MIST WIPER SW
OFF
Windshield washer 09
switch
FRONT WASH. SW
OFF
Ignition switch
(ACC)
31
IG SW(ACC)
ON
Windshield
intermittent wiper
interval
37
WIPER INT TIME
The MUT-II displays

intermittent wiper interval in
response to the intermittent
wiper control positions
Response by the
front-ECU
70
FRONT ECU ACK
NORMAL ACK or HI-BEAM

ACK
Windshield
intermittent wiper
switch
05
INT WIPER SW
OFF
Windshield low06
speed wiper switch
LO WIPER SW
ON
07
Windshield highspeed wiper switch
HI WIPER SW
OFF
Wind shield mist

wiper switch
MIST WIPER SW
OFF
FRONT WASH. SW
OFF
F.WIPER LO
(low speed)
08
08
switch
Ignition switch
(ACC)
31
IG SW(ACC)
ON
Response by the
front-ECU
70
FRONT ECU ACK

ACK

TROUBLESHOOTING
54C-15
Item
Input signals
Normal conditions
F.WIPER HI
(high speed)
Windshield
intermittent wiper
switch
05
INT WIPER SW
OFF
Windshield low06
speed wiper switch
LO WIPER SW
OFF
Windshield high07
speed wiper switch
HI WIPER SW
ON
Wind shield mist

wiper switch
MIST WIPER SW
OFF
switch
FRONT WASH. SW
OFF
Ignition switch
(ACC)
31
IG SW(ACC)
ON
Response by the
front-ECU
70
FRONT ECU ACK

ACK
F.WIPER MIST Windshield

intermittent wiper
switch
05
INT WIPER SW
OFF
Windshield low06
speed wiper switch
LO WIPER SW
OFF
Windshield high07
speed wiper switch
HI WIPER SW
OFF
Wind shield mist

wiper switch
MIST WIPER SW
ON
switch
FRONT WASH. SW
OFF
Ignition switch
(ACC)
31
IG SW(ACC)
ON
Response by the
front-ECU
70
FRONT ECU ACK

ACK
Wind shield mist

wiper switch
08
MIST WIPER SW
OFF
switch
FRONT WASH. SW
ON
Ignition switch
(ACC)
31
IG SW(ACC)
ON
Response by the
front-ECU
70
FRONT ECU ACK

ACK
Headlamp washer
switch
16
HD WASHER SW
ON
Ignition switch
(ACC)
31
IG SW(ACC)
ON
Response by the
front-ECU
70
FRONT ECU ACK

ACK
F.WIPER
WASH
HD WASHER
08
08
54C-16

TROUBLESHOOTING
Rear wiper
Item
Input signals
Normal conditions
REAR WIPER
Rear wiper switch
13
REAR WIPER SW
ON
Rear washer switch 14
REAR WASH. SW
OFF
Ignition switch
(ACC)
31
IG SW(ACC)
ON
Rear wiper switch
13
REAR WIPER SW
ON
Ignition switch
(ACC)
31
IG SW(ACC)
ON
Back-up lamp
switch
41
INHIBITOR SW
ON
Rear washer switch 14
REAR WASH. SW
ON
Ignition switch
(ACC)
31
IG SW(ACC)
ON
Item
Input signals
Normal conditions
OFF
Headlamp switch
00
HEADLAMP SW
OFF
Tail lamp switch
01
TAIL LAMP SW
OFF
Passing lamp
switch
03
PASSING SW
OFF
Ignition switch
(IG1)
30
IG SW(IG1)
ON
Headlamp
automatic
shutdown function
35
HD AUTO-CUT
OFF
Response by the
front-ECU
70
FRONT ECU ACK

ACK
Headlamp switch
00
HEADLAMP SW
OFF
Tail lamp switch
01
TAIL LAMP SW
ON
Passing lamp
switch
03
PASSING SW
OFF
Ignition switch
(IG1)*
30
IG SW(IG1)
ON
Headlamp
automatic
shutdown function
35
HD AUTO-CUT
OFF
Response by the
front-ECU
70
FRONT ECU ACK
NORMAL ACK
REV.
INTERLOCK
REAR
WASHER
Lighting
TAIL LAMP

TROUBLESHOOTING
Item
Input signals
54C-17
Normal conditions
00
HEADLAMP SW
ON
03
PASSING SW
OFF
Ignition switch
(IG1)
30
IG SW(IG1)
ON
Headlamp
automatic
shutdown function
35
HD AUTO-CUT
OFF
Response by the
front-ECU
70
FRONT ECU ACK
NORMAL ACK
HEADLAMP HI Headlamp switch

(high-beam)
Dimmer switch
00
HEADLAMP SW
ON
02
DIMMER SW
ON
Ignition switch
(IG1)
30
IG SW(IG1)
ON
Headlamp
automatic
shutdown function
35
HD AUTO-CUT
OFF
Response by the
front-ECU
70
FRONT ECU ACK
HI-BEAM ACK
Passing lamp
switch
03
PASSING SW
ON
Response by the
front-ECU
70
FRONT ECU ACK

ACK
Headlamp switch
00
HEADLAMP SW
Either of items is ON
Tail lamp switch
01
TAIL LAMP SW
Ignition switch
(IG1)
30
IG SW(IG1)
ON
Headlamp
automatic
shutdown function
35
HD AUTO-CUT
OFF
Request of fog
lamp illumination
36
F.FOG LAMP
ON
Response by the
front-ECU
70
FRONT ECU ACK
NORMAL ACK
Headlamp switch
00
HEADLAMP SW
ON
Tail lamp switch
01
TAIL LAMP SW
ON
Headlamp
automatic
shutdown function
35
HD AUTO-CUT
OFF
Response by the
front-ECU
70
FRONT ECU ACK

ACK
HEADLAMP
Headlamp switch
LO (low-beam) Passing lamp
switch
PASSING
LAMP
F.FOG LAMP
REAR FOG
LAMP
54C-18
Item
TROUBLESHOOTING
Input signals
Normal conditions
00
HEADLAMP SW
Either is on
Tail lamp switch
01
TAIL LAMP SW
Ignition switch
(IG1)
30
IG SW(IG1)
OFF
Drivers door switch 32
DR DOOR SW
ON
Headlamp
automatic
shutdown function
35
HD AUTO-CUT
ON
Response by the
front-ECU
70
FRONT ECU ACK

ACK
HD AUTO-CUT Headlamp switch
NOTE: .
1. When checking the input signals (off, tail, low-beam or high-beam), turn the ignition switch to the "ON"
position in order to disable the headlamp automatic shutdown function. However, the titles on the MUT-II
screen will not be highlamped as this has nothing to do with actual lamp operation.
2. For checking item "HEADLAMP HI", the MUT-II displays "OFF" on the item No.2 "DIMMER SW" when the
headlamps are at high-beam. Therefore, the MUT-II should display "ON" momentarily when the dimmer
switch is operated.
Turn signal lamp
Item
Input signals
Normal conditions
Turn-signal
lamp (RH)
Turn-signal lamp
switch (RH)
10
TURN SIGNAL RH SW
ON
Turn-signal lamp
switch (LH)
11
TURN SIGNAL LH SW
OFF
Ignition switch
(IG1)
30
IGNITION SW IG1
ON
Turn-signal lamp
switch (RH)
10
TURN SIGNAL RH SW
OFF
Turn-signal lamp
switch (LH)
11
TURN SIGNAL LH SW
ON
Ignition switch
(IG1)
30
IGNITION SW IG1
ON
Turn-signal
lamp (LH)

TROUBLESHOOTING
54C-19
Buzzer
Item
Input signals
Normal conditions
00
HEADLAMP SW
Either is on
01
TAIL LAMP SW
30
IGNITION SW IG1
OFF
Drivers door switch 32
DRIVER DOOR SW
ON
Headlamp
automatic
shutdown function
35
HD LAMP AUTOCUT
OFF
Buzzer
43
Buzzer
ON
Lamping
Headlamp switch
monitor buzzer Tail lamp switch
Ignition switch
(IG1)
NOTE: The headlamp automatic shutdown function works in approximately one second after the lamping
monitor buzzer starts sounding, and then the buzzer ceases sounding.
PULSE CHECK
M1549015100313
CAUTION
NOTE: If a problem is found in the "Pulse Check",

refer to the Problems during Input Signal Check
<Service data, function diagnosis or pulse
check> (Refer to 354C).
2. Use the MUT-II or voltmeter to check the following
input signals.
Before connecting or disconnecting the MUT-II,

turn the ignition switch to the "LOCK" (OFF)
position.
1. The input signals (signals other than
communication line signals), which are
compatible with the SWS monitor by using the
MUT-II or voltmeter, can be confirmed by the
Pulse Check.
Switches which are applicable to input signal check, and their check conditions
Input signals
Key reminder switch <vehicles with keyless entry system>
When the inserted ignition key is pulled out.
Hazard warning lamp switch
When the switch is turned from off to on.

A door is opened when all the doors are

closed.
When the drivers key cylinder or inside lock

knob is unlocked or locked.
When the vehicle speed has reached 10 km/

h or more.

Switches
When the switch is turned from off to on.

When a load is applied through multipurpose fuse No.18.
54C-20

MUT-II drive recorder function

M1549017800125
1. The SWS monitor cartridge memory can store the

ECU check results, the service data, the
communication data obtained by the function
diagnosis. This communication data can be
displayed as a chart or graphical form.
2. If data obtained by the drive recorder function has

to be stored for long time, the data can be
transferred to the SWS monitor cartridge. By
doing this, you can disconnect the MUT-II to
prevent excessive battery drain.
NOTE: For the details about the MUT-II drive
recorder function, refer to MUT-II reference
manual.

M1549000800587
Symptom
Inspection
procedure
number
Reference
page
Communication with the SWS monitor is impossible.
A-1
354C
Communication with the column switch (column-ECU) is impossible.
A-2
354C
Communication with the ETACS-ECU is Impossible.
A-3
354C
Communication with the front-ECU is Impossible.
A-4
354C
Communication with the power window main switch (power window

module) is Impossible.
A-5
354C
Inspection
procedure
number
Reference
page
<Function system>
Symptom
Alarm Function
Lamp reminder buzzer function does not

work normally.
B-1
354C

<LH drive vehicles>
354C

<RH drive vehicles>
354C
A door or a tailgate can not be locked or

unlocked by the central door locking
system. <LH drive vehicles>
C-2
354C
A door or a tailgate can not be locked or

unlocked by the central door locking
system. <RH drive vehicles>
C-2
354C
The Ignition Key Reminder Function does

not Work Normally.
C-3
354C
The impact detection door unlock function

does not function.
C-4
354C

Symptom
Power window
Windshield wiper and

washer
54C-21
Inspection
procedure
number
Reference
page
Power windows do not work at all.
D-1
354C
Drivers power window does not work by

D-2
354C
Relevant power window(s) do not work by

means of the front and rear passengers
power window sub switches.
D-3
354C
Front and/or rear passengers power

window(s) do not work by means of the
power window main switch.
D-4
354C
The window glass lowers automatically

while it is rising.
D-5
354C
Power window anti-trap function does not

work normally.
D-6
354C
Keyless entry system does not work.
E-1
354C
Keyless entry hazard warning lamp

answerback function or the room lamp
answerback function does not work
normally.
E-2
354C
Encrypted code cannot be registered.
E-3
354C
The timer lock function does not work after E-4

the doors have been unlocked by the
keyless entry system.
354C
The windshield wipers do not work at all.
F-1
354C
The windshield wipers do not work when

F-2
the wiper switch is at "INT", "Washer" or
"Mist" position. However, the wipers work
at low speed when the switch is at "Lo" and
"Hi" position.
354C
The windshield wipers do not stop at the

F-3
354C
The windshield wipers do not work

normally.
F-4
354C
The intermittent wiper interval cannot be

F-5
354C
The intermittent wiper interval is not

changed according to the vehicle speed.
F-6
354C
The windshield washer does not work.
F-7
354C
54C-22

Symptom
Inspection
procedure
number
Reference
page
Rear wiper does no not work at all.
G-1
354C
The rear wiper does not stop at the

G-2
354C
When the shift lever is moved to "R"

position during the rear wiper operation,
the rear wiper does not operate at the
continuous mode.
G-3
354C
The rear washer does not work.
G-4
354C
Headlamp washer
The headlamp washer does not work.
H-1
354C

illumination lamp
The ignition key cylinder illumination lamp

does not illuminate/extinguish normally.
I-1
354C
The headlamps do not illuminate when the J-1

lighting switch is at "TAIL" or "PASSING"
position, but illuminate only at low beam
when the switch is at "HEAD" position.
However, the headlamps do not illuminate
at high beam.
354C
The tail lamps do not illuminate normally.
J-2
354C
The low-beam headlamps do not illuminate J-3

normally.
354C
The high-beam headlamps do not

J-4
354C
The high-beam and low-beam headlamps

do not illuminate when the passing switch
is operated.
J-5
354C
The headlamp automatic shutdown

function does not work normally.
J-6
354C
Any of tail lamps, position lamps or licence J-7

plate lamp does not illuminate.
354C
Either of the headlamps or high-beam

indicator lamps does not illuminate.
J-8
354C
The turn-signal lamps do not illuminate.
K-1
354C
The hazard warning lamps do not

illuminate.
K-2
354C
Any of the turn-signal lamps does not

illuminate.
K-3
354C
The front fog lamps do not illuminate

normally.
L-1
354C
The rear front fog lamps do not illuminate

normally.
L-2
354C
Either of the front fog lamps does not

L-3
354C
Any of the rear fog lamps does not

illuminate.
L-4
354C
Flasher timer
Fog lamp

Symptom
Interior lamp
Inspection
procedure
number
54C-23
Reference
page

M-1
without keyless entry system>
354C

M-2
354C
Interior lamp automatic shutoff function

does not work normally. <Vehicles with
M-3
354C
The door-ajar warning lamp does not

illuminate/extinguish normally.
M-4
354C

M1549024200136
<Pulse check>
If a problem is found in the Service Data or Pulse
Check inspection, observe the table below.
Symptom
Inspection
procedure
number
Reference
page
The ignition switch (ACC) signal is not received.
N-1
354C
The ignition switch (IG1) signal is not received.
N-2
354C
The back-up lamp switch signal is not received.
N-3
354C
The drivers door switch signal is not received.
N-4
354C
Column switch (lighting and turnsignal lamp switch)
N-5
354C
The tail lamp switch signal is not

received.
The headlamp switch signal is not
received.
The dimmer switch signal is not
received.
The passing switch signal is not
received.
The turn-signal lamp switch (LH)
The turn-signal lamp switch (RH)
The headlamp washer switch signal
is not received.
54C-24

Symptom
Column switch (windshield wiper/

washer and rear wiper washer
switch)
Inspection
procedure
number
Reference
page
N-6
354C
N-7
354C
When the power window main switch N-8

is operated, the switch signals are
not received.
354C
The windshield mist wiper switch

The windshield low-speed wiper
The windshield high-speed wiper
The windshield washer switch signal
is not received.
The rear wiper switch signal is not
received.
The rear washer switch signal is not
received.
volume signal is not received.
The front fog lamp switch signal is not received.
N-9
354C
The rear fog lamp switch signal is not received.
N-10
354C
The key reminder switch signal is not received.
N-11
354C
The hazard warning lamp switch signal is not received.
N-12
354C
All the door switch signals are not received.
N-13
354C
The drivers door lock actuator switch signal is not received.
N-14
354C
The vehicle speed signal is not received.
N-15
354C
Each switch signal of the keyless entry transmitter is not received.
N-16
354C
The interior lamp loaded signal is not detected.
N-17
354C
The passengers door lock key cylinder switch signal is not detected.
N-18
354C
54C-25
OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION PROCEDURES
OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL

INSPECTION PROCEDURES
M1549020300186
If troubles have occurred in the functions which use

the SWS simultaneously, observe the table below to
check input signals.
(This table shows only the input signals which will

cause troubles in at least two functions
simultaneously).
Function
N-1
N-2
N-4
N-5
N-6
N-11
N-13
N-14
N-15
N-17
Control of central door

locking
Door locking released due to impact detection.
Keyless entry hazard

warning lamp answerback
Power window control
Control of windshield wiper

washer
Rear wiper washer control

illumination lamp function
Headlamp control
Tail lamp control
Headlamp automatic
shutdown function
Fog lamp control
Turn-signal lamp control
Dome lamp control
Interior lamp automatic

shutdown function
54C-26

SYMPTOM PROCEDURES
SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-1: Communication with the SWS monitor is impossible.
CAUTION
MUT-II Communication and ETACS-ECU Earth Circuit
ETACSECU
DIAGNOSIS
CONNECTOR
Wire colour code

The SWS monitor may be connected improperly.
Possible causes
Malfunction of the SWS monitor body (I/F
cartridge)
FRONT SIDE
DIAGNOSIS
CONNECTOR
FRONT SIDE
Malfunction of the SWS monitor harness


SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
54C-27

Step 1. Check that the MUT-II communicates with

the other systems.
Use the MUT-II to confirm that it communicates with
the engine-ECU.
Connector: C-219

YES : Go to Step 2.
NO : Diagnose the engine control system. Refer
to 313A.
Harness side
C-219(GR)
Step 2. Check that the MUT-II can communicate

with the system.
When the ignition switch is turned ON, check if the
MUT-II can communicate with the system.
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE


YES : Refer to Inspection Procedure A-3
"Communication with ETACS-ECU is

impossible 354C."
NO : Go to Step 3.
connector
Connector C-219
(Harness side)
AC301541AY
Connector: C-219

OK: 2 W or less
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 4.

YES : Go to Step 6.
NO : Go to Step 5.

earth.
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE


54C-28

SYMPTOM PROCEDURES
Step 6. Connector check: C-24 diagnosis

connector
Connector: C-24

C-24 diagnosis connector terminal Nos. 9 and 1.
Connector: C-24
Harness side
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Harness side
C-24(B)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC301395 AF
C-24(B)
AC301395 AF

YES : Go to Step 7.
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE


SYMPTOM PROCEDURES
54C-29
INSPECTION PROCEDURE A-2: Communication with the column switch (column-ECU) is not
possible.
CAUTION
Column Switch Power Supply and SWS Communication Circuit
FUSIBLE
LINK 1
IGNITION
SWITCH (IG1)
COLUMN-ECU
ETACS-ECU
COLUMN
SWITCH
DIAGNOSIS
CONNECTOR
FRONT SIDE

The power supply circuit to the column switch
(column-ECU) may be defective. If the wiring
harness of the battery power supply circuit for the
ECU (column switch terminal No.1) is defective, also
check the power supply circuit to the ignition switch
(IG1) (column switch terminal No.9) and repair if
necessary.
Wire colour code

B : Black
LG : Light green
G : Green
L: Blue
W : White
Y: Yellow
SB : Sky blue
BR : Brown
O : Orange
GR : Gray
R : Red
P : Pink
V : Violet
54C-30

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 1. ECU check on the SWS monitor
Check that the power supply and earth lines to the
ETACS-ECU and the SWS communication lines are
normal.
Step 3. Measure the voltage at C-310 column

switch connector.
Connector: C-310
Harness side
ECUS TO BE CHECKED
ETACS ECU
OK: "OK" is displayed on the "ETACS ECU"
menu.
YES : Go to Step 2.
NO : Refer to Inspection Procedure A-3

impossible 354C."
5 4 3 2 1
10 9 8 7 6
AC301399 AC

Connector C-310
(Harness side)

connector
YES : Go to Step 3.
5 4 3 2 1
10 9 8 7 6
AC301541BD
(2) Voltage between C-310 column switch connector

No.1 and body earth
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.
54C-31
SYMPTOM PROCEDURES

column switch connector terminal No.1 and
fusible link (1).
NOTE:
Fusible link: No.1
C-02
C-116
C-02
AC301515 AB
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
2324 25 2627 28 2930 3132 33
Connector: C-310
C-116
1 2
Harness side
5 6 7
3 4
8 9
10 1112 1314
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
1617 18 19 20 21
5 4 3 2 1
10 9 8 7 6
AC301399 AC
AC301396 AM

C-204(B)
C-202
Harness side
C-202
6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-204
1
AC210475 AL

intermediate connector C-116, joint connector C-02,
junction block connectors C-202 and C204, and
54C-32
SYMPTOM PROCEDURES



column switch connector No.4 and body earth
Connector: C-310
Step 5. Measure the resistance at C-310 column

switch connector.
Harness side
Connector: C-310
5 4 3 2 1
10 9 8 7 6
AC301399 AC
Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC



connector
Connector C-310
(Harness side)
Connector: C-219
5 4 3 2 1
10 9 8 7 6
Harness side
AC301541BE
(2) Continuity between C-310 column switch

connector No.4 and body earth
OK: 2 W or less
YES : Go to Step 7.
NO : Go to Step 6.
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 8.

SYMPTOM PROCEDURES

and 2.
Connector: C-219
54C-33

ECUS TO BE CHECKED
COLUMN ECU
OK: "OK" is displayed on the "COLUMN
ECU" menu.
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

Check that the ETACS-ECU communicates with the
column switch.
Connector: C-310

Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC
NOTE:
Connector: C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
AC301395 AC

YES : Go to Step 9.
54C-34

SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-3: Communication with the ETACS-ECU is not possible.
CAUTION
Etacs-ECU Power Supply and SWS Communication Circuit
IGNITION
SWITCH (IG1)
FUSIBLE
LINK 1
ETACSECU
POWER
SOURCE
Wire colour code

G : Green L : Blue
DIAGNOSIS
CONNECTOR
COLUMN-ECU
COLUMN
SWITCH
FRONT SIDE

ETACS-ECU is defective, or the wiring harness
between the SWS monitor and the ETACS-ECU or
their connector(s) is damaged. If the battery power
supply circuit to the ECU (terminal No.20 of the
ETACS-ECU) is damaged, also check the power
supply circuit from the ignition switch (IG1) (terminal
No.8 of the ETACS-ECU), and repair if necessary. If

the earth circuit to the ECU (terminal No.3 of the
ETACS-ECU) is defective, also check the earth
circuit to the sensor (terminal No.56 of the ETACSECU), and repair if necessary.
54C-35
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
connector

ETACS-ECU connector terminal No.20 and
fusible link (1).
Fusible link: No.1
Connector: C-217
Junction block side

AC301515 AB
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 2.
Connector: C-217
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
Connector: C-217
AC210476 AC
NOTE:
Connector: C-116
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG
Connector: C-204
Connector C-217
C-204(B)
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
AC301541AS

OK: System voltage
YES : Go to Step 4.
NO : Go to Step 3.
1
AC210474 AD

54C-36

SYMPTOM PROCEDURES



earth.
Connector: C-217

Connector: C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
NOTE:
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
Connector: C-205
AC210476 AC

Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
Connector C-217
AC210474 AE

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC301541AT

OK: 2 W or less
YES : Go to Step 6.
NO : Go to Step 5.


54C-37
SYMPTOM PROCEDURES

connector and C-310 column switch connector
Connector: C-219

and 2.
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE
Harness side
C-219(GR)
Connector: C-310
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
Connector: C-310
Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC

YES : Go to Step 7.
Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC

YES : Go to Step 8.

ECUS TO BE CHECKED
ETACS ECU
menu.

54C-38
SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-4: Communication with the front-ECU is not possible.
CAUTION
Front-ECU Power Supply and SWS Communication Circuit
IGNITION
SWITCH (IG2)
RELAY BOX
(FUSE 22 )
FRONT-ECU
POWER
SOURCE
DIAGNOSIS
CONNECTOR
ETACS-ECU
FRONT SIDE
Wire colour code


front-ECU is defective, or the wiring harness
between the SWS monitor and the front-ECU or their
connector(s) is damaged. If the battery power supply
SB : Sky blue
circuit to the ECU (terminal No.5 of the front-ECU) is

damaged, also check the power supply circuit from
the ignition switch (IG2) (terminal No.22 of the frontECU), and repair if necessary.
54C-39
SYMPTOM PROCEDURES
Possible causes

connector.
Connector: A-11X
DIAGNOSIS PROCEDURE
normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 2.
Relay box side

11 10 9 8 7 6 5 4 3 2 1

impossible 354C."
AC301483 AD

connector
Connector: A-11X

relay box side.
Connector A-11X
(Relay box side)
11 10 9 8 7 6 5 4 3 2 1
AC301541AF

No.5 and body earth
OK: System voltage
Relay box side

YES : Go to Step 6.
NO : Go to Step 4.
11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

YES : Go to Step 3.
54C-40
SYMPTOM PROCEDURES

battery.

connector
Connector: A-12X
Connector: A-11X
Relay box side

Relay box side
3130 29 2827 26 25 24 2322 21
11 10 9 8 7 6 5 4 3 2 1
AC301483 AE
AC301483 AD



YES : Go to Step 6.
54C-41
SYMPTOM PROCEDURES
Step 6. Measure the resistance at A-12X frontECU connector.

Connector: A-12X

front-ECU terminal connector No.21 and body
earth.
Connector: A-12X
Relay box side

Relay box side
3130 29 2827 26 25 24 2322 21
3130 29 2827 26 25 24 2322 21
AC301483 AE

relay box side.
AC301483 AE


Connector A-12X
(Relay box side)
31 30 29 2827 26 25 24 2322 21

connector
AC301541AG
Connector: C-219
(2) Resistance between A-12X front-ECU connector

OK: 2 W or less
YES : Go to Step 8.
NO : Go to Step 7.
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 9.
54C-42
SYMPTOM PROCEDURES

front-ECU connector terminal No.30 and C-219
ETACS-ECU connector terminal No.59.
NOTE:
Connector: A-12X
C-02
C-116
C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
2324 25 2627 28 2930 3132 33
C-116
Relay box side
1 2
3130 29 2827 26 25 24 2322 21
5 6 7
3 4
8 9
10 1112 1314
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
1617 18 19 20 21
AC301396 AM
AC301483 AE
Connector: C-219

Harness side
C-219(GR)

59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

front-ECU and the SWS communication lines are
normal.
Ignition switch: ON
ECUS TO BE CHECKED
FRONT ECU
OK: "OK" is displayed on the "FRONT ECU"
menu.


SYMPTOM PROCEDURES
54C-43
INSPECTION PROCEDURE A-5: Communication with the power window main switch (power window
module) is Impossible.
CAUTION
Power Window Main Switch and SWS Communication Circuit
FUSIBLE
LINK 5
ETACS-ECU
POWER
WINDOW RELAY
FRONT SIDE
DIAGNOSIS
CONNECTOR
POWER WINDOW
MAIN SWITCH
Wire colour code

SB : Sky blue
54C-44
SYMPTOM PROCEDURES

The power window main switch, the power supply
circuit (power window relay driving circuit) or
communication circuit for that switch may be
defective.
Possible causes

Connector: E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
DIAGNOSIS PROCEDURE
AC301418 AC

normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 2.

impossible 354C."

YES : Go to Step 4.

Connector: E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC
Step 2. Check the data list by using the SWS

monitor.
<Selected item> ETACS ECU
Ignition switch: ON
Item No.
Item name
Normal
conditions
Item 30
IG SW(IG1)
ON

Connector E-05
(Harness side)
OK: Normal condition is displayed.

YES : Go to Step 3.

354C."
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301541BH

OK: System voltage
NO : Go to Step 5.
54C-45
SYMPTOM PROCEDURES

relay connector
Connector: C-208
Step 7. Measure the voltage at C-208 power

Connector: C-208
Junction block side
Junction block side
3 2 1
4
5
3 2 1
4
5
AC210474 AF

YES : Go to Step 6.
Step 6. Check the power window relay.

YES : Go to Step 7.
NO : Replace the power window relay.
AC210474 AF
(1) Remove the power window relay, and measure at

the junction block side.
Connector C-208
3 2 1
4
5
AC301541BO
(2) Voltage between C-208 power window relay

OK: System voltage
YES : Go to Step 9.
NO : Go to Step 8.
54C-46
SYMPTOM PROCEDURES

fusible link (5).
Fusible link: No.5


Step 9. Measure the resistance at C-208 power
Connector: C-208
AC301515 AC

Junction block side

3 2 1
4
5
C-203
AC210474 AF
(1) Remove the power window relay, and measure at

the junction block side.
C-208
3 2 1
4
5
Harness side
Junction block side
C-203
C-208
3 2 1
4
5
2
1
6 5 4 3
AC210475 AI
NOTE:
Connector: C-116
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG

Connector C-208
AC301541BP
(2) Resistance between C-208 power window relay

OK: 2 W or less
NO : Go to Step 10.
54C-47
SYMPTOM PROCEDURES

body earth.

terminal No.6.
C-203
C-205
C-208
C-208
Harness side
Junction block side
C-205
C-208
3 2 1
4
5
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
Harness side
Junction block side
C-203
C-208
3 2 1
4
5
2
1
6 5 4 3
AC210475 AP

necessary.
AC210475 AI

E-05

connector
Connector: C-217
E-12
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

AC301419 AC
54C-48
SYMPTOM PROCEDURES
NOTE:
Step 13. Measure the resistance at the E-05

power window main switch connector.
Connector: C-118
Connector: E-05
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
Harness side
AC301395 AH

6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC



Connector E-05
(Harness side)
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301541BI
(2) Resistance between E-05 power window main

OK: 2 W or less
54C-49
SYMPTOM PROCEDURES


connector
Connector: C-219
E-05
Harness side
C-219(GR)
E-12
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC
NOTE:
Connector: C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301395 AH

if necessary.


54C-50
SYMPTOM PROCEDURES

No.4.
NOTE:
C-02
Connector: C-219
C-118
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
E-05
AC301396 AG

E-12
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC


power window main switch (power window module)
and the SWS communication lines are normal.
Ignition switch: ON
ECUS TO BE CHECKED
P/W MODULE
OK: "OK" is displayed on the "P/W
MODULE" menu.


SYMPTOM PROCEDURES
54C-51
TONE ALARM
INSPECTION PROCEDURE B-1: Lamp reminder buzzer function does not work normally.
CAUTION
Lamp Reminder Tone Alarm Function
ETACS-ECU
INPUT SIGNAL
HEADLAMP SWITCH
TAIL LAMP SWITCH

Drivers door switch
Tail lamp switch
Headlamp switch
Possible causes
DIAGNOSIS PROCEDURE
ETACS-ECU and the column switch (column-ECU)
ECUS TO BE CHECKED
ETACS ECU
COLUMN ECU
OK: "OK" is displayed for all the items
"OK" is displayed for all the items : Go to Step 2.
"NG" is displayed on the "ETACS ECU" menu. :
Refer to Inspection Procedure A-3

impossible 354C."
"NG" is displayed on the "COLUMN ECU" menu. :

"Communication with column switch
(column-ECU) is impossible 354C."
54C-52
SYMPTOM PROCEDURES
Step 2. Function diagnosis by using the SWS

monitor
Check the SWS communication signal, which are
related to the lamp reminder function.
<Selected item> BUZZER - LGT MONI. ALRM
Ignition switch: OFF (key removed)
lighting switch: HEAD
Drivers door: open
Item No.
Item name
Normal
conditions
Item 00
HEADLAMP SW ON when the

lighting switch is
at HEAD
Item 01
TAIL LAMP SW
ON when the
lighting switch is
at TAIL
Item 30
IG SW(IG1)
OFF
Item 32
DR DOOR SW
ON
Item 43
BUZZER
ON
OK: Normal conditions are displayed for all

the items.
Normal conditions displayed for all the items : Go
to Step 3.
Normal condition is not displayed for item No.00 or
No.01 : Refer to inspection procedure N-5 "The

switch) signal is not received 354C."
Normal condition is not displayed for item No.30 :

354C."

354C."
Replace the ETACS-ECU.

The lamp reminder buzzer function should work
normally.


SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-1: Central Door Locking System does not Work.
CAUTION
Central Door Lock Power Supply Circuit

FUSIBLE
LINK 1
ETACS-ECU
DOOR
UNLOCK
RELAY
DOOR
LOCK
RELAY
FRONT
DOOR LOCK
ACTUATOR (LH)
Wire colour code

SB : Sky blue
54C-53
54C-54

SYMPTOM PROCEDURES

If the central door locking system does not work at
all, the front door lock actuator (LH) or the ETACSECU may be defective.
POSSIBLE CAUSES
DIAGNOSIS PROCEDURE
normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 2.

impossible 354C."
Step 2. Pulse check
actuator switch.
System switch
Check conditions
Drivers door lock

actuator switch

knob is unlocked or
locked

Connector: E-11
E-11(B)
Harness side
3 2 1
6 5 4
AC301418 AD

YES : Go to Step 4.

YES : Go to Step 5.

connector
Connector: C-217
Junction block
(Rear view)

needle fluctuates.
YES : Go to Step 3.
drivers door lock actuator signal is not

received 354C."
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB

YES : Go to Step 6.
54C-55
SYMPTOM PROCEDURES

ETACS-ECU connector terminal No.2 and fusible
link (1).
NOTE:
Connector: C-116
Connector: C-217
Junction block
(Rear view)
C-116
1 2
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
5 6 7
3 4
8 9
10 11 12 13 14
15
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301396 AB
Connector: C-204
AC210477 AB
C-204(B)
Fusible link: No.1
Harness side
1
AC210474 AD
AC301515 AB

circuit.
YES : Go to Step 7.

normally.

54C-56

SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-2: A Door or a Tailgate can not be Locked or Unlocked by the Central
Door Locking System.
Central Door Lock Circuit
ETACS-ECU
DOOR
LOCK
RELAY
DOOR
UNLOCK
RELAY
FRONT
DOOR LOCK
ACTUATOR (LH)
FRONT
DOOR LOCK
ACTUATOR
(RH)
REAR
DOOR LOCK
ACTUATOR
(LH)
REAR
DOOR LOCK
ACTUATOR
(RH)
Wire colour code

TAILGATE
LOCK
ACTUATOR
SB : Sky blue
54C-57
SYMPTOM PROCEDURES

If a door or the tailgate can not be locked or unlocked
by the central door locking system, the door lock
actuator or the tailgate lock actuator may be
defective.
POSSIBLE CAUSES
Malfunction of the door lock actuator
Malfunction of the tailgate lock actuator

YES : Go to Step 4.
Step 4. Connector check: C-217, C-220 ETACSECU connector
DIAGNOSIS PROCEDURE
Step 1. Confirm which door lock actuator is

defective.
C-217
Q: Which door fails to lock correctly?

Tailgate : Go to Step 18.

actuator (LH)
Connector: E-11
Junction block
(rear view)
C-220
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
E-11(B)
Harness side
AC210477 AF
3 2 1
6 5 4
AC301418 AD

YES : Go to Step 3.

YES : Go to Step 5.
54C-58
SYMPTOM PROCEDURES

ETACS-ECU connector No.22 to E-11 front door
lock actuator (LH) terminal Nos. 6 and 4.
NOTE:
Connector: C-118
C-217
Junction block
(rear view)
C-118
C-220
1 2 3 4 5 6 7 8 9 10 11
C-217
Junction block side
12 13 14 15 16 17 18 19 20 21 22
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
23 24 25 26 27
28 29 30 31 32
C-220
Harness side
AC301396 AE
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
Connector: C-205
AC210477 AF
Connector: E-11
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
E-11(B)
AC210474 AE
Harness side
3 2 1
6 5 4
AC301418 AD


54C-59
SYMPTOM PROCEDURES

Connector: E-25

E-25 front door lock actuator (RH) connector
Connector: C-217
E-25
Harness side
E-25(B)
3 2 1
6 5 4
AC301412 AF
Junction block
(Rear view)

YES : Go to Step 7.
Step 7. Check the front door lock actuator (RH).

Check that the front door lock actuator (RH) works
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

YES : Go to Step 8.

connector
AC210477 AB
Connector: E-25
Connector: C-217
E-25
Harness side
E-25(B)
3 2 1
6 5 4
Junction block
(Rear view)
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB

YES : Go to Step 9.
AC301412 AF
54C-60

SYMPTOM PROCEDURES
NOTE:
Step 11. Check the rear door lock actuator (RH).

Check that the rear door lock actuator (RH) is in
good condition. Refer to GROUP 42 - Door 342.
Connector: C-15

NO : Replace the rear door lock actuator (RH).
2
1
3 4
5 6
10 11 12
7 8 9
13 14 15 16 17 18 19

connector
C-15(GR)
AC301397AD
Connector: C-217
Connector: C-205
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Junction block
(Rear view)
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE

C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1


AC210477 AB

Connector: E-28
E-28(B)
E-28
Harness side
3 2 1
6 5 4
AC301414 AE


54C-61
SYMPTOM PROCEDURES

E-28 rear door lock actuator (RH) connector
NOTE:
Connector: C-209
Connector: C-217
Harness side
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210474 AG
Junction block
(Rear view)
D-02
C-217
Junction block side
D-31
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
D-02
1
2 3
4 5 6 7 8
AC210477 AB
D-31
Connector: E-28
E-28(B)
E-28
Harness side
1 2
3 4
5 6 7 8 9 10
11 12 13 14 15 16
AC301409 AD
3 2 1
6 5 4
AC301414 AE
Prior to the wiring harness inspection, check D-02,

D-31 intermediate connectors and C-209 junction
block connector, and repair if necessary.

54C-62
SYMPTOM PROCEDURES

Connector: E-08

E-08 rear door lock actuator (LH) connector
Connector: C-217
E-08(B)
E-08
Harness side
3 2 1
6 5 4
AC301416 AE
Junction block
(Rear view)

Step 15. Check the rear door lock actuator (LH).

Check that the rear door lock actuator (LH) is in good
condition. Refer to GROUP 42 - Door 342.
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1

NO : Replace the rear door lock actuator (LH).

connector
AC210477 AB
Connector: E-08
Connector: C-217
E-08(B)
E-08
Harness side
Junction block
(Rear view)
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB

3 2 1
6 5 4
AC301416 AE
54C-63
SYMPTOM PROCEDURES
NOTE:
Step 19. Check the tailgate lock actuator.

Check that the tailgate lock actuator is in good
condition. Refer to GROUP 42 - Tailgate 342.
Connector: C-209

NO : Replace the tailgate lock actuator.
Harness side
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210474 AG

connector
Connector: C-217
Connector: D-26
D-26
1
2 3
4 5 6 7 8
Junction block
(Rear view)
AC301410 AB
Prior to the wiring harness inspection, check D-26

intermediate connectors and C-209 junction block
connector, and repair if necessary.
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1


AC210477 AB
Step 18. Connector check: F-06 tailgate lock

actuator connector
Connector: F-06
F-06
Harness side
F-06(B)
3 2 1
6 5 4
AC301665 AE


54C-64
SYMPTOM PROCEDURES

F-06 tailgate lock actuator connector terminal
Nos. 2 and 3.
NOTE:
Connector: C-209
Connector: C-217
Harness side
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210474 AG

Junction block
(Rear view)

C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB
F-06(B)
F-05
F-05
1 2
3 4
5 6 7 8 9 10
F-06
Harness side
3 2 1
6 5 4
AC301666 AG

54C-65
SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-3: The Central Door Locking System can not be Operated by Means of
the Front Passengers Door Lock Key Cylinder.
CAUTION
Central Door Lock (Front Passenger's Door Lock Key Cyilinder Switch) Circuit
FUSIBLE
LINK 1
ETACS-ECU
DOOR
UNLOCK
RELAY
FRONT DOOR
LOCK ACTUATOR (LH)
DOOR
LOCK
RELAY
INPUT SIGNAL
FRONT
PASSENGER'S
DOOR LOCK KEY
CYLINDER SWITCH


If the central door locking system does not work by
means of the front passengers door lock key
cylinder, the front passengers door lock key cylinder
or the ETACS-ECU may be defective.
POSSIBLE CAUSES
cylinder
DIAGNOSIS PROCEDURE
Step 1. Check the operation of the central door
locking system.
normally by means of the drivers door lock key
cylinder and inside lock knob.
YES : Go to Step 2.
NO : Refer to inspection procedure C-1 "Central
door locking system does not work at all

354C."
54C-66

SYMPTOM PROCEDURES

normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 3.

impossible 354C."
Step 3. Pulse check

System switch
Check conditions
Front passengers door

lock key cylinder switch

or unlock position

needle fluctuates.
YES : Go to Step 4.
front passenger's door lock key cylinder

switch signal is not received 354C."
normally by means of the front passenger's door lock
key cylinder.

54C-67
SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-4: The Ignition Key Reminder Function does not Work Normally.
CAUTION
Ignition Key Reminder Function Circuit

FUSIBLE
LINK 1
ETACS-ECU
INPUT SIGNAL
DOOR
UNLOCK
RELAY
FRONT DOOR
LOCK ACTUATOR (LH)
DOOR
LOCK
RELAY
DRIVER'S DOOR
LOCK ACTUCTOR
SWITCH
DRIVER'S DOOR
SWITCH
KEY REMINDER
SWITCH


If the key reminder function does not work normally,
the input signal circuits below or the ETACS-ECU
may be defective.
Key reminder switch
Drivers door switch
Front door lock actuator (LH)
POSSIBLE CAUSES
DIAGNOSIS PROCEDURE
normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 2.

impossible 354C."
54C-68
SYMPTOM PROCEDURES
Step 2. Confirm communication data by using the

SWS monitor.
Check the SWS communication signals, which are
related to the key reminder function.
Step 3. Pulse check

the key reminder function.
System switch
Check conditions

Drivers door: open
Key reminder switch
When the inserted

Drivers door lock

actuator switch

knob is unlocked or
locked
Item No.
Item name
Normal
conditions
Item 32
DR DOOR SW
ON

YES : Go to Step 3.

354C."

needle fluctuates.
4.

354C."

received 354C.
Q: Does the ignition key reminder function work
normally?


SYMPTOM PROCEDURES
54C-69
INSPECTION PROCEDURE C-5: The Impact Detection Door Unlock Function does not Function.
CAUTION
Impact Detection Door Unlock Function Circuit

ETACS-ECU
SRS-ECU
IMPACT-DEPENDENT
DOOR UNLOCK
SIGNAL PROCESSING
CIRCUIT
Wire colour code

SB : Sky blue

If the impact detection door unlock function does not
work normally, the input signal circuit from the impact
detection sensor, the SRS-ECU or the ETACS-ECU
may be defective.

normal.
POSSIBLE CAUSES
ECUS TO BE CHECKED
ETACS ECU
menu.
DIAGNOSIS PROCEDURE

YES : Go to Step 3.

code.
Check that the SRS-ECU sets a diagnosis code.
YES : Refer to GROUP 52B - Troubleshooting
352B.
NO : Go to Step 2.

impossible 354C."
54C-70
SYMPTOM PROCEDURES
Step 3. Connector check: C-115 SRS-ECU

connector
Connector: C-115

SRS-ECU connector terminal No.14 and C-220
ETACS-ECU connector terminal No.29.
Connector: C-115
Harness side
Harness side
2 1
4 3
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
2 1
4 3
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
C-115(Y)
C-115(Y)
AC301397AH
AC301397AH

YES : Go to Step 4.
Connector: C-220
Step 4. Check the SRS-ECU.

Check that the SRS-ECU works normally. Refer to
GROUP 52B - SRS Control Unit (SRS-ECU) 352B
.
Junction block
(Rear view)

YES : Go to Step 5.
NO : Replace the SRS-ECU.

connector
C-220
Harness side
Connector: C-220
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210477 AE
Junction block
(Rear view)

circuit.
YES : Go to Step 7.
C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210477 AE

YES : Go to Step 6.

SYMPTOM PROCEDURES
Step 7. Measure the resistance at the C-115 SRSECU connector.

Connector: C-115
54C-71

SRS-ECU connector terminal No.15 and body
earth.
Connector: C-115
Harness side
Harness side
2 1
4 3
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
2 1
4 3
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
C-115(Y)
C-115(Y)
AC301397AH
1. Disconnect the connector, and measure at the

AC301397AH
2.


4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
Connector C-115
(harness side)

Check that the impact detection door unlock function
works normally.
AC301708 AB
Resistance between C-115 SRS-ECU connector

OK: 2 W or less
YES : Go to Step 9.
NO : Go to Step 8.


54C-72
SYMPTOM PROCEDURES
POWER WINDOWS
INSPECTION PROCEDURE D-1: Power windows do not work at all.
CAUTION
Power Window Relay Circuit
FUSIBLE
LINK 5
ETACS-ECU
Wire colour code

B : Black
LG : Light green
G : Green
L: Blue
W : White
Y: Yellow
SB : Sky blue
BR : Brown
O : Orange
GR : Gray
R : Red
P : Pink
V : Violet
POWER WINDOW
RELAY
POWER
WINDOW
SUB
SWITCH
(FRONT: RH)
CPU

If the power windows do not work at all, the power
window relay, the power window main switch or the
POWER
WINDOW
SUB
SWITCH
(REAR: LH)
POWER
WINDOW
SUB
SWITCH
(REAR: RH)
POWER WINDOW
MAIN SWITCH
Possible causes
54C-73
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
ETACS-ECU and the power window main switch
(power window module) and the SWS
communication lines are normal.
Turn the ignition switch to the ON position.
ECUS TO BE CHECKED
ETACS ECU
P/W MODULE
OK: "OK" are displayed for all the items
"OK" are displayed for all the items : Go to Step 2.

monitor
related to the power windows.
<Selected item> POWER WINDOW
Power window main switch: UP
Item No.
Item name
Normal
conditions
30
IG SW (IG1)
ON
33
P/W SW ACCEPT
PERMIT
71
P/W ECU ACK
INPUT
CHECK (only
momentarily
when switch is
operated)

impossible 354C."

the items.
"NG" is displayed on the "P/W MODULE" menu. :

"Communication with power window main
switch (power window module) is impossible
354C."

to Step 3.
Refer to inspection procedure O-2 "The

354C."
Replace the ETACS-ECU.

Replace the power window main switch.

Step 3. Confirm communication data by using the
SWS monitor.
related to the power windows.
<Selected item> DOOR CNT. COM.
Insert the probe (For the insertion point, refer to
354C).
Power window main switch: UP
Item No.
Item name
Normal
conditions
C0
PASS DOR UP
ON

YES : Go to Step 4.
54C-74

SYMPTOM PROCEDURES

Check that the all the power windows work.

INSPECTION PROCEDURE D-2: Drivers power window does not work by means of the power window
main switch.
Power Window (front: LH) Circuit

POWER
WINDOW
MAIN SWITCH
FRONT
(LH)
POWER WINDOW
MOTOR
(FRONT: LH)
Wire colour code


If the drivers power window does not work by means
of the power window main switch, the power window
main switch or the drivers door power window motor
may be defective.
SB : Sky blue
Possible causes
Malfunction of the power window motor (front LH)
54C-75
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Check that all of the front passengers and rear door
power windows can operate by means of the power
window main switch.

power window motor (front LH) connector
terminal Nos. 1 and 3 to E-05 power window main
switch connector terminal Nos. 7 and 1.

YES : Go to Step 2.
E-13(GR)
windows do not work at all 354C."

E-05
E-12
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-13
Harness side
E-13(GR)
E-05
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
3 2 1
6 5 4
AC301419 AD
E-05
Harness side

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

YES : Go to Step 4.
E-13
Harness side
3 2 1
6 5 4
AC301419 AE

YES : Go to Step 3.

check that the drivers door power window can be
operated by the power window main switch.
(2) Check that the drivers power window works by

(front LH).
54C-76

SYMPTOM PROCEDURES
INSPECTION PROCEDURE D-3: Relevant power window(s) do not work by means of the front and rear
passengers power window sub switches.
Power Window (front: RH) Circuit

FUSIBLE
LINK 5
POWER
WINDOW
RELAY
ETACSECU
POWER
WINDOW
SUB SWITCH
(FRONT: RH)
CPU
POWER WINDOW
MOTOR
(FRONT: RH)
Wire colour code

SB : Sky blue
54C-77
SYMPTOM PROCEDURES
FUSIBLE
LINK 5
POWER
WINDOW
RELAY
ETACS-ECU
POWER
WINDOW
SUB SWITCH
(REAR: RH)
POWER
WINDOW
SUB SWITCH
(REAR: LH)
CPU
CPU
POWER
WINDOW
MOTOR
(REAR: RH)
POWER
WINDOW
MOTOR
(REAR: LH)
Wire colour code


If the front passengers or rear power window does
not work by means of the respective power window
sub switch, the power window sub switch or the
power window motor may be defective.
SB : Sky blue
Possible causes
Malfunction of the power window sub switch (front
RH), power window sub switch (rear RH) or
power window sub switch (rear LH)
Malfunction of the power window motor (front
RH), power window motor (rear RH) or power
window motor (rear LH)
54C-78

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
STEP 4. Measure the resistance at E-17 power


Check that the power window lock switch is turned
off.
YES : Go to Step 2.
NO : Turn off the power window lock switch.
Connector: E-17
E-17
Harness side
3 2
1
8 7 6 5 4
STEP 2. Determine a trouble spot.

Q: Which power window does not work?
AC301412 AB


Connector: E-17
3 2
1
8 7 6 5 4
E-17
Harness side
3 2
1
8 7 6 5 4
Connector E-17
(Harness side)
AC301474 AB

OK: 2W or less
AC301412 AB

YES : Go to Step 4.

YES : Go to Step 6.
NO : Go to Step 5.

SYMPTOM PROCEDURES

54C-79


STEP 6. Measure the voltage at E-17 power
E-17
Connector: E-17
E-24
E-17
Harness side
3 2
1
8 7 6 5 4
E-17
Harness side
3 2
1
8 7 6 5 4
AC301412 AB

E-24
1 2
3
4 5 6 7 8
AC301413 AC
3 2
1
8 7 6 5 4
NOTE:
Connector: C-15
Connector E-17
(Harness Side)
AC301470 AB

OK: System voltage
YES : Go to Step 9.
NO : Go to Step 7.
C-15(GR)
C-15
2
1
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
AC301398 AC

intermediate connector C-15, E-24, and repair if
necessary.
54C-80
SYMPTOM PROCEDURES
STEP 7. Connector check: C-208 power window

relay connector
Connector: C-208

terminal No.4.
E-17
E-24
E-17
Harness side
C-208
Junction block side
3 2
1
8 7 6 5 4
3 2 1
4
5
E-24
1 2
3
4 5 6 7 8
AC210475 AD

YES : Go to Step 8.
AC301413 AC

C-203
C-208
C-203
Harness side
2
1
6 5 4 3
C-208
Junction block side
3 2 1
4
5
AC210475 AB
54C-81
SYMPTOM PROCEDURES
NOTE:

switch (front LH) connector terminal Nos. 5 and
7.
Connector: C-15
E-23(GR)
E-17
C-15(GR)
E-24
C-15
2
1
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
E-17
Harness side
3 2
1
8 7 6 5 4
AC301398 AC


Connector: E-23
E-23
Harness side
3 2 1
6 5 4
E-23(GR)
AC301412 AC

E-23
Harness side
E-24
1 2
3
4 5 6 7 8
3 2 1
6 5 4
AC301413 AB

circuit.

After the power window sub switch (front RH) is
(1) Replace the power window sub switch (front RH).
(2) Check that the front passengers door power
window can be operated by the power window

(front RH).
54C-82
SYMPTOM PROCEDURES

Connector: E-21

E-21
E-21
Harness side
3 2
1
8 7 6 5 4
E-27
AC301414 AC

E-21
Harness side
3 2
1
8 7 6 5 4

E-27
Connector: E-21
1 2
3
4 5 6 7 8
AC301415 AC
E-21
Harness side
NOTE:
Connector: D-02
3 2
1
8 7 6 5 4
D-02
AC301414 AC

1
2 3
4 5 6 7 8
AC301408 AH

necessary.
3 2
1
8 7 6 5 4
Connector E-21
(Harness side)
AC301472 AB

OK: 2W or less
NO : Go to Step 14.



SYMPTOM PROCEDURES

Connector: E-21
54C-83
STEP 16. Connector check: C-208 power window

relay connector
Connector: C-208
E-21
Harness side
3 2
1
8 7 6 5 4
AC301414 AC

C-208
Junction block side
3 2 1
4
5
3 2
1
8 7 6 5 4
AC210475 AD
Connector E-21
(Harness Side)
AC301462 AC

OK: System voltage
NO : Go to Step 16.

54C-84
SYMPTOM PROCEDURES

terminal No.4.
NOTE:
Connector: C-13
E-21
C-13(L)
E-27
C-13
E-21
Harness side
1
2 3
4 5 6 7 8 9
10 11 12 13 14 15
3 2
1
8 7 6 5 4
E-27
AC301398 AB
3
1 2
4 5 6 7 8
Connector: D-02
AC301415 AC
D-02
1
2 3
4 5 6 7 8

C-203
AC301408 AH

necessary.
C-208
C-203
Harness side

2
1
6 5 4 3

C-208
Junction block side
3 2 1
4
5
AC210475 AB
54C-85
SYMPTOM PROCEDURES

Connector: E-20

switch (rear RH) connector terminal Nos. 7 and 5.
E-20(GR)
E-20
Harness side
E-20(GR)
E-21
3 2 1
6 5 4
E-27
AC301414 AB

E-20
Harness side
3 2 1
6 5 4
E-27
E-21
Harness side
1 2
3
4 5 6 7 8
3 2
1
8 7 6 5 4
AC301415 AB

circuit.
54C-86

SYMPTOM PROCEDURES

switch (rear RH).
(2) Check that the rear right door power window can
(rear RH).

(rear RH).

Connector: E-01
E-01
Harness side
3 2
1
8 7 6 5 4
AC301416 AB


Connector: E-01
3 2
1
8 7 6 5 4
Connector E-01
(Harness Side)
E-01
Harness side

OK: 2W or less
3 2
1
8 7 6 5 4
AC301416 AB

AC301461AB

NO : Go to Step 23.

SYMPTOM PROCEDURES

54C-87

Connector: E-01
E-01
E-01
Harness side
3 2
1
8 7 6 5 4
E-09
AC301416 AB

E-01
Harness side
3 2
1
8 7 6 5 4
3 2
1
8 7 6 5 4
E-09
3
1 2
4 5 6 7 8
AC301417 AC
NOTE:
Connector: D-26
Connector E-01
(Harness side)
AC301462 AB

OK: System voltage
D-26

NO : Go to Step 25.
1
2 3
4 5 6 7 8
AC301410 AB

necessary.

54C-88
SYMPTOM PROCEDURES
STEP 25. C-208 power window relay connector

Connector: C-208

terminal No.4.
E-01
E-09
C-208
Junction block side
E-01
Harness side
3 2 1
4
5
3 2
1
8 7 6 5 4
E-09
1 2
3
4 5 6 7 8
AC210475 AD

AC301417 AC

C-203
C-208
C-203
Harness side
2
1
6 5 4 3
C-208
Junction block side
3 2 1
4
5
AC210475 AB
54C-89
SYMPTOM PROCEDURES
NOTE:

Connector: C-117
Connector: E-03
E-03(GR)
E-03
Harness side
3 2 1
6 5 4
AC301416 AC
C-117
1 2 3
111213
4 5 6 7 8 9 10
14 1516 17 1819 20 2122 2324 25

26 27 28 29
32 33 34
35
30 31
36 37
38
AC301396 AC


switch (rear LH) connector terminal Nos. 7 and 5.
Connector: D-26
D-26
E-01
1
2 3
4 5 6 7 8
E-03(GR)
E-09
AC301410 AB

necessary.

E-01
Harness side
3 2
1
8 7 6 5 4
E-03
Harness side
E-09
3
1 2
4 5 6 7 8
3 2 1
6 5 4
AC301417 AB

circuit.
54C-90

SYMPTOM PROCEDURES

can be operated by the power window sub switch
(rear LH).
(2) Check that the rear left door power window can
(rear LH).

(rear LH).
54C-91
SYMPTOM PROCEDURES
INSPECTION PROCEDURE D-4: Front and/or rear passengers power window(s) do not work by
Power Window Circuit
REAR
(RH)
FRONT
(RH)
LOCK
SWITCH
CPU
REAR
(LH)
POWER WINDOW
MAIN SWITCH
CPU
POWER WINDOW
SUB SWITCH
(FRONT: RH)
CPU
POWER WINDOW
SUB SWITCH
(REAR: LH)
CPU
POWER WINDOW
SUB SWITCH
(REAR: RH)
Wire colour code

SB : Sky blue
54C-92
SYMPTOM PROCEDURES

If the passengers and/or rear power window does
not work by means of the power window main switch,
the power window main switch or the respective
power window sub switch(es) may be defective.
Possible causes
(front RH), power window sub switch (rear RH) or
power window sub switch (rear LH)
DIAGNOSIS PROCEDURE
power window main switch (power window module)
ECUS TO BE CHECKED
P/W MODULE
OK: "OK" is displayed on the "P/W
MODULE" menu.
YES : Go to Step 2.
"Communication with power window main

switch (power window module) is impossible
354C."
Step 2. Confirm communication data by using
the SWS monitor.
Check the SWS communication signal from the
power window lock switch to the ETACS-ECU.
Insert a probe between a power window sub
switch of a door of which power window does not
work and the power window main switch (For the
insertion point, refer to 354C).
Power window lock switch: OFF
Item No.
Item name
Normal
conditions
Item CB
P/W LOCK SW
OFF

YES : Go to Step 3.

the SWS monitor.
Check the SWS communication signals, which are
used when the front and/or rear passengers door
power windows are operated by the power window
main switch.
Insert a probe between a power window sub
switch of a door of which power window does not
work and the power window main switch (For the
insertion point, refer to 354C).
Are normal conditions displayed when each
switch of the power window main switch is
operated?
Item No.
Item name
Normal
conditions
C0
PASS DOR UP
ON
C1
PASS DOR DOWN ON
C2
PASS DOR AUTO
ON
C4
REAR RH UP
ON
C5
REAR RH DOWN
ON
C6
REAR RH AUTO
ON
C8
REAR LH UP
ON
C9
REAR LH DOWN
ON
CA
REAR LH AUTO
ON

the items.
Normal conditions are displayed for all of items C0,
C1 and C2 when the front passengers power
window does not work. : Go to Step 6.
Normal conditions are displayed for none of items
C0, C1 and C2 when the front passengers power
window does not work. : Go to Step 4.
C5 and C6 when the rear right power window does
not work. : Go to Step 12.
C4, C5 and C6 when the rear right power window
does not work. : Go to Step 10.
C9 and CA when the rear left power window does
not work. : Go to Step 18.
C8, C9 and CA when the rear left power window
does not work. : Go to Step 16.
Normal condition is displayed for any of the items.
:
Replace the power window main switch.
54C-93
SYMPTOM PROCEDURES

Connector: C-118
Connector: E-05
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF

YES : Go to Step 5.
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22

No.11 to the inserted probe.
23 24 25 26 27
28 29 30 31 32
AC301396 AE
Connector: E-05
Connector: E-12
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
AC301418 AF
NOTE:
Connector: C-15
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
C-15(GR)
AC301419 AF
C-15
1
2
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
AC301398 AC
54C-94

SYMPTOM PROCEDURES
NOTE:
Connector: E-24
Connector: C-15
E-24
1 2
3
4 5 6 7 8
AC301412 AG

C-15(GR)
C-15
2
1
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19

YES : Go to Step 8.

sub switch (front LH) connector
AC301398 AC
Connector: E-17
Connector: C-118
E-17
Harness side
3 2
1
8 7 6 5 4
AC301412 AB

YES : Go to Step 7.
C-118

terminal No.6 to the inserted probe.
Connector: E-17
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
E-17
Harness side
28 29 30 31 32
AC301396 AE
3 2
1
8 7 6 5 4
AC301412 AB

SYMPTOM PROCEDURES
54C-95

sub switch.
works by means of the power window main
switch.
Connector: E-12
E-12

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

Connector: E-05
AC301419 AF
Connector: E-24
E-05
Harness side
E-24
3
1 2
4 5 6 7 8
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF
AC301412 AG

YES : Go to Step 8.

Check that the front passengers power window
works by means of the power window sub switch
(front LH) when the power window lock switch is
turned off.
YES : Go to Step 9.

window sub switches 354C."


Connector: E-05
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF
54C-96
SYMPTOM PROCEDURES
NOTE:
Connector: D-02
Connector: C-13
D-02
1
2 3
4 5 6 7 8
AC301408 AH
C-13(L)
Connector: E-27
C-13
1
2 3
4 5 6 7 8 9
10 11 12 13 14 15
E-27
3
1 2
4 5 6 7 8
AC301414 AH
AC301398 AB
Connector: C-118


Connector: E-21
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
E-21
Harness side
3 2
1
8 7 6 5 4
AC301414 AC
AC301396 AE

54C-97
SYMPTOM PROCEDURES

Connector: C-118
Connector: E-21
E-21
Harness side
3 2
1
8 7 6 5 4
C-118
AC301414 AC
NOTE:
1 2 3 4 5 6 7 8 9 10 11
Connector: C-13
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301396 AE
Connector: D-02
D-02
C-13(L)
1
2 3
4 5 6 7 8
C-13
1
2 3
4 5 6 7 8 9
10 11 12 13 14 15
AC301408 AH
Connector: E-27
AC301398 AB
E-27
1 2
3
4 5 6 7 8
AC301414 AH

54C-98

SYMPTOM PROCEDURES

Check that the rear right power window works by
means of the power window sub switch (rear RH)
when the power window lock switch is turned off.

Connector: E-05


switch.
(2) Check that the rear right power window works by
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AF
NOTE:

C-118

C-117
C-117

Connector: E-05
1 2 3
4 5 6 7 8 9 10
111213
14 1516 17 1819 20 2122 2324 25

26 27 28 29
32 33 34
35
30 31
36 37
38
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
E-05
Harness side
23 24 25 26 27
28 29 30 31 32
AC301396 AD
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Connector: D-26
AC301418 AF
D-26

1
2 3
4 5 6 7 8
AC301410 AB

SYMPTOM PROCEDURES
54C-99

Connector: E-09
Connector: E-01
E-09
3
1 2
4 5 6 7 8
E-09
AC301416 AD
E-01
Harness side
3 2
1
8 7 6 5 4
Connector: E-12
AC301416 AB

E-12
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AF

54C-100
SYMPTOM PROCEDURES

Connector: E-09
Connector: E-01
E-09
3
1 2
4 5 6 7 8
E-01
Harness side
E-09
AC301416 AD
3 2
1
8 7 6 5 4
Connector: E-12
AC301416 AB
NOTE:
E-12
C-118
C-117
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
C-117
1 2 3
4 5 6 7 8 9 10
111213
14 1516 17 1819 20 2122 2324 25

26 27 28 29
32 33 34
35
30 31
36 37
38
C-118
AC301419 AF
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301396 AD

Connector: D-26
D-26
1
2 3
4 5 6 7 8

Check that the rear left power window works by
means of the power window sub switch (rear LH)
when the power window lock switch is turned off.
AC301410 AB



SYMPTOM PROCEDURES
54C-101

can be operated by the power window sub switch.
(2) Check that the rear left power window works by

INSPECTION PROCEDURE D-5: The window glass lowers automatically while it is rising.
If the sliding resistance is too great when the window
is being raised or the window glass encounters an
object, the window glass will lower by approximately
150 mm.
Possible causes
Improper adjusted door window glass
Incorrectly installed or warped glass slider
Malfunction of the window regulator
DIAGNOSIS PROCEDURE
STEP 2. Check the power window operating

current.
service 342).

abnormal.
STEP 1. Check the power window anti-trap

function.
Check that the power window anti-trap function
works. Refer to GROUP 42 - Door - On-vehicle
Service 342.
STEP 3. Check that the door window glasses are

installed correctly.
Check that the door window glasses are installed
correctly. Refer to GROUP 42 - Door - On-vehicle
Service 342.

YES : Go to Step 2.

YES : Go to Step 4.
NO : Adjust the door window glass (Refer to
window anti-trap function does not work

normally 354C."

342).
Check that the power window does not lower
automatically while it is being raised.

of the defective window.
54C-102
SYMPTOM PROCEDURES
INSPECTION PROCEDURE D-6: Power window anti-trap function does not work normally.
Power Window (front) Circuit
POWER
WINDOW MAIN
SWITCH
POWER WINDOW
SUB SWITCH
(FRONT: RH)
CPU
HALL IC
HALL IC
CPU
HALL IC
POWER
WINDOW MOTOR
(FRONT: LH)
Wire colour code
HALL IC
POWER
WINDOW MOTOR
(FRONT: RH)
SB : Sky blue

SYMPTOM PROCEDURES
54C-103
POWER WINDOW
SUB SWITCH
(REAR: LH)
POWER WINDOW
SUB SWITCH
(REAR: RH)
CPU
HALL IC
HALL IC
CPU
HALL IC
POWER
WINDOW MOTOR
(REAR: RH)
POWER
WINDOW MOTOR
(REAR: LH)
Wire colour code

The revolution detection sensor, which is
incorporated in the power window motor, may be
defective.
Possible causes
HALL IC
SB : Sky blue
DIAGNOSIS PROCEDURE
STEP 1. Check the power window operating
current.
service 342).

abnormal.
54C-104
SYMPTOM PROCEDURES
STEP 2. Confirm the power window learning

function.
Check that the power window switch has learned the
fully closed position of the windows (Refer to
GROUP 42 - Door 342).

Nos. 8, 9, 10 and 12 to E-13 power window motor
(front RH) connector terminal Nos. 5, 4, 6 and 2.

YES : Go to Step 3.
NO : Make the power window switch learn the
fully closed position of the windows (Refer

to GROUP 42 - Door 342).
E-13(GR)
E-05
STEP 3. Determine a trouble spot.

Q: Which door does the power window anti-trap
function fail on?

E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-13
Harness side
3 2 1
6 5 4
AC301419 AE

E-13(GR)
E-05

YES : Go to Step 6.

check that the drivers power window anti-trap
function works.
(2) Check that the drivers power window anti-trap
function works.
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-13
Harness side

3 2 1
6 5 4
AC301419 AE

YES : Go to Step 5.

(front LH).
54C-105
SYMPTOM PROCEDURES

Connector: E-23

Connector: E-23
E-23
Harness side
E-23
Harness side
E-23(GR)
3 2 1
6 5 4
E-23(GR)
3 2 1
6 5 4
AC301412 AC
AC301412 AC

YES : Go to Step 8.
NOTE:
Connector: C-15

window motor (front RH) connector.
Connector: E-23
E-23
Harness side
E-23(GR)
3 2 1
6 5 4
C-15(GR)
C-15
AC301412 AC

AC301398 AC
3 2 1
6 5 4
Connector E-23
(Harness side)

AC301471AC

(front RH) connector terminal No.5 and body
earth.
OK: 2W or less
NO : Go to Step 9.
1
2
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19

54C-106

SYMPTOM PROCEDURES

Connector: E-17
E-17
Harness side
3 2
1
8 7 6 5 4

replaced, check that the front passengers anti-trap
switch.
anti-trap function works.
AC301412 AB


motor (front LH) connector terminal Nos. 6, 4 and
2.
E-24
E-17
Harness side
E-23
Harness side

Connector: E-20
E-20(GR)
E-20
Harness side
E-23(GR)
E-17
3 2
1
8 7 6 5 4

(front LH).
E-24
1 2
3
4 5 6 7 8
3 2 1
6 5 4
AC301413 AB

3 2 1
6 5 4
AC301414 AB


SYMPTOM PROCEDURES

window motor (rear RH) connector.
Connector: E-20
54C-107

Connector: E-20
E-20(GR)
E-20(GR)
E-20
Harness side
E-20
Harness side
3 2 1
6 5 4
3 2 1
6 5 4
AC301414 AB

AC301414 AB
NOTE:
Connector: D-02
D-02
3 2 1
6 5 4
Connector E-20
(Harness side)
1
2 3
4 5 6 7 8

(rear RH) connector terminal No.5 and body
earth.
OK: 2W or less
NO : Go to Step 15.
AC301408 AH
AC301471AB


Connector: E-21
E-21
Harness side
3 2
1
8 7 6 5 4
AC301414 AC

54C-108
SYMPTOM PROCEDURES

motor (rear RH) connector terminal Nos. 6, 4 and
2.

Connector: E-03

E-03(GR)
E-20(GR)
E-21
E-03
Harness side
3 2 1
6 5 4
AC301416 AC
E-27

E-20
Harness side

window motor (rear LH) connector.
3 2 1
6 5 4
E-27
E-21
Harness side
1 2
3
4 5 6 7 8
Connector: E-03
3 2
1
8 7 6 5 4
E-03(GR)
AC301415 AB


replaced, check that the rear right door anti-trap
switch.
(2) Check that the rear right power window anti-trap
function works.

(rear RH).
E-03
Harness side
3 2 1
6 5 4
AC301416 AC

3 2 1
6 5 4
Connector E-03
(Harness side)
AC301463 AB

(rear LH) connector terminal No.5 and body
earth.
OK: 2W or less
NO : Go to Step 21.
54C-109
SYMPTOM PROCEDURES

Connector: E-03

motor (rear LH) connector terminal Nos. 6, 4 and
2.
E-03(GR)
E-03
Harness side
E-01
E-03(GR)
3 2 1
6 5 4
E-09
AC301416 AC
NOTE:
Connector: D-26
E-01
Harness side
D-26
3 2
1
8 7 6 5 4
1
2 3
4 5 6 7 8
E-03
Harness side
AC301410 AB


E-09
1 2
3
4 5 6 7 8
3 2 1
6 5 4
AC301417 AB


replaced, check that the rear left door anti-trap
switch.
(2) Check that the rear left power window anti-trap
function works.
Connector: E-01
E-01
Harness side
3 2
1
8 7 6 5 4
AC301416 AB



(rear LH).
54C-110

SYMPTOM PROCEDURES
INSPECTION PROCEDURE E-1: Keyless Entry System does not Work.
CAUTION
Keyless Entry System Function Circuit

ETACS-ECU
KEYLESS ENTRY
RECEIVER
INPUT SIGNAL
ALL OF THE DOOR SWITCHES
DRIVER'S DOOR LOCK ACTUATOR SWITCH
KEY REMINDER SWITCH

If the keyless entry system does not work normally,
the input signal circuits to the components below or
Key reminder switch
POSSIBLE CAUSES
DIAGNOSIS PROCEDURE
normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 2.

impossible 354C."

SYMPTOM PROCEDURES
Step 2. Pulse check

the keyless entry system.
System switch
Check conditions
Key reminder switch
When the inserted


Drivers door lock

actuator switch

knob is unlocked or
locked

switch
needle fluctuates.
3.

key reminder switch signal is not received
354C."

door switch signals are not received 354C
."

received 354C.

transmitter is not received 354C."
54C-111

Check the keyless entry system works normally.

54C-112

SYMPTOM PROCEDURES
INSPECTION PROCEDURE E-2: Keyless Entry Hazard Warning Lamp Answerback Function or the
Room Lamp Answerback Function does not Work Normally.
CAUTION
If the hazard warning lamp and the room lamp work
normally, the ETACS-ECU may be defective.
Alternatively, it is possible that the keyless entry
hazard warning lamp answerback function was
disabled by the adjustment function.
POSSIBLE CAUSES
Defective turn-signal lamp
Step 3. Check the operation of the room lamps.

Check that the room lamps illuminate normally.
YES : Go to Step 4.

extinguish 354C."
normal.
DIAGNOSIS PROCEDURE
ECUS TO BE CHECKED
ETACS ECU
menu.

answerback function has been enabled by using the
adjustment function.

YES : Go to Step 5.

YES : Go to Step 2.
NO : Enable the keyless entry hazard warning
lamp answerback function by using the

adjustment function (Refer to GROUP 54B
- Adjustment function 354B).
Step 2. Check the operation of the hazard
warning lamp.
normally.
YES : Go to Step 3.
NO : Refer to inspection procedure K-2 "The
hazard warning lamps do not illuminate

354C".

impossible 354C."
answerback function or the room lamp answerback
function work normally.


SYMPTOM PROCEDURES
54C-113
INSPECTION PROCEDURE E-3: Encrypted Code cannot be Registered.
CAUTION
Encrypted Transmitter Code Register Mode
ETACS-ECU
INPUT SIGNAL
KEY REMINDER SWITCH

If the encrypted code registration mode is not
entered, the key reminder switch, the hazard warning
lamp switch or the ETACS-ECU may be defective.
If the registration is not possible although the
registration mode is entered, the keyless entry
transmitter or the ETACS-ECU may be defective.
Step 2. Pulse check

the encrypted code of the keyless entry transmitter.
POSSIBLE CAUSES
DIAGNOSIS PROCEDURE
Step 1. Check the encrypted code registration
mode.
Check that the encrypted code registration mode is
entered.
YES : Go to Step 3.
NO : Go to Step 2.
System switch
Check conditions
Key reminder switch
When the inserted

Hazard warning lamp

switch
When the switch is


switch
needle fluctuates.
3.

354C."

not received 354C."

transmitter is not received 354C."
54C-114

SYMPTOM PROCEDURES

Check that the encrypted code can be registered.

INSPECTION PROCEDURE E-4: The Timer Lock Function does not Work after the Doors have been
Unlocked by the Keyless Entry System.
CAUTION
If the keyless entry timer lock does not work
normally, the input signal circuit(s) to the keyless
entry transmitter or the ETACS-ECU may be
defective.
POSSIBLE CAUSES
DIAGNOSIS PROCEDURE
Step 1. Check the operation of the keyless entry
system.
Check that the keyless entry system works normally.
YES : Go to Step 2.
NO : Refer to inspection procedure E-1 "Keyless
entry system does not work 354C."

Check that the timer lock works normally.


SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-1: The windshield wipers does not work at all.
CAUTION
Windshield Wiper Power Supply Circuit

IGNITION
SWITCH (ACC)
FRONT-ECU
WIPER SPEED
SWITCHING
RELAY
WINDSHIELD
WIPER MOTOR
CIRCUIT
BREAKER
Wire colour code

SB : Sky blue
54C-115
54C-116

SYMPTOM PROCEDURES

front-ECU may be defective. If a problem is found in
the ECU check by using the SWS monitor, also
check the wiper backup circuit (between C-310
column switch connector terminal No.8 and A-12X
front-ECU connector terminal No.26) and repair if
necessary.
POSSIBLE CAUSES
DIAGNOSIS PROCEDURE
column switch (column-ECU) and the front-ECU and
the SWS communication lines are normal.
ECUS TO BE CHECKED
COLUMN ECU
FRONT ECU

"NG" is displayed on the "FRONT ECU" menu. :

"Communication with front-ECU is
impossible 354C."

monitor
related to the windshield wiper function.
<Selected item> F.WIPER INT
Turn the ignition switch to the ACC position.
Windshield wiper switch: INT
Item No.
Item name
Normal
conditions
Item 05
INT WIPER SW
ON
Item 31
IGNITION SW
ACC
ON
Item 70
FRONT ECU ACK NORMAL ACK

or HI-BEAM
ACK

the items.
to Step 3.
Replace the column switch.


354C."
Replace the front-ECU.

motor connector
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD

YES : Go to Step 4.
54C-117
SYMPTOM PROCEDURES

assembly.
YES : Go to Step 5

and body earth.
Connector:
B-07
B-07(GR)
B-07
Harness side
assembly.
3 2 1
5 4

Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD
NOTE:
Connector: C-17
AC301521AD

C-17(GR)
3 2 1
5 4
C-17
Harness side
5 4
3 2 1
13 12 11 10 9 8 7 6
Connector B-07
(Harness side)
AC301635 AB
(2) Continuity between B-07 windshield wiper motor

OK: 2W or less
YES : Go to Step 7.
NO : Go to Step 6.
AC301398 AE

junction connector C-17 and repair if necessary.

54C-118
SYMPTOM PROCEDURES

connector
Connector: A-12X

Connector: A-12X
Relay box side
Relay box side
3130 29 2827 26 25 24 2322 21
3130 29 2827 26 25 24 2322 21
AC301483 AE

YES : Go to Step 8.
AC301483 AE

box side.
31 30 29 2827 26 25 24 2322 21
Connector A-12X
(Relay box side)
AC301473 AB

OK: System voltage
NO : Go to Step 9.
54C-119
SYMPTOM PROCEDURES

front-ECU connector terminal No.28 and ignition
switch (ACC).
NOTE:
Connector: C-116
Connector: A-12X
C-116
1 2
Relay box side

3130 29 2827 26 25 24 2322 21
5 6 7
3 4
8 9
10 11 12 13 14
15
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301396 AB
AC301483 AE

C-203
C-202
C-202 Harness side

6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-203 Harness side

2
1
6 5 4 3
AC210475 AM

junction block connectors C-202, C-203 and
necessary.
Check the power supply line from ignition switch
54C-120
SYMPTOM PROCEDURES



The windshield wiper should now work normally at
all.

INSPECTION PROCEDURE F-2: The windshield wipers does not work when the wiper switch is at
"INT", "WASHER" or "MIST" position. However, the wipers work at low speed when the switch is at
"LO" and "HI" position.
CAUTION

FRONT-ECU
WIPER SPEED
SWITCHING
RELAY
INPUT SIGNAL
WINDSHIELD
WIPER MOTOR
CIRCUIT
BREAKER

The system may be at fail-safe mode as the SWS
communication line is defective. If the ETACS-ECU
does not receive the ignition switch (ACC) signal due
to an open circuit in the SWS communication lines or
other reasons when the ignition switch is at the ACC
position, the system will enter the fail-safe mode.
Wire colour code

POSSIBLE CAUSES

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
ECUS TO BE CHECKED
COLUMN ECU
FRONT ECU


impossible 354C."
54C-121

The windshield wiper should now work normally.

54C-122
SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-3: The windshield wipers do not stop at the specified park position
CAUTION
Windshield Wiper Automatic Stop Relay Circuit
IGNITION
SWITCH (ACC)
FRONT-ECU
WIPER
AUTOMATIC
STOP RELAY
WINDSHIELD
WIPER MOTOR
Wire colour code


The windshield wiper motor or the front-ECU may be
defective.
POSSIBLE CAUSES
SB : Sky blue
DIAGNOSIS PROCEDURE
motor connector
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD

YES : Go to Step 2.

SYMPTOM PROCEDURES

assembly.
YES : Go to Step 3
assembly.
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD

3 2 1
5 4
Connector B-07
(Harness side)
AC301636 AB

earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.
54C-123

and ignition switch (ACC).
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD
54C-124
SYMPTOM PROCEDURES
NOTE:
Connector: C-104

connector
C-104(B)
Connector: A-12X
C-104
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301398 AF
Relay box side

3130 29 2827 26 25 24 2322 21
C-203
C-202
AC301483 AE

YES : Go to Step 6.
C-202 Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-203 Harness side

2
1
6 5 4 3
AC210475 AM

junction connectors C-202, C-203 and the
necessary.
Check the power supply line from ignition switch
54C-125
SYMPTOM PROCEDURES

NOTE:
Connector: A-14
Connector: A-12X
A-14(GR)
A-14
1 2 3 4 5 6 7
8 9
10 11
15
14
12 13
16 17
Relay box side

3130 29 2827 26 25 24 2322 21
AC210456 AD
AC301483 AE
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
AC301521AD

intermediate connector A-14 and repair if necessary.
Check the input signal lines.
YES : Go to Step 7.

Check that the windshield wipers stop at the

54C-126
SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-4: The windshield wipers does not work normally.
CAUTION

FRONT-ECU
INPUT SIGNAL
WIPER SPEED
SWITCHING
RELAY
WINDSHIELD
WIPER MOTOR
CIRCUIT
BREAKER

POSSIBLE CAUSES
Wire colour code


the SWS monitor.
related to the windshield wipers.
<Selected item> Column switch (column-ECU)
Ignition switch: ON
Move the windshield wiper switch to each
position.
Item No.
Item name
Normal
condition
Item 05
INT WIPER SW
ON
Item 06
LO WIPER SW
ON
Item 07
HI WIPER SW
ON
Item 08
MIST WIPER SW
ON

the functions of the switch.
Normal conditions are displayed for all the items. :
Go to Step 2.
NO : Replace the column switch

SYMPTOM PROCEDURES

motor connector
Connector:
B-07
B-07(GR)
B-07
Harness side
3 2 1
5 4
54C-127

assembly.
YES : Go to Step 4
assembly.
AC301521AD

YES : Go to Step 3.


INSPECTION PROCEDURE F-5: The intermittent wiper interval can not be adjusted by operating the
windshield intermittent wiper volume control.
CAUTION
Windshield Wiper Intermittent Volume Input Signal

ETACS-ECU
INPUT SIGNAL
WINDSHIELD WIPER
INTERMITTENT VOLUME

The column switch or the front-ECU may be
defective.
POSSIBLE CAUSES
54C-128
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 1. Check the ETACS ANAL data by using the
SWS monitor.
Rotate the windshield intermittent wiper volume.
Item No.
Item name
Normal
conditions
Item 02
WPR VOL VOLT
Displays the
voltage in the
windshield wiper
intermittent
volume. Changes
in accordance with
the position of the
windshield wiper
intermittent
volume.

OK: The intermittent wiper interval is
changed as the intermittent wiper volume is
rotated.


YES : Go to Step 2.
NO : Refer to Inspection Procedure N-7 "The
windshield intermittent wiper volume signal

is not received 354C."
INSPECTION PROCEDURE F-6: The intermittent wiper interval is not changed according to the
vehicle speed.
CAUTION
Vehicle Speed Input Signal

ETACS-ECU
INPUT SIGNAL
VEHICLE SPEED
W3Z04E06AA

The ETACS-ECU calculates the intermittent wiper
interval according to the vehicle speed signal which
is sent by the engine-ECU.
If the intermittent wiper interval does not depend on

the vehicle speed, the input circuit of the vehicle
speed signal and the ETACS-ECU may be defective.

SYMPTOM PROCEDURES
54C-129
POSSIBLE CAUSES
Malfunction of the vehicle speed signal (engineECU)
Step 3. Check the ETACS ANAL data by using the

SWS monitor.
Enter a simulated vehicle speed.
Item No.
Item name
Normal
conditions
DIAGNOSIS PROCEDURE
Item 03
SPEED SENSOR
Displays the
speed which
fluctuates
within 2 km/h
from the
entered vehicle
speed.

YES : Go to Step 2.
intermittent wiper interval cannot be

intermittent wiper volume control 354C
."

YES : Go to Step 4.
NO : Refer to Inspection Procedure N-13 "The
vehicle speed signal is not received 354C

."

Check that "SPEED SEN WIP" is set to
"W.FUNCTION" by using the adjustment function.

Check that the intermittent wiper interval depends on
the vehicle speed.

YES : Go to Step 3.
NO : Set "SPEED SEN WIP" to "W.FUNCTION"

by using the adjustment function.(Refer to

354B).

54C-130
SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-7: The windshield washer does not work.
CAUTION
Windshield Washer Motor Circuit
IGNITION
SWITCH (ACC)
FRONT-ECU
WINDSHIELD
WASHER
RELAY
INPUT SIGNAL
WINDSHIELD WASHER
WINDSHIELD
WASHER MOTOR
Wire colour code


The windshield washer motor, the column switch or
POSSIBLE CAUSES
Malfunction of the windshield washer motor
DIAGNOSIS PROCEDURE
wipers.
Check that the windshield wipers work normally.
YES : Go to Step 2.
windshield wipers does not work at all

354C."

SYMPTOM PROCEDURES

ECUS TO BE CHECKED
COLUMN ECU
FRONT ECU
Step 4. Connector check: A-26 windshield

washer motor connector
Connector: A-26
A-26
Harness side
1
2



impossible 354C."
monitor
related to the windshield washer function.
<Selected item> F.WIPER WASH
Windshield washer switch: ON
Item No.
Item name
Normal
conditions
Item 09
FRONT WASH.
SW
ON
Item 31
IG SW (ACC)
ON
Item 70

or HI-BEAM
ACK

the items.
Normal conditions are displayed for all the items :
Go to Step 4.


354C."
54C-131
AC210453 AF

YES : Go to Step 5.
Step 5. Check the windshield washer motor

assembly.
Refer to GROUP 51 - Windshield washer 351.
YES : Go to Step 6
NO : Replace the windshield washer motor.
54C-132
SYMPTOM PROCEDURES

windshield washer motor connector.
Connector: A-26

Connector: A-26
A-26
Harness side
A-26
Harness side
1
2
1
2
AC210453 AF

AC210453 AF


1
2

connector
Connector A-26
(Harness side)
AC301475 AB
Connector: A-12X
(2) Continuity between A-26 windshield washer

motor connector terminal No.1 and body earth
OK: 2W or less
YES : Go to Step 8.
NO : Go to Step 7.
Relay box side

3130 29 2827 26 25 24 2322 21
AC301483 AE

YES : Go to Step 9.

SYMPTOM PROCEDURES

No.2 and A-12X front-ECU connector terminal
No.31.
54C-133

The windshield washer should now work normally.

Connector: A-12X
Relay box side

3130 29 2827 26 25 24 2322 21
AC301483 AE
Connector: A-26
A-26
Harness side
1
2
AC210453 AF
Check the power supply line from the ignition

switch (ACC) for open circuit.
54C-134

SYMPTOM PROCEDURES
INSPECTION PROCEDURE G-1: The rear wiper does not work at all.
CAUTION
Rear Wiper Drive Circuit
IGNITION
SWITCH (ACC)
ETACS-ECU
REAR
WIPER RELAY
INPUT SIGNAL
REAR WIPER SWITCH
REAR
WIPER MOTOR
Wire colour code


If the rear wiper does not work normally, the input
signal circuits to the components below, the rear
wiper motor or the ETACS-ECU may be defective.
Rear wiper switch
SB : Sky blue
Possible causes
54C-135
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE

connector

column switch (column-ECU) and the ETACS-ECU
Connector: F-02
F-02
Harness side
4 3 2 1
ECUS TO BE CHECKED
COLUMN ECU
ETACS ECU
AC301665 AB



impossible 354C."
monitor
related to the rear wiper function.
<Selected item> REAR WIPER
Rear wiper switch: ON
Item No.
Item name
Normal
conditions
Item 13
REAR WIPER SW
ON
Item 31
IG SW (ACC)
ON

the items.
to Step 3.


354C."

YES : Go to Step 4.

.
YES : Go to Step 5.
54C-136
SYMPTOM PROCEDURES

wiper motor connector.
Connector: F-02
F-02
Harness side
Step 6. Check the wiring harness between F-02

rear wiper motor connector terminal No.1 and
body earth.
Connector: F-02
F-02
Harness side
4 3 2 1
4 3 2 1
AC301665 AB

AC301665 AB


4 3 2 1

connector
Connector F-02
(Harness side)
AC301641AB
Connector: C-217
(2) Resistance between F-02 rear wiper motor

OK: 2 W or less
YES : Go to Step 7.
NO : Go to Step 6.
Junction block
(Rear view)
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210477 AB

YES : Go to Step 8.
54C-137
SYMPTOM PROCEDURES

NOTE:
Connector: C-209
Connector: C-217
Junction block
(Rear view)
C-209 Harness side
7 6 5
15 1413
C-217
Junction block side
12
4 3 2 1
11 10 9 8
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210475 AO
Connector: F-05
AC210477 AB
Connector: F-02
F-02
Harness side
4 3 2 1
AC301665 AB
F-05
1 2
3 4
5 6 7 8 9 10
AC301666 AB

Check the output signal line for open or short
circuit.
Q: 1Is the check result normal?
YES : Go to Step 9.
54C-138
SYMPTOM PROCEDURES

Check that the rear wiper works normally.

INSPECTION PROCEDURE G-2: The rear wiper does not stop at the specified park position.
CAUTION
Rear Wiper Auto-stop Signal Input
IGNITION
SWITCH (ACC)
ETACSECU
REAR
WIPER
RELAY
REAR WIPER
MOTOR
Wire colour code

SB : Sky blue

SYMPTOM PROCEDURES

If the rear wiper does not stop normally within the
predetermined range, the rear wiper motor or the
54C-139
Step 3. Measure the voltage at the F-02 rear wiper

motor connector.
Connector: F-02
F-02
Harness side
Possible causes
4 3 2 1

connector
AC301665 AB
Connector: F-02
F-02
Harness side

4 3 2 1
4 3 2 1
AC301665 AB

YES : Go to Step 2.

.
YES : Go to Step 3.
Connector F-02
(Harness side)
AC301642 AB
(3) Check the voltage between F-02 rear wiper motor

OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.
Step 4. Check the wiring harness between

ignition switch (ACC) and F-02 rear wiper motor
Connector: F-02
F-02
Harness side
4 3 2 1
AC301665 AB
54C-140
SYMPTOM PROCEDURES
NOTE:
Connector: F-05

connector
Connector: C-217
Junction block
(Rear view)
F-05
1 2
3 4
5 6 7 8 9 10
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC301666 AB

AC210477 AB
C-203

YES : Go to Step 6.
C-209
C-203 Harness side

2
1
6 5 4 3
C-209 Harness side

7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210475 AN

connectors C-203, C-209 and repair if necessary.
circuit.

54C-141
SYMPTOM PROCEDURES

NOTE:
Connector: F-05
Connector: C-217
Junction block
(Rear view)
F-05
1 2
3 4
5 6 7 8 9 10
C-217
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC301666 AB
AC210477 AB
Connector: C-209
Connector: F-02
F-02
Harness side
4 3 2 1
AC301665 AB
C-209 Harness side

7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210475 AO

circuit.
YES : Go to Step 7.
54C-142

SYMPTOM PROCEDURES

Check that the rear wiper auto stop function works
normally.

INSPECTION PROCEDURE G-3: When the shift lever is moved to "R" position during the rear wiper
operation, the rear wiper does not operate at the continuous mode.
CAUTION
"R" Position During Rear Wiper Operation Circuit

IGNITION
SWITCH (ACC)
ETACS-ECU
REAR
WIPER
RELAY
INPUT SIGNAL
BACK-UP LAMP SWITCH
("R" POSITION)
REAR WIPER SWITCH
REAR WIPER
MOTOR

If the rear wiper does not operate consecutively
the rear wiper operation, the input signal circuit to the
back-up lamp switch ("R" position) or the ETACSECU may be defective.
Possible causes

SYMPTOM PROCEDURES

monitor
related to the R (reverse) gear-linked rear wiper
operation.
<Selected item> REAR WIPER-REV. INTERLOCK
Ignition switch: ON
Rear wiper switch: ON
Shift position: R position
Item No.
Item name
Normal
conditions
Item 41
INHIBITOR SW
ON

YES : Go to Step 2.
back-up lamp switch signal is not received

354C."
54C-143

Check that the rear wiper operates consecutively
the rear wiper operation.

54C-144

SYMPTOM PROCEDURES
INSPECTION PROCEDURE G-4: The rear washer does not work.
CAUTION
Rear Washer Drive Circuit

IGNITION
SWITCH (ACC)
ETACS-ECU
REAR
WASHER
RELAY
INPUT SIGNAL
REAR WASH. SW
REAR
WASHER
MOTOR
Wire colour code


If the rear washer does not work normally, the input
signal circuits to the rear washer switch, rear washer
motor or the ETACS-ECU may be defective.
Possible causes
Malfunction of the rear washer motor

YES : Go to Step 2.
wiper does not work at all 354C."

SYMPTOM PROCEDURES

monitor
related to the rear washer function.
<Selected item> REAR WIPER-REAR WASHER
Rear washer switch: ON
Item No.
Item name
Normal
conditions
Item 14
REAR WASH. SW
ON
Step 5. Measure the resistance at the A-27 rear

washer motor connector.
Connector: A-27
A-27
Harness side
1
2
A-27(G)

YES : Go to Step 3.
54C-145
AC210453 AG


received 354C."
Step 3. Connector check: A-27 rear washer motor
connector
1
2
Connector: A-27
Connector A-27
(Harness side)
AC301639 AB
(2) Resistance between A-27 rear washer motor

OK: 2 W or less
A-27
Harness side
1
2

YES : Go to Step 7.
NO : Go to Step 6.
A-27(G)
AC210453 AG

YES : Go to Step 4.
Step 4. Check the rear washer motor.

.
YES : Go to Step 5.
NO : Replace the rear washer motor.

rear washer motor connector terminal No.1 and
body earth.
Connector: A-27
A-27
Harness side
1
2
A-27(G)
AC210453 AG


54C-146
SYMPTOM PROCEDURES

connector
Connector: C-220

ETACS-ECU connector terminal No.23 and A-27
rear washer motor connector terminal No.2.
Connector: A-27
A-27
Harness side
Junction block
(Rear view)
1
2
A-27(G)
AC210453 AG
Connector: C-220
C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210477 AE

YES : Go to Step 8.
Junction block
(Rear view)
C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210477 AE

SYMPTOM PROCEDURES
NOTE:
54C-147

Check that the rear washer works normally.
Connector: C-116


C-116
1 2
5 6 7
3 4
8 9
10 11 12 13 14
15
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301396 AB

necessary.
circuit.
YES : Go to Step 9.
54C-148

SYMPTOM PROCEDURES
HEADLAMP WASHER
INSPECTION PROCEDURE H-1: The headlamp washer does not work.
CAUTION
Headlamp Washer Motor Circuit
FUSIBLE
LINK 5
FRONT-ECU
HEADLAMP
WASHER
INPUT SIGNAL
HEADLAMP WASHER
HEADLAMP
WASHER MOTOR
Wire colour code


The headlamp washer motor, the column switch or
Possible causes
Malfunction of the headlamp washer motor

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 3. Connector check: A-25 headlamp washer

motor connector

ECUS TO BE CHECKED
COLUMN ECU
FRONT ECU


impossible 354C."
monitor
related to the headlamp washer function.
<Selected item> HD WASHER
Headlamp washer switch: ON
Item No.
Item name
Normal
conditions
Item 16
HD WASHER SW
ON
Item 31
IG SW (ACC)
ON
Item 70

or HI-BEAM
ACK

the items.
to Step 3.


354C."
54C-149
Connector : A-25
A-25
Harness side
2 1
A-25(B)
AC210453 AI

YES : Go to Step 4.
Step 4. Check the headlamp washer motor

assembly.
Refer to GROUP 51 - Headlamp washer 351.
YES : Go to Step 5
NO : Replace the headlamp washer motor.
54C-150
SYMPTOM PROCEDURES

headlamp washer motor connector.
Connector : A-25

Connector : A-25
A-25
Harness side
A-25
Harness side
2 1
2 1
A-25(B)
AC210453 AI

A-25(B)
AC210453 AI


2 1
Connector A-25
(harness side)

connector
AC301725 AB
Connector: A-11X
(2) Continuity between A-25 headlamp washer motor

OK: 2W or less
YES : Go to Step 7.
NO : Go to Step 6.
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

YES : Go to Step 8.

SYMPTOM PROCEDURES

Connector: A-11X
54C-151

fusible link (5).
Connector: A-11X
Relay box side

Relay box side
11 10 9 8 7 6 5 4 3 2 1
11 10 9 8 7 6 5 4 3 2 1
AC301483 AD
(1) Remove the front-ECU, and measure at the

AC301483 AD
Check the power supply line to the fusible link (5)

for open circuit.

11 10 9 8 7 6 5 4 3 2 1
Connector A-11X
(Relay box side)
AC301726 AB

OK: System voltage
NO : Go to Step 9.
54C-152
SYMPTOM PROCEDURES

Connector: A-11X


Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC301483 AD
Connector : A-25
A-25
Harness side
2 1
A-25(B)

The headlamp washer should now work normally.
AC210453 AI
Check the power supply line from the fusible link

(5) for open circuit.

SYMPTOM PROCEDURES
54C-153
IGNITION KEY HOLE ILLUMINATION

LAMP
INSPECTION PROCEDURE I-1: The ignition key cylinder illumination lamp does not illuminate/
CAUTION
Ignition Key Cylinder Illumination Lamp Circuit
ETACS-ECU
FUSIBLE
LINK 1
KEY
REMINDER SWITCH
KEY CYLINDER
ILLUMINATION LAMP
Wire colour code


<Vehicles without keyless entry system>
Drivers door switch
Key reminder switch
Drivers door switch
signal circuit(s), the ignition key cylinder illumination
lamp or the ETACS-ECU may be defective.
Possible causes
SB : Sky blue
Malfunction of the ignition key cylinder

illumination lamp
DIAGNOSIS PROCEDURE
Check that the dome lamps illuminate and extinguish
normally.
YES : Go to Step 2.

system>354C ." Or refer to inspection
procedure M-2 "The room lamp does not
illuminate/extinguish <vehicles with keyless
entry system>354C ."
54C-154

SYMPTOM PROCEDURES

normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 3.

impossible 354C."
monitor.
related to the ignition key cylinder illumination lamp.
Step 4. Pulse check

the ignition key cylinder illumination lamp.
System switch
Check conditions
Key reminder
switch
When the inserted ignition key

is pulled out

needle fluctuates.
YES : Go to Step 5.

354C."
switch connector
Connector: C-304

Drivers door: open
Harness side
Item No.
Item name
Normal
conditions
Item 30
IG SW(IG1)
OFF
Item 32
DR DOOR SW
ON
OK: Normal conditions displayed for all the

items
Normal conditions are displayed for all the items.
<Vehicles without keyless entry system> : Go to
Step 4.
Normal conditions are displayed for all the items.
<Vehicles with keyless entry system> : Go to Step
5.
Normal condition is not displayed for item No.30. :

354C."

354C."
2
1
7 6 5 4 3
AC301399 AB

YES : Go to Step 6.
Step 6. Check the bulb of the ignition key

cylinder illumination lamp.
Check the bulb of the ignition key cylinder
illumination lamp.
YES : Go to Step 7.
NO : Replace the bulb of the ignition key cylinder
illumination lamp.
54C-155
SYMPTOM PROCEDURES

connector
Connector: C-219

C-304 ignition key cylinder illumination lamp
connector terminal Nos. 1 and 2.
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 8.
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
Connector: C-304
Harness side
2
1
7 6 5 4 3
AC301399 AB

YES : Go to Step 9.

Check that the ignition key cylinder illumination lamp

54C-156

SYMPTOM PROCEDURES
HEADLAMP AND TAIL LAMP
INSPECTION PROCEDURE J-1: The headlamps do not illuminate when the lamping switch is at
"TAIL" or "PASSING" position, but illuminate only at low beam when the switch is at "HEAD" position.
However, the headlamps do not illuminate at high beam.
CAUTION
If the headlamps illuminate only at low beam
regardless of the lighting switch position, the
headlamp fail-safe function may be activated.
Possible causes

ECUS TO BE CHECKED
COLUMN ECU
FRONT ECU


impossible 354C."
Check that the headlamps illuminate normally.


SYMPTOM PROCEDURES
54C-157
INSPECTION PROCEDURE J-2: The tail lamps do not illuminate normally.
CAUTION
Tail Lamp Relay Circuit
BATTERY
FRONT-ECU
INPUT SIGNAL
TAIL LAMP
RELAY
HEADLAMP AUTOMATIC
SHUTDOWN
TAIL LAMP SWITCH
RELAY
BOX
LICENSE PLATE LAMP

POSITION LAMP (LH)
REAR COMBINATION
LAMP (LH)
POSITION LAMP (RH)

REAR COMBINATION
LAMP (RH)

If all the tail lamps do not illuminate, the tail lamp
switch input circuit or the front-ECU may be
defective.
Possible causes
Wire colour code

DIAGNOSIS PROCEDURE
ECUS TO BE CHECKED
COLUMN ECU
FRONT ECU


impossible 354C."
54C-158

SYMPTOM PROCEDURES

monitor
related to the tail lamps.

connector
Connector: A-11X
<Selected item> LIGHTING - TAIL LAMP

Ignition switch: ON
Lighting switch: TAIL
Item No. Item name
Normal
conditions
Item 00
HEADLAMP SW
ON when the
lighting switch is
at HEAD
Item 01
TAIL LAMP SW
ON when the
lighting switch is
at TAIL
Item 03
PASSING SW
OFF
Item 30
IG SW(IG1)
ON
Item 35
HD AUTO-CUT
OFF
Item 70
FRONT ECU ACK
NORMAL ACK

items
Go to Step 3.
Normal condition is not displayed for item 00, 01 or
03. : Refer to inspection procedure N-5 "The


354C."
Refer to Inspection Procedure J-5 "The

headlamp automatic shutdown function
does not work normally 354C."
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

YES : Go to Step 4.

SYMPTOM PROCEDURES

connector.
Connector: A-11X
54C-159

battery.
Connector: A-11X
Relay box side

Relay box side
11 10 9 8 7 6 5 4 3 2 1
11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

box side.
AC301483 AD


Connector A-11X
(Relay box side)
11 10 9 8 7 6 5 4 3 2 1

Check that the tail lamps illuminate normally.
AC301541 AD

OK: System voltage
YES : Go to Step 6.
NO : Go to Step 5.


54C-160

SYMPTOM PROCEDURES
INSPECTION PROCEDURE J-3: The low-beam headlamps do not illuminate normally.
CAUTION
Headlamp Relay (Low-Beam) Circuit
BATTERY
FRONT-ECU
INPUT SIGNAL
HEADLAMP
RELAY: LO
HEADLAMP AUTOMATIC
SHUTDOWN
HEADLAMP SWITCH
RELAY
BOX
HEADLAMP (LH)
HEADLAMP (RH)

If the low-beam headlamps do not illuminate, the
headlamp switch input circuit or the front-ECU may
be defective.
Possible causes
Wire colour code

DIAGNOSIS PROCEDURE
ECUS TO BE CHECKED
COLUMN ECU
FRONT ECU


impossible 354C."

SYMPTOM PROCEDURES

monitor
related to the low-beam headlamps.
54C-161

connector
Connector: A-11X
<Selected item> LIGHTING - HEADLAMP LO

Ignition switch: ON
Lighting switch: HEAD
Item No.
Item name
Normal
conditions
Item 00
HEADLAMP SW
ON
Item 03
PASSING SW
OFF
Item 30
IG SW(IG1)
ON
Item 35
HD AUTO-CUT
OFF
Item 70
FRONT ECU ACK
NORMAL ACK

items
Relay box side

11 10 9 8 7 6 5 4 3 2 1

Go to Step 3.
Normal condition is not displayed for item 00 or 03.
:


354C."

AC301483 AD

YES : Go to Step 4.
54C-162
SYMPTOM PROCEDURES

connector.
Connector: A-11X

front-ECU connector terminal Nos. 8, 9 and the
battery.
Connector: A-11X
Relay box side

Relay box side
11 10 9 8 7 6 5 4 3 2 1
11 10 9 8 7 6 5 4 3 2 1
AC301483 AD

box side.
AC301483 AD


Connector A-11X
(Relay box side)
11 10 9 8 7 6 5 4 3 2 1

Check that the low-beam headlamps illuminate
normally.
AC301541 AE

terminal Nos. 8, 9 and body earth
OK: System voltage
YES : Go to Step 6.
NO : Go to Step 5.



SYMPTOM PROCEDURES
54C-163
INSPECTION PROCEDURE J-4: The high-beam headlamps do not illuminate normally.
CAUTION
Headlamp Relay (High-Beam) Circuit
BATTERY
FRONT-ECU
INPUT SIGNAL
HEADLAMP
RELAY: HI
HEADLAMP AUTOMATIC
SHUTDOWN
HEADLAMP SWITCH
RELAY
BOX
COMBINATION METER
HEADLAMP (LH)
HEADLAMP (RH)

If the high-beam headlamps do not illuminate, the
dimmer switch input circuit or the front-ECU may be
defective.
Possible causes
Wire colour code

DIAGNOSIS PROCEDURE
ECUS TO BE CHECKED
COLUMN ECU
FRONT ECU


impossible 354C."
54C-164

SYMPTOM PROCEDURES

monitor
related to the high-beam headlamps.
<Selected item> LIGHTING - HEADLAMP HI
Ignition switch: ON
Lighting switch: HEAD
Dimmer switch: from OFF to ON, and then to
OFF again
Item No. Item name
Normal conditions
Item 00
HEADLAMP
SW
ON
Item 02
DIMMER SW
from OFF to ON, and

then to OFF again ("ON"
should be displayed
when the dimmer switch
is operated)
Item 03
PASSING SW OFF
Item 30
IG SW(IG1)
ON
Item 35
HD AUTOCUT
OFF
Item 70
FRONT ECU
ACK
NORMAL ACK

items
Go to Step 3.
Normal condition is not displayed for item 00, 02 or
03. : Refer to inspection procedure N-5 "The


354C."


Check that the high-beam headlamps illuminate
normally.

54C-165
SYMPTOM PROCEDURES
INSPECTION PROCEDURE J-5: The high-beam and low-beam headlamps do not illuminate when the
passing switch is operated.
CAUTION
If the low-beam and high-beam headlamps are
normal, the passing switch input signal circuit or the
Possible causes

monitor.
Check the ETACS-ECU signals which are related to
the headlamps.
<Selected item> COLUMN ECU
Passing lamp switch: ON
Item No.
Item name
Normal
conditions
Item 03
PASSING SW
ON

YES : Go to Step 3.
DIAGNOSIS PROCEDURE

Step 1. Check the operation of the headlamps.

YES : Go to Step 2.
NO : Refer to inspection procedure J-2 "The low-
beam headlamps do not illuminate normally

354C." And refer to inspection
procedure J-3 "The high-beam headlamps
do not illuminate normally 354C."

When the passing switch is turned on, check if the
headlamps illuminate normally.

INSPECTION PROCEDURE J-6: The headlamp automatic shutdown function does not work normally.
CAUTION
Headlamp Automatic Shutdown Function
ETACS-ECU
INPUT SIGNAL
HEADLAMP SWITCH
TAIL LAMP SWITCH
54C-166

SYMPTOM PROCEDURES

Drivers door switch
Tail lamp switch
Headlamp switch
signal circuit(s), the front-ECU or the ETACS-ECU
may be defective. On vehicles with keyless entry
system, note that this function can be disabled/
enabled by the customize function (default setting;
enabled).
Possible causes

column switch (column-ECU), the ETACS-ECU and
the front-ECU and the SWS communication lines are
normal.
ECUS TO BE CHECKED
COLUMN ECU
ETACS ECU
FRONT ECU


impossible 354C."
DIAGNOSIS PROCEDURE

impossible 354C."

function.
YES : Go to Step 2.
NO : Enable the headlamp automatic shutdown
function by using the adjustment function.

Refer to GROUP 54B - Configuration
Function 354B.

monitor
related to the headlamp automatic shutdown
function.
<Selected item> LIGHTING - HD AUTO-CUT
Ignition switch: from ON to OFF
Lighting switch: "TAIL" or "HEAD"
Item No.
Item name
Normal
conditions
Item 00
HEADLAMP SW ON when the

lighting switch is
at HEAD
Item 01
TAIL LAMP SW
ON when the
lighting switch is
at TAIL
Item 30
IG SW(IG1)
from ON to OFF
Item 70
FRONT ECU
ACK
SLEEP ACK or
NORMAL ACK

SYMPTOM PROCEDURES
Drivers door: open

Item No.
Item name
Normal
conditions
Item 32
DR DOOR SW
ON
Item 35
HD AUTO-CUT
OFF

items
to Step 4.
:


354C."

354C."
:
54C-167


54C-168
SYMPTOM PROCEDURES
INSPECTION PROCEDURE J-7: Any of tail lamps, position lamps or licence plate lamp does not
illuminate.
CAUTION
Tail Lamps, Position Lamps and License Plate Lamps Circuit
TAIL LAMP
RELAY
FRONT-ECU
RELAY
BOX
HEADLAMP
ASSEMBLY
(POSITION)
(LH)
(RH)
REAR
COMBINATION
LAMP (TAIL: LH)
LICENCE
PLATE LAMP
(LH)
(RH)
Wire colour code


If the tail lamps, the position lamps or the licence
plate lamps do not illuminate, the wiring harness
connector(s), the bulb or the fuse may be defective
or burned out.
REAR
COMBINATION
LAMP (TAIL: RH)
SB : Sky blue
Possible causes
Burned-out bulb
54C-169
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 1. Connector check: D-14 <right tail lamp>

or D-19 <left tail lamp> rear combination lamp
connector, A-29 <right position lamp> or A-16
<left position lamp> headlamp assembly
connector, F-08 <right licence plate lamp> or F10 <left licence plate lamp> licence plate lamp
connector
F-10(GR)
F-08(GR)
Connector: A-16
Harness side
F-08
F-10
2 1
2 1
Harness side
3 2 1
6 5 4
A-16(B)
AC210455 AD
AC301666 AD
Connector: A-29

YES : Go to Step 2.
Harness side
3 2 1
6 5 4
A-29(B)
AC210453 AC
Step 2. Check the bulbs of the tail lamps, the

position lamp or the licence plate lamp.
Check the bulb of the lamp which does not
illuminate.
YES : Go to Step 3.
NO : Replace the bulb of the lamp which does not
illuminate.
D-14
D-19
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
AC301411AB
54C-170
SYMPTOM PROCEDURES
Step 3. Measure the resistance at the D-14 <right

tail lamp> or D-19 <left tail lamp> rear
combination lamp connector, the A-29 <right
position lamp> or A-16 <left position lamp>
headlamp assembly connector, the F-08 <right
licence plate lamp> or F-10 <left licence plate
lamp> licence plate lamp connector.
F-10(GR)
Connector: A-16
F-08(GR)
Harness side
Harness side
3 2 1
6 5 4
A-16(B)
F-08
F-10
2 1
2 1
AC210455 AD
Connector: A-29
AC301666 AD

Harness side
3 2 1
6 5 4
A-29(B)
AC210453 AC

(Harness side)
D-14
D-19
3 2 1
6 5 4
AC301541AI
Resistance between A-16 <position LH>

and body earth
Resistance between A-29 <position RH>
and body earth
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3

(Harness side)
1
2
6 5 4 3
AC301411AB
AC301541BG
54C-171
SYMPTOM PROCEDURES
Resistance between D-14 <right tail lamp> rear

and body earth
Resistance between D-19 <left tail lamp> rear
and body earth
Connector: A-29
Harness side
3 2 1
6 5 4
A-29(B)
Connector F-08, F-10

(Harness side)
AC210453 AC
2 1
D-14
D-19
AC301541BM
Resistance between F-08 <licence plate lamp,

RH> licence plate lamp connector terminal
No.1 and body earth
Resistance between F-10 <licence plate
lamp, LH> licence plate lamp connector
OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
Harness side

lamp> headlamp connector terminal No.1 or F-08
<right licence plate lamp> or F-10 <right licence
plate lamp> licence plate lamp connector
Connector: A-16
Harness side
3 2 1
6 5 4
A-16(B)
AC210455 AD
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
AC301411AB
54C-172

SYMPTOM PROCEDURES

connector
Connector: A-11X
F-10(GR)
F-08(GR)
F-09(GR)
F-09
1 2
3 4
Harness side
F-08
2 1
Relay box side
F-10
11 10 9 8 7 6 5 4 3 2 1
2 1
AC301666 AD

intermediate connector F-09 <licence plate lamp>,
YES : Go to Step 7.
AC301483 AD

YES : Go to Step 6.
54C-173
SYMPTOM PROCEDURES

lamp> headlamp assembly connector terminal
No.2, F-08 <right licence plate lamp> or F-10 <left
licence plate lamp> licence plate lamp connector
terminal No.2 to A-11X front-ECU connector
terminal No.4.
D-14
D-19
Connector: A-11X
Harness side
D-14
D-19
2
1
6 5 4 3
2
1
6 5 4 3
AC301411AB

Relay box side
11 10 9 8 7 6 5 4 3 2 1
F-10(GR)
AC301483 AD
F-08(GR)
Connector: A-16
F-09(GR)
F-09
Harness side
3 2 1
6 5 4
A-16(B)
1 2
3 4
Harness side
F-08
2 1
F-10
AC210455 AD
Connector: A-29
2 1
AC301666 AD
Harness side
3 2 1
6 5 4
A-29(B)
AC210453 AC
54C-174
SYMPTOM PROCEDURES
NOTE:
Connector: D-31
1 2
3 4
5 6 7 8 9 10
1112 13 14 15 16
C-01
C-117
AC301408 AE
C-116
C-01
C-116
1 2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
5 6 7
3 4
10 11 12 13 14
15
8 9
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
C-117
1 2 3
4 5 6 7 8 9 10
111213
14 1516 17 18 19 20 2122 232425

26 2728 29
32 33 34
35
30 31
36 37
38
AC301396 AN


connector C-01 <right tail lamp>, intermediate
connector C-116 <tail lamp and licence plate lamp>,
C-117 <left tail lamp and licence plate lamp>, D-31
<right tail lamp>, F-09 <licence plate lamp>, junction
block connector C-202 <right tail lamp> and C-209
<right tail lamp>, and repair if necessary.
YES : Go to Step 7.

Check that the tail lamps, the position lamps and the
licence plate lamps illuminate normally.
C-202

When the tail lamps do not illuminate : Replace
the rear combination lamp socket assembly.
C-209
When the position lamps do not illuminate :
Replace the position lamp socket.

When the licence plate lamps do not illuminate :
Harness side
C-202
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Replace the licence plate lamp socket.

C-209
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210475 AJ

SYMPTOM PROCEDURES
54C-175
INSPECTION PROCEDURE J-8: The headlamp(s) do not illuminate. <including high-beam indicator>
CAUTION
Headlamps (High-Beam Indicator Lamp) Circuit
FRONT-ECU
HEADLAMP
RELAY: LO
HEADLAMP
RELAY: HI
RELAY BOX
HEADLAMP
(LH)
(RH)
COMBINATION
METER
Wire colour code


If any of the headlamps or the high-beam indicator
does not illuminate, the wiring harness connector(s),
the bulb or the fuse may be defective or burned out.
SB : Sky blue
Possible causes
Malfunction of the headlamp bulbs
Malfunction of the high-beam indicator bulb
54C-176
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 1. Connector check: A-30 <headlamp RH>,
A-15 <headlamp LH> headlamp assembly
connector or C-05 <high-beam indicator>
Connector: A-15
A-15(B)
Harness side
1
3 Y 2
AC210455 AC
Connector: A-30
A-30(B)
Harness side
1
3 Y 2
AC210453 AD
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE

YES : Go to Step 2.
Step 2. Check the bulb(s) of the headlamps or the

high-beam indicator lamp.
YES : Go to Step 3.
54C-177
SYMPTOM PROCEDURES
Step 3. Measure the resistance at A-30

<headlamp RH>, A-15 <headlamp LH> headlamp
assembly connector or C-05 <high-beam
indicator> combination meter connector.
Connector: A-15
and body earth

Resistance between A-15 <left headlamp>
and body earth
Connector C-05
(Harness side)
A-15(B)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
Harness side
1
3 Y 2
AC301541 AO
AC210455 AC
Resistance between C-05 <high-beam indicator

lamp> combination meter connector terminal
No.8 and body earth
OK: 2 W or less
Connector: A-30

YES : Go to Step 5.
NO : Go to Step 4.
A-30(B)
Harness side
1
3 Y 2
AC210453 AD
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE


(Harness side)
1
3 Y 2
AC301541AH
Resistance between A-30 <right headlamp>

54C-178
SYMPTOM PROCEDURES

<right headlamp> or A-15 <left headlamp>
headlamp connector terminal No.2, or C-05
<high-beam indicator lamp> combination meter

connector
Connector: A-11X
Connector: A-15
A-15(B)
Harness side
1
3 Y 2
AC210455 AC
Relay box side
Connector: A-30
11 10 9 8 7 6 5 4 3 2 1
A-30(B)
Harness side
AC301483 AD
1
3 Y 2
AC210453 AD
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE

YES : Go to Step 7.

YES : Go to Step 6.

SYMPTOM PROCEDURES

<right headlamp>, A-15 <left headlamp>
headlamp connector terminal No.1 <low-beam>,
No.3 <high-beam>, C-05 combination meter
connector terminal No.9 <high-beam indicator>
to A-11X front-ECU connector terminal No.6
<low-beam> or No.10 <high-beam>.
54C-179
Connector: A-11X
Connector: A-15
A-15(B)
Harness side
Relay box side
1
3 Y 2
11 10 9 8 7 6 5 4 3 2 1
AC210455 AC
Connector: A-30
AC301483 AD

intermediate connector C-116 <high-beam
indicator>, and repair if necessary.
A-30(B)
Harness side
1
3 Y 2
AC210453 AD

C-05(L)

YES : Go to Step 7.

Check that the headlamps and the high-beam
indicator lamp illuminate/extinguish normally.
C-116
When the high-beam indicator lamp does not

illuminate : Replace the combination meter.
C-116
1 2
5 6 7
3 4
10 11 12 13 14
15
8 9
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
Harness side
C-05
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12

When the headlamps do not illuminate : Replace
the headlamp socket.
AC301396 AJ
54C-180
SYMPTOM PROCEDURES
FLASHER TIMER
INSPECTION PROCEDURE K-1: The turn-signal lamps do not illuminate.
CAUTION
Turn-Signal Lamp Power Supply Circuit
BATTERY
RELAY
BOX
ETACS-ECU
TURN-SIGNAL
LAMP RELAY: RH
TURN-SIGNAL
LAMP RELAY: LH
FRONT TURN SIGNAL

LAMP (LH)
SIDE TURN SIGNAL
LAMP (LH)
REAR
COMBINATION
LAMP
FRONT TURN SIGNAL

LAMP (RH)
SIDE TURN SIGNAL
LAMP (RH)
COMBINATION
METER
Wire colour code


If all the turn-signal lamps do not illuminate, the
ignition switch (IG1), the turn-signal lamp switch
input circuit or the ETACS-ECU may be defective.
Possible causes
SB : Sky blue
DIAGNOSIS PROCEDURE
operate.
normally.
YES : Go to Step 6.
NO : Go to Step 2.

SYMPTOM PROCEDURES

connector
Connector: C-217
54C-181

battery.
Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
AC210476 AC

YES : Go to Step 3.
NOTE:
Connector: C-116

Connector: C-217
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG
Junction block side
Connector: C-202
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC210474 AB
Connector C-217

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC301541AU

OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.


54C-182
SYMPTOM PROCEDURES


monitor
related to the right turn-signal lamps.
<Selected item> TURN SIGNAL - TURN-SIG. RH
Turn-signal lamp switch: RH
Ignition switch: ON
Item No.
Item name
Normal
conditions
Item 10
TURN SIG.RH
ON
Item 11
TURN SIG.LH
OFF
Item 30
IG SW(IG1)
ON

items
Go to Step 7.
:


354C."

monitor
related to the left turn-signal lamps.
<Selected item> TURN SIGNAL - TURN-SIG. LH
Turn-signal lamp switch: LH
Ignition switch: ON
Item No.
Item name
Normal
conditions
Item 10
TURN SIG.RH
OFF
Item 11
TURN SIG.LH
ON

Go to Step 8.
:

Check that the turn-signal lamps illuminate.

54C-183
SYMPTOM PROCEDURES
INSPECTION PROCEDURE K-2: The hazard warning lamps do not illuminate.
CAUTION
Hazard Warning Lamp Circuit
BATTERY
RELAY
BOX
ETACS-ECU
INPUT SIGNAL
TURN-SIGNAL
LAMP RELAY: RH
TURN-SIGNAL
LAMP RELAY: LH
COMBINATION METER
FRONT TURN SIGNAL
LAMP (LH)
REAR COMBINATION
LAMP (LH)
SIDE TURN SIGNAL
LAMP (LH)
HAZARD
WARNING
LAMP SWITCH
COMBINATION METER
FRONT TURN SIGNAL
LAMP (RH)
REAR COMBINATION
LAMP (RH)
SIDE TURN SIGNAL
LAMP (RH)
Wire colour code


If the hazard warning lamps do not illuminate, the
hazard warning lamp input signal circuit or the
Possible causes
SB : Sky blue
DIAGNOSIS PROCEDURE
Step 1. Check that the turn-signal lamps operate.
YES : Go to Step 2.
NO : Refer to inspection procedure K-1 "The turn
signal lamps do not illuminate 354C."
54C-184

SYMPTOM PROCEDURES
Step 2. Pulse check

switch.
System switch
Check conditions
Hazard warning
lamp switch
When the hazard warning lamp

switch is turned from off to on

needle fluctuates.
YES : Go to Step 3.
hazard warning lamp switch signal is not

received 354C."

Check that the hazard warning lamps illuminate.

54C-185
SYMPTOM PROCEDURES
INSPECTION PROCEDURE K-3: Any of the turn-signal lamps does not illuminate.
CAUTION
ETACS-ECU
SIDE TURN
SIGNAL
LAMP
(LH)
HEADLAMP
ASSEMBLY
(FRONT TURN:
LH)
REAR
COMBINATION
LAMP (LH)
COMBINATION
METER
(LH) (RH)
Wire colour code

SB : Sky blue
54C-186

SYMPTOM PROCEDURES
ETACS-ECU
REAR
COMBINATION
LAMP (RH)

If any of the turn-signal lamp does not illuminate
normally, wiring harness connector(s) or the bulb
may be defective.
HEADLAMP
ASSEMBLY
(FRONT TURN:
RH)
SIDE TURN
SIGNAL
LAMP (RH)
Possible causes
Defective turn-signal lamp bulb
54C-187
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE

C-05(L)
Step 1. Connector check: A-29 <front RH> or A16 <front LH> front turn-signal lamp connector,
A-01 <side RH> or A-04 <side LH> side turnsignal lamp connector, D-14 <rear RH> or D-19
<rear LH> rear combination lamp connector, C-05
<turn-signal indicator lamp> and C-04 <turnsignal indicator lamp (LH)> combination meter
connector
C-04

A-01(GR)
Harness side
Harness side
A-01
C-05
C-04
2 1
A-29
41 4039 38 3736 35 3433 32 31

52 51 50 49 48 47 46 4544 43 42
A-29(B)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
3 2 1
6 5 4
AC210453 AJ
A-04(GR)
AC301396 AH

Harness side
D-14
Harness side
A-04
A-16
2 1
3 2 1
6 5 4
D-14
D-19
2
1
6 5 4 3
D-19
A-16(B)
AC210455 AH
2
1
6 5 4 3
AC301410 AH

YES : Go to Step 2.
Step 2. Check the bulb(s) of the turn-signal lamps

or the turn-signal indicator lamps.
YES : Go to Step 3.
54C-188
SYMPTOM PROCEDURES
Step 3. Measure the resistance at the A-29 <front

RH> or A-16 <front LH> front turn-signal lamp
connector, the A-01 <side RH> or A-04 <side LH>
side turn-signal lamp connector, the D-14 <rear
RH> or D-19 <rear LH> rear combination lamp
connector, the C-05 <turn-signal indicator lamp>
and C-04 <turn-signal indicator lamp (LH)>
combination meter connector.

Harness side
D-14
D-14
D-19
2
1
6 5 4 3
D-19
2
1
6 5 4 3
AC301410 AH
A-01(GR)

(2) Measure the resistance between the defective
lamp connector terminal and body earth.
Harness side
A-01
2 1
A-29
A-29(B)
3 2 1
6 5 4
AC210453 AJ
A-04(GR)
3 2 1
6 5 4
Harness side
A-04
A-16
2 1
3 2 1
6 5 4

(Harness side)
AC301541AI
A-16(B)
AC210455 AH
Resistance between A-29 <front RH> headlamp

assembly connector terminal No.1 and body
earth
Resistance between A-16 <front LH>
and body earth
C-05(L)
C-04

(Harness side)
2 1
AC301541AB
Harness side
C-05
C-04
41 4039 38 3736 35 3433 32 31
52 51 50 49 48 47 46 4544 43 42
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AH
Resistance between A-01 <side RH> side turnsignal lamp connector terminal No.1 and body
earth
Resistance between A-04 <side LH> side
body earth

SYMPTOM PROCEDURES

(Harness side)
1
2
6 5 4 3
AC301541BG
Resistance between D-14 <rear RH> rear

and body earth
Resistance between D-19 <rear LH> rear
and body earth
Connector C-05
(Harness side)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301541 AP
Resistance between C-05 <turn-signal indicator

lamp> combination meter terminal No.12 and
body earth
OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
54C-189
54C-190
SYMPTOM PROCEDURES

lamp connector terminal No.2, A-01 <side RH> or
A-04 <side LH> side turn-signal lamp connector
terminal No.1, D-14 <rear RH> or D-19 <rear LH>
rear combination lamp connector terminal No.3,
or C-05 <turn-signal indicator lamp> combination
meter connector terminal No.12 to body earth.

Harness side
D-14
D-14
D-19
2
1
6 5 4 3
D-19
2
1
6 5 4 3
AC301410 AH
A-01(GR)
NOTE:
Connector: C-14
Harness side
A-01
2 1
A-29
A-29(B)
3 4
1 2
5 6 7 8 9 10
3 2 1
6 5 4
AC210453 AJ
A-04(GR)
AC301397 AC

intermediate connector C-14 <side RH>, and repair if
necessary.
Harness side
A-04
A-16
2 1
3 2 1
6 5 4
A-16(B)
AC210455 AH

C-05(L)


connector
C-04
Connector: C-217
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
Harness side
41 4039 38 3736 35 3433 32 31

52 51 50 49 48 47 46 4544 43 42
AC210476 AC
C-05
C-04
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AH

YES : Go to Step 6.
54C-191
SYMPTOM PROCEDURES
Step 6. Check the wiring harness from the A-29

lamp connector terminal No.3, the A-01 <side
RH> or A-04 <side LH> side turn-signal lamp
connector terminal No.2, the D-14 <rear RH> or
D-19 <rear LH> rear combination lamp connector
terminal No.6, the C-05 <turn-signal indicator
lamp RH> combination meter connector terminal
No.10 or C-04 <turn-signal indicator lamp LH>
combination lamp connector terminal No.31 to C217 ETACS-ECU connector terminal No.9 <RH>
or 14 <LH>.

C-05(L)
C-04
C-116
C-116

A-01(GR)
Harness side
C-04
Harness side
A-01
2 1
C-05
41 4039 38 3736 35 3433 32 31

52 51 50 49 48 47 46 4544 43 42
A-29
A-29(B)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AI
3 2 1
6 5 4
AC210453 AJ
Connector: C-217
A-04(GR)
Harness side
A-04
A-16
2 1
3 2 1
6 5 4
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
A-16(B)
AC210476 AC
AC210455 AH

Harness side
D-14
D-14
D-19
2
1
6 5 4 3
D-19
2
1
6 5 4 3
AC301410 AH
54C-192
SYMPTOM PROCEDURES
YES : Go to Step 7.
NOTE:
Connector: C-14

Check that the turn-signal lamps and the indicator
lamps illuminate normally.
1 2
3 4
5 6 7 8 9 10
AC301397 AC



The front turn-signal lamps do not illuminate. :
Replace the socket.

The side turn-signal lamps do not illuminate. :
Replace the socket.

The rear turn-signal lamps do not illuminate. :
C-202
Replace the socket assembly.

The turn-signal indicator lamps do not illuminate. :
C-205
Replace the combination meter.

C-209
Harness side
C-205
C-202
6 5 4
3 2 1
14 13 12 11 10 9 8 7
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-209
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210475 AH
Connector: D-31
3 4
1 2
5 6 7 8 9 10
1112 13 14 15 16
AC301408 AE

intermediate connector C-14 <side RH>, C-116
<front or side LH> or D-31 <rear RH> and junction
block connector C-202 <front and side>, C-209
<rear> or C-205 <turn-signal indicator lamp>, and

SYMPTOM PROCEDURES
54C-193
FOG LAMP
INSPECTION PROCEDURE L-1: The front fog lamps do not illuminate normally.
CAUTION
BATTERY
RELAY
BOX
FRONT FOG
LAMP RELAY
FRONT-ECU
FRONT
FOG LAMP
(LH)
FRONT
FOG LAMP
(RH)
COMBINATION
METER
Wire colour code

OPERATION
Tail lamp switch
Headlamp switch
Fog lamp switch
If the fog lamps do not illuminate normally, these
defective.
SB : Sky blue
Possible causes
54C-194

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
operate.
normally.
YES : Go to Step 2.
NO : Repair the tail lamp(s) and headlamp(s).
Refer to trouble symptom chart 354C.

normal.
ECUS TO BE CHECKED
COLUMN ECU
ETACS ECU
FRONT ECU


impossible 354C."

impossible 354C."

monitor
related to the fog lamps.
<Selected item> LIGHTING - F.FOG LAMP
Ignition switch: ON
Item No.
Item name
Normal conditions
Item 00
HEADLAMP SW ON when the lighting

switch is at HEAD
Item 01
TAIL LAMP SW
ON when the lighting

switch is at TAIL or
HEAD
Item 30
IG SW(IG1)
ON
Item 36
F.FOG LAMP
ON
Item 70
FRONT ECU
ACK
NORMAL ACK or
HI-BEAM ACK

the items.
Go to Step 4.
:
Refer to inspection procedure P-5 "The


354C."

front fog lamp switch signal is not received
354C."
54C-195
SYMPTOM PROCEDURES

connector
Connector: A-05X
Step 6. Measure the voltage at the A-05X fog

Connector: A-05X
Relay box side
Relay box side
Front of
vehicle
Front of
vehicle
AC301483AC

YES : Go to Step 5.
AC301483AC
(1) Remove the fog lamp relay, and measure at the

relay box side.
(2) Check the voltage between the fog lamp relay
Step 5. Check the fog lamp relay.

Refer to GROUP 54A - Fog lamp 354A.
YES : Go to Step 6.
NO : Replace the fog lamp relay.
Connector A-05X
(Relay box side)
AC301541AC
Voltage between A-05X fog lamp relay connector

Voltage between A-05X fog lamp relay
OK: System voltage
YES : Go to Step 8.
NO : Go to Step 7.
54C-196
SYMPTOM PROCEDURES

fog lamp relay connector (terminal Nos. 1 and 2)
and the battery.

connector
Connector: A-11X
Connector: A-05X
Relay box side
Relay box side

2
11 10 9 8 7 6 5 4 3 2 1
Front of
vehicle
AC301483 AD
AC301483AC



YES : Go to Step 9.

SYMPTOM PROCEDURES

fog lamp relay connector terminal No.3 and A11X front-ECU connector terminal No.11.
Connectors: A-05X, A-11X
A-05X
Relay box side
A-11X
11 10 9 8 7 6 5 4 3 2 1
Front of
vehicle
AC301483 AB


Check that the fog lamps illuminate normally.

A-11X
A-05X
54C-197
54C-198
SYMPTOM PROCEDURES
INSPECTION PROCEDURE L-2: The rear front fog lamps do not illuminate normally.
CAUTION
FUSIBLE
LINK 1
REAR
FOG
LAMP
RELAY
COMBINATION
METER
REAR FOG
LAMP
ETACS-ECU
Wire colour code

OPERATION
Tail lamp switch
Headlamp switch
If the rear fog lamps do not illuminate normally, these
defective.
Possible causes
SB : Sky blue
DIAGNOSIS PROCEDURE
operate.
normally.
YES : Go to Step 2.
(Refer to trouble symptom chart 354C).
54C-199
SYMPTOM PROCEDURES

normal.
ECUS TO BE CHECKED
COLUMN ECU
ETACS ECU
FRONT ECU


impossible 354C."

impossible 354C."
monitor
related to the fog lamps.
<Selected item> LIGHTING - REAR FOG LAMP
Ignition switch: ON
Item No. Item name
Normal conditions
Item 00
ON when the
lighting switch is at
HEAD
Item 01
HEADLAMP SW
TAIL LAMP SW
ON when the
lighting switch is at
TAIL

the items.
Go to Step 4.
:
column switch (Lighting and turn-signal

lamp switch) signal is not received 354C
."
Step 4. Pulse check

the rear fog lamps.
System switch
Check conditions

to ON
When the rear fog lamp

to on

needle fluctuates.
5.

354C."
The rear fog lamp switch signal is not received. :

rear fog lamp switch signal is not received
354C."
relay connector
Connector: C-212
Junction block side

2 1
4 3
AC210474 AI

YES : Go to Step 6.
Step 6. Check the rear fog lamp relay.

YES : Go to Step 7.
NO : Replace the rear fog lamp relay.
54C-200
SYMPTOM PROCEDURES
Step 7. Measure the voltage at the C-212 rear fog

Connector: C-212

rear fog lamp relay connector (terminal Nos. 3
Connectors: C-201, C-204, C-205, C-212
C-204
C-201
Junction block side
C-205
2 1
4 3
AC210474 AI
Junction block side

C-212
C-212
(1) Remove the rear fog lamp relay, and measure at

the relay box side.
(2) Check the voltage between the rear fog lamp
2 1
4 3
Harness side
C-201
C-204
5 4 3
2 1
13121110 9 8 7 6
Connector C-212
(Relay box side)
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
2 1
4 3
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210475 AE
NOTE:
AC301541 AR

OK: System voltage
YES : Go to Step 9.
NO : Go to Step 8.
Connector: C-116
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG

necessary.

54C-201
SYMPTOM PROCEDURES

connector
Connector: C-219

rear fog lamp relay connector terminal No.2 and
C-201
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

C-212
Harness side
Junction block side
C-201
C-212
5 4 3
2 1
13121110 9 8 7 6
2 1
4 3
AC210475 AF
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

necessary.

Check that the rear fog lamps illuminate normally.

54C-202

SYMPTOM PROCEDURES
INSPECTION PROCEDURE L-3: The front fog lamp(s) do not illuminate.
CAUTION
BATTERY
RELAY
BOX
FRONT FOG
LAMP RELAY
FRONT-ECU
FRONT
FOG LAMP
(LH)
FRONT
FOG LAMP
(RH)
COMBINATION
METER
Wire colour code


If any of the front fog lamps do not illuminate, the
SB : Sky blue
Possible causes
Burned-out front fog lamp bulb

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 1. Connector check: A-24 <RH> or A-19
<LH> front fog lamp connector, or C-05 <front fog
connector
Connector: A-19
Harness side
A-19(B)
2 1
AC210455 AE
Connector: A-24
Harness side
2 1
A-24(B)
AC210453 AB
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE

YES : Go to Step 2.
54C-203
Step 2. Check the bulbs of the front fog lamps or

the front fog lamp indicator lamp.
YES : Go to Step 3.
54C-204
SYMPTOM PROCEDURES
Step 3. Measure the resistance at A-24 <RH> or

A-19 <LH> front fog lamp connector, or C-05
<front fog lamp indicator lamp> combination
meter connector.
Resistance between A-19 <LH> front fog

Connector C-05
(Harness side)
Connector: A-19
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
Harness side
A-19(B)
AC301541 AP
2 1
AC210455 AE
Connector: A-24
Resistance between C-05 <front fog lamp

OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
Harness side
2 1
A-24(B)
AC210453 AB
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE


(Harness side)
2 1
AC301541 AJ
Resistance between A-24 <RH> front fog


SYMPTOM PROCEDURES

combination meter connector terminal No.12 to
body earth.
54C-205

connector
Connector: A-05X
Connector: A-19
Harness side
A-19(B)
2 1
AC210455 AE
Relay box side
Connector: A-24
Front of
vehicle
Harness side
AC301483AC
2 1
A-24(B)
AC210453 AB
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE



YES : Go to Step 6.
54C-206
SYMPTOM PROCEDURES

combination meter connector terminal No.7 to A05X fog lamp relay connector terminal No.4.
Connector: A-19

YES : Go to Step 7.

Check that the fog lamp and the front fog lamp
Harness side
A-19(B)
2 1
AC210455 AE
Connector: A-24
Harness side
2 1
A-24(B)
AC210453 AB

C-05(L)
C-116
C-116
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
Harness side
C-05
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AJ

intermediate connector C-116 <front fog lamp
indicator lamp>, and repair if necessary.

The fog lamps do not illuminate. : Replace the fog
lamp(s).
The front fog lamp indicator lamp does not
54C-207
SYMPTOM PROCEDURES
INSPECTION PROCEDURE L-4: Any of the rear fog lamps does not illuminate.
CAUTION
FUSIBLE
LINK 1
REAR
FOG
LAMP
RELAY
COMBINATION
METER
REAR FOG
LAMP
ETACS-ECU
Wire colour code


If any of the rear fog lamps do not illuminate, the
SB : Sky blue
Possible causes
Burned-out rear fog lamp bulb
54C-208
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 1. Connector check: F-12 rear fog lamp
connector or C-05 <rear fog lamp indicator lamp>
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE
Connector: F-12
Harness side
2 1
F-12(B)
AC301665 AD

YES : Go to Step 2.
Step 2. Check the bulbs of the rear fog lamps or

the rear fog lamp indicator lamp.
YES : Go to Step 3.
54C-209
SYMPTOM PROCEDURES

fog lamp connector or C-05 <fog lamp indicator
lamp> combination meter connector.
Connector: C-05

YES : Go to Step 5.
NO : Go to Step 4.
C-05(L)

Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12

OK: 2 W or less
AC301395 AE
Connector: C-05
Harness side
Harness side
(front view)
C-05(L)
Connector: F-12
2 1
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
F-12(B)
AC301395 AE
AC301665 AD

Connector F-12
(Harness side)
F-12(B)
2 1
F-09(GR)
Harness side
F-09
F-12
AC301541BN
Resistance between F-12 rear fog lamp relay

Connector C-05
(Harness side)
2 1
AC301666 AF

intermediate connector F-09 <rear fog lamp>, and
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
1 2
3 4

AC301541 AP
Resistance between C-05 <rear fog lamp

54C-210

SYMPTOM PROCEDURES

relay connector
Connector: C-212
Junction block side

2 1
4 3
AC210474 AI

YES : Go to Step 6.
54C-211
SYMPTOM PROCEDURES

connector terminal No.5 to C-212 rear fog lamp
relay connector terminal No.1.
Connector: C-05

C-05(L)
C-05(L)
C-117
Harness side
(front view)
C-117
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
1 2 3
4 5 6 7 8 9 10
111213
14 1516 17 18 19 20 2122 232425
AC301395 AE
26 2728 29
32 33 34
35
30 31
36 37
38
Harness side
C-05

11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
C-201
AC301396 AK

intermediate connector C-117 <rear fog lamp>, F-09
<rear fog lamp> and junction block connector C-201
<rear fog lamp and rear fog lamp indicator lamp>,
C-212
Harness side
Junction block side
C-201
C-212
5 4 3
2 1
13121110 9 8 7 6
2 1
4 3
AC210475 AF

YES : Go to Step 7.

Check that the rear fog lamp and the rear fog lamp

The rear fog lamps do not illuminate. : Replace the
rear fog lamp(s).
The rear fog lamp indicator lamp does not
54C-212
SYMPTOM PROCEDURES
ROOM LAMP
INSPECTION PROCEDURE M-1: The front or rear room lamp does not illuminate or extinguish
normally. <Vehicles without keyless entry system>
CAUTION
Room Lamp Circuit
ETACS-ECU
REAR
ROOM
LAMP
FRONT
ROOM
LAMP
Wire colour code


Key reminder switch
SB : Sky blue

signal circuit(s) or the ETACS-ECU may be
defective.
Possible causes

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 2.

impossible 354C."
monitor.
Item No.
Item name
Normal
conditions
Item 30
IG SW(IG1)
OFF

YES : Go to Step 3.

354C."
54C-213
Step 3. Pulse check

the front or rear dome lamps.
System switch
Check conditions
Key reminder switch When the inserted ignition

key is pulled out
All of the door
switches
A door is opened when all

the doors are closed
Drivers door lock

actuator switch

unlocked or locked

needle fluctuates.
4.

354C."

."

signal is not received 354C."
54C-214
SYMPTOM PROCEDURES

Connector: D-05
Harness side

and 1.
Connector: C-217
1
2
Junction block side
AC301408 AB
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
Connector: D-11
AC210476 AC
D-11(GR)
Connector: D-05
Harness side
2 1
Harness side
1
2
AC301410 AD

YES : Go to Step 5.
Step 5. Check the bulbs of the front and rear

room lamps.
Check the bulbs of the front and rear room lamps.
YES : Go to Step 6.
AC301408 AB
NOTE:
Connector: C-210
Harness side
3 2 1

connector
Connector: C-217
AC210474 AH

YES : Go to Step 8.
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 7.

SYMPTOM PROCEDURES

and 1.
Connector: C-217
54C-215

YES : Go to Step 9.

Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
Connector: D-11
D-11(GR)
Harness side
2 1
AC301410 AD
NOTE:
Connector: C-210
Harness side
3 2 1
AC210474 AH


54C-216
SYMPTOM PROCEDURES
INSPECTION PROCEDURE M-2: The front and rear room lamp do not illuminate or extinguish
normally. <Vehicles with keyless entry system>
CAUTION
Room Lamp Circuit
ETACS-ECU
REAR
ROOM
LAMP
FRONT
ROOM
LAMP
Wire colour code


Key reminder switch
SB : Sky blue

signal circuit(s), the interior lamp automatic
shutdown function or the ETACS-ECU may be
defective. The delay-off setting of this function can
be changed by the adjustment function (default
setting; 15 seconds).
Possible causes

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Check that the room lamp delay-off time has been
set to other than "0 second" by the adjustment
function.
YES : Go to Step 2.
NO : Use the adjustment function to set the room
lamp delay-off time to other than "0 second"

(Refer to GROUP 54B - Adjustment
function 354B).
normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 3.

impossible 354C."
monitor.
Item No.
Item name
Normal
conditions
Item 30
IG SW(IG1)
OFF

YES : Go to Step 4.

354C."
54C-217
Step 4. Pulse check

the front or rear dome lamps.
System switch
Check conditions
Key reminder switch When the inserted ignition

key is pulled out
All of the door
switches
A door is opened when all

the doors are closed
Drivers door lock

actuator switch

unlocked or locked

signal

through multi-purpose fuse
No.18

needle fluctuates.
5.

354C."

."

signal is not received 354C."
The interior lamp loaded signal is not received. :
Refer to inspection procedure N-17 "Interior

lamp loaded signal is not detected 354C
."
54C-218
SYMPTOM PROCEDURES

Connector: D-05
Harness side

and 1.
Connector: C-217
1
2
Junction block side
AC301408 AB
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
Connector: D-11
AC210476 AC
D-11(GR)
Connector: D-05
Harness side
2 1
Harness side
1
2
AC301410 AD

YES : Go to Step 6.
Step 6. Check the bulbs of the front and rear

dome lamps.
Check the bulbs of the front and rear dome lamps.
YES : Go to Step 7.
AC301408 AB
NOTE:
Connector: C-210
Harness side
3 2 1

connector
Connector: C-217
AC210474 AH

YES : Go to Step 9.
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 8.

SYMPTOM PROCEDURES

and 1.
Connector: C-217
54C-219


Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
Connector: D-11
D-11(GR)
Harness side
2 1
AC301410 AD
NOTE:
Connector: C-210
Harness side
3 2 1
AC210474 AH


54C-220

SYMPTOM PROCEDURES
INSPECTION PROCEDURE M-3: Interior lamp automatic shutoff function does not work normally.
CAUTION
FUSIBLE
LINK 1
ETACS-ECU
INPUT SIGNAL
ALL DOOR
SWITCH
FRONT DOOR
SWITCH
IGNITION
SWITCH (ACC)
IGNITION
SWITCH (IG1)
INTERIOR LAMP
LOADED SIGNAL
KEEP RELAY
LOAD
DETERMINATION
CIRCUIT
INTERIOR
LAMP CUT
BACK-UP
CIRCUIT
COMBINATION
METER

The ETACS-ECU operates the interior lamp
automatic shutdown function in accordance with the
input signals below.
Drivers door switch
signal circuit(s) or the ETACS-ECU may be
defective. Note that this function can be disabled/
enabled by the adjustment function (default setting;
enabled).
Possible causes
FRONT ROOM LAMP

REAR ROOM LAMP

DIAGNOSIS PROCEDURE
function.
YES : Go to Step 2.
NO : Enable the interior lamp automatic
shutdown function by using the adjustment

function (Refer to GROUP 54B Adjustment function 354B).

SYMPTOM PROCEDURES

normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
YES : Go to Step 3.

impossible 354C."
monitor.
the interior lamp automatic shutdown function.
54C-221
Step 4. Pulse check

the interior lamp automatic shutdown function.
System switch
Check conditions


signal

fuse No.18

needle fluctuates.
5.

."
The interior lamp loaded signal is not received. :
Refer to inspection procedure N-17 "Interior

lamp loaded signal is not detected 354C
."

Drivers door: open
Item No.
Item name
Normal
conditions
Item 30
IG SW(IG1)
OFF
Item 31
IG SW(ACC)
OFF
Item 32
DR DOOR SW
ON

Go to Step 4.

354C."

354C."

354C."


54C-222

SYMPTOM PROCEDURES
INSPECTION PROCEDURE M-4: The door-ajar warning lamp does not illuminate/extinguish normally.
CAUTION
Door Ajar Indicator Lamp Circuit
ETACS-ECU
INPUT SIGNAL
COMBINATION
METER
ALL DOOR SWITCH

FRONT DOOR SWITCH
Wire colour code

OPERATION
accordance with all the door switch signals. If the
door-ajar warning lamp does not work normally, the
input signal circuits from all the door switches or the
Possible causes
All the door switches are defective.
DIAGNOSIS PROCEDURE
Check that the dome lamps illuminate and extinguish
normally.
YES : Go to Step 2.

system>354C ." Or refer to inspection
with keyless entry system>354C ."
SB : Sky blue

monitor.
Drivers door: open
Item No.
Item name
Normal
conditions
Item 32
DR DOOR SW
ON

YES : Go to Step 3.

354C."
54C-223
SYMPTOM PROCEDURES
Step 3. Pulse check

System switch
Check conditions


connector
Connector: C-219

needle fluctuates.
Harness side

YES : Go to Step 4.
NO : Refer to inspection procedure N-13 "All the

."
Step 4. Connector check: C-05 combination
meter connector
Connector: C-05
C-05(L)
Harness side
(front view)
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 7.

ETACS-ECU connector (terminal Nos. 53 and 71)
to C-05 combination meter connector (terminal
Nos. 20 and 21).
Connector: C-05
C-05(L)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
Harness side
(front view)
AC301395 AE

YES : Go to Step 5.
Step 5. Check the door-ajar warning lamp bulb.

Check the door-ajar warning lamp bulb.
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE
Connector: C-219

YES : Go to Step 6.
NO : Replace the door-ajar warning lamp bulb.
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 8.
54C-224
Step 8. Retest
the system.
door-ajar warning lamp illuminates/extinguishes
normally.
(2) Check that the door-ajar warning lamp

INSPECTION PROCEDURE N-1: The ignition switch (ACC) signal is not received.
CAUTION
Ignition Switch (ACC) Input Circuit
IGNITION
SWITCH (ACC)
ETACS-ECU
Wire colour code


Input signal from the ignition switch (ACC) is used to
SB : Sky blue

Possible causes
54C-225
DIAGNOSIS PROCEDURE
connector
Connector: C-217

Connector: C-217
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 2.
AC210476 AC
NOTE:
Connector: C-203
Harness side
Connector: C-217
2
1
6 5 4 3
AC210474 AC

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

(2) Ignition switch: ACC position


monitor.
Connector C-217
Item No.
Item name
Normal
conditions
Item 31
IG SW(ACC)
ON
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AC301541AV

OK: System voltage
YES : Go to Step 4.
NO : Go to Step 3.


54C-226

INSPECTION PROCEDURE N-2: The ignition switch (IG1) signal is not received.
CAUTION
Ignition Switch (IG1) Input Circuit
IGNITION
SWITCH (IG1)
ETACS-ECU
Wire colour code


Input signal from the ignition switch (IG1) is used to
Turn signal lamp
Room lamps
Possible causes
SB : Sky blue
DIAGNOSIS PROCEDURE
connector
Connector: C-217
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 2.
54C-227

Connector: C-217

Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

(2) Ignition switch: ON position
AC210476 AC
NOTE:
Connector: C-203
Connector C-217
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
2
1
6 5 4 3
AC210474 AC
AC301541AW

OK: System voltage
YES : Go to Step 4.
NO : Go to Step 3.


monitor.
Ignition switch: ON
Item No.
Item name
Normal
conditions
Item 30
IG SW(IG1)
ON


54C-228

INSPECTION PROCEDURE N-3: The back-up lamp switch signal is not received.
CAUTION
Back-up Lamp Switch Input Circuit
IGNITION
SWITCH (IG1)
BACK-UP
LAMP SWITCH
ETACS-ECU
Wire colour code


Input signal from the back-up lamp switch is used to
operate the rear wiper. If the signal is abnormal, the
rear wiper will not work normally.
SB : Sky blue
Possible causes
54C-229
DIAGNOSIS PROCEDURE
Step 1. Connector check: B-114 back-up lamp

switch connector and C-220 ETACS-ECU
connector
Connector: C-220
Connector: B-114
Harness side
Harness side
2 1
B-114(B)
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210476 AF
AC301521 AB
Connector: C-220

(3) Shift lever: R position
Connector C-220
(Harness side)
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210476 AF
AC301541BA

YES : Go to Step 2.
Step 2. Check the back-up lamp switch

Check the back-up lamp switch (Refer to GROUP
22B - Transmission 322B).
YES : Go to Step 3.
NO : Replace the inhibitor switch.

OK: System voltage
NO : Go to Step 4.
54C-230
Step 4. Measure the voltage at the B-114 back-up

Connector: B-114

Connector: B-114
Harness side
:
Harness side
2 1
2 1
:
B-114(B)
AC301521 AB

B-114(B)
AC301521 AB
Connector: C-220
Connector B-114
(Harness side)
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
2 1
AC210476 AF
AC301541AK
(3) Voltage between B-114 back-up lamp switch

OK: System voltage
YES : Go to Step 5.
NO : Go to Step 6.
NOTE:
Connector: C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
AC301395 AC
Connector: C-105
1 2 3 4
5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
AC301397AF

YES : Go to Step 7.
54C-231

Connector: B-114
Harness side
2 1
B-114(B)


monitor.
Ignition switch: ON
Shift lever: R position
Item No.
Item name
Item 41
INHIBITOR SW ON
AC301521 AB
NOTE:
Connector: C-106
Normal
conditions
C-106(GR)
2
1
3 4
5 6
10 11 12
7 8 9
13 14 15 16 17 18 19
AC301397AG

C-203
C-202
Harness side
C-202
6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-203
2
1
6 5 4 3
AC210475 AG

necessary.


54C-232
INSPECTION PROCEDURE N-4: The drivers door switch signal is not received.
CAUTION
Driver's Door Switch Input Circuit
ETACS-ECU
FRONT DOOR
SWITCH (LH)
Wire colour code


Input signal from the drivers door switch is used to
Room lamps
SB : Sky blue
Step 2. Connector check: D-28 door switch (front,

LH) connector
Connector: D-28
Harness side
3 2 1
Possible causes
DIAGNOSIS PROCEDURE
Check that the door switch (front, LH) is installed on
the body correctly.
YES : Go to Step 2.
AC301410 AF

YES : Go to Step 3.
Step 3. Check the door switch (front, LH).

YES : Go to Step 4.
NO : Replace the door switch (front, LH).
54C-233

connector
Connector: C-217
Step 5. Check the wiring harness between D-28

door switch (front, LH) connector terminal No.3
Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
AC210476 AC

YES : Go to Step 5.
Connector: D-28
Harness side
3 2 1
AC301410 AF
NOTE:
Connector: C-209
Harness side
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
AC210474 AG

YES : Go to Step 6.
54C-234

monitor.
Drivers door: open
Item No.
Item name
Normal
conditions
Item 32
DR DOOR SW
ON


INSPECTION PROCEDURE N-5: The column switch (lighting, turn-signal lamp and headlamp washer
CAUTION
Lighting Switch Input Circuit
COLUMN SWITCH
COLUMN-ECU
LO
HI
PASS
LH
DIMMER
PASSING SWITCH
OFF
RH
TURN-SIGNAL
LAMP SWITCH

Input signal from the column switch (lighting, turnsignal lamp and headlamp washer switch) is used to
Fog lamp
Turn signal lamp
Headlamp washer
Possible causes
OFF
HEAD
HEAD
OFF TAIL
TAIL
LIGHTING
SWITCH
DIAGNOSIS PROCEDURE
Step 1. Check the column switch connector.
Check that the wiper and washer switch connector,
the lighting switch connector and the switch body
connector are in good condition.
YES : Go to Step 2.

Step 2. Check the column switch (lighting switch

and switch body).
Refer to GROUP 54A - Column switch 354A.
YES : Go to Step 3.

column switch (column-ECU) and the SWS
ECUS TO BE CHECKED
COLUMN ECU
ECU" menu.
YES : Go to Step 4.
54C-235

monitor.
Operate each function of the switch.
Item No.
Item name
Normal
conditions
Item 00
HEADLAMP SW
ON
Item 01
TAIL LAMP SW
ON
Item 02
DIMMER SW
ON
Item 03
PASSING SW
ON
Item 10
TURN SIG.RH
ON
Item 11
TURN SIG.LH
ON
Item 16
HD WASHER SW
ON



INSPECTION PROCEDURE N-6: The column switch (windshield wiper washer and rear wiper washer
CAUTION
Windshield Wiper and Washer Switch Input Circuit
COLUMN SWITCH
COLUMN-ECU
UPPER
SIDE
WINDSHIELD
WIPER SWITCH
WINDSHIELD
WASHER
SWITCH
REAR
WIPER
SWITCH
REAR
WASHER
SWITCH
54C-236


Input signal from the column switch (wiper switch) is
Possible causes
DIAGNOSIS PROCEDURE
column switch (column-ECU) and the SWS
ECUS TO BE CHECKED
COLUMN ECU
ECU" menu.
YES : Go to Step 2.


monitor.
Operate each function of the switch.
Item No.
Item name
Normal
conditions
Item 05
INT WIPER SW
ON
Item 06
LO WIPER SW
ON
Item 07
HI WIPER SW
ON
Item 08
MIST WIPER SW
ON
Item 09
FRONT WASH.SW
ON
Item 13
REAR WIPER SW
ON
Item 14
REAR WASH.SW
ON


54C-237
INSPECTION PROCEDURE N-7: The windshield intermittent wiper volume signal is not received.
CAUTION
Windshield Intermittent Wiper Interval Adjusting Knob Input Circuit
ETACSECU
COLUMN
SWITCH
WINDSHIELD
INTERMITTENT
WIPER INTERVAL
ADJUSTING KNOB
UPPER
SIDE
Wire colour code


The intermittent wiper interval is calculated in
accordance with the input signal from the windshield
intermittent wiper volume. If this signal is abnormal,
the wiper interval can not be adjusted.
Possible causes
SB : Sky blue
DIAGNOSIS PROCEDURE
connector
Connector: C-310
Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC

YES : Go to Step 2.
54C-238

Connector: C-310

Connector: C-219
Harness side
Harness side
5 4 3 2 1
10 9 8 7 6
C-219(GR)
AC301399 AC

column switch side.
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE
Connector: C-310
Connector C-310
(Harness side)
5 4 3 2 1
10 9 8 7 6
Harness side
5 4 3 2 1
10 9 8 7 6
AC301399 AC
AC301541BC

OK: The resistance should rise from 0 to
1 kW when the windshield intermittent
wiper volume is rotated from "Fast" to
"Slow".
YES : Go to Step 3.

connector
Connector: C-219

YES : Go to Step 5.

monitor.
Wiper switch: INT
Item No.
Item name
Normal
conditions
Item 37
INT WIPE TIME
2.4 to 18.0 s
OK: The display will be changed as the

intermittent wiper volume is rotated.
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 4.


54C-239
INSPECTION PROCEDURE N-8: When the power window main switch is operated, the switch signals
are not received.
CAUTION
Power Window Main Switch Input Circuit
FUSIBLE
LINK 5
ETACS-ECU
POWER
WINDOW RELAY
FRONT SIDE
DIAGNOSIS
CONNECTOR
POWER WINDOW
MAIN SWITCH
Wire colour code

SB : Sky blue
54C-240

Input signal from the power window main switch is
used in order to check the power window main
switch and confirm how the system is communicating
with the ETACS-ECU. If the communication line is
defective, the power windows will not work normally.

No.4.
Connector: C-219
Possible causes
DIAGNOSIS PROCEDURE
Harness side
C-219(GR)
Step 1. Check the operation by using the power

window main switch.
Check if each window can be operated by means of
the power window main switch.
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
Q: Can each power window be operated by means of

the power window main switch?
YES : Go to Step 2.
NO : Go to Step 5.
E-05
E-12

connector and E-05 power window main switch
connector
Connector: C-219
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC
AC210476 AE
Connector: E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC

YES : Go to Step 3.

NOTE:
54C-241

Connector: E-05
C-02
C-118
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC
C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
C-118

YES : Go to Step 6.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32

Connector: E-05
AC301396 AG

YES : Go to Step 4.
Step 4. Replace the power window main switch,

and then retest the system.
Replace the power window main switch, and check
that the power window main switch signal is
received.
(2) Check that the power window main switch signal
is received.
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC

Connector E-05
(Harness side)
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301541BH

OK: System voltage
YES : Go to Step 9.
NO : Go to Step 7.
54C-242


relay connector
Connector: C-208

terminal No.6.
C-203
Junction block side

3 2 1
4
5
AC210474 AF
C-208

YES : Go to Step 8.
Harness side
Junction block side
C-203
C-208
3 2 1
4
5
2
1
6 5 4 3
AC210475 AI
E-05
E-12
E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
E-12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC
54C-243

NO : Go to Step 10.
NOTE:
Connector: C-118

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

AC301395 AH
E-05

E-12


E-05
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Step 9. Measure the resistance at the E-05 power

E-12
Connector: E-05
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
AC301419 AC
NOTE:
Harness side
Connector: C-118
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301418 AC
1 2 3 4 5 6 7 8 9 10 11

Connector E-05
(Harness side)
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301395 AH

if necessary.
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC301541BI
(2) Continuity between E-05 power window main

OK: 2W or less


54C-244

monitor.
<Selected item> Fr-ECU, P/W, S/R
Ignition switch: ON
Item No.
Item name
Normal
conditions
Item 71
P/W ECU ACK
INPUT CHECK

the positions of the switch.

INSPECTION PROCEDURE N-9: The front fog lamp switch signal is not received.
CAUTION
Front Fog Lamp Switch Input Circuit
ETACSECU
FOG LAMP
SWITCH
NOTE
: WITHOUT REAR FOG LAMP
: WITH REAR FOG LAMP
Wire colour code


Input signal from the front fog lamp switch is used to
operate the front fog lamps. If the signal is abnormal,
the front fog lamps will not illuminate and extinguish
normally.
SB : Sky blue
Possible causes
Malfunction of the front fog lamp switch

DIAGNOSIS PROCEDURE
54C-245


connector
Connector: C-03
Connector: C-03
Harness side
6 5 4 3 2 1
Harness side
AC301395 AD
6 5 4 3 2 1
AC301395 AD

YES : Go to Step 2.

Connector C-03
(Harness side)
6 5 4 3 2 1
Step 2. Check the front fog lamp switch.

Refer to GROUP 54A - Front fog lamp switch 354A
.
YES : Go to Step 3.
*2
*1
Note
*1: Without rear fog lamp
*2: With rear fog lamp
AC301541 AM

connector terminal No.2 <vehicles without rear
fog lamps> or 6 <vehicles with rear fog lamps>
and body earth
OK: 2W or less
YES : Go to Step 5.
NO : Go to Step 4.
54C-246
Step 4. Check the wiring harness from C-03 fog

lamp switch connector terminal No.2 <vehicles
without rear fog lamps> or 6 <vehicles with rear
fog lamps> to body earth.
Connector: C-03

ETACS-ECU connector No.54 to C-03 fog lamp
switch connector terminal No.1 <vehicles without
rear fog lamps> or 5 <vehicles with rear fog
lamps>.
Connector: C-03
Harness side
Harness side
6 5 4 3 2 1
6 5 4 3 2 1
AC301395 AD
AC301395 AD

Connector: C-219

Harness side

connector
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
Connector: C-219
AC210476 AE
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69

YES : Go to Step 7.

monitor.
AC210476 AE

YES : Go to Step 6.

Ignition switch: ON
Item No.
Item name
Normal conditions
Item 36
F.FOG LAMP
ON


54C-247
INSPECTION PROCEDURE N-10: The rear fog lamp switch signal is not received.
CAUTION
Rear Fog Lamp Switch Input Circuit
ETACSECU
FOG LAMP
SWITCH
Wire colour code


Input signal from the rear fog lamp switch is used to
operate the rear fog lamps. If the signal is abnormal,
the rear fog lamps will not illuminate and extinguish
normally.
Possible causes
SB : Sky blue
DIAGNOSIS PROCEDURE
connector
Connector: C-03
Harness side
6 5 4 3 2 1
AC301395 AD

YES : Go to Step 2.
Step 2. Check the rear fog lamp switch.

YES : Go to Step 3.
54C-248



connector
Connector: C-219
Connector: C-03
Harness side
Harness side
6 5 4 3 2 1
C-219(GR)
AC301395 AD

Connector C-03
(Harness side)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 6.

fog lamp switch connector terminal No.1.
6 5 4 3 2 1
Connector: C-03
AC301541 AN

OK: 2W or less
YES : Go to Step 5.
NO : Go to Step 4.
Harness side
6 5 4 3 2 1
AC301395 AD
Connector: C-219

fog lamp switch connector terminal No.2 and
body earth.
Harness side
Connector: C-03
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
Harness side
6 5 4 3 2 1
AC301395 AD



YES : Go to Step 7.

54C-249
Step 7. Pulse check

Check the input signal from the rear fog lamp switch.
System switch
Check conditions
When the switch is


needle fluctuates.

INSPECTION PROCEDURE N-11: The key reminder switch signal is not received.
CAUTION
Key Reminder Switch Input Circuit
ETACSECU
KEY
REMINDER
SWITCH
WHEN REMOVING
KEY: ON
Wire colour code


Input signal from the key reminder switch is used to
SB : Sky blue
Room lamps
Possible causes
54C-250

DIAGNOSIS PROCEDURE
Step 3. Measure the resistance at the C-304 key

reminder switch connector.

switch connector
Connector: C-304
Connector: C-304
Harness side
2
1
7 6 5 4 3
Harness side
2
1
7 6 5 4 3
AC301399 AB

YES : Go to Step 2.
Step 2. Check the key reminder switch.

Refer to GROUP 54A - Ignition switch 354A.
AC301399 AB

Connector C-304
(Harness side)
2
1
7 6 5 4 3

YES : Go to Step 3.
NO : Replace the key reminder switch.
AC301541 BB
(2) Resistance between C-304 key reminder switch

OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.

the body earth.
Connector: C-304
Harness side
2
1
7 6 5 4 3
AC301399 AB


54C-251

connector
Connector: C-220

Connector: C-220
Harness side
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210476 AF
AC210476 AF

YES : Go to Step 6.
Connector: C-304
Harness side
2
1
7 6 5 4 3
AC301399 AB

YES : Go to Step 7.
Step 7. Pulse check

Check the input signal from the key reminder switch.
System switch
Check conditions
Key reminder switch
When the inserted


needle fluctuates.

54C-252
INSPECTION PROCEDURE N-12: The hazard warning lamp switch signal is not received.
CAUTION
Hazard Warning Lamp Switch Input Circuit
ETACSECU
HAZARD
WARNING
LAMP SWITCH
Wire colour code


Input signal from the hazard warning lamp switch is
Keyless entry system (encrypted code
registration)
Hazard warning lamp
Possible causes
SB : Sky blue
DIAGNOSIS PROCEDURE
Step 1. Connector check: C-22 hazard warning
lamp switch connector
Connector: C-22
Harness side
4 3 2 1
AC301395 AI

YES : Go to Step 2.
Step 2. Check the hazard warning lamp switch.

Refer to GROUP 54A - Hazard warning lamp switch
354A.
YES : Go to Step 3.
NO : Replace the hazard warning lamp switch.
54C-253
Step 3. Measure the resistance at the C-22 hazard

warning lamp switch connector.

connector
Connector: C-219
Connector: C-22
Harness side
Harness side
4 3 2 1
C-219(GR)
AC301395 AI

Connector C-22
(Harness side)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
AC210476 AE

YES : Go to Step 6.

No.1.
4 3 2 1
Connector: C-22
AC301541 AZ
(2) Resistance between C-22 hazard warning lamp

OK: 2 W or less
Harness side
4 3 2 1

YES : Go to Step 5.
NO : Go to Step 4.
AC301395 AI

No.2 and the body earth.
Connector: C-219
Connector: C-22
Harness side
C-219(GR)
Harness side
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE
4 3 2 1

AC301395 AI



YES : Go to Step 7.
54C-254

Step 7. Pulse check

switch.
System switch
Check conditions
Hazard warning lamp

switch
When the hazard

warning lamp switch is

needle fluctuates.


54C-255
INSPECTION PROCEDURE N-13: All the door switch signals are not received.
CAUTION
All Door Switches Input Circuit
ETACS-ECU
FRONT DOOR
SWITCH
(RH)
REAR DOOR
SWITCH
(RH)
TAILGATE REAR DOOR

SWITCH
SWITCH
(LH)
Wire colour code


Input signals from all the door switches are used to
operate the functions below. If the signal(s) are
Room lamps
FRONT DOOR
SWITCH
(LH)
SB : Sky blue
Possible causes
54C-256
DIAGNOSIS PROCEDURE

monitor.
Drivers door is open
D-01
Item No.
Item name
Normal
conditions
Item 32
DR DOOR SW
ON
D-20
D-28

YES : Go to Step 2.

354C."
Step 2. Connector check: D-28 <front, LH>, D-42
<front, RH>, D-10 <rear, RH> or D-20 <rear, LH>
door switch connectors or F-07 <tailgate>
tailgate switch connector, and C-217 ETACS-ECU
connector
Harness side
D-01
D-20
D-28
3 2 1
3 2 1
3 2 1
AC301411AC
Connector: D-42
Connector: C-217
Harness side
3 2 1
Junction block side
AC301408 AF
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
Connector: F-07
Harness side
1
F-07(B)
AC301665 AC

YES : Go to Step 3.

Check that the door switch is installed on the body
correctly.
YES : Go to Step 4.
54C-257
Step 4. Check the door switch.

Connector: D-42

YES : Go to Step 5.
NO : Replace the door switch.
Harness side
3 2 1
Step 5. Check the wiring harness from terminal

No.2 of the D-28 <front, LH>, D-42 <front, RH>, D10 <rear, RH> or D-20 <rear LH> door switch
connector or terminal No.1 of the F-07 <tailgate>
tailgate switch connector to terminal No.7 of the
C-217 ETACS-ECU connector.
AC301408 AF
Connector: C-217
F-05
F-07(B)
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
Harness side
F-05
F-07
1 2
3 4
5 6 7 8 9 10
D-01
D-20
AC301666 AC
D-28
Harness side
D-01
D-20
D-28
3 2 1
3 2 1
3 2 1
AC301411AC
54C-258
NOTE:
Step 6. Pulse check

Check the input signals from all the door switches.
Connector: C-13
C-13(L)
1
2 3
4 5 6 7 8 9
10 11 12 13 14 15
AC301397AB
C-205
C-209
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-209
7 6 5
15 1413
Check conditions


needle fluctuates.


C-205
System switch
12
4 3 2 1
11 10 9 8
AC210475 AK

intermediate connector F-05 <tailgate> or C-13
<RH> and junction block connector C-205 <RH> or
C-209 <LH and tailgate>, and repair if necessary.
YES : Go to Step 6.
NO : Repair the wiring harness between each of
the door switches and the ETACS-ECU.

54C-259
INSPECTION PROCEDURE N-14: The drivers door lock actuator switch signal is not received.
CAUTION
Door Lock Actuator Input Circuit
ETACS-ECU
DOOR LOCK
ACTUATOR
(FRONT: LH)

Input signal from the drivers door lock actuator is
Room lamps
Possible causes
DIAGNOSIS PROCEDURE
Connector: E-11
E-11(B)
Harness side
3 2 1
6 5 4
AC301418 AD

YES : Go to Step 2.
54C-260

YES : Go to Step 3.

front door lock actuator (LH) connector terminal
No.1 and body earth
Connector: E-11
Step 3. Measure the resistance at the E-11 front

door lock actuator (LH) connector.
E-11(B)
Harness side
Connector: E-11
3 2 1
6 5 4
AC301418 AD
E-11(B)
NOTE:
Harness side
Connector: C-118
3 2 1
6 5 4
AC301418 AD

Connector E-11
(Harness side)
23 24 25 26 27
28 29 30 31 32
AC301395 AH

necessary.
3 2 1
6 5 4
AC301541BK
(2) Resistance between E-11 front door lock actuator

(LH) connector terminal No.1 and body earth
OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22


connector
Connector: C-220
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
44 43 42
41 40 39
AC210476 AF

YES : Go to Step 6.


front door lock actuator (LH) connector (terminal
Nos. 2 and 3) and C-220 ETACS-ECU connector
(terminal Nos. 36 and 35).
Connector: C-220
54C-261
Step 7. Pulse check

actuator switch.
System switch
Check conditions
Drivers door lock

actuator switch

unlocked or locked

needle fluctuates.
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210476 AF
Connector: E-11
E-11(B)
Harness side
3 2 1
6 5 4
AC301418 AD
NOTE:
Connector: C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301395 AH

necessary.
YES : Go to Step 7.


54C-262

INSPECTION PROCEDURE N-15: The vehicle speed signal is not received.
CAUTION
Vehicle Speed Sensor Input Circuit
ETACS-ECU
VEHICLE
SPEED SENSOR
Wire colour code

G : Green L : Blue

Vehicle speed signal is used to operate the
windshield wiper (vehicle speed-dependent wiper
function). If this signal is abnormal, the windshield
wipers do not work normally.
Possible causes
Malfunction of the vehicles speed sensor
DIAGNOSIS PROCEDURE
Step 1. Check the speedometer.
Check that the speedometer works normally.
YES : Go to Step 2.
NO : Diagnose the combination meter (Refer to
GROUP 54A - Combination meter 354A

).
54C-263
Step 2. Connector check: B-115 vehicles speed

sensor connector
Connector: B-115

and the body earth.
Connector: B-115
Harness side
B-115(B)
Harness side
3 2 1
B-115(B)
3 2 1
AC301521AC

YES : Go to Step 3.

vehicles speed sensor connector.
AC301521AC
NOTE:
Connector: C-17
4 5
1 2 3
6 7 8 9 10 1112 13
Connector: B-115
Harness side
B-115(B)
3 2 1
AC301521AC

C-17(GR)
AC301397AE


connector
Connector B-115
(Harness side)
Connector: C-219
3 2 1
AC301541 AL
(2) Resistance between B-115 vehicles speed

sensor connector terminal No.2 and body earth
OK: 2 W or less
YES : Go to Step 5.
NO : Go to Step 4.
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72
71 70 69
AC210476 AE

YES : Go to Step 6.
54C-264

NOTE:
Connector: C-02
Connector: B-115
Harness side
B-115(B)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
3 2 1
AC301395 AC

AC301521AC
Connector: C-219
Harness side
C-219(GR)
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
71 70 69
74 73 72
C-105
C-16(L)
AC210476 AE
C-16
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
C-105
1 2 3 4
5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
AC301398 AD

connector C-02, C-16 and intermediate connector C105, and repair if necessary.
YES : Go to Step 7.

54C-265
Step 7. Pulse check

Check the vehicle speed signal.
System switch
Check conditions

more

needle fluctuates.

INSPECTION PROCEDURE N-16: Each switch signal of the keyless entry transmitter is not received.
CAUTION
Transmitter Input Circuit
ETACS-ECU
KEYLESS ENTRY
RECEIVER

Input signal from the keyless entry transmitter is
used to operate the keyless entry system. If the
signal is abnormal, the keyless entry system will not
work normally.
KEYLESS ENTRY
TRANSMITTER
Possible causes
Defective battery of the keyless entry transmitter
54C-266

DIAGNOSIS PROCEDURE
Step 1. Pulse check
Check whether the ETACS-ECU receives signal from
a transmitter or not. For this check, you should use
the 2-button-type transmitter (integrated with a key),
which cover screw is silver and has already been
registered.
NOTE: For how to register the keyless entry
transmitter encrypted code, refer to GROUP 42 On-vehicle Service 342.
System switch
Check conditions

"LOCK/UNLOCK" switch turned from off to on
needle fluctuates.
YES : Go to Step 2.
NO : Go to Step 4.
Step 2. Check the transmitter battery.

Refer to GROUP 42 - Keyless entry system 342.
YES : Go to Step 3.
NO : Replace the keyless entry transmitter
battery.
Step 3. Register the encrypted code, and then
retest the system.
(1) Register the keyless entry transmitter again.
(2) Check that each signal is received from the
keyless entry transmitter.

NO : Replace the keyless entry transmitter.
Check that each signal is received from the keyless
entry transmitter.

54C-267
INSPECTION PROCEDURE N-17: Interior lamp loaded signal is not detected.
CAUTION
IGNITION
SWITCH (ACC)
FUSIBLE
LINK 1
IGNITION
SWITCH (IG1)
RELAY
BOX
ETACS-ECU
KEEP RELAY
INTERIOR LAMP CUT
BACK-UP CIRCUIT
POWER
SOURCE
LOAD
DETERMINATION
CIRCUIT
COMBINATION
METER
FRONT LAMP
REAR LAMP
Wire colour code


The interior lamp automatic shutdown function
operates in accordance with the interior lamp loaded
signal. If this signal is abnormal, the functions below
will not work normally.
SB : Sky blue
Room lamps
Possible causes
Damaged wiring harness or connector(s)
54C-268

DIAGNOSIS PROCEDURE

normal.
ECUS TO BE CHECKED
ETACS ECU
menu.
Connector: C-217
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 2.

impossible 354C."
connector
Connector: C-217

Connector C-217
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC301541AW
Junction block side

20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC

YES : Go to Step 3.

OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.


Connector: C-217
54C-269

Connector: C-217
Junction block side

Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
NOTE:
Connector: C-203
AC210476 AC

Connector C-217
Harness side
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2
1
6 5 4 3
AC210474 AC


AC301541AX

OK: System voltage
YES : Go to Step 7.
NO : Go to Step 6.
54C-270

Connector: C-217
Step 7. Pulse check

Check the input of the interior lamp loaded signal.
System switch
Check conditions

signal

fuse No.18

needle fluctuates.
Junction block side
20 19 18 17 16 15 14 1312 1110 9 8 7 6 5 4 3 2 1
AC210476 AC
NOTE:
Connector: C-116
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG
Connector: C-202
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC210474 AB

block connector C-202 or intermediate connector C116, and repair if necessary.



54C-271
INSPECTION PROCEDURE N-18: The passengers door lock key cylinder switch signal is not
detected.
CAUTION
Door Lock Key Cylinder Switch Input Circuit
ETACS-ECU
DOOR LOCK
KEY CYLINDER
SWITCH (RH)
Wire colour code


Input signal from the front passengers door lock key
cylinder switch is used to operate the central door
locking function. If the signal is abnormal, the central
door locking function will not work normally.
Possible causes
cylinder switch
SB : Sky blue
DIAGNOSIS PROCEDURE
STEP 1. Connector check: E-18 door lock key
cylinder switch (RH) connector
Connector: E-18
Harness side
E-18(B)
3 2 1
AC301412 AD

YES : Go to Step 2.
54C-272
STEP 2. Check the door lock key cylinder switch

(RH).
YES : Go to Step 3.
NO : Replace the door lock key cylinder switch

Connector: E-18
Harness side
(RH).
E-18(B)
3 2 1
STEP 3. Measure the resistance at E-18 door lock

key cylinder switch (RH) connector.
Connector: E-18
AC301412 AD
Harness side
E-18(B)
NOTE:
Connector: C-15
3 2 1
AC301412 AD

2
1
3 4
5 6
10 11 12
7 8 9
13 14 15 16 17 18 19
C-15(GR)
AC301397AD

Connector E-18
(Harness side)

3 2 1
AC301541BL
(2) Resistance between E-18 door lock key cylinder

switch (RH) connector terminal No.2 and body
earth
OK: 2 W or less

STEP 5. Connector check: C-220 ETACS-ECU
connector
Connector: C-220

YES : Go to Step 5.
NO : Go to Step 4.
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210476 AF

YES : Go to Step 6.


(terminal Nos. 1 and 3) and C-220 ETACS-ECU
connector (terminal Nos. 28 and 27).
Connector: C-220
54C-273
STEP 7. Pulse check

System switch
Check conditions
Passengers door lock

key cylinder switch

or unlock position

needle fluctuates.
Harness side
29 28 27 26 25 24 23 22 21
38 37 3635 34 33 32 31 30
41 40 39
44 43 42
AC210476 AF
Connector: E-18
Harness side
E-18(B)
3 2 1
AC301412 AD
NOTE:
Connector: C-15
2
1
3 4
5 6
7 8 9
10 11 12
13 14 15 16 17 18 19
C-15(GR)
AC301397AD

YES : Go to Step 7.


54C-274


M1549001200607
ETACS-ECU
AC005554AF
NOTE: Terminal numbers 1 to 20 can not be measured as the ETACS-ECU is mounted on the junction block
directly. The values are for reference only.
No.
Check conditions
Normal conditions
Output to the power window relay

operative
System voltage
Power supply to the central door

locking system (battery positive
voltage)
Always
System voltage
Earth (for ECU)
Always
0V
System voltage
Output to room lamp
When the room lamp is on
2 V or less

(battery positive voltage)

function is off)
System voltage
Input from all the door switches
One of the door switches: ON (door 0 V

open)

(IG1)
Ignition switch: ON
Output to right turn-signal lamps
When right turn-signal lamps are on System voltage
10
Input from drivers door switch
Drivers door switch: ON (door

open)
0V
11
Power supply to hazard warning

lamp (battery positive voltage)
Always
System voltage
12

locking the doors)
When the door lock actuators lock

the doors
System voltage
13

unlocking the doors other than the
drivers door)

unlock the doors
System voltage
14
Output to left turn-signal lamps
When the left turn-signal lamps are System voltage

on
15
16
Output to rear wiper
System voltage
17
Input of rear wiper automatic stop

signal
System voltage
18

(ACC)
System voltage
System voltage
54C-275

No.
Check conditions
Normal conditions
19
20
Always
System voltage
21
Input from rear fog lamp switch
0V
22

unlocking the drivers door)

unlock the doors
System voltage
23
Rear washer output
When rear washer is operating
System voltage
24 to 28 -
29
Input of collision signal
30
Input to key reminder switch
Key reminder switch: ON (ignition

key removed)
0V
31 to 34 -
35

(lock switch)
Drivers door lock: Locked
0V
36

(unlock switch)
Drivers door lock: Unlocked
0V
37, 38
39
Input to back-up lamp switch
Ignition switch: ON
Shift lever: R
System voltage
40 to 44 -
51
When diagnosis code is set (the

MUT-II is connected or the
diagnosis connector No.1 is
earthed)
When input check signal is sent
0 V, 12 V (input signal
is fluctuating)
Setting diagnosis code or sending

input check signal
52
53
Output to door-ajar indicator lamp
When door-ajar indicator lamp is on 0 V
54
Input from front fog lamp switch
0V
55
Input from hazard warning lamp

switch
Hazard warning lamp switch: ON
0V
56
Earth (for sensor)
Always
0V
57, 58
59
Always
60 to 62 -
63
Input of vehicle speed signal
When the vehicle is being driven
64, 65
66
Input from windshield intermittent

wiper volume
Turn the ignition switch to the ACC

position, and move the wiper
volume from "Fast" to "Slow."
0 to 2.5 V
67
Input from diagnosis control
When MUT-II is connected
0V
68
Always
69
Output to ignition key cylinder

illumination lamp
When ignition key cylinder

illumination is on
2 V or less
54C-276

No.
Check conditions
Normal conditions
70
71

function is off)
System voltage
72, 73
74
Output to rear fog lamp
When rear fog lamp is on
System voltage

No.
Check conditions
Normal conditions
System voltage
Always
System voltage
Always
Always
Earth
Always
0V
Output to windshield intermittent

wiper volume

0 to 2.5 V
Move the wiper volume from "Fast"
to "Slow."
Back-up output to windshield wiper Windshield low-speed wiper switch 0 V

switch
switch: ON

(IG1)
10
Back-up output to headlamp switch Headlamp switch: ON
Column switch
AC005555AB
Ignition switch: ON
System voltage
0V
Front-ECU
1 2 3 4 5 6 7 8 9 10 11
2122 23242526 272829 30 31

AC103263 AB
NOTE: Measurement is not possible as the front-ECU is mounted on the relay box directly. The values are for
reference only.
54C-277

No.
Check conditions
Normal conditions
Output to headlamp washer
When headlamp washer is

operating
System voltage
Battery power supply (for headlamp Always

washer)
System voltage
Output to tail lamps
When the tail lamps are on
System voltage
Always
System voltage
Output to low-beam headlamps
When low-beam headlamps are on System voltage
Battery power supply (for tail lamps) Always
System voltage
8, 9
Battery power supply (for

headlamps)
Always
System voltage
10
Output to high-beam headlamps
When high-beam headlamps are on System voltage
11
Output to front fog lamps
When front fog lamps are on
System voltage
21
Earth
Always
0V
22

(IG2)
Ignition switch: ON
System voltage
23
24
Output to windshield wiper (high

speed operation)

operating at high speed
System voltage
25
Output to windshield wiper (low

speed operation)

operating at low speed
System voltage
26
Back-up input from windshield

wiper switch
Windshield low-speed wiper switch 0 V

switch: ON
27
Back-up input from headlamp

switch
Headlamp switch: ON
0V
28

(ACC)
System voltage
29
Input of windshield wiper automatic When windshield wipers are

stop signal
operating
System voltage
30
Always
31
Output to windshield washer
When windshield washer is

operating
System voltage
54C-278

1 2 3
4 5 6
7 8 9 10 11 12 13 14
AC103264 AE

No.
Check conditions
Normal conditions
Earth
Always
0V
SWS communication line (to

ETACS-ECU)
Always
Power supply
System voltage

(pulse sensor earth)
0V


operating
10


operating
11
SWS communication line (power

window sub switch)
12

(power supply to pulse sensor)

operating
5V
13, 14
54C-279
Power window sub switch
1
2 3
4 5 6 7 8
AC103265 AE
Termin
al No.
Check items
Check conditions
Normal conditions
Earth
Always
0V
Power supply
System voltage
Sunroof motor assembly
AC005559AC
Termin
al No.
Check items
Check conditions
Normal conditions
Battery power supply (for motor)
Always
System voltage

(IG2)
Ignition switch: ON
System voltage
3, 4
Earth
Always
0V
Input from sunroof switch (close or

open)
Sunroof switch: Close/open
0V
Input from sunroof switch (tilt-up)
Sunroof switch: Tilt up
0V
Input from sunroof switch (open)
Sunroof switch: Open
0V
10
Always
127(6
25-1
GROUP 25
00
11
PROPELLER SHAFT
12
13
14
CONTENTS
15
25
SPECIAL TOOLS . . . . . . . . . . . . . . . .
25
16
25
PROPELLER SHAFT . . . . . . . . . . . . .
25
17
25
LUBRICANTS . . . . . . . . . . . . . . . . . .
25
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
25
25
SEALANT. . . . . . . . . . . . . . . . . . . . . .
25
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
PROPELLER SHAFT
25-2
GENERAL INFORMATION
GENERAL INFORMATION
M1251000100175
For 4WD vehicles, a 3 way split 4-joint type propeller

shaft with centre bearing is used.
M1251000300180
Item
Standard value
Limit
Propeller shaft run-out mm
0.6
Clearance between snap ring and snap ring groove mm
0.02 - 0.06
LUBRICANTS
M1251000400217
Item
Specified lubricant
Quantity
Front propeller shaft sleeve yoke
Hypoid gear oil SAE 75W-90 or 75W-85W or As required

80W conforming to API GL-4
DOJ assembly
Repair kit grease
95 5 g
SEALANT
M1251000500106
Item
Specified sealant
Rubber packings for DOJ assembly
3M Stud Locking 4170 or equivalent
SPECIAL TOOLS
M1251000600170
Tool
Number
Name
Use
MB990840
Universal joint remover

and installer
Disassembly and
reassembly of universal
joint
MD998801
Bearing remover
Removal of centre
bearing assembly
MB990840
AC106983
PROPELLER SHAFT
25-3
PROPELLER SHAFT
PROPELLER SHAFT
M1251001000223
4
Gear Oil:
Hypoid gear oil SAE 75W-90 or 75W-85W
or 80W conforming to API GL-4
4
3
3
N2
1
13 2 Nm
30 4 Nm
5
54 5 Nm
30 4 Nm
13 2 Nm
AC203945 AD
1.
2.
3.
Removal steps
Heat protector
Self locking nut
Insulator
<<A>>
>>A<<
4.
5.

Spacer
Propeller shaft assembly

<<A>> PROPELLER SHAFT ASSEMBLY
REMOVAL
1. Make mating marks on the differential companion
flange and the propeller shaft assembly.
CAUTION
Be careful not to bend the joint portion when
removing the propeller shaft because this will
damage to the joint boot.
Joint boot
Joint assembly
Rag
Rear propeller
shaft
AC101255 AD
2. Insert a rag so as to avoid boot damage, and

remove the propeller shaft assembly in a straight
and level manner.
PROPELLER SHAFT
25-4
PROPELLER SHAFT

>>A<< PROPELLER SHAFT ASSEMBLY
INSTALLATION
Propeller shaft
assembly
Differential
companion flange
CAUTION
Marking
Marking
Oil seal
AC300150AC
Transfer
2. When installing a new rear propeller shaft

assembly, align the mark on the propeller shaft
tube with the mark at the side of the differential
companion flange.
AC101431 AC
Do not damage the oil seal lips on the transfer

case.
Remove oil and grease from the threads of the
mounting bolts and nuts before tightening, or
they will loosen.
Be careful not to bend the joint portion when
removing the propeller shaft, because this
will damage the joint boot.
1. If reusing the propeller shaft, align the mating
marks of differential companion flange and
propeller shaft assembly to install.
INSPECTION
M1251001100167
Check the sleeve yoke and centre yoke for wear,

damage or cracks.
Check the propeller shaft for bends, twisting or
damage.
Check the universal joint for smooth operation in
all directions.
Check the centre bearing for smooth movement.
PROPELLER SHAFT RUNOUT
ACX00643AB
PROPELLER SHAFT
25-5
PROPELLER SHAFT
Limit: 0.6 mm

M1251001200197
1N
6N
1N
187 29 Nm
2N
9
7
3
5
3
12
N 15
10 N 14 N
19 N
17 N
187 29 Nm
18
16
11
13
34 5 Nm
20
14
17
17 16
18 15 19
18
17
15
14
3
Universal joint kit
DOJ boot kit
DOJ kit
AC203968 AD
<<A>>
<>
>>G<<
>>F<<
>>F<<
1.
2.
3.
4.
Disassembly steps
Snap ring
Journal bearing
Journal
Sleeve yoke
<<C>>
<<D>>
>>E<<
>>E<<
>>E<<
5.
6.
7.
8.

Front propeller shaft
Self locking nut
Centre yoke
Centre bearing assembly
PROPELLER SHAFT
25-6
PROPELLER SHAFT
<<D>>
<<D>>
>>D<<
>>D<<
>>D<<
<<E>>
>>C<<
>>B<<
<<F>>
>>A<<
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Bolt
Self locking nut
Companion flange
Centre bearing assembly
Centre propeller shaft
Snap ring
Boot band
DOJ assembly
Rubber packing
DOJ boot
Washer
Rear propeller shaft
PROPELLER SHAFT
25-7
PROPELLER SHAFT
Lubrication and Adhesive Points

Rubber
mount
CAUTION
Do not refill or apply grease excessively.
Otherwise, faulty fitting of bearing caps and
errors in the selection of snap rings may
result.
Repair kit grease:

Quantity: 95 5 g
Adhesive: 3M Stud Locking 4170 or

equivalent
AC203969 AC
PROPELLER SHAFT
25-8
PROPELLER SHAFT
<<C>> CENTRE YOKE REMOVAL
<<A>> SNAP RING REMOVAL

Mating marks
Mating marks
AC003847AD
ACX00645 AD
Make mating marks on the flange yoke and propeller

shaft. Then, remove the snap rings.
<> JOURNAL BEARING REMOVAL
CAUTION
Do not tap the journal bearings to remove them,
as this will upset the balance of the propeller
shaft.
Make mating marks on the centre yoke and centre

propeller shaft, and then remove the centre yoke.
<<D>>CENTRE BEARING ASSEMBLY/BOLT
REMOVAL
1. Make mating marks on the centre propeller shaft,
DOJ assembly and companion flange, and then
remove the bolt.
Center bearing
assembly
MB990840
MD998801
AC101273 AC
MB990840
MB990840
2. Use special tool bearing remover (MD998801) to

remove the centre bearing assembly from the
centre propeller shaft.
<<E>>DOJ ASSEMBLY REMOVAL
MB990840
DOJ assembly
MB990840
ACX00646AC
1. Use special tool universal joint remover and

installer (MB990840) to press in the journal
bearing on one side, and take out the journal
bearing on the opposite side.
2. Insert special tool into the other side and press
the journal to remove the first journal bearing that
was pushed.
DOJ boot
AC101274 AC
1. Remove the DOJ boot from the DOJ assembly.
PROPELLER SHAFT
25-9
PROPELLER SHAFT
>>B<< DOJ ASSEMBLY INSTALLATION

Outer race
Inner
race
Outer race
Inner
race
Circlip
Cage
Circlip
Ball
AC101275 AC
2. Make mating marks on the outer race, cage and

inner race, and then remove the circlip, outer race
and ball.
NOTE: . Note the positions of the balls so that
they can be reinstalled in their original positions.
Cage
Inner race
Puller
Cage
AC101277AC
1. Apply a thin coat of the specified grease to the

ball grooves of the inner and outer races.
Specified grease: Repair kit grease
2. Assemble the DOJ assembly as follows:
(1) Assemble the outer race, cage, balls, and
inner race with their mating marks aligned.
(2) Install the circlip.
AC101276 AC
3. Remove the inner race with cage from the centre

propeller shaft assembly by using a puller
(commercially available).
4. Wipe off the grease and clean the outer race,
inner race, cage and balls.
<<F>> DOJ BOOT REMOVAL
When the DOJ boot is reused, tape the spline part on
the rear propeller shaft and then remove the DOJ
boot.
AC101278 AC
3. Apply specified grease to the DOJ assembly.

Amount to use: 95 5 g
Rubber packing

>>A<< DOJ BOOT INSTALLATION
1. Install the boot band.
2. Wrap a plastic tape around the spline part on the
centre propeller shaft and then install the DOJ
boot.
DOJ assembly
AC101279 AF
4. Apply a thin coat of specified adhesive to the

groove side of DOJ assembly (shown by arrows in
the figure) and install the rubber packing.
Specified adhesive: 3M Stud Locking 4170 or
equivalent
5. Set the groove side of DOJ assembly (for
packing) toward the DOJ boot side and install
them.
PROPELLER SHAFT
25-10
PROPELLER SHAFT
Socket wrench
>>D<< CENTRE BEARING ASSEMBLY/

COMPANION FLANGE/SELF-LOCKING NUT
INSTALLATION
Center bearing
assembly
Companion flange
Self-locking
nut
AC101280 AC
6. Lining up the mating marks on the DOJ assembly

and the centre propeller shaft and using the
socket wrench, install the DOJ assembly to the
Bolt
DOJ boot
AC101281AF
7. Using the bolt, align the bolt holes of the DOJ boot
and the DOJ assembly and install DOJ boot to the
DOJ assembly.
8. Install the rubber packing of the companion flange
side in the same manner as described in (4)
above.
AC101283 AC
1. Set the centre bearing assembly in the direction

shown in the figure and install it to the centre
propeller shaft.
2. Install, lining up the mating marks on the
companion flange and the centre propeller shaft.
3. While tightening the self-locking nut, install the
centre bearing assembly with the companion
flange.
>>E<<CENTRE BEARING ASSEMBLY/CENTRE
YOKE/SELF-LOCKING NUT INSTALLATION
Center
Dust seal
yoke
Rubber
mount
Selflocking
nut
>>C<< BOOT BAND INSTALLATION
CAUTION
AC101284 AC
1. Set the centre bearing assembly in the direction

shown in the figure and install it to the centre
propeller shaft.
2. Align the mating marks on the centre yoke and the
3. While tightening the self-locking nut, install the
centre bearing assembly with the centre yoke.
Mark
Boot
Vent plug
AC107071AB
Clamp the boot by holding down the lever at a

position nearly opposite to the vent groove
provided in the DOJ boot (at arrow marked
position on boot).
Be sure to remove grease, if present, from
around the vent groove. Grease obstructs the
ventilation air passage.
PROPELLER SHAFT
25-11
PROPELLER SHAFT
>>F<< JOURNAL/JOURNAL BEARING

INSTALLATION
CAUTION
4. Align the mating marks on the centre yoke and

rear propeller shaft, and install the propeller shaft
journal bearings in the same manner as described
in (1) and (2) above.
>>G<< SNAP RING INSTALLATION
1. Install a snap ring to one side of the journal.
MB990840
AC101285AC
Do not apply grease excessively. Too much

grease can result in errors in the selection of
snap rings.
1. Apply multi-purpose grease to the following
universal joint kit.
Shaft and journal grease cup
Dust seal lip
SNAP RING
ACX00649 AC

installer (MB990840) at the opposite side of the
installed snap ring to press in the journal bearing
toward the snap ring.
CAUTION
CAUTION
Be careful when pressing the journal bearings. If
they are pressed at an angle, the inside of the
journal bearings will be damaged.
MB990840
Always use snap rings of equal thickness on

both sides.
Snap ring
Groove for
snap ring
ACX00650AC
ACX00647AC

installer (MB990840) to press the journal bearing
into the centre yoke, sleeve yoke or flange yoke
until the snap ring groove is fully visible.
MB990840
MB990840
ACX00648 AC
3. Use the special tool to press the opposite side

journal bearing into the yoke.
3. Install the snap ring on the opposite side, and

measure the clearance of the snap ring groove
with a feeler gauge.
4. If the clearance exceeds the standard value,
adjust by changing the thickness of the snap ring.
Thickness mm
Identification colour
1.28
1.31
Yellow
1.34
Blue
1.37
Purple
1.40
Brown
127(6
26-1
GROUP 26
00
11
FRONT AXLE
12
13
14
CONTENTS
26
15
FRONT AXLE HUB ASSEMBLY . . . .
26
26
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
26
26
26
LUBRICANTS . . . . . . . . . . . . . . . . . .
26
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
26
SPECIAL TOOLS. . . . . . . . . . . . . . . .
26
DRIVE SHAFT ASSEMBLY . . . . . . . .
26
26
16
17
21
22
25
26
26
WHEEL BEARING AXIAL PLAY CHECK . .
26
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
26
26
HUB BOLT REPLACEMENT . . . . . . . . . . .
26
BJ BOOT (RESIN BOOT) REPLACEMENT
26
27
31
32
33
34
35
36
37
42
51
52
54
55
FRONT AXLE
26-2
GENERAL INFORMATION
GENERAL INFORMATION
M1261000100336
The front axle consists of front hubs, knuckles, wheel

bearings and drive shafts, and it has the following
features:
The wheel bearing is a double-row angular
contact ball bearing which incorporates the oil
seals and is highly resistant to a thrust load.
The driveshaft incorporates BJ-PTJ type constant
velocity joints with high transmission efficiency for
low vibration and noise.
The dynamic damper has been mounted on the
left drive shaft to reduce differential gear noise.
Due to the use of the inner shaft and bracket

assembly, the right and left drive shafts are
approximately the same in length. This reduces
noise, vibration and torque steer.<2WD>
Due to the use of the output shaft, the right and
left drive shafts are approximately the same in
length. This reduces noise, vibration and torque
steer.<4WD>
ABS rotors for detecting the wheel speed are
press-fitted to the BJ outer wheels.
NOTE: .
PTJ: Pillow Tripod Joint
BJ: Birfield Joint
SPECIFICATIONS
Item
2WD
Wheel bearing
Driveshaft
4WD
Type
Double-row angular contact ball bearing
Bearing (OD x ID) mm
80 x 40
80 x 40
Outer
BJ
BJ
Inner
PTJ
PTJ
LH
383.5 24
361 22
RH
474.5 24
455 22
Joint type
Length (joint to joint)
diameter mm
CONSTRUCTION DIAGRAM
<2WD>
Strut assembly
PTJ (LH)
Drive shaft (LH)
Knuckle
Bracket assembly
Drive shaft (RH)
Front hub
PTJ (RH)
Dynamic damper
(LH only)
BJ
Inner shaft
ABS rotor
Wheel bearing
AC106952 AD
FRONT AXLE
26-3
<4WD>
Strut assembly
Output shaft
PTJ (LH)
Drive shaft (LH)
Knuckle
Drive shaft (RH)
Front hub
Dynamic damper
(LH only)
PTJ (RH)
BJ
Output shaft
ABS rotor
Wheel bearing
AC106953 AD
M1261000300352
Item
Standard value
Limit
Wheel bearing axial play mm
0.05
Hub starting torque Nm
1.8
Protruding length of stabilizer link mm
9.4 0.4
Setting of PTJ boot length mm 2WD
90 3
4WD
85 3
When the BJ boot band

(small) is crimped
2.9
When the BJ boot band

(large) is crimped
2.9
2.4 - 2.8
Opening dimension of the

special tool (MB991561) mm
Crimped width of the BJ boot band mm
LUBRICANTS
M1261000400359
Item
Specified lubricant
PTJ boot grease
Repair kit grease
Quantity
2WD
210 10 g
4WD
150 10 g
FRONT AXLE
26-4
SPECIAL TOOLS
Item
Specified lubricant
BJ boot grease
Repair kit grease
Quantity
2WD
120 10 g
4WD
85 10 g
Dust seal inner grease
Repair kit grease
14 - 20 g
Dust seal outer grease
Repair kit grease
8 - 12 g
SPECIAL TOOLS
M1261000600353
Tool
Number
Name
Use
MB990767
End yoke holder
Fixing of the hub
MB991618
Hub bolt remover
Removal of the hub bolt
MB991897
Ball joint remover
Knuckle and tie rod end ball joint

disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113)is also used
to disconnect knuckle and tie rod end
ball joint.
MB990241
A: MB990242
B: MB990244
Axle shaft puller

A: Puller shaft
B: Puller bar
Removal of the drive shaft
MB991354
Puller body
MB991056 or
MB991355
Knuckle arm
bridge
B990767
MB991618
AC106827
A
B
MB990241AB
MB991354
Removal of the hub

Removal of the wheel bearing
FRONT AXLE
26-5
SPECIAL TOOLS
Tool
Number
Name
Use
MB991721
Sliding hammer
Removal of the output shaft <4WD>
A: MB991017
B: MB990998
C: MB991000
A, B: Front hub
remover and
installer
C: Spacer
Removal of the hub

Provisional holding of the wheel
bearing
Measurement of hub starting torque
Measurement of wheel bearing axial
play
NOTE: MB991000, which belongs to
MB990998, should be used as a
spacer.
MB990685
Torque wrench
Measurement of hub starting torque
MB990326
Preload socket
MB990810
Side bearing
puller
Removal of the centre bearing

bracket
Removal of the wheel bearing inner
race (outside)
MB991172
Inner shaft
installer base
Press-fitting of the inner shaft
MB991248 or
MB998801
Inner shaft
remover
Removal of the inner shaft
MB991460
Plug
Prevention of transmission fluid drain

and of entry of foreign objects
B
C
AC100320AB
MB990326
MB990810
MB991248
FRONT AXLE
26-6
SPECIAL TOOLS
Tool
Number
Name
Use
MB991561
Boot band
crimping tool
BJ boot (resin boot) band installation
MB990925
Bearing and oil

seal installer set
Removal of the wheel bearing

Removal and installation of the
centre bearing
Press-fitting of the dust seal outer,
inner
MB990890
Rear suspension
bushing base
Installation of the wheel bearing

Press-fitting of the dust seal outer,
inner
MB990883
Rear suspension
bushing arbor
Installation of the wheel bearing
MB991561
MB990925
MB990890
MB990883
Tool
MB990925
Type
Tool number
O D mm
MB990926
39.0
MB990927
45.0
MB990928
49.5
MB990929
51.0
MB990930
54.0
MB990931
57.0
MB990932
61.0
MB990933
63.5
MB990934
67.5
MB990935
71.5
MB990936
75.5
MB990937
79.0
MB990938
MB990939
A
Installer adapter
Brass bar
B
Bar (snap-in type)
Tool box
ACX02372 AC
FRONT AXLE
26-7
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK
M1261000900213
1. Remove the caliper assembly and suspend it with

a wire.
2. Remove the brake disc from the front hub.
MB991618
MB990767
AC102439 AC
AC102438
3. Attach a dial gauge as shown in the illustration,

and then measure the axial play while moving the
hub in the axial direction.
Limit: 0.05 mm
4. If axial play exceeds the limit, disassemble the
front hub assembly and check the parts.
5. Install the brake disc, caliper assembly and
tighten the caliper assembly mounting bolts to the
specified torque 100 10 Nm.
HUB BOLT REPLACEMENT

M1261001000279
1. Remove the caliper assembly and suspend it with

wire so that it does not fall.
2. Remove the brake disc.
3. Use the following special tools to remove the hub

bolts.
End yoke holder (MB990767)
Hub bolt remover (MB991618)
MB990767
Plain
washer
AC102440 AC
4. Install the plain washer to the new hub bolt, and

install the bolt with a nut.
5. Install the brake disc, caliper assembly and
tighten the caliper assembly mounting bolts to the
specified torque 100 10 Nm.
FRONT AXLE
26-8
FRONT AXLE HUB ASSEMBLY

M1261001700331
CAUTION
Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when
removing or installing the drive shaft. Otherwise the ABS rotors will be damaged.
Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing
work.
Check the dust cover for cracks or damage by pushing it
with your finger.
6
25 5 Nm
7 12
13
167 9 Nm
10 N
1
3
245 29 Nm
11
39 5 Nm
5
4N
9
100 10 Nm
108 10 Nm
AC107173 AB
1.
<<A>>
2.
3.
<> >>B<< 4.
>>B<< 5.
>>A<< 6.
>>A<< 7.
Removal steps
Front ABS sensor
Caliper assembly
Brake disc
Drive shaft nut
Washer
Self-locking nut (stabilizer bar
connection)
Stabilizer rubber
<<C>>
<<D>>
8.
9.
10.
11.
12.
13.

Stabilizer link assembly
Lower arm ball joint connection
Self-locking nut (tie rod end
connection)
Drive shaft
Nut (hub and knuckle to strut
connection)
Hub and knuckle
FRONT AXLE
26-9

<<A>> CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, etc.
Bolt
Parallel
<> DRIVE SHAFT NUT REMOVAL
CAUTION
Do not apply pressure to wheel bearing by the
vehicle weight to avoid possible damage when
drive shaft nut is loosened.
MB990767
Knob
Good
Bad
AC106821AB
2. Turn the bolt and knob as necessary to make the

jaws of special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make
sure the knob is in the position shown in the
figure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.
AC102462 AC
Use special tool end yoke holder (MB990767) to fix

the hub and remove the drive shaft nut.
<<C>> SELF-LOCKING NUT (TIE ROD END
CONNECTION) REMOVAL
<<D>> DRIVE SHAFT REMOVAL
MB990767
CAUTION
Do not remove the nut from ball joint. Loosen
it and use the special tool to avoid possible
damage to ball joint threads.
Hang the special tool with cord to prevent it
from falling.
Cord
MB991897
Nut
MB990244
(Three)
MB990242
MB991354
AC102550 AC
1. Use the following special tools to push out the

drive shaft from the hub and knuckle.
Puller shaft (MB990242)
Puller bar (MB990244)
Puller body (MB991354)
Bolt
Ball joint
AC208247AD
1. Install special tool ball joint remover (MB991897)

as shown in the figure.
Drive shaft
AC102551AC
2. Withdraw the drive shaft from the hub by pulling

the bottom of the hub and knuckle towards you.
3. Hang the drive shaft on the vehicle body with a
rope.
FRONT AXLE
26-10

>>A<< SELF-LOCKING NUT (STABILIZER BAR
CONNECTION) INSTALLATION
>>B<< WASHER/ DRIVE SHAFT NUT

INSTALLATION
CAUTION
Before securely tightening the drive shaft nuts,
make sure there is no load on the wheel
bearings. Otherwise the wheel bearings will be
damaged.
Washer
AC107031AB
AC107031
Tighten the self-locking nut so that the protruding

length of the stabilizer link protruding part meets its
standard value (A).
Standard value (A): 9.4 0.4 mm
MB990767
AC102465AD
1. Be sure to install the drive shaft washer in the

specified direction.
2. Using special tool end yoke holder (MB990767),
tighten the drive shaft nut to the specified torque.
INSPECTION
M1261001800220
Check the hub for cracks and spline for wear.

Check the knuckle for cracks.
Check for defective bearing.
NOTE: If the meshing of the wheel bearing outer
race and the knuckle, or of the wheel bearing
inner race and the hub, is loose, replace the
bearing or damaged parts.
FRONT AXLE
26-11

M1261001900186
1
N
4
5
3
AC101684 AD
1.
2.
3.
4.
5.
<<A>>
<>
Disassembly steps
Snap ring
Hub
Dust cover
Wheel bearing
Knuckle
>>A<<
>>B<<
>>C<<
5.
4.
1.
3.
2.
Assembly steps
Knuckle
Wheel bearing
Snap ring
Dust cover
Hub
Hub starting torque check
Wheel bearing axial play check

<<A>> HUB REMOVAL
<> WHEEL BEARING REMOVAL
CAUTION
When the hub has been removed, always replace
the wheel bearing with a new part because wheel
bearing frictional surface will be damaged when
removing the hub.
MB991017
Inner race
(outside)
MB991056 or
MB991355
Outer oil seal

AC102508 AC
MB991000
Tighten the nut

with the bolt
secured
AC100130 AB
Use the following special tools to pull out the hub

from the knuckle.
Knuckle arm bridge (MB991056 or MB991355)
Front hub remover and Installer (MB991017)
Spacer (MB991000)
1. Crush the oil seal in two places so that the tabs of

the special tool will be caught on the wheel
bearing inner race (outside).
FRONT AXLE
26-12
CAUTION
When removing the inner race (outside) from the
hub, be careful not to let the hub drop.
MB990810
>>A<< WHEEL BEARING INSTALLATION

1. Fill the wheel bearing with multipurpose grease.
2. Apply a thin coating of multipurpose grease to the
knuckle and bearing contact surfaces.
CAUTION
Press the outer race when pressing-in the wheel
bearing. Otherwise the wheel bearing will be
damaged.
MB990883
Inner race
(outside)
MB990890
AC102509 AC
2. Remove the wheel bearing inner race (outside)

from the front hub by using special tool side
bearing puller (MB990810).
MB990938
Inner race
(outside)
MB990935
MB991056 or MB991355
AC102511 AC
3. Press-in the bearing by using the following special

tools.
Rear suspension bushing arbor (MB990833)
Rear suspension bushing base (MB990890)
>>B<< HUB STARTING TORQUE CHECK
AC102510 AC
3. Install the inner race (outside) that was removed

from the hub to the wheel bearing, and then use
the following special tools to remove the wheel
bearing.
Knuckle arm bridge (MB991056 or MB991355)
MB991017
MB991000
245 29 Nm
Tighten the nut
with the bolt secured
AC210929 AC
1. Tighten the following special tools to the specified

torque, and then press-in the hub into the knuckle.
Front hub remover and installer (MB991017)
Spacer (MB991000)
2. Rotate the hub in order to seat the bearing.
FRONT AXLE
26-13
>>C<< WHEEL BEARING AXIAL PLAY CHECK

MB990685
MB991000
245 29 Nm
Tighten the nut
with the bolt
secured
MB990326
AC100136 AB
3. Measure the hub starting torque by using the

following special tools.
Torque wrench (MB990685)
Preload socket (MB990326)
Limit: 1.8 Nm
4. The starting torque must be within the limit and
the hub rotation must be smooth.
MB991017
AC100137 AB
1. Measure to determine whether the wheel bearing

axial play is within the limit or not by using the
following special tools.
Spacer (MB991000)
Limit: 0.05 mm
2. If the play is not within the limit range while the nut
is tightened to 245 29 Nm, the bearing, hub
and/or knuckle have probably not been installed
correctly. Replace the bearing and re-install.
INSPECTION
M1261002000067
Check the front hub and brake disc mounting

surfaces for galling and contamination.
Check the knuckle inner surface for galling and
cracks.
FRONT AXLE
26-14
DRIVE SHAFT ASSEMBLY

M1261003500366
CAUTION
Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing
work.
Pre-installation Operation
Transmission Fluid Draining (Refer to GROUP Front Exhaust Pipe Installation (Refer to
GROUP 15, Exhaust Pipe and Muffler 315).
22A, On-vehicle Service - Transmission Oil
Check the Ball Joint Dust Cover for cracks or
Replacement 322A).
Transfer Oil Draining <4WD>
damage by pushing it with your finger.
Transfer Oil Filling<4WD> (Refer to GROUP
(Refer to GROUP 22A, On-vehicle Service 22A, On-vehicle Service - Transfer Oil
Transfer Oil Replacement 322A).
Front Exhaust Pipe Removal (Refer to GROUP
Replacement 322A).
Transmission Fluid Filling (Refer to GROUP
15, Exhaust Pipe and Muffler 315).
22A, On-vehicle Service - Transmission Oil
Replacement 322A).
<2WD>
N6
N 14
<LH>
11
25 5 Nm
41 4 Nm
10 N
4
<RH>
7
2
1N
12
9
39 5 Nm
245 29 Nm
108 10 Nm
AC107141AB
FRONT AXLE
26-15

<4WD>
6N
N 14
25 5 Nm
10 N
3
13
N 14
11
8
1N
9
245 29 Nm
39 5 Nm
108 10 Nm
AC107142 AB
<<A>>
>>C<<
>>C<<
>>B<<
1.
2.
3.
4.
5.
6.
7.
8.
Removal steps
Drive shaft nut
Washer
Front ABS sensor
Front ABS sensor bracket
Brake hose bracket
Self-locking nut
Stabilizer rubber

<<A>> DRIVE SHAFT NUT REMOVAL
CAUTION
Do not apply pressure to the wheel bearing by
the vehicle weight to avoid possible damage
when the drive shaft nut is loosened.
MB990767
AC102462 AC

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

9. Lower arm ball joint connection
10. Self-locking nut (tie rod end
connection)
11. Drive shaft
12. Drive shaft and inner shaft
assembly <2WD-RH>
13. Output shaft <4WD>
14. Circlip
FRONT AXLE
26-16
<> SELF-LOCKING NUT (TIE ROD END

CONNECTION) REMOVAL
<<C>> DRIVE SHAFT/DRIVE SHAFT AND INNER

SHAFT ASSEMBLY <2WD-RH> REMOVAL
CAUTION
it and use special tool to avoid possible
Hang special tool with cord to prevent it from
falling.
MB990767
MB990244
(Three)
Cord
MB990242
MB991354
AC102550 AC
MB991897
Nut
Bolt
Ball joint
AC208247AD


drive shaft or the drive shaft and inner shaft
assembly from the hub.
Bolt
Parallel
Drive shaft
Knob
Good
AC102551AC
Bad
AC106821AB

figure.
tie rod end.
2. Remove the drive shaft from the hub by pulling the

bottom of the brake disc towards you.
CAUTION
Do not pull on the drive shaft; doing so will
damage the PTJ; be sure to use the pry bar.
When pulling the drive shaft out from the
transmission, be careful that the spline part of
the drive shaft does not damage the oil seal.
Transmission
PTJ assembly
Pry bar
AC100141 AF
3. Insert a pry bar between the transmission case

and the drive shaft, and then pry and remove the
drive shaft from the transmission.
FRONT AXLE
26-17
<<D>> OUTPUT SHAFT <4WD> REMOVAL
CAUTION
Bracket assembly
When pulling the output shaft out from the

transmission, be careful that the spline part of
the output shaft does not damage the oil seal.
MB991721
AC102553 AC
4. If the inner shaft is hard to remove from the

transmission, strike the bracket assembly lightly
with a plastic hammer and remove the inner shaft.
Output shaft
AC102556 AC
Use special tool sliding hammer (MB991721) to

remove the output shaft.

>>A<< OUTPUT SHAFT <4WD>/DRIVE SHAFT/
DRIVE SHAFT AND INNER SHAFT ASSEMBLY
<2WD-RH> INSTALLATION
MB991460
AC102554 AC
5. Use special tool plug (MB991460) to prevent the

entry of foreign material into the transmission
case.
CAUTION
When installing the output shaft, the drive shaft
or the drive shaft and inner shaft assembly, be
careful that the spline part of the output shaft,
the drive shaft or the drive shaft and inner shaft
assembly do not damage the oil seal.
>>B<< SELF-LOCKING NUT INSTALLATION
MB991000
MB991017
AC102555 AC
CAUTION
when the drive shaft is removed. If, however,
vehicle weight must be applied to the bearing in
moving the vehicle, temporarily secure the wheel
bearing by using the following special tools.
Spacer (MB991000)
AC107031AB
AC107031
Tighten the self-locking nut so that the protruding

length of the stabilizer link protruding part meets its
standard value (A).
FRONT AXLE
26-18
>>C<< WASHER/DRIVE SHAFT NUT

INSTALLATION
CAUTION
Before securely tightening the drive shaft nuts,
bearings. Otherwise the wheel bearing will be
damaged.
Washer
MB990767
AC102465AD
1. Be sure to install the drive shaft washer in the

specified direction.
2. Using special tool end yoke holder (MB990767),

tighten the drive shaft nut to the specified torque.
FRONT AXLE
26-19

M1261003700412
CAUTION
Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly
and reassembly.
Never disassemble the BJ assembly except when replacing the BJ boot.
18
20
12 8
10
21
19
2 N 1N
15
14
13 N
<2WD-RH>
Bearing dust seal repair kit
12 N
12
<2WD-LH>
17
16
<4WD>
4
11
5
11
12 N
10
4
7
12 N
10
8N
9N
Bracket assembly repair kit
15
20
1 15
21
19
14
13
13
Grease
for PTJ
2 1
Grease
for BJ
4
12
12
PTJ boot repair kit
16
PTJ repair kit
13
12
BJ boot repair kit
AC101959 AD
>>G<<
>>G<<
<<A>>
<>
>>F<<
>>E<<
<<C>>
>>D<<
>>D<<
>>C<<
Disassembly steps
PTJ boot band (large)
PTJ boot band (small)
PTJ case and inner shaft assembly
<2WD-RH>
4. PTJ case
5. Inner shaft <2WD-RH>
6. Dust cover <2WD-RH>
7. Bracket assembly <2WD-RH>
8. Dust sear outer <2WD-RH>
9. Dust seal inner <2WD-RH>
10. Centre bearing <2WD-RH>
1.
2.
3.
<<A>>
<<D>>
>>B<<
>>A<<
>>A<<
>>A<<
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Centre bearing bracket <2WD-RH>
Circlip
Snap ring
Spider assembly
PTJ boot
Damper band <LH>
Dynamic damper <LH>
BJ assembly
BJ boot band (small)
BJ boot band (large)
BJ boot
FRONT AXLE
26-20
NOTE: .
PTJ: Pillow Tripod Joint
BJ: Birfield Joint
LUBRICATION POINTS
Grease: repair kit grease

Amount used:
<2WD>: 120 10 g
<4WD>: 85 10 g
CAUTION

Amount used:
<2WD>: 210 10 g
<4WD>: 150 10 g
CAUTION
The drive shaft joint uses special

grease. Do not mix old and new or
different types of grease.


Amount used:
Dust seal inner: 14 - 20 g
Dust seal outer: 8 - 12 g

AC107123 AC
FRONT AXLE
26-21

<<A>> PTJ CASE/SPIDER ASSEMBLY REMOVAL
<<C>> CENTRE BEARING <2WD-RH> REMOVAL
CAUTION
MB990938
Do not disassemble the spider assembly.

1. Wipe off grease from the spider assembly and the
inside of the PTJ case.
2. Always clean the spider assembly when the
grease contains water or foreign material.
MB990930
<> INNER SHAFT <2WD-RH> REMOVAL

Center bearing bracket
AC102652 AC
Bar
PTJ case
MB991248
or
MD998801
Use the following special tools to remove the centre

bearing from the centre bearing bracket.
Bar (MB990938)
<<D>> PTJ BOOT REMOVAL
1. Wipe off grease from the shaft spline.
2. When reusing the PTJ boot, wrap plastic tape
around the shaft spline to avoid damaging the
boot.
Bar
PTJ case
>>A<< DYNAMIC DAMPER <LH> /DAMPER BAND

<LH> /PTJ BOOT INSTALLATION
CAUTION
MB991248
or
MD998801
There should be no grease adhered to the rubber

part of the dynamic damper.
AC102878 AD
1. Use special tool inner shaft remover (MB991248

or MD998801) to remove the inner shaft assembly
from the PTJ case.
MB990810
AC101695 AC
AC101694 AC
2. Use special tool side bearing puller (MB990810)

to remove the centre bearing bracket from the
inner shaft.
1. Install the dynamic damper in the position (L)

shown in the figure .
L: 237 3 mm <2WD>, 231 3 mm <4WD>
2. Secure the damper bands.
3. Wrap plastic tape around the shaft spline, and
then install the PTJ boot band (small) and PTJ
boot.
FRONT AXLE
26-22
>>B<< SPIDER ASSEMBLY INSTALLATION
CAUTION
The drive shaft joint use special grease. Do
not mix old and new or different types of
grease.
If the spider assembly has been cleaned, take
special care to apply the specified grease.
1. Apply the specified grease furnished in the repair
kit to the spider assembly between the spider axle
and the roller.

Amount used:
Dust seal inner: 14 - 20 g
Dust seal outer: 8 - 12 g
MB990890
Dust seal
inner
AC101696 AC
Chamfered
side
MB990938
MB990934
Dust seal
outer
MB990890
AC102654AC
2. Install the spider assembly to the shaft from the

direction of the spline chamfered side.
AC101697AC
>>C<< CENTRE BEARING <2WD-RH>

INSTALLATION
MB990938
MB990932
2. Use the following special tools to press the dust

seals into the centre bearing bracket until they are
flush with each other.
Rear suspension bushing base (MB990890)
Bar (MB990938)
3. Apply repair kit grease to the lip of each dust seal.
>>E<< INNER SHAFT <2WD-RH> INSTALLATION
Center bearing bracket

AC102655 AC
Inner shaft
Use the following special tools to press-fit the centre

bearing into the centre bearing bracket.
Bar (MB990938)
>>D<< DUST SEAL INNER <2WD-RH> /DUST
SEAL OUTER <2WD-RH> INSTALLATION
CAUTION
When applying grease, make sure that it does not
adhere to anything outside the lip.
1. Apply the specified grease to the rear surface of
all dust seals.
MB991172
AC101698 AC
1. Use special tool inner shaft installer base

(MB991172) to hold the centre bearing inner race,
and then press-in the inner shaft.
FRONT AXLE
26-23
>>G<< PTJ BOOT BAND (SMALL)/PTJ BOOT

BAND (LARGE) INSTALLATION
Inner shaft
PTJ case
AC101699 AD
2. Apply repair kit grease to the inner shaft spline,

then press fit it into the PTJ case.
NOTE: When press-fitting the inner shaft into the
PTJ case, apply a thin coat of repair kit grease to
the dust seal outer lip part and the outside edge of
the PTJ axial part.
>>F<< PTJ CASE INSTALLATION
CAUTION
The drive shaft joint use special grease. Do not
mix old and new or different types of grease.
AC102656 AC
After applying the specified grease to the PTJ case,

insert the drive shaft and apply grease one more
time.
Amount to use:
<2WD>: 210 10 g
<4WD>: 150 10 g
NOTE: The grease in the repair kit should be divided
in half for use, respectively, at the joint and inside the
boot.
AC102657AC
Set the PTJ boot bands at the specified distance in

order to adjust the amount of air inside the PTJ boot,
and then tighten the PTJ boot band (small), PTJ boot
band (large) securely.
Standard value (A):
<2WD>: 90 3 mm
<4WD>: 85 3 mm
INSPECTION
M1261003800129
Check the drive shaft for damage, bending or

corrosion.
Check the inner shaft for damage, bending or
corrosion.
Check the output shaft for damage, bending or
corrosion.
Check the drive shaft spline part for wear or
damage.
Check the inner shaft spline part for wear or
damage.
Check the output shaft spline part for wear or
damage.
Check the spider assembly for roller rotation,
wear or corrosion.
Check the groove inside PTJ case for wear or
corrosion.
Check the dynamic damper for damage or
cracking.
Check the boots for deterioration, damage or
cracking.
Check the centre bearing for seizure,
discolouration or roughness of rolling surface.
Check the dust cover for damage or deterioration.
FRONT AXLE
26-24
BJ BOOT (RESIN BOOT) REPLACEMENT

M1261005200338
NOTE: The adjusting bolt should not be turned

more than once.
Boot
A
Boot band
(small)
B
AC102658
1. Remove the boot bands (large and small).

NOTE: The boot bands cannot be re-used.
2. Remove the BJ boot.
3. Wrap a plastic tape around the shaft spline, and
assemble the boot band and BJ boot.
Projection
AC102661AC
6. Position the BJ boot band (small) so that there is

even clearance at either end (A and B).
CAUTION
Secure the drive shaft in an upright position
and clamp part of the boot band to be
crimped securely in the jaws of special tool.
Crimp the boot band until special tool
touches the stopper.
AC102659
4. Align the centre groove on the BJ boot small end

with the shaft groove.
MB991561
AC102663 AC
MB991561
Stopper
7. Use the special tool to crimp the boot band

(small).
Adjusting bolt
AC102660 AC
5. Turn the adjusting bolt on special tool boot band

crimping tool (MB991561) so that the size of the
opening (W) is at the standard value.
Standard value (W): 2.9 mm
<If it is larger than 2.9 mm>
Tighten the adjusting bolt.
<If it is smaller than 2.9 mm>
Loosen the adjusting bolt.
NOTE: The value of W will change by
approximately 0.7 mm for each turn of the
adjusting bolt.
AC102662 AD
8. Check that the crimping amount (C) of the boot

band is at the standard value.
Standard value (C): 2.4 - 2.8 mm
<If the crimping amount is larger than 2.8
mm >
Readjust the value of (W) in step 5 according
to the following formula, and then repeat the
operation in step 7.
W = 5.5 mm - C
FRONT AXLE
26-25
Example: If C = 2.9 mm, then W = 2.6 mm.

<If the crimping amount is smaller than 2.4
mm >
Remove the BJ boot band, readjust the value
of (W) in step 5 according to the following
formula, and then repeat the operations in
steps 6 and 7 using a new BJ boot band.
W = 5.5 mm - C
Example: If C = 2.3 mm, then W = 3.2 mm.
9. Check that the boot band is not sticking out past
the place where it has been installed. If the boot
band is sticking out, remove it and then repeat
steps 6 to 8, using a new boot band.
CAUTION
The drive shaft joint uses special grease. Do not
mix old and new or different types of grease.
10.Fill the inside of the boot with the specified
amount of the specified grease.
Amount to use:
<2WD>: 120 10 g
<4WD>: 85 10 g
Projection
D
Boot band
(large)
E
Boot
AC102665AC
13.Position the BJ boot band (large) so that there is

even clearance at either end (D and E).
14.Use the special tool to crimp the BJ boot band
(large) in the same way as in step 7.
AC102664 AC
11.Align the centre groove on the BJ boot big end

with the BJ case groove.
12.Follow the same procedure as in step 5 to adjust
the size of the opening (W) on the special tool so
that it is at the standard value.
AC102666 AD
15.Check that the crimping amount (F) of the boot

band is at the standard value.
Standard value (F): 2.4 - 2.8 mm
<If the crimping amount is larger than 2.8
mm >
Readjust the value of (W) in step 12
according to the following formula, and then
repeat the operation in step 14.
W = 5.8 mm - F
Example: If F = 2.9 mm, then W = 2.9 mm.
<If the crimping amount is smaller than 2.4
mm >
Remove the BJ boot band, readjust the value
of (W) in step 12 according to the following
formula, and then repeat the operations in
steps 13 and 14 using a new BJ boot band.
W = 5.8 mm - F
Example: If F = 2.3 mm, then W = 3.5 mm.
16.Check that the boot band is not sticking out past
the place where it has been installed. If the boot
band is sticking out, remove it and then repeat
steps 13 to 15, using a new boot band.
127(6
27-1
GROUP 27
REAR AXLE
00
11
12
13
CONTENTS
14
15
16
REAR AXLE <2WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27A
17
REAR AXLE <4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27B
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
127(6
27A-1
GROUP 27A
00
11
REAR AXLE <2WD>
12
13
14
CONTENTS
27A
27A
15
ON-VEHICLE SERVICE . . . . . . . . . . .
27A
WHEEL BEARING AXIAL PLAY CHECK . .
27A
REAR HUB ROTARY-SLIDING

RESISTANCE CHECK . . . . . . . . . . . . . . . .
27A
SEALANT. . . . . . . . . . . . . . . . . . . . . .
27A
HUB BOLT REPLACEMENT. . . . . . . . . . . .
27A
SPECIAL TOOLS. . . . . . . . . . . . . . . .
27A
REAR AXLE HUB ASSEMBLY . . . . .
27A
27A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
27A
16
17
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
REAR AXLE <2WD>
27A-2
GENERAL INFORMATION
GENERAL INFORMATION
M1271000100285
The rear axle has the following features:

The wheel bearing is a unit ball bearing (doublerow angular contact ball bearing) which
incorporates the oil seals and is highly resistant
to a thrust load.
ABS rotors for detecting the wheel speeds are

press-fitted to the rear hub in vehicles with ABS.
Oil seal
Rear hub
Trailing arm spindle

Wheel bearing
ABS rotor
AC300617AB
M1271000300427
Item
Limit
0.05
Rear hub rotary-sliding resistance N
19
SEALANT
M1271000500249
Item
Specified sealant
Remark
Hub cap
Semi-drying sealant
REAR AXLE <2WD>
27A-3
SPECIAL TOOLS
SPECIAL TOOLS
M1271000600439
Tool
Number
Name
Use
MB990767
End yoke holder
Hub fixing
MB991618
Hub bolt remover
Hub bolt removal
MD998801
Remover
Removal of ABS rotor
MD998812
Installer cap
MD998813
Installer 100
MD998815
Installer adapter
B990767
MB991618
REAR AXLE <2WD>
27A-4
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK
M1271000900377
1. Remove the caliper assembly, and suspend the

caliper assembly with a wire and remove the
brake disc.
4. If limit value is exceeded, loosen the self-locking

nut and then tighten it to the specified torque and
check the rear hub rotary sliding resistance again.
5. Replace the rear hub assembly if an adjustment
cannot be made to within the limit.
HUB BOLT REPLACEMENT

M1271001000214

brake disc.
AC206092 AC
2. Check the bearings axial play. Place a dial gauge

against the hub surface; then move the hub in the
axial direction and check whether or not there is
axial play.
Limit: 0.05 mm
3. If the play exceeds the limit, the self-locking nut
should be tightened to the specified torque and
check the axial play again.
4. Replace the rear hub assembly if an adjustment
cannot be made to within the limit.
REAR HUB ROTARY-SLIDING

RESISTANCE CHECK
M1271001100222

brake disc.
2. Turn the hub a few times to seat the bearing.
MB991618
MB990767
AC301662 AB
2. Use the following special tools to remove the hub

bolts.
Hub bolt remover (MB991618)
NOTE: To retain a space for removing the hub
bolts, remove them near the retainer spring
mounting position.
Plain
washer
MB990767
AC301663 AB
3. Install the plain washer to the new hub bolt, and

install the bolt with a nut.
AC201814
3. Wind a rope around the hub bolt and turn the hub
by pulling at a 90 angle with a spring balance.
Measure to determine whether or not the rotarysliding resistance of the rear hub is at the limit
value.
Limit: 19 N
REAR AXLE <2WD>
27A-5
REAR AXLE HUB ASSEMBLY

M1271002000347
CAUTION
Care must be taken not to scratch or damage the teeth of the ABS rotor. The ABS rotor must never
be dropped. If the teeth of the ABS rotor are chipped, resulting in a deformation of the ABS rotor, it
will not be able to accurately detect the wheel rotation speed, and the system will not function
normally.
The rear hub assembly should not be dismantled. When removing the rear hub assembly, the
wheel bearing inner race may be left at the spindle side. In this case, always replace the rear hub
assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play.
1
60 5 Nm
6
2
175 25 Nm
4N
3
Semi-drying sealant:
3M ATD Part No. 8663 or
equivalent
AC301185 AB
<<A>>
1.
2.
3.
<> >>B<< 4.
Removal steps
Caliper assembly
Brake disc
Hub cap
Self-locking nut
5.
<<C>> >>A<< 6.
7.

Rear hub assembly
ABS rotor
Hub bolt
REAR AXLE <2WD>
27A-6
<<A>> CALIPER ASSEMBLY REMOVAL

Secure the removed caliper assembly with wire, etc.
>>A<< ABS ROTOR INSTALLATION
<> SELF-LOCKING NUT REMOVAL
CAUTION
CAUTION
When installing, take care not to deform the ABS
rotor.
Iron piece
ABS rotor
Rear hub
assembly
Iron piece
AC301112 AB
Do not apply the vehicle weight to the wheel

bearing while loosening the self-locking nut, or
the wheel bearing will be damaged.
<<C>> ABS ROTOR REMOVAL
AC102209 AC
Press-fit the ABS rotor to the rear hub assembly.

CAUTION
175 25 Nm
MD998812
MD998813
AC301113 AB
ABS rotor
MD998815
MD998801
Before securely tightening the self-locking nuts,

bearings. Otherwise the wheel bearing will be
damaged.
Tighten the self-locking nut to the specified torque.
INSPECTION
M1271002100225
Rear hub assembly
AC210936 AC
Use the following special tools to press out ABS rotor

from the rear hub assembly.
Remover (MD998801)
Installer100 (MD998813)
Installer adapter (MD998815)
Check the rear hub assembly for crack or

damage.
Check the oil seal of the rear hub assembly for
crack or damage.
Check the ABS rotor for chipped teeth.
27B-1
GROUP 27B
00
11
REAR AXLE <4WD>
12
13
14
CONTENTS
27B
15
REAR AXLE HUB ASSEMBLY . . . . .
27B
27B
16
27B
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
27B
17
LUBRICANTS . . . . . . . . . . . . . . . . . .
27B
DRIVE SHAFT ASSEMBLY . . . . . . . .
27B
21
27B
SEALANT AND ADHESIVE. . . . . . . .
27B
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
27B
27B
SPECIAL TOOLS. . . . . . . . . . . . . . . .
27B
27B
DIFFERENTIAL CARRIER
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 27B
REAR AXLE TOTAL BACKLASH CHECK .
27B
27B
GEAR OIL LEVEL CHECK . . . . . . . . . . . . .
27B
WHEEL BEARING END PLAY CHECK . . .
27B
DIFFERENTIAL SUPPORT MEMBER

BUSHING REPLACEMENT . . . . . . . . . . . .
27B
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
27B
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
27B
DIFFERENTIAL CARRIER OIL SEAL

REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
27B
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
REAR AXLE <4WD>
27B-2
GENERAL INFORMATION
GENERAL INFORMATION
M1271000100296
The rear axle has the following features.

The wheel bearing is a double-row angular
contact ball bearing which incorporates the oil
seals and is highly resistant to a thrust load.
The drive shaft has BJ-TJ constant velocity joints.
A smaller BJ side boot is used.
ABS rotors for detecting the wheel speed are

press-fitted to the BJ outer wheels.
NOTE: .
TJ: Tripod Joint
BJ: Birfield Joint
SPECIFICATIONS
Item
Wheel bearing
Drive shaft
Specification
Type
Double-row angular contact ball

bearing
Bearing (OD x ID) mm
70 40
Type
Length (joint to joint)
outer diameter mm
Outer
BJ
Inner
TJ
LH
481 22
RH
571 22
Differential carrier
TJ
BJ
Rear hub
Drive shaft
ABS rotor
AC300622 AB
REAR AXLE <4WD>
27B-3
M1271000300438
Item
Standard value
Limit
Rear axle total backlash mm
Wheel bearing rotation starting torque Nm
1.0
Wheel bearing end play mm
0.05
TJ boot assembly dimension mm
80 3
Drive gear backlash mm
0.11 - 0.16
Drive gear runout mm
0.05
Differential gear backlash mm
0 - 0.076
0.2
Drive pinion
turning torque
Nm
0.9 - 1.2
With
Companion flange (oil seal
1.0 - 1.3
oil seal contacting area) with anti-rust
agent
Without oil seal
Companion flange (oil seal

contacting area) with gear oil
applied
0.5 - 0.6
LUBRICANTS
M1271000400219
Item
Specified lubricant
Quantity
Rear differential gear oil
Hypoid gear oil API classification GL-5 or higher

SAE viscosity No. 90, 80W
0.55 L
Drive shaft BJ joint
Repair kit grease
75 10 g
Drive shaft TJ joint
Repair kit grease
110 10 g
SEALANT AND ADHESIVE

M1271000500227
Item
Specified sealant and adhesive
Remark
Differential cover
3M ATD Part No. 8661 or equivalent
Semi-drying sealant
Drive gear and differential case

mounting part
3M Stud Locking 4170 or equivalent
Anaerobic sealant
REAR AXLE <4WD>
27B-4
SPECIAL TOOLS
SPECIAL TOOLS
M1271000600440
Tool
Number
Name
Use
MB991115
Oil seal installer
Press-fitting of the differential

carrier oil seal
(Use together with MB990938)
MB990767
End yoke holder
Rear axle hub fixing
MB990241
A: MB990242
B: MB990244
Axle shaft puller

A: Puller shaft
B: Puller bar
Removal of the drive shaft
MB991354
Puller body
A: MB991017
B: MB990998
C: MB991000
A, B: Front hub
remover and
installer
C: Spacer
Provisional holding of the

wheel bearing
Measurement of wheel
bearing rotation starting
torque
Measurement of wheel
bearing end play
NOTE: MB991000, which
belongs to MB990998,
should be used as a spacer.
MB990883
Rear suspension
bushing arbor
Removal and installation of the

differential support member
bushing
MB990884
Mount bushing
arbor
B990767
A
B
MB990241AB
MB991354
B
C
AC100320AB
MB990883
REAR AXLE <4WD>
27B-5
SPECIAL TOOLS
Tool
Number
Name
Use
MB990909
Working base
Supporting of the differential

carrier
MB991116
Working base
adapter
MB990810
Side bearing puller
Removal of the side bearing

inner race
Removal of the companion
flange
MB990850
End yoke holder
Companion flange fixing
MB990339
Bearing puller
Removal of drive pinion rear

bearing inner race
MB990374
Pinion bearing
remover
MB990835
A: MB990836
B: MB990392
Drive pinion setting Adjustment of the drive pinion

gauge set
height
A: Drive pinion
gauge assembly
B: Cylinder gauge
MB990326
Preload socket
MB990685
Torque wrench
MB990909
MB990810
MB990850
MB990339
MB990326
Measurement of the wheel

bearing rotation starting
torque
Measurement of the drive
pinion turning torque
REAR AXLE <4WD>
27B-6
ON-VEHICLE SERVICE
Tool
Number
Name
Use
MB990728
Bearing installer
Press-fitting of the drive pinion

rear bearing inner race
MB990031 or MB990699
Oil seal installer
Press-fitting of the drive pinion

oil seal
MB990925
A: MB990926 - MB990937
B: MB990938
C: MB990939
Press-fitting of differential
Bearing and oil
carrier oil seal
seal installer set
(Use together with
A: Installer adapter
MB991115)
B: Bar
Inspection of final drive gear
C: Brass bar
tooth contact
drive pinion front/rear bearing
outer race
For details of each installer,
refer to GROUP 26 - Special
Tools326.
MB990728
MB990031
A
C
B
MB990925
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK
M1271001200218
1. Park the vehicle on a flat, level surface.

2. Move the transmission gearshift lever to the
neutral position. Apply the parking brake and jack
up the vehicle.
Mating marks
AC301510AB
AC301509AB
3. Turn the propeller shaft clockwise as far as it will

go. Make the mating marks on the companion
flange and on the differential carrier.
4. Turn the propeller shaft counterclockwise as far as

it will go, and measure the amount of distance
between the mating marks.
Limit: 5 mm
5. If the backlash exceeds the limit value, remove the
differential carrier assembly and check the
following.
Final drive gear backlash (Refer to327B.)
Differential gear backlash (Refer to 327B.)
REAR AXLE <4WD>

ON-VEHICLE SERVICE
GEAR OIL LEVEL CHECK

M1272001200181
Gear oil
Upper
limit
Lower
limit
27B-7
3. If the play exceeds the limit, the drive shaft nut

should be tightened to the specified torque and
check the end play again.
4. Replace the wheel bearing if adjustment cannot
be made to within the limit. (Refer to GROUP 34Trailing Arm334.)
DIFFERENTIAL CARRIER OIL SEAL

REPLACEMENT
8 mm
M1272001300111
AC102739 AD
Check that gear oil level is not 8 mm below the

bottom of filler plug hole.
Specified gear oil:
Hypoid gear oil API classification GL-5 or
higher SAE viscosity Number 90, 80W
1. Remove the drive shaft from the differential

carrier. (Refer to 327B).
2. Remove the differential carrier oil seal.
MB990938
WHEEL BEARING END PLAY CHECK

M1271000900388

brake disc.
MB991115
AC102740 AC
AC206092 AC
2. Fit the dial gauge as shown in the diagram and

move the hub in the axial direction to measure the
play.
Limit: 0.05 mm
3. Use the following special tools to press-fit a new

oil seal.
Oil seal installer (MB991115)
4. Apply multi-purpose grease to the oil seal lip and
drive shaft oil seal seating area.
5. Replace the drive shaft circlip with a new one, and
install the drive shaft to the differential carrier.
(Refer to 327B).
REAR AXLE <4WD>
27B-8

M1271002000358
AC301904 AB
Removal steps
1. Rear hub assembly (Refer to GROUP
34, Trailing arm assembly 334).
2. Hub bolt
INSPECTION
M1271002100236
WHEEL BEARING ROTATION STARTING

TORQUE AND AXIAL PLAY CHECK
MB990685
245 29 Nm
MB991017
MB991000
Wheel bearing
AC102720 AC
1. Tighten the following special tools to the specified

torque.
Spacer (MB991000)
2. Rotate the rear hub in order to seat the bearing.
MB990326
AC301905AB
3. Measure the wheel bearing rotation starting

torque by using the following special tools.
Limit: 1.0 Nm
4. The rotation starting torque must be within the
limit and wheel bearing must rotate smoothly.
REAR AXLE <4WD>

27B-9
6. If the play is not within the limit range while the nut
is tightened to 245 29 Nm, the bearing, trailing
arm and/or rear hub have probably not been
installed correctly. Replace the bearing and reinstall.
AC301906
5. Measure to determine whether the wheel bearing

axial play is within the specified limit or not.
Limit: 0.05 mm

M1271003300147
CAUTION
Be careful not to strike the pole piece at the tip of the rear ABS sensor with tools during servicing
work.
Pre-installation Operation
Differential Gear Oil Draining (Refer to 327B
).
Differential Gear Oil Filling (Refer to 327B).
Rear Wheel Alignment Check and Adjustment
(Refer to GROUP 34, On-Vehicle Service Rear Wheel Alignment Check and Adjustment
334).
245 29 Nm
1N
2
AC201825 AB
Removal steps
<<A>> >>B<< 1. Drive shaft nut

Rear ABS sensor (Refer to GROUP
35B, Wheel Speed Sensor 335B).
Lower arm and trailing arm
connection (Refer to Group 34,
Trailing arm assembly 334).

Control link and trailing arm
connection (Refer to GROUP 34,
Trailing arm assembly 334).
<> >>A<< 2. Drive shaft
5. Circlip
REAR AXLE <4WD>
27B-10
CAUTION
<<A>> DRIVE SHAFT NUT REMOVAL
CAUTION
Do not pull on the drive shaft; doing so will

damage the TJ; be sure to use the pry bar.
When pulling the drive shaft out from the
differential carrier, be careful that the spline
part of the drive shaft does not damage the oil
seal.
MB990767
AC201826 AC

vehicle weight to avoid possible damage to wheel
bearing before tightening drive shaft nut fully.
TJ assembly
Pry bar
AC102552 AE
2. Remove the drive shaft from the differential carrier

by using a pry bar.
<> DRIVE SHAFT REMOVAL

MB990242
(MB990241)
245 29 Nm
MB990767
MB991354
MB990244
(MB990241)
(Three)
MB991017
MB991000
AC102720 AC
AC201827 AC

drive shaft from the hub.
Wheel bearing
CAUTION
bearing by using the following special tools.
Spacer (MB991000)

>>A<< DRIVE SHAFT INSTALLATION
CAUTION
When installing the drive shaft, be careful that
the spline part of the drive shaft does not
damage the oil seal.
REAR AXLE <4WD>

>>B<< DRIVE SHAFT NUT INSTALLATION
27B-11
INSPECTION
M1271003400069
CAUTION
vehicle weight to avoid possible damage to wheel
bearing before tightening drive shaft nut fully.
245 29 Nm
Washer
MB990767
AC201828 AC
1. Assemble the drive shaft washer in the illustrated

direction.
2. Tighten the drive shaft nut to the torque
specification with special tool end yoke holder
(MB990767).
Check the drive shaft for damage, bending or

corrosion.
Check the drive shaft spline part for wear or
damage.
Check the boots for deterioration, damage or
cracking.
Check the dust cover for damage or deterioration.
REAR AXLE <4WD>
27B-12

M1271003500152
CAUTION
Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly
and reassembly.
Never disassemble the BJ assembly except when replacing the BJ boot.
5N
1N
7
N4
2N
3
8N
10
11
N9
1
9
10
6
7
11
1
2
BJ repair kit
TJ repair kit
1
2
7
1
10
9
Grease for TJ
Grease for BJ
BJ boot repair kit
TJ boot repair kit

AC201162 AB
Disassembly steps
>>C<< 1. TJ boot band (large)

>>C<< 2. TJ boot band (small)
<<A>> >>B<< 3. TJ case
4. Circlip
5. Snap ring
<<A>> >>B<< 6. Spider assembly
<> >>A<< 7. TJ boot

8.
9.
<> >>A<< 10.
11.
BJ boot band (large)

BJ boot band (small)
BJ boot
BJ assembly
REAR AXLE <4WD>
27B-13
LUIBRICATION POINTS

Amount used: 110 10 g
CAUTION

Amount used: 75 10 g
CAUTION
AC212165 AC

<<A>> TJ CASE/SPIDER ASSEMBLY REMOVAL
CAUTION
Do not disassemble the spider assembly.
1. Wipe off grease from the TJ case and spider
assembly.
2. If there is water or foreign material in the wiped
grease, be sure to clean the spider assembly.
<> TJ BOOT/BJ BOOT REMOVAL
1. Wipe off grease from the shaft spline part.
PLASTIC TAPE
ACX02368 AB
2. Wrap plastic tape around the spline part on the TJ

side of the drive shaft so that TJ and BJ boots are
not damaged when they are removed.
REAR AXLE <4WD>
27B-14

>>A<< BJ BOOT/TJ BOOT INSTALLATION
Wrap plastic tape around the spline part on the TJ
side of the drive shaft, and then install BJ and TJ
boots.
>>B<< SPIDER ASSEMBLY/TJ CASE
INSTALLATION
CAUTION
The drive shaft joint uses special grease. Do
not mix old and new or different types of
grease.
If the spider assembly has been cleaned, take
special care to apply the specified grease.
1. Apply the specified grease furnished in the repair
kit to the spider assembly between the spider axle
and the roller.
AC102656 AC
3. After applying the specified grease to the TJ case,

insert the driveshaft and apply grease one more
time.
Used amount: 110 10 g
NOTE: The grease in the repair kit should be
divided in half for use, respectively, at the joint
and inside the boot.
>>C<< TJ BOOT BAND (SMALL)/TJ BOOT BAND
(LARGE) INSTALLATION
Chamfered
side
AC102654AC
2. Install the spider assembly to the shaft from the

direction of the spline chamfered side.
A
AC102657AC
Set the TJ boot bands at the specified distance in

order to adjust the amount of air inside the TJ boot,
and then tighten the TJ boot band (large) and TJ
boot band (small) securely.
Standard value (A): 80 3 mm
REAR AXLE <4WD>
27B-15
DIFFERENTIAL CARRIER ASSEMBLY

M1272002000209
Main Muffler and Center Exhaust Pipe Removal (Refer to
GROUP 15, Exhaust Pipe and Muffler 315).
Differential Gear Oil Draining
Drive Shaft Removal (Refer to 327B).
Drive Shaft Installation (Refer to 327B).
Differential Gear Oil Filling (Refer to 327B).
Main Muffler and Center Exhaust Pipe Installation (Refer
to GROUP 15, Exhaust Pipe and Muffler 315).
Rear Wheel Alignment Check and Adjustment (Refer to
GROUP 34, On-Vehicle Service-Rear Wheel Alignment
Check and Adjustment 334).
90 10 Nm
90 10 Nm
7
12
3
2N
44 9 Nm
49 9 Nm
10
11
32 2 Nm
9
N
8
64 4 Nm
90 10 Nm
70 10 Nm
AC203973 AD
<<A>> >>B<< 1.
2.
3.
4.
5.
6.
Removal steps
Propeller shaft connection
Self-locking nut
Dynamic damper
Differential support arm connecting
bolt
Self-locking nut
Differential support arm
>>A<< 7.
8.
9.
10.
11.
12.

Breather hose assembly
Differential mount bracket bolt
Lower stopper
Upper stopper
Differential mount bracket
Differential carrier assembly
REAR AXLE <4WD>
27B-16

<<A>> PROPELLER SHAFT DISCONNECTION
DIFFERENTIAL SUPPORT MEMBER

BUSHING REPLACEMENT
M1272001400066
<DIFFERENTIAL MOUNT BRACKET>

MB990883
Differential
mount bracket
Bushing
Mating marks
AC300150 AB
1. Make mating marks on the differential companion

flange and the propeller shaft assembly.
2. Suspend the removed propeller shaft from the
body with a wire to prevent bending.
Iron piece
Hollow
portion

>>A<< BREATHER HOSE ASSEMBLY
INSTALLATION
CAUTION
Be careful not to apply grease, water or soapy
water to the hose inlet.
Breather hose assembly
Pad
Vent plug
Differential case
Drive shaft
AC211428AD
Fully insert the breather hose into the vent plug.

Install the breather hose pad as shown in the
illustration.
>>B<< PROPELLER SHAFT INSTALLATION
Align the mating marks of differential companion
flange and propeller shaft assembly.
AC107255 AB
1. Use special tool rear suspension bushing arbor

(MB990883) to remove or install the bushing.
2. Press-fit the bushing with its hollow portion facing
in the direction shown.
3. Press-fit the bushing until the bushing outer case
end face is flush with the differential mount
bracket.
REAR AXLE <4WD>
27B-17
<DIFFERENTIAL SUPPORT MEMBER>

MB990984
Differential
support member
<DIFFERENTIAL SUPPORT ARM>

MB990984
Differential
support arm
Bushing
Bushing
Iron piece
Iron piece
LH side
MB990883
Differential
support member
Bushing
Bushing
Marks
45
RH side
Iron piece
Hollow
portion
Bushing
Marks
AC107256 AB
AC102751AD
1. Use the following special tools to remove or install

the bushing.
Mount bushing arbor (MB990984)
Rear suspension bushing arbor (MB990883)
2. Press-fit the bushing with its hollow portion facing
in the direction shown.
end face is flush with the differential mount
bracket.
1. Use special tool mont bushing arbor (MB990984)

to remove or install the bushing.
2. Press-fit the bushing with its marks facing in the
direction shown.
end face is flush with the differential support arm.
REAR AXLE <4WD>
27B-18
DISASSEMBLY
M1272002200203
6N
9 10 18 17 14 1516 13 12 19
5
17
18
11
2N
10
16 15
11
28
32 27
25 26
24
22
34
31
23
20 N
4N
30
29 N
21
33 N
AC301212AB
<<A>>
<<A>>
<<A>>
<>
<<C>>
<<D>>
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Disassembly steps
Inspection before disassembly (Refer
to 327B).
Filler plug
Gasket
Drain plug
Packing
Differential cover
Vent plug
Bearing cap
Differential case assembly
Differential side bearing spacer
Differential side bearing outer race
Differential side bearing inner race
Drive gear
Lock pin
Pinion shaft
Pinion gear
Pinion washer
Side gear
<<E>>
<<F>>
<<F>>
<<G>>
<<H>>
<<H>>
<<H>>
<>
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

Side gear spacer
Differential case
Self-locking nut
Washer
Drive pinion assembly
Companion flange
Drive pinion front shim (For adjusting
preload of drive pinion)
Drive pinion spacer
Drive pinion rear bearing inner race
Drive pinion rear shim (for adjusting
drive pinion height)
Drive pinion
Oil seal
Drive pinion front bearing inner race
Drive pinion front bearing outer race
Drive pinion rear bearing outer race
Oil seal
REAR AXLE <4WD>
27B-19
INSPECTION BEFORE DISASSEMBLY

1. Remove the cover.
MB990909
and
MB991116
2. When runout exceeds the limit value, check for

foreign material between drive gear rear side and
differential case, or for loose drive gear installation
bolts.
3. When step (2) gives normal results, reposition the
drive gear and differential case and remeasure.
4. If adjustment is impossible, replace the differential
case, or replace the drive gear and pinion as a
set.
DIFFERENTIAL GEAR BACKLASH
AC102883 AC
2. Hold the following special tools in a vise, and

install the differential carrier assembly to the
special tool.
Working base (MB990909)
Working base adapter (MB991116)
FINAL DRIVE GEAR BACKLASH
Wedge
Side gear
spacer
Side gear
spacer
AC102885 AC
AC102884
1. With the drive pinion locked in place, use a dial

gauge to measure the drive gear backlash in four
or more places on the drive gear.
2. If the backlash is not within the standard value,
adjust the final drive gear backlash (Refer to
327B).
3. After the adjustment, inspect the final drive gear
tooth contact.
DRIVE GEAR RUNOUT
AC102886
1. Measure the drive gear runout at the shoulder on

the reverse side of the drive gear.
Limit: 0.05 mm
1. Insert a wedge between the side gear and the

pinion shaft to lock the side gear.
2. While locking the side gear with the wedge,
measure the differential gear backlash with a dial
indicator on the pinion gear.
Use the measurement procedure for the other
pinion gear.
Limit: 0.2 mm
3. If the backlash exceeds the limit value, adjust it by
replacing the side gear spacers.
4. If adjustment is not possible, replace the side
gears and pinion gears as a set.
FINAL DRIVE GEAR TOOTH CONTACT
Check the tooth contact of drive gear by following the
steps below.
AC102887
1. Apply a thin, uniform coat of machine blue to both

surfaces of the drive gear teeth.
REAR AXLE <4WD>
27B-20
3. Check the tooth contact condition of the drive gear

and drive pinion.
CAUTION
If the drive gear is rotated too much, the tooth
contact pattern will become unclear and difficult
to check.
MB990939
AC102888 AC
2. Insert special tool brass bar (MB990939) between

the differential carrier and the differential case,
and then rotate the companion flange by hand
(once in the normal direction, and then once in the
reverse direction) while applying a load to the
drive gear so that the revolution torque
(approximately 2.5 - 3.0 Nm) is applied to the
drive pinion.
Standard tooth contact pattern
Problem
1. Narrow tooth side
2. Drive-side tooth surface (the side
applying power during forward movement)
3. Wide tooth side
4. Coast-side tooth surface (the side
applying power during reverse movement)
3
ACX01039 AF
Solution
Tooth contact pattern resulting

from excessive pinion
height
1
AC107261AB
Increase the thickness of

the drive pinion rear shim,
3
and position the drive pinion
AC107260 AB
closer to the center of the
The drive pinion is positioned too drive gear. Also, for
far from the center of the drive
backlash adjustment,
gear.
position the drive gear
farther from the drive
pinion.
Tooth contact pattern resulting
from insufficient pinion
height.
2
AC107263 AB
Decrease the thickness of

the drive pinion rear shim,
3
and position the drive pinion
AC107262 AB
farther from the center of
The drive pinion is positioned too the drive gear. Also, for
close to the center of the drive
backlash adjustment,
gear.
position the drive gear
closer to the drive pinion.
REAR AXLE <4WD>
27B-21
NOTE: Check the tooth contact pattern to confirm

that the adjustments of the pinion height and
backlash have been done properly. Continue to
adjust the pinion height and backlash until the
tooth contact pattern resembles the standard
pattern. If, even after adjustments have been
made, the correct tooth contact pattern cannot be
obtained, it means that the drive gear and the
drive pinion have become worn beyond the
allowable limit. Replace the gear set.
<> DIFFERENTIAL SIDE BEARING INNER

RACE REMOVAL
MB990810
Socket
wrench

<<A>> DIFFERENTIAL CASE ASSEMBLY/
DIFFERENTIAL SIDE BEARING SPACER/
DIFFERENTIAL SIDE BEARING OUTER RACE
REMOVAL
CAUTION
When taking out the differential case assembly,
be careful not to drop and damage the differential
side bearing spacers and differential side
bearing outer races.
AC107274 AB
Use special tool side bearing puller (MB990810) to

pull out the side bearing inner races.
NOTE: There are two notches provided (at the
differential case side) for the claw part of the special
tools; use special tool at that position.
<<C>> DRIVE GEAR REMOVAL
Mating
marks
AC102891 AC
AC102889
Use the wooden handle of a hammer to remove the

differential case assembly, differential side bearing
spacers and differential side bearing outer races.
NOTE: Keep the right and left side bearings and side
bearing spacers separate, so that they do not
become mixed during reassembly.
1. Make the mating marks to the differential case

and the drive gear.
2. Loosen the drive gear attaching bolts in a
diagonal sequence to remove the drive gear.
<<D>> LOCK PIN REMOVAL
AC102892
Drive out the lock pin with a punch.
REAR AXLE <4WD>
27B-22
<<E>> SELF-LOCKING NUT REMOVAL
<<G>> DRIVE PINION REAR BEARING INNER

RACE REMOVAL
MB990339
MB990850
AC102893AC
Use special tool end yoke holder (MB990850) to hold

the companion flange, and then remove the
companion flange self-locking nut.
<<F>> DRIVE PINION ASSEMBLY/COMPANION
FLANGE REMOVAL
CAUTION
The mating mark made on the companion flange
must not be on the coupling surface of the
companion flange and the front propeller shaft.
1. Make mating marks on the drive pinion and
companion flange.
MB990374
AC102895AD
Use the following special tools to pull out the drive

pinion rear bearing inner race.
Bearing puller (MB990339)
Pinion bearing remover (MB990374)
<<H>> OIL SEAL/DRIVE PINION FRONT
BEARING INNER RACE/DRIVE PINION FRONT
BEARING OUTER RACE REMOVAL
MB990939
MB990810
Drive pinion
front bearing
outer race
Drive pinion
front bearing
inner race
Oil seal
AC102896 AC
Companion
flange
AC102894 AD
2. Use special tool side bearing puller (MB990810)

to pull out the companion flange.
Use special tool bras bar (MB990939) to remove the

oil seal, drive pinion front bearing inner race, and
drive pinion front bearing outer race.
<> DRIVE PINION REAR BEARING OUTER
RACE REMOVAL
MB990939
Drive pinion
rear bearing
outer race
AC102897AC
Use special tool brass bar (MB990939) to remove

the drive pinion rear bearing outer race.
REAR AXLE <4WD>
27B-23
REASSEMBLY
M1272002300211
23
15
29 N
27
26 25 17 18 21 20 19 22 23 16
36 5 Nm
34
Final drive gear set
18
17
24
49 9 Nm
33 N
37 2 Nm
30
19
28
25
20
24
26
5
1
8
9
4
13
6
84 4 Nm
10
37 2 Nm
20
15 N
31 N
11
14
12 N
2N
17
18
32
64 4 Nm
17
18
20
Differential gear set
186 29 Nm
AC301213 AB
>>A<<
>>B<<
>>C<<
>>D<<
1.
2.
3.
4.
5.
6.
7.
8.
>>E<<
9.
10.
11.
>>E<< 12.
13.
14.
15.
16.
Reassembly steps
Oil seal
Drive pinion rear bearing outer race
Drive pinion front bearing outer race
Drive pinion height adjustment
Drive pinion
Drive pinion rear shim (for adjusting
drive pinion height)
Drive pinion rear bearing inner race
Drive pinion spacer
Drive pinion turning torque
adjustment
Drive pinion front shim (for adjusting
drive pinion turning torque)
Drive pinion assembly
Drive pinion front bearing inner race
Oil seal
Companion flange
Washer
Self-locking nut
Differential case
>>F<<
>>G<<
>>H<<
>>I<<
>>J<<
>>J<<
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Reassembly steps&RQWLQXHG

Differential gear backlash adjustment
Side gear spacer
Side gear
Pinion washer
Pinion gear
Pinion shaft
Lock pin
Drive gear
Differential side bearing inner race
Differential side bearing outer race
Differential side bearing spacer
Differential case assembly
Bearing cap
Vent plug
Differential cover
Packing
Drain plug
Gasket
Filler plug
Final drive gear backlash adjustment
REAR AXLE <4WD>
27B-24
Lubrication and Adhesive Points
Vent plug
Adhesive:
3M Stud Locking 4170 or
equivalent
2 3 mm
(bead diameter)
Semi-driying sealant:
AC301214 AB

>>A<< OIL SEAL PRESS-FITTING
MB990938
MB991115
AC102740 AC
Use the following special tools to press-fit a new oil

seal.

Oil seal installer (MB991115)
REAR AXLE <4WD>
27B-25
>>B<< DRIVE PINION REAR BEARING OUTER

RACE PRESS-FITTING
CAUTION
There should be no gear oil adhered to the
bearing.
MB990938
MB990935
MB990836
AC102907AD
Use the following special tools to press-fit the drive

pinion rear bearing outer race.
AC102910 AD
MB990685
MB990326
>>C<< DRIVE PINION FRONT BEARING OUTER

RACE PRESS-FITTING
MB990938
MB990932
AC102911 AC
AC102908 AD
Use the following special tools to press-fit the drive

pinion front bearing outer race.
>>D<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following
procedures:
1. Apply multipurpose grease to the washer of
special tool drive pinion gauge asseembly
(MB990836).
3. Tighten the nut of special tool a little at a time,

while measuring the turning torque of the drive
pinion by using the following special tools. Then
confirm that the turning torque (without the drive
pinion oil seal) is at the standard value.
Standard value:
Bearing division
Turning torque
New
0.9 - 1.2 Nm
NOTE: Because the special tool preload socket

(MB990326) cannot be turned one turn, turn it
several times within the range that it can be
turned; then, after fitting to the bearing, measure
the turning torque.
4. Clean the side bearing seat of the differential
carrier and bearing caps.
Notch
MB990392
MB990836
AC102909 AC
2. Install special tool, drive pinion front and rear

bearing inner races to the differential carrier as
A
MB990836
Thickness
gauge
AC102912 AD
REAR AXLE <4WD>
27B-26
5. Place the following special tools in the side

bearing seat of the differential carrier, and position
the notch as shown in the illustration. Then install
the bearing caps.
Cylinder gauge (MB990392)
Drive pinion gauge assembly (MB990836)
6. Use a thickness gauge to measure the clearance
(A) between special tools.
7. Remove the bearing caps and special tools.
11.Fit the selected drive pinion rear shim(s) to the

drive pinion, and press-fit the drive pinion rear
bearing inner race by using special tool bearing
installer (MB990728).
>>E<< DRIVE PINION TURNING TORQUE
ADJUSTMENT/OIL SEAL INSTALLATION
Adjust the drive pinion turning torque by the following
procedures:
1. Insert the drive pinion into the differential carrier,
and then install the following parts in sequence
from the carrier rear side: drive pinion spacer,
drive pinion front shim , drive pinion front bearing
inner race and companion flange.
NOTE: Do not install the oil seal.
MB990850
AC102913 AC
8. Use a micrometer to measure the shown

dimensions (B, C) of special tools.
AC201179 AB
D
Cylinder gauge
AC102914 AC
9. Install the bearing cap, and then use a cylinder

gauge to measure the inside diameter (D) of the
bearing cap.
10.Calculate thickness (F) of the required drive
pinion rear shim by the following formula. Select a
shim which most closely matches this thickness.
F = A + B + C - 1/2D - 86.00 mm
2. Tighten the companion flange self-locking nut to

the specified torque while holding the companion
flange with special tool end yoke holder
(MB990850).
CAUTION
There should be no gear oil adhered to the
bearing.
MB990326
MB990685
MB990728
Drive pinion
rear shim
ACX01062AD
MB990728
ACX02432 AD
3. Use the following special tools MB990685 and

MB990326 to measure the drive pinion turning
torque (without the drive pinion oil seal).
Standard value:
REAR AXLE <4WD>
27B-27
Bearing division
Turning torque
New
0.9 - 1.2 Nm
4. If the drive pinion turning torque is not within the

standard value, adjust the turning torque by
replacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTE:
MB990031
or
MB990699
ACX01064AG
A
Identification
colour
5. Remove the companion flange and drive pinion

again. Then insert the drive pinion front bearing
inner race into the differential carrier. Use special
tool oil seal installer (MB990031 or MB990699) to
press-fit the drive pinion oil seal.
ACX01063 AE
When selecting the drive pinion front shims, if the

number of shims is large, reduce the number of
shims to a minimum by selecting the drive pinion
spacers.
Select the drive pinion spacer from the following
two types.
Height of drive pinion Identification colour
spacer (A) mm
57.08
Red
57.72
MB990850
AC201179 AB
6. Install the drive pinion assembly and companion

flange with the mating marks properly aligned.
Tighten the companion flange self-locking nut to
the specified torque while holding the companion
flange with special tool.
REAR AXLE <4WD>
27B-28
MB990326
2. Temporarily install the pinion shaft.

NOTE: Do not assemble the lock pin yet.
MB990685
Wedge
ACX01062AD
7. Use special tools to measure the drive pinion

turning torque (with drive pinion oil seal) to verify
that the drive pinion turning torque complies with
the standard value.
Standard value:
Bearing
division
Companion
flange
lubrication
Turning
torque
New
None (with antirust agent)
1.0 - 1.3 Nm
Gear oil applied
0.5 - 0.6 Nm
8. If the turning torque is not within the standard

value, check the tightening torque of the
companion flange self-locking nut, and the
installation of the oil seal.
>>F<< DIFFERENTIAL GEAR BACKLASH
ADJUSTMENT
Adjust the differential gear backlash by the following
procedure:
Side gear
spacer
Side gear
spacer
AC102885 AC
3. Insert a wedge between the side gear and the

pinion shaft to lock the side gear.
4. While locking the side gear with the wedge,
measure the differential gear backlash with a dial
indicator on the pinion gear.
Measure by the same procedure for the other
pinion gear.
Limit: 0.2 mm
5. If the backlash exceeds the limit value, adjust it by
replacing the side gear spacers.
6. If adjustment is not possible, replace the side
gears and pinion gears as a set.
7. Check that the backlash is within the limit value
and that the differential gear turns smoothly.
>>G<< LOCK PIN INSTALLATION
1. Align the pinion shaft lock pin hole with the
differential case lock pin hole, and drive in the lock
pin.
ACX01066
1. Assemble the side gears, side gear spacers,

pinion gears, and pinion washers into the
differential case.
ACX02429 AC
2. Stake the lock pin with a punch on both sides.
REAR AXLE <4WD>

>>H<< DRIVE GEAR INSTALLATION

1. Clean the drive gear attaching bolts.
Tap
27B-29
>>J<< BEARING CAP INSTALLATION/FINAL

DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the final drive gear backlash by the following
procedure:
1. Assemble the differential case with the side
bearing outer race to the differential carrier.
ACX01068 AD
2. Remove the adhesive adhered to the threaded

holes of the drive gear by turning the tap (M10 x
1.25). Clean the threaded holes by applying
compressed air.
ACX01071AD
2. Press the differential case to one side to measure

the clearance of the side bearing outer race and
the differential carrier.
3. Select two pairs of side bearing spacers.
Determine the thickness by adding 1/2 of the
clearance to the pre-load 0.05mm.
MB990810
ACX02430 AB
3. Apply the specifed sealant to the threaded holes

of the drive gear.
Specified sealant: 3M stud locking 4170 or
equivalent
4. Install the drive gear onto the differential case with
the mating marks properly aligned. Tighten the
drive gear attching bolts to the specified torque in
a diagonal sequence.
>>I<< DIFFERENTIAL SIDE BEARING INNER
RACE INSTALLATION
Piece of
metal
Piece of
metal
MB990728
AC102942 AC
Use special tool bearing installer (MB990728) to

press-fit the differential side bearing inner races into
the differential case.
Socket
wrench
AC107274 AB
4. Remove the side bearing by using special tool

side bearing puller (MB990810).
NOTE: Hook the claws of special tool with the
side bearing inner race by using the notches (two
areas) of the differential case side.
5. Assemble the selected side bearing spacers to
each side.
REAR AXLE <4WD>
27B-30
Piece of
metal

Piece of
metal
WHEN THE BACKLASH IS SMALL
DECREASED
INCREASED
INCREASED
DECREASED
MB990728
WHEN THE BACKLASH IS LARGE
AC102942 AC
6. Use special tool bearing installer (MB990728) to

press-fit the side bearing inner race into the
differential case. After installing the outer race,
assemble the differential case to the differential
carrier.
7. Align the mating marks of differential carrier and
the bearing cap with each other and tighten the
bearing cap attaching bolts to the specified
torque.
AC107626 AB
9. If the backlash is not within the standard value,

move the side bearing spacer as shown in the
illustration to adjust the backlash.
NOTE: The increment of side bearing spacer
must be the same as the decreased amount.
10.Inspect the tooth condition at the final drive gear
and replace if required. (Refer to 327B).
AC102886
AC102884
8. Measure the final drive gear backlash at four

points or more on the circumference of the drive
gear.
11.Measure the drive gear runout.

Limit: 0.05 mm
12.If drive gear runout exceeds the limit, remove the
differential case and then the drive gears, moving
them to different positions and reinstall them.
13.If adjustment is not possible, replace the
differential case or drive gear and drive pinion as
a set.
31-1
GROUP 31
00
11
WHEEL AND TYRE
12
13
14
CONTENTS
31
15
TYRE INFLATION PRESSURE CHECK . . .
31
TYRE WEAR CHECK . . . . . . . . . . . . . . . . .
31
16
31
WHEEL RUNOUT CHECK . . . . . . . . . . . . .
31
17
31
WHEEL AND TYRE . . . . . . . . . . . . . .
31
21
INSTALLATION SERVICE POINT . . . . . . .
31
31
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
WHEEL AND TYRE
31-2
GENERAL INFORMATION
GENERAL INFORMATION
M1311000100060
The wheels and tyres of the following specifications

have been established.
SPECIFICATIONS
Road wheel and tyre
Item
Comfort
Sport
Wheel
Type
Steel type or Aluminium type*
Aluminium type
Size
16 6JJ
16 6JJ
Amount of wheel offset mm
46
46
Pitch circle diameter (PCD)

mm
114.3
114.3
Size
215/60R16 95H
215/60R16 95H
Tyre
Spare wheel and tyre

Item
Spare
wheel
Spare tyre
Specification
Type
Steel type
Size
16 4T or 16 6JJ*
Amount of wheel offset mm
40 or 46*
Pitch circle diameter (PCD)

mm
114.3
Size
T135/90D16 102M or 215/60R16 95H*
NOTE: The * mark indicates optional item.

NOTE: PCD (Pitch Circle Diameter) indicates the pitch circle diameter of the wheel installation holes.
M1311000300365
ITEM
LIMIT
Tread depth of tyre mm
Minimum 1.6
Wheel runout
<Aluminium wheel>
Radial runout mm
1.0 or less
Lateral runout mm
1.0 or less
Wheel runout
<Steel wheel>
Radial runout mm
1.2 or less
Lateral runout mm
1.2 or less
WHEEL AND TYRE
31-3
TROUBLESHOOTING
TROUBLESHOOTING
DIAGNOSIS
M1311000700363
Symptom
Probable cause
Remedy
Reference page
Rapid wear
at shoulders
Under-inflation
or lack of
rotation
Adjust the tyre

pressure.
For tyre inflation

pressure, refer to
the label on the
drivers side centre
pillar.
Under-inflation
Adjust the tyre

pressure.
For tyre inflation

pressure, refer to
the label on the
drivers side centre
pillar.
Excessive
camber
Check the camber.
Refer to GROUP
33A, On-vehicle
service - Front
wheel alignment
check and
adjustment 333.
ACX00923AB
Rapid wear
at centre
ACX00924 AB
Over-inflation
or lack of
rotation
ACX00925 AB
Cracked
treads
ACX00926AB
ACX00927AB
Wear on one
side
ACX00928 AB
ACX00929 AB
Feathered
edge
Incorrect toe-in
Adjust the toe-in.
ACX00930AB
ACX00931 AB
Bald spots
Unbalanced
wheel
Balance the wheels.
ACX00932AB
ACX00933 AB
331
WHEEL AND TYRE
31-4
TROUBLESHOOTING
Symptom
Probable cause
Remedy
Reference page
Scalloped
wear
Lack of rotation of tyres or worn Rotate the tyres, and

or out-of-alignment suspension check the front
suspension
alignment.
ACX00934
Refer to GROUP
33A, On-vehicle
service - Front
wheel alignment
check and
adjustment 333.
WHEEL BALANCE ACCURACY

M1311001700225
PURPOSE
PROCEDURE <Balancing Tips>
This section contains tips and procedures for

achieving accurate wheel balance. Steering wheel
vibration and/or body shake can result if any of these
procedures are not carefully observed.
1. Wheels and tyres must be properly mounted on a
balancer in order to achieve correct balance.
Centering the wheel on the shaft of the balancer is
essential for proper mounting.
2. Off-the-car wheel balancers must be calibrated
periodically to ensure good balancing results. An
inaccurately calibrated balancer could cause
unnecessary replacement of tyres, shocks,
suspension components, or steering components.
Check your balancers calibration approximately
every 100 balances. Your wheel balancers
instruction manual should include calibration
procedures. If the calibration procedures specifically
for your balancer are missing, use the generic steps
in this section for zero calibration, static balance, and
dynamic balance checks. The wheel balancer
calibration checks are also described in the
flowchart. (Refer to 331).
1. Confirm that the balancers cone and the wheel

mounting cone are undamaged and free of dirt
and rust.
2. On this vehicle, the wheels centre hole on the hub
side has a chamfered edge. Use a back-mounting
cone on your wheel balancer to centre the wheel
on the balancer shaft.
3. Install a wheel mounting cone. The appropriate
size cone for this vehicle is 67.0 mm.
4. Before balancing the wheel, remove any wheel
weights from both sides. Also check both sides for
any damage.
5. When installing wheel weights, hammer them at a
straight (not diagonal) angle.
Hub/shaft assembly
Clamping cup
Wing nut
Spring plate
Wheel mounting cone
AC000041AB
Standard passenger car wheel
WHEEL AND TYRE

TROUBLESHOOTING
<Confirming Proper Balance>

1. After balancing the wheel, loosen the wing nut
and turn the wheel 180 against the balancers
hub. Then re-tighten the wing nut and check the
balance again. Repeat wheel balance if
necessary.
2. Turn the wheel again 180 against the balancers
hub. If the wheel becomes out-of-balance each
time it is turned against the balancers hub, the
wheel balancer may require calibration.
<Wheel Balancer Calibration Checks>

1. Mount an undamaged original-equipment alloy
rim and tyre assembly (wheel) onto your off-thecar wheel balancer. Balance the wheel.
2. <<Zero Calibration Check>>
Loosen the balancer wing nut, rotate the wheel a
half-turn (180), and retighten the nut. Recheck
the balance.
If the imbalance is 5g or less, the zero calibration
is OK. Rebalance the wheel, then go to Step 4 to
check static balance.
If the imbalance is more than 5g, go to Step 3.
3. Loosen the balancer wing nut, rotate the wheel 1/
4 turn (90), and retighten the nut. Recheck the
wheel balance.
If the imbalance is 5g or less, the wheel may not
be centred on the balancer, or the balancing
cones, the cup, and/or wing nut are damaged,
dirty, or inappropriate for the wheel. You may
need to refer to the balancer manufacturers
instructions to verify the correct attachments.
After making the necessary corrections, recheck
the wheel balance. If OK, then go to Step 4.
If the imbalance is more than 5g, the balancer
requires calibration. Contact the balancer
manufacturer for calibration by their repair
representative.
31-5
4. <<Static Balance Check>>

Attach a 5g weight to the outer rim. Recheck the
balancer. The balancer should detect 5 2g of
imbalance 170 to 190 away from the 5g weight.
If the imbalance is within specification, the static
balance calibration is correct. Go to Step 5 to
check the dynamic balance.
If the imbalance is out of specification, the
balancer requires calibration. Contact the
balancer manufacturer for calibration by their
repair representative.
5. <<Dynamic Balance Check>>
Attach a 5g weight to the inner rim at 180
opposite the 5g weight that was added in Step 4.
Recheck the balance. The balancer should detect
5 2g of imbalance 170 to 190 away from both
the inner and outer 5g weights.
If the imbalance is within specification, the
dynamic balance calibration is correct. The
balancer calibration checks are complete.
If the imbalance is out of specification, the
balancer requires calibration. Contact the
balancer manufacturer for calibration by their
repair representative.
WHEEL AND TYRE
31-6
TROUBLESHOOTING
WHEEL BALANCER CALIBRATION

CHECKING FLOW CHART
Balance wheel.
Rotate wheel 1/2 turn.
ZERO CALIBRATION
CHECK
Imbalance = more than 5g
Imbalance = 5g or less
Rebalance wheel.
Rotate wheel 1/4 turn.
Imbalance = 5g or less
Imbalance = more than 5g
Verify wheel is properly centered.

Verify cones, cup, and wing nut are clean,
undamaged, and appropriate for wheel.
Make necessary corrections, then recheck
wheel balance.
Attach a 5g weight to the outer rim.

Is the imbalance 5 2g at 170 190
away from the 5g weight?
YES
NO
Attach a 5g weight to the inner rim at 180

opposite the weight on the outer rim.
Is the imbalance 5 2g at 170 190
away from both 5g weights?
YES
Balancer does not require

calibration.
STATIC BALANCE
CHECK
DYNAMIC BALANCE
CHECK
NO
Balancer requires calibration.

Contact balancer manufacturer.
AC000040 AB
WHEEL AND TYRE
31-7
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK
WHEEL RUNOUT CHECK
M1311000900293
M1311001100320
NOTE: For information on tyre inflation pressure,

refer to the label attached to the centre pillar on the
drivers side.
Radial
TYRE WEAR CHECK

M1311001000301
Measure the tread depth of the tyres.

If the remaining tread depth is less than the minimum
limit, replace the tyre.
NOTE: When the tread depth of the tyres is reduced
to 1.6 mm or less, wear indicators will appear.
Lateral
ACX00651AB
Jack up the vehicle so that the wheels are clear of

the floor. While slowly turning the wheel, measure
wheel runout with a dial indicator.
Limit:
Item
Steel wheel
Radial runout mm 1.2
Aluminium
wheel
1.0
Lateral runout
1.2
1.0
mm
If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TYRE

M1311001300261
Tighten the wheel nuts to the specified torque.

127(6
37-1
GROUP 37
00
11
POWER STEERING
12
13
14
CONTENTS
37
37
LUBRICANTS . . . . . . . . . . . . . . . . . .
SEALANTS . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . .
STEERING COLUMN SHAFT ASSEMBLY

SHOCK ABSORBING MECHANISM CHECK
15
37
17
STEERING WHEEL*. . . . . . . . . . . . . .
37
37
37
21
37
STEERING SHAFT* . . . . . . . . . . . . . .
37
22
37
37
37
37
37
27
31
25
26
STEERING WHEEL FREE PLAY CHECK .
37
POWER STEERING GEAR BOX AND

LINKAGE* . . . . . . . . . . . . . . . . . . . . . .
STEERING ANGLE CHECK . . . . . . . . . . . .
37
37
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
37
16
TIE ROD END BALL JOINT

STARTING TORQUE CHECK . . . . . . . . . .
37
37
32
STATIONARY STEERING EFFORT CHECK
37
TIE ROD END BALL JOINT

DUST COVER REPLACEMENT . . . . . . . . .
37
33
STEERING WHEEL RETURN TO

CENTRE CHECK . . . . . . . . . . . . . . . . . . . .
37
DRIVE BELT TENSION CHECK. . . . . . . . .
37
FLUID LEVEL CHECK . . . . . . . . . . . . . . . .

FLUID REPLACEMENT . . . . . . . . . . . . . . .
34
37
POWER STEERING OIL PUMP

ASSEMBLY. . . . . . . . . . . . . . . . . . . . .
37
37
37
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
37
POWER STEERING SYSTEM AIR

BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
OIL PUMP PRESSURE TEST . . . . . . . . . .
37
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
37
POWER STEERING PRESSURE

SWITCH CHECK . . . . . . . . . . . . . . . . . . . .
37
POWER STEERING HOSES . . . . . . .
37
TIE ROD END BALL JOINT DUST

COVER CHECK . . . . . . . . . . . . . . . . . . . . .
37
37
35
36
37
42
51
52
:$51,1*65(*$5',1*6(59,&,1*2)6833/(0(17$/5(675$,176<67(0656(48,33('9(+,&/(6
WARNING
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
passenger (from rendering the SRS inoperative).
Service or maintenance of any SRS component or SRS-related component must be performed only at an
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
54
55
POWER STEERING
37-2
GENERAL INFORMATION
GENERAL INFORMATION
M1372000100326
FEATURES
Power steering has been adopted in all vehicles to
make the steering system easier to handle.
A 4-spoke steering wheel is used.
A steering column has a shock absorbing
mechanism and a tilt steering mechanism.
Integral-type rack and pinion gear with high
rigidity and excellent response is used.
A vane type pump with a fluid flow rate control

system which change steering effort according to
the engine speed is used.
The separate plastic resin oil reservoir is used to
reduce weight and to make the fluid level
checking easier.
The cooler tube assembly is installed on the
power steering fluid line to improve the cooling
performance of the power steering fluid.
SPECIFICATIONS
Item
Steering wheel
Steering column
Specification
Type
4-spoke type
Outside diameter mm
380
Maximum number of turns
2.7
Column mechanism
Shock absorbing mechanism and Tilt

steering mechanism
Tilt up: 20 mm
Tilt down: 20 mm
Power steering type
Integral type
Oil pump
Type
Vane pump
Basic discharge amount mL/rev.
9.6
Relief pressure MPa
8.8
Reservoir type
Separate type (plastic)
Pressure switch
Equipped
Type
Rack and pinion
Steering gear
Stroke ratio (Rack stroke/Steering wheel 51.45

maximum turning radius)
Rack stroke mm
141
POWER STEERING
37-3
Steering wheel
Steering column
shaft assembly
Oil reservoir
Pressure hose
assembly
Suction hose
Return hose
Oil pump assembly
Steering gear
Cooler tube assembly
AC300061 AB
M1372000300364
Item
Standard value
Limit
Steering wheel free

play mm
With engine running
30
With engine stopped
10 or less
Steering angle
Inside wheel
3450 130
Outside wheel (reference)
2920
At the centre of tyre tread mm
12
Toe-angle (per wheel)
003 05
Tie rod end ball joint starting torque Nm
0.5 - 2.5
Tie rod swing resistance N [Tie rod swing torque Nm]
6 - 19 [1.5 - 4.9]
Stationary steering effort N [Fluctuation allowance N]
29 or less [5.9 or less]
Oil pump pressure

Oil pump relief pressure
MPa (750 100 r/min.) Pressure under no-load conditions
8.8 - 9.5
0.8 - 1.0
8.8 - 9.5
OFF ON
1.5 - 2.0
ON OFF
0.7 - 2.0
Steering gear total pinion torque Nm [Change in torque Nm]
0.7 - 1.6 [0.4 or less]
Opening dimension of special tool boot band crimping tool

(MB991561) mm
2.9
Band crimped width mm
2.4 - 2.8
Toe-in
Steering gear retention hydraulic pressure

Oil pressure switch operating pressure
MPa
POWER STEERING
37-4
LUBRICANTS
LUBRICANTS
M1372000400338
Item
Specified lubricant
Power steering fluid
ATF DEXRON III or DEXRON II Approximately 1.0 L
Steering gear
ATF DEXRON III or DEXRON II As required
Bearing
Quantity
O-ring and seal ring

Oil seal
Special tool (MB991213)
Pinion and valve assembly
seal ring part
Oil pump
Bellows
Silicon grease
As required
Tie rod end ball joint
Multipurpose grease SAE J310, As required

NLGI No.2 or equivalent
Friction surface of rotor vane, ATF DEXRON III or DEXRON II As required

cam ring and pump cover
O-ring
SEALANTS
M1372000500324
Item
Specified sealant
Steering shaft cover assembly bolt hole on the toeboard
Steering gear
3M ATD Part No.8661, 8663 or

equivalent
End plug
Rack support cover
POWER STEERING
37-5
SPECIAL TOOLS
SPECIAL TOOLS
M1372000600321
Tool
Number
Name
Use
MB991897
Ball joint remover

disconnection
(MB990635 or MB991113) is also
available to disconnect knuckle and
tie rod end ball joint.
MB990326
Preload socket
Tie rod end ball joint starting torque

check
MB991548
Power steering oil

pressure gauge
adapter (Pump
side)
Oil pump pressure test
MB991549
Power steering oil

pressure gauge
adapter (Hose
side)
MB990662
Power steering oil

pressure gauge
MB990784
Ornament remover Cover removal
MB990228 or
MB991006
Preload socket
AC106827
MB990326
MB991548
MB991549
MB990662
MB990784
MB991006
Steering gear total pinion torque

check and adjustment
POWER STEERING
37-6
SPECIAL TOOLS
Tool
Number
Name
Use
MB991621
Rack support cover Rack support adjustment

Rack support cover removal
wrench
MB990925
Bearing and oil

seal installer set
Oil seal and bearing installation

MB990927, MB990938, MB990939
(For details, refer to GROUP 26,
Special Tools 326).
MB991120
Needle bearing
puller
Needle roller bearing removal
MB991199
Oil seal and

bearing installer
Oil seal installation
MB991197
Bar (long type)
MB991202
Oil seal and

bearing installer
Needle bearing installation

Lower bearing installation
MB991213
Rack installer
Rack installation
MB991203
Oil seal and

bearing installer
Oil seal and bearing installation
MB991621
MB990925
MB991120
MB991199
AB
MB991197
MB991202
MB991212
MB991203
POWER STEERING
37-7
ON-VEHICLE SERVICE
Tool
Number
Name
Use
MB991317
Seal ring installer
Seal ring installation
MB990941
Torque tube
bearing installer
Lower oil seal installation
MB991561
Boot band crimping Bellows band installation

tool
MB990776
Front axle base
MB991317
MB990941
MB991561
Tie rod end ball joint dust cover

installation
MB990776
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK
M1372001000270
1. With the engine running (hydraulic operation), set

the front wheels straight ahead.
4. If the free play still exceeds the limit value, set the
steering wheel straight ahead with the engine
stopped. Load 5 N towards the steering wheel
circumference and check the play.
Standard value (steering wheel play with the
engine stopped): 10 mm or less
5. If the play exceeds the standard value, remove the
steering gear (Refer to 337). and check the
total pinion torque (Refer to 337).
STEERING ANGLE CHECK

M1372001100341
ACX01122AB
2. Measure the play on the steering wheel

circumference before the wheels start to move
when slightly moving the steering wheel in both
directions.
Limit: 30 mm
3. When the play exceeds the limit, check for the
play on the steering shaft and steering linkage
connection. Correct or replace.
AC000756AB
POWER STEERING
37-8
ON-VEHICLE SERVICE
1. Place the front wheel on a turning radius gauge

and measure the steering angle.
Standard value:
Item
Specification
Inside wheel
3450 130
Outside wheel
(reference)
2920
2. If the steering angle is not within the standard

value, adjust the toe-in as follows.
Standard value:
at the centre of tyre tread: 1 2 mm
Toe angle (per wheel): 003 05
TIE ROD END BALL JOINT STARTING

TORQUE CHECK
M1372001500275
CAUTION
damage to the ball joint threads.
Hang special tool with cord to prevent it from
falling.
Cord
MB991897
Nut
Jam nut
Clip
Bolt
Ball joint
AC208247AD

Bolt
AC006074 AB
3. Loosen the jam nut, and unclip the bellows.

4. Adjust the toe-in by turning the left and right tie
rod turnbuckles by the same amount (in opposite
directions).
NOTE: The toe will move out as the left
turnbuckle is turned toward the front of the vehicle
and the right turnbuckle is turned toward the rear
of the vehicle.
5. Tighten the jam nut to the specified torque, and
tighten the bellows by the clip.
6. Recheck the steering angle.
Parallel
Knob
Good
Bad
AC106821AB

figure.
tie rod end.
POWER STEERING
37-9
ON-VEHICLE SERVICE
Standard value:
Steering effort: 29 N or less
Fluctuation allowance: 5.9 N or less
4. If the measured value exceeds the standard
value, check and adjust the related parts.
MB990326
STEERING WHEEL RETURN TO CENTRE

CHECK
M1372001800287
ACX01129 AB
4. Move the ball joint stud several times and install

the nut on the stud. Using special tool preload
socket (MB990326), measure the ball joint
starting torque.
Standard value: 0.5 - 2.5 Nm
5. If the starting torque exceeds the standard value,
replace the tie rod end.
6. If the starting torque is under the standard value,
check the ball joint for axial play or ratcheting. If
no axial play or ratcheting, the ball joint can be reused.
CAUTION
Always use a new ball joint nut as it is a selflocking nut.
7. Install the tie rod end to the knuckle, then tighten a
new self-locking nut to the specified torque.
STATIONARY STEERING EFFORT CHECK

M1372001700310
1. With the vehicle stopped on a flat and paved

surface, turn the steering wheel to the straight
ahead position.
2. Start the engine and set the engine idle speed.
Conduct a road test:

1. Make both gradual and sudden turns and check
the steering wheel return.
70
70
ACX01130AB
2. At a vehicle speed of approximately 35 km/h, turn

the steering wheel 90, hold a few seconds, then
release. If the steering wheel then returns 70 or
more, the return can be judged satisfactory.
NOTE: There will be a momentary feeling or
"heaviness" when the wheel is turned quickly, but
this is not abnormal (Oil pump discharge amount
is especially apt to be insufficient during idling).
DRIVE BELT TENSION CHECK

M1372001900240
Refer to GROUP 11A, On-vehicle Service - Drive

Belt Tension Check 311A.
FLUID LEVEL CHECK

M1372002000262
1. Park the vehicle on a flat, level surface.

2. Start the engine, and then turn the steering wheel
several times to raise the temperature of the fluid
to approximately 50 - 60C.
3. With the engine running, turn the wheel all the
way to the left and right several times.
ACX01122AB
3. Attach a spring balance to the outer

circumference of the steering wheel and measure
the steering force required to turn the steering
wheel from the straight ahead position to the left
and right (within a range of 1.5 turns). Also check
to be sure that there is no significant change in
the required steering effort.
POWER STEERING
37-10
ON-VEHICLE SERVICE
2. Disconnect the ignition coil connectors (Refer to

GROUP 16, Ignition Coil 316).
Fluid level change: Within 5 mm
CAUTION
While engine running
While engine stopped

ACX01131AC
4. Check the fluid in the oil reservoir for foaming or

milkiness. Check the difference of the fluid level
when the engine is stopped, and while it is
running. If the change of the fluid level is 5 mm or
more, air bleeding should be done.
FLUID REPLACEMENT
M1372002100311
1. Raise and support the front wheels.

Return hose
Return hose
Vinyl hose
Perform air bleeding only while cranking the

engine. If air bleeding is performed while the
engine is running, air could enter the fluid.
During air bleeding, refill the steering fluid
supply so that the level never falls below the
"MIN" mark on the oil reservoir.
3. Turn the steering wheel all the way to the left and
right five or six times while using the starter motor
to crank the engine intermittently several times
(for 15 to 20 seconds).
4. Connect the ignition coil connectors (Refer to
5. Start the engine (idling).
6. Turn the steering wheel to the left and right until
there are no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the
level is between "MAX" and "MIN" marks.
8. Confirm that there is very little change in the fluid
level when the steering wheel is turned left and
right.
CAUTION
AC100369AB
2. Disconnect the return hose connection, and then

connect a vinyl hose to the return hose, and drain
the fluid into a container.
3. Disconnect the ignition coil connectors (Refer to
4. While operating the starter motor intermittently,
turn the steering wheel all the way to the left and
right several times to drain all of the fluid.
5. Connect the return hose securely, and then
secure with the clip.
6. Fill the oil reservoir with specified fluid up to the
lower position of the filler, and then bleed the air.
Specified fluid: ATF DEXRON III or DEXRON
II
POWER STEERING SYSTEM AIR

BLEEDING
M1372002200318
Perform air bleeding procedure as necessary after

replacing the steering gear or the steering fluid lines.
1. Raise and support the front wheels.
If the fluid level rises suddenly after the engine is

stopped, the air has not been completely bled. If
air bleeding is not complete, there will be
abnormal noises from the pump and the flowcontrol valve, and this condition could cause
reduce the life of the power steering
components.
Fluid level change: Within 5 mm
While engine running
While engine stopped

ACX01131AC
9. Confirm that the change in the fluid level is no

more than 5 mm when the engine is stopped and
when it is running.
10.If the change of the fluid level is 5 mm or more,
the air has not been completely bled from the
system. The air bleeding procedure must be
repeated.
POWER STEERING
ON-VEHICLE SERVICE
OIL PUMP PRESSURE TEST

M1372002300296
Temperature
gauge
Pressure
gauge
(MB990662)
Shut-off valve
(fully closed)
Oil reservoir
Adapter
(MB991548)
Oil
pump
Adapter
(MB991549)
37-11
7. If it is not within the standard value, the probable

cause is a malfunction of the oil line or steering
gear, so check these parts and repair as
necessary.
8. Turn the steering wheel all the way to the left or
right; then check whether or not the retention
hydraulic pressure is the standard value.
Standard value: 8.8 - 9.5 MPa
9. If not the standard value, overhaul the steering
gear. Remeasure fluid pressure.
10. Remove the special tools, and then tighten the
pressure hose to the specified torque.
11. Bleed the system (Refer to 337).
POWER STEERING PRESSURE SWITCH

CHECK
M1372007200302
ACX01133 AB
1. Disconnect the pressure hose from the oil pump,

and then connect the following special tools.
MB990662: Power Steering Oil Pressure Gauge
Adapter (Pump Side)
Adapter (Hose Side)
2. Bleed air, then turn the steering wheel several
times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50
- 60C.
3. Start the engine and idle it at 750 100 r/min.
CAUTION
The pressure gauge shut-off valve must not
remain closed for more than 10 seconds.
4. Fully close the shut-off valve of the pressure
gauge and measure the oil pump relief pressure
to confirm that it is within the standard value
range. Open it again immediately after checking
the pressure.
5. If it is not within the standard value, replace the oil
pump.
6. Check whether or not the hydraulic pressure is the
standard value when no-load conditions are
created by fully opening the shut-off valve of the
pressure gauge.
1. Disconnect the pressure hose from the oil pump,

and then connect the following special tools.
Adapter (Pump Side)
Adapter (Hose Side)
2. Bleed air, and then turn the steering wheel several
times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50
- 60C.
3. The engine should be idling.
37-12
POWER STEERING
ON-VEHICLE SERVICE
4. Disconnect the connector for the oil pressure

switch, and place an ohmmeter at the switch.
5. Gradually close the shut-off valve of the pressure
gauge and increase the hydraulic pressure, then
check whether or not the hydraulic pressure that
activates the switch is the standard value.
6. Gradually open the shut-off valve and reduce the
hydraulic pressure; then check whether or not the
hydraulic pressure that deactivates the switch is
the standard value.
pressure hose to the specified torque.
8. Bleed the system (Refer to 337).
TIE ROD END BALL JOINT DUST COVER

CHECK
M1372008600240
WARNING
If the vehicle continues to be driven after
the collision absorbing mechanism has

operated, the steering column shaft may
be damaged while it is in use.
If there is a slack in the one-way capsule,
do not attempt to repair it but replace the
steering column shaft assembly.
Inspection Procedure
1. Remove the lower and upper column covers.
CAUTION
Do not release the tilt lever until the steering
column has been installed to complete this
inspection procedure.
2. Ensure that the tilt lever is in the lock position.
NOTE: If not, place the tilt lever in the lock
position.
3. Loosen the two upper steering column mounting
bolts by two turns.
1. Press the dust cover with your finger to check

whether the dust cover is cracked or damaged.
2. If the dust cover is cracked or damaged, replace
the tie rod end.
NOTE: If the dust cover is cracked or damaged,
the ball joint could be damaged.
STEERING COLUMN SHAFT ASSEMBLY

SHOCK ABSORBING MECHANISM
CHECK
M1372013500067
If a collision accident occurs or severe impact is

applied on the steering wheel, the collision energy
absorbing mechanism may have operated. Once the
mechanism has operated, it will be inoperative even
it has suffered no apparent damage. Determine if the
steering column shaft can be reused by the following
procedure. If the collision energy absorbing
mechanism has already operated, replace the
steering column shaft assembly.
If any excessive radial free play on the steering
wheel is found with the tilt lever in the lock position,
always check the steering shaft assembly.
Steering
column
mounting
bolt
Steering
column
assembly
One way capsule
AC209935 AC
4. Hold the one-way capsules as shown, and then

try to lock them. If there is a slack in either of the
capsules, replace the steering column shaft
assembly.
NOTE: When installing a new steering column
shaft assembly, place the tilt lever in the lock
position, if it is not in place.
POWER STEERING
37-13
STEERING WHEEL
CAUTION
Be careful that nothing is pinched between
the one-way capsules and the body.
Do not release the tilt lever until the steering
column has been installed to complete this
inspection procedure.
5. If no problem is found during the inspection,
tighten the steering column mounting bolts to the
specified torque.
STEERING WHEEL
M1372011400150
WARNING
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions and Air Bag Module and Clock Spring 352B.
When removing and installing the steering wheel, do not let it bump against the air bag
module.
Checking Steering Wheel Position with Wheels Straight
Ahead
Section A - A
Tab
2
1
Section B - B
Tab
1
A
B
50 5 Nm
B
A
AC107402 AB
<<A>>
<>
Removal steps
1. Cover
2. Steering wheel and air bag module
assembly
NOTE: For air bag module removal, refer to GROUP

52B, Air Bag Module and Clock Spring 352B.
POWER STEERING
37-14
STEERING WHEEL
<> STEERING WHEEL AND AIR BAG

MODULE ASSEMBLY REMOVAL
<<A>> COVER REMOVAL
Clock spring
connector
MB990784
Steering
wheel
AC006295 AB
AC006294 AB
Insert special tool ornament remover (MB990784) at

the indicated position to remove the cover.
NOTE: The special tool can be inserted through the
notch behind the area shown.
1. By sliding section A of the clock spring connector

shown in the illustration in the arrow direction,
disconnect the connector.
Hexagonal bit socket
AC102792
AC107462 AD
2. Loosen the bolt completely. Then, remove the

steering wheel and air bag module assembly.
NOTE: Use a hexagonal bit socket or a hexagonal
wrench having an effective length of 75 mm or
more in the hexagonal section and the diameter of
8 mm or more.
POWER STEERING
37-15
STEERING SHAFT
STEERING SHAFT
M1372011500094
WARNING
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions and Air Bag Module and Clock Spring 352B.
Instrument Lower Panel Installation (Refer to GROUP
52A, Instrument Panel 352A).
Steering Wheel and Air bag Module Assembly Installation
(Refer to 337).
Steering Wheel and Air bag Module Assembly Removal
(Refer to 337).
Instrument Lower Panel Removal (Refer to GROUP 52A,
Instrument Panel 352A).
Section A - A
2
Tab
1
5
Section B - B
B
Toe board
12 2 Nm
4
6
6
Specified sealant:
18 2 Nm
5.0 1.0 Nm
AC301263 AB
Removal steps
1. Lower column cover
2. Upper column cover
3. Clock spring and column switch
assembly (Refer to GROUP 52B, Air
Bag Module and Clock Spring
352B).

4. Shaft cover
<<A>> >>A<< 5. Steering column shaft assembly
6. Cover assembly
POWER STEERING
37-16
STEERING SHAFT
<<A>> STEERING COLUMN SHAFT ASSEMBLY

REMOVAL
>>A<< STEERING COLUMN SHAFT ASSEMBLY

INSTALLATION
CAUTION
CAUTION
The tilt lever should be held in the lock position

until the steering column shaft is installed to the
vehicle. If the steering column is removed with
the tilt lever released, or the tilt lever is released
after the steering column shaft was removed
from the vehicle, the steering column can not be
reinstalled correctly. If the steering column is
installed incorrectly, the collision energy
absorbing mechanism may be damaged.
1. Ensure that the tilt lever is in the lock position, and
remove the steering column mounting bolts.
When reusing the steering column, do not

release the tilt lever until the steering column
shaft has been installed.
When the steering column is replaced, do not
release the tilt lever until it has been installed.
Do not remove the tilt lever fixing band until
the installation has completed.
When installing the steering column, do not
leave it fixed temporarily at only one point and
make sure the column shaft is not shaken
strongly. If you fail to do, the collision
absorbing mechanism at the column shaft
mounting location may be damaged.
Clip
4
1
Steering column
shaft
2
3
Tilt lever
AC210969 AD
2. Pinch the steering column shaft clip with pliers,

and pull up the shaft towards the direction shown
to disengage the steering column shaft assembly.
AC209383 AD
Ensure that the tilt lever is in the lock position, and

install the steering column. Tighten the four bolts in
the order shown by hand, and then tighten them to
the specified torque in the order shown.
POWER STEERING
37-17
STEERING SHAFT

M1372011700087
1
2
AC210967AD
<<A>> >>A<< 1.
>>A<< 2.
Disassembly steps
Special bolt
Steering lock bracket

Reverse screw tap
Special bolt
Steering lock
bracket
Steering lock
cylinder
>>A<< 3.
4.

Steering lock cylinder assembly
Steering column shaft assembly
CAUTION
The steering lock bracket and bolts must be
replaced with new ones when the steering lock is
installed.
1. When installing the steering lock cylinder
assembly and steering lock bracket to the column
tube, temporarily install the steering lock in
alignment with the column boss.
ACX01138AB
<<A>> SPECIAL BOLT REMOVAL

1. Drill in the special bolt a hole deep enough for the
tap to stand.
2. Remove the special bolt with a left-hand tap.

>>A<< STEERING LOCK CYLINDER ASSEMBLY/
STEERING LOCK BRACKET/SPECIAL BOLT
INSTALLATION
ACX01139 AB
2. After checking that the lock works properly, tighten

the special bolts until the head twists off.
37-18
POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE

M1372010900215
WARNING
Before removing the steering gear, refer to GROUP 52B, Service Precautions (352B) and
Air Bag Module and Clock Spring (352B). Centre the front wheels. Failure to do so may
damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
Power Steering Fluid Draining (Refer to 337).
Centermember Removal (Refer to GROUP 32, Engine
Roll Stopper and Centermember 332).
Steering Wheel and Air Bag Module Assembly Removal
(Refer to 337).
Clock Spring Removal (Refer to GROUP 52B, Air Bag
Module and Clock Spring 352B).
Stabilizer Link Assembly and Lower Arm Assembly
Removal (Refer to GROUP 33A, Lower Arm 333).
Stabilizer Link Assembly and Lower Arm Assembly
Installation (Refer to GROUP 33A, Lower Arm 333).
Centermember Installation (Refer to GROUP 32, Engine
Roll Stopper and Centermember 332).
Clock Spring Installation (Refer to GROUP 52B, Air Bag
Module and Clock Spring 352B).
Steering Wheel and Air Bag Module Assembly Installation
(Refer to 337).
with your finger.
Power Steering Fluid Supplying (Refer to 337).
Power Steering Fluid Line Bleeding (Refer to 337).
Ahead.
Front Wheel Alignment Adjustment (Refer to GROUP
33A, On-vehicle Service - Front Wheel Alignment Check
and Adjustment 333).
POWER STEERING
37-19
4
2
12 2 Nm
18 2 Nm
11
7
12 2 Nm
15 3 Nm
10
70 10 Nm
25 5 Nm
7
8
70 10 Nm
13
57 7 Nm
18 2 Nm
3
12
49 10 Nm
167 9 Nm
AC300496 AB
<<A>>
Removal steps
1. Shaft cover
2. Steering column shaft assembly and
steering gear connecting bolt
3. Tie rod end and knuckle connection
Rear roll stopper connecting bolt
(Refer to GROUP 32, Engine Roll
Stopper and Centermember 332).
4. Return hose connection
5. Return tube
6. O-ring
7. Pressure hose connection
8. Gasket
<>
>>A<< 9.
10.
11.
12.
13.

Crossmember assembly
Rear roll stopper (Refer to GROUP 32,
Engine Roll Stopper and
Centermember 332).
Joint cover grommet
Steering extension
Return tube
Crossmember
Steering gear
POWER STEERING
37-20

<<A>> TIE ROD END AND KNUCKLE
DISCONNECTION
CAUTION
Hang special tool with a cord to prevent it
from falling.

tie rod end.
<> CROSSMEMBER ASSEMBLY REMOVAL
Piece of wood
Cord
Transmission
jack
MB991897
Nut
Bolt
Ball joint
AC208247AD
1. Install the special tool ball joint remover

(MB991897) as shown in the figure.
AC102600 AD
1. Use a transmission jack to hold the crossmember,

and then remove the crossmember mounting nuts
and bolts.
2. Lower the crossmember with the rear roll stopper,
the stabilizer bar, the return tube, and the steering
gear.

>>A<< JOINT COVER GROMMET INSTALLATION
Bolt
Joint cover
grommet
Parallel
A
Knob
Good
Bad
AC106821AB

jaws of the special tool parallel, tighten the bolt by
figure.
Steering gear
AC301284AB
Align the joint cover grommet notch (arrow A) with

the steering gear lug (arrow B), and then install the
steering joint cover to the steering gear.
POWER STEERING
37-21
INSPECTION
M1372011000204
TIE ROD SWING RESISTANCE CHECK

1. Give 10 hard swings to the tie rod.
STEERING GEAR TOTAL PINION TORQUE

CHECK
CAUTION
When holding the steering gear in a vice, secure
its mounting positions. If it is secured in any
other place, the gear housing may become
deformed or damaged.
MB991006
AC000996 AC
Using special tool preload socket (MB991006), rotate

the pinion gear at the rate of one rotation in
approximately 4 to 6 seconds to check the total
pinion torque.
[Change in torque: 0.4 Nm or less]
NOTE: When measuring, remove the bellows from
the rack housing. Measure the pinion torque through
the whole stroke of the rack.
If the measured value is not within the standard
range, first adjust the rack support cover, and then
check the total pinion torque again.
If the total pinion torque cannot be adjusted to within
the standard range by adjusting the rack support
cover, check the rack support cover, rack support
spring, rack support and replace any parts if
necessary.
AC000997
2. Measure the tie rod swing resistance [tie rod

swing torque] with a spring balance.
Standard value: 6 - 19 N [1.5 - 4.9 Nm]
value, replace the tie rod.
4. If the measured value is below the standard value,
the tie rod can be re-used if it swings smoothly
without excessive play.
TIE ROD END BALL JOINT DUST COVER CHECK
1. Check the dust cover for cracks or damage by
pushing it with your finger.
the tie rod end (Refer to 337).
NOTE: Cracks or damage of the dust cover may
damage the ball joint. If it is damaged during
service work, replace the dust cover (Refer to
337).
POWER STEERING
37-22

M1372011100171
22 4 Nm
Flare nut
13 3 Nm
24
23
22
20
21
19
13
34
35
33
17
16
5
23
21
19
59 10 Nm
Repair kit grease
12
2
18
36
52 2 Nm
15 14
23 2 Nm
-30
25 4 Nm
59 10 Nm
7
9
11 8
11 35
17 31
29 28
32
Steering gear seal kit
11
26
27
10
88 10 Nm
25
32
28
29
31
30
AC100244AC
>>O<< 1.
>>N<<
>>N<<
>>M<<
>>L<<
>>L<<
>>K<<
>>J<<
<<A>> >>J<<
>>I<<
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Disassembly steps
Gear mounting rubber
Gear housing mounting bushing
Feed pipe
O-ring
Jam nut
Tie rod end
Clip
Bellows band
Bellows
Tie rod
Tab washer
Total pinion torque adjustment
Jam nut
Rack support cover
Support spring
Rack support
End plug
Jam nut
Valve housing assembly
<>
<>
<<C>>
<<D>>
<<D>>
>>H<< 19.
20.
>>G<< 21.
>>F<< 22.
>>F<< 23.
24.
<<E>>
<<F>>
<<F>>
<<F>>
<<F>>
<<F>>
<<C>>
>>E<< 25.
26.
>>D<< 27.
>>D<< 28.
29.
>>C<< 30.
31.
32.
<<G>> >>B<< 33.
<<H>> >>B<< 34.
<> >>A<< 35.
36.

Lower oil seal
Pinion and valve assembly
Seal ring
Upper bearing
Upper oil seal
Valve housing
Circlip
Rack stopper
Rack bushing
OIL SEAL
O-ring
Rack assembly
Seal ring
O-ring
Lower bearing
Needle bearing
Oil seal
Gear housing
POWER STEERING
37-23
Fluid:
ATF DXRON III or
DEXRON II
Fluid:
ATF DXRON III or
DEXRON II
Grease:
Multipurpose grease
SAE J310, NLGI No.2
or equivalent
Fluid:
ATF DXRON III or
DEXRON II
Grease: Repair kit grease

Fluid:
ATF DXRON III or
DEXRON II
Sealant:
3M ATD Part No. 8661, 8663
or equivalent
AC200119 AC
Grease: Silicone grease
Fluid:
ATF DXRON III or
DEXRON II

Fluid:
ATF DXRON III or DEXRON II
POWER STEERING
37-24

<<A>> RACK SUPPORT COVER REMOVAL
<<D>> UPPER BEARING/UPPER OIL SEAL

REMOVAL
MB991621
Socket
ACX01145AC
AC103692 AB
Using special tool rack support cover wrench

(MB991621), remove the rack support cover from the
steering gear.
<> LOWER OIL SEAL/PINION AND VALVE
ASSEMBLY REMOVAL
Using a socket, remove the oil seal and the ball

bearing from the valve housing simultaneously.
<<E>> CIRCLIP REMOVAL
CAUTION
If the rack stopper is first turned counterclockwise,
the circlip will get caught in the slot in the housing
and the rack stopper will not turn.
Rack stopper
ACX01143AB
Using a plastic hammer, gently tap the pinion to

remove it.
<<C>> SEAL RING REMOVAL
CAUTION
When cutting the seal ring, be careful not to
damage the pinion and valve assembly or the
rack.
Circlip
ACX01146 AB
1. Turn the rack stopper clockwise until the end of

the circlip comes out of the slot in the rack
housing.
2. Turn the rack stopper counterclockwise to remove
the circlip.
<<F>> RACK STOPPER/RACK BUSHING/OIL
SEAL/O-RING/RACK ASSEMBLY REMOVAL
ACX01144 AB
Cut the seal ring and remove it from the pinion and
valve assembly or the rack.
ACX01147 AB
1. Pull out the rack slowly. Take out the rack stopper
and the rack bushing at the same time.
POWER STEERING
37-25
CAUTION
Do not damage the oil seal press fitting surface.
<> OIL SEAL REMOVAL
CAUTION
Be careful not to damage the inner surface of the
rack cylinder of the gear housing.
Rack bushing
Gear housing
Pipe or similar tool
ACX01148 AB
2. Partially bend the oil seal and remove it from the

rack bushing.
<<G>> LOWER BEARING REMOVAL
Oil seal
AC100259 AB
Use a piece of pipe or similar tool to remove the oil

seal from the gear housing.
MB990939
Valve housing
>>A<< OIL SEAL INSTALLATION

1. Apply a coating of ATF DEXRON III or DEXRON II
to the both sides of the oil seal.
Lower bearing
Gear housing
MB991199
ACX01149 AC
MB991197
Use a brass bar or special tool brass bar

(MB990939) to remove the ball bearing from the gear
housing.
Oil seal
<<H>> NEEDLE BEARING REMOVAL
CAUTION
Do not open special tool excessively to prevent
damaging housing interior.
AC100260 AC
2. Using the following special tools, press the oil seal

into the rack housing.
MB991197: Bar (Long type)
MB991199: Oil Seal and Bearing Installer
MB991120
Valve housing
Needle
bearing
ACX01150 AB
Use special tool needle bearing puller (MB991120)

to remove the needle bearing from the rack housing.
>>B<< NEEDLE BEARING/LOWER BEARING

INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to housing,
bearing and oil seal press fitting surface.
POWER STEERING
37-26
CAUTION
Press-fit straight. The valve housing is
aluminium, and may become deformed if pressfit on an angle.
4. Align the centre of the oil seal with the rack to

prevent the retainer spring from slipping. Slowly
insert the rack from power cylinder side.
>>D<< OIL SEAL/RACK BUSHING INSTALLATION
MB990938
MB990938
Needle bearing
MB991202
MB991202
MB990927
Lower
bearing
ACX01153 AE
2. Press fit needle bearing with the following special

tools.
MB990938: Bar (Snap-in type)
Oil seal
O-ring
Rack
bushing
ACX01156 AE
1. Apply ATF DEXRON III or DEXRON II to the outer

surface of the oil seal. Using the special tool
installer adapter (MB990927), press in the oil seal
until it is flush with the bushing end face.
>>C<< RACK ASSEMBLY INSTALLATION
CAUTION
Rack
Do not close the vent hole in the rack with

grease.
Vent hole
Vinyl tape
Rack bushing
AC100261AB
Seal ring and O-ring

ACX01154 AB
1. Apply a coating of repair kit grease to the rack

teeth face.
2. Apply ATF DEXRON III or DEXRON II to the oil

seal inner surface and the O-ring.
3. Wrap the rack end with plastic tape, and push the
rack bushing onto the rack.
>>E<< CIRCLIP INSTALLATION
CAUTION
Insert the circlip to the rack stopper hole while
turning the rack stopper clockwise.
Oil seal
Circlip
Circlip
MB991213
ACX01155 AB
2. Cover rack serrations with special tool rack

installer (MB991213).
3. Apply ATF DEXRON III or DEXRON II to special
tool, and to the outer surface of the seal ring and
the O-ring.
Slot
Slot
ACX01158 AB
Insert the circlip to the rack stopper hole through

cylinder hole. Turn the rack stopper clockwise and
insert the circlip firmly.
POWER STEERING
37-27
>>F<< UPPER OIL SEAL/UPPER BEARING

INSTALLATION
>>H<< LOWER OIL SEAL INSTALLATION
CAUTION
Approximately
1 mm
MB990938
MB990941
Oil
seal
MB990938
Housing
MB991203
MB991203
Bearing
Oil seal
ACX01161 AC
ACX01159AC
Apply a coating of ATF DEXRON III or DEXRON II to

the outside of the upper oil seal/upper bearing. Using
the following special tools, press the upper oil seal/
upper bearing into the valve housing.
>>G<< SEAL RING INSTALLATION
To eliminate a seal malfunction at the valve

housing alignment surface, the upper surface of
the oil seal should project outward approximately
1 mm from the housing edge surface.
Using special tool torque tube bearing installer
(MB990941), press the oil seal into the valve
housing.
>>I<< END PLUG INSTALLATION
End plug
MB991317
End plug
ACX01160 AB
ACX01162 AB
Because the seal rings expand after installation,

tighten after installing by using special tool seal ring
installer (MB991317) to compress the rings, or press
down by hand.
1. Apply specified sealant to the threaded part of the

end plug.
Specified sealant:
3M ATD Part No.8661, 8663 or equivalent
2. Secure the threaded portion of the end plug at two
places by using a punch.
>>J<< RACK SUPPORT COVER/JAM NUT
INSTALLATION
1. Position the rack at its centre.
2. Apply specified sealant to the threaded part of the
rack support cover.
Specified sealant:
POWER STEERING
37-28
2. If the total pinion torque or the change in torque is

outside the standard value, move the rack support
cover 0 - 30, and adjust the pinion torque again.
>>L<< TAB WASHER/TIE ROD INSTALLATION
MB991621
AC100273 AC
3. Use special tool rack support cover wrench

(MB991621) to tighten the rack support cover to
23 2 Nm.
4. Turn the rack support cover 30 counterclockwise.
5. Use the special tool to hold the rack support
cover, and then tighten the jam nut to 59 10
Nm.
After installing the tie rod to the rack, fold tab washer
end (two locations) to tie rod notch.
>>K<< TOTAL PINION TORQUE ADJUSTMENT
>>M<< BELLOWS BAND INSTALLATION
ACX01163 AB
CAUTION
Be sure there is no ratcheting or catching
when operating the rack towards the shaft.
Measure the total pinion torque through the
whole stroke of the rack.
MB991561
Stopper
W
MB991006
Adjusting bolt
ACX01164 AB
AC100274 AB
1. Using special tool preload socket (MB991006),

rotate the pinion shaft at the rate of one rotation in
four to six seconds to check the total pinion torque
and the change in torque.
Standard value:
Total pinion torque: 0.7 - 1.6 Nm
[Change in torque: 0.4 Nm or less]
CAUTION
When adjusting, set at the highest value of the
NOTE: If the total pinion toque cannot be adjusted
to the standard value within the specified return
angle, check the rack support cover components
and replace any parts if necessary.
1. Turn the adjusting bolt of special tool boot band

crimping tool (MB991561) to adjust the opening
dimension (W) to the standard value.
NOTE: The dimension (W) is adjusted by
approximately 0.7 mm per one turn.
NOTE: Do not turn the adjusting bolt more than
one turn.
<When more than 2.9 mm>: Screw in the
adjusting bolt.
<When less than 2.9 mm>: Loosen the
adjusting bolt.
POWER STEERING
37-29
CAUTION
Hold the rack housing, and use special tool to
crimp the bellows band securely.
Crimp the bellows band until special tool
touches the stopper.
>>N<< TIE ROD END/JAM NUT INSTALLATION

Edge of bellows
assembly groove
Jam nut
MB991561
186 mm
AC001011 AH
ACX01165 AB
2. Use special tool boot band crimping tool

(MB991561) to crimp the bellows band.
Screw in the tie rod end to achieve the right and left
length as illustrated. Lock with the jam nut.
NOTE: The jam nuts must be tightened securely only
after the steering gear is installed to the vehicle and
toe-in is adjusted.
>>O<< GEAR MOUNTING RUBBER
INSTALLATION
220 mm
ACX01166 AB
3. Check that crimped width (A) is within the

standard value.
<When more than 2.8 mm>: Readjust the
dimension (W) of step (1) to the value
calculated by the following equation, and
repeat step (2).
W = 5.5 mm - A [Example: if (A) is 2.9 mm,
(W) is 2.6 mm.]
<When less than 2.4 mm>: Remove the
bellows band, readjust the dimension (W) of
step (1) to the value calculated by the
following equation, and use a new bellows
band to repeat steps (2) to (3).
W = 5.5 mm - A [Example: if (A) is 2.3 mm,
(W) is 3.2 mm.]
AC100275AB
Install the gear mounting rubber to the rack housing

so that the distance is as shown in the illustration.
37-30
POWER STEERING
TIE ROD END BALL JOINT DUST COVER

REPLACEMENT
M1372008200305
If the dust cover is damaged accidentally during

service work, replace the dust cover as follows:
MB990776
AC001012AB
1. Apply specified grease to the lip and inside of the

dust cover.
Specified grease:
Multipurpose grease SAE J310, NLGI No.2 or
equivalent
2. Drive in the dust cover with special tool front axle
base (MB990776) until it is fully seated.
POWER STEERING
37-31
POWER STEERING OIL PUMP ASSEMBLY

M1372005200276
Front Under Cover (RH) and Side Under Cover (RH)
Removal (Refer to GROUP 51, Under Cover 351).
Power Steering Fluid Draining (Refer to 337).
Power Steering Fluid Supplying and Bleeding (Refer to
337).
Drive Belt Tension Check (Refer to GROUP 11A, Onvehicle Service - Drive Belt Tension Check 311A).
Front Under Cover (RH) and Side Under Cover (RH)
Installation (Refer to GROUP 51, Under Cover 351).
12 2 Nm
57 7 Nm
3
4
1
2
5
49 9 Nm
7
22 4 Nm
22 4 Nm
49 9 Nm
6
AC200116 AB
1.
2.
>>A<< 3.
4.
Removal steps
Pressure switch connector
Drive belt
Suction hose
Pressure hose

<<A>> OIL PUMP ASSEMBLY REMOVAL
With the engine lifted by the jack, remove the oil
pump assembly mounting bolt (lower side) at the
pulley side.
<<A>>
5.
6.
7.

Oil pump assembly
A/C compressor harness
Power steering pump bracket
37-32
POWER STEERING

>>A<< SUCTION HOSE INSTALLATION
Suction hose
AC103338 AC
Install the suction hose so that the marking is

positioned as shown in the illustration.
INSPECTION
M1372005300176
Check the drive belt for cracks.

Check the pulley for uneven rotation.
POWER STEERING
37-33

M1372005400281
CAUTION
Never disassemble the terminal assembly. It cannot be reassembled.
11
28 2 Nm
12
13
10
18
2
9
17
8
16
15
9.9 2.1 Nm
: ATF DEXRON III or DEXRON II
15
4
5
7
3
9
6
10
Oil pump seal kit
1.
2.
3.
4.
5.
>>C<< 6.
7.
8.
9.
AC100143 AE
13
13
10
2
28 1 Nm
59 9 Nm
18
14
11
Oil pump cartridge kit
Disassembly steps
Pump cover
O-ring
Snap ring
Pulley and shaft
Vanes
Cam ring
Rotor
Pin
Side plate
Oil pump pulley and shaft kit
>>A<< 10.
>>B<< 11.
12.
>>A<< 13.
14.
>>A<< 15.
16.
17.
>>A<< 18.

O-ring
Oil seal
Terminal assembly
O-ring
Plug assembly
O-ring
Flow control spring
Suction connector
O-ring
POWER STEERING
37-34
MB990938
Plug assembly
Suction connector
MB991203
2
AC000752AB
Terminal assembly
Side plate
Use following special tool to install the oil seal.

>>C<< CAM RING INSTALLATION
CAUTION
Be sure to install the cam ring in the correct

direction as shown.
4
5
AC100170 AB
No.
ID Width mm
15.8 2.4
21.0 1.9
14.8 2.4
3.8 1.9
14.8 1.9
Side plate side
Pump cover side
AC100171AB
Install the cam ring as shown in the illustration.
INSPECTION
M1372005500192
Check the flow control valve of the pump body for

clogging.
Check the pulley and shaft for wear or damage.
Check the rotor and vane groove for "stepped"
wear.
Check the contact surface of cam ring and vanes
for "stepped" wear.
Check the vanes for damage.
POWER STEERING
37-35
POWER STEERING HOSES

M1372005700367

Power Steering Fluid Draining and Refilling (Refer to
337). and Bleeding (Refer to 337).
12 2 Nm
5
6
4
1
12 2 Nm
57 7 Nm
12
12 2 Nm
14
12 2 Nm
12 2 Nm
13
13
12 2 Nm
15
12
57 7 Nm
11
10
15 3 Nm
12 2 Nm
AC300498 AC
>>F<<
>>E<<
>>D<<
>>C<<
>>B<<
1.
2.
3.
4.
5.
6.
7.
8.
Removal steps
Oil reservoir
Return hose
Suction hose
Return hose
Return hose
Return hose
Return tube assembly
Front bumper assembly (Refer to
GROUP 51, Front Bumper Assembly
351).
>>A<< 9.
10.
11.
12.
13.
14.
15.

Tie rod end and knuckle connection
(Refer to 337).
Stabilizer link (Refer to GROUP 33A,
Stabilizer Bar 333).
Return hose
Return tube
O-ring
Eye bolt
Gasket
Pressure hose assembly
Return tube
POWER STEERING
37-36

>>A<< RETURN HOSE INSTALLATION
>>D<< RETURN HOSE INSTALLATION
Return hose
Return tube
Return hose
AC100278 AC
AC100277AB
Install the return hose so that the marking is

>>B<< RETURN HOSE INSTALLATION
Install the return hose so that the markings are

>>E<< SUCTION HOSE INSTALLATION
Return hose
Suction hose
Marking
Return tube
AC201792 AC
AC103338 AC
Marking
Install the suction hose so that the marking is

Cooler tube
assembly
>>F<< RETURN HOSE INSTALLATION
Return hose
Marking
Return tube
AC201922 AC

Return hose
>>C<< RETURN HOSE INSTALLATION

Return tube
Marking
Install the return hose so that the markings are

Return hose
Marking
AC201923 AC
AC201791 AC

21A-1
GROUP 21A
00
11
CLUTCH
12
13
14
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .
21A
21A
LUBRICANTS . . . . . . . . . . . . . . . . . .
21A
21A
CLUTCH PEDAL CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
21A
CLUTCH BLEEDING . . . . . . . . . . . . . . . . .
21A
15
CLUTCH PEDAL. . . . . . . . . . . . . . . . .
21A
21A
CLUTCH CONTROL . . . . . . . . . . . . . .
21A
21A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
21A
21A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
21A
16
17
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
CLUTCH
21A-2
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1211000100160
The clutch is a dry single-disc, diaphragm type;

hydraulic pressure is used for the clutch control.
M1211000300164
Item
Standard value
Clutch pedal height mm
208 2
Clutch pedal clevis pin play mm
1-3
Clutch pedal free play mm
4 - 13
Distance between the clutch pedal and the clutch pedal

stopper when the clutch pedal is released mm
105 or more
LUBRICANTS
M1211000400150
Item
Specified lubricant
Quantity
Clutch fluid
Brake Fluid DOT 3 or DOT 4
As required
Pushrod assembly
Rubber grease
As required
Boot
Rubber grease
As required
Release cylinder push rod
MITSUBISHI genuine grease Part

No.0101011
As required
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND
ADJUSTMENT
Clutch pedal clevis pin play

M1211000900188
Clutch pedal height
B
A
AC100355 AB
Clutch pedal stopper

AC100354 AB
1. Measure the clutch pedal height.

Standard value (A): 208 2 mm
2. Measure the clutch pedal clevis pin play.

Standard value (B): 1 - 3 mm
CLUTCH
21A-3
ON-VEHICLE SERVICE
Setting nut
Clutch pedal
13 2 Nm
AC100356 AB
5. If the clutch pedal free play and the distance

between the clutch pedal and the clutch pedal
stopper when the clutch is disengaged do not
agree with the standard values, it is probably the
result of either air in the hydraulic system or a
faulty master cylinder, release cylinder or clutch.
Bleed the air, or disassemble and inspect the
master cylinder, release cylinder or clutch.
CLUTCH BLEEDING
M1211001400164
Clutch master cylinder bleeding
CAUTION
Do not push in the master cylinder pushrod at
this time, otherwise the clutch will not operate
properly.
3. If the clutch pedal height and clutch pedal clevis
pin play are not within the standard value, loosen
the setting nut to adjust the clutch pedal height
and clevis pin play to the standard value.
Clutch pedal free play
CAUTION
Use the specified brake fluid. Do not mix brake
fluids.
Specified fluid: Brake fluid DOT 3 or DOT 4
1. Disconnect the brake tube clamp and remove the
brake master cylinder with the brake tubes
connected.
2. Remove the brake fluid reservoir with the hoses
connected.
C
AC100355 AC
Distance between the clutch pedal and the

clutch pedal stopper when the clutch is disengaged
Clutch pedal
stopper
AC100357 AB
4. After completing the adjustments, confirm that the

clutch pedal free play (measured at the face of the
pedal pad) and the distance between the clutch
pedal (the face of the pedal pad) and the clutch
pedal stopper when the clutch is disengaged are
within the standard value ranges.
Standard value (C): 4 - 13 mm
Standard value (D): 105 mm or more
AC301530AB
3. Connect a hose with a bottle to the bleeder screw.

4. Open the bleed nipple.
5. Depress the clutch pedal slowly. Open the bleeder
screw to let air and brake fluid out. Close the
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.
6. Check that the brake fluid reservoir level stays
between "MAX" and "MIN" marks throughout the
clutch bleeding process.
Clutch release cylinder bleeding

CAUTION
Use the specified brake fluid. Do not mix brake
fluids.
Specified fluid: Brake fluid DOT 3 or DOT 4
1. Remove the under cover.
CLUTCH
21A-4
CLUTCH PEDAL
4. Depress the clutch pedal slowly. Open the bleeder

screw to let air and brake fluid out. Close the
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.
5. Check that the brake fluid reservoir level stays
between "MAX" and "MIN" marks throughout the
clutch bleeding process.
AC301000AB
2. Connect a hose with a bottle to the bleeder screw.

3. Open the bleed nipple.
CLUTCH PEDAL
M1211001600179
Clutch Pedal Adjustment (Refer to 321A).
7
1
4
3
12 2 Nm
6
AC301004 AB
1.
2.
3.
Removal steps
Instrument panel under cover
(Refer to GROUP 52A, Instrument
panel 352A).
Snap pin
Clevis pin
Clutch master cylinder mounting
nut
4.
5.
6.
7.

Clutch pedal assembly mounting
bolt
Pedal pad
Pedal stopper
Clutch pedal assembly
CLUTCH
21A-5
CLUTCH CONTROL
CLUTCH CONTROL
M1211001900181
Clutch Fluid Draining
Clutch Fluid Supplying
Clutch Line Bleeding (Refer to 321A).
Clutch Pedal Adjustment (Refer to 321A).
15 1 Nm
Release fork
10
Release cylinder
push rod
11
Specified grease:
MITSUBISHI genuine grease
PART No. 0101011
1
4
12 2 Nm
10
30 4 Nm
11
12 2 Nm
18 3 Nm
AC301448 AB
1.
2.
3.
4.
5.
<<A>>
6.
Clutch master cylinder removal

steps
Clevis pin assembly
Eye bolt
Gasket
Reservoir hose
Clevis pin and pushrod assembly
connecting part
Clutch master cylinder
7.
8.
Sealer
Retainer plate
Clutch release cylinder removal
steps
10. Clutch pipe
11. Clutch release cylinder
Clutch line removal steps
9. Clutch hose
10. Clutch pipe
CLUTCH
21A-6
CLUTCH CONTROL
INSPECTION
<<A>> CLUTCH MASTER CYLINDER REMOVAL

1. Disconnect the brake tube clamp and remove the
brake master cylinder with the brake tubes
connected.
2. Remove the brake fluid reservoir with the hoses
connected.
3. Remove the clutch master cylinder.
M1211002000136
Check the master cylinder or clutch hose for fluid

leakage.
Check the clutch hose or tube for cracks or
clogging.

M1211002100166
CLUTCH MASTER CYLINDER
CAUTION
Do not disassemble the piston assembly.
13 2 Nm
3
4
1
2N
5
8
3
4
Piston repair kit
Clutch fluid:
Brake fluid DOT3 OR DOT4
Grease: Rubber grease

AC301952 AB
>>A<<
1.
2.
3.
4.
Disassembly steps
Piston stopper ring
Piston assembly
Pushrod assembly
Boot
5.
6.
7.
8.

Spring pin
Nipple
Seal
Master cylinder body
CLUTCH
CLUTCH CONTROL
21A-7
INSPECTION
M1211002200130
103 0.5 mm
AC001144 AG
>>A<< PUSHROD ASSEMBLY INSTALLATION

Set the length of the pushrod assembly to the
dimension shown to make the adjustment of the
clutch pedal easier.
Check inside the cylinder body for rust and scars.

Check the piston cup for wear and deformation.
Check the piston for rust and scars.
Check the pipe connection for clogging.
127(6
55A-1
GROUP 55A
00
11
HEATER, AIR
CONDITIONER AND
VENTILATION
12
13
14
15
16
17
21
CONTENTS
55A
LUBRICANTS . . . . . . . . . . . . . . . . . .
55A
SPECIAL TOOLS. . . . . . . . . . . . . . . .
55A
55A
55A
SIGHT GLASS REFRIGERANT

LEVEL TEST. . . . . . . . . . . . . . . . . . . . . . . .
55A
MAGNETIC CLUTCH TEST . . . . . . . . . . . .
55A
COMPRESSOR DRIVE BELT

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
55A
SIMPLE INSPECTION OF
THE A/C PRESSURE SENSOR . . . . . . . . .
55A
CHARGING. . . . . . . . . . . . . . . . . . . . . . . . .
55A
REPLACEMENT PROCEDURE . . . . . . . . .
55A
HEATER CONTROL ASSEMBLY

AND A/C SWITCH . . . . . . . . . . . . . . . 55A
25
26
55A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
55A
55A
31
HEATER UNIT, HEATER CORE,

BLOWER ASSEMBLY AND
EVAPORATOR UNIT . . . . . . . . . . . . . 55A
32
55A
HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . .
55A
55A
BLOWER ASSEMBLY. . . . . . . . . . . . . . . . .
55A
55A
CORRECTING LOW REFRIGERANT

LEVEL IN CASE THE SERVICE
CAN IN USED . . . . . . . . . . . . . . . . . . . . . . .
55A
DISCHARGING SYSTEM . . . . . . . . . . . . . .
55A
REFILLING OF OIL IN THE

A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
55A
PERFORMANCE TEST . . . . . . . . . . . . . . .
55A
REFRIGERANT LEAK REPAIR

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . .
55A
55A
COMPRESSOR NOISE CHECK . . . . . . . .
55A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
55A
POWER RELAY CHECK . . . . . . . . . . . . . .
55A
IDLE-UP OPERATION CHECK . . . . . . . . .
55A
CLEAN AIR FILTER
22
BLOWERMOTOR, RESISTOR AND

OUTSIDE/INSIDE AIR SELECTION
DAMPER CONTROL MOTOR . . . . . . 55A
27
33
34
35
36
37
42
51
55A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
55A
52
EVAPORATOR ASSEMBLY . . . . . . . 55A
54
55
55A-2
COMPRESSOR ASSEMBLY AND
TENSION PULLEY . . . . . . . . . . . . . .
55A
REMOVAL AND INSTALLATION . . . . . . . . .
55A
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .
55A
55A
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .
55A
CONDENSER AND CONDENSER

FAN MOTOR . . . . . . . . . . . . . . . . . . .
55A
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
55A
REFRIGERANT LINE. . . . . . . . . . . . . 55A

VENTILATORS. . . . . . . . . . . . . . . . . . 55A
55A
55A
55A
HEATER, AIR CONDITIONER AND VENTILATION
55A-3
M1552000300270
Item
Standard value
Idle speed r/min
750 50
Idle-up speed r/min
850 50
Resistor (for blower motor) W
LO
2.54
ML
1.24
MH
0.6
Air gap (magnetic clutch) mm
0.3 - 0.5
LUBRICANTS
M1552000400288
Item
Specified lubricant
Quantity
Compressor refrigerant unit lubricant SUN PAG 56
120 mL
Each connection of refrigerant line
SUN PAG 56
As required
Refrigerant
R134a (HFC-134a)
550 20 g
55A-4
SPECIAL TOOLS
SPECIAL TOOLS
M1552000600301
Tool
Tool number
Name
Application
MB991367
Special spanner
Armature mounting nut of

compressor removal and
installation
MB991386
Pin
MB991223
A:MB991219
B:MB991220
C:MB991221
D:MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness adapter
D: Probe
B991367
D
MB991223 AC

connector
contact pressure
circuit
circuit
sourced tester
55A-5
TROUBLESHOOTING
TROUBLESHOOTING
M1552009600353
Refer to GROUP 00, How to Use Troubleshooting/

SYMPTOM CHART
M1552009900439
NOTE: Refer to GROUP 14, Trouble shooting for the

condenser fan.
Symptom
Inspection
Procedure
Reference
Page
When the ignition switch is "ON" the A/C does not operate.
355A
Inside/outside air selection is not possible.
355A
When the A/C is operating, temperature inside the passenger

compartment does not decrease (cool air is not emitted).
355A
Blower fan and motor do not turn.
355A
Blower air amount cannot be changed.
355A
The A/C indicator flashes.
355A
Defogger function does not operate.
355A
Defogger Timer function does not operate.
355A
Malfunction of the A/C-ECU power supply system.
355A
Condenser Fan does not operate.
10
Refer to
GROUP 14
314
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: When the Ignition Switch is "ON" the A/C does not Operate.
The blower system or the compressor system may
be defective if there is no cool air coming from the
spit hole.
Malfunction of blower motor
Malfunction of A/C compressor
DIAGNOSIS
Check that the blower motor operation when the
blower switch is moved to the "HI" position.
(2) Turn the blower switch to the "HI" position.
Q: Does the blower motor operate when the blower
switch is moved to the "HI" position?
YES : Refer to Inspection procedure 3 "When the
A/C is operating, temperature inside the

passenger compartment does not decrease
(cool air not emitted) 355A."
NO : Refer to Inspection procedure 4 "Blower fan
and motor do not turn 355A."
55A-6

TROUBLESHOOTING
INSPECTION PROCEDURE 2: Inside/Outside Air Selection is not possible.
Outside/Inside Air Selection Damper Control Motor Circit

IGNITION
SWITCH (IG2)
OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL MOTOR
A/C-ECU

If the inside/outside air selection damper motor does
not operate normally, the inside/outside air selection
damper motor system may be defective.
Malfunction of the inside/outside air selection
damper motor
Damaged the wiring harness or connectors
Malfunction of the manual air conditioner control
panel (A/C-ECU)
Wire colour code

DIAGNOSIS
STEP 1. Check the defogger and A/C operations.
Q: Do the defogger and A/C work normally?
YES : Go to Step 2.
NO : Refer to Inspection procedure 9
"Malfunction of the A/C-ECU power supply

system 355A."

TROUBLESHOOTING
STEP 2. Measure the voltage at the C-311

outside/inside air selection damper control motor
connector.
55A-7
STEP 3. Connector check: C-311 outside/inside

air selection damper control motor connector
Connector: C-311
Harness side
Connector: C-311
Harness side
3 2
1
7 6 5 4
3 2
1
7 6 5 4
AC301547AB
AC301547AB

Connector C-311
(Harness side)
3 2
1
7 6 5 4
AC301541 BT

body earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 3.

YES : Go to Step 4.
55A-8
TROUBLESHOOTING
STEP 4. Check the wiring harness between C-311

connector terminal No.7 and the ignition switch
(IG2).
Connector: C-311
Harness side
Check the outside/inside air selection damper

control motor power supply line for open circuit.

3 2
1
7 6 5 4
STEP 5. Check the outside/inside air selection

damper control motor
Refer to 355A.
AC301547AB
NOTE:
Q: Does outside/inside air selection damper control

motor work normally?
YES : Go to Step 6.
NO : Replace the outside/inside air selection
damper control motor.
Connector: C-10
STEP 6. Connector check: C-311 outside/inside

air selection damper control motor connector
and C-06 A/C-ECU
1
2
3 4 5 6 7
Connector: C-311
Harness side
3 2
1
7 6 5 4
AC301397 AM

Junction Block (Front View)
C-203
AC301547AB
Connector: C-06
C-205
C-06(B)
Harness side
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
Harness side
C-205
C-203
AC301397 AN
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
2
1
6 5 4 3
AC210475 AR

necessary.

YES : Go to Step 7.

TROUBLESHOOTING

connector (terminals 6 and 4) and A/C-ECU C-06
(terminals 2 and 3).
Connector: C-311
Harness side
3 2
1
7 6 5 4
AC301547AB
C-06(B)
C-10
C-10
1
2
3 4 5 6 7
C-06
Harness side
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
AC301398 BD

Check the outside/indside air selection damper
control motor earth line for open or short circuit.
YES : Replace the manual air conditioner control
panel (A/C-ECU).
55A-9
55A-10
TROUBLESHOOTING
INSPECTION PROCEDURE 3: When the A/C is Operating, Temperature Inside the Passenger
Compartment does not Decrease (Cool Air is not Emitted).
A/C Compressor and Air Thermo Sensor Circuit
BATTERY
IGNITION
SWITCH (IG2)
A/C PRESSURE
SENSOR
ENGINEECU
RELAY
BOX
A/C COMPRESSOR
RELAY
A/C-ECU
A/C
REFRIGERANT
TEMPERATURE
SWITCH
A/C
COMPRESSOR
ASSEMBLY
RESISTOR
MAGNETIC
CLUTCH
(OUTLET SIDE)
(INLET SIDE)
Wire colour code

SB : Sky blue
55A-11
TROUBLESHOOTING

If cool air is not distributed when the A/C switch is on,
the air thermo sensor or the A/C compressor relay
system may be defective.
Improper amount of refrigerant
Malfunction of the air thermo sensor
Malfunction of the A/C pressure sensor
Malfunction of the A/C compressor relay
Malfunction of the A/C refrigerant temperature
switch
Malfunction of the magnetic clutch
panel (A/C-ECU)
Malfunction of the engine-A/T-ECU
STEP 4. Measure the voltage at the B-27 A/C

compressor connector.
Connector: B-27
Harness side
1
B-27(B)
AC301648 AB

Connector: C-134
DIAGNOSIS
STEP 1. Check the defogger and outside/inside
air selection damper control motor operation.
Q: Do the defogger and outside/inside air selection
damper control motor work normally?
YES : Go to Step 2.

system 355A."
Harness side
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
AC301397AO
(3) Disconnect engine-ECU connector C-134, and

earth terminal 8.
STEP 2. Check the blower motor operation.

Q: Does the blower motor work normally?
YES : Go to Step 3.
Connector B-27
(Harness side)
STEP 3. Check the A/C compressor.

Check the A/C compressor for compressor oil leaks.
Q: Is the check result satisfactory?
YES : Go to Step 4.
NO : Replace the A/C compressor or the
expansion valve.
AC301541BU

body earth.
OK: System voltage
NO : Go to Step 5.
STEP 5. Check the A/C compressor relay

continuity.
Refer to 355A.
Q: Is the A/C compressor relay in good condition?
YES : Go to Step 6.
NO : Replace the A/C compressor relay.
55A-12
TROUBLESHOOTING
STEP 6. Measure the voltage at B-18X A/C

Connector: B-18X

Connector: B-18X
Relay box side
Relay box side
B-18X
B-18X
Front of
vehicle
Front of
vehicle
AC301483 AG
(1) Remove the relay, and measure at the relay box

side.
Connector B-18X
(Relay box side)
2
Front of
vehicle
AC301541BV

body earth.
OK: System voltage
YES : Go to Step 9.
NO : Go to Step 7.
AC301483 AG

YES : Go to Step 8.
NO : Repair or replace the connector.
55A-13
TROUBLESHOOTING
STEP 8. Check the wiring harness between B-18X

A/C compressor relay connector terminal No.3
NOTE:
Connector: C-106
Connector: B-18X
C-106(GR)
2
1
3 4
5 6
10 11 12
7 8 9
13 14 15 16 17 18 19
AC301397AG

C-203
Relay box side
B-18X
2
C-205
Front of
vehicle
AC301483 AG
Harness side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-203
2
1
6 5 4 3
AC210475 AR

necessary.
Check the A/C compressor relay power supply
line for open circuit.

55A-14
TROUBLESHOOTING

Connector: B-18X

Connector: B-18X
Relay box side
Relay box side
B-18X
B-18X
Front of
vehicle
Front of
vehicle
AC301483 AG
(1) Remove the relay, and measure at the junction

block side.
Connector B-18X
(Relay box side)
2
Front of
vehicle
AC301541BW

body earth.
OK: System voltage
NO : Go to Step 10.
AC301483 AG

55A-15
TROUBLESHOOTING
STEP 11. Check the wiring harness between B18X A/C compressor relay connector terminal
No.4 and the battery.
Connector: B-18X

compressor relay connector and B-27 A/C
compressor connector
Connector: B-18X
Relay box side
Relay box side
B-18X
B-18X
Front of
vehicle
Front of
vehicle
AC301483 AG
NOTE:
AC301483 AG
Connector: B-27
Connector: A-14
Harness side
A-14(GR)
1 2 3 4 5 6 7
8 9
10 11
15
14
12 13
16 17
B-27(B)
AC301648 AB
AC301653AB



55A-16
TROUBLESHOOTING
No.1 and B-27 A/C compressor connector
terminal No.1.

connector and B-18X A/C compressor relay
connector
Connector: B-18X
Connector: B-18X
Relay box side

Relay box side
B-18X
B-18X
2
Front of
vehicle
Front of
vehicle
AC301483 AG
AC301483 AG
Connector: C-134
Connector: B-27
Harness side
1
Harness side
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
B-27(B)
AC301397AO
AC301648 AB
Check the A/C compressor power supply line for

open circuit.

55A-17
TROUBLESHOOTING
STEP 15. Check the wiring harness between C134 engine-ECU connector terminal No.8 and B18X A/C compressor relay connector terminal
No.2.
STEP 16. Measure the voltage at C-06 A/C-ECU

connector.
Connector: B-18X
C-06(B)
C-134
Harness side
Relay box side
C-134
C-06
B-18X
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
Front of
vehicle
AC301398 AU
AC301483 AG
Connector: C-134
(1) Disconnect A/C-ECU connector C-06, and

earth terminal 8.
Connector C-06
(Harness side)
Harness side
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
AC301397AO
Check the A/C compressor relay earth line for

open or short circuit.

8 7 6 5 4 3 2 1
16 15 14 13 121110 9
AC301541BX

body earth.
OK: System voltage
NO : Go to Step 17.
55A-18
TROUBLESHOOTING

compressor relay connector and C-06 A/C-ECU
connector
Connector: B-18X
Relay box side

B-18X
2
Front of
vehicle
AC301483 AG
Connector: C-06
C-06(B)
Harness side
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
AC301397 AN


TROUBLESHOOTING
No.1 and C-06 A/C-ECU connector terminal No.7.
Connector: B-18X
55A-19
Check the A/C compressor relay output line for


connector.
Connector: C-06
-
C-06(B)
Harness side
Relay box side

8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
B-18X
2
AC301397 AN
Front of
vehicle
AC301483 AG

(3) Turn the blower switch to the "ON" position.
Connector C-06
(Harness side)
C-06(B)
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
C-104(B)
AC301541BY

body earth.
OK: System voltage
C-104
1 2 3
4 5 6 7
8 9 10 1112 13 14 15 16

NO : Go to Step 20.
Harness side
C-06
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
AC301398 AY

necessary.
55A-20
TROUBLESHOOTING
STEP 20. Connector check: C-11 resistor

connector and C-06 A/C-ECU connector

resistor connector terminal No.4 and C-06 A/CECU connector terminal No.8.

C-06(B)
C-06(B)
C-11
C-11
Harness side
C-06
C-11
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
2 1
4 3
Harness side
C-06
C-11
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
2 1
4 3
AC301398 AG
AC301398 AG



Cope with Intermittent Malfunction 300)
STEP 22. Check the magnetic clutch operation.
Refer to 355A.
Q: Can the sound of the magnetic clutch (click) be
heard?
NO : Replace the compressor magnet clutch.
STEP 23. Check the refrigerant temperature

switch.
Refer to 355A.
Q: Is the refrigerant temperature switch operating
properly?
NO : Replace the refrigerant temperature switch.
STEP 24. Check the air thermo sensor.

Refer to 355A.
Q: Is the air thermo sensor in good condition?
NO : Replace the air thermo sensor.
55A-21
TROUBLESHOOTING
STEP 25. Connector check: C-10 air thermo

sensor connector and C-06 A/C-ECU connector

air thermo sensor connector (terminals 1, 3, 4
and 5) and C-06 A/C-ECU connector (terminals
14, 16 and 13).
C-06(B)
C-10
C-06(B)
C-10
Harness side
C-06
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
C-10
1
2
3 4 5 6 7
Harness side
C-06
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
C-10
1
2
3 4 5 6 7
AC301398 AH

AC301398 AH
Check the air thermo sensor output and earth line

for open or short circuit.
STEP 27. Check the refrigerant level.

Refer to 355A.
Q: Is the refrigerant level correct?
NO : Correct the refrigerant level (Refer to On-
vehicle Service 355A).

STEP 28. Check the A/C pressure sensor
operation.
Refer to 355A.
Q: Is the A/C pressure sensor operating properly?
NO : Replace the A/C pressure sensor.
55A-22
TROUBLESHOOTING

Connector: A-02
A-02(B)
STEP 30. Check the wiring harness between A-02

A/C pressure sensor connector terminal No.2
and C-06 A/C-ECU connector terminal No.15.
Connector: A-02
A-02(B)
Harness side
Harness side
3 2 1
3 2 1
AC301656 AB
AC301656 AB
Connector: C-06
Connector: C-06
C-06(B)
C-06(B)
Harness side
Harness side
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
AC301397 AN
AC301397 AN

NOTE:
Connector: C-116
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG

necessary.
Check the A/C pressure sensor output line for
55A-23
TROUBLESHOOTING
STEP 31. Connector check: C-134, C-135 engineECU connector and C-06 A/C-ECU connector
STEP 32. Check the wiring harness between C134 engine-ECU connectors terminal No.24 and
C-06 A/C-ECU connector terminal No.5.

C-06(B)
C-06(B)
C-135
C-134
C-134
C-104(B)
Harness side
C-06
C-134
C-135
C-104
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
1 2 3
4 5 6 7
8 9 10 1112 13 14 15 16
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
JAE-E
38 37 36 35 34 33 32 31
46 45 4443 42 41 4039
Harness side
C-06
C-134
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
AC301398 AV
AC301398 AW


necessary.
Check the communication line for open or short
circuit.
55A-24
TROUBLESHOOTING
STEP 33. Check the wiring harness between C135 engine-ECU connectors terminal No.45 and
C-06(B)
C-135
C-104(B)
C-104
1 2 3
4 5 6 7
8 9 10 1112 13 14 15 16
Harness side
C-06
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
C-135
JAE-E
38 37 36 35 34 33 32 31
46 45 4443 42 41 4039
AC301398 AX

necessary.
circuit.
panel (A/C-ECU) or engine-ECU.


TROUBLESHOOTING
55A-25
INSPECTION PROCEDURE 4: Blower Fan and Motor do not Turn.
Blower Motor Circuit

FUSIBLE
LINK 1
IGNITION
SWITCH (IG2)
BLOWER
RELAY
BLOWER
SWITCH
BLOWER
MOTOR
Wire colour code


If the blower fan and motor does not turn when the
blower switch is operated, the blower switch may be
defective.
Malfunction of the blower relay
Malfunction of the blower switch
Malfunction of the blower motor
DIAGNOSIS
STEP 1. Check that the blower motor operates
when the blower switch is moved to the "4 (HI) "
position.
(2) Turn the blower switch to the "4 (HI) " position.
switch is moved to the "4 (HI) " position?
YES : Refer to Inspection procedure 5 "Blower air
amount cannot be changed 355A."

NO : Go to Step 2.
55A-26
TROUBLESHOOTING
STEP 2. Measure the resistance at the C-12

blower motor connector.
Connector: C-12
STEP 3. Connector check: C-12 blower motor

connector
Connector: C-12
Harness side
Harness side
1
2
1
2
AC301397AQ

Connector C-12
(Harness side)
AC301397AQ

YES : Go to Step 4.

blower motor connector terminal No.2 and body
earth.
1
2
Connector: C-12
AC301541 BZ

body earth.
OK: 2 ohm or less
YES : Go to Step 5.
NO : Go to Step 3.
Harness side
1
2
AC301397AQ
Check the blower motor earth line for open circuit.


55A-27
TROUBLESHOOTING
STEP 5. Measure the voltage at C-12 blower

motor connector.

relay connector.
Connector: C-207
Connector: C-12
Harness side
1
2
Junction block side

3 2 1
4
5
AC301397AQ

AC210474 AJ

block side.
Connector C-207
Connector C-12
(Harness side)
3 2 1
4
5
1
2
AC301541CB
AC301541CA

body earth.
OK: System voltage
NO : Go to Step 6.
STEP 6. Check the blower relay continuity.

Refer to 355A.
Q: Is the blower relay continuity in good condition?
YES : Go to Step 7.
NO : Replace the blower relay.

earth.
OK: System voltage
NO : Go to Step 8.
STEP 8. Connector check: C-207 blower relay

connector
Connector: C-207
Junction block side

3 2 1
4
5

YES : Go to Step 9.
AC210474 AJ
55A-28
TROUBLESHOOTING

blower relay connector terminal No.1 and the
STEP 10. Measure the resistance at C-207 blower

relay connector.
Connector: C-207
C-203
Junction block side

3 2 1
4
5
C-207
AC210474 AJ

block side.
Harness side
Junction block side
C-203
C-207
2
1
6 5 4 3
3 2 1
4
5
AC210475 AS
Connector C-207
3 2 1
4
5
AC301541CC

necessary.
Check the blower relay power supply line for open
circuit.


body earth.
OK: 2 ohm or less
NO : Go to Step 11.

connector.
Connector: C-207
Junction block side

3 2 1
4
5
AC210474 AJ

55A-29
TROUBLESHOOTING
STEP 12. Check the wiring harness between C207 blower relay connector terminal No.3 and
earth.

relay connector.
Connector: C-207
Junction block side

3 2 1
4
5
C-205
C-207
AC210474 AJ

block side.
Harness side
Junction block side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-207
3 2 1
4
5
Connector C-207
3 2 1
4
5
AC210475 AT
AC301541CD

junction block connectors C-205, and repair if
necessary.
Check the blower relay earth line for open circuit.

body earth.
OK: System voltage


NO : Go to Step 14.


connector
Connector: C-207
Junction block side

3 2 1
4
5
AC210474 AJ

55A-30
TROUBLESHOOTING
STEP 15. Check the wiring harness between C207 blower relay connector terminal No.5 and
fusible link (1).
STEP 16. Check the blower switch continuity.

Refer to 355A.
Q: Is the blower switch continuity in good condition?
NO : Replace the blower switch.
STEP 17. Connector check: C-08 blower switch

connector and C-207 blower relay connector
C-204(B)
Connector: C-08
C-207
Harness side
Junction block side
Harness side
C-204
C-207
3 2 1
4
5
3 2 1
6 5 4
AC301397 AR
Connector: C-207
AC210475 AU
Junction block side
Connector: C-116
3 2 1
4
5
1 2
5 6 7
3 4

8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC210474 AJ
AC301395 AG

intermediate connectors C-116 and junction block
circuit.

55A-31
TROUBLESHOOTING

blower switch connector terminal No.2 and C-207
blower relay connector terminal No.4.
STEP 19. Connector check: C-12 blower motor

connector and C-08 blower switch connector
Connector: C-08
C-12
Harness side
C-08
3 2 1
6 5 4
AC301397 AR

Harness side
C-203
C-207
Harness side
C-08
C-12
3 2 1
6 5 4
1
2
AC301398 AL
Junction block side
C-203
C-207
2
1
6 5 4 3
3 2 1
4
5
AC210475 AS

junction block connectors C-203, and repair if
necessary.
Check the blower relay output line for open
circuit.

55A-32
TROUBLESHOOTING

blower motor connector terminal No.1 and C-08
blower switch connector terminal No.6.
STEP 21. Check the blower fan and motor

operation.
Refer to 355A.

NO : Replace the blower motor.
C-12
C-08
Harness side
C-08
C-12
3 2 1
6 5 4
1
2
AC301398 AL
Check the blower motor power supply line for

open circuit.


TROUBLESHOOTING
55A-33
INSPECTION PROCEDURE 5: Blower Air Amount cannot be Changed.
Blower Switch and Resistor Circuit

BLOWER
RELAY
BLOWER
SWITCH
RESISTOR
BLOWER
MOTOR
Wire colour code


If the blower air amount can not be changed when
the blower switch is operated, the blower switch may
be defective.
Malfunction of the resistor
Malfunction of the blower switch
DIAGNOSIS
STEP 1. Check that the blower motor operates
when the blower switch is moved to the "4 (HI)"
position.
switch is moved to the "4 (HI)" position?
YES : Go to STEP 2.
STEP 2. Check the blower switch continuity.

Refer to 355A.
Q: Is the blower switch continuity in good condition?
YES : Go to Step 3.
NO : Replace the blower switch.
STEP 3. Check the resistor resistance value.

Refer to 355A.
Q: Is the measured value at the standard value?
YES : Go to Step 4.
NO : Replace the resistor.
55A-34
TROUBLESHOOTING
STEP 4. Connector check: C-08 blower switch

connector and C-11 resistor connector

blower switch connector (terminals 1, 4 and 5)
and C-11 resistor connector (terminals 4, 1 and
3).
C-08
C-11
C-08
C-11
Harness side
C-08
C-11
3 2 1
6 5 4
2 1
4 3
Harness side
C-08
C-11
3 2 1
6 5 4
2 1
4 3
AC301398 AM

YES : Go to Step 5.
AC301398 AM
Check the blower switch output line for open

circuit.
YES : Go to Step 6.
55A-35
TROUBLESHOOTING
STEP 6. Connector check: C-11 resistor

connector and C-12 blower motor connector

blower motor connector (terminal 1) and C-11
resistor connector (terminal 2).

C-11
C-11
C-12
C-12
Harness side
C-11
C-12
2 1
4 3
1
2
Harness side
C-11
C-12
2 1
4 3
1
2
AC301398 AN
AC301398 AN

YES : Go to Step 7.
Check the blower motor power supply line for

open circuit.
YES : No action to be taken.
55A-36
TROUBLESHOOTING
INSPECTION PROCEDURE 6: The A/C Indicator Flashes.
A/C Pressure Sensor and Air Thermo Sensor Circuit

AIR THERMO
SENSOR
(OUTLET SIDE)
(INLET SIDE)
AIR THERMO
SENSOR
A/C PRESSURE
SENSOR
A/C-ECU
Wire colour code


If the A/C indicator flashes then the possible causes
may be due to a defective A/C pressure system or
insufficient refrigerant gas.
panel (A/C-ECU)
DIAGNOSIS
SB : Sky blue
STEP 2. Check the air thermo sensor.

Refer to 355A.
Q: Is the air thermo sensor in good condition?
YES : Go to Step 3.

Refer to 355A.
panel (A/C-ECU).
NO : Correct the refrigerant level (Refer to 355A

operation.
Refer to 355A.
YES : Go to Step 2.
).

TROUBLESHOOTING
55A-37
INSPECTION PROCEDURE 7: Defogger Function does not Operate.
Defogger Circuit
IGNITION
SWITCH (IG2)
FUSIBLE
LINK 1
DEFOGGER
RELAY
A/C-ECU
DEFOGGER
SWITCH
DEFOGGER
Wire colour code


If the defogger does not operate when the defogger
switch is turned on, the defogger relay system may
be defective.
Malfunction of the defogger relay
Malfunction of the defogger
panel (A/C-ECU)
SB : Sky blue
DIAGNOSIS
STEP 1. Check the A/C and outside/inside air
selection damper control motor operation.
Q: Do the A/C and outside/inside air selection damper
control motor work normally?
YES : Go to Step 2.
"Malfunction of the A/C-ECU Power Supply

system 355A."
55A-38
TROUBLESHOOTING
STEP 2. Measure the voltage at defogger

connector F-04.
STEP 4. Measure the voltage at defogger relay

connector C-206.
Connector: C-206
Connector: F-04
F-04(B)
Harness side
1
Junction block side
3 2 1
4
5
AC301658 AB

(3) Turn the defogger switch to the "ON " position.
(operate for approx. 11 minutes)
AC210474 AK

block side.
Connector C-206
3 2 1
4
5
Connector F-04
(Harness side)
AC301541CF
1
AC301541CE

body earth.
OK: System voltage
NO : Go to Step 3.
STEP 3. Check the defogger relay continuity.

Refer to 355A.

body earth.
OK: System voltage
YES : Go to Step 7.
NO : Go to Step 5.
STEP 5. Connector check: C-206 defogger relay

connector
Connector: C-206
Q: Is the Defogger relay continuity in good condition?

YES : Go to Step 4.
NO : Replace the defogger relay.
Junction block side
3 2 1
4
5
AC210474 AK

YES : Go to Step 6.
55A-39
TROUBLESHOOTING

defogger relay connector terminal No.5 and the
fusible link (1).
Check the defogger relay power supply line for

open circuit.

C-204(B)
STEP 7. Measure the voltage at defogger relay

connector C-206.
Connector: C-206
C-206
Junction block side
Harness side
C-204
Junction block side
C-206
3 2 1
4
5
3 2 1
4
5
AC210474 AK

block side.
AC210475 AV
Fusible link: No.1
Connector C-206
3 2 1
4
5
AC301541CG
AC301515 AB
NOTE:
Connector: C-116

earth.
OK: System voltage
NO : Go to Step 8.
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG

55A-40
TROUBLESHOOTING

connector
Connector: C-206

connector and C-06 A/C-ECU connector.
Connector: C-06
C-06(B)
Harness side
Junction block side
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
3 2 1
4
5
AC301397 AN
AC210474 AK

YES : Go to Step 9.

defogger relay connector terminal No.1 and
2
1
6 5 4 3
3 2 1
4
5

C-206
C-203
Junction block side
AC210474 AK
C-203
Harness side
Connector: C-206
Junction block side

C-206
3 2 1
4
5
AC210475 AW

necessary.
open circuit.

55A-41
TROUBLESHOOTING
STEP 11. Check the wiring harness between C206 defogger relay connector terminal No.3 and
Connector: C-06

connector and F-04 defogger connector
Connector: C-206
C-06(B)
Harness side
Junction block side

8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
3 2 1
4
5
AC210474 AK
AC301397 AN
Connector: F-04

Junction Block (Front view)
F-04(B)
Harness side
C-205
C-206
Harness side
AC301658 AB
Junction block side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-206
3 2 1
4
5
AC210475 AX

necessary.
Check the defogger relay earth line for open or
short circuit.

55A-42
TROUBLESHOOTING
F-04 defogger connector terminal No.1.
STEP 14. Measure the resistance at defogger

connector F-01.
Connector: F-01
Harness side
C-206
AC301658 AC

C-209
Harness side
C-209
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
Junction block side

C-206
Connector F-01
(Harness side)
3 2 1
4
5
1
AC210475 AY
Connector: F-04
F-04(B)
Harness side
AC301541CO
(2) Measure the resistance value between terminal 1

and earth.
OK: 2 ohm or less
NO : Go to Step 15.
AC301658 AB

necessary.
Check the defogger relay output line for open
circuit.
STEP 15. Connector check: F-01 defogger

connector
Connector: F-01
Harness side

panel (A/C-ECU).
AC301658 AC


TROUBLESHOOTING
STEP 16. Check the wiring harness between F-01

defogger connector terminal No.1 and earth.
Connector: F-01
55A-43
STEP 17. Check the defogger.

Refer to GROUP 54A, Rear window defogger
354A.
Q: Does the defogger work normally?
Harness side
panel (A/C-ECU).
NO : Repair the defogger.
AC301658 AC
Check the defogger earth line for open circuit.

YES : Check that the defogger system works
normally.
INSPECTION PROCEDURE 8: Defogger Timer Function does not Operate.

Turn ON the defogger switch. If the defogger does
not shut off after roughly 11 minutes then the
defogger timer is malfunctioning.
panel (A/C-ECU)
Check the performance of the defogger timer

operations.
(2) Turn the defogger switch to the "ON" position
(operate for approx. 11 minutes)
Q: Does the defogger timer function work normally?
YES : Intermittent malfunction
NO : Replace the manual air conditioner control
panel (A/C-ECU).
55A-44

TROUBLESHOOTING
INSPECTION PROCEDURE 9: Malfunction of the A/C-ECU Power Supply System.
A/C-ECU Power Supply Circuit

IGNITION
SWITCH (IG2)
A/C-ECU
Wire colour code


The A/C-ECU power system may be defective if the
air conditioner, defogger, and outside/inside air
selection damper motor all do not operate normally.
panel (A/C-ECU)
55A-45
TROUBLESHOOTING
DIAGNOSIS
STEP 1. Measure the voltage at A/C-ECU
connector C-06.

A/C-ECU connector terminal No.10 and the
Connector: C-06
Connector: C-06
C-06(B)
C-06(B)
Harness side
Harness side
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
AC301397 AN
AC301397 AN


C-203
Connector C-06
(Harness side)
C-205
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
Harness side
AC301541CH

body earth.
OK: System voltage
YES : Go to Step 4.
NO : Go to Step 2.
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-203
2
1
6 5 4 3
AC210475 AR

connector
Connector: C-06
C-06(B)

junction block connectors C-203 and C-205, and
Check the A/C-ECU power supply line for open
circuit.
Harness side

8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
AC301397 AN

YES : Go to Step 3.
55A-46
TROUBLESHOOTING
STEP 4. Measure the resistance at the C-06 A/CECU connector.

connector
Connector: C-06
Connector: C-06
C-06(B)
C-06(B)
Harness side
Harness side
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
AC301397 AN

Connector C-06
(Harness side)
AC301397 AN

YES : Go to Step 6.

A/C-ECU connector terminal No.12 and the earth.
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
Connector: C-06
C-06(B)
AC301541CN

body earth.
OK: 2 ohm or less
panel (A/C-ECU).
NO : Go to Step 5.
Harness side
8 7 6 5 4 3 2 1
16 15 14 13 12 1110 9
AC301397 AN
Check the A/C-ECU earth line for open circuit.

panel (A/C-ECU).
55A-47
TROUBLESHOOTING

M1552010300464
<C-06>
1
9 10 11 12 13 14 15 16
AC300861AB
Terminal No. Check item
Checking requirement
Normal condition
Defogger switch: ON
0V
Defogger switch: OFF
System voltage
When the damper is moved to

the inside air recirculation
position
0V

the outside air inside air intake
position
System voltage

the inside air recirculation
position
System voltage

the outside air inside air intake
position
0V
Output to the engine-A/T-ECU

(A/C1)
A/C stopped
0V
A/C switch: ON
Blower switch: ON
System voltage
Output to the engine-A/T-ECU

(A/C2)
When the A/C is under low load System voltage

When the A/C is under high
load
0V
Power supply to the A/C

illumination
Lighting switch: ON
System voltage
Blower switch (lo)
blower switch: lo
System voltage
10
Power supply to the ignition

switch (IG2)
Ignition switch: ON
System voltage
11
Earth to the A/C illumination
Always
0V
12
Earth
Always
0V
13
Air thermo sensor (outlet side)
Sensor probe temperature 25C 2.2 V

(1.5k ohm)
14
Air thermo sensor (inlet side)
Sensor probe temperature 25C 2.2 V

(1.5k ohm)
15
16
Earth to the air thermo sensor
Always
0V
Rear defogger switch

Inside/outside air changeover
damper motor (outside air)
Inside/outside air changeover

damper motor (inside air)
55A-48
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
SIGHT GLASS REFRIGERANT LEVEL
TEST
M1552008400345

2. Operate the air-conditioner, and then set the
temperature to maximum cooling.
3. Hold the engine speed at 1500 r/min.
MAGNETIC CLUTCH TEST

M1552008500386
1. Disconnect the magnetic clutch connector to the

magnetic clutch.
Magnetic cluch
connector
Sufficient or excess
Insufficient
refrigerant
refrigerant
Bubbles
AC005671AC
AC005963 AC
4. Check the refrigerant level (bubble state) through

the sight glass.
CAUTION
Use the low-pressure service valve.
2. Connect positive battery voltage directly to the

connector for the magnetic clutch.
3. If the magnetic clutch is normal, there will be a
"click." If the pulley and armature do not make
contact ("click"), there is a malfunction.
COMPRESSOR DRIVE BELT

ADJUSTMENT
Items
State
Insufficient
Many bubbles are seen.

If refrigerant is extremely
low, it appears white.
Refer to GROUP 11, On-vehicle Service - Drive Belt

Tension Check 311A.
Sufficient or excess
refrigerant
No bubbles are seen.
SIMPLE INSPECTION OF THE A/C

PRESSURE SENSOR
NOTE:
(1) If insufficient, replenish the refrigerant as
follows.
a. Replenish until bubbles disappear from the
sight glass.
b. After the bubbles disappear from the sight
glass, replenish 100 g of refrigerant.
(2) If excessive, replenish the refrigerant as
follows.
a. Drain the refrigerant until bubbles can be
seen through the sight glass.
b. Replenish until bubbles disappear from the
sight glass.
c. After the bubbles disappear from the sight
glass, replenish 100 g of refrigerant.
M1552001000313
M1552014700088
1. Assemble a manifold gauge onto the high

pressure service valve.
2. Turn ON the engine and then turn ON the air
conditioner switch.
55A-49
ON-VEHICLE SERVICE
A/C pressure sensor
1
CHARGING
M1552001200340
High-pressure
valve
Low-pressure
valve
AC206295 AB
Gauge manifold
Output voltage
(V)
5
Charging hose
Adapter
(yellow)
valve
Charging hose
(blue)
Switch
R-134a
R-12
connection
connection
port
port
4
3
2
1
0
1
2
3
Refrigerant pressure (MPa)
AC208297AB
3. Check to see that the voltage between the A/C

pressure sensor terminal No.2 and body earth
reflects the specifications of the Figure.
NOTE: The allowance shall be defined as five
percents.
Vacuum
Quick
pump
joint
adaptor Vacuum
(for low
pump
pressure)
Power supply
plug
Switch
Low-pressure
service valve
A
Sleeve
AC212526AB
1. With the handles turned back all the way (valve

closed), install the adaptor valve to the lowpressure side of the gauge manifold.
2. Connect the charging hose (blue) to the adaptor
valve.
3. Connect the quick joint (for low-pressure) to the
charging hose (blue).
55A-50

ON-VEHICLE SERVICE
CAUTION
Use tools that are suited to R134a.
To install the quick joint, press section when
connecting, run your hand along the hose
while pressing to ensure that there are no
bends in the hose.
low- pressure service valve.
NOTE: The low-pressure service valve should be
connected to the flexible suction hose.
5. Close the high and low-pressure valves of the
gauge manifold.
CAUTION
Do not operate the compressor for evacuation.
Vacuum pump
adaptor switch
CAUTION
Be sure to connect the power plug of the vacuum
pump to the vacuum pump adapter, and then
connect the power plug of the adapter to a 100-V
outlet.
6. Install the vacuum pump adaptor to the vacuum
pump.
7. Connect the charging hose (yellow) to the R-134a
connection port of the vacuum pump adaptor.
8. Tighten the adaptor valve handle (valve open).
9. Open the low-pressure valve of the gauge
manifold.
10.Turn the power switch of the vacuum pump to the
ON position.
NOTE: Even if the vacuum pump power switch is
turned ON, the vacuum pump will not operate
because of the power supply connection in step
(6).
Low-pressure
service valve
Vacuum
pump
AC212535 AB
11.Turn the vacuum pump adaptor switch to the

R134a side to start the vacuum pump.
12.Evacuate to a vacuum reading of 100 kPa or
higher (takes approx. 10 minutes).
CAUTION
Do not operate the compressor in the vacuum
condition; damage may occur.
13.Loosen the valve of the adapter valve fully (valve
closed), and turn off the vacuum pump adapter
switch. Then leave it for five minutes.
14.Check the system for proper sealing (negative
pressure should not decrease).
Valve open
Valve close
Charging valve
Adaptor valve
Service can
AC212536 AB
15.Connect the service can valve to the service can

with the handle loosened fully (valve closed).
16.Turn the handle of the adaptor valve back all the
way (valve closed), remove it from the gauge
manifold and install the service can.
55A-51
ON-VEHICLE SERVICE
17.Tighten the handle of the charging valve (valve

closed) to puncture the service can.
CAUTION
If the service can is inverted, liquid refrigerant
may be drawn into the compressor damaging it
by liquid compression. Keep the service can
upright to ensure that refrigerant is charged in
gas state.
Charging valve
Service can
(Refrigerant container)
Low-pressure
service valve
CAUTION
If the service can is inverted, liquid refrigerant
may be drawn into the compressor damaging it
by liquid compression. Keep the service can
upright to ensure that refrigerant is charged in
gas state.
24.Tighten the handle of the adaptor valve (valve
open) to charge the required volume of
refrigerant.
25.After charging with refrigerant, turn the handle of
the adaptor valve back all the way (valve closed).
26.Tighten the charging valve handle (valve closed).
Remove the quick joint (for low-pressure) from the
low-pressure service valve.
27.Remove the service can.
NOTE: If the service can is not emptied
completely, keep the handles of the charging
valve and adaptor valve closed for the next
charging.
CORRECTING LOW REFRIGERANT

LEVEL IN CASE THE SERVICE CAN IN
USED
M1552014600081
Valve open
Charge valve
Valve close
Adaptor valve
AC212537AB
18.Turn the handle of the charging valve back (valve

open) and tighten the handle of the adaptor valve
(valve open) to charge the system with refrigerant.
19.If the refrigerant is not drawn in, turn the handle of
the adaptor valve back all the way (valve closed).
20.Check for gas leaks using a leak detector. If a gas
leak is detected, re-tighten the connections, and
then repeat the charging procedure from
evacuation in step (11).
CAUTION
The leak detector for R-134a should be used.
21.Start the engine.
22.Operate the A/C and set to the lowest
temperature (MAX. COOL).
23.Fix the engine speed at 1,500 r/min.
Charging hose (blue)

Service can
(Refrigerant
container)
Quick joint (for low-pressure)

AC300372AB
1. Install the charge valve with the handle turned all

the way back (valve open) to the service can.
2. Install the adaptor valve with the handle turned all
the way back (valve close) to the charging valve.
3. Connect the charging hose (blue) to the adaptor
valve.
4. Connect the charging hose (blue) to the quick joint
(for low-pressure).
5. Tighten the handle of the charge valve (valve
close), and pierce the service can.
6. Turn the handle of the adaptor valve to bleed the
air.
55A-52
ON-VEHICLE SERVICE
Quick joint
(for low-pressure)
Compressor oil: SUN PAG 56

Quantity
Evaporator: 60 mL
Condenser: 15 mL
Flexible suction hose: 10 mL
Receiver: 10 mL
PERFORMANCE TEST
Low-pressure
service valve
M1552001400333
AC300373 AB
7. Install the quick joint (for low-pressure) to the lowpressure service valve.
NOTE: The low-pressure service valve should be
connected to the suction hose.
9. Operate the air conditioner and set at the lowest
temperature (MAX. COOL).
10.Fix the engine speed at 1,500 r/min.
11.Tighten the handle of the adaptor valve (valve
open), and replenish refrigerant while checking
the quantity through the sight glass.
12.After replenishing is completed, turn the handle of
the adaptor valve all the way back (valve close),
and remove the quick joint.
NOTE: When there is remainder of refrigerant in
the service can, keep it for next use with the
charge value and the valve of the adaptor valve
being closed.
1. The vehicles to be tested should be in a place that

is not in direct sunlight.
Low-pressure
valve
Gauge manifold
Charging
hose (red)
Charging
hose (blue)
Lowpressure
service
valve
M1552013000086
REFILLING OF OIL IN THE A/C SYSTEM

M1552020000022
Too little oil will provide inadequate compressor

lubrication and cause a compressor failure. Too
much oil will increase discharge air temperature.
When a compressor is installed at the factory, it
contains 120 mL of compressor oil. While the A/C
system is in operation, the oil is carried through the
entire system by the refrigerant. Some of this oil will
be trapped and retained in various parts of the
system.
When the following system components are
changed, it is necessary to add oil to the system to
replace the oil being removed with the component.
Adaptor valve
(for lowpressure)
DISCHARGING SYSTEM
Use the refrigerant recovery unit to discharge
refrigerant gas front the system.
NOTE: Refer to the Refrigerant Recovery and
Recycling Unit instruction Manual for operation of the
unit.
High-pressure
valve
Sleeve
Highpressure
service
valve
Adaptor valve
(for highpressure)
AC001388 AB
2. Close the high and low-pressure valve of the

gauge manifold.
3. Connect the charging hose (blue) to the lowpressure valve and connect the charging hose
(red) to the high-pressure valve of the gauge
manifold.
CAUTION
To connect the quick joint, press section A
firmly against the service valve until a click is
heard.
When connecting, run your hand along the
hose while pressing to ensure that there are
no bends in the hose.
4. Install the quick joint (for low-pressure) to the
charging hose (blue), and connect the quick joint
(for high-pressure) to the charging hose (red).
NOTE: The high-pressure service valve is on the
A/C pipe and the low-pressure service valve is on
the suction hose.
55A-53
ON-VEHICLE SERVICE

low-pressure service valve and connect the quick
joint (for high-pressure) to the high-pressure
service valve.
7. Set the A/C controls as follows:
A/C switch: A/C - ON position
Mode selection: FACE position
Temperature control: MAXIMUM COOLING
position
Air selection: RECIRCULATION position
Blower switch: "4" (Fast) position
8. Adjust engine speed to 1,500 r/min with A/C
clutch engaged.
9. Engine should be warmed up with doors and
windows opened.
Thermometer
AC200070AB
10.Insert a thermometer in the centre air outlet and

operate the engine for 20 minutes.
NOTE: If the clutch cycles, take the reading before
the clutch disengages.
11.Note the discharge air temperature.
Performance Temperature Chart

Garage ambient temperature C
20
25
30
35
Discharge air temperature C
8.0 - 11.0
12.0 - 16.0
17.0 - 21.0
22.5 - 27.5
Compressor high pressure kPa
740 - 840
950 - 1,050
1,160 - 1,300
1,360 - 1,550
Compressor low pressure kPa
150 - 190
190 - 240
240 - 300
300 - 375
LOW CHARGE
REFRIGERANT LEAK REPAIR

PROCEDURE
M1552001500266
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system (Refer to 355A).
2. Charge the system with approximately 550 g of
refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
CAUTION
Replacement filter-drier units must be sealed
while in storage. The drier used in these units
will saturate water quickly upon exposure to the
atmosphere. When installing a drier, have all
tools and supplies ready for quick assembly to
avoid keeping the system open any longer than
necessary.
6. Replace receiver drier.
7. Evacuate and charge system.
If the system has not lost all of its refrigerant charge;

locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.
HANDLING TUBING AND FITTINGS

Kinks in the refrigerant tubing or sharp bends in the
refrigerant hose lines will greatly reduce the capacity
of the entire system. High pressures are produced in
the system when it is operating. Extreme care must
be exercised to make sure that all connections are
pressure tight. Dirt and moisture can enter the
system when it is opened for repair or replacement of
lines or components. The following precautions must
be observed. The system must be completely
discharged before opening any fitting of connection
in the refrigeration system. Open fittings with caution
even after the system has been discharged. If any
pressure is noticed as a fitting is loosened, allow
trapped pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use the
correct line for the installation you are servicing. A
good rule for the flexible hose lines is keep the radius
of all bends at least 10 times the diameter of the
hose.
55A-54

ON-VEHICLE SERVICE
Sharper bends will reduce the flow of refrigerant. The

flexible hose lines should be routed so that they are
at least 80 mm from the exhaust manifold. It is good
practice to inspect all flexible hose lines at least once
a year to make sure they are in good condition and
properly routed.
On standard plumbing fittings with O-rings, these Orings are not reusable.
5. Recheck compressor noise as in Step 1.

6. If noise still exists, loosen compressor mounting
bolts and retighten. Repeat Step 1.
7. If noise continues, replace compressor and repeat
Step 1.
POWER RELAY CHECK

M1552008800280
BLOWER RELAY CONTINUITY CHECK
COMPRESSOR NOISE CHECK

M1552008700261
You must first know the conditions when the noise

occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or any
other special conditions.
Noises that develop during A/C operation can often
be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
caused by loose bolts, nuts, mounting brackets, or a
loose clutch assembly. Verify accessory drive belt
tension (power steering or alternator).
Improper accessory drive belt tension can cause a
misleading noise when the compressor is engaged
and little or no noise when the compressor is
disengaged.
Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the
compressor.
Blower relay
1 2 3
4
5
5
4
1
ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch the
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure), restrict
air flow through the condenser. Install a manifold
gauge set to make sure discharge pressure
doesnt exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt. Check
to assure clutch coil is tight (no rotation or
wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge (Refer to 355A).
AC212555 AB
Battery
voltage
Tester
connection
Specified
condition
Not applied
4-5
Open circuit
Connect
4-5
terminal 1 to
the positive
battery
terminal
Connect
terminal 3 to
the negative
battery
terminal
Less than 2
ohms
55A-55
ON-VEHICLE SERVICE
A/C COMPRESSOR RELAY CONTINUITY

CHECK
FAN CONTROL RELAY CONTINUITY

CHECK
Fan control relay
1
3
2
4
1
4
2
Front of
vehicle
AC212554 AB
AC212554AC
Battery
voltage
Tester
connection
Specified
condition
Battery
voltage
Tester
connection
Specified
condition
Not applied
1-4
Open circuit
Not applied
2-4
Open circuit
Connect
1-4
terminal 3 to
the positive
battery
terminal
Connect
terminal 2 to
the negative
battery
terminal
Less than 2
ohms
Connect
2-4
terminal 1 to
the positive
battery
terminal
Connect
terminal 3 to
the negative
battery
terminal
Less than 2
ohms
IDLE-UP OPERATION CHECK

M1552001600348
1. Before inspection and adjustment, set vehicle in

the following condition:
Engine coolant temperature: 80 - 90 C
Lamps, electric cooling fan and accessories: Set
to OFF
Transmission: Neutral ("N" or "P" for vehicles with
A/T)
Steering wheel: Straightforward
2. Check whether or not the idle speed is the
standard value. Refer to GROUP 13A, On-vehicle
Service - Basic Idle Speed Adjustment 313A
.
55A-56

ON-VEHICLE SERVICE
3. When the A/C is running after turning the A/C

switch to ON, and the blower switch to the 3(MH)
or 4(HI) position, check to be sure that the idle
speed is at the standard value.
NOTE: It is not necessary to make an adjustment,
because the idling speed is automatically
adjusted by the ISC system. If, however, a
deviation from the standard value occurs for some
reason, check the ISC system.
CLEAN AIR FILTER REPLACEMENT

PROCEDURE
M1552020100029
1. Remove the glove box. (Refer to GROUP 52A,

Instrument Panel 352A)
AC301365AC
2. Remove the two screws as shown, and replace

the clean air filter.
3. Install the glove box.

HEATER CONTROL ASSEMBLY AND A/C SWITCH
55A-57
HEATER CONTROL ASSEMBLY

AND A/C SWITCH
M1552002400314
Section A A
Instrument panel
Clip
Center cover
2
1
A
A
3
4
NOTE
: Clip position
>>B<<
1.
>>A<<
2.
3.
AC106926AB
Removal steps
Air mixing door control cable
connection
Mode selection damper control
cable connection
Knob
4.
5.

Centre panel
Manual air conditioner control panel
assembly
55A-58

>>A<< BLOWER VENT CHANGEOVER DAMPER
CABLE
Mode selection
damper link
2. Set the heater units air mix door lever to the MAX
HOT position (turn the damper lever as the left
illustration) and attach the cable.
3. Set the mode locator to the heater unit case and
secure with a clip.
INSPECTION
M1552014300682
BLOWER SWITCH CONTINUITY CHECK

Mode locator
DEF position
FACE position
1
4
AC106925AC
1. Set the heater control assemblys blower vent

changeover knob to the DEF position.
2. Set the heater units blower vent changeover
damper relay to the DEF position (turn the damper
relay to the left until it stops) and install the cable.
3. Set the mode locator to the heater unit case and
secure with a clip.
>>B<< AIR MIX DOOR CABLE CONNECTION
Air mix damper lever
2
5
3
6
AC100615AB
Switch
position
Tester connection
0 (OFF)
1 - 2, 2 - 4, 2 - 5, 2 - 6 Open circuit
1 (LO)
1-2
Less than 2
ohms
2 (ML)
2-4
Less than 2
ohms
3 (MH)
2-5
Less than 2
ohms
4 (HI)
2-6
Less than 2
ohms
Mode locator
MAX. COOL
position
MAX HOT position
AC106924 AC
1. Turn the heater control assemblys temperature

adjustment knob all the way to the HOT side.
Specified
condition
55A-59

M1552014200157
4
8
1
7
6
AC100614 AB
<<A>>
1.
2.
3.
4.
5.
<<A>>
6.
Disassembly steps
Switch panel
Rear window defogger switch
Air conditioner switch
Inside/outside air selection switch
cable
Air mixing damper control cable

<<A>> BLOW VENT CHANGEOVER DAMPER
CABLE AND AIR MIX DAMPER CABLE REMOVAL
(-) flat-tipped
screwdriver
Clip
claw
AC100619AB
Insert a flat-tipped screwdriver into the clip through

the inside of the control base and prize out the clip
claw to disconnect the cables.
7.
8.

Blower switch assembly
(A/C-ECU)
55A-60

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND

EVAPORATOR UNIT
M1552011600253
WARNING
When removing and installing the heater unit, do not let it bump against the SRS-ECU or the
components.
Refrigerant draining and Refilling (Refer to Charging
355A and Discharging 355A).
Engine coolant Draining and Refilling (Refer to GROUP
14, On vehicles service 314).
Instrument Panel Removal and Installation (Refer to
GROUP 52A, Instrument Panel 352A).
Air cleaner cover and air flow sensor assembly Removal
and Installation (Refer to GROUP 14, Air cleaner 315).
55A-61
-Pipe coupling
10
N
6, 7
12 2 Nm
11
O ring
A/C compressor oil:

SUN PAG 56
2
3
AC200906 AB
<<A>>
1.
2.
3.
4.
5.
6.
Removal steps
Intake duct
Joint duct
Blower assembly
Foot duct <front passengers side>
Heater hose connection
Liquid pipe B connection

<<A>> FLEXIBLE SUCTION HOSE AND LIQUID
PIPE B DISCONNECTION
CAUTION
As the compressor oil and receiver are highly
moisture absorbent, use a non-porous material
to plug the hose and nipples.
To prevent the entry of dust or other foreign bodies,
plug the dismantled hose and the nipples of the
expansion valves.
<<A>>

7. Flexible suction hose connection
8. O ring
9. Centre duct
10. Foot duct <drivers side>
11. Heater unit
55A-62
HEATER UNIT
M1551005400194
-Pipe coupling
2
8
3, 4
O ring
A/C compressor oil:

SUN PAG 56
5
3
1
AC106930 AC
1.
2.
3.
4.
5.
Disassembly steps
Evaporator cover
Heater core
Expansion valve
Joint
O ring
6.
7.
8.
9.

Evaporator
Air thermo sensor clip
Air thermo sensor
Heater case

55A-63
BLOWER ASSEMBLY
M1551005500168
3
AC301387AB
1.
2.
Disassembly steps
Outside/inside air selection damper
control motor
Hose
3.
4.
5.

Blower motor
Clean air filter
Blower case
55A-64
BLOWERMOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR
BLOWERMOTOR, RESISTOR AND OUTSIDE/INSIDE AIR

SELECTION DAMPER CONTROL MOTOR
M1551002800308
3
AC200968AB
1.
2.
Blower motor removal step

Blower motor
Resistor removal step
Glove box (Refer to GROUP 52A,
Resistor
3.
Outside/inside air selection

damper control motor removal
step
Outside/inside air selection damper
control motor
INSPECTION
M1551006300264
RESISTER CHECK
Standard value:
Measurement terminal
1 2
3 4
Standard value
(W)
Between terminals 2 and 4 2.54

(LO)
(ML)
(MH)
AC103700
Use an ohmmeter to measure the resistance

between the terminals. Check that the measured
value is at the standard value.

BLOWERMOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR
BLOWER FAN AND MOTOR CHECK
55A-65
OUTSIDE/INSIDE AIR SELECTION DAMPER

CONTROL MOTOR CHECK
CAUTION
INSIDE AIR
OUTSIDE AIR
AC100626 AB
When battery voltage is applied between the

terminals, check that the motor operates. Also, check
that there is no abnormal noise.
AC201501AB
Cut off the battery voltage when the damper is in

the inside/outside air position.
Lever position Battery
connection
Lever
operation
At the inside
position
Connect
terminal 7 to
the positive
battery
terminal
Connect
terminal 4 to
the negative
battery
terminal
The lever
moves from the
inside position
to the outside
position
At the outside
position
Connect
terminal 7 to
the positive
battery
terminal
Connect
terminal 6 to
the negative
battery
terminal
The lever
moves from the
outside position
to the inside
position
55A-66
EVAPORATOR ASSEMBLY
EVAPORATOR ASSEMBLY
M1552003600184

Section A A
Clip
Front floor
console lower
side cover
Section B B
Clip
-Pipe coupling
Front floor
console lower
side cover
11
1, 2, 4, 5
12
2
B
A
<<A>>
<<A>>
<<A>>
<<A>>
<<A>>
1.
2.
3.
4.
5.
6.
12 2 Nm
6N
6N
NOTE
: Clip position
O ring
A/C compressor oil:

SUN PAG 56
6N
3
13
10
Removal steps
Flexible suction hose connection
Liquid pipe B connection
Expansion valve cover
Expansion valve
Joint
O ring
Instrument Panel 352A, 352A
).
7
7.
8.
9.
10.
11.
12.
13.
AC200376AC

Joint duct
Foot duct <drivers side>
Front floor console lower side cover
Evaporator cover
Air thermo sensor clip
Air thermo sensor
Evaporator
55A-67
EVAPORATOR ASSEMBLY

PIPE B DISCONNECTION
INSPECTION
M1552014300693
AIR THERMO SENSOR INSPECTION
CAUTION
plug the dismantled hose and the nipples of the
expansion valves.
Outlet
Inlet
RESISTANCE
25
(k)
20
15
10
5
0
-10 0 10 20 30 40
TEMPERATURE (C)
AC100770 AB
INLET SIDE
Measure the resistance between connector terminals
1 and 3 under at least two different temperatures.
The resistance values should generally match those
in the graph.
NOTE: . The temperature at the check should not
exceed the range in the graph.
OUTLET SIDE
Measure the resistance between connector terminals
4 and 5 under at least two different temperatures.
The resistance values should generally match those
in the graph.
NOTE: The temperature at the check should not
exceed the range in the graph.
55A-68
COMPRESSOR ASSEMBLY AND TENSION PULLEY

M1552004100223
Refrigerant Discharging (Refer to 355A).
Drive Belt Tension Adjustment (Refer to GROUP 11A, Onvehicles Service - Drive Belt Tension Check 311A).
Refrigerant Charging (Refer to 355A).
6
-Pipe coupling
1, 2
O ring
A/C compressor oil:

SUN PAG 56
1
12 2 Nm
AC300862 AB
<<A>>
<<A>>
1.
2.
3.
Removal steps
<>
Flexible suction hose connection
Flexible discharge hose connection <<C>>
O ring
>>A<<
4.
5.
6.

Drive belt
A/C compressor
A/C compressor bracket

<<A>> FLEXIBLE SUCTION HOSE AND
FLEXIBLE DISCHARGE HOSE DISCONNECTION
Auto-tensioner
CAUTION
plug the dismantled hoses and compressor nipples.
<> DRIVE BELT REMOVAL
Hole B
Hole A
AC107640AC


CAUTION
Auto-tensioner
L-shaped
hexagon
wrench
AC107641AB

drive belt.
<<C>> COMPRESSOR REMOVAL
Take care not to spill any compressor oil when
removing the compressor.

>>A<< A/C COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the
amount of oil according to the procedures described
below, and then install the compressor.
1. Measure the amount (X mL) of oil within the
removed compressor.
55A-69
2. Drain (from the new compressor) the amount of oil

calculated according to the following formula, and
then install the new compressor.
New compressor oil amount = 120 mL
120 mL-X mL = Y mL
NOTE: Y mL indicates the amount of oil in the
refrigerant line, the condenser, the evaporator, etc.
NOTE: When replacing the following parts at the
same times as the compressor, subtract the rated oil
amount of the each part from Y mL and discharge
from the new compressor.
Quantity:
Evaporator: 60 mL
Condenser: 15 mL
Suction hose: 10 mL
Receiver: 10 mL
INSPECTION
M1552014300701
COMPRESSOR MAGNETIC CLUTCH

OPERATION CHECK
Magnetic cluch
connector
AC005671AC
Connect the compressor connector terminal to the

battery positive (+) terminal and earth the batterys
negative (-) terminal to the compressor unit. At that
time, the magnetic clutch should make a definite
operating sound.
55A-70

M1552004600381
10
3N
8
7
6
4
16 1 Nm
1.
2.
3.
<<A>>
11
>>D<<
>>C<<
4.
AC100630 AB
Cooling temperature switch

disassembly steps
Snap ring
Refrigerant temperature switch
O ring
Magnetic clutch disassembly
Air gap adjustment
Self-locking nut
>>B<<
>>A<<
5.
6.
7.
8.
9.
10.
11.
Magnetic clutch disassembly

Armature
Snap ring
Rotor
Snap ring
Field core
Shim
A/C compressor
<<A>> SELF-LOCKING NUT REMOVAL
>>A<< FIELD CORE ATTACHMENT
MB991386
Field core projection
MB991367
Compressor
unit pin hole
AC100633 AB
Use the special tools to remove the self-locking nut.

Pin (MB991386)
AC100634 AB
Line up the pin hole on the compressor unit with the

field core projection and attach.
55A-71
>>B<< SNAP RING INSTALLATION
INSPECTION
M1552014300712
Snap ring
Clutch coil
Rotor
REFRIGERANT TEMPERATURE SWITCH

CAUTION
Do not heat more than necessary.
Tapered part
AC001412 AB
Thermometer
Using snap ring pliers, fit the snap ring so that the
snap rings tapered part is on the outside.
Engine oil
>>C<< SELF-LOCKING NUT INSTALLATION

AC100787 AB
MB991386
MB991367
1. Dip the metal part of the cooling temperature

switch into engine oil and increase the oil
temperature using a gas burner or similar.
120C
150C
Contiunity
No continuity
AC100633 AB
Use the special tools to install the self-locking nut.

Pin (MB991386)
Oil temprature
AC100810 AD
>>D<< AIR GAP ADJUSTMENT
2. When the oil temperature reaches the standard

value, check that voltage is supplied between the
terminals.
Standard value:
Thickness
gauge
AC100637AB
Apply voltage from the battery to the magnetic clutch

and check that the clutch air gap is inside the
standard value. If outside the standard value, use a
shim to adjust the gap.
Item
Temperature
Less than 2
ohms
Slightly below 150C
No continuity
150C or more
NOTE: When the oil temperature is 150C or

more and there is no continuity, the resistance will
not be 2W or lower until the oil temperature
reduces to 120C or less.
55A-72
CONDENSER AND CONDENSER FAN MOTOR

M1552006700351

-Pipe coupling
12
10
11
4.9 0.9 Nm
2
1, 2
O ring
A/C compressor oil:
SUN PAG 56
1
N
13
6
5
7N
4
AC300948 AC
<<A>>
<<A>>
>>A<<
1.
2.
3.
4.
5.
6.
7.
8.
Condenser removal steps

Liquid pipe A connection
Flexible discharge hose connection
O ring
Condenser assembly
Receiver
Clamp
O ring
Condenser
9.
10.
11.
12.
13.
Fan shroud assembly removal

steps
Fan shroud assembly
Fan
Fan motor
Fan shroud
Air guide panel removal steps
Front bumper (Refer to 51, Front
bumper 351).
Air guide panel


PIPE A DISCONNECTION
CAUTION
plug the dismantled hose and condenser assembly
nipples.
55A-73
INSPECTION
M1552014300723
CONDENSER FAN MOTOR CHECK

1
2

>>A<< CONDENSER INSTALLATION
When replacing the condenser, refill it with a
specified amount of compressor oil and install it. (to
the vehicle).
Quantity: 15 mL
AC103523 AC
Check to be sure that the condenser fan motor

operates when battery voltage is applied to terminal
2 and terminal 1 earthed.
55A-74
REFRIGERANT LINE
REFRIGERANT LINE
M1552006400372

Refrigerant Draining and Refilling (Refer to Charging and
Discharging 355A).
Radiator Grille Removal and Installation (Refer to
GROUP 51, Radiator Grille 351).
7N
-Pipe coupling
13 1 Nm
Low-pressure side
service valve
Hign-Pressure
Side Service Valve
5
1, 2, 3, 5, 6
7N
O-ring
6
4.9 0.9 Nm
2
1
7N
O-ring
12 2 Nm
A/C compressoroil:
SUN PAG 56
25 4 Nm
7N
<<A>>
<<A>>
<<A>>
>>A<<
1.
2.
3.
4.
Removal steps
Flexible discharge hose
Flexible suction hose
Liquid pipe B
Evaporator cover
AC301420 AB
<<A>>
<<A>>
5.
6.
7.

Liquid pipe A
A/C pressure sensor
O ring
<<A>> HOSE/PIPE DISCONNECTION
>>A<< SUCTION HOSE INSTALLATION

When replacing the suction hose, refill them with a
specified amount of compressor oil, and then install
them.
Quantity: Suction hose: 10 cm3
CAUTION
To prevent the entry of other foreign bodies, plug the
condenser, compressor, and expansion valve
nipples.
55A-75
VENTILATORS
VENTILATORS
M1553001600307
3
1
4
5
9
8
10
AC106927AB
1.
2.
3.
Defroster nozzle and distribution

duct removal steps
Instrument panel (Refer to 52A
352A.)
Side defroster duct
Defroster nozzle
Distribution duct
4.
5.
6.
Foot duct and rear heater duct

removal steps
Under cover (Refer to GROUP
52A, Instrument panel 352A.)
Rear heater duct A <drivers side>
Rear heater duct B upper side
<drivers side>
55A-76

VENTILATORS
Foot duct and rear heater duct
removal steps&RQWLQXHG

7. Foot duct <front passengers side>
10. Rear heater duct A <front
passengers side>
Floor carpet
Front seat assembly (Refer to

GROUP 52A, Front seat assembly
352A.)

GROUP 52A, Floor console 352A
.)
11. Rear heater duct B lower side
<drivers side>
12. Rear heater duct B <front
passengers side>
CROSS-SECTION A-A
13
13
A
A
A
A
AC101905AD
Rear ventilation duct removal

steps
Rear bumper assembly (Refer to

GROUP 51, Rear bumper 351.)
13. Rear ventilation duct
55-1
GROUP 55
HEATER, AIR
CONDITIONER AND
VENTILATION
00
11
12
13
14
15
16
17
CONTENTS
21
22
HEATER, AIR CONDITIONER AND VENTILATION . . . . . . . . . 55A
25
26
AUTOMATIC AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . 55B
27
31
32
33
34
35
36
37
42
51
52
54
55
127(6
55B-1
GROUP 55B
00
11
AUTOMATIC AIR
CONDITIONER
12
13
14
15
16
CONTENTS
17
SPECIAL TOOL . . . . . . . . . . . . . . . . .
55B
55B
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
55B
55B
SENSORS . . . . . . . . . . . . . . . . . . . . . . 55B
AUTOMATIC AIR CONDITIONER
PANEL ASSEMBLY (A/C-ECU) . . . .
HEATER UNIT . . . . . . . . . . . . . . . . . .
55B
55B
55B
55B
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
55B
EVAPORATOR ASSEMBLY . . . . . . . 55B
55B
DISASSEMBLY AND REASSEMBLY. . . . .
55B
AIR MIXING DOOR MOTOR, AIR

OUTLET CHANGEOVER DAMPER
MOTOR AND BLOWER MOTOR . . . 55B
22
25
26
27
55B
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
55B
31
AMBIENT TEMPERATURE SENSOR 55B
32
55B
21
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
55B
33
OTHER PARTS. . . . . . . . . . . . . . . . . . 55B
34
OTHER PARTS . . . . . . . . . . . . . . . . . . . . . .
55B
35
36
37
42
51
52
54
55
55B-2
M1554000300083
Item
Standard value
Resistance value for air mixing damper control motor

and potentiometer kW
MAX HOT
Approximately 5.35
MAX COOL
Approximately 0.65
Resistance value for mode selection damper control

motor and potentiometer kW
DEF position
Approximately 0.65
FACE position
Approximately 5.35
SPECIAL TOOL
M1555000600054
Tool
Number
Name
Use
MB991502
MUT-II subassembly
Automatic A/C check
MB991529
Diagnosis code
check harness
Automatic A/C check with a

voltmeter
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe

connector
contact pressure
circuit
circuit
D: For connecting a locally sourced
tester
B991502
MB991529
MB991223
55B-3
TROUBLESHOOTING
TROUBLESHOOTING
DIAGNOSIS FUNCTION
M1554004800121
M1554004700102

How to read diagnosis code

Connect the MUT-II to the 16-pin diagnosis
connector to read diagnosis code (Refer to GROUP
00, How to Use Troubleshooting/Inspection Service
Points 300).
How to erase diagnosis code


M1554004900140
Code No.
Diagnostic item
Reference page
11
Interior temperature senor system (open circuit)
355B
12
Interior temperature sensor system (short circuit)
13
Outside thermo sensor system (open circuit)
14
Outside thermo sensor system (short circuit)
15
Heater water temperature sensor system (open circuit)
16
Heater water temperature sensor system (short circuit)
21
Air thermo sensor system (open circuit)
22
Air thermo sensor system (short circuit)
31
Air mixing damper control motor and potentiometer sensor system
355B
32
Mode selection damper control motor and potentiometer sensor

system
355B
41
Air mixing damper control motor and potentiometer activating

system
355B
42
Mode selection damper control motor and potentiometer activating 355B

system
355B
355B
355B
55B-4

TROUBLESHOOTING

PROCEDURES
Diagnosis code No.11, 12: Interior temperature sensor system
Interior Temperature Sensor Circuit

A/C-ECU
INTERIOR
TEMPERATURE
SENSOR
Wire colour code


This code is set when the interior temperature sensor
circuit is open (Code No.11) or is short (Code No.12).
Possible causes
Malfunction of the interior temperature sensor
Malfunction of the auto air conditioner control
panel (A/C-ECU)
SB : Sky blue
DIAGNOSIS
Step 1. Check the interior temperature sensor.
Refer to 355B.
YES : Go to Step 2.
NO : Replace the interior temperature sensor.

TROUBLESHOOTING
Step 2. Connector check: C-27 A/C-ECU

connector and C-127 interior temperature sensor
connector
Connector: C-27
55B-5

A/C-ECU connector (terminals 1 and 20) and C127 interior temperature sensor connector
Connector: C-27
C-27(B)
C-27(B)
Harness side
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
Connector: C-127
Connector: C-127
Harness side
Harness side
2 1
2 1
AC301395 AM
AC301395 AM

YES : Go to Step 3.
Check the sensor signal line and earth line for

YES : Replace the auto air conditioner control
panel (A/C-ECU)
55B-6
TROUBLESHOOTING
Diagnosis code 13, 14: Outside thermo sensor system
Outside Thermo Sensor Circuit

A/C-ECU
OUTSIDE
THERMO
SENSOR
Wire colour code


This code is set when the outside thermo sensor
circuit is open (Code No.13) or is short (Code No.14).
SB : Sky blue
Step 2. Connector check: A-18 outside thermo

Connector: A-18
Possible causes
Malfunction of the outside thermo sensor
Damaged the wiring harness and connectors
panel (A/C-ECU)
DIAGNOSIS
Harness side
A-18(BR)
Step 1. Check the outside thermo sensor.

Refer to 355B.
YES : Go to Step 2.
NO : Replace the outside thermo sensor.
AC301653AC
Connector: C-27
C-27(B)
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS

YES : Go to Step 3.

TROUBLESHOOTING

outside thermo sensor connector (terminals 1
and 2) and C-27 A/C-ECU connector (terminals 20
and 7).
Connector: A-18
Harness side
A-18(BR)
AC301653AC
Connector: C-27
C-27(B)
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
NOTE:
Connector: C-116
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG

necessary.
panel (A/C-ECU)
55B-7
55B-8
TROUBLESHOOTING
Diagnosis code 15, 16: Heater water temperature sensor system
Heater Water Temperature Sensor Circuit

HEATER WATER
TEMPERATURE
SENSOR
A/C-ECU
Wire colour code


This code is set when the heater water temperature
sensor circuit is open (Code No.15) or is short (Code
No.16).
Possible causes
Malfunction of the heater water temperature
sensor
panel (A/C-ECU)
SB : Sky blue
DIAGNOSIS
Step 1. Check the heater water temperature
sensor.
Refer to 355B.
YES : Go to Step 2.
NO : Replace the heater water temperature
sensor.
55B-9
TROUBLESHOOTING

connector and C-314 heater water temperature
connector
Connector: C-27

A/C-ECU connector (terminals 4 and 20) and C314 heater water temperature sensor connector
C-27(B)
C-27(B)
C-36
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
Connector: C-314
C-36
1 2
3 4 5
6 7 8 9 10 11 12 13
Harness side
1
2
Harness side
C-27
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301544 AB

YES : Go to Step 3.
AC301398 AO
Connector: C-314
Harness side
1
2
AC301544 AB

panel (A/C-ECU)
55B-10
TROUBLESHOOTING
Diagnosis code 21, 22: Air thermo sensor system
Air Thermo Sensor Circuit

HEATER WATER
TEMPERATURE
SENSOR
AIR THERMO
SENSOR
A/C-ECU
Wire colour code


This code is set when the air thermo sensor circuit is
open (Code No.21) or is short (Code No.22).
Possible causes
panel (A/C-ECU)
SB : Sky blue
DIAGNOSIS
Step 1. Check the air thermo sensor.
Refer to 355B.
YES : Go to Step 2.

TROUBLESHOOTING

connector and C-316 air thermo sensor
connector
Connector: C-27
C-27(B)
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
Connector: C-316
Harness side
1
2
AC301544 AC

YES : Go to Step 3.
55B-11
55B-12
TROUBLESHOOTING

A/C-ECU connector (terminals 8 and 20) and C316 air thermo sensor connector (terminals 1 and
2).

panel (A/C-ECU)
C-27(B)
C-36
C-36
1 2
3 4 5
6 7 8 9 10 11 12 13
Harness side
C-27
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301398 AO

C-314
C-316
Harness side
C-314
C-316
1
2
1
2
AC301545 AB

intermediate connector C-36 and heater water
temperature sensor connector C-314, and repair if
necessary.
55B-13
TROUBLESHOOTING
Diagnosis code 31: Air mixing damper control motor potentiometer system
Air Mixing Damper Control Motor Potentiometer Circuit

MODE SELECTION DAMPER
CONTROL MOTOR AND
POTENTIOMETER
AIR MIXING DAMPER

CONTROL MOTOR AND
POTENTIOMETER
HEATER WATER
TEMPERATURE
SENSOR
A/C-ECU
Wire colour code


This code is set when the air mixing damper control
motor potentiometer does not send any signal to the
A/C-ECU due to short or open circuit.
Possible causes
Malfunction of the air mixing damper control
motor and potentiometer
panel (A/C-ECU)
SB : Sky blue
DIAGNOSIS
Step 1. Check the air mixing damper control
motor and potentiometer.
Refer to 355B.
YES : Go to Step 2.
NO : Replace the air mixing damper control
55B-14
TROUBLESHOOTING

connector and C-313 air mixing damper control
motor and potentiometer connector
Connector: C-27
C-27(B)
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
Connector: C-313
Harness side
1
2
6 5 4 3
AC301544 AD

YES : Go to Step 3.

TROUBLESHOOTING

A/C-ECU connector (terminals 10, 5 and 20) and
C-313 air mixing damper control motor and
potentiometer connector (terminals 2, 5 and 6).
Check the potentiometer power supply, earth and

signal line for open or short circuit.
panel (A/C-ECU).
C-27(B)
C-36
C-36
1 2
3 4 5
6 7 8 9 10 11 12 13
Harness side
C-27
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301398 AO
C-315
C-313
C-314
Harness side
C-313
2
1
6 5 4 3
C-314
1
2
C-315
1
2
6 5 4 3
AC301545 AC

intermediate connector C-36, mode selection
damper control motor and potentiometer connector
C-315 and heater water temperature sensor
55B-15
55B-16
TROUBLESHOOTING
Diagnosis code 32: Mode selection damper control motor potentiometer system
Mode Selection Damper Control Motor Potentiometer Circuit

MODE SELECTION
DAMPER CONTROL
MOTOR AND
POTENTIOMETER
HEATER WATER
TEMPERATURE
SENSOR
A/C-ECU
Wire colour code


This code is set when the mode selection damper
control motor potentiometer does not send any
signal to the A/C-ECU due to short or open circuit.
SB : Sky blue

connector and C-315 mode selection damper
control motor and potentiometer connector
Possible causes
Malfunction of the mode selection damper control
panel (A/C-ECU)
DIAGNOSIS
Connector: C-27
C-27(B)
Harness side
Step 1. Check the mode selection damper control

Refer to 355B.
YES : Go to Step 2.
NO : Replace the mode selection damper control
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
Connector: C-315
Harness side
1
2
6 5 4 3
AC301544 AE
YES : Go to Step 3.

TROUBLESHOOTING

A/C-ECU connector (terminals 10, 6 and 20) and
C-315 mode selection damper control motor and
potentiometer connector (terminals 2, 5 and 6).
Check the potentiometer power supply, earth and

signal line for open or short circuit.
YES : Malfunction of the auto air conditioner
control panel (A/C-ECU)

C-27(B)
C-36
C-36
1 2
3 4 5
6 7 8 9 10 11 12 13
Harness side
C-27
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301398 AO
C-315
C-314
Harness side
C-314
C-315
1
2
2
1
6 5 4 3
AC301545 AD

intermediate connector C-36 and heater water
temperature sensor connector C-314, and repair if
necessary.
55B-17
55B-18
TROUBLESHOOTING
Diagnosis code 41: Air mixing damper control motor system
Air MIxing Damper Control motor Circuit

AIR MIXING DAMPER CONTROL
MOTOR AND POTENTIOMETER
A/C-ECU
MOTOR
DRIVE CIRCUIT
Wire colour code


This code is set when the air mixing damper cannot
be rotated to the preset opening angle.
Possible causes
Malfunction of the air mixing damper control
panel (A/C-ECU)
DIAGNOSIS
Step 1. Check the air mixing damper control
Refer to 355B.
YES : Go to Step 2.
NO : Replace the air mixing damper control
SB : Sky blue

connector and C-313 air mixing damper control
motor and potentiometer connector
Connector: C-26
C-26(B)
Harness side
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301397 AV
Connector: C-313
Harness side
1
2
6 5 4 3
AC301544 AD

YES : Go to Step 3.

TROUBLESHOOTING

A/C-ECU connector (terminals 22 and 25) and C313 air mixing damper control motor and
potentiometer connector (terminals 3 and 1).
C-36
C-26(B)
C-36
1 2
3 4 5
6 7 8 9 10 11 12 13
Harness side
C-26
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301398 AP
Connector: C-313
Harness side
1
2
6 5 4 3
AC301544 AD

Check the motor activating lines for open or short
circuit.
YES : Malfunction of the auto air conditioner
control panel (A/C-ECU).

55B-19
55B-20
TROUBLESHOOTING
Diagnosis code 42: Mode selection damper control motor system
Mode Selection Damper Control Motor And Potentiometer Circuit

MODE SELECTION DAMPER CONTROL
MOTOR AND POTENTIOMETER
A/C-ECU
MOTOR
DRIVE CIRCUIT
Wire colour code


This code is set when the mode selection damper
cannot be rotated to the preset opening angle.
Possible causes
Malfunction of the mode selection damper control
panel (A/C-ECU)
DIAGNOSIS
Step 1. Check the mode selection damper control
Refer to 355B.
YES : Go to Step 2.
NO : Replace the mode selection damper control
SB : Sky blue

connector and C-315 mode selection damper
control motor and potentiometer connector
Connector: C-26
C-26(B)
Harness side
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301397 AV
Connector: C-315
Harness side
2
1
6 5 4 3
AC301544 AE

YES : Go to Step 3.

TROUBLESHOOTING

A/C-ECU connector (terminals 21 and 24) and C315 mode selection damper control motor and
potentiometer connector (terminals 3 and 1).
C-36
C-26(B)
C-36
1 2
3 4 5
6 7 8 9 10 11 12 13
Harness side
C-26
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301398 AP
Connector: C-315
Harness side
2
1
6 5 4 3
AC301544 AE

circuit.
panel (A/C-ECU).
55B-21
55B-22
TROUBLESHOOTING

M1554005000140
Symptom
Inspection procedure
number
Reference page
Communication with the MUT-II is not possible.
355B
The air conditioner does not work at all.
355B
A/C outlet air temperature cannot be set.
355B
The blower does not work.
355B
The blower air volume cannot be changed.
355B
When sunlight intensity changes, air outlet temperature

does not change.
355B
The A/C indicator flashes.
355B
The inside/outside air changeover is impossible.
355B
Defogger function does not operate.
355B
Malfunction of the A/C-ECU power supply system.
10
355B
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Communication with the MUT-II is not possible.
Data Link Connector Circuit

A/C-ECU
DIAGNOSIS
CONNECTOR
FRONT SIDE
Wire colour code

SB : Sky blue
55B-23
TROUBLESHOOTING

If communication with all other systems is not
possible, there is a high possibility that there is a
malfunction of the diagnosis line. If only the A/C
system can not communicate with the MUT-II, the
diagnosis line between the A/C-ECU and the
diagnosis connector may be defective.
Possible causes
panel (A/C-ECU)
DIAGNOSIS

A/C-ECU connector (terminal 17 and 18) and C-24
diagnosis connector (terminal 11 and 1).
Connector: C-24
Harness side
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
C-24(B)
Step 1. Check the communication with other

systems.
Q: Is the communication with the other systems
possible using the MUT-II?
YES : Go to Step 2.
NO : Check the diagnosis line using the MUT-II,
AC301395 AF
Connector: C-27
C-27(B)

STEP 2. Check operations of the air conditioner,
defogger and outside/inside air selection damper
control motor.
Q: Does the air conditioner, defogger or outside/
inside air selection damper control motor operate?
YES : Go to Step 3.

system 355B."
connector and C-24 diagnosis connector
Connector: C-24
Harness side
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
C-24(B)
AC301395 AF
Connector: C-27
C-27(B)
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS

YES : Go to Step 4.
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
Check the communication lines for open or short

circuit.
panel (A/C-ECU).
55B-24
TROUBLESHOOTING
INSPECTION PROCEDURE 2: The air conditioner does not work at all.
A/C Compressor Circuit

IGNITION
SWITCH (IG2)
BATTERY
A/C PRESSURE
SENSOR
RELAY
BOX
A/C
COMPRESSOR
RELAY
ENGINE-ECU
A/C
REFRIGERANT
TEMPERATURE
SWITCH
MAGNETIC
CLUTCH
A/C
COMPRESSOR
ASSEMBLY
A/C-ECU
Wire colour code

CIRCUIT OPERATION
If cool air is not distributed when the A/C switch is on,
A/C compressor relay system may be defective.
Possible causes
Improper amount of refrigerant
SB : Sky blue

Malfunction of the A/C compressor relay
Malfunction of the magnetic clutch
Malfunction of the A/C refrigerant temperature
switch
55B-25
TROUBLESHOOTING

panel (A/C-ECU)
DIAGNOSIS
STEP 5. Measure the voltage at B-27 A/C

compressor connector.
Connector: B-27

code.
On completion, check that the diagnosis code is not
reset.
Harness side
1

YES : Go to Step 2.
NO : Refer to diagnosis code chart 355B.
B-27(B)
AC301648 AB
Step 2. Check the blower operation.

(2) Blower knob: Other than OFF
(3) Check that the air comes out of the blower.

Connector: C-134

YES : Go to Step 3.
NO : Refer to Inspection Procedure 4 "The blower
does not work."

YES : Go to Step 4.
Harness side
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
AC301397AO

earth terminal 8.

system 355B."
STEP 4. Check the A/C compressor.
Check the A/C compressor for compressor oil leaks.
Q: Is the check result satisfactory?
YES : Go to Step 5.
NO : Replace the A/C compressor or the
Connector B-27
(Harness side)
expansion valve.
AC301541BU
(4) Voltage between terminal 1 and body earth.

OK: System voltage
NO : Go to Step 6.
STEP 6. Check the A/C compressor relay

continuity.
Refer to GROUP 55A, On vehicle service, power
relay 355A.
Q: Is the A/C compressor relay in good condition?
YES : Go to Step 7.
NO : Replace the A/C compressor relay.
55B-26
TROUBLESHOOTING

Connector: B-18X

Connector: B-18X
Relay box side
Relay box side
B-18X
B-18X
Front of
vehicle
Front of
vehicle
AC301483 AG
(1) Remove the relay, and measure at the relay block

side.
Connector B-18X
(Relay box side)
2
Front of
vehicle
AC301541BV

OK: System voltage
NO : Go to Step 8.
AC301483 AG

YES : Go to Step 9.
55B-27
TROUBLESHOOTING
STEP 9. Check the wiring harness between B-18X

A/C compressor relay connector terminal No.3
NOTE:
Connector: C-106
Connector: B-18X
C-106(GR)
2
1
3 4
5 6
10 11 12
7 8 9
16
13 14 15 17 18 19
AC301397AG

C-203
Relay box side
B-18X
2
C-202
Front of
vehicle
AC301483 AG
Harness side
C-202
6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-203
2
1
6 5 4 3
AC210475 AG

block connectors C-203, C-202 and intermediate

55B-28
TROUBLESHOOTING

Connector: B-18X

Connector: B-18X
Relay box side
Relay box side
B-18X
B-18X
Front of
vehicle
Front of
vehicle
AC301483 AG
(1) Remove the relay, and measure at the relay block

side.
Connector B-18X
(Relay box side)
2
Front of
vehicle
AC301541BW

OK: System voltage
NO : Go to Step 11.
AC301483 AG

55B-29
TROUBLESHOOTING
No.4 and the battery.
Connector: B-18X

compressor relay connector and B-27 A/C
compressor connector
Connector: B-18X
Relay box side
Relay box side
B-18X
B-18X
Front of
vehicle
Front of
vehicle
AC301483 AG
NOTE:
AC301483 AG
Connector: B-27
Connector: A-14
Harness side
A-14(GR)
1 2 3 4 5 6 7
8 9
10 11
15
14
12 13
16 17
B-27(B)
AC301648 AB
AC301653AB

YES : Check that the air conditioner works
normally.
NO : Repair the wiring harness. Check that the
air conditioner works normally.

55B-30
TROUBLESHOOTING
No.1 and B-27 A/C compressor connector
terminal No.1.

connector and B-18X A/C compressor relay
connector
Connector: C-134
Connector: B-18X
Harness side
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
AC301397AO
Connector: B-18X
Relay box side

B-18X
2
Front of
vehicle
AC301483 AG
Connector: B-27
Relay box side

B-18X
Harness side
1
Front of
vehicle
AC301483 AG
B-27(B)
AC301648 AB

Check the A/C compressor relay earth line for

open circuit.
55B-31
TROUBLESHOOTING
STEP 16. Check the wiring harness between C134 engine-ECU connector terminal No.8 and B18X A/C compressor relay connector terminal
No.2.

connector.
Connector: B-18X
C-134
C-26(B)
Harness side
C-26
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
C-134
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
Relay box side

B-18X
2
Front of
vehicle
AC301398 BA
AC301483 AG
Connector: C-134

earth terminal 8.
Connector C-26
(Harness side)
Harness side
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301397AO


AC301541CP
(4) Continuity between terminal 33 and body earth.

OK: System voltage
NO : Go to Step 18.
55B-32
TROUBLESHOOTING

compressor relay connector and C-26 A/C-ECU
connector
Connector: B-18X
Relay box side

B-18X
2
Front of
vehicle
AC301483 AG
Connector: C-26
C-26(B)
Harness side
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301397 AV


TROUBLESHOOTING
No.1 and C-26 A/C-ECU connector terminal
No.33.
55B-33


Connector: B-18X
STEP 20. Check the magnetic clutch operation.

Refer to 355A.
Q: Can the sound of the magnetic clutch (click) be
heard?
NO : Replace the compressor magnet clutch.
STEP 21. Check the refrigerant temperature

switch.
Refer to 355A.
Relay box side
Q: Is the refrigerant temperature switch operating

properly?
NO : Replace the refrigerant temperature switch.
B-18X
2
Front of
vehicle

Refer to 355A.
AC301483 AG

NO : Correct the refrigerant level (Refer to On-
vehicle Service 355A).

operation.
Refer to 355A.
C-26(B)

C-104(B)
C-104
1 2 3
4 5 6 7
8 9 10 1112 13 1415 16
Harness side
C-26
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301398 AQ

necessary.
Check the A/C compressor relay output line for
open circuit.
55B-34
TROUBLESHOOTING

Connector: A-02
A-02(B)
STEP 25. Check the wiring harness between A-02

A/C pressure sensor connector terminal No.2
and C-27 A/C-ECU connector terminal No.11.
Connector: A-02
A-02(B)
Harness side
Harness side
3 2 1
3 2 1
AC301656 AB
AC301656 AB
Connector: C-27
Connector: C-27
C-27(B)
C-27(B)
Harness side
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS

NOTE:
Connector: C-116
1 2
5 6 7
3 4
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG

necessary.
Check the A/C pressure sensor signal line for
open circuit.
55B-35
TROUBLESHOOTING
STEP 26. Connector check: C-134, C-135 engineECU connector and C-26 A/C-ECU connector
STEP 27. Check the wiring harness between C134 engine-ECU connector terminal No.24 and C26 A/C-ECU connector terminal No.32.

C-135
C-134
C-26(B)
C-134
C-26(B)
C-104(B)
Harness side
C-104
C-26
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
C-134
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
Harness side
C-26
C-135
JAE-E
38 37 36 35 34 33 32 31
46 45 4443 42 41 4039
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
C-134
JAE-E
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 1918 17 16 15 14
AC301398 AR
AC301398 BB


necessary.
Check the communication line for open circuit.
55B-36
TROUBLESHOOTING
STEP 28. Check the wiring harness between C135 engine-ECU connector terminal No.45 and C26 A/C-ECU connector terminal No.34.
C-135
C-26(B)
C-104(B)
C-104
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
Harness side
C-135
C-26
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
JAE-E
38 37 36 35 34 33 32 31
46 45 4443 42 41 4039
AC301398 BC

necessary.
YES : Replace the A/C-ECU or engine-ECU.
INSPECTION PROCEDURE 3: A/C outlet air temperature cannot be set.

When the blower air temperature can not be changed
even if the preset temperature is changed, the
sensors, the air mixing damper control motor and
potentiometer or the A/C-ECU may be defective.
Possible causes
Malfunction of the A/C-ECU
DIAGNOSIS
Read diagnosis code by using the MUT-II.
NO : Replace the auto air conditioner control
panel (A/C-ECU).

TROUBLESHOOTING
55B-37
INSPECTION PROCEDURE 4: The blower does not work.

FUSIBLE
LINK 1
IGNITION
SWITCH (IG2)
BLOWER
RELAY
BLOWER
LINEAR
CONTROLLER
A/C-ECU

If the blower motor does not operate, the blower
motor circuit system may be defective.
Possible causes
Malfunction of the blower motor (blower linear
controller).
panel (A/C-ECU)
Wire colour code

DIAGNOSIS
Step 1. MUT-II actuator test
Carry out the actuator test.
Item 01, 02, 03, 04: Blower motor
panel (A/C-ECU).
NO : Go to Step 2.
55B-38
TROUBLESHOOTING
Step 2. Measure the voltage at the C-32 blower

linear controller connector.
Step 4. Measure the voltage at C-207 blower relay

connector.
Connector: C-207
Connector: C-32
Harness side
Junction block side

3 2 1
4
5
2
1
6 5 4 3
AC301397 AT

Connector C-32
(Harness side)
AC210474 AJ

block side.
Connector C-207
2
1
6 5 4 3
3 2 1
4
5
AC301541CI

body earth.
OK: System voltage
NO : Go to Step 3.
Step 3. Check the blower relay.

Refer to GROUP 55A, On-vehicle Service - Power
relay check 355A.
AC301541CB

OK: System voltage
YES : Go to Step 7.
NO : Go to Step 5.
Step 5. Connector check: C-207 blower relay

connector
Connector: C-207
Q: Is the blower relay in good condition?

YES : Go to Step 4.
NO : Replace the blower relay.
Junction block side
3 2 1
4
5

YES : Go to Step 6.
AC210474 AJ
55B-39
TROUBLESHOOTING

blower relay connector terminal No.1 and the
Step 7. Measure the voltage at C-207 blower relay

connector.
Connector: C-207
C-203
Junction block side

3 2 1
4
5
C-207
AC210474 AJ

block side.
Harness side
Junction block side
C-203
C-207
2
1
6 5 4 3
3 2 1
4
5
Connector C-207
3 2 1
4
5
AC210475 AS
AC301541CD

necessary.
circuit.


OK: System voltage
NO : Go to Step 8.

connector
Connector: C-207
Junction block side

3 2 1
4
5

YES : Go to Step 9.
AC210474 AJ
55B-40
TROUBLESHOOTING

blower relay connector terminal No.5 and fusible
link (1).

circuit.

C-204(B)
Step 10. Measure the resistance at C-207 blower

relay connector.
Connector: C-207
C-207
Junction block side
Harness side
C-204
C-207
3 2 1
4
5
Junction block side

3 2 1
4
5
AC210474 AJ

block side.
AC210475 AU
Connector C-207
Fusible link: No.1
3 2 1
4
5
AC301541CC
AC301515 AB
NOTE:
Connector: C-116
1 2
5 6 7
3 4

body earth
OK: 2W or less
NO : Go to Step 11.
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG

55B-41
TROUBLESHOOTING

connector
Connector: C-207

connector and C-32 blower linear controller
connector
Connector: C-207
Junction block side

3 2 1
4
5
Junction block side

3 2 1
4
5
AC210474 AJ

AC210474 AJ
Connector: C-32

blower relay connector terminal No.3 and body
earth.
Harness side
2
1
6 5 4 3
AC301397 AT

C-205
C-207
Harness side
Junction block side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-207
3 2 1
4
5
AC210475 AT

necessary.
Check the blower relay earth wires for open
circuit.

55B-42
TROUBLESHOOTING

blower relay connector terminal No.4 and C-32
blower linear controller connector terminal No.6.

blower linear controller connector.
Connector: C-32

C-203
Harness side
2
1
6 5 4 3
AC301397 AT
C-207

Harness side
Junction block side
C-203
C-207
2
1
6 5 4 3
3 2 1
4
5
Connector C-32
(Harness side)
2
1
6 5 4 3
AC210475 AS
AC301541CJ
(2) Continuity between terminal 3 and body earth

OK: 2W or less
Connector: C-32

NO : Go to Step 16.
Harness side
Step 16. Connector check: C-32 blower liner

controller
2
1
6 5 4 3
AC301397 AT

necessary.
Check the blower linear controller power supply

Connector: C-32
Harness side
2
1
6 5 4 3
AC301397 AT

55B-43
TROUBLESHOOTING

blower linear controller connector terminal No.3
and body earth.
Connector: C-32

A/C-ECU connector terminal No.2 and C-32
Harness side
C-32
C-27(B)
2
1
6 5 4 3
AC301397 AT
Check the blower linear controller earth line for

open circuit.

connector
Harness side
C-27
10 9 8 7 6 5 4 3 2 1
20191817161514131211
C-32
2
1
6 5 4 3
AC301398 AT

circuit.
YES : Replace the air conditioner control panel (A/
C-32
C-27(B)
Harness side
C-27
10 9 8 7 6 5 4 3 2 1
20191817161514131211
C-32
2
1
6 5 4 3
AC301398 AT

C-ECU) or the blower motor (blower linear

controller).
55B-44
TROUBLESHOOTING
INSPECTION PROCEDURE 5: The blower air volume cannot be changed.

BLOWER
RELAY
BLOWER
LINEAR
CONTROLLER
A/C-ECU
Wire colour code

If the blower air volume can not be changed when
the blower switch is operated, the circuit between
blower motor and A/C-ECU may be defective.
Possible causes
Blower motor (blower linear controller)
panel (A/C-ECU)

connector
C-32
C-27(B)

Item 01, 02, 03, 04: Blower motor
panel (A/C-ECU)
Harness side
NO : Go to Step 2.
C-27
10 9 8 7 6 5 4 3 2 1
20191817161514131211
C-32
2
1
6 5 4 3
AC301398 AT

YES : Go to Step 3.

TROUBLESHOOTING

A/C-ECU connector terminal No.2 and C-32
C-32
C-27(B)
Harness side
C-27
10 9 8 7 6 5 4 3 2 1
20191817161514131211
C-32
2
1
6 5 4 3
AC301398 AT

circuit.
YES : Replace the air conditioner control panel (A/
C-ECU) or the blower motor (blower linear

controller).
55B-45
55B-46

TROUBLESHOOTING
INSPECTION PROCEDURE 6: When sunlight intensity changes, blower air temperature does not
Change.
Photo Sensor Circuit

A/C-ECU
PHOTO SENSOR
Wire colour code

CIRCUIT OPERATION
When the blower air temperature can not be changed
even if the preset temperature is changed, the
sensors may be defective.
Malfunction of the photo sensor
DIAGNOSIS
YES : Go to Step 2.

system 355B."
SB : Sky blue

code.
On completion, check that the diagnosis code is not
reset.
YES : Go to Step 3.
NO : Carry the diagnosis code procedures. Refer
to 355B.
Step 3. Check the MUT-II data list.
Item 14: Photo sensor
OK: Check that the volume of insolation
takes inverse proportion with the MUT-II
displayed voltage.
panel (A/C-ECU).
NO : Go to Step 4.
55B-47
TROUBLESHOOTING

connector and C-123 photo sensor connector.
Connector: C-27

photo sensor connector (terminal 1, 2) and C-27
A/C-ECU connector (terminal 19, 9).
Connector: C-27
C-27(B)
C-27(B)
Harness side
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
Connector: C-123
Connector: C-123
Harness side
Harness side
2 1
2 1
AC301395 AN
AC301395 AN

YES : Go to Step 5.
Check the photo sensor signal lines for open or

short circuit.
YES : Replace the Photo sensor.
55B-48
TROUBLESHOOTING
INSPECTION PROCEDURE 7: The A/C indicator flashes.
A/C-ECU
OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL
MOTOR
A/C PRESSURE
SENSOR
Wire colour code

CIRCUIT OPERATION
If the A/C indicator flashes then the possible causes
may be due to a defective A/C pressure system or
insufficient refrigerant gas.
Malfunction of the outside thermo sensor
DIAGNOSIS
operation.
Refer to GROUP 55A, On vehicle service - A/C
pressure sensor check 355A.
YES : Go to Step 2.
SB : Sky blue
STEP 2. Check the outside thermo sensor.

Refer to 355B.
Q: Is the outside thermo sensor in good condition?
YES : Go to Step 3.

Refer to GROUP 55A, On vehicle service - sight
glass refrigerant level test 355A.
panel (A/C-ECU).
NO : Correct the refrigerant level. (Refer to
GROUP 55A, On-vehicle Service355A).
55B-49
TROUBLESHOOTING
INSPECTION PROCEDURE 8: The inside/outside air changeover is impossible.
Outside/Inside Air Selection Damper Control Motor Circuit

IGNITION
SWITCH (IG2)
A/C-ECU
MOTOR DRIVE
CIRCUIT
OUTSIDE/INSIDE AIR
SELECTION DAMPER
CONTROL MOTOR
Wire colour code


When inside air cannot be changed to outside air
vice versa even if its changeover switch is on, the
system may be defective.
Possible causes
Malfunction of the outside/inside air selection
panel (A/C-ECU)
SB : Sky blue
DIAGNOSIS
Item 13, 14: outside/inside air selection damper
control motor
panel (A/C-ECU)
NO : Go to Step 2.
55B-50
TROUBLESHOOTING
Step 2. Measure the voltage at C-311 outside/

inside air selection damper control motor
connector.
Step 3. Connector check: C-311 outside/inside air

selection damper control motor connector
Connector: C-311
Harness side
Connector: C-311
Harness side
3 2
1
7 6 5 4
3 2
1
7 6 5 4
AC301547AB
AC301547AB

Connector C-311
(Harness side)
3 2
1
7 6 5 4
AC301541 BT

body earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 3.

YES : Go to Step 4.

TROUBLESHOOTING

connector terminal No.7 and the ignition switch
(IG2).
Connector: C-311
Harness side
55B-51
Check the motor power supply line for open

circuit.

3 2
1
7 6 5 4
Step 5. Check the outside/inside air selection

Refer to GROUP 55A, Resistor, blower motor and
inside/outside air selection damper control motor
355A.
AC301547AB
NOTE:
Connector: C-36

YES : Go to Step 6.
NO : Replace the outside/inside air selection
damper control motor.

connector and C-311 outside/inside air selection
damper control motor connector
Connector: C-26
1 2
3 4 5
6 7 8 9 10 11 12 13
AC301397 AU

C-26(B)
Harness side
C-203
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301397 AV
Connector: C-311
C-205
Harness side
3 2
1
7 6 5 4
Harness side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-203
2
1
6 5 4 3
AC301547AB

YES : Go to Step 7.
AC210475 AR

necessary.
55B-52
TROUBLESHOOTING

A/C-ECU connector (terminals 23 and 26) and C311 outside/inside air selection damper control
motor connector (terminals 6 and 4).
C-36
C-26(B)
C-36
1 2
3 4 5
6 7 8 9 10 11 12 13
Harness side
C-26
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301398 AP
Connector: C-311
Harness side
3 2
1
7 6 5 4
AC301547AB

circuit.
panel (A/C-ECU).
55B-53
TROUBLESHOOTING
INSPECTION PROCEDURE 9: Defogger function does not operate.
Defogger Circuit
IGNITION
SWITCH (IG2)
FUSIBLE
LINK 1
DEFOGGER
RELAY
DEFOGGER
A/C-ECU
DEFOGGER
SWITCH
Wire colour code

CIRCUIT OPERATION
If the defogger does not operate when the defogger
switch is turned on, the defogger relay system may
be defective.
Malfunction of the defogger relay
Malfunction of the defogger
SB : Sky blue
DIAGNOSIS
STEP 1. Check the A/C and outside/inside air
selection damper control motor operation.
Q: Do the A/C and outside/inside air selection damper
control motor work normally?
YES : Go to Step 2.

system 355B."
55B-54
TROUBLESHOOTING
STEP 2. Measure the voltage at F-04 defogger

connector.
STEP 4. Measure the voltage at C-206 defogger

relay connector.
Connector: C-206
Connector: F-04
F-04(B)
Harness side
1
Junction block side
3 2 1
4
5
AC301658 AB

(2) Turn the defogger switch to the "ON" position.
AC210474 AK

block side.
Connector C-206
Connector F-04
(Harness side)
3 2 1
4
5
1
AC301541CF
AC301541CE

body earth.
OK: System voltage
NO : Go to Step 3.
STEP 3. Check the defogger relay continuity.

Refer to 355A.
Q: Is the defogger relay in good condition?
YES : Go to Step 4.
NO : Replace the defogger relay.

body earth.
OK: System voltage
YES : Go to Step 7.
NO : Go to Step 5.

connector
Connector: C-206
Junction block side

3 2 1
4
5
AC210474 AK

YES : Go to Step 6.
55B-55
TROUBLESHOOTING

defogger relay connector terminal No.5 and the
fusible link (1).


C-204(B)
STEP 7. Measure the voltage at C-206 defogger

relay connector.
Connector: C-206
C-206
Junction block side
Harness side
C-204
Junction block side
C-206
3 2 1
4
5
3 2 1
4
5
AC210474 AK

block side.
AC210475 AV
Fusible link: No.1
Connector C-206
3 2 1
4
5
AC301541CG
AC301515 AB
NOTE:
Connector: C-116
1 2
5 6 7
3 4

OK: System voltage
NO : Go to Step 8.
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG

55B-56
TROUBLESHOOTING

connector
Connector: C-206

connector and C-27 A/C-ECU connector
Connector: C-27
C-27(B)
Junction block side

3 2 1
4
5
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
AC210474 AK
Connector: C-206

YES : Go to Step 9.

defogger relay connector No.1 and ignition
switch (IG2).

C-206
C-203
2
1
6 5 4 3
3 2 1
4
5
AC210474 AK
C-203
Harness side
Junction block side
Junction block side

C-206
3 2 1
4
5
AC210475 AW

necessary.
Check the defogger power supply line for open
circuit.

55B-57
TROUBLESHOOTING
STEP 11. Check the wiring harness between C206 defogger relay connector No.3 and C-27 A/CECU connector No.16.
Connector: C-27

connector and F-04 defogger connector
Connector: C-206
C-27(B)
Junction block side

3 2 1
4
5
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC210474 AK
AC301397 AS
Connector: F-04

Junction Block (Front view)
F-04(B)
Harness side
C-205
C-206
Harness side
AC301658 AB
Junction block side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-206
3 2 1
4
5
AC210475 AX

necessary.
Check the defogger relay line for open or short
circuit.

55B-58
TROUBLESHOOTING
F-04 defogger connector terminal No.1.
STEP 14. Measure the resistance at F-01

defogger connector.
Connector: F-01
Harness side
C-206
AC301658 AC

C-209
Harness side
C-209
7 6 5
15 1413
12
4 3 2 1
11 10 9 8
Junction block side

C-206
Connector F-01
(Harness side)
3 2 1
4
5
1
AC210475 AY
Connector: F-04
F-04(B)
AC301541CO

OK: 2 ohm or less
NO : Go to Step 15.
Harness side
STEP 15. Connector check: F-01 defogger

connector
AC301658 AB

necessary.
Check the defogger power supply line for open or
short circuit.
Connector: F-01
Harness side

panel (A/C-ECU).
AC301658 AC


TROUBLESHOOTING
STEP 16. Check the wiring harness between F-01

defogger connector terminal No.1 and earth.
55B-59

Refer to GROUP 54A, Defogger355A.
Q: Does the defogger work normally?
Connector: F-01

NO : Repair the defogger.
Harness side
AC301658 AC
Check the defogger earth line for open or short

circuit.

NO : Repair or replace the wiring harness.
55B-60
TROUBLESHOOTING
INSPECTION PROCEDURE 10: Malfunction of the A/C-ECU power supply system.
A/C-ECU Power Supply Circuit

IGNITION
SWITCH (IG2)
FUSIBLE
LINK 1
A/C-ECU
BATTERY
BACK-UP
Wire colour code

CIRCUIT OPERATION
The A/C-ECU power system may be defective if the
air conditioner, defogger, and outside/inside air
selection damper motor all do not operate normally.
SB : Sky blue
55B-61
TROUBLESHOOTING
DIAGNOSIS
STEP 1. Measure the voltage at A/C-ECU
connector C-26.

A/C-ECU connector terminal No.28 and the
Connector: C-26
Connector: C-26
C-26(B)
C-26(B)
Harness side
Harness side
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301397 AV
AC301397 AV

NOTE:
C-203
Connector C-26
(Harness side)
C-205
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
Harness side
AC301541CK

body earth.
OK: System voltage
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-203
2
1
6 5 4 3

YES : Go to Step 4.
NO : Go to Step 2.
AC210475 AR

connector
Connector: C-26

block connectors C-205 and C-203, and repair if
necessary.
Check the A/C-ECU power supply line for open or
short circuit.

C-26(B)
Harness side
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301397 AV

YES : Go to Step 3.
55B-62
TROUBLESHOOTING
STEP 4. Measure the resistance at C-26 A/C-ECU

connector.
Connector: C-26

A/C-ECU connector terminal No.27 and the earth.
Connector: C-26
C-26(B)
C-26(B)
Harness side
Harness side
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301397 AV

block side.
AC301397 AV
Check the A/C-ECU earth line for open or short

circuit.
Connector C-26
(Harness side)
panel (A/C-ECU).

connector.
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
Connector: C-27
AC301541CL
C-27(B)

OK: 2 ohm or less
YES : Go to Step 7.
NO : Go to Step 5.
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS

connector

Connector: C-26
Connector C-27
(Harness side)
C-26(B)
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
28 27 26 25 24 23 22 21
36 35 34 33 323130 29
AC301397 AV
AC301541CM

YES : Go to Step 6.

earth.
OK: System voltage
NO :
panel (A/C-ECU).
Go to Step 8.
55B-63
TROUBLESHOOTING

connector
Connector: C-27
NOTE:
C-204(B)
C-27(B)
C-202
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS

YES : Go to Step 9.
Harness side
C-202

A/C-ECU connector terminal No.3 and fusible link
(1).
C-204
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Connector: C-27
AC210475 BA
C-27(B)
C-02
Harness side
10 9 8 7 6 5 4 3 2 1
20191817161514131211
AC301397 AS
Fusible link: No.1

C-116
C-02
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
2324 25 2627 28 2930 3132 33
C-116
1 2
AC301515 AB
5 6 7
3 4
8 9
10 1112 1314
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
1617 18 19 20 21
AC301396 AM

block connectors C-202, C-204, intermediate connectors
C-116 and joint connector C-02, and repair if necessary.
Check the A/C-ECU power supply (battery backup) line for open or short circuit.

55B-64
TROUBLESHOOTING

M1554005100103
Item No.
Check items
Inspection conditions
Normal condition
11
Interior temperature sensor
Turn the ignition switch to

the ON position.
Room temperature is the

same as MUT-II displayed
temperature.
12
Outside thermo sensor

the ON position.
Outside temperature is the

same as MUT-II displayed
temperature.
13
Heater water temperature

sensor

the ON position.
Heater core wall surface

temperature is the same as
MUT-II displayed
temperature.
14
Photo sensor
Turn the ignition switch to The volume of insolation

the ON position.
takes inverse proportion with
Change the volume of
the MUT-II displayed voltage.
insolation.
16
Air thermo sensor

the ON position.
17
Air mixing damper control

Turn the ignition switch to Opening angle: approximately

the ON position.
100%
Door position: MAX HOT
Evaporator outlet temperate

is the same as MUT-II
displayed temperature

the ON position.
0%
Door position: MAX HOT
18
Mode selection damper

control motor and
potentiometer

the ON position.
0%
Damper position: FACE
the ON position.
60%
Damper position: FOOT
the ON position.
80%
Damper position: FOOT/
DEF
the ON position.
100%
Damper position: DEF
ACTUATOR TEST TABLE

M1554005200100
Item No.
Check items
Drive content
01
Blower motor
Stop
02
Low speed
03
Middle speed
04
High speed
55B-65
TROUBLESHOOTING
Item No.
Check items
Drive content
05
Air mixing damper control motor
Open angle: Approximately 0% (MAX COOL)
06
Opening angle: approximately 50%
07
Open angle: Approximately 100% (MAX COOL)
08
Mode selection damper control motor FACE
09
FOOT
10
DEF
11
Compressor output
OFF
12
ON
13
Outside air
14
outside/inside air selection damper

control motor
15
Idle-up
OFF (A/C high pressure)
16
Inside air
ON (A/C low pressure)
CHECK AT ENGINE-A/T ECU TERMINALS

M1554005400148
<C-134>
JAE-E
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
<C-135>
<C-137>
JAE-E
31 3233 34 3536 37 38
39 40 41 42 43 44 45 46
JAE-E
71 72 73 7475 76 7778 79 8081
8283 84 8586 87 88 89 90 91 92
AC301466AB
Terminal
No.
Check items
Check conditions
Normal conditions
Output to A/C compressor
A/C compressor relay: OFF
System voltage
A/C compressor relay: ON
0V
Air conditioner switch: OFF
4.9 - 5.1 V
Air conditioner switch: ON
0V
21
Output to fan controller
24
Input from A/C-ECU (A/C1)
When the A/C is in operation (When the air System voltage

thermo sensor detects 3C or more).
42
Input from A/C pressure

sensor
2.6MPa
3.9 V
45
Input from A/C-ECU (A/C2)
When the A/C is under low load
System voltage
81
A/C pressure sensor power

supply
Always
4.9 - 5.1 V
92
A/C pressure sensor earth
Always
0V
55B-66
TROUBLESHOOTING
CHECK AT A/C-ECU TERMINALS

M1554005400159
<C-27>
<C-26>
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 2223 24 25 26 27 28
29 30 31 32 33 34 35 36
AC300196 AB

No.
Check conditions
Normal
conditions
Sensor temperature: 25C (4kW)
2.1- 2.7V
Output to blower pulse controller
When the blower is operating.
0 - 2.5V (Effective
alternating
voltage)
Back-up power supply
Always
System voltage
Input from heater water temperature

sensor
2.1 - 2.7V
Input from air mixing damper control

motor potentiometer
When the damper flaps is moving to

the MAX HOT position.
4.1 - 4.6 V
Input from mode selection damper

control motor potentiometer
When the damper is moved to the

DEF position.
4.1 - 4.6 V
Input from the outside thermo sensor Sensor temperature: 25C (4kW)
2.1 - 2.7 V
Input from the air thermo sensor
2.1 - 2.7 V
Photo sensor (-)
Brightness is 0 lux
4.9 - 5.1 V
Brightness is 100000 lux or more
Approximately 0 V
10
Potentiometer power supply
Always
5V
11
Input from the A/C pressure sensor
2.6 Mpa
3.9 V
12 - 15
16
Rear defogger
When the rear defogger is operating. 2.0 V or less

When the rear defogger is stopped
System voltage
17
Diagnosis set
Ignition switch: ON
A voltmeter needle
fluctuates between
0 and 12 V.
18
Input from diagnosis
Ignition switch: ON
Approximately 5 V
19
Photo sensor (+)
Always
0V
20
Sensors and potentiometers earth
Always
0V
21
Air outlet changeover damper motor

(FACE)

FACE position.
10 V

DEF position.
Faint voltage (0.5

V)

the MAX COOL position.
10 V

Faint voltage (0.5

V)
22
Air mix damper motor (MAX COOL)
55B-67
TROUBLESHOOTING
No.
Check conditions
Normal
conditions
23

inside air recirculation position
10 V (When the
motor is stopped)

outside air inside air intake position
2.0 or less
24
25
26

control motor (outside)
Mode selection damper control motor When the damper is moved to the
and potentiometer (DEF)
FACE position.
Air mixing damper control motor and

potentiometer (MAX HOT)

control motor (inside)
Faint voltage (0.5

V)

DEF position.
10 V

the MAX COOL position.
Faint voltage (0.5

V)

10 V

inside air recirculation position
2.0 V or less

outside air inside air intake position
10 V (When the
motor is stopped)
27
Earth
Always
Continuity exists.
28
IG2 power supply
Ignition switch: ON
System voltage
29
Illumination earth
Always
Continuity exists.
30
ILL power supply
Lighting switch: ON
System voltage
31
32
Input from the engine-A/T-ECU

(A/C2)
When the A/C is under low load
System voltage
33
Input from the compressor relay
Compressor: ON
System voltage
34
Input from the engine-A/T-ECU

(A/C1)
When the A/C is stopped
0V
35
36
ACC power supply
System voltage
When the A/C is operating (When the System voltage

compressor is operating)
55B-68
AUTOMATIC AIR CONDITIONER PANEL ASSEMBLY (A/C-ECU)

PANEL ASSEMBLY (A/C-ECU)
M1554010900042
2
5
AC301496 AB
1.
2.
Removal steps
Centre panel (Refer to GROUP
52A, Instrumental Panel352A).
Knob
Panel
3.
4.
5.

Rear defogger knob
Outside/inside air selection knob
Automatic air conditioner control
panel (A/C-ECU)
55B-69
HEATER UNIT
HEATER UNIT
M1554009100097
Refer to GROUP 55A, Heater Unit Blower assembly 355A.

M1554009200072
12
13
14
8
7
10
3
6 N
4
1
11
5
AC301506AB
1.
2.
3.
4.
5.
6.
7.
8.
Disassembly steps
Evaporator cover
Heater core
Expansion valve
Joint
Evaporator
O ring
Air thermo sensor
Heater water temperature sensor

Aspirator hose
Aspirator
Wiring harness
13. Air mixing damper control motor
and potentiometer
14. Heater case
9.
10.
11.
12.
55B-70

AIR MIXING DOOR MOTOR, AIR OUTLET CHANGEOVER DAMPER MOTOR AND BLOWER MOTOR
AIR MIXING DOOR MOTOR, AIR OUTLET CHANGEOVER

DAMPER MOTOR AND BLOWER MOTOR
M1554011100050
AC301512 AB
1.

and potentiometer removal
steps
and potentiometer
2.
3.

removal steps
Blower motor removal steps
Blower motor
INSPECTION
M1552014300778
CHECK THE AIR MIXING DAMPER

CONTROL MOTOR AND
POTENTIOMETER
AC301517
Check the air mixing damper control motor

Battery
Battery
Lever operation
connection
connection
(+) terminal (-) terminal
1
Rotate to the HOT

position.
Rotate to the COOL

position.

AIR MIXING DOOR MOTOR, AIR OUTLET CHANGEOVER DAMPER MOTOR AND BLOWER MOTOR
Potentiometer check
When the resistances between terminals 2 and 5 as
well as terminals 5 and 6 are measured at the air
mixing damper motor check, the resistance value
should change gradually within the standard value.
Standard value: Approximately 0.65 - 5.35
kW
MODE SELECTION DAMPER CONTROL

MOTOR AND POTENTIOMETER CHECK
55B-71
Potentiometer check
When the resistances between terminals 2 and 5 as
well as terminals 5 and 6 are measured at the mode
selection damper control motor check, the resistance
value should change gradually within the standard
value.
Standard value: Approximately 0.65 - 5.35
kW
BLOWER MOTOR CHECK

Execute actuator test item No.01 to 04 by using MUTII with the vehicle body, and check that the blower
motor works normally. (Refer to 355B).
AC301519
Mode selection damper control motor check

Battery
Battery
Lever operation
connection
connection
(+) terminal (-) terminal
1
Rotate to the DEF

position.
Rotate to the FACE

position.
55B-72
SENSORS
SENSORS
M1554001900077
AC301526AB
1.

removal steps
Instrument lower panel (Refer to
GROUP 52A, Instrumental Panel
352A).
2.
<<A>>
>>A<<
3.

removal steps
Foot duct <front passengers side>
(Refer to GROUP 55A, Ventilator
355A).
Photo sensor removal steps
Instrument lower panel (Refer to
GROUP 52A, Instrumental Panel
352A).
Photo sensor

<<A>> PHOTO SENSOR REMOVAL
Tape
String
AC301536 AB
Binding the photo sensor connector with a cord and

rapping a tape around the connector as its surface is
flatly to pull out the photo sensor toward the

instrument panel upper.
55B-73
EVAPORATOR ASSEMBLY

>>A<< PHOTO SENSOR INSTALLATION
Defroster nozzle
Check to see that the resistance shown in the graph

is almost satisfied when measuring the resistance
between the terminals under two or more different
temperature conditions.
HEATER WATER TEMPERATURE

SENSOR CHECK
Resis
tance
(k)
Photo sensor
harness
Tape
AC301539AB
20
15
10
Tape the photo sensor under the defroster nozzle.
INSPECTION
0
20 40 60
-10 0
Temperature (C)
M1552014300767
INTERIOR TEMPERATURE SENSOR

CHECK
Resis
tance
(k)
80
AC103488 AB
15

10
PHOTO SENSOR CHECK
20
5
0
20 40 60
-10 0
Temperature (C)
80
AC103488 AB
Check that the blower rotation comes down if the

photo sensor is covered with hands, when the
automatic A/C is operating (in summer sunbeam). If
not the rotation comes down, replace the photo
sensor.
EVAPORATOR ASSEMBLY
M1552003600195
Refer to GROUP 55A, Evaporator assembly 355A).
INSPECTION
M1552014300734
AIR THERMO SENSOR CHECK

Resistance
25
(k)
20
15
10
5
0
-10 0 10 20 30 40
Temperature (C)
AC103661AB


NOTE: The temperature should be within the shown
range.
55B-74
AMBIENT TEMPERATURE SENSOR
AMBIENT TEMPERATURE SENSOR

INSPECTION
M1552014300745
Ambient air temperature sensor
AC301106 AC
Resistance
50
(k)
40
30
20
10
0
-30 -20 0 20 40 60
Temperature (C)
AC103489AB

between the sensor terminals under two or more
different temperature conditions.

OTHER PARTS
55B-75
OTHER PARTS
OTHER PARTS
Item
The following maintenance service points are the

same as for the manual A/C.
Reference
page
Heater unit and blower assembly
355A
Item
Blower motor and outside/inside

355A
air selection damper control motor
M1554004000073
On-vehicle
service
Reference
page
Refrigerant level 355A
test
Magnetic clutch
test
355A
Compressor
drive belt
adjustment
355A
A/C pressure
sensor simple
check
355A
Charging
355A
Correcting low
refrigerant level
in case the
service can in
used
355A
Discharging
system
355A
Refilling of oil in
the A/C system
355A
Performance test 355A

Refrigerant leak 355A
repair procedure
Compressor
noise check
355A
Power relay
continuity check
355A
Idle-up operation 355A

check
Clean air filter
replacement
procedure
355A
Evaporator and air thermo sensor 355A

A/C compressor
355A
Condenser and condenser fan

motor
355A
Refrigerant line
355A
Ventilators
355A
127(6
52A-1
GROUP 52A
00
11
INTERIOR
12
13
14
CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . .
52A
HEADLINING . . . . . . . . . . . . . . . . . . . 52A
INSTRUMENT PANEL ASSEMBLY*.
15
52A
52A
52A
52A
INSIDE REAR VIEW MIRROR . . . . . . 52A

FRONT SEAT ASSEMBLY* . . . . . . . . 52A
FLOOR CONSOLE ASSEMBLY . . . .
52A
52A
52A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
52A
52A
52A
TRIMS. . . . . . . . . . . . . . . . . . . . . . . . .
52A
52A
REAR SEAT ASSEMBLY. . . . . . . . . . 52A
52A
52A
TAILGATE TRIM . . . . . . . . . . . . . . . .
52A
52A
17
21
22
25
26
27
52A
52A
31
FRONT SEAT BELT* . . . . . . . . . . . . . 52A
32
DOOR TRIM . . . . . . . . . . . . . . . . . . . . 52A

16
52A
33
REAR SEAT BELT . . . . . . . . . . . . . . . 52A
34
52A
35
36
37
:$51,1*65(*$5',1*6(59,&,1*2)6833/(0(17$/5(675$,176<67(0656(48,33('9(+,&/(6
WARNING
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
NOTE
The SRS includes the following components: front impact sensors, side impact sensors, SRS-ECU, SRS warning lamp, air bag
module, clock spring and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in
connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).
42
51
52
54
55
INTERIOR
52A-2
SPECIAL TOOL
SPECIAL TOOL
M1521000600264
Tool
Tool number
Name
Use
MB990784
Ornament remover
Removal of switch, trim, etc.
MB990784
INSTRUMENT PANEL ASSEMBLY

M1521001700394
WARNING
For removal and installation of the passengers side air bag module, always observe the
service procedures described in GROUP 52B, Air Bag Module and Clock Spring 352B.
The following bolts and screws are used for installing the instrument panel. Bolts and screws are indicated as
marks shown in the illustration in the sections of "Removal and Installation" and "Disassembly and Assembly."
Name
Symbol
Size (D L) mm
Colour
Tapping screw
5 12
5 16
5 16
Black
5 12
5 20
Shape
AC104450
AC104436
Washer assembly bolt
6 16
6 16
6 16 (Earth)
8 20
10 60
AC104417
AC200304
INTERIOR
52A-3
CAUTION
Refer to GROUP 52B-SRS Service Precautions 352B and Air bag Module and Clock Spring
352B before removing the passenger side air bag module.
Do not subject the SRS-ECU to any shocks when removing or installing the instrument panel.
Removal and Installation of Front Floor Console (Refer to
352A).
Removal and Installation of Steering Wheel and Air Bag
Module Assembly (Refer to 337).
2
5
26
44 10 Nm
25
44 10 Nm
12
j
10
25
e
d
11
15
24 N
17
13
22
20
c f
18
a
16
19
AC301272 AB
21
<<A>>
1.
2.
3.
4.
5.
6.
7.
8.
23
14
Removal steps
Instrument panel clock garnish
Instrument panel air outlet (centre)
Clock
Instrument panel drivers side
garnish
Meter bezel
Combination meter
Junction block cover
Hood lock release handle (Refer to
342).
Instrument panel parcel box
9.
10.
11.
12.
<<A>>
>>A<<
13.
14.
15.

Floor harness (RH) and junction
block connection
Instrument lower panel
Instrument panel air outlet (LH)
Instrument lower panel bracket
Column cover
Air mix door cable, blow vent
changeover damper cable
connection (Refer to 355A).
Knob
Centre panel
Centre panel assembly
INTERIOR
52A-4
16.
17.
18.
19.
20.
21.
22.
23.
24.

Radio plug
Centre lower panel
Centre lower box
Centre lower cover
Front scuff plate, cowl side trim
(Refer to 352A).
Back bone spacer
Glove box stopper
Glove box
Connector block

25. Instrument panel side cover
Roof harness connection
Instrument panel harness earth

connection
Instrument panel and body harness

connection
Steering shaft harness connector

and clamp
Stop lamp switch harness

connector (Refer to 335A).
SRS-ECU harness connector

(Refer to 352B).
Shift lock cable clamp
Steering shaft installation bolt

(Refer to 337).
26. Instrument panel assembly
INTERIOR
52A-5
CLIP AND CLAW POSITIONS
A
D
B B
D
C
C
E
G
H
I
J
H
K
NOTE
(1)
: Clip position
(2)
: Claw position
Section A A
Instrument
panel side
cover
Section B B
Clip
Meter bezel
Instrument panel
drive's side garnish
Section G G
Clip
Clumn cover
Instrument lower
panel
Claw
Section I I
Center panel
Claw
Clip
Instrument panel
assembly
Claw
Center panel
Section J J
Section K K
Clip
Radio plug
Meter bezel
Section H H
Instrument panel
assembly
Instrument panel
clock garnish
Clip
Claw
Section F F
Section E E
Instrument panel
assembly
Section D D
Instrument panel
assembly
Section C C
Instrument panel
side cover
Instrument panel
assembly
Clip
Claw
Instrument panel
assembly
Junction brock cover
Clip
Instrument panel
assembly
Centr lower panel
AC301617 AB
52A-6
INTERIOR
INSTALLATION SERVICE
<<A>> INSTRUMENT PANEL AIR OUTLET

REMOVAL
>>A<< CENTRE PANEL ASSEMBLY

INSTALLATION
Air mix door cable and blow vent changeover damper
cable connection (Refer to 355A).
Ball
Spring
AC103520AB
The instrument panel air outlet may remain on the

instrument panel side when disassembling the lower
panel of the instrument panel and the instrument
panel garnish. Carefully disassemble the parts
remaining on the instrument panel side to prevent
the ball and spring from falling. Assemble the ball
and spring according to the figure to the left if they
fall off.
INTERIOR
52A-7

M1521001900321
1
10
11
15
f
11
a
11
a
11
3
a
a
f
14
12
5
a
f
13
a
a
a
AC212544AB
1.
2.
3.
4.
5.
6.
7.
8.
Disassembly steps
Side defroster duct
Defroster nozzle assembly
Distribution duct
Front deck crossmember
Passengers side air bag module
bracket
cover
Glove box striker

Instrument panel reinforcement
Meter bracket
Instrument panel holder
Instrument panel under cover
passengers side
13. Side air outlet assembly (RH)
14. Centre cover drivers side
Instrument panel harness

connector clamp
15. Instrument panel
9.
10.
11.
12.
INTERIOR
52A-8
FLOOR CONSOLE ASSEMBLY

M1521002200295
1
7
6
4
C
11
C
11
2
9
13
D
D
12
11 2 Nm
11 2 Nm
NOTE
: Clip position
10
Section A A
Section B B
Section C C
Section D D
Clip
Clip
12
13
11
11
12
Clip
12
Clip
AC301787 AB
1.
2.
3.
4.
5.
6.
Removal steps
Shift knob
Floor console panel cover
Front floor console panel
Harness connector <Vehicles with
heated seat>
Heated seat switch <Vehicles with
heated seat>
Coin holder
7.
8.
9.
10.
11.
12.
13.

Ashtray
Shift lever cover
Rear floor console assembly
Rear floor console bracket
Front floor console lower side cover
Front floor console
Front floor console bracket
INTERIOR
52A-9

M1521002400103
7
5
1
6
3
2
11
10
9
8
AC106397AH
1.
2.
3.
4.
5.
6.
Disassembly steps
Lid assembly
Tray outer
Tray inner
Lock knob
Lid inner
Hinge assembly
7.
8.
9.
10.
11.

Lid cover
Hinge support bracket
Rear console box
Rear console
Rear console panel
INTERIOR
52A-10
TRIMS
TRIMS
M1521001100381
16
15
6
44 10 Nm
10
14
44 10 Nm
12
11
13
7
2
17
3
19
18
1.
2.
<<A>>
3.
4.
5.
6.
7.
8.
9.
Front scuff plate

Cowl side trim
Rear seat cushion assembly (Refer
to 352A).
Rear scuff plate
Front door opening trim
Rear door opening trim
Front pillar trim
Centre pillar trim lower
Front seat belt shoulder anchor bolt
Centre pillar trim upper
20
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
AC301338 AB
Convenience hook
Parcel strap hook A
Ventilation cap
Quarter trim lower
Rear seat belt shoulder anchor bolt
Quarter trim upper cap
Quarter trim upper
Rear end trim
Luggage floor box
Parcel strap hook B
Rear seat board
INTERIOR
52A-11
TRIMS
CLIP AND CLAW POSITION

D
D
D
B
B
C
C
A
NOTE
: Clip position
Section A A
Section B B
Clip
Section C C
Front pillar
trim
Front scuff plate,

rear scuff plate
Section D D
Center pillar
trim upper
Clip
Clip
Cowl side trim
Section E E
Clip
Section G G
Section F F
Qauter trim
upper
Qauter trim
lower
Rear end trim
Clip
Clip
Clip
AC301349 AB
INTERIOR
52A-12
TRIMS

<<A>> FRONT PILLAR TRIM REMOVAL
Section A A
Front pillar trim
Front pillar trim
A
A
Instrument panel
AC101299AC
Unclip the front pillar trim and slide out it in the

direction shown.
INTERIOR
52A-13
DOOR TRIM
DOOR TRIM
M1521006400116
<Front door trim>
2
A
1
View A
Section B B
Section C C
Clip
3
Clip
3
NOTE
:Clip position
AC106408 AB
<<A>>
1.
2.
Removal steps
Speaker garnish
Door inside handle cover
3.

Delta cover (Refer to 351).
Door trim assembly
INTERIOR
52A-14
DOOR TRIM
<Rear door trim>
2
A
View A
B
Section B B
Section C C
Clip
Clip
3
NOTE
: Clip position
C
AC106406 AB
1.
Removal steps
Speaker garnish
<<A>>
2.
3.

Door inside handle cover
Door trim assembly
INTERIOR
52A-15
DOOR TRIM

<<A>> DOOR INSIDE HANDLE COVER REMOVAL
Tapping screw cap
Door inside
handle cover
A
Special tool
insertion
position
B
MB990784
AC100003AF
1. Insert a flat-tipped screwdriver into the back end

of the tapping screw cap of the door inside handle
cover.
2. Try the screwdriver in the direction of the arrow.
Remove the cap, then remove the tapping screw.
Section B B
Section A A
Door inside
handle cover
Door trim
Claw
Claw
Door inside
handle cover
Claw
AC100004 AD
3. Insert the special tool ornament remover

(MB990784) in the gap between the door inside
handle cover and door inside handle in the area
shown. Then remove the thumb clamp of the door
inside handle cover and door inside handle.
4. Insert a special tool from the back end of the door
inside handle cover to lift it in the direction of the
arrow. Then remove the door inside handle cover.
INTERIOR
52A-16
DOOR TRIM

M1521006900081
<Front door>
3
6
5
4
<Rear door>
7
3
6
2
1
AC212484 AB
1.
2.
3.
4.
Disassembly steps
Door weather-strip
Arm rest assembly
Power window switch panel
assembly
Arm rest
5.
6.
7.

Door harness
Power window switch
Door trim
INTERIOR
52A-17
TAILGATE TRIM
TAILGATE TRIM
M1521006500094
4
2
5
AC102381AC
1.
2.
3.
Removal steps
Tailgate upper trim
Tailgate trim
Tailgate lower trim
4.
5.

Tailgate side trim
Tailgate pull handle
INTERIOR
52A-18
TAILGATE TRIM
CLIP AND CLAW POSITION

B
Tailgate upper trim
A
H
Tailgate side trim
Tailgate side trim
Tailgate trim
D
G
D
G
Tailgate lower trim
NOTE
: Clip position
: Claw position
Tailgate pull handle

A
Section B B
Claw
Section A A
Clip
Section C C
Tailgate trim
Tailgate
side trim
Claw
Tailgate
upper trim
Tailgate
upper trim
Section D D
Tailgate
lower trim
Section E E
Tailgate
trim
Section F F
Tailgate
side trim
Tailgate
lower trim
Tailgate
lower trim
Clip
Clip
Section G G
Tailgate
trim
Clip
Craw
Tailgate
lower trim
Claw
Tailgate
side trim
Tailgate
lower trim
Claw
View A
Section H H
Tailgate
lower trim
Section I I
Clip
Tailgate
lower trim
I
Claw
Tailgate
side trim
Tailgate
pull handle
Tailgate
pull handle
AC102835 AC
INTERIOR
52A-19
HEADLINING
HEADLINING
M1521001400304

Removal and Installation of Front Pillar Trim, Centre Pillar
Trim Upper, Quarter Trim Upper (Refer to 352A).
7
6
2
4
1
5
3
5
1.
2.
3.
4.
<<A>>
5.
Removal steps
Assist grip
Rear room lamp assembly
Front room lamp/map lamp
assembly
Sun roof switch cover <Vehicles
with sun roof>
Sun visor holder

<<A>> SUN VISOR HOLDER REMOVAL
MB990784
Sun visor holder
MB990784
AC005512 AD
Insert the special tool ornament remover

(MB990784) into side claws of the sun visor holder
through the both sides to remove the hinges.
AC301290 AB
6.
7.
8.
9.

Sun visor assembly
Front headlining trim <Vehicles with
sun roof>
Rear headlining trim <Vehicles with
sun roof>
Headlining
INTERIOR
52A-20
INSIDE REAR VIEW MIRROR
INSIDE REAR VIEW MIRROR

M1521002600185
2. Push the claw B toward arrow 2 direction to

unlock, and pull out the mirror toward arrow 3
direction.
3
Claw A
2
Cover
1
Claw B
AC209066 AD
1. Disengage the claw A and lower the cover toward

arrow 1 direction.
INTERIOR
52A-21
FRONT SEAT ASSEMBLY
FRONT SEAT ASSEMBLY

M1522001300311
CAUTION
For the removal of the front seat assembly on vehicles with the side air bags, refer to GROUP 52B Service Precautions (Refer to 352B) and Air Bag Module and Clock Spring (Refer to 352B).
Removal and Installation of Rear Floor Console Assembly
(Refer to 352A).
44 10 Nm
30 5 Nm
Claw
44 10 Nm
Section A A
8
3
4, 5
Section B B
30 5 Nm
7
4
A
Claw
NOTE
: Claw position
5
4
1.
2.
3.
4.
5.
Headrest
Heated seat switch <Vehicles with
heated seat>
Front seat assembly removal
steps
Front seat anchor cover
Seat anchor cover outer
Seat anchor cover inner
AC301693 AB
6.
7.
>>A<<
8.
Front seat assembly removal

steps&RQWLQXHG
side-air bag>
heated seat>
Front seat assembly
INTERIOR
52A-22
FRONT SEAT ASSEMBLY

>>A<< FRONT SEAT ASSEMBLY INSTALLATION
INSPECTION
M1522005500061
HEATED SEAT SWITCH CHECK
AC301696AB
1. Temporarily tighten the nuts and bolts in all

mounting locations shown in the illustration with
no load applied to the front seat cushion and
check the operation of the seat slide.
2. Tighten the nuts and bolts in all mounting
locations to the specified torque.
Switch position
Drivers seat side
Front passengers seat

side
ACX00625
1. Check for continuity between terminals.
Tester connection
Specified condition
HI
1 - 3, 1 - 5, 1 - 8, 3 - 5,
3 - 8, 5 - 8
Less than 2 ohms
OFF
1 - 3, 1 - 5, 1 - 8, 3 - 5,
3 - 8, 5 - 8
Open circuit
LO
3 - 5, 3 - 8, 5 - 8
Less than 2 ohms
HI
4 - 5, 4 - 8, 4 - 9, 5 - 8,
5 - 9, 8 - 9
Less than 2 ohms
OFF
4 - 5, 4 - 8, 4 - 9, 5 - 8,
5 - 9, 8 - 9
Open circuit
LO
2. Check that the indicator is lighted at HI or LO
when battery voltage is supplied to terminal 5, and
terminal 8 is grounded.
5 - 8, 5 - 9, 8 - 9
Less than 2 ohms
3. Check that indicator is lighted when battery
voltage is supplied to terminals 2 and 6.
INTERIOR
52A-23
FRONT SEAT ASSEMBLY
SEAT CUSHION HEATER CHECK
HEATED SEAT RELAY CONTINUITY

CHECK
Heated seat relay

1
2 3
AC200099
Measure the resistance between terminals.

Standard value:
Measured Resistance
Note
terminals value
2-3
1-3
Junction block
Approximately At room
4.8 W 10 % temperature 20 C
1 2
3 4
5.2 W 10 %
1
3
SEATBACK HEATER CHECK

AC300127 AB
1
2
AC200100
Measure the resistance between terminals.

Standard value: Approximately 4.8 W 10 %
(At room temperature 20 C)
Battery voltage
Tester
connection
Specified
condition
Not applied
1-4
Open circuit
Connect
1-4
terminal 3 to the
positive battery
terminal
Connect
terminal 2 to the
negative battery
terminal
Less than 2
ohms
INTERIOR
52A-24
FRONT SEAT ASSEMBLY

M1522001500393
12
Section A A
21
17 16
20 15
Claw
27
10, 11
44 10 Nm
18
14
13
9
19
N
18
6
7
4
8
12 2 Nm
A
26
23
7.6 0.7 Nm
1
3
2
10
22
24
11
NOTE
: Claw position
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
25
A
44 10 Nm
24
Disassembly steps
Reclining knob
Pin
Height adjuster knob
Heater harness assembly
<Vehicles with heated seat>
Front seat cushion assembly
Front seat cushion cover
Front seat cushion pad
Front seat cushion frame
Seat cushion heater <Vehicles with
heated seat>
Reclining cover
Shield cover
Front seatback assembly
Lumbar support cap
27
<<A>>
AC301697 AB
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

Lumbar support lever
Headrest guide
Front seatback cover
Front seatback pad
Lumber support clip
Lumber support
Front seatback frame
Seatback heater <Vehicles with
heated seat>
Inner seat belt
Shaft
Pin
Slide handle
Shaft protector
Seat slide adjuster
INTERIOR
52A-25
REAR SEAT ASSEMBLY
REMOVAL SERVISE POINT

<<A> HEADREST GUIDE REMOVAL
ACX01300
REAR SEAT ASSEMBLY

M1522001800264
1
5
44 10 Nm
95 15 Nm
2
44 10 Nm
44 10 Nm
3
44 10 Nm
6
AC300146 AB
INTERIOR
52A-26
REAR SEAT ASSEMBLY

1.
>>A<<
2.
3.
Headrest
Removal steps
Rear seat cushion assembly
Inner seat belt and centre seat belt
installation bolt

>>A<< REAR SEAT CUSHION ASSEMBLY
INSTALLATION
Rear seat cushion
assembly
Rear seat hook

AC005521AB
Fit the rear seat cushion into the rear seat hook
securely.
4.
5.
6.

Rear seatback assembly (LH)
Rear seatback assembly (RH)
Rear seat hook
INTERIOR
52A-27
REAR SEAT ASSEMBLY

M1522002000324
19
11
20
23
25
26
24
44 10 Nm
12
31
27
29
30
8
12
22
10
18
44 10 Nm
28
7
17
16
15
44 10 Nm
13
32
2
28
14
44 10 Nm
14
3
21
1N
AC200082AB
AB
1.
2.
3.
4.
5.
6.
7.
8.
9.
Rear seat cushion disassembly

steps
Hog ring
Rear seat cushion cover
Rear seat cushion pad
Rear seatback (LH side)
disassembly steps
Arm rest assembly
Arm rest cup holder
Arm rest board
Tether anchor garnish
Reclining knob
Cap
<<A>>
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

disassembly steps&RQWLQXHG
Reclining knob garnish
Centre seat belt garnish
Headrest guide
Rear seatback cover
Reclining cover
Rear seatback pad
Rear seatback frame assembly
Arm rest bushing
Reclining cable
Centre seat belt cover
INTERIOR
52A-28
REAR SEAT ASSEMBLY
20.
21.
22.
23.
24.

Centre seat belt
Reclining adjuster
Rear seatback (RH side)
disassembly steps
Tether anchor garnish
Reclining knob
Cap

<<A>> HEADREST GUIDE REMOVAL
ACX01300
<<A>>
25.
26.
27.
28.
29.
30.
31.
32.
Rear seatback (RH side)

Reclining knob garnish
Headrest guide
Rear seatback cover
Reclining adjuster cover
Rear seatback pad
Rear seatback frame
Reclining cable
Reclining adjuster
INTERIOR
52A-29
FRONT SEAT BELT
FRONT SEAT BELT

M1523001300314
CAUTION
SRS: Before removing and installing the seat belts with pre-tensioner, refer to GROUP 52B, Seat Belt
with Pre-tensioner (Refer to 352B).
Turn the ignition key to the LOOK (OFF) position.
Disconnect the negative battery terminal.
44 10 Nm
44 10 Nm
44 10 Nm
44 10 Nm
AC301332 AC
1.
2.
3.
Outer seat belt removal steps

Sash guide cover
Centre pillar trim lower (Refer to
352A).
Bracket
Outer seat belt (Refer to GROUP
52B, Seat Belt with Pre-tensioner
352B).
4.
5.
6.
Outer seat belt removal steps

Centre pillar trim upper (Refer to
352A).
Adjustable seat belt anchor
Inner seat belt removal steps
Shield cover (Refer to 352A).
Inner seat belt
INTERIOR
52A-30
REAR SEAT BELT
REAR SEAT BELT

M1523001600315
44 10 Nm
5
44 10 Nm
3
4
44 10 Nm
44 10 Nm
44 10 Nm
2
1
1.
2.
3.
Removal steps
Rear seatback assembly (Refer to
352A).
Inner seat belt
Centre seat belt inner
Centre seat belt garnish
Quarter trim upper (Refer to 352A
).
AC301334 AB
4.
5.
6.
7.
8.

Centre seat belt outer (Refer to
352A).
Sash guide cover
Seat belt shoulder anchor bolt
Seat belt lower anchor bolt
Outer seat belt
52-1
GROUP 52
INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM(SRS)
00
11
12
13
14
15
16
17
21
22
CONTENTS
25
26
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . 52B
27
31
32
33
34
35
36
37
42
51
52
54
55
127(6
15-1
GROUP 15
00
11
INTAKE AND
EXHAUST
12
13
14
15
16
CONTENTS
17
15
15
AIR CLEANER . . . . . . . . . . . . . . . . . .
15
INTAKE MANIFOLD . . . . . . . . . . . . .
15
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
15
EXHAUST MANIFOLD . . . . . . . . . . . .
15
15
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
15
EXHAUST PIPE AND MAIN

MUFFLER . . . . . . . . . . . . . . . . . . . . . .
15
27
15
31
15
SPECIAL TOOL . . . . . . . . . . . . . . . . .
15
15
21
22
25
26
32
33
34
35
36
37
42
51
52
54
55
INTAKE AND EXHAUST
15-2
GENERAL INFORMATION
GENERAL INFORMATION
M1151000100394
The exhaust pipe is divided into three parts.
M1151000300398
Item
Standard value
Limit
Manifold distortion of the installation surface mm
0.15 or less
0.20
SPECIAL TOOL
M1151000600377
Tool
Number
Name
Use
MD998770
Oxygen sensor wrench

oxygen sensor
INTAKE AND EXHAUST
15-3
AIR CLEANER
AIR CLEANER
M1151002100442
CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
Avoid any shock or load to these parts when removing and installing them.
When installing, securely set the air cleaner cover and the resonator clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws
3.9 1.0 Nm
11
6
12
1*
5
3.9 1.0 Nm
Clamp
8.8 1.0 Nm
3*
8.8 1.0 Nm
4*
10*
8
7
2*
11 1 Nm
8.8 1.0 Nm
13
22 4 Nm
AC203703 AB
1.
2.
3.
4.
5.
6.
7.
Removal steps
Resonator
Air cleaner element
Air duct
Air cleaner body
Air flow sensor connector
Breather hose connection
Air cleaner cover and air flow sensor
assembly
8.
9.
10.
11.
12.
13.

Air flow sensor assembly
Gasket
Air cleaner cover
Resonator
Air intake hose
Air cleaner bracket
INTAKE AND EXHAUST
15-4
INTAKE MANIFOLD
INTAKE MANIFOLD
M1151003000686
Throttle Body Removal (Refer to GROUP 13A, Throttle
Body 313A).
Fuel Delivery Pipe and Fuel Injector assembly Removal
(Refer to GROUP 13A, Injector 313A).
Fuel Delivery Pipe and Fuel Injector assembly Installation
(Refer to GROUP 13A, Injector 313A).
Throttle Body Installation (Refer to GROUP 13A, Throttle
Body 313A).
Adjustment 317).
Fuel Leak Check
2
5.0 1.0 Nm
1
3
5.0 1.0 Nm
4
11 1 Nm
5
6
10
8
13 1 Nm
7
N9
(Engine oil)
1.
2.
3.
4.
AC301313 AB
Removal steps
connector
connector
5.
6.
7.
8.
9.
10.

Earth cable connection
Emission control equipment hose
PCV hose
Oil level gauge and guide
O-ring
Detonation sensor connector clamp
INTAKE AND EXHAUST
15-5
INTAKE MANIFOLD
11 1 Nm
11
9.0 1.0 Nm
14
36 6 Nm
20 2 Nm
20 2 Nm
16
36 6 Nm
12
13 N
36 6 Nm
17 N
20 2 Nm
15
31 3 Nm
11.
12.
13.
14.
Removal steps
Vacuum hose and pipe assembly
EGR valve
EGR valve gasket
Brake booster vacuum hose
connection
INSPECTION
Check the following points; replace the part if a
problem is found.
Intake Manifold Check
1. Check for damage or cracking of any part.
AC301314 AB

15. Intake manifold stay
16. Intake manifold assembly
17. Intake manifold gasket
M1151003100553
2. Clogging of the negative pressure (vacuum) outlet

port, or clogging of the exhaust gas recirculation
passages.
3. Using a straight edge and feeler gauge, check for
distortion of the cylinder head installation surface.
Limit: 0.20 mm
INTAKE AND EXHAUST
15-6
EXHAUST MANIFOLD
EXHAUST MANIFOLD
M1151003300535
8N
7
29 3 Nm
14 1 Nm
44 5 Nm
29 3 Nm
14 1 Nm
49 5 Nm
35 6 Nm
5
44 5 Nm
4N
49 10 Nm
AC301312 AB
Removal steps
<<A>> >>A<< 1. Oxygen sensor

2. Exhaust manifold cover
3. Front exhaust pipe connection
4. Exhaust pipe gasket
5.
6.
7.
8.

Exhaust manifold bracket
Engine hanger
Exhaust manifold
Exhaust manifold gasket
INTAKE AND EXHAUST

EXHAUST MANIFOLD

<<A>> OXYGEN SENSOR REMOVAL
MD998770
Oxygen sensor
AC212566 AB
Use special tool oxygen sensor wrench (MD998770)

to remove the oxygen sensor.

>>A<< OXYGEN SENSOR INSTALLATION
MD998770
Oxygen sensor
AC212566 AB

to install the oxygen sensor.
INSPECTION
M1151003400480
Check the following points; replace the part if a

problem is found.
Exhaust Manifold Check
1. Check for damage or cracking of any part.
2. Using a straight edge and a feeler gauge, check
for distortion of the cylinder head installation
surface.
Limit: 0.20 mm
15-7
INTAKE AND EXHAUST
15-8
EXHAUST PIPE AND MAIN MUFFLER
EXHAUST PIPE AND MAIN MUFFLER

M1151008700282
13 2 Nm
5
13 2 Nm
6
1
13 2 Nm
13 2 Nm
10 N
11
3
2
7N
9N
49 10 Nm
45 5 Nm
59 10 Nm
49 10 Nm
AC301054 AB
1.
4.
5.
6.
2.
4.
7.
8.
Exhaust main muffler removal

steps
Exhaust main muffler
Exhaust pipe gasket
Hanger
Exhaust pipe damper
Centre exhaust pipe removal
steps
Centre exhaust pipe
Exhaust pipe gasket
Exhaust pipe gasket
Hanger
Front exhaust pipe removal

steps
Centre under cover (front) (Refer to

GROUP 51, Under Cover 351).
3. Front exhaust pipe
11. Hanger
17-1
GROUP 17
00
11
ENGINE AND
EMISSION
CONTROL
12
13
14
15
16
17
21
CONTENTS
ENGINE CONTROL . . . . . . . . . .
17
22
CRANKCASE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . .
17
25
17
GENERAL INFORMATION (CRANKCASE

EMISSION CONTROL SYSTEM) . . . . .
17
26
17
COMPONENT LOCATION (CRANKCASE

17
27
17
POSITIVE CRANKCASE VENTILATION

SYSTEM CHECK . . . . . . . . . . . . . . . . . .
17
31
17

(PCV) VALVE CHECK . . . . . . . . . . . . . .
17
ACCELERATOR CABLE CHECK AND

ADJUSTMENT. . . . . . . . . . . . . . . . . . . .
ACCELERATOR CABLE AND

PEDAL . . . . . . . . . . . . . . . . . . . . . .
17
17
EMISSION CONTROL <MPI> . .
17
17
EMISSION CONTROL DEVICE

REFERENCE TABLE . . . . . . . . . .
17
17
SPECIAL TOOL . . . . . . . . . . . . . . .
17
VACUUM HOSE. . . . . . . . . . . . . . .
17
VACUUM HOSE PIPING DIAGRAM . . .
17
VACUUM CIRCUIT DIAGRAM . . . . . . .
17
VACUUM HOSE CHECK. . . . . . . . . . . .
17
VACUUM HOSE INSTALLATION . . . . .
17
EVAPORATIVE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . .
17
32
33
34
GENERAL INFORMATION (EVAPORATIVE

17
35
COMPONENT LOCATION (EVAPORATIVE

17
36
PURGE CONTROL SYSTEM CHECK. .
17
PURGE PORT VACUUM CHECK . . . . .
17
37
PURGE CONTROL SOLENOID VALVE

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .
17
CANISTER . . . . . . . . . . . . . . . . . . . . . . .
17
51
17
52
EXHAUST GAS RECIRCULATION (EGR)

SYSTEM . . . . . . . . . . . . . . . . . . . . .
17
54
GENERAL INFORMATION
(EGR SYSTEM). . . . . . . . . . . . . . . . . . .
17
COMPONENT LOCATION
(EGR SYSTEM) . . . . . . . . . . . . . . . . . . .
17
42
55
17-2
EGR SYSTEM CHECK. . . . . . . . . . . . . . . . .
17
EGR VALVE CHECK. . . . . . . . . . . . . . . .
17
EGR PORT VACUUM CHECK . . . . . . . .
17
EGR CONTROL SOLENOID VALVE

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .
17
CATALYTIC CONVERTER . . . . . .
17
17
17
ENGINE AND EMISSION CONTROL
17-3
ENGINE CONTROL
ENGINE CONTROL
GENERAL INFORMATION
M1171000100255
A cable-type accelerator mechanical suspendedtype pedal has been adopted.
M1171000300077
Items
Standard value
Accelerator cable play mm
1.0 - 2.0
Engine idle speed r/min
750 100
ON-VEHICLE SERVICE
7. If there is too much slack or no slack, adjust play

by the following procedures.
ACCELERATOR CABLE CHECK AND

ADJUSTMENT
Adjusting nut
M1171000900284
1. Turn A/C and lights OFF. Inspect and adjust at no

load.
2. Warm engine until stabilized at idle.
3. Confirm idle speed is at standard value.
4. Stop engine. [ignition switch: LOCK (OFF)
position].
5. Confirm there are no sharp bends in the
accelerator cable.
6. Check the inner cable for correct slack.
Plate
Accelerator cable
AC301055 AB
(1) Loosen the adjusting bolt to release the cable.

(2) Move the plate until the inner cable play is at
the standard value, and then tighten the
adjusting bolt.
(3) After adjusting, check that the throttle lever is
touching the stopper.
17-4
ENGINE CONTROL
ACCELERATOR CABLE AND PEDAL

M1171001200329
Adjusting the Accelerator Cable (Refer to 317).
5.0 1.0 Nm
3
1
2
12 2 Nm
9
7
10
11
N5
12 N
13
AC301187 AB
1.
2.
3.
1.
4.
Accelerator cable assembly

removal steps
Inner cable connection (Accelerator
pedal side)
Inner cable connection (Throttle body
side)
Accelerator cable assembly
Accelerator pedal assembly
removal steps
Inner cable connection (Accelerator
pedal side)

>>A<< ACCELERATOR PEDAL PAD
INSTALLATION
CAUTION
To prevent damages to the Pedal Pad, warm the
thumb area of the Pedal Pad with a dryer, etc.
prior to assembling it.
NOTE: If it is difficult to assemble, apply soapy water
to the thumb area to enhance the assembling
process.
5.
6.
7.
8.
9.
10.
11.
>>A<< 12.
13.

Push-on spring nut
Accelerator arm and accelerator
pedal pad assembly
Bushing
Spring
Stopper
Accelerator pedal bracket
Accelerator arm
Accelerator pedal pad
Accelerator pedal stopper
17-5
EMISSION CONTROL <MPI>

GENERAL INFORMATION
M1173000100370
The emission control system consists of the following

subsystems:
Items
Name
Crankcase emission control system

Evaporative emission control system
Exhaust emission control system
Specification
Crankcase emission control

system
Positive crankcase ventilation

(PCV) valve
Variable flow type

(Purpose: HC reduction)
Evaporative emission control

system
Canister
Equipped
(Purpose: HC reduction)
Exhaust emission control system
Air-fuel ratio control device - MPI

system
Oxygen sensor feedback type

(Purpose: CO, HC, NOx reduction)
Exhaust gas recirculation system

EGR valve
Equipped
Single type
(Purpose: NOx reduction)
Catalytic converter
Monolith type
(Purpose: CO, HC, NOx reduction)
EMISSION CONTROL DEVICE

REFERENCE TABLE
M1173006600135
Related parts
Crankcase
emission
control
system
PCV valve
Evaporative
emission
control
system
MPI system component
Air/fuel ratio Catalytic

control
converter
system
Exhaust gas
recirculation
system
Catalytic converter
EGR valve
M1173000300288
Items
Standard value
Purge control solenoid valve coil resistance (at 20C) W
30 - 34
EGR control solenoid valve coil resistance (at 20C) W
29 - 35
17-6
SPECIAL TOOL
M1173000600171
Tool
Number
Name
Use
MD998770
Oxygen sensor wrench

oxygen sensor
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
M1173000900321
Air cleaner
Air
To
fuel tank
Fuel pressure
From
regulator
fuel pump
PCV valve
EGR valve
Canister
Oxygen sensor
(front)
Catalytic
converter
EGR control
solenoid valve
Purge control
solenoid valve

Catalytic
converter
AK204364AB
17-7
VACUUM CIRCUIT DIAGRAM

M1173007100207
Intake manifold
Throttle body
To
combustion
chamber
From
air
cleaner
W
R
Fuel
pressure
regulator
G
Vacuum hose colour
B: Black
G: Green
R: Red
W: White
Y: Yellow
EGR
valve
EGR
control
solenoid
valve
VACUUM HOSE CHECK

M1173007300137
1. Using the piping diagram as a guide, check to be

sure that the vacuum hoses are correctly
connected.
2. Check the connection condition of the vacuum
hoses, (removed, loose, etc.) and check to be
sure that there are no bends or damage.
VACUUM HOSE INSTALLATION

M1173007200099
1. When connecting the vacuum hoses, they should

be securely inserted onto the nipples.
2. Connect the hoses correctly, using the vacuum
hose piping diagram as a guide.
Canister
B
B
Purge
control
solenoid
valve
AK201210 AC
CRANKCASE EMISSION CONTROL

SYSTEM
GENERAL INFORMATION (CRANKCASE
EMISSION CONTROL SYSTEM)
M1173005000237
The crankcase emission control system prevents

blow-by gases from escaping inside the crankcase
into the atmosphere.
Fresh air is sent from the air cleaner into the
crankcase through the breather hose.
The air becomes mixed with the blow-by gases
inside the crankcase.
The blow-by gas inside the crankcase is drawn into
the intake manifold through the positive crankcase
ventilation (PCV) valve.
The PCV valve lifts the plunger according to the
intake manifold vacuum so as to regulate the flow of
blow-by gas properly.
In other words, the blow-by gas flow is regulated
during low load engine operation to maintain engine
stability, while the flow is increased during high load
operation to improve the ventilation performance.
17-8
SYSTEM DIAGRAM
Air cleaner
Air
Ventilation hose
Breather hose
PCV valve
AK204365AB
COMPONENT LOCATION (CRANKCASE

M1173007400156
PCV valve
AKX00336 AD
PCV valve
AK204366AB

SYSTEM CHECK
M1173001100179
1.
2.
3.
4.
Remove the ventilation hose from the PCV valve.

Remove the PCV valve from the rocker cover.
Reinstall the PCV valve at the ventilation hose.
Start the engine and run at idle.
5. Place a finger at the opening of the PCV valve

and check that vacuum of the intake manifold is
felt.
NOTE: At this moment, the plunger in the PCV
valve moves back and forth.
6. If vacuum is not felt, clean the PCV valve or
replace it.
17-9

(PCV) VALVE CHECK
EVAPORATIVE EMISSION CONTROL

SYSTEM
M1173001200187
GENERAL INFORMATION (EVAPORATIVE

M1173005100320
PCV valve
AK100010 AC
1. Insert a thin rod into the PCV valve from the side
shown in the illustration (rocker cover installation
side), and move the rod back and forth to check
that the plunger moves.
2. If the plunger does not move, there is a clogging
in the PCV valve. In this case, clean or replace the
PCV valve.
The evaporative emission control system prevents

fuel vapours generated in the fuel tank from escaping
into the atmosphere.
Fuel vapours from the fuel tank flow through the fuel
tank pressure control valve and vapour pipe/hose to
be stored temporarily in the canister.
When driving the vehicle, fuel vapours stored in the
canister flow through the purge solenoid and purge
port and go into the intake manifold to be sent to the
combustion chamber.
When the engine coolant temperature is low or when
the intake air quantity is small (when the engine is at
idle, for example), the engine control unit turns the
purge solenoid off to shut off the fuel vapour flow to
the intake manifold.
This does not only insure the driveability when the
engine is cold or running under low load but also
stabilize the emission level.
SYSTEM DIAGRAM
Throttle body
Engine-ECU
From
fuel
tank
Canister
Air flow sensor
OFF
Purge
control
ON Solenoid
valve
Battery
Engine coolant
temperature sensor
Control
relay
Intake air
temperature sensor
Barometric pressure
sensor
AK204367AB
17-10
COMPONENT LOCATION (EVAPORATIVE

PURGE PORT VACUUM CHECK

M1173001500133
M1173007500164
Vacuum hose
Plug
Purge control
solenoid valve
AK201225 AD
AK201217 AC
PURGE CONTROL SYSTEM CHECK

M1173001400211
1. Disconnect the vacuum hose (red stripe) from the

throttle body and connect a hand vacuum pump to
the nipple.
2. Plug the vacuum hose (red stripe).
Vacuum hose
Vacuum
Plug
AK201220AC
Engine speed (r/min)

AK100011AC
1. Disconnect the vacuum hose (red stripe) from

throttle body and connect it to a hand vacuum
pump.
2. Plug the nipple from which the vacuum hose was
removed.
3. When the engine is cold or hot, apply a vacuum of
53 kPa, and check the condition of the vacuum.
When engine is cold
(Engine coolant temperature: 40C or less)
Engine condition
Normal condition
At idle
Vacuum is maintained.
3,000 r/min
When engine is hot
(Engine coolant temperature: 80C or higher)
Engine condition
Normal condition
At idle
Vacuum is maintained.
3,000 r/min (within 3

minutes after engine
starts)
Vacuum will leak.

4. Check that a fairly constant negative pressure is
generated regardless of the engine speed.
5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.
17-11
PURGE CONTROL SOLENOID VALVE

CHECK
M1173001700193
NOTE: When disconnecting the vacuum hose,

always make a mark so that it can be reconnected at
original position.
A
2. Disconnect the harness connector.

3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
4. Check airtightness by applying a vacuum with
voltage applied directly from the battery to the
purge control solenoid valve and without applying
voltage.
Battery voltage
Normal condition
Applied
Vacuum leaks
Not applied
Vacuum maintained
5. Measure the resistance between the terminals of
the solenoid valve.
Battery
AK100012 AC
AK100013
1. Disconnect the vacuum hose from the solenoid

valve.
17-12
CANISTER
M1173004800296

Air Cleaner Cover and Air Intake Hose Removal and
Installation (Refer to GROUP 15 - Air Cleaner 315).
3
2
6
AC301056 AB
1.
2.
3.
4.
Removal steps
Purge hose connection
Vapour hose
Vent connector
Vapour hose
5.
6.
7.
8.

Hose clamp
Canister
Fuel high-pressure hose clamp
Canister bracket
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

GENERAL INFORMATION (EGR SYSTEM)
M1173005200264
The exhaust gas recirculation (EGR) system lowers

the nitrogen oxide (NOx) emission level.
When the air/fuel mixture combustion temperature is
high, a large quantity of nitrogen oxides (NOx) is
generated in the combustion chamber.
Therefore, this system recirculates part of emission
gas from the exhaust port of the cylinder head to the
combustion chamber through the intake manifold to
decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.
The EGR flow rate is controlled by the EGR valve so
as not to decrease the driveability.
OPERATION
The EGR valve is being closed and does not
recirculate exhaust gases under one of the following
conditions.
Otherwise, the EGR valve is opened and recirculates
exhaust gases.
The engine coolant temperature is low.
The engine is at idle.
The throttle valve is widely opened.
17-13
SYSTEM DIAGRAM
EGR
control
Solenoid
valve
OFF
Engine-ECU
EGR valve
Barometric pressure
sensor
ON
Air flow sensor
Control
relay
Engine coolant
temperature sensor
Crank angle sensor
Battery
AK204368 AB
COMPONENT LOCATION (EGR SYSTEM)
EGR SYSTEM CHECK
M1173007600172
M1173002600326
Three-way terminal
Green stripe
EGR control
solenoid valve
EGR valve
AK201234AC
EGR valve
AK200375AE
1. Disconnect the vacuum hose (Green stripe) from

the EGR valve, and then connect a hand vacuum
pump via the three-way terminal.
2. When the engine is hot or cold, check the
condition of vacuum by racing the engine.
When engine is cold
(Engine coolant temperature: 20C or less)
Throttle valve
Normal vacuum condition
AK201237AC
Open quickly
No vacuum will generate (the

same as barometric pressure.)
When engine is hot

(Engine coolant temperature: 80C or higher)
Throttle valve
Normal vacuum condition
Open quickly
It will momentarily rise over 13

kPa
17-14
EGR PORT VACUUM CHECK
3. Disconnect the three-way terminal.
M1173002900145
Green stripe
white stripe
EGR valve
AK200376 AC
AK201247 AC
4. Connect the hand vacuum pump to the EGR valve

nipple.
5. Check whether the engine stalls or the idling is
unstable when a vacuum of 30 kPa or higher is
applied during idling.
1. Disconnect the vacuum hose (White stripe) from

the throttle body EGR vacuum nipple and connect
a hand vacuum pump to the nipple.
2. Plug the vacuum hose (White stripe).
EGR VALVE CHECK

M1173002800212
1. Remove the EGR valve and inspect for sticking,

carbon deposits, etc. If found, clean with a
suitable solvent so that the valve seats correctly.
2. Connect a hand vacuum pump to the EGR valve.
3. Apply 67 kPa of vacuum, and check that the
vacuum is maintained.
Vacuum
Engine speed (r/min)

AK100011AC

4. Check that a fairly constant negative pressure is
generated regardless of the engine speed.
5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.
AKX00348
4. Apply a vacuum and check the passage of air by

blowing through one side of the EGR passage.
Vacuum
Passage of air
5.3 kPa or less
Air is not blown out
27 kPa or more
Air is blown out
5. Replace the gasket, and tighten to the specified
torque.

EGR CONTROL SOLENOID VALVE

CHECK
M1173003100216
NOTE: When disconnecting the vacuum hose,

always make a mark so that it can be reconnected at
original position.
A
2. Disconnect the harness connector.

3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
4. Check air tightness by applying a vacuum with
voltage applied directly from the battery to the
EGR control solenoid valve and without applying
voltage.
Battery
voltage
B nipple
condition
Normal condition
Not applied
Open
Vacuum
maintained
Applied
Open
Vacuum leaks
B
C
Closed
Battery
AK201251AB
AK100016
1. Disconnect the vacuum hose from the solenoid

valve.
17-15
Vacuum
maintained
5. Measure the resistance between the terminals of
the solenoid valve.
17-16

M1173010500153

Air Cleaner Cover and Air Intake Hose Removal and
Installation (Refer to GROUP 15 - Air Cleaner 315).
1
2
20 2 Nm
3N
AC301219 AB
1.
Removal steps
Vacuum hose connection
2.
3.

EGR valve
EGR valve gasket
CATALYTIC CONVERTER
M1173003900353
44 5 Nm
2
N
4
3N
59 10 Nm
6
49 10 Nm
<<A>>
>>A<<
1.
2.
3.
Removal steps
Oxygen sensor
Centre exhaust pipe connection
Exhaust pipe gasket
AC212565 AC
4.
5.
6.

Front exhaust pipe connection
Exhaust pipe gasket
Catalytic converter
17-17
<<A>> OXYGEN SENSOR REMOVAL
>>A<< OXYGEN SENSOR INSTALLATION
MD998770
Oxygen sensor
AC212566 AB

to remove the oxygen sensor.
MD998770
Oxygen sensor
AC212566 AB

to install the oxygen sensor.
127(6
14-1
GROUP 14
00
11
ENGINE COOLING
12
13
14
CONTENTS
14
FAN CONTROLLER CHECK . . . . . . . . . . .
14
16
14

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
17
RADIATOR FAN MOTOR CHECK . . . . . . .
14
THERMOSTAT . . . . . . . . . . . . . . . . . .
14
14
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
14
25
WATER PUMP . . . . . . . . . . . . . . . . . .
14
26
14
27
31
LUBRICANT. . . . . . . . . . . . . . . . . . . .
14
SEALANT. . . . . . . . . . . . . . . . . . . . . .
14
SPECIAL TOOL . . . . . . . . . . . . . . . . .
15
14
21
22
14
14
WATER HOSE AND WATER PIPE . .
14
14
14
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
14
32
ENGINE COOLANT LEAK CHECK . . . . . .

RADIATOR CAP VALVE OPENING
PRESSURE CHECK. . . . . . . . . . . . . . . . . .
14
ENGINE COOLANT REPLACEMENT . . . .
14
RADIATOR . . . . . . . . . . . . . . . . . . . . .
14
33
CONCENTRATION MEASUREMENT . . . .
14
14
34
35
36
37
42
51
52
54
55
ENGINE COOLING
14-2
GENERAL INFORMATION
GENERAL INFORMATION
M1141000100359
The cooling system is designed to keep every part of

the engine at appropriate temperature in whatever
condition the engine may be operated. The cooling
method is of the water-cooled, pressure forced
circulation type in which the water pump pressurizes
coolant and circulates it throughout the engine. If the
coolant temperature exceeds the prescribed
Item
Radiator
temperature, the thermostat opens to circulate the

coolant through the radiator as well so that the heat
absorbed by the coolant may be radiated into the air.
The water pump is of the centrifugal type and is
driven by the drive belt from the crankshaft. The
radiator is the corrugated fin, down flow type.
Specification
Performance kJ/h
225,628
M1141000300364
Item
Standard value
Limit
High-pressure valve opening pressure of radiator cap kPa
93 - 123
Minimum 83
Range of coolant antifreez concentration of radiator %
30 - 60
Thermostat
Valve opening temperature of thermostat C
82 1.5
Full-opening temperature of thermostat C
95
Valve lift mm
8.5 or more
LUBRICANT
M1141000400305
Item
Specified coolant
Quantity L
Engine coolant
(including condense
tank)
DIAQUEEN SUPER LONG LIFE COOLANT or an 7.0

equivalent
SEALANT
M1141000500302
Item
Specified sealant
Thermostat case, Water outlet fitting
MITSUBISHI GENUINE Part No.MD970389 or equivalent
Cylinder block drain plug
3M Nut Locking Part No.4171 or equivalent
ENGINE COOLING
14-3
SPECIAL TOOL
SPECIAL TOOL
M1141000600224
Tool
Number
Name
Use
MB991871
LLC changer
Coolant refilling
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Making voltage and

resistance measurement
A: Connector pin contact
pressure inspection
connection
MB991871
D
MB991223 AC
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE
SYMPTOMS
M1141005600337
Trouble symptom
Inspection
procedure No.
Reference page
Radiator fan and condenser fan do not operate
314
Radiator fan and condenser fan do not change speed or stop
314
Radiator fan does not operate
314
Condenser fan does not operate
314
ENGINE COOLING
14-4
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1: Radiator Fan and Condenser Fan do not Operate
Radiator Fan and Condenser Fan Drive Circut
ENGINE-ECU
FUSIBLE
LINK 2
ENGINE CONTROL
RELAY
FAN CONTROL
RELAY
FAN
CONTROLLER
CONDENSER
FAN MOTOR
RADIATOR
FAN MOTOR
Wire colour code

G : Green L : Blue
AC301898 AB
CIRCUIT OPERATION
The fan controller is powered from fusible link (2).
The engine-ECU uses input signals from the A/C
switch, the engine coolant temperature sensor
and the output shaft speed sensor to control the
speed of the radiator fan motor and condenser
fan motor.
The engine-ECU controls the fan controller to
activate the radiator fan motor and the condenser
fan motor.
TECHNICAL DESCRIPTION
The cause could be a malfunction of the fan
controller power supply or earth circuit.
The cause could also be a malfunction of the fan
controller or the engine-ECU.
Malfunction of fusible link (2)
Malfunction of fan control relay
Malfunction of engine control relay
Malfunction of fan controller
ENGINE COOLING
14-5
Malfunction of radiator fan motor

Malfunction of engine-ECU
Damaged wiring harness or connector
STEP 5. Measure at fan control relay A-10X

connector.
Connector: A-10X
DIAGNOSIS
A-10X
STEP 1. Check fusible link (2).

3

YES : Go to Step 2.
NO : Replace fusible link (2).
4
1
Front of vehicle
STEP 2. Check continuity at fan control relay A10X.

Refer to 314.
YES : Go to Step 3.
NO : Replace the fan control relay.
STEP 3. Check the radiator fan motor.

Refer to 314.
YES : Go to Step 4.
NO : Replace the radiator fan motor.
STEP 4. Check at fan control relay A-10X

connector.
YES : Go to Step 5.
NO : Repair or replace the fan control relay.
AC301900AB
(1) Check the power supply line for short or open

circuit.
(2) Disconnect the fan control connector, and
measure the voltage between terminal 4 and
earth at the relay box side.
OK: System voltage
YES : Go to Step 6.
NO : Check the wiring harness between fan
control relay A-10X (terminal 4) and fusible

link (2), and repair if necessary.
connector.
Connector: A-10X
A-10X
3
2
4
1
Front of vehicle
AC301900AB

OK: System voltage
NO : Go to Step 7.
STEP 7. Check continuity at engine control relay

B-17X.
Refer to 313A.
YES : Go to Step 8.
NO : Replace the engine control relay.
14-6
ENGINE COOLING
STEP 8. Check at engine control relay A-17X

connector.
YES : Go to Step 9.
NO : Repair or replace the engine control relay.
STEP 9. Check the wiring harness between fan

control relay A-10X (terminal 1) and engine
control relay A-17X (terminal 1).
Connector: A-10X
A-10X
3
2
4
1
Front of vehicle
AC301900AB
Connector: B-17X
B-17X
1
Front of vehicle
AC301900AC

circuit.
NOTE:
Connector: C-17
1 2 3
4 5
6 7 8 9 10 11 12 13
AC301918 AB
Connector: A-14
1 2
3 4 5 6 7
8 9
10 11
15
12 13 14
16 17
AC301917AB

connector C-17 and front wiring harness (LH) and
control wiring harness combination connector A14, and repair if necessary.
ENGINE COOLING
14-7


control relay A-17X (terminal 1), and repair if
necessary.
connector.
STEP 12. Measure at fan controller connector A20.

Connector: A-20
A-20
3 2 1
Connector: A-10X
AC301902 AB
A-10X
3

circuit.
4
1
Front of vehicle
AC301900AB
(1) Check the earth line for open circuit.

measure the resistance between terminal 3 and
OK: Continuity exists.
control relay A-10X (terminal 3) and body

earth, and repair if necessary.
STEP 11. Check fan controller connector A-20.
NO : Repair the fan controller connector.
Connector A-20
(Conponent side)
3 2
AC201418 AF
(2) Disconnect the fan controller connector, and

earth at the wiring harness side.
OK: System voltage
controller A-20 (terminal 3) and fan control

relay A-10X (terminal 2), and repair if
necessary.
ENGINE COOLING
14-8

Connector: A-20
STEP 14. Measure at engine-ECU connector C134.

Connector: C-134
A-20
3 2 1
Engine-ECU
AC301902 AB
Connector A-20
(Conponent side)
3 2
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AC301901AB
AC201414 AF

body earth at the wiring harness side.
Connector C-134
(harness side)
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
controller A-20 (terminal 1) and body earth,

AC301903 AB
(1) Connect the engine-ECU connector, and

body earth.
Engine: Idling
A/C switch: ON
OK: 0.7 V or more (A/C compressor is
working)
NO : Go to Step 15.
STEP 15. Check engine-ECU connector C-134.

NO : Repair the engine-ECU connector.
ENGINE COOLING

controller A-20 (terminal 2) and engine-ECU C134 (terminal 21).
Connector: A-20
14-9

controller A-20 (terminal 2) and engine-ECU

C-134 (terminal 21), and repair if necessary.
STEP 17. Verify that the condition described by
the customer exists.
A-20
Q: Does a malfunction take place again?

YES : An intermittent malfunction is suspected
3 2 1
AC301902 AB
Connector: C-134
Engine-ECU
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AC301901AB
(1) Check the output line for short or open circuit.

NOTE:
Connector: A-14
1 2
3 4 5 6 7
8 9
10 11
15
12 13 14
16 17
AC301917AB
Prior to the wiring harness inspection, check front

wiring harness (LH) and control wiring harness
combination connector A-14, and repair if
necessary.
(Refer to GROUP 00, How to cope with

intermittent malfunctions 300).
14-10
ENGINE COOLING
INSPECTION PROCEDURE 2: Radiator Fan and Condenser Fan do not Change Speed or Stop
Radiator Fan and Condenser Fan Drive Circuit
Refer to 314.
CIRCUIT OPERATION
The engine-ECU uses input signals from the A/C
switch, the engine coolant temperature sensor
and the output shaft speed sensor to control the
speed of the radiator fan motor and condenser
fan motor.
The engine-ECU controls the fan controller to
activate the radiator fan motor and the condenser
fan motor.
The fan controller has variable control of the radiator
fan motor and the condenser fan motor speeds using
signals transmitted from the engine-ECU.
Malfunction of fan control relay
Malfunction of engine-ECU
DIAGNOSIS
STEP 1. Check continuity at fan control relay A10X.
Refer to 314.
YES : Go to Step 2.
NO : Replace the fan control relay.
STEP 2. Check at fan control relay A-10X

connector.
YES : Go to Step 3.
NO : Repair or replace the fan control relay.

connector.
Connector: A-10X
A-10X
3
2
4
1
Front of vehicle
AC301900AB

circuit.
OK: System voltage
YES : Go to Step 4.
control relay A-10X (terminal 4) and fusible

link (2), and repair if necessary.
connector.
Connector: A-10X
A-10X
3
2
4
1
Front of vehicle
AC301900AB

OK: System voltage
YES : Go to Step 6.
NO : Go to Step 5.
ENGINE COOLING
14-11

control relay A-17X (terminal 1).
Connector: A-10X
A-10X
3

YES : Go to Step 6.

control relay A-17X (terminal 1), and repair if
necessary.
connector.
Connector: A-10X
Front of vehicle
AC301900AB
A-10X
3
Connector: B-17X
4
1
Front of vehicle
B-17X
1
AC301900AB
Front of vehicle
AC301900AC

circuit.
NOTE:
Connector: C-17

YES : Go to Step 7.
control relay A-10X (terminal 3) and body

earth, and repair if necessary.
STEP 7. Check fan controller connector A-20.
YES : Go to Step 8.
NO : Repair the fan controller connector.
1 2 3
4 5
6 7 8 9 10 11 12 13
AC301918 AB
Connector: A-14
1 2
3 4 5 6 7
8 9
10 11
15
12 13 14
16 17
AC301917AB

connector C-17 and front wiring harness (LH) and
control wiring harness combination connector A14, and repair if necessary.
ENGINE COOLING
14-12

Connector: A-20
STEP 10. Measure at engine-ECU connector C134.

Connector: C-134
A-20
3 2 1
Engine-ECU
AC301902 AB

circuit.
earth at the wiring harness side.
OK: System voltage
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

YES : Go to Step 9.
controller A-20 (terminal 3) and fan control

relay A-10X (terminal 2), and repair if
necessary.
AC301901AB
Connector C-134
(harness side)
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
Connector: A-20
AC301903 AB
A-20
3 2 1
AC301902 AB

body earth at the wiring harness side.
controller A-20 (terminal 1) and body earth,

(1) Connect the engine-ECU connector, and

body earth.
Engine: Idling
A/C switch: ON
OK: 0.7 V or more (A/C compressor is
working)
NO : Go to Step 11.
STEP 11. Check engine-ECU connector C-134.

NO : Repair the engine-ECU connector.
ENGINE COOLING

controller A-20 (terminal 2) and engine-ECU C134 (terminal 21).
Connector: A-20
14-13

controller A-20 (terminal 2) and engine-ECU

C-134 (terminal 21), and repair if necessary.
A-20

3 2 1
AC301902 AB
Connector: C-134
Engine-ECU
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AC301901AB
(1) Check the output line for short or open circuit.

NOTE:
Connector: A-14
1 2
3 4 5 6 7
8 9
10 11
15
12 13 14
16 17
AC301917AB
Prior to the wiring harness inspection, check front

wiring harness (LH) and control wiring harness
combination connector A-14, and repair if
necessary.

14-14
ENGINE COOLING
INSPECTION PROCEDURE 3: Radiator Fan does not Operate

The cause could be a malfunction of the radiator fan
motor or an open circuit between the fan controller
and the radiator fan motor.
Malfunction of radiator fan motor
DIAGNOSIS
STEP 1. Check the radiator fan motor.
Refer to 314.
Q: Is the radiator fan motor in good condition?
YES : Go to Step 2.
NO : Replace the radiator fan motor.
STEP 2. Check the fan controller

Refer to 314.
Q: Is the fan controller in good condition?
YES : Go to Step 3.
NO : Replace the radiator fan controller.


NO : Return to Step 1.
INSPECTION PROCEDURE 4: Condenser Fan does not Operate

CIRCUIT OPERATION
The engine-ECU judges the required revolution
speed of radiator fan motor and condenser fan
motor using the input signals transmitted from A/
C switch, automatic compressor controller,
vehicle speed sensor and engine coolant
temperature sensor. The engine-ECU activates
the fan controller to drive the radiator fan motor
and condenser fan motor.
The cause could be a malfunction of the condenser
fan motor or fan controller.
Malfunction of condenser fan motor
DIAGNOSIS
STEP 1. Check the condenser fan motor.
Refer to GROUP 55, Condenser and Condenser Fan
Motor 355A.
Q: Is the condenser fan motor in good condition?
YES : Go to Step 2.
NO : Replace the condenser fan motor, then go
to Step 3.
STEP 2. Check the fan controller.
Refer to 314.
Q: Is the fan controller in good condition?
YES : Go to Step 3.
NO : Replace the fan controller, then go to Step
3.
STEP 3. Check the symptoms.
Q: Does the condenser fan operate correctly?
NO : Return to Step 1.
ENGINE COOLING
14-15
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK
M1141001000281
WARNING
When pressure testing the cooling system,
slowly release cooling system pressure to
avoid getting burned by hot coolant.
CAUTION
Be sure to completely clean away any
moisture from the places checked.
When the tester is taken out, be careful not to
spill any coolant.
Be careful when installing and removing the
tester and when testing not to deform the
filler neck of the radiator.
Cap adapter
Adapter
2. Increase the pressure until the indicator of the

gauge stops moving.
Minimum limit: 83 kPa
Standard value: 93 - 123 kPa
3. Replace the radiator cap if the reading does not
remain at or above the limit.
ENGINE COOLANT REPLACEMENT

M1141001200401
WARNING
When removing the radiator cap, use care to
avoid contact with hot coolant or steam.
Place a shop towel over the cap and turn the
cap counterclockwise a little to let the
pressure escape through the vinyl tube.
After relieving the steam pressure, remove
the cap by slowly turning it
counterclockwise.
1. Drain the water from the radiator, heater core and
engine after unplugging the radiator drain plug
and removing the radiator cap.
Intake side
ACX01844 AC
1. Check that the coolant level is up to the filler neck.

Install a radiator tester and apply 160 kPa
pressure, and then check for leakage from the
radiator hose or connections.
2. If there is leakage, repair or replace the
appropriate part.
RADIATOR CAP VALVE OPENING

PRESSURE CHECK
Cylinder block
drain plug
AC200630 AC
<4WD>
M1141001300356
NOTE: Be sure that the cap is clean before

testing. Rust or other foreign material on the cap
seal will cause an improper reading.
Cap adapter
30 3 Nm
Water feed tube assembly

AC301654 AB
AC211643 AB
1. Use a cap adapter to attach the cap to the tester.
2. Drain the water in the water jacket by unplugging

the drain plug of the cylinder block. On 4WD, drain
engine coolant from the water feed tube assembly
of the transfer.
3. Remove the reserve tank and drain the coolant.
4. Drain the coolant then clean the path of the
coolant by injecting water into the radiator from
the radiator cap area.
ENGINE COOLING
14-16
ON-VEHICLE SERVICE
Cylinder block
drain plug
10.Start the engine and let it warm up until the

thermostat opens.
11.After repeatedly revving the engine up to 3,000 r/
min several times, then stop the engine.
12.Remove the radiator cap after the engine has
become cold, and pour in coolant up to the brim.
Reinstall the cap.
CAUTION
AC200625 AC
5. Apply the designated sealant to the screw area of

the cylinder block drain plug, and then tighten to
the standard torque.
Specified sealant: 3M Nut Locking Part
No.4171 or equivalent
6. Securely tighten the drain plug of the radiator.
7. Assemble the reserve tank.
CAUTION
Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze
can cause corrosion of the aluminium
components.
MB991871
Air hose
Do not overfill the reserve tank.

13.Add coolant to the reserve tank between the
"FULL" and "LOW" mark if necessary.
CONCENTRATION MEASUREMENT
M1141001100330
Measure the temperature and specific gravity of the

engine coolant to check the antifreeze concentration.
Standard value: 30 - 60% (allowable
concentration range)
Recommended antifreeze: DIAQUEEN SUPER
LONG LIFE COOLANT or equivalent
CAUTION
If the concentration of the anti-freeze is below 30
%, the anti-corrosion property will be adversely
affected. In addition, if the concentration is above
60%, both the anti-freezing and engine cooling
properties will decrease, affecting the engine
adversely. For these reasons, be sure to maintain
the concentration level within the specified
range.
FAN CONTROLLER CHECK

M1141007400038
AC200579AC
8. By referring to the section on coolant, select an

appropriate concentration for safe operating
temperature within the range of 30 to 60 %. Use
special tool LLC changer (MB991871) to refill the
coolant. A convenient mixture is a 50 % water and
50 % antifreeze solution (freezing point: -31C).
Recommended antifreeze: DIAQUEEN SUPER
LONG LIFE COOLANT or equivalent
Quantity: 7.0 L
NOTE: For how to use special tool MB991871,
refer to its manufacturers instructions.
9. Reinstall the radiator cap.
AC103011
1. Remove the fan controller connector.

2. Turn the ignition switch to the "ON" position, and
measure the voltage between the harness-side
connector terminals.
Standard value: System voltage
ENGINE COOLING
14-17
ON-VEHICLE SERVICE

CHECK
Fan controller
M1141006200257
Fan control relay

1 2
AC103010 AD
3. Connect the fan controller connector, and

disconnect the condenser fan motor connector.
4. Ensure that the A/C switch is off, and start the
engine and run it at idle.
5. Measure the voltage between the fan controllerside connector terminals.
Standard value: 1V or less
AC211776
WARNING
Stay clear of the fan when the fan starts
running.
6. Turn the A/C switch to the "ON" position.
7. Measure the voltage between the fan controllerside connector terminals while the fan is running.
The voltage should repeat the values below.
Standard value:
8.2 2.6 V
System voltage 2.6 V
8. If the voltage does not repeatedly change as
indicated, replace the fan controller.
2
1
3
4
2
1
AC301712 AB
Battery
voltage
Terminal No.to
Continuity test
be connected to results
tester
Not applied
4-2
Open circuit
Connect
terminal
No.1 and
battery (-)
terminal.
Connect
terminal
No.3 and
battery (+)
terminal.
4-2
Less than 2 ohms
RADIATOR FAN MOTOR CHECK

M1141007100059
2 1
Radiator
fan motor
AC103006AE
1. Remove the radiator fan motor connector.
ENGINE COOLING
14-18
THERMOSTAT
2. Check to see that the fan motor of the radiator

turns when applying battery power between the
connector terminals of the radiator fan motor. Also
check to see that there is no abnormal sound
coming from the radiator fan motor at this time.
3. If the radiator fan motor is defective, replace it.
THERMOSTAT
M1141002400378

Engine Coolant Draining and Refilling (Refer to 314).
Air Cleaner Removal and Installation (Refer to GROUP
15, Air Cleaner 315).
Battery Removal and Installation
1
13 2 Nm
4
3
1.
2.
Removal steps
Engine coolant temperature gauge
unit connector
connector
<<A>>
>B<<
>>A<<
3.
4.
5.
AC301429 AB

Radiator lower hose connection
Water inlet fitting
Thermostat
ENGINE COOLING
14-19
THERMOSTAT

<<A>> RADIATOR LOWER HOSE

DISCONNECTION
INSPECTION
M1141002500364
THERMOSTAT CHECK
Mating marks
AC200641AC


>>A<< THERMOSTAT INSTALLATION
CAUTION
Make absolutely sure that no oil adheres to the
rubber ring of the thermostat. Also do not fold or
scratch the rubber ring during installation.
ACX00400 AB
1. Immerse the thermostat in water, and heat the

water while stirring. Check the thermostat valve
opening temperature.
Standard value:
Valve opening temperature: 82 1.5C
Jiggle valve
Valve lift
ACX00401AC
Rubber ring
AC000279 AB
Install the thermostat so that the jiggle valve is facing

straight up. Be careful not to fold or scratch the
rubber ring.
>>B<< RADIATOR LOWER HOSE CONNECTION
Projection
Water inlet pipe,

water outlet fitting
or radiator
Mating marks
AC200642 AC

water inlet fitting.
2. Check that the amount of valve lift is at the

standard value when the water is at the fullopening temperature.
NOTE: Measure the valve height when the
thermostat is fully closed, and use this
measurement to compare the valve height when
the thermostat is fully open.
Standard value:
Full-opening temperature: 95C
Amount of valve lift: 8.5 mm or more
ENGINE COOLING
14-20
WATER PUMP
WATER PUMP
M1141002700391
Engine Coolant Draining (Refer to 314).
Timing Belt Removal (Refer to GROUP 11A, Timing Belt
311A).
Timing Belt Installation (Refer to GROUP 11A, Timing Belt
311A).
Engine Coolant Refilling (Refer to 314).
N4
1
Bolt specifications
22 4 Nm
8 70
3N
23 3 Nm
8 22
8 14
8 25
14 1 Nm
8 22
Screw diameter length mm
AC301467AB
1.
2.
Removal steps
Alternator brace
Water pump

Water pump
O-ring
Water inlet pipe

AC103005 AD
Fit the O-ring to the groove in the water inlet pipe.

Then lubricate the O-ring and the inside of the water
pump with water, and then insert the pipe to the
water pump.
>>A<<
3.
4.

Water pump gasket
O-ring
ENGINE COOLING
14-21
WATER HOSE AND WATER PIPE

M1141003300385

Engine Coolant Draining and Supplying (Refer to 314
).
Air Cleaner Removal and Installation (Refer to GROUP
15, Air Cleaner 315).
Thermostat Removal and Installation (Refer to 314).
9
8
13 2 Nm
7
3
13 2 Nm
2
23 4 Nm
5
3 mm
3 mm
Sealant: Mitsubishi Genuine Part No. MD970839 or equivalent

AC301428 AB
<<A>>
>>C<<
>>B<<
>>B<<
1.
2.
3.
4.
5.
Removal steps
Radiator upper hose connection
Water outlet fitting
Water hose
Water hose
Thermostat case assembly
6.
7.
>>A<<
8.
9.

Heater hose connection
Transfer water return hose
connection <4WD>
Water inlet pipe assembly
O-ring
ENGINE COOLING
14-22

<<A>> RADIATOR UPPER HOSE
DISCONNECTION
Mating marks
>>B<< THERMOSTAT CASE ASSEMBLY/WATER

OUTLET FITTING INSTALLATION
1. Use a gasket scraper or wire brush to completely
eliminate all gasket material on the gasket
mounting surface.
2. Apply a bead of the specified sealant.
Specified Sealant: MITSUBISHI GENUINE
PART No.MD970389 or equivalent
3. With the sealant still wet (within 15 minutes after
the sealant is applied), install the thermostat case
or water outlet fitting. Do not apply the sealant in
an area more than the required.
AC200641AC
After making mating marks on the radiator hose and

hose clamp, disconnect the radiator hose.
>>C<< RADIATOR UPPER HOSE CONNECTION

Projection

CAUTION
Water pump or thermostat case
Water inlet pipe,

or radiator
O-ring
Water inlet pipe

AC200644 AC
Do not allow engine oil or other grease to adhere

to the O-ring
Insert the O-ring to the water pipe, and coat the outer
portion of the O-ring with water or engine coolant.
Mating marks
AC200642 AC

water outlet fitting.
INSPECTION
M1141003400274
WATER PIPE AND HOSE CHECK

Check the water pipe and hose for cracks, damage
and clogs. Replace them if necessary.
ENGINE COOLING
14-23
RADIATOR
RADIATOR
M1141001500424
315).
Engine Coolant Refilling and Level Check (Refer to 314
).
Engine Coolant Draining (Refer to 314).
315).
12 2 Nm
12 2 Nm
3
10
6
12
14
13
11
<<A>>
<<A>>
>>A<<
>>A<<
1.
2.
3.
4.
5.
6.
7.
8.
9.
Radiator removal steps

Drain plug
Radiator cap
Rubber hose
Reserve tank assembly
Radiator upper hose
Radiator lower hose
Upper insulator
Radiator assembly
Lower insulator
<<A>>
>>A<<
AC301650 AB
Radiator removal steps

10. Fan controller
11. Cooling fan assembly
Radiator fan motor removal
steps
3. Rubber hose
5. Radiator upper hose
11. Cooling fan assembly
12. Radiator fan
13. Radiator fan motor
14. Shroud assembly
ENGINE COOLING
14-24
RADIATOR
<<A>> RADIATOR UPPER HOSE/RADIATOR

LOWER HOSE DISCONNECTION
>>A<< RADIATOR LOWER HOSE/RADIATOR

UPPER HOSE CONNECTION
Projection
Mating marks
AC200641AC

Water inlet pipe,

or radiator
Mating marks
AC200642 AC

water inlet fitting.
42-1
GROUP 42
00
11
BODY
12
13
14
CONTENTS
HOOD. . . . . . . . . . . . . . . . . . . . .
42
15
TAILGATE WINDOW GLASS . . . .

ADJUSTMENT OF CLEARANCE AROUND
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENT OF ALIGNMENT OF
HOOD STEPPED PORTION AND HOOD
STRIKER . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENT OF HOOD HEIGHT . . .
42
42
42
42
ROOF WINDOW GLASS . . . . . . . .

DOOR . . . . . . . . . . . . . . . . . . . .
42
42
16
17
42
42
42
21
22
25
42
42
42
SEALANT . . . . . . . . . . . . . . . . . . . .
42
27
FENDER. . . . . . . . . . . . . . . . . . .
42
SPECIAL TOOLS . . . . . . . . . . . . . .
42
31
SPECIAL TOOL . . . . . . . . . . . . . . .
42
42
32
FENDER. . . . . . . . . . . . . . . . . . . . .
42
42
42
42
FUEL FILLER LID . . . . . . . . . . .
42
HOOD. . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION .
42
WINDOW GLASS . . . . . . . . . . .
42
ADHESIVE . . . . . . . . . . . . . . . . . . .
42
SPECIAL TOOL . . . . . . . . . . . . . . .
42
GENERAL . . . . . . . . . . . . . . . . . . .
42
WINDSHIELD. . . . . . . . . . . . . . . . .
42
42
QUARTER WINDOW GLASS . . . .

42
42
DOOR FIT ADJUSTMENT . . . . . . . . . . .

DOOR WINDOW GLASS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . .
GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT. . . . . . . . . . . . . . . .
POWER WINDOW SAFETY MECHANISM
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER WINDOW OPERATING
CURRENT CHECK . . . . . . . . . . . . . . . .
POWER WINDOW RELAY CHECK. . . .
CIRCUIT BREAKER (INCORPORATED
IN THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . .
POWER WINDOW CHECK . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . .
DOOR OUTSIDE HANDLE PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR INSIDE HANDLE PLAY
ADJUSTMENT . . . . . . . . . . . . . . . . . . . .
42
42
42
42
42
26
33
34
35
36
37
42
51
42
42
52
42
54
42
55
42
42-2
DOOR ASSEMBLY . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . .
DOOR GLASS AND REGULATOR

INSPECTION. . . . . . . . . . . . . . . . . . . . . .
DOOR HANDLE AND LATCH . . .

INSPECTION. . . . . . . . . . . . . . . . . . . . . .
WINDOW GLASS RUNCHANNEL

AND DOOR OPENING
WEATHERSTRIP . . . . . . . . . . . . .
42
42
42
TAILGATE HANDLE AND LATCH
42
42
42
KEYLESS ENTRY SYSTEM. . .
42
SPECIAL TOOLS. . . . . . . . . . . . . .
42
42
42
42
42
42
42
42
42
TAILGATE . . . . . . . . . . . . . . . .
42
42
SEALANTS . . . . . . . . . . . . . . . . . .
42
SPECIAL TOOL . . . . . . . . . . . . . .

INSPECTION . . . . . . . . . . . . . . . . . . . . .
KEYLESS ENTRY SYSTEM CHECK . .

KEYLESS ENTRY SYSTEM TIMER
LOCK FUNCTION INSPECTION . . . . . .
HOW TO REPLACE THE TRANSMITTER
BATTERY. . . . . . . . . . . . . . . . . . . . . . . .
ENABLING/DISABLING THE
ANSWERBACK FUNCTION . . . . . . . . .
HOW TO REGISTER SECRET CODE .
42
42
42
42
42
42
42
SUNROOF ASSEMBLY . . . . . .
42
42
42
42
42
TAILGATE FIT ADJUSTMENT . . . . . . . .
TAILGATE HANDLE PLAY CHECK . . . .
ADJUSTMENT OF TAILGATE HEIGHT .
TAILGATE . . . . . . . . . . . . . . . . . . .
42
42
42
42
42
42
42
WATER TEST . . . . . . . . . . . . . . . . . . . .
42
SUNROOF FIT ADJUSTMENT . . . . . . .
42
SUNROOF CHECK . . . . . . . . . . . . . . . .
42
SUNROOF SAFETY FUNCTION CHECK 42
ROOF LID GLASS OPERATION CURRENT
CHECK. . . . . . . . . . . . . . . . . . . . . . . . . .
42
SUNROOF INITIALIZATION . . . . . . . . .
42
SUNROOF ASSEMBLY. . . . . . . . .
42
42
BODY
42-3
HOOD
HOOD
ON-VEHICLE SERVICE
ADJUSTMENT OF HOOD HEIGHT

M1421007400101
ADJUSTMENT OF CLEARANCE AROUND

HOOD
M1421007200107
Y0215AU
Section A A
Hood
AC103720
ADJUSTMENT OF ALIGNMENT OF HOOD

STEPPED PORTION AND HOOD
STRIKER
16.5 mm
M1421007300104
Hood bumper
X0424CA
AC005948AF
Rotate the hood bumper by using the arrow mark on

the hood bumper as a guide to adjust the hood
height. If the hood bumper is rotated just one turn,
the hood height changes by approximately 3 mm.
AC005947
BODY
42-4
HOOD
HOOD
M1421001600301
2
6
21 4 Nm
11 2 Nm
1
9
7
11 2 Nm
5
1
1
2
9.0 2.0 Nm
AC107422AB
Removal
1. Hood bumper
Hood latch and hood lock release
cable removal steps
Radiator grille (Refer to GROUP 51,
Radiator grille 351).
2. Hood latch
Splash shield (Refer to 342).
3. Hood lock release handle
4. Hood lock release cable
Hood and hood hinge removal steps

5. Hood insulator
6. Hood weatherstrip
Washer hose (Refer to GROUP 51,
Windshield washer 351).
7. Hood
8. Hood support rod
Front deck garnish (Refer to GROUP
51, Windshield wiper 351).
9. Hood hinge
BODY
42-5
HOOD
Clip positions
5
Section A A
7
A
Clip
5
Note
: Clip positions
AC200023 AB
BODY
42-6
FENDER
FENDER
SPECIAL TOOL
M1421000600212
Tool
Number
Name
Use
MB990784
Ornament remover
Side turn-signal lamp removal
MB990784
FENDER
M1421001900283

Front Bumper Removal and Installation (Refer to GROUP
51, Front Bumper 351).
Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper 351).
4
3
1
2
Note
: Clip positions
AC301492 AB
Removal Steps
Side sill garnish (Refer to GROUP 51,
Garnish 351).
1. Splash shield
2. Front pillar pad
Removal Steps&RQWLQXHG
<<A>> >>A<< 3. Side turn signal lamp

Headlamp assembly (Refer to
GROUP 54A, Headlamp 354A).
4. Fender
BODY
42-7
FENDER
<<A>> SIDE TURN SIGNAL LAMP REMOVAL
>>A<< SIDE TURN SIGNAL LAMP INSTALLATION
: Front of vehicle
Hook
A
A
Claw
Fender panel
Fender panel
Side turn signal lamp
: Front of vehicle
Section A A
MB990784
Fender panel
Claw
AC101384 AC
Use an appropriate tool such as MB990874 to pry

out the tab from the fender, and remove the side turn
signal lamp.
AC005719 AB
Engage the hook with the fender panel, and install

the side turn signal lamp.
BODY
42-8
FUEL FILLER LID
FUEL FILLER LID

M1421002500255

Rear Seat Removal and Installation (Refer to GROUP
52A, Rear Seat 352A).
Front Seat Assembly (Drivers Seat Side) Removal and
Installation (Refer to GROUP 52A, Front Seat 352A).
Front Seat Belt Anchor Bolt (Drivers Side) Removal and
Installation (Refer to GROUP 52A, Front Seat Belt 352A
).
Front Scuff Plate (Drivers Side), Rear Scuff Plate
(Drivers Side), Centre Pillar Lower Trim (Drivers Side)
Removal and Installation (Refer to GROUP 52A, Trims
352A).
Floor Console Removal and Installation (Refer to GROUP
52A, Floor Console 352A).
Fuel filler lid height and clearance

adjustment
5
3
5.0 1.0 Nm
AC107424 AB
Removal steps
1. Fuel filler lid panel assembly
2. Clip
3. Fuel filler lid hook assembly
4. Fuel filler lid lock release handle
Quarter lower trim (Refer to

GROUP 52A, Trims 352A).
Protector C (Refer to GROUP 36,

Parking brake 336).
5. Fuel filler lid lock release cable
BODY
42-9
WINDOW GLASS
WINDOW GLASS
ADHESIVE
M1422000500069
Item
Specified adhesive
Windshield
3M ATD Part No.8609 Super Fast Urethane Auto Glass

Sealant or equivalent
3M ATD Part No.8608 Super Fast Urethane Primer or
equivalent
Quarter window glass

Tailgate window glass
Roof window glass
SPECIAL TOOL
M1422000600271
Tool
Number
Name
Use
MB990480
Window glass holder Window glass removal and installation
MB990480
GENERAL
M1422000100340
The windshield, quarter window glass, tailgate

window glass and roof window glass are attached by
an urethane-base adhesive to the window frame.
This adhesive provides improved glass holding and
sealing, and also gives body openings a greater
structural strength.
ITEMS
Name
Remark
Adhesive
3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or

equivalent
Primer
3M ATD Part No.8608 Super Fast Urethane Primer or equivalent
Spacers
Available as service part
Dam
Available as service part
Anti-rust solvent (or Tectyl

506T.Valvoline Oil Company)
For rust prevention
Isopropyl alcohol
For grease removal from bonded surface
Steel piano wire
Dia. length... 0.6mm 1m For cutting adhesive
Glass adhesive knife
For cutting adhesive
Adhesive gun
For pressing-out adhesive
HANDLING OF AUTO WINDOW SEALER

Keep the sealant in a cool place, not exposed to the
direct rays of the sun. Do not place any heavy article
on the sealant nor press it, otherwise it will become
deformed. Avoid storing the sealant for more than 6
months, because it will lose its sealing effect.
BODY PINCH-WELD FLANGE SERVICING

Before servicing the body pinch-weld flange, remove
old adhesive completely. If the flange requires
painting, bake it after painting is completed.
BODY
42-10
WINDOW GLASS
WINDOW GLASS INSTALLATION

Window glass installation procedure
Body side
Window glass side
Reusing the glass
Replace the glass
Cleaning of adhesion surface

Cut off the residual adhesive until the
thickness is less than 2 mm. clean the
adhesion surface with isopropyl alcohol,
and let dry for 3 minutes or more.

Completely cut off all of the residual
adhesive. clean the adhesive surface
with isopropyl alcohol, and let dry for
3 minutes or more.

Clean off any dirt adhering to the adhesion
surface with isopropyl alcohol, and let dry
for 3 minutes or more.
Attaching of dual lock fastener

Attach the dual lock fastener to set
the positions for the glass to be installed.
Gluing of window dam, window spacer, dual lock fastener and glass stopper
Glue the window dam, window spacer, dual lock fastener and glass stopper to the glass,
following the standard position all the way around the inside edge of the glass.
Application of primer
Apply the primer to the adhesion surface
of the body, and let dry for 3 minutes or
more.
Application of primer
Apply sufficient primer evenly to the adhesion surface so that there is no patchiness.
After application, let dry for 3 to 30 minutes.
Application of adhesive
Within 30 minutes after applying the primer , apply the adhesive evenly all the way around
the inside edge of the glass.
Installing the glass

After applying the adhedive, lighty press the glass evenly so that it adheres
completely.
Cleaning
After removing excess adhesive from the body or glass with a spatula, etc.
clean off with isopropyl alcohol.
Checking for water leaks

Carry out a shower test to check that no water will leaks through.
AC300393
BODY
42-11
WINDOW GLASS
WINDSHIELD
M1422001000294

Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper 351).
Roof Drip Moulding Removal and Installation (Refer to
GROUP 51, Moulding 351).
Front Pillar Trim Removal and Installation (Refer to
4N
3N
4N
N5
AC301503
N5
Apply the primer and adhesive along the fictitious lines (seal line)
between each of the marks.
Section A A
A
15
A
Ceramic line
Seal line
center
Units: mm
Seal line
center
Section B B
Primer
Primer
Section C C
15
15
Mark
Seal line center
Seal line
C
Primer
C
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
AC301615 AB
Removal steps
1. Harness connector (Refer to GROUP
51, Wiper deicer 351).
<<A>> >>B<< 2. Windshield
>>A<< 3. Windshield moulding

>>A<< 4. Glass stopper
>>A<< 5. Windshield spacer
BODY
42-12
WINDOW GLASS

<<A>> WINDSHIELD REMOVAL
1. To protect the body (paint surface), apply cloth
tape to all body areas around the installed
windshield.
2. Make mating marks on the windshield and body.
Keep glass adhesive knife at right angles with the

windshield edge, and put the blade at windshield
edge and surface. Then cut away adhesive along
the windshield edge.
MB990480
ACX00475AB
ACX00474 AB
3. Using piano wire.

(1) Using a sharp-point drill, make a hole in the
windshield adhesive.
(2) Pass the piano wire from the inside of the
vehicle through the hole.
5. Use special tool (MB990480) to remove the

windshield.
CAUTION
CAUTION
Do not let the piano wire touch the edge of the
windshield.
(3) Pull the piano wire alternately from the inside
and outside along the windshield to cut the
adhesive.
ACX00476 AB
CAUTION
AC002060
Be careful not to remove more adhesive than

is necessary.
Be careful also not to damage the paintwork
on the body surface with the knife. If the
paintwork is damaged, repair the damaged
area with repair paint or anti-rust agent.
6. Use a knife to cut away the remaining adhesive so
that the thickness is within 2 mm around the entire
circumference of the body flange.
7. Finish the flange surfaces so that they are
smooth.
CAUTION
Allow the cleaned area to dry for at least three
minutes. Do not touch any surface that has been
cleaned.
8. When reusing the windshield, remove the
adhesive still adhering to the windshield, and
clean with isopropyl alcohol.
9. Clean the body side in the same way.
AC207478 AD
Inserting the glass adhesive knife too deeply into

windshield adhesive may damage windshield.
4. Using glass adhesive knife
BODY
42-13
WINDOW GLASS

>>A<< WINDSHIELD SPACER/GLASS STOPPER/
WINDSHIELD MOULDING INSTALLATION
CAUTION
Leave the degreased parts for 3 or more minutes
to dry well, before starting on the next step. Do
not touch the degreased parts.
1. Use isopropyl alcohol to degrease the inside and
outside of the windshield and the body flanges.
Glass stopper and windshield spacer installation position
Windshield end line
Seal line
18.1 mm
Glass stopper
Windshield
Align the glass

stopper end with
the windshield mark.
Ceramic line
Windshield center line
Seal line
Windshield
spacer
Ceramic line
Ceramic line
65 mm
43.9 mm
43.9 mm
Seal line
Windshield
center line
Seal line
Windshield
spacer
Align the windshield

spacer end with the
ceramic notch.
AC300403AB
2. The inner side of the windshield is curved,

therefore, make a point to assemble the glass
stopper and windshield spacer without any lifting
and assemble in the position shown.
3. Install the windshield moulding.
>>B<< WINDSHIELD INSTALLATION

1. When replacing the windshield, temporarily set
the windshield against the body, and place a
mating mark on the windshield and body.
BODY
42-14
WINDOW GLASS
CAUTION
The primer strengthens the adhesive, so be
sure to apply it evenly around the entire
circumference. However, a too thick
application will weaken the adhesive.
Do not touch the coated surface.
2. Soak a sponge in the primer, and apply evenly to
the windshield and the body in the specified
places.
3. Allow the windshield to dry for at least three
minutes after applying primer.
4. Fill a sealant gun with adhesive. Then apply the

adhesive evenly around the windshield within 30
minutes after applying the primer.
NOTE: Cut the tip of the sealant gun nozzle into a
V shape to simplify adhesive application.
5. Align the mating marks on the windshield and the
body, and lightly press the windshield evenly so
that it adheres completely.
6. Use a spatula or similar tool to remove any
excessive adhesive. Clean the surface with
isopropyl alcohol. Avoid moving the vehicle until
the adhesive sets.
7. Bond the windshield to the body, and install the
roof drip moulding quickly before the adhesive
cures. (Refer to GROUP51, Moulding 351).
CAUTION
10 mm
15 mm
ACX00480 AB
Do not move the vehicle unless absolutely

necessary.
When testing for water leakage, do not pinch
the end of the hose to spray the water.
8. Wait 30 minutes or more, and then test for water
leakage.
BODY
42-15
WINDOW GLASS
QUARTER WINDOW GLASS

M1422002500225

Quarter Trim Upper Removal and Installation (Refer to
2N
1
N3
N4
3N
Units: mm
Apply the primer and adhesive

along the fictitious lines (seal line)
Ceramic line
Align the tape

end with the quarter
window glass mark.
A
A
Seal line
C
Ceramic line
Mark
Seal line
B
B
Section A A
Seal line
center
Primer
Section B B
Seal line
center
Section C C
1
15
Seal line
center
1
15
15
Primer
Primer
Adhesive tape: Double-sided tape [ 15 mm width, 15 mm length and 0.8 mm thickness ]
AC107211AB
Removal steps
<<A>> >>B<< 1. Quarter window glass assembly

>>A<< 2. Dual lock fastener

>>A<< 3. Clip
>>A<< 4. Gasket
BODY
42-16
WINDOW GLASS
MB990480
<<A>> QUARTER WINDOW GLASS REMOVAL
AC103605 AC
Cloth tape
AC103600AC
1. Apply cloth tape to protect the quarter window

glass.
4. Make mating marks on the quarter window glass

and body.
5. Use special tool (MB990480) to remove the
quarter window glass.
CAUTION
AC002060
2. Use glass adhesive knife to cut away adhesive.
CAUTION
AC301614 AB
Inserting the adhesive knife too deeply into

windshield adhesive may damage quarter
window glass.
3. Keep the glass adhesive knife at right angles with
body flange (from inside the vehicle), and put the
blade at body flange. Then cut away adhesive
along the body flange.
ACX00476 AB
Be careful not to remove more adhesive than

is necessary.
Be careful also not to damage the paintwork
on the body surface with the knife. If the
paintwork is damaged, repair the damaged
area with repair paint or anti-rust agent.
6. Use a knife to cut away the remaining adhesive so
that the thickness is within 2 mm around the entire
circumference of the body flange.
7. Finish the flange surfaces so that they are
smooth.
CAUTION
Allow the cleaned area to dry for at least three
minutes. Do not touch any surface that has been
cleaned.
8. When reusing the quarter window glass, remove
the adhesive still adhering to the quarter window
glass, and clean with isopropyl alcohol.
9. Clean the body side in the same way.
BODY
42-17
WINDOW GLASS

>>A<< GASKET/CLIP/DUAL LOCK FASTENER
INSTALLATION
1. Carry out the following procedure to re-install
quarter window glass.
CAUTION
Do not forget gasket.
(1) Fit clips into body.
CAUTION
outside of the quarter window glass and the body
flanges.
Dual lock fastener

Cut off these convex parts
Body flange end line
AC107213AB
AC103606 AC
(2) Cut away clip fitting convex on quarter window

glass.
NOTE: Convex gets broken when quarter
window glass is removed.
3. Assemble the dual lock fastener according to the

standard location of the body flange.
4. Assemble the dual lock fastener to the quarter
window glass relative to the body flange dual lock
fastener.
>>B<< QUARTER WINDOW GLASS
INSTALLATION
Remove the quarter window glass using the same
procedure as for the windshield removal (Refer to
342).
BODY
42-18
WINDOW GLASS
TAILGATE WINDOW GLASS

M1422003700158

Tailgate Trim Removal and Installation (Refer to GROUP
52A, Tailgate Trim 352A).
Rear Wiper Arm Assembly Removal and Installation
(Refer to GROUP 51, Rear Wiper and Washer 351).
N3
N4
2N
Section B B
Section A A
Apply the primer and adhesive

along the fictitious lines (seal line)
A
Seal line
center
15
Units: mm
Seal line center
Primer
15
1
Ceramic line
C
Primer
Section C C
MARK
Mark
Seal line
Primer
B
B
Seal line
center
15
AC107209AB
Removal steps
Harness connector
<<A>> >>B<< 1. Tailgate window glass
>>A<< 2. Dual lock fastener
>>A<< 3. Glass stopper

>>A<< 4. Window dam
BODY
42-19
WINDOW GLASS

<<A>> TAILGATE WINDOW GLASS REMOVAL

Remove the tailgate window glass using the same
procedure as for the windshield. (Refer to 342).
>>A<< WINDOW DAM/GLASS STOPPER/DUAL

LOCK FASTENER INSTALLATION
CAUTION
outside edges of the tailgate window glass and
the surface of the tailgate flange.
Glass stopper, window dam and dual lock fastener installation position
Glass end line
Install the window
dam along the glass
end line.
Glass end line

Seal line
25.5 0.5 mm
Align the window dam

end with the ceramic notch.
Seal line
Ceramic line
Glass stopper
Seal line
Align the glass stopper

and with the tailgate
window glass mark.
Window dam
Tailgate window glass

Dual lock fastener
Align the dual lock fastener and with

the tailgate window glass mark.
2. Assemble the window dam, glass stopper and

dual lock fastener to the tailgate window glass
location shown.
Ceramic line
AC107210 AB
BODY
42-20
WINDOW GLASS
Flange convex
at the tailgate flange
Dual lock fastener

AC107208AB
3. Assemble the dual lock fastener in alignment with

the protrusion of the tailgate flange.
>>B<< TAILGATE WINDOW GLASS

INSTALLATION
Install the tailgate window glass in the same way as
for the windshield installation (Refer to 342).
BODY
42-21
WINDOW GLASS
ROOF WINDOW GLASS

M1422004300045
AC301504
Seal line
A
A
A
Section A A
Seal line center
6 mm
Primer
15 mm
Adhesive tape: Double-sided tape [ 6 mm width, 0.5 mm thickness ]
AC301821 AB
<<A>>
>>A<<
1.
Removal steps
Frame assembly (Refer to GROUP
52A - Headlining 352A).
Roof window glass assembly

<<A>> ROOF WINDOW GLASS ASSEMBLY
REMOVAL
Remove by the same procedure as for the quarter
window glass (Refer to 342).
BODY
42-22
DOOR

>>A<< ROOF WINDOW GLASS ASSEMBLY
INSTALLATION
Install by the same procedure as for the windshield
(Refer to 342).
DOOR
M1423000300079
Item
Standard value
Power window operation current (Power supply voltage 14.5 0.5 V, at 25 C) A
51
Door outside handle play mm
Front door
2.6 2.5
Rear door
1.3 1.3
Front door
10.4 9.6
Rear door
10 9.6
Door inside handle play mm
SEALANT
M1423000500073
Item
Specified sealant
Door waterproof film
SPECIAL TOOLS
M1423000600315
Tool
Number
Name
Use
MB990480
Window glass holder
Removal of power window regulator

and motor assembly
MB990900 or
MB991164
Door hinge adjusting

wrench
Door alignment
MB990480
MB990900
BODY
42-23
DOOR
Tool
A
Number
Name
Use
MB990925
A: MB990939
Bearing and oil seal

installer set
A: Brass bar
Door striker adjustment
MB990211
Sliding hammer
MB990241
A: MB990243
Axle shaft puller

A: Body puller
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness adapter
D: Probe
MB990925AF
MB990211
A
MB990241AE
Terminal voltage measurement

contact pressure
B: For checking power supply circuit
C: For checking power supply circuit
D: For connecting a locally sourced
tester
D
MB991223 AD
TROUBLESHOOTING
M1423000700282
The door system is controlled by the Smart Wiring

System (SWS). For troubleshooting, refer to GROUP
54B, Diagnosis 354B or GROUP 54C, Diagnosis
354C.
ON-VEHICLE SERVICE
DOOR FIT ADJUSTMENT
M1423001100164
CAUTION
Attach protection tape to the fender and door
edges where the hinge is installed.
Do not rotate special tool (MB991164) with a
torque of over 98 Nm.
MB990900
or
MB991164
AC000592 AB
BODY
42-24
DOOR
1. Use special tool (MB990900 or MB991164) to

loosen the hinge mounting bolts on the body side,
and then adjust the clearance around the door so
that it is uniform on all sides.
2. If a door is not flush with its surrounding panels,
loosen the door-side door hinge mounting bolts
and obtain the flushness by moving the door.
NOTE:
Weld point
MB990939
Temporary
bolt
Washer
Striker
AC006109AB
Bolt
Door hinge
Weld point
Washer
(1) Adjustment by using the striker (toward the

inside of the vehicle and vertical direction)
Install an appropriate bolt instead of the striker
mounting bolt, and use special tool
(MB990939) and a hammer to tap the bolt to
the desired direction.
AC206498 AE
If the door hinge mounting bolt washers are

welded, grind off the welding according to the
procedure below beforehand.
.
1. Remove the door hinge (Refer to 342).
2. Use a chisel or grinder to release the door
hinge mounting bolt washer, which is welded
to the door hinge.
3. On completion, paint the affected area with a
suitable touch-in brush to prevent corrosion.
4. Install the door hinge (Refer to 342).
3. When the door is stiff to lock and unlock:
MB990211
MB990243
Striker
AC006110 AB
(2) Adjustment by using the striker (toward the

outside of the vehicle)
Use special tools (MB990211 and MB990243)
to pull the striker toward the outside of the
vehicle.
Shim
Striker
AC006111AB
(3) Adjustment by using shims (forward and

rearward)
Increase or decrease the number of shims so
that the striker engages with the door latch
properly.
BODY
42-25
DOOR
DOOR WINDOW GLASS ADJUSTMENT

M1423001000305
Check that the door glass moves while contacting the

door glass channel when it is raised and lowered
fully. If not, adjust the door window according to the
following procedures.
1. Remove the door trim assembly (Refer to GROUP
52A, Door trim 352A).
2. Remove the waterproof film. (Refer to 342).
<Front>
<Rear>
1. Remove the door trim assembly. (Refer to

GROUP 52A, Door trim 352A).
2. Remove the waterproof film. (Refer to 342).
3. Remove the window regulator assembly from the
door window glass, and then raise and lower the
door window glass by hand to check the operation
force.
NOTE: Insert a cushion or similar object to
prevent damage to the glass if it should happen to
fall down.
Runchannel
Adjusting
hole
Y0238AU
Door
sash
Adjusting
hole
Y0239AU
Lower
sash
AC006112 AB
3. Loosen the door glass mounting screw via the

adjusting hole with the door window glass fully
closed, then lower the window glass a little.
4. Fully close the door window glass again and
tighten the door glass mounting screw firmly via
the adjusting hole.
GLASS SLIDING MECHANISM CHECK

AND ADJUSTMENT
M1429000900080
If the window glass automatically starts moving

downwards at the wrong time while it is being raised,
carry out the following adjustment or replacement
procedures.
AC003777AB
4. If the door window glass does not move up and

down smoothly, check or repair the following
points.
Check the installation condition of the
runchannel.
Repair any twisting in the door sash.
Check the installation condition of the lower sash
or the centre sash.
5. If repair or adjustment is not possible, replace the
door assembly.
BODY
42-26
DOOR
POWER WINDOW SAFETY MECHANISM

CHECK
POWER WINDOW RELAY CHECK

M1429001800183
M1429001000251
Power window relay
Junction block
AC103294
1. Place a wooden board about 10 mm thick as

shown. Then, raise the window glass.
2. Check that the window lowers by about 150 mm
when the window clamps the board. If this doesnt
happen, carry out troubleshooting. Refer to
GROUP 54B, Diagnosis 354B, refer to
GROUP 54C, Diagnosis 354C.
NOTE: If the anti-trap function (safety
mechanism) is activated consecutively three
times or more, make the power window switch
learn the fully closed position of the power window
(Refer to 342).
POWER WINDOW OPERATING CURRENT

CHECK
M1429001100162
AC208065AC
1. Remove the power window fuse and connect an

ammeter as shown in the illustration.
2. When the power window switch is pressed to the
UP position, a large amount of current flows at
the time the window starts to close and when it is
fully closed, so measure the operation current in
the interval between these two points.
Standard value: 5 1A (Power supply
voltage 14.5 0.5V, 25C)
3. If the operation current is outside the standard
value, refer to GROUP 54B, Diagnosis 354B,
refer to GROUP 54C, Diagnosis 354C.
1 2 3
5
1
AC207981
5
AC106844
AC300331 AB
BATTERY
VOLTAGE
TESTER
CONNECTION
SPECIFIED
CONDITION
Not applied
4-5
Open circuit
Connect
terminal No.1
and the positive
battery
terminal.
Connect
terminal No.3
and the
negative
battery
terminal.
Less than 2
ohms
CIRCUIT BREAKER (INCORPORATED IN

THE POWER WINDOW MOTOR)
INSPECTION
M1429001700108
1. Pull the power window switch to the UP position

to fully close the door window glass, and keep
pulling the switch for 10 additional seconds.
2. Release the power window switch from the UP
position and immediately press it to the DOWN
position. The condition of the circuit breaker is
good if the door window glass starts to move
downwards within 60 seconds.
BODY
42-27
DOOR
POWER WINDOW CHECK

M1429004400173
Check the system as described below. If the system

does not work, carry out troubleshooting. Refer to
GROUP 54B, Diagnosis 354B or GROUP 54C,
Diagnosis 354C.
Operate the power window switch of each seat to
check that the power window works.
Turn on the power window lock switch of the
power window main switch, and operate the front
passengers and rear power window sub switches
to check that the power windows do not work.
Turn on the power window lock switch of the
power window main switch, and operate the
power window main switch to check that each
power window operates.
2. If the door outside handle play is not within the

standard value range, check the door outside
handle or the door latch assembly. Replace if
necessary.
DOOR INSIDE HANDLE PLAY

ADJUSTMENT
M1423001500270
Section A A
A
A
B

INSPECTION
M1427001100111
Check that the central door locking system works by

operating the key cylinder and the inside lock knob
(drivers door).Carry out troubleshooting if the
system does not activate. Refer to GROUP 54B,
Diagnosis 354B, refer to GROUP 54C,
Diagnosis 354C.
DOOR OUTSIDE HANDLE PLAY CHECK

M1423001600255
Y0705AU
AC006114 AB
1. Check that the door inside handle play is within

the standard value range.
Standard value (B):
Front door: 10.4 9.6 mm
Rear door: 10 9.6 mm
2. If the door inside handle play is outside the
3. Remove the door trim assembly (Refer to GROUP
52A, Door trim 352A).
4. Remove the waterproof film (Refer to 342).
Inner cable
Outer cable end
AC006113AB
1. Check that the door outside handle play is within

the standard value range.
Standard value (A):
Front door: 2.6 2.5 mm
Rear door: 1.3 1.3 mm
Clip
Door inside handle

Inside handle rod
AC100404 AB
5. Adjust the door inside handle play with the outer

cable end connecting the door inside handle and
inside lock cable.
BODY
42-28
DOOR
DOOR ASSEMBLY
M1423002200261
Door Fit Adjustment (Refer to 342).
<Front door>
27 5 Nm
11 2 Nm
5
21 4 Nm
2
9.0 2.0 Nm
27 5 Nm
21 4 Nm
9
1.5 0.5 Nm
<Rear door>
11 2 Nm
6
27 5 Nm
5, 6
21 4 Nm
1
1.5 0.5 Nm
2
27 5 Nm
21 4 Nm
9.0 2.0 Nm
9
AC103073 AC
Removal
1. Damper
Door assembly removal steps
Scuff Plate and Cowl Side Trim (Refer
to GROUP 52A, Trims 352A).
2. Harness connector
3. Door check connecting bolt
4. Door assembly
Door assembly removal steps

5. Door upper hinge
6. Door lower hinge
Striker removal steps
>>A<< 7. Striker
8. Striker shim
Door switch removal
9. Door switch
BODY
42-29
DOOR
INSPECTION
M1423006000300
>>A<< STRIKER INSTALLATION
DOOR SWITCH CHECK
Latch center
Striker center
+1.5 mm
1
-1.5 mm
Striker
Latch
AC006126AB
Align the centre of the striker and latch within 1.5

mm, and install.
AC211414 AC
SWITCH
POSITION
TESTER
CONNECTION
SPECIFIED
CONDITION
Released (ON)
1 - switch body, Less than 2

2 - switch body, ohms
3 - switch body
Depressed
(OFF)
1 - switch body, Open circuit

2 - switch body,
3 - switch body
BODY
42-30
DOOR
DOOR GLASS AND REGULATOR

M1429001300285
Door Trim Assembly Removal (Refer to GROUP 52A,
Door Trim 352A).
Waterproof Film Removal (Refer to 342).
Door Window Glass Adjustment (Refer to 342).
Waterproof Film Installation (Refer to 342).
Door Trim Assembly Installation (Refer to GROUP 52A,
Door Trim 352A).
1
AC101370
<Front door>
<Rear door>
4
4
2
2
3
AC300452 AB
Power window switch removal steps

Post-installation operation check
1. Power window switch (Refer to
GROUP 52A, Door trim 352A).
>>B<<
Door window regulator assembly

removal steps
>>B<< Post-installation operation check
<<A>> >>A<< 2. Window regulator assembly
<<A>>
3. Power window motor assembly
BODY
42-31
DOOR
Door window glass removal steps
Window glass runchannel <Rear
door> (Refer to 342).
Lower sash <rear door> (Refer to
342).
Door latch assembly <Rear door>
(Refer to 342).
Door beltline moulding (Refer to 342
).
Door beltline inner weatherstrip
(Refer to 342).
4. Door window glass
<<A>> WINDOW REGULATOR ASSEMBLY/

POWER WINDOW MOTOR ASSEMBLY REMOVAL
1. Remove the door window glass installation bolts.
>>A<< WINDOW REGULATOR ASSEMBLY

INSTALLATION
<Front door>
CAUTION
If tinting film is adhered to the door window
glass, attach special tool MB990480 to the
outside of the glass to prevent the film from
peeling off.
7
3
2
1
6
MB990480
<Rear door>
1
4
6
AC100009AB
2. Lift the door window glass, and attach special tool

MB990480 to the glass as shown to prevent the
glass from falling.
3. Remove the window regulator assembly and
power window motor assembly.
3
2
5
AC102851AC
When installing the window regulator assembly,

tighten the bolts to the specified torque in the order
shown.
>>B<< Post-installation operation check
When the following procedures are carried out, make
the power window switch learn the fully closed
position of the power window. (Refer to 342).
Power window regulator removal or replacement
Power window switch removal or replacement
BODY
42-32
DOOR
INSPECTION
M1429001400260
How to make the power window switch

learn the fully closed position of the
power window
How to make the power window switch learn the
fully closed position when the power window
switch is removed, or the power window
regulator assembly is removed or replaced
1. If the anti-trap function (safety mechanism) is
activated consecutively three times or more, the
fully closed position that the power window switch
has learned will be erased (initialized).
2. Operate the power window switch and fully open
the door window glass.
CAUTION
The anti-trap function does not work until the
power window switch completes learning the
fully closed position (It is because the anti-trap
function is reset).
3. Operate the power window switch and fully close
the door window glass. The power window
activates for 0.7 seconds and stops automatically
when the power window switch is pressed once.
Repeat this operation until the door window glass
fully closes and release the switch once. Then,
hold the power window switch to the fully closed
side again for one second so that the power
window switch completes learning the fully closed
position.
NOTE: If the power window switch is operated to

open the door window glass while the switch is
learning, learning will be cancelled. If this
happens, return to step 2.
How to make the power window switch learn the
fully closed position when the power window
switch is replaced with a new one
CAUTION
The anti-trap function does not work until the
power window switch completes learning the
fully closed position (It is because the anti-trap
function is reset).
Operate the power window main switch to fully close
the door window glass by one-shot up action so that
the power window switch will complete learning
(Initialization is not needed).
NOTE: When the power window sub switch of each
seat is replaced, operate the power window main
switch to fully close the applicable power window by
one-shot up action (It is because the power window
sub switch does not have one-shot up/down
function).
BODY
42-33
DOOR
DOOR HANDLE AND LATCH

M1423004600306
Door Trim Assembly Removal (Refer to GROUP 52A
Door Trim 352A).
Door Inside Handle Play Check (Refer to 342).
Door Outside Handle Play Check (Refer to 342).
Door Trim Assembly Installation (Refer to GROUP 52A,
Door Trim 352A).
<Rear door>
<Front door>
3
4
5.0 1.0 Nm
5.0 1.0 Nm
9.0 2.0 Nm
9.0 2.0 Nm
8
5
8
1
2
5.0 1.0 Nm
5
5.0 1.0 Nm
2
AC101531AD
Door handle and door latch assembly

removal steps
>>C<< 1. Door inside handle
Waterproof film (Refer to 342).
>>B<< 2. Lower sash
3. Door outside handle
4. Door lock key cylinder
5. Door latch assembly
Door handle and door latch assembly

6. Inside lock cable
7. Inside lock rod
8. Inside handle rod
Door check removal steps
>>A<< 9. Door check
BODY
42-34
DOOR

>>A<< DOOR CHECK INSTALLATION
INSPECTION
M1423004700370
FRONT DOOR LOCK ACTUATOR CHECK

Front door
<Left side>
Lock
Identification mark
Unlock
View A
1 2 3
4 5 6
Lever
ACX00541AB
Install the door check so that the identification mark

faces upwards.
ITEM
Unlock
IDENTIFICATION
MARK
Front Door
Rear Door
39L
Right door
39R
Left door
40L
Right door
40R
Lever
>>B<< LOWER SASH INSTALLATION

Securely insert the rear lower sash into the window
rear sash.
>>C<< DOOR INSIDE HANDLE INSTALLATION
Clip
Door inside handle

AC100404 AB
1. Install the inside lock cable to the door inside

handle as follows:
(1) Install the inner cable end in the inside lock
cable to the clip in the door inside handle.
(2) Turn the inside lock knob to the door lock
position.
(3) Install the outer cable end to the door inside
handle securely.
(4) Install the clip to the inner cable.
2. Install the inside handle rod to the door inside
handle.
3. Install the door inside handle to the door.
AC005657AD
Actuator Operation Check <Left side>

LEVER
BATTERY
LEVER
POSITION CONNECTION
OPERATION
At the
"LOCK"
position
Connect terminal
No.6 and the
negative battery
terminal.
Connect terminal
No.4 and the
positive battery
terminal.
The lever
moves from the
"LOCK"
position to the
"UNLOCK"
position.
At the
"UNLOCK"
position
Connect terminal
No.4 and the
negative battery
terminal.
Connect terminal
No.6 and the
positive battery
terminal.
The lever
moves from the
"UNLOCK"
position to the
"LOCK"
position.
Outer cable end
Inside handle rod
Lock
View B
1 2 3
4 5 6
Left door
Inner cable
<Right side>
Actuator Switch Check <Left side>

LEVER
TESTER
SPECIFIED
POSITION
CONNECTION CONDITION
At the "LOCK"
position
1-3
Less than 2
ohms
At the
"UNLOCK"
position
1-2
Less than 2
ohms
BODY
42-35
DOOR
Actuator Operation Check <Right side>

LEVER
BATTERY
LEVER
POSITION CONNECTION
OPERATION
At the
"LOCK"
position
At the
"UNLOCK"
position
Connect terminal
No.4 and the
negative battery
terminal.
Connect terminal
No.6 and the
positive battery
terminal.
The lever
moves from
the "LOCK"
position to the
"UNLOCK"
position.
Connect terminal
No.6 and the
negative battery
terminal.
Connect terminal
No.4 and the
positive battery
terminal.
The lever
moves from
the "UNLOCK"
position to the
"LOCK"
position.
REAR DOOR LOCK ACTUATOR CHECK

Rear door
<Left side>
View A
Lock
1 2 3
4 5 6
Unlock
Lever
<Right side>
Lock
View B
1 2 3
4 5 6
Unlock
B
Lever
AC005658 AD
Actuator Operation Check <Left side>

LEVER
BATTERY
LEVER
POSITION CONNECTION
OPERATION
At the
"LOCK"
position
Connect terminal
No.3 and the
negative battery
terminal.
Connect terminal
No.2 and the
positive battery
terminal.
The lever
moves from
the "LOCK"
position to the
"UNLOCK"
position.
At the
"UNLOCK"
position
Connect terminal
No.2 and the
negative battery
terminal.
Connect terminal
No.3 and the
positive battery
terminal.
The lever
moves from
the "UNLOCK"
position to the
"LOCK"
position.
BODY
42-36
DOOR
Actuator Operation Check <Right side>

LEVER
BATTERY
LEVER
POSITION CONNECTION
OPERATION
At the
"LOCK"
position
At the
"UNLOCK"
position
Connect terminal
No.2 and the
negative battery
terminal.
Connect terminal
No.3 and the
positive battery
terminal.
The lever
moves from
the "LOCK"
position to the
"UNLOCK"
position.
Connect terminal
No.3 and the
negative battery
terminal.
Connect terminal
No.2 and the
positive battery
terminal.
The lever
moves from
the "UNLOCK"
position to the
"LOCK"
position.
DOOR LOCK KEY CYLINDER SWITCH

CHECK
3
AC101318
<Right side>
SWITCH
POSITION
TESTER
CONNECTION
SPECIFIED
CONDITION
LOCK
1-2
Less than 2
ohms
NEUTRAL
(OFF)
1 - 2, 2 - 3
Open circuit
UNLOCK
2-3
Less than 2
ohms
BODY
42-37
DOOR
WINDOW GLASS RUNCHANNEL AND

DOOR OPENING WEATHERSTRIP
M1423003100278
<Front door>
: Sectional view
of clip position
6
7
Section A A
7
1
Door
Note
: The convex position of the door
Sealant: 3M ATD Part No. 8633

or equivalent
AC103084 AC
Waterproof film removal steps

Door trim assembly (Refer to GROUP
52A, Door Trim 352A).
1. Pull handle bracket
2. Waterproof film
Door inner opening weatherstrip
removal steps
Cowl side trim (Refer to GROUP 52A,
Trims 352A).
3. Door inner opening weatherstrip
(body side)
Door outer opening weatherstrip
removal steps
Front door check mounting bolt (body
side) (Refer to 342).
<<A>> >>C<< 4. Door outer opening weatherstrip

removal steps
5. Door beltline inner weatherstrip
Door window glass runchannel
removal steps
2. Waterproof film
>>B<< 6. Door window glass runchannel
Door beltline moulding removal steps
Door mirror assembly (Refer to
GROUP 51, Door Mirror 351).
7. Door beltline moulding
BODY
42-38
DOOR
DOUBLE-SIDED TAPE POSITION

B
a
A
Clip hole
Clip hole
Door outer opening

weatherstrip
Section A A
Section B B
Door outer opening
weatherstrip
Door outer opening
weatherstrip
Adhesive tape: Double-sided tape a [ 7 mm width, 100 mm length and 0.8 mm

thickness ], b [ 7 mm width, 130 mm length and 0.8 mm thickness ]
AC103492 AC
BODY
42-39
DOOR
<Rear door>
5
7
: Sectional view
of clip position
8N 4
Section A A
Door
Note
: The convex position of the door
Sealant: 3M ATD Part No. 8633

or equivalent
AC103491AC
Waterproof film removal steps

2. Waterproof film
Door inner opening weatherstrip
removal steps
Rear seat (Refer to GROUP 52A,
Trims 352A).
Scuff plate (Refer to GROUP 52A,
Trims 352A).
3. Door inner opening weatherstrip
(body side)
Door outer opening weatherstrip
removal steps
Rear door check mounting bolt (body
side) (Refer to 342).
<<A>> >>C<< 4. Door outer opening weatherstrip

removal steps
Door window glass runchannel
removal steps
2. Waterproof film
6. Door window glass runchannel
Door beltline moulding removal
7. Door beltline moulding
Door tape removal steps
>>A<< 8. Door tape
BODY
42-40
DOOR
DOUBLE-SIDED TAPE POSITION

20 mm
B
Clip hole
a
7 mm
b
B
Clip hole
A
d
Clip hole
Door outer opening

weatherstrip
C
C
Clip hole
Section A A
Door outer opening
weatherstrip
Section B B
Door outer opening
weatherstrip
Section C C
Door outer opening
weatherstrip
Adhesive tape: Double-sided tape a, d [ 7 mm width and 0.8 mm thickness ],

b [ 7 mm width, 110 mm length and 0.8 mm thickness ], c [ 7 mm width, 62 mm length and 0.8 mm thickness ]
AC103128 AC
BODY
42-41
DOOR

<<A>> DOOR OUTER OPENING WEATHERSTRIP
REMOVAL
>>B<< DOOR WINDOW GLASS RUNCHANNEL

<FRONT DOOR> INSTALLATION
Section A A
Door panel
Fabricated
tool
15 mm
4 mm
Runchannel
8 mm
Thickness:
1 mm
Door mirror
claw position
ACX00555AB
Notch
Door mirror
Make a fabricated tool as shown in the illustration to

remove the door weatherstrip.
Door mirror
claw position

>>A<< DOOR TAPE <REAR DOOR>
INSTALLATION
Runchannel
AC103753 AC
Assemble the run channel cut-out area with the

thumb of the door mirror.
Door tape
Section A A
Door panel
Door tape
>>C<< DOOR OUTER OPENING WEATHERSTRIP

INSTALLATION
The clip colour identifies the left and right
weatherstrips so be sure to see the colours so as to
install correctly.
Adjust the end of the

door tape to the corner
end of the door panel.
AC106848AB
Apply the door tape in the location shown in the

Figure of the instructions.
APPLICABLE SIDE
IDENTIFICATION
COLOUR
Left door
Natural (White)
Right door
Pink
BODY
42-42
TAILGATE
TAILGATE
M1421000300244
Item
Standard value
Tailgate handle play mm
2.3 to 5.9
SEALANTS
M1424000500076
Item
Specified sealant
Tailgate waterproof film
Tailgate hinge
3M ATD Part No.8531 Heavy drip check sealer, 3M

ATD Part No.8646 Automotive joint and seam sealer
or equivalent
SPECIAL TOOL
M1424000600158
Tool
A
Number
Name
Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Terminal voltage measurement

contact pressure
circuit
circuit
sourced tester
D
MB991223 AD
TROUBLESHOOTING
M1424000700188
The tailgate system is controlled by the Smart Wiring

System (SWS). For troubleshooting, refer to GROUP
54B, Diagnosis 354B or GROUP 54C, Diagnosis
354C.
ON-VEHICLE SERVICE
TAILGATE FIT ADJUSTMENT
M1424000900115
1. If the striker and latch mesh badly, replace the

striker and striker installation blots with
replacement parts (striker: MR523105, striker
installation blot: MU000474).
AC203659
2. Move the replaced striker forward and backward

or to the left and right to adjust, after bolt the
striker temporarily.
BODY
42-43
TAILGATE
3. After adjusting, tighten the bolts to the specified

torque [24 4 Nm].
NOTE:
Grind here
2. If it deviates from the standard value, remove the

lower tailgate trim (Refer to GROUP 52A, tailgate
trim 352A) and waterproof film (Refer to 342
).
3. Remove the holder from the tailgate handle and
adjust according to the tailgate latch rod and
tailgate handle connection position.
ADJUSTMENT OF TAILGATE HEIGHT

M1424003500075
A
AC203660AB
When the bolt head interferes with the rear end

trim, rasp the interference area with a round file.
Section A A
17.4mm
Bumper
AC201556
4. If uneven clearance is present between tailgate

and body, reposition the hinge to adjust the
clearance.
TAILGATE HANDLE PLAY CHECK

M1424002400116
Section A A
Holder
A
Rod
A
AC103270 AC
1. Check the tailgate handle play.

Standard value (B): 2.3 - 5.9 mm
Body
AC103269 AC
Turn the tailgate bumper using the arrow of the

tailgate bumper as a guideline to adjust the height of
the tailgate. The bumper height is altered by
approximately 3mm by turning the tailgate bumper
one rotation.
BODY
42-44
TAILGATE
TAILGATE
M1424001100156
CAUTION
Do not disassemble or throw the tailgate gas spring into fire.
Punch a hole in the gas spring before disposal to release the gas inside.
Ensure the tailgate gas spring piston rod does not come into contact with foreign material.
Tailgate Spoiler Assembly Removal (Refer to GROUP 51,
Tailgate Spoiler 351).
Tailgate Trim Assembly Removal (Refer to GROUP 52A,
Tailgate Trim 352A).
Rear Wiper Motor Removal (Refer to GROUP 51, Rear
Wiper and Washer 351).
Tailgate Fit Adjustment (Refer to 342).
Rear Wiper Motor Installation (Refer to GROUP 51, Rear
Wiper and Washer 351).
Tailgate Trim Assembly Installation (Refer to GROUP
Tailgate Spoiler Assembly Installation (Refer to GROUP
51, Tailgate Spoiler 351).
3
4
9.0 2.0 Nm
Sealant: 3M ATD Part No. 8633 or equivalent
12 2 Nm
9.0 2.0 Nm
2
7
12 2 Nm
5
3
6
12 2 Nm
1
AC102859 AC
BODY
42-45
TAILGATE
<<A>>
Tailgate assembly removal steps

1. Bumper
2. Rear washer hose
3. Waterproof film
4. Tailgate wiring harness
5. Tailgate gas spring
6. Tailgate assembly
Tailgate assembly removal steps

Headlining (Refer to GROUP 52A,
Headlining 352A).
>>B<< 7. Tailgate hinge
Tailgate opening weatherstrip removal
>>A<< 8. Tailgate opening weatherstrip
>>B<< TAILGATE HINGE INSTALLATION
<<A>> TAILGATE GAS SPRING REMOVAL

Tailgate hinge
Bolt
Pin
AC104148 AC
AC103607 AD
As shown in the Figure, slide the pin upward, then

remove the tailgate gas spring in the direction of the
arrow to unscrew the bolt.

>>A<< TAILGATE OPENING WEATHERSTRIP
INSTALLATION
Tailgate opening
weatherstrip
Positioning
mark
AC103272AD
Assemble so the tailgate opening weatherstrip

marking is at the centre of the body.
Apply the specified sealing agent to the tailgate

hinge assembly surface to assembly the tailgate
hinge.
Specified Adhesive: 3M ATD Part No.8531
Heavy drip check sealer, 3M ATD Part
No.8646 Automotive joint and seam sealer or
equivalent
BODY
42-46
TAILGATE
TAILGATE HANDLE AND LATCH

M1424001700147
Tailgate Handle Play Check (Refer to 342).
5.0 1.0 Nm
5.0 1.0 Nm
7
6
5
9.0 2.0 Nm
22 4 Nm
1
AC102861AC
Striker removal steps

Rear end trim (Refer to GROUP 52A,
Trims 352A).
>>A<< 1. Striker
Tailgate handle and lock key cylinder
removal steps
Lower tailgate trim (Refer to GROUP
2. Tailgate Lock Actuator Connection
3. Tailgate lock key cylinder
4. Tailgate handle
Tailgate latch removal steps

5. Bolt (earth)
6. Tailgate latch assembly
Tailgate lock actuator removal steps
7. Tailgate lock actuator
BODY
42-47
TAILGATE
TAILGATE LATCH CHECK <Vehicles for

>>A<< STRIKER INSTALLATION
Lock
Latch center
Striker center
Lever
1
+1.5 mm
Unlock
-1.5 mm
2
Striker
Latch
AC006126AB
Assemble so the distance between the centre of the

striker and centre of the latch is 1.5mm or less.
INSPECTION
M1424001200120
TAILGATE LOCK ACTUATOR CHECK
Lever
A
View A
Unlock
Lock
AC103292 AC
LEVER
POSITION
BATTERY
CONNECTION
LEVER
OPERATION
At the
"LOCK"
position
Connect terminal
No.2 and the
negative battery
terminal.
Connect terminal
No.3 and the
positive battery
terminal.
The lever
moves from the
"LOCK"
position to the
"UNLOCK"
position.
At the
"UNLOCK"
position
Connect terminal
No.3 and the
negative battery
terminal.
Connect terminal
No.2 and the
positive battery
terminal.
The lever
moves from the
"UNLOCK"
position to the
"LOCK"
position.
AC103291AD
LEVER
POSITION
TESTER
CONNECTION
SPECIFIED
CONDITION
At the "LOCK"
position
1 - 2 (Earth)
Open circuit
At the
"UNLOCK"
position
Less than 2
ohms
BODY
42-48

SPECIAL TOOLS
M1428000600257
Tool
Number
Name
Use
MB991502
MUT-II sub-assembly
Encrypted code registration
MB991529
Diagnosis code check

harness
B991502
MB991529
TROUBLESHOOTING
M1428000700254
The keyless entry system is controlled by the Smart

GROUP 54B, Diagnosis 354B or GROUP 54C,
Diagnosis 354C.
ON-VEHICLE SERVICE
KEYLESS ENTRY SYSTEM CHECK
M1428001400074
Check the system as described below. If the system

does not work, carry out troubleshooting. Refer to
GROUP 54B, Diagnosis 354B, refer to GROUP
54C, Diagnosis 354C.
Operate the transmitter to check that the doors
and tailgate can be locked and unlocked.
Operate the transmitter to check that the
answerback function works in response to door
and tailgate locking/unlocking.
NOTE: .
The adjustment function allows you to change
the answerback setting as follows. Prior to
that check, confirm which setting is activated.
The hazard warning lamps flash twice
when locked and once when unlocked.
The room lamp flashes twice when locked
and illuminates for 15 seconds when
unlocked.
The hazard warning lamps do not flash
when locked and flash once when
unlocked. The room lamp flashes twice
when locked and illuminates for 15
seconds when unlocked.
The hazard warning lamps flash twice
when locked and do not flash when
unlocked. The room lamp flashes twice
when locked and illuminates for 15

seconds when unlocked.
The hazard warning lamps do not flash
when both locked and unlocked. The room
lamp flashes twice when locked and
illuminates for 15 seconds when unlocked.
KEYLESS ENTRY SYSTEM TIMER LOCK

FUNCTION INSPECTION
M1428004000097
Push the transmitter unlock button and check to see

that the doors and tailgate lock within 30 seconds. If
it doesnt, then execute troubleshooting remedies.
Refer to GROUP 54B, Diagnosis 354B, refer to
GROUP 54C, Diagnosis 354C.
HOW TO REPLACE THE TRANSMITTER

BATTERY
M1428000900236
CAUTION
Do not allow water or dust to enter the inside of
the transmitter when it is open. Also, do not
touch the precision electronic device.
Battery
Claw
Screw
AC000509AB
1. Remove the set screw to remove the battery from

the transmitter.
BODY
2. Install a battery with its (+) side face-down.

Battery required for replacement: Coin type
battery CR2032
3. Insert the claw first, and assemble the transmitter.
4. Verify that the keyless entry system operates.
ENABLING/DISABLING THE
ANSWERBACK FUNCTION
M1428003200195
If the keyless entry system locks or unlocks the

doors, the room lamp flashes or illuminates, the
hazard warning lamp flashes (hazard answerback
function). The hazard answerback function can be
enabled or disabled according to the following
procedure:
ENABLING/DISABLING THE HAZARD

ANSWERBACK FUNCTION
The hazard answerback function can be enabled or
disabled by one of the two following procedures.
<When using the transmitter after diagnosis
connector (1) is earthed>
1. Enter the hazard answerback customize mode by
performing one of the following steps. If the
ETACS-ECU enters the customize mode, its
buzzer will sound once.
(1) Turn the ignition switch to LOCK(OFF)
position.
(2) Turn off the hazard warning lamp switch.
CAUTION
Before connecting or disconnecting the earth,
position.
Diagnosis
connector
MB991529
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC107528 AC
(3) Connect the diagnosis connector to the

special tool (MB991529).
(4) Close the driver's side door.
(5) Keep the windshield washer switch on for at
least ten seconds. Then the ETACS-ECU
42-49
2. If the transmitter LOCK button is pushed

consecutively twice (within two seconds), the
ETACS-ECU buzzer will sound, indicating that the
hazard answerback function can be enabled or
disabled when the doors are locked.
Enable the hazard answerback function
when the doors are locked: The ETACSECU buzzer will sound once.
Disable the hazard answerback function
when the doors are locked: The ETACSECU buzzer will sound twice.
3. If the transmitter UNLOCK button is pushed
disabled when the doors are unlocked.
when the doors are unlocked: The
ETACS-ECU buzzer will sound once.
ETACS-ECU buzzer will sound twice.
4. Exit the hazard answerback customize mode by
observing one of the following steps.
(1) Disconnect diagnosis connector terminal (1)
form the earth.
(2) Turn the ignition switch to position other then
LOCK(OFF), or remove the ignition key.
(3) Open the driver's side door,
(4) Any other warning buzzer output occurs.
NOTE: If any operation is not done for at least three
minutes after the ETACS-ECU has entered the
customize mode, the hazard answerback customize
mode will be canceled automatically.
<When the transmitter is used after connecting
MUT-II to the diagnosis connector>
1. Enter the hazard answerback customize mode by
performing one of the following steps. If the
ETACS-ECU enters the customize mode, its
(1) Turn the ignition switch to LOCK(OFF)
position.
(2) Turn off the hazard warning lamp switch.
BODY
42-50
CAUTION
position.
(4) Any other warning buzzer output occurs.

NOTE: If any operation is not done for at least three
minutes after the ETACS-ECU has entered the
customize mode, the hazard answerback customize
mode will be canceled automatically.
HOW TO REGISTER SECRET CODE

M1428001000269
16 Pin
MB991502
AC107200AC
(3) Connect the MUT-II to the diagnosis

connector.
(4) Close the drivers side door.
(5) Keep the windshield washer switch on for at
least ten seconds. Then the ETACS-ECU
2. If the transmitter LOCK button is pushed
disabled when the doors are locked.
when the doors are locked: The ETACSECU buzzer will sound once.
when the doors are locked: The ETACSECU buzzer will sound twice.
3. If the transmitter UNLOCK button is pushed
disabled when the doors are unlocked.
ETACS-ECU buzzer will sound once.
ETACS-ECU buzzer will sound twice.
4. Exit the hazard answerback customize mode by
observing one of the following steps.
(1) Disconnect MUT-II from the diagnosis
connector.
(2) Turn the ignition switch to position other then
LOCK(OFF), or remove the ignition key.
(3) Open the driver's side door,
Each individual secret code is registered inside the

transmitter, and so it is necessary to resister these
codes with the EEPROM inside the receiver in the
following cases.
When the transmitter or ETACS-ECU is replaced
If more transmitters are to be used
If it appears that a problem is occurring because
of faulty registration of a code.
A maximum of four different codes can be stored in
the EEPROM memory (four different transmitters can
be used). When the code for the first transmitter is
registered, the previously registered codes for all
transmitters are cleared. Therefore, if you are using
four transmitters or are adding more transmitters, the
codes for all transmitters must be registered at the
same time.
When the MUT-II is not used

1. Check that the doors lock normally when the key
is used.
2. Insert the ignition key.
CAUTION
Before connecting or disconnecting the earth,
position.
Diagnosis
connector
MB991529
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC107528 AC
3. Connect the diagnosis connector to the special

tool (MB991529).
NOTE: This will connect terminal (1) of the
diagnosis connector to earth, and the system will
be in secret code registration standby mode.
BODY
42-51
CAUTION
position.
Ground connected
Within 10 seconds
Hazard
warning
switch
ON
OFF
ACX00571 AG
4. Press the hazard warning lamp switch six times

within 10 seconds.
NOTE: Once the process is completed six times,
then it will operate with all doors and tailgate lock
and unlock operations once and then go to the
save mode.
NOTE: The hazard warning lamp switch is turned
on and off alternately whenever it is pushed.
5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will
register the code.
6. Once the program is saved, it will operate once
with the all doors and tailgate lock and unlock
operations.
7. If you are using two or more transmitters or have
added a second transmitter, the same registration
procedure should be carried out within one minute
after registering the code for the first transmitter.
8. Registration mode will be canceled under the
following conditions:
When the secret code for four transmitters has
been registered;
When one minute has passed after registration
mode started;
When the diagnosis connector is disconnected
from earth
When the key is removed from the key cylinder;
9. After the registration is completed, remove the
ignition key and close all the doors, and then
check that the keyless entry system operates
normally.
When the MUT-II is used

1. Check that the doors lock normally when the key
is used.
2. Insert the ignition key.
16 Pin
MB991502
AC107200AC

MUT-II connected
Within 10 seconds
Hazard
warning
switch
ON
OFF
ACX00571 AB
4. Press the hazard warning switch six times within

10 seconds.
NOTE: Once the process is completed six times,
then it will operate with all doors and tailgate lock
and unlock operations once and then go to the
save mode.
NOTE: The hazard warning lamp switch is turned
on and off alternately whenever it is pushed.
5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will
register the code.
6. Once the program is saved, it will operate once
with the all doors and tailgate lock and unlock
operations.
7. If you are using two or more transmitters or have
added a second transmitter, the same registration
procedure should be carried out within one minute
after registering the code for the first transmitter.
8. Registration mode will be canceled under the
following conditions:
When the secret code for four transmitters has
been registered;
When one minute has passed after registration
mode started;
When the MUT-II is disconnected from the
diagnosis connector
BODY
42-52
SUNROOF ASSEMBLY
When the key is removed from the key cylinder;
9. After the registration is completed, remove the

ignition key and close all the doors, and then
check that the keyless entry system operates
normally.
SUNROOF ASSEMBLY
M1421000300255
Item
Standard value
Roof lid glass operation current A (at 20 C)
7 or less
TROUBLESHOOTING
CHECK CHART FOR TROUBLE
SYMPTOMS
M1426002000095
Symptom
Inspection
procedure
number
Reference
page
Sunroof does not work at all.
342
Any of the sunroof switch positions is defective.
342
Sunroof anti-trap function does not work normally.
342
BODY
42-53
SUNROOF ASSEMBLY
INSPECTION PROCEDURE 1: The sunroof does not work at all.
CAUTION
Sunroof-ECU Power Supply Circuit
FUSIBLE
LINK 5
IGNITION
SWITCH (IG2)
SUNROOF
MOTOR ASSEMBLY
CONTROL CIRCUIT
SUNROOF
SWITCH
Wire colour code


If the sunroof does not work at all, these power
supply circuit(s), these earth circuit(s), sunroof switch
or the sunroof motor assembly (sunroof ECU) may
be defective.
Possible causes
Malfunction of the sunroof switch
Malfunction of the sunroof motor assembly
(sunroof ECU)
BODY
42-54
SUNROOF ASSEMBLY
Diagnostic procedure
STEP 3. Measure the resistance at the D-06

sunroof switch connector.
STEP 1. Connector check: D-06 sunroof switch

connector
Connector: D-06
Connector: D-06
D-06(B)
D-06(B)
Harness side
6 5 4 3 2 1
Harness side
6 5 4 3 2 1
AC301408 AC
AC301408 AC


YES : Go to Step 2.
STEP 2. Check the sunroof switch.

Refer to sunroof switch continuity check342.
6 5 4 3 2 1

YES : Go to Step 3.
NO : Replace the sunroof switch.
Connector D-06
(Harness side)
AC301721AB
(2) Continuity between D-06 sunroof switch

OK: 2W or less
YES : Go to Step 5.
NO : Go to Step 4.
BODY
42-55
SUNROOF ASSEMBLY
STEP 4. Check the wiring harness between D-06

sunroof switch connector terminal No.4 and body
earth.
Connector: D-06
STEP 6. Measure the voltage at the D-09 sunroof

motor assembly connector.
Connector: D-09
D-06(B)
Harness side
Harness side
4 3
2 1
10 9 8 7 6 5
6 5 4 3 2 1
AC301408 AD
AC301408 AC
NOTE:
(1) Disconnect the sunroof motor assembly

connector, and measure at the harness side.
Connector: C-218
4 3
2 1
10 9 8 7 6 5
1 2 3 4 5
AC210476 AD
Connector D-09
(Harness side)
AC301722 AB

necessary.

STEP 5. Connector check: D-09 sunroof motor
assembly connector
Connector: D-09
Harness side
4 3
2 1
10 9 8 7 6 5
AC301408 AD

YES : Go to Step 6.
4 3
2 1
10 9 8 7 6 5
Connector D-09
(Harness side)
AC301723 AB
(2) Check the voltage between the sunroof motor

assembly connector and body earth.
Voltage between D-09 sunroof motor
earth.
Voltage between D-09 sunroof motor
earth.
OK: Battery positive voltage
YES : Go to Step 8.
NO : Go to Step 7.
BODY
42-56
SUNROOF ASSEMBLY

sunroof motor assembly connector (terminal
Nos. 1 and 2) and the battery.
Connector: C-203, C-210

C-203
Connector: D-09
Harness side
4 3
2 1
10 9 8 7 6 5
C-210
AC301408 AD
C-203
Junction block side
2
1
6 5 4 3
NOTE:
Connector: C-116
C-210
Junction block side
3 2 1
AC210475 AZ
Connector: C-218
C-116
1 2
5 6 7
3 4
8 9
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
1 2 3 4 5
1617 18 1920 21
AC301396 AB
AC210476 AD

junction block connectors C-203, C-210 and the
intermediate connectors C-218, C-116 and repair if
necessary.

BODY
42-57
SUNROOF ASSEMBLY
STEP 8. Measure the resistance at the D-09

sunroof motor assembly connector.
Connector: D-09

sunroof motor assembly connector terminal No.5
and body earth.
Connector: D-09
Harness side
Harness side
4 3
2 1
10 9 8 7 6 5
4 3
2 1
10 9 8 7 6 5
AC301408 AD
(1) Disconnect the sunroof motor assembly

connector, and measure at the harness side.
AC301408 AD
NOTE:
Connector: C-218
4 3
2 1
10 9 8 7 6 5
1 2 3 4 5
Connector D-09
(Harness side)
(2) Check the resistance between the sunroof motor

assembly connector and body earth.
Resistance between D-09 sunroof motor
earth.
OK: 2W or less
NO : Go to Step 9.
AC210476 AD
AC301724 AB

necessary.
Check body earth line for open circuit.

connector
Connector: D-06
D-06(B)
Harness side
6 5 4 3 2 1
AC301408 AC

BODY
42-58
SUNROOF ASSEMBLY

The sunroof assembly should now work normally.

NO : Replace the sunroof motor assembly.
INSPECTION PROCEDURE 2: Any of the sunroof switch positions is defective.
CAUTION
Sunroof Switch Circuit

SUNROOF
MOTOR ASSEMBLY
CONTROL CIRCUIT
SUNROOF
SWITCH
Wire colour code


If any of the sunroof switch positions is defective, the
communication line between the sunroof switch and
the sunroof motor assembly (sunroof-ECU) may be
defective.
SB : Sky blue
Possible causes
Malfunction of the sunroof switch
(sunroof ECU)
BODY
42-59
SUNROOF ASSEMBLY

connector
Q: Which switch position is defective?

"TILT UP" : Go to Step 5.
"OPEN" : Go to Step 6.
"CLOSE/DOWN" : Go to Step 7.
Connector: D-06
D-06(B)
Harness side
6 5 4 3 2 1

and D-06 sunroof switch connector terminal
No.3.
AC301408 AC
D-09
D-06(B)

YES : Go to Step 2.
STEP 2. Check the sunroof switch.

Refer to sunroof switch continuity check342.
YES : Go to Step 3.
NO : Replace the sunroof switch.
Harness side
D-06
STEP 3. Connector check: D-09 sunroof motor

assembly connector
6 5 4 3 2 1
D-09
4 3
2 1
10 9 8 7 6 5
Connector: D-09
AC301409 AC
Harness side
4 3
2 1
10 9 8 7 6 5
AC301408 AD

YES : Go to Step 4.

YES : Replace the sunroof motor assembly.
BODY
42-60
SUNROOF ASSEMBLY

No.5.

D-09
D-06(B)
Harness side
D-06
6 5 4 3 2 1

No.6.
D-09
D-06(B)
Harness side
D-09
4 3
2 1
10 9 8 7 6 5
D-06
6 5 4 3 2 1
D-09
4 3
2 1
10 9 8 7 6 5
AC301409 AC

AC301409 AC

INSPECTION PROCEDURE 3: Sunroof anti-trap function does not work normally.
CAUTION
OPERATION
This function is activated by the sunroof motor
assembly (sunroof-ECU).
If the sunroof anti-trap function does not work, the
sunroof motor assembly (sunroof-ECU) may be
defective.
Possible causes
(sunroof ECU)
Retest the system.
Check that the sunroof anti-trap function work
normally.

NO : Replace the sunroof motor assembly.
BODY
SUNROOF ASSEMBLY
ON-VEHICLE SERVICE
WATER TEST
M1426000900241
Check if there are any leaks in the sunroof by the

following procedure.
1. Fully close the roof lid glass.
2. Adjust the water pressure so that water comes out
of the hose to a height of approximately 50 cm
when the hose is held vertically facing upwards.
Hose
Approx
30 cm
42-61
5. Adjust the roof lid glass height according to the

number of the adjusting plate pieces. Check to
see that the height of the roof lid glass is even with
the body.
6. After adjustment, check to be sure that the
sunroof operates smoothly.
SUNROOF CHECK
M1426004700089
Check to see that the sunroof operates by pressing

the sunroof switch. Perform troubleshooting if
operations malfunction. (Refer to 342).
SUNROOF SAFETY FUNCTION CHECK

M1426004400107
ACX00572 AB
3. Hold the end of the hose approximately 30 cm

above the roof and let the water run onto the
weatherstrip for 5 minutes or more.
4. Check if any water leaks can be found in the room
while watering. Even though there are any water
leaks around the roof lid glass, it can be
acceptable as long as water is caught in the drip
area.
1. Close the roof lid glass by applying an

approximately 10mm thickness wood chip placed
at a right angle to the roof lid glass.
2. Check to see if the roof lid glass opens after the
motor turns when the roof lid glass catches the
wooden chip. (Refer to 342).
ROOF LID GLASS OPERATION CURRENT

CHECK
M1426003200133
SUNROOF FIT ADJUSTMENT

M1426001000252
1. Fully close the roof lid glass.

2. Fully open the sunshade.
3. Remove the decoration cover (Refer to 342).
AC102847AC
4. To adjust the roof lid glass in the front/back or left/

right direction, loosen the nuts securing the roof
lid glass assembly, then move the roof lid glass
assembly to the front/back or left/right. Check to
see that the space between the roof lid glass and
body is even across the entire circumference.
AC107524AC
1. Remove the fuse of the sunroof, then connect the

circuit tester as shown in the Figure.
2. Turn ON the sunroof switch, then measure the
operating current of the intermediary segment
when the sunroof is moving, with the sunroof fully
closed, when the sunroof is fully opened and
when the sunroof is tilted fully up.
Standard value: 7 A or less (at 20 C)
3. Check the following areas if the operating current
of exceeds the standard value.
Sunroof installation, deformation and appearance
of any foreign substances.
Drive cable installation.
Tilting of roof lid glass.
42-62
BODY
SUNROOF ASSEMBLY
SUNROOF INITIALIZATION
M1426004600093
1. Assemble the roof lid glass assembly and sunroof

motor assembly to the sunroof assembly.
2. Connect the sunroof motor assembly connector
and sunroof switch connector to the wire ring
harness connector on the vehicle side.
3. Fully open the roof lid glass by pressing the
sunroof switch, then fully close the sunroof by
pressing the close switch again.
4. Continuously press the close switch for a

minimum of 3 seconds after the sunroof is fully
closed.
5. Press the open switch to fully open the sunroof,
then press the close switch to fully close the
sunroof.
NOTE: Do not stop the sunroof before the sunroof is
fully opened or fully closed in Step 5, above. If the
fully open or closed operation is interrupted/stopped,
start over from Step 3.
BODY
42-63
SUNROOF ASSEMBLY
SUNROOF ASSEMBLY
M1426001200278
Post-installation Operation <Roof lid glass assembly,

Sunroof assembly>
Sunroof Water Test (Refer to 342).
Sunroof Fit Adjustment (Refer to 342).
Sunroof Initializing Adjustment (Refer to 342).
Section A A
Claw
2
9
3
Section B B
Claw
9
8
6
7
5
B
B
7
Note
: Claw positions
1.
2.
3.
4.
5.
6.
Removal
Deflector assembly
Roof lid glass assembly removal
steps
Decoration cover
Adjusting plate
Roof lid glass assembly
Sunroof switch removal steps
Sunroof switch cover
Sunroof switch
AC
Drain pipe removal steps

5. Sunroof switch cover
Headlining 352A).
Cowl side trim (Refer to GROUP 52A,
Trims 352A).
>>A<< 7. Drain pipe
BODY
42-64
SUNROOF ASSEMBLY
5.
8.
5.
6.
>>A<< 7.
9.
Sunroof motor assembly removal

steps
Headlining 352A).
Sunroof assembly removal steps
Sunroof switch
Headlining (Refer to GROUP 52A
352A).
Drain pipe connection
Sunroof assembly

>>A<< DRAIN PIPE INSTALLATION
INSPECTION
M1426001600113
SUNROOF SWITCH CONTINUITY CHECK

Up
Grommet
Open
25 5 mm
Close/
Down
1 2 3 4 5 6
1 2 3 4 5 6
AC002392 AD
Install the grommet, and then position the drain pipe

so that it protrudes from the grommet as shown in
the illustration.
AC005659 AB
SWITCH
POSITION
TESTER
CONNECTION
SPECIFIED
CONDITION
Open
4-5
Less than 2
ohms
OFF
3 - 4, 3 - 5,
3 - 6, 4 - 5,
4 - 6, 5 - 6
Open circuit
Up
3-4
Less than 2
ohms
Close/Down
4-6
Less than 2
ohms
BODY
42-65
SUNROOF ASSEMBLY
DISASSEMBLY AND ASSEMBLY

M1426001400250
10
13
5N
3
4N
7
1
2
6
12
12
13
11
10
1.
2.
3.
4.
>>A<< 5.
6.
Disassembly steps
Deflector assembly
Decoration cover (Refer to 342).
Adjusting plate
Roof lid glass assembly
Weatherstrip
Weatherstrip inner
AC102840 AD
7.
8.
9.
10.
11.
12.
13.

Operating unit
Sun shade assembly
Lifter link
Guide assembly
Drip plate
Seal tape
Frame assembly
BODY
42-66
SUNROOF ASSEMBLY

>>A<< WEATHERSTRIP INNER INSTALLATION
1. Degrease the weatherstrip inner assembling
surface of the roof lid glass side with unleaded
gasoline.
A
A
400 mm
Glass
centre line
Section A A
Weatherstrip
inner
20 mm
AC102846 AC
2. Assemble the weatherstrip inner in the location

shown.
127(6
33-1
GROUP 33
00
11
FRONT
SUSPENSION
12
13
14
15
16
CONTENTS
17
33
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
33
33
21
33
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
33
22
LUBRICANT. . . . . . . . . . . . . . . . . . . .
33
LOWER ARM . . . . . . . . . . . . . . . . . . .
33
25
33
SPECIAL TOOLS. . . . . . . . . . . . . . . .
33
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
33
26
33
BALL JOINT DUST COVER

REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
33
27
FRONT WHEEL ALIGNMENT CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
33
LOWER ARM REAR BUSHING

REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
33
LOWER ARM BALL JOINT AXIAL PLAY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
STABILIZER BAR* . . . . . . . . . . . . . . .
33
BALL JOINT DUST COVER CHECK . . . . .
33
33
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
33
STABILIZER LINK BALL JOINT DUST

COVER REPLACEMENT . . . . . . . . . . . . . .
34
33
35
STRUT ASSEMBLY. . . . . . . . . . . . . .
33
33
31
32
33
36
37
:$51,1*65(*$5',1*6(59,&,1*2)6833/(0(17$/5(675$,176<67(0656(48,33('9(+,&/(6
WARNING
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
passenger (from rendering the SRS inoperative).
Service or maintenance of any SRS component or SRS-related component must be performed only at an
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
42
51
52
54
55
FRONT SUSPENSION
33-2
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1332000100225
The front suspension is a McPherson strut with coil

spring. The shock absorber is gas-filled hydraulic
double-acting type.
Stiffener plate
Coil spring
Stabilizer bar
Strut assembly
Crossmember
Lower arm
AC301358AB
SPECIFICATIONS
COIL SPRING
Item
2WD
4WD
Wire diameter mm
14
14
Average diameter mm
160
160
Free length mm
300
305
FRONT SUSPENSION
33-3
M1332000300326
Item
Toe-in
Standard value
12
003 05
Toe-out angle on turns (inner wheel when outer wheel at 20)
2200 130
Steering angle
Inner wheel
3450 130
Outer wheel (reference)
2920
Camber
-010 30*
Caster
315 30*
Kingpin inclination
1225 130
Side slip mm (per 1m)
03
Lower arm ball joint starting torque Nm
0 - 3.9
Protruding length of stabilizer link thread part mm
9.4 0.4
Stabilizer link ball joint turning torque Nm
0.5 - 1.5
NOTE: *: difference between right and left wheels

must be less than 30
LUBRICANT
M1332000400130
Item
Lower arm ball joint
Lip portion of dust cover

Inside of dust cover
Stabilizer link ball joint
Inside of dust cover
Specified lubricant
Quantity
Multipurpose grease SAE J310,

As required
FRONT SUSPENSION
33-4
SPECIAL TOOLS
SPECIAL TOOLS
M1332000600275
Tool
Number
Name
Use
MB991004
Wheel alignment gauge

attachment
Wheel alignment
measurement <Vehicles
with aluminium wheels>
A: MB991237
B: MB991238
A: Spring compressor
body
B: Arm set
Coil spring compression
MB991680
A: MB991681
B: MB991682
Wrench set
A: Wrench
B: Socket
Strut assembly
disassembly and
reassembly
MB991006
Preload socket
Lower arm ball joint

starting torque check
MB990800
Ball joint remover and

installer
Lower arm ball joint dust

cover installation
MB991004
A
B
MB991237
MB991680
MB991006
MB990800
FRONT SUSPENSION
33-5
ON-VEHICLE SERVICE
Tool
Number
Name
Use
MB990883
Rear suspension bushing

arbor
Lower arm bushing

removal and press-fitting
MB990972
Torsion bar bushing

remover base
MB990887
Ring
MB990890
Rear suspension bushing

base
MB990326
Preload socket
MB990883
MB990971
MB990890
Stabilizer link ball joint

turning torque check
MB990326
ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
M1331000900400
Measure wheel alignment with alignment equipment

on a level surface. The front suspension, steering
system, wheels, and tires should be serviced to
normal condition before measuring wheel alignment.
TOE-IN
Standard value:
at the centre of tyre tread: 1 2 mm
Jam nut
Clip
AC006074 AB
1. Adjust the toe-in by undoing the clip and jam nut,

and turning the left and right tie rod turnbuckles by
the same amount (in opposite directions).
NOTE: The toe will move out as the left
turnbuckle is turned toward the front of the vehicle
and the right turnbuckle is turned toward the rear
of the vehicle.
2. Install the clip and tighten the jam nut to the
specified torque.
FRONT SUSPENSION
33-6
ON-VEHICLE SERVICE
3. Confirm that the toe-in is at the standard value.
4. Use a turning radius gauge to check that the
steering angle is at the standard value.
STEERING ANGLE
Standard value:
Item
Specification
Inner wheels
3450 130
Outer wheels (reference)
2920
TOE-OUT ANGLE ON TURNS

To check the steering linkage, especially after the
vehicle has been involved in an accident or if an
accident is presumed, it is advisable to check the
toe-out angle on turns in addition to the wheel
alignment.
Conduct this test on the left turn as well as on the
right turn.
Standard value:
Item
Specification
Toe-out angle on turns

(inner wheel when outer
wheel at 20)
2200 130
CAUTION
Never subject the wheel bearings to the vehicle
load when the driveshaft nuts are loosened.
NOTE:
MB991004
AC001079 AB
For vehicles with aluminium wheels, attach the

camber/caster/kingpin gauge to the driveshaft by
using special tool wheel alignment gauge attachment
(MB991004). Tighten the special tool to the same
torque 245 29 Nm as the driveshaft nut.
SIDE SLIP
Measure the side slip with a side slip tester.
Standard value: 0 3 mm (per 1 m)
LOWER ARM BALL JOINT AXIAL PLAY

CHECK
M1332011300063
CAMBER, CASTER AND KINGPIN INCLINATION

Standard value:
Item
Specification
Camber
-010 30*
Caster
315 30*
Kingpin inclination
1225 130
NOTE: *: difference between right and left wheels

must be less than 30
NOTE: Camber and caster are preset at the factory
and cannot be adjusted.
1. Raise the vehicle.

2. Remove the stabilizer link from the lower arm.
3. Move the lower arm up and down with your hands
to check for an excessive play in the axial
direction of the ball joint. If there is an excessive
play, replace the lower arm assembly.
BALL JOINT DUST COVER CHECK

M1332008600309
1. Press the dust cover with your finger to check that

there are no cracks or damage in the dust cover.
the lower arm assembly.
NOTE: If the dust cover is cracked or damaged, it
is possible that there may also be damage to the
ball joint.
FRONT SUSPENSION
33-7
STRUT ASSEMBLY
STRUT ASSEMBLY
M1332001100284
CAUTION
Be careful when handling the pole piece at the tip of the front ABS sensor so as not to damage it by
striking against other parts.
Washer Tank Assembly Removal (Refer to GROUP 51,
Windshield Wiper and Washer 351). <Pre-removal of
the strut assembly (RH)>
Washer Tank Assembly Installation (Refer to GROUP 51,
Windshield Wiper and Washer 351). <Postinstallation of the strut assembly (RH)>
Front Wheel Alignment Adjustment (Refer to 333).
44 5 Nm
7
3
167 9 Nm
AC202820 AB
1.
2.
3.
4.
Removal steps
Front ABS sensor harness bracket
Brake hose bracket
Knuckle connection
Strut mounting nut
5.
6.
7.

Insulator clip
Stiffener plate
Strut assembly
INSPECTION
M1332001200236
Check for oil leaks from the strut assembly.

Check the strut assembly for damage or
deformation.
FRONT SUSPENSION
33-8
STRUT ASSEMBLY

M1332001300277
60 10 Nm
1
2
3
8
4
5
7
9
6
10
AC301222 AB
<<A>> >>A<< 1.
2.
3.
4.
5.
Disassembly steps
Self-locking nut
Strut insulator assembly
Bearing
Upper spring seat
Upper spring pad
<>
6.
7.
8.
9.
10.

Dust cover
Bump stopper
Coil spring
Lower spring pad
Strut assembly
FRONT SUSPENSION
33-9
STRUT ASSEMBLY
<> STRUT ASSEMBLY DISPOSAL
WARNING
Wear goggles when drilling to protect your
eyes from flying metal debris.
CAUTION
Install special tool arm set (MB991238) evenly,
and so that the maximum length will be
attained within the installation range.
Do not use an impact wrench to tighten the
bolt of special tool spring compressor body
(MB991237), otherwise the special tool will
break.
MB991238
AC001087
MB991237
AC001085 AB
The gas must be discharged from the strut assembly

before discarding it. Place the strut assembly
horizontally with its piston rod extended. Then drill a
hole of approximately 3 mm in diameter at the
location shown in the illustration and discharge the
gas.
1. Use following special tools to compress the coil

spring.
MB991237: Spring Compressor Body
MB991238: Arm Set
WARNING
Do not use an impact wrench to remove the
self-locking nut. Vibration of the impact
wrench will cause special tools (MB991237
and MB991238) to slip and cause personal
injury.
Do not use an impact wrench to tighten the bolt

of special tool spring compressor body
(MB991237), otherwise the special tool will break.
>>A<< SELF-LOCKING NUT INSTALLATION

1. Ensure that the bearing is seated correctly.
CAUTION
MB991238
MB991237
MB991682
MB991681
AC001085 AB
AC006091 AB
2. Use following special tools to secure the strut, and

then remove the self-locking nut.
MB991681: Wrench
MB991682: Socket
2. Install following special tools to the strut assembly

same as its removal.
MB991238: Arm Set
3. While the coil spring is being compressed by the
special tools, temporarily tighten the self-locking
nut.
FRONT SUSPENSION
33-10
STRUT ASSEMBLY
INSPECTION
M1332001400177
Check the bearing for wear or rust.

Check the rubber parts for damage or
deterioration.
Check the spring for deformation, deterioration or
damage.
Check the shock absorber for deformation.
Rod
AC006091 AB
4. Align the hole in the strut assembly lower spring

seat with the hole in the upper spring seat.
NOTE: Using a rod as shown facilitates the
alignment.
5. Align both ends of the coil spring with the grooves
in the spring seat, and then loosen the special
tools.
CAUTION
Do not use an impact wrench to tighten the selflocking nut, otherwise the self-locking nut will be
damaged.
MB991682
MB991681
AC006091 AB
6. Using following special tools, tighten the selflocking nut to 60 10 Nm.

MB991681: Wrench
MB991682: Socket
FRONT SUSPENSION
33-11
LOWER ARM
LOWER ARM
M1332001600308
CAUTION
*
: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in an unladen condition.
with your finger.
Front Wheel Alignment Check and Adjustment (Refer to
333).
AC107030
Specified grease :
186 10 Nm*
167 9 Nm
39 5 Nm
AC107017
108 10 Nm
AC200961 AB
1.
>>A<< 2.
3.
4.
Removal steps
Lower arm and knuckle connection
Self-locking nut
Stabilizer rubber
5.
6.

Lower arm and crossmember
connection
Lower arm assembly
FRONT SUSPENSION
33-12
LOWER ARM

>>A<< SELF-LOCKING NUT INSTALLATION
A

the lower arm assembly.
NOTE: Cracks or damage to the dust cover may
cause damage to the ball joint. When it is
damaged during service work, replace the dust
cover.
BALL JOINT DUST COVER

REPLACEMENT
M1332008200259
AC107031AB
AC107031
Tighten the self-locking nut until the stabilizer link

thread part protruding length meets the standard
value.
INSPECTION
If the dust cover is damaged accidentally during

service work, replace the dust cover as follows:
1. Remove the dust cover.
2. Apply specified grease to the lip and the inside of
a new dust cover.
Specified grease: Multipurpose grease
SAE J310, NLGI No.2 or equivalent
Grease amount for the inside the dust
cover (reference): 8 - 10g
M1332001700264
Check the bushing for wear and deterioration.

Check the lower arm for bend or breakage.
Check all bolts for condition and straightness.
LOWER ARM BALL JOINT STARTING TORQUE
CHECK
MB990800
Dust cover
MB991006
AC006135 AB
3. Using special tool ball Joint remover and installer

(MB990800), drive in the dust cover until it is fully
seated.
AC001091 AB
1. After shaking the ball joint stud several times, use

special tool preload socket (MB991006) to
measure the starting torque of the ball joint.
Standard value: 0 - 3.9 Nm
2. If the measured value is not within the standard
value, or if the ball joint is difficult to turn or does
not turn smoothly, replace the lower arm
assembly.
LOWER ARM BALL JOINT DUST COVER CHECK
Dust cover
22 mm
AC107030 AB
4. Position the dust cover as shown in the

illustration. Make sure that there is no abnormal
bulge or pressure applied on the dust cover.
FRONT SUSPENSION
33-13
LOWER ARM
LOWER ARM REAR BUSHING

REPLACEMENT
MB990883
M1332008100337
MB990972
Bushing
Lower arm
assembly
Outer tube
MB990887
MB990890
AC107098 AB
Replace the bushing as follows:
Lower arm assembly

30
MB990883
Projection
AC006138 AC
MB990972
Lower arm
assembly
MB990887
MB990890
AC006137 AC
1. Use following special tools to drive out the

bushing.
MB990883: Rear Suspension Bushing Arbor
MB990972: Torsion Bar Bushing Remover Base
MB990887: Ring
MB990890: Rear Suspension Bushing Base
2. Position the bushing so that its projection is as

shown, and then use the special tools to press in
the bushing.
3. Press the bushing until its outer tube is flush with
the lower arm assembly surface.
FRONT SUSPENSION
33-14
STABILIZER BAR
STABILIZER BAR
M1332004000253
CAUTION
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B - Service
Precautions and Air Bag Module and Clock Spring. Also, put the front wheels in straight-ahead
position. Failure to do so may damage the SRS clock spring and render the SRS air bag
inoperative, which results serious driver injury.
*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.
Side Under Cover and Centre Under Cover Removal
(Refer to GROUP 51, Under Cover 351).
Steering Wheel and Air Bag Module Assembly Removal
(Refer to GROUP 37A, Steering Wheel 337).
Clock Spring Removal (Refer to GROUP 52B, Air Bag
Modules and Clock Spring 352B).
Centre Member Removal (Refer to GROUP 32, Engine
Roll Stopper, Centre Member 332).
Centre Member Installation (Refer to GROUP 32, Engine
Roll Stopper, Centre Member 332).
Clock Spring Installation (Refer to GROUP 52B, Air Bag
Modules and Clock Spring 352B).
Steering Wheel and Air Bag Module Assembly Installation
(Refer to GROUP 37A, Steering Wheel 337).
Check the dust covers for cracks or damage by pushing it
with your finger.
Ahead
333).
Side Under Cover and Centre Under Cover Installation
(Refer to GROUP 51, Under Cover 351).
FRONT SUSPENSION
33-15
STABILIZER BAR
18 2 Nm
4
AC107102
Specified grease:
21 4 Nm
5
11
6
7
8
10
9
2
49 10 Nm
52 7 Nm*
167 9 Nm
39 5 Nm
AC107023
167 9 Nm
1.
2.
3.
4.
<<A>>
>>A<<
5.
Removal steps
Power steering hose clamp
Rear roll stopper connecting
bolt
Steering shaft cover
Steering gear and joint
connecting bolt
Fixture
<<A>>
>>A<<
>>B<<
<<A>>
<<A>>
>>A<<
6.
7.
8.
9.
10.
11.
AC200962 AB

Bushing
Self-locking nut
Stabilizer rubber
Stabilizer link
Stabilizer rubber
Stabilizer bar
FRONT SUSPENSION
33-16
STABILIZER BAR

<<A>> FIXTURE/BUSHING/STABILIZER LINK/
STABILIZER BAR REMOVAL
Carry out the following operations to ensure working
space in order to remove the fixtures, the bushings,
the stabilizer links and the stabilizer bar.

A
Piece of wood
AC107031AB
AC107031
Transmission
jack
AC102600 AD
1. Use a transmission jack to hold the crossmember,

and then remove the crossmember mounting nuts
and bolts.
CAUTION
Be careful not to lower the crossmember
excessively, otherwise the power steering return
hose bracket may deform.
2. Lower the crossmember until the fixtures, the
bushings, the stabilizer links and the stabilizer bar
can be removed.

value.
INSPECTION
M1332002000246
Check the bushings for wear and deterioration.

Check the stabilizer bar for deterioration or
damage.
STABILIZER LINK BALL JOINT TURNING
TORQUE CHECK
MB990326

>>A<< STABILIZER BAR/BUSHING/FIXTURE
INSTALLATION
Outside of
vehicle
Approximately
10 mm
Identification
mark
Bushing (LH)
Fixture (LH)
AC006141AD
Align the stabilizer bar identification mark with the

right end of the bushing (LH).
AC001129 AB
1. After shaking the ball joint stud several times,

install the nut to the stud and use special tool
preload socket (MB990326) to measure the
turning torque of the ball joint.
2. When the measured value exceeds the standard
value, replace the stabilizer link.
3. When the measured value is lower than the
standard value, check that the ball joint turns
smoothly without excessive play. If so, it is
possible to re-use that ball joint.
FRONT SUSPENSION
33-17
STABILIZER BAR
STABILIZER LINK BALL JOINT DUST COVER

CHECK
the stabilizer link.
cover (Refer to 333).

COVER REPLACEMENT
M1332008300104
Only when the dust cover is damaged accidentally

during service work, replace the dust cover as
follows:
Clip ring
AC006188AB
1. Remove the clip ring and the dust cover.

2. Apply specified grease to the inside of a new dust
cover.
Specified grease: Multipurpose grease SAE
J310, NLGI No.2 or equivalent
3. Wrap plastic tape around the stabilizer link stud,
and then install the dust cover to the stabilizer link.
4. Secure the dust cover by the clip ring.
pushing it with finger.
127(6
34-1
GROUP 34
00
11
REAR SUSPENSION
12
13
14
CONTENTS
34
34
LUBRICANT. . . . . . . . . . . . . . . . . . . .
34
SPECIAL TOOLS. . . . . . . . . . . . . . . .
34
34
15
TRAILING ARM ASSEMBLY . . . . . . .
34
34
34
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
34
TRAILING ARM BUSHING

REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
21
34
22
SHOCK ABSORBER ASSEMBLY . . .
34
25
34
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
34
26
16
17
REAR WHEEL ALIGNMENT CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
34
34
LOWER ARM PILLOW BALL BUSHING

AXIAL PLAY CHECK . . . . . . . . . . . . . . . . .
27
34
STABILIZER BAR. . . . . . . . . . . . . . . .
34
31
34
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
34
32

COVER REPLACEMENT . . . . . . . . . . . . . .
34
33

COVER INSPECTION . . . . . . . . . . . . . . . .
CONTROL LINK, UPPER ARM AND

LOWER ARM . . . . . . . . . . . . . . . . . . .
34
34
34
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
34
LOWER ARM BUSHING AND LOWER

ARM PILLOW BALL BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
34
34
REAR SUSPENSION
CROSSMEMBER . . . . . . . . . . . . . . . .
34
34
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
34
35
36
37
42
51
52
54
55
REAR SUSPENSION
34-2
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1341000100320
A trailing arm type multi-link suspension has been

adopted as the rear suspension. The shock absorber
is a hydraulic, cylindrical double-acting type.
Rear suspension
crossmember
Shock absorber
Stabilizer bar
Bump rubber
Upper arm
Coil spring
Lower arm
Control link
Trailing arm bracket

Trailing arm
AC301439 AB
SPECIFICATION
COIL SPRING
Item
2WD
4WD
Wire diameter mm
11
11
Average diameter mm
91
91
Free length mm
342
350
M1341000300379
Item
Toe-in
Standard value
32
008 05
Camber
-040 30 (Difference between right and left within 30)
Thrust angle
000 09
Control link pillow ball bushing starting torque

Nm
0.5 - 3.0
Upper arm pillow ball bushing starting torque Nm 0.5 - 3.0

Lower arm pillow ball bushing starting torque Nm 0.5 - 3.0
Stabilizer link ball joint turning torque Nm
1.7 - 3.1
REAR SUSPENSION
34-3
LUBRICANT
LUBRICANT
M1341000400161
Item
Specified lubricant
Quantity
Stabilizer link ball joint (inside of dust cover)
Multipurpose grease SAE J310, NLGI No.2

or equivalent
As required
SPECIAL TOOLS
M1341000600369
Tool
Number
Name
Use
MB991014

attachment
Wheel alignment
measurement <2WDvehicles with aluminium
wheels>
MB991004

attachment
Wheel alignment
measurement <4WDvehicles with aluminium
wheels>
MB990326
Preload socket
Pillow ball bushing

starting torque check
Stabilizer link ball
joint turning torque
check
MB991447
Bushing remover and

installer
Lower arm bushing

MB991448
Bushing remover and

installer base
MB991449
Bushing remover and

installer supporter
MB991004
MB991004
MB990326
REAR SUSPENSION
34-4
SPECIAL TOOLS
Tool
B
A
Number
Name
Use
MB990957
A: MB990969
B: MB990971
Lower arm bushing

remover and installer
A: Guide
B: Base
Lower arm pillow ball

bushing removal and
press-fitting
MB990996
Lower arm bushing arbor
MB990767
End yoke holder
Rear axle hub fixing
MB990241
A: MB990243
B: MB990244
C: MB990242
Axle shaft puller

A: Puller body
B: Puller bar
C: Puller shaft
Drive shaft removal

<4WD>
MB991354
Puller body
Removal of the drive

shaft <4WD>
Rear hub assembly
removal <4WD>
A: MB991017
B: MB990998
C: MB991000
A, B: Front hub remover

and installer
C: Spacer
Provisional holding of
the wheel bearing
<4WD>
MB990590
A: MB990212
B: MB990211
Rear axle shaft oil seal

remover
A: Adapter
B: Sliding hammer
Rear hub assembly

removal <4WD>
MB990560
Bearing remover
Wheel bearing inner

race removal <4WD>
MB990957
B990996
B990767
MB990241
MB991354
B
C
AC100320AB
MB990590
MB990560
REAR SUSPENSION
34-5
SPECIAL TOOLS
Tool
Number
Name
Use
MB990934
Adapter
Wheel bearing removal

<4WD>
MB990938
Bar
MB991400
Rear wheel bearing and

hub installer
Wheel bearing pressfitting <4WD>

Rear hub assembly
press-fitting <4WD>
MB991401

hub installer base
Wheel bearing pressfitting <4WD>
MB991411

hub installer
Rear hub assembly

press-fitting <4WD>
MB991444
Bushing remover and

installer arbor
Trailing arm bushing

MB991445
Bushing remover and

installer base
A: MB991237
B: MB991239
A: Spring compressor
body
B: Arm set
B990938
MB991400
MB991401
MB991411
B991444
A
B
MB991237
Coil spring removal and

installation
REAR SUSPENSION
34-6
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
REAR WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
M1341011000349
Measure wheel alignment with an alignment

equipment on level earth.
The rear suspension, wheels, and tyres should be
serviced to the normal condition prior to wheel
alignment measurement.
CAMBER
Standard value: -0 40 30 (Left/right
deviation within 30)
NOTE: Camber is preset at the factory and cannot
be adjusted.
CAUTION
Never subject the wheel bearings to the vehicle
load when the trailing arm spindle self-locking
nuts (2WD), the driveshaft nuts (4WD), or the
special tool wheel alignment gauge attachment
(MB991004 or MB991014) are loosened.
NOTE:
<2WD-vehicles with aluminium wheels>
MB991014
NOTE:
<4WD-vehicles with aluminium wheels>
MB991004
AC001079 AE
For 4WD-vehicles with aluminium wheels, attach the

camber/caster/kingpin gauge to the driveshaft by
using special tool wheel alignment gauge attachment
(MB991004). Tighten the special tool to the same
torque 245 29 Nm as the driveshaft nut.
TOE-IN
Standard value:
At the centre of tyre tread: 3 2 mm
If toe-in is not within the standard value, adjust by
following procedures.
CAUTION
To prevent bushings from breakage, the toe
adjusting bolt should be temporarily tightened,
and then fully tightened with the vehicle on the
ground in the unladen condition.
AC001079 AD
<Control link front view> <Control link rear view>
For 2WD-vehicles with aluminium wheels, attach the

camber/caster/kingpin gauge to the trailing arm
spindle by using special tool wheel alignment gauge
attachment (MB991014). Tighten the special tool to
the same torque 175 25 Nm as the trailing arm
spindle self-locking nut.
Toe adjusting bolt

Control link
120 10 Nm
Control link
AC107070 AC
Carry out adjustment by turning the toe adjusting bolt

(control link mounting bolt which is located on the
inner side of the body).
NOTE: .
LH: Clockwise viewed from the front Toe-in
RH: Clockwise viewed from the front Toe-out
Turning the toe adjusting bolt by one groove of
the scale, toe can be changed approximately 2.6
mm (single side toe angle equivalent to 16).
REAR SUSPENSION
34-7
CONTROL LINK, UPPER ARM AND LOWER ARM

AXIAL PLAY CHECK
M1341016900046
1. Raise the vehicle.

2. Remove the stabilizer link and shock absorber
from the lower arm assembly.
3. Move the lower arm up and down with your hands
to check for an excessive play in the axial
direction of the pillow ball bushing. If there is an
excessive play, replace the lower arm pillow ball
bushing (Refer to 334).
4. After inspection, install the stabilizer link and

shock absorber to the lower arm assembly (Refer
to 334).

COVER INSPECTION
M1341012800252
1. Check dust covers for cracks or damage by

2. If a dust cover is cracked or damaged, replace the
stabilizer link.
NOTE: Cracks or damage to the dust cover may
cause damage to the ball joint.

M1341004800161
CAUTION
*
the ground in an unladen condition.
334).
120 10 Nm*
39 5 Nm
95 15 Nm*
2
120 10 Nm*
90 10 Nm*
120 10 Nm*
1
95 15 Nm*
<<A>> >>A<< 1.
>>A<< 2.
Control link and upper arm

removal steps
Control link
Upper arm
95 15 Nm*
AC107089 AC
<>
3.
4.
5.
6.
Lower arm removal steps

Stabilizer link connection
connection
Shock absorber connection
Lower arm
REAR SUSPENSION
34-8
INSPECTION
M1341004900146
<<A>> CONTROL LINK REMOVAL

Check the control link, upper arm and lower arm
for bending or breakage.
CONTROL LINK/UPPER ARM/LOWER ARM
PILLOW BALL BUSHING STARTING TORQUE
CHECK
Mating mark
Control link pillow ball bushing

AC107125 AB
After making a mating mark on the toe-in adjusting

bolt, remove the control link.
<> LOWER ARM AND TRAILING ARM
DISCONNECTION
Upper arm pillow ball bushing
Lower arm pillow ball bushing
Piece of wood
AC107126 AB
After supporting the lower arm with a jack, separate

the lower arm and the trailing arm.

>>A<< UPPER ARM/CONTROL LINK
INSTALLATION
AC107127 AC
Check each pillow ball bushing as follows.

1. Insert the mounting bolt to the pillow ball bushing.
In the opposite direction, insert a washer, then
install the mounting nut.
MB990326
Identification colour
Upper arm
Control link
AC102498 AC
Trailing arm
AC300343 AB
Install the upper arm/control link as shown so that its

identification colour faces the trailing arm.
2. After rotating the inner sleeve (contained washer)

several times, measure the starting torque of the
pillow ball bushing using special tool preload
socket (MB990326).
value, replace the control link, the upper arm, or
the lower arm pillow ball bushing.
REAR SUSPENSION
34-9
4. If the measured value is lower than the standard

value, check that the pillow ball bushing turns
smoothly without excessive play. If there is no
excessive play and it turns smoothly, the pillow
ball bushing can be reused.
LOWER ARM BUSHING AND LOWER

ARM PILLOW BALL BUSHING
REPLACEMENT
M1341011800196
Lower arm pillow

ball bushing
MB991447: Bushing Remover and Installer

MB991448: Bushing Remover and Installer Base
MB991449: Bushing Remover and Installer
Supporter
After press fitting, the space between the edges of
the bushing outer sleeve and of the lower arm should
be 1.5 mm.
REPLACEMENT
MB990996
3 mm
Lower arm bushing
Lower arm
MB990969
MB990971
AC107128 AC
Replace the lower arm bushing and lower arm pillow

ball bushing as follows.
LOWER ARM BUSHING REPLACEMENT
CAUTION
Because the outside of both edges of the
bushing are different, be careful not to mistake
the direction.
Driving Out
MB991447
Lower arm
MB991449
MB991448
AC006168 AC
Press-Fitting
MB991447
1.5 mm
Lower arm
MB991449
MB991448
AC006169 AC
Use following special tools to drive out and press fit

the bushing.
AC102522 AC
Use following special tools to drive out and press fit

the bushing.
MB990957: Lower Arm Bushing Remover and
Installer
MB990969: Guide
MB990971: Base
MB990996: Lower Arm Bushing Arbor
After press fitting, the space between the edges of
the bushing outer sleeve and of the lower arm should
be 3 mm.
REAR SUSPENSION
34-10
TRAILING ARM ASSEMBLY

M1341002200323
CAUTION
*
the ground in the unladen condition.
Brake Fluid Draining
Rear ABS Sensor Removal (Refer to GROUP 35B, ABS
Sensor 335B).
Rear Brake Caliper Assembly Removal (Refer to GROUP
35A, Rear Disc Brake Assembly 335A).
Rear Hub Assembly Removal (Refer to GROUP 27A,
Rear Axle Hub Assembly 327A).
Rear Hub Assembly Installation (Refer to GROUP 27A,
Rear Axle Hub Assembly 327A).
Rear Brake Caliper Assembly Installation (Refer to
GROUP 35A, Rear Disc Brake Assembly 335A).
Rear ABS Sensor Installation (Refer to GROUP 35B, ABS
Sensor 335B).
Brake Fluid Supplying and Bleeding (Refer to GROUP
35A, On-vehicle Service - Bleeding 335A).
334).
Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service - Parking Brake Lever Stroke
120 10 Nm*
15 2 Nm
90 10 Nm*
120 10 Nm*
10
11
39 5 Nm
4
8
63 7 Nm
95 15 Nm*
95 15 Nm
1
7
AC301223 AB
1.
2.
3.
4.
Removal steps
Parking brake cable connection
(Refer to GROUP 36, Parking
Brake Cable 336).
Brake hose and trailing arm
connection
Lower arm and stabilizer link
connection
Lower arm and shock absorber
connection
5.
6.
<<A>>
7.
8.
9.

connection
Upper arm and trailing arm
connection
connection
Rear parking brake assembly
Trailing arm and trailing arm
bracket connecting bolt
REAR SUSPENSION
34-11

10. Trailing arm
11. Trailing arm bracket

<<A>> LOWER ARM AND TRAILING ARM
DISCONNECTION
Piece of wood
AC107126 AB

the lower arm and trailing arm connection.
REAR SUSPENSION
34-12

M1341002200334
CAUTION
*:
Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
Rear ABS Sensor Removal (Refer to GROUP 35B, ABS
Sensor 335B).
120 10 Nm*
4
120 10 Nm*
90 10 Nm*
Rear ABS Sensor Installation (Refer to GROUP 35B, ABS
Sensor 335B).
Brake Fluid Supplying and Bleeding (Refer to GROUP
35A, On-vehicle Service - Bleeding 335A).
334).
Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service - Parking Brake Lever Stroke
15 2 Nm
60 5 Nm
17
14 7
N 16
39 5 Nm
1
12
6
15
5
95 15 Nm
10 N
95 15 Nm*
63 7 Nm
13
245 29 Nm
2
1.
2.
3.
4.
5.
6.
7.
<<A>>
8.
11
Removal steps
Brake hose and trailing arm
connection
Parking brake cable
Rear brake caliper assembly
Upper arm and trailing arm
connection
Lower arm and stabilizer link
connection
Lower arm and shock absorber
connection
connection
connection
AC300347 AB
9.
<>
>>C<<
<<C>>
<<D>>
>>B<<
<<E>>
>>A<<
10.
11.
12.
13.
14.
15.
16.
17.

Trailing arm and trailing arm
bracket connecting bolt
Drive shaft nut
Brake disc
Drive shaft connection
Rear hub assembly
Rear parking brake assembly
Trailing arm bracket
Snap ring
Wheel bearing
Trailing arm
REAR SUSPENSION
34-13

DISCONNECTION

the rear axle hub, and then remove the drive shaft
nut.
<<C>> DRIVE SHAFT DISCONNECTION
MB990242
(MB990241)
MB990767
MB990244
(MB990241)
(Three)
Piece of wood
AC107126 AB
MB991354

<> DRIVE SHAFT NUT REMOVAL
CAUTION
the vehicle weight to avoid possible damage to
the wheel bearing before tightening the drive
shaft nut fully.
MB990767
AC102719 AC
1. Use following special tools to push out the drive

shaft from the hub.
MB990241: Axle Shaft Puller
MB990242: Puller Shaft
MB990244: Puller Bar
MB990767: End Yoke Holder
MB991354: Puller Body
2. Hang the drive shaft on the vehicle body with a
rope.
CAUTION
245 29 Nm
AC102718 AC
MB991017
MB991000
Wheel bearing
AC102720 AC
MB990767
AC201826 AC

bearing by using special tools front hub remover
and installer, and spacer (MB991000 and
MB991017).
REAR SUSPENSION
34-14
<<D>> REAR HUB ASSEMBLY REMOVAL

MB990938
CAUTION
Replace the wheel bearing with a new part
because wheel bearing frictional surface will be
damaged when removing the hub.
MB990934
Trailing arm
MB990211
AC103550AC
MB991354
MB990244 (Three)
AC203557 AC
Use following special tools to pull out the rear hub

assembly.
MB990211: Sliding Hammer
MB990241: Axle Shaft Puller
MB990244: Puller Bar
MB991354: Puller Body
2. Use following special tools to remove the wheel

bearing from the trailing arm.
MB990934: Adapter
MB990938: Bar

>>A<< WHEEL BEARING INSTALLATION
MB991400
Wheel bearing
<<E>> WHEEL BEARING REMOVAL

Wheel bearing
inner race
(outside)
Trailing arm
Socket
MB991401
MB990560
Rear hub
assembly
AC103549 AC
1. Use special tool bearing remover (MB990560) to

remove the wheel bearing inner race (outside)
from the rear hub assembly.
AC103551 AC
Use following special tools to press-in the wheel

bearing.
MB991400: Rear Wheel Bearing and Hub
Installer
Installer Base
REAR SUSPENSION
34-15
>>B<< REAR HUB ASSEMBLY INSTALLATION
CAUTION
If the wheel bearing inner race has been pushed
out, set the wheel bearing to the trailing arm
again before installing the rear hub assembly.
2. Use special tool end yoke holder (MB990767) to

fix the rear axle hub, and the tighten the drive
shaft nut fully.
INSPECTION
M1341002300171

Check the trailing arm for bending or damage.
MB991400
TRAILING ARM BUSHING

REPLACEMENT
Rear hub assembly
M1341011300209
Driving Out
MB991444
Trailing arm
Trailing arm
MB991411
MB991445
AC102542AD
1. Use following special tools to drive out the trailing

arm bushing.
MB991444: Bushing Remover and Installer Arbor
MB991445: Bushing Remover and Installer Base
AC103682 AC
Use following special tools to press-in the rear hub

assembly.
Installer
Installer
Parallel
>>C<< DRIVE SHAFT NUT INSTALLATION
CAUTION
AC102539 AC

the vehicle weight to avoid possible damage to
the wheel bearing before tightening the drive
shaft nut fully.
245 29 Nm
MB990767
Washer
AC102721 AC
1. Assemble the drive shaft washer in the illustrated

direction.
2. Set the installation direction and installation

location of the trailing arm bushing.
(1) Place the long projection end of the trailing
arm bushing inner pipe towards the inside of
the vehicle.
(2) Make sure that the hollow of the trailing arm
bushing is located as shown in the illustration.
REAR SUSPENSION
34-16
Press-Fitting
MB991444
16.2 0.5 mm
Trailing arm
MB991445
AC102542AE
3. Using the special tools, press the trailing arm

bushing into the position shown.
REAR SUSPENSION
34-17
SHOCK ABSORBER ASSEMBLY

M1341002500238
CAUTION
*
3
44 5 Nm
39 5 Nm
4
95 15 Nm*
95 15 Nm*
2
AC107092 AB
<<A>>
1.
2.
3.
Removal steps
Stabilizer link connection
connection
Shock absorber mounting nut
4.
>>A<< 5.

Shock absorber and lower arm
connecting bolt
Shock absorber assembly
REAR SUSPENSION
34-18

DISCONNECTION
>>A<< SHOCK ABSORBER ASSEMBLY

INSTALLATION
Spring seat
stepped section
Piece of wood
AC006176AB
AC107126 AB

Install the spring seat stepped section so that it

points towards the rear side of the vehicle.
INSPECTION
M1341002600149
Check the rubber parts for cracks and wear.

Check the shock absorber for malfunctions, oil
leakage, or abnormal noise.

M1341005300211
25 5 Nm
1
11
5
3
12
9
4
13
10
AC209952 AC
<<A>> >>D<< 1.
2.
3.
>>C<< 4.
5.
6.
7.
8.
Disassembly steps
Self-locking nut
Washer
Upper bushing B
Bracket assembly
Collar
Upper bushing A
Plate
Bump rubber
>>A<< 9.
10.
>>B<< 11.
>>A<< 12.
<>
13.

Upper spring pad
Dust cover
Coil spring
Lower spring pad
Shock absorber
REAR SUSPENSION
34-19
<> SHOCK ABSORBER DISPOSAL
WARNING
Wear goggles when drilling to protect your
eyes from flying metal debris.
CAUTION
To hold the coil spring securely, install
special tool arm set (MB991239) evenly, and
so that the space between both arms of the
special tool will be maximum within the
installation range.
Do not use an impact wrench to tighten the
bolt of special tool spring compressor body
(MB991237). It will break the special tool.
MB991237
AC102270 AC
The gas must be discharged from the shock

absorber before discarding it. Place the shock
absorber horizontally with its piston rod extended.
Then drill a hole of approximately 3 mm in diameter
at the location shown in the illustration and discharge
the gas.
MB991239
AC001070 AB

spring.
MB991239: Arm Set

>>A<< LOWER SPRING PAD/UPPER SPRING
PAD INSTALLATION
Upper spring pad
stepped section
WARNING
Do not use an impact wrench to remove the
self-locking nut. Vibration of the impact
wrench will cause special tools (MB991237
and MB991239) to slip and cause personal
injury.
Spring seat
stepped section
AC107186AB
Piston rod
AC102268AC
2. While holding the piston rod, remove the selflocking nut.
<LOWER SPRING PAD>

Align the stepped section of the lower spring pad
with the stepped section of the spring seat of the
shock absorber, and install the lower spring pad.
<UPPER SPRING PAD>
Align the stepped section of the upper spring pad
with the end of the coil spring, and install the upper
spring pad.
REAR SUSPENSION
34-20
>>B<< COIL SPRING INSTALLATION
>>C<< BRACKET ASSEMBLY INSTALLATION
CAUTION
Do not use an impact wrench to tighten the bolt
of special tool spring compressor body
(MB991237). It will break the special tool.
MB991237
Lower bushing inner pipe
Bracket assembly
mounting bolt
MB991239
AC001070 AB

spring, and install it to the lower spring pad.
MB991239: Arm Set
2. Align the end of the coil spring with the stepped
section of the lower spring pad.
Lower bushing
inner pipe
AC107187 AB
Install the bracket assembly so that the lower

bushing inner pipe of the shock absorber and the line
between the bracket mounting bolts are straight
when looking from above.
>>D<< SELF-LOCKING NUT INSTALLATION
1. Temporarily tighten the self-locking nut.
CAUTION
Do not use an impact wrench to tighten the selflocking nut, otherwise the self-locking nut will be
damaged.
self-locking nut to 25 5 Nm.
REAR SUSPENSION
34-21
STABILIZER BAR
STABILIZER BAR
M1341003000236
Press the dust cover with your finger to check that there
are no cracks or damage in the dust cover.
4 <2WD>
2
3
12 2 Nm
39 5 Nm
4 <4WD>
12 2 Nm
1
2
39 5 Nm
39 5 Nm
1
Specified grease:
AC301224 AB
>>A<<
1.
2.
Removal steps
Stabilizer link
Fixture
>>A<<
>>A<<
3.
4.

Bushing
Stabilizer bar
REAR SUSPENSION
34-22
STABILIZER BAR

INSTALLATION
Outside of vehicle
Bushing (LH)
Stopper
Fixture (LH)
AC200960 AC
Install the stabilizer bar, the bushings and the fixtures

so that the stoppers come inboard of the bushings.
INSPECTION
M1341001400272

Check the stabilizer bar for deterioration or
damage.
STABILIZER LINK BALL JOINT TURNING
TORQUE CHECK
3. If the measured value is lower than the standard

value, check that the ball joint turns smoothly
without excessive play. If so, it is possible to reuse that ball joint.
STABILIZER LINK BALL JOINT DUST COVER
CHECK
the stabilizer link.
cover (Refer to 334).

COVER REPLACEMENT
M1341010900220
Only when the dust cover is damaged accidentally

during service work, replace the dust cover as
follows:
MB990326
Clip ring
AC006188AB
AC001129 AB
1. After shaking the ball joint stud several times,

install the nut to the stud and use special tool
preload socket (MB990326) to measure the
turning torque of the ball joint.
value, replace the stabilizer link.
1. Remove the clip ring and the dust cover.

2. Apply specified grease to the inside of a new dust
cover.
Specified grease: Multipurpose grease SAE
J310, NLGI No.2 or equivalent
3. Wrap plastic tape around the stabilizer link stud,
and then install the dust cover to the stabilizer link.
4. Secure the dust cover by the clip ring.
pushing it with finger.
REAR SUSPENSION
34-23
REAR SUSPENSION CROSSMEMBER
REAR SUSPENSION CROSSMEMBER

M1341006800156
Main Muffler, Centre Exhaust Pipe Removal (Refer to
GROUP 15, Exhaust pipe and Main Muffler 315).
Control Link, Upper Arm, Lower Arm Removal (Refer to
334).
Stabilizer Bar Removal (Refer to 334).
Fuel Filler Neck Protector Removal (Refer to GROUP
13B, Fuel Tank 313B).
Fuel Filler Neck Protector Installation (Refer to GROUP
13B, Fuel Tank 313B).
Stabilizer Bar Installation (Refer to 334).
Control Link, Upper Arm, Lower Arm Installation (Refer to
334).
Main Muffler, Centre Exhaust Pipe Installation (Refer to
GROUP 15, Exhaust pipe and Main Muffler 315).
334).
90 10 Nm
90 10 Nm
44 9 Nm
95 15 Nm
AC107129 AB
1.
2.
Removal steps
Dynamic damper <4WD>
Differential support arm connecting
bolt <4WD>
3.
4.
5.

Rear suspension crossmember
Differential support arm <4WD>
Plug
INSPECTION
M1341006900067
Check the crossmember for cracks or

deformation.
127(6
36-1
GROUP 36
00
11
PARKING BRAKES
12
13
14
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS . . . . . . . . . . .
PARKING BRAKE LEVER STROKE
CHECK AND ADJUSTMENT . . . . . . . . . . .
LINING RUNNING-IN . . . . . . . . . . . . . . . . .
PARKING BRAKE SWITCH CHECK . . . . .
36
15
PARKING BRAKE LEVER . . . . . . . . .
36
36
PARKING BRAKE CABLE. . . . . . . . .
36
36
36
36
36
16
17
21
22
36
PARKING BRAKE LINING AND

DRUM . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
36
36
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
36
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
PARKING BRAKES
36-2
GENERAL INFORMATION
GENERAL INFORMATION
M1361000100300
The parking brake is of a mechanical rear-wheel

acting type, and its operation utilises a parking brake
lever.
SPECIFICATIONS
Item
Specification
Type
Drum-in disc
Clearance adjustment
Automatic
Drum-in disc brake
Parking brake lever
Parking brake cable
AC301225 AB
SPECIFICATIONS
M1361000300359
Item
Standard value
Limit
Parking brake lever stroke
4 - 5 notches
Rear brake lining thickness mm
2.8
1.0
Rear drum inside diameter mm
168.0
169.0
PARKING BRAKES
ON-VEHICLE SERVICE
36-3
ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE
CHECK AND ADJUSTMENT
M1361000900317
Pull the parking brake lever with a force of

approximately 200 N and count the number of
notches.
Standard value: 4 - 5 notches
1. If the parking brake lever stroke is not the
standard value, adjust as described below.
(1) Remove the floor console assembly (Refer to
GROUP 52A, Rear Floor Console 352A).
Cable rod
CAUTION
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
rear brakes may drag.
(4) Adjust the parking brake lever stroke to the
standard value by turning the adjusting nut.
After the adjustment, ensure that there is no
free play between the adjusting nut and the
parking brake lever.
(5) After the parking brake lever stroke is
adjusted, raise the rear of the vehicle. Release
the parking brake, turn the rear wheels to
confirm that the rear brakes are not dragging.
LINING RUNNING-IN
M1361001100239
CAUTION
Adjusting nut
AC107239 AD
(2) Loosen the adjusting nut to move it to the

cable rod end so that the cable will be free.
Adjuster
AC202320 AC
(3) Remove the rear brake adjusting hole plug.

Then insert a flat-tipped screwdriver to turn
the adjuster to the arrow direction (to expand
the shoe) until the parking brake shoe makes
contact and the disc can no longer be turned.
Back off the adjuster to the opposite direction
by five notches.
Carry out running-in in a place with good

visibility, and pay careful attention to safety.
Carry out running-in by the following procedure when
replacing the parking brake linings or the rear brake
disc rotors, or when brake performance is
insufficient.
1. Adjust the parking brake lever stroke to the
specified value.
Specified value: 4 - 5 notches [Operation
force: Approx. 200 N]
2. Hook a spring balance onto the centre of the
parking brake lever grip and pull it with a force of
100 - 150 N in a direction perpendicular to the
handle.
3. Drive the vehicle at a constant speed of 35 - 50
km/h for 100 metres.
4. Release the parking brake and let the brakes cool
for 5 - 10 minutes.
5. Repeat the procedure in steps 2 to 4 four or five
times.
PARKING BRAKES
36-4
ON-VEHICLE SERVICE
PARKING BRAKE SWITCH CHECK

M1361003300347
AC300397
1. Remove the floor console assembly (Refer to

GROUP 52A, Rear Floor Console 352A).
2. Check for continuity between the parking brake
switch terminal and the switch mounting bolt.
When parking brake lever is
pulled
Less than 2 W
When parking brake lever is

released
Open circuit
PARKING BRAKES
36-5
PARKING BRAKE LEVER
PARKING BRAKE LEVER

M1361001300307
Rear Floor Console Assembly Removal (Refer to GROUP
Parking Brake Lever Stroke Adjustment (Refer to 336).
Rear Floor Console Assembly Installation (Refer to
GROUP 52A, Floor Console 352A).
1
5
3
2
AC107292
AC107457AC
Section A - A
Section B - B
B
A
Ratchet pawl
B
AC107247
1.
2.
3.
4.
5.
Removal steps
Adjusting nut
Parking brake switch connector
Parking brake lever assembly
Parking brake switch
AC107249
AC107248
PARKING BRAKES
36-6
PARKING BRAKE CABLE
PARKING BRAKE CABLE

M1361001900462
Rear Floor Console Assembly Removal (Refer to GROUP
Parking Brake Lever Stroke adjustment (Refer to 336).
Rear Floor Console Assembly Installation (Refer to
GROUP 52A - Floor Console 352A).
1
2
AC301226 AB
Removal steps
Shoe and lining assembly (Refer to
336).
Loosen the adjusting nuts.
Turn up the drivers side carpet.
1.
2.
3.

Parking brake cable
PARKING BRAKES
36-7
PARKING BRAKE LINING AND DRUM

M1361002500274
Parking Brake Lever Stroke Check and Adjustment (Refer
to 336).
Lining Running-in (Refer to 336).
Floor Console Installation (Refer to GROUP 52A, Floor
Console 352A).
12
15
13
5
14
60 5 Nm
3
8
16
63 7 Nm
13
11
10
AC300145 AB
13
13
7
16
Brake grease: Multipurpose grease
<<A>>
Removal steps
1. Rear brake caliper assembly
2. Rear brake disc
>>B<< 3. Shoe-to-anchor spring
>>B<< 4. Shoe-to-anchor spring
5. Shoe guide plate
6. Adjusting wheel spring
>>A<< 7. Adjuster assembly
8. Strut
9. Strut-to-shoe spring
10. Shoe hold-down cup

Shoe hold-down spring
Shoe hold-down pin
Shoe and lining assembly
Clip
Rear hub assembly (For 2WD, refer
to GROUP 27A, Rear Hub
Assembly 327A. For 4WD, refer
to GROUP 27B, Rear Hub
Assembly 327B).
16. Backing plate
11.
12.
13.
14.
15.
PARKING BRAKES
36-8
INSPECTION
<<A>> REAR BRAKE CALIPER ASSEMBLY

REMOVAL
Remove the rear brake caliper assembly and support
it with wire or something similar.
M1361002600226
PARKING BRAKE LINING AND BRAKE

DRUM CHECK

>>A<< ADJUSTER ASSEMBLY INSTALLATION
ACX00708AB
Shoe adjusting bolt

AC202301AC
Install the adjuster so that the shoe adjusting bolt for

the left hand wheel is attached towards the rear of
the vehicle, and the shoe adjusting bolt for the right
hand wheel is towards the front of the vehicle.
1. Measure the thickness of the brake lining at

several places.
Limit: 1.0 mm
2. If the thickness of the brake lining is below the
limit, replace the shoe and lining assemblies on
both sides of the vehicle. Never replace only one
side.
>>B<< SHOE-TO-ANCHOR SPRING

INSTALLATION
Front of the vehicle
ACX00709
Blue paint
Yellow paint
AC202302AC
The shoe-to-anchor springs are not interchangeable

as their constants are different. The one with blue
paint mark should be install at the front of the vehicle,
and the other with yellow paint at the rear of the
vehicle, respectively.
NOTE: The illustration shows the left rear wheel. The
right rear wheel is symmetrical to that.
3. Measure the inside diameter of the brake disc in

two places or more.
Limit: 169.0 mm
4. If the inside diameter exceeds the limit, or if it is
excessively worn on one side, replace the brake
disc.
35-1
GROUP 35
SERVICE BRAKES
00
11
12
13
CONTENTS
14
15
16
BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A
17
ANTI-SKID BRAKING SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . 35B
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
127(6
35A-1
GROUP 35A
00
11
BASIC BRAKE
SYSTEM
12
13
14
15
16
CONTENTS
17
35A
35A
LUBRICANTS . . . . . . . . . . . . . . . . . .
35A
SEALANT. . . . . . . . . . . . . . . . . . . . . .
35A
SPECIAL TOOLS. . . . . . . . . . . . . . . .
35A
35A
BRAKE PEDAL CHECK AND ADJUSTMENT

..................................
35A
BRAKE BOOSTER OPERATING TEST . . .
35A
CHECK VALVE OPERATION CHECK . . . .
35A
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . .
35A
BRAKE FLUID LEVEL SENSOR CHECK. .
35A
DISC BRAKE PAD CHECK AND

REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
35A
DISC BRAKE ROTOR CHECK. . . . . . . . . .
35A
BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A
21
35A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A
22
MASTER CYLINDER ASSEMBLY AND

BRAKE BOOSTER . . . . . . . . . . . . . . . 35A
25
35A
MASTER CYLINDER . . . . . . . . . . . . . . . . .
35A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A
26
27
31
FRONT DISC BRAKE ASSEMBLY . . 35A
32
35A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A
35A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A
34
REAR DISC BRAKE ASSEMBLY . . . 35A
35
35A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A
35A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A
33
36
37
42
51
52
54
55
BASIC BRAKE SYSTEM
35A-2
GENERAL INFORMATION
GENERAL INFORMATION
M1351000100406
The brake system offers high dependability and

durability along with improved braking performance
and brake sensitivity.
CONFIGURATION DIAGRAM
Brake booster
Hydraulic unit
(Integrated with ABS-ECU)
Parking brake
Master cylinder
Rear disc brake
Front disc brake
AC300584 AC
SPECIFICATIONS
Item
Master cylinder
Brake booster
Specification
Type
Tandem type
I.D. mm
25.4
Type
Vacuum type, tandem
Effective dia. of power cylinder mm
205 + 230
Boosting ratio
7.5
Rear wheel hydraulic control method
Electronic brake-force distribution (EBD)
Front brakes
Floating caliper, 2 piston, ventilated disc
Type
Disc effective diameter thickness mm 246 24
Rear disc brakes
Wheel cylinder I.D. mm
42.9
Automatic
Type
Floating caliper, 1 piston, solid disc
Disc effective dia. thickness mm
226 10
Wheel cylinder I.D. mm
38.1
Automatic
BASIC BRAKE SYSTEM
35A-3
M1351000300433
Item
Standard value
Limit
Brake pedal height mm
150 - 153
Brake pedal free play mm
3-8
Brake pedal to floor board clearance mm
100 or more
Disc brake pad thickness mm
10.0
2.0
Front
24.0
22.4
Rear
10.0
8.4
Front
0.04
Rear
0.05
Disc brake drag force N
Front/Rear
68 or less
Front/Rear
0.05
10.15 - 10.40
Disc brake disc thickness mm

Disc brake disc run-out mm
Brake booster push rod protruding length mm (When applying

negative pressure of 66.7 kPa to the brake booster)
LUBRICANTS
M1351000400377
Item
Specified lubricant
Brake fluid
DOT3 or DOT4
Guide pin
Repair kit grease
Lock pin
Guide pin boot inner surface
Lock pin boot inner surface
Piston boot mounting grooves
Brake piston boot inner surface
Guide pin bush inner surface
SEALANT
M1351000500329
Item
Specified sealant
Remark
Rear hub cap <2WD>
Semi-drying sealant
Fitting thread part
BASIC BRAKE SYSTEM
35A-4
SPECIAL TOOLS
SPECIAL TOOLS
M1351000600326
Tool
A
B
Number
Name
Use
MB991568
Push rod adjusting Adjustment of the brake booster

push rod protrusion amount
socket
MB990964
A: MB990520
Brake tool set

A: Disc brake
piston expander
Pushing-in of the disc brake

piston
MB990964
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND
ADJUSTMENT
M1351000900394
BRAKE PEDAL HEIGHT

1. Turn up the carpet, etc. under the brake pedal.
Clevis
AC006217AD
A
AC200515 AC
2. Measure the brake pedal height as illustrated.

Standard value (A): 150 - 153 mm
[From the surface of floor board to the face
of pedal pad]
3. If the brake pedal height is not within the standard
value, follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Remove the brake booster (Refer to 335A
).
NOTE: With the master cylinder and brake
pipe connected, remove the brake booster
only.
(3) Adjust the brake pedal height by turning the

clevis.
NOTE: When the clevis is turned 180, the
pedal height is changed approximately 2.4
mm.
(4) Install the brake booster (Refer to 335A).
(5) Measure the brake pedal height, and ensure
that the measured value is within the standard
value. When it is out of the standard value,
repeat Step (2) - (5).
BASIC BRAKE SYSTEM
35A-5
ON-VEHICLE SERVICE
CLEARANCE BETWEEN BRAKE PEDAL

AND FLOOR BOARD
Stopper
1. Turn up the carpet, etc. under the brake pedal.
0.5 - 1.0 mm
AC101091AD
(6) Screw in the stop lamp switch until its thread

contacts the stopper, and fix the stop lamp
switch by turning it approximately one quarter
of a turn clockwise.
(7) Check that the clearance between the stop
lamp switch and the stopper is as shown.
CAUTION
Check that the stop lamp does not illuminate
when the brake pedal is not depressed.
(8) Connect the connector at the stop lamp
switch.
4. Return the carpet, etc.
BRAKE PEDAL FREE PLAY
C
AC107452AC
2. Start the engine, depress the brake pedal with

approximately 490 N of force, and measure the
clearance between the brake pedal and the floor
board.
Standard value (C): 100 mm or more
[From the surface of floor board to the face
of pedal pad]
3. If the clearance is outside the standard value,
check for air trapped in the brake line, thickness of
the disc brake pad, clearance between the lining
and the drum and dragging in the parking brake.
And then adjust and replace defective parts as
required.
4. Return the carpet etc. to its original position.
BRAKE BOOSTER OPERATING TEST

M1351001000327
1. For simple checking of the brake booster

operation, carry out the following tests:
B
AC200011AC

position, depress the brake pedal two or three
times. After eliminating the vacuum in the brake
booster, press the pedal down by hand, and
confirm that the amount of movement before
resistance is met (free play) is within the standard
value range.
Standard value: 3 - 8 mm
2. If the brake pedal play is not within the standard
value, check the following, and adjust or replace if
necessary:
Excessive play between the brake pedal and the
clevis pin, or between the clevis pin and the brake
booster operating rod
Brake pedal height
Installation position of the stop lamp switch, etc.
Good
No good
AC000870 AE
(1) Run the engine for one or two minutes, and

then stop it. If the pedal depresses fully the
first time but gradually becomes higher when
depressed succeeding times, the booster is
operating properly. If the pedal height remains
unchanged, the booster is defective. Go to
step 2.
BASIC BRAKE SYSTEM
35A-6
ON-VEHICLE SERVICE
When engine
is stopped
When engine
is started
CAUTION
If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.
Valve
Spring
B
Intake manifold
side
(does not hold)
AC000871AE
(2) With the engine stopped, step on the brake

pedal several times. Then step on the brake
pedal and start the engine. If the pedal moves
downward slightly, the booster is in good
condition. If there is no change, the booster is
defective. Go to step 3.
Good
No good
Booster side
(holds)
AC000873 AE
2. Check the operation of the check valve by using a

vacuum pump.
Vacuum pump
connection
Accept/reject criteria
Connection at the brake

booster side (A)
A negative pressure
(vacuum) is created and
held.
Connection at the intake A negative pressure

manifold side (B)
(vacuum) is not created.
BLEEDING
AC000872 AE
(3) With the engine running, step on the brake

pedal and then stop the engine. Hold the pedal
depressed for 30 seconds. If the pedal height
does not change, the booster is in good
condition, if the pedal rises, the booster is
defective.
2. If the above three tests are okay, the booster is
OK. If one of the above three tests is not okay, the
check valve, vacuum hose, or booster is defective.
Check the check valve (Refer to 335A),
vacuum hose for leaks, high volume engine
vacuum applied to booster. Repair or replace as
necessary. If these are OK, replace the booster
and repeat this test starting at Step 1.
M1351001400400
CAUTION
Use only brake fluid DOT 3 or DOT 4. Never mix
the specified brake fluid with other fluid as it will
influence the braking performance significantly.
MASTER CYLINDER BLEEDING
The master cylinder used has no check valve, so if
bleeding is carried out by the following procedure,
bleeding of air from the brake pipeline will become
easier (When brake fluid is not contained in the
master cylinder).
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
CHECK VALVE OPERATION CHECK

M1351009000321
CAUTION
The check valve should not be removed from the
vacuum hose.
1. Remove the vacuum hose (Refer to 335A).
Outlet
Outlet
AC301227 AB
3. Have another person cover the master cylinder

outlet with a finger.
BASIC BRAKE SYSTEM

ON-VEHICLE SERVICE
4. With the outlet still closed, release the brake

pedal.
5. Repeat steps 2 - 4 three or four times to fill the
inside of the master cylinder with brake fluid.
BRAKE LINE BLEEDING
35A-7
CAUTION
Whenever a pad must be replaced, replace
both LH and RH wheel pads as a set to
prevent the vehicle from pulling to one side
when braking.
If there is a significant difference in the
thicknesses of the pads on the left and right
sides, check the sliding condition of the
piston and slide pins.
<Front>
3
AC301228 AB
Start the engine and bleed the air in the sequence

shown in the figure.
BRAKE FLUID LEVEL SENSOR CHECK

M1351009100351
AC102357
The brake fluid level sensor is in good condition if

there is no continuity when the float surface is above
"MIN" and if there is continuity when the float surface
is below "MIN".
DISC BRAKE PAD CHECK AND

REPLACEMENT
M1351002300343
NOTE:
When new
When worn
Pad
Wear indicator
Brake
disc
AC000879 AD
The brake pads have indicators that contact the

brake disc when the brake pad thickness becomes 2
mm, and emit a squealing sound to warn the driver.
<Rear>
AC301229 AB
1. Check the brake pad thickness through the caliper

body check port.
BASIC BRAKE SYSTEM
35A-8
ON-VEHICLE SERVICE
CAUTION
Do not wipe off the special grease that is on the
lock pin or allow it to contaminate the lock pin.
<Front>
3
2
1
<Front>
5
3
<Rear>
3
2
<Rear>
5
4
1
3
AC301229 AC
2. Remove the guide/lock pin bolt. Pivot the caliper

assembly and hold it with wires.
AC301230 AB
3. Remove the following parts from caliper support.

(1) Pad assembly or Pad and wear indicator
assembly
(2) Pad assembly
(3) Clip
(4) Inner shim
(5) Outer shim
4. In order to measure the brake drag force after pad
installation, measure the rotary-sliding resistance
of the hub with the pads removed. For the front
brakes, refer to 335A. For the rear brakes,
refer to 335A.
5. Install the pads and caliper assembly, and then
check the brake drag force. For the front brakes,
refer to 335A. For the rear brakes, refer to
335A.
BASIC BRAKE SYSTEM

ON-VEHICLE SERVICE
35A-9
DISC BRAKE ROTOR CHECK

M1351002900293
CAUTION
Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.
Before turning the brake disc, the following
conditions should be checked.
Inspection item
Remark
Scratches, rust, saturated lining materials and wear
If the vehicle is not driven for a long period of

time, sections of the discs that are not in contact
with the pads will become rusty, causing noise
and shuddering.
If grooves and scratches resulting from excessive
disc wear are not removed prior to installing a
new pad assembly, there will be inadequate
contact between the disc and the lining (pad) until
the pads conform to the disc.
Run-out
Excessive run-out of the discs will increase the pedal

depression resistance due to piston kick-back.
Change in thickness (parallelism)
If the thickness of the disc changes, this will cause

pedal pulsation, shuddering and surging.
Inset or warping (flatness)
Overheating and improper handling while servicing

will cause warping or distortion.
BRAKE DISC THICKNESS CHECK
2. If the disc thickness is less than the limits, replace

it with a new one.
ACX00668
1. Using a micrometer, measure disc thickness at

eight positions, approximately 45 apart and 10
mm in from the outer edge of the disc.
Standard value:
<Front> 24.0 mm
<Rear> 10.0 mm
Minimum limit:
<Front> 22.4 mm
<Rear> 8.4 mm
NOTE: Thickness variation (at least 8 positions)
should not be more than 0.015 mm.
BASIC BRAKE SYSTEM
35A-10
ON-VEHICLE SERVICE
CAUTION
After a new brake disc is installed, always
grind the brake disc with on-the-car type
brake lathe. If this step is not carried out, the
brake disc run-out exceeds the specified
value, resulting in judder.
M12 Flat washer
ACX00669
3. Place a dial gauge approximately 5 mm from the

outer circumference of the brake disc, and
measure the run-out of the disc.
Limit:
<Front> 0.04 mm
<Rear> 0.05 mm
Chalk marks
M12 Flat washer
AC006226AD
When the on-the-car type lathe is used, first

install M12 flat washer on the stud bolt in the
brake disc side according to the figure, and
then install the adapter. If the adapter is
installed with M12 flat washer not seated, the
brake disc rotor may be deformed, resulting
in inaccurate grinding.
Grind the brake disc with all wheel nuts
diagonally and equally tightened to the
specified torque 100 Nm. When all numbers
of wheel nuts are not used, or the tightening
torque is excessive or not equal, the brake
disc rotor or drum may be deformed, resulting
in judder.
3. If thickness variation exceeds the specification,
turn rotor with an on-the-car type brake lathe
("MAD, DL-8700PF" or equivalent). If the
calculated final thickness after turning the rotor is
less than the standard value, replace the disc.
BRAKE DISC RUN-OUT CHECK AND
CORRECTION
1. Remove the brake caliper assembly, and then
hold it with wire.
2. Temporarily install the disc with the hub nut.
AC201323 AC
4. If the brake disc run-out exceeds the limit, correct

it as follows:
(1) Chalk phase marks on the wheel stud and the
brake disc, which run-out is excessive as
shown.
AC102407
(2) Remove the brake disc. Then place a dial

gauge as shown, and measure the wheel
bearing axial play by pushing and pulling the
wheel hub.
Limit: 0.05 mm
(3) If the axial play exceeds the limit, disassemble
the hub and knuckle/trailing arm assembly to
check each part.
BASIC BRAKE SYSTEM
35A-11
ON-VEHICLE SERVICE
(4) If the axial play does not exceed the limit,

dephase the brake disc and secure it. Then
recheck the brake disc run-out.
CAUTION
After a new brake disc is installed, always
grind the brake disc with on-the-car type
brake lathe. If this step is not carried out, the
brake disc run-out exceeds the specified
value, resulting in judder.
M12 Flat washer
M12 Flat washer
AC006226AD
When the on-the-car type lathe is used, first

install M12 flat washer on the stud bolt in the
brake disc side according to the figure, and
then install the adapter. If the adapter is
installed with M12 flat washer not seated, the
brake disc rotor may be deformed, resulting
in inaccurate grinding.
Grind the brake disc with all wheel nuts
diagonally and equally tightened to the
specified torque 100 Nm. When all numbers
of wheel nuts are not used, or the tightening
torque is excessive or not equal, the brake
disc rotor or drum may be deformed, resulting
in judder.
5. If the run-out cannot be corrected by changing the
phase of the brake disc, replace the brake disc or
grind it with the on-the-car type brake lathe
("MAD, DL-8700PF" or equivalent).
BASIC BRAKE SYSTEM
35A-12
BRAKE PEDAL
BRAKE PEDAL
M1351003400354
Brake Pedal Adjustment (Refer to 335A).
8
9
12 2 Nm
5
12 2 Nm
2
6
14 3 Nm
AC301350AB
1.
2.
3.
4.
5.
Removal steps
Harness connector
Stop lamp switch
Adjuster
Pedal stopper
Snap pin
6.
7.
8.
9.

Pin assembly
Pedal pad
Reinforced bracket
Brake pedal and pedal support
member
INSPECTION
M1351003500180
STOP LAMP SWITCH CHECK
No continuity
2. There should be no continuity between the

terminals when the plunger is pushed in as
shown. There should be continuity when it is
released.
Continuity
4 mm
AC006235AB
1. Connect an ohmmeter between the stop lamp

switch connector terminals.
BASIC BRAKE SYSTEM
35A-13
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

M1351003700355
Air Intake Hose and Air Cleaner Removal (Refer to
12 2 Nm
Brake Fluid Supplying and Air Bleeding (Refer to 335A
).
Brake Pedal Adjustment (Refer to 335A).
Air Intake Hose and Air Cleaner Installation (Refer to
14
16 1 Nm
14
3M ATD Part No. 8661, 8663 or equivalent
1
4
3
5
10
15 2 Nm
6
8
14 3 Nm
11
10 2 Nm
13
6
7
15 2 Nm
12
AC301351AB
>>C<<
1.
2.
3.
4.
5.
6.
7.
8.
1.
6.
7.
8.
Master cylinder removal steps

Brake fluid level sensor connector
Reservoir cap assembly
Reservoir
Brake fluid level sensor
Reservoir hose
Brake pipe connection
Bracket
Master cylinder
Brake booster removal steps
Brake fluid level sensor connector
Bracket
Master cylinder
>>B<<
>>A<< 9.
10.
11.
12.
13.
>>A<<
9.
14.
Brake booster removal steps

Push rod protrusion amount check
and adjustment
Vacuum hose (with built-in check
valve)
Snap pin
Pin assembly
Brake booster
Sealer
Fitting removal steps
Vacuum hose (with built-in check
valve)
Fitting
BASIC BRAKE SYSTEM
35A-14

>>A<< VACUUM HOSE CONNECTION
Insert vacuum hose with its paint mark facing
upward.
>>B<< PUSH ROD PROTRUSION AMOUNT
CHECK AND ADJUSTMENT
Rod spline
Angle-nose pliers
Measuring distance A
MB991568
AC200306AC
2. If the protrusion amount is not within the standard

value range, adjust the push rod length by turning
the push rod. Use special tool push rod adjusting
socket (MB991568) to turn the push rod while
holding the rod spline with angle-nose pliers.
Block gauge
AC102457BD
1. Use the vacuum pump to measure dimension "A"

applying a negative pressure of 66.7 kPa to the
brake booster.
NOTE: When a negative pressure of 66.7 kPa is
not applied to the brake booster, the push rod
protrusion amount (A) should be 8.85 - 9.10 mm.
>>C<< RESERVOIR HOSE CONNECTION

Paint mark
Paint mark
Master cylinder
AC200460AC
Insert the reservoir hose with its paint mark facing

front of the vehicle.
BASIC BRAKE SYSTEM
35A-15
MASTER CYLINDER
M1351004200320

4
5
6
3
5N
Master cylinder kit
6N
7
6
AC102644 AE
1.
2.
3.
4.
Disassembly steps
Spring pin
Nipple
Reservoir seal
Piston retainer
Brake fluid: DOT 3 or DOT 4
Disassembly steps &RQWLQXHG

5. Primary piston assembly
6. Secondary piston assembly
7. Master cylinder body
INSPECTION
M1351004300253
Check the inner surface of master cylinder body

for rust or pitting.
Check the primary and secondary pistons for
rust, scoring, wear or damage.
BASIC BRAKE SYSTEM
35A-16
FRONT DISC BRAKE ASSEMBLY

M1351006000377
).
100 10 Nm
4
30 5 Nm
2
3
AC301353 AB
Removal steps
1. Brake hose connection
2. Gasket

>>A<< BRAKE CALIPER ASSEMBLY
INSTALLATION
>>A<< 3. Brake caliper assembly

4. Brake disc
CAUTION
Do not let any oil, grease or other contamination
get onto the friction surfaces of the pads and
brake discs.
2. After re-installing the caliper support to the
knuckle, install the pad clips and the pads to the
caliper support.
MB990520
Spring balance
AC000906AF
1. In order to measure the brake drag torque,

measure the hub torque with the pads removed by
the following procedure.
Use a spring balance to measure the hub torque
in the forward direction. Record hub torque with
pads removed.
AC301354 AB
3. Clean the piston and insert into cylinder with

special tool disc brake piston expander
(MB990520).
4. Be careful that the piston boot does not become
caught, when lowering the caliper assembly and
installing the guide pin bolt.
BASIC BRAKE SYSTEM

5. Check the brake drag force as follows.

(1) Start the engine and hold the brake pedal
down for 5 seconds. (Pedal depression force:
approximately 200 N)
(2) Stop the engine.
(3) Turn the brake disc forward 10 times.
35A-17
(5) Calculate the drag force of the disc brake

[difference between hub torque with pads
installed and hub torque with pads removed].
Standard value: 68 N or less
6. If the brake drag force exceeds the standard
value, disassemble and clean the piston. Check
for corrosion or worn piston seal, and check the
sliding condition of the lock pin and guide pin.
INSPECTION
M1351006100277
BRAKE DISC CHECK

Disc wear (Refer to 335A).
Disc run-out (Refer to 335A).
Spring balance
AC000908 AE
(4) Use a spring balance to measure the hub

torque with pads installed in the same
direction as earlier.
BASIC BRAKE SYSTEM
35A-18

M1351006200423
14
14
12
11
74 10 Nm
14
13
9
Clip set
14
6
7.9 0.9 Nm
74 10 Nm
9
5
10
8
7
6
AC202238 AD
5
9 11
8 7
11
13
6
3
9
10
5
Caliper kit
4
6
12
5.
6.
7.
8.
Disassembly steps
Lock pin
Bushing
Guide pin
Caliper support (including pad, clip,
and shim)
Pin boot
Boot ring
Piston boot
Piston
7
Grease
Shim set
Pad set
1.
2.
3.
4.
<<A>>
<<A>>
<>
9.
10.
11.
12.
13.
14.
Caliper seal kit

Piston seal
Caliper body
Pad and wear indicator assembly
Pad assembly
Outer shim
Clip
BASIC BRAKE SYSTEM

35A-19
LUBRICATION POINTS
Piston seal
! CAUTION
The piston seal inside the caliper seal
kit is coated with a special grease.
Do not wipe this grease off.
AC202239 AD
35A-20
BASIC BRAKE SYSTEM


When disassembling the disc brakes, disassemble
both sides (left and right) as a set.
<<A>> PISTON BOOT/PISTON REMOVAL
CAUTION
Blow air little by little to remove the pistons.
The pistons will rush out if a force of air is
applied suddenly.
If one piston has been removed completely, it
will become impossible to remove the second
piston.
INSPECTION
M1351006300345
Check the cylinder for wear, damage or rust.

Check the piston surface for wear, damage or
rust.
Check the caliper body or sleeve for wear.
Check the pad for damage or adhesion of grease,
check the backing metal for damage.
PAD WEAR CHECK
WARNING
Always replace both brake pads on each
wheel as a set. Failure to do so will result

in uneven braking, which may cause
unreliable brake operation.
If there is significant difference in the
thickness of the pads on the left and right
sides, check the sliding condition of the
piston and slide pins.
AC202257
Remove the pistons and the piston boots by pumping

in air from the brake hose connection. Be sure to use
the handle of a plastic hammer and adjust the height
of the two pistons so that the pistons protrude evenly.
<> PISTON SEAL REMOVAL
ACX00690
CAUTION
Do not use a flat-tipped screwdriver or similar
tool to remove the piston seal. These may
damage the inner side of the cylinder.
AC301355AB
1. Remove the piston seal with your finger tip.

2. Clean the piston surface and inner cylinder with
alcohol or brake fluid DOT 3 or DOT 4.
1. Measure thickness at the thinnest and most worn

area of the pad.
2. Replace the pad assembly if pad thickness is less
than the limit value.
BASIC BRAKE SYSTEM
35A-21
REAR DISC BRAKE ASSEMBLY

M1351007000239
).
15 2 Nm
60 5 Nm
3
AC201830 AC
Removal steps
1. Brake hose connection

>>A<< 2. Brake caliper assembly
3. Brake disc

>>A<< BRAKE CALIPER ASSEMBLY
INSTALLATION
CAUTION
Do not let any oil, grease or other contamination
get onto the friction surfaces of the pads and
brake discs.
2. After re-installing the caliper support to the
backing plate, install the pad clips and the pads to
the caliper support.
AC201814
1. In order to measure the brake drag torque,

measure the hub torque with the pads removed by
the following procedure.
Use a spring balance to measure the hub torque
in the forward direction. Record hub torque with
pads removed.
MB990520
AC301357 AB
3. Clean the piston and insert into cylinder with

special tool disc brake piston expander
(MB990520).
4. Be careful that the piston boot does not become
caught, when lowering the caliper assembly and
installing the lock pin.
35A-22
BASIC BRAKE SYSTEM

5. Check the brake drag force as follows.

(1) Start the engine and hold the brake pedal
down for 5 seconds. (Pedal depression force:
approximately 200 N)
(2) Stop the engine.
(3) Turn the brake disc forward 10 times.
(5) Calculate the drag force of the disc brake

[difference between hub torque with pads
installed and hub torque with pads removed].
Standard value: 68 N or less
6. If the brake drag force exceeds the standard
value, disassemble and clean the piston. Check
for corrosion or worn piston seal, and check the
sliding condition of the lock pin and guide pin.
INSPECTION
M1351007100236
BRAKE DISC CHECK

Disc wear (Refer to 335A).
Disc run-out (Refer to 335A).
AC201815
(4) Use a spring balance to measure the hub

torque with pads installed in the same
direction as earlier.
BASIC BRAKE SYSTEM
35A-23

M1351007200233
13
12
44 5 Nm
13
14
7.9 0.9 Nm
15
10
5
11
7
44 5 Nm
13
Clip set
13
6
2
2
9
8
8
6
Grease
AC203578 AE
10
3
11
5
9
Seal and boot repair kit
12
15
14
8
4
2
5
7
12
11
15
Grease
Brake caliper kit
<<A>>
<<A>>
1.
2.
3.
4.
5.
6.
7.
8.
Shim set
Pad set
Disassembly steps
Lock pin
Bushing
Guide pin
Caliper support
Pin boot
Boot ring
Piston
Piston boot
<>
9.
10.
11.
12.
13.
14.
15.

Piston seal
Caliper body
Pad and wear indicator assembly
Inner shim
Clip
Pad assembly
Outer shim
35A-24
BASIC BRAKE SYSTEM

LUBRICATION POINTS
Piston seal
AC203550
! CAUTION
The piston seal inside the seal and boot
kit is coated with a special grease.
Do not wipe this grease off.
AC202232 AC
BASIC BRAKE SYSTEM


When disassembling the disc brakes, disassemble
both sides (left and right) as a set.
<<A>> PISTON BOOT/PISTON REMOVAL
CAUTION
35A-25
<> PISTON SEAL REMOVAL
CAUTION
Do not use a flat-tipped screwdriver or similar
tool to remove piston seal. These may damage
the inner side of the cylinder.
Blow air little by little to remove the piston. The

piston will rush out if a force of air is applied
suddenly.
ACX00689
ACX00697
Place a piece of wood, etc. against the caliper body

as shown. Blow compressed air through the brake
hose to remove the piston boot and piston.
1. Remove the piston seal with your finger tip.

2. Clean the piston surface and inner cylinder with
alcohol or brake fluid DOT 3 or DOT 4.
INSPECTION
M1351007300229
Refer to 335A.
127(6
35B-1
GROUP 35B
00
11
ANTI-SKID
BRAKING SYSTEM
(ABS)
12
13
14
15
16
17
21
CONTENTS
35B
35B
SPECIAL TOOLS. . . . . . . . . . . . . . . .
35B
35B
35B
ABS SENSOR OUTPUT VOLTAGE

MEASUREMENT . . . . . . . . . . . . . . . . . . . .
35B
HYDRAULIC UNIT CHECK . . . . . . . . . . . .
35B
IN THE EVENT OF A DISCHARGED

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .
22
35B
25
HYDRAULIC UNIT . . . . . . . . . . . . . . . 35B
26
35B
ABS SENSOR. . . . . . . . . . . . . . . . . . . 35B
27
31
35B
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35B
32
G-SENSOR . . . . . . . . . . . . . . . . . . . . . 35B
33
35B
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35B
34
35
36
37
42
51
52
54
55
ANTI-SKID BRAKING SYSTEM (ABS)
35B-2
GENERAL INFORMATION
GENERAL INFORMATION
M1352000100410
FEATURES
EBD CONTROL
The 4ABS ensures directional stability and

controllability during hard braking.
This ABS uses a 4-sensor 3-channel system that
controls the right and left front wheels independently
of each other and controls the rear wheels
simultaneously (select low control*). The basic
system is the same as that of former COLT/LANCER.
4WD models are equipped with G-sensor.
NOTE: *Select low control: Control system that
compares the speeds of the right and left wheels and
performs the same fluid pressure control on both
wheels according to the speed of the wheel that is
likely to be locked.
The system has the following features:
EBD (Electronic Brake-force Distribution system)
control has been added to provide the ideal
braking force for the rear wheels.
Fail-safe function which ensures that safety is
maintained
Diagnostic function which provides improved
serviceability
In ABS, electronic control is used so the rear wheel

brake hydraulic pressure during braking is regulated
by rear wheel control solenoid valves in accordance
with the vehicles rate of deceleration, and the front
and rear wheel slippage which are calculated from
the signals received from the various ABS sensors.
EBD control is a control system which provides a
high level of control for both vehicle braking force and
vehicle stability. The system has the following
features:
Because the system provides the optimum rear
wheel braking force regardless of vehicle load
conditions and the condition of the road surface,
the system reduces the required pedal
depression force, particularly when the vehicle is
heavily loaded or driven on road surfaces with
high frictional coefficients.
Because the duty placed on the front brakes is
reduced, the increases in pad temperature can
be controlled during front brakes application to
improve the wear resistance characteristics of the
pad.
Control valves such as the proportioning valve
are no required.
SPECIFICATIONS
Item
Specification
ABS control method
4-sensor, 3-channel
Number of ABS rotor teeth Front
43
Rear
43
Type
Magnet coil type
ABS sensor
Maximum gap between sensor and rotor 0.85 <Front>

mm <Non-adjustable>
0.89 <Rear (2WD)>
0.96 <Rear (4WD)>
35B-3
ABS warning lamp
Hydraulic unit and

ABS-ECU
Diagnosis
connector
ABS sensor (rear)
Stop lamp switch

ABS rotor (front)
G-sensor <4WD>
ABS rotor (rear)
ABS sensor (front)
AC301089 AC
M1352000300544
Item
Standard value
ABS sensor internal resistance kW
1.24 - 1.64
G-sensor output voltage <4WD> V
Stationary vehicles
2.4 - 2.6
Arrow facing downward
3.4 - 3.6
35B-4
SPECIAL TOOLS
SPECIAL TOOLS
M1352000600590
Tool
Number
Name
Use
MB991502
MUT-II sub assembly
Checking the ABS

(Diagnosis display using
the MUT-II)
MB991529
Diagnosis code check

harness
Checking the ABS

(Diagnosis display using
the ABS warning lamp)
MB991348
Test harness set
Checking the G-sensor

<4WD>
B991502
MB991529
MB991348
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
M1352011100511

NOTES WITH REGARD TO DIAGNOSIS

M1352012600177
1. The ABS is a system which controls the brake

pressure by means of the operation of the ECU.
Accordingly, the following symptoms may occur at
times, but these are a sign of normal ABS
operation, and do not indicate a malfunction.
Phenomenon
Explanation of phenomenon
When the engine starts, a knocking sound can be heard coming This sound occurs as a result of system
from the engine compartment.
operation checking, and is not a
malfunction.
Sound of the motor inside the ABS hydraulic unit operation.

(whine)
Sound is the generated along with vibration of the brake
pedal. (scraping)
When ABS operates, sound is generated from the vehicle
chassis due to repeated brake application and release.
(Thump: suspension; squeak: tyres)
This is the sound of normal system

operation, and is not a malfunction.
Shocks are felt if the brake pedal is depressed when driving at

low speed.
This is due to system operation checking

(starting-of check when the vehicle speed
reaches a certain number of km/h) and is
not a malfunction.
35B-5
TROUBLESHOOTING
2. For road surfaces such as snow-covered roads

and gravel roads, the braking distance for vehicles
with ABS can sometimes be longer than that for
other vehicles. Accordingly, advise the customer
to drive safely on such roads by lowering the
vehicle speed and not being too overconfident.
3. Diagnosis detection condition can vary depending
on the diagnosis code. Make sure that checking
requirements listed in the "Comment" are satisfied
when checking the trouble symptom again.
NOTE: The ABS waning lamp may remain on until

the vehicle reaches a speed of several km/h. This
is limited to cases where diagnosis code Nos. 21
to 24, 41 to 44, or 53 to 55 have been recorded
because of a previous problem occurring. In this
case, the ABS-ECU keeps the warning lamp
illuminated until the problem corresponding to that
diagnosis code can be detected.
4. If the illumination is other than the above, check
the diagnosis codes.
ABS WARNING LAMP INSPECTION
DIAGNOSIS FUNCTION
M1352011200541
M1352012000197
READING DIAGNOSIS CODES

When Using the MUT-II
When Using the ABS Warning Lamp
position.
Diagnosis connector
Approx. 3 s
Approx. 3 s
ABS
Illuminated
warning
lamp Not
illuminated
Ignition
switch
MB991529
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC107528 AH
START
ON
ACC
AC301359 AB
Check that the ABS warning lamp illuminates as

follows.
1. When the ignition switch is turned to the "ON"
position, the ABS warning lamp illuminates for
approximately 3 seconds and then switches off.
2. When the ignition switch is turned to the "START"
position, the ABS warning lamp remains
illuminated.
3. When the ignition switch is turned from the
"START" position back to the "ON" position, the
ABS warning lamp illuminates for approximately 3
seconds and then switches off.
2. Use special tool diagnosis code check harness

(MB991529) to earth terminal number 1
(diagnosis control terminal) of the diagnosis
connector.
3. Turn the ignition switch to the "ON" position.
ABS warning lamp
AC301437 AB
4. Read out a diagnosis code by observing how the

warning lamp flashes.
35B-6
TROUBLESHOOTING
When the diagnosis code No.24 is set
When no diagnosis code is set

0.5 sec.
1.5 secs.
0.25 sec.
0.5 sec.
Illuminated
Illuminated
Switched
off
Switched
off
Pause
time
3 secs.
Tens
signal
Place
division
2 secs.
Units
signal
ACX01778 AD
ACX01777 AD

position.
6. Disconnect special tool diagnosis code check

harness (MB991529).
ERASING DIAGNOSIS CODES

When Using the MUT-II
Diagnosis connector
When not Using the MUT-II

NOTE: If the ABS-ECU functions have stopped due
to the fail-safe function, the diagnosis code cannot
be erased.
position.
MB991529
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC107528 AH
2. Use special tool diagnosis code check harness

(MB991529) to earth terminal number 1 of the
Ignition switch
Stop lamp switch
ABS warning lamp
ON
OFF(OFF)
ON
OFF
ON
OFF
3 sconds
ABS-ECU memory
Within
3 sconds
Within Within Within Within Within Within Within Within

Within Within
1
1
1
1
1
1
1
1
1
1
seconds seconds seconds seconds seconds seconds seconds seconds seconds seconds
1st
3. Depress the brake pedal and hold it.

5. After turning the ignition switch to the "ON",
release the pedal within three seconds. Repeat
this process of pressing and releasing the brake
pedal 10 continuous times.
2nd
3rd
4th
5th
6th
7th
8th
9th
1
seconds
10th
Erasing of ABS-ECU
diagnosis codes complete.
AC000937AD

position.
7. Disconnect special tool diagnosis code check
harness (MB991529).
35B-7
TROUBLESHOOTING
INSPECTION CHART FOR DIAGNOSIS

CODE
M1352011300559
Follow the inspection chart that is appropriate for the

diagnosis code.
Diagnosis code Inspection item
Diagnostic content
No.
Open circuit or short circuit
Reference page
335B
11
Front right ABS sensor
12
Front left ABS sensor
13
Rear right ABS sensor
14
Rear left ABS sensor
16
ABS-ECU power supply system ABS-ECU power supply

voltage below or above the
specified value. Not
displayed if the voltage
recovers.
335B
21
Front right ABS sensor
335B
22
Front left ABS sensor
23
Rear right ABS sensor
24
Rear left ABS sensor
32
G sensor system <4WD>
335B
33
Stop lamp switch system
335B
41
ABS front right solenoid valve
335B
42
ABS front left solenoid valve
43
ABS rear right solenoid valve
44
ABS rear left solenoid valve
51
Valve relay problem (stays on)
Replace the hydraulic

unit (Integrated with
ABS-ECU).
52
Valve relay problem (stays off)
335B
53
Motor relay problem (stays off)
54
Motor relay problem (stays on)

ABS-ECU).
55
Motor system (seized pump motor)
335B
63
ABS-ECU abnormality
Improperly installed ABS-ECU <2WD>

ABS-ECU).
NOTE:
diagnosis code No.16, 52, 63
.
Code No.16 is cleared from the memory by turning the ignition switch to the "ACC" position. When the
system is properly reset, this code is also cleared from the memory.
Code No.52 and 63 are cleared from the memory by turning the ignition switch to the "ACC" position.
35B-8
TROUBLESHOOTING

PROCEDURES
Code No.11, 12, 13 and 14: ABS Sensor (Open Circuit or Short Circuit)
ABS Sensor Circuit
ABS SENSOR
(FRONT: LH)
(FRONT: RH)
(REAR: LH)
(REAR: RH)
ABS-ECU
Wire colour code

SB : Sky blue
AC301686AB
OPERATION
A toothed ABS rotor generates a voltage pulse as
it moves across the pickup field of each ABS
sensor.
The amount of voltage generated at each wheel
is determined by the clearance between the ABS
rotor teeth and the ABS sensor, and by the speed
of rotation.
The ABS sensors transmit the frequency of the
voltage pulses and the amount of voltage
generated by each pulse to the ABS-ECU.
The hydraulic unit modulates the amount of
braking force individually applied to each wheel
cylinder.

Diagnosis codes No.11, 12, 13 and 14 are set when
signal is not input due to breakage of the wires of the
four ABS sensors.
PROBABLE CAUSES
The most likely causes for these diagnosis codes to
set are:
Malfunction of the ABS sensor
Malfunction of the hydraulic unit (integrated with
ABS-ECU)
35B-9
TROUBLESHOOTING
DIAGNOSIS
STEP 1. Using MUT-II, check data list item 11, 12,
13, 14: ABS sensor.
Set MUT-II to data reading mode, and check the data
list items by driving the vehicle.
Item 01: Front right ABS sensor
Item 02: Front left ABS sensor
Item 03: Rear right ABS sensor
Item 04: Rear left ABS sensor
OK: The reading on the speedometer nearly
matches the indication on MUT-II, when
driving.
STEP 3. Measure the resistance at ABS-ECU

connector B-03.
Connector: B-03
B-03 (GR)
Harness side
Q: Is the ABS sensor input normal?

YES : This malfunction is intermittent. Refer to
GROUP 00, How to Use Troubleshooting/

With Intermittent Malfunction 300.
NO : Go to Step 2.
STEP 2. Inspect the ABS sensor.
Refer to 335B.
AC301441AB
(1) Disconnect ABS-ECU connector B-03 and

measure at the harness side.
Connector B-03
(harness side)
Check items:
ABS sensor internal resistance: 1.24 - 1.64 kW
Insulation between the ABS sensor body and the
connector terminals
Q: Is the ABS sensor damaged?
YES : Replace it and then go to Step 8.
NO : Go to Step 3.
AC301683 AB
(2) Measure the resistance between ABS-ECU

connector terminals 16 and 26, 9 and 10, 27 and
28, or 11 and 17.
Standard Value: 1.24 - 1.64 kW
Q: Is the resistance between terminals 16 and 26, 9
and 10, 27 and 28, or 11 and 17 within the standard
value?
When resistances between all terminals are within
the standard value : Erase the diagnosis code
memory, and recheck if any diagnosis code

sets. If diagnosis code No.11, 12, 13 or 14
sets, replace the hydraulic unit (integrated
with ABS-ECU). Then go to Step 8.
When resistance between terminals 16 and 26 is
not within the standard value : Go to Step 4.
When resistance between terminals 9 and 10 is not
within the standard value : Go to Step 5.
35B-10
TROUBLESHOOTING
STEP 4. Check the harness wires between ABSECU connector B-03 (terminals 16 and 26) and
ABS sensor <front: LH> connector A-13
Q: Is any harness wire between ABS-ECU connector

B-03 (terminals 16 and 26) and ABS sensor <front:
LH> connector A-13 (terminals 1 and 2) damaged?
YES : Repair it and go to Step 8.
NO : This malfunction is intermittent. Refer to

with Intermittent Malfunction300.
Connector: A-13
A-13 (B)
Harness side
AC301443 AB
Connector: B-03
B-03 (GR)
Harness side
AC301441AB
NOTE:
Connector : A-14
A-14(GR)
AC210455 AG
After inspecting ABS-ECU connector B-03,

intermediate connector A-14 and ABS sensor <front:
LH> connector A-13, inspect the wire. If any of these
connectors is damaged, repair or replace it. Then go
to Step 8.

TROUBLESHOOTING
ABS sensor <front: RH> connector A-31
Connector: A-31
35B-11
NOTE:
Connector: C-14
1 2
3 4
5 6 7 8 9 10
A-31 (B)
Harness side
AC301397 AC
Connector : C-104
AC301444 AB
Connector: B-03
C-104 (B)
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B-03 (GR)
AC301397AL

intermediate connectors C-14 and C-104, and ABS
sensor <front: RH> connector A-31, inspect the wire.
If any of these connectors is damaged, repair or
replace it. Then go to Step 8.
Harness side
AC301441AB

RH> connector A-31 (terminals 1 and 2) damaged?

with Intermittent Malfunction300.
35B-12
TROUBLESHOOTING
ABS sensor <rear: LH> connector D-22
NOTE:
Connector : C-104
Connector: B-03
C-104 (B)
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B-03 (GR)
AC301397AL
Connector: C-117
Harness side
AC301441AB
Connector: D-22
C-117
1 2 3
D-22 (B)
Harness side
111213
4 5 6 7 8 9 10
14 1516 17 1819 20 2122 2324 25

26 27 28 29
32 33 34
35
30 31
36 37
38
AC301446AB
AC301396 AC
Connector : D-24
D-24
1
2 3
4 5 6 7 8
AC301410 AG
After inspecting ABS-ECU connector B-03, intermediate

connectors C-104, C-117 and D-24, and ABS sensor <rear: LH>
connector D-22, inspect the wire. If any of these connectors is
damaged, repair or replace it. Then go to Step 8.
Q: Is any harness wire between ABS-ECU connector B-03
(terminals 28 and 27) and ABS sensor <rear: LH>
connector D-22 (terminals 1 and 2) damaged?
YES : Repair it and then go to Step 8.

NO : This malfunction is intermittent. Refer to GROUP
Service Points - How to Cope with Intermittent
Malfunction300.
35B-13
TROUBLESHOOTING
ABS sensor <rear: RH> connector D-13
NOTE:
Connector : C-104
Connector: B-03
C-104 (B)
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B-03 (GR)
AC301397AL
Connector: C-117
Harness side
AC301441AB
Connector: D-13
C-117
1 2 3
D-13 (B)
111213
4 5 6 7 8 9 10
14 1516 17 1819 20 2122 2324 25
Harness side
AC301445 AB
26 27 28 29
32 33 34
35
30 31
36 37
38
AC301396 AC
Connector : D-24
D-24
1
2 3
4 5 6 7 8
AC301410 AG

intermediate connectors C-104, C-117 and D-24, and
ABS sensor <rear: RH> connector D-13, inspect the
wire. If any of these connectors is damaged, repair or
B-03 (terminals 11 and 17) and ABS sensor <rear:
RH> connector D-13 (terminals 1 and 2) damaged?
NO : Go to Step 8.
35B-14

TROUBLESHOOTING
STEP 8. Recheck for the diagnosis code.

Q: Is diagnosis code No.11, 12, 13 or 14 set?
YES : Start over at Step 1.
Code No.16: ABS-ECU Power Supply System (ABS-ECU Power Supply Voltage or Valve Relay Power
Supply Voltage below or above the Specified Value)
ABS-ECU Power Supply Circuit
IGNITION
SWITCH (IG2)
ABS-ECU
POWER
SOURCE
Wire colour code
SB : Sky blue
AC301687 AB
OPERATION
The ABS-ECU power is supplied to the ABS-ECU
(terminal 20) from the ignition switch (IG2) through
the multi-purpose fuse number 12 in the junction
block.
DIAGNOSIS

Output is provided when ABS-ECU power supply
voltage drops below or rises above the specified
value. Output is not provided if the power supply
voltage meets the specified voltage.
Q: Is the battery damaged?

YES : Charge or replace the battery and then go
PROBABLE CAUSES
The most likely causes for this diagnosis code to set
are:
Malfunction of battery
Malfunction of hydraulic unit and ABS-ECU
STEP 1. Check the battery.

Refer to GROUP 54A, Battery - On-vehicle Service
- Battery Test 354A.
to Step 4.
NO : Go to Step 2.
STEP 2. Check the charging system.

Refer to GROUP 16, Charging System - Diagnosis
316.
Q: Is the charging system damaged?
YES : Repair the Charging System and then go to
Step 4.
NO : Go to Step 3.
35B-15
TROUBLESHOOTING

junction block connector C-203 terminal 2 and
ABS-ECU connector B-03 terminal 20.
NOTE:
Connector: C-106
Connector: B-03
2
1
3 4
5 6
7 8 9
10 11 12
16
13 14 15 17 18 19
C-106(GR)
B-03 (GR)
AC301397AG
Connector: C-202
Harness side
AC301441AB
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
Connector: C-203
AC210474 AB
Harness side
2
1
6 5 4 3
AC210474 AC

intermediate connector C-106, and junction block
connector C-202 and C-203, inspect the wire. If any
of these connectors is damaged, repair or replace it.
Then go to Step 4.
Q: Is the harness wire between junction block
connector C-203 terminal 2 and ABS-ECU
connector B-03 terminal 20 damaged?
NO : Erase the diagnosis code memory, and
recheck if any diagnosis code sets. If

diagnosis code No.16 sets, replace the
hydraulic unit (integrated with ABS-ECU)
and then go to Step 4 . If diagnosis code
No.16 is not set then an intermittent
malfunction is suspected. Refer to GROUP
Service Points - How to Cope with
Intermittent Malfunction 300.
35B-16
TROUBLESHOOTING
Code No.21, 22, 23, 24: ABS Sensor

ABS Sensor Circuit
ABS SENSOR
(FRONT: LH)
(FRONT: RH)
(REAR: LH)
(REAR: RH)
ABS-ECU
Wire colour code

SB : Sky blue
AC301686AB
OPERATION
A toothed ABS rotor generates a voltage pulse as
it moves across the pickup field of each ABS
sensor.
The amount of voltage generated at each wheel
is determined by the clearance between the ABS
rotor teeth and the ABS sensor, and by the speed
of rotation.
The ABS sensors transmit the frequency of the
voltage pulses and the amount of voltage
generated by each pulse to the ABS-ECU.
The hydraulic unit modulates the amount of
braking force individually applied to each wheel
cylinder.

Diagnosis codes No.21, 22, 23 and 24 are set in the
following cases:
Open circuit is not found but no input is received
by one or more of the four ABS sensors at 10 km/
h or more.
ABS sensor output drops due to a malfunctioning
ABS sensor or warped ABS rotor.
PROBABLE CAUSES
set are:
Malfunction of the ABS sensor
ABS-ECU)
Malfunction of the ABS rotor
35B-17
TROUBLESHOOTING
Malfunction of the wheel bearing

Excessive clearance between the ABS sensor
and ABS rotor
Teeth lack or clogging of the ABS rotor
STEP 4. Measure the resistance at the ABS-ECU

connector B-03.
Connector: B-03
DIAGNOSIS
STEP 1. Using MUT-II, check data list item 11, 12,
13, 14: ABS sensor.
list items by driving the vehicle.
Item 01: Front right ABS sensor
Item 02: Front left ABS sensor
Item 03: Rear right ABS sensor
Item 04: Rear left ABS sensor
OK: The reading on the speedometer nearly
matches the indication on MUT-II, when
driving.
Q: Is the ABS sensor input normal?

NO : Go to Step 2.
B-03 (GR)
Harness side
AC301441AB

Connector B-03
(harness side)
STEP 2. Check the ABS sensor installation.

Q: Is the ABS sensor bolted securely in place at the
front knuckle <front> or the trailing arm <rear>?
YES : Go to Step 3.
NO : Install it properly (Refer to 335B) and go
to Step 11.
STEP 3. Inspect the ABS sensor and ABS rotor.
Refer to 335B.
Check items:
ABS sensor internal resistance: 1.24 - 1.64 kW
Insulation between the ABS sensor body and the
connector terminals
Toothed ABS rotor check
Q: Is the ABS sensor or ABS rotor damaged?
YES : Replace it and then go to Step 11.
NO : Go to Step 4.
AC301683 AB
(2) Measure the resistance between ABS-ECU

connector terminals 16 and 26, 9 and 10, 11 and
17, or 27 and 28.
Standard Value: 1.24 - 1.64 kW
Q: Is the resistance between terminals 16 and 26, 9
and 10, 27 and 28, or 11 and 17 within the standard
value?
When resistances between all terminals are within
the standard value : Go to Step 9.
When resistance between terminals 9 and 10 is not
within the standard value : Go to Step 6.
35B-18
TROUBLESHOOTING
ABS sensor <front: LH> connector A-13

LH> connector A-13 (terminals 1 and 2) damaged?

Connector: A-13
A-13 (B)
Harness side
AC301443 AB
Connector: B-03
B-03 (GR)
Harness side
AC301441AB
NOTE:
Connector : A-14
A-14(GR)
AC210455 AG

intermediate connector A-14 and ABS sensor <front:
LH> connector A-13, inspect the wire. If any of these
to Step 11.

TROUBLESHOOTING
ABS sensor <front: RH> connector A-31
Connector: A-31
35B-19
NOTE:
Connector: C-14
1 2
3 4
5 6 7 8 9 10
A-31 (B)
Harness side
AC301397 AC
Connector : C-104
AC301444 AB
Connector: B-03
C-104 (B)
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B-03 (GR)
AC301397AL

intermediate connectors C-14 and C-104, and ABS
sensor <front: RH> connector A-31, inspect the wire.
If any of these connectors is damaged, repair or
Harness side
AC301441AB

RH> connector A-31 (terminals 1 and 2) damaged?

35B-20
TROUBLESHOOTING
ABS sensor <rear: LH> connector D-22
NOTE:
Connector : C-104
Connector: B-03
C-104 (B)
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B-03 (GR)
AC301397AL
Connector: C-117
Harness side
AC301441AB
Connector: D-22
C-117
1 2 3
D-22 (B)
Harness side
111213
4 5 6 7 8 9 10
14 1516 17 1819 20 2122 2324 25

26 27 28 29
32 33 34
35
30 31
36 37
38
AC301446AB
AC301396 AC
Connector : D-24
D-24
1
2 3
4 5 6 7 8
AC301410 AG
After inspecting ABS-ECU connector B-03, intermediate

connectors C-104, C-117 and D-24, and ABS sensor <rear: LH>
connector D-22, inspect the wire. If any of these connectors is

LH> connector D-22 (terminals 1 and 2) damaged?
NO : This malfunction is intermittent. Refer to GROUP
Service Points - How to Cope With Intermittent
Malfunction 300.
35B-21
TROUBLESHOOTING
ABS sensor <rear: RH> connector D-13
NOTE:
Connector : C-104
Connector: B-03
C-104 (B)
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B-03 (GR)
AC301397AL
Connector: C-117
Harness side
AC301441AB
Connector: D-13
C-117
1 2 3
D-13 (B)
111213
4 5 6 7 8 9 10
14 1516 17 1819 20 2122 2324 25
Harness side
AC301445 AB
26 27 28 29
32 33 34
35
30 31
36 37
38
AC301396 AC
Connector : D-24
D-24
1
2 3
4 5 6 7 8
AC301410 AG

intermediate connectors C-104, C-117 and D-24, and
ABS sensor <rear: RH> connector D-13, inspect the
wire. If any of these connectors is damaged, repair or
RH> connector D-13 (terminals 1 and 2) damaged?
NO : Go to Step 11.
35B-22

TROUBLESHOOTING
STEP 9. Check the ABS sensor output voltage.

Refer to 335B.
Output Voltage:
When measured with a voltmeter: 42 mV or more
When measured with an oscilloscope (maximum
voltage): 200 mV or more
Q: Does the voltage meet the specification?
YES : Erase the diagnosis code memory, and

diagnosis code No.21, 22, 23 or 24 sets,
replace the hydraulic unit (integrated with
ABS-ECU). Then go to Step 11.
NO : Go to Step 10.
STEP 10. Check the wheel bearing.

<Front>: Refer to GROUP 26, On-vehicle Service Wheel Bearing Axial Play Check 326.
<Rear (2WD)>: Refer to GROUP 27A, On-vehicle
Service - Wheel Bearing Axial Play Check 327A.
<Rear (4WD)>: Refer to GROUP 27B, On-vehicle
Service - Wheel Bearing Axial Play Check 327B.
NO : Replace it and then go to Step 11.

Q: Is diagnosis codes No.21, 22, 23 or 24 set?
35B-23
TROUBLESHOOTING
Code No.32 G-sensor System <4WD>
G-sensor Circuit
IGNITION
SWITCH (IG2)
G SENSOR
ABS-ECU
Wire colour code

SB : Sky blue
AC301688 AB
OPERATION
The G-sensor detects the acceleration level in the
forward/reverse direction of the vehicle, converts the
signals into voltage signals and then sends that
signal to the ABS-ECU.
This code is set in the following case.
When the G-sensor output is 1.0V or lower or
4.0V or higher (disconnected G-sensor or Gsensor short circuit)
If the G-sensor output power does not change
(G-sensor output fastening).
PROBABLE CAUSES
are:
Malfunction of the G-sensor
ABS-ECU)
35B-24
TROUBLESHOOTING
DIAGNOSIS
STEP 1. Using MUT-II, check the data list item 32:
G-sensor.
list item.
Item 32: G-sensor
OK:
When vehicle is stationary (level): 2.4 - 2.6 V
When vehicle is being driven: 1.0 - 4.0 V

junction block connector C-202 terminal 8 and Gsensor connector D-35 terminal 1.
Connector: C-202
Harness side
Q: Is the G-sensor input normal?

YES : This malfunctions is intermittent. Refer to

with Intermittent Malfunction 300.
NO : Go to Step 2.
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC210474 AB
Connector: D-35
Harness side
STEP 2. Measure the voltage at G-sensor

connector D-35.
D-35 (B)
Connector: D-35
Harness side
D-35 (B)
AC301440 AB
NOTE:
Connector: C-106
AC301440 AB
(1) Disconnect G-sensor connector D-35, and check

at the harness side.
Connector D-35
(harness side)
C-106(GR)
AC301397AG
After inspecting the junction block connector C-202,

intermediate connector C-106, and G-sensor
connector D-35, inspect the wire. If any of these
connector is damaged, repair or replace it. Then go
to Step 8.
AC301684AB

earth.
OK: System voltage
YES : Go to Step 4.
NO : Go to Step 3.
2
1
3 4
5 6
10 11 12
7 8 9
13 14 15 16 17 18 19

connector C-202 terminal 8 and G-sensor
connector D-35 terminal 1 damaged?
NO : This malfunctions is intermittent. Refer to

35B-25
TROUBLESHOOTING
STEP 4. Measure the resistance at G-sensor

connector D-35.
Connector: D-35
STEP 5. Check the harness wire between Gsensor connector D-35 terminal 3 and ABS-ECU
connector B-03 terminal 8.
Connector: D-35
Harness side
Harness side
D-35 (B)
D-35 (B)
AC301440 AB
(1) Disconnect G-sensor connector D-35, and check

at the harness side.
AC301440 AB
Connector: B-03
Connector D-35
(harness side)
B-03 (GR)
AC301684AC
Harness side

earth.
OK: 2 W or less
YES : Go to Step 6.
NO : Go to Step 5.
AC301441AB
Q: Is the harness wire between G-sensor connector D35 terminal 3 and ABS-ECU connector B-03
terminal 8 damaged?

and then go to Step 8 .
35B-26
TROUBLESHOOTING
STEP 6. Check G-sensor output voltage.
Label
STEP 7. Check the harness wire between Gsensor connector D-35 terminal 2 and ABS-ECU
connector B-03 terminal 15.
Connector: D-35
Harness side
MB991348
D-35 (B)
Connector: D-35
(Harness side)
AC301440 AB
Label
Connector: B-03
B-03 (GR)
AC103662AK
(1) Disconnect G-sensor connector D-35, and

connect special tool harness set (MB991348)
between the disconnected connectors.
earth.
OK:
When vehicle is stationary (level): 2.4 2.6 V
When vehicle is being driven: 1.0 - 4.0 V
Q: Is G-sensor output voltage normal?
YES : Go to Step 7.
NO : Replace the G-sensor and go to Step 8.
Harness side
AC301441AB
Q: Is the harness wire between G-sensor connector D35 terminal 2 and ABS-ECU connector B-03
terminal 15 damaged?

and then go to Step 8 .
35B-27
TROUBLESHOOTING
Code No.33 : Stop Lamp Switch System
Stop Lamp Switch Circuit

BATTERY
RELAY
BOX
STOP
LAMP
SWITCH
STOP LAMPS
ABS-ECU
Wire colour code

OPERATION
The "ON" signal when the brake pedal is pressed or
the "OFF" signal when the brake pedal is released is
input to the ABS-ECU (terminal 3).
Diagnosis code No.33 is set in the following cases:
Stop lamp switch is not operating properly and
remains in ON state for more than 15 minutes.
SB : Sky blue
AC301689AB
Stop lamp switch system harness is damaged

and no signal is input to ABS-ECU.
PROBABLE CAUSES
are:
Malfunction of the stop lamp switch
ABS-ECU)
35B-28
TROUBLESHOOTING
DIAGNOSIS
STEP 1. Check the stop lamp operation.
Q: Does the stop lamp come on and go out correctly?
YES : Go to Step 4.
NO : Go to Step 2.
STEP 2. Check the stop lamp switch installation

condition.
Q: Is the stop lamp switch installed properly?
YES : Go to Step 3.
NO : Repair it and then go to Step 7.
STEP 3. Check the stop lamp switch continuity.

(1) Remove the stop lamp switch (Refer to GROUP
35A, Brake Pedal 335A).
No continuity
Continuity
4 mm
ACX00671AE
(2) Connect an ohmmeter to stop lamp switch

terminals 1 and 2, and check whether there is
continuity when the plunger of the stop lamp
switch is pushed in and when it is released.
(3) The stop lamp switch is in good condition if there
is no continuity when the plunger is pushed in to
a depth of within 4 mm from the outer case edge
surface, and if there is continuity when it is
released.
Q: Is the stop lamp switch continuity correct?
YES : Check the stop lamp circuit and repair and
then go to Step 7.
NO : Replace the stop lamp switch and then go to
Step 7.
STEP 4. Using MUT-II, check data list item 36:

Stop lamp switch.
list item.
Item 36: Stop lamp switch
OK:
Brake pedal stepped down: ON
Brake pedal released: OFF
Q: Is the stop lamp switch input normal?

NO : Go to Step 5.

TROUBLESHOOTING
STEP 5. Measure the voltage at ABS-ECU

connector B-03.
Connector: B-03
B-03 (GR)
Harness side
AC301441AB

(2) Depress the brake pedal to turn on the stop lamp
switch.
Connector B-03
(harness side)
AC301683 AC

earth.
OK: System voltage

diagnosis code No.33 set, replace the
hydraulic unit (integrated with ABS-ECU).
Then go to Step 7.
NO : Go to Step 6.
35B-29
35B-30
TROUBLESHOOTING
STEP 6. Check the harness wire between ABSECU connector B-03 terminal 3 and stop lamp
switch connector C-101 terminal 1.
NOTE:
Connector: B-03
B-03 (GR)
AC301397
Connector : C-104
Harness side
AC301441AB
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
Connector : C-101
Harness side
C-104 (B)
AC301397AL
C-101
AC301395 AL

intermediate connectors C-16 and C-104, and stop
lamp switch connector C-101, inspect the wire. If any
of these connectors is damaged, repair or replace it.
Then go to Step 7.
Q: Is the harness wire between ABS-ECU connector
B-03 terminal 3 and stop lamp switch connector C101 terminal 1 damaged?

35B-31
TROUBLESHOOTING
Code No.41, 42, 43, and 44: ABS Solenoid Valve inside Hydraulic Unit (Open Circuit or Short Circuit)
Code No.52: Valve Relay Problem (Stays off)
Code No.53: Motor Relay Problem (Stays off)
Code No.55: Motor System (Seized Pump Motor)
Solenoid Valve and Motor power Supply Circuit
FUSIBLE
LINK 3
HYDRAULIC UNIT
MOTOR
SOLENOID
VALVE POWER
SOURCE
ABS SOLENOID
VALVES
MOTOR POWER
SOURCE
ABS-ECU
Wire colour code

SB : Sky blue
AC301690AB
OPERATION
Power is continuously supplied to the ABS-ECU
through fusible link number 3 to operate the solenoid
valve and motor.
These codes are set if the power supply circuit of
solenoid valve or motor is open or shorted.
PROBABLE CAUSES
set are:
ABS-ECU)
35B-32
TROUBLESHOOTING
DIAGNOSIS
connector B-03.
STEP 2. Check the harness wires between fusible

link number 3 and ABS-ECU connector B-03
Connector: B-03
Fusible link
No.3
B-03 (GR)
AC208065AD
Connector: B-03
Harness side
B-03 (GR)
AC301441AB

Connector B-03
(harness side)
Harness side
AC301441AB
NOTE:
AC301683 AD

earth, and 19 and earth.
OK: System voltage
Connector : A-14
A-14(GR)


diagnosis code No.41, 42, 43, 44, 52, 53, or
55 set, replace the hydraulic unit (integrated
with ABS-ECU). Then go to Step 3. If
diagnosis code No.41, 42, 43, 44, 52, 53, or
55 is not set, an intermittent malfunction is
suspected. Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points How to Cope with Intermittent Malfunction
300.
NO : Go to Step 2.
AC210455 AG
After inspecting intermediate connector A-14,

inspect the wire. If the connector is damaged, repair
or replace it. Then go to Step 3.
Q: Is any harness wire between fusible link number 3
and ABS-ECU connector B-03 (terminal 1 and 19)
damaged?

35B-33
TROUBLESHOOTING

Q: Is diagnosis code No.41, 42, 43, 44, 52, 53 or 55
set?
INSPECTION CHART FOR TROUBLE SYMPTOMS

M1352011400567
NOTE: If steering movements are made when

driving at high speed, or when driving on road
surfaces with low frictional resistance, or when
passing over bumps, the ABS may operate although
sudden braking is not being applied. Because of this,
when getting information from the customer, check if
the problem occurred while driving under such
conditions as these.
Trouble symptoms
Communication between MUT-II and the whole
system is not possible.
NOTE: During ABS operation, the brake pedal may

vibrate a little or may not be able to be pressed. Such
conditions are due to intermittent changes in
hydraulic pressure inside the brake line to prevent
the wheels from locking. This is normal.
Inspection procedure No.
Reference page
GROUP 13A,
Diagnosis 313A
Communication between MUT-II and the ABS-ECU is 1

not possible.
335B
When the ignition switch is turned to the "ON"

position (Engine stopped), the ABS warning lamp
does not illuminate.
335B
The ABS warning lamp remains illuminated after the 3

engine is started.
335B
Faulty ABS operation
335B
35B-34
TROUBLESHOOTING
INSPECTION PROCEDURE FOR

TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1: Communication between MUT-II and the ABS-ECU is not Possible.
Diagnosis Connector Circuit
IGNITION
SWITCH (IG2)
ABS-ECU
POWER
SOURCE
DIAGNOSIS
CONNECTOR
FRONT SIDE
Wire colour code

OPERATION
The diagnostic output is made from the ABSECU (terminal 13) to the diagnosis output
terminal (terminal 7) of the diagnosis connector.
SB : Sky blue
AC301691AB
When the diagnosis connectors diagnosis test

mode control terminal (terminal 1) is grounded,
the ABS-ECU (terminal 4) will go into diagnosis
mode.
35B-35
TROUBLESHOOTING

When communication with the MUT-II is not possible,
the cause is probably an open circuit in the ABSECU power circuit or an open circuit in the diagnostic
output circuit.

ABS-ECU connector B-03 terminal 20.
Connector: B-03
PROBABLE CAUSES
The most likely causes for this case are:
Blown fuse
Malfunction of the hydraulic unit (Integrated with
ABS-ECU)
B-03 (GR)
DIAGNOSIS
Harness side

connector B-03.
Connector: B-03
AC301441AB
Connector: C-202
B-03 (GR)
Harness side
Harness side
6 5 4
3 2 1
14 13 12 11 10 9 8 7
AC210474 AB
NOTE:
AC301441AB

(2) Start the engine.
Connector B-03
(harness side)
Connector: C-106
2
1
3 4
5 6
7 8 9
10 11 12
13 14 15 16 17 18 19
C-106(GR)
AC301397AG
AC301683 AE

earth.
OK: System voltage
YES : Go to Step 3.
NO : Go to Step 2.
After inspecting ABS-ECU connector B-03, junction

block connector C-202 and intermediate connector
C-106, inspect the wire. If any of these connectors is

35B-36
TROUBLESHOOTING
diagnosis connector C-24 (terminals 1 and 7).
NOTE:
Connector: C-02
Connector: B-03
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
B-03 (GR)
AC301395 AC
Connector : C-104
Harness side
AC301441AB
C-104 (B)
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
Connector: C-24
AC301397AL
Connector: C-105
1 2 3 4
5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
Harness side
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
C-24(B)
AC301395 AF
AC301397AF
After inspecting ABS-ECU connector B-03, diagnosis

connector C-24, and intermediate connectors C-02,
C-104 and C-105, inspect the wires. If any of these
to Step 5.
Q: Is any of the harness wires between ABS-ECU
connector B-03 (terminals 4 and 13) and diagnosis
connector C-24 (terminals 1 and 7) damaged?
NO : Go to Step 4.

TROUBLESHOOTING
earth (No.9).
Connector: B-03
B-03 (GR)
Harness side
AC301441AB
Relay box
Earth (No.9)
AC208089AC
Q: Is any of the harness wires between ABS-ECU

connector B-03 (terminals 2 and 18) and earth
(No.9) damaged?
NO : Check the troubleshooting condition. To
reproduce the troubleshooting state replace

the hydraulic unit (integrated with ABSECU).Then go to Step 5. If the state of
failure is not reproduced then a intermittent
malfunction is suspected. Refer to GROUP
Service Points - How to Cope with
Intermittent Malfunction 300.
35B-37

Q: Does the MUT-II communicate with the ABS
system?
NO : Start over at Step 1.
35B-38

TROUBLESHOOTING
INSPECTION PROCEDURE 2: When the Ignition Key is Turned to the "ON" position (Engine Stopped),
the ABS Warning Lamp does not Illuminate.
ABS Warning Lamp Circuit
IGNITION
SWITCH (IG1)
COMBINATION
METER
ABS-ECU
Wire colour code

SB : Sky blue
AC301692 AB
OPERATION
The ABS warning lamp is lit up by transistor
control in the ABS-ECU. However, the
relationship of the reverse circuit movement in the
combination meter will vary from usual in terms of
transistor ON/OFF and ABS warning lamp ON/
OFF, in that the ABS warning lamp will lamp up
when the transistor is turned OFF for this circuit.
This is how the ABS warning lamp lights up even
when the ABS-ECU connector is connected
improperly or if the ABS-ECU function has
terminated.
The ABS-ECU also lights up the ABS warning
lamp during the initial check (approximately 3
seconds) when the ignition switch is turned to the
"ON" position in addition to when the system is
malfunctioning.

Possible causes include the combination meter
power circuit, disconnected earth circuit, dead lamp
bulb, or short circuited ABS warning lamp.
PROBABLE CAUSES
Blown fuse
Burnt out ABS warning lamp bulb
Combination meter defect
ABS-ECU)
35B-39
TROUBLESHOOTING
DIAGNOSIS

meter connector C-04.
STEP 1. Check the ABS warning lamp circuit at

ABS-ECU connector B-03.
Connector: C-04
C-04
Connector: B-03
Harness side
(front view)
B-03 (GR)
AC301395 AK
(1) Disconnect connector C-04, and check at the

harness side.
Harness side
Connector C-04
(harness side)
AC301441AB
(1) Disconnect ABS-ECU connector B-03.

Q: Does the ABS warning lamp illuminate?
YES : To check and reproduce the state of
malfunction replace the hydraulic unit

(integrated with ABS-ECU). Then go to Step
7. If the malfunction is not reproduced, an
NO : Go to Step 2.
STEP 2. Check the ABS warning lamp bulb.
(1) Remove the combination meter (Refer to GROUP
54A, Combination Meter 354A).
(2) Check the ABS warning lamp bulb.
Q: Is the bulb burned out?
YES : Replace the bulb and then go to Step 7.
NO : Go to Step 3.
AC301685 AB

earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.
35B-40
TROUBLESHOOTING

combination meter C-04 terminal 42.
Connector: C-04
STEP 5. Check the harness wire between the

combination meter connector C-05 terminal 12
and earth (No.6).
Connector: C-05
C-04
C-05(L)
Harness side
(front view)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AK
AC301395 AE
Connector: C-203
Earth (No.6)
Harness side
2
1
6 5 4 3
AC210474 AC
NOTE:
Junction
block
AC208084AE
Q: Is the harness wire between combination meter

connector C-05 terminal 12 and earth (No.6)
damaged?
YES : Repair the harness wire and go to Step 7.
NO : Go to Step 6.
Connector: C-205
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE
After inspecting junction block connectors C-203 and

C-205, and combination meter connector C-04,
inspect the wire. If any of these connectors is
connector C-203 terminal 6 and combination meter
C-04 terminal 42 damaged?


TROUBLESHOOTING

and ABS-ECU connector B-03 terminal 12.
Connector: C-05
C-05(L)
Harness side
(front view)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE
Connector: B-03
B-03 (GR)
Harness side
AC301441AB
NOTE:
Connector: C-105
1 2 3 4
5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
AC301397AF
After inspecting combination meter connector C-05,

ABS-ECU connector B-03 and intermediate
connector C-105, inspect the wire. If any of these
to Step 7.
Q: Is the harness wire between the combination meter
NO : Replace the combination meter and go to
Step 7.
35B-41

Q: Does the ABS warning lamp illuminate for 3
seconds when the ignition switch is turned to the
"ON" position with engine stopped or upon startup?
35B-42
TROUBLESHOOTING
INSPECTION PROCEDURE 3: The ABS Warning Lamp Remains Illuminated after the Engine is
Started.
NOTE: This diagnosis procedure is limited to cases where communication with the MUT-II is possible (ABSECU power supply is normal) and no diagnosis code outputs.
ABS Warning Lamp Circuit
IGNITION
SWITCH (IG1)
COMBINATION
METER
ABS-ECU
Wire colour code

SB : Sky blue
AC301692 AB
OPERATION
Refer to 335B.
Disconnected ABS warning lamp output line of ABSECU is suspected.
PROBABLE CAUSES
ABS-ECU)
35B-43
TROUBLESHOOTING
DIAGNOSIS
STEP 1. Check the ABS warning lamp circuit at
ABS-ECU connector B-03.

and ABS-ECU connector B-03 terminal 12.
Connector: C-05
C-05(L)
Connector: B-03
Harness side
(front view)
B-03 (GR)
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301395 AE
Connector: B-03
Harness side
B-03 (GR)
AC301441AB
(1) Disconnect ABS-ECU connector B-03.

Connector B-03
(harness side)
Harness side
AC301441AB
AC301683AF
(2) Connect ABS-ECU connector B-03 terminal

number 12 to earth.
NOTE:
Connector: C-105
1 2 3 4
5 6 7 8 9
10 11 12 13 1415 16 1718 19 20 21 22
Q: Does the ABS warning lamp go off?

YES : To check and reproduce the state of
malfunction replace the hydraulic unit

(integrated with ABS-ECU). Then go to Step
3. If the malfunction is not reproduced, an
NO : Go to Step 2.
AC301397AF
After inspecting combination meter connector C-05,

ABS-ECU connector B-03 and intermediate
connector C-105, inspect the wire. If any of these
to Step 3.
Q: Is the harness wire between combination meter
YES : Repair the harness wire and then go to Step
3.
NO : Replace the combination meter (printed
circuit board) and then go to Step 3.
35B-44

TROUBLESHOOTING

Q: Does the ABS warning lamp turn off in 3 seconds
after start-up?
INSPECTION PROCEDURE 4: Faulty ABS Operation

The cause depends on driving and road surface
conditions, so diagnosis may be difficult. However, if
no diagnosis code is set, carry out the following
inspection.
DIAGNOSIS
Check the hydraulic unit (Refer to 335B). If the
hydraulic unit (integrated with ABS-ECU) is
malfunctioning, replace it. Then check that the
malfunction symptom is eliminated.
PROBABLE CAUSES
The most likely cause for this case is:
Malfunction of the hydraulic unit

M1352011500564
The following items can be read by the MUT-II from

the ABS-ECU input data.
When the system is normal.
Item
No.
Check item
Checking requirements
Normal valve
11
Front-right ABS sensor
Perform a test run
12
Front-left ABS sensor
13
Rear-right ABS sensor
Vehicle speeds
displayed on the
speedometer and
MUT-II are identical.
14
Rear-left ABS sensor
21
ABS-ECU power supply voltage
Ignition switch: ON
10 - 16 V
32
G-sensor <4WD>
Ignition switch: ON
When vehicle is parked on a level
surface.
2.4 - 2.6 V
When vehicle is accelerated
4.0 - 1.0 V
When vehicle is decelerated
1.0 - 4.0 V
Depress the brake pedal.
ON
Release the brake pedal.
OFF
36
Stop lamp switch
When the ABS-ECU shut off ABS operation.

When the diagnosis system stops the ABS-ECU, the
MUT-II display data will be unreliable.
35B-45
TROUBLESHOOTING
ACTUATOR TEST REFERENCE TABLE

M1352011600527
Lock lever
The MUT-II activates the following actuators for

testing.
NOTE: If the ABS-ECU runs down, actuator testing
cannot be carried out.
NOTE: Actuator testing is only possible when the
vehicle is stationary.
ACTUATOR TEST SPECIFICATIONS
AC200022AE
Activation pattern
Start of
activation
Solenoid
valve
Pump
motor
End of
activation
ABS-ECU connector
A
B
C
1. Move the lock lever of the ABS-ECU connector as

ABS-ECU connector.
Connector cover
1s
0.05 s
ON
2s
0.01 s
OFF
AC103604AC
NOTE
A: Hydraulic pressure increases
B: Hydraulic pressure holds
C: Hydraulic pressure decreases
2. Insert the flat-tipped screwdriver to the aperture

(arrow area as shown in the illustration) between
ABS-ECU connector and connector cover to
disengage the claw and remove the connector
cover.
AC100172 AG
TERMINAL VOLTAGE CHECK CHART
No. Item
01
Solenoid valve for frontleft wheel
02
Solenoid valve for frontright wheel
03
Solenoid valve for rearleft wheel
04
Solenoid valve for rearright wheel
Solenoid valves
and pump motors
in the hydraulic
unit (simple
inspection mode)
AC300659
CHECK AT ABS-ECU
M1352011800554
Use the following steps to remove the connector

cover and measure the terminal voltage.
1. Measure the voltages between earth terminal (2)

or (18) and each respective terminal.
2. The terminal layouts are shown in the illustrations
below.
NOTE: Do not measure terminal voltage for
approximately three seconds after the ignition switch
is turned to the "ON" position. The ABS-ECU
performs the initial check during that period.
35B-46
TROUBLESHOOTING
Terminal No. Check item
Checking requirements
Normal condition
Solenoid valve power Always

supply
System voltage
Stop lamp switch

input
Stop lamp switch: "ON"
System voltage
Stop lamp switch: "OFF"
Approximately 0 V
Diagnosis changeover When the MUT-II is connected

input
When the MUT-II is not connected
Approximately 0 V
G-sensor earth
<4WD>
Approximately 0 V
12
ABS-ECU warning
Ignition
lamp transistor output switch: "ON"
13
MUT-II
Always
System voltage
When the lamp is switched off
Approximately 0 V
When the lamp is illuminated
System voltage
When the MUT-II is connected
Serial
communication with
MUT-II
When the MUT-II is not connected
Approximately 0 V
15
G-sensor input
<4WD>

Horizontal state of vehicle
2.4 - 2.6 V
19
Motor power supply
Always
System voltage
20
ABS-ECU power
supply
System voltage
Ignition switch: "START"
Approximately 0 V

TROUBLESHOOTING
RESISTANCE AND CONTINUITY BETWEEN

HARNESS-SIDE CONNECTOR TERMINALS
AC300662

position and disconnect the ABS-ECU connectors
before checking resistance and continuity.
2. Check the resistance and continuity between the
terminals indicated in the table below.
3. The terminal layout is shown in the illustration.
ABS-ECU terminal No.
Signal
Normal condition
9 - 10
Front-right ABS sensor
1.24 - 1.64 kW
11 - 17
Rear-right ABS sensor
1.24 - 1.64 kW
16 - 26
Front-left ABS sensor
1.24 - 1.64 kW
27 - 28
Rear-left ABS sensor
1.24 - 1.64 kW
2 - body earth
Earth
Less than 2 W
18 - body earth
Earth
Less than 2 W
35B-47
35B-48
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ABS SENSOR OUTPUT VOLTAGE
MEASUREMENT
M1352001600485
Lift up the vehicle and release the parking brake.
11 10 9 8 7 6 5 4 3
17 16 15
14 13 12
28 27 26 25 24 23 22 21 20
19
18
3. If the output voltage is lower than that given

above, the cause may be the following, so check
or replace the ABS sensor if necessary.
ABS sensor pole piece-to-ABS rotor clearance
too large
Faulty ABS sensor
WAVE PATTERN INSPECTION USING AN
OSCILLOSCOPE
After checking the connection of the ABS sensor
harness and the connector, take a reading of the
output voltage wave patterns for each ABS sensor
using an oscilloscope as follows.
Start the engine, the transmission shift lever to 1st
gear, and then spin the wheel.
NOTE:
When turned by hand
Harness connector
AC201294 AH
1. Disconnect the ABS-ECU connector, and

measure the output voltage at the harness side
connector.
2. Manually turn the wheel to be measured 1/2 to 1
turn/second. Measure the output voltage with a
voltmeter or oscilloscope.
Terminal No.
Front left
Front right
Rear left
Rear right
16
27
11
26
10
28
17
Output voltage:
42 mV or higher when measured using a
multimeter
120 mVP-P or higher when measured using a
oscilloscope
When idling (5 6 km/h), with 1st gear
[10.0 ms/DIV IV/DIV]
AC000949 AF
You can also take a reading of the wave pattern

by actually driving the vehicle in this condition.
The output voltage will be lower when the wheel
speed is lower, and will become higher as the
wheel speed becomes higher.
35B-49
ON-VEHICLE SERVICE
POINTS IN WAVEFORM MEASUREMENT

Symptom
Probable causes
Too small or zero waveform
amplitude
Remedy
Faulty ABS sensor or excessive

gap between it and the ABS rotor
Replace ABS sensor
Waveform amplitude fluctuates

Axle hub eccentric or with large
excessively (This is no problem if runout
the minimum amplitude is 100 mV Faulty ABS-ECU earth
or more)
Replace hub assembly
Noisy or disturbed waveform
Open circuit in ABS sensor
Replace ABS sensor
Open circuit in harness
Repair harness wire
Incorrectly mounted ABS sensor
Mount ABS sensor correctly
ABS rotor with missing or

damaged teeth
Replace ABS rotor
Repair harness wires
NOTE: The ABS sensor cable moves in relation to motion of the front or rear suspension. Therefore, it is
likely that it has an open circuit only when driving on rough roads but it functions normally when driving on
smooth roads. It is recommended to observe sensor output voltage waveform also under special conditions,
such as driving on a rough road.
HYDRAULIC UNIT CHECK

M1352001700460
CAUTION
The roller of the braking force tester and the
tyre should be dry during testing.
When testing the front brakes, apply the
parking brake. When testing the rear brakes,
stop the front wheels with chocks.
1. Jack up the vehicle. Then support the vehicle with
rigid racks at the specified jack-up points or place
the front or rear wheels on the rollers of the
braking force tester.
2. Release the parking brake, and feel the drag force
(drag torque) on each road wheel. When using the
braking force tester, take a reading of the brake
drag force.
CAUTION
ignition switch to the "LOOK" (OFF) position
before connecting or disconnecting the MUT-II.
16 Pin
MB991502
AC107200AC

position and set the MUT-II as shown in the
illustration.
4. After checking that the shift lever is in neutral,
start the engine.
5. Use the MUT-II to force-drive the actuator.
NOTE: The ABS system will switch to the MUT-II
mode and the ABS warning lamp will illuminate.
NOTE: When the ABS has been interrupted by
the fail-safe function, the MUT-II actuator testing
cannot be used.
35B-50
ON-VEHICLE SERVICE
Depressed
Pedal
operation
MUT-II actuator test

(Item No.01, 02, 03, 04) start
Released
Increase in pressure
Solenoid
valve
position
2 seconds
Steady pressure
1 seconds
Reduction in pressure
Checking
the brake
force
Lock
3 seconds
Drag force when the

pedal is free
Approx. 0.05 seconds

AC000954 AE
6. Turn the wheel by hand and check the change in

braking force when the brake pedal is depressed.
When using the braking force tester, depress the
brake pedal until the braking force is at the
following values, and check that the braking force
changes to the brake drag force inspected in step
2 when the actuator is force-driven. The result
should be as shown in the diagram above.
Diagnosis Table
Front wheel
785 - 981 N
Rear wheel
588 - 784 N
7. If the result of inspection is abnormal, repair
according to the Diagnosis Table below.
MUT-II
Display
Operation
Inspection
result
Judgment Probable cause Remedy
01 FR VALBE
02 FL VALBE
03 RR VALBE
04 RL VALBE
Depress brake pedal

to lock wheel.
Using the MUT-II,
select the wheel to be
checked and force
the actuator to
operate.
Turn the selected
wheel manually to
check the change of
brake force.
Brake force is
released for
three seconds
after wheels
have been
locked.
Normal
Wheel does not Abnormal

lock when brake
pedal is
depressed.
Clogged brake
line other than
hydraulic unit
Check and
clean brake line
Clogged
hydraulic circuit
in hydraulic unit
Replace
hydraulic unit
assembly
Brake force is
not released
Incorrect
hydraulic unit
brake tube
connection
Connect
correctly
Hydraulic unit
Replace
solenoid valve
hydraulic unit
not functioning
assembly
correctly
8. After inspection, disconnect the MUT-II
immediately after turning the ignition switch to the
"LOCK" (OFF) position.

ON-VEHICLE SERVICE
IN THE EVENT OF A DISCHARGED

BATTERY
M1352003500495
WARNING
If the ABS is not operating, the vehicle
posture will be unstable during braking, Do
not drive the vehicle with the ABS-ECU
connector disconnected or with the ABS not
operating for any other reason.
If the engine is started using a booster cable when
the battery is completely flat, and the vehicle is then
driven without waiting for the battery to be recharged,
the engine may misfire and it may not be possible to
drive the vehicle. This is because the ABS consumes
a large amount of current when carrying out its initial
checks. If this happens, recharge the battery fully.
35B-51
35B-52
HYDRAULIC UNIT
HYDRAULIC UNIT
M1352008600420
NOTE: The ABS-ECU is integrated in the hydraulic unit.

Brake Fluid Filling
Bake Line Bleeding (Refer to GROUP 35A, On-vehicle
Service - Bleeding 335A).
Hydraulic Unit Check (Refer to 335B).
15 2 Nm
3
1
2
25 6 Nm
4
25 6 Nm
25 6 Nm
AC300471 AB
<<A>>
1.
>>A<< 2.
<>
3.
4.
Removal steps
Harness connector
Hydraulic unit and ABS-ECU
Hydraulic unit bracket assembly
35B-53
HYDRAULIC UNIT
<<A>> HARNESS CONNECTOR

DISCONNECTION
>>A<< BRAKE PIPE CONNECTION
Lock lever
4
5
6
AC100240AD
AC200022AE
Move the lock lever of the ABS-ECU connector as

harness connector.
<> HYDRAULIC UNIT AND ABS-ECU
REMOVAL
WARNING
The hydraulic unit is heavy. Use care when
removing it.
CAUTION
The hydraulic unit cannot be disassembled.
Never loosen its nuts or bolts.
Do not drop or shock the hydraulic unit.
Do not turn the hydraulic unit upside down or
lay it on its side.
Connect the brake pipes to the hydraulic unit as

1. From the master cylinder (secondary)
2. To the front brake (LH)
3. To the rear brake (RH)
4. To the rear brake (LH)
5. To the front brake (RH)
6. From the master cylinder (primary)
35B-54
ABS SENSOR
ABS SENSOR
M1352020700038
ABS Sensor Output Voltage Measurement (Refer to
335B).
<Front>
<Rear (2WD)>
3
4
<Rear (4WD)>
3
4
<<A>>
1.
2.
Front ABS sensor removal steps

Front ABS sensor
Front ABS rotor (Refer to GROUP
26, Driveshaft 326).
<<A>>
3.
4.
AC301105 AB
Rear ABS sensor removal steps

Rear ABS sensor
Rear ABS rotor (Refer to GROUP
27A, Rear Hub Assembly 327A
for 2WD, or GROUP 27B,
Driveshaft 327B for 4WD).
35B-55
ABS SENSOR

<<A>> FRONT ABS SENSOR/REAR ABS
SENSOR REMOVAL
3. If the internal resistance of the ABS sensor is not

within the standard value, replace it with a new
ABS sensor.
CAUTION
ACX01120
<Front, Rear (4WD)>
<Rear (2WD)>
AC100242 AE
Be careful when handling the projection at the tip

of the ABS sensor and the toothed edge of the
ABS rotor so as not to damage them by
contacting other parts.
INSPECTION
M1352020800035
ABS SENSOR CHECK

1. Check whether any metallic foreign material has
adhered to the projection at the ABS sensor tip.
Remove any foreign material. Also check whether
the pole piece is damaged. Replace it with a new
one if it is damaged.
NOTE: The projection can become magnetized
due to the magnet inside the ABS sensor, causing
foreign material to easily adhere to it. The
projection may not be able to correctly sense the
wheel rotation speed if foreign matter is on it or if it
is damaged.
<Front>
4. Remove all connections from the ABS sensor.

The circuit should be open between terminals (1)
and (2) and the body of the ABS sensor. If the
circuit is not open, replace with a new ABS
sensor.
5. Check the ABS sensor cable for breakage,
damage or disconnection. Replace with a new
one if a problem is found.
NOTE: When checking for cable damage, remove
the cable clamp part from the body and then
gently bend and pull the cable near the clamp.
TOOTHED ABS ROTOR CHECK
<Rear>
AC000965
Check whether the ABS rotor teeth are broken or

deformed. Replace the BJ assembly of the
driveshaft, or the ABS rotor (2WD-rear side),
respectively, if the teeth are damaged or deformed.
AC201428 AD
2. Measure the resistance between the ABS sensor

terminals.
35B-56
G-SENSOR
G-SENSOR
M1352010100251
CAUTION
Do not drop or apply a shock on the G-sensor.
Rear Floor Console Assembly Removal and Installation
(Refer to GROUP 52A, Floor Console Assembly 352A
).
G-sensor
AC200354AC
INSPECTION
M1352018000065
G-SENSOR CHECK
Label
MB991348
Connector: D-35
(Harness side)
Label
AC103662 AJ
1. Disconnect the G-sensor connector and connect

special tool Test Harness Set (MB991348),
between the disconnected connectors.
2. Turn the ignition switch to the "ON" position, and

then read the voltage between terminals number
2 and number 3.
Standard Value: 2.4 - 2.6 V
3. With special tool Test Harness Set (MB991348)
connected, rotate so that the arrow faces straight
down. Read output voltage between terminals
number 2 and number 3.
Standard Value: 1.0 - 4.0 V
4. If the voltage deviates from the standard value,
make sure that nothing is wrong with the power
supply wire and earth wire and then replace the
G-sensor.
00-1
GROUP 00
00
11
GENERAL
12
13
14
CONTENTS
00
15
SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) . . . . . . . . . . . . . . . . . .
00
SRS SERVICE PRECAUTIONS . . . . .
00
17
HOW TO USE TROUBLESHOOTING/

INSPECTION SERVICE POINTS. . . .
00
VEHICLE IDENTIFICATION . . . . . . .
00
SUPPORT LOCATIONS FOR LIFTING

AND JACKING . . . . . . . . . . . . . . . . . . 00
GENERAL DATA AND

SPECIFICATIONS . . . . . . . . . . . . . . .
00
STANDARD PART/TIGHTENINGTORQUE TABLE . . . . . . . . . . . . . . . .
PRECAUTIONS BEFORE SERVICE.
16
00
21
22
25
00
26
27
31
32
33
34
35
36
37
42
51
52
54
55
GENERAL
00-2

M1001000100518
SCOPE OF MAINTENANCE, REPAIR AND

SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components. For
detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
after they have been removed from the vehicle,
please refer to separate manuals covering the
engine and the transmission.
ON-VEHICLE SERVICE
"On-vehicle Service" is procedures for performing
inspections and adjustments of particularly important
locations with regard to the construction and for
maintenance and servicing, but other inspection (for
looseness, play, cracking, damage, etc.) must also
be performed.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be kept functionally or in strength. It is a value
established outside the range of standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
DANGER, WARNING, AND CAUTION
DANGER, WARNING, and CAUTION call special
attention to a necessary action or to an action that
must be avoided. The differences among DANGER,
WARNING, and CAUTION are as follows:
If a DANGER is not followed, the result is severe
bodily harm or even death.
If a WARNING is not followed, the result could be
bodily injury.
If a CAUTION is not followed, the result could be
damage to the vehicle, vehicle components or
service equipment.
INDICATION OF TIGHTENING TORQUE

Tightening torques (units: Nm) are set to take into
account the central value and the allowable
tolerance. The central value is the target value, and
the allowable tolerance provides the checking range
for tightening torques. If bolts and nuts are not
provided with tightening torques, refer to 300.
MODEL INDICATIONS
The following abbreviations are used in this manual
for identification of model types.
MPI: Indicates the multipoint injection.
DOHC: Indicates an engine with the double
overhead camshaft.
M/T: Indicates the manual transmission.
A/C: Indicates the air conditioner.
GENERAL
127(6
00-3
00-4
GENERAL
EXPLANATION OF MANUAL CONTENTS

Indicates procedures to be performed
before the work in that section is started,
and procedures to be performed after the
work in that section is finished.
Component diagram
A diagram of the component parts is provided near the front of each section in order
to give the reader a better understanding of
the installed condition of component parts.
Maintenance and servicing procedures

The numbers provided within the diagram indicate the
sequence for maintenance and servicing procedures
procedures.
Removal steps :
The part designation number corresponds to the
number in the illustration to indicate removal
steps.
Disassembly steps :
The part designation number corresponds to the
number in the illustration to indicate disassembly.
Installation steps :
Specified in case installation is impossible in

reverse order of removal steps. Omitted if
installation is possible in reverse order of removal
steps.
Reassembly steps :
Specified in case reassembly is impossible in
reverse order of dissasembly steps. Omitted if
reassembly is possible in reverse order of
dissasembly steps.
Classifications of major maintenance / service points

When there are major points relative to maintenance and servicing procedures (such as essential maintenance
and service points, maintenance and service standard values, information regarding the use of special tools, etc.)
<<A>> : Indicates that there are essential points for removal or disassembly.
>>A<< : Indicates that there are essential points for installation or reassembly.
Symbols for lubrication, sealants and adhesives

Symbols are used to show the locations for lubrication and
for application of sealants and adhesives.
These symbols are included in the diagram of component
parts or on the page following the component parts page.
The symbols do not always have accompanying text to
support that symbol.
: Grease
(Multi-purpose grease unless there is a
brand or type specified)
: Sealant or adhesive
: Brake fluid or automatic transmission fluid
: Engine oil, gear oil or air conditioning
compressor oil
: Adhesive tape or butyl rubber tape
AC301960
GENERAL
00-5

Indicates
the group
number.
Indicates the
section title.
Indicates the
group title.
Indicates
the page
number.
BASIC BRAKE SYSTEM


Post- installation Operation

Brake Fluid Supplying and Air Bleeding (Refer to .)
100 10 Nm
Denotes tightening torque.

For bolts and nuts which do not
have a tightening torque listed,
refer to the "Standard Parts
tightening-torque Table".
30 5 Nm
<2-piston type>
<1-piston type>
Mark denotes nonreusable part.
Grease
Brake caliper kit
1.
2.
>>A<< 3.
4.
Pad set
Shim kit
Repair kit or parts sets are

shown. (Only very frequently
used parts are shown.)
Seal and boot repair kit
Removal steps
Brake hose connection
Gasket
Brake caliper assembly
Brake disc

>>A<< DISC BRAKE ASSEMBLY INSTALLATION
1. To check the brake drag force after mounting the pad,
measure the hub torque in the advancing direction using a
spring balance with the pad is removed.
Operating procedures, cautions,

etc. On removal, installation,
disassembly and reassembly
are described.
CAUTION
Do not allow any oil, grease or other contamination to
contact the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the knuckle, install
the pad clips and the pads to the caliper support.
The title of the page (following

the page on which the diagram
of component parts is
presented) indicating the
locations of lubrication and
sealing procedures.
PISTON
SEAL
GREASEREPAIR KIT GREASE
Indicates (by symbols) where

lubrication is necessary.
AC300860
GENERAL
00-6
HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS
HOW TO USE TROUBLESHOOTING/

INSPECTION SERVICE POINTS
M1001000200429
CONTENTS OF TROUBLESHOOTING
Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline
described below. Even in systems for which the MUT-II cannot be used, some of these systems still follow
this outline.
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from
that given below, or if additional explanation is required, the details of such differences or additions will also
be listed.
Diagnosis method
Gathering information
from the customer.
Check trouble symptom.
Reoccurs
Read the diagnosis code.
No diagnosis code
or communication
with MUT-II not
possible
Does not reoccur
Diagnosis code
displayed.
Diagnosis code
displayed.
After taking note of the

malfunction code, erase the
diagnosis code memory.
No diagnosis
code.
Recheck trouble symptom.

Read the diagnosis codes.
Diagnosis code
displayed.
Refer to the INSPECTION CHART

FOR TROUBLE SYMPTOMS
(Refer to applicable group.)
Read the diagnosis code.
Refer to the INSPECTION CHART

FOR DIAGNOSIS CODES
(Refer to applicable group.)
No diagnosis
code.
INTERMITTENT MALFUNCTIONS
AC300864AB
2. SYSTEM OPERATION AND SYMPTOM

VERIFICATION TESTS
If verification of the symptom(s) is difficult,
procedures for checking operation and verifying
symptoms are shown.
3. DIAGNOSIS FUNCTION
Details which are different from those in the
"Diagnosis function 300" section are described.
4. DIAGNOSIS CODE CHART

Diagnostic trouble codes and diagnostic items are
shown.
5. DIAGNOSIS CODE PROCEDURES
Indicates the inspection procedures corresponding to
each diagnosis code (Refer to How to read
inspection procedure 300).
GENERAL
00-7
6. TROUBLE SYMPTOM CHART

If there are trouble symptoms even though the MUTII does not find any diagnosis codes, Inspection
procedures for each trouble symptom will be found
by means of this chart.
7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptoms classified in the Symptom Chart
(Refer to How to read inspection procedure 300).
ERASING DIAGNOSIS CODE (BY USING THE

MUT-II)
CAUTION
position.
Steering shaft
8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgment values have
been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors,
inspection items, and judgment values have been
provided in this chart as reference information.
10. INSPECTION PROCEDURE BY USING AN
OSCILLOSCOPE
When there are inspection procedures using an
oscilloscope, these are described here.
DIAGNOSIS FUNCTION
HOW TO READ DIAGNOSIS CODE
CAUTION
position.
Steering shaft
MUT-II
AC300830 AB
Connect the MUT-II to the diagnosis connector, and

erase the diagnosis code.
ERASING DIAGNOSIS CODE (BY USING NO
MUT-II)
CAUTION
Some diagnosis codes can not be erased
according to the procedure below. If you attempt
to erase a diagnosis code, refer to an applicable
GROUP.
position.
2. Disconnect the negative battery cable, wait for at
least 10 minutes, and then reconnect it.
3. Start the engine and let it run at idle for 10
minutes.
INPUT SIGNAL CHECK (WHEN USING THE MUTII) <SWS>
MUT-II
CAUTION
position.
AC300830 AB
Connect the MUT-II to the diagnosis connector, and

read the diagnosis code.
NOTE: The ABS warning lamp may flash when the
ignition switch is turned ON with the MUT-II
connected. This is because the diagnosis display
function of the ABS warning lamp is activated by
grounding the diagnosis connector terminal No.1,
and is not detrimental in any way.
Steering shaft
MUT-II
AC300830 AB
1. Connect the MUT-II to the diagnosis connector,

and erase the diagnosis code.
00-8
GENERAL
2. If the MUT-II buzzer sounds once when each

switch is operated (ON/OFF), the input signal for
that switch circuit system is normal.
INPUT SIGNAL CHECK (WHEN USING A

VOLTMETER) <SWS>
Steering shaft
MB991529
9 10 11 12 13 14 15 16
AC300831AB
1. Use the special tool diagnosis code check

harness (MB9915299) to connect the ETACS
terminal (terminal 9) and the earth terminals
(terminals 4 and 5) of the diagnosis connector to
the voltage meter.
2. If the needle of the voltage meter flickers once
when each switch is operated (ON/OFF), the input
signal for that switch circuit system is normal.
GENERAL
00-9
HOW TO USE THE INSPECTION

PROCEDURES
The causes of many of the problems occurring in
electric circuitry are generally the connectors,
components, the ECU, the wiring harnesses
between connectors, in that order. These inspection
procedures follow this order. They first try to discover
a problem with a connector or a defective
component.
Code No. P0100 Air Flow Sensor System
Air flow sensor circuit
Battery
Air flow sensor
Relevant circuit(s) of the component which

the Code No. indicates are described.
J/C (1)
Engine-ECU
Wire colour code
B : Black LG : Light green G : Green
L : Blue
W : White
Y : Yellow
SB : Sky blue
BR : Brown
O : Orange
GR : Gray
AC301964AB
00-10
GENERAL
Explains about the basic

operation of the components.
Start of diagnosis
procedure
Describes
inspection
procedure.
TROUBLESHOOTING
Explains about
technical details.
Describes the
conditions for that
diagnosis code being
set.
DIAGNOSIS PROCEDURE
OPERATION
Power is supplied to the air flow sensor (terminal
No. 4) from the engine control relay (terminal No. 1) STEP 1. MUT-II data list
and earthed to the engine-ECU (terminal No. 5).
Refer to Date list reference table
A power voltage of 5 V is applied to the air flow
M1131152000735 P. 13A-288.
sensor output terminal (terminal No. 3) from the
a. Item 12: Air flow sensor.
An air flow sensor filter reset signal is inputted to
the air flow sensor (terminal No. 7) from the engineYES : Intermittent malfunction (Refer to GROUP
ECU (terminal No. 19).
00 How to Use Troubleshooting/
Inspection Service Points M1001000200429).
FUNCTION
NO : Go to Step 2 M1131750100051s2.
Air flow sensor outputs a puls signal proprtional to
the intake Air flow rate.
connector
The engine-ECU determines the basic injection
timing of the injector using the pulse signal output
Connector: B-08
from the air flow sensor and the engine speed
signal.
When the throttle position sensor output is low, the
engine-ECU causes the power transisitor in the unit
to be ON to send an air flow sensor filter reset
signal, the air flow sensor resets the filter circuit to
improve the ability of the air flow sensor to measure
the air flow rate in the area where the intake air flow
rate is low.
TROUBLE JUDGEMENT
Describes possible
causes(s) for that
diagnosis code.
Check Condition

YES : Go to Step 3 M1131750100051s3.
NO : Repair.
Judgement Criterion
Sensor output frequency of 3.3 Hz or less for 2
seconds.
PROBABLE CAUSE
Open/short circuit in air flow sensor circuit or loose
connector contact
Failed engine-ECU
AC301965AB
HARNESS CHECK
Check for an open or short circuit in the harness
between the terminals which were faulty according to
the connector measurements. Carry out this
inspection while referring to the Electrical Wiring
Manual. Here, "Check the wiring harness between
the power supply and terminal xx" also includes

checking for blown fuse. For inspection service
points when there is a blown fuse, refer to
"Inspection Service Points for a Blown Fuse 300
."
MEASURES TO TAKE AFTER REPLACING THE
ECU
If the trouble symptoms have not disappeared even
after replacing the ECU, repeat the inspection
procedure from the beginning.
GENERAL
00-11
CONNECTOR MEASUREMENT SERVICE

POINTS
Turn the ignition switch to the "LOCK" (OFF) position
when connecting and disconnecting the connectors.
Turn the ignition switch to "ON" when measuring,
unless there are instructions to the contrary.
IF INSPECTING WITH THE CONNECTOR
CONNECTED
IF INSPECTING WITH THE CONNECTOR

DISCONNECTED
<When Inspecting a Female Pin>
<Waterproof Connectors>
MD998459
MB991219
ACX00865AB
AC300881AB
Be sure to use special tool harness connector

(MD998459). Never insert a test probe from the
harness side, as this will reduce the waterproof
performance and result in corrosion.
Use the special tool inspection harness (MB991219)

(inspection harness for connector pin contact
pressure in the harness set for inspection). The
inspection harness for connector pin contact
pressure should be used. the test bar should never
be forcibly inserted, as it may cause a defective
contact.
<When Inspecting a Male Pin>
CAUTION
<Ordinary (non-waterproof) Connectors>
AC300890
Connector
AC300882AB
Check by inserting the multi-meter test probe from

the harness side. Note that if the connector (control
unit, etc.) is too small to permit insertion of the test
probe, it should not be forced; use the backprobing
tool for this purpose.
At this time, be careful not to short the connector

pins with the test bars. To do so may damage the
circuits inside the ECU.
Touch the pin directly with the test bar.
GENERAL
00-12
CONNECTOR INSPECTION SERVICE

POINTS
CONNECTOR PIN INSPECTION
VISUAL INSPECTION
Connector disconnected or
improperly connected
AC300898
If the connector pin stopper is damaged, the terminal

connections (male and female pins) will not be
perfect even if the connector body is connected, and
the pins may pull out of the reverse side of the
connector. Therefore, gently pull the harnesses one
by one to make sure that no pins pull out of the
connector.
Stretched or broken wires
CONNECTOR ENGAGEMENT INSPECTION
MB991219
Harness wire breakage
at terminal section
Low contact
pressure
Good
Bad
AC300899AB
AC300896AB
Connector is disconnected or improperly

connected
Connector pins are pulled out
Due to harness tension at terminal section
Low contact pressure between male and female
terminals
Low connection pressure due to rusted terminals
or foreign matter lodged in terminals
Use the special tool inspection harness (MB991219)

(connector pin connection pressure inspection
harness of the inspection harness set) to inspect the
engagement of the male pins and females pins. (Pin
drawing force: 1 N or more)
GENERAL
INSPECTION SERVICE POINTS FOR A

BLOWN FUSE
00-13
HOW TO COPE WITH INTERMITTENT

MALFUNCTIONS
NOTE: If determining the cause is difficult, the flight
recorder function of the MUT-II can also be used.
Battery
Fuse
Load
switch
Short-circuit
occurrence
section
Load
AC300900AB
Remove the blown fuse and measure the resistance

between the load side of the blown fuse and the
earth. Close the switches of all circuits which are
connected to this fuse. If the resistance is almost 0 W
at this time, there is a short somewhere between
these switches and the load. If the resistance is not 0
W, there is no short at the present time, but a
momentary short has probably caused the fuse to
blow.
The main causes of a short circuit are the following.
Harness being clamped by the vehicle body
Damage to the outer casing of the harness due to
wear or heat
Water getting into the connector or circuitry
Human error (mistakenly shorting a circuit, etc.)
AC300901
Intermittent malfunctions often occur under certain

conditions, and if these conditions can be
ascertained, determining the cause becomes simple.
In order to ascertain the conditions under which an
intermittent malfunction occurs, first ask the
customer for details about the driving conditions,
weather conditions, frequency of occurrence and
trouble symptoms, and then try to recreate the
trouble symptoms. Next, ascertain whether the
reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or
some other factor. If vibration is thought to be the
cause, carry out the following checks with the
connectors and components to confirm whether the
GENERAL
00-14
VEHICLE IDENTIFICATION
trouble symptom occurs. The objects to be checked

are connectors and components which are indicated
by inspection procedures or given as probable
causes (which generates diagnosis codes or trouble
symptoms).
Gently shake the connector up, down and to the
left and right.
Gently shake the wiring harness up, down and to

the left and right.
Gently rock each sensor and relay, etc. by hand.
Gently shake the wiring harness at suspensions
and other moving parts.
M1001000400553
VEHICLE IDENTIFICATION CODE PLATE

1
Item
Content
MODEL
CU2WXNMM CU2W:
L6
Vehicle model
XNMML6:
Model series
No.
ENGINE
4G63
Engine model
EXT
W83A
Exterior code
TRANS AXLE F5M42

4687
F5M42:Trans
mission
model
4687: Rear
differential (a
decimal point
is omitted)
COLOUR
W83
W83: Body
colour code
INT
62A
62A: Interior
code
OPT
ZP3
ZP3:
Equipment
code
AC301477AB
The vehicle information code plate is riveted to the

back of the hood.
The plate shows model code, engine model,
transmission model and body colour code.
For monotone colour vehicles, the body colour code

shall be indicated.
MODELS
Model code
Engine model
Price class
Transmission
model
Fuel supply
system
CU2W
4G63-DOHC (1,997
mL)
Comfort
F5M42
<2WD, 5M/T>
MPI
XNMML6
XNMMZL6
XNHMZL6
Sport
W5M42
<4WD, 5M/T>
GENERAL
00-15
MODEL CODE
CU 2 W X N M M Z L 6
2 3 4 5 6 7 8 9 10
No.
Item
Content
Specification
engine feature
M: MPI-DOHC
Special feature
None: 2WD
Z: 4WD
Steering wheel
location
L: Left hand
10
Destination
6: For Europe
CHASSIS NUMBER
AC301363 AB
No.
Item
Content
Development
CU: MITSUBISHI
OUTLANDER
Engine type
2: 1,997 mL petrol engine
Sort
W: Wagon
Body style
X: 5-door hatchback
Transmission
type
N: 5-speed manual
transmission
Trim level
M: COMFORT
H: SPORT
AC300903AB
The chassis number is stamped on the toeboard

inside the engine compartment.
M B
CU
000001
10
11
AC301362AB
No.
Item
Content
Fixed figure
Asia
Distribution channel
Japan channel
Destination
For Europe, left hand drive
Body style
5-door hatchback
Transmission type
5-speed manual transmission
Development order
CU
OUTLANDER
Engine
1,997 mL petrol engine
Soft
Station wagon
Model year
2003
10
Plant
Mizushima
11
Serial number
GENERAL
00-16
GENERAL DATA AND SPECIFICATIONS
ENGINE MODEL STAMPING
This engine model numbers is as shown as follow.

Engine model
Engine displacement
4G63
1,997 mL
The engine serial number is stamped near the

engine model number.
AC300905AC
The engine model is stamped on the cylinder block.
GENERAL DATA AND SPECIFICATIONS

M1001000900417
8
7
9
4
6
5
AC300072AB
Items
CU2W
XNMML6
Vehicle
dimensions mm
Front track
1,495
Overall width
1,750
Front overhang
945
Wheel base
2,625
Rear overhang
975
Overall length
4,545
Earth clearance (unladen)
195
Overall height (unladen)
1,620/1,670*
Rear track
1,505
Vehicle weight kg Kerb weight
1,435
1,535
Max. gross vehicle weight
1,970
2,070
Max. axle weight rating-front
1,050
Max. axle weight rating-rear
1,065
Max. trailer weight
With brake
1,500
Without brake
570
Max. trailer-nose weight

Seating capacity
XNMMZL6
75
5
XNHMZL6
GENERAL
00-17
PRECAUTIONS BEFORE SERVICE
Items
CU2W
XNMML6
Engine
Transmission
Fuel system
XNMMZL6
Model code
4G63
Total displacement mL
1,997
Model code
F5M42
Type
5-speed manual
Fuel supply system
MPI
XNHMZL6
W5M42
NOTE: *: Vehicles with roof rails

M1001000500389
SUPPLEMENTAL RESTRAINT SYSTEM

(SRS)
1. Items to review when servicing SRS:
1. Be sure to read GROUP 52B - Supplemental
Restraint System (SRS). For safe operation,
please follow the directions and heed all
warnings.
2. Wait at least 60 seconds after disconnecting
the battery cable before doing any further
work. The SRS system is designed to retain
enough voltage to deploy the air bag even
after the battery has been disconnected.
Serious injury may result from unintended air
bag deployment if work is done on the SRS
system immediately after the battery cable is
disconnected.
3. Warning labels must be heeded when
servicing or handling SRS components.
Warning labels can be found in the following
locations.
Front impact sensor
Hood
Sun visor
Glove box
SRS-ECU
Steering wheel
Clock spring
Steering joint cover
Air bag module (Drivers or front
passengers)
Side air bag module (Drivers side or front
passengers side)
Side impact sensor
Seat belt pre-tensioner
Instrument panel
4. Always use the designated special tools and
test equipment.
5. Store components removed from the SRS in
a clean and dry place. The air bag module
should be stored on a flat surface and placed
so that the pad surface is facing upward. Do
not place anything on top of it.
6. Never attempt to disassemble or repair the
SRS components (SRS-ECU, air bag module
and clock spring).
7. Whenever you finish servicing the SRS,
check the SRS warning lamp operation to
make sure that the system functions properly.
8. Be sure to deploy the air bag before disposing
of the air bag module or disposing of a vehicle
equipped with an air bag (Refer to GROUP
52B - Air Bag Module Disposal Procedures).
2. Observe the following when carrying out
operations on places where SRS components
are installed, including operations not directly
related to the SRS air bag.
1. When removing or installing parts, do not
allow any impact or shock to the SRS
components.
2. If heat damage may occur during paint work,
remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, the side
impact sensor, and the seat belt pretensioner.
SRS-ECU, air bag module, clock spring,
front impact sensor, the side impact
sensor: 93 C or more
Seat belt pre-tensioner: 90 C or more
GENERAL
00-18
SERVICING ELECTRICAL SYSTEM
VEHICLE WASHING
CAUTION
Before connecting or disconnecting the negative
(-) cable, be sure to turn off the ignition switch
and the lighting switch (If this is not done, there
is the possibility of semiconductor parts being
damaged).
Approximately 40 cm
AC300832AB
AC300693
Before replacing a component related to the

electrical system and before undertaking any repair
procedures involving the electrical system, be sure to
first disconnect the negative (-) cable from the
battery in order to avoid damage caused by shortcircuiting.
If high-pressure car-washing equipment or steam

car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to
avoid damage to plastic components, etc.
Spray nozzle distance: Approx. 40 cm or more
Spray pressure: 3,900 kPa or less
Spray temperature: 82C or less
Time of concentrated spray to one point: within
30 sec.
MUT-II
MUT-II Sub-assembly
APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats.
Rom pack
PRE-INSPECTION CONDITION
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine
inspection can be carried out. If you see the words
"Set the vehicle to the pre-inspection condition". In
this manual, it means to set the vehicle to the
following condition.
Engine coolant temperature 80 to 90C
Lamps, electric cooling fan and all accessories:
OFF
M/T: Neutral
AC300834AB
Refer to the "MUT-II REFERENCE MANUAL" or

"MUT-II OPERATING INSTRUCTIONS" for
instructions on handling the MUT-II.
CAUTION
16-pin
MUT-II
AC107200AG
Turn the ignition switch to the "LOCK" (OFF)

position before connecting or disconnecting the
MUT-II.
Connect the MUT-II to the diagnosis connector as
GENERAL
IN ORDER TO PREVENT VEHICLES

FROM FIRE
"Improper installation of electrical or fuel related
parts could cause a fire. In order to retain the high
quality and safety of the vehicle, it is important that
any accessories that may be fitted or modifications/
repairs that may be carried out which involve the
electrical or fuel systems, MUST be carried out in
accordance with MMCs information/Instructions".
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them.
Other precautions:
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
00-19
Wear protective clothing, including impervious

gloves where practicable.
Avoid contaminating clothes, particularly
underpants, with oil.
Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
Do not wear heavily soiled clothing and oilimpregnated foot-wear. Overalls must be cleaned
regularly and kept separately from personal
clothing.
Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
Obtain First Aid treatment immediately for open
cuts and wounds.
Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
If skin disorders develop, obtain medical advice
without delay.
GENERAL
00-20
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

M1001009800020
The Supplemental Restraint System (SRS) and seat

belt with pre-tensioner is designed to supplement the
drivers and front passengers seat belts to help
reduce the risk or severity of injury to the driver and
front passenger by activating and deploying both
front air bags in certain frontal collisions.
The SRS consist of four air bag modules, SRS air
bag control unit (SRS-ECU), two front impact
sensors, two side impact sensors, SRS warning
lamp, clock spring and seat belt pre-tensioner. Front
air bags are located in the centre of the steering
wheel and above the glove box. Side air bag are
located inside the front seatback assemblies. Each
air bag is made up of a folded air bag and an inflator
unit. The SRS-ECU under the front floor console
monitors the system and has a front air bag safing G-
sensor, front air bag analog G-sensor and a side air

bag safing G-sensor. The front impact sensor is
assembled outside the headlamp support panel to
monitor impact in case of front impact. The side
impact sensors inside the centre pillars monitor the
shock incurred by the sides of the vehicle. The
warning lamp on the instrument panel indicates the
operational status of the SRS. The clock spring is
installed in the steering column. The seat belt pretensioner is built into the drivers and passengers
front seat belt retractor.
Only authorized service personnel should do work on
or around the SRS components. Those service
personnel should read this manual carefully before
starting any such work.
SRS warning lamp
Seat belt with pre-tensioner
Driver's air bag

module
Passenger's (front)
air bag module
Side air bag module
Side impact sensor
Clock spring
SRS-ECU
Side impact sensor

Side air bag module
Front impact sensor
AC301343 AB
GENERAL
00-21
SRS SERVICE PRECAUTIONS

M1001006000047
DANGER
In order to avoid injury to yourself or others
from accidental deployment of the air bag
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION
CAUTION
SRS-ECU connector
Do not use any electrical test equipment on or

near SRS components, except those specified on
352B.
AC300634 AB
CAUTION
Never Attempt to Repair the Following
Components:
1. SRS air bag control unit (SRS-ECU)
2. Front impact sensor
3. Clock spring
4. Drivers and front passengers air bag
modules
5. Side air bag module
6. Side impact sensor
7. Seat belt with pre-tensioner
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE
procedures in this manual, starting at page 352B
.
SRS-ECU terminal No. Destination of harness
Do not attempt to repair the wiring harness

connectors of the SRS. If a defective wiring
harness is found, repair or replace it by referring
to the table below.
Remedy
1, 2
Instrument panel wiring harness

Front wiring harness (RH) Front
impact sensor (RH)
Correct or replace each wiring

harness.
3, 4

Front wiring harness (LH) Front
impact sensor (LH)

harness.

Earth
Correct or replace the instrument

panel wiring harness.

SRS warning lamp

9, 10

Air bag module (Front passengers
side)

11, 12

Clock spring Air bag module
(Drivers side)
Correct or replace instrument panel

wiring harness. Replace the clock
spring.
13

Junction block (fuse No.3)

16


00-22
GENERAL
SRS-ECU terminal No.
Destination of harness
Remedy
20

Diagnosis connector

21, 22
Floor wiring harness (RH) Side air Correct or replace the floor wiring
bag module (LH)
harness.
23, 24
bag module (RH)
harness.
27, 28
Floor wiring harness (RH) Seat

belt pre-tensioner (Front
passengers side)
Connect or replace the floor wiring

harness.
29, 30
Floor wiring harness (LH) Seat

belt pre-tensioner (drivers side)

harness.
34, 36
Floor wiring harness (LH) Side

impact sensor (LH)

harness.
40, 42
Floor wiring harness (RH) Side

impact sensor (RH)

harness.
GENERAL
CAUTION
DANGER
Insulating tape
Battery
Battery cable
00-23
SRS-Harness connector
AC300580AB
After disconnecting the battery cable, wait 60

seconds or more before proceeding with the
following work. In addition, insulate the
negative battery terminal with a tape. The
condenser inside the SRS-ECU is designed
to retain enough voltage to deploy the air
bag for a short time even after the battery
has been disconnected, so serious injury
may result from unintended air bag
deployment if work is done on the SRS
system immediately after the battery cables
are disconnected.
CAUTION
The SRS components and seat belt with pretensioner should not be subjected to heat, so
remove the SRS-ECU, drivers and front
passengers air bag modules, clock spring, side
air bag modules, and seat belt pre-tensioner
before drying or baking the vehicle after painting.
SRS-ECU, air bag modules, clock spring,
impact sensors: 93C or more
Seat belt with pre-tensioner 90C or more
CAUTION
Whenever you finish servicing the SRS, always
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.

(rear side)
AC300673AB
If checks are carried out by using the SRS-ECU

harness connector, observe the following
procedures: Insert the special tool (probe in the
harness set) MB991222 into connector from
harness side (rear side), and connect the tester
to this probe. If any tool than special tool is used,
damage to the harness and other components
will result. Never insert the probe directly to the
terminals from the front of the connector. The
terminals are plated to increase their
conductivity, so that if they are touched directly
by the probe, the plating may break, which will
cause drops in reliability.
GENERAL
00-24
SUPPORT LOCATIONS FOR LIFTING AND JACKING

M1001000700093
SUPPORT POSITIONS FOR A GARAGE JACK, AXLE STANDS, SINGLE-POST LIFT OR

DOUBLE-POST LIFT AND PLATE TYPE LIFT
CAUTION
Do not support the vehicles at locations other than specified supporting points. Doing so will cause
damage, etc.
GARAGE JACK
CAUTION
Never support any point other than the specified one, or that point will be deformed.
<2WD>
Rear suspension crossmember
<4WD>
Rear differential
AC300835
GENERAL
00-25
AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT
CAUTION
If rubber attachments with grooves that are too thick are used at the front support positions, the front
fender may become bent, so be sure to use rubber attachments with groove thicknesses of 18 mm or
less.
If attachments which are not high enough are used, they may damage areas such as the side step. Be
sure to use attachments which are high enough, or remove the side step if not using attachments.
AXLE STANDS
Bolts
Bolts
Rubber
Rubber
SINGLE-POST LIFT
OR DOUBLE-POST LIFT
Bolts
Bolts
AC300836AB
GENERAL
00-26
STANDARD PART/TIGHTENING-TORQUE TABLE
PLATE TYPE LIFT
CAUTION
To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift.
Support the side sill flange with a lift.
STANDARD PART/TIGHTENING-TORQUE TABLE

M1001001100362
Each torque value in the table is a standard value for

tightening under the following conditions.
1. Bolts, nuts and washers are all made of steel and
plated with zinc.
2. The threads and bearing surface of bolts and
nuts are all in dry condition.
The values in the table are not applicable:
1. If toothed washers are inserted.

2. If plastic parts are fastened.
3. If bolts are tightened to plastic or die-cast
inserted nuts.
4. If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque

Thread size
Torque Nm
Bolt nominal
diameter (mm)
Pitch
(mm)
Head mark "4"
Head mark "7"
Head mark "8"
M5
0.8
2.5 0.5
5.0 1.0
6.0 1.0
M6
1.0
5.0 1.0
9.0 2.0
10 2
M8
1.25
12 2
22 4
25 4
M10
1.25
24 4
44 10
53 7
M12
1.25
41 8
83 12
98 12
M14
1.5
73 12
140 20
155 25
M16
1.5
110 20
210 30
235 35
M18
1.5
165 25
300 40
340 50
M20
1.5
225 35
410 60
480 70
M22
1.5
300 40
555 85
645 95
M24
1.5
395 55
735 105
855 125
Flange bolt and nut tightening torque

Thread size
Torque Nm
Bolt nominal
diameter (mm)
Pitch
(mm)
Head mark "4"
Head mark "7"
Head mark "8"
M6
1.0
5.0 1.0
10 2
12 2
M8
1.25
13 2
24 4
27 5
M10
1.25
26 4
49 9
58 7
M10
1.5
24 4
45 8
55 10
M12
1.25
46 8
95 15
105 15
M12
1.75
43 8
83 12
98 12
NOTE: .
Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater
the bolt strength.
52B-1
GROUP 52B
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
00
11
12
13
14
15
16
17
CONTENTS
52B
SRS CONTROL UNIT (SRS-ECU) . . . 52B

REMOVAL AND INSTALLATION . . . . . . . . 52B
21
22
25
SERVICE PRECAUTIONS. . . . . . . . .
52B
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B
SPECIAL TOOLS. . . . . . . . . . . . . . . .
52B
AIR BAG MODULE(S) AND

CLOCK SPRING . . . . . . . . . . . . . . . . . 52B
27
TEST EQUIPMENTS . . . . . . . . . . . . .
52B
31
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B
52B
SIDE IMPACT SENSOR . . . . . . . . . . . 52B
SRS MAINTENANCE. . . . . . . . . . . . . 52B
WARNING/CAUTION LABELS . . . . . 52B

FRONT IMPACT SENSORS . . . . . . . 52B
32
33
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B
34
SEAT BELTS WITH

PRE-TENSIONER . . . . . . . . . . . . . . . . 52B
35
POST-COLLISION DIAGNOSIS . . . . 52B

INDIVIDUAL COMPONENT
SERVICE . . . . . . . . . . . . . . . . . . . . . . 52B
26
36
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B
37
AIR BAG MODULE AND

SEAT BELT PRE-TENSIONER
DISPOSAL PROCEDURES . . . . . . . . 52B
42
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 52B
51
52
54
WARNING
Carefully read and observe the information in the SERVICE PRECAUTIONS prior to any service.
For information concerning diagnosis or maintenance, always observe the procedures in the SRS Diagnosis or
the SRS Maintenance sections, respectively.
If any SRS components are removed or replaced in connection with any service procedures, be sure to follow the
procedures in the INDIVIDUAL COMPONENT SERVICE section for the comportments involved.
If you have any questions about the SRS, please contact your local distributor.
55
52B-2

GENERAL INFORMATION
GENERAL INFORMATION
M1524000100387
The Supplemental Restraint System (SRS) and seat

belt with pre-tensioner is designed to supplement the
drivers and front passengers seat belts to help
reduce the risk or severity of injury to the driver and
front passenger by activating and deploying both
front air bags in certain frontal collisions.
The SRS consist of four air bag modules, SRS air
bag control unit (SRS-ECU), two front impact
sensors, two side impact sensors, SRS warning
lamp, clock spring and seat belt pre-tensioner. Front
air bags are located in the centre of the steering
wheel and above the glove box. Each air bag is made
up of a folded air bag and an inflator unit. Side air
bags are located inside the front seatback
assemblies. The SRS-ECU under the front floor
console monitors the system and has a front air bag
safing G-sensor, front air bag analog G-sensor and a

side air bag safing G-sensor. The front impact sensor
is assembled outside the headlamp support panel to
monitor impact in case of front impact. The side
impact sensors inside the centre pillars monitor the
shock incurred by the sides of the vehicle. The
warning lamp on the instrument panel indicates the
operational status of the SRS. The clock spring is
installed in the steering column. The seat belt pretensioner is built into the drivers and passengers
front seat belt retractor.
Only authorized service personnel should do work
on or around the SRS components. Those service
personnel should read this manual carefully before
starting any such work.
SRS warning lamp
Driver's air bag

module
Passenger's (front)
air bag module
Side air bag module
Side impact sensor
Clock spring
SRS-ECU
Side impact sensor

Side air bag module
Front impact sensor
AC301343 AB

SERVICE PRECAUTIONS
52B-3
SERVICE PRECAUTIONS
M1524000300369
DANGER
In order to avoid injury to yourself or others
from accidental deployment of the air bag
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION
CAUTION
SRS-ECU connector
Do not use any electrical test equipment on or

near SRS components, except those specified on
352B.
AC300634 AB
CAUTION
Never Attempt to Repair the Following
Components:
1. SRS air bag control unit (SRS-ECU)
2. Front impact sensor
3. Clock spring
4. Drivers and front passengers air bag
modules
5. Side air bag module
6. Side impact sensor
7. Seat belt with pre-tensioner
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE
procedures in this manual, starting at page 352B
.
SRS-ECU terminal No. Destination of harness
Do not attempt to repair the wiring harness

connectors of the SRS. If a defective wiring
harness is found, repair or replace it by referring
to the table below.
Remedy
1, 2

Front wiring harness (RH) Front
impact sensor (RH)

harness.
3, 4

Front wiring harness (LH) Front
impact sensor (LH)

harness.

Earth


SRS warning lamp

9, 10

Air bag module (Front passengers
side)

11, 12

Clock spring Air bag module
(Drivers side)
Correct or replace instrument panel

wiring harness. Replace the clock
spring.
13


16


52B-4
SERVICE PRECAUTIONS
SRS-ECU terminal No.
Destination of harness
Remedy
20

Diagnosis connector

21, 22
bag module (LH)
harness.
23, 24
bag module (RH)
harness.
27, 28
Floor wiring harness (RH) Seat

belt pre-tensioner (Front
passenger's side)

harness.
29, 30
Floor wiring harness (LH) Seat

belt pre-tensioner (driver's side)

harness.
34, 36
Floor wiring harness (LH) Side

impact sensor (LH)

harness.
40, 42
Floor wiring harness (RH) Side

impact sensor (RH)

harness.
CAUTION
DANGER
Insulating tape
Battery
Battery cable
AC300580AB
After disconnecting the battery cable, wait 60

seconds or more before proceeding with the
following work. In addition, insulate the
negative battery terminal with a tape. The
condenser inside the SRS-ECU is designed
to retain enough voltage to deploy the air
bag for a short time even after the battery
has been disconnected, so serious injury
may result from unintended air bag
deployment if work is done on the SRS
system immediately after the battery cables
are disconnected.
The SRS components and seat belt with pretensioner should not be subjected to heat, so
remove the SRS-ECU, drivers and front
passengers air bag modules, clock spring, side
air bag modules, and seat belt pre-tensioner
before drying or baking the vehicle after painting.
SRS-ECU, air bag modules, clock spring,
impact sensors: 93C or more
CAUTION
Whenever you finish servicing the SRS, always
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.

SERVICE PRECAUTIONS
CAUTION
SRS-Harness connector

(rear side)
AC300673AB
If checks are carried out by using the SRS-ECU

harness connector, observe the following
procedures: Insert the special tool (probe in the
harness set) MB991222 into connector from
harness side (rear side), and connect the tester
to this probe. If any tool than special tool is used,
damage to the harness and other components
will result. Never insert the probe directly to the
terminals from the front of the connector. The
terminals are plated to increase their
conductivity, so that if they are touched directly
by the probe, the plating may break, which will
cause drops in reliability.
52B-5
52B-6
SPECIAL TOOLS
SPECIAL TOOLS
M1524000700356
Tool
No.
Name
Application
MB990784
Ornament remover
Removal of cover.
MB991502
MUT-II sub assembly
Reading and erasing

diagnosis code
Reading trouble period
Reading erase times
MB991865
Dummy resistor
SRS air bag and seat belt with

pre-tensioner circuit check
MB991866
Resistor harness
SRS air bag circuit check
MB991884
Resistor harness (For

Pre-tensioner)

circuit check
MB991885
Pre-tensioner adapter
harness
Deployment of seat belt with

pre-tensioner inside the
vehicle
Deployment of seat belt with
pre-tensioner outside the
vehicle
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Checking the continuity and

measuring the voltage at the
MB990784
B991502
MB991865
MB991866
MB991884
MB991885
D
MB991223AW
52B-7
TEST EQUIPMENTS
Tool
No.
Name
Application
MB686560
SRS air bag adapter

harness
Deployment of air bag module

(Front passengers side) inside
the vehicle
Deployment of air bag module
(Front passengers side)
outside the vehicle
MB686560
TEST EQUIPMENTS
M1524000800278
Tool
Name
Application
Digital multi-meter
Checking SRS electrical circuitry (Use

multi-meter for which the maximum test
current is 2 mA or less at minimum range
of resistance measurement
AC300683
TROUBLESHOOTING
M1524003100353

SRS WARNING LAMP CHECK

M1524004300297
SRS warning lamp
DIAGNOSIS FUNCTION
M1524003200349
DIAGNOSIS CODES CHECK

CAUTION
Turn off the ignition switch before connecting or
disconnecting the MUT-II.
Connect the MUT-II to the diagnosis connector (16pin) under the instrument under cover, then check
diagnosis codes (Refer to GROUP 00 - How to Use
Troubleshooting/Inspection Service Points 300).
ERASING DIAGNOSIS CODE

CAUTION
Turn off the ignition switch before connecting or
disconnecting the MUT-II.
Connect the MUT-II to the diagnosis connector and
erase the diagnosis code.
AC301667 AB
1. Check that the SRS warning lamp comes on when

the ignition switch is turned ON.
2. Check that the SRS warning lamp illuminates for
about 7 seconds and then goes out.
3. If this is not the cause, check the diagnosis codes.
52B-8

TROUBLESHOOTING
CHECK CHART FOR DIAGNOSIS CODES

M1524003300476
Inspect according to the inspection chart that is appropriate for the diagnosis code.
Code No.
Diagnosis item
Reference Page
11
Front impact sensor short-circuited
352B
12
One front impact sensor open-circuited
352B
13
Two front impact sensor open-circuited
352B
14
Analog G-sensor malfunction
352B
15
Safing G-sensor (for frontal collision) short-circuited
352B
16
Safing G-sensor (for frontal collision) open-circuited
352B
17
Safing G-sensor (for side collision) malfunction
352B
21*2
Drivers air bag module (squib) system (short-circuited

between terminals of the squib circuit)
352B
22*2
Drivers air bag module (squib) system (open-circuited in the 352B

squib circuit)
24*2
Passengers (front) air bag module (squib) system (shortcircuited between terminals of the squib circuit)
352B
25*2
Passengers (front) air bag module (squib) system (opencircuited in the squib circuit)
352B
26*2
Drivers pre-tensioner (squib) system (short-circuited

352B
27*2
Drivers seat belt pre-tensioner (squib) system (opencircuited in the squib circuit)
352B
28*2
Passengers (front) seat belt pre-tensioner (squib) system

(short-circuit between terminals of the squib circuit)
352B
29*2
Passengers (front) seat belt pre-tensioner (squib) system

(open-circuited in the squib circuit)
352B
31
SRS-ECU capacitor circuit voltage too high
352B
32
SRS-ECU capacitor circuit voltage too low
352B
34*1
SRS-ECU connector lock out of order
352B
35
Ignition of the air bag completed
352B
41*1
Power supply voltage (IG1 (A) voltage) drops abnormally.
352B
42*1
Power supply voltage (IG1 (B) voltage) drops abnormally.
352B
43*1
SRS warning lamp circuit

open-circuited
Lamp does not illuminate
352B
Lamp does not switch off
352B
44*1
SRS warning lamp circuit malfunction
352B
45
SRS-ECU non-volatile memory (EEPROM) and A/D

converter system
352B
51
Drivers air bag squib activating circuit short-circuited
352B
52
Drivers air bag squib activating circuit open-circuited
352B
54
Passengers (front) air bag squib activating circuit shortcircuited
352B
55
Passengers (front) air bag squib activating circuit opencircuited
352B
52B-9
TROUBLESHOOTING
Code No.
Diagnosis item
Reference Page
56
Drivers seat belt pre-tensioner (squib ignition drive circuit)

system detected short
352B
57
Drivers seat belt pre-tensioner (squib ignition drive circuit)

system detected open
352B
58
Passengers seat belt pre-tensioner (squib ignition drive

circuit) system detected short
352B
59
Passengers seat belt pre-tensioner (squib ignition drive

circuit) system detected open
352B
61
Driver's air bag module (squib) system (short-circuited to the 352B

power supply)
62
Driver's air bag module (squib) system (short-circuited to the 352B

earth)
64
Passenger's (front) air bag module (squib) system (shortcircuited to the power supply)
352B
65
Passenger's (front) air bag module (squib) system (shortcircuited to the earth)
352B
66
Driver's seat belt pre-tensioner (squib) system (shortcircuited to the power the supply)
352B
67
Driver's seat belt pre-tensioner (squib) system (shortcircuited to the earth)
352B
68
Passenger's (front) seat belt pre-tensioner (squib) system

(short-circuited to the power supply)
352B
69
Passenger's (front) seat belt pre-tensioner (squib) system

(short-circuited to the earth)
352B
71*2
Side air bag module (squib) (RH) system (short-circuited

352B
72*2
Side air bag module (squib) (RH) system (open-circuited in

the squib circuit)
352B
73
Side air bag squib (RH) drive circuit shorted
352B
74
Side air bag squib (RH) drive circuit open
352B
75
Side air bag module (squib) (RH) system (short-circuited to

the power supply)
352B
76
Side air bag module (squib) (RH) system (short-circuited to

the earth)
352B
79
Side impact sensor (LH) communication error
352B
81*2
Side air bag module (squib) (LH) system (short-circuited

352B
82*2
Side air bag module (squib) (LH) system (open-circuited in

the squib circuit)
352B
83
Side air bag squib (LH) drive circuit shorted
352B
84
Side air bag squib (LH) drive circuit open
352B
85
Side air bag module (squib) (LH) system (short-circuited to

the power supply)
352B
86
Side air bag module (squib) (LH) system (short-circuited to

the earth)
352B
52B-10

TROUBLESHOOTING
Code No.
Diagnosis item
Reference Page
89
Side impact sensor (RH) communication error
352B
91*1
Side impact sensor (LH) voltage error
352B
92
G-sensor of side impact sensor (LH) failure
352B
93
Side impact sensor (LH) communication impossible
352B
94*1
Side impact sensor (RH) voltage error
352B
95
G-sensor of side impact sensor (RH) failure
352B
96
Side impact sensor (RH) communication impossible
352B
NOTE: .
1. *1: If the vehicle condition returns to normal, the diagnosis code will be automatically erased, and the SRS
warning lamp will return to normal.
2. *2: However, if no diagnosis code resets, the SRS warning lamp will be switched off (The diagnosis code
will be retained).
3. If the vehicle has a discharged battery, it will store the diagnosis code 41 or 42. When these diagnosis
codes are read, check the battery.

PROCEDURES
Code No.11: Front impact sensor short-circuited

Code No.12: One front impact sensor open-circuited
Code No.13: Two front impact sensor open-circuited
Front Impact Sensor Circuit
SRS-ECU
MICROCOMPUTER
INTERFACE CIRCUIT
FRONT IMPACT
SENSOR (LH)
FRONT IMPACT
SENSOR (RH)
Wire colour code

G : Green L : Blue
AC301793AB

TROUBLESHOOTING
OPERATION
When the left and right front impact sensors
detect a collision, the switches inside the sensors
turns ON.
SRS-ECU judges how severe a collision is by
detecting signals from the front impact sensors
and the front air bag analog G-sensor. If the
impact is over a predetermined level, the SRSECU outputs an ignition signal. At this time, if the
front air bag safing G-sensor is on, the SRS air
bag will inflate.
52B-11
52B-12

TROUBLESHOOTING

These diagnosis codes are set if these is abnormal
resistance between the input terminals of the front
impact sensors.
The most likely causes for these codes to be set are
shown in the table below:
Code No.
Trouble causes
11
Short circuit in front impact sensor or harness

Short circuit in front impact sensor harness leading to the vehicle body
earth
Short circuit in front impact sensor harness leading to the power
supply
12
Open circuit in either left or right from impact sensor or harness

supply
13
Open circuit in both left and right front impact sensor or harness
supply
PROBABLE CAUSES
Malfunction of the front impact sensor
Damaged wiring harnesses or connectors
52B-13
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 2. Measure the resistance at SRS-ECU

connector C-115.
STEP 1. Check the front impact sensor.
Connector: C-115
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
(1) Disconnect SRS-ECU connector C-115 and

measure at the harness side (rear side).
CAUTION
C-115 Harness side
connector
(rear view)
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC201934
(1) Measure the resistance between terminals and

check whether it is within the standard value.
Standard value: 820 82 W
AC300941AB
Do not insert a test probe into the terminal from

its front side directly as the connector contact
pressure may be weakened.
terminal 4.
OK: 820 82 W
YES : Go to Step 4.
NO : Go to Step 3.
AC200633
(2) Check for continuity between the terminal and

bracket.
OK: No continuity
Q: Does the resistance meet the value above, and is
there no continuity?
YES : Go to Step 2.
NO : Replace front impact sensor. Refer to
352B.
52B-14
TROUBLESHOOTING
STEP 3. Connector check: SRS-ECU connector

C-115, front impact sensor (LH) connector A-17
and intermediate connector C-116

connector C-115.
Connector: C-115
Connector: C-115
SRS-ECU
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
Connector: A-17
Harness side
connector
(front view)
AC301661AC

measure at the harness side (rear side).
CAUTION
C-115 Harness side
connector
(rear view)
A-17 (Y)
Harness side
connector
(front view)
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
2 1
AC301613 AC
Connector: C-116
1 2
5 6 7
3 4
AC300942 AB

terminal 2.
OK: 820 82 W
8 9
1617 18 1920 21
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
AC301395 AG

YES : Check the harness wires for open or short
circuit between SRS-ECU connector C-115

(terminal No.3 and 4) and front impact
sensor (LH) connector A-17 (terminal No.1
and 2), and repair if necessary. Then go to
Step 6.
NO : Repair or replace it. Then go to Step 6.

check the diagnosis code. If diagnosis code

11, 12 or 13 sets, replace the SRS-ECU.
Refer to 352B. Then go to Step 6 .
NO : Go to Step 5.

TROUBLESHOOTING

C-115, front impact sensor (RH) connector A-28
and intermediate connector C-14
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
CONNECTOR: A-28
A-28 (Y)
Harness side
connector
(front view)
2 1
AC210453 AH
Connector: C-14
1 2
3 4
5 6 7 8 9 10
AC301397 AC


(terminal No.1 and 2) and front impact
sensor (RH) connector A-28 (terminal No.1
and 2), and repair if necessary. Then go to
Step 6.
52B-15
STEP 6. Recheck the diagnosis code.

Q: Is any of diagnosis code 11, 12 or 13 set?
YES : Return to Step 1.
NO : The procedure is complete (If no

to GROUP 00 - How to Use
300).
52B-16
TROUBLESHOOTING
Code No.14: Analog G-sensor malfunction

Code No.15: Safing G-sensor (for frontal collision) short-circuited
Code No.16: Safing G-sensor (for frontal collision) open-circuited
Code No.17: Safing G-sensor (for side collision) malfunction
Code No.31: SRS-ECU capacitor circuit voltage too high
Code No.32: SRS-ECU capacitor circuit voltage too low
Code No.45: SRS-ECU non-volatile memory (EEPROM) and A/D converter system
Code No.51: Drivers air bag squib activating circuit short-circuited
Code No.52: Drivers air bag squib activating circuit open-circuited
Code No.54: Passengers (front) air bag squib activating circuit short-circuited
Code No.55: Passengers (front) air bag squib activating circuit open-circuited
Code No.56: Drivers seat belt pre-tensioner (squib ignition drive circuit) system detected short
Code No.57: Drivers seat belt pre-tensioner (squib ignition drive circuit) system detected open
Code No.58: Passengers seat belt pre-tensioner (squib ignition drive circuit) system detected short
Code No.59: Passengers seat belt pre-tensioner (squib ignition drive circuit) system detected open
Code No.73: Side air bag squib (RH) drive circuit shorted
Code No.74: Side air bag squib (RH) drive circuit open
Code No.83: Side air bag squib (LH) drive circuit shorted
Code No.84: Side air bag squib (LH) drive circuit open
PROBABLE CAUSE
These diagnosis codes are set when a fault is
detected in the SRS-ECU. The most likely causes
for this code to be set are shown in the table
below:
Code No.
Part/Circuit integral to SRSTrouble causes
ECU
14
Analog G-sensor
When the analog G-sensor is not operating

When the characteristics of the analog G-sensor are
abnormal
When the output from the analog G-sensor is
abnormal
15
Safing G-sensor (for frontal

collision)
Short circuit in the safing G-sensor
16
Open circuit in the safing G-sensor
17
Safing G-sensor (for side

collision)
When the safing G-sensor is not operating

When the characteristics of the safing G-sensor are
abnormal
When the output from the safing G-sensor is abnormal
31
Capacitor circuit
Voltage at the capacitor terminal is higher than the

specified value for five seconds or more
32
Voltage at the capacitor terminal is lower than the

specified value for five seconds or more (This is not
detected if diagnosis code No.41 or 42 indicating
battery positive voltage drop has been output).
45
Non-volatile memory (EEPROM)

and A/D converter
When the non-volatile memory (EEPROM) and A/D

converter system are abnormal
51
Drivers air bag module (squib

ignition drive circuit)
Short circuit in the squib ignition drive circuit
Front passengers air bag module

(squib ignition drive circuit)
52
54
55
Open circuit in the squib ignition drive circuit


TROUBLESHOOTING
52B-17
Code No.
Part/Circuit integral to SRSECU
Trouble causes
56
Drivers seat belt pre-tensioner

(squib ignition drive circuit)
Passengers seat belt pretensioner (squib ignition drive

circuit)
Side air bag module (RH) (squib

Side air bag module (LH) (squib

57
58
59
73
74
83
84
DIAGNOSIS PROCEDURE
Replace the SRS-ECU (Refer to 352B).


52B-18
TROUBLESHOOTING
Code No.21: Drivers air bag module (squib) system (short-circuited between terminals of the squib
circuit)
Driver's Air Bag Module (Squib) Circuit

SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
CLOCK
SPRING
AIR BAG MODULE

(SQUIB)
(DRIVER'S SIDE)
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
Wire colour code

OPERATION
The SRS-ECU judges how severe a collision is
by detecting signals from the front impact sensors
bag will inflate.
The ignition signal is input to the air bag module
via the clock spring to inflate the air bag.
SB : Sky blue
AC301790 AB

This diagnosis code is set if one drivers air bag
squib wire shorted to the other. However, if no
diagnosis code resets, the SRS warning lamp will be
switched off (diagnosis code will be retained).
PROBABLE CAUSES
Improper engaged connector or defective short
spring*
Short circuit in the clock spring
Short circuit between the drivers air bag module
(squib) circuit terminals
Damaged connector(s)
52B-19
TROUBLESHOOTING
NOTE: *: The squib circuit connectors integrate a

"short" spring (which prevents the air bag from
deploying unintentionally due to static electricity by
shorting the positive wire to the earth wire in the
squib circuit when the connectors are disconnected).
Therefore, if connector C-115, C-307 or C-306 is
damaged or improperly engaged, the short spring
may not be released when the connector is
connected.

C-115, clock spring connector C-307 and drivers
air bag module connector C-306
(1) Disconnect the negative battery terminal.
Connector: C-115
SRS-ECU
Center lower
panel
DIAGNOSIS PROCEDURE
C-115 (Y)
STEP 1. Using MUT-II, read the diagnosis code.
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
CAUTION
(2) Check if the diagnosis code is set.
(3) Turn the ignition switch to the "LOOK" (OFF)
position.
Harness side
connector
(front view)
AC301661AC

Clock spring
C-307 (Y)
Harness side
connector
(front view)
C-306
2
Q: Is diagnosis code 34 set?

YES : Go to Step 2.
NO : Go to Step 3.
C-307
C-306
4 3 2 1
AC301399 AH

C-115
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
Q: Is the connector correctly engaged?

YES : Go to Step 3.
NO : Engage the connector correctly. Then go to
Step 7.
(2) Disconnect connectors C-115, C-307 and C-306,

and then reconnect them.
(3) Connect the negative battery terminal.
(4) Erase the diagnosis code memory, and check the
diagnosis code.
YES : Go to Step 4.
NO : The procedure is complete. It is assumed
that diagnosis code 21 set as connector C115, C-307 or C-306 was engaged
improperly.
52B-20
TROUBLESHOOTING
STEP 4. Check the drivers air bag module.

STEP 5. Check the clock spring.

MB991865 (Dummy
resistor : 3 )
C-306 Air bag

module connector
MB991866
(Resistor harness)
A
1 2 3 4
Steering wheel
(Rear view)
AC300156AB
(2) By sliding the A section (in the figure) of air bag

module connector C-306 in the arrow direction,
MB991865
(Dummy resistor : 3)
MB991866
(Resistor harness)
C-306 Air bag

module
connector
AC300945AB
(3) Connect special tool dummy resistor (MB991865)

to special tool resistor harness (MB991866).
CAUTION
(4) Insert special tool (MB991866) into clock spring
side air bag module connector C-306 by
backprobing.
diagnosis code.
YES : Go to Step 5.
NO : Replace the drivers air bag module (Refer
to 352B). Then go to Step 7.
C-307 Clock spring

connector
AC300949AB
(2) Disconnect the clock spring connector C-307.

CAUTION
harness side connector C-307 (terminal No.3 and
4) by backprobing.
diagnosis code.
YES : Go to Step 6.
NO : Replace the clock spring (Refer to 352B
). Then go to Step 7.
52B-21
TROUBLESHOOTING
STEP 6. Measure the resistance at the SRS-ECU

connector C-115.
Connector: C-115
C-115 Harness side

connector (rear view)
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
(1) Disconnect SRS-ECU connector C-115.
DANGER
Connector: C-307
Clock spring
C-307 (Y)
Harness side
connector
(front view)
AC301399 AF
To prevents the air bag from deploying

unintentionally, disconnect the clock spring
connector C-307 to short the squib circuit.
CAUTION
(front view)
Terminal
Cable tie
A
A
4 mm or more
AC300953 AB

(4) Measure the resistance between C-115 harness
side connector terminals 11 and 12.
OK: Open circuit
4 3 2 1
Section
A-A
CAUTION
Short spring
AC300951 AB
Insert an insulator such as a cable tie to a depth

of 4 mm or more, otherwise the short spring will
not be released.
(3) Insert a cable tie [3 mm wide, 0.5 mm thick]
between terminals 11, 12 and the short bar to
release the short spring.

21 sets, replace the SRS-ECU (Refer to
352B). Then go to Step 7 .
NO : Repair the harness wires between SRSECU connector C-115 (terminal No.11 and
12) and clock spring connector C-307
(terminal No.3 and 4). Then go to Step 7.

300).
52B-22
TROUBLESHOOTING
Code No.22: Drivers air bag module (squib) system (open-circuited in the squib circuit)

SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
CLOCK
SPRING
AIR BAG MODULE

(SQUIB)
(DRIVER'S SIDE)
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
Wire colour code

OPERATION
bag will inflate.
This diagnosis code is set if drivers air bag squib
wire(s) are open-circuited. However, if no diagnosis
code resets, the SRS warning lamp will be switched
off (diagnosis code will be retained).
SB : Sky blue
AC301790 AB
PROBABLE CAUSES
Open circuit in the clock spring
Open circuit due to improper neutral position of
the clock spring
Open circuit in the driver's air bag module (squib)
circuit
Disengaged driver's air bag module (squib)
connector
Improper connector contact
52B-23
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

MB991865 (Dummy
resistor : 3 )
MB991866
(Resistor harness)
C-306 Air bag

module connector
1 2 3 4
(Rear view)
Steering wheel
AC300156AB

module connector C-306 in the arrow direction,
MB991865
MB991866
(Resistor harness)
C-306 Air bag

module
connector
AC300945AB

CAUTION
backprobing.
diagnosis code.
YES : Go to Step 2.
C-307 Clock spring

connector
AC300949AB

CAUTION
4) by backprobing.
diagnosis code.
YES : Go to Step 3.
52B-24
TROUBLESHOOTING
STEP 3. Measure the resistance between the

SRS-ECU connector C-115 (terminal No.11 and
12) and the clock spring connector C-307
(terminal No.3 and 4).
Connector: C-115
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
Connector: C-307
Clock spring
C-307 (Y)
Harness side
connector
(front view)
4 3 2 1
AC301399 AF
(1) Disconnect SRS-ECU connector C-115 and clock

spring connector C-307.
CAUTION
C-115 Harness
side connector
(rear view)
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
C-307 Harness
side connector
(rear view)
1 2 3 4
AC300955 AB

(2) Measure the resistance between the following

terminals.
SRS-ECU connector C-115 terminal No.11
and the clock spring connector C-307 terminal
No.3
and the clock spring connector C-307 terminal
No.4
OK: Less than 2 W


300).
52B-25
TROUBLESHOOTING
Code No.24: Passengers (front) air bag module (squib) system (short-circuited between terminals of
the squib circuit)
Passenger's (Front) Air Bag Module (Squib) Circuit
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
AIR BAG MODULE

(SQUIB)
(PASSENGER'S
SIDE)
OPERATION
bag will inflate.
This diagnosis code is set if one passengers (front)
air bag squib wire shorted to the other. However, if no
PROBABLE CAUSES
spring*
Short circuit between the passenger's air bag
module (squib) circuit terminals
Wire colour code

G : Green L : Blue
AC301794 AB

squib circuit when the connectors are
disconnected).Therefore, if connector C-115 or C-09
is damaged or improperly engaged, the short spring
may not be released when the connector is
connected.
DIAGNOSIS PROCEDURE
CAUTION
position.
YES : Go to Step 2.
NO : Go to Step 3.
52B-26
TROUBLESHOOTING

C-115
Connector: C-115
STEP 4. Check the passenger's air bag module.

Connector: C-09
SRS-ECU
Glove box striker
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
Harness side
connector (front view)
C-09 (R)
2 1
AC301661AC

YES : Go to Step 3.
AC301718 AC
(2) Unclip passengers air bag module connector C09.

MB991865 (Dummy
resistor : 3 )
Step 6.
C-115 and passengers air bag module connector
C-09
C-09 Harness side

connector
MB991866
(Resistor harness)
Connector: C-115
C-09 Passenger's
air bag module connector
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
Connector: C-09
Glove box striker
Harness side
C-09 (R)
2 1
AC301718 AC
(2) Disconnect connectors C-115 and C-09, and then

reconnect them.
diagnosis code.
YES : Go to Step 4.
that diagnosis code 24 set as connector C115 or C-09 was engaged improperly.
AC300956AB

CAUTION
(4) Disconnect the passenger's air bag module
connector C-09 and insert special tool
(MB991866) into the harness side connector by
backprobing.
diagnosis code.
YES : Go to Step 5.
NO : Replace the passenger's air bag module
(Refer to 352B). Then go to Step 6.
52B-27
TROUBLESHOOTING

connector C-115.
C-115 Harness side

connector
(rear view)
Connector: C-115
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
CAUTION
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC

Connector: C-09
Glove box striker
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC300971AB

OK: Open circuit
Harness side
C-09 (R)
2 1
AC301718 AC
DANGER
unintentionally, disconnect the passengers
air bag module connector C-09 to short the
squib circuit.
(3) Disconnect the passengers air bag module
connector C-09.
CAUTION
C-115 Harness side
Terminal
Section
A-A
Cable tie
A
A
4 mm or more
Short spring
AC300958AB

of 4 mm or more, otherwise the short spring will
not be released.
between terminals 9, 10 and the short spring to

10) and passengers air bag module
connector C-09 (terminal No.1 and 2). Then
go to Step 6.
NO : The procedure is complete. (If no

300).
52B-28
TROUBLESHOOTING
Code No.25: Passengers (front) air bag module (squib) system (open-circuited in the squib circuit)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
AIR BAG MODULE

(SQUIB)
(PASSENGER'S
SIDE)
OPERATION
bag will inflate.
Wire colour code

G : Green L : Blue
AC301794 AB

This diagnosis code is set if passengers (front) air
bag squib wire(s) are open-circuited. However, if no
PROBABLE CAUSES
Open circuit in the passenger's air bag module
(squib) circuit

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Check the passengers air bag module.
Connector: C-09
Glove box striker
C-09 (R)
AC301718 AB

MB991865 (Dummy
resistor : 3 )
C-09 Harness side
connector
MB991866
(Resistor harness)
C-09 Passenger's
AC300956AB

CAUTION
connector C-09, and insert special tool
backprobing.
diagnosis code.
YES : Go to Step 2.
52B-29
52B-30
TROUBLESHOOTING
STEP 2. Measure the resistance between SRSECU connector C-115 (terminal No.9 and 10) and
the passengers air bag module connector C-09
Connector: C-09
Glove box striker
Harness side
C-09 (R)
2 1
AC301718 AC

Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
2 1
4 3
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC

passenger's air bag module connector C-09.
CAUTION
C-09 Harness side
C-115 Harness side
1 2
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC300973 AB

terminals.
SRS-ECU connector C-115 terminal No.9 and
the passengers air bag module connector C09 terminal No.1
and the passengers air bag module
connector C-09 terminal No.2
OK: Less than 2 W


go to Step 3.

300).
52B-31
TROUBLESHOOTING
Code No.26: Drivers pre-tensioner (squib) system (short-circuited between terminals of the squib
circuit)
Driver's Seat Belt Pre-Tensioner (Squib)

SRS-ECU
MICROCOMPUTER
AIR BAG
DRIVE CIRCUIT
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
CONNECTOR
LOCK
SWITCH
SEAT BELT
PRETENSIONER
(LH)
CONNECTOR
LOCK
SWITCH
Wire colour code

SB : Sky blue
AC301789AB
OPERATION
The SRS-ECU judges how severe a collision is by
detecting signals from the front impact sensors and
the front air bag analog G-sensor. If the impact is
over a predetermined level, the SRS-ECU outputs an
ignition signal. At this time, if the front air bag safing
G-sensor is on, the pre-tensioner will deploy.
This diagnosis code is set if one drivers pretensioner squib wire shorted to the other.
PROBABLE CAUSES
spring*
Short circuit between the driver's seat belt pretensioner (squib) circuit terminals
Therefore, if connector C-114 or D-29 is damaged or
improperly engaged, the short spring may not be
released when the connector is connected.
52B-32
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
CAUTION
position.

C-114 and drivers seat belt pre-tensioner
connector D-29
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34

YES : Go to Step 2.
NO : Go to Step 3.
AC301661AE

C-114
Connector: D-29
Connector: C-114
Harness side
connector
(front view)
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
2 1
AC301410 AI
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
D-29 Driver's seat

belt pre-tensioner
connector
AC301661AE

YES : Go to Step 3.
Flat-tip screw
driver
Locking button
Step 7.
D-29 Harness side connector
AC300147AE
(2) Disconnect connectors C-114 and D-29, and then

reconnect them. For connector D-29, use a flattipped screwdriver to pull out the locking button at
the harness side connector, and then disconnect
the connector.
(3) Connector the negative battery terminal.
diagnosis code.
YES : Go to Step 4.
that diagnosis code 26 set as connector C114 or D-29 was engaged improperly.

TROUBLESHOOTING
STEP 4. Check the drivers seat belt pretensioner.

Connector: D-29
Harness side
connector
(front view)
2 1
AC301410 AI
D-29 Driver's seat

belt pre-tensioner
connector
Flat-tip screw
driver
Locking button

AC300147AE
(2) Disconnect drivers seat belt pre-tensioner

connector D-29. Use a flat-tipped screwdriver to
pull out the locking button at the harness side
connector, and then disconnect the connector.
MB991884
MB991865 MB991885
(Dummy resistor : 3 )
MB991884
(Resistor
harness)
AC300975AD

(4) Connect special tool (MB991884) to the D-29
harness side connector.
(6) Erase diagnosis code memory, and then check
the diagnosis code.
YES : Go to Step 5.
NO : Replace the drivers seat belt pre-tensioner
52B-33
52B-34
TROUBLESHOOTING

connector C-114.
CAUTION
(front view)
Terminal
Connector: C-114
SRS-ECU
Section
A-A
Center lower
panel
C-114 (Y)
Cable tie
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
DANGER
Connector: D-29
4 mm or more
Short spring
AC300977AB

of 4mm or more, otherwise the short bar will not
be released.
CAUTION
Harness side
connector
(front view)
C-114 Connector
harness side (rear view)
2 1
AC301410 AI

unintentionally, disconnect the drivers seat
belt pre-tensioner connector D-29 to short
the squib circuit.
D-29 Driver's seat
belt pre-tensioner
connector
Flat-tip screw
driver
Locking button
21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC300985AB

OK: Open circuit

AC300147AE


NO : Go to Step 6.

TROUBLESHOOTING

C-114, drivers seat belt pre-tensioner connector
D-29 and intermediate connector D-31
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Connector: D-29
Foward
Harness side
connector
(front view)
D-29 (B)
2 1
AC301767 AC
Connector: D-31
1 2
3 4
5 6 7 8 9 10
1112 13 14 15 16
AC301408 AE

YES : Check the harness wires for short circuit
between SRS-ECU connector C-114

(terminal No.29 and 30) and drivers seat
belt pre-tensioner connector D-29 (terminal
No.1 and 2), and repair if necessary. Then
go to Step 7.
52B-35


300).
52B-36

TROUBLESHOOTING
Code No.27: Drivers seat belt pre-tensioner (squib) system (open-circuited in the squib circuit)

SRS-ECU
MICROCOMPUTER
AIR BAG
DRIVE CIRCUIT
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
CONNECTOR
LOCK
SWITCH
SEAT BELT
PRETENSIONER
(LH)
CONNECTOR
LOCK
SWITCH
Wire colour code

SB : Sky blue
AC301789AB
OPERATION

This diagnosis code is set if drivers seat belt pretensioner squib wire(s) are open-circuited.
PROBABLE CAUSES
Open circuit in the drivers seat belt pre-tensioner
(squib) circuit

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-29
Harness side
connector
(front view)
2 1
AC301410 AI
D-29 Driver's seat

belt pre-tensioner
connector
Flat-tip screw
driver
Locking button

AC300147AE

MB991884
MB991865 MB991885
MB991884
(Resistor
harness)
AC300975AD

the diagnosis code.
YES : Go to Step 2.
52B-37
52B-38
TROUBLESHOOTING
STEP 2. Measure the resistance between SRSECU connector C-114 (terminal No.29 and 30)
and the drivers seat belt pre-tensioner D-29
MB991884
Connector: C-114
SRS-ECU
D-29
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
Harness side
connector
AC201287AJ
(2) Connect D-29 harness side connector to special

tool resistor harness (MB991884).
CAUTION
AC301661AE
C-114 Harness
side connector
(rear view)
Connector: D-29
21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
Harness side
connector
(front view)
Special tool
MB991884
1
2
2 1
AC300989AB
AC301410 AI
D-29 Driver's seat

belt pre-tensioner
connector
Flat-tip screw
driver
Locking button

AC300147AE

drivers seat belt pre-tensioner connector D-29,
and measure at the wiring harness side. For
connector D-29, use a flat-tipped screwdriver to

terminals.
and special tool terminal No.1
and special tool terminal No.2
OK: Less than 2 W

diagnosis code 27 sets, replace the SRSECU (Refer to 352B). Then go to Step
4.
NO : Go to Step 3.

TROUBLESHOOTING

D-29 and intermediate connector D-31
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Connector: D-29
Foward
Harness side
connector
(front view)
D-29 (B)
2 1
AC301767 AC
Connector: D-31
1 2
3 4
5 6 7 8 9 10
1112 13 14 15 16
AC301408 AE

YES : Check the harness wires for open circuit

(terminal No.29 and 30) and drivers seat
belt pre-tensioner connector D-29 (terminal
No.1 and 2), and repair if necessary. Then
go to Step 4.
52B-39


300).
52B-40
TROUBLESHOOTING
Code No.28: Passengers (front) seat belt pre-tensioner (squib) system (short-circuit between
terminals of the squib circuit)
Passenger's (Front) Seat Belt Pre-tensioner (Squib)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SEAT BELT
PRE-TENSIONER
(RH)
OPERATION
This diagnosis code is set if one passengers seat
belt pre-tensioner squib wire shorted to the other.
PROBABLE CAUSES
spring*
Short circuit between the passenger's seat belt
pre-tensioner (squib) circuit terminals
Wire colour code

G : Green L : Blue
AC301795 AB

DIAGNOSIS PROCEDURE
CAUTION
position.
YES : Go to Step 2.
NO : Go to Step 3.
52B-41
TROUBLESHOOTING

C-114
Connector: C-114
SRS-ECU

C-114 and passengers seat belt pre-tensioner
connector D-43
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
C-114 (Y)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Q: Is connector correctly engaged?

YES : Go to Step 3.
Harness side
connector
(front view)
Center lower
panel
AC301661AE
Connector: D-43
Step 6.
Harness side
connector
(front view)
2 1
AC301408AI
D-43 Passenger's
seat belt
pre-tensioner
connector
Flat-tip screw
driver
Locking button
AC300147AF

reconnect them. For connector D-43, use a flattipped screwdriver to pull out the locking button at
the harness side connector, and then disconnect
the connector.
(3) Connector the negative battery terminal.
diagnosis code.
YES : Go to Step 4.
52B-42
TROUBLESHOOTING
STEP 4. Check the passengers seat belt pretensioner.

Connector: D-43
Harness side
connector
(front view)
2 1
AC301408AI
D-43 Passenger's
seat belt
pre-tensioner
connector
Flat-tip screw
driver
Locking button
AC300147AF
(2) Disconnect passengers seat belt pre-tensioner

MB991865 MB991884
MB991885
MB991884
(Resistor
harness)
AC300975AE

the diagnosis code.
YES : Go to Step 5.
NO : Replace the passengers seat belt pre-
tensioner (Refer to 352B). Then go to

Step 6.
52B-43
TROUBLESHOOTING

connector C-114.
CAUTION
C-114 Harness side
Connector: C-114
SRS-ECU
Terminal
Cable tie
Harness side
connector
(front view)
Center lower
panel
C-114 (Y)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
DANGER
Connector: D-43
Section
A-A
Short bar
4 mm or more
AB
AC300994 AB

of 4 mm or more, otherwise the short bar will not
be released.
CAUTION
Harness side
connector
(front view)
C-114 Harness side

2 1
AC301408AI

unintentionally, disconnect the passengers
seat belt pre-tensioner connector D-43 to
short the squib circuit.
D-43 Passenger's
seat belt
pre-tensioner
connector
Flat-tip screw
driver
Locking button
21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC300996AB

OK: Open circuit.
AC300147AF

check diagnosis code. If diagnosis code 28

sets, replace the SRS-ECU (Refer to 352B
). Then go to Step 6 .
28) and passengers seat belt pre-tensioner
connector D-43 (terminal No.1 and 2). Then
go to Step 6.
52B-44
TROUBLESHOOTING
STEP 6. Recheck for diagnosis code.


300).
Code No.29: Passengers (front) seat belt pre-tensioner (squib) system (open-circuited in the squib
circuit)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SEAT BELT
PRE-TENSIONER
(RH)
OPERATION
Wire colour code

G : Green L : Blue
AC301795 AB

This diagnosis code is set if the passengers seat belt
pre-tensioner squib wire(s) are open-circuited.
PROBABLE CAUSES
Open circuit in the passengers seat belt pretensioner (squib) circuit

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-43
Harness side
connector
(front view)
2 1
AC301408AI
D-43 Passenger's
seat belt
pre-tensioner
connector
Flat-tip screw
driver
Locking button
AC300147AF

MB991865 MB991884
MB991885
MB991884
(Resistor
harness)
AC300975AE

the diagnosis code.
YES : Go to Step 2.

Step 3.
52B-45
52B-46
TROUBLESHOOTING
and the passengers seat belt pre-tensioner
connector D-43 (terminal No.1 and 2).
Connector: C-114
Harness side
connector
(front view)
C-114 (Y)
C-114 Harness
side connector
(rear view)
21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
SRS-ECU
Center lower
panel
CAUTION
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Connector: D-43
Harness side
connector
(front view)
Special tool
MB991884
1
2
AC300997AB

terminals.
and the special tool terminal No.2
and the special tool terminal No.1
OK: Less than 2 W
2 1
AC301408AI
D-43 Passenger's
seat belt
pre-tensioner
connector
Flat-tip screw
driver
Locking button

28) passengers seat belt pre-tensioner
go to Step 3.
STEP 3.Recheck the diagnosis code.
AC300147AF

passengers seat belt pre-tensioner connector D43. For connector D-43, use a flat-tipped
screwdriver to pull out the locking button at the
harness side connector, and then disconnect the
connector.
MB991884
D-43
Harness side
connector
AC201287AK
(2) Connect D-43 harness side connector to special

tool resistor harness (MB991884).


300).

TROUBLESHOOTING
52B-47
Code No.34: SRS-ECU connector lock out of order

This diagnosis code is set if a poor connection at the
SRS-ECU is detected. However, if the vehicle
condition returns to normal, diagnosis code number
34 will be automatically erased, and the SRS
warning lamp will go out.
PROBABLE CAUSES
Damaged connectors
DIAGNOSIS PROCEDURE
C-114 and C-115.
(1) Disconnect SRS-ECU connectors C-114 and C115.
SRS-ECU
Center lower
panel
C-115 (Y) C-114 (Y)
AC301661AF
SRS-ECU Harness side

Connector lock
switch terminal
AC301001AB
(2) Check the connector lock switch terminal inside

the harness side connector for improper contact
or deformation.
Q: Are the SRS-ECU connector C-114 and C-115 in
good condition?

NO : Repair or replace the SRS-ECU connector
C-114 and C-115. Then go to Step 2.


300).
52B-48

TROUBLESHOOTING
Code No.35: Ignition of the air bag completed

This diagnosis code is set after the air bag has
deployed. If this diagnosis code is set before the air
bag has deployed, the cause is probably a
malfunction inside the SRS-ECU.
PROBABLE CAUSE
DIAGNOSIS PROCEDURE
Replace the SRS-ECU. (Refer to 352B).
Check the diagnosis code.

TROUBLESHOOTING
52B-49
Code No.41: Power supply voltage (IG1 (A) voltage) drops abnormally.
IG1 Power Supply Circuit System (Fuse No.2 Circuit)

IGNITION
SWITCH (IG1)
SRS-ECU
POWER SOURCE
CIRCUIT
D.C.-D.C.
CONVERTER
BACK-UP
CAPACITOR
MICROCOMPUTER
WARNING LAMP
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
COMBINATION
METER
Wire colour code

G : Green L : Blue
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AC301798 AB
52B-50
TROUBLESHOOTING
OPERATION
The SRS-ECU is powered from the ignition
switch (IG1).
The SRS-ECU power is supplied from two
circuits. Even if one circuit is shut off, the air bag
can inflate.
This diagnosis code is set if the voltage between the
IG1 terminals (fuse No.2 circuit) and earth is lower
than a predetermined value for a continuous period
of 5 second or more. However, if the vehicle
warning lamp will switch off.
PROBABLE CAUSES
STEP 2. Measure the voltage at the SRS-ECU

connector C-115.
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC

CAUTION
DIAGNOSIS PROCEDURE
STEP 1. Check junction block fuse number 2.
C-115 Harness side

1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
Junction block
Fuse No.2
AC301002AB
AC201423AC
Q: Is the fuse burned out?

YES : Go to Step 4.
NO : Go to Step 2.

(5) Measure the voltage between C-115 harness
side connector terminal 16 and body earth.
OK: 9 V or more.

NO : Go to Step 3.
52B-51
TROUBLESHOOTING

C-115, ignition switch connector C-303, junction
block connector C-203 and C-205.
Connector: C-115
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
Connector: C-303
STEP 4. Check a burned-out fuse.

(1) Replace the fuse.
(2) Turn the ignition switch to the "ON" position, wait
for at least one minute and then turn the ignition
switch to the "LOCK" (OFF) position.
(3) Check the fuse.
Q: Is the fuse in good condition?
NO : Go to Step 5.
STEP 5. Measure the resistance at the junction

block connector C-205.
Connector: C-205
Clock spring
C-303
Harness side
connector
(front view)
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
3 2 1
6 5 4
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE
AC301399 AG

(1) Disconnect junction block connector C-205, and

CAUTION
C-203
C-205 Harness side

1 2 3 4 5 6 7 8 9 10 11121314
1516 171819 20 212223242526 2728
C-205
AC301014AB
Harness side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-203
2
1
6 5 4 3
AC210475 AR

YES : Check the harness wire for open circuit

(terminal No.16) and the ignition switch
connector C-303 (terminal No.2), and repair
if necessary. Then go to Step 10.

body earth.
OK: Open circuit
YES : Go to Step 6.
NO : Go to Step 8.
52B-52
TROUBLESHOOTING
STEP 6. Measure the resistance at junction block

connector C-205.
Connector: C-205
STEP 7. Connector check: junction block

connector C-205 and combination meter
connector C-04
Connector: C-205
Harness side
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE

CAUTION
AC210474 AE
Connector: C-04
C-04
C-205 Harness side

connector (rear view)Y1729AU
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Harness side
(front view)
15 16 17 18 19 20 21 22 23 24 25 26 27 28
AC301395 AK
AC301015AB

body earth.
OK: Open circuit
YES : Check the other circuit, which flows through
fuse number 2.
NO : Go to Step 7.

YES : Check the harness wire for short circuit
between junction block connector C-205

(terminal No.25) and combination meter
52B-53
TROUBLESHOOTING

connector C-115.

C-115 and junction block connector C-205
Connector: C-115
Connector: C-115
SRS-ECU
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AB
(1) Disconnect SRS-ECU connector C-115, and

AC301661AC
Connector: C-205
CAUTION
C-115 Harness side
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE
AC201665 AF

body earth.
OK: Open circuit

41 sets, replace the SRS-ECU. (Refer to
NO : Go to Step 9.


(terminal No.16) and junction block
connector C-205 (terminal No.24), and
repair if necessary. Then go to Step 10.

300).
52B-54
TROUBLESHOOTING
Code No.42: Power supply voltage (IG1 (B) voltage) drops abnormally.
IG1 Power Supply Circuit System (Fuse No.3 Circuit)

IGNITION
SWITCH (IG1)
SRS-ECU
POWER SOURCE
CIRCUIT
D.C.-D.C.
CONVERTER
BACK-UP
CAPACITOR
MICROCOMPUTER
WARNING LAMP
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
COMBINATION
METER
Wire colour code

G : Green L : Blue
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AC301798 AC
52B-55
TROUBLESHOOTING
OPERATION
switch (IG1).
can inflate.
This diagnosis code is set if the voltage between the
IG1 terminals (fuse No.3 circuit) and earth is lower
than a predetermined value for a continuous period
of 5 second or more. However, if the vehicle
warning lamp will switch off.
PROBABLE CAUSES
DIAGNOSIS PROCEDURE
STEP 2. Measure the voltage at SRS-ECU

connector C-115.
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC

CAUTION
C-115 Harness side
STEP 1. Check junction block fuse number 3.
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
Fuse No.3
AC301016 AB
Junction
block
Q: Is the fuse burned out?

YES : Go to Step 4.
NO : Go to Step 2.
AC201425AD

OK: 9 V or more
YES : Erase the diagnosis connector memory, and

352B). Then go to Step 8.
NO : Go to Step 3.
52B-56
TROUBLESHOOTING

C-115, ignition switch connector C-303, junction
block connector C-203 and C-205
Connector: C-115
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
Connector: C-303
STEP 4. Check a burned-out fuse.

(1) Replace the fuse.
(2) Turn the ignition switch to the "ON" position, wait
for at least one minute and then turn the ignition
switch to the "LOCK" (OFF) position.
(3) Check the fuse.
Q: Is the fuse in good condition?
YES : Go to Step 8.
NO : Go to Step 5.
STEP 5. Measure the resistance at the junction

block connector C-205.
Connector: C-205
Clock spring
C-303
Harness side
connector
(front view)
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
3 2 1
6 5 4
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE
AC301399 AG


CAUTION
C-205 Harness side
C-203
1 2 3 4 5 6 7 8 9 10 11121314
1516 171819 20 212223242526 2728
C-205
AC301017AB
Harness side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-203
2
1
6 5 4 3
AC210475 AR

body earth.
OK: Open circuit
YES : Check the other circuit, which flows through
fuse number 3.

(terminal No.13) and the ignition switch
NO : Go to Step 6.
52B-57
TROUBLESHOOTING

connector C-115.
Connector: C-115

C-115 and junction block connector C-205
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
SRS-ECU
Harness side
connector
(front view)
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC

AC301661AC
Connector: C-205
CAUTION
C-115 Harness side
1 2
3 4
5 6 7 8 9 10 11 12
Harness side
13 14 15 16 17 18 19 20
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE
AC202026 AH

body earth.
OK: Open circuit

42 sets, replace the SRS-ECU. (Refer to
NO : Go to Step 7.


(terminal No.13) and junction block

300).
52B-58
TROUBLESHOOTING
Code No.43: SRS warning lamp circuit open-circuited (Lamp does not Illuminate).
SRS Warning Lamp Drive Circuit
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONNECTOR
LOCK
SWITCH
SRS-ECU
WARNING LAMP
DRIVE CIRCUIT
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
Wire colour code

OPERATION
Power for the SRS warning lamp is supplied from
the ignition switch (IG1).
The SRS warning lamp illuminates when the
ignition switch is turned to the "ON" position and
goes out after approximately 7 seconds if there is
not a malfunction in the SRS system.
SB : Sky blue
AC301799AB

This diagnosis code is set when an open circuit is
detected for a continuous period of 5 seconds while
the SRS-ECU is monitoring the SRS warning lamp
and the lamp is OFF (transistor OFF). However, if the
vehicle condition returns to normal, diagnosis code
PROBABLE CAUSES
52B-59
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Check the SRS warning lamp.

connector C-115.
Connector: C-115
Connector: C-115
SRS-ECU
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
(2) Disconnected the SRS-ECU connector C-115.

Q: Does the warning lamp illuminate?

NO : Go to Step 2.
Harness side
connector
(front view)
AC301661AC
(2) Disconnected the SRS-ECU connector C-115.

CAUTION
C-115 Harness side
3 4
1 2
5 6 7 8 9 10 11 12
13 1415 16 17 18 19 20
AC201527 AG

side connector terminal 7 and earth.
OK: Less than 2 W
YES : Go to Step 3.
NO : Go to Step 4.
52B-60
TROUBLESHOOTING
STEP 3. Check the harness for open circuit

between ignition switch connector C-303
(terminal No.2) and combination meter C-04
(terminal No.42), and between combination meter
C-05 (terminal No.11) and SRS-ECU connector C115 (terminal No.8).
Connector: C-303

C-203
C-205
Clock spring
C-303
Harness side
connector
(front view)
3 2 1
6 5 4
Harness side
C-205
AC301399 AG
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-203
2
1
6 5 4 3

C-05(L)
C-04
AC210475 AR
NOTE: After inspecting intermediate connectors C05, C-04, C-205 and C-203 inspect the wiring
harness. If intermediate connectors C-05, C-04, C205 and C-203 are damaged, repair or replace them.
Then go to Step 5 .
YES : Replace the combination meter (Refer to
Harness side
C-05
C-04
41 4039 38 3736 35 3433 32 31
52 51 50 49 48 47 46 4544 43 42
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
AC301396 AH
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
GROUP 54A - Combination Meters

Assembly and Vehicle Speed Sensor
354A). Then go to Step 5 .
NO : Repair the harness wires between SRSECU connector C-115 (terminal No.8) and
the ignition switch connector C-303
(terminal No.2). Then go to Step 5.

TROUBLESHOOTING

C-115 and earth
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
Blower
assembly
AC208080AE

YES : Repair the harness wires between SRS-
ECU connector C-115 (terminal No.7) and

earth. Then go to Step 5.
52B-61


300).
52B-62
TROUBLESHOOTING
Code No.43: SRS warning lamp circuit open-circuited (Lamp does not Switch Off).
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONNECTOR
LOCK
SWITCH
SRS-ECU
WARNING LAMP
DRIVE CIRCUIT
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
Wire colour code

OPERATION
SB : Sky blue
AC301799AB

This diagnosis code is set when a short to earth
occurs in the harness between the SRS warning
lamp and SRS-ECU while SRS-ECU is monitoring
the lamp and the lamp is ON. However, if the vehicle
condition returns to normal, diagnosis code 43 will be
automatically erased, and the SRS warning lamp will
go out.
PROBABLE CAUSES
52B-63
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
C-115
Connector: C-115
Q: Does the SRS warning lamp go out?

YES : Go to Step 3.
NO : Replace the combination meter (Refer to
GROUP 54A - Combination Meters

Assembly and Vehicle Speed Sensor
354A). Then go to Step 4 .
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
STEP 3. Check the harness for short circuit to

earth between SRS-ECU connector C-115
(terminal No.8) and combination meter connector
C-05 (terminal No.11).
Connector: C-115
SRS-ECU
AC301661AC
(1) Disconnect SRS-ECU connectors C-115.

C-115 SRS-ECU Harness side
Terminal
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
Connector: C-05
C-05(L)
Short spring
AC302001AB
(2) Check the short spring for the warning lamp

inside the harness side connector for improper
contact or deformation.
YES : Then go to Step 2.
NO : Repair or replace the SRS-ECU connector
STEP 2. Check the SRS warning lamp.

(1) Disconnect the negative battery cable.
C-05(L)
Harness side
(front view)
AC301395 AE

NO : Repair the harness wire between SRS-ECU
connector C-115 (terminal No.8) and
combination meter connector C-05 (terminal
No.11). Then go to Step 4.
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 1514 13 12

C-115. Then go to Step 4.
Connector: C-05
Harness side
(front view)
AC301395 AE
(2) Disconnect the combination meter connector C05.

(3) Connect the negative battery cable.


300).
52B-64
TROUBLESHOOTING
Code No.44: SRS warning lamp circuit malfunction

IGNITION
SWITCH (IG1)
COMBINATION
METER
CONNECTOR
LOCK
SWITCH
SRS-ECU
WARNING LAMP
DRIVE CIRCUIT
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
Wire colour code

CIRCUIT OPERATION
This diagnosis code is set under one of the following
cases while the SRS-ECU is monitoring the warning
lamp drive circuit:
When a short circuit occurs in the warning
lamp drive circuit.
When a malfunction is detected in the output
transistor inside the SRS-ECU.
SB : Sky blue
AC301799AB
However, if the vehicle condition returns to normal,

diagnosis code 44 will be automatically erased, and
the SRS warning lamp will go out.
PROBABLE CAUSES
DIAGNOSIS PROCEDURE
Check the SRS warning lamp drive circuit system.
Refer to 352B.
52B-65
TROUBLESHOOTING
Code No.61: Drivers air bag module (squib) system (short-circuited to the power supply)

SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
CLOCK
SPRING
AIR BAG MODULE

(SQUIB)
(DRIVER'S SIDE)
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
Wire colour code

OPERATION
bag will inflate.
SB : Sky blue
AC301790 AB

This diagnosis code is set if the drivers air bag squib
wire(s) are short-circuited to the power supply.
However, if no diagnosis code resets, the SRS
warning lamp will be switched off (diagnosis code will
be retained).
PROBABLE CAUSES
Malfunction of the clock spring
Short to the power supply in the driver's air bag
module (squib) harness
52B-66
TROUBLESHOOTING
DIAGNOSIS PROCEDURE


MB991865 (Dummy
resistor : 3 )
MB991866
(Resistor harness)
C-306 Air bag

module connector
1 2 3 4
A
Steering wheel
AC300156AB

module connector C-306 in arrow direction,
MB991865
MB991866
(Resistor harness)
C-306 Air bag

module
connector
AC300945AB

CAUTION
backprobing.
diagnosis code.
Q: Is diagnosis code 61 out put?
YES : Go to Step 2.
(Rear view)
C-307 Clock spring

connector
AC300949AB

CAUTION
4) by backprobing.
diagnosis code.
YES : Go to Step 3.

TROUBLESHOOTING

connector C-115.
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC



300).
DANGER
Connector: C-307
Clock spring
C-307 (Y)
52B-67
Harness side
connector
(front view)
4 3 2 1
AC301399 AF

CAUTION
C-115 Harness side
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC301030AB

side connector terminals 11, 12 and body earth.
OK: 0 V
52B-68
TROUBLESHOOTING
Code No.62: Drivers air bag module (squib) system (short-circuited to the earth)

SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
CLOCK
SPRING
AIR BAG MODULE

(SQUIB)
(DRIVER'S SIDE)
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
Wire colour code

OPERATION
bag will inflate.
SB : Sky blue
AC301790 AB

This diagnosis code is set if the drivers air bag squib
wire(s) are short-circuited to the earth. However, if no
PROBABLE CAUSES
Malfunction of the clock spring
Short to the earth in the drivers air bag module
(squib) harness
52B-69
TROUBLESHOOTING
DIAGNOSIS PROCEDURE


MB991865 (Dummy
resistor : 3 )
MB991866
(Resistor harness)
C-306 Air bag

module connector
1 2 3 4
A
Steering wheel
AC300156AB

module connector C-306 in arrow direction,
CAUTION
MB991865
MB991866
(Resistor harness)
C-306 Air bag

module
connector
AC300945AB

backprobing.
diagnosis code.
YES : Go to Step 2.
(Rear view)
C-307 Clock spring

connector
AC300949AB

CAUTION
4) by backprobing.
diagnosis code.
YES : Go to Step 3.
52B-70
TROUBLESHOOTING
STEP 3. Check the drivers air bag module circuit

at the SRS-ECU connector C-115.
Connector: C-115
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC



300).
DANGER
Connector: C-307
Clock spring
C-307 (Y)
Harness side
connector
(front view)
4 3 2 1
AC301399 AF

CAUTION
C-115 Harness side connector (rear view)
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC301033AB

(3) Check for continuity between C-115 harness side
connector terminals 11, 12 and body earth.
OK: Open circuit
52B-71
TROUBLESHOOTING
Code No.64: Passengers (front) air bag module (squib) system (short-circuited to the power supply)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
AIR BAG MODULE

(SQUIB)
(PASSENGER'S
SIDE)
OPERATION
bag will inflate.
Wire colour code

G : Green L : Blue
AC301794 AB

This diagnosis code is set if the passengers (front)
air bag squib wire(s) are short-circuited to the power
supply. However, if no diagnosis code resets, the
SRS warning lamp will be switched off (diagnosis
code will be retained).
PROBABLE CAUSES
Short to the power supply in the passengers air
bag module (squib) harness
52B-72
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP1. Check the passengers air bag module.
Connector: C-09
Glove box striker
Harness side
C-09 (R)
2 1
AC301718 AC

MB991865 (Dummy
resistor : 3 )
C-09 Harness side
connector
MB991866
(Resistor harness)
C-09 Passenger's
AC300956AB

CAUTION
backprobing.
diagnosis code.
YES : Go to Step 2.

TROUBLESHOOTING

connector C-115.
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
CAUTION
52B-73


go to Step 3.

300).
Connector: C-09
Glove box striker
Harness side
C-09 (R)
2 1
AC301718 AC

unintentionally, disconnect the passengers air
bag module connector C-09 to short the squib
circuit.
(2) Disconnect the passengers air bag module
connector C-09.
CAUTION
C-115 Harness side
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC301034 AB

OK: 0 V
52B-74
TROUBLESHOOTING
Code No.65: Passengers (front) air bag module (squib) system (short-circuited to the earth)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
AIR BAG MODULE

(SQUIB)
(PASSENGER'S
SIDE)
OPERATION
bag will inflate.
Wire colour code

G : Green L : Blue
AC301794 AB

This diagnosis code is set if the passengers (front)
air bag squib wire(s) are short-circuited to the earth.
However, if no diagnosis code resets, the SRS
warning lamp will be switched off (diagnosis code will
be retained).
PROBABLE CAUSES
Short to the earth in the passengers air bag
module (squib) harness

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Check the passengers air bag module.
Connector: C-09
Glove box striker
Harness side
C-09 (R)
2 1
AC301718 AC

MB991865 (Dummy
resistor : 3 )
C-09 Harness side
connector
MB991866
(Resistor harness)
C-09 Passenger's
AC300956AB

CAUTION
backprobing.
diagnosis code.
YES : Go to Step 2.
52B-75
52B-76
TROUBLESHOOTING

connector C-115.
Connector: C-115
SRS-ECU
Center lower
panel
C-115 (Y)
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
CAUTION


10) and passenger's air bag module
go to Step 3.

300).
Connector: C-09
Glove box striker
Harness side
C-09 (R)
2 1
AC301718 AC

unintentionally, disconnect the passengers air
bag module connector C-09 to short the squib
circuit.
CAUTION
C-115 Harness side connector (rear view)
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC301035AB

OK: Open circuit
52B-77
TROUBLESHOOTING
Code No.66: Drivers seat belt pre-tensioner (squib) system (short-circuited to the power supply)

SRS-ECU
MICROCOMPUTER
AIR BAG
DRIVE CIRCUIT
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
CONNECTOR
LOCK
SWITCH
SEAT BELT
PRETENSIONER
(LH)
CONNECTOR
LOCK
SWITCH
Wire colour code

SB : Sky blue
AC301789AB
OPERATION

This diagnosis code is set if the drivers seat belt pretensioner wire(s) are short-circuited to the power
supply.
PROBABLE CAUSES
Short to the power supply in the drivers seat belt
pre-tensioner (squib) harness
52B-78
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector C-114.

Connector: C-114
SRS-ECU
Connector: D-29
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
2 1
AC301410 AI
D-29 Driver's seat

belt pre-tensioner
connector
Flat-tip screw
driver

CAUTION
Locking button
C-114 Harness side


AC300147AE

MB991884
MB991865 MB991885
MB991884
(Resistor
harness)
AC300975AD

(6) Erase diagnosis code memory, and check the
diagnosis code.
YES : Go to Step 2.
21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC301037AB

OK: 0 V
Q: Is the measured voltage within the specified
range?

NO : Go to Step 3.

TROUBLESHOOTING

D-29 and intermediate connector D-31.
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Connector: D-29
Foward
Harness side
connector
(front view)
D-29 (B)
2 1
AC301767 AC
Connector: D-31
1 2
3 4
5 6 7 8 9 10
1112 13 14 15 16
AC301408 AE

YES : Check the harness wires for short circuit to
power supply between SRS-ECU connector

C-114 (terminal No.1 and 2) and drivers
seat belt pre-tensioner connector D-29
(terminal No.29 and 30), and repair if
necessary. Then go to Step 4.
52B-79


300).
52B-80

TROUBLESHOOTING
Code No.67: Drivers seat belt pre-tensioner (squib) system (short-circuited to the earth)

SRS-ECU
MICROCOMPUTER
AIR BAG
DRIVE CIRCUIT
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
CONNECTOR
LOCK
SWITCH
SEAT BELT
PRETENSIONER
(LH)
CONNECTOR
LOCK
SWITCH
Wire colour code

SB : Sky blue
AC301789AB
OPERATION

This diagnosis code is set if the drivers seat belt pretensioner wire(s) are short-circuited to the earth.
PROBABLE CAUSES
Short to the earth in the drivers seat belt pretensioner (squib) harness

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-29
Harness side
connector
(front view)
2 1
AC301410 AI
D-29 Driver's seat

belt pre-tensioner
connector
Flat-tip screw
driver
Locking button

AC300147AE

MB991884
MB991865 MB991885
MB991884
(Resistor
harness)
AC300975AD

diagnosis code.
YES : Go to Step 2.
52B-81
52B-82
TROUBLESHOOTING

connector C-114.
Connector: C-114
CAUTION
C-114 Harness side
2122
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
SRS-ECU
Center lower
panel
C-114 (Y)
AC201666 AI
AC301661AD

Connector: D-29

OK: Open circuit
Harness side
connector
(front view)
2 1
AC301410 AI
D-29 Driver's seat

belt pre-tensioner
connector
Flat-tip screw
driver
Locking button

AC300147AE


NO : Go to Step 3.

TROUBLESHOOTING

D-29
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Connector: D-29
Foward
Harness side
connector
(front view)
D-29 (B)
2 1
AC301767 AC
Connector: D-31
1 2
3 4
5 6 7 8 9 10
1112 13 14 15 16
AC301408 AE

YES : Check the harness wires for short circuit to
the earth between SRS-ECU connector C114 (terminal No.29 and 30) and drivers
seat belt pre-tensioner connector D-29
(terminal No.1 and 2), and repair if
NO : Repair or replace it. Then go to Step 4 .
52B-83


300).
52B-84
TROUBLESHOOTING
Code No.68: Passengers (front) seat belt pre-tensioner (squib) system (short-circuited to the power
supply)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SEAT BELT
PRE-TENSIONER
(RH)
OPERATION
Wire colour code

G : Green L : Blue
AC301795 AB

This diagnosis code is set if passengers (front) seat
belt pre-tensioner wire(s) are short-circuited to the
power supply.
PROBABLE CAUSES
Short to the power supply in the passengers seat
belt pre-tensioner (squib) harness

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-43
Harness side
connector
(front view)
2 1
AC301408AI
D-43 Passenger's
seat belt
pre-tensioner
connector
Flat-tip screw
driver
Locking button
AC300147AF

MB991865 MB991884
MB991885
MB991884
(Resistor
harness)
AC300975AE

the diagnosis code.
YES : Go to Step 2.

Step 3.
52B-85
52B-86
TROUBLESHOOTING

connector C-114.
C-114 Harness side

Connector: C-114
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-114 (Y)
CAUTION
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE

Connector: D-43
21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC301038AB

OK: 0 V
Harness side
connector
(front view)
2 1
AC301408AI
D-43 Passenger's
seat belt
pre-tensioner
connector
Flat-tip screw
driver

go to Step 3.
Locking button

AC300147AF

(3) Turn the ignition switch to the "ON" position,

300).
52B-87
TROUBLESHOOTING
Code No.69: Passengers (front) seat belt pre-tensioner (squib) system (short-circuited to the earth)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SEAT BELT
PRE-TENSIONER
(RH)
OPERATION
Wire colour code

G : Green L : Blue
AC301795 AB

This diagnosis code is set if passengers (front) seat
belt pre-tensioner wire(s) are short-circuited to the
earth.
PROBABLE CAUSES
Short to the earth in the passengers seat belt
pre-tensioner (squib) harness
52B-88
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-43
Harness side
connector
(front view)
2 1
AC301408AI
D-43 Passenger's
seat belt
pre-tensioner
connector
Flat-tip screw
driver
Locking button
AC300147AF

MB991865 MB991884
MB991885
MB991884
(Resistor
harness)
AC300975AE

the diagnosis code.
YES : Go to Step 2.
tensioner. (Refer to 352B). Then go to

Step 3.
52B-89
TROUBLESHOOTING

connector C-114.
Connector: C-114
CAUTION
C-114 Harness side
2122
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-114 (Y)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE

Connector: D-43
AC201663 AG

OK: Open circuit
Harness side
connector
(front view)
2 1
AC301408AI
D-43 Passenger's
seat belt
pre-tensioner
connector
Flat-tip screw
driver

go to Step 3.
Locking button

AC300147AF


300).
52B-90
TROUBLESHOOTING
Code No.71: Side air bag module (squib) (RH) system (short-circuited between terminals of the squib
circuit)
Side Air Bag Module (RH) (Squib) Circuit
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SIDE AIR BAG

MODULE
(SQUIB)
(RH)
Wire colour code

G : Green L : Blue
AC301796AB
OPERATION
by detecting signals from the left and right side
impact sensors. If the impact is over a
predetermined level, the SRS-ECU outputs an
ignition signal. At this time, if the side air bag
safing G-sensor is on, the SRS side air bag will
inflate.
The ignition signal is input to the side air bag
module to inflate the side air bag.


This diagnosis code is set if one side air bag squib
(RH) wire shorted to the other.
PROBABLE CAUSES
spring*
Short between the side air bag module (RH)
(squib) circuit terminals
DIAGNOSIS PROCEDURE
CAUTION
position.
YES : Go to Step 2.
NO : Go to Step 3.

TROUBLESHOOTING

C-114
52B-91
STEP 4. Check the side air bag module (RH).

Connector: D-40
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
2 1
D-40 (R)
AC202027AM
AC301661AE

YES : Go to Step 3.
Step 6.
C-114 and side air bag module (RH) connector D40
(2) Disconnect the side air bag module (RH)

connector D-40.
MB991865 (Dummy
resistor : 3 )
D-40 Harness side
connector
MB991866
(Resistor harness)
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
D-40 Side air bag

module (RH) connector
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Connector: D-40
Harness side
connector
(front view)
AC301039AB

CAUTION
(4) Insert special tool (MB991866) into the D-40
harness side connector by backprobing.
diagnosis code.
YES : Go to Step 5.
NO : Replace the seat back assembly of the front
2 1
D-40 (R)
seat (RH) (Refer to GROUP 52A - Front

Seat 352A). Then go to Step 6.
AC202027AM

reconnect them.
diagnosis code.
YES : Go to Step 4.
52B-92
TROUBLESHOOTING

connector C-114.
Connector: C-114
C-114 Harness side

SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-114 (Y)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
DANGER
Connector: D-40
Harness side
connector
(front view)
D-40 (R)
AC202027AM

unintentionally, disconnect the side air bag
module (RH) connector D-40 to short the
squib circuit.
(2) Disconnect side air bag module connector D-40.
CAUTION
C-114 Harness side
Terminal
Cable tie A
A
4 mm or more
21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC301042AB

OK: Open circuit
2 1
Section
A-A
CAUTION
Short spring
AC301041AB

of 4mm or more, otherwise the short spring will
not be released.
(4) Measure at the wiring harness side.

24) and side air bag module (RH) connector
D-40 (terminal No.1 and 2). Then go to Step
6.

300).
52B-93
TROUBLESHOOTING
Code No.72: Side air bag module (squib) (RH) system (open-circuited in the squib circuit)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SIDE AIR BAG

MODULE
(SQUIB)
(RH)
OPERATION
inflate.
Wire colour code

G : Green L : Blue
AC301796AB

This diagnosis code is set if the side air bag squib
(RH) wire(s) are open-circuited.
PROBABLE CAUSES
Open circuit in the side air bag module (RH)
(squib) circuit
52B-94

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-40
Harness side
connector
(front view)
2 1
D-40 (R)
AC202027AM

connector D-40.
MB991865 (Dummy
resistor : 3 )
D-40 Harness side
connector
MB991866
(Resistor harness)
D-40 Side air bag
AC301039AB

CAUTION
diagnosis code.
YES : Go to Step 2.


TROUBLESHOOTING
and the side air bag module (RH) connector D-40
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE


3.

300).
Connector: D-40
Harness side
connector
(front view)
2 1
D-40 (R)
AC202027AM
(1) Disconnect SRS-ECU connector C-114 and side

air bag module (RH) connector D-40.
CAUTION
D-40 Harness side
C-114 Harness side
52B-95
1 2
21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC301043AB

terminals.
and the side air bag module (RH) connector
D-40 terminal No.2
and the side air bag module (RH) connector
D-40 terminal No.1
OK: Less than 2 W
52B-96
TROUBLESHOOTING
Code No.75: Side air bag module (squib) (RH) system (short-circuited to the power supply)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SIDE AIR BAG

MODULE
(SQUIB)
(RH)
OPERATION
inflate.
Wire colour code

G : Green L : Blue
AC301796AB

(RH) wire(s) are short-circuited to the power supply.
PROBABLE CAUSES
Short to the power supply in the side air bag
module (RH) (squib) harness

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-40
Harness side
connector
(front view)
2 1
D-40 (R)
AC202027AM

connector D-40.
MB991865 (Dummy
resistor : 3 )
D-40 Harness side
connector
MB991866
(Resistor harness)
D-40 Side air bag
AC301039AB

CAUTION
diagnosis code.
YES : Go to Step 2.

52B-97
52B-98
TROUBLESHOOTING

connector C-114.
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
DANGER


3.

300).
Connector: D-40
Harness side
connector
(front view)
2 1
D-40 (R)
AC202027AM

squib circuit.
(2) Disconnect side air bag module (RH) connector
D-40.
CAUTION
C-114 Harness side

21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC301044 AB

side connector terminals 23 and 24 and body
earth.
OK: 0 V
52B-99
TROUBLESHOOTING
Code No.76: Side air bag module (squib) (RH) system (short-circuited to the earth)
SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SIDE AIR BAG

MODULE
(SQUIB)
(RH)
OPERATION
inflate.
Wire colour code

G : Green L : Blue
AC301796AB

(RH) wire(s) are short-circuited to the earth.
PROBABLE CAUSES
Short to earth in the side air bag module (RH)
(squib) harness
52B-100

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-40
Harness side
connector
(front view)
2 1
D-40 (R)
AC202027AM

connector D-40.
MB991865 (Dummy
resistor : 3 )
D-40 Harness side
connector
MB991866
(Resistor harness)
D-40 Side air bag
AC301039AB

CAUTION
diagnosis code.
YES : Go to Step 2.


TROUBLESHOOTING

connector C-114.
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
DANGER
52B-101


3.

300).
Connector: D-40
Harness side
connector
(front view)
2 1
D-40 (R)
AC202027AM

squib circuit.
(2) Disconnect side air bag module (RH) connector
D-40.
CAUTION
C-114 Harness side

21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC301045AB

OK: Open circuit
52B-102

TROUBLESHOOTING
Code No.79: Side impact sensor (LH) communication error

Code No.93: Side impact sensor (LH) communication impossible
Side Impact Sensor (LH) Power Supply Circuit

SIDE IMPACT
SENSOR (LH)
ANALOG
G SENSOR
CONSTANT
VOLTAGE CIRCUIT
SRS-ECU
INTERFACE
CIRCUIT
MICROCOMPUTER
Wire colour code

SB : Sky blue
AC301792 AB
OPERATION
The side impact sensor includes an analog G sensor
and CPU, etc. The CPU monitors the analog G
sensor output signal. If the CPU judges that the side
air bags should be deployed, it sends a fire signal to
the SRS-ECU to deploy the side air bags. Besides
that, the CPU diagnoses the internal components of
the side impact sensor. If a malfunction occurs, it
requests the SRS-ECU to set a diagnosis code.
DIAGNOSIS PROCEDURE

These diagnosis codes are set if communication
between the side impact sensor (LH) and the SRSECU is not possible or communication is faulty.
Q: Is diagnosis code 89 or 96 set?

YES : Replace the side impact sensor (LH) with a
PROBABLE CAUSES
Malfunction of the side impact sensor (LH)
STEP 1. Check the side impact sensor (LH).

(2) Replace the side impact sensor (LH) with the side
impact sensor (RH).
diagnosis code.
new one (Refer to 352B). Then go to

Step 3.
NO : Go to Step 2.

TROUBLESHOOTING
STEP 2. Check the harness wires for open circuit

or short circuit between SRS-ECU connector C114 (terminal No.34 and 36) and side impact
sensor (LH) connector D-27 (terminal No.1 and
2).
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Connector: D-27
Harness side
connector
(front view)
Front seat belt
2 1
D-27
Front seat
AC201281AE
Connector: D-31
1 2
3 4
5 6 7 8 9 10
1112 13 14 15 16
AC301408 AE
NOTE: After inspecting intermediate connector D-31

inspect the wiring harness. If the intermediate
connector D-31 is damaged, repair or replace it.
Then go to Step 3. If any harness wires between
SRS-ECU connector C-114 and side impact sensor
(LH) connector D-27 are damaged, repair or replace
it.
52B-103


79 or 93 sets, replace the SRS-ECU (Refer
36) and side impact sensor (LH) connector
3.

300).
52B-104
TROUBLESHOOTING
Code No.81: Side air bag module (squib) (LH) system (short-circuited between terminals of the squib
circuit)
Side Air Bag Module (LH) (Squib) Circuit

SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SIDE AIR BAG

MODULE
(SQUIB)
(LH)
OPERATION
inflate.
This diagnosis code is set if one side air bag squib
(LH) wire shorted to the other.
PROBABLE CAUSES
spring*
Short circuit between the side air bag module
(LH) (squib) circuit terminals
Wire colour code

G : Green L : Blue
AC301797AB

(Refer to 352B). Therefore, if connector C-114 or
D-08 is damaged or improperly engaged, the short
spring may not be released when the connector is
connected.
DIAGNOSIS PROCEDURE
YES : Go to Step 2.
NO : Go to Step 3.

TROUBLESHOOTING

C-114
52B-105
STEP 4. Check the side air bag module (LH).

Connector: D-08
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
2 1
D-08 (R)
AC202027AO
AC301661AE

YES : Go to Step 3.
Step 6.
C-114 and side air bag module (LH) connector D08
(2) Disconnect the side air bag module (LH)

connector D-08.
MB991865 (Dummy
resistor : 3 )
D-08 Harness side
connector
MB991866
(Resistor harness)
Connector: C-114
D-08 Side air bag
module (LH) connector
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Connector: D-08
Harness side
connector
(front view)
AC301039AC

CAUTION
diagnosis code.
YES : Go to Step 5.
2 1
seat (LH) (Refer to GROUP 52A - Front

D-08 (R)
AC202027AO

reconnect them.
diagnosis code.
YES : Go to Step 4.
52B-106
TROUBLESHOOTING

connector C-114.
Connector: C-114
C-114 Harness side

SRS-ECU
Center lower
panel
C-114 (Y)
CAUTION
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
DANGER
Connector: D-08
Harness side
connector
(front view)
21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC301047AB

connector terminals 21 and 22.
OK: Open circuit
2 1
D-08 (R)
AC202027AO

module (LH) connector D-08 to short the
squib circuit.
(2) Disconnect left hand side air bag module (LH)
connector D-08.
CAUTION
Terminal
Short spring


300).
C-114 Harness side

A

22) and side air bag module (LH) connector
6.
Cable tie
Section
A-A
4 mm or more
AC301046 AB

of 4mm or more, otherwise the short spring will
not be released.
52B-107
TROUBLESHOOTING
Code No.82: Side air bag module (squib) (LH) system (open-circuited in the squib circuit)

SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SIDE AIR BAG

MODULE
(SQUIB)
(LH)
OPERATION
inflate.
Wire colour code

G : Green L : Blue
AC301797AB

(LH) wire(s) are open-circuited.
PROBABLE CAUSES
Open circuit in the side air bag module (squib)
(LH) circuit
52B-108
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-08
Harness side
connector
(front view)
2 1
D-08 (R)
AC202027AO

connector D-08.
MB991865 (Dummy
resistor : 3 )
D-08 Harness side
connector
MB991866
(Resistor harness)
D-08 Side air bag
AC301039AC

CAUTION
the diagnosis code.
YES : Go to Step 2.


TROUBLESHOOTING
STEP 2. Measure the resistance between the

SRS-ECU connector C-114 (terminal No.21 and
22) and the side air bag module (LH) connector
D-08 (terminal No.1 and 2).
Connector: C-114
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-114 (Y)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE

Connector: D-08
Harness side
connector
(front view)
2 1
D-08 (R)
AC202027AO
(2) Disconnect side air bag module (LH) connector

D-08.
CAUTION
D-08 Harness
side connector C-114 Harness
(rear view)
side connector
(rear view)
1 2
2122
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC202032 AH

terminals.
SRS-ECU connector C-114 (terminal No.21)
and the side air bag module (LH) connector
D-08 (terminal No.1)
and the side air bag module (LH) connector
D-08 (terminal No.2)
OK: Less than 2 W
52B-109


3.

300).
52B-110
TROUBLESHOOTING
Code No.85: Side air bag module (squib) (LH) system (short-circuited to the power supply)

SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SIDE AIR BAG

MODULE
(SQUIB)
(LH)
OPERATION
inflate.
Wire colour code

G : Green L : Blue
AC301797AB

(LH) wire(s) are short-circuited to the power supply.
PROBABLE CAUSES
Short to the power supply in the side air bag
module (LH) (squib) harness

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-08
Harness side
connector
(front view)
2 1
D-08 (R)
AC202027AO

connector D-08.
MB991865 (Dummy
resistor : 3 )
D-08 Harness side
connector
MB991866
(Resistor harness)
D-08 Side air bag
AC301039AC

CAUTION
diagnosis code.
YES : Go to Step 2.

52B-111
52B-112
TROUBLESHOOTING

connector C-114.
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
DANGER


3.

300).
Connector: D-08
Harness side
connector
(front view)
2 1
D-08 (R)
AC202027AO

module (LH) connector D-08 to short the
squib circuit.
(2) Disconnect left hand side air bag module (LH)
connector D-08.
CAUTION
C-114 Harness side

21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC301050AB

OK: 0 V
52B-113
TROUBLESHOOTING
Code No.86: Side air bag module (squib) (LH) system (short-circuited to the earth)

SRS-ECU
MICROCOMPUTER
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
AIR BAG DRIVE

CIRCUIT
CONNECTOR
LOCK
SWITCH
CONNECTOR
LOCK
SWITCH
SIDE AIR BAG

MODULE
(SQUIB)
(LH)
OPERATION
inflate.
Wire colour code

G : Green L : Blue
AC301797AB

(LH) wire(s) are short-circuited to the earth.
PROBABLE CAUSES
Short to earth in the left hand side air bag module
(squib) harness
52B-114
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: D-08
Harness side
connector
(front view)
2 1
D-08 (R)
AC202027AO

connector D-08.
MB991865 (Dummy
resistor : 3 )
D-08 Harness side
connector
MB991866
(Resistor harness)
D-08 Side air bag
AC301039AC

CAUTION
diagnosis code.
YES : Go to Step 2.


TROUBLESHOOTING

connector C-114.
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE

Connector: D-08
52B-115


3.

300).
Harness side
connector
(front view)
2 1
D-08 (R)
AC202027AO
(2) Disconnect side air bag module (LH) connector

D-08.
CAUTION
C-114 Harness side

21 22
23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC301058AB

connector terminals 21, 22 and body earth.
OK: Open circuit
52B-116

TROUBLESHOOTING
Code No.89: Side impact sensor (RH) communication error

Code No.96: Side impact sensor (RH) communication impossible
Side Impact Sensor (RH) Circuit
ANALOG
G SENSOR
SIDE IMPACT
SENSOR (RH)
CONSTANT
VOLTAGE CIRCUIT
SRS-ECU
INTERFACE
CIRCUIT
MICROCOMPUTER
Wire colour code

SB : Sky blue
AC301791AB
OPERATION
DIAGNOSIS PROCEDURE

These diagnosis codes are set if communication
between the side impact sensor (RH) and the SRSECU is not possible or faulty.
Q: Is diagnosis code 79 or 93 out put?

YES : Replace the side impact sensor (RH) with a
PROBABLE CAUSES
Malfunction of the side impact sensor (RH)
STEP 1. Check the side impact sensor (RH).

(2) Replace the side impact sensor (RH) with the
side impact sensor (LH).
diagnosis code.
new one (Refer to 352B). Go to Step

3.
NO : Go to Step 2.

TROUBLESHOOTING

sensor (RH) connector D-41 (terminal No.1 and
2).
Connector: C-114
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
AC301661AE
Connector: D-41
Harness side
connector
(front view)
Front seat belt
2 1
D-41
Front seat
AC201282 AH
NOTE: If any harness wires between SRS-ECU

connector C-114 and side impact sensor (RH)
connector D-41 are damaged, repair or replace it.
Then go to Step 3.

89 or 96 sets, replace the SRS-ECU (Refer
42) and side impact sensor (RH) connector
3.
52B-117


300).
52B-118

TROUBLESHOOTING
Code No.91: Side impact sensor (LH) voltage error
Side Impact Sensor (LH) Power Supply Circuit

SIDE IMPACT
SENSOR (LH)
ANALOG
G SENSOR
CONSTANT
VOLTAGE CIRCUIT
SRS-ECU
INTERFACE
CIRCUIT
MICROCOMPUTER
Wire colour code

SB : Sky blue
AC301792 AB
OPERATION

This diagnosis code will set when the power supply
voltage to the side impact sensor (LH) remains less
than a predetermined value for 5 seconds. However,
if the system returns to normal condition, code
number 91 will be erased automatically and the SRS
PROBABLE CAUSES
Damaged wiring harness or connectors
Malfunction of the side air bag module (LH)
(squib)
52B-119
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Measure the voltage at the side impact
sensor (LH) connector D-27.
Connector: D-27

sensor (LH) connector D-27 (terminal No.1 and
2).
Connector: C-114
SRS-ECU
Front seat belt
Center lower
panel
C-114 (Y)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
D-27
Front seat
AC201281AF
(2) Disconnect side impact sensor (LH) connector D27, and measure at the wiring harness side.
Harness side
connector
(front view)
AC301661AE
Connector: D-27
Harness side
connector
(front view)
Front seat belt
CAUTION
2 1
D-27
D-27 Harness side

Front seat
AC201281AE
1 2
Connector: D-31
AC201627AM

(5) Measure the voltage between D-27 harness side
connector terminal 2 and the earth.
OK: 9 V or more
YES : Replace the side impact sensor (LH) (Refer

NO : Go to Step 2.
1 2
3 4
5 6 7 8 9 10
1112 13 14 15 16
AC301408 AE
NOTE: After inspecting intermediate connector D-31

inspect the wiring harness. If the intermediate
connector D-31 is damaged, repair or replace it.
Then go to Step 3.

36) and side impact sensor (LH) connector
3.
52B-120

TROUBLESHOOTING


300).
Code No.92: G-sensor of side impact sensor (LH) failure

Code No.95: G-sensor of side impact sensor (RH) failure
These diagnosis codes are set if the followings are
detected from the analog G-sensor inside the side
impact sensor output.
Analog G-sensor is not operating.
Analog G-sensor characteristics are abnormal.
Analog G-sensor inside the side impact sensor
output is abnormal.
PROBABLE CAUSE
Malfunction of side impact sensor (LH) (for diagnosis
code 92) and side impact sensor (RH) (for diagnosis
code 95)
DIAGNOSIS PROCEDURE
Replace side impact sensor (LH) (for diagnosis code
92) and side impact sensor (RH) (for diagnosis code
95). (Refer to 352B).
Check the diagnosis code.
Q: Is any of diagnosis code 92 or 95 set?
YES : Replace the SRS-ECU (Refer to 352B
).

TROUBLESHOOTING
52B-121
Code No.94: Side Impact Sensor (RH) voltage error
Side Impact Sensor (RH) Circuit
ANALOG
G SENSOR
SIDE IMPACT
SENSOR (RH)
CONSTANT
VOLTAGE CIRCUIT
SRS-ECU
INTERFACE
CIRCUIT
MICROCOMPUTER
Wire colour code

SB : Sky blue
AC301791AB
OPERATION

This diagnosis code is set if the power supply voltage
of the side impact sensor (RH) drops below the rated
value for a continuous period of 5 seconds or more.
However, diagnosis code number 94 will be
automatically cleared and the SRS warning lamp will
switch off if the condition returns to normal.
PROBABLE CAUSES
Malfunction of the side air bag module (RH)
(squib)
52B-122
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Measure the voltage at the side impact
sensor (RH) connector D-41.
Connector: D-41
Harness side
connector
(front view)

sensor (RH) connector D-41 (terminal No.1 and
2).
Connector: C-114
Front seat belt
2 1
D-41
SRS-ECU
Center lower
panel
C-114 (Y)
Harness side
connector
(front view)
24 23
22 21
33 32 31 30 29 28 27 26 25
42 41 40 39 38 37 36 35 34
Front seat
AC201282 AH
(2) Disconnect side impact sensor (RH) connector D41, and measure at the wiring harness side.
CAUTION
AC301661AE
Connector: D-41
Harness side
connector
(front view)
Front seat belt
2 1
D-41
D-41 Harness side

Front seat
AC201282 AH
1 2
AC201627 AN

(5) Measure the voltage between the D-41 harness
OK: 9 V or more
YES : Replace the side impact sensor (RH) (Refer
Q: Are the harness wires between SRS-ECU

connector C-114 (terminal No.40 and 42) and side
impact sensor (RH) connector D-41 (terminal No.1
and 2) in good condition?

42) and side impact sensor (RH) connector
3.

NO : Go to Step 2.


300).
52B-123
TROUBLESHOOTING
CHECK CHART FOR TROUBLE

SYMPTOMS
M1524003400417
Trouble
Inspection procedure No.
Reference page
Communication with MUT-II MB991502 is not

possible (Communication with all systems is not
possible).
GROUP 13A Troubleshooting

313A
Communication with MUT-II MB991502 is not

possible (Communication is not possible with
SRS).
352B
When the ignition switch is turned to the "ON"

position (engine stopped), the SRS warning
lamp does not illuminate.
Refer to diagnosis code No.43.
352B
After the ignition switch is turned to the "ON"

Refer to diagnosis code No.43.
position, the SRS warning lamp does not go off
within approximately 7 seconds.
352B
52B-124
TROUBLESHOOTING
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Communication with MUT-II MB991502 is not possible. (Communication

is not possible with SRS).
SRS-ECU Power Supply Circuit

IGNITION
SWITCH (IG1)
SRS-ECU
POWER SOURCE
CIRCUIT
D.C.-D.C.
CONVERTER
BACK-UP
CAPACITOR
MICROCOMPUTER
WARNING LAMP
DRIVE CIRCUIT
MUT-II INTERFACE
CIRCUIT
CONNECTOR
LOCK
SWITCH
DIAGNOSIS
CONNECTOR
FRONT SIDE
NOTE
CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF
Wire colour code

SB : Sky blue
AC301800 AB
52B-125
TROUBLESHOOTING
OPERATION
switch (IG1).
can inflate.
The SRS system diagnosis can be done by
connecting MUT-II MB991502 to the diagnosis
connector.
If communication is not possible with the SRS only,
the cause is probably an open circuit in the on-board
diagnostic output circuit of the SRS or in the power
circuit (including earth circuit).
PROBABLE CAUSES
Incorrect MUT-II (MUT-II) ROM pack
DIAGNOSIS PROCEDURE
STEP 1. Check that the MUT-II can communicate
with the other systems.
Q: Can the MUT-II communicate with the other
systems?
YES : Go to Step 2.
NO : Refer to GROUP 13A - Troubleshooting
313A.
STEP 2. Measure the resistance between SRSECU connector C-115 (terminal No.20) and
diagnosis connector C-24 (terminal No.7)
Connector: C-115
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
CONNECTOR: C-24
Center lower panel
Harness side
connector
(front view)
C-24 (B)
1 2 3 4 5 6 7 8
9 10 111213141516
AC208056 AF

diagnosis connector C-24, and measure at the
CAUTION
C-115 Harness side
C-24 Connector connector (rear view)
(front view)
1 2
3 4
1 2 3 4 5 6 7 8
9 10 111213141516
5 6 7 8 9 10 1112
131415 1617 181920
AC201667AI

of the SRS-ECU connector C-115 its front side
directly as the connector contact pressure may
be weakened.
terminals.
and diagnosis connector C-24 (terminal No.7)
OK: Less than 2 W
Q: Is the check results normal?
YES : Go to Step 3.
NO : Go to Step 5.
52B-126
TROUBLESHOOTING
STEP 3. Check the earth circuit to the SRS-ECU.

Connector: C-115
STEP 4. Check the power supply circuit to the

SRS-ECU.
Connector: C-115
SRS-ECU
SRS-ECU
Center lower
panel
Center lower
panel
C-115 (Y)
C-115 (Y)
AC301661AB

CAUTION
C-115 Harness side
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC301661AB

CAUTION
C-115 Harness side
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC301059AB

(2) Check for continuity between terminal 7 and body
earth.
OK: Less than 2 W
YES : Go to Step 4.
NO : Go to Step 6.
AC301060 AB

(4) Measure the voltage between terminals 13, 16
and body earth.
OK: 9 V or more
YES : Recheck the trouble symptom. If it is not
solved, replace the SRS-ECU (Refer to

352B). Then go to Step 8.
NO : Go to Step 7.
52B-127
TROUBLESHOOTING

C-115 and diagnosis connector C-24
Connector: C-115

C-115 and earth
Connector: C-115
SRS-ECU
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
Harness side
connector
(front view)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
AC301661AC
CONNECTOR: C-24
Center lower panel
Harness side
connector
(front view)
Blower
assembly
C-24 (B)
1 2 3 4 5 6 7 8
9 10 111213141516
AC208056 AF
AC208080AE

Connector: C-02

(terminal No.7) and earth, and repair if
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2324 25 2627 282930 3132 33
AC301395 AC


(terminal No.20) and diagnosis connector C24 (terminal No.7), and repair if necessary.
Then go to Step 8.
52B-128
TROUBLESHOOTING

C-115 and ignition switch connector C-303
Connector: C-115
SRS-ECU
Harness side
connector
(front view)
Center lower
panel
C-115 (Y)
4 3
2 1
12 1110 9 8 7 6 5
20 19 18 17 16 15 1413
AC301661AC
Connector: C-303
Clock spring
C-303
Harness side
connector
(front view)
3 2 1
6 5 4
AC301399 AG

C-203
C-205
Harness side
C-205
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-203
2
1
6 5 4 3
AC210475 AR


(terminal No.13 and 16) and ignition switch

Q: Does the MUT-II communicate normally with the
SRS system?
YES : The procedure is complete (If no

300).
NO : There is no action to be taken.
52B-129
SRS MAINTENANCE
SRS MAINTENANCE
M1524003900263
The SRS must be inspected by an authorized dealer

10 years after the date of vehicle registration.
FRONT IMPACT SENSORS
SRS WARNING LAMP CHECK

SRS warning lamp
Front impact sensors
AC300581AB
AC301667 AB
Turn the ignition key to the "ON" position. Does the

SRS warning lamp illuminate for about 7 seconds,
turn off and then remain extinguished for at least 5
seconds? If yes, SRS system is functioning properly.
If no, consult page 352B.
SRS COMPONENT VISUAL CHECK

DANGER
SIDE IMPACT SENSOR
Insulating tape
Battery
Battery cable
1. Check the front side member and front impact

sensor for deformation or rust.
2. Check the front impact sensor for dents, cracks,
deformation or rust.
3. Check the sensor harnesses for binding, the
connectors for damage, and the terminals for
deformation.
NOTE: The figures show front impact sensors (LH).
The side impact sensors (RH) is symmetrical with the
side impact sensors (LH).
WARNING
The SRS may not activate if the impact
sensors are not installed properly, which
could result in serious injury or death to the
vehicles driver or front passenger.
Side impact sensor
AC300580AB
Wait at least 60 seconds after disconnecting

the battery cable before doing any further
work (Refer to 352B).
Center pillar
Turn the ignition key to the "LOCK" position,

disconnect the negative battery cable and tape the
terminal.
AC201282 AF
1. Check the centre pillar for deformation or rust.

2. Check the side impact sensors for dents, cracks,
deformation and rust.
3. Check the connector for damage and the
terminals for deformation.
NOTE: The figures show side impact sensors (RH).
The side impact sensors (LH) is symmetrical with the
side impact sensors (RH).
52B-130

SRS MAINTENANCE
SRS CONTROL UNIT (SRS-ECU)

WARNING
The SRS may not activate if the SRS-ECU is
not installed properly, which could result in
serious injury or death to the vehicles driver
or front passenger.
<Driver's side>
Inflator case
SRS-ECU
Connector
<Front passenger's side>
AC300582 AB
1. Check the SRS-ECU case and brackets for dents,

cracks, deformation or rust.
2. Check the connector for damage, and check the
terminals for deformation or rust.
Replace the SRS-ECU if it fails the visual checks
above (Refer to 352B).
AIR BAG MODULES, STEERING WHEEL

AND CLOCK SPRING
WARNING
The removed air bag module should be
stored in a clean, dry place with the pad
cover face up.
Inflator case
Connector
AC300170AB
3. Check the connector for damage and deformed

terminals, and check the harness for binding.
4. Check the air bag inflator case for dents, cracks or
deformation.
5. Check the harness (built into the steering wheel)
and connectors for damage, and check the
Case
1. Remove the air bag module, steering wheel and

clock spring (Refer to 352B).
2. Check the pad cover for dents, cracks or
deformation.
Protective tubes
AC300585AB
6. Check the clock spring connectors and protective

tube for damage, and terminals for deformities.
7. Visually check the case for damage.

SRS MAINTENANCE
WARNING
If the clock springs mating mark is not
properly aligned, the steering wheel may not
be completely rotational during a turn, or the
flat cable within the clock spring may be
severed, obstructing normal operation of the
SRS and possibly leading to serious injury to
the vehicles driver or front passenger.
52B-131
DANGER
The SRS may not activate if any of the above
components is not installed properly, which
could result in serious injury or death to the
vehicles driver or front passenger.
11.Check the steering wheel for excessive free play.
12.REPLACE ANY VISUALLY INSPECTED PART IF
IT FAILS THAT INSPECTION (Refer to 352B
).
FRONT SEATBACK ASSEMBLY WITH

SIDE AIR BAG MODULE
Air bag module

deployment
section
Mating marks
AC300168 AB
8. Align the mating marks of the clock spring and,

after turning the vehicles front wheels to straightahead position, install the clock spring to the
column switch.
Mating Marks Alignment;
Turn the clock spring clockwise fully. Then turn it
back approximately 3 3/4 turns counterclockwise
to align the mating marks.
AC300172AB
1. Check the side air bag module deployment

section in the seat for dents and deformation.
2. Check the harness for binds, the connector for
damage and the terminals for deformation.
SEAT BELT WITH PRE-TENSIONER

1. Check the seat belt pre-tensioner for dents or
deformation.
2. Check that the seat belt pre-tensioner is installed
correctly to the vehicle body.
Air bag module

AC300586 AB
9. Install the steering column covers, steering wheel

and air bag module (Refer to 352B).
10.Check the steering wheel for noise, binding or
difficult operation.
52B-132
SRS MAINTENANCE
INSTRUMENT PANEL WIRING HARNESS/FRONT WIRING HARNESS/FLOOR WIRING

HARNESS
Clock spring connector
Air bag module connector

<passenger's side>
SRS-ECU connector
Air bag module

connector
<driver's side>
Front impact sensor

connector (LH)
Front impact sensor

connector (RH)
Side impact sensor

connector (RH)
Side air bag module

connector

connector (RH)

connector (LH)
Side impact sensor

connector (LH)
AC301669AB

POST-COLLISION DIAGNOSIS
1. Check connector for poor connection.

2. Check harnesses for binds, connectors for
damage, and terminals for deformation.
REPLACE ANY CONNECTORS OR HARNESS
THAT FAIL THE VISUAL INSPECTION (Refer to
352B).
52B-133
POST-INSTALLATION INSPECTION
SRS warning lamp
AC301667 AB
Reconnect the negative battery terminal. Turn the

ignition key to the "ON" position. Does the SRS
warning lamp illuminate for about 7 seconds, turn off
and then remain extinguished for at least 5 seconds?
If yes, SRS system is functioning properly. If no,
consult page 352B.
M1524001100391
Whether or not the air bags have deployed, check

and service the vehicle after collision as follows:
SRS-ECU MEMORY CHECK

CAUTION
16 Pin
MB991502
AC107200 AF
Refer to that the ignition switch is "LOCK" (OFF)

when connecting or disconnecting MUT-II.
(Refer to GROUP 00 - How to Use
Troubleshooting/Inspection Service Points 300
).
2. Read (and write down) all displayed diagnosis

codes (Refer to 352B).
NOTE: If battery power supply has been shut
down by the collision, the MUT-II cannot
communicate with the SRS-ECU. Check and,
repair if necessary, the instrument panel wiring
harness before the next job.
52B-134
3. Use the MUT-II to read the data list (how long

trouble(s) have continued and how often memory
have been erased).
Data list
No
Service Data Item
Applicability
92
Number indicating how often the memory is Maximum time to be stored: 250
cleared
93
How long a problem has lasted (How long it Maximum time to be stored: 9,999 minutes
takes from the occurrence of the problem till (approximately 7 days)
the first air bag squib igniting signal)
94
How long a problem has lasted (How long it

takes from the first air bag squib igniting
signal till now).
4. Erase the diagnosis codes and after waiting 5

seconds or more read (and write down) all
displayed diagnosis codes.
REPAIR PROCEDURE
WHEN FRONT AIR BAGS DEPLOY IN A
COLLISION.
1. Replace the following parts with new ones.
SRS-ECU (Refer to 352B).
Air bag modules (Refer to 352B).
Seat belt with pre-tensioner (Refer to 352B).
Front impact sensors (Refer to 352B).
Instrument panel (Refer to GROUP 52A Instrument Panel Assembly <LH drive vehicles
352A>, <RH drive vehicles 352A>).
2. Check the following parts and replace if there are
any malfunctions.
Clock spring (Refer to 352B).
Steering wheel, steering column and shaft
assembly
(1) Check the wiring harness (built into the
steering wheel) and connectors for damage,
and terminals for deformation.
(2) Install the air bag module to check fit or
alignment with the steering wheel.
(3) Check the steering wheel for noise, binds or
difficult operation and excessive free play.
(4) Check the steering column shaft shock
absorbing mechanism (Refer to GROUP 37A
- On-Vehicle Service 337).
3. Check the harness for binding, connectors for
damage, poor connections, and terminals for
deformation (Refer to352B).
WHEN SIDE AIR BAGS DEPLOY IN A COLLISION.

1. Replace the following parts with new ones.
SRS-ECU (Refer to 352B).
Side impact sensors (Refer to 352B).
Front seatback assembly (Refer to GROUP 52A
- Front Seat Assembly 352A).
2. Check the harness for binding, connectors for
damage, poor connections, and terminals for
deformation (Refer to352B).
WHEN AIR BAGS DO NOT DEPLOY IN LOWSPEED COLLISION.
Check the SRS components. If visible damage such
as dents, cracks, or deformation are found on the
SRS components, replace them with new ones.
Concerning parts removed for inspection,
replacement with new parts and cautions in working,
refer to INDIVIDUAL COMPONENT SERVICE,
352B

Front impact sensor
52B-135
Air bag modules

<Driver's side>
Inflator case
Front impact sensors
AC300581AB
1. Check the front side member and front impact

sensor for deformation or rust.
3. Check the sensor harnesses for binding, the
connectors for damage, and the terminals for
deformation.
NOTE: The figures show front impact sensors (LH).
The side impact sensors (RH) is symmetrical with the
side impact sensors (LH).
SRS-ECU
SRS-ECU
Connector
Inflator case
Connector
AC300170AB

deformation.
2. Check the connector for damage, terminals
deformities, and the harness for binding.
deformities.
4. Check the air bag modules for proper installation.
Front seatback assembly (Side air bag module)
AC300582 AB
1. Check the SRS-ECU case and brackets for dents,

cracks or deformation.
2. Check the connector for damage, and the
3. Check the SRS-ECU and bracket for installation
condition.
Air bag module

deployment
section
AC300172AB
1. Check the side air bag module deployment

section in the seat for dents and deformation.
2. Check the connectors for damage, the terminals
for deformation, and the harness for binds.
52B-136
INDIVIDUAL COMPONENT SERVICE
Clock spring
3. Check the connector for damage and the

NOTE: The figures show side impact sensors
(RH). The side impact sensors (LH) is
symmetrical with the side impact sensors (RH).
Case
Protective tubes
AC300585AB
1. Check the clock spring connectors and protective

tube for damage, and the terminals for
deformation.
Side impact sensor
Steering wheel, steering column and shaft

assembly
1. Check the wiring harness (built into the steering
wheel) and the connectors for damage, and the
2. Install the air bag module to check fit or alignment
with the steering wheel.
3. Check the steering wheel for noise, binding or
difficult operation and excessive free play.
4. Check the steering column shaft shock absorbing
mechanism (Refer to GROUP 37A - On-Vehicle
Service 337).
1. Check the seat belt for damage or deformation.
2. Check the seat belt with pre-tensioner for cracks
or deformation.
3. Check that the unit is installed correctly to the
vehicle body.
Center pillar
AC201282 AG
1. Check the centre pillar for deformation or rust.

2. Check the side impact sensors for dents, cracks,
Harness connector (Front wiring harness,

instrument panel wiring harness and floor wiring
harness)
Check harnesses for binding, connectors for damage
and terminals for deformation (Refer to 352B).
INDIVIDUAL COMPONENT SERVICE

M1524002900323
WARNING
If heat damage may occur during paint work, remove the SRS-ECU, the air bag modules,
the clock spring, front seats, and the seat belt with pre-tensioner. Recheck the SRS
system operability after reinstalling them (Refer to GROUP 00 - Maintenance Service).
SRS-ECU, air bag module, clock spring and impact sensor: 93 C or more
If the SRS components are removed for the purpose of check, sheet metal repair, painting,
etc., they should be stored in a clean, dry place until they are reinstalled.
If the SRS components are to be removed or replaced as a result of maintenance, troubleshooting etc., follow
the service procedures that follow. (Front impact sensor; refer to 352B, SRS-ECU; refer to 352B,
Air bag modules and clock spring; refer to 352B, Side impact sensor; refer to 352B, Seat belt with
pre-tensioner; refer to 352B).
52B-137
WARNING/CAUTION LABELS
WARNING/CAUTION LABELS
M1524003000107
Caution labels on the SRS are attached in the vehicle as shown. Follow label instructions when servicing the
SRS. If the label(s) are dirty or damaged, replace with new one(s).
Driver's air bag module
B
Steering wheel
A
Passenger's (front)
air bag module
Clock spring
C
Sun visor
SRS-ECU
Glove box
F
E
F
D
Steering joint cover
Side impact sensors

(left and right)
Side air bag module

(driver's and
front passenger's seat)

(driver's and passenger's seat)
Center
pillar
Hood
Front impact sensors (left and right)

Battery
Instrument panel
Front bumper
AC301342 AB
52B-138

M1524001500258
WARNING
Disconnect the negative battery terminal and wait for 60 seconds or more before starting
work. Furthermore, the disconnected battery terminal should be covered with tape to
insulate it.
Never attempt to disassemble or repair the front impact sensor. If faulty, replace it.
Do not drop or subject the front impact sensor to impact or vibration. If denting, cracking,
deformation, or rust are discovered in the front impact sensor, replace it with a new front
impact sensor. Discard the old one.
After deployment of an air bag, replace the front impact sensor with a new one.
Turn the ignition key to the "LOCK" (OFF) position.
Disconnect the Negative Battery Terminal.
5.0 1.0 Nm
AC300078AB
1.
>>A<<
>>B<<
>>C<<
1.
Removal step
Front impact sensor
Installation steps
Pre-installation inspection
Front impact sensor
Negative battery cable connection
Post-installation inspection
NOTE: The figure on the left indicates the left front

impact sensor.


>>A<<PRE-INSTALLATION INSPECTION
When the new front impact sensor refer to the
previous item "INSPECTION."
>>B<<FRONT IMPACT SENSOR INSTALLATION
WARNING
The SRS may not activate properly if a front
impact sensor is not installed properly.
1. Securely connect the connector.
2. Position the front impact sensor facing toward the
front of the vehicle as shown by the arrow on the
label, and install it securely.
52B-139
INSPECTION
M1524001600222
WARNING
If a dent, crack, deformation or rust is
detected, replace with a new sensor.
WARNING
Always replace the sensor with a new one if
the resistance shows a short or open circuit.
>>C<<POST-INSTALLATION INSPECTION
2. Turn the ignition key to "ON" position.
SRS warning lamp
AC300129
2. Measure the resistance between terminals and

check whether it is within the standard value.
Standard value: 820 82 W
AC301667 AB
3. Does the SRS warning lamp illuminate for about 7

seconds, and then remain extinguished for at
least 5 seconds after turning OFF?
4. If no, refer to troubleshooting (Refer to352B).
AC300130
3. Check the continuity between the terminal and

bracket. If there is a continuity, the insulation is
malfunctioned, and replace the sensor with a new
one.
4. Check the head lamp support pane for
52B-140

M1524002100350
WARNING
insulate it.
Never attempt to disassemble or repair the SRS-ECU. If faulty, replace it.
Do not drop or subject the SRS-ECU to impact or vibration. If denting, cracking,
deformation, or rust are discovered in the SRS-ECU, replace it with a new front impact
sensor. Discard the old one.
After deployment of an air bag, replace the SRS-ECU with a new one.
Never use an ohmmeter on or near the SRS-ECU, and use only the special test equipment
described on 352B.
Turn the ignition switch to the "LOCK" (OFF) position.
5.0 1.0 Nm
5.0 1.0 Nm
5.0 1.0 Nm
AC300137 AB
1.
2.
Removal steps
GROUP 52A - Floor console
assembly 352A).
SRS-ECU
SRS-ECU bracket
>>A<<
>>B<<
2.
1.
Installation steps
SRS-ECU bracket
SRS-ECU
GROUP 52A - Floor console
assembly 352A).

AIR BAG MODULE(S) AND CLOCK SPRING
52B-141
INSPECTION
M1524002200302
>>A<< SRS-ECU INSTALLATION
WARNING
The SRS may not activate if SRS-ECU is not
installed properly.
>>B<< POST-INSTALLATION INSPECTION
SRS warning lamp
WARNING
If any problems are found, replace the SRSECU.
Check the SRS-ECU and brackets for dents,
cracks or deformation.
Check the SRS-ECU connector for damage, and
the terminals for deformation.
NOTE: For the checks other than the items above,
refer to "Troubleshooting" (Refer to 352B).
AC301667 AB


M1524002400403
WARNING
work. Also, the disconnected battery terminal should be insulated with tape (Refer to
352B).
Never attempt to disassemble or repair the air bag modules and clock spring. If faulty, just
replace with new one(s).
Do not drop the air bag modules or clock spring or allow contact with water, grease or oil.
Replace if a dent, crack, deformation or rust are present.
Store the air bag modules on a flat surface with the deployment surface facing up. Do not
place anything on top of them.
Do not store the air bag modules in a place more than 93C.
When the drivers and front passengers air bags have been deployed, replace the drivers
and passengers air bag modules with new ones.
Put on gloves and safety glasses when handling deployed air bags.
When discarding the undeployed air bag module(s), be sure to deploy the air bag(s) in
advance as specified in the service procedure (Refer to 352B).
<Side air bag module>

For removal and installation of the front seatback assembly with side air bag module, refer to GROUP 52A Front Seat 352A.
52B-142
<Air bag module (drivers side) and clock spring>
2
3
7.5 0.5 Nm
0.69 0.15 Nm
Column switch
A
A
1
5
Section A - A
Claw
3
Section B - B
Claw
1
1
3
Section C - C
Section D - D
50 5 Nm
Claw
Claw
NOTE
: Claw positions
<<A>>
<>
<<C>>
<<A>>
<>
<<D>>
Air bag module removal steps

1. Cover
assembly
3. Steering wheel
4. Air bag module
Clock spring removal steps
1. Cover
assembly
Column cover lower (Refer to
GROUP 37A - Steering shaft 337
).
5. Clock spring
Air bag module installation steps
>>A<< Pre-installation inspection
4. Air bag module
AC300120 AC

3. Steering wheel
>>C<< 2. Steering wheel and air bag module
assembly
1. Cover
>>D<< Post-installation inspection
Clock spring installation steps
>>B<< 5. Clock spring
Column cover lower (Refer to
GROUP 37A - Steering shaft 337
).
>>C<< 2. Steering wheel and air bag module
assembly
1. Cover
52B-143
>>D<<
Clock spring installation steps

<Air bag module (front passengers side)>
AC300153 AB
Air bag module removal steps

Instrument panel assembly (Refer to
GROUP 52A - Instrument panel
352A).
Distribution duct (Refer to GROUP
52A - Instrument panel352A).
1. Air bag module bracket
<<E>>
2. Air bag module
2. Air bag module

1. Air bag module bracket
Distribution duct (Refer to GROUP
52A - Instrument panel 352A).
Instrument panel assembly (Refer to
GROUP 52A - Instrument panel
352A).
>>D<< Post-installation inspection

<<A>>COVER REMOVAL
<> STEERING WHEEL AND AIR BAG

MODULE ASSEMBLY REMOVAL
MB990784
C-306 Air bag

module connector
A
AC300154AB
Insert the special tool ornament remover

(MB990784) as shown in the illustration to remove
the cover.
Steering wheel
AC300156AB
1. By sliding the A section (in the figure) of the air

bag module connector in the arrow direction,
52B-144

Hexagonal bit
socket
>>A<< PRE-INSTALLATION INSPECTION
WARNING
When discarding the air bag module or seat
back assembly, deploy the air bag as
specified in the service procedure (Refer to
352B).
AC102792
AC107462 AC
2. Insert the hexagonal bit socket into the arrow

section in the figure. Completely loosen the bolt,
and then remove the steering wheel air bag
module assembly.
NOTE: Use a hexagonal bit socket or a hexagonal
wrench having an effective length of 75 mm or
more in the hexagonal section and the diameter of
8 mm or more.
<<C>> DRIVERS AIR BAG MODULE REMOVAL
WARNING
The air bag module must not be measured
with such equipment as an ohmmeter, nor

disassembled.
The removed air bag module should be
stored in a clean, dry place with the
deployment surface facing up.
<<D>> CLOCK SPRING REMOVAL
WARNING
The removed clock spring should be stored
in a clean, dry place.
<<E>> AIR BAG MODULE REMOVAL (FRONT
PASSENGERS SIDE)
WARNING
When the passengers air bag module is
removed, do not damage the engagement

of the pawls.
The removed passengers air bag module
should be stored in a clean, dry place with
facing the deployment surface facing up.
1. Even new air bag modules, clock spring and front

seat back assembly require inspection before
installation.
WARNING
position when connecting and disconnecting
the MUT-II.
(16- pin).
5. Read a diagnosis code to refer to that the SRS is
operating properly except an open in the air bag
module circuit.
WARNING
Wait at least 60 seconds after the
disconnection of the battery cable before
any further job (Refer to 352B).
7. Disconnect the negative battery cable and
insulate with tape.
>>B<< CLOCK SPRING INSTALLATION
1. Confirm that the steering wheel is at the straightahead position.
WARNING
Unless the mating marks are properly
aligned, the steering wheel gets stuck amid a
turn or the flat cable in the clock spring is
cut. These hinder the SRS air bag from
proper operation, resulting in serious injury
to the vehicle's driver.
Mating marks
AC300168 AB
2. Align the mating marks of the clock spring.

(1) Turn the clock spring clockwise fully. Then turn

it back approximately 3 3/4 turns
counterclockwise to align the mating marks.
(2) Then install the clock spring to the column
switch.
>>C<< STEERING WHEEL AND AIR BAG
MODULE ASSEMBLY INSTALLATION
CAUTION
Be sure when installing the steering wheel, that
the harness of the clock spring does not become
caught or tangled.
1. Refer to first that the clock spring has been
centered properly. Then, install the steering
wheel.
2. After clamping, turn the steering wheel all the way
in both directions to confirm that steering is
normal.
>>D<< POST-INSTALLATION INSPECTION
52B-145
INSPECTION
M1524002500381
AIR BAG MODULE CHECK
WARNING
If any component damage is found during
the following inspection, replace the air

bag module(s) with a new one. Dispose of
the old one according to the specified
procedure (Refer to 352B).
Never attempt to measure the circuit
resistance of he air bag module (squib)
even if you are using the specified tester.
If the circuit resistance is measured with a
tester, accidental air bag module(s)
deployment will result in serious personal
injury.
deformation.
<Driver's side>
Inflator case
SRS warning lamp
Connector
AC301667 AB

4. If no, refer to troubleshooting (Refer to 352B).
Inflator case
Connector
AC300170AB
2. Check the connectors for damage, the terminals

for deformation, and the harness for binds.
deformation.
4. Install the air bag module (drivers side) to the
steering wheel and check fit and alignment with
the wheel.
5. Install the air bag module (front passengers side)
to the instrument panel and front deck
crossmember and check fit and alignment.
52B-146
FRONT SEATBACK ASSEMBLY WITH SIDE AIR

BAG MODULE CHECK
WARNING
If any improper part is found during the
following inspection, replace the front

seatback assembly with a new one.
Dispose of the old one according to the
specified procedure (Refer to 352B).
resistance of the air bag module (squib)
tester, accidental air bag deployment will
result in serious personal injury.
1. Check the connectors and protective tube for

damage, and the terminals for deformation.
3. Check to see that there is a charge (continuity)
between the C-308 clock spring connector
terminal 1 and C-305 horn switch.
CAUTION
C-306 Air bag

module connector
(driver's side)
Air bag module

deployment
section
Plobe
(MB991222)
Clock spring
AC300172AB
1. Check the air bag module deployment section for

dents or deformation.
2. Check the connector for damage, the terminals for
deformation, and the harness for binds.
CLOCK SPRING CHECK
Case
C-308 Clock spring

connector
1 2 3 4 5 6
Protective tube
C-306 Air bag
module connector
C-305 Horn switch
AC300312AB
If any malfunction is found in the following

inspections, replace the clock spring with a new one.
C-306 Air bag

module connector
(driver's side)
Digital
multi-meter
AC300374 AB
Do not directly insert a probe, etc. into the

terminal from the front of the connector.
4. Insert the special tool probe in the harness set
(MB991222) from behind the C-306 air bag
module connector (drivers side).
5. As shown in the Figure, connect the circuit tester
to the special tool probe in the harness set
(MB991222) and check to see that there is a
charge between the terminals.

SIDE IMPACT SENSOR
52B-147
SIDE IMPACT SENSOR

M1524004600243
WARNING
insulate it.
Never attempt to disassemble or repair the side impact sensors. If faulty, replace it.
Do not drop or subject the side impact sensors to impact or vibration. If denting, cracking,
deformation, or rust are discovered in the side impact sensors, replace it with a new front
impact sensor. Discard the old one.
After deployment of an air bag, replace the side impact sensors with a new one.
Never use an ohmmeter on or near the side impact sensors, and use only the special test
equipment described on 352B.
Center pillar
5.0 1.0 Nm
1
Front of vehicle
AC300142 AB
1.
>>A<<
>>B<<
1.
Removal steps
GROUP 52A - Trims 352A).
Seat belt pre-tensioner (Refer to
GROUP 52A - Front seat belt
352A).
Side impact sensor
Installation steps
Side impact sensor
>>C<<
Installation steps&RQWLQXHG

Seat belt pre-tensioner (Refer to
GROUP 52A - Front seat belt
352A).
Negative battery cable connector
NOTE: The figure shows the side impact sensor

(RH).
52B-148

SEAT BELTS WITH PRE-TENSIONER

Even new side impact sensor requires inspection
before installation. (Refer to the previous item
"INSPECTION"
>>B<< SIDE IMPACT SENSOR INSTALLATION
WARNING
The side impact sensor, unless properly
installed, does not operate properly, thereby
resulting in serious injury or death of the
vehicles occupants.
INSPECTION
M1524004700206
WARNING
If any problems, replace the sensor.
1. Check the side impact sensor and bracket for
dents, cracks or deformation.
2. Check the connector for damage, and terminal for
deformation.
3. Check that there is no bending or corrosion in the
centre pillar.
NOTE: For the checks other than the items above,
refer to Troubleshooting (Refer to 352B) .
>>C<< POST-INSTALLATION INSPECTION

SRS warning lamp
AC301667 AB


M1524004100237
WARNING
Never attempt to disassemble or repair the seat belt pre-tensioner. If faulty, replace it.
Be extremely careful when handling the seat with pre-tensioner. Do not subject it to
shocks, drop it, bring it close to strong magnets or allow contact with water, grease or oil.
Always replace it with a new part if any dents, cracks or deformation is found.
Do not place anything on top of the seat belt pre-tensioner.
Do not expose the seat belt pre-tensioner to temperatures over 90C.
After operating the seat belt pre-tensioner, replace the seat belt pre-tensioner with a new
part.
Gloves and protective goggles should be worn when handling a seat belt pre-tensioner
once it has been used.
If disposing of a seat belt with pre-tensioner which has not yet been operated, its seat belt
pre-tensioner should be operated first before disposal (Refer to 352B).

52B-149
44 10 Nm
4
6
3
44 10 Nm
AC300144AB
1.
2.
3.
<<A>>
4.
5.
6.
>>A<<
6.
Removal steps
Sash guide cover
Seat belt shoulder anchor bolt
Seat belt lower anchor bolt
Centre pillar trim, lower (Refer to
Pre-tensioner connector connection
Bracket
Installation steps
Installation steps&RQWLQXHG

5. Bracket
>>B<< 4. Pre-tensioner connector connection
Centre pillar trim, lower (Refer to
3. Seat belt lower anchor bolt
2. Seat belt shoulder anchor bolt
1. Sash guide cover
>>C<< Post-installation inspection
NOTE: The figure shows the seat belt with pretensioner (RH).
52B-150


<<A>>PRE-TENSIONER CONNECTOR
DISCONNECTION
Pre-tensioner
connector
Flat-tip screw
driver
>>B<< PRE-TENSIONER CONNECTOR

CONNECTION
Connect the pretensioner connector then securely
lock the locking button of the harness-side connector.
>> C<< POST-INSTALLATION INSPECTION
SRS warning lamp
Locking button
AC300147AB
1. Use a flat-tipped screwdriver to pull out forward

and unlock the locking button of the harness-side
connector.
2. Disconnect the pretensioner connector.

WARNING
When discarding the seat belt with pretensioner, operate the pre-tensioner as
specified in the service procedure (Refer to
352B).
1. Even new seat belt with pre-tensioner require
inspection before installation.
CAUTION
position when connecting and disconnecting the
MUT-II.
(16- pin).
4. Turn the ignition switch to the ON position.
5. Read a diagnosis code to refer to that the SRS is
operating properly except an open in the seat belt
with pre-tensioner circuit.
DANGER
7. Disconnect the negative battery cable and
insulate with tape.
AC301667 AB

INSPECTION
M1524004200223
WARNING
If any component damage is found during
the following inspection, replace the seat

belt with pre-tensioner with a new one.
Dispose of the old one according to the
specified procedure (Refer to 352B).
resistance of the seat belt pre-tensioner
tester, accidental seat belt pre-tensioner
operation will result in serious personal
injury.
1. Check the pre-tensioner deployment section for
dents and deformation.
2. Check the harness and connector for damage and
the terminals for deformation.

AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES
52B-151
AIR BAG MODULE AND SEAT BELT PRE-TENSIONER

DISPOSAL PROCEDURES
M1524001200354
Before disposing of an air bag or a vehicle equipped

with an air bag, follow the procedures below to
deploy the air bag.
3. Remove the column cover lower (Refer to GROUP

37A - Steering shaft 337).
UNDEPLOYED AIR BAG MODULE

DISPOSAL
WARNING
If the vehicle is to be scrapped or
otherwise disposed of, deploy the air
bags and operate the seat belt pretensioner inside the vehicle. If the vehicle
will continue to be used and only the air
bag modules and seat belt pre-tensioner
are to be disposed of, deploy the air bags
and operate the seat belt pre-tensioner
outside the vehicle.
Since a large amount of smoke is
produced when the air bag is deployed
and the seat belt pre-tensioner is
operated, avoid residential areas
whenever possible.
Since there is loud noise when the air
bags are deployed and when the seat belt
pre-tensioner are operated, avoid
residential areas whenever possible. If
anyone is nearby, give warning of the
impending noise.
Suitable ear protection should be worn by
personnel performing these procedures
or by people in the immediate area.
DEPLOYMENT INSIDE THE VEHICLE (when

disposing of a vehicle) <Air bag module (drivers
side)>
1. Move the vehicle to an isolated spot.
DANGER
2. Disconnect the negative and positive battery
cables from the battery terminals, and then
remove the battery from the vehicle.
C-307 Clock spring

connector (4-pin)
C-307 Harness side

connector
(4-pin, yellow)
AC300379 AB
4. Remove the connection between the C-307 clock

spring connector (4-pin) and the harness side
connector (4-pin, yellow).
NOTE: Once disconnected from the instrument
panel wiring harness, both electrodes of the clock
spring connector short automatically. This
prevents the drivers air bag from accidental
deployment caused by static, etc.
Deployment wires
Connector
6m or longer
AC300381AB
5. Obtain two suitable wires, which are 6 meters or

longer, as deployment wires. Then connect the
wires at one end to short.
6. Touch the vehicles body with bare hands to
discharge static in you.
52B-152

WARNING
C-307
Clock spring
connector (4-pin)
C-307 Harness side

connector
(4-pin, yellow)
Deployment wire
Connection
Insulator tape
AC300384 AB
7. Cut with a pliers, etc. the instrument panel wiring

harness shown in the figure of the instructions,
while the C-307 clock spring connector is
disconnected.
NOTE: The disconnection location should be
sufficiently away from the C-307 harness side
connector with consideration to the expansion
harness connection location upon disconnections.
8. Connect the deployment wires on the two
instrument panel wiring harnesses disconnected,
cover the connection areas with insulation tape
and then pull out the deployment wires outside the
vehicle.
9. Connect the C-307 harness side connector
connected with an expansion harness to the C307 clock spring connector.
WARNING
Before deploying the air bag in this
manner, first check to be sure that there is

no one in or near the vehicle. Wear safety
glasses.
The inflator will be quite hot immediately
following the deployment, so wait at least
30 minutes to allow it to cool before
attempting to handle it. Although not
poisonous, do not inhale gas from the air
bag deployment. See Deployed Air Bag
Module and Operated Seat Belt Pretensioner Disposal (Refer to 352B)
for post-deployment handling
instructions.
If the air bag module fails to deploy, do
not go near the module. Contact your
distributor.
11.At a location as far away from the vehicle as
possible, disconnect the two connected wires
from each other, and connect them to the two
terminals of the battery (which has been removed
from the vehicle) to deploy the air bag.
12.After deployment, dispose of the air bag module
according to the Deployed Air Bag Module and
Operated Seat Belt Pre-tensioner Disposal (Refer
to 352B).
disposing of a vehicle) <Air bag module (front
passengers side)>
Cover
DANGER
any further job (Refer to 337).
Deployment wire
6m or longer
AC300388AB
If the glass is scratched, air bag deployment

could cause it to crack and fly out of the
vehicle, so always put a cover over the
vehicle.
10.To suppress the operation sound as much as
possible completely close all door windows, close
the doors and put the cover on the vehicle.

3. Remove the glove box (Refer to GROUP 52A Instrument Panel 352A).

52B-153
WARNING
Cover
Glove box striker
C-09 Air bag module

connector (2-pin, red)
Deployment wire
6m or longer
AC300418 AB
4. Remove the connection between the C-09 air bag

module (front passengers side) connector (2-pin,
red) and the harness side connector (2-pin, red).
NOTE: Once disconnected from the instrument
panel wiring harness, both electrodes of the
passengers air bag module short automatically.
This prevents the passengers air bag from
accidental deployment caused by static, etc.
AC300388AB

vehicle.
7. To suppress the operation sound as much as
WARNING
Connection
Deployment wires
6 m Long or more
MB686560
Insulator tape
AC300419AB
5. Connect deployment wires longer than 6 m to

each special tool SRS air bag adapter harness
(MB686560) and insulate the connections with
plastic tape. Also, connect the deployment wires
in the other ends to short, thereby preventing the
passengers air bag from accidental deployment
caused by static etc.
MB686560
C-09 Air bag module

Deployment wires
AC300420AB
6. Connect the C-09 air bag module (front

passengers side) connector (2-pin, red) to special
tool SRS air bag adapter harness (MB686560)
and move the deployment wires out of the vehicle.

glasses.
Module and Operated Seat Belt Pretensioner Disposal (Refer to 352B")
instructions.
distributor.
8. At a location as far away from the vehicle as
9. After deployment, dispose of the air bag module
according to the Deployed Air Bag Module and
Operated Seat Belt Pre-tensioner Disposal (Refer
to 352B).
52B-154

disposing of a vehicle) <Side air bag module>
WARNING
the battery cables before doing any further
work (Refer to 337).
WARNING
MB686560
Deployment wires
D-08 or D-40
Side air bag module
AC300444 AB
5. Connect the D-08 or D-40 side air bag module

connector (2-pin, red) to special tool SRS air bag
adapter harness (MB686560) and move the
deployment wire out of the vehicle.
D-08 or D-40 Harness

side connector
(2-pin, red)
WARNING
Cover
D-08 or D-40
Side air bag
connector
(2-pin, red)
AC300442AB
The side air bag modules for both the

drivers side and passengers side should be
deployed.
3. Remove the connection between the D-08 or D-40
side air bag module connector (2-pin, red) and the
harness side connector (2-pin, red).
NOTE: Once disconnected from the side air bag
wiring harness, both electrode of the side air bag
module connector short automatically. This
prevents the side air bag from accidental
deployment caused by static etc.
Connection
Deployment wires
MB686560
6 m Long or more
Insulator tape
AC300419AB

Deployment wire
6m or longer
AC300388AB

vehicle.
the doors and put the vehicle.

WARNING
D-29 or D-43
Seat belt
pre-tensioner
connector (2-pin)

glasses.
instructions.
distributor.
8. After deployment, dispose of the front seatback
assembly (air bag module) according to the
Deployed Air Bag Module and Operated Seat Belt
Pre-tensioner Disposal (Refer to 352B).
disposing of a vehicle) <Seat belt pre-tensioner>
DANGER
3. Remove the centre pillar lower trim (Refer to
GROUP 52A - TRIMS 352A).
52B-155
Flat-tip screw
driver
Locking buttom
D-29 or D-43
Harness side
connector
(2-pin, black)
AC300446AB
4. Execute the following steps to disconnect the

connection between D-29 or D-43 seat belt pretensioner connector (2-pin) and harness side
connector (2-pin, black).
NOTE: Once disconnected from the seat belt pretensioner wiring harness, both electrode of the
side air bag module connector short automatically.
This prevents the seat belt pre-tensioner from
accidental deployment caused by static etc.
(1) Use a flat-tipped screwdriver to pull out
forward and unlock the locking button of the
harness-side connector (2-pin, black).
(2) Disconnect the D-29 or D-43 harness side
connector.
Connection
Deployment wires
MB991885
6 m Long or more
Insulator tape
AC300447AB

MB991885
D-29 or D-43
Seat belt
pre-tensioner
2-pin connector
Deployment
wires
AC300448AB
52B-156

6. Connect the D-29 or D-43 seat belt pre-tensioner

2-pin connector (red) to special tool SRS air bag
adapter harness (MB991885) and move the
deployment harness out of the vehicle.
WARNING
9. After operation, dispose of the seat belt pretensioner according to the Deployed Air Bag
Module operated seat belt pre-tensioner Disposal
(Refer to 352B).
DEPLOYMENT OUTSIDE THE VEHICLE <Air bag
module (drivers side)>
Cover
WARNING
This should be carried out in a wide, flat
area at least 6 m away from obstacles and

other people.
Do not deploy outside if wind is high.
Even in a soft wind, ignite to windward of
the air bag modules.
Deployment wire
6m or longer
AC300388AB
If the glass is scratched, seat belt pretensioner operation could cause it to crack
and fly out of the vehicle, so always put a
cover over the vehicle.
WARNING
Before operating the seat belt pretensioner in this manner, first check to be
sure that there is no one in or near the
vehicle. Wear safety glasses.
following the operation, so wait at least 30
minutes to allow it to cool before
attempting to handle it. Although no
poisonous, do not inhale gas from the
seat belt pre-tensioner operation. See
Deployed Air Bag and Operated Seat Belt
pre-tensioner Disposal (Refer to 352B
) for post-operation handling
instructions.
If the seat belt pre-tensioner fails to
operate, do not go near the seat belt pretensioner. Contact your distributor.
from each the, and connect them to the two
from the vehicle) to operating the seat belt pretensioner.
DANGER
WARNING
Once disconnected, both electrodes of the
drivers air bag module connector short
automatically to prevent accidental
deployment caused by static etc. Still, in
consideration of the accidental deployment,
store the air bag module on flat place with
deployment surface facing up. Also, do not
put anything on it.
2. Remove the air bag module from the vehicle
(Refer to 352B).
Deployment wires
Shorted
6 m or longer
AC300458 AB
3. Obtain two suitable wires, which are 6 meters or

longer, as deployment wires. Then connect the
wires at one end to short.
4. Touch the vehicles body with bare hands to
discharge static in you.

Deployment wires
Air bag module
52B-157
8. Place three old tyres without wheels on the tyre

secured with the drivers air bag module.
WARNING
Before deployment, check carefully to be
sure that no one is nearby.

Connection
Insulator tape
AC300459 AB
5. Using pliers, cut the drivers air bag module

connector from the harnesses. Connect the
deployment wires to each harness that has been
cut and insulate the connections with plastic tape.
Driver's air bag module

poisonous, do not inhale gas from air bag
deployment. See Deployed Air Bag
instructions.
If the air bag fails to deploy, do not go
near the module. Contact your distributor.
Deployment wires
AC300477AB
6. Install a nut to the bolt behind the drivers air bag

module and tie thick wire there for securing.
7. Route the deployment wires connected to the
drivers air bag module beneath an old tyre and
wheel assembly. Then, using the wire tied to the
bolt, secure the drivers air bag module to the tyre
and wheel assembly with the deployment surface
facing up.
Tyre without wheels
Air bad module inside
Deployment wires
AC300478 AB
Deployment
wires
Vehicle battery
AC300493AB
9. At a location as far away from the air bag module

as possible, and from a shielded position,
disconnect the two connected wires from each
other, and connect them, to the two terminals of
the battery (which has been removed from the
vehicle) to deploy the air bag.
10.Discard the deployed air bag module as specified
in Deployed Air Bag Module and Operated Seat
Belt Pre-tensioner Disposal (Refer to 352B).
52B-158
DEPLOYMENT OUTSIDE THE VEHICLE <Air bag

module (front passengers side)>
Front passenger's air bag module
WARNING

other people.
DANGER
WARNING
front passengers air bag module connector
short automatically to prevent accidental
put anything on it.
Deployment wires
AC300520 AB
4. Connect the deployment wires to special tool SRS

air bag adapter harness (MB686560), pass it
beneath the tyre and wheel assembly, and
connect it to the air bag module.
CAUTION
The adapter harness below the wheel should
be loose. If it is too tight, the reaction when
the air bag deploys could damage the adapter
harness.
During deployment, the connector of special
tool SRS air bag adapter harness (MB686560)
must not be between the tyres.
5. Pass the thick wire through the air bag module
mounting hole, and then secure the air bag
module to an old tyre with a wheel in it so that the
pad on the module is facing upwards.
2. Remove the air bag module from the vehicle

(Refer to 352B).
Tyres without wheels
Connection
Deployment wires
MB686560
6 m Long or more
Deployment wires
AC300521AB
Insulator tape
AC300419AB

6. Place three old tyres without wheels on top of the

tyre secured to the air bag module, and secure all
tyres together with ropes (four locations).

WARNING

instructions.
52B-159
WARNING
side air bag module connector short
automatically to prevent accidental
put anything on it.
2. Remove the front seatback assembly with side air
bag module from the vehicle (Refer to 352B
).
Connection
Deployment wires
6 m Long or more
MB686560
Insulator tape
AC300419AB
Deployment wires
AC300522 AB

other, and connect them to the two terminals of
vehicle) to deploy the air bag.
8. Discard the deployed air bag module as specified
in Deployed Air Bag Module and Operated Seat
Belt Pre-tensioner Disposal (Refer to 352B).

Front seatback assembly
DEPLOYMENT OUTSIDE VEHICLE <Side air bag

module>
WARNING

other people.
DANGER
MB686560
AC300528AB
4. Place the front seatback assembly with its back

contact with the earth.
5. Connect the special tool SRS air bag adapter
harness (MB686560) with the deployment wires to
the side air bag module connector.
52B-160

WARNING

Module and Operated Seat Belt Pretensioner Disposal (Refer to 352B)
instructions.
WARNING
Store the operated seat belt pre-tensioner
the correct way up with its operation surface
upper most on a flat surface. Do not place
anything on top of them.
2. Remove the seat belt pre-tensioner from the
vehicle (Refer to 352B).
D-29 or D-43
Seat belt
pre-tensioner
connector (2-pin)
Flat-tip screw
driver
Locking buttom
D-29 or D-43
Harness side
connector
(2-pin, black)
AC300446AB
3. Use a flat-tipped screwdriver to unlock the locking

button of the harness-side connector (2-pin,
black) by with drawing it toward you in two stages.
4. Disconnect the D-29 or D-43 harness side
connector.
Deployment wires
Connection
AC300532 AB
6. Disconnect the deployment wires as far from the

front seatback assembly possible and connect the
harnesses to the battery removed from the
vehicle. Then, deploy.
7. Remove the deployed air bag module from the
seatback assembly and discard as specified in the
Deployed air bag module and Operated Seat
Back Pre-tensioner (Refer to 352B).
DEPLOYMENT OUTSIDE THE VEHICLE <Seat
belt pre-tensioner>
WARNING

other people.
DANGER
Deployment wires
MB991885
6 m Long or more
Insulator tape
AC300447AB

6. Connect the special tool SRS air bag adapter
harness (MB991885), which the deployment wires
is attached to, to the seat belt pre-tensioner
connector.
CAUTION
The adapter harness below the wheel should be
loose. If it is too tight, the reaction when the seat
belt pre-tensioner operates could damage the
adapter harness.
7. Pass the thick wires through the hole on the seat
belt pre-tensioner bracket and secure them to the
front (raised part) of the wheel on two place.

Tyres
without
wheels
Seat belt
Deployment
wires
AC300552AB
8. Pull the seat belt out the outside of the tyre, and
then place one tyre without a wheel inside on top
of the existing tyre.
WARNING
<Seat belt pre-tensioner>
Deployment wires
Vehicle battery
AC300555 AB
Before operation, check carefully to be sure

that no one is nearby.
following the operation, so wait at least 30
minutes to allow it to cool before
poisonous, do not inhale gas from seat
belt pre-tensioner operation. See
Deployed Air Bag Module and Operated
Seat Belt pre-tensioner Disposal (Refer to
352B) for post-operation handling
instructions.
If the seat belt pre-tensioner fails to
operate, do not go near the seat belt pretensioner. Contact your distributor.
other, and connect them to the two terminals of
vehicle) to operated seat belt pre-tensioner.
52B-161
10.Discard the operated seat belt pre-tensioner as

specified in Deployed Air Bag Module and Seat
Belt pre-tensioner Disposal (Refer to 352B).
DEPLOYED AIR BAG MODULE AND

OPERATED SEAT BELT PRE-TENSIONER
DISPOSAL
After deployment and operation, the air bag module
and seat belt pre-tensioner should be disposed of in
the same manner as any other scrap parts, adhering
to local laws and/or legislation. Observe the following
precautions during air bag or seat belt pre-tensioner
disposal:
1. The inflator will be quite hot immediately following
deployment, so wait at least 30 minutes to allow it
cool before attempting to handle it.
2. Do not put water or oil on the air bag after
deployment or on the seat belt pre-tensioner after
operation.
WARNING
If after following these precautions, any
material does get into the eyes or on the
skin, immediately rinse the affected area with
a large amount of clean water. If any irritation
develops, seek medical attention.
3. There may be material on the deployed air bag
module or the operated seat belt pre-tensioner,
that could irritate the eye and/or skin. Wear gloves
and safety glasses when handling a deployed air
bag module or the operated seat belt pretensioner.
Strong plastic bag

Air bag module
AC300562 AB
4. Tightly seal the air bag module and seat belt pretensioner in a strong plastic bag for disposal.
5. Be sure to always wash your hands after
completing this operation.
127(6
32-1
GROUP 32
00
11
POWER PLANT
MOUNT
12
13
14
15
16
CONTENTS
17
SPECIAL TOOL . . . . . . . . . . . . . . . . .
ENGINE MOUNTING . . . . . . . . . . . . .
32
32
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
32
32
32
32
32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
32
TRANSMISSION MOUNTING . . . . . .
32
21
22
ENGINE ROLL STOPPER,

CENTERMEMBER . . . . . . . . . . . . . . .
32
32
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
32
26
CROSSMEMBER . . . . . . . . . . . . . . . .
32
27
32
31
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
32
25
32
33
34
35
36
37
42
51
52
54
55
POWER PLANT MOUNT
32-2
GENERAL INFORMATION
GENERAL INFORMATION
M1321000100328
The liquid-filled transmission mount improves

riding comfort by its refined insulator.
Installation of roll mount in the upper area limits
engine rolling. Further more, large diameter
insulator reduces idle vibration.
The inertia axial system has been adopted for the

engine mount system.
Pressurized liquid-filled longitudinally installed
cylindrical engine mount is adopted to reduce
vibration during acceleration and cornering.
Engine mount
Transmission mount
AC301341
<2WD>
<4WD>
Rear roll stopper
Roll rod
Front roll stopper
Roll rod bracket
Centermember
AC107318
AC301640 AB
M1321000300292
Item
Standard value
Protruding length of stabilizer link thread part mm
9.4 0.4
POWER PLANT MOUNT
32-3
SPECIAL TOOL
SPECIAL TOOL
M1321000600312
Tool
Number
Name
Use
MB991897
Ball joint remover

disconnection
(MB990635 or MB991113) is also
available to disconnect knuckle and
tie rod end ball joint.
AC106827
ENGINE MOUNTING
M1321001100417
CAUTION
*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.
Raise the engine and transmission assembly until its weight
is not applied to the insulator, and support it securely.
12 2 Nm
44 10 Nm
1
N
70 4 Nm
44 10 Nm
AC301670AB
1.
2.
Removal steps
Pressure hose clamp
Engine mounting
POWER PLANT MOUNT
32-4
TRANSMISSION MOUNTING
INSPECTION
M1321001200191
Check the engine mounting for cracks or

damage.
M1321001400388
CAUTION
Raise the engine and transmission assembly until its
weight is not applied to the insulator, and support it
securely.
315).
Centermember and Front Roll Stopper Removal (Refer to
332).
Rear Roll Stopper Removal (Refer to 332).
Rear Roll Stopper Installation (Refer to 332).
Centermember and Front Roll Stopper Installation (Refer
to 332).
315).
82 7 Nm
47 7 Nm
AC301677 AB
>>A<<
1.
2.
Removal steps
Transmission mounting
Transmission mounting stopper
POWER PLANT MOUNT


>>A<< TRANSMISSION MOUNTING STOPPER
INSTALLATION
Engine side
Transmission
mounting
stopper
Transmission
mounting
AC200645AD
Install the transmission mounting stopper so that its

arrow points upward.
32-5
INSPECTION
M1321001500136
Check the transmission mounting insulator for

cracks, separation or deformation.
POWER PLANT MOUNT
32-6
ENGINE ROLL STOPPER, CENTERMEMBER

M1321002300265
CAUTION
<2WD>
<4WD>
11
11 1 Nm
7
8 9
45 5 Nm
70 10 Nm
45 5 Nm
52 7 Nm
52 7 Nm
5
52 7 Nm
12
10
45 5 Nm
1
4 2
3
69 10 Nm
52 7 Nm
69 10 Nm
AC301682 AB
1.
2.
>>A<<
3.
4.
5.
6.
7.
Front roll stopper and

centermember removal steps
Under cover (Refer to GROUP 51,
Under cover 351).
Front roll stopper connecting bolt
Centermember and front roll
stopper assembly
Centermember
Front roll stopper
Rear roll stopper removal steps
<2WD>
Rear roll mount bracket assembly
Rear roll stopper removal steps

<2WD>&RQWLQXHG
8. Clamp bracket
9. Rear roll mount bracket
10. Rear roll stopper
Rear roll rod bracket removal
steps <4WD>
Front exhaust pipe (Refer to

GROUP 15, Exhaust pipe 315).
5. Rear roll mount connecting bolt
11. Rear roll rod
Transfer assembly (Refer to

GROUP 22A, Transfer 322A).
12. Rear roll rod bracket
POWER PLANT MOUNT


>>A<< FRONT ROLL STOPPER INSTALLATION
Hole
Front of vehicle
AC208360 AC
Install the front roll stopper so that its hole points

towards the front side of the vehicle.
32-7
INSPECTION
M1321002400046
Check the roll stopper for cracks, separation or

deformation.
Check the centermember for cracks or damage.
POWER PLANT MOUNT
32-8
CROSSMEMBER
CROSSMEMBER
M1321003200346
CAUTION
Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so that they are
facing straight forward, and remove the ignition key. If you fail to do this, the SRS clock spring will
be damaged, causing the SRS air bag to be inoperative and serious injury.
*1: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
*2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in the unladen condition.
Centermember Removal (Refer to 332).
Steering Wheel Air Bag Module Assembly Removal
(Refer to GROUP 37, Steering Wheel 337).
Power Steering Fluid Draining (Refer to GROUP 37A, Onvehicle Service 337).
Centermember Installation (Refer to 332).
Steering Wheel Air Bag Module Assembly Installation
(Refer to 37, Steering Wheel 337).
Power Steering Fluid Supplying (Refer to GROUP 37A,
On-vehicle Service 337).
Power Steering Fluid Line Bleeding (Refer to GROUP
37A, On-vehicle Service 337).
Press the dust cover with a finger to check whether the
dust cover cracked or damaged.
Ahead.
GROUP 37A, On-vehicle Service 337).
POWER PLANT MOUNT
32-9
CROSSMEMBER
<4WD>
13
12 2 Nm
45 5 Nm
70 10 Nm
70 10 Nm
10
52 7 Nm
18 2 Nm
15
52 7 Nm
57 7 Nm
7
16
45 5 Nm
<2WD>
13
18
14
6
25 4 Nm
8
12
11 N
21 4 Nm
17
21 4 Nm
52 7 Nm
2N
108 10 Nm
3
4
19
1
186 10 Nm
39 5 Nm
167 9 Nm
49 10 Nm
>>B<<
Removal steps
1. Lower arm and knuckle connection
2. Self-locking nut
3. Stabilizer link assembly
4. Lower arm assembly
5. Return hose connection
6. Eye bolt
7. Pressure hose connection
8. Gasket
9. Shaft cover
10. Steering shaft assembly and gear
box connecting bolt
<<A>>
<>
>>A<<
AC301765 AB
11.
12.
13.
14.
15.
16.
17.
18.
19.

Self-locking nut
Tie rod end and knuckle connection
Rear roll rod connection bolt
Rear roll stopper <2WD>
Rear roll rod <4WD>
Rear roll rod bracket <4WD>
Crossmember assembly
Stabilizer bar
Steering gear and linkage
Crossmember
POWER PLANT MOUNT
32-10
CROSSMEMBER
<> CROSSMEMBER ASSEMBLY REMOVAL
<<A>> TIE ROD END AND KNUCKLE

DISCONNECTION
CAUTION
it and use special tool ball joint remover
(MB991897) to avoid possible damage to ball
joint threads.
Hang special tool ball joint remover
(MB991897) with a cord to prevent it from
falling.
Transmission jack
AC200018 AC
Retain the crossmember with a transmission jack,

and then remove the crossmember mounting bolt.
Cord

MB991897
Nut
Outside of
vehicle
Bolt
Ball joint

INSTALLATION
Approximately
10 mm
Identification
mark
AC208247AD
1. Install the special tool ball joint remover

(MB991897) as shown in the figure.
Bolt
Bushing (LH)
Fixture (LH)
AC006141AD
Parallel
Align the stabilizer bar identification mark with the

right end of the bushing (LH).
Knob
Good

Bad
AC106821AB

jaws of the special tool ball joint remover
(MB991897) parallel, tighten the bolt by hand and
confirm that the jaws are still parallel.
figure.
tie rod end.
AC107031AB
AC107031

value.
INSPECTION
M1321003300172
Check the crossmember for cracks and damage.
21-1
GROUP 21
CLUTCH
00
11
12
13
CONTENTS
14
15
16
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A
17
CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
127(6
22-1
GROUP 22
MANUAL
TRANSMISSION
00
11
12
13
14
15
CONTENTS
16
17
MANUAL TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A

MANUAL TRANSMISSION OVERHAUL . . . . . . . . . . . . . . . . . . 22B
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
127(6
51-1
GROUP 51
00
11
EXTERIOR
12
13
14
CONTENTS
FRONT BUMPER ASSEMBLY .
51

51
51
REAR BUMPER ASSEMBLY . .
51

51
51
RADIATOR GRILLE . . . . . . . . .
15
WINDSHIELD WIPER AND

WASHER . . . . . . . . . . . . . . . . .
51
16
17
51
21
SERVICE SPECIFICATION . . . . . .
51
22
51
51
WINDSHIELD WIPER. . . . . . . . . . .
51

INSPECTION . . . . . . . . . . . . . . . . . . . . .
51
51
51
26
GARNISHES . . . . . . . . . . . . . . .
51
WINDSHIELD WASHER. . . . . . . . .
ADHESIVE . . . . . . . . . . . . . . . . . . .
51

INSPECTION . . . . . . . . . . . . . . . . . . . . .
51
51
51
31
SPECIAL TOOL . . . . . . . . . . . . . . .
51
REAR WIPER AND WASHER . . . . . .
51
GARNISHES . . . . . . . . . . . . . . . . .
51
51
SERVICE SPECIFICATION . . . . . .
51
51
34
51
35
CHECK OF REAR WIPER OPERATION

WHEN SELECTOR LEVER IS AT THE "R"
POSITION . . . . . . . . . . . . . . . . . . . . . . .
51
36
MOULDINGS . . . . . . . . . . . . . . .
51
SPECIAL TOOL . . . . . . . . . . . . . . .
51
MOULDINGS . . . . . . . . . . . . . . . . .
51
51
REAR WIPER AND WASHER . . . .
TAILGATE SPOILER. . . . . . . . .
51

INSPECTION . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL . . . . . . . . . . . . . . .
51
TAILGATE SPOILER. . . . . . . . . . .
51
51
ROOF RAIL . . . . . . . . . . . . . . . .
51
51
UNDER COVER . . . . . . . . . . . . .
51
WIPER DEICER . . . . . . . . . . . .
51
51
51
25
27
32
33
37
42
51
51
52
51
54
51
WIPER DEICER . . . . . . . . . . . . . . .
51
51
INSPECTION . . . . . . . . . . . . . . . . . . . . .
55
51-2
HEADLAMP WASHER . . . . . . . . . . .
51
DOOR MIRROR . . . . . . . . . . . .
51
51
51
HEADLAMP WASHER . . . . . . . . .
51
51
DOOR MIRROR . . . . . . . . . . . . . . .
51
51
INSPECTION. . . . . . . . . . . . . . . . . . . . . .
51
MARK . . . . . . . . . . . . . . . . . . . .
51
51
51
INSPECTION . . . . . . . . . . . . . . . . . . . . .
51
EXTERIOR
51-3
FRONT BUMPER ASSEMBLY

M1511001400422
Splash shield
3
Splash shield
Front under cover
0.8 0.1 Nm
Front under cover
1N
5
4
4
4
AC301935 AB
Removal steps
Radiator grille (Refer to 351).
1. Rubber nut
2. Licence plate garnish
3. Splash shield mounting clips

4. Front under cover mounting clips
Fog lamp connector connection
5. Front bumper assembly
6. Front bumper beam
EXTERIOR
51-4

M1511001600415
10
11
3N
N
12
AC300676 AB
Disassembly steps
1. Centre cover
<<A>> >>A<< 2. Rivets A
<<A>> >>A<< 3. Rivets B
4. Front bumper side plate
5. Front bumper centre reinforcement
6. Oil cooler duct

7. Air intake bezel (Vehicles without fog
lamp)
8. Fog lamp bezel
9. Fog lamp assembly
10. Front bumper core
11. Three-diamond mark
12. Front bumper face
EXTERIOR
51-5
<<A>> RIVETS A / RIVETS B REMOVAL
>>A<< RIVETS B / RIVETS A INSTALLATION

Unit: mm
Rivet A
Drill
12
Bumper face
Rivet
4.0
AC005971
Rivet B
8.0
AC100411AB
4.0
Use a drill (f 4.0 mm) to make a hole in the rivet to

break it, and then remove the rivet.
AC005972
Recommended
tool
Front bumper
face
Front bumper
side plate
Y0412AU
Front bumper face

Section C
1
Rivet
2
Recommended
tool
3
Flange
4
Rivet
18E0192
AC005885 AB
Use recommended tool shown in the illustration to

connect the rivet by the following procedure.
1. Insert rivets A and rivets B into the front bumper
face and front bumper upper plate.
2. Place the recommended tool over section C of
rivet.
3. While pushing the flange surface of the rivet with
the recommended tool, press the handle of the
tool.
4. The thin part of section C of the rivet will break
and the rivet will then be attached.
EXTERIOR
51-6
REAR BUMPER ASSEMBLY

M1511001900375
Section A A
4
6
3
4
1
5
AC300293
AC300454 AB
Removal steps
Rear combination lamp
Rear end trim
1. Mud guard
2. Rear splash shield
3. Tapping screw
Ventilation cap (Refer to GROUP
52A, Trims 352A).
<<A>>

4. Clips
Rear bumper harness connector
connection
5. Rear bumper assembly
6. Rear bumper beam
EXTERIOR

<<A>> CLIPS REMOVAL
Section A A
Clip
Claw
Claw
A
A
Plier
Quarter trim lower
AC200942 AB
Remove the clip with a pair of pliers by removing the

thumb of the clip from the cabin side.
51-7
EXTERIOR
51-8

M1511002100338
3N
N3
9
7
10
2
8
AC300244 AB
Disassembly steps
1. Side cover
2. Muffler cover
<<A>> >>A<< 3. Rivets
4. Rear bumper side plate
5. Rear bumper harness

6. Rear bumper reinforcement
7. Licence plate lamp assembly
8. Reflector
9. Licence plate bracket
10. Rear bumper face
EXTERIOR
51-9
<<A>> RIVETS REMOVAL
>>A<< RIVETS INSTALLATION

Drill
Bumper face
Recommended tool
Rear bumper
face
Rivet
Rear bumper
side plate
AC100411AB
Use a drill (f 4.0 mm) to make a hole in the rivet to

break it, and then remove the rivet.
Y0412AU
Rear bumper face

Section A
1
Rivet
2
Recommended
tool
3
Flange
4
Rivet
18E0192
AC005876 AB
Use recommended tool shown in the illustration to

connect the rivet by the following procedure.
1. Insert the rivet into the base material (rear bumper
face, rear bumper side plate).
2. Place the recommended tool over section A of
rivet.
3. While pushing the flange surface of the rivet with
the recommended tool, press the handle of the
tool.
4. The thin part of section A of the rivet will break
and the rivet will then be attached.
EXTERIOR
51-10
RADIATOR GRILLE
RADIATOR GRILLE
M1511002900204
Section A A
Section B B
Clip
2
Front bumper
assembly
2
Headlight
Clip
Section C C
2
1
Front bumper
assembly
1
B
C
<<A>>
Removal steps
1. Clips
>>A<< 2. Radiator grilles
AC200008 AB
EXTERIOR
51-11
GARNISHES

<<A>> CLIPS REMOVAL
>>A<< RADIATOR GRILL INSTALLATION

Install the radiator grill with the clips installed.
Section A A
Flat-tipped screwdriver
Front bumper
assembly
Clip
Claw
Radiator grill
Radiator grill
AC201231AB
To remove the clips from the radiator grill gently pull

forward the radiator grill, and use a flat-tipped
screwdriver to hold the thumb of the clip in the
direction of the arrow.
GARNISHES
ADHESIVE
M1511000500352
Application
Brand
Side sill garnish
Double-sided tape [5.0 mm width 0.8 mm thickness,

5.0 width 1.2mm thickness]
SPECIAL TOOL
M1511000600995
Tool
MB990784
Number
Name
Application
MB990784
Ornament remover
Removal of side sill garnish
EXTERIOR
51-12
GARNISHES
GARNISHES
GARNISH REMOVAL AND INSTALLATION
M1511004100088
Section A A
Splash
shield
Clip
1
Section B B
B
Clip
1
B
AC301940 AB
Removal steps
Front deck garnish (Refer to 351).
<<A>> >>A<< 1. Side sill garnish
DOUBLE-SIDED TAPE AFFIXED LOCATION

B
B
Side sill garnish
AC107438AB
AC107438
Double-sided tape: Generic products

A : 5.0 mm width, 0.8 mm thickness, B : 5.0 mm width, 1.2 mm thickness
EXTERIOR
51-13
GARNISHES

<<A>> SIDE SILL GARNISH REMOVAL
Gently lift and remove the side sill garnish. If there is
any double-sided tape remaining on the side sill
garnish, remove according to the following
instructions.
<Remove both-side tape remaining on the body
surface>
<Remove double-sided tape remaining on side

sill garnish and adhere double-sided tape (when
re-using side sill garnish)>
Double-sided tape
AC103187
Protection tape
AC200049AB
1. Attach protection tape all the way along the edges

of the double-sided tape which is still adhering to
the body.
1. Scrape off the double-sided tape on the side sill

garnish with a resin spatula as possible.
2. Wipe the side sill garnish surface and clean it with
a rag moistened with isopropyl alcohol.
3. Remove only a small portion of the residual
adhesive.
4. Adhere the double-sided tape as specified on the
side sill garnish. (Refer to double-sided tape
adherence location).
Double-sided tape

>>A<< SIDE SILL GARNISH INSTALLATION.
Backing paper
AC200050AB
2. Scrape off the double-sided tape with a resin

spatula as possible.
3. Peel off the protection tape.
4. Wipe the body surface and clean it with a rag
moistened with isopropyl alcohol.
Adhesive tape
AC103247 AC
1. Tear off the double-sided tape backing paper.

NOTE: If you attach the adhesive tape to the edge
of the backing paper, it will be easy to tear off.
2. Install the side sill garnish.
NOTE: If the double-sided tape is difficult to affix
in cold temperature, etc., warm the bonding
surfaces of the body and side sill garnish to about
40 - 60C before affixing the tape.
3. Firmly press in the side sill garnish.
EXTERIOR
51-14
MOULDINGS
MOULDINGS
SPECIAL TOOL
M1511000601006
Tool
Number
Name
Application
MB990449
Window moulding remover Removal of drip moulding
MB990449
MOULDINGS
M1511004700132
Section A A
C
<Vehicle without roof rail>
1, 2
3
Clip
C
Section B B
1, 2
B
A
Clip
A
B
Section C C
1, 3
<Vehicle with roof rail>
Clip
AC301945 AB
Roof drip moulding removal steps

<Vehicles without roof rail>
<<A>> >>A<< 1. Roof drip moulding
Roof drip moulding removal steps

<Vehicles with roof rail>
Roof rail (Refer to 351).
<<A>> >>A<< 2. Front roof drip moulding
<<A>> >>A<< 3. Centre roof drip moulding
EXTERIOR
MOULDINGS
51-15
<<A>> ROOF DRIP MOULDING REMOVAL
>>A<< ROOF DRIP MOULDING INSTALLATION

Install the clips to the roof drip moulding before
installing the moulding to the vehicle body.
CAUTION
If the moulding has become warped, it should not
be reused.
MB990449
AC003626 AB
Use special tool MB990449 to pry out the moulding.
EXTERIOR
51-16
TAILGATE SPOILER
TAILGATE SPOILER
SPECIAL TOOL
M1511000601017
Tool
Number
Name
Application
MB990784
Ornament remover
Removal of tailgate spoiler
MB990784
TAILGATE SPOILER
M1511020800043
Section A A
Clip
5.1 0.2 Nm
2
3
5.1 0.2 Nm
Removal steps
Tailgate upper trim (Refer to GROUP
52A, Tailgate trim 352A).
High-mounted stop lamp connector
connection
AC103231 AC

Rear washer hose connection
1. Tailgate spoiler assembly
2. High-mounted stop lamp assembly
3. Tailgate spoiler
EXTERIOR
51-17
ROOF RAIL
ROOF RAIL
M1511016600165
2
4
8.5 1.5 Nm
8.5 1.5 Nm
6
5
5.0 1.0 Nm
5.0 1.0 Nm
AC300386 AB
F
F
C
C
F
F
C
C
A
B
D
E
NOTE
: Claw positions
Section A A
Section B B
Section C C
1
Claw
1
Claw
Claw
Claw
Claw
4
4
4
Section D D
Section E E
Section F F
Claw
Claw
4
Claw
4
Claw
EXTERIOR
51-18
UNDER COVER
4. Roof rail
5. Front roof rail bracket
6. Centre roof rail bracket
Removal steps
1. Front roof rail cover
2. Centre roof rail cover
3. Rear roof rail cover
UNDER COVER
M1511019600108
Splash shield
4
3
Splash shield
Front bumper assembly
AC107344 AB
1
Removal steps
1. Front bumper assembly mounting
clips
2. Front under cover (LH)

3. Front under cover (RH)
4. Side under cover (LH)
5. Side under cover (RH)
EXTERIOR
51-19

M1511000300295
Item
Standard value
Stop position of the windshield wiper arm/blade assembly (Distance between

the edge of the wiper blade and the end of the deck garnish) mm
25 5
TROUBLESHOOTING
M1511000700248
The windshield wiper and washer are controlled by

the smart wiring system (SWS). For troubleshooting,
refer to GROUP 54B, SWS Diagnosis 354B.
NOTE: Even when the ETACS-ECU has failed, the

windshield wiper can work at low speed in fail-safe
mode. (Normally, the windshield wiper operates
when the ignition switch is at the "ACC" or "ON"
position. But, if it enters the fail-safe mode, the wiper
can operate only when the ignition switch is at the
"ON" position).
EXTERIOR
51-20
WINDSHIELD WIPER
M1511007900124
Section B B
View A
Windshield
Claw
Section C C
NOTE
: Clip position
: Claw position
Clip
Section D D
2
4
Claw
1
3
27 2 Nm
D
D
7.4 1.4 Nm
8
9
AC107419AB
Wiper blade removal steps

1. Wiper blade assembly
>>B<< 2. Wiper blade
Windshield wiper motor and link

>>A<< 3. Wiper arm and blade assembly
4. Hood weather strip
EXTERIOR
51-21

Windshield wiper motor and link
assembly removal steps&RQWLQXHG
5. Roof drip moulding and front deck
garnish connection
6. Front deck garnish
7. Windshield wiper motor and link
assembly
8. Link assembly
9. Windshield wiper motor assembly
>>B<< WIPER BLADE ASSEMBLY

INSTALLATION
NOTE: For removal and installation of the wiper and

washer switch, refer to GROUP 54A, Column switch
354A.

>>A<< WIPER BLADE INSTALLATION
CAUTION
<Passenger's side>
Front deck garnish terminal

AC000427AD
Install the wiper blade at the specified position

(standard value).
Standard value: (A) 25 5 mm
INSPECTION
M1511008000135
Backing
A
Wiper blade
Backing
Section A A
WINDSHIELD WIPER MOTOR CHECK

Inspect the windshield wiper motor by removing the
harness connector with the motor attached to the
vehicle.
Wiper motor at low-speed and high-speed
operation
Wiper blade
1 2 3
4 5
<Driver's side>
Backing
Backing
A
Wiper blade
A
Backing
AC103612 AC
For good windshield wiper wiping performance,

use a passenger-side windshield wiper without
an curve in the backing of the wiper blade. The
windshield wiper on the drivers side should be a
wiper blade with a curved backing.
Check operation
1 2 3
4 5
High speed
1 2 3
4 5
Low speed
AC200893 AB
Connect the battery to the windshield wiper motor to

inspect the operation of motor rotation in low or high
speed.
EXTERIOR
51-22
Wiper motor at stop position operation
1 2 3
4 5
Stop position check

1 2 3
4 5
Switch position
Tester
connection
Specified
condition
OFF
6 - 11, 6 - 10, Open circuit

6 - 9, 6 - 8
Windshield mist
wiper switch
6 - 11
Less than 2
ohms
Windshield
intermittent wiper
switch
6 - 10
Less than 2
ohms
Windshield lowspeed wiper

switch
6-9
Less than 2
ohms
Windshield highspeed wiper

switch
6-8
Less than 2
ohms
WINDSHIELD INTERMITTENT WIPER VOLUME

CHECK
(A) Low speed
1 2 3
4 5
(B) Automatical stop
AC200895 AB
1. Connect the battery to the windshield wiper motor

as shown in the illustration (A).
2. Run the windshield wiper motor at low speed,
then disconnect the battery in the middle of the
motor turning and check to see that the motor
stops.
3. As shown in the illustration (B), connect the
terminals of the windshield wiper motor
connectors.
4. Check to see that the windshield wiper motor runs
at low speed and then stops at the automatic stop
position.
WINDSHIELD WIPER SWITCH CHECK
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
AC201004
Check that the resistance varies between 0 and 1

when the windshield intermittent volume is turned
from FAST to SLOW by after measuring resistance
between connector terminals 3 and 6 at the column
switch.
AC000417
Check continuity between the switch terminals.
EXTERIOR
51-23
WINDSHIELD WASHER
M1511008200236
Section A A
Claw
Claw
3
1
2
A
A
5.0 1.0 Nm
AC200400AB
Windshield washer nozzle removal

steps
Connection of windshield washer
hose
1. Windshield washer nozzle
Washer hose removal steps
2. Front splash shield (LH) mounting clip
Connection of windshield washer
nozzle
3. Windshield washer hose
Washer tank removal steps

Front under cover (RH) (Refer to
351).
2. Front splash shield (RH) mounting
clip
Connection of front washer hose and
rear washer hose
4. Washer tank assembly
5. Windshield washer motor
Head lamp washer motor (Refer to
351).
6. Rear washer motor
7. Washer tank
EXTERIOR
51-24

Washer motor removal steps
Front under cover (LH) (Refer to
351).
Connection of front washer hose and
rear washer hose
5. Windshield washer motor
6. Rear washer motor
1
2

354A.
AC107604AC
INSPECTION
M1511008300125
WINDSHIELD WASHER MOTOR CHECK
1. Remove the washer tank assembly with the

washer hose attached. Then fill the washer tank
with water.
2. Check to see that the water is vigorously sprayed
when connecting the positive battery terminal to
terminal number 2 and terminal number 1 to the
negative battery terminal.
WINDSHIELD WASHER FLUID EJECTION CHECK

Move the nozzle to adjust the position so that the
spray is in the area shown in the illustration.
Units: mm
Windshield washer
nozzle perpendicular
Windshield washer
nozzle perpendicular
50
50
<Right>
<Left>
120
120
50
50
70
285
310
60
130
120
Windshield ceramic
line terminal
70 90
120
110
600
Windshield washer nozzle
AC107158 AC
EXTERIOR
51-25
WINDSHIELD WASHER SWITCH CHECK

1
2
3
4
5
6
7
8
9
10
11
Switch position
Tester
connection
Specified
condition
OFF
6-7
Open circuit
Windshield
washer switch
6-7
Less than 2
ohms
AC000417

M1511000300303
Item
Standard value
Rear wiper arm and blade assembly stop position (Distance from end wiper
blade and the end of tailgate galss) mm
30 5
ON-VEHICLE SERVICE
TROUBLESHOOTING
M1511000700259
The rear wiper and washer are controlled by the

smart wiring system (SWS). For troubleshooting,
refer to GROUP 54B, SWS Diagnosis 354B.
CHECK OF REAR WIPER OPERATION

WHEN SELECTOR LEVER IS AT THE "R"
POSITION
M1511022100039
1. When the selector lever is moved to the "R"

position with the rear wiper switch at the "INT"
position, the wiper should operate twice or three
times at low speed after approximately one
second.
2. If not, troubleshoot the system (Refer to GROUP
54B, Diagnosis 354B).
EXTERIOR
51-26

M1511008500141

Washer Tank Assembly and Rear Washer Motor Removal
and Installation (Refer to 351).
6
5
3
1
2
5.4 1.4 Nm
7.4 1.4 Nm
AC300618 AB
Wiper blade assembly removal steps

1. Wiper blade assembly
>>B<< 2. Wiper blade
Rear wiper motor removal steps
>>A<< 3. Wiper arm and blade assembly
Tailgate lower trim (Refer to GROUP
Tailgate waterproof film (Refer to
GROUP 42, Tailgate 342).
4. Rear wiper motor assembly
Rear washer nozzle removal steps
High-mounted stop lamp assembly
(Refer to GROUP 54A, High-mounted
stop lamp 354A).
5. Rear washer nozzle
Washer hose removal steps

Cowl side trim, front scuff plate,
centre pillar trim lower, rear scuff
plate, rear pillar trim and rear shelf
trim (Refer to GROUP 52A, Trims
352A).
Tailgate lower trim, tailgate side trim,
tailgate upper trim (Refer to GROUP
High-mounted stop lamp assembly
(Refer to GROUP 54A, High-mounted
stop lamp 354A).
6. Rear washer hose

354A.
EXTERIOR
51-27
INSPECTION
>>A<< REAR WIPER ARM AND BLADE

ASSEMBLY INSTALLATION
REAR WIPER MOTOR CHECK
M1511008600171
End of tailgate galss

A
1
AC100519 AC
Before installing the rear wiper arm and blade

assembly, operate the rear wiper motor so that the
motor stops at the predetermined park position.
Install the rear wipe arm and blade assembly and
adjust the rear wiper blade position so that the blade
end stops at the predetermined position (standard
position).
Standard value: (A) 30 5 mm
>>B<< WIPER BLADE INSTALLATION
CAUTION
Backing
Section A A
Wiper blade
Wiper
blade
Backing
(A) Operation check

1 2 3 4
(B) Stop position check
1 2 3 4
AC103246 AC
Inspect the rear wiper motor by removing the

harness connector with the motor attached to the
vehicle.
Wiper motor operation
Connect the battery to the rear wiper motor as shown
in the illustration (A) and check the motor operation.
A
A
Backing
AC101090AD
Use a curved backing like that shown for the

backing of a wiper blade to ensure sustained
wiper wiping performance.
Wiper motor at stop position operation

1. Connect the battery to the rear wiper motor as
shown in the illustration (A).
2. Disconnect the battery cable from the rear
windshield wiper motor while it is turning and then
check to see that the motor stops.
3. Re-connect the battery as shown in Figure (B).
4. Check to see that the rear windshield wiper motor
runs and then stops at the automatic stop
position.
EXTERIOR
51-28
REAR WASHER MOTOR CHECK

1
2
AC107605 AC
1. Remove the rear washer tank assembly with the

washer hose attached. Then fill the washer tank
with water.
REAR WASHER FLUID EJECTION CHECK
Move the nozzle to adjust the position so that the
spray is in the area shown in the illustration.
Rear washer
nozzle
Rear washer nozzle

perpendicular
Units: mm
25
Ceramic line
terminal
130
210
50
30
50
25
AC100520 AC
EXTERIOR
51-29
WIPER DEICER
REAR WIPER AND WASHER SWITCH CHECK

1
2
3
4
5
6
7
8
9
10
11
Switch position
Tester
connection
Specified
condition
OFF
4 - 6, 5 - 6
Open circuit
Rear wiper switch 4 - 6
Less than 2
ohms
Rear washer
switch
Less than 2
ohms
5-6
AC000417
WIPER DEICER
GENERAL INFORMATION
M1511000100495
Wiper Deicer operation

The defogger relay switch is activated (ON) by
turning on the A/C-ECU built-in defogger switch
when the ignition switch is in the "ON" position.
When the defogger relay is turned ON, power is
supplied to the rear defogger and wiper deicer, and
TROUBLESHOOTING
M1511014600095

the heater of the wiper deicer starts operations. The

defogger comes with a timer function and will
automatically turn OFF the switch approximately
about 11 minutes <manual A/C> or about 20 minutes
<automatic A/C> after the defogger switch is turned
ON. The wiper deicer operations are also terminated
along with the rear defogger, at this time.
EXTERIOR
51-30
WIPER DEICER
SYMPTOM PROCEDURES
INSPECTION PROCEDURE : Wiper Deicer Does not Operate
Wiper deicer Circuit
DEFOGGER
RELAY
BATTERY
DEFOGGER
RELAY
BOX
WIPER
DEICER
RELAY
WIPER
DEICER
Wire colour code


The wiper deicer should work for approximately 11
minutes <manual A/C> or 20 minutes <automatic A/
C> when the rear defogger switch is turned on. If the
wiper deicer does not work for the specified period,
the defogger relay circuit and the power supply and/
or earth circuit to the wiper deicer may be defective.
The wiper deicer itself or its relay may be also

defective.
Possible causes
Malfunction of the wiper deicer
Malfunction of the wiper deicer relay
EXTERIOR
51-31
WIPER DEICER
DIAGNOSIS PROCEDURE
Check that the rear defogger works normally.
YES : Go to Step 2.
NO : 7URXEOHVKRRWWKHUHDUGHIRJJHU5HIHUWR
*5283$-6\PSWRPFKDUW355ARU
*5283%-7URXEOHV\PSWRPFKDUW
355B
STEP 3. Check the wiper deicer relay.

Check that the wiper deicer relay works normally
(Refer to wiper deicer relay check 351).
YES : Go to Step 4.
NO : Replace the wiper deicer relay.
STEP 4. Connector check: B-32 wiper deicer

connector
Connector:
B-32
B-32(B)
STEP 2. Connector check: A-08X wiper deicer

relay connector
B-32
Harness side
2 1
Connector: A-08X
AC301521AE

YES : Go to Step 5.
STEP 5. Check the wiper deicer.

Check that the wiper deicer works normally (Refer to
wiper deicer check 351).
Relay box side

YES : Go to Step 6.
NO : Replace the wiper deicer.
Front of
vehicle
AC301483AH

YES : Go to Step 3.
EXTERIOR
51-32
WIPER DEICER
STEP 6. Measure the resistance at the A-08X

wiper deicer relay connector.
Connector: A-08X
STEP 7. Check the wiring harness between A-08X

wiper deicer relay connector terminal No.3 and
body earth.
Connector: A-08X
Relay box side
Relay box side
Front of
vehicle
Front of
vehicle
AC301483AH

relay box side.
AC301483AH

Connector A-08X
(relay box side)

AC301834 AB
(2) Resistance between A-08X wiper deicer relay

OK: 2 W or less
YES : Go to Step 8.
NO : Go to Step 7.
EXTERIOR
51-33
WIPER DEICER
STEP 8. Measure the voltage at the A-08X wiper

deicer relay connector.
(2) Defogger switch: ON
STEP 9. Connector check: C-205 junction block

connector
Connector: C-205
Connector: A-08X
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE

Relay box side
Front of
vehicle
AC301483AH

relay box side.
Connector A-08X
(relay box side)
AC301835 AB
(4) Voltage between A-08X wiper deicer relay

OK: System voltage
NO : Go to Step 9.
EXTERIOR
51-34
WIPER DEICER
STEP 10. Check the wiring harness between A08X wiper deicer relay connector terminal No.2
and C-205 junction block connector terminal
No.3.
NOTE:
Connector: C-116
Connector: A-08X
C-116
1 2
Relay box side
5 6 7
3 4
10 11 12 13 14
15
8 9
1617 18 1920 21
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
Front of
vehicle
AC301396 AB
AC301483AH
Connector: C-205

necessary.

Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE
EXTERIOR
51-35
WIPER DEICER
STEP 11. Measure the voltage at B-32 wiper

deicer connector.
Connector:
B-32
B-32(B)
STEP 12. Measure the voltage at the A-08X wiper

deicer relay connector.
Connector: A-08X
B-32
Harness side
2 1
AC301521AE

Relay box side
Front of
vehicle
2 1
Connector B-32
(haness side)
AC301483AH

relay box side.
AC301837AB
(4) Voltage between B-32 wiper deicer connector

OK: System voltage
NO : Go to Step 12.
Connector A-08X
(relay box side)
AC301836 AB
(2) Voltage between A-08X wiper deicer relay

OK: System voltage
NO : Go to Step 13.
EXTERIOR
51-36
WIPER DEICER
and the battery.
Connector: A-08X
Relay box side
Front of
vehicle
AC301483AH


EXTERIOR
51-37
WIPER DEICER
and B-32 wiper deicer connector terminal No.2.
NOTE:
Connector: C-106
Connector: A-08X
C-106(GR)
2
1
3 4
5 6
7 8 9
10 11 12
16
13 14 15 17 18 19
AC301397AG
Connector: C-116
Relay box side
Front of
vehicle
AC301483AH
Connector:
B-32
B-32(B)
C-116
B-32
Harness side
2 1
1 2
5 6 7
3 4
8 9
10 11 12 13 14
15
22 23 24 25 26
27 28 29
30 31 32 33
34 35 36 37
38 39 40
41 4243
1617 18 1920 21
AC301396 AB
AC301521AE

intermediate connectors C-106 and C-116, and

EXTERIOR
51-38
WIPER DEICER
STEP 15. Measure the resistance at B-32 wiper

deicer connector.
Connector:
B-32
B-32(B)
B-32
Harness side
2 1
STEP 16. Check the wiring harness between B-32

wiper deicer connector terminal No.1 and body
earth.
Connector:
B-32
B-32(B)
B-32
Harness side
2 1
AC301521AE

AC301521AE

NOTE:
Connector: C-17
4 5
1 2 3
6 7 8 9 10 1112 13
2 1
Connector B-32
(haness side)
AC301838AB
(2) Resistance between B-32 wiper deicer connector

OK: 2 W or less

NO : Go to Step 16.
C-17(GR)
AC301397AE


EXTERIOR
51-39
HEADLAMP WASHER
WIPER DEICER
WIPER DEICER RELAY CHECK
INSPECTION
Wiper deicer relay

M1511019100396
WIPER DEICER CHECK

Windshield
2
AC211776
Windshield wiper motor

AC301953 AB
There should be continuity between the wiper deicer

connector terminal Nos.1 and 2.
1 2
3 4
4
3
AC301954 AB
Battery
voltage
Terminal
number to be
connected to
tester
Continuity test
results
Not applied
1-4
Open circuit
Connect
terminal
No.3 and
battery (-)
terminal.
Connect
terminal
No.2 and
battery (+)
terminal.
1-4
Less than 2 ohms
HEADLAMP WASHER
TROUBLESHOOTING
M1511000700293
The headlamp washer is controlled by the Smart

GROUP 54B, Troubleshooting 354B.
EXTERIOR
51-40
HEADLAMP WASHER
HEADLAMP WASHER
M1511009700041

Radiator Grille Removal and Installation (Refer to 351
).
Front Bumper Extension Removal and Installation (Refer
to 351).
Under Cover Removal and Installation (Refer to 351).
1
13
15
14
7
3
N 10
8
10 N
5
9
4
11
12
12
11
AC300298 AB
Removal steps
Washer fluid draining

1. Headlamp washer hose connection
2. Headlamp washer motor connector
3. Headlamp washer hose
4. Headlamp washer joint
6. Headlamp washer motor
7. Headlamp washer motor packing
Front bumper (Refer to 351).

8. Headlamp washer cover
9. Headlamp washer nozzle
10. O-ring
11. Headlamp washer actuator
assembly
EXTERIOR
51-41
MARK
INSPECTION
M1511009800060
HEADLAMP WASHER MOTOR CHECK

1 2
AC300406 AB
1. Remove the headlamp washer motor connector.
MARK
M1511011800391
2
1
AC300472 AC
1. Front three-diamond mark
>>A<< 2. Rear three-diamond mark

>>A<< 3. Outlander mark and 4WD mark
EXTERIOR
51-42
MARK

>>A<< ATTACHMENT OF EACH POINT
ATTACHED POSITION
OUTLANDER mark and 4WD nark
Units: mm
Tailgate panel end line

50
AC301886 AB
Three-diamond mark
Units: mm
66 1
Press line
Center line
of vehicle
AC200088 AB
1. Remove grease on the marked surface of the

body with unleaded gasoline.
2. Peel off the protection sheet on the back of the
mark to paste it on the installation position.
CAUTION
Carry out this work in a location which has an
ambient temperature of 20 - 38C and which
is free from dust.
If ambient temperature is lower than 20C,
heat the mark and the vehicle body
(application location) to 20 - 30C.
Be sure to pressure the mark immediately
after the pasting is done.
EXTERIOR
51-43
DOOR MIRROR
DOOR MIRROR
GENERAL INFORMATION
M1511000100503
Remote Controlled Mirror Operation

The mirror on the door mirror moves up/down and
left/right by operating the remote controlled door
mirror switch when the ignition switch is in the "ON"
or "ACC" position.
Heated Door Mirror operation
The defogger relay switch is activated (ON) by
turning on the A/C-ECU built-in defogger switch
when the ignition switch is in the "ON" position.
When the defogger relay is turned ON, power is
supplied to the defogger and door mirror, and the
heater of the door mirror (heated door mirror) starts
operations. The defogger comes with a timer function

and will automatically turn OFF the switch
approximately about 11 minutes <manual A/C> or
about 20 minutes <automatic A/C> after the defogger
switch is turned ON. The heated door mirror
operations are also terminated along with the
defogger, at this time.
TROUBLESHOOTING
M1511014600103


M1511015000115
SYMPTOM
INSPECTION REFERENCE
PROCEDURE PAGE
All heated door mirrors do not operate
351
The right or left heated door mirror does not operate
351
EXTERIOR
51-44
DOOR MIRROR
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: All Heated Door Mirrors do not Operate
Heated door mirror Circuit
DEFOGGER
RELAY
DEFOGGER
REMOTE
CONTROLLED
MIRROR (LH)
MIRROR
HEATER
MIRROR
HEATER
REMOTE
CONTROLLED
MIRROR (RH)
Wire colour code


The heated door mirrors should work for
approximately 11 minutes <manual A/C> or 20
minutes <automatic A/C> when the rear defogger
switch is turned on. If the mirror heater does not work
for the specified period, the defogger relay circuit
(heated door mirror power supply circuit) may be
defective.
SB : Sky blue
Possible causes
EXTERIOR
51-45
DOOR MIRROR
DIAGNOSIS PROCEDURE
Check that the rear defogger system should work
normally.

connector
Connector: C-205

YES : Go to Step 2.
NO : Troubleshoot the rear defogger (Refer to
GROUP 55A - Trouble symptom chart

355A or GROUP 55B - Trouble symptom
chart 355B).
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE


Malfunction 300).
EXTERIOR
51-46
DOOR MIRROR
INSPECTION PROCEDURE 2: Right or Left Heated Door Mirror does not Operate
Heated door mirror Circuit
DEFOGGER
RELAY
DEFOGGER
REMOTE
CONTROLLED
MIRROR (LH)
MIRROR
HEATER
MIRROR
HEATER
REMOTE
CONTROLLED
MIRROR (RH)
Wire colour code


If either of the heated door mirrors does not work, the
door mirror assembly may be defective.
Possible causes
Malfunction of the door mirror assembly
DIAGNOSIS PROCEDURE
STEP 1. Verify the operation of each heated door
mirror.
Q: Which door mirror does not heat?
Door mirror (RH) : Go to Step 2.
Door mirror (LH) : Go to Step 9.
SB : Sky blue
STEP 2. Check the door mirror assembly (RH).

Check that the heater element of the door mirror
assembly (RH) is in good condition (Refer to the
heated door mirror check 351).
YES : Go to Step 3.
NO : Replace the door mirror assembly (RH).
EXTERIOR
51-47
DOOR MIRROR
STEP 3. Connector check: E-16 door mirror

assembly (RH) connector
Connector: E-16

door mirror assembly (LH) connector terminal
Connector: E-16
E-16
Harness side
2
1
7 6 5 4 3
E-16
Harness side
AC301412 AE

YES : Go to Step 4.
2
1
7 6 5 4 3
AC301412 AE

NOTE:
Connector: C-15
STEP 4. Measure the resistance at the E-16 door

mirror assembly (RH) connector.
Connector: E-16
E-16
Harness side
2
1
7 6 5 4 3
C-15(GR)
AC301412 AE

C-15
1
2
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
AC301398 AC

2
1
7 6 5 4 3

Connector E-16
(harness side)
AC301694 AC
(2) Resistance between E-16 door mirror assembly

OK: 2 W or less
YES : Go to Step 6.
NO : Go to Step 5.

Malfunction 300).
EXTERIOR
51-48
DOOR MIRROR
STEP 6. Measure the voltage at the E-16 door

mirror assembly (RH) connector.

door mirror assembly (RH) connector terminal
No.1 and C-205 junction block connector
terminal No.3.
Connector: E-16
Connector: E-16
E-16
Harness side
E-16
Harness side
2
1
7 6 5 4 3
2
1
7 6 5 4 3
AC301412 AE

AC301412 AE
Connector: C-205
Harness side
2
1
7 6 5 4 3
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE
Connector E-16
(harness side)
AC301695 AB
(4) Voltage between E-16 door mirror assembly

OK: System voltage

NOTE:
Connector: C-15


Malfunction 300).
NO : Go to Step 7.
connector
Connector: C-205
C-15(GR)
C-15
1
2
3 4
5 6
7 8 9 10 11 12
13 14 15 16 17 18 19
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE

YES : Go to Step 8.
AC301398 AC

EXTERIOR
51-49
DOOR MIRROR

Malfunction 300).
STEP 9. Connector check: E-06 door mirror
assembly (LH) connector
Connector: E-06
STEP 11. Measure the resistance at the E-06 door

mirror assembly (LH) connector.
Connector: E-06
E-06
Harness side
2
1
7 6 5 4 3
AC301418 AE

E-06
Harness side
2
1
7 6 5 4 3
AC301418 AE

STEP 10. Check the door mirror assembly (LH).

Check that the heater element of the door mirror
assembly (LH) is in good condition (Refer to the
heated door mirror check 351).
NO : Replace the door mirror assembly (LH).
2
1
7 6 5 4 3
Connector E-06
(harness side)
AC301694 AB
(2) Resistance between E-06 door mirror assembly

OK: 2 W or less
NO : Go to Step 12.
EXTERIOR
51-50
DOOR MIRROR

Connector: E-06

connector
Connector: C-205
E-06
Harness side
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
2
1
7 6 5 4 3
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE
AC301418 AE

NOTE:
Connector: C-118

STEP 14. Measure the voltage at the E-06 door

mirror assembly (LH) connector.
Connector: E-06
E-06
Harness side
C-118
2
1
7 6 5 4 3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301418 AE

AC301396 AE

necessary.

Malfunction 300).
2
1
7 6 5 4 3
Connector E-06
(harness side)
AC301695 AC
(4) Voltage between E-06 door mirror assembly

OK: System voltage

Malfunction 300).
NO : Go to Step 15.
EXTERIOR
DOOR MIRROR

No.1 and C-205 junction block connector
terminal No.3.
Connector: E-06
E-06
Harness side
2
1
7 6 5 4 3
AC301418 AE
Connector: C-205
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC210474 AE

NOTE:
Connector: C-118
C-118
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27
28 29 30 31 32
AC301396 AE

necessary.
51-51


Malfunction 300).
EXTERIOR
51-52
DOOR MIRROR
DOOR MIRROR
M1511006700053
Section A A
Section B B
1
7
Claw
Claw
Clip
3
6
4
3
5
B
B
A
AC201696 AB
Door mirror removal steps

1. Delta cover
2. Tweeter
>>A<< 3. Door mirror assembly
4. Door mirror body assembly
<<A>>
5. Mirror
Remote controlled mirror switch

removal steps
6. Instrument panel lower cover (Refer
to GROUP 52A, Instrument panel
352A).
7. Remote controlled mirror switch
EXTERIOR
51-53
DOOR MIRROR
<<A>> MIRROR REMOVAL
>>A<< DELTA COVER INSTALLATION
CAUTION
CAUTION
Section A A
Pivot plate
Mirror
Clip
Flat-tipped
screwdriver
Claw
Flat-tipped
screwdriver
Mirror
A
Delta cover
Section A A
Delta cover
A
Clip
Protective tape
Door panel
Notch
AC107642 AB
If the delta cover is placed with the clip on the

door panel, the clip may be pushed into the door
panel and fall off. Thus, special care is
necessary.
Install the delta cover with the clip installed.
Claw
Claw
AC103244 AC
The thumb of the mirror is prone to breakage

when working in cold temperatures. Always
warm up the mirror thumb and thumb periphery
to 20C or higher before handling.
Slant the mirror upward with your hands. Then insert
a flat-tipped screwdriver wrapped with protective
tape between the pivot plate and mirror through the
cut-out from behind the mirror. Now pry off the mirror
thumb and remove the mirror as shown.
EXTERIOR
51-54
DOOR MIRROR
INSPECTION
>>B<< DOOR MIRROR ASSEMBLY

INSTALLATION
M1511006800050
ELECTRIC REMOTE CONTROL MIRROR

OPERATION CHECK
CAUTION
Section A A
Door panel
Runchannel
Door mirror
claw position
Notch
Door mirror
Door mirror
claw position
Runchannel
Check that the mirror moves as described in the

table when each terminal is connected to the battery.
AC103753 AC
When assembling the door mirror, check to see

that the thumb of the door mirror is inserted in
the cut-out of the front door run channel.
Battery connection
Direction
operation
Connect terminal 5 to the negative

battery terminal.
Connect terminal 7 to the positive
battery terminal.
Up

battery terminal.
battery terminal.
Down

battery terminal.
battery terminal.
Right

battery terminal.
battery terminal.
Left
EXTERIOR
51-55
DOOR MIRROR
DOOR MIRROR CONTROL SWITCH CONTINUITY

CHECK
HEATED DOOR MIRROR CHECK
CAUTION
When relocating the car between locations with
extremely different temperatures (warm and
cold), leave the car in the location for a while to
adapt to the temperature prior to checking it.
3 4
1 2
5 6 7 8 9 10 11
AC005970
Switch position
Tester
connection
OFF
9 - 2, 9 - 3, 9 - 6, Open circuit
9 - 10, 9 - 11,
1 - 2,
1 - 3, 1 - 6,
1 - 10,
1 - 11
Left side OFF
Up
Right
side
Specified
condition
9 - 6, 9 - 10,
9 - 11,
1 - 6, 1 - 10,
1 - 11
Open circuit
1 - 6, 9 - 11
Less than 2
ohms
Resistance
()
12
10
8
6
4
2
0
-10
Down
1 - 11, 6 - 9
Less than 2
ohms
Right
1 - 6, 9 - 10
Less than 2
ohms
Left
1 - 10, 6 - 9
Less than 2
ohms
OFF
9 - 2, 9 - 3, 9 - 6, Open circuit
1 - 2, 1 - 3, 1 - 6
Up
1 - 6, 3 - 9
Less than 2
ohms
Down
1 - 3, 6 - 9
Less than 2
ohms
Right
1 - 6, 2 - 9
Less than 2
ohms
Left
1 - 2, 6 - 9
Less than 2
ohms
Upper limit value
Lower limit value

0
10
20
Temperature (C)
30
40
AC201611 AC

is almost satisfied when measuring the resistance of
terminal 1 and 2 of the door mirror connectors under
2 or more different temperature conditions.
127(6

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GROUP INDEX

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

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

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

All information, illustrations and product descriptions Front Suspension . . . . . . . . . . . . . . .

TECHNICAL INFORMATION MANUAL

Mitsubishi Motors Europe B.V.

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL

EXHAUST MANIFOLD REMOVAL AND

WATER PUMP AND WATER HOSE . 11B

ROCKER ARMS AND CAMSHAFT . . 11B

ROCKER ARMS AND CAMSHAFT

ROCKER ARMS AND CAMSHAFT

CYLINDER HEAD AND VALVES. . . . 11B

ALTERNATOR AND IGNITION

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

FUEL AND EMISSION PARTS . . . . . 11B

INTAKE MANIFOLD REMOVAL AND

CYLINDER HEAD AND VALVES

OIL PAN AND OIL PUMP. . . . . . . . . . 11B

TIMING BELT REMOVAL AND

FUEL AND EMISSION PARTS REMOVAL

CYLINDER HEAD AND VALVES

OIL PAN AND OIL PUMP REMOVAL AND

OIL PAN AND OIL PUMP INSPECTION. . .

PISTON AND CONNECTING ROD . . 11B

PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD

CRANKSHAFT AND CYLINDER BLOCK

CRANKSHAFT AND CYLINDER BLOCK

CRANKSHAFT AND CYLINDER BLOCK

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

Classification of Service Points

<<A>>: Outward-pointing brackets denote removal service points

Lubricant and Sealant Symbols

HOW TO USE THIS MANUAL

CRANKSHAFT AND CYLINDER BLOCK

Denotes non-reusable part.

INSTALLATION SERVICE POINTS

The alphabetical character in this category of

VEHICLE AND ENGINE MODELS

Double overhead camshaft, 16-valve

Double overhead camshaft

Number of intake valves

Roller cam followers

Fuel injection system

Electronically controlled multi-point injection (MPI)

Electronically controlled two-coil system

Alternator (with built-in IC regulator)

Gear reduction drive type

Auto-tensioner rod extension length

Auto-tensioner rod extension length (when free) mm

Auto-tensioner rod retraction length

Less than 0.05

ROCKER ARMS AND CAMSHAFTS

Cylinder head gasket surface grinding limit

Cylinder head overall height mm

Cylinder head bolt nominal length mm

Valve stem diameter mm

Valve face angle

Valve spring free height mm

Valve spring load/height N/mm

WATER PUMP AND WATER HOSE . 11B

ROCKER ARMS AND CAMSHAFT . . 11B

CYLINDER HEAD AND VALVES. . . . 11B

FUEL AND EMISSION PARTS . . . . . 11B

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

PISTON AND CONNECTING ROD . . 11B