Руководство по ремонту mitsubishi l200 1996

Выпуск 1996 — 2008гг.
Бензиновые двигатели V6 6G72 3.0l, 6G74 3.5l

Язык: Русский
Формат: PDF
Размер: 73,1 Мб

Язык: Русский
Формат: PDF
Размер: 227 Мб

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5. L200 1996
6. Workshop manual

• Page 1
  Workshop Manual chassis Pub. No. PWTE96E1…
• Page 4
  13A-1 FUEL 13109000924 CONTENTS MULTIPOINT FUEL INJECTION (MPI)…………….13A ELECTRONIC CONTROL TYPE CARBURETTOR………….13B CONVENTIONAL TYPE CARBURETTOR …………..13C VARIABLE VENTURI TYPE CARBURETTOR…………13D DIESEL FUEL ………………….. 13E FUEL SUPPLY………………….13F TRACTION CONTROL SYSTEM (TCL)……………13H DIESEL FUEL <4D5-STEP III> ………………13I NOTE THE GROUPS MARKED BY ARE NOT IN THIS MANUAL…
• Page 7
  55-1 HEATER, AIR CONDITIONER AND VENTILATION CONTENTS HEATER, AIR CONDITIONER AND VENTILATION …………. 55 AUTOMATIC AIR CONDITIONER …………….55B…
• Page 8
  GENERAL Click on the applicable bookmark to selected the required model year…
• Page 10
  00-2 GENERAL – How to Use This Manual HOW TO USE THIS MANUAL 00100010210 SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS AND SERVICING EXPLANATIONS STANDARD VALUE This manual provides explanations, etc. concerning Indicates the value used as the standard for judging procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection and servicing of the subject model.
• Page 11
  00-3 GENERAL – How to Use This Manual MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. M/T: Indicates the manual transmission, or models equipped with the manual transmission. A/T: Indicates the automatic transmission, or models equipped with the automatic transmission. SOHC: Indicates an engine with the single overhead camshaft, or a model equipped with such an engine.

• Page 12: Explanation Of Manual Contents

  00-4 GENERAL – How to Use This Manual EXPLANATION OF MANUAL CONTENTS Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Component Diagram A diagram of the component parts is provided near the front of each section in order to give a reader a better under-…

• Page 13
  00-5 GENERAL – How to Use This Manual Indicates the Indicates the Indicates the Indicates the group title. section title. group num- page number. ber. Denotes non-reus- able part. Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Standard Parts- tightening-torque Table”.

• Page 14: Troubleshooting Contents

  00-6 GENERAL – How to Use Troubleshooting/Inspection Service Points HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS 00100020091 Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems still follow this outline.

• Page 15
  00-7 GENERAL – How to Use Troubleshooting/Inspection Service Points 4. INSPECTION CHART FOR DIAGNOSIS CODES 5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-9 for how to read the inspection procedures.) 6.
• Page 16
  00-8 GENERAL – How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP 1. Use the special tool to earth No.1 terminal (diagnosis control terminal) of the diagnosis connector. Diagnosis connector 2. To check ABS system, remove the valve relay. NOTE That is because the valve relay is off and the warning lamp remains illuminated if there is a fault in the ABS…

• Page 17: How To Use The Inspection Procedures

  00-9 GENERAL – How to Use Troubleshooting/Inspection Service Points HOW TO USE THE INSPECTION PROCEDURES The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order, and they first try to discover a problem with a connector or a defective component.

• Page 18
  00-10 GENERAL – How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to OFF when connecting disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to be contrary. IF INSPECTING WITH THE CONNECTOR CONNECTED Harness connector (WITH CIRCUIT IN A CONDITION OF CONTINUITY)
• Page 19
  00-11 GENERAL – How to Use Troubleshooting/Inspection Service Points CONNECTOR INSPECTION Connector disconnected or improperly connected VISUAL INSPECTION Connector is disconnected or improperly connected Connector pins are pulled out Due to harness tension at terminal section Low contact pressure between male and female terminals Low connection pressure due to rusted terminals or foreign matter lodged in terminals Defective connector contact…
• Page 20
  00-12 GENERAL – How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE Remove the fuse and measure the resistance between the load side of the fuse and the earth. Set the switches of all 0 Ω circuits which are connected to this fuse to a condition of continuity.
• Page 21
  00-13 GENERAL – Treatment Before/After the Fording of a Stream TREATMENT BEFORE/AFTER THE FORDING OF A STREAM (4WD VEHICLES) 00100060031 INSPECTION AND SERVICE BEFORE FORDING A STREAM Vehicles which are driven through water, or which Seal the speedometer cable with a may possibly be driven through water, should be water-resistant grease or tape.
• Page 22
  00-14 GENERAL – Treatment Before/After the Fording of a Stream Apply grease to the lubricating points of the front suspension, steering linkage and propeller shaft. Pitman arm Tie rod Tie rod ends Upper arm…
• Page 23
  00-15 GENERAL – Treatment Before/After the Fording of a Stream INSPECTION AND SERVICE AFTER FORDING A STREAM After fording a stream, check the following points. Apply grease to the lubricating points of the If abnormal condition is evident, clean, replace or front suspension, steering linkage and propeller shaft.

• Page 24: Model Code

  00-16 GENERAL – Vehicle Identification VEHICLE IDENTIFICATION 00100540061 VEHICLE INFORMATION CODE PLATE LOCATION Vehicle information code plate is riveted on the upside of the headlamp support panel inside the engine compartment. CODE PLATE DESCRIPTION The plate shows model code, engine model, transmission model, and body colour code.

• Page 25
  00-17 GENERAL – Vehicle Identification MODELS 00100550064 Model Code Engine model Transmission model Fuel supply system K62T JERDEL6 4G63-SOHC (1,997 m ) R4AW2 (2WD-4A/T) ENDEL6 R5M21 (2WD-5M/T) K64T YNDL6 4D56 (2,477m ) R5M21 (2WD-5M/T) Fuel injection ZNDL6 ENDL6 ENDR6 CENDL6 JENDL6 K75T CENDEL6…
• Page 26
  00-18 GENERAL – Vehicle Identification MODEL CODE 00100040134 1 2 3 4 5 6 7 8 9 10 11 12 Items Contents Vehicle line K: L200 6: 2WD Drive system 7: 4WD Engine type 2: 1,997 m Petrol engine 4: 2,477 m Diesel engine 5: 2,351 m Petrol engine Group T: Truck…

• Page 27: Table Of Contents

  00-19 GENERAL – Vehicle Identification CHASSIS NUMBER 00100560067 The chassis number is stamped on the side wall of the frame near the rear wheel (R.H.). 1 2 3 4 5 6 7 8 9 10 11 Items Contents Continent ASIA Country THAILAND Register code…

• Page 28
  00-20 GENERAL – Vehicle Identification ENGINE MODEL NUMBER <4G63, 4G64> 00100570060 1. The engine model number is stamped at the cylinder block as shown in the following. Front of engine Engine model Engine displacement m 4G63 1,997 4G64 2,351 4D56 2,477 2.
• Page 29
  00-21 GENERAL – Major Specifications MAJOR SPECIFICATIONS 00100090146 <2WD Single cab> Items K62T K64T K64T K64T ENDEL6 ENDL6 YNDL6 ENDR6 Vehicle Overall length 4,935 4,935 4,775 4,935 dimensions dimensions Overall width 1,695 1,695 1,695 1,695 Overall height (unladen) 1,585 1,585 1,585 1,585 Wheelbase…
• Page 30
  00-22 GENERAL – Major Specifications <2WD Double cab, Club cab> Items K64T K62T K64T K64T CENDL6 JERDEL6 JENDL6 ZENDL6 Vehicle Overall length 5,050 4,935 4,935 4,775 dimensions dimensions Overall width 1,695 1,695 1,695 1,695 Overall height (unladen) 1,605 1,610 1,610 1,625 Wheelbase 2,950…
• Page 31
  00-23 GENERAL – Major Specifications <4WD Single cab, Club cab> Items K74T K74T K75T K74T YNDFL6 ENDFR6 CENDEL6 CENDFL6 Vehicle Overall length 4,810 4,935 5,050 5,050 dimensions dimensions Overall width 1,695 1,695 1,695 1,695 Overall height (unladen) 1,755 1,755 1,775 1,775 Wheelbase 2,960…
• Page 32
  00-24 GENERAL – Major Specifications <4WD Double cab> Items K74T K74T K74T K74T K74T JENDFL6 ZNDFL6 JERDFL6 JENHFL6 GJENXFL6 Vehicle Overall length 4,935 4,810 4,935 4,935 4,935 dimen dimen- Overall width 1,695 1,695 1,695 1,695 1,775 sions mm Overall height (unladen) 1,780 1,795 1,780…

• Page 33: Precautions Before Service

  00-25 GENERAL – Precautions Before Service PRECAUTIONS BEFORE SERVICE 00100050144 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B – Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Always use the designated special tools and test equipment.

• Page 34
  00-26 GENERAL – Precautions Before Service SERVICING THE ELECTRICAL SYSTEM Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (–) cable from the battery in order to avoid damage caused by short-circuiting.
• Page 35
  00-27 GENERAL – Precautions Before Service MUT-II MUT-II sub-assembly Refer to the MUT-II INSTRUCTION MANUAL for instructions on handling the MUT-II. ROM pack Connect the MUT-II to the diagnosis connector as shown in the illustration. Caution Connection and disconnection of the MUT-II should always be made with the ignition switch in the OFF position.
• Page 36
  00-28 GENERAL – Precautions Before Service Other precautions: Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Avoid contaminating clothes, particularly underpants, with oil. Do not put oily rags in pockets, the use of overalls without pockets will avoid this.
• Page 37
  00-29 GENERAL – Supplemental Restraint System (SRS) SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 00100590066 GENERAL INFORMATION To improve safety, the SRS is available as optional Only authorized service personnel should do work on or around the SRS components. Those service part. These system enhance collision safety by restraining the driver in case of an accident.
• Page 38
  00-30 GENERAL – Supplemental Restraint System (SRS) SRS SERVICE PRECAUTIONS 00100600066 1. In order to avoid injury to yourself or others 3. Never Attempt to Repair the Following from accidental deployment of the air bag during Components: servicing, read and carefully follow all the SRS Diagnosis unit (SDU) Clock Spring precautions and procedures described in this…
• Page 39
  00-31 GENERAL – Supplemental Restraint System (SRS) Harness connector Destination of harness Corrective action (No. of terminals, terminal colour) Body wiring harness ! Clock spring 2 pins, red 1, 2 Replace clock spring – 3, 4 – – – 5, 6 –…

• Page 40: Support Locations For Lifting And Jacking

  00-32 GENERAL – Support Locations for Lifting and Jacking SUPPORT LOCATIONS FOR LIFTING AND JACKING 00100070058 Caution Do not support the vehicles at locations other than specified supporting points. If do so, this will cause damage, etc. SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS <2WD>…

• Page 41
  00-33 GENERAL – Support Locations for Lifting and Jacking <4WD> AXLE STANDS GARAGE JACK…
• Page 42
  00-34 GENERAL – Support Locations for Lifting and Jacking SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT AND H-BAR LIFT Caution When service procedures require removing rear anchor vehicle to hoist to prevent tipping of suspension, spare tyre and rear bumper, place centre of gravity changes.
• Page 43
  00-35 GENERAL – Support Locations for Lifting and Jacking <4WD> DOUBLE-POST LIFT SINGLE-POST LIFT H-BAR LIFT…
• Page 44
  00-36 GENERAL – Standard Parts-tightening-torque Table STANDARD PARTS-TIGHTENING-TORQUE TABLE 00100110033 Each torque value in the table is a standard value The values in the table are not applicable: for tightening under the following conditions. (1) If toothed washers are inserted. (1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
• Page 65
  SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-98E00-503 Date <Model> <M/Y> 1998-12-15 CORRECTION TO DIAGNOSIS CODE READING (EC,EXP)COLT 96-10 Subject: PROCEDURE FOLLOWED WHEN USING (CA0A,CC0A) 97-10 WARNING LAMP (EC,EXP) 97-10 Group: GENERAL Draft No.: 98AL051414…
• Page 66
  00-8 GENERAL — How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP 1. Use the special tool to earth NO.1 terminal (diagnosis control terminal) of the diagnosis connector. Diagnosis connector 2. To check ABS system, remove the valve relay. NOTE That is because the valve relay is off and the warning lamp MB991529…
• Page 67
  00-8 GENERAL — How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP 1. Use the special tool to earth No.1 terminal (diagnosis control Diagnosis connector terminal) of the diagnosis connector. 2. To check ABS system, remove the valve relay. NOTE That is because the valve relay is off and the warning lamp remains illuminated if there is a fault in the ABS system.
• Page 68
  00-8 GENERAL — How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP 1. Use the special tool to earth NO.1 terminal (diagnosis control Diagnosis connector terminal) of the diagnosis connector. 2. To check ABS system, remove the valve relay. NOTE That is because the valve relay is off and the warning lamp remains illuminated if there is a fault in the ABS system.
• Page 69
  SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-00E00-003 Date 2000-05-30 <Model> <M/Y> Subject: YEAR MODEL CHANGES FOR 2001 L200 (EC)L200(K60, K70) 00-10 Group: GENERAL Draft No.: 00SY0022915 INFORMATION/ INTERNATIONAL CORRECTION ADMINISTRATIO T.NITTA — PROJECT LEADER OFFICE AFTER SALES SERVICE &…
• Page 71
  All information, illustrations and product d scriptions contained in this manual are current as at the time of publication. We, however, re- serve the right to make changes at any time without prior notice or obligation. © Mitsubishi Motors Corporation 2000…
• Page 72
  00-1 GENERAL – vehicle identification GROUP 00 GENERAL VEHICLE IDENTIFICATION MODELS Model Code Engine model Transmission model Fuel supply sys- 4G63-SOHC (1,997mℓ ) K62T JERDEL6 R4AW2 (2WD-4A/T ENDEL6 R5M21 (2WD-5M/T) 4D56 (2,477mℓ ) K64T ENDL6 R5M21 (2WD-M/T) Fuel injection ENDR6 CENDL6 JENDL6 4G64-SOHC (2,351 mℓ…

• Page 73: Continent

  00-2 GENERAL – vehicle identification CHASSIS NUMBER Y0015AA Items Contents Continent ASIA Country THAILAND Register code Follow register Body shape Club cab Double cab Single cab Single cab without rear body Double cab without rear body Transmission type 5-speed manual transmission 4-speed automatic transmission Vehicle line Mitsubushi L200…

• Page 74
  NOTES…
• Page 75
  12-1 ENGINE LUBRICATION – General/On-vehicle Service GROUP 12 ENGINE LUBRICATION GENERAL OUTLINE OF CHANGES • A quality of the engine oil has been changed. ON-VEHICLE SERVICE <4G6> Barometric temperature specified engine oil (ACEA and API classification): <4G6> ACEA A1, A2, A3/API SG or higher <4D5>…
• Page 76
  NOTES…
• Page 77
  42-1 BODY – General/Keyless Entry System GROUP 42 BODY GENERAL OUTLINE OF CHANGES The following service procedures have been added due to the introduction of the keyless entry system as an optional equipment <GLS>. KEYLESS ENTRY SYSTEM SPECIAL TOOL Tool Number Name MB991502…
• Page 78
  42-2 BODY – Keyless entry system 2. Exit conditions from the adjustment mode The ETACS-ECU cancels the adjustment mode when any of the following conditions is satisfied: • Diagnosis control: OFF (Disconnect the MUT-II>) • Key reminder switch: ON (Pull out the ignition key.) •…
• Page 79
  42-3 BODY – Keyless Entry System INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 None of the doors can be locked or unlocked using Probable cause the transmitter. • The cause may be a malfunction of the transmitter or ETACS- Malfunction of transmitter •…
• Page 80
  42-4 BODY – Keyless Entry System From previous page MUT-II Pulse Check Key reminder switch continuity check • Key reminder switch input signal OK: MUT-II buzzer sounds once when removing Repair and inserting ignition key. Check the following connectors: C-72, C-79, C-86, C-91 Replace the transmitter.
• Page 81
  42-5 BODY – Keyless Entry System INSPECTION PROCEDURE 3 Encrypted codes cannot be registered Probable cause • Malfunction of MUT-II The cause may be a malfunction of the diagnosis con- • Malfunction of connector or wiring harness nector, ETACS-ECU or diagnosis output circuit. •…
• Page 82
  42-6 BODY – Keyless Entry System ON – VEHICLE SERVICE Battery HOW TO REPLACE A BATTERY OF THE TRANSMITTER 1. Remove the set screw to remove the battery from the transmitter. Install a battery with its (+) side face-down. Battery required for replacement: Coin type battery CR2032 3.
• Page 83
  42-7 BODY – Keyless Entry System 3. Within 10 seconds after connecting the MUT-II, turn Ignition switch the ignition switch to ACC ON for 1 second an then to OFF for 1 second; repeat this procedure three times. NOTE The doors will lock and unlock once at this tim and the system will switch to registration mode.
• Page 84
  42-8 BODY – Keyless Entry System KEYLESS ENTRY SYSTEM REMOVAL AND INSTALLATION Junction block A18VO187 AY0014AA Keyless entry receiver-ECU removal steps ETACS-ECU removal • 2. ETACS-ECU Glove box assembly (Refer to GROUP 52A*.) 1. Keyless entry receiver-ECU NOTE *: Refer to ’97 L200 Workshop Manual <Pub. No. PWTE96E1>…
• Page 85
  52A-1 INTERIOR – General/front Seat Belt GROUP 52A INTERIOR GENERAL OUTLINE OF CHANGE • The following service procedures have been added due to the introduction of the adjustable seat belt anchor. • On dual cab models, three-point ELR/child seat fixing mechanism (ALR) seat belts have been added for rear seat as an optional equipment.
• Page 86
  NOTES…
• Page 87
  54-1 CHASSIS ELECTRICAL – High-Mounted Stop Lamp GROUP 54 CHASSIS ELECTRAL GENERAL OUTLINE IF CHANGES • The following procedure has been added due to the addition of the high-stop lamp <4WD>. HIGH-MOUNTED STOP LAMP REMOVAL AND INSTALLATION A16V0088 Removal steps 1.
• Page 88
  00-1 GENERAL CONTENTS HOW TO USE THIS MANUAL ….MAJOR SPECIFICATIONS ….VEHICLE IDENTIFICATION .
• Page 89
  00-2 GENERAL – How to Use This Manual HOW TO USE THIS MANUAL INDICATION OF TIGHTENING TORQUE Tightening torques (units: N·m) are set to take into If bolts and nuts are not provided with tightening account the central value and the allowable torques, refer to P.00-11.

• Page 90: Vehicle Identification

  00-3 GENERAL – Vehicle Identification VEHICLE IDENTIFICATION MODELS Model Code Engine model Transmission model Fuel supply system K64T ENDFL6 4D56-Turbocharger with R5M21 (2WD-5M/T) Fuel injection intercooler (2 477 mL) intercooler (2,477 mL) ENDFR6 <Emission regulation- step III> CENDFL6 JENDFL6 JERDFL6 R4AW2 (2WD-4A/T) ENDPL6 4D56 (2,477 mL)

• Page 91: Country

  00-4 GENERAL – Vehicle Identification CHASSIS NUMBER Items Contents Continent ASIA Country THAILAND Register code Follow register Body shape Club cab Double cab Single cab Single cab without rear body Double cab without rear body 5-speed manual transmission Transmission type 4-speed automatic transmission Vehicle line Mitsubishi L200…

• Page 92
  00-5 GENERAL – Major Specifications MAJOR SPECIFICATIONS <2WD Single cab, club cab> Items K64T K64T K64T K64T ENDFL6 ENDFR6 ENDPL6 CENDFL6 Vehicle di- Overall length 5,010 5,010 5,010 5,125 mensions mensions Overall width 1,695 1,695 1,695 1,695 Overall height (unladen) 1,585 1,585 1,585…
• Page 93
  00-6 GENERAL – Major Specifications <2WD Double cab> Items K64T K64T K64T JENDFL6 JERDFL6 JENDPL6 Vehicle Overall length 5,010 5,010 5,010 dimensions Overall width 1,695 1,695 1,695 Overall height (unladen) 1,610 1,610 1,610 Wheelbase 2,950 2,950 2,950 Track-front 1,450 1,450 1,450 Track-rear 1,435…
• Page 94
  00-7 GENERAL – Major Specifications <4WD Single cab, club cab> Items K74T K74T K75T K74T K74T ENDFL6 ENDFR6 CENDEL6 CENDFL6 GCENXFL6 Vehicle Overall length 5,010 5,010 5,125 5,125 5,125 dimensions dimensions Overall width 1,695 1,695 1,695 1,695 1,775 Overall height (unladen) 1,750 1,750 1,775…
• Page 95
  00-8 GENERAL – Major Specifications <4WD Double cab> Items K74T K74T K74T K74T JENDFL6 JENDFR6 JERDFL6 JENHFL6 Vehicle Overall length 5,010 5,010 5,010 5,010 dimen- Overall width 1,695 1,695 1,695 1,695 sions mm sions mm Overall height (unladen) 1,780 1,780 1,780 1,780 Wheelbase…
• Page 96
  00-9 GENERAL – Major Specifications <4WD Double cab> Items K75T K74T K74T K74T GJENXEL6 GJENXFL6 GJENXFR6 GJERXFL6 Vehicle Overall length 5,010 5,010 5,010 5,010 dimen- Overall width 1,775 1,775 1,775 1,775 sions mm sions mm Overall height (unladen) 1,800 1,800 1,800 1,800 Wheelbase…
• Page 97
  00-10 GENERAL – Major Specifications <4WD Double cab> Items K74T K74T K74T K74T K74T JENDPL6 JERDPL6 GJENXPR6 GJENXPR6 GJERXPL6 Vehicle Overall length 5,010 5,010 5,010 5,010 5,010 dimensions dimensions Overall width 1,695 1,695 1,775 1,775 1,775 Overall height (unladen) 1,780 1,780 1,800 1,800…
• Page 98
  00-11 GENERAL – Standard Part/Tightening-Torque Table STANDARD PART/TIGHTENING-TORQUE TABLE Each torque value in the table is a standard value The values in the table are not applicable: for tightening under the following conditions. (1) If toothed washers are inserted. (1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
• Page 99
  NOTES…
• Page 100
  <4G6> ENGINE Click on the applicable bookmark to selected the required model year…
• Page 101
  11A-2 ENGINE <4G6> CONTENTS 11109000399 Lash Adjuster Check ……GENERAL INFORMATION ….CAMSHAFT OIL SEAL .
• Page 102
  11A-3 ENGINE <4G6> – General Information/Service Specifications GENERAL INFORMATION 11100010322 Items 4G63 4G64 Total displacement m 1,997 2,351 Bore Stroke mm 85.0 x 88.0 86.5 x 100.0 Compression ratio Combustion chamber Pentroof type Pentroof type Camshaft arrangement SOHC SOHC Intake Number of valve Number of valve Exhaust…
• Page 103
  11A-4 ENGINE <4G6> – Service Specifications Items Standard value Limit A/C compres- Tension N When checked 355 – 445 – sor drive belt sor drive belt When a used belt is installed 355 – 445 – tension When a new belt is installed 530 –…
• Page 104
  11A-5 ENGINE <4G6> – Sealant/Special Tools SEALANT 11100050218 Item Specified sealant Remark Oil pan MITSUBISHI GENUINE PART Semi-drying sealant MD970389 or equivalent SPECIAL TOOLS 11100060310 Tool Number Name MB991502 MUT-II Checking the idle speed sembly Erasing of diagnosis code MD998738 Adjusting screw Holding the auto tensioner Timing belt tension adjustment…
• Page 105
  11A-6 ENGINE <4G6> – Special Tools Tool Number Name MD998776 Crankshaft rear oil Press-fitting the crankshaft rear oil seal seal installer MB990938 Handle Press-fitting the crankshaft rear oil seal MD998747 Crankshaft pulley Supporting of crankshaft sprocket holder MD998375 Crankshaft front oil Press-fitting the crankshaft front oil seal seal installer MD998767…
• Page 106
  11A-7 ENGINE <4G6> – On-vehicle Service ON-VEHICLE SERVICE 11100090326 Tension gauge DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys as shown in the illustration.
• Page 107
  11A-8 ENGINE <4G6> – On-vehicle Service POWER STEERING OIL PUMP DRIVE BELT TENSION 98 N CHECK AND ADJUSTMENT Power 11100110145 steering 1. Use a belt tention gauge to check that the belt tension Deflection pump pulley is at the standard value at a point half-way between the two pulleys (indicated by an arrow in the illustration).
• Page 108
  11A-9 ENGINE <4G6> – On-vehicle Service AIR CONDITIONER COMPRESSOR DRIVE BELT Tension pulley TENSION CHECK AND ADJUSTMENT 11100100135 Crankshaft 98 N 1. Use a belt tention gauge to check that the belt tension pulley is at the standard value at a point half-way between the two pulleys (indicated by an arrow in the illustration).
• Page 109
  11A-10 ENGINE <4G6> – On-vehicle Service IGNITION TIMING CHECK AND ADJUSTMENT 11100170167 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Insert a paper clip into the noise filter connector (1 pin) as shown in the illustration at left. 3.
• Page 110
  11A-11 ENGINE <4G6> – On-vehicle Service 16. Attach a sealing tape to the fixing bolt and nut only for vehicles for Switzerland. NOTE Sealing tape is attached to all new vehicles. IDLE SPEED CHECK 11100190330 1. Before inspection, set the vehicle to the pre-inspection condition.
• Page 111
  11A-12 ENGINE <4G6> – On-vehicle Service Fuel pressure Injector Ignition coil, spark plug cable, spark plug Leak in the EGR system and in the EGR valve 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.
• Page 112
  11A-13 ENGINE <4G6> – On-vehicle Service 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: max. 100 kPa 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 (7) and (8).
• Page 113
  11A-14 ENGINE <4G6> – On-vehicle Service LASH ADJUSTER CHECK 11100290214 NOTE Good Soon after the engine is started or while it is running, abnormal noise (clattering) which may be attributed to the adjuster sounds but does not stop. In this case, check the following. 1.
• Page 114
  11A-15 ENGINE <4G6> – On-vehicle Service 3. If any abnormal noise is not eliminated by racing, check Exhaust valve side the lash adjuster. (1) Stop the engine. (2) Set the engine so that cylinder No. 1 is positioned at the top dead centre of the compression. (3) Press the rocker arm at the area indicated by the white arrow mark to check whether the rocker arm is lowered or not.
• Page 115
  11A-16 ENGINE <4G6> – Camshaft Oil Seal CAMSHAFT OIL SEAL 11200190272 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Distributor Removal and Installation 10 – 12 Nm 10 Nm Engine oil 88 Nm 24 Nm 10 – 12 Nm Removal steps «CA 4.
• Page 116
  11A-17 ENGINE <4G6> – Camshaft Oil Seal 3. Insert the special tool into the rubber plug hole in the timing belt cover assembly rear and turn it gently. Stop turning the special tool when it can no longer be turned gently.
• Page 117
  11A-18 ENGINE <4G6> – Camshaft Oil Seal «CA CAMSHAFT SPROCKET SPACER INSTALLATION Align the mating marks on the camshaft sprocket and the camshaft sprocket spacer (groove), and then install them. Mating marks…
• Page 118
  11A-19 ENGINE <4G6> – Oil Pan, Oil Screen OIL PAN AND OIL SCREEN 11200250185 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Engine Oil Draining and Refilling (Refer to GROUP 12 – On-vehicle Service.) Front of engine f 4.0 mm Bolt…
• Page 119
  11A-20 ENGINE <4G6> – Oil Pan, Oil Screen REMOVAL SERVICE POINT MD998727 MD998727 AA» OIL PAN REMOVAL After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Perform this slowly to avoid deformation of the oil pan flange.
• Page 120
  11A-21 ENGINE <4G6> – Cylinder Head Gasket CYLINDER HEAD GASKET 11200400351 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Distributor installation (Refer to GROUP 14 – On-vehicle Service.) Air Cleaner Assembly installation Fuel Line Pressure Releasing (Refer to GROUP 15.) (Refer to GROUP 13A –…
• Page 121
  11A-22 ENGINE <4G6> – Cylinder Head Gasket 2.9 – 3.4 Nm <Cold engine> 78 Nm ! 0 N!m 20 N!m +90_! +90_ 22 Nm 10 – 12 Nm 10 Nm 88 Nm 24 Nm 10 – 12 Nm 12 – 15 Nm AA»…
• Page 122
  11A-23 ENGINE <4G6> – Cylinder Head Gasket REMOVAL SERVICE POINTS AA» CAMSHAFT SPROCKET REMOVAL Timing mark 1. Rotate the crankshaft in the forward (right) direction and align the timing mark. Caution Camshaft The crankshaft must always be rotated in the forward Timing sprocket mark…
• Page 123
  11A-24 ENGINE <4G6> – Cylinder Head Gasket INSTALLATION SERVICE POINTS «AA CYLINDER HEAD GASKET INSTALLATION Identification mark 1. Wipe off all oil and grease from the gasket mounting surface. 2. Install the gasket to the cylinder block with the identification mark facing upwards.
• Page 124
  11A-25 ENGINE <4G6> – Cylinder Head Gasket «CA CAMSHAFT SPROCKET INSTALLATION 1. Use the special tool to stop the camshaft sprocket from turning, and then install the camshaft sprocket bolt. 2. Remove the special tool from the rubber plug hole. MB990767 3.
• Page 125
  11A-26 ENGINE <4G6> – Timing Belt, Timing Belt B TIMING BELT, TIMING BELT B 11200430336 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling (Refer to GROUP 14 – On-vehicle Service.) Cooling Fan Removal and Installation (Refer to GROUP 14.) Distributor Removal and Installation 10 –…
• Page 126
  11A-27 ENGINE <4G6> – Timing Belt, Timing Belt B REMOVAL SERVICE POINTS AA» AUTO TENSIONER REMOVAL Timing marks 1. Turn the crankshaft clockwise (right turn) to align each timing marks and to set the No. 1 cylinder to compression top dead centre. Caution Never turn the crankshaft anticlockwise.
• Page 127
  11A-28 ENGINE <4G6> – Timing Belt, Timing Belt B 2. Holding the timing belt ”B” tensioner up with your finger in the direction of the arrow, apply pressure on the timing belt so that the tension side of the belt is taut. Now tighten Shaft the bolt to fix the tensioner.
• Page 128
  11A-29 ENGINE <4G6> – Timing Belt, Timing Belt B 3. Install the timing belt by the following procedure. (1) Place the timing belt onto the tensioner pulley and Camshaft sprocket crankshaft sprocket, and hold it with your left hand so that it doesn’t slip. (2) While pulling the timing belt with your right hand, place it onto the oil pump sprocket.
• Page 129
  11A-30 ENGINE <4G6> – Timing Belt, Timing Belt B 4. Slowly compress the push rod of the auto tensioner until pin hole A in the push rod is aligned with pin hole B Pin hole A in the cylinder. Pin hole B Caution Never compress the push rod too fast, or the push rod may be damaged.
• Page 130
  11A-31 ENGINE <4G6> – Timing Belt, Timing Belt B «EA TIMING BELT TENSION ADJUSTMENT 1. Turn the crankshaft 1/4 of a revolution in the anticlockwise 48 Nm direction, then turn it in the clockwise direction until the timing marks are aligned. Tension direction 2.
• Page 131
  11A-32 ENGINE <4G6> – Crankshaft Front Oil Seal CRANKSHAFT FRONT OIL SEAL 11200340226 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt, Timing Belt B Removal and Installation (Refer to P.11A-26.) Crankshaft Engine oil 108 – 127 Nm Removal steps AA»…
• Page 132
  11A-33 ENGINE <4G6> – Crankshaft front oil seal REMOVAL SERVICE POINT AA» CRANKSHAFT SPROCKET REMOVAL 1. Temporarily install the crankshaft pulley, and then use the V-ribbed belt and the special tool to stop the crankshaft MD998747 pulley from turning. Caution (1) Do not use the vehicle’s V-ribbed belt, or the belt may be damaged.
• Page 133
  11A-34 ENGINE <4G6> – Crankshaft front oil seal 2. Temporarily install the crankshaft pulley, and then use the V-ribbed belt and the special tool to stop the crankshaft pulley from turning. Caution (1) Do not use the vehicle’s V-ribbed belt, or the belt MD998747 may be damaged.
• Page 134
  11A-35 ENGINE <4G6> – Crankshaft Rear Oil Seal CRANKSHAFT REAR OIL SEAL 11200370232 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Transmission Assembly Removal and Installation <2WD> (Refer to GROUP 22, 23.) Transmission and Transfer Assembly Removal and Installation <4WD> (Refer to GROUP 22.) <M/T>…
• Page 135
  11A-36 ENGINE <4G6> – Crankshaft Rear Oil Seal REMOVAL SERVICE POINT AA» FLYWHEEL BOLT <M/T>/DRIVE PLATE BOLT <A/T> REMOVAL MD998781 INSTALLATION SERVICE POINTS «AA CRANKSHAFT REAR OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip.
• Page 136
  11A-37 ENGINE <4G6> – Engine Assembly ENGINE ASSEMBLY 11200100350 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Hood Removal (Refer to GROUP 42.) Transmission and Transfer Assembly Installation Fuel Line Pressure Releasing <4WD> (Refer to GROUP 22.) (Refer to GROUP 13A – On-vehicle Service.) Transmission Assembly Installation <2WD>…
• Page 137
  11A-38 ENGINE <4G6> – Engine Assembly 24 Nm 39 Nm 14 Nm 22 Nm 9.8 Nm 34 Nm 15. Drive belt (for Power steering) 20. Alternator connector AA» 16. Power steering oil pump assembly 24. Heat protector 17. Drive belt (for A/C) 25.
• Page 138
  11A-39 ENGINE <4G6> – Engine Assembly REMOVAL SERVICE POINTS AA» POWER STEERING OIL PUMP ASSEMBLY AND A/C COMPRESSOR ASSEMBLY REMOVAL 1. Remove the oil pump and A/C compressor (with the hose attached). 2. Suspend the removed oil pump (by using wire or similar material) at a place where no damage will be caused during removal/installation of the engine assembly.
• Page 139
  NOTES…
• Page 140
  11A-2 ENGINE <4G6> CONTENTS GENERAL ……. . . Compression Pressure Check .
• Page 141
  11A-3 ENGINE <4G6> – General/Service Specifications/Special Tools GENERAL OUTLINE OF CHANGE The following procedures have been established to correspond to the change of the ignition system. Other procedures are the same as before. SERVICE SPECIFICATIONS Item Standard value Limit 750 ± 100 Idle speed r/min –…
• Page 142
  11A-4 ENGINE <4G6> – ENGINE <4G6> – On-vehicle Service On-vehicle Service ON-VEHICLE SERVICE IGNITION TIMING CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to “LOCK” (OFF) position and then connect the MUT-II to the diagnosis connector. 3.
• Page 143
  11A-5 ENGINE <4G6> – Camshaft Oil Seal CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Engine oil 11 ± 1 N·m 88 ± 10 N·m 24 ± 4 N·m 10 ± 2 N·m 11 ± 1 N·m 24 ± 4 N·m 10 ± 2 N·m Removal steps AB»…
• Page 144
  11A-6 ENGINE <4G6> – Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Resonance Tank Installation Fuel Line Pressure Releasing Air Cleaner Assembly Installation Battery and Battery Tray Removal Battery and Battery Tray Installation Air Cleaner Assembly Removal Engine Coolant Refilling Resonance Tank Removal…
• Page 145
  11A-7 ENGINE <4G6> – Cylinder Head Gasket 3.4 ± 0.5 N·m <Cold engine> 78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90_ → +90_ 22 ± 2 N·m 11 ± 1 N·m 88 ± 10 N·m 24 ±…
• Page 146
  11A-8 ENGINE <4G6> – Timing Belt and Timing Belt B TIMING BELT AND TIMING BELT B REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling Cooling Fan Removal and Installation 11 ± 1 N·m 24 ± 4 N·m 11 ±…
• Page 147
  11A-9 ENGINE <4G6> – Crankshaft Front Oil Seal CRANKSHAFT FRONT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt, Timing Belt B Removal and Installation (Refer to P.11A-8.) Crankshaft Engine oil 162 ± 5 N·m Removal steps AA» «BA 1. Crankshaft sprocket «BA 3.
• Page 148
  11A-10 ENGINE <4G6> – ENGINE <4G6> – Crankshaft Front Oil Seal Crankshaft Front Oil Seal INSTALLATION SERVICE POINTS «AA CRANKSHAFT FRONT OIL SEAL INSTALLATION MD998375 1. Apply engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal until it is flush with the front case. «BA CRANKSHAFT SPROCKET B/CRANKSHAFT Crankshaft Crankshaft…
• Page 149
  <4D5> ENGINE Click on the applicable bookmark to selected the required model year…
• Page 151
  11B-2 ENGINE <4D5> – General Information GENERAL INFORMATION 11100010339 Items 4D56 Total displacement m 2,477 Bore x Stroke mm 91.1 x 95.0 Compression ratio Combustion chamber Vortex chamber type Camshaft arrangement SOHC Number of valve Intake Exhaust Valve timing Intake Opening BTDC 20_, Closing ABDC 49_ Exhaust Opening BBDC 55_, Closing ATDC 22_…
• Page 152
  11B-3 ENGINE <4D5> – Service Specifications/Sealants SERVICE SPECIFICATIONS 11100030359 Items Standard value Limit Alternator drive belt Tension N When checked 245 – 441 – tension (for each tension (for each When a used belt is installed 294 – 392 – belt) When a new belt is installed 392 –…
• Page 153
  11B-4 ENGINE <4D5> – Special Tools SPECIAL TOOLS 11100060327 Tool Number Name MD998384 Prestroke measur- Adjustment of the injection timing ing adapter MD998721 Crankshaft pulley Holding the crankshaft pulley holder MB990767 End yoke holder Holding the camshaft sprocket MD998719 Crankshaft pulley holder pin MD998381 Camshaft oil seal…
• Page 154
  11B-5 ENGINE <4D5> – Special Tools/On-vehicle Service Tool Number Name MD998781 Flywheel stopper Securing the flywheel MD998376 Crankshaft rear oil Press-fitting the crankshaft rear oil seal seal installer ON-VEHICLE SERVICE 11100090333 Water pump pulley DRIVE BELT TENSION CHECK AND 98 N ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Use a belt tension gauge to check that the belt tension is…
• Page 155
  11B-6 ENGINE <4D5> – On-vehicle Service ALTERNATOR DRIVE BELT TENSION ADJUSTMENT Lock bolt 1. Loosen the nut of the alternator pivot bolt. 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Adjusting Standard value (for each belt): bolt…
• Page 156
  11B-7 ENGINE <4D5> – On-vehicle Service 2. If the tension or deflection is outside the standard value, adjust by the following procedure. (1) Loosen power steering oil pump fixing bolts A, B and (2) Adjust the amount of belt deflection using adjusting bolt D.
• Page 157
  11B-8 ENGINE <4D5> – On-vehicle Service (4) Check the belt deflection amount and tension, and readjust if necessary. Caution Check after turning the crankshaft once or more clockwise (right turn). VALVE CLEARANCE CHECK AND Timing marks Timing marks ADJUSTMENT 11100150109 1.
• Page 158
  11B-9 ENGINE <4D5> – On-vehicle Service 6. If the clearance is outside the standard value, loosen the lock nut of the rocker arm and adjust by turning the adjusting screw while using a thickness gauge to measure Thickness gauge the clearance. 7.
• Page 159
  11B-10 ENGINE <4D5> – On-vehicle Service 5. Remove the timing check plug at the rear of the injection pump. Timing check plug 6. Before installation of special tool, make sure that push rod is protruding by 10 mm. Protrusion of push rod can be adjusted with an inner nut.
• Page 160
  11B-11 ENGINE <4D5> – On-vehicle Service 14. If the needle is outside the standard value, adjust the Injection pipe injection timing by the following procedure. union nuts (4 places) (1) Loosen the injection pipe union nuts (4 places) on the injection pump. (Do not remove the union nuts.) Caution When loosening the nuts, hold the delivery valve holders with a spanner so that they don’t turn…
• Page 161
  11B-12 ENGINE <4D5> – On-vehicle Service 2. Connect the speedometer to the injection nozzle or the injection pipe. Caution When the speedometer is connected to the injection pipe, the pipe mounting clamps should all be removed. Speedometer 3. Start the engine and run it at idle. 4.
• Page 162
  11B-13 ENGINE <4D5> – On-vehicle Service 7. Check the engine speed when a negative pressure of 87 kPa is applied. Lock nut Standard value: 1,900 100 r/min Adjusting screw 8. If the engine speed is outside the standard value, loosen the lock nut on the actuator rod and adjust by turning the adjusting screw.
• Page 163
  11B-14 ENGINE <4D5> – On-vehicle Service 5. Set compression gauge to one of the glow plug holes. Compression gauge 6. Crank the engine and measure the compression pressure. Standard value (at engine speed of 280 r/min): 3,040 kPa Limit (at engine speed of 280 r/min): min. 2,200 kPa 7.
• Page 164
  11B-15 ENGINE <4D5> – On-vehicle Service 4. Loosen the tensioner pivot side bolt 1 turn and slot side bolt 1 or 2 turns. Slot side bolt Pivot side bolt 5. Turn the crankshaft clockwise and stop at the second Camshaft sprocket lobe of the camshaft sprocket.
• Page 165
  11B-16 ENGINE <4D5> – On-vehicle Service 4. Remove the access cover. Access cover 5. Loosen the tensioner pivot side bolt 1 mm and slot side nut 1 or 2 turns. Pivot side 6. First tighten tensioner slot side nut, and then tighten pivot bolt side bolt to the specified torque.

• Page 166: Crankshaft Pulley

  11B-17 ENGINE <4D5> – Crankshaft Pulley CRANKSHAFT PULLEY 11200160242 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11B-5.) Under Cover Installation 167 – 186 Nm 25 Nm Removal steps 1. Drive belt (for A/C) 2.

• Page 167
  11B-18 ENGINE <4D5> – Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL 11200190289 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Intercooler Removal and Installation <4WD> (Refer to GROUP 15.) 5.9 Nm Sealant: 3M ATD Part No. 8660 or equivalent 34 –…
• Page 168
  11B-19 ENGINE <4D5> – Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS Timing marks AA» CAMSHAFT SPROCKET REMOVAL 1. Rotate crankshaft clockwise (to the right) and align timing marks. Caution Never turn the crankshaft anticlockwise. No. 1 T.D.C 2. Tie the camshaft sprocket and timing belt together with Timing belt cord so that timing mark is not maladjusted.
• Page 169
  11B-20 ENGINE <4D5> – Camshaft and Camshaft Oil Seal INSTALLATION SERVICE POINTS «AA CAMSHAFT BEARING CAP INSTALLATION Cap No. The cap numbers are embossed on the top surface of the bearing caps, so install in the order of the numbers. However, no numbers are embossed on bearing caps 1 and 5.
• Page 170
  11B-21 ENGINE <4D5> – Oil Pan and Oil Screen OIL PAN AND OIL SCREEN 11200250192 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Engine Oil Draining and Supplying (Refer to GROUP 12 – On-vehicle Service.) Front of engine 5 <2WD>…
• Page 171
  11B-22 ENGINE <4D5> – Oil Pan and Oil Screen Caution The use of a screwdriver or chisel in place of the special tool can damage the gasket seat surface and cause oil leakage. INSTALLATION SERVICE POINTS «AA OIL PAN INSTALLATION 1.
• Page 172
  11B-23 ENGINE <4D5> – Cylinder Head Gasket CYLINDER HEAD GASKET 11200400368 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Intake and Exhaust Manifold Removal Timing Belt Installation (Refer to P.11B-26.) (Refer to GROUP 15.) Intake and Exhaust Manifold Installation Timing Belt Removal (Refer to P.11B-26.) (Refer to GROUP 15.) Engine Coolant Draining Fuel Line Air Bleeding…
• Page 173
  11B-24 ENGINE <4D5> – Cylinder Head Gasket REMOVAL SERVICE POINTS AA» RADIATOR UPPER HOSE DISCONNECTION After making mating marks on the radiator upper hose and the hose clamp, disconnect the radiator upper hose. AB» FUEL INJECTION PIPE REMOVAL When loosening nuts at both ends of injection pipe, hold Delivery holder the delivery holder (for pump side) and the injection nozzle assembly (for nozzle side) with wrench and loosen nut.
• Page 174
  11B-25 ENGINE <4D5> – Cylinder Head Gasket INSTALLATION SERVICE POINTS Identification mark «AA CYLINDER HEAD GASKET INSTALLATION 1. Wipe off any oil or grease from the gasket mounting surface. 2. Check the rank from the number of identification holes on the cylinder head gasket that was removed, and select a cylinder head gasket of the same rank.
• Page 175
  11B-26 ENGINE <4D5> – Timing Belt and Timing B TIMING BELT AND TIMING BELT B 11200430343 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Cooling Fan Removal (Refer to GROUP 14.) Cooling Fan Installation (Refer to GROUP 14.) Engine Adjustment (Refer to P.11B-5.) 25 Nm 25 Nm 9.8 –…
• Page 176
  11B-27 ENGINE <4D5> – Timing Belt and Timing Belt B REMOVAL SERVICE POINTS AA» CRANKSHAFT PULLEY REMOVAL 1. Position the No. 1 cylinder at compression TDC and remove the crankshaft pulley. NOTE The No. 1 cylinder is at compression TDC when the marks are aligned as shown in the figure.
• Page 177
  11B-28 ENGINE <4D5> – Timing Belt and Timing Belt B 3. Install timing belt B and make sure there is no deflection Timing mark on the tension side. Tensioner 4. Press the deflection side of timing belt B (indicated by 24 Nm arrow (A)) with the hand and fully stretch the tensioner side.
• Page 178
  11B-29 ENGINE <4D5> – Timing Belt and Timing Belt B 4. Loosen the tensioner mounting bolts and apply tension with the spring. Camshaft sprocket 5. Turn the crankshaft clockwise and stop at the second lobe of the camshaft sprocket. Caution 1.
• Page 179
  11B-30 ENGINE <4D5> – Crankshaft Front Oil Seal CRANKSHAFT FRONT OIL SEAL 11200340233 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt and Timing Belt “B” Removal and Installation (Refer to P.11B-26.) (Engine oil) Removal steps 1. Crankshaft sprocket B AA»…
• Page 180
  11B-31 ENGINE <4D5> – Crankshaft Rear Oil Seal CRANKSHAFT REAR OIL SEAL 11200370249 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Oil Pan Removal and Installation (Refer to P.11-21.) Transmission Assembly Removal and Installation (Refer to GROUP 22, 23.) 127 – 137 Nm 127 –…
• Page 181
  11B-32 ENGINE <4D5> – Crankshaft Rear Oil Seal «BA OIL SEPARATOR INSTALLATION Oil separator Oil seal case Install the oil separator in such a way that its oil hole come at the case bottom (indicated by an arrow in the illustration). Oil hole Oil pan mounting surface «CA FLYWHEEL <M/T>/ADAPTOR PLATE <A/T>…
• Page 182
  11B-33 ENGINE <4D5> – Engine Assembly ENGINE ASSEMBLY 11200100367 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Hood Removal (Refer to GROUP 42.) Transmission and Transfer Assembly Installation Intercooler Removal <4WD> (Refer to GROUP 15.) <4WD> (Refer to GROUP 22, 23.) Air Cleaner and Air Intake Hose Removal Transmission Assembly Installation <2WD>…
• Page 183
  11B-34 ENGINE <4D5> – Engine Assembly 22 Nm 22 Nm 44 Nm 30 Nm 14 Nm 22 Nm 9.8 Nm 34 Nm 15. Drive belt (for Power steering) 21. Engine oil cooler hose connection AA» 16. Power steering oil pump assembly 22.
• Page 184
  11B-35 ENGINE <4D5> – Engine Assembly REMOVAL SERVICE POINTS AA» POWER STEERING OIL PUMP ASSEMBLY AND A/C COMPRESSOR ASSEMBLY REMOVAL 1. Remove the oil pump and A/C compressor (with the hose attached). 2. Suspend the removed oil pump (by using wire or similar material) at a place where no damage will be caused during removal/installation of the engine assembly.
• Page 185
  NOTES…
• Page 186
  11B-1 ENGINE <4D5> CONTENTS GENERAL ……. . . Injection Timing Check and Adjustment .
• Page 187
  General/General Information/ 11B-2 ENGINE <4D5> – Service Specifications/Special Tools GENERAL OUTLINE OF CHANGES The following service procedures have been established due to the introduction of the electronic-controlled injection pump. Other service procedures are the same as before. <4D56-Step III> Oil pan cover has been adopted. <4D56-Step III> The tightening torque of the cylinder head bolts and the cylinder head gasket have been changed.<4D56-Step III>…
• Page 188
  11B-3 ENGINE <4D5> – Service Specifications/On-vehicle Service ON-VEHICLE SERVICE INJECTION TIMING CHECK AND ADJUSTMENT Inspection and adjustment are the same as before. The electronic-controlled injection pump does not have a cold start device (wax-type). IDLE SPEED CHECK 1. Set the vehicle to the pre-inspection condition. 2.
• Page 189
  11B-4 ENGINE <4D5> – Oil Pan <4D56-Step III> OIL PAN <4D56-Step III> REMOVAL AND INSTALLATION Oil pan cover 9.0 ± 1.0 N·m…
• Page 190
  11B-5 ENGINE <4D5> – Cylinder Head Gasket <4D56-Step III> CYLINDER HEAD GASKET <4D56-Step III> INSTALLATION SERVICE POINT CYLINDER HEAD GASKET AND CYLINDER HEAD INSTALLATION 1. Wipe off any oil or grease from the gasket mounting Identification mark surface. 2. If you replace the cylinder head gasket only, check the identification mark of the cylinder head gasket removed, select the cylinder head gasket that has same identification mark (size) from the table below.
• Page 191
  11B-6 ENGINE <4D5> – Cylinder Head Gasket <4D56-Step III> 7. Tighten the cylinder head bolts according to the following procedure (angle-tightening procedure.) (1) Use the special tool to tighten the cylinder head bolts in the order of the illustrated numbers to 29 ± 2 N·m. MD998051 Front of engine (2) Place the special tool in a wrench to tighten the…
• Page 192
  11B-7 ENGINE <4D5> – Timing Belt and Timing B <4D56-Step III> TIMING BELT AND TIMING BELT B <4D56-Step III> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Cooling Fan Removal (Refer to GROUP 14.) Cooling Fan Installation (Refer to GROUP 14.) Engine Adjustment 26 ±…
• Page 193
  NOTES…
• Page 194
  ENGINE LUBRICATION Click on the applicable bookmark to selected the required model year…
• Page 196
  12-2 ENGINE LUBRICATION – General Information GENERAL INFORMATION 12100010053 The lubrication method is a fully force-fed, full-flow The corrugate fin type of engine oil cooler have filtration type. been adopted, and installed forward of the radiator. <4D56> Items 4G63 4G64 4D56 Oil pump type Involute gear type…
• Page 197
  12-3 ENGINE LUBRICATION – Lubricants/Special Tools/On-vehicle Service LUBRICANTS 12100040076 Items 4G63 4G64 4D56 4D56-Turbo Engine oil API classification SG or higher SG or higher CD or higher CD or higher Engine oil quan- Oil filter tity tity Oil cooler – –…
• Page 198
  12-4 ENGINE LUBRICATION – On-vehicle Service 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. 5. Refill with specified quantity of oil. <Petrol-powered vehicles>…
• Page 199
  12-5 ENGINE LUBRICATION – On-vehicle Service 8. Apply a small amount of engine oil to the O-ring of the new oil filter. 9. Install the oil filter. NOTE Tightening torque: <4G6> When using the oil filter of MD135737: 14 Nm <4G6>…
• Page 200
  12-6 ENGINE LUBRICATION – Engine Oil Cooler <4D56> ENGINE OIL COOLER <4D56> 12100130087 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Radiator Grille Removal Radiator Grille Installation Engine Oil Checking and Supplying (Refer to P.12-3.) <M/T> 44 Nm 29 – 34 Nm 44 Nm <A/T>…
• Page 201
  12-7 ENGINE LUBRICATION – ENGINE LUBRICATION – Engine Oil Cooler <4D56> Engine Oil Cooler <4D56> REMOVAL SERVICE POINT AA» EYE BOLTS REMOVAL Caution Be sure to hold the weld nut of the oil cooler while loosening the eye bolt. INSTALLATION SERVICE POINTS «AA OIL COOLER HOSE ASSEMBLY (ENGINE SIDE) INSTALLATION Markings…
• Page 202
  NOTES…
• Page 203
  SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-00E12-502 Date 2001-07-11 <Model> <M/Y> Subject: CORRECTION OF DESCRIPTIONS (EC)GALANT(EA0) 97-99 CONCERNING OIL FILTER WRENCH (EC)SPACE STAR 99-99 (DG0A) 99-99 (EC)SPACE 99-99 RUNNER/SPACE 97-97 ENGINE Group: Draft No.: 00AL092714…
• Page 204
  Manual Pub. No. Language Page(s) ’99 SPACE STAR CMXE99E1 (English) 12-3, 4, 5 Workshop Manual chassis CMXS99E1 (Spanish) CMXF99E1 (French) CMXG99E1 (German) CMXD99E1 (Dutch) CMXW99E1 (Swedish) CMXI99E1 (Italian) ’99 SPACE RUNNER/SPACE WAGON PWDE9803 (English) 12-3, 5 Workshop Manual chassis PWDS9804 (Spanish) PWDF9805 (French)
• Page 205
  3. Details: ’97 GALANT Workshop Manual chassis 12-3 ENGINE LUBRICATION – Lubricants/Special Tools/On-vehicle Service LUBRICANTS 12100040151 Items Engine oil (API classification) SG or higher SG or higher CD or higher Engine oil quantity ℓ Oil filter Oil cooler Total SPECIAL TOOLS 12100100163 Tool Number…
• Page 206
  ’97 GALANT Workshop Manual chassis 12-4 ENGINE LUBRICATION – On-vehicle Service <Petrol-powered vehicles> 5. Refill with specified quantity of oil Barometric temperature Specified Engine Oil (API classification): <4G6, 6A1> SG or higher <4D6> CD or higher Total quantity (includes volume inside oil filter and oil M03B019 cooler): <Diesel-powered vehicles>…
• Page 207
  ’97 GALANT Workshop Manual chassis 12-5 ENGINE LUBRICATION – On-vehicle Service Number Engine Tool Tightening torque MD135737 MB991396 or equivalent tool Approx. 1 turn (14 Nm) <Incorrect> MD136466 MB991610 or equivalent tool Approx. 3/4 turn (17 Nm) MD336080 Commercially-available tool Approx.
• Page 208
  ’99 GALANT Workshop Manual chassis 12-2 ENGINE LUBRICATION – General/Lubricants/Special Tool GENERAL <Deleted> OUTLINE OF CHANGE 4G64-GDI engines have been introduced. Accordingly, service procedures have been added as follows. LUBRICANTS Items 4G64 Engine oil (API classification) SG or higher Engine oil quantity ℓ Oil filter Total SPECIAL TOOL…
• Page 209
  ’99 GALANT Workshop Manual chassis 12-4 ENGINE LUBRICATION – On-vehicle Service <4G64> OIL FILTER REPLACEMENT MB991610 1. Start the engine and warm it up until coolant reaches 80°C or commer- cially- to 90°C. available 2. Remove the engine oil filler cap. tool 3.
• Page 210
  ’99 SPACE STAR Workshop Manual chassis 12-3 ENGINE LUBRICATION – Lubricants/Special Tools/On-vehicle Service LUBRICANTS 12100040243 Quantity ℓ Items Engine oil (API classification) Oil filter SG or higher Total quantity SPECIAL TOOLS 12100060140 Tool Number Name MB991396 Oil filter wrench Removal and installation of engine oil filter (when using the oil filter of MD135737) B991396 MB991610…
• Page 211
  ’99 SPACE STAR Workshop Manual chassis 12-4 ENGINE LUBRICATION – On-vehicle Service ENGINE OIL REPLACEMENT 12100100255 <GDI> Drain plug gasket 1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80°C to 90°C. 2.
• Page 212
  ’99 SPACE STAR Workshop Manual chassis 12-5 ENGINE LUBRICATION – On-vehicle Service 6. Apply a small amount of engine oil to the O-ring of a new oil filter 7. Once the O-ring of the oil filter is touching the flange, use the respective tool in the following table to tighten the oil filter to the specified torque.
• Page 213
  ’99 SPACE RUNNER/SPACE WAGON Workshop Manual chassis 12-3 ENGINE LUBRICATION – Service Specifications/Sealant/Lubricants/Special Tools SERVICE SPECIFICATIONS Item Standard value Limit Oil pressure kPa at idle 29 or more at 3,500 r/min 294 – 686 SEALANT Item Specified sealant Remark Oil pressure switch 3M ATD Part No.
• Page 214
  ’99 SPACE RUNNER/SPACE WAGON Workshop Manual chassis 12-5 ENGINE LUBRICATION – On-vehicle Service OIL FILTER REPLACEMENT MB991610 1. Start the engine and allow it to warm up until the or commer- cially- temperature of the coolant reaches 80°C to 90°C. available 2.
• Page 215
  ’99 PAJERO SPORT Workshop Manual chassis 12-3 ENGINE LUBRICATION – Lubricants/Special Tools/On-vehicle Service LUBRICANTS 12100040304 Items Engine oil API classification SG or higher CD or higher Engine oil quantity ℓ Oil filter Oil cooler Total SPECIAL TOOLS 12100060171 Tool Number Name MB991610 Oil filter wrench…
• Page 216
  ’99 PAJERO SPORT Workshop Manual chassis 12-4 ENGINE LUBRICATION – On-vehicle Service <6G7> 5. Refill with specified quantity of oil. Barometric temperature Specified Engine Oil (API classification): <6G7> SG or higher <4D5> CD or higher Total quantity (includes volume inside oil filter and oil M03B019 cooler): <4D5>…
• Page 217
  ’99 PAJERO SPORT Workshop Manual chassis 12-5 ENGINE LUBRICATION – On-vehicle Service 8. Apply a small amount of engine oil to the O-ring of the new oil filter 9. 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.
• Page 218
  ’97 L200 Workshop Manual chassis 12-3 ENGINE LUBRICATION – Lubricants/Special Tools/On-vehicle Service LUBRICANTS 12100040076 Items 4G63 4G64 4D56 4D56-Turbo Engine oil API classification SG or higher SG or higher CD or higher CD or higher Engine oil quantity ℓ Oil filter Oil cooler Total SPECIAL TOOLS…
• Page 219
  ’97 L200 Workshop Manual chassis 12-4 ENGINE LUBRICATION – On-vehicle Service 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. <Petrol-powered vehicles> 5.
• Page 220
  SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-00E00-003 Date 2000-05-30 <Model> <M/Y> Subject: YEAR MODEL CHANGES FOR 2001 L200 (EC)L200(K60, K70) 00-10 Group: GENERAL Draft No.: 00SY0022915 INFORMATION/ INTERNATIONAL CORRECTION ADMINISTRATIO T.NITTA — PROJECT LEADER OFFICE AFTER SALES SERVICE &…
• Page 222
  All information, illustrations and product d scriptions contained in this manual are current as at the time of publication. We, however, re- serve the right to make changes at any time without prior notice or obligation. © Mitsubishi Motors Corporation 2000…
• Page 223
  00-1 GENERAL – vehicle identification GROUP 00 GENERAL VEHICLE IDENTIFICATION MODELS Model Code Engine model Transmission model Fuel supply sys- 4G63-SOHC (1,997mℓ ) K62T JERDEL6 R4AW2 (2WD-4A/T ENDEL6 R5M21 (2WD-5M/T) 4D56 (2,477mℓ ) K64T ENDL6 R5M21 (2WD-M/T) Fuel injection ENDR6 CENDL6 JENDL6 4G64-SOHC (2,351 mℓ…

• Page 224: Register Code

  00-2 GENERAL – vehicle identification CHASSIS NUMBER Y0015AA Items Contents Continent ASIA Country THAILAND Register code Follow register Body shape Club cab Double cab Single cab Single cab without rear body Double cab without rear body Transmission type 5-speed manual transmission 4-speed automatic transmission Vehicle line Mitsubushi L200…

• Page 225
  NOTES…
• Page 226
  12-1 ENGINE LUBRICATION – General/On-vehicle Service GROUP 12 ENGINE LUBRICATION GENERAL OUTLINE OF CHANGES • A quality of the engine oil has been changed. ON-VEHICLE SERVICE <4G6> Barometric temperature specified engine oil (ACEA and API classification): <4G6> ACEA A1, A2, A3/API SG or higher <4D5>…
• Page 227
  NOTES…
• Page 228
  42-1 BODY – General/Keyless Entry System GROUP 42 BODY GENERAL OUTLINE OF CHANGES The following service procedures have been added due to the introduction of the keyless entry system as an optional equipment <GLS>. KEYLESS ENTRY SYSTEM SPECIAL TOOL Tool Number Name MB991502…
• Page 229
  42-2 BODY – Keyless entry system 2. Exit conditions from the adjustment mode The ETACS-ECU cancels the adjustment mode when any of the following conditions is satisfied: • Diagnosis control: OFF (Disconnect the MUT-II>) • Key reminder switch: ON (Pull out the ignition key.) •…
• Page 230
  42-3 BODY – Keyless Entry System INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 None of the doors can be locked or unlocked using Probable cause the transmitter. • The cause may be a malfunction of the transmitter or ETACS- Malfunction of transmitter •…
• Page 231
  42-4 BODY – Keyless Entry System From previous page MUT-II Pulse Check Key reminder switch continuity check • Key reminder switch input signal OK: MUT-II buzzer sounds once when removing Repair and inserting ignition key. Check the following connectors: C-72, C-79, C-86, C-91 Replace the transmitter.
• Page 232
  42-5 BODY – Keyless Entry System INSPECTION PROCEDURE 3 Encrypted codes cannot be registered Probable cause • Malfunction of MUT-II The cause may be a malfunction of the diagnosis con- • Malfunction of connector or wiring harness nector, ETACS-ECU or diagnosis output circuit. •…
• Page 233
  42-6 BODY – Keyless Entry System ON – VEHICLE SERVICE Battery HOW TO REPLACE A BATTERY OF THE TRANSMITTER 1. Remove the set screw to remove the battery from the transmitter. Install a battery with its (+) side face-down. Battery required for replacement: Coin type battery CR2032 3.
• Page 234
  42-7 BODY – Keyless Entry System 3. Within 10 seconds after connecting the MUT-II, turn Ignition switch the ignition switch to ACC ON for 1 second an then to OFF for 1 second; repeat this procedure three times. NOTE The doors will lock and unlock once at this tim and the system will switch to registration mode.
• Page 235
  42-8 BODY – Keyless Entry System KEYLESS ENTRY SYSTEM REMOVAL AND INSTALLATION Junction block A18VO187 AY0014AA Keyless entry receiver-ECU removal steps ETACS-ECU removal • 2. ETACS-ECU Glove box assembly (Refer to GROUP 52A*.) 1. Keyless entry receiver-ECU NOTE *: Refer to ’97 L200 Workshop Manual <Pub. No. PWTE96E1>…
• Page 236
  52A-1 INTERIOR – General/front Seat Belt GROUP 52A INTERIOR GENERAL OUTLINE OF CHANGE • The following service procedures have been added due to the introduction of the adjustable seat belt anchor. • On dual cab models, three-point ELR/child seat fixing mechanism (ALR) seat belts have been added for rear seat as an optional equipment.
• Page 237
  NOTES…
• Page 238
  54-1 CHASSIS ELECTRICAL – High-Mounted Stop Lamp GROUP 54 CHASSIS ELECTRAL GENERAL OUTLINE IF CHANGES • The following procedure has been added due to the addition of the high-stop lamp <4WD>. HIGH-MOUNTED STOP LAMP REMOVAL AND INSTALLATION A16V0088 Removal steps 1.
• Page 239
  12-1 Engine Lubrication – General/Lubricant GROUP 12 ENGINE LUBRICATION GENERAL OUTLINE OF CHANGE Due to the adoption of the VG (Variable Geometry) turbocharger, the engine oil quantity has been changed. <4WD vehicles with 4D56-Step III engine> LUBRICANT 4WD vehicles with 4D56-Step III 4WD vehicles with 4D56 Ste Items Items…
• Page 240
  NOTES…
• Page 241
  MULTIPOINT FUEL INJECTION (MPI) Click on the applicable bookmark to selected the required model year…
• Page 242
  13A-2 MULTIPOINT FUEL INJECTION (MPI) CONTENTS 13109000287 Fuel Pump Operation Check ….GENERAL INFORMATION ….Component Location .
• Page 243
  13A-3 MPI – General Information MULTIPOINT FUEL INJECTION (MPI) 13100010265 GENERAL INFORMATION The Multipoint Fuel Injection System consists activities such as fuel injection control, idle of sensors which detect the engine conditions, speed control and ignition timing control. In the engine-ECU which controls the system addition, the engine-ECU is equipped with based on signals from these sensors, and several…

• Page 244: General Specifications

  13A-4 MPI – General Information OTHER CONTROL FUNCTIONS 1. Fuel Pump Control 3. Purge Control Solenoid Valve Control Turns the fuel pump relay ON so that current Refer to GROUP 17. is supplied to the fuel pump while the engine 4.

• Page 245
  13A-5 MPI – General Information MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM l1 Injector *1 Oxygen sensor Engine-ECU l2 Purge control solenoid valve *2 Air flow sensor l3 Idle speed control servo *3 Intake air temperature sensor l4 EGR control solenoid valve *4 Throttle position sensor *5 Idle position switch *6 Top dead centre sensor…
• Page 246
  13A-6 MPI – Service Specifications/Sealant SERVICE SPECIFICATIONS 13100030216 Items Specifications Basic idle speed r/min 750 50 Idle speed when A/C is ON r/min 900 at neutral position Throttle position sensor adjusting voltage mV 400 – 1,000 Throttle position sensor resistance kΩ 3.5 –…
• Page 247
  13A-7 MPI – Special Tools SPECIAL TOOLS 13100060208 Tool Number Name MB991223 Harness set Measurement of terminal voltage A: MB991219 A: Test harness A: Connector pin contact pressure inspection B: MB991220 B: LED harness B, C: Power circuit inspection C: MB991221 C: LED harness D: Commercial tester connection adapter…
• Page 248
  13A-8 MPI – Special Tools/Troubleshooting Tool Number Name MD998706 Injector test set Checking the spray condition of injectors MB991607 Injector test harness MD998741 Injector test adaptor MB991608 Clip TROUBLESHOOTING 13100850034 DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.
• Page 249
  13A-9 MPI – Troubleshooting Engine warning lamp inspection items Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor Top dead centre sensor Barometric pressure sensor Ignition timing adjustment signal Injector Immobilizer system Caution…
• Page 250
  13A-10 MPI – Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE 13100910190 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 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…
• Page 251
  13A-11 MPI – Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Oxygen sensor system Probable cause D Malfunction of the oxygen sensor Range of Check D 3 minutes have passed after engine was started. D Improper connector contact, open circuit D Engine coolant temperature is approx.
• Page 252
  13A-12 MPI – Troubleshooting Code No. 12 Air flow sensor system Probable cause D Malfunction of the air flow sensor Range of Check D Engine speed is 500 r/min or more. D Improper connector contact, open circuit Set conditions short-circuited harness wire of the air flow sensor D Sensor output frequency is 3 Hz or less for 4 seconds.
• Page 253
  13A-13 MPI – Troubleshooting Code No. 14 Throttle position sensor system Probable cause D Malfunction of the throttle position sensor or Range of Check D Ignition switch: ON maladjustment D Excluding 60 seconds after the ignition switch is turned to ON or immediately D Improper connector contact,…
• Page 254
  13A-14 MPI – Troubleshooting Code No. 21 Engine coolant temperature sensor system Probable cause D Malfunction of the engine coolant temperature sensor Range of Check D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the engine coolant after the engine starts.
• Page 255
  13A-15 MPI – Troubleshooting Code No. 22 Crank angle sensor system Probable cause D Malfunction of the crank angle sensor Range of Check D Engine is cranking. D Improper connector contact, open circuit Set conditions short-circuited harness wire of the crank angle sensor D Sensor output voltage does not change for 4 seconds (no pulse signal input.) D Malfunction of the engine-ECU Measure at the distributor connector A-72.
• Page 256
  13A-16 MPI – Troubleshooting Code No. 23 Top dead centre sensor system Probable cause D Malfunction of the camshaft position sensor Range of Check D Ignition switch: ON D Improper connector contact, open circuit D Engine speed is approx. 50 r/min or more. short-circuited harness wire of the top dead centre Set conditions sensor circuit…
• Page 257
  13A-17 MPI – Troubleshooting Code No. 24 Vehicles speed sensor system Probable cause D Malfunction of the vehicle speed sensor Range of check D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed after the engine starts.
• Page 258
  13A-18 MPI – Troubleshooting Code No. 25 Barometric pressure sensor system Probable cause D Malfunction of the barometric pressure sensor Range of Check D Ignition switch: ON D Improper connector contact, open circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the barometric pressure after the engine starts.
• Page 259
  13A-19 MPI – Troubleshooting Code No. 36 Ignition timing adjustment signal system Probable cause D Short circuit to earth of the ignition timing adjustment Range of Check D Ignition switch: ON signal line D Malfunction of the engine-ECU Set conditions D The ignition timing adjusting signal wire is shorted to the earth.
• Page 260
  13A-20 MPI – Troubleshooting Code No.54 Immobilizer system Probable cause D Radio interference of ID codes Range of Check D Ignition switch: ON D Incorrect ID code D Malfunction of harness or connector Set Conditions D Improper communication between the engine-ECU and immobilizer-ECU D Malfunction of immobilizer-ECU D Malfunction of engine-ECU NOTE…
• Page 261
  13A-21 MPI – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS 13100880217 Trouble symptom Inspection Reference page procedure Communication Communication with all systems is not possible. 13A-23 with MUT-II is with MUT-II is impossible. Communication with engine-ECU only is not possible. 13A-24 Engine warning The engine warning lamp does not illuminate right after the 13A-25…
• Page 262
  13A-22 MPI – Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Symptom Starting Won’t start The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine won’t start. Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
• Page 263
  13A-23 MPI – Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. Probable cause (Communication with all systems is not possible.) D Malfunction of the connector The cause is probably a defect in the power supply system (including earth) for the D Malfunction of the harness wire diagnosis line.
• Page 264
  13A-24 MPI – Troubleshooting INSPECTION PROCEDURE 2 MUT-II communication with engine-ECU is impossible. Probable cause One of the following causes may be suspected. <Vehicles without immobilizer system> D No power supply to engine-ECU. D Malfunction of engine-ECU power supply circuit D Defective earth circuit of engine-ECU.
• Page 265
  13A-25 MPI – Troubleshooting INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after Probable cause the ignition switch is turned to the ON position. D Burnt-out bulb Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp D Defective warning lamp circuit to illuminate for five seconds immediately after the ignition switch is turned to ON.
• Page 266
  13A-26 MPI – Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (starting impossible) Probable cause D Malfunction of the ignition system In cases such as the above, the cause is probably that a spark plug is defective, D Malfunction of the fuel pump system or that the supply of fuel to the combustion chamber is defective.
• Page 267
  13A-27 MPI – Troubleshooting INSPECTION PROCEDURE 6 Initial combustion but no complete combustion Probable cause (starting impossible) D Malfunction of the ignition system In such cases as the above, the cause is probably that the spark plugs are generating D Malfunction of the injector system sparks but the sparks are weak, or the initial mixture for starting is not appropriate.
• Page 268
  13A-28 MPI – Troubleshooting INSPECTION PROCEDURE 7 In takes too long time to start. (Incorrect starting) Probable cause D Malfunction of the ignition system In cases such as the above, the cause is probably that the spark is weak and ignition D Malfunction of the injector system is difficult, the initial mixture for starting is not appropriate, or sufficient compression D Inappropriate gasoline use…
• Page 269
  13A-29 MPI – Troubleshooting INSPECTION PROCEDURE 8 Unstable idling (Rough idling, hunting) Probable cause D Malfunction of the ignition system In cases as the above, the cause is probably that the ignition system, air/fuel mixture, D Malfunction of air-fuel ratio control system idle speed control (ISC) or compression pressure is defective.
• Page 270
  13A-30 MPI – Troubleshooting INSPECTION PROCEDURE 9 Idling speed is high. (Improper idling speed) Probable cause D Malfunction of the ISC servo system In such cases as the above, the cause is probably that the intake air volume during D Malfunction of the throttle body idling is too great.
• Page 271
  13A-31 MPI – Troubleshooting INSPECTION PROCEDURE 10 Idling speed is low. (Improper idling speed) Probable cause D Malfunction of the ISC servo system In cases such as the above, the cause is probably that the intake air volume during D Malfunction of the throttle body idling is too small.
• Page 272
  13A-32 MPI – Troubleshooting INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idling. (Die out) Probable cause D Malfunction of the ISC servo system In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate D Malfunction of the throttle body when the engine is cold, or that the intake air volume is insufficient.
• Page 273
  13A-33 MPI – Troubleshooting INSPECTION PROCEDURE 12 When the engine is hot, it stalls at idling. (Die out) Probable cause D Malfunction of the ignition system In such cases as the above, the cause is probably that ignition system, air/fuel mixture, D Malfunction of air-fuel ratio control system idle speed control (ISC) or compression pressure is defective.
• Page 274
  13A-34 MPI – Troubleshooting INSPECTION PROCEDURE 13 The engine stalls when starting the car. (Pass out) Probable cause D Drawing air into intake system In cases such as the above, the cause is probably misfiring due to a weak spark, D Malfunction of the ignition system or an inappropriate air/fuel mixture when the accelerator pedal is depressed.
• Page 275
  13A-35 MPI – Troubleshooting INSPECTION PROCEDURE 15 Hesitation, sag or stumble Probable cause D Malfunction of the ignition system In cases such as the above, the cause is probably that ignition system, air/fuel mixture D Malfunction of air-fuel ratio control system or compression pressure is defective.
• Page 276
  13A-36 MPI – Troubleshooting INSPECTION PROCEDURE 17 The feeling of impact or vibration when decelerating. Probable cause D Malfunction of the ISC system Malfunction of the ISC system is suspected. MUT-II Self-Diag code Refer to P.13A-10, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed? CODES.
• Page 277
  13A-37 MPI – Troubleshooting INSPECTION PROCEDURE 19 Surge Probable cause D Malfunction of the ignition system Defective ignition system, abnormal air-fuel ratio, etc. are suspected. D Malfunction of air-fuel ratio control system D Malfunction of the EGR control solenoid valve system MUT-II Self-Diag code Refer to P.13A-10, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?

• Page 278: Too High Co And Hc Concentration When Idling

  13A-38 MPI – Troubleshooting INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling Probable cause D Malfunction of the air-fuel ratio control system Abnormal air-fuel ratio is suspected. D Deteriorated catalyst MUT-II Self-Diag code Refer to P.13A-10, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed? CODES.

• Page 279
  13A-39 MPI – Troubleshooting INSPECTION PROCEDURE 23 Power supply system and ignition switch-IG system Probable cause D Malfunction of the ignition switch When an ignition switch ON signal is input to the engine-ECU, the engine-ECU turns D Malfunction of the control relay the control relay ON.
• Page 280
  13A-40 MPI – Troubleshooting INSPECTION PROCEDURE 24 Fuel pump system Probable cause D Malfunction of the fuel pump relay The engine-ECU turns the control relay ON when the engine is cranking or running, D Malfunction of the fuel pump and this supplies power to drive the fuel pump. D Improper connector contact,…
• Page 281
  13A-41 MPI – Troubleshooting INSPECTION PROCEDURE 26 Ignition switch-ST system <M/T> Probable cause D Malfunction of ignition switch The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is D Improper cranking. connector contact, open circuit The engine-ECU controls fuel injection, etc. during starting based on this input. short-circuited harness wire D Malfunction of the engine-ECU 1.
• Page 282
  13A-42 MPI – Troubleshooting INSPECTION PROCEDURE 27 Ignition switch-ST and inhibitor switch system <A/T> Probable cause D The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine D Malfunction of ignition switch D Malfunction of inhibitor switch is cranking.
• Page 283
  13A-43 MPI – Troubleshooting INSPECTION PROCEDURE 28 Power steering fluid pressure switch system Probable cause D Malfunction of power steering fluid pressure switch The presence or absence of power steering load is input to the engine-ECU. D Improper The engine-ECU controls the idle speed control (ISC) servo based on this input. connector contact, open…
• Page 284
  13A-44 MPI – Troubleshooting INSPECTION PROCEDURE 30 Ignition circuit system Probable cause D Malfunction of ignition switch. The engine-ECU interrupts the ignition coil primary current by turning the power transistor D Malfunction of power transistor unit inside the engine-ECU ON and OFF. D Improper connector contact,…
• Page 285
  13A-45 MPI – Troubleshooting INSPECTION PROCEDURE 31 Idle speed control (ISC) servo (Stepper motor) system Probable cause D Malfunction of ISC servo The engine-ECU controls the intake air volume during idling by opening and closing D Improper the servo valve located in the bypass air passage. connector contact, open…
• Page 286
  13A-46 MPI – Troubleshooting INSPECTION PROCEDURE 33 EGR control solenoid valve system Probable cause D Malfunction of solenoid valve The EGR control solenoid valve is controlled by the negative pressure resulting from D Improper EGR operation leaking to port “A” of the throttle body. connector contact, open…
• Page 287
  13A-47 MPI – Troubleshooting INSPECTION PROCEDURE 34 MUT-II: Inspection of no initial combustion MUT-II Data list Check the power supply and ignition switch-IG system. 16 Voltage of engine-ECU power source (Refer to P.13A-57.) (Refer to P.13A-39, INSPECTION PROCEDURE 23.) Check timing belt for breakage. Does the camshaft rotate at the engine cranking? (When oil filler cap is removed.) Refer to P.13A-10, INSPECTION CHART FOR DIAGNOSIS…
• Page 288
  13A-48 MPI – Troubleshooting INSPECTION PROCEDURE 36 MUT-II: Check if uncomplete combustion occurs. MUT-II Self-Diag code Refer to P.13A-10, INSPECTION CHART FOR DIAGNOSIS CODE Are diagnosis codes displayed? Check the fuel pump system. MUT-II Actuator test (Refer to P.13A-40, INSPECTION PROCEDURE 24.) 07 Fuel pump (Refer to P.13A-62.) Check the engine coolant temperature sensor system.
• Page 289
  13A-49 MPI – Troubleshooting INSPECTION PROCEDURE 38 MUT-II: Check if idling speed is unstable. MUT-II Data list Check the idle position switch system. 26 Idle position switch (Refer to P.13A-57.) (Refer to P.13A-40, INSPECTION PROCEDURE 25.) Check the intake air temperature sensor system. (Refer to P.13A-12, MUT-II Data list INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.) 13 Intake air temperature sensor (Refer to P.13A-57.)
• Page 290
  13A-50 MPI – Troubleshooting INSPECTION PROCEDURE 39 MUT-II: Engine stalling inspection when the engine is warmed up and idling. MUT-II Data list Check the idle position switch system. 26 Idle position switch (Refer to P.13A-57.) (Refer to P.13A-40, INSPECTION PROCEDURE 25.) Check the intake air sensor system.
• Page 291
  13A-51 MPI – Troubleshooting INSPECTION PROCEDURE 40 MUT-II: Check if hesitation, sug, stumble or poor acceleration occurs. MUT-II Data list Check the idle position switch system. 26 Idle position switch (Refer to P.13A-57.) (Refer to P.13A-40, INSPECTION PROCEDURE 25.) Check the intake air sensor system. (Refer to P.13A-12, INSPEC- MUT-II Data list TION PROCEDURE FOR DIAGNOSIS CODE 13.) 13 Intake air temperature sensor (Refer to P.13A-57.)
• Page 292
  13A-52 MPI – Troubleshooting INSPECTION PROCEDURE 41 MUT-II: Check if surge occurs. MUT-II Data list Check the idle position switch system. 26 Idle position switch (Refer to P.13A-57.) (Refer to P.13A-40, INSPECTION PROCEDURE 25.) Check the intake air sensor system. (Refer to P.13A-12, INSPEC- MUT-II Data list TION PROCEDURE FOR DIAGNOSIS CODE 13.) 13 Intake air temperature sensor (Refer to P.13A-57.)
• Page 293
  13A-53 MPI – Troubleshooting INSPECTION PROCEDURE 42 Check the engine-ECU power supply and earth circuit. 1. NG Check following Measure the engine-ECU connectors, C-49, C-50, C-51. Repair D Disconnect the connector and measure at the harness side connector. C-88 1. Voltage between 62 and earth (Ignition switch: ON) OK: System voltage 2, 3.
• Page 294
  13A-54 MPI – Troubleshooting INSPECTION PROCEDURE 44 Check the fuel pump drive control circuit. Check following Measure at the fuel pump relay connector C-54. Repair D Disconnect the connector and measure at the harness side. connector. C-88 D Voltage between 4 and earth (Ignition switch: ON) OK: System voltage Check trouble symptom.
• Page 295
  13A-55 MPI – Troubleshooting INSPECTION PROCEDURE 46 Check throttle position sensor (TPS) output circuit. Check following Measure at the engine-ECU connector C-51. Repair D Connect the connector. connector. C-51 D Voltage between 64 and earth (Ignition switch: ON) OK: 0.3 – 1.0 V (Throttle valve at idle position) 4.5 –…
• Page 296
  13A-56 MPI – Troubleshooting INSPECTION PROCEDURE 48 Check ignition coil and power transistor unit circuit. Check the ignition coil. (Refer to GROUP 16 – Ignition System.) Replace Check the power transistor unit. Replace (Refer to GROUP 16 – Ignition System.) 1.
• Page 297
  13A-57 MPI – Troubleshooting DATA LIST REFERENCE TABLE 13100890180 Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE *1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes 10% higher than the standard frequency.
• Page 298
  13A-58 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Intake air Ignition switch: ON or When intake air –20_C Code No. 13A-12 temperature with engine running temperature is –20_C sensor sensor When intake air temperature is 0_C When intake air 20_C…
• Page 299
  13A-59 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Crank angle Engine: Cranking Compare the engine Accord Code No. 13A-15 sensor Tachometer: speed readings on Connected the tachometer and the MUT-II. Engine: Idling When engine 1,275 –…
• Page 300
  13A-60 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page A/C switch Engine: Idling A/C switch: OFF Procedure 13A-43 (when A/C switch is No. 29 ON, A/C compressor A/C switch: ON should be operating.) Inhibitor Ignition switch: ON P or N P or N…
• Page 301
  13A-61 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Engine coolant A/C switch: OFF 2 – 25 STEP – – (stepper) temperature: motor 80 – 95_C position * osition Lamps and all Lam s and all A/C switch: Increases by accessories: OFF…
• Page 302
  13A-62 MPI – Troubleshooting ACTUATOR TEST REFERENCE TABLE 13100900210 Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No.1, Engine: Idling condition Code No. 13A-19 No.3 injector After having warmed up/En- becomes different gine is idling (becomes unsta-…
• Page 303
  13A-63 MPI – Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS Needle-nosed wire probe 13100920186 TERMINAL VOLTAGE CHECK CHART 1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) 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.
• Page 304
  13A-64 MPI – Troubleshooting Engine-ECU Connector Terminal Arrangement NOTE *: Vehicles with immobilizer system Terminal No. Check item Check condition (Engine condition) Normal condition No.1, No.3 injector While engine is idling after having From 11 – 14 V, momentarily warmed up suddenly depress the warmed u , suddenly de ress the drops slightly dro s slightly…
• Page 305
  13A-65 MPI – Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Oxygen sensor heater Engine: Idling after warming up 0 – 3V Engine r/min: 5,000r/min. System voltage Ignition switch: OFF ! ON 0 – 3V ! 9 – 13V Engine warning lamp (After several seconds have elapsed)
• Page 306
  13A-66 MPI – MPI – Troubleshooting Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Engine coolant Ignition switch: When engine 3.2 – 3.8V temperature sensor coolant tempera- ture is 0_C When engine 2.3 – 2.9V coolant tempera- ture is 20_C When engine 1.3 –…
• Page 307
  13A-67 MPI – Troubleshooting CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart.
• Page 308
  13A-68 MPI – Troubleshooting Terminal No. Inspection item Normal condition (Check condition) 28 – 33 Ω (At 20_C) 4 – 12 Stepper motor coil (A1) 17 – 12 Stepper motor coil (A2) 5 – 12 Stepper motor coil (B1) 18 – 12 Stepper motor coil (B2) 36 –…
• Page 309
  13A-69 MPI – Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER Analyzer 13100930127 AIR FLOW SENSOR (AFS) Special patterns Measurement Method pickup 1. Disconnect the air flow sensor connector, and connect the special tool (test harness: MB991348) in between. (All terminals should be connected.) 2.
• Page 310
  13A-70 MPI – Troubleshooting Examples of Abnormal Wave Patterns Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency.
• Page 311
  13A-71 MPI – Troubleshooting Standard wave pattern 2 engine revolution (1 camshaft revolution) The time (cycle time) T is 75_ BTDC reduced when the engine 5_ BTDC speed increases Crank angle sensor output wave pattern Top dead centre sensor output wave pattern Time TDC: Top dead centre…
• Page 312
  13A-72 MPI – MPI – Troubleshooting Troubleshooting INJECTOR Analyzer Measurement Method 1. Disconnect the injector connector, and then connect the special tool (test harness: MB991348) in between. (Both the power supply side and engine-ECU side should be connected.) 2. Connect the analyzer special patterns pickup to terminal Special 2 of the injector connector.
• Page 313
  13A-73 MPI – Troubleshooting Wave Pattern Observation Points Explanation of Wave Pattern NOTE Because the fuel injection method is a group other injector may still the normal, and in this injection method (injection with injectors case a normal wave pattern will be output. grouped together in sets of two).
• Page 314
  13A-74 MPI – Troubleshooting STEPPER MOTOR Analyzer Measurement Method 1. Disconnect the stepper motor connector, and connect the special tool (test harness: MD998463) in between. Special 2. Connect the analyzer special patterns pickup to the patterns stepper motor-side connector terminal 1 (red clip of special pickup tool), terminal 3 (blue clip), terminal 4 (black clip) and terminal 6 (yellow clip) respectively.
• Page 315
  13A-75 MPI – Troubleshooting Wave Pattern Observation Points Check that the standard wave pattern appears when the stepper motor is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern Probable cause Induced electromotive force does not appear or is extremely small.
• Page 316
  13A-76 MPI – Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Ignition coil primary signal Refer to GROUP 16 – Ignition System. Power transistor control signal Measurement Method Special 1. Disconnect the distributor connector, and connect the patterns special tool (test harness: MB991348) in between. (All pickup terminals should be connected.) 2.
• Page 317
  13A-77 MPI – Troubleshooting Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage Probable cause Rises from approx. 2V to approx. 4.5V at the top-right Normal 2V rectangular wave Open-circuit in ignition primary circuit…
• Page 318
  13A-78 MPI – MPI – On-vehicle Service On-vehicle Service ON-VEHICLE SERVICE 13100100115 THROTTLE BODY (THROTTLE VALVE AREA) CLEANING 1. Start the engine and warm it up until the coolant is heated to 80_C or higher and then stop the engine. 2.
• Page 319
  13A-79 MPI – On-vehicle Service 7. Slowly turn the throttle position sensor clockwise and find the point where the idle position switch turns off. Securely tighten the throttle position sensor mounting bolt at this point. 8. Check the throttle position sensor output voltage. Standard value: 400–1,000 mV 9.
• Page 320
  13A-80 MPI – On-vehicle Service 3. 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.

• Page 321: Fuel Pressure Test

  13A-81 MPI – On-vehicle Service 8. Switch OFF the ignition switch. 9. Disconnect the jumper wire from the ignition timing adjustment terminal and return the connector to its original condition. 10. Disconnect the MUT-II. 11. Start the engine again and let it run at idle speed for about 10 minutes;…

• Page 322
  13A-82 MPI – On-vehicle Service 7. Disconnect the jumper wire from the fuel pump drive terminal to stop the fuel pump. 8. Start the engine and run at idle. 9. Measure fuel pressure while the engine is running at idle. Standard value: Approx.
• Page 323
  13A-83 MPI – On-vehicle Service 14. 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 Remedy…
• Page 324
  13A-84 MPI – On-vehicle Service FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE) 13100090191 When removing the fuel pipe, hose, etc., since fuel pressure in the fuel pipe line is high, do the following operation so as to release fuel pressure in the line and prevent fuel from running out.

• Page 325: Component Location

  13A-85 MPI – On-vehicle Service COMPONENT LOCATION 13100210238 Name Symbol Name Symbol A/C relay Fuel pump check terminal A/C switch Idle speed control servo Air flow sensor (with intake air temperature Ignition coil and power transistor unit sensor and barometric pressure sensor) Control relay and fuel pump relay Inhibitor switch <A/T>…

• Page 326
  13A-86 MPI – On-vehicle Service CONTROL RELAY AND FUEL PUMP RELAY Control relay and CONTINUITY CHECK 13100990095 fuel pump relay Battery voltage Terminal No. Not supplied Equipment side connector Supplied INTAKE AIR TEMPERATURE SENSOR CHECK Equipment 13100280147 side connector 1. Disconnect the air flow sensor connector. 2.
• Page 327
  13A-87 MPI – On-vehicle Service 4. Apply sealant to threaded portion. Specified sealant: 3M NUT Locking Part No.4171 or equivalent 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 Nm THROTTLE POSITION SENSOR CHECK 13100320177 Equipment 1.

• Page 328: Oxygen Sensor Check

  13A-88 MPI – On-vehicle Service OXYGEN SENSOR CHECK Equipment side 13100510116 connector 1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (7 – 40 Ω at 20_C) between terminal 1 (red clip of special tool) and terminal 3 (blue clip of special tool) on the oxygen sensor connector.

• Page 329: Injector Check

  13A-89 MPI – On-vehicle Service INJECTOR CHECK 13100520171 Injectors Measurement of Resistance between Terminals 1. Remove the injector connector. 2. Measure the resistance between terminals. Standard value: 13–16 Ω (at 20_C) 3. Install the injector connector. Checking the Injection Condition 1.

• Page 330
  13A-90 MPI – MPI – On-vehicle Service On-vehicle Service 5. Activate the injector and check the atomized spray Main hose Return hose condition of the fuel. The condition can be considered satisfactory unless it is extremely poor. Injector Battery 6. Stop the actuation of the injector, and check for leakage from the injector’s nozzle.
• Page 331
  13A-91 MPI – On-vehicle Service PURGE CONTROL SOLENOID VALVE CHECK 13100560111 Refer to GROUP 17 – Emission Control System. EGR CONTROL SOLENOID VALVE CHECK 13100570107 Refer to GROUP 17 – Emission Control System.
• Page 332
  13A-92 MPI – Injector INJECTOR 13100710226 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Fuel Discharge Prevention (Refer to P.13A-84.) Accelerator Cable Adjustment (Refer to GROUP 17 – On-vehicle Service.) Throttle Cable Adjustment (Refer to GROUP 23 – On-vehicle Service.) 5 Nm 12 Nm 12 Nm 12 Nm…
• Page 333
  13A-93 MPI – Injector REMOVAL SERVICE POINT AA» DELIVERY PIPE/INJECTOR REMOVAL Remove the delivery pipe (with the injectors attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector. INSTALLATION SERVICE POINT «AA INJECTOR/FUEL PRESSURE REGULATOR/ HIGH-PRESSURE FUEL HOSE INSTALLATION (1) Apply a drop of new engine oil to the O-ring.

• Page 334: Throttle Body

  13A-94 MPI – Throttle Body THROTTLE BODY 13100770200 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Accelerator Cable Adjustment (Refer to GROUP 17 – On-vehicle Service.) Throttle Cable Adjustment (Refer to GROUP 23 – On-vehicle Service.) Engine Coolant Supplying 4 Nm 18 Nm 12 Nm…

• Page 335
  13A-95 MPI – Throttle Body DISASSEMBLY AND REASSEMBLY 13100970204 3.5 Nm 3.5 Nm 5 Nm Disassembly steps 1. Bracket NOTE «AA 2. Throttle position sensor The fixed SAS is correctly adjusted at the factory and 3. Idle speed control body assembly should not be removed.
• Page 336
  13A-96 MPI – Throttle Body REASSEMBLY SERVICE POINT «AA THROTTLE POSITION SENSOR (TPS) INSTALLATION 1. Install the TPS so that it faces as shown in the illustration, and then tighten it with the screw. 2. Connect a multimeter between terminal (4) (TPS power supply) and terminal (3) (TPS output) of the TPS connector, and check that the resistance increases gradually as the throttle valve is opened slowly to the…
• Page 402
  13A-2 MULTIPOINT FUEL INJECTION (MPI) CONTENTS GENERAL ……. Inspection Procedure Classified by Diagnosis Code .
• Page 403
  13A-3 MPI – General/General Information/Service Specifications GENERAL OUTLINE OF CHANGES With the modification below, the service procedure of the part that is different from previous part has been established. Adopting On-board Diagnostics System filled out the diagnostic item and modified diagnostic code numbering system.
• Page 404
  13A-4 MPI – Special Tools/Troubleshooting SPECIAL TOOLS Tool Number Name Measurement of voltage during MB991658 Test harness set troubleshooting Measurement of voltage during MB991709 Test harness troubleshooting Inspection using an analyzer Measurement of voltage during MD998478 Test harness troubleshooting (3-pin, triangle) Inspection using an analyzer TROUBLESHOOTING DIAGNOSIS FUNCTION…
• Page 405
  13A-5 MPI – Troubleshooting Code No. Diagnosis item 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 No. 2 injector system P0203 No. 3 injector system P0204 No.
• Page 406
  13A-6 MPI – MPI – Troubleshooting Troubleshooting METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points on the ’97 L200 Workshop Manual (Pub. No. PWTE96E1). DIAGNOSIS USING DIAGNOSIS 2 MODE 1. Switch the diagnosis mode of the engine control unit to DIAGNOSIS 2 mode using the MUT-II.
• Page 407
  13A-7 MPI – Troubleshooting Display item list Data item Unit Engine coolant temperature sensor Engine speed r/min Vehicle speed km/h Long-term fuel compensation (long-term fuel trim) Short-term fuel compensation (short-term fuel trim) Fuel control Open loop condition condition Closed loop Open loop owing to OL-DRV.
• Page 408
  13A-8 MPI – Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning item Control contents during malfunction Air flow sensor 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…
• Page 409
  13A-9 MPI – MPI – Troubleshooting Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page P0100 Air flow sensor system 13A-10 P0105 Barometric pressure sensor system 13A-12 P0110 Intake air temperature sensor system 13A-14 P0115 Engine coolant temperature sensor system 13A-16 P0120 Throttle position sensor system…
• Page 410
  13A-10 MPI – Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No. P0100 Air flow sensor system Probable cause D Malfunction of air flow sensor Range of Check D Engine speed: 500 r/min or more D Open or short circuit in air flow sensor circuit or Set Conditions loose connector contact D The sensor output frequency is 3.3 Hz or less for four seconds.
• Page 411
  13A-11 MPI – Troubleshooting From the previous page Repair Measure at air flow sensor connector Check the following connector: A-77. C-49 D Use test harness (MB991348) to connect the connector, and measure at the pick-up harness. Check the harness between the air Repair D Ignition switch: ON flow sensor and the engine-ECU.
• Page 412
  13A-12 MPI – Troubleshooting Code No. P0105 Barometric pressure sensor system Probable cause D Malfunction of barometric pressure sensor Range of Check D Two seconds have passed since the ignition switch is turned ON or the D Open or short circuit in barometric pressure engine starting process is completed.
• Page 413
  13A-13 MPI – Troubleshooting From the previous page (1) NG Measure at air flow sensor connector Check the following connectors: Repair (3) NG A-77. C-94, C-97 D Connect connector terminals No. 1, No. 2 and No. 5 only by using test harness (MB991348), and measure at the pick-up harness.
• Page 414
  13A-14 MPI – Troubleshooting Code No. P0110 Intake air temperature sensor system Probable cause D Malfunction of intake air temperature sensor Range of Check D Two seconds have passed since the ignition switch is turned ON or the D Open or short circuit in intake air temperature engine starting process is completed.
• Page 415
  13A-15 MPI – Troubleshooting From the previous page Repair Measure at air flow sensor connector Check the following connectors: A-77. C-94, C-97 D Use the test harness (MB991348) to connect only terminals 5 and 6, and then measure at the Check the harness between the air pick-up harness.
• Page 416
  13A-16 MPI – MPI – Troubleshooting Troubleshooting Code No. P0115 Engine coolant temperature sensor Probable cause system D Malfunction of engine coolant temperature sensor Range of Check D Engine: Two seconds after the engine has been started D Open or short circuit in the engine coolant Set Conditions temperature sensor circuit or loose connector D The sensor output voltage is 4.6 V or more for four seconds (equivalent to…
• Page 417
  13A-17 MPI – Troubleshooting From the previous page (1) NG Measure at engine-ECU connector Measure at engine coolant Check the following connector: C-97. temperature sensor connector A-64. C-97 D Measure the voltage at the D Disconnect the connector and engine-ECU terminal. measure at the harness side.
• Page 418
  13A-18 MPI – Troubleshooting Code No. P0120 Throttle position sensor system Probable cause D Malfunction of throttle position sensor Range of Check D Excluding two seconds after the ignition switch is turned ON or immediately D Improper connector contact, open circuit or after the engine starts.
• Page 419
  13A-19 MPI – Troubleshooting From the previous page (1) NG Measure at throttle position sensor Repair Check the following connector: (2) NG connector A-47. C-97 D Use test harness (MB991348) to connect the connector, and measure at the pick-up harness. Check the harness wire between the D Ignition switch: ON throttle position sensor and the…
• Page 420
  13A-20 MPI – Troubleshooting Code No. P0125 Feedback system Probable cause D Malfunction of oxygen sensor (front) Range of Check D The engine coolant temperature is approx. 80_C or more. D Open or short circuit in the oxygen sensor (front) D During stoichiometric feedback control circuit or loose connector contact D The vehicle is not being decelerated.
• Page 421
  13A-21 MPI – Troubleshooting Code No. P0130 Oxygen sensor (front) system Probable cause <sensor 1> D Malfunction of oxygen sensor (front) Range of Check D Three minutes have been passed since the engine has been started. D Open or short circuit in the oxygen sensor (front) D The engine coolant temperature is approx.
• Page 422
  13A-22 MPI – Troubleshooting Repair Check the following connector: B-03 Check the following connectors: Repair Measure at oxygen sensor (front) C-60, C-94, C-97 connector B-03. D Disconnect the connector and measure at the harness side. D Resistance between terminal 2 Repair Check the harness wire between the and earth…
• Page 423
  13A-23 MPI – Troubleshooting Code No. P0135 Oxygen sensor heater (front) system Probable cause <sensor 1> D Malfunction of oxygen sensor heater (front) Range of Check D The engine coolant temperature is approx. 20_C or more. D Open or short circuit in the oxygen sensor heater D The oxygen sensor heater (front) remains on.
• Page 424
  13A-24 MPI – MPI – Troubleshooting Troubleshooting Code No. P0136 Oxygen sensor (rear) system <sensor 2> Probable cause D Malfunction of oxygen sensor (rear) Range of Check D Three minutes have been passed since the engine has been started. D Open or short circuit in the oxygen sensor (rear) D The engine coolant temperature is approx.
• Page 425
  13A-25 MPI – Troubleshooting Code No. P0141 Oxygen sensor heater (rear) system Probable cause <sensor 2> D Malfunction of oxygen sensor heater (rear) Range of Check D The engine coolant temperature is approx. 20_C or more. D Open or short circuit in the oxygen sensor heater D The oxygen sensor heater (rear) remains on.
• Page 426
  13A-26 MPI – Troubleshooting Code No. P0170 Abnormal fuel system Probable cause D Incorrect fuel pressure Range of Check D Engine: Being learning the air/fuel ratio D Malfunction of fuel supply system D Malfunction of oxygen sensor (front) Set Conditions D Ten seconds or more have been passed while the fuel injection amount D Malfunction of intake air temperature sensor D Malfunction of barometric pressure sensor…
• Page 427
  13A-27 MPI – Troubleshooting Code No. P0201 No. 1 injector system Probable cause Code No. P0202 No. 2 injector system Code No. P0203 No. 3 injector system Code No. P0204 No. 4 injector system D Malfunction of the injector Range of Check D Engine speed is approx.
• Page 428
  13A-28 MPI – Troubleshooting Code No. P0300 Random cylinder misfire detected Probable cause D Malfunction of the ignition system Range of Check D Engine speed is approx. 50 – 4,500 r/min. D Abnormal compression D When the engine is running except deceleration and sudden acceleration D Malfunction of injector D Abnormal signal from the crank angle sensor Set Conditions…
• Page 429
  13A-29 MPI – MPI – Troubleshooting Troubleshooting Code No. P0301 No. 1 cylinder misfire detected Probable cause Code No. P0302 No. 2 cylinder misfire detected Code No. P0303 No. 3 cylinder misfire detected Code No. P0304 No. 4 cylinder misfire detected D Malfunction of the ignition system Range of Check D The engine speed is 500 –…
• Page 430
  13A-30 MPI – Troubleshooting From the previous page Repair Check the following connector: A-70 Measure at engine-ECU connector C-51. D Connect the connector. Check trouble symptom. D Voltage between terminal 58 and earth. (Engine: 3.000 r/min) Repair Check the harness wire between the OK: 0.3 –…
• Page 431
  13A-31 MPI – Troubleshooting Code No. P0335 Crank angle sensor system Probable cause D Malfunction of the crank angle sensor. Range of Check D Engine is cranking D Open or short circuit in the crank angle sensor Set Conditions circuit or loose connector contact. D Sensor output voltage does not change for 4 seconds (no pulse signal input).
• Page 432
  13A-32 MPI – MPI – Troubleshooting Troubleshooting Code No. P0340 Camshaft position sensor system Probable cause D Malfunction of the camshaft position sensor Range of Check D Ignition switch: ON D Open or short circuit in the camshaft position D Engine speed: 50 r/min or more sensor circuit or loose connector contact.
• Page 433
  13A-33 MPI – Troubleshooting Code No. P0403 EGR control solenoid valve system Probable cause D Malfunction of the EGR control solenoid valve Range of Check D Ignition switch: ON D Open or short circuit in the EGR control solenoid D Battery voltage is 10 V or more. valve circuit or loose connector contact D Malfunction of engine-ECU Set Conditions…
• Page 434
  13A-34 MPI – Troubleshooting Code No. P0420 Catalyst malfunction Probable cause D Malfunction of catalyst Range of Check D The engine speed is 3,000 r/min or less. D Malfunction of the oxygen sensor (front) D During driving D Malfunction of the oxygen sensor (rear) D During air/fuel ratio feedback control D Malfunction of engine-ECU Set Conditions…
• Page 435
  13A-35 MPI – Troubleshooting Code No. P0443 Purge control solenoid valve system Probable cause D Malfunction of the purge control solenoid valve Range of Check D Ignition switch: ON D Open or short circuit in the purge control solenoid D Battery voltage is 10 V or more. valve circuit or loose connector contact D Malfunction of engine-ECU Set Conditions…
• Page 436
  13A-36 MPI – Troubleshooting Code No. P0500 Vehicle speed sensor system Probable cause D Malfunction of the vehicle speed sensor (reed Range of Check D Engine: Two seconds after the engine was started switch) D Idle switch: OFF D Open or short circuit in the vehicle speed D Engine speed: 2,500 r/min or more sensor circuit or loose connector contact D During high engine load…
• Page 437
  13A-37 MPI – Troubleshooting Code No. P0505 Idle speed control (ISC) system Probable cause D Malfunction of idle speed control (ISC) servo Check Area D Vehicle speed has reached 1.5 km/h at least once. D Improper connector contact, open circuit or D Under the closed loop idle speed control.
• Page 438
  13A-38 MPI – Troubleshooting MUT-II Self-Diag code Refer to P.13A-9, INSPECTION CHART Is any diagnosis code other than No. FOR DIAGNOSIS CODES. P0505 output? Check intake air hose and intake Repair manifold for air intake. Check the throttle body (around the Clean around the throttle valve.
• Page 439
  13A-39 MPI – MPI – Troubleshooting Troubleshooting From the previous page Check the following connector: Repair C-49 Check the harness wires between Repair the engine control relay and the idle speed control servo, and between the idle speed control servo and the engine-ECU.
• Page 440
  13A-40 MPI – Troubleshooting Code No. P0551 Power steering fluid pressure switch Probable cause system D Power steering fluid pressure switch failed. Check Area D Intake air temperature is –10_C or higher. D Open or shorted power steering fluid pressure D Barometric pressure is 76 kPa or higher.
• Page 441
  13A-41 MPI – Troubleshooting Code No. P1610 Immobilizer system Probable cause D Open or short circuit, or loose connector contact Range of Check D Ignition switch: ON D Malfunction of the immobilizer-ECU D Malfunction of the engine-ECU Set Conditions D Improper communication between the engine-ECU and the immobilizer-ECU NOTE (1) If the registered ignition keys are close each other when starting the engine, radio interference may cause this code to be displayed.
• Page 442
  13A-42 MPI – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference procedure page Communication Communication with all systems is not possible. 13A-43 with MUT-II is with MUT-II is Communication with engine-ECU is not possible. 13A-43 impossible. Engine warning The engine warning lamp does not illuminate right after the ignition 13A-44 lamp and…
• Page 443
  13A-43 MPI – Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. Probable cause (Communication with all systems is not possible.) D Malfunction of the connector The cause is probably a defect in the power supply system (including earth) for the D Malfunction of the harness wire diagnosis line.
• Page 444
  13A-44 MPI – MPI – Troubleshooting Troubleshooting INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after Probable cause the ignition switch is turned to the ON position. D Burnt-out bulb Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp D Defective warning lamp circuit to illuminate for five seconds immediately after the ignition switch is turned to ON.
• Page 445
  13A-45 MPI – Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (Starting impossible) Probable cause D Malfunction of the ignition system In cases such as the above, the cause is probably that a spark plug is defective, D Malfunction of the fuel pump system or that the supply of fuel to the combustion chamber is defective.
• Page 446
  13A-46 MPI – Troubleshooting INSPECTION PROCEDURE 6 Initial combustion but no complete combustion Probable cause (Starting impossible) D Malfunction of the ignition system In such cases as the above, the cause is probably that the spark plugs are generating D Malfunction of the injector system sparks but the sparks are weak, or the initial mixture for starting is not appropriate.
• Page 447
  13A-47 MPI – Troubleshooting INSPECTION PROCEDURE 7 It takes too long time to start. (Incorrect starting) Probable cause D Malfunction of the ignition system In cases such as the above, the cause is probably that the spark is weak and ignition D Malfunction of the injector system is difficult, the initial mixture for starting is not appropriate, or sufficient compression D Inappropriate gasoline use…
• Page 448
  13A-48 MPI – Troubleshooting INSPECTION PROCEDURE 8 Unstable idling (Rough idling, hunting) Probable cause D Malfunction of the ignition system In cases as the above, the cause is probably that the ignition system, air/fuel mixture, D Malfunction of air/fuel ratio control system idle speed control (ISC) or compression pressure is defective.
• Page 449
  13A-49 MPI – Troubleshooting From the previous page Check the oxygen sensor (rear) system. (Refer to P.13A-24, IN- MUT-II Data list SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136.) 59 Oxygen sensor (rear) D Transmission: 2nd gear D Driving with throttle widely open OK: 600 –…
• Page 450
  13A-50 MPI – MPI – Troubleshooting Troubleshooting INSPECTION PROCEDURE 9 Idling speed is high. (Improper idling speed) Probable cause D Malfunction of the ISC system In such cases as the above, the cause is probably that the intake air volume during D Malfunction of the throttle body idling is too great.
• Page 451
  13A-51 MPI – Troubleshooting INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idling. (Die out) Probable cause D Malfunction of the ISC system In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate D Malfunction of the throttle body when the engine is cold, or that the intake air volume is insufficient.
• Page 452
  13A-52 MPI – Troubleshooting INSPECTION PROCEDURE 12 When the engine is hot, it stalls at idling. (Die out) Probable cause D Malfunction of the ignition system In such cases as the above, the cause is probably that ignition system, air/fuel mixture, D Malfunction of air/fuel ratio control system idle speed control (ISC) or compression pressure is defective.
• Page 453
  13A-53 MPI – Troubleshooting From the previous page MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13A-21, IN- 11 Oxygen sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE P0130.) OK: Changes between 600 – 1,000 mV during sudden racing Check the fuel pressure.
• Page 454
  13A-54 MPI – Troubleshooting INSPECTION PROCEDURE 13 The engine stalls when starting the car. (Pass out) Probable cause D Drawing air into intake system In cases such as the above, the cause is probably misfiring due to a weak spark, D Malfunction of the ignition system or an inappropriate air/fuel mixture when the accelerator pedal is depressed.
• Page 455
  13A-55 MPI – Troubleshooting INSPECTION PROCEDURE 15 Hesitation, sag or stumble Probable cause D Malfunction of the ignition system In cases such as the above, the cause is probably that ignition system, air/fuel mixture D Malfunction of air/fuel ratio control system or compression pressure is defective.
• Page 456
  13A-56 MPI – Troubleshooting From the previous page MUT-II Data list Check the fuel pressure. 1. Inspect the intake of 11 Oxygen sensor (Refer to P.13A-81*.) air into the air intake OK: Changes between 0 – 400 mV and 600 – 1,000 mV during system.
• Page 457
  13A-57 MPI – Troubleshooting INSPECTION PROCEDURE 18 Poor acceleration Probable cause D Malfunction of the ignition system Defective ignition system, abnormal air/fuel ratio, poor compression pressure, etc. D Malfunction of air/fuel ratio control system are suspected. D Malfunction of the fuel supply system D Poor compression pressure D Clogged exhaust system MUT-II Self-Diag code…
• Page 458
  13A-58 MPI – Troubleshooting From the previous page 1. Inspect the intake of MUT-II Data list Check the fuel pressure. air into the air intake 11 Oxygen sensor (Refer to P.13A-81*.) system. OK: Changes between 0 – 400 mV and 600 – 1,000 mV during D Broken intake idling…
• Page 459
  13A-59 MPI – Troubleshooting INSPECTION PROCEDURE 19 Surge Probable cause D Malfunction of the ignition system Defective ignition system, abnormal air/fuel ratio, etc. are suspected. D Malfunction of air/fuel ratio control system D Malfunction of the EGR control solenoid valve system MUT-II Self-Diag code Refer to P.13A-9, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed?
• Page 460
  13A-60 MPI – Troubleshooting INSPECTION PROCEDURE 20 Knocking Probable cause D Inappropriate heat value of the spark plug In cases as the above, the cause is probably that the heat value of the spark plug is inappropriate. Check the following items. D Spark plugs D Check if foreign materials (water, alcohol, etc.) got into fuel.
• Page 461
  13A-61 MPI – Troubleshooting INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling Probable cause D Malfunction of the air/fuel ratio control system Abnormal air/fuel ratio is suspected. D Deteriorated catalyst MUT-II Self-Diag code Refer to P.13A-9, INSPECTION CHART FOR DIAGNOSIS Are diagnosis codes displayed? CODES.
• Page 462
  13A-62 MPI – Troubleshooting INSPECTION PROCEDURE 23 Engine-ECU power supply and earth circuit system Probable cause D Improper The engine-ECU may be defective, or that one of the malfunctions listed at right connector contact, open circuit has occurred. short-circuited harness wire in the engine-ECU power supply circuit.
• Page 463
  13A-63 MPI – Troubleshooting INSPECTION PROCEDURE 24 Power supply system and ignition switch-IG system Probable cause D Malfunction of the ignition switch When an ignition switch ON signal is input to the engine-ECU, the engine-ECU turns D Malfunction of the engine control relay the engine control relay ON.
• Page 464
  13A-64 MPI – Troubleshooting MUT-II Actuator test Normal 07 Fuel pump (Refer to P.13A-72.) Check the fuel pump relay. (Refer to Replace P.13A-86*.) Check the following connector: Measure at fuel pump relay connector Repair C-88 C-54. D Disconnect the connector, and measure at the harness side.
• Page 465
  13A-65 MPI – MPI – Troubleshooting Troubleshooting INSPECTION PROCEDURE 26 Ignition switch-ST system Probable cause D Malfunction of ignition switch The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is D Improper cranking. connector contact, open circuit The engine-ECU controls fuel injection, etc.
• Page 466
  13A-66 MPI – Troubleshooting INSPECTION PROCEDURE 28 Ignition circuit system Probable cause D Malfunction of ignition coil. The engine-ECU interrupts the ignition coil primary current by turning the power transistor D Malfunction of power transistor unit. inside the engine-ECU ON and OFF. D Improper connector contact, open circuit or short-circuited harness wire D Malfunction of the engine-ECU…
• Page 467
  13A-67 MPI – Troubleshooting DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE *1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes 10 % higher than the standard frequency.
• Page 468
  13A-68 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Intake Ignition switch: ON or When intake air tem- –20_C Code No. 13A-14 temperature with engine running perature is –20_C P0110 sensor sensor When intake air tem- perature is 0_C When intake air tem- 20_C…
• Page 469
  13A-69 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Crank angle Engine: Cranking Compare the engine Accord Code No. 13A-31 sensor Tachometer: speed readings on P0335 Connected the tachometer and the MUT-II. Engine: Idling When engine cool- 1,275 –…
• Page 470
  13A-70 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Injectors* Engine: Cranking When engine cool- 60 – 90 ms – – ant temperature is 0_C (injection is car- ried out for all cylin- ders simultaneously) When engine cool- 30 –…
• Page 471
  13A-71 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Oxygen Transmission: 3,500 r/min 600 – 1,000 mV Code No. 13A-24 sensor 2nd gear P0136 (rear) Drive with throttle widely open Long-term Engine: Warm, 2,500 r/min without any load –12.5 –…
• Page 472
  13A-72 MPI – Troubleshooting ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. Engine: After having warmed Idling condition Code No. 13A-27 1 injector up/Engine is idling becomes different P0201 (becomes unsta…
• Page 473
  13A-73 MPI – Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS Needle-nosed wire probe TERMINAL VOLTAGE CHECK CHART 1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) 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.
• Page 474
  13A-74 MPI – Troubleshooting Engine-ECU Connector Terminal Arrangement NOTE: *: Vehicles with immobilizer system Terminal No. Check item Check condition (Engine condition) Normal condition No. 1 injector While engine is idling after having From 11 – 14 V, momentarily warmed up suddenly depress the warmed up, suddenly depress the drops slightly drops slightly…
• Page 475
  13A-75 MPI – Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Ignition switch: OFF → ON 0 – 3 V → 9 – 13 V Engine warning lamp (After several seconds have elapsed) Power steering fluid Engine: Idling after When steering System voltage pressure switch…
• Page 476
  13A-76 MPI – Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Backup power supply Ignition switch: OFF System voltage Sensor impressed Ignition switch: ON 4.5 – 5.5 V voltage Ignition switch-IG Ignition switch: ON System voltage Engine coolant Ignition switch: When engine 3.2 –…
• Page 477
  13A-77 MPI – Troubleshooting CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart.
• Page 478
  13A-78 MPI – Troubleshooting Terminal No. Inspection item Normal condition (Check condition) 28 – 33 Ω (At 20_C) 4 – 12 Stepper motor coil (A1) 17 – 12 Stepper motor coil (A2) 5 – 12 Stepper motor coil (B1) 18 – 12 Stepper motor coil (B2) 36 –…
• Page 479
  13A-79 MPI – Troubleshooting INSPECTION PROCEDURE USING AN Camshaft position sensor Analyzer connector ANALYZER Special patterns CAMSHAFT POSITION SENSOR AND CRANK ANGLE pick-up SENSOR Measurement Method 1. Disconnect the camshaft position sensor connector and connect the special tool (test harness: MB991709) in between.
• Page 480
  13A-80 MPI – Troubleshooting Standard wave pattern 2 engine revolutions (1 camshaft revolution) The time (cycle time) T is reduced when the engine 75_BTDC 5_BTDC speed increases Crank angle sensor output wave pattern 145° 130° 35° 50° Camshaft posi- tion sensor out- put wave pat- tern Time…
• Page 481
  13A-81 MPI – Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Ignition coil primary signal Refer to 16 – Ignition System. Power transistor control signal Measurement Method 1. Disconnect the power transistor connector, and connect Special pattern the special tool (test harness: MB991348) in between. pickup (All terminals should be connected.) 2.
• Page 482
  13A-82 MPI – Troubleshooting Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage Probable cause Rises from approx. 2V to approx. 4.5V at the top-right Normal 2V rectangular wave Open-circuit in ignition primary circuit…
• Page 483
  13A-83 MPI – On-vehicle Service ON-VEHICLE SERVICE COMPONENT LOCATION Name Symbol Name Symbol Camshaft position sensor Oxygen sensor (front) Crank angle sensor Oxygen sensor (rear) Ignition coil Power transistor unit…
• Page 484
  13A-84 MPI – On-vehicle Service OXYGEN SENSOR CHECK Equipment side connector <Oxygen sensor (front)> 1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. Oxygen sensor (front) 2. Make sure that there is continuity (4.5 – 8.0 Ω at 20_C) between terminal 1 (red clip of special tool) and terminal 3 (blue clip of special tool) on the oxygen sensor connector.
• Page 485
  13A-85 MPI – On-vehicle Service <Oxygen sensor (rear)> Equipment side Oxygen sensor connector (rear) 1. Disconnect the oxygen sensor connector and connect the special tool (test harness set) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 – 18 Ω at 20_C) between terminal 1 (red clip of special tool) and terminal 3 (blue clip of special tool) on the oxygen sensor connector.
• Page 486
  NOTES…

• Page 487: Diesel Fuel

  DIESEL FUEL Click on the applicable bookmark to selected the required model year…

• Page 489
  General Information/Service Specifications/ 13E-2 DIESEL FUEL – Special Tool/On-vehicle Service GENERAL INFORMATION 13300010025 The fuel is drawn out of the fuel tank by means Engine speed (fuel injection amount) control is of the feed pump which is built into the fuel injection carried out by means of a centrifugal-type governor pump.
• Page 490
  13E-3 DIESEL FUEL – DIESEL FUEL – On-vehicle Service On-vehicle Service EVACUATION OF AIR FROM FUEL LINE 13300130028 Hand pump Bleed the air from the fuel line after refilling the fuel. When fuel is drained for service. When fuel filter is replaced. When main fuel line is removed.
• Page 491
  13E-4 DIESEL FUEL – DIESEL FUEL – On-vehicle Service On-vehicle Service FUEL CUT VALVE CONTROLLER OPERATION CHECK <Vehicles with immobilizer system> Fuel cut valve When a sound scope is held against the fuel cut valve controller controller and the ignition switch is turned to “ON”, check that the sound of the valve operating can be heard.
• Page 492
  13E-5 DIESEL FUEL – On-vehicle Service INJECTION SPRAY CONDITION CHECK 1. Move the lever of the nozzle tester rapidly (4 – 6 times per second) to eject the fuel continuously. Check to be sure that the injection spray comes out evenly in a cone shape (injection spray angle is 10 _C).
• Page 493
  13E-6 DIESEL FUEL – Injection Nozzle INJECTION NOZZLE 13300270010 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Intercooler Removal <4WD> (Refer to GROUP 15.) Intercooler installation <4WD> (Refer to GROUP 15.) Accelerator Cable Adjustment (Refer to GROUP 17 – On-vehicle Service.) Throttle Cable Adjustment (Refer to GROUP 23 –…
• Page 494
  13E-7 DIESEL FUEL – Injection Nozzle AB» NUT/FUEL RETURN PIPE REMOVAL 1. While using a spanner or similar tool to hold the hexagonal nut of the fuel return pipe, remove the nut. Caution If an attempt is made to loosen the nut without first Fuel return pipe holding the fuel return pipe, the pipe may be broken or otherwise damaged.
• Page 495
  13E-8 DIESEL FUEL – Injection Nozzle DISASSEMBLY AND REASSEMBLY 13300350011 39 Nm Disassembly steps AA» «AA 1. Retaining nut 2. Nozzle tip 3. Distance piece 4. Retaining pin 5. Pressure ring 6. Shim 7. Nozzle holder body DISASSEMBLY SERVICE POINT AA»…
• Page 496
  13E-9 DIESEL FUEL – Injection Nozzle INSPECTION 13300360014 NOZZLE TIP 1. Check the nozzle tip for carbon deposits. Scape off carbon deposits with a piece of wood and clean each part with Plunger petrol. After cleaning, keep parts submerged in diesel fuel.
• Page 497
  13E-10 DIESEL FUEL – Injection Pump INJECTION PUMP 13300240011 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Timing Belt Installation (Refer to GROUP 11B.) Intercooler Removal <4WD> (Refer to GROUP 15.) Intercooler Installation <4WD> Timing Belt Removal (Refer to GROUP 11B.) (Refer to GROUP 15.) Engine Coolant Supplying Injection Timing Adjustment (Refer to GROUP 11B…
• Page 498
  13E-11 DIESEL FUEL – Injection Pump REMOVAL SERVICE POINTS AA» INJECTION PIPE REMOVAL Delivery holder Loosen the nuts at the end of the injection pipe with the delivery holder (for pump side) and injection nozzle assembly (for nozzle side) retained by a spanner, etc. AB»…
• Page 499
  NOTES…
• Page 502
  FUEL SUPPLY Click on the applicable bookmark to selected the required model year…
• Page 503
  13F-1 FUEL SUPPLY CONTENTS 13509000111 GENERAL INFORMATION ….FUEL FILTER <Diesel-powered Vehicles> ……… FUEL TANK .
• Page 504
  13F-2 FUEL SUPPLY – General Information GENERAL INFORMATION 13500010083 The fuel tank is equipped with a valve assembly (roll-over valve). It prevents fuel from leaking out of the fuel tank if the vehicle rolls over.

• Page 505: Fuel Tank

  13F-3 FUEL SUPPLY – Fuel Tank FUEL TANK 13500190152 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Fuel Draining Fuel Refilling Rear Body Side Gate Stay (LH) Removal Fuel Line Air Bleeding (Refer to GROUP 13E – On-vehicle Service.) Fuel Leakage Inspection Rear Body Side Gate Stay (LH) Installation <Petrol-powered vehicles>…

• Page 506
  13F-4 FUEL SUPPLY – Fuel Tank <Diesel-powered vehicles> (Single cab and (Double cab) club cab) 2 – 3 Nm (4WD) 2 – 3 Nm 24 – 29 Nm 2 – 3 Nm 24 – 29 Nm 22 Nm Removal steps 1.
• Page 507
  13F-5 FUEL SUPPLY – Fuel Tank «BA FILLER HOSE INSTALLATION Align the mating marks and install. INSPECTION 13500300074 FUEL CUT-OFF VALVE CHECK If the sound of the float valve moving (knocking sound) can be heard when the valve assembly is gently shaken up and down, then the valve is okay.
• Page 508
  13F-6 FUEL SUPPLY – Fuel Filter <Diesel-powered vehicles> FUEL FILTER <DIESEL-POWERED VEHICLES> 13500270016 REMOVAL AND INSTALLATION <Vehicles without fuel line heater> <Vehicles with fuel line heater> 14 Nm 14 Nm 4.9 – 6.8 Nm 4.9 – 6.8 Nm 12 – 15 Nm 12 –…
• Page 509
  13F-7 FUEL SUPPLY – Fuel Filter <Diesel-powered vehicles> FUEL LINE HEATER CONTINUITY CHECK There should be continuity between the terminals when the fuel filter pump is cooled –4_C or bellow and continuity should disappear when the pump is gradually heated. If this is true then the heater is working properly.
• Page 510
  NOTES…
• Page 511
  DIESEL FUEL <4D5-Step III>…
• Page 512
  13I-1 DIESEL FUEL <4D5-Step III> CONTENTS GENERAL ……. . . Accelerator Pedal Position Sensor (APS) Check .
• Page 513
  13I-2 DIESEL FUEL <4D5-Step III> – General/General Information GENERAL OUTLINE OF CHANGE Service procedures have been established since the electronic-controlled fuel injection pump specifications has been added to comply with emission regulation step III. GENERAL INFORMATION The electronic-controlled fuel injection system consists of sensors which detect the condition of the diesel engine, an engine-ECU which controls the system based on signals from these sensors, and actuators which operate according to control commands from the engine-ECU.
• Page 514
  13I-3 DIESEL FUEL <4D5-Step III> – General Information OTHER CONTROL FUNCTIONS 1. Power Supply Control When the ignition switch is turned to ON, the relay turns on and power is supplied to components such as the timing control solenoid valve. 2.
• Page 515
  13I-4 DIESEL FUEL <4D5-Step III> – General Information CONTROL SYSTEM DIAGRAM L1. Pump speed sensor l1. GE actuator (electronic governor) Engine L2. Crank angle sensor l2. Timing control valve -ECU L3. Engine coolant temperature sensor l3. EGR control solenoid valve No. 1 L4.
• Page 516
  13I-5 DIESEL FUEL <4D5-Step III> – Service Specifications/Sealant SERVICE SPECIFICATIONS Item Standard value Fuel injection initial pressure kPa 14,710 – 15,490 Accelerator pedal position sensor reference voltage V 0.985 – 1.085 Accelerator pedal position sensor resistance kΩ 3.5 – 6.5 When the temperature is 20_C 2.3 –…
• Page 517
  13I-6 DIESEL FUEL <4D5-Step III> – Special Tools SPECIAL TOOLS Tools Number Name Application MB991502 MUT-II sub Electronically controlled fuel injection system check assembly MB991529 Diagnosis code Diagnosis code reading check harness MB991348 Test harness set Boost pressure sensor check Variable geometry control pressure sensor check MB991658…
• Page 518
  13I-7 DIESEL FUEL <4D5-Step III> – Troubleshooting TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) Engine warning lamp is lit when any abnormality takes place Engine warning lamp (check engine lamp) in the item related to electronically controlled fuel injection…
• Page 519
  13I-8 DIESEL FUEL <4D5-Step III> – Troubleshooting FAIL-SAFE, BACKUP FUNCTIONS When abnormalities in the major sensors are detected by diagnosis functions, pre-set control logic operates to maintain a safe driving condition for the vehicle. Diagnosis item Control features in malfunction Accelerator pedal position sensor Accelerator pedal released (idle switch ON) Acceleration opening degree = 0 %…
• Page 520
  13I-9 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Accelerator pedal position sensor (main) system 13I-10 Boost pressure sensor system 13I-11 Barometric pressure sensor (ECU built-in) system 13I-12 Fuel temperature sensor system 13I-12 Engine coolant temperature sensor system 13I-13…
• Page 521
  13I-10 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODE Code No. 11 Accelerator pedal position sensor (main) Probable cause system D Accelerator pedal position sensor inoperative Range of Check D Ignition switch: ON, accelerator pedal position sensor (sub) operative, except D Accelerator pedal position sensor open circuit, for during engine cranking short circuit, or connector contact inoperative…
• Page 522
  13I-11 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 12 Boost pressure sensor (boost sensor) Probable cause system D Boost pressure sensor inoperative Range of Check D Ignition switch: ON, except for during engine cranking D Boost pressure sensor open circuit, short circuit, Set Conditions or connector contact inoperative D Sensor output voltage for one second is 4.5 V or higher…
• Page 523
  13I-12 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 13 Barometric pressure sensor system Probable cause Range of Check Engine-ECU inoperative D Ignition switch: ON, except for during engine cranking Set Conditions D The sensor output voltage is for 3 seconds is 4.5 V or higher (the barometric pressure is approximately 114 kPa or over).
• Page 524
  13I-13 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 15 Engine coolant temperature sensor system Probable cause D Engine coolant temperature sensor inoperative Range of Check D Ignition switch: ON, except for during engine cranking D Engine coolant temperature sensor open circuit, Set Conditions short circuit, or connector contact inoperative D The sensor output voltage for 3 seconds is 4.9 V or higher (the coolant…
• Page 525
  13I-14 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 17 Vehicle speed sensor system Probable cause D Vehicle speed sensor inoperative Range of Check D Ignition switch: ON D Vehicle speed sensor open circuit, short circuit, or D Engine speed: 2800 r/min or higher connector contact inoperative D Driving with heavy load D Engine-ECU inoperative…
• Page 526
  13I-15 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 18 Pump speed sensor system Probable cause D Malfunction of pump speed sensor Range of Check D Ignition switch: ON D Open circuit or short-circuit in pump speed sensor D Not during the engine cranking circuit, or poor sensor contact D Engine-ECU inoperative Set Conditions…
• Page 527
  13I-16 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 21 Crank angle sensor system Probable cause D Malfunction of crank angle sensor Range of Check D Engine cranking D Open circuit or short-circuit in crank angle sensor Set Conditions circuit, or poor connector contact D Sensor output voltage does not change for 2 seconds (no pulse signal input) D Engine-ECU inoperative Range of Check…
• Page 528
  13I-17 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 23 Idle switch (accelerator pedal position Probable cause sensor built-in) system D Accelerator pedal position sensor inoperative Range of Check D Accelerator pedal position sensor open circuit, Ignition switch: ON, accelerator pedal position sensor (main, sub) operative, except for during engine cranking short circuit, or connector contact inoperative D Idle switch “ON”…
• Page 529
  13I-18 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 25 Timer piston position sensor system Probable cause D Timer piston position sensor inoperative Range of Check D Ignition switch: OK D Timer piston position sensor open circuit, short D Not during the engine cranking circuit, or connector contact inoperative D Engine-ECU inoperative Set Conditions…
• Page 530
  13I-19 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 26 Control sleeve position sensor system Probable cause D Control sleeve position sensor inoperative Range of Check D Ignition switch: ON D Control sleeve position sensor open circuit, short Set Conditions circuit, or connector contact inoperative D The sensor output voltage for 0.3 second is 4.5 V* or more D Engine-ECU inoperative…
• Page 531
  13I-20 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 27 Accelerator pedal position sensor (sub) Probable cause system D Accelerator pedal position sensor inoperative Range of Check D Ignition switch: ON, accelerator pedal position sensor (main) operative, except D Accelerator pedal position sensor open circuit, for during engine cranking short circuit, or connector contact inoperative D Engine-ECU inoperative…
• Page 532
  13I-21 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 41 Throttle solenoid valve system Probable cause D Throttle solenoid valve inoperative Range of Check D Ignition switch: OFF D Throttle solenoid valve open circuit, short circuit, or D Barometric pressure is 95.4 kPa or over (equivalent to 500m). connector contact inoperative D Engine-ECU inoperative Set Conditions…
• Page 533
  13I-22 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 43 Timing control valve system Probable cause D Timing control valve inoperative Range of Check D Engine coolant temperature 80_C or higher and the engine running D Timing control valve open circuit, short circuit, or Set Conditions connector contact inoperative D Target value minus actual value is 0.64 V or more (duty ratio) for 5 seconds.
• Page 534
  13I-23 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 46 Injection correction ROM system Probable cause D Injection correction ROM inoperative Range of Check D Ignition switch: ON D Engine-ECU inoperative Set Conditions D When communication fails Repair Measure at A-117 injection correction ROM Check the following connector: C-51 connector.
• Page 535
  13I-24 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 48 GE actuator (in the middle of control sleeve Probable cause position sensor inoperative) system D Control sleeve position sensor inoperative Range of Check D Ignition switch: ON D GE actuator inoperative D Control sleeve position sensor open circuit, short Set Conditions D Target value minus actual value is 1 V or more (duty ratio) for 1 second…
• Page 536
  13I-25 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 49 Over boost <4WD> Probable cause D Malfunction of the variable geometry actuator Range of Check D Ignition switch: ON D Malfunction of variable geometry solenoid valve D Variable geometry solenoid valve open circuit, short Set Conditions D Boost pressure is higher than the barometric pressure + 133 kPa.
• Page 537
  13I-26 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 51 EGR valve position sensor system Probable cause D EGR valve position sensor inoperative Range of Check D Ignition switch: ON, except during engine cranking D EGR valve position sensor open circuit, short Set Condition circuit or connector circuit inoperative D Output voltage of EGR valve position sensor for 3 seconds is 4.85 V or…
• Page 538
  13I-27 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 52 Variable geometry control pressure sensor Probable cause system D Variable geometry control pressure sensor Range of Check D Ignition switch: ON, except during engine cranking inoperative D Variable geometry control pressure sensor open Set Condition D 4.5 V or higher, or 0.2 V or lower circuit, short circuit or connector contact…
• Page 539
  13I-28 DIESEL FUEL <4D5-Step III> – Troubleshooting Code No. 54 Immobilizer system Probable cause D Radio interference of encrypted codes Range of Check D Ignition switch: ON D Incorrect encrypted code D Malfunction of harness or connector Set Conditions D Improper communication between the engine-ECU and immobilizer-ECU D Malfunction of immobilizer-ECU D Engine-ECU inoperative NOTE…
• Page 540
  13I-29 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble Symptom Inspection Reference procedure page No communication can No communication can be established with all systems. 13I-30 established established No communication can be established only with the 13I-30 tween MUT-II and the engine-ECU.
• Page 541
  13I-30 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 No communication can be established between MUT-II Probable cause and all systems. D Diagnosis connector inoperative Probable cause can be found in troubles with the power supply circuit and the D Harness inoperative earth circuit to the diagnosis connector.
• Page 542
  13I-31 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 3 Immediately after the ignition switch is “ON”, the engine Probable cause warning lamp does not turn on. D The engine warning lamp blown The engine-ECU turns on the engine warning lamp for 5 seconds immediately D The engine warning lamp circuit inoperative after turning on the ignition switch to check the bulb for being blown.
• Page 543
  13I-32 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (unable to start) Probable cause D Control system inoperative Probable causes can be found in troubles with control system, injection pump, D Injection pump inoperative glow system, and power supply system. D Intake system inoperative D Glow system inoperative D Engine-ECU inoperative…
• Page 544
  13I-33 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 7 Starting performance is bad regardless of whether the Probable cause engine is hot or cold (unable to start) D Control system inoperative Probable causes can be found in troubles with control system, injection pump, D Injection pump inoperative fuel system, and intake system.
• Page 545
  13I-34 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 10 Low idling speed (improper idling speed) Probable cause D Control system inoperative Probable causes can be found in troubles with control system, injection pump, D Injection pump inoperative and fuel. D Fuel system inoperative D Engine-ECU inoperative MUT-II Self-Diag code…
• Page 546
  13I-35 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 13 The engine stalls during idling. Probable cause D Control system inoperative Probable causes can be found in troubles with control system, injection pump, D Injection pump inoperative intake system, EGR system, and power supply. D Fuel system inoperative D Intake system inoperative D EGR system inoperative…
• Page 547
  13I-36 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 16 Abnormal black smoke Probable cause D Control system inoperative Probable causes can be found in troubles with control system, injection pump, D Injection pump inoperative fuel system, intake system, and EGR system. D Fuel system inoperative D Intake system inoperative D EGR system inoperative…
• Page 548
  13I-37 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 19 A/C condenser fan operating problem Probable cause D Malfunction of A/C condenser fan motor relay The power transistor inside the engine-ECU turns on and off to control the A/C D Malfunction of A/C condenser fan motor condenser fan motor relay.
• Page 549
  13I-38 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 20 Intercooler fan operating problem Probable cause D Malfunction of intercooler fan motor relay The power transistor inside the engine-ECU turns on and off to control the D Malfunction of intercooler fan motor intercooler fan motor relay.
• Page 550
  13I-39 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 21 Engine-ECU power supply and earth circuit check (1) NG Repair Measure at C-49, C-50, C-97 Check the following connectors: engine-ECU connectors. C-79, C-88 D Disconnect the connector and (2), (3) NG measure at the harness side.
• Page 551
  13I-40 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 23 EGR control solenoid valve No. 1 circuit inspection EGR control solenoid valve No. 1 Replace check (Refer to GROUP 17 – Service Adjustment Procedures.) Measure at EGR control solenoid Check the harness between the valve No.
• Page 552
  13I-41 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE 25 Glow plug relay inspection Glow plug relay check. (Refer to Replace GROUP 16 – Glow System.) Repair Measure at glow plug relay Check the following connector: connector A-88. C-49 D Disconnect the connector and measure at the harness side.
• Page 553
  13I-42 DIESEL FUEL <4D5-Step III> – Troubleshooting DATA LIST REFERENCE TABLE VARIABLE Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. Boost Ignition switch: ON or Code No. 13I-13 When the intake air –20_C…
• Page 554
  13I-43 DIESEL FUEL <4D5-Step III> – Troubleshooting Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. Vehicle When driving Compare the engine Matched Code No. 13I-14 speed speed displayed in the sensor speed meter with that in MUT-II…
• Page 555
  13I-44 DIESEL FUEL <4D5-Step III> – Troubleshooting Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. Accelerator Ignition switch: ON Code No. 13I-20 Accelerator pedal: pedal Idling position position Accelerator pedal: 99 –…
• Page 556
  13I-45 DIESEL FUEL <4D5-Step III> – Troubleshooting Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. Condenser Ignition switch: ON A/C switch: OFF Procedure 13I-37 fan relay No. 19 (engine coolant temperature at 102_C or higher)
• Page 557
  13I-46 DIESEL FUEL <4D5-Step III> – Troubleshooting Item Check item Inspection conditions Value to be Code No. Reference determined or inspec- page as normal tion proce- dure No. EGR control Engine: After warming Procedure 13I-40 Idling (stable condi- solenoid up the engine No.
• Page 558
  13I-47 DIESEL FUEL <4D5-Step III> – Troubleshooting Item Check item Drive Con- Inspection Value to be determined Code No. Reference tents conditions as normal or inspec- page tion proce- dure No. Turn the GE GE actuator Ignition Measure the wave Code No.
• Page 559
  13I-48 DIESEL FUEL <4D5-Step III> – Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART Engine-ECU Connector Terminal Arrangement NOTE Vehicles with immobilizer system Terminal Check item Inspection conditions (engine status) Normal condition: GE actuator Ignition switch: ON (Engine stops) 9 V or higher Fuel cut solenoid valve Other than below…
• Page 560
  13I-49 DIESEL FUEL <4D5-Step III> – Troubleshooting Terminal Check item Inspection conditions (engine status) Normal condition: Engine is idling 4.4 – 10.1 V Variable geometry Engine: After warm- solenoid valve <4WD> ing up the engine Engine is suddenly raced Voltage rises A/C switch: OFF →…
• Page 561
  13I-50 DIESEL FUEL <4D5-Step III> – Troubleshooting Terminal Check item Inspection conditions (engine status) Normal condition: Intake air temperature: 3.2 – 3.8 V Boost air temperature Ignition switch: ON sensor Intake air temperature: 2.3 – 2.9 V 20_C Intake air temperature: 1.4 –…
• Page 562
  13I-51 DIESEL FUEL <4D5-Step III> – Troubleshooting Engine-ECU Harness Side Connector Terminal Arrangement Terminal No. Inspection item Normal condition (Check condition) 0.64 – 0.72 Ω 1 – 15 GE actuator 6.8 – 9.2 Ω 2 – Body earth Fuel cut solenoid valve 10.8 –…
• Page 563
  13I-52 DIESEL FUEL <4D5-Step III> – Troubleshooting Terminal No. Inspection item Normal condition (Check condition) 83 – 61 Engine coolant temperature sensor 5.1 – 6.5 kΩ (when the engine coolant temperature is 0_C) 2.1 – 2.7 kΩ (when the engine coolant temperature is 20_C) 0.9 –…
• Page 564
  13I-53 DIESEL FUEL <4D5-Step III> – Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER CRANK ANGLE SENSOR An analyzer can be used to observe the wave pattern in order to visually check the crankshaft rotation and abnormalities in the sensor output. Measurement Method Analyzer 1.
• Page 565
  13I-54 DIESEL FUEL <4D5-Step III> – Troubleshooting Standard wave pattern 1 engine revolution Crank angle BTDC9_ sensor output ATDC wave pattern ATDC BTDC35_ Explanation of Wave Pattern The crank angle sensor detects the rotation of a sensing plate. Accordingly, the period T (seconds) can be measured and the engine speed can be calculated from the following formula.
• Page 566
  13I-55 DIESEL FUEL <4D5-Step III> – Troubleshooting PUMP SPEED SENSOR An analyzer can be used to observe the wave pattern in order to visually check the pump shaft rotation and abnormalities in the sensor output. Measurement Method Analyzer 1. Disconnect the pump speed sensor connector and Sensor side connector connect the special tool (test harness: MD991658) in between.
• Page 567
  13I-56 DIESEL FUEL <4D5-Step III> – Troubleshooting Standard wave pattern 0.85 Pump speed sensor output wave pattern –0.85 1 cranking Explanation of Wave Pattern The pump speed sensor detects the rotation of the pump shaft. Accordingly, the period T (seconds) can be measured and the engine speed can be calculated from the following formula.
• Page 568
  13I-57 DIESEL FUEL <4D5-Step III> – On-vehicle Service ON-VEHICLE SERVICE INJECTION TIMING CHECK AND ADJUSTMENT Refer to GROUP 11B – Engine Adjustment. IDLE SPEED CHECK AND ADJUSTMENT Refer to GROUP 11B – Engine Adjustment. INJECTION NOZZLE CHECK AND ADJUSTMENT Caution Never touch the injection spray that is injected from the nozzle.
• Page 569
  13I-58 DIESEL FUEL <4D5-Step III> – On-vehicle Service 2. Check to be sure that no fuel drips after injection is completed. 3. If there are any drips, disassemble the nozzle, clean it and reinspect, or replace the nozzle. NOZZLE FUEL-TIGHT CHECK 1.
• Page 570
  13I-59 DIESEL FUEL <4D5-Step III> – On-vehicle Service CONTROL RELAY CONTINUITY CHECK Control relay System voltage Terminal No. When no current is supplied Connector at When current is the control relay supplied ACCELERATOR PEDAL POSITION SENSOR (APS) CHECK 1. Disconnect the APS connector. 2.
• Page 571
  13I-60 DIESEL FUEL <4D5-Step III> – On-vehicle Service Normal condition: Accelerator pedal Continuity Step on None Release 3. Replace APS if it is inoperative. NOTE Make an adjustment on APS after replacement.(Refer to P.13I-58.) BOOST AIR TEMPERATURE SENSOR (INTAKE Boost air temperature sensor AIR TEMPERATURE SENSOR) CHECK 1.
• Page 572
  13I-61 DIESEL FUEL <4D5-Step III> – On-vehicle Service 2. Measure the resistance between the terminals of the connectors while immersing the sensor part of the engine coolant temperature sensor in the hot water. Standard value: 2.1 – 2.7 kΩ (at 20_C) 0.26 –…
• Page 573
  13I-62 DIESEL FUEL <4D5-Step III> – On-vehicle Service EGR VALVE POSITION SENSOR CHECK Equipment side connector 1. Disconnect the EGR valve position sensor connector. 2. Measure the resistance between the EGR valve position sensor side connector terminal No. 2 and terminal No. Standard value: 3.5 –…
• Page 574
  13I-63 DIESEL FUEL <4D5-Step III> – On-vehicle Service GE ACTUATOR (ELECTRONIC GOVERNOR) CHECK Connector at the equipment (12 pin) 1. Disconnect the injection pump connector (12 pin). 2. Measure the resistance between terminal No. 6 and terminal No. 10. Standard value: 0.64 – 0.72 Ω FUEL TEMPERATURE SENSOR CHECK Connector at the equipment (12 pin)
• Page 575
  13I-64 DIESEL FUEL <4D5-Step III> – On-vehicle Service DIESEL FUEL <4D5-Step III> – On-vehicle Service THROTTLE SOLENOID VALVE CHECK Throttle solenoid valve INSPECTION PROCEDURE 1. Disconnect the vacuum hose (white stripe and yellow stripe) from the solenoid valve. 2. Disconnect the harness connector. 3.
• Page 576
  13I-65 DIESEL FUEL <4D5-Step III> – On-vehicle Service VARIABLE GEOMETRY SOLENOID VALVE CHECK Refer to GROUP 15 – On-vehicle Service. EGR CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 – Emission Control System <4D5>.
• Page 577
  13I-66 DIESEL FUEL <4D5-Step III> – Injection Nozzle/Injection Pump INJECTION NOZZLE REMOVAL AND INSTALLATION Refer to GROUP 13E of the ’97 L200 Workshop Manual (Pub. No. PWTE96E1). INJECTION PUMP REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Timing Belt Installation Battery and Battery Tray Removal Intercooler Installation (Refer to GROUP 15.) Intercooler Removal (Refer to GROUP 15.)
• Page 578
  13I-67 DIESEL FUEL <4D5-Step III> – Injection Pump REMOVAL SERVICE POINTS AA» INJECTION PIPE REMOVAL Delivery holder Loosen the nuts at the end of the injection pipe with the delivery holder (for pump side) and injection nozzle assembly (for nozzle side) retained by a spanner, etc. AB»…
• Page 579
  NOTES…
• Page 580
  ENGINE COOLING Click on the applicable bookmark to selected the required model year…
• Page 582
  General Information/ 14-2 ENGINE COOLING – Service Specifications/Lubricant/Sealants GENERAL INFORMATION 14100010125 The cooling system is designed to keep every part The water pump is of the centrifugal type and is of the engine at appropriate temperature in driven by the drive belt from the crankshaft. whatever condition the engine may be operated.
• Page 583
  14-3 ENGINE COOLING – On-vehicle Service ON-VEHICLE SERVICE 14100100082 Cap adapter ENGINE COOLANT LEAK CHECKING 1. Confirm that the coolant level is up to the filler neck. Adapter Install a radiator cap tester and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections.
• Page 584
  14-4 ENGINE COOLING – On-vehicle Service 5. Coat the thread of the cylinder block drain plug with the <4D56> specified sealant and tighten to the specified torque. Cylinder block drain plug Specified sealant: 3M Nut Locking Part No. 4171 or equivalent 6.
• Page 585
  14-5 ENGINE COOLING – Cooling Fan COOLING FAN 14100210020 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-3.) Radiator Upper Hose Removal and Installation (Refer to P. 14-14.) <4G6> 4.9 Nm 9.8 – 12 Nm 12 Nm 4.9 Nm <4D56>…
• Page 586
  14-6 ENGINE COOLING – Cooling Fan INSPECTION 14100220023 COOLING FAN CHECK Check blades for damage and cracks. Check for cracks and damage around bolt holes in fan hub. If any portion of fan is damaged or cracked, replace cooling fan. FAN CLUTCH CHECK Check to ensure that fluid in fan clutch is not leaking at case joint and seals.
• Page 587
  14-7 ENGINE COOLING – Thermostat THERMOSTAT 14100240166 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P. 14-3.) <4G6> <4D56> 13 Nm 13 Nm Removal steps «BA 3. O-ring <4G6> 1. Radiator lower pipe assembly <4G6>…
• Page 588
  14-8 ENGINE COOLING – Thermostat <4D56-4WD> Hold the thermostat at the angle shown in the illustration, and install it while being careful not to wrinkle or damage Thermostat housing the rubber ring. Caution Do not apply any oil or grease to the rubber ring of the Rubber thermostat under any circumstances.

• Page 589: Water Pump

  14-9 ENGINE COOLING – Water Pump WATER PUMP 14100270271 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P. 14-3.) Timing Belt Removal and Installation (Refer to GROUP 11.) <4G6> <4D56> 12 – 15 Nm (2WD) 12 –…

• Page 590
  14-10 ENGINE COOLING – Water Pump REMOVAL SERVICE POINT AA» POWER STEERING OIL PUMP REMOVAL 1. Remove the power steering oil pump from the bracket with the hose still attached. 2. Place the power steering oil pump somewhere where it will not to be a hindrance to working, being careful not to put too much strain on the hose.
• Page 591
  14-11 ENGINE COOLING – Water Hose and Water Pipe WATER HOSE AND WATER PIPE 14100330221 REMOVAL AND INSTALLATION <4G6> Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P. 14-3.) Thermostat Removal and Installation (Refer to P. 14-7.) Exhaust Manifold Removal and Installation (Refer to GROUP 15.) 24 Nm…
• Page 592
  14-12 ENGINE COOLING – Water Hose and Water Pipe <4D56> Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-3.) Injection Pipe Removal and Installation (Refer to GROUP 13E – Injection Nozzle.) Intake, Exhaust Manifold Removal and Installation (Refer to GROUP 15.) (2WD) 9.8 –…
• Page 593
  14-13 ENGINE COOLING – Water Hose and Water Pipe INSTALLATION SERVICE POINTS «AA O-RING INSTALLATION Insert the O-ring to pipe, and coat the outer circumference of the O-ring with water. O-ring Caution Care must be taken not to permit engine oil or other greases to adhere to the o-ring.
• Page 594
  14-14 ENGINE COOLING – Radiator RADIATOR 14100150162 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining (Refer to P. 14-3.) Engine Coolant Supplying (Refer to P. 14-3.) A/T Fluid Supplying and Checking (Refer to GROUP 23 – On-vehicle Service.) <4D56-4WD>…
• Page 595
  14-15 ENGINE COOLING – Radiator REMOVAL SERVICE POINT AA» TRANSMISSION FLUID COOLER HOSE REMOVAL After removing the hose from the radiator, plug the hose and the radiator nipple to prevent dust or foreign particles from getting in.
• Page 596
  NOTES…
• Page 598
  14-1 ENGINE COOLING CONTENTS GENERAL ……. . . THERMOSTAT <4D56-Step III> .
• Page 599
  General/General Specifications <4D56-Step III>/ 14-2 ENGINE COOLING – Service Specification <4D56-Step III> GENERAL OUTLINE OF CHANGES With the modification below by additional emission regulation step III compatible 4D56 engine, the service procedure of the part that is different from previous service procedure has been established. The integrated radiator shroud of resin has been adopted for lightness.
• Page 600
  14-3 ENGINE COOLING – Cooling Fan <4D56-Step III> COOLING FAN <4D56-Step III> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Engine Coolant Refilling Drive Belt Tension Adjustment <2WD> 5.0 ± 1.0 N·m <4WD> 5.0 ± 1.0 N·m 11 ± 1 N·m 11 ±…
• Page 601
  14-4 ENGINE COOLING – Thermostat <4D56-Step III> THERMOSTAT <4D56-Step III> INSPECTION THERMOSTAT CHECK Check that the amount of valve lift is at the standard value when the water is at the full-opening temperature. Standard value: Items 4D56-Step III Full-opening temperature _C Amount of valve lift mm 8.5 or more NOTE…
• Page 602
  14-5 ENGINE COOLING – Water Pump <4D56-Step III> WATER PUMP <4D56-Step III> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling Thermostat Removal and Installation Timing Belt Removal and Installation 22 ± 4 N·m 14 ± 1 N·m 14 ±…
• Page 603
  14-6 ENGINE COOLING – Water Pump <4D56-Step III> INSTALLATION SERVICE POINTS «AA WATER PUMP ASSEMBLY INSTALLATION Hardness category Bolt diameter (d) x length (l) mm (Head mark) 8 x 40 8 x 25 8 x 70 «BA O-RING INSTALLATION Thermostat housing Rinse the mounting location of the O-ring and water pipe with water, and install the O-ring and water pipe.
• Page 604
  14-7 ENGINE COOLING – Water Hose and Water Pipe <4D56-Step III> WATER HOSE AND WATER PIPE <4D56-Step III> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling EGR Valve, EGR Cooler Removal and Installation Air Cleaner Removal and Installation (Refer to GROUP 17.) (Refer to GROUP 15.) Intake, Exhaust Manifold Removal and Installation…
• Page 605
  14-8 ENGINE COOLING – Radiator <4D56-Step III> RADIATOR <4D56-Step III> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Engine Coolant Draining Engine Coolant Refilling A/T Fluid Supplying and Checking 12 ± 2 N·m <2WD> <4WD> 12 ± 2 N·m 5.0 ± 1.0 N·m 5.0 ±…
• Page 606
  INTAKE AND EXHAUST Click on the applicable bookmark to selected the required model year…
• Page 608
  Service Specifications/ 15-2 INTAKE AND EXHAUST – Sealant/On-vehicle Service SERVICE SPECIFICATIONS 15100030128 Items Standard value Limit Waste gate actuator activation pressure kPa Approx. 83 – Intake air temperature switch _C OFF (no continuity) 55 or less – ON (continuity) 57 or more –…
• Page 609
  15-3 INTAKE AND EXHAUST – On-vehicle Service WASTE GATE ACTUATOR CHECK <4D56-with turbocharger> 15100120023 1. Connect a manual pump (pressure-application type) to nipple. 2. While gradually applying pressure, check the pressure that begins to activate (approx. 1 mm stroke) the waste gate actuator rod.

• Page 610: Air Cleaner

  15-4 INTAKE AND EXHAUST – Air Cleaner AIR CLEANER 15100210058 REMOVAL AND INSTALLATION <4G63> 4 Nm 4 Nm 9 Nm 9 Nm 9 Nm <4G64> 4 Nm 9 Nm 4 Nm 9 Nm 9 Nm Removal steps 1. Breather hose connection 6.

• Page 611
  15-5 INTAKE AND EXHAUST – Air Cleaner <4D56-2WD> 9 Nm 2.0 Nm 4 Nm 4 Nm 9 Nm 9 Nm 4 Nm 4 Nm <4D56-4WD> 9 Nm 2.0 Nm 9 Nm 9 Nm 4 Nm 4 Nm 4 Nm Removal steps 1.
• Page 612
  15-6 INTAKE AND EXHAUST – Intercooler and Intercooler Fan-ECU INTERCOOLER AND INTERCOOLER FAN-ECU 15100420031 REMOVAL AND INSTALLATION 9 Nm 9 Nm 9 Nm 9 Nm Intercooler fan-ECU removal steps Intercooler removal steps 1. Scuff plate 4. Intake air temperature switch 2.
• Page 613
  15-7 INTAKE AND EXHAUST – Intercooler and Intercooler Fan-ECU DISASSEMBLY AND REASSEMBLY 15100660013 9 Nm 6 Nm 6 Nm 9 Nm Disassembly steps 1. Air hose A-2 6. Air hose B 2. Blanch tube 7. Intake air temperature switch 3. Blanch tube bracket 8.
• Page 614
  15-8 INTAKE AND EXHAUST – Intercooler and Intercooler Fan-ECU INTAKE AIR TEMPERATURE SWITCH CHECK 15100630014 1. Immerse the intake air temperature switch in the hot water shown in the figure. 2. When changing the water temperature, check for continuity between the terminals with the circuit tester. Standard value: Temperature Continuity…
• Page 615
  15-9 INTAKE AND EXHAUST – Intake Manifold <4G6> INTAKE MANIFOLD <4G6> 15100300274 REMOVAL AND INSTALLATION Pre-removal Operation Post -installation Operation Fuel Discharge Prevention Engine Coolant Supplying (Refer to GROUP 13A – On-vehicle Service) Battery and Battery Tray Installation Engine Coolant Draining Air Cleaner Installation (Refer to P.15-4.) Air Cleaner Removal (Refer to P.
• Page 616
  15-10 INTAKE AND EXHAUST – Intake Manifold <4G6> REMOVAL SERVICE POINT AA» DELIVERY PIPE AND INJECTOR REMOVAL Remove the delivery pipe (with the injectors and pressure regulator attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector.
• Page 617
  Intake and Exhaust 15-11 INTAKE AND EXHAUST – Manifold <4D56-2WD> INTAKE AND EXHAUST MANIFOLD <4D56-2WD> 15100360029 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and Installation (Refer to P.15-19.) 18 Nm 18 Nm 18 Nm 12 – 15 Nm 18 Nm Removal steps 1.
• Page 618
  Turbocharger and Exhaust 15-12 INTAKE AND EXHAUST – Manifold <4D56-4WD> TURBOCHARGER AND EXHAUST MANIFOLD <4D56-4WD> 15100450023 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Intercooler Removal and Installation (Refer to P. 15-6.) Air Cleaner Cover and Air Intake Hose Removal and Brake Master Cylinder Heat Protector Removal and Installation (Refer to P.
• Page 619
  Turbocharger and Exhaust 15-13 INTAKE AND EXHAUST – Manifold <4D56-4WD> 60 Nm 9 Nm 60 Nm 12 – 15 Nm 13. Exhaust fitting 14. Exhaust fitting gasket 15. Oil-return pipe 16. Oil-return pipe gasket 17. Exhaust manifold 18. Turbocharger gasket «AA 19.
• Page 620
  Turbocharger and Exhaust 15-14 INTAKE AND EXHAUST – Manifold <4D56-4WD> OIL PIPE AND OIL RETURN PIPE CHECK 15100650010 Check the oil pipe and oil return pipe for clogging, bending, or other damage. If there is clogging, clean it. EXHAUST MANIFOLD CHECK 15100340108 Damage or cracking of any part.
• Page 621
  15-15 INTAKE AND EXHAUST – Turbocharger TURBOCHARGER 15100600015 DISASSEMBLY AND REASSEMBLY 5 Nm Disassembly steps «EA 1. Coupling «DA 2. Turbine housing AA» «CA 3. Snap ring AB» «BA 4. Turbine wheel assembly 5. Compressor cover «AA 6. O-ring DISASSEMBLY SERVICE POINTS AA»…
• Page 622
  15-16 INTAKE AND EXHAUST – Turbocharger AB» TURBINE WHEEL ASSEMBLY REMOVAL Remove turbine wheel assembly, striking circumference of the compressor cover with a plastic hammer. The turbine wheel assembly may be a little hard to remove due to an O-ring put on the outer circumference. Turbine wheel as- sembly…
• Page 623
  15-17 INTAKE AND EXHAUST – Turbocharger «DA TURBINE HOUSING INSTALLATION Install the turbine housing in relation to the dowel pin. Caution Use care not to damage the blades of turbine wheel. Dower pin Dower pin hole «EA COUPLING INSTALLATION Install the coupling and tighten to specified torque. Coupling INSPECTION 15100610018…
• Page 624
  15-18 INTAKE AND EXHAUST – Exhaust Manifold <4G6> EXHAUST MANIFOLD <4G6> 15100330327 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and Installation (Refer to P. 15-19.) Air Cleaner Removal and Installation (Refer to P. 15-4.) Exhaust Manifold mounting bolt tightening torque 14 Nm : 29 Nm : 49 Nm…

• Page 625: Exhaust Pipe And Main Muffler

  15-19 INTAKE AND EXHAUST – Exhaust Pipe and Main Muffler EXHAUST PIPE AND MAIN MUFFLER 15100540249 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Under Cover Removal and Installation <2WD> Front Under Cover and Transfer Case Protector Removal and Installation <4WD> <4G63>…

• Page 626
  15-20 INTAKE AND EXHAUST – Exhaust Pipe and Main Muffler <4D56> 13 Nm 25 Nm 25 Nm 30 Nm 25 Nm <4G64> 3, 6, 13 13 Nm 25 Nm 25 Nm 44 Nm 50 Nm 50 Nm 48 Nm Main muffler removal steps Front exhaust pipe removal steps 1.
• Page 632
  15-1 INTAKE AND EXHAUST CONTENTS GENERAL ……. . . Variable Geometry Solenoid Valve Check .
• Page 633
  15-2 INTAKE AND EXHAUST – General/Special Tool <4G64>/Service Specifications GENERAL OUTLINE OF CHANGES With the modification below by additional emission regulation step compatible 4D56 engine, the service procedure of the part that is different from previous service procedure has been established. As the VG (Variable Geometry) turbocharger cannot be disassembled, the service procedure for the VG turbocharger is not described.
• Page 634
  15-3 On-vehicle Service INTAKE AND EXHAUST – ON-VEHICLE SERVICE TURBOCHARGER SUPERCHARGING PRESSURE CHECK <Step III compatible 4D56-2WD and Step III compatible 4D56-4WD> Caution Conduct the driving test in a location where driving at full acceleration can be done with safety. Two person should be in the vehicle when the test is conducted;…
• Page 635
  15-4 On-vehicle Service INTAKE AND EXHAUST – SUPERCHARGING PRESSURE CONTROL SYSTEM CHECK <Step III compatible 4D56-4WD> 1. Set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to “LOCK” (OFF) position, and connect the diagnosis connector to the MUT-II. 3.
• Page 636
  15-5 On-vehicle Service INTAKE AND EXHAUST – VARIABLE GEOMETRY ACTUATOR CHECK <Step III compatible 4D56-4WD> 1. Connect the hand vacuum pump to nipple. 2. While gradually applying vacuum, check the vacuum that begins to active (approximately 1 mm stroke) the variable geometry actuator rod.
• Page 637
  On-vehicle Service/Air Cleaner <4D56-Step 15-6 INTAKE AND EXHAUST – III>/Intercooler <4D56-Step III> WASTE GATE ACTUATOR CHECK <Step III compatible 4D56-2WD> 1. Connect a manual pump (pressure-application type) to nipple. 2. While gradually applying pressure, check the pressure that begins to activate (approx. 1 mm stroke) the waste gate actuator rod.
• Page 638
  Intake and Exhaust Manifold and 15-7 INTAKE AND EXHAUST – Turbocharger <4D56-Step III> INTAKE AND EXHAUST MANIFOLD AND TURBOCHARGER <4D56-Step III> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Intercooler Removal and Installation (Refer to P.15-6.) EGR Valve and EGR Cooler Removal and Installation Air Cleaner Cover and Air Intake Hose Removal and (Refer to GROUP 17.) Installation (Refer to P.15-6.)
• Page 639
  Intake and Exhaust Manifold and 15-8 INTAKE AND EXHAUST – Turbocharger <4D56-Step III> Removal steps 1. Brake master cylinder heat 16. Gasket protector 17. Oil pipe assembly 2. Air temperature sensor connector 18. Gasket 3. Throttle solenoid valve connector 19. Intake manifold 4.
• Page 640
  Intake and Exhaust Manifold and 15-9 INTAKE AND EXHAUST – Turbocharger <4D56-Step III> <4WD> 5.0 ± 1.0 N·m 18 ± 2 N·m 24 ± 4 N·m 14 ± 1 N·m 18 ± 2 N·m 14 ± 1 N·m 9.0 ± 1.0 N·m 20 ±…
• Page 641
  Intake and Exhaust Manifold and 15-10 INTAKE AND EXHAUST – Turbocharger <4D56-Step III> 59 ± 10 N·m 9.0 ± 1.0 N·m 36. Oil return pipe 39. Turbocharger gasket «AA 40. Turbocharger assembly 37. Oil return pipe gasket 38. Exhaust manifold INSTALLATION SERVICE POINT «AA TURBOCHARGER ASSEMBLY INSTALLATION 1.
• Page 642
  15-11 INTAKE AND EXHAUST – Exhaust Pipe and Main Muffler <4G64> EXHAUST PIPE AND MAIN MUFFLER <4G64> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Under Cover Removal and Installation <2WD> Front Under Cover and Transfer Case Protector Removal and Installation <4WD> 2, 6, 11 12 ±…
• Page 643
  NOTES…
• Page 644
  ENGINE ELECTRICAL Click on the applicable bookmark to selected the required model year…

• Page 646: Charging System

  16-2 ENGINE ELECTRICAL – Charging System CHARGING SYSTEM GENERAL INFORMATION 16100010228 The charging system uses the alternator output to keep the battery charged at a constant level under various electrical loads. OPERATION Voltage Rotation of the excited field coil generates AC voltage in the stator.

• Page 647
  16-3 ENGINE ELECTRICAL – Charging System ALTERNATOR SPECIFICATIONS Items 4G63, 4G64 4D56 Type Battery voltage sensing Battery voltage sensing Rated output V/A 12/60 12/65, 12/75* Voltage regulator Electronic built-in type Electronic built-in type NOTE *: Vehicles with over fender SERVICE SPECIFICATIONS 16100030149 Items Standard value…
• Page 648
  16-4 ENGINE ELECTRICAL – Charging System ON-VEHICLE SERVICE 16100090192 ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST Ammeter Alternator Voltmeter Battery B-terminal This test determines whether the wiring from the output wire. (Connect the (+) lead of the alternator “B” terminal to the battery (+) terminal ammeter to the “B”…
• Page 649
  16-5 ENGINE ELECTRICAL – Charging System (6) Connect a tachometer. (Refer to GROUP 11 (11)If the value displayed on the voltmeter is above – On-vehicle Service.) the limit value, there is probably a malfunction (7) Reconnect the negative battery cable. in the alternator output wire, so check the wiring (8) Leave the hood open.
• Page 650
  16-6 ENGINE ELECTRICAL – Charging System This test determines whether the alternator output (10)Turn the light switch on to turn on headlamps current is normal. and then start the engine. (1) Before the test, always be sure to check the (11)Immediately after setting the headlamps to high following.
• Page 651
  16-7 ENGINE ELECTRICAL – Charging System REGULATED VOLTAGE TEST 16100110195 Load Ignition Charging warning Alternator MD998467 switch lamp Alternator relay Ammeter Voltmeter Battery Yellow This test determines whether the voltage regulator (6) Connect a DC test ammeter with a range of is correctly controlling the alternator output voltage.
• Page 652
  16-8 ENGINE ELECTRICAL – Charging System (14)If the voltage reading conforms to the value (17)Remove the tachometer. in the voltage regulation, then the voltage (18)Disconnect the negative battery cable. regulator is operating normally. (19)Disconnect the ammeter and voltmeter. If the voltage is not within the standard value, (20)Connect the alternator output wire to the alternator “B”…
• Page 653
  16-9 ENGINE ELECTRICAL – Charging System WAVEFORM CHECK USING AN ANALYZER Special Analyzer patterns 16100120143 Alternator pickup MEASUREMENT METHOD Connect the analyzer special patterns pick-up to the alternator B terminal. B terminal STANDARD WAVEFORM Observation Conditions FUNCTION SPECIAL PATTERNS PATTERN HEIGHT VARIABLE VARIABLE knob Adjust while viewing the wave-…
• Page 654
  16-10 ENGINE ELECTRICAL – Charging System EXAMPLES OF ABNORMAL WAVEFORMS NOTE 1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the analyzer. 2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not operating).
• Page 655
  16-11 ENGINE ELECTRICAL – Charging System ALTERNATOR 16100140187 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to GROUP 11 – On-vehicle Service.) Under Cover Installation <4G6> 14 Nm 9.8 Nm 20 – 25 Nm 12 –…
• Page 656
  16-12 ENGINE ELECTRICAL – Charging System DISASSEMBLY AND REASSEMBLY 16100160169 <4G6> Disassembly steps AA» AC» 1. Front bracket assembly 8. Stator AB» 2. Pulley 9. Plate «BA 3. Rotor AC» «AA 10. Regulator assembly 4. Rear bearing 11. Brush 5. Bearing retainer 12.
• Page 657
  16-13 ENGINE ELECTRICAL – Charging System DISASSEMBLY AND REASSEMBLY <4D56> Disassembly steps 1. Check valve 12. Rear bearing 2. Nipple 13. Bearing retainer 3. Vacuum pump housing 14. Front bearing 4. O-ring 15. Front bracket «CA 5. Vane AC» 16. Stator «CA 6.
• Page 658
  16-14 ENGINE ELECTRICAL – Charging System DISASSEMBLY SERVICE POINTS AA» FRONT BRACKET REMOVAL 1. Remove the bolts. 2. Insert a flat-tipped screwdriver between front bracket and stator core and pry downwards. Caution Do not insert a screwdriver too deep, as the stator coil will be damaged.
• Page 659
  16-15 ENGINE ELECTRICAL – Charging System Rear bracket Brush Wire «BA ROTOR INSTALLATION 1. When installing the rotor on the alternator rear bracket, wrap vinyl tape around the splined shaft to prevent Wind vinyl damage to the oil seal. <4D56> tape 2.
• Page 660
  16-16 ENGINE ELECTRICAL – Charging System INSPECTION 16100170162 ROTOR 1. Check rotor coil for continuity. Check that there is no continuity between slip rings. If resistance is too small, it means that there is a short circuit. If there is no continuity or if there is a short circuit, replace rotor assembly.
• Page 661
  16-17 ENGINE ELECTRICAL – Charging System 2. Check for continuity between negative rectifier and stator coil lead connection terminal. If there is continuity in both directions, diode is shorted, and rectifier assembly must be replaced. 3. Check three diodes for continuity by connecting an ammeter to both ends of each diode.

• Page 662: Starting System

  16-18 ENGINE ELECTRICAL – Starting System STARTING SYSTEM 16200010191 GENERAL INFORMATION If the ignition switch is turned to the “START” and M terminal to conduct. Thus, current flows to position, current flows in the pull-in and holding engage the starter motor. provided inside magnetic switch, attracting the When the ignition switch is returned to the ”ON”…

• Page 663
  16-19 ENGINE ELECTRICAL – ENGINE ELECTRICAL – Starting System Starting System SERVICE SPECIFICATIONS Items Standard value Limit Pinion gap mm 0.5 – 2.0 – Commutator outer diameter mm 32.0 31.0 Commutator runout mm 0.05 Commutator undercut mm – STARTER MOTOR Switch 16200110174 INSPECTION…
• Page 664
  16-20 ENGINE ELECTRICAL – Starting System MAGNETIC SWITCH PULL-IN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect battery between S-terminal M-terminal. Caution Battery This test must be performed quickly (in less than Field coil wire 10 seconds) to prevent coil from burning.
• Page 665
  16-21 ENGINE ELECTRICAL – Starting System MAGNETIC SWITCH RETURN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between M-terminal and body. Caution Battery This test must be performed quickly (in less than Starter 10 seconds) to prevent coil from burning.
• Page 666
  16-22 ENGINE ELECTRICAL – Starting System DISASSEMBLY AND REASSEMBLY <DIRECT DRIVE TYPE> 16200120214 Disassembly steps 1. Screw 9. Brush holder assembly AA» 2. Magnetic switch 10. Yoke assembly 3. Packing 11. Armature 4. Plate 12. Lever 5. Screw 13. Washer AC»…
• Page 667
  16-23 ENGINE ELECTRICAL – Starting System DISASSEMBLY AND REASSEMBLY <REDUCTION DRIVE TYPE – 4G6> Disassembly steps 1. Screw 12. Packing A AA» 2. Magnetic switch 13. Packing B 3. Screw 14. Plate 4. Screw 15. Planetary gear 5. Rear bracket 16.
• Page 668
  16-24 ENGINE ELECTRICAL – Starting System DISASSEMBLY AND REASSEMBLY <REDUCTION DRIVE TYPE – 4D56> Disassembly steps 1. Screw 13. Plate AA» AB» 2. Magnetic switch 14. Ball 3. Screw 15. Planetary gear 4. Screw 16. Lever AC» «AA 17. Snap ring 5.
• Page 669
  16-25 ENGINE ELECTRICAL – Starting System DISASSEMBLY SERVICE POINTS Magnetic switch “S” terminal AA» MAGNETIC SWITCH REMOVAL Disconnect field coil wire from “M” terminal of magnetic switch. “B” terminal “M” terminal Field coil wire AB» ARMATURE/BALL REMOVAL Caution When removing the armature, take care not to lose the ball (which is used as a bearing) in the armature end.
• Page 670
  16-26 ENGINE ELECTRICAL – ENGINE ELECTRICAL – Starting System Starting System REASSEMBLY SERVICE POINTS «AA STOP RING/SNAP RING INSTALLATION Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring. Stop ring Overrunning clutch Stop ring Snap ring INSPECTION 16200130194 COMMUTATOR CHECK…
• Page 671
  16-27 ENGINE ELECTRICAL – Starting System FIELD COIL GROUND TEST <DIRECT DRIVE TYPE>, <REDUCTION DRIVE TYPE-4D56> Field brush Check the continuity between field coil brush and yoke. If there is no continuity, the field coil is free from earth. Yoke BRUSH HOLDER CHECK Check the continuity between brush holder plate and brush Insulated…
• Page 672
  16-28 ENGINE ELECTRICAL – Starting System <DIRECT DRIVE TYPE>, <REDUCTION DRIVE TYPE-4D56> 1. Brushes that are worn beyond wear limit line, or are oil-soaked, should be replaced. 2. When replacing field coil brushes, crush worn brush with pliers, taking care not to damage pigtail. 3.
• Page 673
  16-29 ENGINE ELECTRICAL – Ignition System IGNITION SYSTEM 16300010194 GENERAL INFORMATION When the primary current stops suddenly in the timing. ignition coil, high voltage appears in the secondary The engine-ECU detects the crankshaft position side of the coil. The distributor supplies the high by the crank angle sensor incorporated in the voltage to the applicable spark plug.
• Page 674
  16-30 ENGINE ELECTRICAL – Ignition System DISTRIBUTOR SPECIFICATIONS Items Specifications Type Contact pointless Advance mechanism Electronic Firing order 1 – 3 – 4 – 2 IGNITION COIL SPECIFICATIONS Items Specifications Type Molded single-coil SPARK PLUG SPECIFICATIONS Items Specifications BKR5E-11 NIPPON DENSO K16PR-U11 SERVICE SPECIFICATIONS 16300030190…
• Page 675
  16-31 ENGINE ELECTRICAL – Ignition System ON-VEHICLE SERVICE High-voltage 16300120231 terminal IGNITION COIL CHECK 1. Measurement of the primary coil resistance Measure the resistance between (+) terminal and (–) terminal. Standard value: 0.67 – 0.81 Ω 2. Measurement of secondary coil resistance Measure the resistance between the high-voltage terminals and (+) terminal.
• Page 676
  16-32 ENGINE ELECTRICAL – Ignition System SPARK PLUG CHECK AND CLEANING 16300150056 1. Remove the spark plug cables. Caution When pulling off the spark plug cable from the plug always hold the cable cap, not the cable. 2. Remove the spark plugs. 3.
• Page 677
  16-33 ENGINE ELECTRICAL – Ignition System WAVEFORM CHECK USING AN ANALYZER 16300170274 Ignition Secondary Voltage Check MEASUREMENT METHOD 1. Clamp the high-tension cable with the secondary pickup. 2. Clamp the spark plug cable with the trigger pickup. (Basically, clamp the spark plug cable of the No.1 cylinder.) NOTE The waveform of the cylinder clamped to the trigger pickup appears at the left edge of the screen.
• Page 678
  16-34 ENGINE ELECTRICAL – 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 Concentration of Ignition timing…
• Page 679
  16-35 ENGINE ELECTRICAL – Ignition System EXAMPLES OF ABNORMAL WAVEFORMS Abnormal waveform Wave characteristics Cause of problem Example 1 Spark line is high and short. Spark plug gap is too large. 01P0215 Example 2 Spark line is low and long, and is Spark plug gap is too small.
• Page 680
  16-36 ENGINE ELECTRICAL – Ignition System Ignition Primary Voltage Waveform Check MEASUREMENT METHOD 1. Disconnect the power transistor connector and connect the special tool (test harness: MB991348) in between. (All of the terminals should be connected.) Ignition coil Power transistor 2.
• Page 681
  16-37 ENGINE ELECTRICAL – Ignition System STANDARD WAVEFORM Observation conditions FUNCTION SECONDARY PATTERN HEIGHT HIGH (or LOW) PATTERN SELECTOR RASTER Engine Speed Curb idle speed Zener voltage (Point C) Spark line (Approx. 40 10V) (Point A) Vibration damping section (Point B) Dwell section Ignition…
• Page 682
  16-38 ENGINE ELECTRICAL – Ignition System WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line (refer to abnormal waveform examples 1, 2, 3 and 4) show the following trends. Spark line Plug gap Condition of Compression Concentration of Ignition timing…
• Page 683
  16-39 ENGINE ELECTRICAL – Ignition System EXAMPLES OF ABNORMAL WAVEFORMS Abnormal waveform Wave characteristics Cause of problem Example 1 Spark line is high and short. Spark plug gap is too large. Example 2 Spark line is low and long, and is Spark plug gap is too small.
• Page 684
  16-40 ENGINE ELECTRICAL – Ignition System DISTRIBUTOR 16300200140 REMOVAL AND INSTALLATION Post-installation Operation Engine Adjustment (Refer to GROUP 11A – On-vehicle Service.) Grease: SAE J310, NLGI No.3 10 – 12 Nm 10 Nm 24 Nm 13 Nm Removal steps 1. Timing belt upper cover 5.
• Page 685
  16-41 ENGINE ELECTRICAL – Ignition System «BA CAMSHAFT SPROCKET SPACER INSTALLATION Install the camshaft sprocket spacer so that the mating marks on the camshaft sprocket spacer and the camshaft sprocket are aligned. Mating marks «CA DISTRIBUTOR ASSEMBLY INSTALLATION 1. Apply 2 grams of grease in the places shown in the illustration.
• Page 686
  16-42 ENGINE ELECTRICAL – Ignition System DISASSEMBLY AND REASSEMBLY 16300220122 Disassembly steps 1. Distributor cap 2. Rotor 3. Cover 4. Distributor housing…
• Page 687
  16-43 ENGINE ELECTRICAL – Glow System GLOW SYSTEM 16400010029 GENERAL INFORMATION SELF-REGULATING GLOW SYSTEM The self-regulating glow system reduces the time also the glow indicator lamp illumination time in required for starting at low temperatures to provide accordance with the engine coolant temperature. a degree of starting and operation that is identical The resistances of the heating coils which are built to petrol-engine vehicles by preheating the glow…
• Page 688
  16-44 ENGINE ELECTRICAL – Glow System SERVICE SPECIFICATIONS 16400030025 Item Standard value Resistance between glow plug plate and glow plug body 0.10 – 0.15 (parallel resistance for 4 glow plugs) (at 20 _C) Ω Voltage between glow plug plate and Immediately after igni- 9 –…
• Page 689
  16-45 ENGINE ELECTRICAL – Glow System ON-VEHICLE SERVICE 16400100023 SELF-REGULATING GLOW SYSTEM CHECK 1. Check that the battery voltage is 11 – 13 V. 2. Check that the engine coolant temperature is 40 _C or less. NOTE If the engine coolant temperature is too high, disconnect the engine coolant temperature sensor connector.
• Page 690
  16-46 ENGINE ELECTRICAL – Glow System <Reference> Glow Plug Energization Timing Chart START Ignition switch Glow indicator lamp Glow plug relay Alternator L terminal : Glow indicator lamp : Glow plug relay drive time after ignition switch is turned ON : Glow plug relay drive time after engine starts (after glow) NOTE After glow time T…
• Page 691
  16-47 ENGINE ELECTRICAL – Glow System 1. Measure the voltage at the control unit terminals. NOTE 1. Inspect with the control unit connector connected. 2. When measuring the voltage, connect the control unit terminal (10) to the earth. Terminal Voltage Reference Table Inspection Inspection item Inspection condition…
• Page 692
  16-48 ENGINE ELECTRICAL – Glow System GLOW PLUG RELAY CHECK 16400250032 1. Check to be sure that there is continuity (approx. 3 Ω) between glow plug relay terminal (1) and the bracket Glow plug relay (earth). 2. Use jumper cables to connect terminal (1) of the glow plug relay to the battery (+) terminal and the bracket to the battery (–) terminal Caution…
• Page 693
  16-49 ENGINE ELECTRICAL – Glow System ENGINE COOLANT TEMPERATURE SENSOR Engine coolant temperature gauge unit CHECK (engine coolant temperature sensor) 16400280031 1. Remove the engine coolant temperature sensor. 2. While the sensor section of the engine coolant temperature sensor is immersed, measure the resistance between (B) terminal and the body.

• Page 694: Glow Plug

  16-50 ENGINE ELECTRICAL – Glow System GLOW PLUG 16400180027 REMOVAL AND INSTALLATION 1.8 Nm 1.8 Nm 18 Nm Removal steps 1. Connector connection 2. Glow plug plate AA» 3. Glow plug REMOVAL SERVICE POINT AA» GLOW PLUG REMOVAL Remove glow plug by hand after loosening with tool as its ceramic part is fragile.

• Page 698
  16-1 ENGINE ELECTRICAL CONTENTS IGNITION SYSTEM ….IGNITION COIL AND POWER TRANSISTOR <4G6> ….GENERAL .
• Page 699
  16-2 ENGINE ELECTRICAL – Ignition System IGNITION SYSTEM GENERAL OUTLINE OF CHANGE The following service procedures have been ignition system. Other procedures are the same established to correspond to the change of the as before. GENERAL INFORMATION This system is provided with two ignition coils (A The engine-ECU controls the two power transistors and B) and two power transistors (A and B) for (A and B) to turn them alternately ON and OFF.
• Page 700
  16-3 ENGINE ELECTRICAL – Ignition System ON-VEHICLE SERVICE IGNITION COIL CHECK 1. Measurement of the primary coil resistance Measure the resistance between (+) terminal and (–) terminal. Standard value: 0.74 – 0.90 Ω 2. Measurement of secondary coil resistance Measure the resistance between the high-voltage terminals and (+) terminal.
• Page 701
  16-4 ENGINE ELECTRICAL – Ignition System WAVEFORM CHECK USING AN ANALYZER Ignition Secondary Voltage Waveform Check MEASUREMENT METHOD 1. Clamp the secondary pickup around the spark plug cable. NOTE (1) The peak ignition voltage will be reversed when the spark cables No. 2 and No. 4, or No. 1 and No. 3 cylinders are clamped.
• Page 702
  16-5 ENGINE ELECTRICAL – Ignition System STANDARD WAVEFORM Observation Conditions Function Secondary Pattern height High (or Low) Pattern selector Raster Engine revolutions Curb idle speed Spark line (point A) Ignition voltage (point D) Wave damping reduction section (point B) Dwell section Secondary ignition…
• Page 703
  16-6 ENGINE ELECTRICAL – 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 Concentration of Ignition timing…
• Page 704
  16-7 ENGINE ELECTRICAL – Ignition System EXAMPLES OF ABNORMAL WAVEFORMS Abnormal waveform Wave characteristics Cause of problem Example 1 Spark line is high and short. Spark plug gap is too large. 01P0215 Example 2 Spark line is low and long, and is Spark plug gap is too small.
• Page 705
  16-8 ENGINE ELECTRICAL – Ignition System Ignition Primary Voltage Waveform Check MEASUREMENT METHOD (1) Disconnect the power transistor connector and connect the special tool (harness connector: MB991348) in between. (Connect all the terminals.) (2) Connect the analyzer primary pickup to the power transistor connector terminal 8 when observing the No.
• Page 706
  16-9 Ignition System ENGINE ELECTRICAL – Observation Conditions (The only change from above condition is the pattern selector.) Pattern selector Display No. 2 cylinder No. 4 cylinder No. 1 cylinder ignition noise Ignition primary voltage Time wave pattern Neutral section WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line (refer to abnormal waveform examples 1, 2, 3 and 4) show the following trends.
• Page 707
  16-10 ENGINE ELECTRICAL – Ignition System ABNORMAL WAVEFORMS EXAMPLES Abnormal waveform Wave characteristics Cause of problem Example 1 Spark line is high and short. Spark plug gap is too large. Example 2 Spark line is low, long, and sloping. Spark plug gap is too small. Also, the second half of the spark line is distorted.
• Page 708
  16-11 ENGINE ELECTRICAL – Ignition System IGNITION COIL AND POWER TRANSISTOR <4G6> REMOVAL AND INSTALLATION 5.0 ± 1.0 N·m 10 ± 2 N·m Ignition coil removal steps Power transistor removal steps 1. Ignition coil connector connection 5. Power transistor connector 2.
• Page 709
  16-12 ENGINE ELECTRICAL – Ignition System CRANK ANGLE SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt Removal and Installation <4G6> (Refer to GROUP 11A.) Timing Belt Cover Removal and Installation <4D56-Step III> (Refer to GROUP 11B.) <4G6> 35 ± 6 N·m 8.8 ±…
• Page 710
  16-13 ENGINE ELECTRICAL – Ignition System/Glow System CAMSHAFT POSITION SENSOR <4G6> REMOVAL AND INSTALLATION 8.8 ± 1.0 N·m Camshaft position sensor GLOW SYSTEM GENERAL OUTLINE OF CHANGE Due to the introduction of the electronic-controlled injection system, the engine-ECU controls the glow system.
• Page 711
  NOTES…
• Page 712
  ENGINE AND EMISSION CONTROL Click on the applicable bookmark to selected the required model year…
• Page 714
  17-2 EXHAUST GAS RECIRCULATION (EGR) EGR Valve Check ……SYSTEM ……. EGR Port Vacuum Check .
• Page 715
  17-3 ENGINE AND EMISSION CONTROL – Engine Control System ENGINE CONTROL SYSTEM 17100010027 GENERAL INFORMATION A Cable-type accelerator mechanism and a suspended-type pedal have been adopted. SERVICE SPECIFICATIONS 17100020013 Items Standard value Accelerator cable play mm 1 – 2 Engine idle speed r/min SEALANT 17300050018 Items…
• Page 716
  17-4 ENGINE AND EMISSION CONTROL – Engine Control System ACCELERATOR CABLE AND PEDAL 17100120164 REMOVAL AND INSTALLATION Post-installation Operation Adjusting the Accelerator Cable (Refer to P. 17-3.) <L.H. drive vehicles> <4G6> 12 Nm <4D56> 10 Nm 3.4 Nm Accelerator cable removal steps 8.
• Page 717
  17-5 ENGINE AND EMISSION CONTROL – Engine Control System <R.H. drive vehicles> 22 Nm 10 Nm 3.4 Nm Toe board Sealant: 3M Nut Locking Part No. 4171 or equivalent Accelerator cable removal steps Accelerator pedal removal steps 1. Inner cable connection 2.
• Page 718
  ENGINE AND 17-6 EMISSION CONTROL – Emission Control System <MPI> EMISSION CONTROL SYSTEM <MPI> 17300010184 GENERAL INFORMATION The emission control system consists of the following subsystems: Crankcase emission control system Evaporative emission control system Exhaust emission control system Items Name Specification Crankcase emission Positive crankcase ventilation (PCV) valve…

• Page 719: Vacuum Hose

  ENGINE AND 17-7 EMISSION CONTROL – Emission Control System <MPI> SERVICE SPECIFICATIONS 17300030173 Items Standard value Purge control solenoid valve coil resistance (at 20_C) Ω 36 – 44 EGR control solenoid valve coil resistance (at 20_C) Ω 36 – 44 SPECIAL TOOL 17100060022 Tool…

• Page 720: Vacuum Circuit Diagram

  ENGINE AND 17-8 EMISSION CONTROL – Emission Control System <MPI> VACUUM CIRCUIT DIAGRAM Intake manifold Throttle body From combustion chamber cleaner Fuel pressure Purge control regulator solenoid valve (ON : OPEN) Canister EGR control solenoid valve (ON : CLOSE) EGR valve Vacuum hose colour B: Black G: Green…

• Page 721: Crankcase Emission Control System

  ENGINE AND 17-9 EMISSION CONTROL – Emission Control System <MPI> VACUUM HOSE CHECK 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.

• Page 722
  ENGINE AND 17-10 EMISSION CONTROL – Emission Control System <MPI> COMPONENT LOCATION Positive crankcase ventilation valve POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 17300110044 1. Remove the ventilation hose from the positive crankcase ventilation valve. 2. Remove the positive crankcase ventilation valve from the rocker cover.
• Page 723
  ENGINE AND 17-11 EMISSION CONTROL – Emission Control System <MPI> EVAPORATIVE EMISSION CONTROL SYSTEM 17300510240 GENERAL INFORMATION The evaporative emission control system prevents sent to the combustion chamber. fuel vapours generated in the fuel tank from When the engine coolant temperature is low or escaping into the atmosphere.

• Page 724: Purge Control System Check

  ENGINE AND 17-12 EMISSION CONTROL – Emission Control System <MPI> PURGE CONTROL SYSTEM CHECK 17300140241 1. Disconnect the vacuum hose (red stripe) from the throttle body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3.

• Page 725
  ENGINE AND 17-13 EMISSION CONTROL – Emission Control System <MPI> 2. Start the engine and check that, after raising the engine Vacuum speed by racing the engine, purge vacuum raises according to engine speed. NOTE If there is a problem with the change in vacuum, the throttle body purge port may be clogged and require cleaning.
• Page 726
  ENGINE AND 17-14 EMISSION CONTROL – Emission Control System <MPI> EXHAUST GAS RECIRCULATION (EGR) SYSTEM 17300520182 GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers the exhaust port of the cylinder head to the combustion chamber through the intake manifold the nitrogen oxide (NOx) emission level.
• Page 727
  ENGINE AND 17-15 EMISSION CONTROL – Emission Control System <MPI> EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK 17300260206 1. Disconnect the vacuum hose (green stripe) from the EGR valve valve, and then connect a hand vacuum pump via the three-way terminal. 2.
• Page 728
  ENGINE AND 17-16 EMISSION CONTROL – Emission Control System <MPI> EGR PORT VACUUM CHECK 17300290144 1. Disconnect the vacuum hose (green stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple. EGR port vacuum nipple 2.

• Page 729: Catalytic Converter

  ENGINE AND 17-17 EMISSION CONTROL – Emission Control System <MPI> CATALYTIC CONVERTER 17300530123 GENERAL INFORMATION The three-way catalytic converter, together with When the mixture is controlled at stoichiometric air-fuel ratio, the three-way catalytic converter the closed loop air-fuel ration control based on oxygen sensor signal,…

• Page 730
  ENGINE AND 17-18 EMISSION CONTROL – Emission Control System <MPI> INSPECTION 17300400066 Check for damage, cracking or deterioration. Replace if failty. Caution 1. Stop the engine immediately if engine misfiring occurs, otherwise an abnormally hot exhaust system will damage the catalytic converter or other underbody parts.
• Page 731
  ENGINE AND 17-19 EMISSION CONTROL – Emission Control System <MPI> INSTALLATION SERVICE POINT «AA TWO-WAY VALVE INSTALLATION Tank side Be careful about the installation direction of the two-way valve. Canister side INSPECTION 17300490063 Two-way valve TWO-WAY VALVE SIMPLE CHECK Attach a clean hose and check the operation of the two-way valve.
• Page 732
  NOTES…
• Page 740
  17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM EMISSION CONTROL SYSTEM <DIESEL> ……<DIESEL> .
• Page 741
  17-2 ENGINE AND EMISSION CONTROL – Engine Control System <Diesel> ENGINE CONTROL SYSTEM <DIESEL> GENERAL OUTLINE OF CHANGE Since the emission regulation step III compatible 4D56 engine has been added, the following has been changed. Due to this, the service procedures regarding the different description from the previous version have been established.
• Page 742
  17-3 ENGINE AND EMISSION CONTROL – Engine Control System <Diesel> ACCELERATOR PEDAL <4D56-Step III> REMOVAL AND INSTALLATION Post-installation Operation Accelerator Pedal Position Sensor Check and Adjustment (Refer to GROUP 13I – On-vehicle Service.) <L.H. drive vehicles> <R.H. drive vehicles> 3.5 ± 1.0 N·m 3.5 ±…
• Page 743
  17-4 ENGINE AND EMISSION CONTROL – Emission Control System <MPI> EMISSION CONTROL SYSTEM <MPI> GENERAL OUTLINE OF CHANGE A new purge control solenoid valve, which flow rate is enhanced, has been used. Due to this, the service procedures regarding the different description from the previous version have been established. SERVICE SPECIFICATIONS Item Standard value…
• Page 744
  17-5 ENGINE AND EMISSION CONTROL – Emission Control System <Diesel> EMISSION CONTROL SYSTEM <DIESEL> GENERAL OUTLINE OF CHANGE Since the emission regulation step III compatible 4D56 engine has been added, the following has been changed. Due to this, the service procedures regarding the different description from the previous version have been established.
• Page 745
  17-6 ENGINE AND EMISSION CONTROL – Emission Control System <Diesel> COMPONENT LOCATION EGR solenoid valve No.2 EGR solenoid valve No.1 EGR valve EGR valve position sensor FUNCTION CHECK 1. Start the engine and warm it up until the engine coolant temperature reaches 65°C or above.
• Page 746
  17-7 ENGINE AND EMISSION CONTROL – Emission Control System <Diesel> EGR solenoid valve No. 1 <EGR solenoid valve No. 1> Battery voltage Normal condition When current is Vacuum leaks (Vacuum is maintained flowing when nipple B is plugged). When current is not Vacuum is maintained.
• Page 747
  17-8 ENGINE AND EMISSION CONTROL – Emission Control System <Diesel> EGR VALVE, EGR COOLER <4D56-Step III> REMOVAL AND INSTALLATION 17 ± 2 N·m 17 ± 2 N·m 22 ± 4 N·m 22 ± 4 N·m 22 ± 4 N·m 17 ± 2 N·m Removal steps «BA 9.
• Page 748
  17-9 ENGINE AND EMISSION CONTROL – Emission Control System <Diesel> INSTALLATION SERVICE POINT EGR pipe «AA EGR PIPE GASKET INSTALLATION Make sure that the projection of the EGR pipe gasket is installed in the location shown. EGR cooler cylinder block EGR pipe gasket projection «BA O-RING INSTALLATION…
• Page 749
  NOTES…
• Page 750
  CLUTCH Click on the applicable bookmark to selected the required model year…
• Page 752
  General Information/Service Specifications/ 21-2 CLUTCH – Lubricants/On-vehicle Service GENERAL INFORMATION 21100010093 The clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control. SERVICE SPECIFICATIONS 21100030136 Items Standard value Clutch pedal height mm 176 – 181 Clutch pedal clevis pin play mm 1 –…
• Page 753
  21-3 CLUTCH – On-vehicle Service 4. Measure the clutch pedal play. Clutch pedal clevis pin play Standard value (B): 1 – 3 mm 5. If the clutch pedal play is not within the standard value, loosen the locking nut and move the push rod to adjust. Caution Do not push in the master cylinder push rod at this time.

• Page 754: Clutch Pedal

  21-4 CLUTCH – Clutch Pedal CLUTCH PEDAL 21100160163 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Removal of Relay Box in Passenger Compartment Clutch Pedal Adjustment (Refer to P.21-2.) <L.H. drive vehicles> Installation of Relay Box in Passenger Compart- ment <L.H. drive vehicles> <2WD, 4WD (4G64)>…

• Page 755: Clutch Control

  21-5 CLUTCH – Clutch Control CLUTCH CONTROL 21100190162 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Clutch Fluid Draining Clutch Fluid Supplying Clutch Fluid Bleeding (Refer to P. 21-3.) Clutch Pedal Adjustment (Refer to P. 21-2.) L.H. drive vehicles R.H. drive vehicles Release fork 13 Nm 13 Nm…

• Page 756
  21-6 CLUTCH – Clutch Control DISASSEMBLY AND REASSEMBLY 21100210134 CLUTCH MASTER CYLINDER Grease: Rubber grease Clutch fluid: Piston repair kit Brake fluid DOT 3 or DOT 4 Disassembly steps 1. Piston stop ring 5. Reservoir cap 2. Damper and push rod 6.
• Page 757
  MANUAL TRANSMISSION Click on the applicable bookmark to selected the required model year…
• Page 759
  22-2 MANUAL TRANSMISSION – General Information GENERAL INFORMATION 22100010113 Items Vehicles with 4G63 engine Vehicles with 4D56 engine Transmission model R5M21-5 R5M21-5 Type 5-speed, floor-shift 5-speed, floor-shift Gear ratio 4.330 4.330 2.355 2.355 1.509 1.509 1.000 1.000 0.827 0.827 Reverse 4.142 4.142 Speedometer gear ratio (driven/drive)

• Page 760: Transmission Oil Check

  22-3 MANUAL TRANSMISSION – Lubricants/Sealants/On-vehicle Service LUBRICANTS 22100040167 Items Specified lubricants Quantity Transmission oil Hypoid gear oil SAE 75W-90, 75W-85W or 80W <R5M21> 2.3 conforming to API GL-4 <V5M21,V5MT1> 2.2 Transfer oil Hypoid gear oil SAE 75W-90, 75W-85W or 80W conforming to API GL-4 SEALANTS 22100050054…

• Page 761
  22-4 MANUAL TRANSMISSION – On-vehicle Service OIL REPLACEMENT 22100100179 Transmission-R5M21, V5M21 Oil filler plug 1. Remove oil filler plug and oil drain plug. 2. Drain oil. 3. Tighten the oil drain plug to the specified torque. Specified torque: <R5M21,V5M21> 32 Nm <V5MT1>…
• Page 762
  22-5 MANUAL TRANSMISSION – On-vehicle Service 4WD DETECTION SWITCH CONTINUITY CHECK <4WD> 22100170026 Check the continuity between terminals of the black connector indicated in the illustration. Transfer lever position Terminal No. HIGH/LOW DETECTION SWITCH CONTINUITY CHECK <4WD> 22100210025 Check the continuity between terminals of the gray connector indicated in the illustration.
• Page 763
  22-6 MANUAL TRANSMISSION – Transmission Control <2WD> TRANSMISSION CONTROL <2WD> 22100380146 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Front Console Removal (Refer to GROUP 52A.) (1) Check the Operation of the Transmission Control (2) Shift the Control Lever to the N position Lever and the Movement in Each Lever Position (2) Front Console Installation (Refer to GROUP 52A.) Caution: SRS…
• Page 764
  22-7 MANUAL TRANSMISSION – Transmission Control <2WD> INSTALLATION SERVICE POINTS «AA CONTROL LEVER ASSEMBLY INSTALLATION 1. Remove the adhesive sticking to the control lever assembly mounting bolts. 2. Use a tap (M8 x 1.25) to remove the adhesive sticking to the bolt holes in the control housing, and clean it by blowing in air.
• Page 765
  22-8 MANUAL TRANSMISSION – Transmission Control <4WD> TRANSMISSION CONTROL <4WD> 22100380153 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Front Floor Console Assembly Removal (1) Check the Operation of the Transmission and (Refer to GROUP 52A.) Transfer Control Levers and the Movement in Each (2) Shift the Transmission Control Lever to the N Lever Position.
• Page 766
  22-9 MANUAL TRANSMISSION – Transmission Control <4WD> INSTALLATION SERVICE POINTS <Transfer> «AA STOPPER PLATE INSTALLATION Install the stopper plates so that they face as shown in the illustration. Front <Transmission> Front «BA TRANSFER CONTROL LEVER ASSEMBLY/ <L.H. drive vehicles> TRANSMISSION CONTROL LEVER ASSEMBLY Front 1.
• Page 767
  22-10 MANUAL TRANSMISSION – Transmission Assembly <2WD> TRANSMISSION ASSEMBLY <2WD> 22100270191 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Transmission Control Lever Removal (1) Propeller Shaft Installation (Refer to GROUP 25.) (Refer to P. 22-6.) (2) Transmission Oil Filling (Refer to 22-4.) (2) Transmission Oil Draining (Refer to P.
• Page 768
  22-11 MANUAL TRANSMISSION – Transmission Assembly <2WD> AC» TRANSMISSION ASSEMBLY REMOVAL Caution When removing the transmission assembly from the engine, care must be taken not to shake or rock with force, because to do so might cause damage to the end of the main drive gear, the pilot bearing, or the clutch disc, etc.
• Page 769
  22-12 MANUAL TRANSMISSION – Transmission Assembly <4WD> TRANSMISSION ASSEMBLY <4WD> 22100350031 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Transmission and Transfer Control Lever Removal (1) Front and Rear Propeller Shaft Installation (Refer to P. 22-8.) (Refer to GROUP 25.) (2) Transfer Case Protector Removal (2) Transmission and Transfer Oil Filling (3) Transmission and Transfer Oil Draining…
• Page 770
  22-13 MANUAL TRANSMISSION – Transmission Assembly <4WD> REMOVAL SERVICE POINTS AA» CLUTCH RELEASE CYLINDER, BRACKET ASSEMBLY <4G64>/CLUTCH RELEASE CYLINDER <4D56> REMOVAL Remove the clutch release cylinder without disconnecting fluid line. Then suspend them with a cord. AB» STARTER MOTOR REMOVAL Remove the starter motor with the starter motor harnesses still connected, and secure it inside the engine compartment.
• Page 771
  22-14 MANUAL TRANSMISSION – Transmission Assembly <4WD> «BA TRANSFER ROLL STOPPER INSTALLATION Transfer roll stopper a: Approx. 10 mm outer 1. Tighten the transfer roll stopper provisionally. 2. Make the engine and transmission assembly rest on the engine mount. 3. Tighten the transfer roll stoppers inner and outer finally so that the clearance (a) between the two are at the Transfer roll shown dimension.
• Page 772
  22-15 MANUAL TRANSMISSION – 4WD Indicator-ECU 4WD INDICATOR-ECU 22100620019 REMOVAL AND INSTALLATION Removal steps 1. Front scuff plate attaching screw 2. Cowl side trim 3. Rear differential lock-ECU 4. 4WD indicator-ECU INSPECTION 4WD INDICATOR-ECU 1. Measure the voltage with the control unit and harness still connected.
• Page 773
  22-16 MANUAL TRANSMISSION – 4WD Indicator-ECU Terminal No. Inspection item Inspection condition Inspection condition Terminal voltage 1: Ignition switch 2: Transfer lever position Free wheel engage System voltage switch switch 4WD detection System voltage switch switch 4H, 4L Ignition switch (IG1) –…
• Page 775
  22-1 MANUAL TRANSMISSION – General/General Information GROUP 22 MANUAL TRANSMISSION GENERAL OUTLINE OF CHANGE Due to the addition of the vehicles with emission regulation step III compatible 4D5 engine, R5M21 type transmission has been changed. GENERAL INFORMATION Items Specifications Engine model 4D56-Step III Transmission model R5M21-5…
• Page 776
  NOTES…
• Page 777
  AUTOMATIC TRANSMISSION Click on the applicable bookmark to selected the required model year…
• Page 779
  General Information/ 23-2 AUTOMATIC TRANSMISSION – Service Specifications GENERAL INFORMATION 23100010141 Items Vehicles with 4G63 engine Vehicles with 4D56 engine Transmission model R4AW2-6 V4AW2-6 Type 4-speed full automatic 4-speed full automatic Gear ratio 2.826 2.826 1.493 1.493 1.000 1.000 0.730 0.688 Reverse 2.703…
• Page 780
  23-3 AUTOMATIC TRANSMISSION – Lubricants/Sealants/Special Tool LUBRICANTS 23100040119 Items Specified lubricants Quantity Transmission fluid DEXRON-II or equivalent R4AW2: Approx. 6.8 V4AW2: Approx. 7.2 Transfer oil Hypoid gear 75W-90, 75W-85W or 80W confirming to API GL-4 O-ring for oil filler pipe DEXRON-II or equivalent As required SEALANTS…

• Page 781: Road Test

  23-4 AUTOMATIC TRANSMISSION – Troubleshooting TROUBLESHOOTING 23100760152 STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING Automatic transmission malfunctions may be caused by the following conditions. (1) Improper maintenance and adjustment (2) Shift control system malfunction (3) Mechanical malfunctions (4) Hydraulic malfunctions (5) Poor engine performance Troubleshooting in the event of any such malfunctions should begin by checking fluid level, ATF condition, manual linkage adjustment, throttle control cable adjustment and other conditions whose deviation from standards can be readily known.

• Page 782
  23-5 AUTOMATIC TRANSMISSION – Troubleshooting D RANGE TEST TEST 1 Start with throttle valve opened (50 % and full), and check upshift TEST 2 from 1-speed ! 2-speed, 2-speed ! 3-speed and 3-speed ! 4-speed. Check that shifting points match shift pattern. D 1 –…
• Page 783
  23-6 AUTOMATIC TRANSMISSION – Troubleshooting TEST 4 When traveling in 3-speed or 4-speed, shift to 2 and L. Does the TEST 5 engine brake function in each range? Brake No. 1 malfunction Does the engine brake function in 2 range? Brake No.
• Page 784
  23-7 AUTOMATIC TRANSMISSION – Troubleshooting 2 RANGE TEST TEST 1 Start with throttle valve opening at 50% and full. Does the shifting TEST 2 points conform with the shift pattern when upshifting from 1-speed ! 2-speed? D 1 – 2 shift valve malfunction Does the upshift from 1-speed to 2-speed occur? D Governor malfunction Incorrect…
• Page 785
  23-8 AUTOMATIC TRANSMISSION – Troubleshooting SHIFT PATTERN <4G63 engine> Throttle opening Lock-up ON Lock-up OFF 1000 2000 3000 4000 5000 Output shaft speed r/min Vehicle speed km/h <4D56 engine> Throttle opening Lock-up ON Lock-up OFF 1000 2000 3000 4000 Output shaft speed r/min Vehicle speed km/h…
• Page 786
  23-9 AUTOMATIC TRANSMISSION – Troubleshooting CHECK AT OVERDRIVE CONTROL RELAY 23101130013 Terminal Voltage Reference Table Overdrive control relay connector Inspection Inspection item Check requirement Standard value terminal Overdrive Ignition switch: ON Overdrive switch: OFF System voltage switch switch Overdrive switch: ON Ignition switch Ignition switch: OFF Ignition switch: ON…
• Page 787
  23-10 AUTOMATIC TRANSMISSION – On-vehicle Service ON-VEHICLE SERVICE 23100090121 AUTOMATIC TRANSMISSION FLUID CHECK 1. Place the vehicle on a level surface. 2. Before removing the dipstick, wipe all dirt from area around the dipstick. 3. With the selector lever in the “P” position and the parking brake applied, start the engine.
• Page 788
  23-11 AUTOMATIC TRANSMISSION – On-vehicle Service AUTOMATIC TRANSMISSION FLUID CHANGE upper limit 23100100145 Caution lower limit COLD If ATF change is required due to damage to the upper limit COLD transmission, be sure to clean the cooler system. lower limit (1) Raise the vehicle on hoist.
• Page 789
  23-12 AUTOMATIC TRANSMISSION – On-vehicle Service TRANSFER OIL REPLACEMENT 23100120066 1. Remove the oil filler plug and oil drain plug. 2. Drain oil. Oil filler plug 3. Tighten the oil drain plug to the specified torque. Specified torque: 33 Nm 4.
• Page 790
  23-13 AUTOMATIC TRANSMISSION – On-vehicle Service THROTTLE CABLE CHECK AND 4G63 Adjusting nut ADJUSTMENT 0 – 1 mm 23100280047 <4G63> Dust cover (1) Check the throttle lever and the bracket for deformation. (2) Measure the distance between the inner cable stopper and the end of the dust cover when the throttle lever is fully opened.
• Page 791
  23-14 AUTOMATIC TRANSMISSION – On-vehicle Service SELECTOR LEVER OPERATION CHECK Push button 23100130038 1. Shift selector lever to each range and check that lever moves smoothly and is controlled. Check the position indicator is correct. 2. Check the selector lever can be moved to each position (by button operation as shown in the illustration).
• Page 792
  23-15 AUTOMATIC TRANSMISSION – On-vehicle Service AUTOMATIC TRANSMISSION FLUID TEMPERATURE SWITCH CHECK Inhibitor switch 23100350038 1. Remove the automatic transmission fluid temperature switch from the transmission. Caution Use care to prevent foreign materials from entering the automatic transmission fluid temperature switch mounting hole.
• Page 793
  23-16 AUTOMATIC TRANSMISSION – On-vehicle Service A/T CONTROL COMPONENT LOCATION 23100860128 Name Symbol Name Symbol Detection switch Overdrive solenoid valve Engine coolant temperature switch Overdrive switch <4G6> Inhibitor switch Vehicle speed sensor Overdrive control relay – –…
• Page 794
  23-17 AUTOMATIC TRANSMISSION – On-vehicle Service A/T CONTROL COMPONENT CHECK 23100140222 INHIBITOR SWITCH CHECK Refer to P.23-14. OVERDRIVE SOLENOID VALVE CHECK 23101120010 1. Disconnect the overdrive solenoid valve connector. Overdrive solenoid valve 2. Measure the resistance between terminal (2) of the overdrive solenoid valve connector and the body earth.
• Page 795
  23-18 AUTOMATIC TRANSMISSION – On-vehicle Service ENGINE COOLANT TEMPERATURE SWITCH 23101020020 1. Disconnect the engine coolant temperature switch connector. Engine coolant temperature switch 2. Immerse the sensing portion of switch in hot water and check the continuity between the switch connector terminal and the switch body.
• Page 796
  23-19 AUTOMATIC TRANSMISSION – On-vehicle Service CONVERTER STALL TEST 23100540138 In this test, the engine maximum speed when the (5) Start the engine. torque converter stalls with the shift lever in the (6) With the selector lever in the “D” range, fully depress the accelerator pedal and read off the “D”…
• Page 797
  23-20 AUTOMATIC TRANSMISSION – On-vehicle Service HYDRAULIC PRESSURE TEST 23100550131 The hydraulic pressure tests (governor pressure and line pressure tests) are important in determining the causes of transmission failures. Before conducting these tests, fluid level and condition and throttle cable adjustment, etc. must be checked for defects or abnormalities.
• Page 798
  23-21 AUTOMATIC TRANSMISSION – On-vehicle Service LINE PRESSURE TEST (1) Place the vehicle on a chassis dynamometer. (2) Remove the plug from the line pressure take off port. MD998920 (3) Install special tool as shown in the figure and place the meter inside vehicle.
• Page 799
  23-22 AUTOMATIC TRANSMISSION – On-vehicle Service HYDRAULIC CIRCUIT 23100880100 N (NEUTRAL) To oil 1. Lock-up clutch 21. Oil cooler 2. Torque converter 22. Damping check valve 3. Overdrive clutch 23. Oil pump 4. Overdrive brake 24. Strainer 5. Forward clutch 25.

• Page 800: Transmission Control

  23-23 AUTOMATIC TRANSMISSION – Transmission Control TRANSMISSION CONTROL 23100660162 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Caution: SRS Front Floor Console Removal and Installation (Refer Be careful not to subject the SRS diagnosis unit to GROUP 52A.) to any shocks during removal and installation of the selector lever assembly.

• Page 801
  23-24 AUTOMATIC TRANSMISSION – Transmission Control INSTALLATION SERVICE POINT «AA DUST COVER INSTALLATION Install the dust cover as shown in the illustration. Front…
• Page 802
  23-25 AUTOMATIC TRANSMISSION – Selector Lever Assembly SELECTOR LEVER ASSEMBLY 23100680106 DISASSEMBLY AND REASSEMBLY 2.0 Nm 1.5 Nm 12 Nm 12 Nm Removal steps AA» «AA 9. Sleeve 1. Overdrive switch and indicator lamp connector 10. Lever assembly 2. Overdrive switch 11.
• Page 803
  23-26 AUTOMATIC TRANSMISSION – Selector Lever Assembly DISASSEMBLY SERVICE POINT AA» OVERDRIVE SWITCH AND INDICATOR LAMP Terminal CONNECTOR REMOVAL Disconnect the connector and remove the terminal from the connector. Screwdriver REASSEMBLY SERVICE POINTS «AA SLEEVE INSTALLATION Sleeve Shift the selector lever to the N position, and then turn the sleeve so that the clearance between the sleeve and lever assembly end is within the standard value.
• Page 804
  23-27 AUTOMATIC TRANSMISSION – Transmission Assembly <2WD> TRANSMISSION ASSEMBLY <2WD> 23100570168 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Selector Lever Removal (Refer to P.23-23.) (1) Propeller Shaft Installation (Refer to GROUP 25.) (2) Transmission Fluid Draining (Refer to P.23-11.) (2) Transmission Fluid Filling (Refer to P.23-11.) (3) Propeller Shaft Removal (Refer to GROUP 25.) (3) Selector Lever Installation (Refer to P.23-23.)
• Page 805
  23-28 AUTOMATIC TRANSMISSION – Transmission Assembly <2WD> 25 Nm 50 Nm 20 – 24 Nm 35 – 42 Nm 50 Nm 47 Nm 47 Nm 22 Nm D Support the transmission with a 14. Breather hose transmission jack 15. Throttle cable clamp 18.
• Page 806
  23-29 AUTOMATIC TRANSMISSION – Transmission Assembly <2WD> REMOVAL SERVICE POINTS AA» STARTER MOTOR REMOVAL Remove the starter motor with the starter motor harnesses still connected, and secure it inside the engine compartment. AB» TORQUE CONVERTER AND DRIVE PLATE CONNECTION BOLTS REMOVAL 1.
• Page 807
  23-30 AUTOMATIC TRANSMISSION – Transmission Assembly <4WD> TRANSMISSION ASSEMBLY <4WD> 23100630033 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Selector Lever and Transfer Control Lever Removal (1) Front and Rear Propeller Shaft Installation (Refer to P.23-23.) (Refer to GROUP 25.) (2) Transfer Case Protector Removal (2) Transfer Oil Filling (Refer to P.23-12.) (3) Transmission Fluid Draining (Refer to P.23-11.)
• Page 808
  23-31 AUTOMATIC TRANSMISSION – Transmission Assembly <4WD> 50 Nm 45 Nm 24 Nm 45 Nm 22 Nm 50 Nm 35 – 42 Nm 40 Nm 26 Nm 22 Nm 65 Nm 16. Filler tube assembly 20. Transfer roll stopper 17. O-ring 21.
• Page 809
  23-32 AUTOMATIC TRANSMISSION – Transmission Assembly <4WD> REMOVAL SERVICE POINTS AA» STARTER MOTOR REMOVAL Remove the starter motor with the starter motor harnesses still connected, and secure it inside the engine compartment. AB» TORQUE CONVERTER AND DRIVE PLATE CONNECTION BOLTS REMOVAL 1.
• Page 810
  Transmission Assembly <4WD> 23-33 AUTOMATIC TRANSMISSION – /4WD Indicator-ECU «BA THROTTLE CABLE INSTALLATION After installing the throttle cable, adjust it by the following Outer cable procedure. (1) Pull out the cable from the boot outer cable side until the inner cable stopper can be seen. (2) Open the throttle lever completely and adjust the cable with the adjusting nut so that the distance between the inner cable stopper and the outer cable end is at the…
• Page 811
  23-34 AUTOMATIC TRANSMISSION – Transmission Oil Cooler TRANSMISSION OIL COOLER 23100700017 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation (1) Radiator Grille Removal and Installation (Refer to GROUP 51.) <4WD> (2) Transmission Fluid Draining and Supplying (Refer to P.23-11.) (3) Skid Plate, and Front Under Cover Removal and Installation <2WD>…
• Page 815
  SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-99E23-001 Date <Model> <M/Y> 1999-12-15 Subject: ADDITION OF DESCRIPTION OF ABS IDLE-UP (EC,EXP) L200 99-10 SOLENOID VALVE ABOLISHMENT (K00) Group: AUTOMATIC Draft No.: 99SY031213 TRANSAXLE INFORMATION…
• Page 816
  23-3 AUTOMATIC TRANSMISSION — Transmission Oil Cooler INSTALLATION SERVICE POINT » FEED TUBE/RETURN TUBE INSTALLATION 1. Temporarily tighten the feed tube flare nut and return tube flare nut to the transmission assembly. 2. Connect the return hose to the return tube, and feed «…
• Page 817
  35B/35C-1 ABS <2WD/4WD> — General GROUP 35B/35C ANTI-SKID BRAKING SYSTEM (ABS) <2WD/4WD> GENERAL OUTLINE OF CHANGES • The ABS idle-up solenoid valve has been abolished. <4D56> Idle-up solenoid valve <Abolished> 16V0202 16V0104 <Added>…
• Page 818
  23-1 AUTOMATIC TRANSMISSION – General/Service Specifications/Troubleshooting GROUP 23 AUTOMATIC TRANSMISSION GENERAL OUTLINE OF CHANGES With additional vehicle with emission regulation step III compatible 4D5 engine, the service procedure different from service adjustment procedure of the vehicle with 4D5 engine has been established. SERVICE SPECIFICATIONS Items Standard value…
• Page 819
  23-2 AUTOMATIC TRANSMISSION – Troubleshooting/On-vehicle Service <4WD> Throttle opening (%) Lock-up ON Lock-up OFF Output shaft speed 1,000 4,000 5,000 2,000 3,000 (r/min) Vehicle speed (km/h) ON-VEHICLE SERVICE ACCELERATOR CABLE AND THROTTLE CABLE CHECK AND ADJUSTMENT 1. Check the accelerator cable and the throttle cable for bends.
• Page 820
  23-3 AUTOMATIC TRANSMISSION – On-vehicle Service 5. Remove the throttle cable boot and check the dimension A/T throttle control cable of the inner cable stopper and the outer cable end. link assembly Standard value: 0.8 – 1.5 mm Lock nut 6.
• Page 821
  NOTES…
• Page 822
  Click on the applicable bookmark to selected the required model year…
• Page 824
  25-2 PROPELLER SHAFT – General Information/Service Specifications GENERAL INFORMATION 25100010039 For 2WD and 4WD, the rear propeller shaft is a the front propeller shaft is a 2-joint type. 3-joint type with intermediate bearing. For 4WD, Rear propeller shaft Center bearing Front propeller shaft Rear propeller shaft Rear…
• Page 825
  25-3 PROPELLER SHAFT – Lubricant/Special Tools LUBRICANT 25100040045 Item Specified lubricant Quantity Sleeve yoke Hypoid gear oil SAE 75W-85W conforming to API As required GL-4 or higher SPECIAL TOOLS 25100060041 Tool Number Name MB990840 Universal joint re- Disassembly and reassembly of the universal mover and installer joint MB991410…
• Page 826
  25-4 PROPELLER SHAFT – Propeller Shaft PROPELLER SHAFT 25100100057 REMOVAL AND INSTALLATION Pre-removal Operation <4WD> Post-installation Operation <4WD> Set the Transfer Shift Lever to ”2H” Transfer Gear Oil Supplying Front Under Cover Removal (M/T: Refer to GROUP 22 – On-vehicle Service.) Transfer Gear Oil Draining (A/T: Refer to GROUP 23 –…
• Page 827
  25-5 PROPELLER SHAFT – Propeller Shaft REMOVAL SERVICE POINT Mating marks AA» PROPELLER SHAFT ASSEMBLY/REAR PROPELLER SHAFT ASSEMBLY/FRONT PROPELLER SHAFT ASSEMBLY REMOVAL (1) Make mating marks on the differential companion flange and flange yoke and remove the propeller shaft. (2) Use the plug as a cover so that no foreign material gets into the transmission or transfer.
• Page 828
  25-6 PROPELLER SHAFT – Propeller Shaft DISASSEMBLY AND REASSEMBLY 25100120046 <2WD> Rubber mount <Type 1 (External snap ring type)> 186 Nm Universal joint kit Disassembly steps AA» «CA 1. Snap ring 6. Propeller shaft (rear) AB» «BA 2. Journal bearing AC»…
• Page 829
  25-7 PROPELLER SHAFT – Propeller Shaft <4WD> <Type 1> Rubber mount <Type 2> Front propeller shaft <Type 1 (External snap ring type)> Universal joint kit 186 Nm Rear propeller shaft <Type 2 (Internal snap ring type)> Disassembly steps AA» «CA 1. Snap ring 7.
• Page 830
  25-8 PROPELLER SHAFT – Propeller Shaft DISASSEMBLY SERVICE POINTS Type 1 Type 2 Mating marks AA» SNAP RING REMOVAL Make mating marks on the yokes of the universal joint that is to be disassembled. Mating marks AB» JOURNAL BEARING REMOVAL MB990840 (1) Use the special tool to press in the journal bearing on one side, and take out the journal bearing on the opposite…
• Page 831
  25-9 PROPELLER SHAFT – Propeller Shaft REASSEMBLY SERVICE POINTS Self-locking nut Center bearing «AA CENTER BEARING ASSEMBLY/CENTER YOKE assembly Center yoke INSTALLATION Front propeller shaft (1) Install the center bearing assembly to the front propeller shaft as shown in the illustration. (2) Align the mating marks on the center yoke and front propeller shaft.
• Page 832
  25-10 PROPELLER SHAFT – Propeller Shaft «CA SNAP RING INSTALLATION Type 1 Type 2 (1) Install a snap ring to one side of the journal. (2) Use the special tool at the opposite side of the installed Type 1 Type 2 MB990804 MB990804 snap ring to press in the journal bearing towards the…
• Page 833
  FRONT AXLE Click on the applicable bookmark to selected the required model year…
• Page 835
  26-2 FRONT AXLE – General Information GENERAL INFORMATION 26100010111 The front hub assembly which uses a double taper For vehicles with ABS, a rotor for detecting the roller bearing is mounted on the knuckle spindle. wheel speed is press-fitted into the front hub. The front axle consists of the hub assembly, drive A vacuum-type freewheel clutch has been shaft, inner shaft, front differential, freewheel clutch…
• Page 836
  26-3 FRONT AXLE – General Information <Gears> Item 4D56 4G64, 4D56 <Vehicles without wide tyre> <Vehicles with wide tyre> Reduction gear type Hypoid gear type Hypoid gear type Reduction ratio 4.636 4.875 Differential Differential Side gear Straight bevel gear x 2 Straight bevel gear x 2 gear type gear ty e…
• Page 837
  26-4 FRONT AXLE – Service Specifications/Lubricants SERVICE SPECIFICATIONS 26100030131 Item Standard value Limit Front axle total backlash mm – Drive shaft axial play mm 0.4 – 0.7 – Solenoid valve resistance Ω 36 – 46 – Hub rotary sliding resistance N 7 –…
• Page 838
  26-5 FRONT AXLE – Sealants/Special Tools SEALANTS 26100050038 Items Specified sealants Remarks Contact surface of drive flange or freewheel hub 3M ATD Part No. 8661 or equivalent Semi-drying sealant and front axle hub Contact surface of hub cap and drive flange Contact surface of differential cover and differential carrier Vent plug…
• Page 839
  26-6 FRONT AXLE – Special Tools Tool Number Name MB990955 Oil seal installer Press-fitting of housing tube dust seal Press-fitting of front axle hub oil seal (Used together with MB990938) Press-fitting of rotor <2WD> (Used together with MB990938) MB990956 Needle bearing Press-fitting of knuckle needle bearing (Used installer together with MB990938)
• Page 840
  26-7 FRONT AXLE – Special Tools Tool Number Name MB990909 Working base Support of front differential carrier assembly MB991116 Adapter Support of front differential carrier assembly MB990810 Side bearing puller Removal of side bearing inner race MB990811 Differential side bearing cap MB990850 End yoke holder Removal and installation of companion flange…
• Page 841
  26-8 FRONT AXLE – Special Tools Tool Number Name MB990326 Preload socket MB990802 Bearing installer Press-fitting of drive pinion front bearing inner race Press-fitting of side bearing inner race MB990031 Drive pinion oil Press-fitting of drive pinion oil seal seal installer MB990699 MB990813 Removal of adhesive…
• Page 842
  26-9 FRONT AXLE – On-vehicle Service ON-VEHICLE SERVICE 26100110071 <2WD> WHEEL BEARING PLAY CHECK 1. Check the play of the bearings while the vehicle is jacked Caution Do not confuse this play with the ball joint play. 2. If there is some play in the bearings, tighten the wheel bearing nuts to 29 Nm, and then turn the front hub assembly to run in the bearings.
• Page 843
  26-10 FRONT AXLE – On-vehicle Service 5. If the amount of movement exceeds the limit value, check the following. (1) Final drive gear backlash (2) Differential gear backlash (3) Play in the serrations and splines of the side gears, drive shaft, inner shaft and drive flange FRONT AXLE GEAR OIL LEVEL CHECK 26200090026 Remove the filler plug, and check the gear oil level.
• Page 844
  26-11 FRONT AXLE – On-vehicle Service 9. Use the special tool to remove the oil seal. MB990590 10. Press-fit the oil seal positively by using the special tools. MB990934 MB990938 11. Apply multi-purpose grease to the lip of the oil seal and install the drive shaft (L.H.).
• Page 845
  26-12 FRONT AXLE – On-vehicle Service 3. Connect a hand vacuum pump to solenoid valve B and carry out the following inspections. (1) Even if the hand pump is operated with no other operation, no negative pressure develops. (2) Negative pressure does not develop when battery voltage is applied to solenoid valve B.
• Page 846
  26-13 FRONT AXLE – Front Hub Assembly <2WD> FRONT HUB ASSEMBLY <2WD> 26100170123 REMOVAL AND INSTALLATION 88 Nm 29 Nm 0 Nm 7.8 Nm Removal steps AA» «AA 4. Wheel bearing nut 1. Caliper assembly 2. Hub cap 5. Washer AB»…
• Page 847
  26-14 FRONT AXLE – Front Hub Assembly <2WD> INSTALLATION SERVICE POINT «AA WHEEL BEARING NUT INSTALLATION 1. Tighten the wheel bearing nuts to 29 Nm, and then turn the front hub assembly to run in the bearings. 2. Loosen the nuts to 0 Nm. 3.
• Page 848
  26-15 FRONT AXLE – FRONT AXLE – FRONT AXLE – Front Hub Assembly <2WD> Front Hub Assembly <2WD> Front Hub Assembly <2WD> AB» OUTER BEARING OUTER RACE/INNER BEARING Inner bearing Outer bearing OUTER RACE REMOVAL MB990939 outer race outer race INSTALLATION SERVICE POINTS Outer bearing Inner bearing…
• Page 849
  26-16 FRONT AXLE – Front Hub Assembly <4WD> FRONT HUB ASSEMBLY <4WD> 26100170130 REMOVAL AND INSTALLATION 90 Nm Sealant: 3M ATD Part No. 8661 or equivalent 90 Nm 127 – 196 Nm 0 Nm 25 Nm 49 – 59 Nm Front hub shim set Removal steps AA»…
• Page 850
  26-17 FRONT AXLE – Front Hub Assembly <4WD> AC» FRONT HUB ASSEMBLY REMOVAL Do not drop the outer bearing inner race. Outer bearing inner race INSTALLATION SERVICE POINTS «AA LOCK NUT INSTALLATION MB990954 Using the special tool, tighten the lock nut by the following procedures.
• Page 851
  26-18 FRONT AXLE – Front Hub Assembly <4WD> 3. Install a dial gauge as shown in the illustration, and then move the hub in the axial direction and measure how far the front wheel bearing moves. Standard value: 0.05 mm or less 4.
• Page 852
  26-19 FRONT AXLE – Front Hub Assembly <4WD> REMOVAL SERVICE POINTS Outer bearing Inner bearing MB990939 outer race outer race AA» OUTER BEARING OUTER RACE/INNER BEARING OUTER RACE REMOVAL AB» BRAKE DISC REMOVAL Make the mating marks on the brake disc and front hub, and then separate the front hub and brake disc, if necessary.
• Page 853
  26-20 FRONT AXLE – Knuckle <2WD> KNUCKLE <2WD> 26100240084 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Front Hub Assembly Removal. (Refer to P. 26-13.) Front Hub Assembly Installation. (Refer to P. 26-13.) Wheel Alignment Check and Adjustment. (Refer to GROUP 33A – On-vehicle Service.) 74 Nm 39 Nm 147 Nm…
• Page 854
  26-21 FRONT AXLE – Knuckle <2WD> AB» LOWER ARM BALL JOINT DISCONNECTION Caution MB990804 Use the special tool to loosen the nut only; do not remove it from the ball joint. INSPECTION 26100250049 Check the knuckle for wear or cracks.
• Page 855
  26-22 FRONT AXLE – Knuckle <4WD> KNUCKLE <4WD> 26100240091 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Front Hub Assembly Removal. (Refer to P. 26-16.) Front Hub Assembly Installation. (Refer to P. 26-16.) Wheel Alignment Check and Adjustment. (Refer to GROUP 33A – On-vehicle Service.) 74 Nm 34 –…
• Page 856
  26-23 FRONT AXLE – Knuckle <4WD> REMOVAL SERVICE POINT MB991113 or AA» TIE ROD END /LOWER ARM BALL JOINT MB990635 /UPPER ARM BALL JOINT DISCONNECTION Caution 1. Use the special tool to loosen the nut only; do not Cord remove it from the ball joint. 2.
• Page 857
  26-24 FRONT AXLE – Knuckle <4WD> DISASSEMBLY AND REASSEMBLY 26100320023 Disassembly steps «CA 1. Oil seal «BA 2. Spacer AA» «AA 3. Needle bearing 4. Knuckle…
• Page 858
  26-25 FRONT AXLE – Knuckle <4WD> DISASSEMBLY SERVICE POINT AA» NEEDLE BEARING REMOVAL MB990939 REASSEMBLY SERVICE POINTS MB990938 «AA NEEDLE BEARING INSTALLATION Caution MB990956 Use care to prevent driving the needle bearing too far MB990956 «BA SPACER INSTALLATION Install the spacer to the knuckle with the chamfered side toward the center of vehicle.

• Page 859: Drive Shaft

  26-26 FRONT AXLE – Drive Shaft DRIVE SHAFT 26100350152 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Front Under Cover Removal Gear Oil Supplying (Refer to P. 26-10.) Gear Oil Draining (Refer to P. 26-10.) Front Under Cover installation Wheel Alignment Check and Adjustment. (Refer to GROUP 33A –…

• Page 860
  26-27 FRONT AXLE – Drive Shaft REMOVAL SERVICE POINTS AA» CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire so that it does not fall. AB» TIE ROD END /LOWER ARM BALL JOINT /UPPER ARM BALL JOINT DISCONNECTION MB991113 or MB990635 Caution 1.
• Page 861
  26-28 FRONT AXLE – Drive Shaft INSTALLATION SERVICE POINTS «AA DRIVE SHAFT (LEFT SIDE) INSTALLATION Caution Do not damage the oil seal of the differential carrier by the drive shaft splines. «BA KNUCKLE AND FRONT HUB ASSEMBLY INSTALLATION 1. Insert knuckle and front hub assembly to drive shaft. Caution Do not damage knuckle oil seal with drive shaft spline.
• Page 862
  26-29 FRONT AXLE – Drive Shaft INSPECTION 26100360087 Check the boot for damage or deterioration. Check the ball joint for operating condition and excessive looseness. Check the splines for wear or damage. Check the differential carrier oil seal (L.H.) for damaged.
• Page 863
  26-30 FRONT AXLE – Drive Shaft DISASSEMBLY AND REASSEMBLY 26100370165 (L.H.) (R.H.) B.J. repair kit (B.J.) (L.H.) (R.H.) B.J. repair kit L.H. D.O.J. repair kit Boot repair kit (D.O.J.) Disassembly steps Reassembly steps 1. D.O.J. boot band (large) 12. Circlip 2.
• Page 864
  26-31 FRONT AXLE – Drive Shaft Lubrication Points Grease: Repair kit grease Grease: Repair kit grease 100 g (60 g inside joint, 40 g inside boot) Caution Do not mix old and new or different types of grease, as a special grease is used in the joint. DISASSEMBLY SERVICE POINTS AA»…
• Page 865
  26-32 FRONT AXLE – Drive Shaft AC» D.O.J. BOOT REMOVAL Wrap plastic tape around the spline part on the D.O.J. side of the drive shaft so that D.O.J. boot is not damaged when Plastic tape they are removed. REASSEMBLY SERVICE POINTS Ball «AA D.O.J.
• Page 866
  26-33 FRONT AXLE – Drive Shaft 3. Secure the boot band (large) on D.O.J. boot. Direction of drive Caution shaft rotation when vehicle is moving Be sure that the installation direction of the boot bands forward is correct. Boot band B.J.
• Page 867
  26-34 FRONT AXLE – Drive Shaft 5. Place the B.J. boot band (small) against the projection B.J. boot at the edge of the boot, and then secure it so that there is a clearance left as shown by (A) in the illustration. B.J.
• Page 868
  26-35 FRONT AXLE – Drive Shaft 10. Install the B.J. boot band (large) so that there is the clearance (C) between it and the B.J. housing is at the standard value. Standard value (C): 0.1 – 1.55 mm 11. Follow the same procedure as in step (4) to adjust the size of the opening (W) on the special tool so that it is at the standard value.
• Page 869
  26-36 FRONT AXLE – Inner Shaft INNER SHAFT 26100400031 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Under Cover Removal and Installation Gear Oil Draining and Supplying (Refer to P. 26-10.) 88 Nm 17 Nm 93 Nm 88 Nm 49 – 59 Nm Removal steps AA»…
• Page 870
  26-37 FRONT AXLE – Inner Shaft REMOVAL SERVICE POINTS AA» CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire so that it does not fall. AB» INNER SHAFT REMOVAL Caution When pulling the inner shaft out from the front differential MB990906 carrier, be careful that the spline part of the inner shaft does not damage the oil seal.
• Page 871
  26-38 FRONT AXLE – Inner Shaft DISASSEMBLY AND REASSEMBLY 26100420020 Disassembly steps AA» 1. Inner shaft 4. Housing tube «CA 2. Bearing «AA 5. Dust seal «BA 3. Dust cover DISASSEMBLY SERVICE POINT AA» BEARING REMOVAL 1. Bend the outside periphery of dust cover inward with a hammer.
• Page 872
  26-39 FRONT AXLE – Inner Shaft 3. Press out the inner shaft from the bearing. MB990560 REASSEMBLY SERVICE POINTS «AA DUST SEAL INSTALLATION Press-fit the new dust seal into the housing tube by using MB990938 the special tools, until it is flush with the housing tube end face.
• Page 873
  26-40 FRONT AXLE – Differential Carrier DIFFERENTIAL CARRIER 26200210019 REMOVAL AND INSTALLATION 17 Nm 93 Nm 44 Nm 88 Nm 49 – 59 Nm 35 Nm Sealant: 3M ATD Part No. 8661 or equivalent 93 Nm 88 Nm 88 Nm 59 –…
• Page 874
  26-41 FRONT AXLE – Differential Carrier REMOVAL SERVICE POINT Mating marks AA» FRONT PROPELLER SHAFT REMOVAL Make the mating marks on the flange yoke and the differential carrier companion flange and then remove the front propeller shaft. INSTALLATION SERVICE POINTS «AA CLUTCH GEAR BEARING AXIAL PLAY Spacer INSPECTION…
• Page 875
  26-42 FRONT AXLE – Differential Carrier INSPECTION BEFORE DISASSEMBLY 26200430026 1. Remove the cover and gasket. MB990909 and 2. Hold the special tool in a vise, and install the differential MB991116 carrier assembly to the special tool. DRIVE GEAR BACKLASH 1.
• Page 876
  26-43 FRONT AXLE – Differential Carrier 2. If the backlash exceeds the limit, adjust by using the side gear thrust spacers. 3. If adjustment is impossible, replace the side gear and pinion gear as a set. DRIVE GEAR TOOTH CONTACT Check the tooth contact of drive gear by following the steps below.
• Page 877
  26-44 FRONT AXLE – Differential Carrier Standard tooth contact pattern Problem Solution Narrow tooth side Tooth contact pattern resulting from Drive-side tooth surface (the side excessive pinion height applying power during forward movement) Wide tooth side Coast-side tooth surface (the side applying power during re- verse movement) Increase the thickness of the drive…
• Page 878
  26-45 FRONT AXLE – Differential Carrier DISASSEMBLY 26200230039 26 25 21 22 18 19 20 Disassembly steps D Inspection before disassembly 18. Drive pinion (Refer to P. 26-42.) 19. Drive pinion front shim (for pinion 1. Cover height adjustment) AG» 2.
• Page 879
  26-46 FRONT AXLE – Differential Carrier DISASSEMBLY SERVICE POINTS AA» DIFFERENTIAL CASE ASSEMBLY REMOVAL Caution When taking out the differential case assembly, be careful not to drop and damage the side bearing outer races. NOTE Keep the right and left side bearings and side bearing adjusting spacers separate, so that they do not become mixed at the time of reassembly.
• Page 880
  26-47 FRONT AXLE – Differential Carrier AF» DRIVE PINION ASSEMBLY REMOVAL 1. Make mating marks on the drive pinion and companion flange. Caution The mating mark made on the companion flange must not be on the coupling surface of the flange yoke and the front propeller shaft.
• Page 881
  26-48 FRONT AXLE – Differential Carrier REASSEMBLY 26200250035 15 16 17 6 10 11 13 12 78 – 88 Nm 186 Nm 27 26 25 19 54 – 64 Nm 23 24 21 22 21 20 26 27 49 Nm 22 21 20 19 19 Nm…
• Page 882
  26-49 FRONT AXLE – Differential Carrier Lubrication, Sealing and Adhesive Points Adhesive: 3M Stud Locking 4170 or equivalent Sealant: Sealant: 3M ATD Part No. 8661 or equivalent 3M ATD Part No. 8661 or equivalent…
• Page 883
  26-50 FRONT AXLE – Differential Carrier REASSEMBLY SERVICE POINTS «AA OIL SEAL INSTALLATION MB990938 MB990934 Oil seal «BA DRIVE PINION FRONT BEARING OUTER RACE INSTALLATION MB990938 MB990936 «CA DRIVE PINION REAR BEARING OUTER RACE MB990938 INSTALLATION MB990933 «DA PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedure.
• Page 884
  26-51 FRONT AXLE – Differential Carrier Standard value: Bearing division Bearing lubrication Rotation torque MB990685 None (With 0.5 – 0.7 Nm MB990326 anti-rust agent) New or reusing Gear oil applied 0.3 – 0.4 Nm NOTE The special tool cannot be turned a full revolution, so turn it several times within the range of movement to run in the bearing, and then measure the rotation torque.
• Page 885
  26-52 FRONT AXLE – Differential Carrier 11. Fit the selected drive pinion front shim(s) to the drive pinion, and press-fit the drive pinion front bearing inner race by using the special tool. MB990802 «EA DRIVE PINION TURNING TORQUE ADJUSTMENT Adjust the drive pinion rotation torque by using the following procedure: Without Oil Seal 1.
• Page 886
  26-53 FRONT AXLE – Differential Carrier Drive pinion spacer Identification colour height (mm) 46.67 White 47.01 – 5. Remove the companion flange and drive pinion again. Then, after inserting the drive pinion rear bearing inner race into the gear carrier, use the special tool to press-fit the oil seal.
• Page 887
  26-54 FRONT AXLE – Differential Carrier «FA DIFFERENTIAL GEAR BACKLASH ADJUSTMENT 1. Assemble the side gears, side gear spacers, pinion gears and pinion washers into the differential case. 2. Temporarily install the pinion shaft. NOTE Do not drive in the lock pin yet. 3.
• Page 888
  26-55 FRONT AXLE – Differential Carrier 3. Apply the specified adhesive to the threaded holes of the drive gear. Specified adhesive: 3M Stud Locking 4170 or equivalent 4. Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the specified torque in a diagonal sequence.
• Page 889
  26-56 FRONT AXLE – Differential Carrier 4. Install the side bearing adjusting spacers and differential case assembly, as shown in the illustration, to the gear carrier. 5. Tap the side bearing adjusting spacers with the special tool to fit them to the side bearing outer race. MB990939 6.
• Page 890
  26-57 FRONT AXLE – Differential Carrier 10. Measure the drive gear runout at the shoulder on the reverse side of the drive gear. Limit: 0.05 mm 11. If the drive gear runout exceeds the limit, reinstall by changing the phase of the drive gear and differential case, and remeasure.
• Page 891
  26-58 FRONT AXLE – Freewheel Clutch FREEWHEEL CLUTCH 26200270017 REMOVAL AND INSTALLATION 17 Nm 93 Nm 88 Nm 35 Nm 88 Nm Freewheel clutch removal steps 1. Inner shaft (Refer to P. 26-36.) 8. Pin 2. Circlip 9. Spacer 3. Freewheel engage switch connector 10.
• Page 892
  26-59 FRONT AXLE – Freewheel Clutch 9 Nm 12 Nm 9 Nm Solenoid valve assembly removal steps 14. Solenoid valve connector 17. Vacuum tank bracket «CA 15. Solenoid valve assembly «BA 18. Check valve 19. Vacuum pipe Vacuum tank and vacuum hose 20.
• Page 893
  26-60 FRONT AXLE – Freewheel Clutch «BA CHECK VALVE INSTALLATION Install so that air direction arrow points to the vacuum side. Vacuum side Solenoid valve side Air direction arrow «CA SOLENOID VALVE ASSEMBLY INSTALLATION Identification colour (blue) Install so that the identification colours of the vacuum hoses match those of the solenoid valve assembly.
• Page 894
  26-61 FRONT AXLE – FRONT AXLE – Freewheel Clutch Freewheel Clutch INSPECTION 26200280010 FREEWHEEL ENGAGE SWITCH Shaft (switch) Terminal No. 1 Terminal No. 2 position Shaft Pressed (ON) OFF ON Released (OFF) Contact Pole DISASSEMBLY AND REASSEMBLY 26200290044 Removal steps AA»…
• Page 895
  26-62 FRONT AXLE – Freewheel Clutch 2. Press out the mainshaft from the bearing. Caution Do not allow the mainshaft to drop. MB990560 AB» CLUTCH GEAR/BEARING REMOVAL 1. Use a press and steel plate to remove the clutch gear and bearing together. Iron 2.
• Page 896
  26-63 FRONT AXLE – FRONT AXLE – FRONT AXLE – Freewheel Clutch Freewheel Clutch Freewheel Clutch 2. Use the special tool to press-fit the bearing to the side of the clutch housing. MB990890 Caution MB990891 Place the special tool against the outer race of the bearing.
• Page 897
  NOTES…
• Page 898
  SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-98E33-501 Date <Model> <M/Y> 1998-11-15 CORRECTION OF PART NUMBER OF PINION (EC,EXP)L200 97-10 Subject: HEIGHT GAUGE SET’S COMPONENT PART (K60,70) Group: FRONT SUSPENSION Draft No.: 98SY070111…
• Page 899
  26-7 FRONT AXLE — Special Tools Tool Number Name MB990909 Working base Support of front differential carrier assembly B990909 MB991116 Adapter Support of front differential carrier assembly MB990810 Side bearing puller Removal of side bearing inner race B990810 MB990811 Differential side bearing cap MB990850 End yoke holder…
• Page 900
  26-51 FRONT AXLE — Differential Carrier Standard value: MB990685 MB990326 Bearing division Bearing lubrication Rotation torque None (With anti- 0.5 — 0.7 Nm rust agent) New or reusing Gear oil applied 0.3 — 0.4 Nm NOTE The special tool cannot be turned a full revolution, so turn it several times within the range of movement to run in the bearing, and then measure the rotation torque.
• Page 901
  SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-98E33-501REV Date 1999-09-30 <Model> <M/Y> Subject: CORRECTION OF PART NUMBER OF PINION (EC,EXP) L200 97-10 HEIGHT GAUGE SET’S COMPONENT PART (K00) (REVISED) Group: FRONT SUSPENSION Draft No.: 98SY070111…
• Page 902
  26-7 FRONT AXLE — Special Tools Tool Number Name MB990909 Working base Support of front differential carrier assembly B990909 MB991116 Adapter Support of front differential carrier assembly MB990810 Side bearing puller Removal of side bearing inner race B990810 MB990811 Differential side bearing cap MB990850 End yoke holder…
• Page 903
  26-51 FRONT AXLE — Differential Carrier Standard value: MB990685 MB990326 Bearing division Bearing lubrication Rotation torque None (With anti- 0.5 — 0.7 Nm rust agent) New or reusing Gear oil applied 0.3 — 0.4 Nm NOTE The special tool cannot be turned a full revolution, so turn it several times within the range of movement to run in the bearing, and then measure the rotation torque.
• Page 904
  REAR AXLE Click on the applicable bookmark to selected the required model year…
• Page 906
  27-2 REAR AXLE – General Information GENERAL INFORMATION 27100010118 The rear axle is a banjo-type semi-floating type. Differential gear has 4 different types. A The axle shaft bearings are: *Single taper torque-responsive mechanical-type limited slip differential has a high performance against bearings for vehicles without ABS or rear differential lock.
• Page 907
  27-3 REAR AXLE – General Information <4WD> Item 4G64, 4D56 <Vehicles with wide tyre> 4D56 <Vehicles without wide tyre> Drive gear type Hypoid gear Hypoid gear Reduction ratio 4.875 4.636 Limited slip differential type Torque sensitivity type mechanical Torque sensitivity type mechanical Differential gear type Side gear Straight bevel gear x 2…
• Page 908
  27-4 REAR AXLE – Service Specifications SERVICE SPECIFICATIONS 27100030121 Item Standard value Limit Rear axle total backlash mm – Axle shaft axial play mm Vehicles without ABS or rear differential lock 0.05 – 0.20 – Vehicles with ABS or rear differential lock 0 –…
• Page 909
  27-5 REAR AXLE – Service Specifications/Lubricants/Sealants Item Standard value Limit Horizontal difference between friction plate and friction disc thickness mm 0 – 0.05 – Clearance between friction plate and friction disc mm 0.06 – 0.20 – Clearance in side gear axial direction mm 0.05 –…
• Page 910
  27-6 REAR AXLE – Special Tools SPECIAL TOOLS 27100060113 Tool Number Name MB990767 End yoke holder Measurement of the limited slip differential preload MB990590 Rear axle shaft oil Removal of axle shaft (Use together with seal remover MB990241, MB990211) A: MB990212 A: Adapter Removal of axle housing oil seal B: MB990211…
• Page 911
  27-7 REAR AXLE – Special Tools Tool Number Name MB990787 Axle shaft bearing Installation of rotor remover MB990909 Working base Supporting of the differential carrier MB990201 Side bearing Removal and adjustment of the side bearing adjusting special spanner MB990810 Side bearing puller Removal of the side bearing inner race MB990811 Side bearing cup…
• Page 912
  27-8 REAR AXLE – Special Tools Tool Number Name MB991171 Pinion height Measurement of the pinion height gauge set A: MB990819 B: MB991170 A: Drive pinion C: MB991169 gauge B: Cylinder gauge C: Drive pinion gauge attach- ment MB990685 Torque wrench Measurement of the starting torque of drive pinion MB990326…
• Page 913
  27-9 REAR AXLE – Special Tools/On-vehicle Service MB990988 Tool number Name O.D. mm MB990551 – MB990989 Base – (MB990990) Tool A (MB990991) Tool B (MB990992) Tool C ON-VEHICLE SERVICE 27100120057 Mating marks REAR AXLE TOTAL BACKLASH CHECK 1. Park the vehicles on a flat, level surface. 2.
• Page 914
  27-10 REAR AXLE – On-vehicle Service AXLE SHAFT AXIAL PLAY ADJUSTMENT O-ring 27100140015 <Vehicles without ABS or rear differential lock> Shim 1. Insert a 1 mm thick shim and O-ring into the left side rear axle housing. 2. Apply the specified sealant to the mating surface of the bearing case, install the left axle shaft into rear axle housing and tighten the nuts 49 –…
• Page 915
  27-11 REAR AXLE – On-vehicle Service GEAR OIL LEVEL CHECK 27200120043 Check that gear oil level is not 8 mm below the bottom of filler plug hole. Specified gear oil: 8 mm <Conventional differential> Upper limit Hypoid gear oil API classification GL-5 or higher SAE viscosity No.
• Page 916
  27-12 REAR AXLE – On-vehicle Service 2. Use special tools with hook attached to remove the oil seal. 3. Apply multipurpose grease to the oil seal fitting area of the rear axle housing. MB990212 MB990211 4. Drive the new oil seal into the rear axle housing end MB990930 by using the special tool.
• Page 917
  27-13 REAR AXLE – On-vehicle Service REAR DIFFERENTIAL LOCK SYSTEM AIR LEAKAGE CHECK 27200110033 1. Remove the rear differential lock air pump and remove the air hose from the air pump. (Refer to P.27-26.) 2. Connect a pressure gauge and air regulator to the air hose.

• Page 918: Axle Assembly

  27-14 REAR AXLE – Axle Assembly AXLE ASSEMBLY 27100170038 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Filling and Air Bleeding (Refer to GROUP 35A – On-vehicle Service.) Parking Brake Lever Stroke Adjustment (Refer to GROUP 36 – On-vehicle Service.) 49 –…

• Page 919
  27-15 REAR AXLE – Axle Assembly REMOVAL SERVICE POINTS Mating marks AA» PROPELLER SHAFT REMOVAL Place a mating marks on the companion flange and flange yoke, disconnect the propeller shaft from the companion flange. Caution Suspend the propeller shaft from the body with wire, etc. to prevent it from falling.

• Page 920: Axle Shaft

  27-16 REAR AXLE – Axle Shaft AXLE SHAFT 27100250039 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying and Air Bleeding (Refer to GROUP 35A – On-vehicle Service.) Parking Brake Lever Stroke Adjustment (Refer to GROUP 36 – On-vehicle Service.) Vehicles with ABS or rear Vehicles without ABS or differential lock…

• Page 921
  27-17 REAR AXLE – Axle Shaft REMOVAL SERVICE POINTS AA» AXLE SHAFT ASSEMBLY REMOVAL MB990241 Caution MB990211 Be careful not to damage the oil seal when pulling axle shaft. AB» OIL SEAL REMOVAL MB990212 MB990211 INSTALLATION SERVICE POINTS MB990930 «AA OIL SEAL INSTALLATION MB990938 «BA AXLE SHAFT AXIAL PLAY ADJUSTMENT O-ring…
• Page 922
  27-18 REAR AXLE – Axle Shaft 4. Measure the clearance between the bearing case and rear axle housing end with a thickness gauge. NOTE Confirm that the measurement values no differ in the horizontal and vertical positions. 5. Select shims of the thickness which is equal to the sum of the measured clearance and 0.05 –…
• Page 923
  27-19 REAR AXLE – Axle Shaft DISASSEMBLY AND REASSEMBLY 27100270011 <VEHICLES WITHOUT ABS OR REAR DIFFERENTIAL LOCK> Apply to entire inside diameter of oil seal lip Sealant: 3M ATD Part No. 8661 or equivalent Disassembly steps «GA 1. Snap ring AD»…
• Page 924
  27-20 REAR AXLE – Axle Shaft <VEHICLES WITH ABS OR REAR DIFFERENTIAL LOCK> Apply to entire inside Sealant: 3M ATD Part No. diameter of oil seal lip 8661 or equivalent Disassembly steps Reassembly steps «AA 11. Bearing outer race 1. Snap ring «BA 9.
• Page 925
  27-21 REAR AXLE – Axle Shaft DISASSEMBLY SERVICE POINTS AA» RETAINER REMOVAL 1. Remove one retainer bolt from the backing plate. Backing plate Retainer bolt 2. Apply gummed cloth tape around the edge of the bearing Grinder case for protection. 3.
• Page 926
  27-22 REAR AXLE – Axle Shaft AB» AXLE SHAFT REMOVAL Vehicles without ABS or rear differential lock <VEHICLES WITHOUT ABS OR REAR DIFFERENTIAL MB991552 LOCK> 1. Set the special tool by fixing its plate to the bearing case Hanger as shown in the figure and adjust the height of the hanger. <VEHICLES WITH ABS OR REAR DIFFERENTIAL LOCK>…
• Page 927
  27-23 REAR AXLE – Axle Shaft <VEHICLES WITH ABS OR REAR DIFFERENTIAL LOCK> Reinstall the outer bearing inner race that was removed MB990799 previously, and then use the special tool and a press to remove the bearing outer race. Bearing outer race REASSEMBLY SERVICE POINTS «AA BEARING OUTER RACE INSTALLATION MB990938…
• Page 928
  27-24 REAR AXLE – Axle Shaft «CA BEARING INNER RACE INSTALLATION 1. Apply multipurpose grease to the roller surface and ends Axle shaft of the bearing. Bearing case 2. Place the bearing case and the bearing inner race onto Bearing inner the axle shaft in that order.
• Page 929
  27-25 REAR AXLE – Axle Shaft «FA ROTOR INSTALLATION MB990787 Rotor Retainer «GA SNAP RING INSTALLATION Vehicles without ABS 1. After installing the snap ring, measure the clearance (A) between the snap ring and the retainer with a thickness gauge, and check that it is within the standard value. Snap ring Standard value (A): 0 –…
• Page 930
  27-26 REAR AXLE – Rear Differential Lock REAR DIFFERENTIAL LOCK 27200270038 REMOVAL AND INSTALLATION 12 Nm 36 Nm 1. Rear differential lock switch Rear differential lock air pump removal steps Rear differential lock-ECU removal 5. Hose steps 6. Rear differential lock air pump 2.
• Page 931
  27-27 REAR AXLE – Rear Differential Lock INSPECTION 27200330026 REAR DIFFERENTIAL LOCK SWITCH CHECK Switch Terminal No. position position REAR DIFFERENTIAL LOCK-ECU CHECK 27200320023 1. Measure the terminal voltage under each condition. 2. With the ECU connected to the harness and the probe inserted into rear of the harness connector, measure the voltage between terminal No.6 (earth terminal) and each terminal.
• Page 932
  27-28 REAR AXLE – Rear Differential Lock REAR DIFFERENTIAL LOCK AIR PUMP CHECK Battery (–) 27200310020 1. Install air hose to the differential. Battery (+) 2. Connect a pressure gauge to the air pump discharge T-joint outlet nozzle, via the air hose and T-joint. 3.
• Page 933
  27-29 REAR AXLE – Differential Carrier DIFFERENTIAL CARRIER 27200200068 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Differential Gear Oil Draining Axle Shaft Assembly Installation (Refer to P.27-16.) Axle Shaft Assembly Removal (Refer to P.27-16.) Differential Gear Oil Filling (Refer to P.27-10.) 49 Nm Sealant: 3M ATD Part No.8661 or equivalent…
• Page 934
  27-30 REAR AXLE – Differential Carrier AB» DIFFERENTIAL CARRIER REMOVAL Remove the attaching nuts and strike the lower part of differential carrier assembly with a piece of timber several times to loosen, then remove the assembly. Caution Use care not to strike the companion flange. INSTALLATION SERVICE POINT «AA PROPELLER SHAFT INSTALLATION Align the mating marks on the flange yoke and the companion…
• Page 935
  27-31 REAR AXLE – Differential Carrier DRIVE GEAR RUNOUT 1. Measure the drive gear runout at the shoulder on the reverse side of the drive gear. Limit: 0.05 mm 2. If the runout exceeds the limit value, check that there is no foreign material between the reverse side of the drive gear and the differential case, or that there is no looseness in the drive gear mounting bolt.
• Page 936
  27-32 REAR AXLE – Differential Carrier 2. Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once MB990939 in the reverse direction) while applying a load to the drive gear, so that the revolution torque (approximately 2.5 –…
• Page 937
  27-33 REAR AXLE – Differential Carrier DISASSEMBLY 27200220040 <VEHICLES WITHOUT REAR DIFFERENTIAL LOCK> <Conventional differential> 6 14 13 10 11 12 29 11 13 14 20 21 22 23 24 17 25 <Limited slip differential> Disassembly steps D Inspection before disassembly 16.
• Page 938
  27-34 REAR AXLE – Differential Carrier <VEHICLES WITH REAR DIFFERENTIAL LOCK> 22 23 28 21 19 20 26 27 31 16 17 Disassembly steps D Inspection before disassembly 17. Washer AG» (P.27-30.) 18. Drive pinion assembly 1. Lock plate 19. Drive pinion front shim (For adjusting AA»…
• Page 939
  27-35 REAR AXLE – Differential Carrier DISASSEMBLY SERVICE POINTS AA» SIDE BEARING NUT REMOVAL MB990201 NOTE Keep the right and left side bearings and side bearing nuts separate, so that they do not become mixed at the time of reassembly. AB»…
• Page 940
  27-36 REAR AXLE – Differential Carrier AF» SELF-LOCKING NUT REMOVAL MB990850 AG» DRIVE PINION ASSEMBLY REMOVAL 1. Make the mating marks to the drive pinion and companion flange. Caution Do not make mating marks on the contact surfaces of the companion flange and propeller shaft. 2.
• Page 941
  27-37 REAR AXLE – Differential Carrier INSPECTION 27200210016 DIFFERENTIAL PRELOAD CHECK MB990992 1. Use the special tool to measure the differential preload. Standard value: <When installing a new clutch plate> 39 – 74 Nm <When reinstalling the current clutch plate> 25 –…
• Page 942
  27-38 REAR AXLE – Differential Carrier REASSEMBLY 27200230043 <VEHICLES WITHOUT REAR DIFFERENTIAL LOCK> <Conventional differential> 19 Nm 69 – 78 Nm 216 Nm 9 10 2 6 5 4 19 Nm 78 – 88 Nm <Limited slip differential> 19 Nm 19 Nm 78 –…
• Page 943
  27-39 REAR AXLE – Differential Carrier <VEHICLES WITH REAR DIFFERENTIAL LOCK> 19 Nm 3.7 – 7.8 Nm 15 Nm 19 Nm 69 – 78 Nm 9 Nm 19 Nm 36 Nm 25 24 216 Nm 78 – 88 Nm Reassembly steps 1.
• Page 944
  27-40 REAR AXLE – Differential Carrier Lubrication and Adhesive Points <Conventional differential> <Limited slip differential or rear differential lock> Adhesive: 3M Stud Locking 4170 or equivalent DISASSEMBLY SERVICE POINTS «AA DRIVE PINION REAR BEARING OUTER RACE MB990938 PRESS-FITTING MB990936 <2WD> MB990937 <4WD>…
• Page 945
  27-41 REAR AXLE – Differential Carrier «CA DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedures: 1. Apply multipurpose grease to the washer of the special Drive pinion For vehicles tool. attachment with 4WD, 2. Install special tools and drive pinion front and rear bearing replace with inner races to the gear carrier in the sequence shown MB991169.
• Page 946
  27-42 REAR AXLE – Differential Carrier 9. Install the bearing cap, and then use a cylinder gauge to measure the inside diameter (D) of the bearing cap. 10. Calculate the thickness (F) of the required drive pinion rear shim by the following formula, and then select a shim which most closely matches this thickness.
• Page 947
  27-43 REAR AXLE – Differential Carrier Height of drive pinion spacer mm Identification colour 56.67 – 57.01 White 5. Remove the companion flange and drive pinion again. Then insert the drive pinion front bearing inner race into the gear carrier and use the special tool to press-fit the MB990727 oil seal.
• Page 948
  27-44 REAR AXLE – Differential Carrier «EA DIFFERENTIAL GEAR BACKLASH ADJUSTMENT Adjust the differential gear backlash by the following procedure. 1. Assemble the side gears, side gear thrust spacers, pinion gears, and pinion washers into the differential case. 2. Temporarily install the pinion shaft. NOTE Do not assemble the thrust block and lock pin yet.
• Page 949
  27-45 REAR AXLE – Differential Carrier 3. Apply the specified adhesive to the threaded holes of the drive gear. Specified adhesive: 3M Stud Locking 4170 or equivalent 4. Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the specified torque in a diagonal sequence.
• Page 950
  27-46 REAR AXLE – Differential Carrier 3. Using the special tool (MB990201), adjust the backlash When backlash is to standard value by moving the side bearing nut as insufficient shown. Tighten Loosen NOTE First turn the side bearing nut for loosening, and then turn (by the same amount) the side bearing nut for tightening.
• Page 951
  27-47 REAR AXLE – Differential Case Assembly DIFFERENTIAL CASE ASSEMBLY 27200240039 DISASSEMBLY AND REASSEMBLY Gear oil: MITSUBISHI Genuine Gear Oil Part No. 8149630EX, CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD (GL-5, SAE 80W-90) or equivalent Caution Apply the specified gear oil to each component especially careful to coat contact surfaces and sliding surfaces.
• Page 952
  27-48 REAR AXLE – Differential Case Assembly DISASSEMBLY SERVICE POINT AA» SCREW REMOVAL 1. Check the mating marks. NOTE The mating marks are represented by one of the following methods. (1) Engraving by a punch or electric pen. (2) Identical arabic numerals. 2.
• Page 953
  27-49 REAR AXLE – Differential Case Assembly 3. Assemble the pressure ring’s internal components (differential pinion shaft and pressure ring) and the friction discs and friction plates, and then as shown in the figure, measure the overall width. 4. Calculate the total value (A) of the thickness of the spring plates plus the value measured in (3) above.
• Page 954
  27-50 REAR AXLE – Differential Case Assembly 12. Install the thrust washer as shown in the figure, and then select a thrust washer so that the difference between the left and right dimensions from the pressure ring rear face to the thrust washer end face is the standard value. Standard value: 0 –…
• Page 955
  27-51 REAR AXLE – Differential Case Assembly «CA DIFFERENTIAL PRELOAD INSPECTION FOR LIMITED SLIP DIFFERENTIAL MB990992 1. After assembly, in order to check the frictional force of the clutch plate, use the special tools to measure the starting torque. Standard value: <When a new clutch plate is used>…
• Page 956
  27-52 REAR AXLE – Differential Case Assembly INSPECTION 27200250056 Friction disc DIFFERENTIAL CASE COMPONENT CONTACT SLIDING SURFACE INSPECTION 1. Clean the disassembled parts with cleaning oil and dry them with compressed air. 2. Check the following items for each plate and disc and Friction plate for the pressure ring.
• Page 957
  SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-98E27-501 Date <Model> <M/Y> 1998-11-15 CORRECTION TO THICKNESS OF (EC,EXP) L200 97-10 Subject: DIFFERENTIAL CASE FRICTION DISC (K60,70) Group: REAR AXLE Draft No.: 98SY070316 OVERSEAS CORRECTION…
• Page 958
  27-48 REAR AXLE — Differential Case Assembly DISASSEMBLY SERVICE POINT ! ! ! ! » » » » SCREW REMOVAL 1. Check the mating marks. NOTE The mating marks are represented by one of the following methods. (1) Engraving by a punch or electric pen. (2) Identical Arabic numerals.
• Page 959
  WHEEL AND TYRE Click on the applicable bookmark to selected the required model year…
• Page 961
  31-2 WHEEL AND TYRE – General Information/Service Specifications GENERAL INFORMATION 31100010146 Both steel type and aluminium type wheels have been adopted. The type of wheel used depends on the vehicle model. Items Wheel Type Steel type Steel type Aluminium type Size 14 x 6JJ 16 x 6JJ…
• Page 962
  31-3 WHEEL AND TYRE – Troubleshooting TROUBLESHOOTING 31100070083 Symptom Probable cause Remedy Reference page Rapid wear at Under-inflation Adjust the tyre 31-4. shoulders or lack of rotation pressure. Rapid wear at Over-inflation or centre lack of rotation Cracked treads Under-inflation Adjust the tyre 31-4.
• Page 963
  31-4 WHEEL AND TYRE – On-vehicle Service/Wheel and Tyre ON-VEHICLE SERVICE 31100090034 TYRE INFLATION PRESSURE CHECK Check the inflation pressure of the tyres. If it is not within the standard value, make the necessary adjustment. TYRE WEAR CHECK 31100100034 Measure the tread depth of tyres. Limit: 1.6 mm If the remaining tread depth is less than the limit, replace the tyre.
• Page 966
  31-1 WHEEL AND TYRE – General/General Information GROUP 31 WHEEL AND TYRE GENERAL OUTLINE OF CHANGE New 16-inch aluminium wheels has been adopted. <Vehicles with o > ver fender GENERAL INFORMATION Items Items Vehicle with over fender Vehicle with over fender Wheel Type Aluminium type…
• Page 967
  NOTES…
• Page 968
  POWER PLANT MOUNT Click on the applicable bookmark to selected the required model year…
• Page 970
  32-2 POWER PLANT MOUNT – General Information GENERAL INFORMATION 32100010129 2WD vehicles An engine and transmission support method (the 1 place at the transmission.) 3-point support method) by which insulators are The No. 2 crossmember is bolted to the frame and used at three places (2 places at the engine itself, supports the transmission.
• Page 971
  32-3 POWER PLANT MOUNT – Front Engine Mounting FRONT ENGINE MOUNTING 32100110140 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Cleaner Assembly Removal and Installation (Refer to GROUP 15.) Front Under Cover Removal and Installation <4D56-2WD> <4G6> 10 Nm 25 Nm <4D56-4WD>…
• Page 972
  32-4 POWER PLANT MOUNT – Front Engine Mounting INSTALLATION SERVICE POINT «AA FRONT ENGINE SUPPORT INSULATOR INSTALLATION Make sure that the locating boss and hole are in alignment. Caution Do not distort rubber portions, and never stain rubber portions with fuel or oil. INSPECTION 32100120075 Check insulators for cracks, separation or deformation.
• Page 973
  32-5 POWER PLANT MOUNT – Rear Engine Mounting REAR ENGINE MOUNTING 32100110157 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Under Cover and Transfer Case Protector <4WD> Removal and Installation <2WD> 22 Nm 22 Nm <M/T> <A/T> 20 – 25 Nm 20 –…
• Page 974
  32-6 POWER PLANT MOUNT – Rear Engine Mounting REMOVAL SERVICE POINTS AA» NO. 2 CROSSMEMBER REMOVAL Remove the No. 2 crossmember while supporting the transmission with a transmission jack. AB» TRANSFER ROLL STOPPER REMOVAL Remove the transfer roll stopper while supporting the transmission with a transmission jack.
• Page 975
  32-7 POWER PLANT MOUNT – Rear Engine Mounting INSPECTION <2WD> 32100120082 756 0.5 Check insulators for cracks, separation or deformation. Check transfer mounting bracket for deformation or corrosion. Check transfer support bracket for deformation or 98 0.5 corrosion. Check No. 2 crossmember for deformation or corrosion. <4WD>…
• Page 976
  32-8 POWER PLANT MOUNT – Front Differential Mounting FRONT DIFFERENTIAL MOUNTING 32100170032 REMOVAL AND INSTALLATION Pre-removal and Post installation Operation Front Under Cover and Skid Plate Removal and Installation 45 Nm 95 Nm 95 Nm 90 Nm 70 Nm 36 Nm Removal steps AA»…
• Page 977
  Front Differential Mounting/ 32-9 POWER PLANT MOUNT – Front Suspension Crossmember INSPECTION 32100180028 Check the differential mounting brackets for deformation and damage. Check the differential support bracket for deformation and damage. Check insulators for cracks, separation or deformation. Check differential mounting rubber for cracks and damage. FRONT SUSPENSION CROSSMEMBER 32100350016 REMOVAL AND INSTALLATION…
• Page 978
  NOTES…
• Page 979
  FRONT SUSPENSION Click on the applicable bookmark to selected the required model year…
• Page 981
  33A-2 FRONT SUSPENSION – General Information GENERAL INFORMATION 33200010105 The front suspension on 2WD vehicles is an front suspension vehicles independent suspension system having the double independent suspension having double wishbone combined with the coil spring, while the wishbone combined with the torsion bar spring. COIL SPRING <2WD>…
• Page 982
  33A-3 FRONT SUSPENSION – Service Specifications/Sealant SERVICE SPECIFICATIONS 33200030088 Items Standard value Limit Toe-in At the centre of tyre thread mm 0 – 7 – Toe-angle 0_ – 0_19’ – (per wheel) ( er wheel) 0_ – 0_16’ – <Vehicles with 205/80 R16 tyre>…
• Page 983
  33A-4 FRONT SUSPENSION – Special Tools SPECIAL TOOLS 33200060070 Tool Number Name MB990792 Front coil spring Front suspension coil spring compression compressor <2WD> MB991406 Steering linkage puller Upper or lower arm ball joint disconnection MB990968 Torque wrench Upper arm ball joint rotation torque measurement MB990326 Preload socket…
• Page 984
  33A-5 FRONT SUSPENSION – Special Tools Tool Number Name MB991522 Torsion bar bushing Lower arm bushing (A) removal and remover and installer press-fitting <4WD> MB990883 Rear suspension Lower arm bushing (B) removal and bushing arbor press-fitting <4WD> MB990957 Lower arm bushing remover and installer A: MB990971 A: Base…
• Page 985
  33A-6 FRONT SUSPENSION – On-vehicle Service ON-VEHICLE SERVICE 33100090113 FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT Measure the wheel alignment with the vehicle parked on a level surface. The front suspension, steering system, and wheels should be serviced to normal condition prior to measurement of wheel alignment.
• Page 986
  33A-7 FRONT SUSPENSION – On-vehicle Service 2. Increase or decrease shims between upper arm shaft and crossmember to adjust the camber and caster. (Refer to Charts for Shim Increase or Decrease.) Caution 1. Difference in shim thickness between front and rear must be 4 mm or less.
• Page 987
  33A-8 FRONT SUSPENSION – On-vehicle Service <4WD> Standard value: Camber 0_10’ – 1_10’ (Difference between right and left within 30’) Caster 1_15’ – 3_15’ (Difference between right and left within 30’) If the standard value is not obtained, make adjustment by the following procedure.
• Page 988
  33A-9 FRONT SUSPENSION – On-vehicle Service Charts for Shim Increase or Decrease HOW TO USE CHARTS EXAMPLE These charts show how shims are added to or To decrease camber by 30’ and caster by 40’, removed from existing shims. increase combined front side shim thickness by 3 mm and increase combined rear side shim thickness by 2 mm.
• Page 989
  33A-10 FRONT SUSPENSION – Shock Absorber and Upper Arm <2WD> SHOCK ABSORBER AND UPPER ARM <2WD> 33200250026 REMOVAL AND INSTALLATION Post-installation Operation Front Wheel Alignment Check and Adjustment (Refer to P.33A-6.) 98 – 118 Nm 12 Nm 15 Nm 74 Nm Upper arm ball joint Sealant:…
• Page 990
  33A-11 FRONT SUSPENSION – Shock Absorber and Upper Arm <2WD> REMOVAL SERVICE POINTS AA» UPPER ARM BALL JOINT DISCONNECTION 1. Install the special tool to compress the coil spring slightly. MB990792 2. Use the special tool to disconnect the upper arm ball joint from the knuckle.
• Page 991
  33A-12 FRONT SUSPENSION – Shock Absorber and Upper Arm <2WD> INSPECTION 33200260029 MB990968 UPPER ARM BALL JOINT STARTING TORQUE CHECK MB990326 1. After shaking the upper arm ball joint stud several times, install the nut to the stud and use the special tool to measure the starting torque of the upper arm ball joint.
• Page 992
  33A-13 FRONT SUSPENSION – Shock Absorber and Upper Arm <4WD> SHOCK ABSORBER AND UPPER ARM <4WD> 33200250033 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to GROUP 35A – On-vehicle Service.) Front Wheel Alignment Check and Adjustment (Refer to P.33A-6.) 25 Nm…
• Page 993
  33A-14 FRONT SUSPENSION – Shock Absorber and Upper Arm <4WD> REMOVAL SERVICE POINTS AA» ANCHOR ARM ASSEMBLY ADJUSTING NUT LOOSENING Loosen the anchor arm bolt of the torsion bar all the way. NOTE When the anchor arm assembly installation nut is loosened, use a jack to support the lower arm of the side to be loosened, thus the work easier.
• Page 994
  33A-15 FRONT SUSPENSION – Shock Absorber and Upper Arm <4WD> «CA SHOCK ABSORBER INSTALLATION Install the shock absorber so that the distance (A) shown in the illustration is at the standard value. Standard value (A): 1 – 2 mm INSPECTION 33200260036 MB990968 UPPER ARM BALL JOINT STARTING TORQUE CHECK…
• Page 995
  Lower Arm, Coil Spring and 33A-16 FRONT SUSPENSION – Strut Bar <2WD> LOWER ARM, COIL SPRING AND STRUT BAR <2WD> 33200280032 REMOVAL AND INSTALLATION Pre-removal Post-installation Operation Under Cover Removal Front Wheel Alignment Check and Adjustment (Refer to P.33A-6.) Under Cover Installation 15 Nm 74 –…
• Page 996
  Lower Arm, Coil Spring and 33A-17 FRONT SUSPENSION – Strut Bar <2WD> REMOVAL SERVICE POINT AA» LOWER ARM BALL JOINT DISCONNECTION 1. Install the special tool to compress the coil spring slightly. MB990792 2. Use the special tool to disconnect the lower ball joint from the knuckle.
• Page 997
  Lower Arm, Coil Spring and 33A-18 FRONT SUSPENSION – Strut Bar <2WD> INSPECTION 33200290028 LOWER ARM BALL JOINT END PLAY Check the lower arm ball joint assembly end play by following the steps below. 1. Measure the lower arm ball joint assembly end play with a dial indicator.
• Page 998
  33A-19 FRONT SUSPENSION – Lower Arm and Torsion Bar <4WD> LOWER ARM AND TORSION BAR <4WD> 33200280049 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover and Skid Plate Removal Front Wheel Alignment Check and Adjustment (Refer to P.33A-6.) Under Cover and Skid Plate Installation 44 Nm 88 –…
• Page 999
  33A-20 FRONT SUSPENSION – Lower Arm and Torsion Bar <4WD> REMOVAL SERVICE POINT AA» LOWER ARM BALL JOINT DISCONNECTION MB991406 Caution 1. Use the special tool to loosen the nut only do not Cord remove it from the ball joint. 2.
• Page 1000
  33A-21 FRONT SUSPENSION – Lower Arm and Torsion Bar <4WD> 2. With the vehicle in an unladen condition, measure the distance from the bump stopper to the bump stopper bracket to check if it is at the standard value. Standard value (A): 71 – 73 mm 3.
• Page 1001
  33A-22 FRONT SUSPENSION – Lower Arm and Torsion Bar <4WD> NOTE Front of vehicle Install the lower arm bushing (A) in a arrow direction. LOWER ARM BUSHING (B) REPLACEMENT 33200810064 MB990883 1. Remove the lower arm bushing (B) from the lower arm by using special tools.
• Page 1002
  33A-23 FRONT SUSPENSION – Stabilizer Bar <4WD> STABILIZER BAR <4WD> 33200400049 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover and Skid Plate Removal and Installation 12 Nm 12 Nm Removal steps «AA D Stabilizer link assembly mounting nut 3. Stabilizer bracket adjustment 4.
• Page 1003
  NOTES…
• Page 1004
  REAR SUSPENSION Click on the applicable bookmark to selected the required model year…
• Page 1006
  34-2 REAR SUSPENSION – General Information/Service Specifications GENERAL INFORMATION 34100010123 The leaf spring type of rear suspension has been noise transmitted to the body during off-road driving adopted. The leaf spring is secured to the rear are reduced by the bump stopper. axle housing by U-bolts, so that the vibration and The shock absorbers have a bias arrangement.
• Page 1007
  34-3 REAR SUSPENSION – On-vehicle Service ON-VEHICLE SERVICE 34101100034 REAR WHEEL ALIGNMENT The rear suspension assembly must be free of worn, loose or damaged parts prior to measurement of rear wheel alignment. Standard value: Toe-in 0 mm Camber 0_ NOTE Toe-in and camber are set at the factory and cannot be adjusted.

• Page 1008: Rear Suspension Assembly

  34-4 REAR SUSPENSION – Rear Suspension Assembly REAR SUSPENSION ASSEMBLY 34100100011 REMOVAL AND INSTALLATION Pre-removal Operation Support the axle housing with a jack 22 Nm* 52 Nm* 157 Nm* 98 – 118 Nm Removal steps 1. Parking brake cable attaching bolt 9.

• Page 1009
  BASIC BRAKE SYSTEM Click on the applicable bookmark to selected the required model year…
• Page 1010
  35A-2 BASIC BRAKE SYSTEM CONTENTS 35109000197 GENERAL INFORMATION ….Load Sensing Spring Length Check and Adjustment ……. . . SERVICE SPECIFICATIONS .
• Page 1011
  35A-3 BASIC BRAKE SYSTEM – General Information GENERAL INFORMATION 35100010120 The brake system has high reliability and durability The following type of brake have been adopted. which maintains excellent braking performance and Front: Floating caliper, 2-piston, ventilated disc brakes (V4-W43, V5-W43) or floating caliper, braking feeling.

• Page 1012: Configuration Diagram

  35A-4 BASIC BRAKE SYSTEM – General Information CONFIGURATION DIAGRAM <L.H. drive vehicles> Load sensing proportioning valve Brake booster Rear brake Front brake Rear brake Master cylinder Front brake <R.H. drive vehicles> Load sensing proportioning valve Rear brake Brake booster Master cylinder Rear brake Front brake…

• Page 1013
  35A-5 BASIC BRAKE SYSTEM – Service Specifications SERVICE SPECIFICATIONS 35100030119 Items Standard value Limit Brake pedal height mm 176 – 181 – Brake pedal free play mm 3 – 8 – Brake pedal to floor board clearance mm 95 or more –…
• Page 1014
  35A-6 BASIC BRAKE SYSTEM – Lubricants/Sealants/Special Tools LUBRICANTS 35100040105 Items Specified lubricant Brake fluid DOT3 or DOT4 Brake piston seal Repair kit grease Guide pin boot inner surface Lock pin boot inner surface Piston boot mounting grooves Brake piston boot inner surface Lock pin bush inner surface Piston cup surface Rear brake shoe and backing plate contact surface…
• Page 1015
  35A-7 BASIC BRAKE SYSTEM – Troubleshooting TROUBLESHOOTING 35100070081 Symptom Probable cause Remedy Vehicle pulls to one side Grease or oil on pad or lining surface Replace when brakes are applied when brakes are a lied Inadequate contact of pad or lining Correct Auto adjuster malfunction Adjust…
• Page 1016
  35A-8 BASIC BRAKE SYSTEM – Troubleshooting Symptom Probable cause Remedy Insufficient parking brake function Worn brake lining or pad Replace Grease or oil on lining or pad surface Parking brake cable sticking Stuck wheel cylinder or caliper piston Excessive parking brake lever stroke Adjust the parking brake lever stroke or check the parking brake cable routing Auto adjuster malfunction…
• Page 1017
  35A-9 BASIC BRAKE SYSTEM – Troubleshooting Symptom Probable cause Remedy Squealing noise Bent or warped backing plate causing interference with drum Replace when brakes are when brakes are Drum brakes – Weak, damaged or incorrect shoe-to-shoe not applied spring Poor return of brake booster, master cylinder or wheel cylinder Loose or extra parts in brakes Retighten…
• Page 1018
  35A-10 BASIC BRAKE SYSTEM – On-vehicle Service ON-VEHICLE SERVICE 35100090131 BRAKE PEDAL CHECK AND ADJUSTMENT Stop lamp BRAKE PEDAL HEIGHT Operating switch 1. Turn back the carpet etc. under the brake pedal. 2. Measure the brake pedal height as illustrated. If it is not Stop lamp Operating switch lock nut…
• Page 1019
  35A-11 BASIC BRAKE SYSTEM – On-vehicle Service CREARANCE BETWEEN BRAKE PEDAL AND FLOOR BOARD 1. Turn back the carpet etc. under the brake pedal. 2. Start the engine, depress the brake pedal with approximately 490 N of force, and measure the clearance between the brake pedal and the floorboard.
• Page 1020
  35A-12 BASIC BRAKE SYSTEM – On-vehicle Service 3. With the engine running, step on the brake pedal and then stop the engine. No good Good Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective.
• Page 1021
  35A-13 BASIC BRAKE SYSTEM – On-vehicle Service 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.
• Page 1022
  35A-14 BASIC BRAKE SYSTEM – On-vehicle Service 2. While the lever of the load sensing proportioning valve Hole Lever is touching the stopper bolt, install the spring support so that the distance (A) from the edge of the spring mounting section of the lever to the place on the spring Spring support support shown in the illustration is at the standard value.
• Page 1023
  35A-15 BASIC BRAKE SYSTEM – On-vehicle Service DISC BRAKE PAD CHECK AND When new When worn REPLACEMENT 35100150129 NOTE 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. Brake disc Wear indicator 1.
• Page 1024
  35A-16 BASIC BRAKE SYSTEM – On-vehicle Service FRONT DISC BRAKE ROTOR CHECK 35100270061 CAUTION When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation. Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.
• Page 1025
  35A-17 BASIC BRAKE SYSTEM – On-vehicle Service (3) If the play does not exceed the standard value specification, install the brake disc at a position 180_ away from the chalk mark, and then check the run-out of the brake disc once again. 5.
• Page 1026
  35A-18 BASIC BRAKE SYSTEM – On-vehicle Service BRAKE DRUM INSIDE DIAMETER CHECK 35100320124 1. Remove the brake drum. 2. Measure the inside diameter of the brake drum at two or more locations. Standard value: <2WD> 254.0 mm <4WD> 270.0 mm Limit: <2WD>…

• Page 1027: Brake Pedal

  35A-19 BASIC BRAKE SYSTEM – Brake Pedal BRAKE PEDAL 35100340182 REMOVAL AND INSTALLATION Post-installation Operation Brake Pedal Adjustment (Refer to P.35A-10.) 30 Nm 22 Nm 14 Nm Removal steps 1. Stop lamp switch 7. Brake pedal 2. Brake pedal return spring 8.

• Page 1028
  35A-20 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER 35100370150 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-12.) Brake Pedal Adjustment (Refer to P.35A-10.) <4D56-L.H.
• Page 1029
  35A-21 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster INSTALLATION SERVICE POINTS «AA VACUUM HOSE CONNECTION Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting, and then secure by using the hose clip. «BA CLEARANCE ADJUSTMENT BETWEEN BRAKE BOOSTER PUSH ROD AND PRIMARY PISTON Calculate clearance A from the B, C and D measurements.
• Page 1030
  35A-22 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster MASTER CYLINDER 35100420114 DISASSEMBLY AND REASSEMBLY Master cylinder kit 2.5 Nm Brake fluid: DOT3 or DOT4 Disassembly steps 1. Reservoir cap assembly 10. Gasket AA» 2. Reservoir cap 11. Piston stopper ring 3.
• Page 1031
  35A-23 BASIC BRAKE SYSTEM – Load Sensing Proportioning Valve LOAD SENSING PROPORTIONING VALVE 35100540018 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-12.) 15 Nm Removal steps 1. Spring holder Caution «AA 2.
• Page 1032
  35A-24 BASIC BRAKE SYSTEM – Front Disc Brake FRONT DISC BRAKE 35100600112 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-12.) <2WD> 90 Nm 15 Nm 15 Nm <4WD> 90 Nm 15 Nm 90 Nm Removal steps…
• Page 1033
  35A-25 BASIC BRAKE SYSTEM – Front Disc Brake INSTALLATION SERVICE POINT «AA FRONT BRAKE ASSEMBLY INSTALLATION 1. Measure hub torque (A) with pad removed to measure brake drag torque after pad installation. 2. Securely attach the pad clip to the caliper support. Caution For the vehicles with 4WD, engage 2WD before measurement.
• Page 1034
  35A-26 BASIC BRAKE SYSTEM – Front Disc Brake DISASSEMBLY AND REASSEMBLY 35100620132 <2WD> (Repair kit grease) 74 Nm 8 Nm 74 Nm Caution (Repair kit The piston seal inside the seal grease) and boot kit is coated with special grease, so do not wipe this grease off.
• Page 1035
  35A-27 BASIC BRAKE SYSTEM – Front Disc Brake <4WD> (Repair kit grease) 74 Nm 8 Nm (Repair kit grease) Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off. (Repair kit grease) Brake fluid: DOT3 or DOT4…
• Page 1036
  35A-28 BASIC BRAKE SYSTEM – Front Disc Brake DISASSEMBLY SERVICE POINTS When disassembling the front disc brakes, disassemble both sides (left and right) as a set. AA» PISTON BOOT/PISTON REMOVAL Protect caliper body with cloth. Blow compressed air through brake hose to remove piston boot and piston. Caution Blow compressed air gently.
• Page 1037
  35A-29 BASIC BRAKE SYSTEM – Front Disc Brake INSPECTION 35100630104 Check cylinder for wear, damage or rust. Check piston surface for wear, damage or rust. Check caliper body or sleeve for wear. Check pad for damage or adhesion of grease, check backing metal for damage.
• Page 1038
  35A-30 BASIC BRAKE SYSTEM – Rear Drum Brake REAR DRUM BRAKE 35100750091 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Loosening the Parking Brake Cable Adjusting Nut. Brake Fluid Filling and Air Bleeding (Refer to Brake Fluid Draining P.35A-12 or GROUP 35B – On-vehicle Service.) Parking Brake Lever Stroke Adjustment (Refer to GROUP 36 –…
• Page 1039
  35A-31 BASIC BRAKE SYSTEM – Rear Drum Brake REMOVAL SERVICE POINT Pin of shoe assembly AA» RETAINER REMOVAL Use a flat-tipped screwdriver or the like to open up the retainer joint, and remove retainer. Retainer INSTALLATION SERVICE POINTS «AA WAVE WASHER INSTALLATION Shoe assembly Washer Install the washer in the direction shown in the illustration.
• Page 1040
  35A-32 BASIC BRAKE SYSTEM – Rear Drum Brake WHEEL CYLINDER 35100770080 DISASSEMBLY AND REASSEMBLY Grease Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Wheel cylinder repair kit 8 Nm Disassembly steps 1. Boots 2. Piston assembly «AA 3. Pistons «AA 4.
• Page 1041
  35A-33 BASIC BRAKE SYSTEM – Rear Drum Brake REASSEMBLY SERVICE POINT «AA PISTON CUP/PISTON REASSEMBLY MB990623 (1) Use alcohol or specified brake fluid to clean the wheel cylinder and the piston. (2) Apply the specified brake fluid to the piston cups and the special tool.
• Page 1042
  NOTES…
• Page 1043
  35A-1 BASIC BRAKE SYSTEM – General/Front Disc Brake GROUP 35A BASIC BRAKE SYSTEM GENERAL OUTLINE OF CHANGE The following service procedures have been established due to the changes of 16-inch 2-pot disc brake <Vehicles with over fender>. FRONT DISC BRAKE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation…
• Page 1044
  35A-2 BASIC BRAKE SYSTEM – Front Disc Brake DISASSEMBLY AND REASSEMBLY 7.9 ± 1.0 N·m Shim set Clip set 27 ± 4 N·m Grease Brake caliper kit Seal and boots kit Pad set Caliper assembly disassembly Pad assembly disassembly steps steps 1.
• Page 1045
  35A-3 BASIC BRAKE SYSTEM – BASIC BRAKE SYSTEM – Front Disc Brake Front Disc Brake LUBRICATION POINTS Grease: Repair kit grease Caution The piston seal inside the seal and boot kit is coated with a special grease, so do not wipe this grease off. Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Grease: Repair kit grease…
• Page 1046
  NOTES…
• Page 1047
  ANTI-SKID BRAKING SYSTEM (ABS) <2WD> Click on the applicable bookmark to selected the required model year…
• Page 1049
  35B-2 Bleeding ……..Motor Relay and Valve Relay Continuity Check .
• Page 1050
  35B-3 ABS <2WD> – General Information GENERAL INFORMATION 35200010123 The ABS consists of wheel speed sensors, stop OFF. (However, it will be erased if the battery is lamp switch hydraulic unit and the ABS-ECU. If disconnected.) a problem occurs in the system, the malfunctioning In addition, reading of diagnosis codes and data system can be identified by means of the diagnosis list and actuator testing are possible using the…
• Page 1051
  35B-4 ABS <2WD> – Service Specifications/Lubricants/Sealants/Special Tools SERVICE SPECIFICATIONS 35200030136 Items Standard value Limit Booster push rod to master cylinder piston clearance mm Diesel-powered vehicles 0.70 – 1.10 – Petrol-powered vehicles 0.90 – 1.30 – Front disc brake pad thickness mm Hydraulic unit solenoid valve internal resistance Ω…
• Page 1052
  35B-5 ABS <2WD> – Troubleshooting TROUBLESHOOTING 35201110143 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. NOTES WITH REGARD TO DIAGNOSIS The phenomena listed in the following table are not abnormal. Phenomenon Explanation of phenomenon System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment, but this is because the system operation check is being…
• Page 1053
  35B-6 ABS <2WD> – Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES 35201130156 Inspect according to the inspection chart that is appropriate for the malfunction code. Diagnosis Inspection item Diagnosis content Reference page code No. Front right wheel speed sensor Open or short circuit 35B-7 Front left wheel speed sensor Rear right wheel speed sensor…
• Page 1054
  35B-7 ABS <2WD> – Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11, 12, 13, 14 Wheel speed sensor open circuit Probable cause or short circuit Code No. 21, 22, 23, 24 Wheel speed sensor abnormal D Malfunction of wheel speed sensor The ABS-ECU determines that an open circuit or short circuit occurs in more than D Malfunction of wiring harness or connector one line of wheel speed sensors.
• Page 1055
  35B-8 ABS <2WD> – Troubleshooting Code No. 15 Wheel speed sensor (Abnormal output signal) Probable cause D Improper installation of wheel speed sensor A wheel speed sensor outputs an abnormal signal (other than an open or short-circuit). D Malfunction of wheel speed sensor D Malfunction of rotor D Malfunction of wheel bearing D Malfunction of wiring harness or connector…
• Page 1056
  35B-9 ABS <2WD> – Troubleshooting Code No. 33 Stop lamp switch system Probable cause D Malfunction of stop lamp switch These codes are output at the following times: D When the stop lamp switch is not be turned off (when the stop lamp switch stays D Malfunction of harness or connector D Malfunction of ABS-ECU on for 15 minutes or more although the ABS is not operating)
• Page 1057
  35B-10 ABS <2WD> – Troubleshooting Code No. 41, 42, 43 Solenoid valve Probable cause D Malfunction of wiring harness The ABS-ECU always monitors the solenoid valve drive circuit. It determines that D Malfunction of hydraulic unit there is an open or short-circuit in the solenoid coil or in a harness: When no current D Malfunction of ABS-ECU flows in the solenoid even though the ABS-ECU turns on it, and vice versa.
• Page 1058
  35B-11 ABS <2WD> – Troubleshooting Code No. 51 Valve relay Probable cause D Malfunction of valve relay When the ignition switch is turned to ON, the ABS-ECU switches the valve relay D Malfunction of wiring harness or connector off and on during the initial check. In that way, the ABS-ECU compares the signals D Malfunction of ABS-ECU sent to the valve relay with the voltage in the valve power monitor line.
• Page 1059
  35B-12 ABS <2WD> – Troubleshooting Code No. 53 Motor relay, motor Probable cause D Malfunction of motor relay These codes are output at the following times: D Malfunction of wiring harness or connector When the motor relay is on but no signal is input to the motor monitor line (motor D Malfunction of hydraulic unit is not operating, etc.) D Malfunction of ABS-ECU…
• Page 1060
  35B-13 ABS <2WD> – Troubleshooting ABS WARNING LAMP INSPECTION 35201200079 Petrol-powered vehicles Check that the ABS warning lamp illuminates as follows. 1. When the ignition key is turned to “ON”, the ABS warning lamp illuminates for approximately 3 seconds* and then switches off.
• Page 1061
  35B-14 ABS <2WD> – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS 35201140142 Get an understanding of the trouble symptoms and check according to the inspection procedure chart. Trouble symptoms Inspection Reference procedure No. page Communication with MUT-II Communication with all systems is not possible. 35B-15 is not possible is not ossible.
• Page 1062
  35B-15 ABS <2WD> – Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Communication with MUT-II is not possible. Probable cause (Communication with all systems is not possible.) D Malfunction of connector The reason is probably a defect in the power supply system (including earth) for D Malfunction of harness the diagnosis line.
• Page 1063
  35B-16 ABS <2WD> – Troubleshooting Inspection Procedure 3 When ignition key is turned to ”ON” (engine stopped), Probable cause ABS warning lamp does not illuminate. D Blown fuse When current flows in the ABS-ECU, the valve relay turns from off to on, off and D Burnt out ABS warning lamp bulb back to on again as the initial check.
• Page 1064
  35B-17 ABS <2WD> – Troubleshooting Inspection Procedure 5 When ignition key is turned to ”START”, ABS warning Probable cause lamp does not illuminate. D Malfunction of wiring harness or connector Current does not flow in the ABS-ECU when the ignition switch is turned to START. D Malfunction of ABS-ECU Current flows in the ABS warning lamp even when the ignition switch is turned to START.
• Page 1065
  35B-18 ABS <2WD> – Troubleshooting Inspection Procedure 7 Brake operation is abnormal. Probable cause D Improper installation of wheel speed sensor This varies depending on the driving conditions and the road surface conditions, so D Incorrect sensor harness contact problem diagnosis is difficult. However, if a normal diagnosis code is displayed, carry D Foreign material adhering to wheel speed sensor out the following inspection.
• Page 1066
  35B-19 ABS <2WD> – Troubleshooting DATA LIST REFERENCE TABLE 35201150091 The following items can be read by the MUT-II from the ABS-ECU input data. 1. When the system is normal Item No. Check item Checking requirements Normal value Front-right wheel speed sensor Perform a test run Vehicle speeds dis layed on the…
• Page 1067
  35B-20 ABS <2WD> – Troubleshooting CHECK AT ABS-ECU 35201180120 TERMINAL VOLTAGE CHECK CHART 1. Measure the voltages between terminals (15), (16), (25) and (42) (earth terminals) and each respective terminal. 2. The terminal layouts are shown in the illustrations below. Connector Signal Checking requirements…
• Page 1068
  35B-21 ABS <2WD> – Troubleshooting Connector Signal Checking requirements Normal condition terminal No. Idle-up solenoid valve (–) Ignition switch: ON (The motor is on approximately 2 V or less 1 second after engine is started.) Ignition switch Ignition switch: ON System voltage Ignition switch: START Input from diagnosis indication…
• Page 1069
  35B-22 ABS <2WD> – Troubleshooting RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS 1. Turn the ignition switch off and disconnect the ABS-ECU connectors before checking resistance and continuity. 2. Check them between the terminals indicated in the table below. 3. The terminal layouts are shown in the illustrations below. Connector terminal No.
• Page 1070
  35B-23 ABS <2WD> – On-vehicle Service ON-VEHICLE SERVICE 35200150108 BLEEDING Caution Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. Specified brake fluid: DOT3 or DOT4 MASTER CYLINDER BLEEDING The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier.
• Page 1071
  35B-24 ABS <2WD> – On-vehicle Service 2. Remove guide pin. Lift caliper assembly and retain with wires. Caution Do not wipe off the special grease that is on the lock pin or allow it to contaminate the guide pin. 3. Remove the following parts from caliper support. (1) Pad and wear indicator assembly (2) Pad assembly (3) Clip…
• Page 1072
  35B-25 ABS <2WD> – On-vehicle Service Inspecting Waveforms With An Oscilloscope Use the following method to observe the output voltage waveform from each wheel sensor with an oscilloscope. When turning by hand Start the engine, and rotate the rear wheels by engaging 1st gear (vehicles with manual transmission) or D range (vehicles with automatic transmission).
• Page 1073
  35B-26 ABS <2WD> – On-vehicle Service HYDRAULIC UNIT CHECK 35200170166 Caution Turn the ignition switch off before connecting or disconnecting the MUT-II. 1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points or place the wheels which are checked on the rollers of the braking force tester.
• Page 1074
  35B-27 ABS <2WD> – On-vehicle Service Diagnosis Table Operation Judgement Judgement Probable cause Remedy – Normal – Abnormal (1) Depress brake pedal Brake force Wheel does not Clogged brake line Check and clean to lock wheel. released for lock when brake other than hydraulic brake line (2) Using…
• Page 1075
  35B-28 ABS <2WD> – On-vehicle Service MOTOR RELAY AND VALVE RELAY Diesel-powered vehicles-L.H. CONTINUITY CHECK 35201090133 Valve relay Motor relay Motor relay Battery voltage Terminal No. Power is not supplied Power is supplied Except diesel-powered vehicles-L.H. Valve relay Valve relay Battery voltage Terminal No.
• Page 1076
  35B-29 ABS <2WD> – Master cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER 35200400159 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Battery Removal Brake Fluid Supplying Brake Fluid Draining Brake Line Bleeding (Refer to P. 35B-23.) Brake Pedal Adjustment (Refer to GROUP 35A – On-vehicle Service.) <4D56 –…
• Page 1077
  35B-30 ABS <2WD> – Master Cylinder and Brake Booster INSTALLATION SERVICE POINTS «AA VACUUM HOSE CONNECTION Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting, and then secure by using the hose clip. «BA CLEARANCE ADJUSTMENT BETWEEN BRAKE BOOSTER PUSH ROD AND PRIMARY PISTON Calculate clearance A from the B, C and D measurements.
• Page 1078
  35B-31 ABS <2WD> – Master Cylinder and Brake Booster MASTER CYLINDER 35200450109 DISASSEMBLY AND REASSEMBLY Master cylinder kit Brake fluid: DOT3 or DOT4 Disassembly steps 1. Reservoir cap assembly 11. Gasket AA» 2. Reservoir cap 12. Piston stopper ring 3. Diaphragm 13.
• Page 1079
  35B-32 ABS <2WD> – Master Cylinder and Brake Booster/Front Disc Brake INSPECTION 35200460027 Check the inner surface of master cylinder body for rust or pitting. Check the primary and secondary pistons for rust, scoring, wear, damage or wear. Check the diaphragm for cracks and wear. FRONT DISC BRAKE 35200600016 REMOVAL AND INSTALLATION…
• Page 1080
  35B-33 ABS <2WD> – Front Disc Brake INSTALLATION SERVICE POINT «AA FRONT BRAKE ASSEMBLY INSTALLATION 1. Measure hub torque (A) with pad removed to measure brake drag torque after pad installation. 2. Securely attach the pad clip to the caliper support. 3.
• Page 1081
  35B-34 ABS <2WD> – Front disc Brake DISASSEMBLY AND REASSEMBLY 35200620012 14 Nm 8 Nm Caution The piston seal inside the seal and boot kit is coated with special 74 Nm grease, so do not wipe this grease off. Brake fluid: DOT3 or DOT4 Grease Brake caliper kit Pad kit…
• Page 1082
  35B-35 ABS <2WD> – Front Disc Brake DISASSEMBLY SERVICE POINTS When disassembling the disc brakes, disassemble both sides (left and right) as a set. AA» PISTON BOOT/PISTON REMOVAL Pump in compressed air through the brake hose installation hole and remove the piston and piston boot. Caution When removing the pistons, be sure to use the handle of a plastic hammer and adjust the height of the two…
• Page 1083
  35B-36 ABS <2WD> – Front Disc Brake PAD WEAR CHECK Measure thickness at the thinnest and worn area of the pad. Replace pad assembly if pad thickness is less than the limit value. Standard value: 10 mm Limit value: 2.0 mm Caution 1.
• Page 1084
  35B-37 ABS <2WD> – Hydraulic Unit HYDRAULIC UNIT 35200860179 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Lines Bleeding (Refer to P. 35B-23.) Hydraulic Unit Checking (Refer to P. 35B-26.) 15 Nm 15 Nm 15 Nm <Diesel-powered <Except diesel-powered…
• Page 1085
  35B-38 ABS <2WD> – Hydraulic Unit REMOVAL SERVICE POINT AA» HYDRAULIC UNIT REMOVAL Caution 1. The hydraulic unit is heavy, and so care should be take when removing it. 2. The hydraulic unit is not to be disassembled; its nuts and bolts should absolutely not be loosened.
• Page 1086
  35B-39 ABS <2WD> – Wheel Speed Sensor WHEEL SPEED SENSOR 35200830163 REMOVAL AND INSTALLATION Post-installation Operation Wheel Speed Sensor Output Voltage Checking (Refer to P. 35B-24.) Front Rear 1. Front speed sensor 2. Front rotor (Refer to GROUP 26 – Front Hub.) 3.
• Page 1087
  35B-40 ABS <2WD> – Wheel Speed Sensor (3) Check the speed sensor cable for breakage, damage or disconnection; replace with a new one if a problem is found. NOTE When checking for cable damage, remove the cable clamp part from the body and then bend and pull the cable near the clamp to check whether or not temporary disconnection occurs.
• Page 1088
  35B-41 ABS <2WD> – ABS-ECU ABS-ECU 35200980141 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Driver’s Side Under Cover Removal and Installation (Refer to GROUP 52A – Instrument Panel.) Junction Block Installation Nut Removal and Installation. ABS-ECU INSPECTION 35200990106 Refer to P. 35B-20.
• Page 1089
  NOTES…
• Page 1114
  SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-00E35-001 2000-05-30 Date <Model> <M/Y> CHANGE TO ERASING OF ABS DIAGNOSTIC Subject: (EC)COLT/LANCER 96-10 CODES (CKOA,CJOA) (EC)PAJERO 95-10 (V10, 20, 30,40) (EC)L400 95-10 Group: SERVICE BRAKE Draft No.: 99AL122308…
• Page 1115
  Manual Pub. No. Language Page(s) ’97 L200 PWTE96E1 (English) 35b-5 Workshop Manual Chassis PWTS96E1 (Spanish) PWTF96E1 (French) PWTG96E1 (German) 2000 L200 PWTE96E2 (English) 35b-5 Workshop Manual Chassis PWTS96E2 (Spanish) PWTF96E2 (French) PWTG96E2 (German) 3. Effective date: Model Effective Date ABS-ECU part No. COLT/LANCER From March 1998 MR445910…
• Page 1116
  35B-6 ABS <2WD> — Troubleshooting TROUBLESHOOTING 35201110129 STANDARD FOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. NOTES WITH REGARD TO DIAGNOSIS The phenomena listed in the following table are not abnormal. Phenomenon Explanation of phenomenon System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment, but…
• Page 1117
  <New> With the MUT-II Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. When diagnostic trouble codes (Nos. 21 to 24) (for vehicle wheel speed sensor system failures) occur, normal MUT-II operation may not erase those codes. In that case, erase the diagnostic trouble codes using the following procedures.
• Page 1118
  35-36-4 SERVICEBRAKES – > ABS Troubleshooting <Vehicles built from June,1994 4. Remedy the malfunctions indicated by th diagnosis codes, disconnect the diagnosis code check harness, and then install the valve relay. Then turn the ignition switch to ON again t check the ABS warning lamp.
• Page 1119
  <New> With the MUT-II Connect the MUT-II to the diagnosis connector (16-pin), then erase the diagnosis codes. Caution Turn the ignition switch off before connecting or disconnecting the MUT-II. When diagnostic trouble codes (Nos. 21 to 24) (for vehicle wheel speed sensor system failures) occur, normal MUT-II operation may not erase those codes.
• Page 1120
  35B-7 ABS <2WD> — Troubleshooting 4. Remedy the malfunctions indicated by th diagnosis codes, disconnect the diagnosis code check harness, and then reconnect the valve relay harness. Then turn the ignition switch to ON again to check the ABS warning lamp. (Refer to P.35B-19.) If the lamp indicates a malfunction, the valve relay system may be defective.
• Page 1121
  <New> With the MUT-II Connect the MUT-II to the diagnosis connector (16-pin), then erase the diagnosis codes. Caution Turn the ignition switch off before connecting or disconnecting the MUT-II. When diagnostic trouble codes (Nos. 21 to 24) (for vehicle wheel speed sensor system failures) occur, normal MUT-II operation may not erase those codes.
• Page 1122
  35B-4 ABS <4WD> — Troubleshooting TROUBLESHOOTING 35201110501 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points NOTES WITH REGARD TO DIAGNOSIS The Phenomena listed in the following table are not abnormal. Phenomenon Explanation of phenomenon System check sound When starting the engine, a thudding sound can sometimes be hear coming from inside the engine compartment, but this is because the…
• Page 1123
  35B-5 ABS <4WD> — Troubleshooting Without the MUT-II 1. Use the special tool to earth terminal (1) (diagnosis control terminal) of the diagnosis connector. (Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.) 2. Stop the engine. 3. Turn on the stop lamp switch. 4.
• Page 1124
  35B-5 ABS <2WD> — Troubleshooting TROUBLESHOOTING 35201110143 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points NOTES WITH REGARD TO DIAGNOSIS The Phenomena listed in the following table are not abnormal. Phenomenon Explanation of phenomenon System check sound When starting the engine, a thudding sound can sometimes be hear coming from inside the engine compartment, but this is because the…
• Page 1125
  <New> With the MUT-II Connect the MUT-II to the diagnosis connector (16-pin), then erase the diagnosis codes. Caution Turn the ignition switch off before connecting or disconnecting the MUT-II. When diagnostic trouble codes (Nos. 21 to 24) (for vehicle wheel speed sensor system failures) occur, normal MUT-II operation may not erase those codes.
• Page 1126
  35B-4 ABS <2WD> — Troubleshooting WHEN USING THE ABS WARNING LAMP 1. Use the special tool to earth No.1. terminal (diagnosis control terminal) of the diagnosis connector. Diagnostic connector 2. Turn on the ignition switch. 3. Read out a diagnosis code by observing how the ABS warning lamp flashes.
• Page 1127
  35B-5 ABS <2WD> — Troubleshooting 4. After carrying out steps 1. To 3., turn the ignition switch to ON. Within 3 seconds after turning the ignition switch to ON, turn off the stop lamp <Changed> switch (release the brake). Then, turn the sto lamp switch on and off a total of 10 times.
• Page 1128
  ANTI-SKID BRAKING SYSTEM (ABS) <4WD> Click on the applicable bookmark to selected the required model year…
• Page 1130
  35C-2 For the items below, refer to GROUP For the items below, refer to GROUP 35A. 35B. SEALANTS ON-VEHICLE SERVICE Bleeding ON-VEHICLE SERVICE Disc Brake Pad Check and Replacement Brake Pedal Check and Adjustment Wheel Speed Sensor Output Voltage Check Stop Lamp Switch Inspection Hydraulic Unit Check Brake Booster Operating Test…
• Page 1131
  35C-3 ABS <4WD> – General Information GENERAL INFORMATION 35200010130 The ABS consists of wheel speed sensors, stop OFF. (However, it will be erased if the battery is lamp switch hydraulic unit and the ABS-ECU. If disconnected.) a problem occurs in the system, the malfunctioning In addition, reading of diagnosis codes and data system can be identified by means of the diagnosis list and actuator of testing are possible using the…
• Page 1132
  35C-4 ABS <4WD> – Service Specification/Lubricants/Special Tools SERVICE SPECIFICATION 35200030143 Items Standard value Limit Front disc brake pad thickness mm G-sensor output voltage V When installed 2.4 – 2.6 – When removed with 3.4 – 3.6 – arrow mark facing down LUBRICANTS 35200040030…
• Page 1133
  35C-5 ABS <4WD> – Troubleshooting TROUBLESHOOTING 35101110143 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. NOTES WITH REGARD TO DIAGNOSIS The phenomena listed in the following table are not abnormal. Phenomenon Explanation of phenomenon System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment, but this is because the system operation check is being…
• Page 1134
  35C-6 ABS <4WD> – Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES 35201130163 Inspect according to the inspection chart that is appropriate for the malfunction code. Diagnosis Inspection item Diagnosis content Reference page code No. Front right wheel speed sensor Open or short circuit Refer to GROUP 35B –…
• Page 1135
  35C-7 ABS <4WD> – Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODES For diagnosis code numbers other than those listed below, refer to GROUP 35B – Troubleshooting. Code No. 25 Free wheel engage switch Probable cause D Malfunction of wiring harness or connector ABS-ECU determines that an open circuit exists in the free wheel engage switch D Malfunction of 4WD indicator-ECU system.
• Page 1136
  35C-8 ABS <4WD> – Troubleshooting Code No. 26 4WD position detection switch Probable cause D Malfunction of wiring harness or connector This code is output at the following times: D Malfunction of free wheel engage switch ABS-ECU determines that an open circuit exists in the 4WD detection switch system. D Malfunction of 4WD indicator-ECU The free wheel engage switch is off and the 4WD detection switch is on at a vehicle D Malfunction of 4WD position detection switch…
• Page 1137
  35C-9 ABS <4WD> – Troubleshooting Code No. 27 Rear differential lock detection switch Probable cause <Vehicles with rear differential lock> D Malfunction of wiring harness or connector The ABS-ECU determines that an open circuit occurs in rear differential detection D Malfunction of rear differential lock-ECU switch system.
• Page 1138
  35C-10 ABS <4WD> – Troubleshooting Code No. 32 G-sensor system Probable cause D Malfunction of G-sensor This code is output at the following times: D Malfunction of wiring harness or connector The G-sensor output is less than 0.5 V or more than 4.5 V. D Malfunction of ABS-ECU An open or short circuit is present in the G-sensor system.
• Page 1139
  35C-11 ABS <4WD> – Troubleshooting DATA LIST REFERENCE TABLE 35201150107 The following items can be read by the MUT-II from the ABS-ECU input data. 1. When the system is normal Item No. Check item Checking requirements Normal value Front-right wheel speed sensor Perform a test run Vehicle speeds displayed on the…
• Page 1140
  35C-12 ABS <4WD> – Troubleshooting CHECK AT ABS-ECU 35201180137 TERMINAL VOLTAGE CHECK CHART 1. Measure the voltages between terminals (15), (16), (25) and (42) (earth terminals) and each respective terminal. NOTE Do not measure terminal voltage for approx. 3 seconds after the ignition switch is turned on. The ABS-ECU performs the initial check for that period.
• Page 1141
  35C-13 ABS <4WD> – Troubleshooting Connector Signal Checking requirements Normal condition terminal Output to valve relay Ignition Approximately 1 second 2 V or less switch: ON after engine is started. The relay is on. The system runs down. System voltage The relay is off.
• Page 1142
  35C-14 ABS <4WD> – Troubleshooting RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS 1. Turn the ignition switch off and disconnect the ABS-ECU connectors before checking resistance and continuity. 2. Check them between the terminals indicated in the table below. 3. The terminal layouts are shown in the illustrations below. Connector terminal No.
• Page 1143
  35C-15 ABS <4WD> – Front Disc Brake FRONT DISC BRAKE 35200600023 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Brake Line Bleeding (Refer to GROUP 35B – On-vehicle Service.) 90 Nm 15 Nm 90 Nm Removal steps 1.
• Page 1144
  35C-16 ABS <4WD> – Front Disc Brake DISASSEMBLY AND REASSEMBLY 35200620029 8 Nm 74 Nm Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off. Brake fluid: DOT3 or DOT4 Grease Brake caliper kit Pad kit…
• Page 1145
  35C-17 ABS <4WD> – Front Disc Brake DISASSEMBLY SERVICE POINTS When disassembling the disc brakes, disassemble both sides (left and right) as a set. AA» PISTON BOOT/PISTON REMOVAL Pump in compressed air through the brake hose installation hole and remove the pistons and piston boot. Caution When removing the pistons, be sure to use the handle of a plastic hammer and adjust the height of the two…
• Page 1146
  35C-18 ABS <4WD> – Front Disc Brake PAD WEAR CHECK Measure thickness at the thinnest and worn area of the pad. Replace pad assembly if pad thickness is less than the limit value. Standard value: 10 mm Limit: 2.0 mm Caution 1.
• Page 1147
  35C-19 ABS <4WD> – Wheel Speed Sensor WHEEL SPEED SENSOR 35200830170 REMOVAL AND INSTALLATION Post-installation Operation Wheel Speed Sensor Output Voltage Checking (Refer to GROUP 35B – On-vehicle Service.) 1. Front speed sensor 2. Front rotor (Refer to GROUP 26 – Front Hub.) NOTE The rear wheel speed sensor is the same as 2WD.
• Page 1148
  35C-20 ABS <4WD> – G-Sensor G-SENSOR 35201010078 REMOVAL AND INSTALLATION CAUTION: SRS Pre-removal and Post-installation Operation When removing and installing the G-sensor SRS diagnostic unit Removal and Installation from/to vehicles equipped with SRS, do not let it (Refer to GROUP 52B.) bump against the SRS diagnostic unit or other components.
• Page 1160
  PARKING BRAKES Click on the applicable bookmark to selected the required model year…
• Page 1162
  36-2 PARKING BRAKES – General Information/Service Specifications GENERAL INFORMATION 36100010110 The parking brake is of a mechanical rear-wheel There are two types of parking brake. — stick type brake construction in all vehicles. and lever type. CONSTRUCTION DIAGRAM SERVICE SPECIFICATIONS 36100030116 Item Standard value…
• Page 1163
  36-3 PARKING BRAKES – On-vehicle Service ON-VEHICLE SERVICE 36100090114 PARKING BRAKE LEVER STROKE CHECK <LEVER TYPE> 1. Pull the parking brake lever with a force of approx. 196 N and count the number of notches. Caution The 196 N force of the parking brake lever must be strictly observed.
• Page 1164
  36-4 PARKING BRAKES – On-vehicle Service 2. Pull Rod Stroke Adjustment Adjusting Loosen the adjusting nut and release the parking brake rear cable. Adjust by the following procedures. (1) With the engine idling, forcefully depress the brake pedal five or six times and confirm that the pedal stroke stops changing.
• Page 1165
  36-5 PARKING BRAKES – Parking Brake Lever <Lever Type> PARKING BRAKE LEVER <LEVER TYPE> 36100130120 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Rear Floor Console Removal Rear Floor Console Installation <Vehicles with rear floor console> <Vehicles with rear floor console> (Refer to GROUP 52A –…
• Page 1166
  36-6 PARKING BRAKES – PARKING BRAKES – Parking Brake Pull Rod <Stick Type> Parking Brake Pull Rod <Stick Type> PARKING BRAKE PULL ROD <STICK TYPE> 36100280016 REMOVAL AND INSTALLATION Post-installation Operation Parking Brake Pull Rod Stroke Adjustment (Refer to P.36-3.) Removal steps «AA 1.

• Page 1167: Parking Brake Cable

  36-7 PARKING BRAKES – Parking Brake Cable PARKING BRAKE CABLE 36100190166 REMOVAL AND INSTALLATION <LEVER TYPE> Pre-removal Operation Post-installation Operation Rear Floor Console Removal Rear Floor Console Installation <Vehicles with rear floor console> <Vehicles with rear floor console> (Refer to GROUP 52A – Floor Console.) (Refer to GROUP 52A –…

• Page 1168
  36-8 PARKING BRAKES – Parking Brake Cable REMOVAL AND INSTALLATION <STICK TYPE> Post-installation Operation Parking Brake Pull Rod Stroke Adjustment (Refer to P.36-3.) (contact surface) Removal steps D Shoe and lining assembly (Refer to 6. Parking brake rear cable end GROUP 35A –…
• Page 1169
  STEERING Click on the applicable bookmark to selected the required model year…
• Page 1171
  37A-2 STEERING – General Information GENERAL INFORMATION 37100010025 Engine speed-responsive hydraulic power steering The steering column in all vehicles has a shock or manual steering has been used. absorber mechanism and a tilt steering mechanism. The main features are as follows. The steering A vane-type oil pump with a fluid flow control system wheel four…
• Page 1172
  37A-3 STEERING – Service Specifications SERVICE SPECIFICATIONS 37100030021 Items Standard value Limit Steering wheel free play mm With engine running – With engine stopped 10 or less – Steering angle Inner wheel 33_55’ – 36_55’ – Outer wheel 30_57’ – Inner wheel 29_40’…

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