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00-1

GROUP 00

GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . .

00-2

SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) . . . . . . . . . . . . . . . . . .

00-27

SRS SERVICE PRECAUTIONS . . . . .

00-28

HOW TO USE
TROUBLESHOOTING/INSPECTION
SERVICE POINTS . . . . . . . . . . . . . . .

00-6

VEHICLE IDENTIFICATION . . . . . . .

00-16

SUPPORT LOCATIONS FOR LIFTING


AND JACKING . . . . . . . . . . . . . . . . . . 00-31

GENERAL DATA AND


SPECIFICATIONS . . . . . . . . . . . . . . .

00-20

STANDARD PART/TIGHTENINGTORQUE TABLE . . . . . . . . . . . . . . . .

PRECAUTIONS BEFORE SERVICE.

00-22

00-33

GENERAL

00-2

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL


M1001000100660

SCOPE OF MAINTENANCE, REPAIR AND


SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components. For
detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
after they have been removed from the vehicle,
please refer to separate manuals covering the
engine and the transmission.
ON-VEHICLE SERVICE
"On-vehicle Service" is procedures for performing
inspections and adjustments of particularly important
locations with regard to the construction and for
maintenance and servicing, but other inspection (for
looseness, play, cracking, damage, etc.) must also
be performed.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well.

DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be kept functionally or in strength. It is a value
established outside the range of standard value.

REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
DANGER, WARNING, AND CAUTION
DANGER, WARNING, and CAUTION call special
attention to a necessary action or to an action that
must be avoided. The differences among DANGER,
WARNING, and CAUTION are as follows:
If a DANGER is not followed, the result is severe
bodily harm or even death.
If a WARNING is not followed, the result could be
bodily injury.
If a CAUTION is not followed, the result could be
damage to the vehicle, vehicle components or
service equipment.

INDICATION OF TIGHTENING TORQUE


Tightening torques (units: Nm) are set to take into
account the central value and the allowable
tolerance. The central value is the target value, and
the allowable tolerance provides the checking range
for tightening torques. If bolts and nuts are not
provided with tightening torques, refer to P.00-33.

MODEL INDICATIONS
The following abbreviations are used in this manual
for identification of model types.
MPI::Indicates the multipoint injection.
SOHC::Indicates an engine with the single overhead
camshaft.
DOHC::Indicates an engine with the double
overhead camshaft.
2000:: Indicates models equipped with the 2,000 mL
<4G63> petrol engine.
2400::Indicates models equipped with the 2,400 mL
<4G69> petrol engine.
M/T:: Indicates the manual transmission.
A/T:: Indicates the automatic transmission.
A/C:: Indicates the air conditioner.

GENERAL
HOW TO USE THIS MANUAL

NOTES

00-3

00-4

GENERAL
HOW TO USE THIS MANUAL

(s
.
<<A>>
>>A<<

Symbols are used to show the locations for lubrication


.
These symbols are included in the diagram of component parts or on the page following the component
parts page. The symbols do not always have accompanying text to support that symbol.

disassembly.
or reassembly.

Multi-purpose grease unless there is a

AC301960

GENERAL

00-5

HOW TO USE THIS MANUAL

For bolts and nuts which do


not have a tightening torque
listed, refer to the "Standard
Parts tightening-torque Table"

parts sets are

On removal,
reassembly are described

AC300860

00-6

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE


POINTS
M1001000200582

CONTENTS OF TROUBLESHOOTING
Troubleshooting of electronic control systems for which the MUT-II/III can be used follows the basic outline
described below. Even in systems for which the MUT-II/III cannot be used, some of these systems still follow
this outline.
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from
that given below, or if additional explanation is required, the details of such differences or additions will also
be listed.

Diagnosis method
Gathering information
from the customer.
Check trouble symptom.
Reoccurs
Read the diagnosis code.

No diagnosis code
or communication
with MUT-II/III not
possible

Does not reoccur

Diagnosis code
displayed.

Diagnosis code
displayed.

After taking note of the


malfunction code, erase the
diagnosis code memory.

No diagnosis
code.

Recheck trouble symptom.


Read the diagnosis codes.
Diagnosis code
displayed.

Refer to the INSPECTION CHART


FOR TROUBLE SYMPTOMS
(Refer to applicable group.)

Read the diagnosis code.

Refer to the INSPECTION CHART


FOR DIAGNOSIS CODES
(Refer to applicable group.)

No diagnosis
code.

INTERMITTENT MALFUNCTIONS

AC300864AC

2. SYSTEM OPERATION AND SYMPTOM


VERIFICATION TESTS
If verification of the symptom(s) is difficult,
procedures for checking operation and verifying
symptoms are shown.
3. DIAGNOSIS FUNCTION
Details which are different from those in the
"Diagnosis function " section are described.

4. DIAGNOSIS CODE CHART


Diagnostic trouble codes and diagnostic items are
shown.
5. DIAGNOSIS CODE PROCEDURES
Indicates the inspection procedures corresponding to
each diagnosis code (Refer to How to read
inspection procedure ).

GENERAL

00-7

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

6. TROUBLE SYMPTOM CHART


If there are trouble symptoms even though the
MUT-II/III does not find any diagnosis codes,
Inspection procedures for each trouble symptom will
be found by means of this chart.
7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptoms classified in the Symptom Chart
(Refer to How to read inspection procedure P.00-9).

<Using the MUT-III>


<Using the MUT-III>

16-PIN

8. SERVICE DATA REFERENCE TABLE


Inspection items and normal judgment values have
been provided in this chart as reference information.

MB991911
MB991824

9. CHECK AT ECU TERMINALS


Terminal numbers for the ECU connectors,
inspection items, and judgment values have been
provided in this chart as reference information.
10. INSPECTION PROCEDURE BY USING AN
OSCILLOSCOPE
When there are inspection procedures using an
oscilloscope, these are described here.

DIAGNOSIS FUNCTION
HOW TO READ DIAGNOSIS CODE

CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>
<Using the MUT-II>
Steering shaft

MUT-II

AC300830 AC

Connect the MUT-II to the diagnosis connector, and


read the diagnosis code.

MB991827

AC308915 AC

Connect the MUT-III to the 16-pin diagnosis


connector, and read the diagnosis code.
NOTE: For details on how to use the MUT-III, refer to
the "MUT-III operation manual."
1. Ensure that the ignition switch is at the
"LOCK" (OFF).
2. Start up the personal computer.
3. Connect MUT-III USB cable MB991827 to
special tool Vehicle Communication Interface
(V.C.I.) MB991824 and the personal
computer.
4. Connect MUT-III main harness B MB991911
to the V.C.I.
5. Connect MUT-III main harness B to the
diagnosis connector.
6. Turn the V.C.I. power switch to the "ON"
position.
NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green
colour.
7. Start the MUT-III system on the PC and turn
the ignition switch to the "ON" position.
8. Read the diagnosis code.
9. Disconnecting the MUT-III is the reverse of
the connecting sequence, making sure that
the ignition switch is at the "LOCK" (OFF).

GENERAL

00-8

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

NOTE: The ABS warning lamp may flash when the


ignition switch is turned ON with the MUT-II/III
connected. This is because the diagnosis display
function of the ABS warning lamp is activated by
grounding the diagnosis connector terminal No.1,
and is not detrimental in any way.
ERASING DIAGNOSIS CODE (BY USING THE
MUT-II/III)

CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>

ERASING DIAGNOSIS CODE (BY USING NO


MUT-II/III)

CAUTION
Some diagnosis codes can not be erased
according to the procedure below. If you attempt
to erase a diagnosis code, refer to an applicable
GROUP.
1. Turn the ignition switch to the "LOCK" (OFF)
position.
2. Disconnect the negative battery cable, wait for at
least 10 minutes, and then reconnect it.
3. Start the engine and let it run at idle for 10
minutes.
INPUT SIGNAL CHECK (WHEN USING THE
MUT-II/III) <SWS>

Steering shaft

MUT-II

CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>

AC300830 AC

Steering shaft

<Using the MUT-III>

MUT-II
16-PIN
AC300830 AC

<Using the MUT-III>

MB991911
16-PIN
MB991824

MB991911
MB991827

AC308915 AC

MB991824

Connect the MUT-II/III to the diagnosis connector,


and erase the diagnosis code. The procedure is the
same as "HOW TO READ DIAGNOSIS CODE ".

MB991827

AC308915 AC

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

1. Connect the MUT-II/III to the diagnosis connector,


and erase the diagnosis code.
2. If the MUT-II/III buzzer sounds once when each
switch is operated (ON/OFF), the input signal for
that switch circuit system is normal.
INPUT SIGNAL CHECK (WHEN USING A
VOLTMETER) <SWS>

00-9

1. Use the special tool diagnosis code check


harness (MB991529) to connect the ETACS
terminal (terminal 9) and the earth terminals
(terminals 4 and 5) of the diagnosis connector to
the voltmeter.
2. If the needle of the voltmeter flickers once when
each switch is operated (ON/OFF), the input
signal for that switch circuit system is normal.

HOW TO USE THE INSPECTION


PROCEDURES

Steering shaft
MB991529

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

AC300831AB

The causes of many of the problems occurring in


electric circuitry are generally the connectors,
components, the ECU, the wiring harnesses
between connectors, in that order. These inspection
procedures follow this order. They first try to discover
a problem with a connector or a defective
component.

00-10

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Relevant circuit(s) of the component which


the Code No. indicates are described.

AC301964AB

GENERAL

00-11

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Explains about the basic


operation of the components.

Start of diagnosis
procedure

Describes
inspection
procedure.

Explains about
technical details.

Describes the
conditions for that
diagnosis code being
set.

Describes possible
causes(s) for that
diagnosis code.

AC301965AB

HARNESS CHECK
Check for an open or short circuit in the harness
between the terminals which were faulty according to
the connector measurements. Carry out this
inspection while referring to the Electrical Wiring
Manual. Here, "Check the wiring harness between
the power supply and terminal xx" also includes
checking for blown fuse. For inspection service
points when there is a blown fuse, refer to
"Inspection Service Points for a Blown Fuse ."
MEASURES TO TAKE AFTER REPLACING THE
ECU
If the trouble symptoms have not disappeared even
after replacing the ECU, repeat the inspection
procedure from the beginning.

CONNECTOR MEASUREMENT SERVICE


POINTS
Turn the ignition switch to the "LOCK" (OFF) position
when connecting and disconnecting the connectors.
Turn the ignition switch to "ON" when measuring,
unless there are instructions to the contrary.

IF INSPECTING WITH THE CONNECTOR


CONNECTED
<Waterproof Connectors>
MD998459

AC300881AB

Be sure to use special tool harness connector


(MD998459). Never insert a test probe from the
harness side, as this will reduce the waterproof
performance and result in corrosion.

GENERAL

00-12

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

<Ordinary (non-waterproof) Connectors>

Use the special tool inspection harness (MB991219)


(inspection harness for connector pin contact
pressure in the harness set for inspection). The
inspection harness for connector pin contact
pressure should be used. the test bar should never
be forcibly inserted, as it may cause a defective
contact.
<When Inspecting a Male Pin>

Connector

CAUTION
AC300882AB

Check by inserting the multi-meter test probe from


the harness side. Note that if the connector (control
unit, etc.) is too small to permit insertion of the test
probe, it should not be forced; use the backprobing
tool for this purpose.
IF INSPECTING WITH THE CONNECTOR
DISCONNECTED
<When Inspecting a Female Pin>

AC300890

At this time, be careful not to short the connector


pins with the test bars. To do so may damage the
circuits inside the ECU.Touch the pin directly
with the test bar.
MB991219

ACX00865AB

GENERAL

00-13

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR INSPECTION SERVICE


POINTS
VISUAL INSPECTION

Low connection pressure due to rusted terminals


or foreign matter lodged in terminals
CONNECTOR PIN INSPECTION

Connector disconnected or
improperly connected

AC300898

Stretched or broken wires

If the connector pin stopper is damaged, the terminal


connections (male and female pins) will not be
perfect even if the connector body is connected, and
the pins may pull out of the reverse side of the
connector. Therefore, gently pull the harnesses one
by one to make sure that no pins pull out of the
connector.
CONNECTOR ENGAGEMENT INSPECTION

Harness wire breakage


at terminal section

MB991219

Low contact
pressure
Good
Bad

AC300899AB
AC300896AB

Connector is disconnected or improperly connected


Connector pins are pulled out
Due to harness tension at terminal section
Low contact pressure between male and female
terminals

Use the special tool inspection harness (MB991219)


(connector pin connection pressure inspection
harness of the inspection harness set) to inspect the
engagement of the male pins and females pins. (Pin
drawing force: 1 N or more)

GENERAL

00-14

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

INSPECTION SERVICE POINTS FOR A


BLOWN FUSE

Battery

Fuse

Load
switch

Short-circuit
occurrence
section

Load

AC300900AB

Remove the blown fuse and measure the resistance


between the load side of the blown fuse and the
earth. Close the switches of all circuits which are
connected to this fuse. If the resistance is almost 0
at this time, there is a short somewhere between
these switches and the load. If the resistance is not 0
, there is no short at the present time, but a
momentary short has probably caused the fuse to
blow.
The main causes of a short circuit are the following.
Harness being clamped by the vehicle body
Damage to the outer casing of the harness due to
wear or heat
Water getting into the connector or circuitry
Human error (mistakenly shorting a circuit, etc.)

GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

HOW TO COPE WITH INTERMITTENT


MALFUNCTIONS
NOTE: If determining the cause is difficult, the flight
recorder function of the MUT-II/III can also be used.

AC300901

00-15

Intermittent malfunctions often occur under certain


conditions, and if these conditions can be
ascertained, determining the cause becomes simple.
In order to ascertain the conditions under which an
intermittent malfunction occurs, first ask the
customer for details about the driving conditions,
weather conditions, frequency of occurrence and
trouble symptoms, and then try to recreate the
trouble symptoms. Next, ascertain whether the
reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or
some other factor. If vibration is thought to be the
cause, carry out the following checks with the
connectors and components to confirm whether the
trouble symptom occurs. The objects to be checked
are connectors and components which are indicated
by inspection procedures or given as probable
causes (which generates diagnosis codes or trouble
symptoms).
Gently shake the connector up, down and to the
left and right.
Gently shake the wiring harness up, down and to
the left and right.
Gently rock each sensor and relay, etc. by hand.
Gently shake the wiring harness at suspensions
and other moving parts.

GENERAL

00-16

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION
M1001000400713

VEHICLE IDENTIFICATION CODE PLATE


1

The plate shows model code, engine model,


transmission model and body colour code.
No.

Item

Content

MODEL

CU2WXNMM CU2W:
L6
Vehicle model

XNMML6:
Model series

AC301477AB

The vehicle information code plate is riveted to the


back of the hood.

ENGINE

4G63

Engine model

EXT

W83A

Exterior code

TRANS AXLE F5M42

F5M42:Trans
mission
model

COLOUR

W83

W83: Body
colour code

INT

62A

62A: Interior
code

OPT

ZP3

ZP3:
Equipment
code

For monotone colour vehicles, the body colour code


shall be indicated.

MODELS
Model code

Engine model

Price class

Transmission
model

Fuel supply
system

CU2W

4G63-DOHC (1,997
mL)

Comfort

F5M42
<2WD, 5M/T>

MPI

XNMML6
XNMMZL6
XNHMZL6

CU5W

XNMYZL6

Sport
4G69-SOHC MIVEC
(2,378 mL)

Comfort

XRMYZL6

XRHYZL6
XRHYZR6

W5M42
<4WD, 5M/T>
W4A42
<4WD, 4A/T with
sport mode>

XRMYZR6
XNHYZL6

W5M42
<4WD, 5M/T>

Sport

W5M42
<4WD,5M/T>
W4A42
<4WD, 4A/T with
sport mode>

GENERAL

00-17

VEHICLE IDENTIFICATION

MODEL CODE

CU 2 W X N M M Z L 6

2 3 4 5 6 7 8 9 10

No.

Item

Content

Development

CU: MITSUBISHI
OUTLANDER

Engine type

2: 1,997 mL petrol engine


5: 2,378 mL petrol engine

Sort

W: Wagon

Body style

X: 5-door hatchback

Transmission
type

N: 5-speed manual
transmission
R: 4-speed automatic
transmission

Trim level

M: COMFORT
H: SPORT

Specification
engine feature

M: MPI-DOHC
Y: MPI-SOHC MIVEC

Special feature

None: 2WD
Z: 4WD

Steering wheel
location

L: Left hand
R: Right hand

10

Destination

6: For Europe

AC301363 AB

GENERAL

00-18

VEHICLE IDENTIFICATION

CHASSIS NUMBER

The chassis number is stamped on the toeboard


inside the engine compartment.

AC300903AB

M B

CU

000001

10

11

AC309285AB

No.

Item

Content

Fixed figure

Asia

Distribution channel

Japan channel

Destination

For Europe, right hand drive

For Europe, left hand drive

Body style

5-door hatchback

Transmission type

5-speed manual transmission

4-speed automatic transmission

Development order

CU

OUTLANDER

Engine

1,997 mL petrol engine

2,378 mL petrol engine

Soft

Station wagon

Model year

2004

10

Plant

Mizushima

11

Serial number

GENERAL

00-19

VEHICLE IDENTIFICATION

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block.


This engine model numbers are shown as follows.

<4G63>

Engine model

Engine displacement

4G63

1,997 mL

4G69

2,378 mL

The engine serial number is stamped near the


engine model number.
Front of the
vehicle
AC300905AD

<4G69>

Front of the vehicle

AC309481AB

GENERAL

00-20

GENERAL DATA AND SPECIFICATIONS

GENERAL DATA AND SPECIFICATIONS


M1001000900558

8
7
9

4
6

5
AC300072AB

Items

CU2W
XNMML6

Vehicle
dimensions mm

Front track

1,495

Overall width

1,750

Front overhang

945

Wheel base

2,625

Rear overhang

975

Overall length

4,545

Ground clearance (unladen)

195

Overall height (unladen)

1,620/1,670*

Rear track

1,505

Vehicle weight kg Kerb weight

1,435

1,540

Max. gross vehicle weight

1,970

2,070

Max. axle weight rating-front

1,050

Max. axle weight rating-rear

1,065

Max. trailer weight

With brake

1,500

Without brake

570

Max. trailer-nose weight


Seating capacity
Engine
Transmission
Fuel system

XNMMZL6

75
5

Model code

4G63

Total displacement mL

1,997

Model code

F5M42

Type

5-speed manual

Fuel supply system

MPI

NOTE: *: Vehicles with roof rails

W5M42

XNHMZL6

GENERAL

00-21

GENERAL DATA AND SPECIFICATIONS

Items

CU5W
XNMYZL6

Vehicle
dimensions
mm

Vehicle
weight kg

XRMYZL6/R XNHYZL6
6

XRHYZL6/R
6

LHD: 1,560,
RHD: 1,565

1,540

LHD: 1,560,
RHD: 1,565

W5M42

W4A42

W5M42

W4A42

Type

5-speed
manual

4-speed
automatic

5-speed
manual

4-speed
automatic

Fuel supply system

MPI

Front track

1 1,495

Overall width

2 1,750

Front overhang

3 945

Wheel base

4 2,625

Rear overhang

5 975

Overall length

6 4,545

Ground clearance (unladen)

7 195

Overall height (unladen)

8 1,620/1,670*

Rear track

9 1,505

Kerb weight

1,540

Max. gross vehicle weight

2,070

Max. axle weight rating-front

1,050

Max. axle weight rating-rear

1,065

Max. trailer weight With brake

1,500

Without
brake
Max. trailer-nose weight

570
75

Seating capacity

Engine

Model code

4G69

Total displacement mL

2,378

Transmission Model code

Fuel system

NOTE: *: Vehicles with roof rails

00-22

GENERAL
PRECAUTIONS BEFORE SERVICE

PRECAUTIONS BEFORE SERVICE


M1001000500538

SUPPLEMENTAL RESTRAINT SYSTEM


(SRS)
CAUTION
Items to review when servicing SRS:
1. Be sure to read GROUP 52B Supplemental
Restraint System (SRS). For safe operation,
please follow the directions and heed all
warnings.
2. Wait at least 60 seconds after disconnecting
the battery cable before doing any further
work. The SRS system is designed to retain
enough voltage to deploy the air bag even
after the battery has been disconnected.
Serious injury may result from unintended air
bag deployment if work is done on the SRS
system immediately after the battery cable is
disconnected.
3. Warning labels must be heeded when
servicing or handling SRS components.
Warning labels can be found in the following
locations.
Front impact sensor
Hood
Sun visor
Glove box
SRS-ECU
Steering wheel
Clock spring
Steering joint cover
Air bag module (Driver's or front
passenger's)
Side air bag module (Driver's side or front
passenger's side)
Side impact sensor
Seat belt pre-tensioner
Instrument panel
4. Always use the designated special tools and
test equipment.
5. Store components removed from the SRS in a
clean and dry place. The air bag module
should be stored on a flat surface and placed
so that the pad surface is facing upward. Do
not place anything on top of it.
6. Never attempt to disassemble or repair the
SRS components (SRS-ECU, air bag module
and clock spring).
7. Whenever you finish servicing the SRS, check
the SRS warning lamp operation to make sure
that the system functions properly.

8. Be sure to deploy the air bag before


disposing of the air bag module or disposing
of a vehicle equipped with an air bag (Refer to
GROUP 52B Air Bag Module Disposal
Procedures).
Observe the following when carrying out
operations on places where SRS components are
installed, including operations not directly
related to the SRS air bag.
1. When removing or installing parts, do not
allow any impact or shock to the SRS
components.
2. If heat damage may occur during paint work,
remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, the side
impact sensor, and the seat belt
pre-tensioner.
SRS-ECU, air bag module, clock spring,
front impact sensor, the side impact
sensor: 93 C or more
Seat belt pre-tensioner: 90 C or more

GENERAL
PRECAUTIONS BEFORE SERVICE

00-23

INITIALIZATION PROCEDURE FOR


LEARNING VALUE IN MPI ENGINE

LEARNING PROCEDURE FOR IDLING IN


MPI ENGINE

Initialization Procedure
1. After the ignition switch is in "LOCK" (OFF)
position, connect MUT-II/III with the diagnosis
connector.
2. Select the item on the screen of the initialization
for learning, and perform the initialization.

Purpose
When the engine-ECU <M/T> or the
engine-A/T-ECU <A/T> is replaced, or when the
learning value is initialized, the idling is not stabilized
because the learning value in MPI engine is not
completed. In this case, carry out the learning
method for the idling through the following
procedures.

Service

Item

At replacing engine
assembly *1,*2

All ranges

*3

Misfire-related

At replacing injector and Learning value for


air/fuel ratio
at cleaning *2
At replacing throttle body Idle speed
control-related
and at cleaning *2
At replacing detonation
sensor

Learning value for


knocking

NOTE: *1: Initialize A/T-related learning value.


NOTE: *2: After initializing the learning value, the
idling learning in MPI engine is required (Refer to
LEARNING PROCEDURE FOR IDLING IN MPI
ENGINE).
NOTE: *3: The datum items on MUT-II/III display are
shown, but do not use them.

Learning Procedure
1. Start the engine and carry out the warm-up for the
engine coolant temperature to reach 80C or
more.
2. When the engine coolant temperature is 80C or
more, the warm-up is not needed if the ignition
switch is in "ON" position once.
3. Place the ignition switch in "LOCK" (OFF) position
and stop the engine.
4. After 10 seconds or more, start the engine again.
5. For 10 minutes, carry out the idling under the
condition shown below and then confirm the
engine has the normal idling.
Transmission: Neutral (A/T: "P" range)
Operation in ignition-related, fan and
attachments: Not to be operated
Engine coolant temperature: 80C or more
NOTE: When the engine stalls during the idling,
check the dirtiness (on the throttle valve) of the
throttle body and then perform the service from
Procedure 1 again.

00-24

GENERAL
PRECAUTIONS BEFORE SERVICE

SERVICING ELECTRICAL SYSTEM

PRE-INSPECTION CONDITION

CAUTION
Before connecting or disconnecting the negative
() cable, be sure to turn off the ignition switch
and the lighting switch (If this is not done, there
is the possibility of semiconductor parts being
damaged).

"Pre-inspection condition" refers to the condition that


the vehicle must be in before proper engine
inspection can be carried out. If you see the words
"Set the vehicle to the pre-inspection condition". In
this manual, it means to set the vehicle to the
following condition.
Engine coolant temperature 80 to 90C
Lamps, electric cooling fan and all accessories:
OFF
M/T: Neutral
A/T: P range

VEHICLE WASHING

AC300693

Before replacing a component related to the


electrical system and before undertaking any repair
procedures involving the electrical system, be sure to
first disconnect the negative () cable from the
battery in order to avoid damage caused by
short-circuiting.

APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats.

Approximately 40 cm

AC300832AB

If high-pressure car-washing equipment or steam


car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to
avoid damage to plastic components, etc.
Spray nozzle distance: Approx. 40 cm or more
Spray pressure: 3,900 kPa or less
Spray temperature: 82C or less
Time of concentrated spray to one point: within
30 sec.

GENERAL

00-25

PRECAUTIONS BEFORE SERVICE

MUT-II/III

MUT-III sub assembly

MUT-II Sub-assembly
Vehicle communication interface (V.C.I.)

Rom pack
MB991824

MUT-III USB cable


AC300834AB

MB991827

MUT-III main harness A

Do not used
MB991910

MUT-III main harness B

MB991911

MUT-III measurement adapter

MB991825

MUT-III trigger harness

MB991826
AC305090AB

Refer to the "MUT-II REFERENCE MANUAL",


"MUT-II OPERATING INSTRUCTIONS" or "MUT-III
OPERATION MANUAL" for instructions on handling
the MUT-II/III.

GENERAL

00-26

PRECAUTIONS BEFORE SERVICE

ENGINE OILS

CAUTION
<Using the MUT-II>
Steering shaft

MUT-II

AC300830 AC

<Using the MUT-III>

16-PIN

MB991911
MB991824

MB991827

AC308915 AC

Turn the ignition switch to the "LOCK" (OFF)


position before connecting or disconnecting the
MUT-II/III.
Connect the MUT-II/III to the diagnosis connector as
shown in the illustration.

IN ORDER TO PREVENT VEHICLES


FROM FIRE
"Improper installation of electrical or fuel related parts
could cause a fire. In order to retain the high quality
and safety of the vehicle, it is important that any
accessories that may be fitted or
modifications/repairs that may be carried out which
involve the electrical or fuel systems, MUST be
carried out in accordance with MMC's
information/Instructions".

Health Warning
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them.
Other precautions:
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.
Avoid contaminating clothes, particularly
underpants, with oil.
Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separately from
personal clothing.
Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
Obtain First Aid treatment immediately for open
cuts and wounds.
Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
If skin disorders develop, obtain medical advice
without delay.

GENERAL

00-27

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)


M1001009800020

The Supplemental Restraint System (SRS) and seat


belt with pre-tensioner is designed to supplement the
driver's and front passenger's seat belts to help
reduce the risk or severity of injury to the driver and
front passenger by activating and deploying both
front air bags in certain frontal collisions.
The SRS consist of four air bag modules, SRS air
bag control unit (SRS-ECU), two front impact
sensors, two side impact sensors, SRS warning
lamp, clock spring and seat belt pre-tensioner. Front
air bags are located in the centre of the steering
wheel and above the glove box. Side air bag are
located inside the front seatback assemblies. Each
air bag is made up of a folded air bag and an inflator
unit. The SRS-ECU under the front floor console
monitors the system and has a front air bag safing

G-sensor, front air bag analog G-sensor and a side


air bag safing G-sensor. The front impact sensor is
assembled outside the headlamp support panel to
monitor impact in case of front impact. The side
impact sensors inside the centre pillars monitor the
shock incurred by the sides of the vehicle. The
warning lamp on the instrument panel indicates the
operational status of the SRS. The clock spring is
installed in the steering column. The seat belt
pre-tensioner is built into the driver's and
passenger's front seat belt retractor.
Only authorized service personnel should do work on
or around the SRS components. Those service
personnel should read this manual carefully before
starting any such work.

SRS warning lamp

Seat belt with pre-tensioner

Driver's air bag


module

Passenger's (front)
air bag module
Side air bag module
Side impact sensor

Clock spring

SRS-ECU

Side impact sensor


Side air bag module
Front impact sensor
AC301343 AB

00-28

GENERAL
SRS SERVICE PRECAUTIONS

SRS SERVICE PRECAUTIONS


M1001006000047

CAUTION

DANGER

In order to avoid injury to yourself or others


from accidental deployment of the air bag
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.

SRS-ECU connector

CAUTION
Do not use any electrical test equipment on or
near SRS components, except those specified on
P.52B-9.
CAUTION
Never Attempt to Repair the Following
Components:
1. SRS air bag control unit (SRS-ECU)
2. Front impact sensor
3. Clock spring
4. Driver's and front passenger's air bag
modules
5. Side air bag module
6. Side impact sensor
7. Seat belt with pre-tensioner
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE
procedures in this manual, starting at page
P.52B-174.
SRS-ECU terminal No. Destination of harness

AC300634 AB

Do not attempt to repair the wiring harness


connectors of the SRS. If a defective wiring
harness is found, repair or replace it by referring
to the table below.

Remedy

1, 2

Instrument panel wiring harness


Front wiring harness (RH) Front
impact sensor (RH)

Correct or replace each wiring


harness.

3, 4

Instrument panel wiring harness


Front wiring harness (LH) Front
impact sensor (LH)

Correct or replace each wiring


harness.

Instrument panel wiring harness


Earth

Correct or replace the instrument


panel wiring harness.

Instrument panel wiring harness


SRS warning lamp

Correct or replace the instrument


panel wiring harness.

9, 10

Instrument panel wiring harness


Air bag module (Front passenger's
side)

Correct or replace the instrument


panel wiring harness.

11, 12

Instrument panel wiring harness


Clock spring Air bag module
(Driver's side)

Correct or replace instrument panel


wiring harness. Replace the clock
spring.

13

Instrument panel wiring harness


Junction block (fuse No.3)

Correct or replace the instrument


panel wiring harness.

GENERAL
SRS SERVICE PRECAUTIONS

00-29

SRS-ECU terminal No.

Destination of harness

Remedy

16

Instrument panel wiring harness


Junction block (fuse No.2)

Correct or replace the instrument


panel wiring harness.

20

Instrument panel wiring harness


Diagnosis connector

Correct or replace the instrument


panel wiring harness.

21, 22

Floor wiring harness (RH) Side air Correct or replace the floor wiring
bag module (LH)
harness.

23, 24

Floor wiring harness (RH) Side air Correct or replace the floor wiring
bag module (RH)
harness.

27, 28

Floor wiring harness (RH) Seat


belt pre-tensioner (Front
passenger's side)

Connect or replace the floor wiring


harness.

29, 30

Floor wiring harness (LH) Seat


belt pre-tensioner (driver's side)

Connect or replace the floor wiring


harness.

34, 36

Floor wiring harness (LH) Side


impact sensor (LH)

Connect or replace the floor wiring


harness.

40, 42

Floor wiring harness (RH) Side


impact sensor (RH)

Connect or replace the floor wiring


harness.

DANGER
Insulating tape
Battery

Battery cable

AC300580AB

After disconnecting the battery cable, wait 60


seconds or more before proceeding with the
following work. In addition, insulate the
negative battery terminal with a tape. The
condenser inside the SRS-ECU is designed
to retain enough voltage to deploy the air
bag for a short time even after the battery
has been disconnected, so serious injury
may result from unintended air bag
deployment if work is done on the SRS
system immediately after the battery cables
are disconnected.

GENERAL

00-30

SRS SERVICE PRECAUTIONS

CAUTION
The SRS components and seat belt with
pre-tensioner should not be subjected to heat, so
remove the SRS-ECU, drivers and front
passengers air bag modules, clock spring, side
air bag modules, and seat belt pre-tensioner
before drying or baking the vehicle after painting.
SRS-ECU, air bag modules, clock spring,
impact sensors: 93C or more
Seat belt with pre-tensioner 90C or more
CAUTION
Whenever you finish servicing the SRS, always
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.
CAUTION
SRS-Harness connector

SRS-ECU harness connector


(rear side)

AC300673AB

If checks are carried out by using the SRS-ECU


harness connector, observe the following
procedures: Insert the special tool (probe in the
harness set) MB991222 into connector from
harness side (rear side), and connect the tester
to this probe. If any tool than special tool is used,
damage to the harness and other components
will result. Never insert the probe directly to the
terminals from the front of the connector. The
terminals are plated to increase their
conductivity, so that if they are touched directly
by the probe, the plating may break, which will
cause drops in reliability.

GENERAL
SUPPORT LOCATIONS FOR LIFTING AND JACKING

00-31

SUPPORT LOCATIONS FOR LIFTING AND JACKING


M1001000700093

SUPPORT POSITIONS FOR A GARAGE JACK, AXLE STANDS, SINGLE-POST LIFT OR


DOUBLE-POST LIFT AND PLATE TYPE LIFT
CAUTION
Do not support the vehicles at locations other than specified supporting points. Doing so will cause
damage, etc.
GARAGE JACK
CAUTION
Never support any point other than the specified one, or that point will be deformed.
<2WD>

Rear suspension crossmember

<4WD>

Rear differential

AC300835

GENERAL

00-32

SUPPORT LOCATIONS FOR LIFTING AND JACKING

AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT


CAUTION
If rubber attachments with grooves that are too thick are used at the front support positions, the
front fender may become bent, so be sure to use rubber attachments with groove thicknesses of
18 mm or less.
If attachments which are not high enough are used, they may damage areas such as the side step.
Be sure to use attachments which are high enough, or remove the side step if not using
attachments.
AXLE STANDS
Bolts

Bolts

Rubber
Rubber

SINGLE-POST LIFT
OR DOUBLE-POST LIFT
Bolts

Bolts

AC300836AB

GENERAL

00-33

STANDARD PART/TIGHTENING-TORQUE TABLE

PLATE TYPE LIFT

CAUTION
To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift.
Support the side sill flange with a lift.

STANDARD PART/TIGHTENING-TORQUE TABLE


M1001001100362

Each torque value in the table is a standard value for


tightening under the following conditions.
1. Bolts, nuts and washers are all made of steel and
plated with zinc.
2. The threads and bearing surface of bolts and
nuts are all in dry condition.
The values in the table are not applicable:
1. If toothed washers are inserted.
Thread size
Torque Nm

2. If plastic parts are fastened.


3. If bolts are tightened to plastic or die-cast
inserted nuts.
4. If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque

Bolt nominal
diameter (mm)

Pitch
(mm)

Head mark "4"

Head mark "7"

Head mark "8"

M5

0.8

2.5 0.5

5.0 1.0

6.0 1.0

M6

1.0

5.0 1.0

9.0 2.0

10 2

M8

1.25

12 2

22 4

25 4

M10

1.25

24 4

44 10

53 7

M12

1.25

41 8

83 12

98 12

M14

1.5

73 12

140 20

155 25

M16

1.5

110 20

210 30

235 35

M18

1.5

165 25

300 40

340 50

M20

1.5

225 35

410 60

480 70

M22

1.5

300 40

555 85

645 95

M24

1.5

395 55

735 105

855 125

Flange bolt and nut tightening torque


Thread size
Torque Nm
Bolt nominal
diameter (mm)

Pitch
(mm)

Head mark "4"

Head mark "7"

Head mark "8"

M6

1.0

5.0 1.0

10 2

12 2

M8

1.25

13 2

24 4

27 5

M10

1.25

26 4

49 9

58 7

M10

1.5

24 4

45 8

55 10

M12

1.25

46 8

95 15

105 15

M12

1.75

43 8

83 12

98 12

NOTE: .
Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the
bolt strength.

NOTES


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11A-1

GROUP 11A

00
11

ENGINE
MECHANICAL

12
13
14
15
16

CONTENTS

17
GENERAL INFORMATION . . . . . . . .

11A

SERVICE SPECIFICATIONS. . . . . . .

11A

SEALANTS . . . . . . . . . . . . . . . . . . . .

11A

SPECIAL TOOLS. . . . . . . . . . . . . . . .

11A

ON-VEHICLE SERVICE. . . . . . . . . . .

CAMSHAFT AND VALVE STEM


SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . .

11A

22

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A

25

REMOVAL AND INSTALLATION <2WD>. .

11A

REMOVAL AND INSTALLATION <4WD>. .

11A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11A

27

CRANKSHAFT OIL SEAL . . . . . . . . . 11A

31

11A

DRIVE BELT TENSION CHECK. . . . . . . . .

11A

AUTO-TENSIONER CHECK . . . . . . . . . . .

11A

IGNITION TIMING CHECK . . . . . . . . . . . . .

11A

IDLE SPEED CHECK . . . . . . . . . . . . . . . . .

11A

IDLE MIXTURE CHECK . . . . . . . . . . . . . . .

11A

COMPRESSION PRESSURE CHECK. . . .

11A

MANIFOLD VACUUM CHECK . . . . . . . . . .

11A

LASH ADJUSTER CHECK . . . . . . . . . . . . .

11A

REMOVAL AND INSTALLATION . . . . . . . .

11A

CYLINDER HEAD GASKET . . . . . . . . 11A


REMOVAL AND INSTALLATION . . . . . . . .

11A

TIMING BELT . . . . . . . . . . . . . . . . . . . 11A

11A

26

32
33
34
35

REMOVAL AND INSTALLATION . . . . . . . .

11A

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11A

36

ENGINE ASSEMBLY . . . . . . . . . . . . . 11A

37

CRANKSHAFT PULLEY . . . . . . . . . . 11A


REMOVAL AND INSTALLATION . . . . . . . .

21

REMOVAL AND INSTALLATION . . . . . . . .

11A

42
51
52
54
55

ENGINE MECHANICAL

11A-2

GENERAL INFORMATION

GENERAL INFORMATION
M1111000100356

Item

4G63

Total displacement mL

1,997

Bore Stroke mm

85 88

Compression ratio

10.0

Compression chamber

Pentroof

Camshaft arrangement

DOHC

Number of valve
Valve timing

Intake

Exhaust

Intake opening

BTDC 17

Intake closing

ABDC 51

Exhaust opening

BBDC 57

Exhaust closing

ATDC 13

Fuel system

Electronically controlled multipoint fuel injection

Rocker arm

Roller type

Auto-lash adjuster

Equipped

SERVICE SPECIFICATIONS
M1112000300234

Item

Standard value

Limit

Vibration frequency Hz
(Reference)

110 - 144

Tension N (Reference)

245 - 412

Basic ignition timing

5 BTDC 2

Ignition timing

Approximately
10 BTDC

Idle speed r/min

750 100

CO contents %

0.5 or less

HC contents ppm

100 or less

Compression pressure kPa-r/min

1,370 - 250

930 - 250

Compression pressure difference of all cylinders kPa

Maximum 98

Intake manifold vacuum kPa

Minimum 60

Cylinder head bolt nominal length mm

99.4

Drive belt tension

Balancer timing belt tension (When


adjusted)

Deflection mm

5-7

Balancer timing belt tension (When


replaced)

Deflection mm

5-7

ENGINE MECHANICAL

11A-3

SEALANTS

Item

Standard value

Limit

5 - 10

Timing belt tensioner adjuster rod protrusion amount mm

3.8 - 4.5

Timing belt tensioner adjuster rod movement mm

Within 1

Balancer timing belt tension (When


checked)

Deflection mm

SEALANTS
M1112000500238

Item

Specified Sealant

Remark

Cylinder head

MITSUBISHI GENUINE PART MD970389 or


equivalent

Semi-drying
sealant

Camshaft position sensor support


Rocker cover
Camshaft end seal

3M ATD Part No.8660 or equivalent

Rocker cover gasket

MITSUBISHI GENUINE PART MD970389 or


equivalent

Engine oil pan <2WD>


Engine upper oil pan <4WD>
Engine lower oil pan <4WD>

SPECIAL TOOLS
M1112000600279

Tool

Number

Name

Use

MB991502

MUT-II sub assembly

Drive belt tension check


Checking the ignition timing
Checking the idle speed

MB991668

Belt tension meter set

Drive belt tension check (used


together with MUT-II)

MD998772

Valve spring compressor

Compressing valve spring

MD998737

Valve stem seal installer

Valve stem seal installation

B991502

B991668

MD998772

ENGINE MECHANICAL

11A-4

SPECIAL TOOLS

Tool

Number

Name

Use

MD998713

Camshaft oil seal installer

Camshaft oil seal installation

MD998727

Oil pan remover

Oil pan removal <2WD>

MD998781

Flywheel stopper

Supporting the flywheel

MB990938

Installer bar

Crankshaft rear oil seal


installation

MD998776

Crankshaft rear oil seal


installer

MD998285

Crankshaft front oil seal


guide

MD998375

Crankshaft front oil seal


installer

MB991654

Cylinder head bolt wrench


(12)

D998713

D998727

D998781

B990938

D998776

Crankshaft front oil seal


installation

D998285

B991654

Removal and installation of


cylinder head bolt

ENGINE MECHANICAL

11A-5

SPECIAL TOOLS

Tool

Number

Name

Use

MD998738

Adjusting bolt

Supporting the timing belt


tensioner arm and timing belt
tensioner adjuster

MB991367

Special spanner

Holding the crankshaft camshaft


drive sprocket

MB991385

Pin

MD998767

Tensioner wrench

D998738

B991367

B991385

D998767

Valve timing belt tension


adjustment

ENGINE MECHANICAL

11A-6

ON-VEHICLE SERVICE

Tool

Number

Name

Use

MB991454

Engine hanger balancer

MB991527

Hanger

When the engine hanger is used:


Supporting the engine assembly
during removal and installation of
the transmission assembly
NOTE: Special tool MB991454 is
a part of engine hanger
attachment set MB991453.

MB991895

Engine hanger

B991454

B991527

Z203830

MB991928
A: MB991929
B: MB991930
E C: MB991931
D: MB991932
E: MB991933
F: MB991934

Slide bracket (HI)

F
A

D
B

Engine hanger
A: Joint (50) 2
B: Joint (90) 2
C: Joint (140) 2
D: Foot (standard) 4
E: Foot (short) 2
F: Chain and hook
assembly

C
B991928

ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003100399

CAUTION
Check the drive belt tension after turning the
crankshaft clockwise one turn or more.

Indicator mark

AC107639AB

1. Make sure that the indicator mark is within the


area marked with A in the illustration.

2. If the mark is out of the area, replace the drive


belt. (Refer to 311A.)
NOTE: The drive belt tension check is not
necessary as auto-tensioner is adopted.

ENGINE MECHANICAL

11A-7

ON-VEHICLE SERVICE

AUTO-TENSIONER CHECK
M1111003000154

CAUTION

OPERATION CHECK
1. Turn OFF the engine from the idle state then
check to see that the drive belt is not protruding
from the pulley width of the auto-tensioner.
2. Remove the drive belt.(Refer to 311A.)

16-pin

MUT-II

AC107640AB

3. Securely insert the spindle handle or ratchet


handle with a 12.7 mm insertion angle into the jig
hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.
4. If there are any problems in the procedure 1 or 3,
replace the auto-tensioner.(Refer to 311A.)
5. Install the drive belt.(Refer to 311A.)

FUNCTION CHECK
You can verify if the auto-tensioner is defective or not
by checking the drive belt tension.
When using MUT-II
1. Check the drive belt tension. (Refer to 311A.)
2. Measure the drive belt tension vibration frequency
by the following procedures:

MB991668
AC211862 AB

To prevent damage to MUT-II, always turn the


ignition switch to the "LOCK" (OFF) position
before connecting or disconnecting MUT-II.
(1) Connect special tool belt tension meter set
(MB991668) to the MUT-II.
(2) Connect the MUT-II to the diagnosis
connector.
(3) Turn the ignition switch to ON position, and
select "BELT TENSION" on the menu screen.

ENGINE MECHANICAL

11A-8

ON-VEHICLE SERVICE

CAUTION
The temperature of the surface of the belt
should be as close to normal temperature as
possible.
Do not allow any contaminants such as water
or oil to get onto the microphone.
If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual
values.
If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not
correspond to actual values.
Do not take the measurement while the
vehicles engine is running.
Power steering
oil pump pulley

Power steering
oil pump pulley

Water pump
pulley

AC102807AB

2. Use a belt tension gauge in the middle of the belt


between the pulleys (at the place indicated by the
arrow) to measure that the belt tension is within
the standard value.
Standard value: 245 - 412 N
3. If not within the standard value, replace the autotensioner.(Refer to 311A.)

IGNITION TIMING CHECK

15

MB991668
Water pump
pulley

10 20 mm

Belt tension gauge

M1111001700425

15

AC102022
Y0195AU

MUT-II
Gentry tap with
your finger
AC102806 AB

(4) Hold special tool belt tension meter set


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

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition.


2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the MUT-II to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Use the MUT-II to measure engine idle speed and
check that it is within the standard value.
Standard value: 750 100 r/min
6. Select No. 17 of the MUT-II Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5 BTDC 2
8. If the basic ignition timing is outside the standard
value, inspect the MPI system (Refer to 313A,
GROUP 13A - Troubleshooting - Inspection chart
for diagnosis code).

ENGINE MECHANICAL

11A-9

ON-VEHICLE SERVICE

CAUTION
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this
condition may damage the engine.
9. Press the MUT-II clear key (Select a forced driving
cancel mode) to release the Actuator test.
10.Check that ignition timing is at the standard value.
Standard value: approximately 10 BTDC
NOTE: .
The ignition timing may fluctuate within 7
BTDC. This is normal.
In higher altitude, the ignition timing is more
advanced than the standard value by
approximately 5.
11.Remove the timing light.
12.Turn off the ignition switch and then remove the
MUT-II.

Standard value: 750 100 r/min


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

IDLE MIXTURE CHECK


M1111002100255

AC102022
Y0195AU

MUT-II

IDLE SPEED CHECK


M1111003500472

AC102022
Y0195AU
AK000871 AC

MUT-II

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition.


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

1. Before inspection, set the vehicle to the preinspection condition.


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

Engine speed
ditection connector

AK000899 AC

Engine speed
ditection connector

AK000899 AC

5. Start the engine and let it run at idle.


6. Check that ignition timing is at the standard value.
Standard value: approximately 10 BTDC
7. Check the idle speed.

5. Start the engine and let it run at idle.


6. Check that ignition timing is at the standard value.
Standard value: approximately 10 BTDC
7. Run the engine at 2,500 r/min for 2 minutes.
8. Set the CO, HC tester.
9. Check the CO contents and the HC contents at
idle.
Standard value
CO contents: 0.5 % or less
HC contents: 100 ppm or less
10.If there is a deviation from the standard value,
check the following items:

ENGINE MECHANICAL

11A-10

ON-VEHICLE SERVICE

Diagnosis output
Fuel pressure
Injector
Ignition coil, spark plug cable, spark plug
EGR control system
Evaporative emission control system
Compression pressure
NOTE: Replace the three way catalyst when the
CO and HC contents are not within the standard
value, even though the result of the inspection is
normal on all items.

COMPRESSION PRESSURE CHECK


M1111002600465

Crank angle
sensor
connector

AK201364AC

1. Before inspection, set the vehicle to the preinspection condition.


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

8. Measure the compression pressure for all the


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

MANIFOLD VACUUM CHECK


M1111002700417

AC102022
Y0195AU

MUT-II

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

AK000871 AC

1. Before inspection, set the vehicle to the preinspection condition.


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

Fuel pressure
regulator

AK201369AB

ENGINE MECHANICAL

11A-11

ON-VEHICLE SERVICE

4. Attach a three-way joint to the vacuum hose


between the fuel pressure regurator and the air
intake plenum, and connect a vacuum gauge.
5. Start the engine and check that idle speed is
within the standard valve.
Standard value: 750 100 r/min
6. Check the intake manifold vacuum.
Limit: Minimum 60 kPa
7. Turn off the ignition switch.
8. Remove the vacuum gauge and the three-way
joint, and then connect the vacuum hose.
9. Remove the engine tachometer or the MUT-II.

LASH ADJUSTER CHECK


M1111002900336

If an abnormal noise (knocking) that seems to be


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

3. While the engine is idling, check that the noise


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

<LASH ADJUSTER AIR BLEEDING>


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

Good
Max
Min.
AKX00328 AE

1. Check the engine oil and replenish or replace the


oil if necessary.

ENGINE MECHANICAL

11A-12

ON-VEHICLE SERVICE

NOTE: .
If there is an only small amount of oil, air will
be drawn in through the oil screen and will get
into the oil passage.
If the amount of oil is greater than normal, then
the oil will being mixed by the crankshaft and a
large amount of air may get mixed into the oil.
If the oil is degenerated, air and oil will not
separate easily in oil, and the amount of air
mixed into the oil will increase.

High-pressure chamber
AK100001AC

If the air which has been mixed in with the oil


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

Drive pattern for air breeding


Gradually open
Close the throttle valve
the throttle valve
Approximately
3,000 r/min
Idle speed

15 s

15 s

Once
AKX00330AE

2. Run the engine at idle for 1 - 3 minutes to let it


warm up.
3. With no load on the engine, repeat the drive
pattern shown in the illustration above and check
if the abnormal noise disappears (The noise
should normally disappear after 10 - 30
repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is
probably not due to air inside the lash adjusters).
4. After the noise has disappeared, repeat the drive
pattern shown in the illustration above a further 5
times.
5. Run the engine at idle for 1 - 3 minutes and check
that the noise has disappeared.

ENGINE MECHANICAL
CRANKSHAFT PULLEY

11A-13

CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600409

Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).

Post-installation Operation
Drive Belt Tension Check (Refer to 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).

2
1

25 4 Nm

AC300537AB

<<A>>

1.
2.

Removal steps
Drive belt
Crank shaft damper pulley

ENGINE MECHANICAL

11A-14

CRANKSHAFT PULLEY

REMOVAL SERVICE POINT

CAUTION

<<A>> DRIVE BELT REMOVAL


The following operations will be needed due to the
serpentine drive system with the drive belt autotensioner.

To reuse the drive belt, draw an arrow indicating


the rotating direction (clockwise) on the back of
the belt using chalk.
Auto-tensioner

Auto-tensioner

Hole B

L-shaped
hexagon
wrench
Hole A

AC107641AB

AC107640AC

1. Securely insert the spindle handle or ratchet


handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner, and turn the autotensioner anti-clockwise until it hits the stopper.

2. Align hole A with hole B, insert an L-shaped


hexagon wrench, etc. to fix and then remove the
drive belt.

ENGINE MECHANICAL

11A-15

CAMSHAFT AND VALVE STEM SEAL

CAMSHAFT AND VALVE STEM SEAL


REMOVAL AND INSTALLATION
M1112006600211

CAUTION
*Remove and assemble the marked parts in each cylinder unit.
Pre-removal Operation
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Air Cleaner and Air Cleaner Bracket Removal (Refer to
GROUP 15, Air Cleaner 315).
Battery and Battery Tray Removal
Valve Timing Belt Removal (Refer to 311A).

Post-installation Operation
Valve Timing Belt Installation (Refer to 311A).
Battery and Battery Tray Installation
Air Cleaner and Air Cleaner Bracket installation (Refer to
GROUP 15, Air Cleaner 315).
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Drive Belt Tension Check (Refer to 311A).

11 1 Nm
3.0 0.5 Nm

11 1 Nm

4
6
3.5 0.5 Nm

5
8
9.0 2.0 Nm

1
8.8 1.0 Nm

11 1 Nm

9
N

11

12
11 1 Nm

N 10

AC300538 AB

1.
2.
3.
4.

Removal steps
Accelerator cable connection
Rocker cover centre cover
Crank angle sensor connector
Control wiring harness connection
Spark plug cables and ignition coils
(Refer to GROUP 16, Ignition Coil
316).

>>N<<
>>M<<

Removal steps &RQWLQXHG


5. Rocker cover PCV hose
6. Rocker cover breather hose
7. Control wiring harness connection
8. Rocker cover
9. Camshaft end seal
10. Spark plug hole gaskets

ENGINE MECHANICAL

11A-16
<<A>>

CAMSHAFT AND VALVE STEM SEAL

>>L<<
>>K<<

Removal steps &RQWLQXHG


11. Rocker cover gasket
12. Radiator upper hose connection

22

20

24

25

23

20 1 Nm

Apply engine oil to all


moving parts before
installation.

21

26

19
17

N 18

11 1 Nm

89 9 Nm

13

30
29

25 4 Nm

22 4 Nm

15
31*
32*
33*
N 34*

16

27
28

10 2 Nm

14 N
14 1 Nm

31*
32*
33*
35* N
AC300539 AB

<<B>>

>>J<<
>>I<<
>>H<<
>>G<<
>>F<<
>>F<<
>>F<<
>>F<<
>>F<<

Removal steps
13. Camshaft position sensor support
cover
14. Camshaft position sensor support
cover gasket
15. Camshaft position sensing cylinder
16. Camshaft position sensor support
17. Camshaft sprockets
18. Camshaft oil seals
19. Camshaft bearing caps, front
20. Camshaft bearing caps, rear
21. Camshaft bearing caps, No.2
22. Camshaft bearing caps, No.5
23. Camshaft bearing caps, No.3

>>F<<
>>E<<
>>E<<
>>D<<
<<C>>

>>C<<
>>B<<
>>A<<
>>A<<

24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

Removal steps &RQWLQXHG


Camshaft bearing caps, No.4
Inlet camshaft
Exhaust camshaft
Rocker arms
Rocker arm lash adjusters
Oil delivery body
Spark plugs
Valve spring retainer locks
Valve spring retainers
Valve springs
Inlet valve stem seals
Exhaust valve stem seals

ENGINE MECHANICAL

11A-17

CAMSHAFT AND VALVE STEM SEAL

LUBRICATION AND SEALING POINTS


<The bottom view of the rocker cover>

10 mm

10 mm

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent


Rocker
cover

<View A>

10 mm

10 mm

Cylinder
head

A
10 mm

Sealant:
MITSUBISHI GENUINE
PART MD970389 or
equivalent

Sealant: 3M ATD Part No.8660


or equivalent
A
A

3 mm

Sealant: MITSUBISHI GENUINE


PART MD970389 or equivalent

(Lip section)

Engine oil

AC300541

<Top view of cylinder head>

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

ENGINE MECHANICAL

11A-18

CAMSHAFT AND VALVE STEM SEAL

REMOVAL SERVICE POINTS

<<C>> VALVE SPRING RETAINER LOCKS


REMOVAL

<<A>> RADIATOR UPPER HOSE


DISCONNECTION

CAUTION
When removing valve spring retainer locks, leave
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the
cylinder if the piston is not properly in the TDC
position.

Mating marks

MD998772

AC200641AC

Make mating marks on the radiator hose and the


hose clamp. Disconnect the radiator hose.
<<B>> CAMSHAFT SPROCKETS REMOVAL

AC201799 AB

Use special tool valve spring compressor


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

INSTALLATION SERVICE POINTS


>>A<< EXHAUST VALVE STEM SEALS/INLET
VALVE STEM SEALS INSTALLATION
Gray

Gray green

Inlet side

Exhaust side

AC201457AB

1. Hold the hexagon part of the camshaft with a


wrench.
2. Loosen the camshaft sprocket mounting bolts and
remove the camshaft sprocket.

AC201542AB

1. Check the valve stem seal colour to identify the


inlet side or exhaust side.
2. Apply a small amount of engine oil to the valve
stem seals.

ENGINE MECHANICAL

11A-19

CAMSHAFT AND VALVE STEM SEAL

CAUTION
Valve stem seals cannot be reused.
The special tool valve stem seal installer
(MD998737) must be used to install the valve
stem seal. Improper installation could result
in oil leaking past the valve guide.
MD998737
Valve
Valve stem
seal
Valve guide
AC107414 AC

3. Use special tool to fill a new valve stem seal in the


valve guide using the valve stem area as a guide.

>>D<< ROCKER ARM LASH ADJUSTERS


INSTALLATION

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

CAUTION
Engine front

>>B<< VALVE SPRINGS INSTALLATION

Slit

Rocker arm side


Exhaust camshaft
AC201458AB

Do not install wrong camshaft at the side of inlet


or exhaust. The exhaust camshaft has a slit at the
rear surface.
3. Install the camshaft to the cylinder head.

Identification
colour
AC201453AB

Install the valve springs with its identification colour


painted end facing the locker arm.
>>C<< VALVE SPRING RETAINER LOCKS
INSTALLATION

>>F<< CAMSHAFT BEARING CAPS, NO. 4/


CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT
BEARING CAPS, NO. 5/CAMSHAFT BEARING
CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/
CAMSHAFT BEARING CAPS, FRONT
INSTALLATION
Approximately 3

MD998772

Dowel pin

AC201799 AB

Use special tool valve spring compressor


(MD998772) to compress the valve spring in the
same manner as removal.

Inlet side

Exhaust side
AC201459AB

1. Set the dowel pin of the camshaft to the position


as shown in the illustration.

ENGINE MECHANICAL

11A-20

E4

Engine front

CAMSHAFT AND VALVE STEM SEAL

Bearing
cap No.
Identification of
inlet side and
exhaust side
AC201460AB

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

5. Check the identification marks on the camshaft


bearing caps, front so that inlet side and exhaust
side cannot be mistaken in the same way as that
of bearing caps No.2 - 5.

CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
adhesion surface during that time.
6. Tighten the bearing cap mounting bolts increasing
the pressure in 2 to 3 times and finally tighten to
the specified torque.
Tightening torque: 20 1 Nm
7. Ensure that the rocker arms are installed properly.
NOTE: Remove an excess of sealant completely.
>>G<< CAMSHAFT OIL SEALS INSTALLATION

Engine front

MD998713

AC201461AB

3. Apply sealant to the positions (6 areas) of the


upper side of the cylinder head as shown in the
illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the camshaft bearing caps, rear
and camshaft bearing caps, front within 15
minutes after applying liquid gasket.

Engine front

Front
marking

AC201462AB

4. Position the camshaft bearing caps, rear in the


direction as shown in the illustration for
installation.

AC102323 AB

1. Apply engine oil to the entire inner diameter of the


oil seal lip.
2. Use special tool camshaft oil seal installer
(MD998713) to press-fit the oil seals.
>>H<< CAMSHAFT SPROCKETS INSTALLATION

AC201457AB

1. Hold the hexagon part of the camshaft with a


wrench in the same manner as removal.
2. Tighten the camshaft sprocket mounting bolts to
the specified torque.
Tightening torque: 89 9 Nm

ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL

>>I<< CAMSHAFT POSITION SENSOR SUPPORT


INSTALLATION
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.

11A-21

2. Install the vane (small) of the camshaft position


sensing cylinder at an angle of approximately 45
degrees to the position of the dowel pin of the
exhaust camshaft.
3. Tighten the camshaft position sensing cylinder
mounting bolts to the specified torque.
Tightening torque: 22 4 Nm
>>K<< RADIATOR UPPER HOSE CONNECTION
Projection

3 mm

AC201463 AB

2. Apply the sealant to the camshaft position sensor


support flange in a continuous bead as shown in
the illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the camshaft position sensor
support within 15 minutes after applying liquid
gasket.
3. Install the camshaft position sensor support to the
cylinder head.

CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
adhesion surface during that time.
4. Tighten the camshaft position sensor support
mounting bolts to the specified torque.
Tightening torque: 14 1 Nm

Water outlet fitting

Mating marks
AC200642 AE

1. Insert each hose as far as the projection of the


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

>>J<< CAMSHAFT POSITION SENSING


CYLINDER INSTALLATION
Approximately 45

Dowel pin

Vane (small)

Vane (large)
AC201464AB

1. Set the dowel pin of the exhaust camshaft to the


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

AC201465AB

2. Apply sealant to the positions (4 areas) of the


lower side of the rocker cover as shown in the
illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the rocker cover gasket within 15
minutes after applying liquid gasket.
3. Install the rocker cover gasket to the rocker cover.

ENGINE MECHANICAL

11A-22

CAMSHAFT AND VALVE STEM SEAL

>>M<< CAMSHAFT END SEAL INSTALLATION


>>N<< ROCKER COVER INSTALLATION
Engine front

AC201469AB

1. Apply sealant to the positions of the rocker cover


gasket (6 areas) as shown in the illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the rocker cover within 15 minutes
after applying liquid gasket.
2. Install the rocker cover to the cylinder head.

10 mm
10 mm

Cylinder head
AC201468 AB

Apply sealant to the positions of the camshaft end


seal as shown in the illustration and install to the
cylinder head.
Specified sealant: 3M ATD Part No.8660 or
equivalent
NOTE: Install the camshaft end seal within 15
minutes after applying liquid gasket.

CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
adhesion surface during that time.
3. Tighten the rocker cover mounting bolts to the
specified torque.
Tightening torque: 3.5 0.5 Nm

ENGINE MECHANICAL

11A-23

OIL PAN

OIL PAN
REMOVAL AND INSTALLATION <2WD>
M1112002800592

Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).

Post-installation Operation
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).

5
N

35 6 Nm

39 5 Nm

9.0 3.0 Nm

2
26 5 Nm
9.0 1.0 Nm

9.0 3.0 Nm

1.
2.
3.

Removal steps
Exhaust manifold bracket
Flywheel housing front lower cover
Engine oil pan drain plug

AC300542 AB

>>B<< 4.
<<A>> >>A<< 5.

Removal steps &RQWLQXHG


Engine oil pan drain plug gasket
Engine oil pan

ENGINE MECHANICAL

11A-24

OIL PAN

REMOVAL SERVICE POINT

3. Assemble the engine oil pan to the cylinder block.

<<A>> ENGINE OIL PAN REMOVAL


1. Remove the engine oil pan mounting bolts.

CAUTION
Perform this slowly to avoid deformation of the
engine oil pan flange.

CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
sealant surface during that time.

MD998727

MD998727

M6 8 mm
AC102698 AB

INSTALLATION SERVICE POINTS

4. Tighten the engine oil pan mounting bolts to the


specified torque. Be careful when installing, as the
oil pan mounting bolts (indicated in the illustration)
have different lengths from the other bolts.
Tightening torque: 9.0 3.0 Nm

>>A<< ENGINE OIL PAN INSTALLATION


1. Remove sealant from the engine oil pan and
cylinder block surfaces.

>>B<< ENGINE OIL PAN DRAIN PLUG GASKET


INSTALLATION

AC102324 AB

2. Remove the engine oil pan using special tool oil


pan remover (MD998727).

Engine
oil pan
side

4 mm
Groove portion Bolt hole portion

AC102133AB

2. Apply a bead of the sealant to the cylinder block


mating surface of the engine oil pan as shown.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the engine oil pan within 15 minutes
after applying sealant.

AC102325 AE

Replace the gasket with a new gasket. Install the


new gasket in the direction shown in the illustration.

ENGINE MECHANICAL

11A-25

OIL PAN

REMOVAL AND INSTALLATION <4WD>


M1112002800600

Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Centre Member Removal (Refer to GROUP 32, Engine
Roll Stopper and Centre Member 332).

Post-installation Operation
Centre Member Installation (Refer to GROUP 32, Engine
Roll Stopper and Centre Member 332).
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).

9.0 3.0 Nm

9.0 3.0 Nm

39 5 Nm

44 10 Nm

9.0 1.0 Nm

22 4 Nm

5
9.0 3.0 Nm

9.0 3.0 Nm
AC300543 AB

>>D<<

1.

>>C<<

2.
3.
4.

Removal steps
Transmission housing front lower
cover stay
Flywheel housing front lower cover
Engine oil pan drain plug
Engine oil pan drain plug gasket

<<A>>
<<B>>

>>B<<
>>A<<

5.
6.

Removal steps &RQWLQXHG


Engine lower oil pan
Engine upper oil pan

ENGINE MECHANICAL

11A-26

OIL PAN

REMOVAL SERVICE POINTS

INSTALLATION SERVICE POINTS

<<A>> ENGINE LOWER OIL PAN REMOVAL


1. Remove the engine lower oil pan mounting bolts.

>>A<< ENGINE UPPER OIL PAN INSTALLATION


1. Remove sealant from the engine upper oil pan
and cylinder block surfaces.

CAUTION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.

4 mm
Bolt hole
portion

Groove
portion

Engine lower oil pan


AC102931AB

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


strike it with a hammer to remove the engine lower
oil pan.
<<B>> ENGINE UPPER OIL PAN REMOVAL
1. Remove the engine upper oil pan mounting bolts.

CAUTION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.

AC102242AB

2. Apply a bead of the sealant to the mating surface


of the engine upper oil pan as shown.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the engine upper oil pan within 15
minutes after applying sealant.
3. Assemble the engine upper oil pan to the cylinder
block.

CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
sealant surface during that time.
B

B
A

A
B

AC102946AB

2. Screw in the bolt into bolt hole A in the location


shown. Then lift the upper oil pan and remove it.

B
B
A

A
AC102929AB

4. Insert the bolts to the engine upper oil pan as


shown, and tighten them to the specified torque.

ENGINE MECHANICAL

11A-27

OIL PAN

Name

Symbol

Flange bolt A
B

Quantity

Size mm
(D L)

Name

M6 16

Flange bolt A

16

M6 18

NOTE: D: Nominal diameter, L: Nominal length


Tightening torque: 9.0 3.0 Nm
>>B<< ENGINE LOWER OIL PAN INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan.

Symbol

Quantity

Size mm
(D L)

M6 75

11

M6 10

NOTE: D: Nominal diameter, L: Nominal length


Tightening torque: 9.0 3.0 Nm
>>C<< ENGINE OIL PAN DRAIN PLUG GASKET
INSTALLATION

Engine lower
oil pan side

4 mm
AC102325 AF

Bolt hole
portion

Groove
portion

AC102243AB

2. Apply a bead of the sealant to the mating surface


of the engine lower oil pan as shown.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the engine lower oil pan within 15
minutes after applying sealant.
3. Assemble the engine lower oil pan to the engine
upper oil pan.

CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
sealant surface during that time.
B-1

B-11

M1112002900210

B-7
B-6
A-3

B-8
B-9

B-12

B-2

>>D<< TRANSMISSION HOUSING FRONT


LOWER COVER STAY INSTALLATION
Install the transmission housing front lower cover
stay in the following order.
1. Tighten the engine side four mounting bolts to the
specified torque.
Tightening torque: 22 4 Nm
2. Tighten the transmission side two mounting bolts
to the specified torque.
Tightening torque: 44 10 Nm

INSPECTION

B-10

B-4
B-5

Replace the gasket with a new one. Install the new


gasket in the direction shown in the illustration.

AC102930AB

4. Insert the bolts to the engine lower oil pan as


shown, and tighten them to the specified torque in
the order shown.

Check the oil pan for cracks.


Check the oil pan sealant-coated surface for
damage and deformation.

ENGINE MECHANICAL

11A-28

CRANKSHAFT OIL SEAL

CRANKSHAFT OIL SEAL


REMOVAL AND INSTALLATION
M1112003100273

132 5 Nm

4
5
7

8
9

3
N

Lip section

Lip section

Engine oil

AC300544 AB

>>D<<

1.

>>C<<

2.
3.

Crankshaft front oil seal removal


steps
Valve timing belt, balancer timing
belt (Refer to 311A).
Crankshaft balancer shaft drive
sprocket
Crankshaft key
Crankshaft front oil seal

<<A>>
<<B>>

>>B<<

>>A<<

4.
5.
6.
7.
8.
9.

Crankshaft rear oil seal removal


steps
Transmission assembly
Flywheel bolts
Flywheel adapter plate
Flywheel assembly
Flywheel adapter plate
Crankshaft bush
Crankshaft rear oil seal

ENGINE MECHANICAL

11A-29

CRANKSHAFT OIL SEAL

REMOVAL SERVICE POINTS


<<A>> TRANSMISSION ASSEMBLY REMOVAL

CAUTION

2. Use the following special tools to press-fit the oil


seal.
Installer bar (MB990938)
Crankshaft rear oil seal installer (MD998776)
>>B<< FLYWHEEL BOLTS INSTALLATION

Engine front

MD998781

Flywheel
assembly
Flywheel bolt
AC300897 AB

Do not remove the flywheel bolt shown by the


arrow. If this bolt is removed, the flywheel
assembly will become out of balance and
damaged.
Refer to GROUP 22A, Transmission Assembly
322A.
<<B>> FLYWHEEL BOLTS REMOVAL

AC211914AC

1. Use special tool flywheel stopper (MD998781) to


secure the flywheel in the same manner as
removal.
2. Tighten the flywheel bolts to the specified torque.
Tightening torque: 132 5 Nm
>>C<< CRANKSHAFT FRONT OIL SEAL
INSTALLATION

MD998781

Crankshaft

MD998375

(Engine oil)
AC211914AC

1. Use special tool flywheel stopper (MD998781) to


secure the flywheel.
2. Remove the flywheel bolts.

INSTALLATION SERVICE POINTS


>>A<< CRANKSHAFT REAR OIL SEAL
INSTALLATION
Oil seal

MB990938
(Engine oil)

MD998776

Crankshaft
AC102328 AB

1. Apply a small amount of engine oil to the entire


inner diameter of the oil seal lip.

MD998285
(Oil applied to the
circumference)

Oil seal
AC102329 AC

1. Apply a small amount of engine oil to the entire


inner diameter of the oil seal lip.
2. Apply a small amount of engine oil to the outer
diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft.
3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal.

ENGINE MECHANICAL

11A-30

CYLINDER HEAD GASKET

>>D<< CRANKSHAFT BALANCER SHAFT DRIVE


SPROCKET INSTALLATION
: Clean
: Clean and degrease

Crankshaft

Front case
Crankshaft
balancershaft
drive sprocket

Engine front

AC211222 AB

1. Clean or degrease the front case, the crankshaft


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

CYLINDER HEAD GASKET


REMOVAL AND INSTALLATION
M1112004000655

Pre-removal Operation
Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service - Fuel Pump Connector Disconnection
(How to Reduce Pressurized Fuel Lines) 313A.]
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Air Cleaner and Air Cleaner Bracket Removal (Refer to
GROUP 15, Air Cleaner 315).
Battery Removal
Rocker Cover Centre Cover Removal (Refer to 311A
).
Valve Timing Belt Removal (Refer to 311A).

Post-installation Operation
Valve Timing Belt Installation (Refer to 311A).
Rocker Cover Centre Cover Installation (Refer to 311A
).
Battery Installation
Air Cleaner and Air Cleaner Bracket installation (Refer to
GROUP 15, Air Cleaner 315).
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Check and
Adjustment 317).
Drive Belt Tension Check (Refer to 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
Fuel Leak Check

ENGINE MECHANICAL

11A-31

CYLINDER HEAD GASKET

9
10

5.0 1.0 Nm

16

12

7
17

6
14

5.0 1.0 Nm

4
18

15
9.0 2.0 Nm

13 11

20
2

13 1 Nm

(Engine oil)

19

AC300545 AB

Removal steps
A/C compressor connector
Power steering fluid pressure
switch connector
3. Crank angle sensor connector
4. Ignition coil connectors
5. Detonation sensor connector
6. Purge control solenoid valve
connector
7. EGR control solenoid valve
connector
8. Injector connectors
9. Throttle position sensor connector
10. Idle speed control servo connector
11. Camshaft position sensor
connector
1.
2.

Removal steps &RQWLQXHG


12. Oxygen sensor connector
13. Engine coolant temperature sensor
connector
14. Engine coolant temperature gauge
unit connector
15. Capacitor connector
16. Accelerator cable connection
17. Brake booster vacuum hose
connection
18. Engine oil level gauge and guide
assembly
19. O-ring
20. Canister vacuum hose connection

ENGINE MECHANICAL

11A-32

CYLINDER HEAD GASKET

24
25

26

<Cold engine>
78 2 Nm 0 Nm 20 2 Nm +90 +90

5.0 1.0 Nm

27 N

(Engine oil)

28

(Engine oil)

29

22
11 1 Nm

21
30 N
31 3 Nm

23

AC300546 AB

21.
22.
23.

24.

Removal steps
Detonation sensor connection
Battery wiring harness connection
Inlet manifold stay
Exhaust manifold (Refer to GROUP
15, Exhaust Manifold 315).
Water outlet fitting and thermostat
case assembly (Refer to GROUP
14, Water Hose and Water Pipe
314).
Rocker cover (Refer to 311A).
Heater water hose connection

>>C<<
<<A>>

>>C<<
>>B<<
>>A<<

25.
26.
27.
28.
29.
30.

Removal steps &RQWLQXHG


Fuel return line hose connection
Fuel high-pressure hose
connection
O-ring
Cylinder head bolts
Cylinder head assembly
Cylinder head gasket

ENGINE MECHANICAL

11A-33

CYLINDER HEAD GASKET

REMOVAL SERVICE POINT


<<A>> CYLINDER HEAD BOLTS REMOVAL

Identification
mark "63"
MB991654

Exhaust side
AC107217AC

2. Assemble to the cylinder block so the cylinder


head gasket identification mark "63" is at the top
surface and on the exhaust side.

Engine front

>>B<< CYLINDER HEAD BOLTS INSTALLATION


3

10

2
(Engine oil)

AC201623 AB

Using special tool cylinder head bolt wrench


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

INSTALLATION SERVICE POINTS


>>A<< CYLINDER HEAD GASKET INSTALLATION

CAUTION
Do not allow any foreign materials to get into the
coolant passages, oil passages and cylinder.
1. Remove the gasket from the cylinder head and
cylinder block.

A
AC102537AB

1. Check that the nominal length of each cylinder


head bolt meets the limit. If it exceeds the limit,
replace the bolt with a new one.
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.

ENGINE MECHANICAL

11A-34

CYLINDER HEAD GASKET

CAUTION
The bolt is not tightened sufficiently if the bolt is
tightened less than 90 degree angle.
(5) Tighten the bolt an additional 90 degree angle
as shown. Then check to see that the paint
mark on the head of the cylinder head bolts
and the paint mark on the cylinder head are
aligned.
(6) If tightening the bolt 90 degree angle results in
moving the paint mark on the bolt past the
paint mark on the cylinder head, remove the
bolt and start over from step 1.

MB991654

Engine front

>>C<< O-RING/FUEL HIGH-PRESSURE HOSE


INSTALLATION

10

Do not let any engine oil get into the delivery


pipe.
1. Apply a small amount of new engine oil to the Oring.
2. Turning the fuel high-pressure hose to the right
and left, install it to the delivery pipe, while being
careful not to damage the O-ring. After installing,
check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage.
After this, re-insert it to the delivery pipe and
check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
Tightening torque: 5.0 1.0 Nm

AC201625 AB

3. Use special tool cylinder head bolt wrench


(MB991654) to tighten the cylinder head bolts as
follows:
(1) Tighten the cylinder head bolts to 78 2 Nm
in the order shown.
(2) Loosen the bolts fully in the reverse order of
that shown.
(3) Tighten the cylinder head bolts to 20 2 Nm
in the order shown.
Step (4)
90

Paint marking

Step (5)
90

Paint marking
AC102331AB

(4) Apply a paint mark to the heads of the cylinder


head bolts and cylinder head, then tighten 90
degree angle as shown.

CAUTION

ENGINE MECHANICAL

11A-35

TIMING BELT

TIMING BELT
REMOVAL AND INSTALLATION
M1112004300656

Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Crankshaft Shaft Damper Pulley Removal (Refer to
311A).

Post-installation Operation
Crankshaft Shaft Damper Pulley Installation (Refer to
311A).
Drive Belt Tension Check (Refer to 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).

10
9
2

48 5 Nm

11 1 Nm
21 4 Nm

3
8.8 1.0 Nm

23 3 Nm

11

1
6
44 10 Nm

5
4
22 4 Nm

>>H<<

1.
2.
3.
4.
5.
6.
7.

7
11 1 Nm

79 5 Nm

9.0 1.0 Nm

Removal steps
Control wiring harness connection
Timing belt upper cover
Water pump pulley
Idler pulley
End cap
Auto-tensioner
Timing belt lower cover

AC300547 AB

Removal steps &RQWLQXHG


Engine front mounting bracket
(Refer to GROUP 32, Engine
Mount 332).

Valve timing belt tension


adjustment
8. Valve timing belt
9. Timing belt tensioner pulley
10. Timing belt tensioner arm
11. Timing belt tensioner adjuster

>>G<<
<<A>>

>>F<<
>>E<<
>>D<<

ENGINE MECHANICAL

11A-36

TIMING BELT

12

22 4 Nm

16
35 6 Nm

21
20

22 4 Nm

13

19 3 Nm

14
(Engine oil)
49 9 Nm

15
18

19

49 9 Nm

17
8.8 1.0 Nm

167 Nm
AC300548 AB

<<B>>

Removal steps
12. Power steering fluid pressure
switch connector
13. Power steering oil pump assembly
14. A/C compressor connector
15. Power steering oil pump bracket
16. Timing belt idler pulley
17. Crank angle sensor

<<C>>

<<D>>

>>C<<
>>C<<
>>B<<

18.
19.

>>A<<
>>A<<

20.
21.

Removal steps &RQWLQXHG


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

REMOVAL SERVICE POINTS


<<A>> VALVE TIMING BELT REMOVAL

CAUTION
Never turn the crankshaft anti-clockwise.

MD998738

Timing mark

Timing belt
under cover
AC102492 AB

AC102487

1. Turn the crankshaft clockwise, align each timing


mark to set No.1 cylinder to TDC of its
compression stroke.

2. Remove the timing belt under cover rubber plug


and then set the special tool adjusting bolt
(MD998738).

ENGINE MECHANICAL

11A-37

TIMING BELT

CAUTION
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
screwed in all at once, the timing belt tensioner
adjuster rod will not easily retract and the special
tool may bend.
Timing belt
tensioner arm

MD998738

AC107289 AB

<<B>> POWER STEERING OIL PUMP ASSEMBLY


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

MB991385

3. Screw in the special tool until it comes in contact


with the timing belt tensioner arm.
MB991367

AC102332 AB

AC102775AB

4. Gradually screw in the special tool. Then align the


timing belt tensioner adjuster rod set hole A with
the timing belt tensioner adjustor cylinder set hole
B.
Timing belt
tensioner pulley
mounting bolt

1. Use the following special tools to support the


crankshaft camshaft drive sprocket.
Special spanner (MB991367)
Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft camshaft drive sprocket.
<<D>> BALANCER TIMING BELT REMOVAL

CAUTION
To reuse the balancer timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk.

INSTALLATION SERVICE POINTS


>>A<< BALANCER TIMING BELT/BALANCER
TIMING BELT TENSIONER INSTALLATION

Wire

Balancershaft sprocket
Belt tension side
AC107185 AB

Timing mark

Timing mark

5. Insert a wire, etc.in the set hole.

CAUTION
To reuse the valve timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk.
6. After removal of adjusting bolt special tool, loosen
the timing belt tensioner pulley mounting bolt and
remove the valve timing belt.

Crankshaft
balancershaft
drive sprocket

AC102689 AB

1. Ensure that the crankshaft balancershaft drive


sprocket timing marks and balancershaft sprocket
timing marks are aligned.

ENGINE MECHANICAL

11A-38

TIMING BELT

2. Install the balancer timing belt on the crankshaft


balancershaft drive sprocket and balancershaft
sprocket. There should be no slack on the tension
side.
Centre of the
mounting bolt

1. With your fingers, lift the balancer timing belt


tensioner in the direction of the arrow. Apply
pressure of 3.0 0.4 Nm to the balancer timing
belt. Tighten the assembling bolt to the specified
torque. Then, fix the balancer timing belt
tensioner.
Tightening torque: 19 3 Nm
Balancershaft sprocket

Timing mark

Centre of
the pulley

Timing mark

AC102690 AB

3. Assemble and temporarily fix the centre of the


pulley of the balancer timing belt tensioner so that
it is at the top left from the centre of the mounting
bolt, and the pulley flange is at the front-side of
the engine.
4. Adjust the balancer timing belt tension.
>>B<< BALANCER TIMING BELT TENSION
ADJUSTMENT

CAUTION
When tightening the mounting bolt, ensure that
the tensioner does not rotate with the bolt.
Allowing it to rotate with the bolt can cause
excessive tension of the belt.

AC102691

Crankshaft
balancershaft
drive sprocket

AC102689AC

2. Turn the crankshaft clockwise two turns to set


No.1 cylinder to TDC of its compression stroke
and check that the sprocket timing marks are
aligned.

ENGINE MECHANICAL

11A-39

TIMING BELT

Approximately 100 N

Deflection

AC102693 AB

3. Apply a pressure of approximately 100N at the


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

2. Install the crankshaft angle sensing blade and


crankshaft camshaft drive sprocket in the direction
shown.
3. Place the larger chamfer side of the crank shaft
pulley washer in the direction shown and then
assemble on the crankshaft pulley centre bolt.
4. Apply some engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
Crankshaft
camshaft
drive
sprocket

MB991367

AC102332 AB

5. Use the following special tool as during removal to


support the crankshaft camshaft drive sprocket.
Special spanner (MB991367)
Pin (MB991385)
6. Tighten the crankshaft pulley centre bolts to the
specified torque.
Tightening torque: 167 Nm
>>D<< TIMING BELT TENSIONER ADJUSTER
INSTALLATION
1. Install according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.

Crankshaft pulley
center bolt
Crankshaft camshaft
drive sprocket

CAUTION
Crankshaft

If the compression is too fast, the procedure may


damage the rod.
A

Crankshaft
pulley washer
Engine front

MB991385

Crankshaft angle
sensing blade
AC211535AB

1. Clean or degrease the crankshaft, the crankshaft


angle sensing blade, the crankshaft camshaft
drive sprocket and crankshaft pulley washer as
shown.
NOTE: Also clean the degreased surfaces.

AC102334 AB

(1) Slowly compress the timing belt tensioner


adjuster rod using a press or vice, then align
the set hole A of the rod with set hole B of the
timing belt tensioner adjuster cylinder.

ENGINE MECHANICAL

11A-40

TIMING BELT

>>F<< VALVE TIMING BELT INSTALLATION


Wire
Timing mark

AC102335 AB

(2) Insert a wire or pin into the aligned set hole.


NOTE: When replacing the timing belt
tensioner adjuster with new parts, the timing
belt tensioner adjuster is set with a pin.
2. Assemble the timing belt tensioner adjuster to the
engine, then tighten the assembling bolt to the
specified torque. Do not remove the wire or pin
until the tension of the valve timing belt is
adjusted.
Tightening torque: 23 3 Nm

Camshaft sprocket

Crankshaft
camshaft
drive sprocket

Timing mark
Timing mark

>>E<< TIMING BELT TENSIONER PULLEY


INSTALLATION

Engine oil
pump sprocket

AC102486 AC

1. Align the timing marks on the camshaft sprocket,


crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Bolt
Balancershaft

Timing belt tensioner


pulley hole

Plug
AC102336AB

Temporarily tighten the timing belt tensioner pulley as


shown.

Cylinder
block
AC102337 AE

2. Adjust the timing mark of the engine oil pump


sprocket. Unplug the cylinder block plug. Insert a
bolt (M6 sectional width 10 mm, minor diameter
45 mm) from the plug hole and then check. If the
bolt comes in contact with the balancer shaft turn
the sprocket one rotation. Re-adjust the timing
mark and then check to see that the bolt fits. Do
not remove the bolt until the valve timing belt is
assembled.

ENGINE MECHANICAL
TIMING BELT

3. Install the valve timing belt as follows:


Inlet side
camshaft sprocket

11A-41

Timing mark
Timing mark

Exhaust side
camshaft sprocket

AC201802 AB

Timing belt
tensioner
pulley

Crankshaft
camshaft
drive
sprocket

Timing belt
idler pulley

(3) Use two wrenches to align the timing mark on


the rocker cover with that on the camshaft
sprocket. Pass the valve timing belt around the
inlet-side camshaft sprocket.

Engine
oil pump
sprocket

AC102488 AC

(1) Pass the valve timing belt around the


crankshaft camshaft drive sprocket, the engine
oil pump sprocket and the timing belt idler
pulley in that order.

Paper clip

AC201803AB

(4) Hold the valve timing belt with paper clips.


(5) Pass the valve timing belt around the timing
belt tensioner pulley.

CAUTION
Paper clip

Incorporate the valve timing belt. Then apply


reverse rotation (anti-clockwise rotation)
pressure to the cam shaft sprocket. Re-check to
see that each timing mark is aligned while the
tension side of the belt is tight.
(6) Remove the two paper clips.

AC201801AB

(2) Pass the valve timing belt around the exhaustside camshaft sprocket, and hold the valve
timing belt with paper clip.
MD998767

AC102694 AB

4. Turn the timing belt tensioner in the direction


shown using special tool tensioner wrench
(MD998767) to apply tension to the valve timing
belt. Then pre-tighten the timing belt tensioner
pulley.
5. Check that the timing marks are aligned.

ENGINE MECHANICAL

11A-42

TIMING BELT
Bolt
Balancershaft

CAUTION
When tightening the mounting bolt, ensure that
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.

Plug
Cylinder
block
AC102337 AE

6. Remove the bolt inserted in Step 2 above, then


assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified
torque.
Tightening torque: 30 3 Nm
8. Adjust the valve timing belt tension.
>>G<< VALVE TIMING BELT TENSION
ADJUSTMENT

MD998767

AC102695AB

6. With special tool tensioner wrench (MD998767)


and torque wrench, apply tension torque 3.5 Nm,
and tighten the timing belt tensioner pulley
mounting bolt to the specified torque.
Tightening torque: 48 5 Nm

MD998738

Wire

Timing belt
under cover
AC102492 AB

1. Set special tool adjusting bolt (MD998738) when


removing the valve timing belt.

CAUTION
Always screw in special tool by hand, since use
of a spanner or other tools may damage the wire
or pin inserted in the timing belt tensioner
adjuster.
2. Gradually screw in special tool until the wire or pin
inserted in the timing belt tensioner adjuster lightly
moves.
3. Turn the crankshaft 1/4 turn anti-clockwise.
4. Turn the crankshaft in the clockwise direction until
you align each timing mark to set No.1 cylinder to
TDC of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting
bolt.

AC102776 AB

7. Remove wire or pin inserted to timing belt


tensioner.

MD998738

Timing belt
under cover
AC102492 AB

8. Remove the special tool adjusting bolt


(MD998738), and install the rubber plug to the
timing belt under cover.
9. Rotate the crankshaft clockwise two turns, and
leave it for about 15 minutes.

ENGINE MECHANICAL

11A-43

TIMING BELT

CAUTION
Always check the tightening torque of the crank
shaft pulley centre bolt when turning the crack
shaft pulley centre bolt anti-clockwise. Retighten if it is loose.

Wire

Timing mark

AC102776 AB

10.Insert wire or pin removed in Step 7 again, and


ensure that it can be pulled out easily. When wire
or pin can be easily removed, appropriate tension
is applied on timing belt. In this case, remove wire
or pin.

Camshaft
sprocket

Crankshaft
camshaft
drive sprocket

Timing belt
tensioner
adjuster

Timing mark
Timing mark

AC102338AB

If the projection of timing belt tensioner adjuster


rod is within the standard value, appropriate
tension is applied.
Standard value (A): 3.8 - 4.5 mm
11.If wire or pin cannot be easily pulled out, repeat
Step 1 through Step 9 to reach proper valve timing
belt tension.

Engine
oil pump
sprocket

AC201411AB

12.Check again that the timing marks on sprockets


are aligned.
>>H<< END CAP INSTALLATION

CAUTION
Always replace the end cap with new parts since
there may be fall-off or sealing defect if the end
cap is re-used.

INSPECTION
M1112004400352

TIMING BELT TENSIONER ADJUSTER


CHECK
1. Check for oil leak from seal, and replace it if leak
is detected.
2. Check for wear or damage at the top of the rod.
Replace it, if required.

ENGINE MECHANICAL

11A-44

TIMING BELT

98 196 N

Movement

BALANCER TIMING BELT TENSION


CHECK
Check the balancer timing belt tension as follows:

B
Approximately 100 N

Rod

Timing belt
tensioner
adjuster
AC102339 AB

3. Hold the timing belt tensioner adjuster by hand,


and press the top end of the rod onto the metal
(e.g. cylinder block) under a pressure of 98 - 196
N to measure the movement of the rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
4. If the measured value is out of the standard value,
replace the timing belt tensioner adjuster.

Deflection

AC102693 AB

1. Apply a pressure of approximately 100 N at the


centre (arrow area) between the sprocket as
shown then inspect whether the deflection is
within the standard value.
Standard value: 5 - 10 mm
2. If not within the standard value, adjust the belt
tension. (Refer to 311A).

ENGINE MECHANICAL
ENGINE ASSEMBLY

11A-45

ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001000720

CAUTION
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Pre-removal Operation
Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service - Fuel Pump Connector Disconnection
(How to Reduce Pressurized Fuel Lines) 313A.]
Hood Removal (Refer to GROUP 42, Hood 342).
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Air Cleaner and Air Cleaner Bracket Removal (Refer to
GROUP 15, Air Cleaner 315).
Battery and Battery Tray Removal
Rocker Cover Centre Cover Removal (Refer to 311A
).
Radiator Assembly Removal (Refer to GROUP 14,
Radiator 314).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Starter Assembly Removal (Refer to GROUP 16, Starter
Motor Assembly 316).

Post-installation Operation
Starter Assembly Installation (Refer to GROUP 16,
Starter Motor Assembly 316).
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Radiator Assembly Installation (Refer to GROUP 14,
Radiator 314).
Battery and Battery Tray Installation
Rocker Cover Centre Cover Installation (Refer to 311A
).
Air Cleaner and Air Cleaner Bracket installation (Refer to
GROUP 15, Air Cleaner 315).
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service - Engine Coolant Replacement 314).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Check and
Adjustment 317).
Drive Belt Tension Check (Refer to 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
Hood Installation (Refer to GROUP 42, Hood 342).
Fuel Leak Check

ENGINE MECHANICAL

11A-46

ENGINE ASSEMBLY

9
5.0 1.0 Nm

10

17

12

7
5

6
14

5.0 1.0 Nm

15
11

9.0 2.0 Nm

13

2
1

9.0 2.0 Nm

18
5.0 1.0 Nm

16

9.0 2.0 Nm
5.0 1.0 Nm

1.
2.
3.
4.
5.
6.
7.
8.
9.

Removal steps
A/C compressor connector
Power steering fluid pressure
switch connector
Crank angle sensor connector
Ignition coil connectors
Detonation sensor connector
Purge control solenoid valve
connector
EGR control solenoid valve
connector
Injector connectors
Throttle position sensor connector

10.
11.
12.
13.
14.

<<A>>

15.
16.
17.
18.

AC300549 AB

Removal steps &RQWLQXHG


Idle speed control servo connector
Camshaft position sensor
connector
Oxygen sensor connector
Engine coolant temperature sensor
connector
Engine coolant temperature gauge
unit connector
Capacitor connector
Battery wiring harness connection
Accelerator cable connection
Drive belt

ENGINE MECHANICAL

11A-47

ENGINE ASSEMBLY

23
24
19

25
5.0 1.0 Nm

26 N

(Engine oil)

12 2 Nm

20
44 10 Nm*

22 4 Nm

27

22
22 4 Nm

45 5 Nm*

29
28
21
AC300550 AB

<<B>>
<<B>>

Removal steps
19. Brake booster vacuum hose
connection
20. Canister vacuum hose connection
21. A/C compressor and clutch
assembly
22. Power steering oil pump assembly
23. Heater water hoses connection
24. Fuel return line hose connection

>>E<<
<<C>>
<<D>>
<<E>>

>>E<<
>>D<<
>>C<<
>>B<<
>>A<<

Removal steps &RQWLQXHG


25. Fuel high-pressure hose
connection
26. O-ring

Transmission assembly
27. Self-locking nuts
28. Engine front mounting bracket
29. Engine assembly

ENGINE MECHANICAL

11A-48

ENGINE ASSEMBLY

REMOVAL SERVICE POINTS

<<C>> TRANSMISSION ASSEMBLY REMOVAL

<<A>> DRIVE BELT REMOVAL


The following operations will be needed due to the
serpentine drive system with the drive belt autotensioner.
Auto-tensioner

AC300950AB

Hole B

Hole A

AC107640AC

1. Securely insert the spindle handle or ratchet


handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner, and turn the autotensioner anti-clockwise until it hits the stopper.

CAUTION
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk.

1. Pre-tighten the 2 bolts on the car to assemble the


radiator support upper insulator to set the special
tools engine hanger MB991895 or engine hanger
MB991928.
2. Remove the transmission assembly (Refer to
GROUP 22A, Transmission Assembly 322A).
<<D>> ENGINE FRONT MOUNTING BRACKET
REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.
MB991895
MB991527

Auto-tensioner

L-shaped
hexagon
wrench

MB991454
AC107631AB
AC107641AB

2. Align hole A with hole B, insert an L-shaped


hexagon wrench, etc. to fix and then remove the
drive belt.
<<B>> A/C COMPRESSOR AND CLUTCH
ASSEMBLY/POWER STEERING OIL PUMP
ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly, and power steering oil pump
assembly from the bracket.
NOTE: Secure the removed A/C compressor and
clutch assembly, and power steering oil pump
assembly with cord or rope at a position where they
will not interfere with the removal of the engine
assembly.

(1) <Special tool engine hanger (MB991895) is


used>
Remove special tool MB991895.
MB991928

MB991527
MB991454
AC211405 AB

(2) <Special tool engine hanger (MB991928) is


used>
Remove special tool MB991928.

ENGINE MECHANICAL

11A-49

ENGINE ASSEMBLY

2. Support the engine assembly with a garage jack.


3. Remove the chain block.
4. Use the following special tool as during removal to
support the engine.

MB991454
MB991527

MB991895
MB991527

AC107632 AB

3. Hold the engine assembly with a chain block, etc.


4. Place a garage jack against the engine oil pan
with a piece of wood in between so that the weight
of the engine assembly is no longer being applied
to the engine front mounting bracket.
5. Loosen the engine front mounting bracket
mounting nuts and bolt, and remove the engine
front mounting bracket.

MB991454
AC107631AB

(1) <Special tool engine hanger (MB991895) is


used>
Set special tool MB991895. (Refer to
GROUP 22A, Transmission Assembly
322A).

<<E>> ENGINE ASSEMBLY REMOVAL


After checking that all cables, hoses and wiring
harness connectors and so on are disconnected
from the engine, lift the chain block slowly to remove
the engine assembly upward from the engine
compartment.

MB991928

MB991527

INSTALLATION SERVICE POINTS


>>A<< ENGINE ASSEMBLY INSTALLATION

MB991454
AC211405 AB

(2) <Special tool engine hanger (MB991928) is


used>
Set special tool MB991928 (Refer to
GROUP 22A, Transmission Assembly
322A).

MB991454
MB991527

>>C<< SELF-LOCKING NUTS INSTALLATION

CAUTION
Install the engine assembly, being careful not to
pinch the cables, hoses or wiring harness
connectors.

Do not tighten the self-locking nuts while the


engine is hot.
Tighten the self-locking nuts to the specified torque
while the engine is cold.
Tightening torque: 45 5 Nm

>>B<< ENGINE FRONT MOUNTING BRACKET


INSTALLATION
1. Place a garage jack against the engine oil pan
with a piece of wood in between, and install the
engine front mounting bracket while adjusting the
position of the engine.

>>D<< TRANSMISSION ASSEMBLY


INSTALLATION
1. Install the transmission assembly (Refer to
GROUP 22A, Transmission Assembly 322A).

AC107632 AB

ENGINE MECHANICAL

11A-50

ENGINE ASSEMBLY

>>E<< O-RING/FUEL HIGH-PRESSURE HOSE


INSTALLATION

CAUTION

AC300950AB

2. Remove from the car the 2 bolts, to assemble the


radiator support upper insulator.

Do not let any engine oil get into the delivery


pipe.
1. Apply a small amount of new engine oil to the Oring.
2. Turning the fuel high-pressure hose to the right
and left, install it to the delivery pipe, while being
careful not to damage the O-ring. After installing,
check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage.
After this, re-insert it to the delivery pipe and
check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
Tightening torque: 5.0 1.0 Nm

11B-1

GROUP 11B

00
11

ENGINE OVERHAUL

12
13
14

CONTENTS
HOW TO USE THIS MANUAL. . . . . .

11B

GENERAL INFORMATION . . . . . . . .

11B

GENERAL SPECIFICATIONS . . . . . .

11B

SERVICE SPECIFICATIONS. . . . . . .

11B

EXHAUST MANIFOLD REMOVAL AND


INSTALLATION . . . . . . . . . . . . . . . . . . . . . .

15
11B

WATER PUMP AND WATER HOSE . 11B


WATER PUMP AND WATER HOSE
REMOVAL AND INSTALLATION . . . . . . . .

16
17
21

11B

ROCKER ARMS AND CAMSHAFT . . 11B

22
25

11B

ROCKER ARMS AND CAMSHAFT


REMOVAL AND INSTALLATION . . . . . . . .

11B

26

TORQUE SPECIFICATIONS . . . . . . .

11B

ROCKER ARMS AND CAMSHAFT


INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11B

27

SEALANTS . . . . . . . . . . . . . . . . . . . .

11B

CYLINDER HEAD AND VALVES. . . . 11B

31

SPECIAL TOOLS. . . . . . . . . . . . . . . .

11B

REWORK DIMENSIONS . . . . . . . . . .

ALTERNATOR AND IGNITION


SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION . . . . . . . .

TIMING BELT. . . . . . . . . . . . . . . . . . .

11B

11B

TIMING BELT INSPECTION. . . . . . . . . . . .

11B

FUEL AND EMISSION PARTS . . . . . 11B

INTAKE MANIFOLD REMOVAL AND


INSTALLATION. . . . . . . . . . . . . . . . . . . . . .

EXHAUST MANIFOLD. . . . . . . . . . . .

32

CYLINDER HEAD AND VALVES


INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11B

33

OIL PAN AND OIL PUMP. . . . . . . . . . 11B

11B

INTAKE MANIFOLD . . . . . . . . . . . . .

11B

11B

TIMING BELT REMOVAL AND


INSTALLATION. . . . . . . . . . . . . . . . . . . . . .

FUEL AND EMISSION PARTS REMOVAL


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

CYLINDER HEAD AND VALVES


REMOVAL AND INSTALLATION . . . . . . . .

35

OIL PAN AND OIL PUMP REMOVAL AND


INSTALLATION . . . . . . . . . . . . . . . . . . . . . .

11B

OIL PAN AND OIL PUMP INSPECTION. . .

11B

36

PISTON AND CONNECTING ROD . . 11B

37

PISTON AND CONNECTING ROD


REMOVAL AND INSTALLATION . . . . . . . .

11B

PISTON AND CONNECTING ROD


INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11B

42
51
52

11B

11B

34

CRANKSHAFT AND CYLINDER BLOCK


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

11B

CRANKSHAFT AND CYLINDER BLOCK


REMOVAL AND INSTALLATION . . . . . . . .

11B

11B

CRANKSHAFT AND CYLINDER BLOCK


INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11B

54
55

ENGINE OVERHAUL

11B-2

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL


M1113025100155

HOW TO USE THIS MANUAL


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

Classification of Service Points


Key service points, service standards, and instructions for
using special tools are collated as service points and explained in detail.

<<A>>: Outward-pointing brackets denote removal service points


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

Lubricant and Sealant Symbols


Every location where a lubricant or sealant must be applied
or added is indicated using a relevant symbol in the component part drawing and/or on the page after the component
part drawing.

. . . . . . . . . . Grease
. . . . . . . . . . Sealant or form-in-place gasket (FIPG)
. . . . . . . . . . Brake fluid
. . . . . . . . . . Engine oil or gear oil

Inspection
Only those inspection procedures which use special tools or measuring appliances are described. You must perform general visual inspection and part cleaning whenever necessary although their procedures are not described in this manual.

AK202851

ENGINE OVERHAUL

11B-3

HOW TO USE THIS MANUAL

Page number

Section title

ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

11-54

CRANKSHAFT AND CYLINDER BLOCK


REMOVAL AND INSTALLATION
3
Apply engine oil
to all moving
parts before
installtion.

Denotes non-reusable part.


1

11 1 Nm

16

11 1 Nm

15

132 5 Nm

9.0 1.0 Nm

Tightening torque
14

13

12
11
10

25 2 Nm + 90 to 100

AK204351AB

Removal steps
1. Drive plate bolt
2. Adapter plate
3. Drive plate
4. Crankshaft bushing
5. Rear plate
6. Bellhousing cover
>>E<< 7. Oil seal case
>>D<< 8. Oil seal
>>C<< 9. Bearing cap bolt
10. Bearing cap
>>B<< 11. Crankshaft bearing, lower
>>A<< 12. Crankshaft

INSTALLATION SERVICE POINTS


>>A<< THRUST BEARING INSTALLATION

Grooves
AK100786AB

The alphabetical character in this category of


heading matches that of the relevant removal
steps, installation steps, disassembly steps, or
reassembly steps.

Procedures and cautions for removal, installation, disassembly, and reassembly are explained under this category of heading.

AK300250

ENGINE OVERHAUL

11B-4

GENERAL INFORMATION

GENERAL INFORMATION
M1113000100233

VEHICLE AND ENGINE MODELS


Vehicle name

Vehicle
model

Engine model

Displacement Specification
mL

Outlander

CU2W

4G63-7

1,997

Double overhead camshaft, 16-valve

GENERAL SPECIFICATIONS
M1113000200478

Items

Specification

Bore stroke mm

85 88

Displacement mL

1,997

Combustion chamber

Pentroof type

Number of cylinders

Valve mechanism

Type

Double overhead camshaft

Number of intake valves

Number of exhaust
valves

Lash adjusters

Hydraulic

Rocker arms

Roller cam followers

Compresssion ratio

10.0

Fuel injection system

Electronically controlled multi-point injection (MPI)


system

Ignition system

Electronically controlled two-coil system

Generator

Alternator (with built-in IC regulator)

Starter motor

Gear reduction drive type

SERVICE SPECIFICATIONS
M1113000300419

Items

Standard value

Limit

Auto-tensioner rod extension length


(with timing belt installed) mm

3.8 - 4.5

Auto-tensioner rod extension length (when free) mm

12.0

Auto-tensioner rod retraction length


(when pressed with force of 98 to 196 N) mm

Less than 1

34.91

34.41

Less than 0.05

0.2

TIMING BELT

ROCKER ARMS AND CAMSHAFTS


Cam height mm
CYLINDER HEAD AND VALVES
Cylinder head gasket surface warp mm

ENGINE OVERHAUL

11B-5

SERVICE SPECIFICATIONS

Items

Standard value

Limit

Cylinder head gasket surface grinding limit


(including cylinder block grinding amount) mm

0.2

Cylinder head overall height mm

131.9 - 132.1

Cylinder head bolt nominal length mm

99.4

Valve margin mm

Intake valves

1.0

0.5

Exhaust valves

1.5

1.0

Valve stem diameter mm

6.6

Valve face angle

45.5

Intake valves

0.02 - 0.05

0.10

Exhaust valves

0.05 - 0.09

0.15

Intake valves

109.5

109.0

Exhaust valves

109.7

109.2

Intake valves

49.2

49.7

Exhaust valves

48.4

48.9

Valve spring free height mm

48.3

47.3

Valve spring load/height N/mm

294/40

Valve spring squareness

1.5or less

Valve face-to-seat contact width mm

0.9 - 1.3

Valve guide inside diameter mm

6.6

Valve guide press-in height mm

19.2 - 19.8

Drive gear

0.08 - 0.14

Driven gear

0.06 - 0.12

85.0

Valve stem-to-guide clearance mm


Valve height mm
Valve stem projection mm

OIL PAN AND OIL PUMP


Oil pump gear side clearance mm

PISTONS AND CONNECTING RODS


Piston outside diameter mm
Piston ring side clearance in ring
groove mm

No. 1

0.02 - 0.06

0.1

No. 2

0.02 - 0.06

0.1

Piston ring end gap mm

No. 1

0.20 - 0.30

0.8

No. 2

0.30 - 0.45

0.8

Oil ring

0.10 - 0.40

1.0

Piston pin outside diameter mm

22.0

Piston pin press-in load (at ambient temperature) N

7,350 - 17,100

Oil clearance at crankshaft pins mm

0.03 - 0.05

0.1

Connecting rod big end thrust clearance mm

0.10 - 0.25

0.4

Crankshaft end play mm

0.05 - 0.25

0.4

Crankshaft journal diameter mm

57.0

Crankshaft pin diameter mm

45.0

Oil clearance at crankshaft journals mm

0.03 - 0.04

0.1

Cylinder block gasket surface warp mm

0.05

0.1

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL

11B-6

REWOK DIMENSIONS

Items

Standard value

Limit

Cylinder block gasket surface grinding limit


(including cylinder head grinding amount) mm

0.2

Cylinder block overall height mm

284

Cylinder bore diameter mm

85

Taper of cylinder mm

0.01 or less

Cylinder-to-piston clearance mm

0.02 - 0.04

Crankshaft bearing cap bolt nominal length mm

71.1

REWOK DIMENSIONS
M1113024300178

Items

Standard value

CYLINDER HEAD AND VALVES


Diameter of oversize valve seat ring hole in cylinder head
mm

Intake
Exhaust

Diameter of oversize valve guide hole in cylinder head mm

0.03 oversize

35.30 - 35.33

0.06 oversize

35.60 - 35.63

0.03 oversize

33.30 - 33.33

0.06 oversize

33.60 - 33.63

0.05 oversize

12.05 - 12.07

0.25 oversize

12.25 - 12.27

0.50 oversize

12.50 - 12.52

TORQUE SPECIFICATIONS
M1113023400503

Items

Tightening torque Nm

ALTERNATOR AND IGNITION COIL


Oil level gauge guide bolts

13 1

Idler pulley bolt

79 5

Auto-tensioner assembly bolts (M8)

22 4

Auto-tensioner assembly bolts (M10)

44 10

Water pump pulley bolt

8.8 1.0

Alternator brace bolt (flange bolt)

23 3

Alternator brace bolt (washer assembled bolt)

22 4

Alternator nuts

44 10

Crankshaft pulley bolt

25 4

Center cover bolts

3.0 0.5

Ignition coil bolts

10 2

Spark plugs

25 5

TIMING BELT
Timing belt cover bolts (flange bolts)

11 1

Timing belt cover bolts (washer-assembled bolts)

9.0 1.0

ENGINE OVERHAUL

11B-7

TORQUE SPECIFICATIONS

Items

Tightening torque Nm

Power steering pump bracket bolts

49 9

Tensioner pulley bolt

48 5

Tensioner arm bolt

21 4

Auto-tensioner bolts

23 3

Idler pulley bolt

35 6

Crank angle sensor bolts

8.8 1.0

Oil pump sprocket nut

54 4

Crankshaft bolt

167

Tensioner B bolt

19 3

Counterbalance shaft sprocket bolt

45 3

Rocker cover bolts

3.5 0.5

Engine support bracket bolts

49 5

Camshaft sprocket bolt

88 10

FUEL SYSTEM
Vacuum hose and pipe clamp bolt

11 1

Throttle body bolts

19 3

EGR valve bolts

20 2

Fuel pressure regulator bolts

9.0 2.0

Delivery pipe and injector assembly bolts

11 1

Solenoid valve assembly bolts

9.0 1.0

INTAKE MANIFOLD
Intake manifold stay bolts

31 3

Intake manifold bolts (M8)

20 2

Intake manifold bolts and nuts (M10)

36 6

Engine hanger bolt

19 3

EXHAUST MANIFOLD
Oxygen sensor

44 5

Exhaust manifold cover bolts

14 1

Exhaust manifold bracket bolt (Cylinder block side)

35 6

Exhaust manifold bracket bolt (Exhaust manifold side)

44 5

Exhaust manifold nuts (M8)

29 3

Exhaust manifold nuts (M10)

49 5

WATER PUMP AND WATER HOSE


Coolant temperature sensor

29 10

Coolant temperature gauge unit

10.8 1.0

Water inlet fitting bolts

13 2

Water outlet fitting bolts

13 2

Thermostat housing bolts

23 4

Water inlet pipe bolts

13 2

Water pump bolts

14 1

11B-8

ENGINE OVERHAUL
TORQUE SPECIFICATIONS

Items

Tightening torque Nm

Knock sensor

23 2

ROCKER ARMS AND CAMSHAFTS


Camshaft position sensor bolts

8.8 1.0

Cover bolts

10 2

Camshaft position sensing cylinder bolt

22 4

Camshaft position sensor support bolts

14 1

Bearing cap bolts

20 1

Oil delivery body bolts

11 1

CYLINDER HEAD AND VALVES


Cylinder head bolts

78 2 loosen completely 20 2
90 + 90

OIL PUMP CASE AND OIL PAN


Drain plug

39 5

Transmission stay bolts

22 4

Oil pan upper section bolts

9.0 3.0

Oil pan lower section bolts

9.0 3.0

Oil screen bolts

19 3

Oil pressure switch

19 3

Relief plug

44 5

Oil filter bracket bolts

19 3

Plug cap

23 3

Flange bolts

36 3

Oil pump case bolts

23 3

Oil pump cover bolts

17 1

Oil pump cover screws

10 2

PISTONS AND CONNECTING RODS


Connecting rod cap nuts

20 2 90 to 94

CRANKSHAFT AND CYLINDER BLOCK


Flywheel bolts

132 5

Rear plate bolts

11 1

Bell housing cover bolts

9.0 1.0

Rear oil seal case bolts

11 1

Beam bearing cap bolts

25 2 90 to 100

ENGINE OVERHAUL

11B-9

SEALANTS

SEALANTS
M1113000500402

Items

Specified sealants

Engine support bracket bolts

Mitsubishi Genuine Part No.MD970389


or equivalent

Semicircular packing

3M ATD No.8660 or equivalent

Rocker cover

Mitsubishi Genuine Part No. MD970389


or equivalent

Engine coolant temperature sensor

3M Nut Locking Part No.4171 or


equivalent

Engine coolant temperature e gauge unit

3M ATD No.8660 or equivalent

Water outlet fitting*


Thermostat housing*

Mitsubishi Genuine Part No. MD970389


or equivalent

Cylinder head (camshaft bearing cap fitting section)

3M ATD No.8660 or equivalent

Camshaft position sensor support*

Mitsubishi Genuine Part No. MD970389


or equivalent

Oil pressure switch

3M ATD No.8660 or equivalent

Oil pan*

Mitsubishi Genuine Part No. MD970389


or equivalent

Rear oil seal case*


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

CLEANING FIPG APPLICATION SURFACE


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

ENGINE OVERHAUL

11B-10

SPECIAL TOOLS

SPECIAL TOOLS
M1113000600465

Tool

Number

Name

Use

MD998781

Flywheel stopper

Retention of flywheel

MD998778

Crankshaft sprocket
puller

Removal of crankshaft sprocket


and crankshaft sprocket B

MD998785

Sprocket stopper

Retention of counterbalancer
shaft sprocket

MD998767

Tension pulley socket Manipulation of tensioner pulley


wrench
during adjustment of timing belt
tension

MD998738

Set screw

Retention of tentioner arm and


auto-tensioner during timing belt
installation

MD998713

Camshaft oil seal


installer

Installation of camshaft oil seal

MD998442

Air bleed wire

Air bleeding of lash adjuster

D998781

D998767

D998738

D998713

ENGINE OVERHAUL

11B-11

SPECIAL TOOLS

Tool

Number

Name

Use

MB991654

Cylinder head bolt


wrench

Removal and installation of


cylinder head bolts

MD998772

Valve spring
compressor

Compression of valve spring

MD998735

Valve spring
compressor

Compression of valve spring

MD998737

Valve stem seal


installer

Installation of valve stem seal

MD998162

Plug wrench

Removal and installation of front


case plug cap
(Use with MD998783.)

MD998783

Plug wrench retainer

Removal and installation of front


case plug cap
(Use with MD998162.)

MD998371

Silent shaft bearing


puller

Removal of counterbalancer shaft


front bearing

MD998372

Silent shaft bearing


puller

Removal of counterbalancer shaft


front and rear bearings

B991654

ENGINE OVERHAUL

11B-12

SPECIAL TOOLS

Tool

Number

Name

Use

MB991603

Silent shaft bearing


installer stopper

Guide and stopper for removal


and press-fitting of
counterbalancer shaft rear
bearing

MD998705

Silent shaft bearing


installer

Press-fitting of counterbalancer
shaft front and rear bearings

MD998375

Crankshaft front oil


seal installer

Installation of crankshaft front oil


seal

MD998285

Crankshaft front oil


seal guide

Guide for installation of


crankshaft front oil seal

MD998780

Piston pin setting tool Removal and press-fitting of


piston pin

MD998776

Crankshaft rear oil


seal installer

Installation of crankshaft rear oil


seal

MB990938

Handle

Installation of crankshaft rear oil


seal
(Use with MD998776.)

D998285

D998776

B990938

ENGINE OVERHAUL

11B-13

ALTERNATOR AND IGNITION SYSTEM

ALTERNATOR AND IGNITION SYSTEM


REMOVAL AND INSTALLATION
M1113001000392

12

3.0 0.5 Nm

N2

10 2 Nm

13
14

15

13 1 Nm

25 5 Nm

3
10

44 10 Nm

N4

9
22 4 Nm

8
7
44 10 Nm

23 3 Nm

8.8 1.0 Nm

25 4 Nm

11

79 5 Nm

6N
22 4 Nm

1.
2.
3.
4.
5.
6.
7.
8.

Removal steps
Oil level gauge
O-ring
Oil level gauge guide
O-ring
Idler pulley
Cap
Auto-tensioner assembly
Water pump pulley

AK204441AB

Removal steps &RQWLQXHG


9. Alternator brace
10. Alternator
11. Crankshaft pulley
12. Center cover
13. Spark plug cable
14. Ignition coil
15. Spark plug

ENGINE OVERHAUL

11B-14

TIMING BELT

TIMING BELT
REMOVAL AND INSTALLATION
M1113001900500

21

11 1 Nm

3.5 0.5 Nm

24

25

22

28
20

48 5 Nm

N 23

21 4 Nm

12

11 1 Nm

26 N

7
23 3 Nm

27 N
32
11 1 Nm

11 1 Nm

11
167 Nm

33

29

49 5 Nm
9.0 1.0 Nm

31

45 3 Nm

16 17

19 3 Nm

14

30

34
19

88 10 Nm

18
13
8

8.8 1.0 Nm

49 9 Nm

15

10

35 6 Nm

AK204445 AB

54 5 Nm

<<A>>

<<B>>
<<C>>

Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Power steering pump bracket
>>M<< 4. Timing belt
>>L<< 5. Tensioner pulley
6. Tensioner arm
>>K<< 7. Auto-tensioner
8. Idler pulley
9. Crank angle sensor
>>J<< 10. Oil pump sprocket
>>I<< 11. Crankshaft bolt

Removal steps &RQWLQXHG


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

<<D>> >>I<<
>>I<<

ENGINE OVERHAUL
TIMING BELT

>>D<<
>>D<<
>>C<<
>>B<<
<<H>> >>A<<

Removal steps &RQWLQXHG


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

REMOVAL SERVICE POINTS


<<A>> TIMING BELT REMOVAL

11B-15

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

Crosspoint
screwdriver
AK202756AB

1. If the timing belt is to be reused, make an arrow


mark with something like chalk on the back of the
belt indicating the direction of rotation so it may be
reinstalled in the same direction.
Timing mark

AK202825 AB

1. Remove the plug on the left side of cylinder block.


2. Insert a crosspoint screwdriver (shank diameter 8
mm) to prevent the counterbalancer shaft from
rotating.
3. Remove the flange bolt.
4. Remove the oil pump sprocket.
<<C>> CRANKSHAFT BOLT REMOVAL

AK202757 AB

MD998781
AK202738 AB

1. Hold the drive plate with the special tool Fly wheel
stopper(MD998781).
2. Remove the crankshaft bolt.

ENGINE OVERHAUL

11B-16

TIMING BELT

<<D>> CRANKSHAFT SPROCKET REMOVAL

1. Use the special tool Sprocket stopper


(MD998785) to prevent the counterbalancer shaft
sprocket from rotating.
2. Remove the counterbalancer shaft mounting bolt.

MD998778

<<G>> CRANKSHAFT SPROCKET B REMOVAL

MD998778
AK202741 AB

Use the special tool Crankshaft sprocket puller


(MD998778) if the sprocket is stuck and hard to
remove.
AK202740AB

<<E>> TIMING BELT B REMOVAL

Use the special tool Crankshaft sprocket puller


(MD998778) if the sprocket is stuck and hard to
remove.
<<H>> CAMSHAFT SPROCKET BOLT REMOVAL

AK202758AB

If the timing belt is to be reused, make an arrow mark


with something like chalk on the back of the timing
belt indicating the direction of rotation so it may be
reinstalled in the same direction.
AK202858AB

<<F>> COUNTERBALANCER SHAFT SPROCKET


REMOVAL

MD998785

AK202739AB

Remove the camshaft sprocket bolt while preventing


the camshaft from rotation using a wrench fitted on
the hexagonal portion of the camshaft.

ENGINE OVERHAUL

11B-17

TIMING BELT

INSTALLATION SERVICE POINTS


>>A<< CAMSHAFT SPROCKET BOLT INSTALLATION

>>C<< SEMICIRCULAR PACKING INSTALLATION


1. Remove thoroughly the old sealant and FIPG
remaining on the semicircular packing, cylinder
head, and rocker cover.

AK202858AB
AK202860AB

2. Apply sealant to the surface indicated in the


drawing of the semicircular packing.
Specified sealant:
3M ATD No.8660 or equivalent
3. Install the semicircular packing on the cylinder
head.
10 mm
AK202859

Tighten the camshaft sprocket bolt to 88 10 Nm


while preventing the camshaft from rotation using a
wrench fitted on the hexagonal portion of the camshaft.
>>B<< ENGINE SUPPORT BRACKET
INSTALLATION

10 mm

Semicircular
packing
Cylinder head

AK202861 AB

4. Apply sealant to the area indicated in the drawing


of the semicircular packing and cylinder head.
Specified sealant:
3M ATD No.8660 or equivalent
>>D<< ROCKER COVER/ROCKER COVER
GASKET A INSTALLATION
Timing belt side
AK202743AB

1. Remove thoroughly the old sealant remaining on


the indicated bolt and in its hole.
2. Coat the bolt with sealant, then install and tighten
it.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent

AK202862 AB

1. Apply beads of FIPG on the surfaces of the rocker


cover indicated in the drawing.

ENGINE OVERHAUL

11B-18

TIMING BELT

Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
2. Install the rocker cover gasket A on the rocker
cover before the FIPG hardens.

>>F<< SPACER INSTALLATION


Spacer

Oil
seal

Timing belt side

Chamfer

Counterbalancer
shaft
AK202820 AB

CAUTION
AK202863 AB

3. Apply beads of FIPG to the surfaces of the rocker


cover indicated in the drawing.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
4. Install the rocker cover on the cylinder head
before the FIPG hardens.

If the spacer is opposite in direction to that


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

>>E<< CRANKSHAFT SPROCKET B


INSTALLATION
MD998785

Sprocket "B"
Crankshaft

AK202739AB

Degrease
Front case

AK101651AC

Clean and then degrease the crankshaft sprocket B


and the sprocket fitting surface of the crankshaft.
NOTE: Degreasing is necessary to prevent lack of
frictional coefficient between the mating surfaces.

1. Use the special tool Sprocket stopper


(MD998785) as shown in the drawing to prevent
the counterbalancer shaft sprocket from rotating.
2. Tighten the sprocket mounting bolt to 45 3 Nm.

ENGINE OVERHAUL

11B-19

TIMING BELT

>>H<< TIMING BELT B INSTALLATION

Timing
marks

5. Make sure that the timing marks on the oil pump


case and those of the sprockets are all aligned
with each other.
5 7 mm

Timing
marks

AK202920 AB

1. Align the timing marks on the crankshaft sprocket


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

Tension section of belt


Timing
belt B

AK202919 AB

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


section lightly with an index to see if it deflects 5 7 mm.
>>I<< CRANKSHAFT BOLT/CRANKSHAFT
SPROCKET/CRANKSHAFT SENSING BLADE
INSTALLATION
Crankshaft sensing blade
Crankshaft bolt
Crankshaft
Clean

Tensioner B
center
Mounting bolt center

AK202921 AB

3. Make sure that the tensioner B center is


positioned as shown in the drawing relative to the
mounting bolt center.

Washer
Chamfer
Degrease
Crankshaft sprocket
AK202838 AB

1. Clean and then degrease the crankshaft sprocket,


sprocket fitting surface of the crankshaft, and
crankshaft sensing blade. Install the crankshaft
sprocket and crankshaft sensing blade on the
crankshaft.
2. Clean the bolt hole in the crankshaft, and then
washer.
3. Apply a necessary minimum amount of oil to the
threads and seating surface of the crankshaft bolt.

AK202922AB

4. Lift the tensioner B with fingers to move it in the


direction of the arrow until the tension section of
the timing belt becomes taut. While keeping the
tensioner B in this position, tighten its bolt.
NOTE: When the bolt is tightened, prevent the
tensioner B shaft from turning. If the shaft turns,
the belt will be overtightened.

MD998781
AK202738 AB

ENGINE OVERHAUL

11B-20

TIMING BELT

4. Hold the drive plate using the special tool Fly


wheel stopper(MD998781).
5. Tighten the crankshaft bolt to a torque of 167 Nm.
>>J<< OIL PUMP SPROCKET INSTALLATION

AK202767

2. Install the auto-tensioner in position. Leave the


wire installed until the auto-tensioner is
completely installed.
Crosspoint screwdriver
AK202732 AB

>>L<< TENSIONER PULLEY INSTALLATION

1. Prevent the counterbalancer shaft from rotating in


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

AK202759AB

Install the tensioner pulley with its holes aligned as


shown in the drawing.
>>M<< TIMING BELT INSTALLATION
Timing marks
AK202768 AB

1. If the auto-tensioner rod remains in its fully


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

AK202903 AB

1. Bring the timing mark on the exhaust camshaft


sprocket to a point one sprocket tooth away from
the timing mark on the rocker cover in the
counterclockwise direction.
NOTE: If the timing marks were aligned, the
exhaust camshaft would be turned counterclockwise by one sprocket tooth and stay there by the
force of the valve springs.

ENGINE OVERHAUL
TIMING BELT

Timing marks

AK202904 AB

2. Align the timing mark on the intake camshaft


sprocket with that on the rocker cover.
NOTE: The intake camshaft will be turned slightly
clockwise from where the timing marks are
aligned by the force of the valve springs and stay
there.

11B-21

(2) Insert a crosspoint screwdriver with a shank


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

Timing marks

AK202761 AB

(3) Turn the oil pump sprocket counterclockwise


by one sprocket tooth.

AK202760

3. Bring the timing mark on the crankshaft sprocket


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

5. Install the timing belt on the exhaust camshaft


sprocket, and hold it in place with a paper clip at
the point indicated in the drawing.

Plug

Crosspoint
screwdriver
AK202752 AB

4. Align the timing mark on the oil pump sprocket


with that on the cylinder block.
(1) Remove the plug from the cylinder block.
AK202772

ENGINE OVERHAUL

11B-22

TIMING BELT

6. Turn the intake camshaft sprocket


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

9. Install the timing belt on the tensioner pulley.


NOTE: Turning slightly the intake camshaft
sprocket counterclockwise will facilitate installation of the belt on the tensioner pulley.
Crankshaft
sprocket

Timing marks

AK202763AB

AK202847 AB

7. Turn the exhaust camshaft sprocket clockwise to


align the timing marks, and make sure that the
intake camshaft sprocket timing marks are also
aligned.

10.Turn slightly the crankshaft sprocket clockwise to


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

MD998767

Crankshaft
sprocket

Oil pump
sprocket
AK202762AB

8. Install the timing belt on the idler pulley, oil pump


sprocket, and crankshaft sprocket, in this order.
NOTE: There should be no slack in the installed
portion of the belt.

Camshaft
sprocket
Tensioner
pulley

AK202773 AB

AK202764 AB

12.Turn the tensioner pulley counterclockwise using


the special tool Tension pulley socket wrench
(MD998767) to give tension to the belt and hold
the tensioner in position by temporarily tightening
the tensioner lock bolt.
NOTE: Take up the slack in the belt portion
between the intake and exhaust camshaft sprockets.
13.Turn the crankshaft clockwise to make the timing
mark align with the No.1 cylinder top dead center
mark.

ENGINE OVERHAUL

11B-23

TIMING BELT

20.Check that the wire (inserted in the auto-tensioner


when it was installed) can be moved freely. If the
wire can be pulled freely, the belt tensioner is
adjusted properly. Remove the wire. At that time,
check that the auto-tensioner rod extends by the
specified amount.
Standard value: 3.8 - 4.5 mm

MD998738

CAUTION
AK202774 AB

14.Install the special tool Set screw (MD998738) and


turn down the tool until the wire (inserted in the
auto-tensioner when it was installed) can be
moved freely.

Be sure to check the tightening torque of the


crankshaft bolt anytime the crankshaft has been
turned counterclockwise. If the torque lower than
specification, tighten the bolt to the specified
torque.
21.If the wire cannot be pulled out freely, perform the
steps 14. through 18. again to make the belt
tension proper.

INSPECTION
M1113002000362

TIMING BELT
Check closely the entire timing belt.
Replace it if any of the following conditions is found.

MD998767

AK202775 AB

CAUTION
Prevent the timing belt from slipping as it
becomes loose following rotation of the intake
and exhaust camshafts.
15.Loosen the tensioner pulley lock bolt.
16.Turn the torque wrench attached to the special
tool Tension pulley socket wrench (MD998767)
counterclockwise until the slack in the timing belt
is taken up.
17.Turn the torque wrench clockwise from the
position of step 16. until the torque wrench
reading becomes 3.5 Nm, then tighten the
tensioner pulley lock bolt.

AK202794

1. Hardened back side rubber


Back side surface is glossy, lacking in elasticity,
and so hard that no impression is left when
pressed with fingernail.
Cracks

Peeling of canvas

Cracks

Cracks in sides

Extension
amount

Cracks in tooth roots


AK202829 AB

18.Remove the special tool that was installed in step


14.
19.Turn the crankshaft clockwise two turns, then let it
alone for approx. 15 minutes.

2.
3.
4.
5.

Cracks in back rubber surface


Cracks in canvas
Cracks in tooth roots
Cracks in belt sides

AK202793 AB

ENGINE OVERHAUL

11B-24

TIMING BELT

AUTO-TENSIONER

Rounded edge

12 mm

Abnormal wear
(Fluffy strand)

AK202795 AB

6. Abnormally worn belt sides;


NOTE: belt sides are normal if they have knifecut surfaces.
Canvas lost and
rubber exposed
Missing
Tooth

AK202796 AB

7. Badly worn teeth


Initial stage: Canvas is worn (canvas fiber is fluffy;
teeth look whitish due to worn-out rubber; canvas
texture is unclear)
Second stage: Canvas is lost and rubber is exposed
(tooth width narrows down)
8. Missing tooth

AK202765 AB

1. Check the auto-tensioner for leaks from the


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

Movement

AK202766 AB

4. Press the rod with a force of 98 to 196 N and


measure the amount of retraction. If the
measurement exceeds the standard value,
replace the auto-tensioner.
Standard value: 1 mm maximum

ENGINE OVERHAUL

11B-25

FUEL AND EMISSION PARTS

FUEL AND EMISSION PARTS


REMOVAL AND INSTALLATION
M1113002200355

7
8

11 1 Nm
9.0 1.0 Nm

18
10 N

9.0 2.0 Nm

17
2

11 1 Nm

15 N
16

19 3 Nm

14

13 N
5

11
12

4
20 2 Nm

6
11 1 Nm

11 1 Nm

AK204439AB

>>C<<

>>B<<

1.
2.
3.
4.
5.
6.
7.
8.
9.

Removal steps
Vacuum hose and pipe
Vacuum pipe
Throttle body assembly
Throttle body gasket
EGR valve
EGR gasket
Vacuum hose
Fuel hose
Fuel pressure regulator

>>A<<

Removal steps &RQWLQXHG


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

11B-26

ENGINE OVERHAUL
FUEL AND EMISSION PARTS

INSTALLATION SERVICE POINTS


>>A<< INJECTOR INSTALLATION
1. Apply a thin coat of engine oil to a new O-ring.

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

CAUTION
Prevent engine oil from getting into the delivery
pipe.
2. Insert the fuel pressure regulator into the delivery
pipe while turning it in both directions carefully not
to damage the O-ring.

3. Check that the fuel pressure regulator turns


smoothly. If it does not, the O-ring may be
jamming, so remove the fuel pressure regulator
and check the O-ring for damage. If the O-ring is
intact, insert it into the delivery pipe and check it
for smooth rotation again.
>>C<< THROTTLE BODY GASKET
INSTALLATION
Tab

AK202905 AB

Install the throttle body gasket with its tab located as


shown in the drawing.

ENGINE OVERHAUL

11B-27

INTAKE MANIFOLD

INTAKE MANIFOLD
REMOVAL AND INSTALLATION
M1113002700286

36 6 Nm

19 3 Nm

4
3

36 6 Nm
20 2 Nm

31 3 Nm

AK204438 AB

Removal steps

>>A<< 1. Intake manifold stay


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

INSTALLATION SERVICE POINTS


>>A<< INTAKE MANIFOLD STAY INSTALLATION

Intake manifold
stay
AK202865 AB

Tighten the bolts to the specified torque 31 3 Nm


on both ends after making sure that the stay is in
close contact with the bosses on the intake manifold
and cylinder block.

ENGINE OVERHAUL

11B-28

EXHAUST MANIFOLD

EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1113004900383

14 1 Nm
44 5 Nm
29 3 Nm

14 1 Nm

6
4

49 5 Nm

35 6 Nm

44 5 Nm
AK204437 AB

Removal steps
1. Oxygen sensor
2. Exhaust manifold cover
3. Exhaust manifold bracket

Removal steps &RQWLQXHG


4. Engine hanger
5. Exhaust manifold
6. Exhaust manifold gasket

ENGINE OVERHAUL

11B-29

WATER PUMP AND WATER HOSE

WATER PUMP AND WATER HOSE


REMOVAL AND INSTALLATION
M1113017900220

13 2 Nm

9
13 2 Nm

13 2 Nm

6
1
23 4 Nm

11
10

5
4

10.8 1.0 Nm

3
29 10 Nm

14
23 2 Nm

13
12
14 1 Nm
AK204436AB

>>E<<
>>D<<
>>C<<
>>B<<
>>A<<
>>A<<
>>A<<

Removal sequence
1. Water hose
2. Water hose
3. Coolant temperature sensor
4. Coolant temperature gauge unit
5. Water inlet fitting
6. Thermostat
7. Water outlet fitting
8. Thermostat housing
9. O-ring
10. Water inlet pipe
11. O-ring
12. Water pump
13. Water pump gasket
14. Knock sensor

INSTALLATION SERVICE POINTS


>>A<< O-RING/WATER INLET PIPE INSTALLATION

CAUTION
Never allow any oil or grease to touch the Orings.
Clamp the water inlet pipe only after installation of the thermostat case.
Replace the O-rings at both ends of the water inlet
pipe with new ones. Insert the O-rings into the water
pump and thermostat housing after wetting their
peripheries with water.

11B-30

ENGINE OVERHAUL
WATER PUMP AND WATER HOSE

>>B<< THERMOSTAT HOUSING INSTALLATION

>>D<< COOLANT TEMPERATURE GAUGE UNIT


INSTALLATION

AK202918AB

1. Remove all old FIPG remaining on the thermostat


housing and cylinder head.
2. Apply a 2.7 0.3 mm diameter bead of FIPG on
the indicated surface of the thermostat housing.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
>>C<< WATER OUTLET FITTING INSTALLATION

AK202800AB

1. Remove all old sealant remaining on the threaded


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

AK202755AB

1. Remove all old FIPG remaining on the water


outlet fitting and thermostat housing.
2. Apply a 2.7 0.3 mm diameter bead of FIPG to
the indicated surface of the water outlet fitting.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent

AK202799AB

CAUTION
When using a tool, avoid letting it touch the connector portion which is made of plastic.
1. Remove all old sealant remaining on the threads
of the coolant temperature sensor and in the
threaded hole in the thermostat housing.
2. Apply sealant to the coolant temperature sensors
threads indicated in the drawing.
Specified sealant:
3M ATD Part No.8660 or equivalent

ENGINE OVERHAUL

11B-31

ROCKER ARMS AND CAMSHAFT

ROCKER ARMS AND CAMSHAFT


REMOVAL AND INSTALLATION
M1113005400455

10 2 Nm

N4

11
14
13
20 1 Nm

6
9

12

14 1 Nm

2N
1

10
22 4 Nm

15

8.8 1.0 Nm
11 1 Nm

18

N7

16
17

Apply engine oil


to all moving
parts before
installation.

AK202894 AB

>>F<<
>>E<<
>>D<<
>>C<<
>>C<<

1.
2.
3.
4.
5.
6.
7.
8.
9.

Removal steps
Camshaft position sensor
O-ring
Cover
Gasket
Camshaft position sensing cylinder
Camshaft position sensor support
Camshaft oil seal
Bearing cap, rear right
Bearing cap, rear left

>>C<<
>>C<<
>>C<<
>>C<<
>>C<<
>>B<<
<<A>> >>A<<

Removal steps &RQWLQXHG


10. Bearing cap, front
11. Bearing cap No.5
12. Bearing cap No.2
13. Bearing cap No.3
14. Bearing cap No.4
15. Camshaft
16. Rocker arm
17. Lash adjuster
18. Oil delivery body

ENGINE OVERHAUL

11B-32

ROCKER ARMS AND CAMSHAFT

SERVICE POINTS FOR REMOVAL

1. Set each camshaft with its dowel pin at the top.

<<A>> LASH ADJUSTER REMOVAL

CAUTION
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
311B, the instruction under LASH ADJUSTER
in the INSPECTION section.)

INSTALLATION SERVICE POINTS


>>A<< LASH ADJUSTER INSTALLATION

CAUTION
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
311B, the instruction under LASH ADJUSTER
in the INSPECTION section.)
Install the lash adjuster into the rocker arm, being
careful not to spill the diesel fuel it contains.
>>B<< CAMSHAFT INSTALLATION
Timing belt side

Cap number
Intake/exhaust
identification
letter

AK202870 AB

2. The bearing caps No. 2 to 5 are identical in shape


for both intake and exhaust camshafts. Check the
identification mark on each cap before installation.
Identification mark (stamped on front and
Nos. 2 - 5 bearing caps)
I: intake camshaft
E: exhaust camshaft
3. Remove completely sealant remaining on the
bearing caps and cylinder head.

Slit

Exhaust camshaft
AK202869 AB
AK202871AB

CAUTION
Do not confuse the intake camshaft with the
exhaust camshaft.
The exhaust camshaft has a 4 mm wide slit at
the rear end.
>>C<< BEARING CAP INSTALLATION
Dowel pin

AK203979 AC

4. Apply sealant to the surfaces indicated in the


drawing.
Specified sealant:
3M ATD No.8660 or equivalent
5. Install each bearing cap and tighten its bolts in
two or three passes.
6. Finally tighten the bolts to 20 1 Nm.
7. Check that the rocker arms are correctly installed.
NOTE: Wipe off any squeezed out sealant completely.

ENGINE OVERHAUL

11B-33

ROCKER ARMS AND CAMSHAFT

>>D<< CAMSHAFT OIL SEAL INSTALLATION


MD998713

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


dead center position.
NOTE: The camshaft will slightly turn counterclockwise by the force of the exhaust valve spring.
2. Install the camshaft position sensing cylinder with
the smaller vane located as shown in the drawing.

INSPECTION
M1113005500388

CAMSHAFT
AK202872 AB

Use the special tool Camshaft oil seal installer


(MD998713) to drive each oil seal into position in the
cylinder head.
>>E<< CAMSHAFT POSITION SENSOR
SUPPORT INSTALLATION
AK202797AB

Measure the cam height (nose-to-heel diameter).


If any cam is worn beyond the limit, replace the camshaft.
Standard value: 34.91 mm
Limit: 34.41 mm
AK202754AB

1. Remove completely the FIPG remaining on the


camshaft position sensor support and cylinder
head.
2. Apply a 3 1 mm diameter bead of FIPG to the
indicated surface of the camshaft position sensor
support.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent

LASH ADJUSTERS

CAUTION
The lash adjuster is a precision-engineered
component. Do not allow dust or other foreign
matter to enter it.
Do not disassemble lash adjusters.
Use only non-contaminated diesel fuel to
clean the lash adjuster.
For rough
cleaning

For finish
cleaning

For diesel
fuel filling

>>F<< CAMSHAFT POSITION SENSING


CYLINDER INSTALLATION
Smaller vane
A

AK202836 AB

Cam position
sensor
AK202844 AB

1. Prepare three containers and approximately five


liters of diesel fuel. Pour into each container the
diesel fuel in an amount enough for a lash
adjuster placed in the container in its upright
position to completely submerge.

ENGINE OVERHAUL

11B-34

ROCKER ARMS AND CAMSHAFT

CAUTION
The hole in the side of the lash adjuster must be
directed toward the inside of container A. Never
direct it against any person.
4. Take the lash adjuster out of the container, then
move the plunger by pushing the steel ball gently
to discharge the diesel fuel from the pressure
chamber.
AK202837

2. Place the lash adjuster in container A and wash


its outside surface.
NOTE: Use a nylon brush if there are hard-toremove deposits.
Diesel fuel
MD998442
AK202839 AB

CAUTION

Diesel fuel
MD998442
AK202839 AB

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

The steel ball spring of the lash adjuster is


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

MD998442
Diesel fuel
AK202840 AB

CAUTION

MD998442
Diesel fuel
AK202840 AB

The hole in the side of the lash adjuster must be


directed toward the inside of container B. Never
direct it against any person.
6. Take the lash adjuster out of the container, then
move the plunger by pushing the steel ball gently
to discharge the diesel fuel from the pressure
chamber.

ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT

11B-35

8. Place the lash adjuster upright with the plunger at


the top. Push the plunger firmly until it makes a full
stroke, then return the plunger slowly and release
the hold of the steel ball to allow the pressure
chamber to be filled with diesel fuel.

MD998442

Diesel fuel
AK202841 AB

CAUTION
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could
enter the pressure chamber when the chamber is
filled with diesel fuel.
7. Soak the lash adjuster in the diesel fuel in
container C. Gently push the internal steel ball
using the special tool Air bleed wire (MD998442).

MD998442

Diesel fuel
AK202842 AB

AK202843

9. Take the lash adjuster out of the container, place it


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

ENGINE OVERHAUL

11B-36

CYLINDER HEAD AND VALVES

CYLINDER HEAD AND VALVES


REMOVAL AND INSTALLATION
M1113006900389

78 2 Nm loosen completely
20 2 Nm 90 + 90

1
2

4
5
6
12 N
13
16 N

8
9
10
14 N
15
17 N

20

19 N
11

18 N
7

3N

Apply engine oil


to all moving
parts before
installation.

AK202895 AB

Removal steps

<<A>> >>D<< 1. Cylinder head bolt


<<B>> >>C<<
>>B<<

2.
3.
4.
5.
6.

Cylinder head assembly


Cylinder head gasket
Retainer lock
Valve spring retainer
Valve spring

<<B>> >>C<<
>>B<<
>>A<<

Removal steps &RQWLQXHG


7. Intake valve
8. Retainer lock
9. Valve spring retainer
10. Valve spring
11. Exhaust valve
12. Valve stem seal
13. Valve spring seat

ENGINE OVERHAUL

11B-37

CYLINDER HEAD AND VALVES


Removal steps &RQWLQXHG

>>A<< 14. Valve stem seal


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

INSTALLATION SERVICE POINTS


>>A<< VALVE STEM SEAL INSTALLATION

MD998737

REMOVAL SERVICE POINTS


<<A>> CYLINDER HEAD BOLT REMOVAL
AK202874 AB

CAUTION
MB991654

AK202723 AB

Use the special tool Cylinder head bolt wrench


(MB991654) to loosen the cylinder head bolts.
<<B>> RETAINER LOCK REMOVAL
MD998772

The special tool must always be used when


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

AK202742 AB

Exhaust valve stem seal


Colour: Grayish green

AK202875 AB

NOTE: Do not confuse the stem seals for intake


valves with those for exhaust valves.

MD998735

>>B<< VALVE SPRING INSTALLATION

Painted
end
AK202873 AB

Compress the valve spring using the special tool


Valve spring compressor (MD998772), then remove
the retainer lock.
NOTE: Store removed valves, springs and other
parts, after putting to each of them a tag that identifies its cylinder No. or installation location.

Spring
retainer

Stem
seal
Spring
seat
AK202551AB

Install each valve spring with the painted end toward


the rocker arm.

ENGINE OVERHAUL

11B-38

CYLINDER HEAD AND VALVES

>>C<< RETAINER LOCK INSTALLATION


MD998772

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


bolt.
NOTE: Use the special tool Cylinder head bolt
wrench (MB991654) to tighten the bolts.
Timing belt side

10

AK202742 AB

MD998735

7
AK202806 AB

3. Tighten the bolts to 78 2 Nm in the indicated


sequence.
4. Loosen all the bolts completely.
5. Tighten the bolts again to a torque of 20 2 Nm
in the indicated sequence.
AK202873 AB

Compress the valve spring using the special tool


Valve spring compressor (MD998772), then install
the retainer lock.

90

>>D<< CYLINDER HEAD BOLT INSTALLATION


90

Paint marks
AK202720 AB

CAUTION
Nominal length

AK202750 AB

MB991654

If the tightening angle is smaller than 90,


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

AK202723 AB

1. When reusing a cylinder head bolt, check that its


nominal length (shank length) is not greater than
the limit. If the limit is exceeded, replace the bolt.
Limit: 99.4 mm

INSPECTION
M1113007000378

CYLINDER HEAD
1. Before cleaning the cylinder head, check it for
traces of water and gas leakage and for cracks
and any other damage.

ENGINE OVERHAUL

11B-39

CYLINDER HEAD AND VALVES

2. Thoroughly remove oils, scale, sealants, carbon


and other contamination. Clean the oil passages,
then check using compressed air that they are not
blocked.

Standard values:
Intake 1.0 mm
Exhaust 1.5 mm
Limits:
Intake 0.5 mm
Exhaust 1.0 mm

AK202724

Total length

CAUTION
The thickness of the metal that can be removed
by grinding from both the cylinder head and the
mating cylinder block is limited to 0.2 mm in
total.
3. Check the cylinder head gasket surface for warp
using a straightedge and thickness gauge.
If the surface is warped beyond the limit, grind the
surface for rectification.
Gasket surface warp
Standard value: Less than 0.05 mm
Limit: 0.2 mm
Grinding limit: 0.2 mm
Cylinder head height (standard value for new
part):
131.9 - 132.1 mm
VALVES
1. Check the valve face for correct contact with the
seat. Reface the valve if the contact is partial or
one sided.

AK202876 AB

3. Measure the total length of the valve.


Replace the valve if the length is less than the
limit.
Standard values:
Intake 109.50 mm
Exhaust 109.70 mm
Limits:
Intake 109.00 mm
Exhaust 109.20 mm
VALVE SPRINGS
Out of square

Free height

AK202706 AB

Contact
(Should be at
center of face)
Margin

AK202729 AB

2. Measure the margin.


Replace the valve if its margin is smaller than the
limit.

1. Measure the free height of the spring.


Replace the spring if its height is smaller than the
limit.
Standard value: 47.0 mm
Limit: 46.0 mm
2. Measure the squareness of the spring.
Replace the spring if it is out of square beyond the
limit.
Standard value: 1.5 or smaller
Limit: 4

ENGINE OVERHAUL

11B-40

CYLINDER HEAD AND VALVES

VALVE GUIDE

With the valve installed in position and its face


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

valve
guide

Stem diameter
Guide inside diameter

AK202709 AB

Measure the valve guide inside diameter and valve


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

Limits:
Intake 49.70 mm
Exhaust 48.90 mm

VALVE SEAT RECONDITIONING


1. Before reconditioning the valve seat, check the
clearance between the valve guide and valve
stem and, if necessary, replace the valve guide.
0.9 1.3 mm

0.9 1.3mm

65

65

Limits:
Intake 0.10 mm
Exhaust 0.15 mm

25

15

VALVE SEATS

44
Valve stem
end
Valve stem
projection
Spring
seating
surface
AK202814 AB

AK202850 AB

2. Resurface the valve seat to the indicated width


and angles.
3. After resurfacing, lap the valve and valve seat
using lapping compound.

ENGINE OVERHAUL

11B-41

CYLINDER HEAD AND VALVES

VALVE SEAT REPLACEMENT

4. Resurface the valve seat. See the VALVE SEAT


RECONDITIONING section.

0.5 1 mm

VALVE GUIDE REPLACEMENT


1. Force out the valve guide toward the cylinder
block using a press.
Cut

CAUTION
0.5 1 mm

AK202707 AB

1. Cut inside of the valve seat to be replaced until its


wall becomes thin enough for removal, then
remove the valve seat.

Do not use a replacement valve guide of the


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

Valve seat
height

Oversize hole diameter


AK202708 AB

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


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

19.2 19.8 mm
AK202877 AB

3. Press-fit the valve guide until it remains protruded


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

ENGINE OVERHAUL

11B-42

OIL PAN AND OIL PUMP

OIL PAN AND OIL PUMP


REMOVAL AND INSTALLATION
M1113008100301

19 3 Nm

10

Apply engine oil


to all moving
parts before
installtion.

32
31

28

30

21
23 3 Nm
10 2 Nm

23 3 Nm

29

22

20

23 24

16

19 3 Nm

19 3 Nm

26

15

17 1 Nm

25
19

14
13

27

17 18

9.0 3.0 Nm

36 3 Nm

11
3

23 3 Nm

23 3 Nm

12

39 5 Nm

2
44 5 Nm

9.0 3.0 Nm
39 5 Nm

9.0 3.0 Nm

22 4 Nm

1
9.0 3.0 Nm

AK202676 AB

9.0 3.0 Nm

>>O<<
>>N<<
<<A>>
<<B>>
<<C>>

>>M<<
>>L<<
>>L<<

Removal steps
1. Drain plug
2. Drain plug gasket
3. Oil filter
4. Transmission stay <4WD>
5. Oil pan <2WD>
6. Oil pan lower section <4WD>
7. Oil pan upper section <4WD>
8. Oil screen
9. Gasket
10.Oil pressure switch

>>K<<

<<D>>

>>J<<

<<E>>

>>I<<
>>H<<

Removal steps &RQWLQXHG


11.Relief plug
12.Gasket
13.Relief spring
14.Relief plunger
15.Oil filter bracket
16.Gasket
17.Plug
18.O-ring
19.Flange bolt
20.Front case

ENGINE OVERHAUL

11B-43

OIL PAN AND OIL PUMP

>>G<<
>>G<<
>>F<<
>>E<<
>>D<<
<<F>> >>C<<
<<G>> >>B<<
<<G>> >>A<<

Removal steps &RQWLQXHG


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

REMOVAL SERVICE POINTS


<<A>> OIL PAN REMOVAL <2WD>

<<C>> OIL PAN UPPER SECTION REMOVAL


<4WD>
A

AK202692 AB

Screw bolts into the bolt holes A shown in the drawing (holes at both ends) to remove the oil pan.

CAUTION
Do not use a scraper or the special tool to
remove the oil pan.

MD998727

<<D>> PLUG REMOVAL


MD998162

AK202574 AB

1. Remove the oil pan bolts.


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

MD998783
AK202585 AB

Fit the teeth of the special tool in notches of the plug


as shown in the drawing and support the tool with the
special tool to loosen the plug.
Plug wrench (MD998162)
Plug wrench retainer (MD998783)
<<E>> FLANGE BOLT REMOVAL

CAUTION
Do not use a scraper or the special tool to
remove the oil pan.
Plug

Crosspoint
screwdriver
AK202586 AB

1. Remove the plug on the left side of the cylinder


block. Insert a cross point screwdriver (shank
diameter 8 mm) into the plug hole more than 60
mm to prevent the left counterbalancer shaft from
rotating.

ENGINE OVERHAUL

11B-44

OIL PAN AND OIL PUMP

2. When removing the rear bearing of the left


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

INSTALLATION SERVICE POINTS


AK202642

2. Loosen and remove the flange bolt.

>>A<< LEFT COUNTERBALANCER SHAFT REAR


BEARING INSTALLATION
MB991603

<<F>> COUNTERBALANCER SHAFT FRONT


BEARING REMOVAL

MD998705
AK202548 AB

Front
bearing

1. Install the special tool Silent shaft bearing installer


stopper (MB991603) on the cylinder block.

MD998371
AK202633 AB

CAUTION
Remove the front bearing first. Otherwise, the
special tool cannot be used.
Use the special tool Silent shaft bearing puller
(MD998371) to remove the counterbalancer shaft
front bearing from the cylinder block.
<<G>> COUNTERBALANCER SHAFT REAR
BEARING REMOVAL
1. Use the special tool Silent shaft bearing puller
(MD998371) to remove the counterbalancer shaft
rear bearings from the cylinder block.
MB991603

MD998372

AK202634 AB

MB991603
MD998705

Rear bearing
AK202635 AB

2. Set the rear bearing on the special tool Silent


shaft bearing installer (MD998705).
NOTE: The left counterbalancer shaft rear bearing has no oil hole.
3. Force the rear bearing into the cylinder block by
sticking the special tool.

ENGINE OVERHAUL

11B-45

OIL PAN AND OIL PUMP

>>B<< RIGHT COUNTERBALANCER SHAFT


REAR BEARING INSTALLATION

MD998705

Guide pin
AK202581 AB

AK202579 AB

1. Install the guide pin on the cylinder block.

>>C<< COUNTERBALANCER SHAFT FRONT


BEARING INSTALLATION

Rear bearing (Right)


Ratchet ball

Oil
hole

Tool element for


rear bearing
installation
AK202582 AB

AK202549 AB

2. Set the bearing on the special tool Silent shaft


bearing installer (MD998705) with its oil hole on
the ratchet ball.

1. Detach from the special tool Silent shaft bearing


installer (MD998705) its element for rear bearing
installation.

MD998705

Guide pin
Guide pin
AK202579 AB

AK202580 AB

3. Insert the special tool Silent shaft bearing installer


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

2. Install the guide pin on the cylinder block.


Front bearing
Ratchet ball

Oil
hole

AK202549 AC

3. Set the bearing on the special tool Silent shaft


bearing installer (MD998705) with its oil hole on
the ratchet ball.

ENGINE OVERHAUL

11B-46

OIL PAN AND OIL PUMP

>>E<< COUNTERBALANCER SHAFT OIL SEAL


INSTALLATION
MD998705
Socket wrench

Oil seal

Front case

Guide pin
AK202580 AB

4. Insert the special tool Silent shaft bearing installer


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

AK202646 AB

Use an appropriate socket wrench to install the counterbalancer shaft oil seal.
>>F<< CRANKSHAFT OIL SEAL INSTALLATION

MD998375
Oil seal
Front case
AK202583AB

>>D<< OIL PUMP OIL SEAL INSTALLATION

Oil seal

Socket
wrench

AK202645 AB

Use the special tool Crankshaft front oil seal installer


(MD998375) to install the crankshaft oil seal.
>>G<< OIL PUMP DRIVEN GEAR/OIL PUMP
DRIVE GEAR INSTALLATION

Front case
Alignment
marks
AK202639 AB

Use an appropriate socket wrench to install the oil


pump oil seal.
AK202660 AB

Apply engine oil generously to the gears and line up


the alignment marks.

ENGINE OVERHAUL

11B-47

OIL PAN AND OIL PUMP

>>H<< FRONT CASE INSTALLATION


Counterbalancer
shaft, left

MD998285

1. Insert a correspond screwdriver (shank diameter


8 mm) into the hole in the left side of the cylinder
block to prevent the counterbalancer shaft from
rotating.

Counterbalancer
shaft, right

AK202577 AB

1. Install the special tool crankshaft front oil seal


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

AK202642

2. Tighten the flange bolts.


>>J<< PLUG INSTALLATION
1. Install a new O-ring on the front case.
MD998162

MD998783
AK202585 AB

2. Use the special tool to tighten the plug to the


specified torque.
Plug wrench (MD998162)
Plug wrench retainer (MD998783)

MD998285

AK202656 AB

4. Tighten all the bolts to the specified torques.

>>K<< OIL PRESSURE SWITCH INSTALLATION

>>I<< FLANGE BOLT INSTALLATION

AK202625AB

Crosspoint
screwdriver

CAUTION
AK202641 AB

Be careful not to block the oil passage with sealant.


1. Apply sealant to the threaded portion.
Specified Sealant:
3M ATD Part No.8660 or equivalent

ENGINE OVERHAUL

11B-48

OIL PAN AND OIL PUMP

Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
NOTE: In the grooved areas on the oil pan flange,
apply FIPG bead along the center of the groove.

MD998054

M6 16
AK204037AD

2. Tighten the oil pressure switch together with the


cylinder block by the specified torque using of the
special tool Oil pressure switch wrench
MD998054.
Tightening torque: 19 3 Nm
>>L<< OIL PAN UPPER SECTION/OIL PAN
LOWER SECTION INSTALLATION <4WD>

CAUTION
Do not apply FIPG over remaining old FIPG.
Doing so could result in oil leakage.
1. Clean the gasket surfaces of the cylinder block
and oil pan.
Timing belt side

AK202685 AB

3. Install the shorter bolts in the locations indicated


in the drawing.

CAUTION
Do not apply FIPG over remaining old FIPG.
Doing so could result in oil leakage.
4. Thoroughly remove old FIPG from the gasket
surfaces of the oil pan upper and lower sections.
Timing belt side

Bolt hole
area

Grooved
area

Bolt hole
area

Grooved area
AK202688 AB

CAUTION
Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could
result in leakage.
2. Apply a 4 mm diameter bead of FIPG to the flange
surface all around the oil pan.

AK202686 AB

CAUTION
Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could
result in leakage.

ENGINE OVERHAUL

11B-49

OIL PAN AND OIL PUMP

5. Apply a 4 mm diameter bead of FIPG to the flange


surface all around the oil pan.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
NOTE: In the grooved areas on the oil pan flange,
apply FIPG bead along the center of the groove.

Timing belt side


M6 8

Timing belt side


9

Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
NOTE: In the grooved areas on the oil pan flange,
apply FIPG bead along the center of the groove.

12

1
11

3
2

AK202693 AB

10
AK202687 AB

6. Install the oil pan lower section by tightening the


bolts in the indicated sequence.
>>M<< OIL PAN INSTALLATION <2WD>

3. Install the shorter bolts in the locations indicated


in the drawing.
>>N<< OIL FILTER INSTALLATION
Bracket side

CAUTION
Do not apply FIPG over remaining old FIPG.
Doing so could result in oil leakage.
1. Thoroughly remove old FIPG from the gasket
surfaces of the cylinder block and oil pan.

Engine oil

Timing belt side


AK202556 AB

Bolt hole
area

Grooved
area

AK202694 AB

CAUTION
Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could
result in leakage.
2. Apply a 4 mm diameter bead of FIPG to the flange
surface all around the oil pan.

1. Clean the installation surface of the filter bracket.


2. Apply engine oil to the o-ring of the oil filter.
3. Install the oil filter to the bracket and tighten it to
the specified torque.
Tightening torque: 14 2 Nm
4. If no torque wrench can be used for tightening,
use the following procedure:
(1) Screw in the oil filter until its o-ring contacts
the oil filter bracket.
(2) Tighten the oil filter 3/4 turn.

ENGINE OVERHAUL

11B-50

OIL PAN AND OIL PUMP

>>O<< DRAIN PLUG GASKET INSTALLATION


Drain plug

AK202835AB

Oil pan
Gasket

Oil pan
side

2. Check the journals for seizure, damage and


defective contact with bearings.
If any of these faults is found, replace the
counterbalance shaft, bearings and/or oil pump
case assembly.
OIL PUMP

AK202603AB

CAUTION
Installing the gasket with the wrong side facing
the oil pan will result in oil leakage.
Replace the drain plug gasket with a new one. Install
it with the side indicated in the drawing toward the oil
pan.

INSPECTION
M1113008200212

COUNTERBALANCE SHAFTS
1. Check that the oil holes are not blocked.
Clean if necessary.

AK202831

1. Install the drive and driven gears in the oil pump


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

ENGINE OVERHAUL

11B-51

PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD


REMOVAL AND INSTALLATION
M1113008400528

6
7
8

Apply engine oil to


all moving parts
before
installation.

10
4

9
12
11

3
2
1

20 2 Nm + 90 to 94

AK202896 AB

>>G<<
<<A>> >>F<<
>>E<<
>>D<<
>>C<<

1.
2.
3.
4.
5.
6.

Removal steps
Connecting rod cap nut
Connecting rod cap
Connecting rod bearing
Piston and connecting rod assembly
Connecting rod bearing
Piston ring No. 1

Removal steps &RQWLQXHG

>>C<< 7. Piston ring No. 2


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

ENGINE OVERHAUL

11B-52

PISTON AND CONNECTING ROD

REMOVAL SERVICE POINTS


<<A>> CONNECTING ROD CAP REMOVAL
Push rod

Cylinder
number

Front mark
Front
mark

Guide C

AK202812 AB

Mark the cylinder number on the side of the connecting rod big end as a guide for reassembly.

Base

<<B>> PISTON PIN REMOVAL


Push
rod

Guide A: 17.9 mm
Guide B
AK202781 AB

Guide A: 18.9 mm

GuidE C
Guide A: 20.9 mm
Base

1. Insert the tool element, Push rod, into the piston


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

INSTALLATION SERVICE POINTS


Guide A: 21.9 mm

>>A<< PISTON PIN INSTALLATION


Timing belt side

Crankshaft
bore size mark

AK202783 AB

No.4
No.3
No.2
No.1

The special tool Piston pin setting tool (MD998780),


consists of the elements shown in the drawing.

AK202923 AB

1. When replacing a piston, check the cylinder bore


size mark stamped at the indicated location on the
cylinder block and select an appropriate
replacement piston using the following table.
Cylinder bore size mark

Piston size mark

II

No mark

III

ENGINE OVERHAUL

11B-53

PISTON AND CONNECTING ROD

NOTE: The piston size mark is located on the piston top surface.

3 mm + L

Guide B

Guide A
AK202789 AB

Connecting rod
Piston

8. Screw the tool element, Guide B, into the tool


element, Guide A until the gap between both the
elements is equal to the dimension L (obtained in
step 3.) plus 3 mm.

Piston pin

Push rod
Piston pin

AK202784 AB

2. Measure the following dimensions:


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

Front
mark

Front mark

Guide A
Base

Guide B

AK202782 AB

9. Place the piston and connecting rod assembly


onto the element, Piston setting base, with the
front marks facing up.
10.Install the piston pin using a press. If the required
press force is less than the standard value,
replace the piston and piston pin assembly or the
connecting rod, or both.
Standard value: 7,350 - 17,100 N

ENGINE OVERHAUL

11B-54

PISTON AND CONNECTING ROD

>>B<< OIL RING INSTALLATION

>>C<< PISTON RING NO. 2/PISTON RING NO. 1


INSTALLATION

Lower
side
rail
end gap

Upper
side
rail
end gap

Piston ring
expander
Spacer end gap

AK202879 AB
AK202786 AB

1. Fit the oil ring spacer into the piston ring groove.
Install the upper side rail, then the lower side rail.
NOTE: .
1. Locate the side rail and spacer end gaps as
shown in the drawing.
2. New spacers and side rails are an identified by
color marks as follows:
Size

Color mark

Standard

Non mark

0.50 mm oversize

Blue

1.00 mm oversize

Yellow

Identification mark
Size marks

No. 1
No. 2

AK202807 AB

CAUTION
Use of ring expander to expand the side rail end
gap can break the side rail, unlike other piston
rings.
Side rail end

Using a piston ring expander, install the piston rings


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

Size mark

Standard No. 1 ring No mark


(blue paint on periphery)
No. 2 ring No mark
(green paint on periphery)
AK202785 AB

2. To install each side rail, first fit one end of the rail
into the piston groove, then press the remaining
portion progressively into position by finger as
shown in the drawing.
3. Make sure that the installed side rails move
smoothly in either direction.

0.50 mm oversize

50

1.00 mm oversize

100

>>D<< PISTON AND CONNECTING ROD


ASSEMBLY INSTALLATION
1. Apply engine oil generously to the pistons outside
surface, piston rings, and oil ring.

ENGINE OVERHAUL

11B-55

PISTON AND CONNECTING ROD


Side rail
No. 1

No. 2

2. Crankshaft pin diameter marks are stamped in the


indicated locations.

Side rail
AK202730 AB

2. Align the end gaps of the piston rings and oil ring
(side rails and spacer) as shown in the drawing.
3. Insert the piston and connecting rod assembly
from the top of cylinder with the front mark on the
crown toward the camshaft sprocket.

AK202719AB

3. Connecting rod bearing identification mark is


stamped in the indicated location on each
bearing.
Crankshaft pin

Connecting rod
bearing

Identification Diameter mm
mark

Identification
mark

44.995 - 45.000 1

II

44.985 - 44.995 2

III

AK202798

CAUTION
Do not strike the assembly with a large force.
Doing so could break the piston rings.
When striking the assembly into cylinder, do
not allow it to interfere with the oil jet.
4. Use a piston ring band to hold the piston rings
compressed when inserting the piston and
connecting rod assembly into the cylinder.

44.980 - 44.985 3
<Bearing selection example>
If the crankshaft pin diameter mark is I, select a
bearing marked 1.
If the crankshaft pin diameter mark is illegible,
measure the pin diameter and select a bearing
with the mark corresponding to the measurement.
4. Install the upper and lower halves of the selected
bearing on the connecting rod big end and cap,
respectively.
>>F<< CONNECTING ROD CAP INSTALLATION

>>E<< CONNECTING ROD BEARING


INSTALLATION
1. When replacing the connecting rod bearing,
select a bearing of the size appropriate for the
crankshaft pin diameter in accordance with the
crankshaft pin and connecting rod bearing
matching table shown below.
Locations of crankshaft pin diameter
marks

No. 1

No. 4

Cylinder
number

Bearing
locating
notches

No. 2
No. 3

AK202909 AB

AK202813 AB

1. Install the bearing cap on the connecting rod while


aligning the marks made during disassembly. If
the connecting rod is new and has no alignment
mark, assemble it with the cap such that the both
bearing locating notches are on the same side as
shown in the drawing.

ENGINE OVERHAUL

11B-56

PISTON AND CONNECTING ROD

CAUTION
If the tightening angle is less than 90, adequate tightness could not be assured.
If the tightening angle exceeds 94, loosen the
nut completely and then perform the tightening procedure again beginning with the first
step.
7. Turn the nut 90 to 94 to bring the mark on the
nut into alignment with that on the bolt.
AK202821

2. Make sure that the thrust clearance of the


connecting rod big end is proper.
Standard value: 0.10 - 0.25 mm
Limit: 0.4 mm
>>G<< CONNECTING ROD CAP NUT
INSTALLATION
1. The connecting rod cap bolts and nuts are
tightened using the torque-to-yield method. For
this reason, each bolt to be reused must be
checked for elongation before installation.
Whether or not the bolt has been elongated can
be determined by running a nut with fingers
through all the threads of the bolt. If the nut does
not turn smoothly over all the threads, the bolt has
been elongated and must be replaced.
2. Apply engine oil to the threads and bearing
surface of each nut before installation.
3. Finger-tighten the nuts on the bolts, then tighten
the nuts alternately and repeatedly to install the
cap properly.
4. Tighten the nuts to a torque of 20 2 Nm.
90 to 94

INSPECTION
M1113008500365

PISTON RING

AK202787

1. Measure the clearance between each piston ring


and its groove. If the limit is exceeded, replace the
ring or piston, or both.
Standard values:
No. 1 ring: 0.03 - 0.07 mm
No. 2 ring: 0.02 - 0.06 mm
Limits: 0.1 mm
Force ring down
with piston

Paint marks

Paint marks

Piston ring
Nut

Bolt
AK202721 AB

5. Make a paint mark on the head of each nut.


6. Make a paint mark on the bolt at a point 90to 94
away from the paint mark made on the nut in the
tightening direction.

End gap

AK202788 AB

2. Install a piston ring or oil ring side rail into the


cylinder bore and force it down with the head of a
piston until the ring is at right angles to the
cylinder wall. Measure the end gap with a
thickness gauge.
NOTE: If the end gap is excessive, replace the
piston ring.
Standard values:
No. 1 ring: 0.25 - 0.35 mm
No. 2 ring: 0.40 - 0.55 mm
Oil ring: 0.10 - 0.40 mm

ENGINE OVERHAUL
PISTON AND CONNECTING ROD

11B-57

Limits:
No. 1 ring: 0.8 mm
No. 2 ring: 0.8 mm
Oil ring: 1.0 mm
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC
GAUGE METHOD)
1. Wipe off oil from the crankshaft pin and
connecting rod bearing.
2. Cut a piece of plastic gauge whose length is
equivalent to the width of the bearing and place it
on the crankshaft pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten
the nuts to the specified torque20 2 Nm + 90 to
94.
4. Remove the nuts, then remove the connecting rod
cap carefully.

AK202848

5. Measure the largest width of the crushed plastic


gauge using the ruler printed on the bag of the
plastic gauge.
Standard value: 0.03 - 0.05 mm
Limit: 0.1 mm

ENGINE OVERHAUL

11B-58

CRANKSHAFT AND CYLINDER BLOCK

CRANKSHAFT AND CYLINDER BLOCK


REMOVAL AND INSTALLATION
M1113008700507

CAUTION
On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown
in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in
damage.

3
Apply engine oil
to all moving
parts before
installtion.

2
1

11 1 Nm

16

11 1 Nm

15

132 5 Nm

9.0 1.0 Nm

14

13

12
11
10

25 2 Nm + 90 to 100

AK204351AB

>>E<<
>>D<<

1.
2.
3.
4.
5.
6.
7.
8.

Removal steps
Flywheel bolt
Adapter plate
Flywheel
Adapter plate
Crankshaft bushing
Rear plate
Bell housing cover
Oil seal case

Removal steps &RQWLQXHG

>>C<< 9. Oil seal


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

>>B<< 13. Crankshaft


>>A<< 14. Crankshaft bearing, upper
15. Thrust bearing
16. Cylinder block

ENGINE OVERHAUL

11B-59

CRANKSHAFT AND CYLINDER BLOCK

INSTALLATION SERVICE POINTS


>>A<< THRUST BEARING INSTALLATION

If the crankshaft journal diameter mark is 0 and


the cylinder block bearing bore mark is 1, then
select a bearing with a 2 mark as the No. 1, 2, 4
or 5 bearing and a bearing with a 1 mark as the
No. 3 bearing.
If the crankshaft journal diameter mark is illegible,
measure the journal diameter and select a
bearing with the mark corresponding to the
measurement.

Groove
Timing belt side
AK202769 AB

Diameter identification marks of


bearing bores in cylinder block

Install the two thrust bearings in the No. 3 bearing


bore in the cylinder block. Each thrust bearing must
be installed with the grooved end toward the crankshaft web.
NOTE: Applying engine oil to the bearings will help
facilitate holding them in position.

No. 4
No. 5

No. 3
No. 1 No. 2

>>B<< CRANKSHAFT BEARING INSTALLATION

Cylinder
bore size
mark

Location of crankshaft journal


diameter marks

No. 2
No. 1

No. 3
AK202777 AB

No. 4

No. 5

AK202908 AB

1. Location of crankshaft journal diameter marks


<Bearing selection example>
Crankshaft journal diameter
Identification mark Journal diameter
measurement mm
0

56.994 - 57.000

56.988 - 56.994

56.982 - 56.988

2. The diameter identification marks of the bearing


bores in the cylinder block are stamped in the
location shown in the drawing.

Cylinder block
bearing bore
marking

No. 1, 2, 4 and 5
bearing

No. 3 bearing

Crankshaft bearing marking

ENGINE OVERHAUL

11B-60

CRANKSHAFT AND CYLINDER BLOCK

Crankshaft bearing size mark location


size mark

10

Size mark
AK202753 AB

3. The size mark of each crankshaft bearing is


indicated by ink in the location shown in the
drawing.

Groove

Arrow

AK202737 AB

4. Tighten the bolts to 25 2 Nm in the indicated


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

Paint mark

Paint mark

Upper bearing half


Lower bearing half
90 to 100

AK202770 AB

4. Install bearing halves with oil grooves in the


cylinder block bearing bores.
5. Install bearing halves with no oil grooves in the
beam bearing cap.
>>C<< BEAM BEARING CAP/BEARING CAP
BOLT INSTALLATION
1. Install the beam bearing cap on the cylinder block
with the arrow pointing to the timing belt.

AK202722 AB

CAUTION
If the tightening angle is less than 90, adequate tightness could not be assured.
If the tightening angle exceeds 100, loosen
the bolt completely and then perform the
tightening again beginning with the first step.
7. Turn clockwise the bolts 90 to 100 in the
indicated tightening sequence to bring the mark
on each bolt head into alignment with that on the
bearing cap.

Nominal length
AK202805 AB

2. Measure the nominal length of each bearing cap


bolt before installation. If the measurement
exceeds the limit, replace the bolt.
Limit: 71.1 mm
3. Apply engine oil to the threads and bearing
surface of the bolt.

AK202823

8. After installing the beam bearing cap, measure


the end play of the crankshaft. If the end play
exceeds the limit, replace the crankshaft bearings.
Standard value: 0.05 - 0.25 mm

ENGINE OVERHAUL

11B-61

CRANKSHAFT AND CYLINDER BLOCK

Limit: 0.4 mm
>>D<< REAR OIL SEAL INSTALLATION

MB990938

Measure the crankshaft oil clearance using a plastic


gauge as follows:
1. Wipe off oil from the crankshaft journal surface
and the crankshaft bearing inner surface.
2. Install the crankshaft.
Plastic gauge

MD998776

AK202827 AB

Use the special tools to press-fit the rear oil seal in


the rear oil seal case.
Handle (MB990938)
Crankshaft rear oil seal installer (MD998776)
>>E<< REAR OIL SEAL CASE INSTALLATION
1. Remove completely old FIPG remaining on the
rear oil seal case and cylinder block.

AK202826 AB

3. Cut a piece of plastic gauge whose length is


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

AK202824AB

2. Apply a bead of FIPG to the surface of the rear oil


seal case as shown in the drawing.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
3. Install the oil seal into the cylinder block after
applying an appropriate amount of engine oil to
the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts
to 11 1 Nm.

INSPECTION
M1113008800366

CRANKSHAFT OIL CLEARANCE


(PLASTIC GAUGE METHOD)
This plastic gauge method is recommended as a
simplest way of measuring the crankshaft oil clearance.

Plastic gauge
AK202822 AB

6. Measure the largest width of the crushed plastic


gauge using the ruler printed on the bag of the
plastic gauge.
Standard value: 0.02 - 0.04 mm
Limit: 0.1 mm
CYLINDER BLOCK
1. Visually check the cylinder block for scratches,
rust, and any other corrosion. Also check it for
cracks using a flaw detecting penetrant.
If any defect is evident, replace the cylinder block.

11B-62

ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

BORING CYLINDERS
1. Select an oversize of the pistons to be used based
on the largest of the cylinder bores.

AK202833

2. Use a straightedge and thickness gauge to check


the cylinder block top surface for warp.
Make sure that the surface is free from remaining
gasket material and other foreign matter.
Standard value: 0.05 mm
Limit: 0.1 mm
3. Check cylinder walls for scratches and seizure.
If defects are evident, rebore to oversize or
replace the cylinder block.

11.65 mm
Piston diameter
AK202880 AB

2. Oversize pistons are available in two oversizes:


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

CAUTION
12 mm

AK202731 AB

4. Use a cylinder gauge to measure the cylinder


bore diameter and taper.
If the cylinder is worn badly, rebore it to an
oversize and replace the piston and piston rings
with ones matched with the new bore size.
Standard value: 85.00 mm
Taper: 0.01 mm

To prevent deformation of cylinder block that


would result from the heat generated by boring,
bore the cylinders in the following sequence: No.
2 No. 4 No. 1 No. 3.
4. Bore all the cylinders to the calculated boring
finish dimension.
5. Hone the bored cylinders to the final finish
dimension (piston diameter + clearance between
piston and cylinder).
6. Check the clearance between the piston and
cylinder.
Standard value: 0.02 - 0.04 mm

11C-1

GROUP 11C

ENGINE
MECHANICAL
<4G69>
CONTENTS
GENERAL INFORMATION . . . . . . . .

11C-2

SERVICE SPECIFICATIONS. . . . . . .

11C-2

SEALANTS . . . . . . . . . . . . . . . . . . . .

11C-3

SPECIAL TOOLS. . . . . . . . . . . . . . . .

11C-4

ON-VEHICLE SERVICE. . . . . . . . . . .

11C-8

REMOVAL AND INSTALLATION . . . . . . . .

11C-17

CAMSHAFT AND VALVE STEM


SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11C-18
REMOVAL AND INSTALLATION . . . . . . . .

11C-18

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11C-23


REMOVAL AND INSTALLATION . . . . . . . .

11C-23

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11C-26

DRIVE BELT TENSION CHECK. . . . . . . . .

11C-8

AUTO-TENSIONER CHECK . . . . . . . . . . .

11C-8

VALVE CLEARANCE CHECK AND


ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .

11C-11

ROCKER ARM PISTON OPERATION


CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11C-11

IGNITION TIMING CHECK . . . . . . . . . . . . .

11C-13

IDLE SPEED CHECK . . . . . . . . . . . . . . . . .

11C-14

IDLE MIXTURE CHECK . . . . . . . . . . . . . . .

11C-14

REMOVAL AND INSTALLATION . . . . . . . .

11C-36

COMPRESSION PRESSURE CHECK. . . .

11C-15

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11C-45

MANIFOLD VACUUM CHECK . . . . . . . . . .

11C-16

CRANKSHAFT OIL SEAL . . . . . . . . . 11C-26


REMOVAL AND INSTALLATION . . . . . . . .

11C-26

CYLINDER HEAD GASKET . . . . . . . . 11C-30


REMOVAL AND INSTALLATION . . . . . . . .

11C-30

TIMING BELT . . . . . . . . . . . . . . . . . . . 11C-36

ENGINE ASSEMBLY . . . . . . . . . . . . . 11C-47


CRANKSHAFT PULLEY . . . . . . . . . . 11C-17

REMOVAL AND INSTALLATION . . . . . . . .

11C-47

ENGINE MECHANICAL <4G69>

11C-2

GENERAL INFORMATION

GENERAL INFORMATION
M1111000100505

Item

4G69

Total displacement mL

2,378

Bore Stroke mm

87 100

Compression ratio

9.5

Compression chamber

Pentroof

Camshaft arrangement

SOHC

Number of valve

Intake

Exhaust

Valve timing

Intake valve

Open (BTDC)

10 <low speed cam A>


12 <low speed cam B>
24 <High speed cam>

Closes (ABDC)

42 <low speed cam A>


44 <low speed cam B>
68 <High speed cam>

Exhaust valve

Open (BTDC)

58

Closes (ABDC)

18

Fuel system

Electronically controlled multipoint fuel injection

Rocker arm

Roller type

SERVICE SPECIFICATIONS
M1112000300278

Item

Standard value

Limit

A/C compressor type:


MSC90CA

113 145

A/C compressor type:


MSC105CA

120 154

340 555

Intake valve

0.20

Exhaust valve

0.30

Basic ignition timing

5 BTDC 3

Ignition timing

Approximately
10 BTDC

M/T

680 100

A/T

750 100

CO contents %

0.5 or less

HC contents ppm

100 or less

Compression pressure kPa-r/min

1,560 200

1,130 200

Compression pressure difference of all cylinders kPa

Maximum 98

Drive belt tension

Vibration frequency Hz
(Reference)

Tension N (Reference)
Valve clearance (at hot) mm

Idle speed r/min

ENGINE MECHANICAL <4G69>

11C-3

SEALANTS

Item

Standard value

Limit

Intake manifold vacuum kPa

Minimum 60

Cylinder head bolt nominal length mm

99.4

Balancer timing belt tension (When adjusted) Deflection mm

57

Balancer timing belt tension (When replaced) Deflection mm

57

Balancer timing belt tension (When checked)

5 10

Timing belt tensioner adjuster rod protrusion amount mm

3.8 4.5

Timing belt tensioner adjuster rod movement mm

Within 1

Deflection mm

SEALANTS
M1112000500294

Item

Specified sealant

Remark

Camshaft position sensor support

MITSUBISHI GENUINE PART MD970389 or


equivalent

Semi-drying
sealant

LOCTITE203MP

Anaerobic
sealant

Engine upper oil pan


Engine lower oil pan
Taper plug

ENGINE MECHANICAL <4G69>

11C-4

SPECIAL TOOLS

SPECIAL TOOLS
M1112000600332

Tool

Number

Name

Use

MB991502

MUT-II sub assembly

Drive belt tension check


Checking the ignition timing
Checking the idle speed

MB991955
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991825
F: MB991826

MUT-III sub assembly


A: Vehicle communication
interface (V.C.I.)
B: MUT-III USB cable
C: MUT-III main harness A
(Vehicles with CAN
communication system)
D: MUT-III main harness B
(Vehicles without CAN
communication system)
E: MUT-III measurement
adapter
F: MUT-III trigger harness

Drive belt tension check


Checking the ignition timing
Checking the idle speed

MB991668

Belt tension meter set

Drive belt tension check (used


together with MUT-II or MUT-III)

B991502

MB991824

MB991827

DO NOT USED
MB991910

MB991911

MB991825

MB991826
MB991955

B991668

ENGINE MECHANICAL <4G69>

11C-5

SPECIAL TOOLS

Tool

Number

Name

Use

MB990767

Front hub and flange yoke


holder

Holding the camshaft sprocket

MD998719

Pin

MD998772

Valve spring compressor

Compressing valve spring

MD998774

Valve stem seal installer

Valve stem seal installation

MD998713

Camshaft oil seal installer

Camshaft oil seal installation

MD998781

Flywheel stopper

Supporting the flywheel


assembly <M/T>
Supporting the A/T drive plate
<A/T>

MB990938

Installer bar

Crankshaft rear oil seal


installation

MD998776

Crankshaft rear oil seal


installer

B990767

D998719

MD998772

D998713

D998781

B990938

D998776

ENGINE MECHANICAL <4G69>

11C-6

SPECIAL TOOLS

Tool

Number

Name

Use

MD998285

Crankshaft front oil seal


guide

Crankshaft front oil seal


installation

MD998375

Crankshaft front oil seal


installer

MD998738

Adjusting bolt

Supporting the timing belt


tensioner arm and timing belt
tensioner adjuster

MB991654

Cylinder head bolt wrench


(12)

Removal and installation of


cylinder head bolt

MB991367

Special spanner

Holding the crankshaft camshaft


drive sprocket

MB991385

Pin

MD998767

Tensioner wrench

D998285

D998738

B991654

B991367

B991385

D998767

Valve timing belt tension


adjustment

ENGINE MECHANICAL <4G69>

11C-7

SPECIAL TOOLS

Tool

Number

Name

Use

MB991454

Engine hanger balancer

MB991527

Hanger

When the engine hanger is


used: Supporting the engine
assembly during removal and
installation of the transmission
assembly
NOTE: Special tool MB991454
is a part of engine hanger
attachment set MB991453.

MB991895

Engine hanger

B991454

B991527

Z203830

MB991928
A: MB991929
B: MB991930
E C: MB991931
D: MB991932
E: MB991933
F: MB991934

Slide bracket (HI)

F
A

D
B
C

B991928

Engine hanger
A: Joint (50) 2
B: Joint (90) 2
C: Joint (140) 2
D: Foot (standard) 4
E: Foot (short) 2
F: Chain and hook assembly

ENGINE MECHANICAL <4G69>

11C-8

ON-VEHICLE SERVICE

ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003100548

CAUTION
Check the drive belt tension after turning the
crankshaft clockwise one turn or more.

4. If there are any problems in the procedure 1 or 3,


replace the auto-tensioner.(Refer to P.11C-36).
5. Install the drive belt.(Refer to P.11C-17).

FUNCTION CHECK
You can verify if the auto-tensioner is defective or not
by checking the drive belt tension.
When using MUT-II
1. Check the drive belt tension. (Refer to P.11C-8).
2. Measure the drive belt tension vibration frequency
by the following procedures:

Indicator mark

CAUTION
AC301702AB

1. Make sure that the indicator mark is within the


area marked with A in the illustration.
2. If the mark is out of the area, replace the drive
belt. (Refer to P.11C-17).
NOTE: The drive belt tension check is not
necessary as auto-tensioner is adopted.

16-pin

AUTO-TENSIONER CHECK
M1111003000251

MUT-II

OPERATION CHECK
1. Turn OFF the engine from the idle state then
check to see that the drive belt is not protruding
from the pulley width of the auto-tensioner.
2. Remove the drive belt.(Refer to P.11C-17).
MB991668
AC211862 AB

AC301703

3. Securely insert the spindle handle or ratchet


handle with a 12.7 mm insertion angle into the jig
hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.

To prevent damage to MUT-II, always turn the


ignition switch to the "LOCK" (OFF) position
before connecting or disconnecting MUT-II.
(1) Connect special tool belt tension meter set
(MB991668) to the MUT-II.
(2) Connect the MUT-II to the diagnosis
connector.
(3) Turn the ignition switch to "ON" position, and
select "BELT TENSION" on the menu screen.

ENGINE MECHANICAL <4G69>

11C-9

ON-VEHICLE SERVICE

CAUTION
The temperature of the surface of the belt
should be as close to normal temperature as
possible.
Do not allow any contaminants such as water
or oil to get onto the microphone.
If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual
values.
If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not
correspond to actual values.
Do not take the measurement while the
vehicle's engine is running.

Standard value:
<A/C compressor type: MSC90CA> 113 145
Hz
<A/C compressor type: MSC105CA> 120 154
Hz
3. If not within the standard value, replace the
auto-tensioner. (Refer to P.11C-36).
When using V.C.I.
1. Check the drive belt tension. (Refer to P.11C-8).
2. Measure the drive belt tension vibration frequency
by the following procedures:

CAUTION

16-pin

Water
pump
pulley

MB991668

15
15

10 20 mm
MB991824

Gentry tap
with your
finger

MB991668
MB991911

Alternator
pulley

AC301266AB

(4) Hold special tool belt tension meter set


(MB991668) to the middle of the drive belt
between the pulleys (at the place indicated by
arrow), approximately 10 20 mm away from
the rear surface of the belt so that it is
perpendicular to the belt (within an angle of
15 degree).
(5) Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and
measure that the vibration frequency of the
belt is within the standard value.

AC211863AB

To prevent damage to special tool V.C.I.


(MB991824), always turn the ignition switch to
the "LOCK" (OFF) position before connecting or
disconnecting special tool V.C.I. (MB991824).
(1) Connect special tool belt tension meter set
(MB991668) to special tool V.C.I. (MB991824).
(2) Connect special tool MUT-III main harness B
(MB991911) to special tool V.C.I. (MB991824).
(3) Connect special tool MUT-III main harness B
(MB991911) to the diagnosis connector.
(4) Turn the ignition switch to "ON" position, and
select "Belt Tension" on the menu screen.

ENGINE MECHANICAL <4G69>

11C-10

ON-VEHICLE SERVICE

CAUTION
The temperature of the surface of the belt
should be as close to normal temperature as
possible.
Do not allow any contaminants such as water
or oil to get onto the microphone.
If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual
values.
If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not
correspond to actual values.
Do not take the measurement while the
vehicle's engine is running.

Water
pump
pulley

15

3. If not within the standard value, replace the


alternator drive belt auto tensioner. (Refer to
P.11C-36).
When using a tension gauge
1. Check the drive belt tension. (Refer to P.11C-8).

Water pump
pulley

MB991668

15

(6) Gently tap the middle of the belt between the


pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and
measure that the vibration frequency of the
belt is within the standard value.
Standard value:
<A/C compressor type: MSC90CA> 113 145
Hz
<A/C compressor type: MSC105CA> 120 154
Hz

Belt tension
gauge

10 20 mm

Gentry tap
with your
finger

Alternator
pulley

Alternator
pulley

AC301267AB
AC301266AB

(5) Hold special tool belt tension meter set


(MB991668) to the middle of the drive belt
between the pulleys (at the place indicated by
arrow), approximately 10 20 mm away from
the rear surface of the belt so that it is
perpendicular to the belt (within an angle of
15 degree).

2. Use a belt tension gauge in the middle of the belt


between the pulleys (at the place indicated by the
arrow) to measure that the belt tension is within
the standard value.
Standard value: 340 555 N
3. If not within the standard value, replace the
auto-tensioner. (Refer to P.11C-36).

ENGINE MECHANICAL <4G69>

11C-11

ON-VEHICLE SERVICE

Standard value (hot engine):


Intake valve: 0.20 mm
Exhaust valve: 0.30 mm

VALVE CLEARANCE CHECK AND


ADJUSTMENT
M1111001500131

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


engine coolant temperature reaches 80 95C.
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Remove all ignition coils.
4. Remove all spark plugs from the cylinder head for
easy inspection.
5. Remove the rocker cover.
6. Turn the crankshaft clockwise until the notch on
the pulley is lined up with the "T" mark on the
timing indicator.
7. Move the rocker arms on the No.1 and No.4
cylinders up and down by hand to determine
which cylinder has its piston at the top dead
center on the compression stroke. If both intake
and exhaust valve rocker arms have a valve lash,
the piston in the cylinder corresponding to these
rocker arms is at the top dead center on the
compression stroke.

10.While holding the adjusting screw with a


screwdriver to prevent it from turning, tighten the
lock nut to the specified torque.
Tightening torque: 9 1 Nm
11.Turn the crankshaft through 360 to line up the
notch on the crankshaft pulley with the "T" mark
on the timing indicator.
12.Repeat steps (9) and (10) on other valves for
clearance adjustment.
13.Install the rocker cover.
14.Install the spark plugs and tighten to the specified
torque.
Tightening torque: 25 4 Nm
15.Install the ignition coils.

ROCKER ARM PISTON OPERATION


CHECK
M1111051000023

Intake valve side

Taper plug
Oil control valve

Ignition coils
No. 2 No. 3
No. 1
Exhaust valve side

No. 4
Rocker cover

AK303689 AB

8. Valve clearance inspection and adjustment can be


performed on rocker arms indicated by white
arrow mark when the No.1 cylinder piston is at the
top dead centre on the compression stroke, and
on rocker arms indicated by black arrow mark
when the No.4 cylinder piston is at the top dead
centre on the compression stroke.
9. Measure the valve clearance.
If the valve clearance is not as specified, loosen
the rocker arm lock nut and adjust the clearance
using a thickness gauge while turning the
adjusting screw.

1.
2.
3.
4.
5.

AK304505AB

Remove all of the ignition coils.


Remove the rocker cover.
Remove the oil control valve.
Remove the taper plug.
Turn the crankshaft clockwise until the notch on
the crankshaft pulley is lined up with "T" mark on
the lower cover of timing belt.
6. Move the rocker arms on the No.1 and No.4
cylinders up and down by hand to determine
which cylinder has its piston at the top dead
centre on the compression stroke.

ENGINE MECHANICAL <4G69>

11C-12

ON-VEHICLE SERVICE

NOTE:
Intake valve side

No. 2 No. 3
No. 1
Exhaust valve side

No. 4
AK303689 AC

The rocker arm piston operation check can be


performed on rocker arms indicated by white arrow
mark when the No.1 cylinder piston is at the top dead
centre on the compression stroke, and on rocker
arms indicated by black arrow mark when the No.4
cylinder piston is at the top dead centre on the
compression stroke.
Rocker arm

Rocker arm
piston

Oil passage
Blow
compression
air

AK302684AC

7. While shutting up the oil passage hole at the


depth of the oil control valve's installation hole by
finger not to leak air, blow compression air into the
taper plug's installation hole by air blowgun. At
this time, confirm that the rocker arm piston can
operate.
NOTE: To fully confirm the check, prevent the
compression air from leaking as much as possible by
installing the O-ring to the end of air blowgun.
8. Turn the crankshaft clockwise until the notch on
the crankshaft pulley is lined up with "T" mark on
the lower cover of timing belt.
9. Confirm the rest of the rocker arm pistons under
the procedure 7.
10.When the rocker arm piston does not operate,
replace the rocker arm assy.
11.Apply sealant to threaded portion.
Specified sealant: LOCTITE203MP

CAUTION
Do not start the engine within one hour after the
engine taper plug has been installed.
12.Install the taper plug and tighten to the specified
torque.
Tightening torque: 10 2 Nm
13.Install the oil control valve. (Refer to Camshaft
and Valve Stem Seal Removal and Installation
P.11C-18.)
14.Install all of the ignition coils.
15.Install the rocker cover.

ENGINE MECHANICAL <4G69>


ON-VEHICLE SERVICE

IGNITION TIMING CHECK


M1111001700607

16 PIN

MB991502
AK303691AF

11C-13

2. Turn the ignition switch to the "LOCK" (OFF)


position and then connect the MUT-II/III to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Use the MUT-II/III to measure engine idle speed
and check that it is within the standard value.
Standard value
: 680 100 r/min <M/T>
: 750 100 r/min <A/T>
6. Select No. 17 of the MUT-II/III Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5 BTDC 3
8. If the basic ignition timing is outside the standard
value, inspect the MPI system (Refer to P.13B-20,
GROUP 13B Troubleshooting Inspection chart
for diagnosis code).

16-PIN

MB991911
MB991824

MB991827

AK303690AB

1. Before inspection, set the vehicle to the


pre-inspection condition.

CAUTION
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this
condition may damage the engine.
9. Press the MUT-II/III clear key (Select a forced
driving cancel mode) to release the Actuator test.
10.Check that ignition timing is at the standard value.
Standard value: approximately 10 BTDC
NOTE: .
The ignition timing may fluctuate within 7
BTDC. This is normal.
In higher altitude, the ignition timing is more
advanced than the standard value by
approximately 5.
11.Remove the timing light.
12.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the MUT-II/III.

ENGINE MECHANICAL <4G69>

11C-14

ON-VEHICLE SERVICE

IDLE SPEED CHECK


M1111003500654

7. If the idle speed is outside the standard value,


inspect the MPI system (Refer to P.13B-20,
GROUP 13B Troubleshooting Inspection chart
for diagnosis code).
8. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the MUT-II/III.

IDLE MIXTURE CHECK


M1111002100426

16 PIN

MB991502
AK303691AF

16-PIN

16 PIN

MB991502
AK303691AF

MB991911
16-PIN
MB991824

MB991911
MB991827

AK303690AB

1. Before inspection, set the vehicle to the


pre-inspection condition.
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the MUT-II/III to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Check that ignition timing is at the standard value.
Standard value: approximately 10 BTDC
6. Check the idle speed.
Standard value
: 680 100 r/min <M/T>
: 750 100 r/min <A/T>
NOTE: .
The idle speed is controlled automatically by
the idle speed control system.
When using the MUT-II/III, select item No. 22
and take a reading of the idle speed.

MB991824

MB991827

AK303690AB

1. Before inspection, set the vehicle to the


pre-inspection condition.
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the MUT-II/III to the
diagnosis connector.
3. Connect a timing light.
4. Start the engine and let it run at idle.
5. Check that ignition timing is at the standard value.
Standard value: approximately 10 BTDC
6. Run the engine at 2,500 r/min for 2 minutes.
7. Set the CO, HC tester.

ENGINE MECHANICAL <4G69>


ON-VEHICLE SERVICE

8. Check the CO contents and the HC contents at


idle.
Standard value
CO contents: 0.5 % or less
HC contents: 100 ppm or less
9. If there is a deviation from the standard value,
check the following items:
Diagnosis output
Fuel pressure
Injector
Ignition coil, spark plug
EGR control system
Evaporative emission control system
Compression pressure
NOTE: Replace the three way catalyst when the
CO and HC contents are not within the standard
value, even though the result of the inspection is
normal on all items.
10.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the MUT-II/III.

COMPRESSION PRESSURE CHECK


M1111002600636

Crank angle
sensor
connector

AK303421AB

1. Before inspection, set the vehicle to the


pre-inspection condition.
2. Remove all of the ignition coils and spark plugs.
3. Disconnect the crank angle sensor connector.
NOTE: Doing this will prevent the
engine-ECU<M/T> or engine-A/T-ECU<A/T> from
carrying out ignition and fuel injection.

11C-15

CAUTION
Keep away from the spark plug hole when
cranking.
If compression is measured with water, oil,
fuel, etc., that has come from cracks inside
the cylinder, these materials will become
heated and will gush out from the spark plug
hole, which is dangerous.
4. Cover the spark plug hole with a shop towel etc.,
and after the engine has been cranked, check that
no foreign material is adhering to the shop towel.
5. Set compression gauge to one of the spark plug
holes.
6. Crank the engine with the throttle valve fully open
and measure the compression pressure.
Standard value (at engine speed of 200
r/min):
1,560 kPa
Limit (at engine speed of 200 r/min):
Minimum 1130 kPa
7. Measure the compression pressure for all the
cylinders, and check that the pressure differences
of the cylinders are below the limit.
Limit: Maximum 98 kPa
8. If there is a cylinder with compression or a
compression difference that is outside the limit,
pour a small amount of engine oil through the
spark plug hole, and repeat the operations in
steps from (5) to (7).
(1) If the compression increases after oil is added,
the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
surface.
(2) If the compression dose not rise after oil is
added, the cause is a burnt or defective valve
seat, or pressure is leaking from the gasket.
9. Connect the crank angle sensor connector.
10.Install the spark plugs and tighten to the specified
torque.
Tightening torque: 25 4 Nm
11.Install the ignition coils.
12.Use the MUT-II/III to erase the diagnosis codes.
NOTE: This will erase the diagnosis code
resulting from the crank angle sensor connector
being disconnected.

ENGINE MECHANICAL <4G69>

11C-16

ON-VEHICLE SERVICE

MANIFOLD VACUUM CHECK


M1111002700569

1. Before inspection, set the vehicle to the


pre-inspection condition.
2. Turn the ignition switch to the "LOCK" (OFF)
position and then connect the MUT-II/III to the
diagnosis connector.
Ventilation hose

16 PIN

MB991502
AK303691AF

PCV valve

Plug
Vacuum gauge

AK303422 AB

16-PIN

MB991911
MB991824

3. Disconnect the ventilation hose from the PCV


valve, and connect a vacuum gauge to the
ventilation hose.
4. Plug the PCV valve.
5. Start the engine and check that idle speed is
within the standard valve.
Standard value
: 680 100 r/min <M/T>
: 750 100 r/min <A/T>
6. Check the intake manifold vacuum.
Limit: Minimum 60 kPa

MB991827

AK303690AB

7. Turn off the ignition switch.


8. Remove the vacuum gauge and then connect the
ventilation hose.
9. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the MUT-II/III.

ENGINE MECHANICAL <4G69>


CRANKSHAFT PULLEY

11C-17

CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600539

Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-19).

Post-installation Operation
Drive Belt Tension Check (Refer to P.11C-8).
Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).

25 4 Nm

AC308973AB

<<A>>

1.
2.

Removal steps
Drive belt
Crank shaft damper pulley

REMOVAL SERVICE POINT


<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the
introduction of the serpentine drive system with the
drive belt auto-tensioner.
Auto-tensioner

AC301703

1. Securely insert the spindle handle or ratchet


handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.

CAUTION
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk, etc.
Auto-tensioner

Hole B

Hole A
AC301704AB

L-shaped
hexagon
wrench

AC301705AB

3. Insert an L-shaped hexagon wrench, etc. into the


hole to fix and then remove the drive belt.

ENGINE MECHANICAL <4G69>

11C-18

CAMSHAFT AND VALVE STEM SEAL

CAMSHAFT AND VALVE STEM SEAL


REMOVAL AND INSTALLATION
M1112006600330

CAUTION
* Remove and assemble the marked parts in each cylinder unit.
Pre-removal Operation
Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-4).
Ignition Coils Removal (Refer to GROUP 16, Ignition
System Ignition Coil P.16-41).
Timing Belt Upper Cover Removal (Refer to P.11C-36).

Post-installation Operation
Timing Belt Upper Cover Installation (Refer to P.11C-36).
Ignition Coils Installation (Refer to GROUP 16, Ignition
System Ignition Coil P.16-41).
Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-4).
Drive Belt Tension Check (Refer to P.11C-8).
Valve Clearance Check and Adjustment (Refer to
P.11C-11).

3.5 0.5 Nm

1
7

N8

4
9.0 2.0 Nm

11 1 Nm

24 3 Nm

3
5
6N

(Engine oil)
44 5 Nm

10

AC308974 AB

1.
2.

>>J<<
>>J<<

3.
4.
5.
6.

Camshaft removal steps


Rocker cover PCV hose connection
Rocker cover breather hose
connection
Control wiring harness connection
Engine hanger
Oil control valve
O-ring

7.
8.
9.
10.

Camshaft removal steps


Rocker cover assembly
Rocker cover gasket
Spark plug guide oil seals
Accumulator assembly
Valve timing belt (Refer to
P.11C-36).

ENGINE MECHANICAL <4G69>

11C-19

CAMSHAFT AND VALVE STEM SEAL

Apply engine oil to all


moving parts before
installation.

31 3 Nm

11

13 1 Nm

11 1 Nm

18
12

19
47 7 Nm

21
22
16

14 1 Nm

25 4 Nm

22 4 Nm

23

13

24*
25*
26*
N 28*
29*

17
20
24*
25*
27*
28* N
29*

89 9 Nm

15 N
14

>>I<<
<<A>>
<<B>>
<<B>>

>>H<<
>>G<<
>>F<<
>>F<<
>>E<<
>>E<<
>>D<<

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

21.
22.

Camshaft removal steps


Connector bracket
Camshaft position sensor support
Camshaft position sensing cylinder
Camshaft sprocket
Camshaft oil seal
Exhaust rocker arm shaft caps
Exhaust rocker arm and shaft
assembly
Inlet rocker arm shaft caps
Inlet rocker arm and shaft assembly <<B>>
Camshaft
Water inlet fitting and thermostat
<<B>>
case assembly (Refer to GROUP
14, Water Hose and Water Pipe
<<C>>
P.14-27).
Cylinder head plug
Oil control valve filter

AC308975AB

1.
2.

>>F<<
>>F<<
>>E<<
>>E<<
>>C<<
>>B<<
>>B<<
>>A<<

3.
4.
7.
8.
9.
16.
17.
18.
19.
23.
24.
25.
26.
27.
28.
29.

Valve stem seal removal steps


Rocker cover PCV hose connection
Rocker cover breather hose
connection
Control wiring harness connection
Engine hanger
Rocker cover assembly
Rocker cover gasket
Spark plug guide oil seals
Exhaust rocker arm shaft caps
Exhaust rocker arm and shaft
assembly
Inlet rocker arm shaft caps
Inlet rocker arm and shaft assembly
Spark plugs
Valve spring retainer locks
Valve spring retainers
Inlet valve springs
Exhaust valve springs
Valve stem seals
Valve spring seats

11C-20

ENGINE MECHANICAL <4G69>


CAMSHAFT AND VALVE STEM SEAL

REMOVAL SERVICE POINTS


<<A>> CAMSHAFT SPROCKET REMOVAL

Use special tool valve spring compressor


(MD998772) to compress the valve spring and then
remove the valve spring retainer lock.

INSTALLATION SERVICE POINTS

MB990767

>>A<< VALVE STEM SEALS INSTALLATION


1. Apply a small amount of engine oil to the valve
stem seals.
MD998719

AC102532AB

1. Use the following special tools to hold the


camshaft sprocket.
Front hub and flange yoke holder (MB990767)
Pin (MD998719)
2. Loosen the camshaft sprocket mounting bolt and
remove the camshaft sprocket.
<<B>> EXHAUST ROCKER ARM AND SHAFT
ASSEMBLY/INLET ROCKER ARM AND SHAFT
ASSEMBLY REMOVAL

CAUTION
Never disassemble the exhaust rocker arm and
shaft assembly, and inlet rocker arm and shaft
assembly.
<<C>> VALVE SPRING RETAINER LOCKS
REMOVAL

CAUTION
When removing valve spring retainer locks, leave
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the
cylinder if the piston is not properly in the TDC
position.

MD998772

CAUTION
Do not re-use the valve stem seal.
Special tool valve stem seal installer
(MD998774) must be used to install the valve
stem seal. Improper installation could result
in oil leaking past the valve guide.
MD998774
Valve
Valve stem
seal
Valve guide
AC308654AB

2. Use the special tool to fill a new valve stem seal in


the valve guide using the valve stem area as a
guide.
>>B<< EXHAUST VALVE SPRINGS/INLET VALVE
SPRINGS INSTALLATION
Rocker arm side

Identification
colour
Inlet side:
Light blue
Exhaust side:
Orange

AC107415AC

Install the valve springs with its identification colour


painted end facing the locker arm.

AC301867AB

ENGINE MECHANICAL <4G69>


CAMSHAFT AND VALVE STEM SEAL

>>C<< VALVE SPRING RETAINER LOCKS


INSTALLATION

MD998772

11C-21

1. Place the inlet rocker shaft so that its 5.5 mm hole


faces toward the cylinder head.
2. Install the inlet rocker arm shaft caps.
3. Tighten the inlet rocker shaft mounting bolts to the
specified torque.
Tightening torque: 31 3 Nm
>>F<< EXHAUST ROCKER ARM AND SHAFT
ASSEMBLY/EXHAUST ROCKER ARM SHAFT
CAPS INSTALLATION

AC301867AB

Engine front

Use special tool valve spring compressor


(MD998772) to compress the valve spring and then
install the valve spring retainer lock in the same
manner as removal.
>>D<< CAMSHAFT INSTALLATION
Notch
Dowel pin

AC301870AB

AC301868AB

Set the dowel pin of the camshaft in the position


shown in the figure.

1. Install the exhaust rocker shaft so that its notch is


positioned as shown.
2. Install the exhaust rocker arm shaft caps.
3. Tighten the exhaust rocker shaft mounting bolts to
the specified torque.
Tightening torque: 13 1 Nm
>>G<< CAMSHAFT OIL SEAL INSTALLATION
Camshaft oil seal

>>E<< INLET ROCKER ARM AND SHAFT


ASSEMBLY/INLET ROCKER ARM SHAFT CAPS
INSTALLATION
Engine front

(Engine oil)
5.5 mm

MD998713

AC301869AB

AC102323AC

1. Apply engine oil to the entire inner diameter of the


oil seal lip.
2. Use special tool camshaft oil seal installer
(MD998713) to press-fit the oil seal as shown.

11C-22

ENGINE MECHANICAL <4G69>


CAMSHAFT AND VALVE STEM SEAL

>>H<< CAMSHAFT SPROCKET INSTALLATION

MB990767

NOTE: Install the camshaft position sensor


support within 15 minutes after applying the
sealant.
3. Install the camshaft position sensor support to the
cylinder head.

CAUTION
Wait at least one hour. Never start the engine or
let engine oil or coolant touch the adhesion
surface during that time.

MD998719

AC102532AB

1. Use the following special tool as during removal to


hold the camshaft sprocket.
Front hub and flange yoke holder (MB990767)
Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
the specified torque.
Tightening torque: 89 9 Nm
>>I<< CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.

4. Tighten the camshaft position sensor support


mounting bolts to the specified torque.
Tightening torque: 14 1 Nm
>>J<< O-RING/OIL CONTROL VALVE
INSTALLATION

CAUTION
Never re-use the O-ring.

Tape

3 mm
AK303651AD

AC301268AB

2. Apply the sealant to the camshaft position sensor


support flange in a continuous bead as shown in
the illustration.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent

Before installing O-ring, wind the tape with the


soft adhesion (sealing tape) around the oil
passages cut-out area of engine oil control
valve to prevent the damage. If the O-ring is
damaged, it can be the cause of oil leak.
1. Apply a small amount of engine oil to the O-ring
and then install it to the oil control valve.
2. Assemble the oil control valve to the cylinder
head.
3. Tighten the oil control valve mounting bolt to the
specified torque.
Tightening torque: 11 1 Nm

ENGINE MECHANICAL <4G69>

11C-23

OIL PAN

OIL PAN
REMOVAL AND INSTALLATION
M1112002800763

Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-19).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service Engine Oil Replacement P.12-3).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-13).
Centre Member Removal (Refer to GROUP 32, Engine
Roll Stopper and Centre Member P.32-12).

Post-installation Operation
Centre Member Installation (Refer to GROUP 32, Engine
Roll Stopper and Centre Member P.32-12).
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-13).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service Engine Oil Replacement P.12-3).
Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).

48 7 Nm

2
8
N

1
12 2 Nm

48 7 Nm

9.0 3.0 Nm

4
N

6
9.0 3.0 Nm
44 10 Nm

39 5 Nm

9.0 3.0 Nm

2.

>>D<<

3.

9.0 1.0 Nm

5
7

1.

Removal steps
Engine oil cooler tube gaskets
<M/T>
Engine oil cooler hose and bracket
assembly <M/T>
Transmission housing front lower
cover stay

22 4 Nm

9.0 3.0 Nm

AC308976 AB

4.

<<A>>
<<B>>

>>C<<
>>B<<
>>A<<

5.
6.
7.
8.

Removal steps (Continued)


Flywheel housing front lower cover
<M/T> or torque converter housing
front lower cover <A/T>
Engine oil pan drain plug
Engine oil pan drain plug gasket
Engine lower oil pan
Engine upper oil pan

ENGINE MECHANICAL <4G69>

11C-24

OIL PAN

REMOVAL SERVICE POINTS


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

CAUTION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.

2. Screw in the bolt into bolt hole A in the location


shown. Then lift the upper oil pan and remove it.

INSTALLATION SERVICE POINTS


>>A<< ENGINE UPPER OIL PAN INSTALLATION
1. Remove sealant from the engine upper oil pan
and cylinder block surfaces.

4 mm

Engine lower oil pan


AC102931AB

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


strike it with a hammer to remove the engine
lower oil pan.
<<B>> ENGINE UPPER OIL PAN REMOVAL
1. Remove the engine upper oil pan mounting bolts.

CAUTION
Do not use special tool oil pan remover
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.

A
A

AC102946AB

Groove
portion

Bolt hole
portion

AC102242AB

2. Apply a bead of the sealant to the mating surface


of the engine upper oil pan as shown.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the engine upper oil pan within 15
minutes after applying sealant.
3. Assemble the engine upper oil pan to the cylinder
block.

ENGINE MECHANICAL <4G69>

11C-25

OIL PAN

CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
sealant surface during that time.
B

CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
sealant surface during that time.

B
B

2. Apply a bead of the sealant to the mating surface


of the engine lower oil pan as shown.
Specified sealant: MITSUBISHI GENUINE
PART MD970389 or equivalent
NOTE: Install the engine lower oil pan within 15
minutes after applying sealant.
3. Assemble the engine lower oil pan to the engine
upper oil pan.

B-1
B

B-11

B-10

B-4
B-7

B-5

B-8

B
B
A

B-9

A
AC102929AB

4. Insert the bolts to the engine upper oil pan as


shown, and tighten them to the specified torque.
Name

B-6
A-3

Symbol

Flange bolt A
B

Quantity

Size mm
(D L)

M6 16

16

M6 18

NOTE: D: Nominal diameter, L: Nominal length


Tightening torque: 9.0 3.0 Nm
>>B<< ENGINE LOWER OIL PAN INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan.

B-2

B-12

AC102930AB

4. Insert the bolts to the engine lower oil pan as


shown, and tighten them to the specified torque in
the order shown.
Name

Symbol

Flange bolt A
B

Quantity

Size mm
(D L)

M6 75

11

M6 10

NOTE: D: Nominal diameter, L: Nominal length


Tightening torque: 9.0 3.0 Nm
>>C<< ENGINE OIL PAN DRAIN PLUG GASKET
INSTALLATION

Engine lower
oil pan side

AC102325 AF

4 mm
Groove
portion

Bolt hole
portion

AC102243AB

Replace the gasket with a new one. Install the new


gasket in the direction shown in the illustration.

ENGINE MECHANICAL <4G69>

11C-26

CRANKSHAFT OIL SEAL

>>D<< TRANSMISSION HOUSING FRONT


LOWER COVER STAY INSTALLATION
Install the transmission housing front lower cover
stay in the following order.
1. Tighten the engine side four mounting bolts to the
specified torque.
Tightening torque: 22 4 Nm

2. Tighten the transmission side two mounting bolts


to the specified torque.
Tightening torque: 44 10 Nm

INSPECTION
M1112002900254

Check the oil pan for cracks.


Check the oil pan sealant-coated surface for
damage and deformation.

CRANKSHAFT OIL SEAL


REMOVAL AND INSTALLATION
M1112003100411

<M/T>
6

132 5 Nm

8
5

7
9N
3

(Lip section)

(Lip section)

Engine oil

3N
1

AC308977 AB

>>D<<

1.

>>C<<

2.
3.

Crankshaft front oil seal removal


steps
Valve timing belt, balancer timing
belt (Refer to P.11C-36).
Crankshaft balancer shaft drive
sprocket
Crankshaft key
Crankshaft front oil seal

<<A>>
<<B>>

>>B<<

>>A<<

4.
5.
6.
7.
8.
9.

Crankshaft rear oil seal removal


steps
Transmission assembly
Flywheel bolts
Flywheel adapter plate
Flywheel assembly
Flywheel adapter plate
Crankshaft bush
Crankshaft rear oil seal

ENGINE MECHANICAL <4G69>

11C-27

CRANKSHAFT OIL SEAL

<A/T>

6
N

132 5 Nm

5
7

(Lip section)

(Lip section)

Engine oil

3N
1

AC308978AB

>>D<<
>>C<<

1.
2.
3.

Crankshaft front oil seal removal


steps
Valve timing belt, balancer timing
belt (Refer to P.11C-36).
Crankshaft balancer shaft drive
sprocket
Crankshaft key
Crankshaft front oil seal

<<B>>

>>B<<

>>A<<

4.
5.
6.
7.
8.

Crankshaft rear oil seal removal


steps
Transmission assembly (Refer to
GROUP 23A, Transmission
Assembly P.23A-172).
A/T drive plate bolts
A/T drive plate adapter plate
A/T drive plate
Crankshaft bush
Crankshaft rear oil seal

ENGINE MECHANICAL <4G69>

11C-28

CRANKSHAFT OIL SEAL

REMOVAL SERVICE POINTS


<<A>> TRANSMISSION ASSEMBLY REMOVAL

CAUTION
AC300897

Engine front
Flywheel
assembly

1. Apply a small amount of engine oil to the entire


inner diameter of the oil seal lip.
2. Use the following special tools to press-fit the oil
seal.
Installer bar (MB990938)
Crankshaft rear oil seal installer (MD998776)
>>B<< FLYWHEEL BOLTS/A/T DRIVE PLATE
BOLTS INSTALLATION

Flywheel
bolt
MD998781

AC308604 AB

Do not remove the flywheel bolt shown by the


arrow. If this bolt is removed, the flywheel
assembly will become out of balance and
damaged.
Refer to GROUP 22A, Transmission Assembly
P.22A-15.
<<B>> FLYWHEEL BOLTS/A/T DRIVE PLATE
BOLTS REMOVAL

MD998781

AC301855AB

1. Use special tool flywheel stopper (MD998781) to


secure the flywheel assembly or A/T drive plate in
the same manner as removal.
2. Tighten the flywheel bolts or A/T drive plate bolts
to the specified torque.
Tightening torque: 132 5 Nm
>>C<< CRANKSHAFT FRONT OIL SEAL
INSTALLATION
Crankshaft

MD998375

AC301854AB

(Engine oil)

1. Use special tool flywheel stopper (MD998781) to


secure the flywheel assembly or A/T drive plate.
2. Remove the flywheel bolts or A/T drive plate bolts.

INSTALLATION SERVICE POINTS


>>A<< CRANKSHAFT REAR OIL SEAL
INSTALLATION
Oil seal

MB990938
(Engine oil)

MD998776

Crankshaft
AC102328 AB

MD998285
(Oil applied to the
circumference)

Oil seal
AC102329AC

1. Apply a small amount of engine oil to the outer


diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft.
2. Apply a small amount of engine oil to the entire
inner diameter of the oil seal lip.
3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal.

ENGINE MECHANICAL <4G69>


CRANKSHAFT OIL SEAL

>>D<< CRANKSHAFT BALANCER SHAFT DRIVE


SPROCKET INSTALLATION
: Clean
: Clean and degrease
Crankshaft
balancershaft
drive sprocket

Crankshaft
Front case

Engine front

AC301346AB

11C-29

1. Clean or degrease the front case, the crankshaft


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

ENGINE MECHANICAL <4G69>

11C-30

CYLINDER HEAD GASKET

CYLINDER HEAD GASKET


REMOVAL AND INSTALLATION
M1112004000848

Pre-removal Operation
Fuel Line Pressure Reduction [Refer to GROUP 13B,
On-vehicle Service Fuel Pump Connector
Disconnection (How to Reduce Pressurized Fuel Lines)
P.13B-428].
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-17).
Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-4).
Accelerator Cable Removal (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).

Post-installation Operation
Accelerator Cable Installation (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).
Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-4).
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-17).
Accelerator Cable Adjustment (Refer to GROUP 17,
On-vehicle Service Accelerator Cable Check and
Adjustment P.17-5).
Fuel Leak Check

5.0 1.0 Nm

3
2

9.0 2.0 Nm

13 1 Nm

14 3 Nm

(Engine oil)

AC308979AB

1.
2.
3.
4.

Removal steps
Control wiring harness connection
Battery wiring harness connection
Radiator lower hose clamp
Canister vacuum hose connection

5.
6.
7.

Removal steps (Continued)


Brake booster vacuum hose
connection
Engine oil level gauge and guide
assembly
O-ring

ENGINE MECHANICAL <4G69>

11C-31

CYLINDER HEAD GASKET

13
14

(Engine oil)

<Cold engine>
78 2 Nm 0 Nm 20 2 Nm +90 +90

15

12

(Engine oil)

16

8
11 1 Nm

17 N

11
31 3 Nm

10

31 3 Nm

89 9 Nm

Removal steps
Detonation sensor connection
Battery wiring harness connection
Inlet manifold stay
Exhaust manifold (Refer to GROUP
15, Exhaust Manifold P.15-11).
Timing belt upper cover (Refer to

P.11C-36).
11. Camshaft sprocket
12. Radiator upper hose connection
13. Water hose connection

8.
9.
10.

<<A>>
<<B>>

>>E<<
>>D<<

AC308980AB

<<C>>

>>C<<

14.

<<D>>

>>B<<
>>A<<

15.
16.
17.

Removal steps (Continued)


Water inlet fitting and thermostat
case assembly (Refer to GROUP
14, Water Hose and Water Pipe
P.14-27).
Fuel high-pressure hose
connection
Rocker cover assembly (Refer to
P.11C-18).
Cylinder head bolts
Cylinder head assembly
Cylinder head gasket

ENGINE MECHANICAL <4G69>

11C-32

CYLINDER HEAD GASKET

REMOVAL SERVICE POINTS


<<A>> CAMSHAFT SPROCKET REMOVAL

3. Screw in the special tool until it comes in contact


with the timing belt tensioner arm.
AC107621

CAUTION
Never turn the crankshaft anti-clockwise.

Wiring band

Timing mark
AC301451AC

AC301450AB

1. Turn the crankshaft clockwise, align the timing


marks on the camshaft sprocket to set No.1
cylinder to TDC of its compression stroke.

4. Secure the camshaft sprocket and valve timing


belt with wiring bands and so on to prevent
slippage between the camshaft sprocket and
valve timing belt.

MB990767
MD998738
MD998719

Timing belt
under cover
AC301452AB

2. Remove the timing belt under cover rubber plug


and then set special tool adjusting bolt
(MD998738).

AC100302 AB

5. Use the following special tools to hold the


camshaft sprocket.
Front hub and flange yoke holder (MB990767)
Pin (MD998719)

CAUTION
Do not rotate the crankshaft after camshaft
sprocket removal.

Timing belt
tensioner arm
MD998738

AC301373AB

6. Remove the camshaft sprocket with the valve


timing belt and place it on the timing belt lower
cover.

ENGINE MECHANICAL <4G69>

11C-33

CYLINDER HEAD GASKET

<<B>> RADIATOR UPPER HOSE


DISCONNECTION

2. Remove the fuel high-pressure hose in the


direction shown in the figure while the retainer is
pulled up.
NOTE: If the retainer is released, install it after
removing the fuel high-pressure hose.
<<D>> CYLINDER HEAD BOLTS REMOVAL

Mating marks
AC200641AB

MB991654

Make mating marks on the radiator upper hose and


the hose clamp. Disconnect the radiator upper hose.
<<C>> FUEL HIGH-PRESSURE HOSE REMOVAL

Engine front

10

Stopper

AC304581AB

1. Remove the fuel high-pressure hose stopper.

AC301454AB

Use special tool cylinder head bolt wrench


(MB991654) to loosen the cylinder head bolts in two
or three steps in the order of the numbers shown in
the illustration. If the cylinder head bolts cannot be
pulled out due to the washer being trapped in the
valve spring, raise the bolt slightly, then remove it
while holding it by using a magnet.
Retainer
AC304582AB

ENGINE MECHANICAL <4G69>

11C-34

CYLINDER HEAD GASKET

INSTALLATION SERVICE POINTS


>>A<< CYLINDER HEAD GASKET
INSTALLATION

CAUTION
Do not allow any foreign materials get into the
coolant passages, oil passages and cylinder.

MB991654

1. Degrease the cylinder head gasket mounting


surface.

Engine front
Identification
mark "381"

10

Exhaust side

AC302180AB

2. Assemble to the cylinder block so the cylinder


head gasket identification mark of "381" is at the
top surface and on the exhaust side.
>>B<< CYLINDER HEAD BOLTS INSTALLATION
(Engine oil)

AC301456AB

3. Use special tool cylinder head bolt wrench


(MB991654) to tighten the cylinder head bolts in
the following procedures.
(1) Tighten the bolts to 78 2 Nm in the order
shown.
(2) Loosen the bolts fully in the reverse sequence
to that shown.
(3) Tighten the bolts to 20 2 Nm in the order
shown.
Step (4)

90

Step (5)
90

AC102537AC

1. Check that the nominal length of each cylinder


head bolt meets the limit. If it exceeds the limit,
replace the bolts with a new one.
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.

Paint marking

Paint marking
AC102331AB

(4) Apply a paint mark to the heads of the cylinder


head bolts and cylinder head, then tighten 90
degree angle as shown.

ENGINE MECHANICAL <4G69>


CYLINDER HEAD GASKET

CAUTION
The bolt is not tightening sufficiently if the
tightening angle is less than a 90 degree
angle.
If the tightening angle exceeds the standard
specification, remove the bolt and start over
from step 1.
(5) Tighten in a 90 degree angle as shown in the
instructions of the figure, then check to see
that the paint mark on the head of the cylinder
head bolts and the paint mark on the cylinder
head is on a linear line.
>>C<< FUEL HIGH-PRESSURE HOSE
INSTALLATION

CAUTION
Fuel
high-pressure
hose

11C-35

>>D<< RADIATOR UPPER HOSE CONNECTION


Projection

Water outlet fitting

Mating marks
AC200642 AB

1. Insert radiator upper hose until it contacts the


projection on the water outlet fitting.
2. Align the mating marks on the radiator upper hose
and hose clamp, and then secure the radiator
upper hose.

3 mm

>>E<< CAMSHAFT SPROCKET INSTALLATION

MB990767
Fuel line pipe
(Engine oil applied)
AC301864AB

MD998719

AC100302 AB

Stopper

AC304583AB

After connecting the fuel high-pressure hose,


slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.

1. Use the following special tool as during removal to


hold the camshaft sprocket.
Front hub and flange yoke holder (MB990767)
Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
the specified torque.
Tightening torque: 89 9 Nm

ENGINE MECHANICAL <4G69>

11C-36

TIMING BELT

TIMING BELT
REMOVAL AND INSTALLATION
M1112004300827

Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-19).
Crankshaft Shaft Damper Pulley Removal (Refer to
P.11C-17).

Post-installation Operation
Crankshaft Shaft Damper Pulley Installation (Refer to
P.11C-17).
Drive Belt Tension Check (Refer to P.11C-8).
Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).

2
14 3 Nm

11 1 Nm

3
5

4
12

14 1 Nm

11
48 5 Nm
14 1 Nm

6
9

8.8 1.0 Nm

11 1 Nm
21 4 Nm

8
13

44 10 Nm

23 3 Nm

10

22 4 Nm

79 5 Nm
11 1 Nm

9.0 1.0 Nm
AC308981AB

1.
2.
3.

4.
5.
6.

Removal steps
Control wiring harness connection
Battery wiring harness connection
Connector bracket
Engine front mounting bracket
(Refer to GROUP 32, Engine
Mount P.32-5).
Harness bracket
Timing belt upper cover
Water pump pulley

>>G<<
<<A>>

>>F<<
>>E<<
>>D<<

7.
8.
9.

10.
11.
12.
13.

Removal steps (Continued)


Idler pulley
Auto-tensioner
Timing belt lower cover
Valve timing belt tension
adjustment (Installation only)
Valve timing belt
Timing belt tensioner pulley
Timing belt tensioner arm
Timing belt tensioner adjuster

ENGINE MECHANICAL <4G69>


TIMING BELT

11C-37

14
35 6 Nm

22
21
19 3 Nm

18

(Engine oil)

20
19
167 Nm

17

16
15
8.5 0.5 Nm
AC308982 AB

<<B>>
<<B>>
<<B>>

>>C<<
>>C<<
>>C<<

14.
15.
16.
17.
18.
19.

Removal steps
Timing belt Idler pulley
Timing belt lower cover bracket
Crank angle sensor
Crankshaft pulley centre bolt
<<C>>
Crankshaft pulley washer
Crankshaft camshaft drive sprocket

>>C<<
>>B<<
>>A<<
>>A<<

Removal steps (Continued)


20. Crankshaft angle sensing blade
Balancer timing belt tension

adjustment (Installation only)


21. Balancer timing belt tensioner
22. Balancer timing belt

ENGINE MECHANICAL <4G69>

11C-38

TIMING BELT

REMOVAL SERVICE POINTS


<<A>> VALVE TIMING BELT REMOVAL

CAUTION
Never turn the crankshaft anti-clockwise.

2. Remove the timing belt under cover rubber plug


and then set special tool adjusting bolt
(MD998738).
Timing belt
tensioner arm

Timing mark
MD998738

AC301373AB

Camshaft
sprocket

3. Screw in the special tool with hands until it


contacts the timing belt tensioner arm.
Timing mark

Timing mark
Crankshaft
camshaft
drive sprocket

Engine oil pump


sprocket

CAUTION
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
screwed in all at once, the timing belt tensioner
adjuster rod will not easily retract and the special
tool may bend.
A

AC301866AB

1. Turn the crankshaft clockwise, align each timing


mark to set No.1 cylinder to TDC of its
compression stroke.

MD998738
AC301856 AB

Timing belt
under cover
AC301452AB

4. Gradually screw in the special tool and then align


the timing belt tensioner adjuster rod set hole A
with the timing belt tensioner adjuster cylinder set
hole B.

ENGINE MECHANICAL <4G69>

11C-39

TIMING BELT

INSTALLATION SERVICE POINTS

Timing belt tensioner


pulley mounting bolt

>>A<< BALANCER TIMING BELT/BALANCER


TIMING BELT TENSIONER INSTALLATION

Wire or pin

Balancershaft
sprocket
Belt tension
side

AC302414AB

5. Insert a wire or pin in the set hole aligned.

CAUTION
To reuse the valve timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk, etc.

Timing
mark
Timing
mark

6. After removal of the special tool, loosen the timing


belt tensioner pulley mounting bolts and remove
the valve timing belt.
Crankshaft
balancershaft
drive sprocket

<<B>> CRANKSHAFT PULLEY CENTRE


BOLT/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT CAMSHAFT DRIVE
SPROCKET REMOVAL
Crankshaft
camshaft
drive
sprocket

MB991385

MB991367

AC301402AB

1. Ensure that the crankshaft balancer shaft drive


sprocket timing marks and balancer shaft
sprocket timing marks are aligned.
2. Install the balancer timing belt on the crankshaft
balancer shaft drive sprocket and balancer shaft
sprocket. There should be no slack on the tension
side.
Centre of the
mounting bolt

AC102332AB

1. Use the following special tools to hold the


crankshaft camshaft drive sprocket.
Special spanner (MB991367)
Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft pulley washer and
crankshaft camshaft drive sprocket.
<<C>> BALANCER TIMING BELT REMOVAL

CAUTION
To reuse the balancer timing belt, draw an arrow
indicating the rotating direction on the back of
the belt using chalk, etc.

Centre of
the pulley
AC301403AB

3. Assemble and temporarily fix the centre of the


pulley of the balancer timing belt tensioner so that
it is at the top left from the centre of the
assembling bolt, and the pulley flange is at the
front-side of the engine.
4. Adjust the balancer timing belt tension.

11C-40

ENGINE MECHANICAL <4G69>


TIMING BELT

>>B<< BALANCER TIMING BELT TENSION


ADJUSTMENT

CAUTION
When tightening the mounting bolts, ensure that
the tensioner does not rotate with the bolts.
Allowing it to rotate with the bolts can cause
excessive tension of the belt.

Balancershaft
sprocket

Timing
mark
Timing
mark

AC301404

1. Lift with your fingers the balancer timing belt


tensioner in the direction of the arrow. Apply a
tensile torque of 3.0 0.4 Nm to the balancer
timing belt so the belt is tense without any
looseness. Tighten the assembling bolt to the
specified torque in this state. Then, fix the
balancer timing belt tensioner.
Tightening torque: 19 3 Nm

Crankshaft
balancershaft
drive sprocket
AC301402AC

2. Turn the crankshaft clockwise two turns to set


No.1 cylinder to TDC of its compression stroke
and check that sprocket timing marks are aligned.

Approximately 100 N

Deflection

AC301405AB

3. Apply a pressure of approximately 100 N at the


centre (arrow area) between the sprocket as
shown in the figure, then inspect whether the belt
deflection is within the standard value.
Standard value:
<When adjusting> 5 7 mm
<When replacing> 5 7 mm
4. If not within the standard value, adjust the belt
tension again.

ENGINE MECHANICAL <4G69>

11C-41

TIMING BELT

>>C<< CRANKSHAFT ANGLE SENSING


BLADE/CRANKSHAFT CAMSHAFT DRIVE
SPROCKET/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT PULLEY CENTRE BOLT
INSTALLATION
: Clean
: Clean and degrease
: Apply engine oil

Crankshaft pulley
centre bolt
Crankshaft angle
sensing blade
Crankshaft
pulley washer

5. Use the following special tool as during removal to


hold the crankshaft camshaft drive sprocket.
Special spanner (MB991367)
Pin (MB991385)
6. Tighten the crankshaft pulley centre bolt to the
specified torque.
Tightening torque: 167 Nm
>>D<< TIMING BELT TENSIONER ADJUSTER
INSTALLATION
1. Set according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.

CAUTION
If the compression is too fast the procedure may
damage the rod. Make a point to slowly and
thoroughly compress.
A

Crankshaft camshaft
drive sprocket
Engine front

Crankshaft

AC301347AB

1. Clean or degrease the crankshaft, the crankshaft


angle sensing blade, the crankshaft camshaft
drive sprocket and crankshaft pulley washer as
shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft angle sensing blade and
crankshaft camshaft drive sprocket in the
direction shown.
3. Place the larger chamfer side of the crankshaft
pulley washer in the direction shown in the Figure
and then assemble on the crankshaft pulley
centre bolt.
4. Apply a small of engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
Crankshaft
camshaft
drive
sprocket

AC302024 AB

(1) Slowly compress the timing belt tensioner


adjuster rod using a press or vice, then align
the set hole A of the rod with set hole B of the
timing belt tensioner adjuster cylinder.
Wire or pin

AC302025AB

MB991385

MB991367

AC102332AB

(2) Insert a wire or pin in the set hole aligned.


NOTE: When replacing the timing belt
tensioner adjuster with new parts, the timing
belt tensioner adjuster is set with a pin.
2. Install the timing belt tensioner adjuster to the
engine and then tighten the mounting bolt to the
specified torque. Do not remove the wire or pin
until the tension of the valve timing belt is
adjusted.

ENGINE MECHANICAL <4G69>

11C-42

TIMING BELT

Tightening torque: 23 3 Nm
>>E<< TIMING BELT TENSIONER PULLEY
INSTALLATION

2. Adjust the timing mark of the engine oil pump


sprocket. Unplug the cylinder block plug. Insert a
bolt (M6, section width 10 mm, nominal length 45
mm) from the plug hole. If the bolt comes in
contact with the balancer shaft, turn the engine oil
sprocket one rotation. Re-adjust the timing mark
and then check to see that the bolt fits. Do not
remove the bolt until the valve timing belt is
assembled.
Camshaft
sprocket

Timing belt tensioner


pulley hole
AC102336AB

Temporarily tighten the timing belt tensioner pulley


as shown.
>>F<< VALVE TIMING BELT INSTALLATION

Timing belt
tensioner
pulley

Belt tension
side

Timing mark
Timing belt
Idler pulley

Camshaft
sprocket

Crankshaft
camshaft
drive sprocket

Engine oil pump


sprocket
AC301372AC

Timing mark

Timing mark
Engine oil pump
sprocket

Crankshaft
camshaft
drive sprocket

AC301374AB

1. Align the timing marks on the camshaft sprocket,


crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Bolt

CAUTION
Incorporate the valve timing belt. Then apply
reverse rotation (anti-clockwise rotation)
pressure to the camshaft sprocket. Re-check to
see that each timing mark is aligned while the
tension side of the belt is right.
(4) Place the valve timing belt on the camshaft
sprocket.

Balancershaft

Plug
Cylinder block

3. Incorporate the valve timing belt in the following


manner so that the tensile force of the belt is not
lax.
(1) Place the valve timing belt on the timing belt
tensioner pulley and crankshaft camshaft
driver sprocket and then support it with your
left hand so it does not slide.
(2) Place the valve timing belt on the engine oil
pump sprocket while pulling it with the right
hand.
(3) Place the valve timing belt on the timing belt
idler pulley.

AC301871AB

ENGINE MECHANICAL <4G69>

11C-43

TIMING BELT
Bolt
MD998767

Balancershaft

Plug
AC301858 AB

4. Turn the timing belt tensioner pulley in the


direction shown in the figure using special tool
tensioner wrench (MD998767) to apply tension to
the valve timing belt. Then temporarily tighten and
fix the timing belt tensioner pulley mounting bolt.

Cylinder block

AC301871AB

6. Remove the bolt inserted in Step 2 above, then


assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified
torque.
Tightening torque: 30 3 Nm
8. Adjust the valve timing belt tension.

Timing mark

>>G<< VALVE TIMING BELT TENSION


ADJUSTMENT
MD998738
Camshaft
sprocket

Timing mark
Timing belt
under cover
AC301452AB

Timing mark
Crankshaft
camshaft
drive sprocket

Engine oil pump


sprocket
AC301372AB

5. Check that the timing marks are aligned.

1. Set special tool adjusting bolt (MD998738) used


when removing the valve timing belt.

CAUTION
Always screw in the special tool in with your
hands, since use of a spanner or other tools may
damage the wire or pin inserted in the timing belt
tensioner adjuster.
2. Gradually screw in the special tool to a position in
which the wire or pin inserted in the timing belt
tensioner adjuster lightly moves.
3. Turn the crankshaft 1/4 of a revolution in the
anti-clockwise direction.

ENGINE MECHANICAL <4G69>

11C-44

TIMING BELT

Tightening torque: 48 5 Nm
Timing mark
Wire or pin

Camshaft
sprocket
AC301857AB

Timing mark

Timing mark
Crankshaft
camshaft
drive sprocket

7. Remove wire or pin inserted to timing belt


tensioner adjuster.

MD998738
Engine oil pump
sprocket
AC301372AB

4. Turn the crankshaft in the clockwise direction,


align each timing mark to set No.1 cylinder to TDC
of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting
bolt.

CAUTION
When tightening the mounting bolt, ensure that
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.

Timing belt
under cover
AC301452AB

8. Remove special tool adjusting bolt (MD998738),


and install the rubber plug to the timing belt under
cover.
9. Rotate crankshaft clockwise two turns, and leave
it for about 15 minutes.

Wire or pin
MD998767

AC301857AB
AC301859 AB

6. With special tool tensioner wrench (MD998767)


and torque wrench, apply tension torque 3.5 Nm
to the valve timing belt, and tighten the timing belt
tensioner pulley mounting bolt to the specified
torque.

10.Insert wire or pin removed in Step 7 again, and


ensure that it can be pulled out with a light load.
When wire or pin can be lightly removed,
appropriate tension is applied on timing belt. In
this case, remove wire or pin.

ENGINE MECHANICAL <4G69>

11C-45

TIMING BELT

12.Check again that the timing marks on sprockets


are aligned.

INSPECTION

M1112004400460

Rod

AC301375AB

Also the projection of timing belt tensioner


adjuster rod (A) is within the standard value,
appropriate tension is applied.
Standard value (A): 3.8 4.5 mm
11.If wire or pin cannot be easily pulled out, repeat
Step 1 through Step 9 to reach proper valve timing
belt tension.

CAUTION
Always check the tightening torque of the
crankshaft pulley centre bolt when turning the
crankshaft pulley centre bolt anti-clockwise.
Re-tighten if it is loose.
Timing mark

1. Check for oil leak from seal, and replace it if leak


is detected.
2. Check for wear or damage at the top of the rod.
Replace it, if required.
98 196 N
A

Movement
Rod

AC301376AB

3. Hold the timing belt tensioner adjuster by hand,


and press top end of the rod onto the metal (e.g.
cylinder block) under a pressure of 98 196 N to
measure the movement of the rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A B: Movement
4. If the measured value is out of the standard value,
replace the timing belt tensioner adjuster.

Camshaft
sprocket

Timing mark

Timing mark
Crankshaft
camshaft
drive sprocket

TIMING BELT TENSIONER ADJUSTER


CHECK

Engine oil pump


sprocket
AC301866AB

ENGINE MECHANICAL <4G69>

11C-46

TIMING BELT

BALANCER TIMING BELT TENSION


CHECK
Check the balancer timing belt tension in the
following procedures.

Approximately 100 N

Deflection

AC301405AB

1. Apply a pressure of approximately 100 N at the


centre (arrow area) between the sprocket as
shown in the figure, then inspect whether the
flexure is within the standard value.
Standard value: 5 10 mm
2. If not within the standard value, adjust the belt
tension. (Refer to P.11C-36).

ENGINE MECHANICAL <4G69>


ENGINE ASSEMBLY

11C-47

ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001000946

<M/T>
CAUTION
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-19).
Fuel Line Pressure Reduction [Refer to GROUP 13B,
On-vehicle Service Fuel Pump Connector
Disconnection (How to Reduce Pressurized Fuel Lines)
P.13B-428].
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service Engine Oil Replacement P.12-3).
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-17).
Transmission Oil Draining (Refer to GROUP 22A,
On-vehicle Service Transmission Oil Replacement
P.22A-8).
Transfer Oil Draining (Refer to GROUP 22A, On-vehicle
Service Transfer Oil Replacement P.22A-8).
Hood Removal (Refer to GROUP 42, Hood P.42-4).
Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-4).
Battery and Battery Tray Removal
Accelerator Cable Removal (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).
Radiator Assembly Removal (Refer to GROUP 14,
Radiator P.14-29).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-13).

Post-installation Operation
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-13).
Radiator Assembly Installation (Refer to GROUP 14,
Radiator P.14-29).
Accelerator Cable Installation (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).
Battery and Battery Tray Installation
Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-4).
Hood Installation (Refer to GROUP 42, Hood P.42-4).
Transfer Oil Refilling (Refer to GROUP 22A, On-vehicle
Service Transfer Oil Replacement P.22A-8).
Transmission Oil Refilling (Refer to GROUP 22A,
On-vehicle Service Transmission Oil Replacement
P.22A-8).
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-17).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service Engine Oil Replacement P.12-3).
Accelerator Cable Adjustment (Refer to GROUP 17,
On-vehicle Service Accelerator Cable Check and
Adjustment P.17-5).
Fuel Leak Check
Drive Belt Tension Check (Refer to P.11C-8).
Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service Front Wheel Alignment
Check and Adjustment P.33-6).

ENGINE MECHANICAL <4G69>

11C-48

ENGINE ASSEMBLY
9.0 2.0 Nm

9.0 2.0 Nm

5.0 1.0 Nm

6N

48 7 Nm

9.0 2.0 Nm

5.0 1.0 Nm

12 2 Nm

48 7 Nm
AC308983 AB

1.
2.
3.
4.

Removal steps
Control wiring harness connection
Battery wiring harness connection
Canister vacuum hose connection
Brake booster vacuum hose
connection

<<A>>

5.
6.
7.

Removal steps (Continued)


Drive belt
Engine oil cooler tube gaskets
Engine oil cooler hose and bracket
assembly

ENGINE MECHANICAL <4G69>

11C-49

ENGINE ASSEMBLY

11

10

(Engine oil)

15
24 4 Nm

13

44 10 Nm

70 4 Nm*

44 10 Nm*

22 4 Nm

44 10 Nm*

12
14

AC308984 AB

<<B>>
<<C>>
<<D>>

Removal steps
Power steering oil pump and
bracket assembly
9. A/C compressor and clutch
assembly
10. Heater water hoses connection
11. Fuel high-pressure hose
connection
8.

>>E<<

<<E>>

>>D<<

<<F>>
<<G>>

>>B<<
>>A<<

12.
13.
14.
15.

Removal steps (Continued)


Transmission assembly
Earth cable connection
Self-locking nuts
Engine front mounting bracket
Engine assembly

11C-50

ENGINE MECHANICAL <4G69>


ENGINE ASSEMBLY

<A/T>
CAUTION
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
P.51-19).
Fuel Line Pressure Reduction [Refer to GROUP 13B,
On-vehicle Service Fuel Pump Connector
Disconnection (How to Reduce Pressurized Fuel Lines)
P.13B-428].
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service Engine Oil Replacement P.12-3).
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-17).
Transmission Fluid Draining (Refer to GROUP 23A,
On-vehicle Service Automatic Transmission Fluid
Change P.23A-144).
Transfer Oil Draining (Refer to GROUP 23A, On-vehicle
Service Transfer Oil Replacement P.23A-147).
Hood Removal (Refer to GROUP 42, Hood P.42-4).
Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-4).
Battery and Battery Tray Removal
Accelerator Cable Removal (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).
Radiator Assembly Removal (Refer to GROUP 14,
Radiator P.14-29).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-13).

Post-installation Operation
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-13).
Radiator Assembly Installation (Refer to GROUP 14,
Radiator P.14-29).
Accelerator Cable Installation (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).
Battery and Battery Tray Installation
Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-4).
Hood Installation (Refer to GROUP 42, Hood P.42-4).
Transfer Oil Refilling (Refer to GROUP 23A, On-vehicle
Service Transfer Oil Replacement P.23A-147).
Transmission Fluid Refilling (Refer to GROUP 23A,
On-vehicle Service Automatic Transmission Fluid
Change P.23A-144).
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-17).
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service Engine Oil Replacement P.12-3).
Accelerator Cable Adjustment (Refer to GROUP 17,
On-vehicle Service Accelerator Cable Check and
Adjustment P.17-5).
Fuel Leak Check
Drive Belt Tension Check (Refer to P.11C-8).
Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).
Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service Front Wheel Alignment
Check and Adjustment P.33-6).

ENGINE MECHANICAL <4G69>

11C-51

ENGINE ASSEMBLY
9.0 2.0 Nm

1
3

9.0 2.0 Nm

5.0 1.0 Nm

9.0 2.0 Nm

5.0 1.0 Nm
AC308985AB

1.
2.
3.

Removal steps
Control wiring harness connection
Battery wiring harness connection
Canister vacuum hose connection

4.

<<A>>

5.

Removal steps (Continued)


Brake booster vacuum hose
connection
Drive belt

ENGINE MECHANICAL <4G69>

11C-52

ENGINE ASSEMBLY

9
(Engine oil)

13
24 4 Nm

44 10 Nm

44 10 Nm*

11

45 5 Nm*
22 4 Nm

44 10 Nm*

10
12

<<B>>

6.

<<C>>

7.

<<D>>

>>E<<

8.
9.

Removal steps
Power steering oil pump and
bracket assembly
A/C compressor and clutch
assembly
Heater water hoses connection
Fuel high-pressure hose
connection

7
<<E>>

>>D<<

<<F>>
<<G>>

>>C<<
>>B<<
>>A<<

10.
11.
12.
13.

AC308986AB

Removal steps (Continued)


Transmission assembly
Earth cable connection
Self-locking nuts
Engine front mounting bracket
Engine assembly

ENGINE MECHANICAL <4G69>

11C-53

ENGINE ASSEMBLY

REMOVAL SERVICE POINTS


<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the
introduction of the serpentine drive system with the
drive belt auto-tensioner.
Auto-tensioner

AC301703

Hole B

NOTE: After removing the power steering oil pump


and bracket assembly, secure it with a cord in the
location where the removal and installation of the
engine assembly cannot be hindered.
<<C>> A/C COMPRESSOR AND CLUTCH
ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly from the bracket.
NOTE: After removing the A/C compressor and
clutch assembly, secure it with a cord in the location
where the removal and installation of the engine
assembly cannot be hindered.

Hole A
AC301704AB

<<D>> FUEL HIGH-PRESSURE HOSE REMOVAL

1. Securely insert the spindle handle or ratchet


handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.

CAUTION
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk, etc.
Auto-tensioner

L-shaped
hexagon
wrench

Stopper

AC304581AB

1. Remove the fuel high-pressure hose stopper.

AC301705AB

3. Insert an L-shaped hexagon wrench, etc. into the


hole to fix and then remove the drive belt.
<<B>> POWER STEERING OIL PUMP AND
BRACKET ASSEMBLY REMOVAL
With the hose installed, remove the power steering
oil pump and bracket assembly from the engine
assembly.

Retainer
AC304582AB

2. Remove the fuel high-pressure hose in the


direction shown in the figure while the retainer is
pulled up.
NOTE: If the retainer is released, install it after
removing the fuel high-pressure hose.

ENGINE MECHANICAL <4G69>

11C-54

ENGINE ASSEMBLY

<<E>> TRANSMISSION ASSEMBLY REMOVAL

(2) <Special tool engine hanger (MB991928) is


used>
Remove special tool MB991928.
MB991454
MB991527

AC300950AB

1. Pre-tighten the 2 bolts on the car to assemble the


radiator support upper insulator to set special tool
engine hanger MB991895 or engine hanger
MB991928.
2. Remove the transmission assembly (M/T: Refer to
GROUP 22A, Transmission Assembly P.22A-15,
A/T: Refer to GROUP 23A, Transmission
Assembly P.23A-172).
<<F>> ENGINE FRONT MOUNTING BRACKET
REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.
MB991895
MB991527

AC107632 AB

3. Hold the engine assembly with a chain block, etc.


4. Place a garage jack against the engine oil pan
with a piece of wood in between so that the weight
of the engine assembly is no longer being applied
to the engine front mounting bracket.
5. Loosen the engine front mounting bracket
mounting nuts and bolts, and remove the engine
front mounting bracket.
<<G>> ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and wiring
harness connectors and so on are disconnected
from the engine, lift the chain block slowly to remove
the engine assembly upward from the engine
compartment.

INSTALLATION SERVICE POINTS


>>A<< ENGINE ASSEMBLY INSTALLATION
MB991454
AC107631AB

MB991454
MB991527

(1) <Special tool engine hanger (MB991895) is


used>
Remove special tool MB991895.
MB991928

AC107632 AB

Install the engine assembly, being careful not to


pinch the cables, hoses or wiring harness
connectors.

MB991527
MB991454
AC211405AB

ENGINE MECHANICAL <4G69>

11C-55

ENGINE ASSEMBLY

>>B<< ENGINE FRONT MOUNTING BRACKET


INSTALLATION
1. Place a garage jack against the engine oil pan
with a piece of wood in between, and install the
engine front mounting bracket while adjusting the
position of the engine.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
4. Use the following special tool as during removal to
support the engine.

>>D<< TRANSMISSION ASSEMBLY


INSTALLATION
1. Install the transmission assembly. (M/T: Refer to
GROUP 22A, Transmission Assembly P.22A-15,
A/T: Refer to GROUP 23A, Transmission
Assembly P.23A-172).

MB991895
MB991527

AC300950AB

MB991454

2. Remove from the car the two bolts, to assemble


the radiator support upper insulator.

AC107631AB

(1) <Special tool engine hanger (MB991895) is


used>
Set special tool MB991895. (M/T: Refer to
GROUP 22A, Transmission Assembly
P.22A-15, A/T: Refer to GROUP 23A,
Transmission Assembly P.23A-172).

>>E<< FUEL HIGH-PRESSURE HOSE


INSTALLATION

CAUTION
Fuel
high-pressure
hose

3 mm

MB991928

Fuel line pipe


(Engine oil applied)
MB991527

AC301864AB

MB991454
AC211405AB

(2) <Special tool engine hanger (MB991928) is


used>
Set special tool MB991928. (M/T: Refer to
GROUP 22A, Transmission Assembly
P.22A-15, A/T: Refer to GROUP 23A,
Transmission Assembly P.23A-172).
>>C<< SELF-LOCKING NUTS INSTALLATION

CAUTION
Do not tighten the self-locking nuts while the
engine is hot.
Tighten the self-locking nuts to the specified torque
while the engine is cold.
Tightening torque: 45 5 Nm

Stopper

AC304583AB

After connecting the fuel high-pressure hose,


slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.

NOTES

12-1

GROUP 12

ENGINE
LUBRICATION
CONTENTS
GENERAL INFORMATION . . . . . . . .

12-2

SERVICE SPECIFICATION . . . . . . . .

12-2

LUBRICANT. . . . . . . . . . . . . . . . . . . .

12-2

SEALANT. . . . . . . . . . . . . . . . . . . . . .

12-3

SPECIAL TOOLS. . . . . . . . . . . . . . . .

12-3

ON-VEHICLE SERVICE . . . . . . . . . . .

12-3

ENGINE OIL CHECK . . . . . . . . . . . . . . . . .

12-3

ENGINE OIL REPLACEMENT . . . . . . . . . .

12-3

ENGINE OIL FILTER REPLACEMENT. . . .

12-4

OIL PRESSURE CHECK . . . . . . . . . . . . . .

12-5

ENGINE OIL COOLER . . . . . . . . . . . .

12-6

REMOVAL AND INSTALLATION . . . . . . . .

12-6

ENGINE LUBRICATION

12-2

GENERAL INFORMATION

GENERAL INFORMATION
M1121000100346

The lubrication method is a fully force-fed, full-flow


filtration type. The oil pump is a gear type which is
driven by the crankshaft via the timing belt.

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

Avoid contaminating clothes, particularly


underpants, with oil.
Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separate from
personal clothing.
Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
Obtain First Aid treatment immediately for open
cuts and wounds.
Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
If skin disorders develop, obtain medical advice
without delay.

SERVICE SPECIFICATION
M1121000300254

Item

Standard value

Oil pressure kPa

at idle

29 or more

at 3,500 r/min

294 686

LUBRICANT
M1121000400529

Item

Specification

Engine oil ACEA classification

A1, A2 or A3

Engine oil API classification

SG or higher

Engine oil quantity L

4G63, 4G69 (A/T)


4G69 (M/T)

Oil filter

0.3

Total

4.3

Oil filter

0.3

Oil cooler

0.3

Total

4.6

ENGINE LUBRICATION

12-3

SEALANT

SEALANT
M1121000500258

Item

Specified sealant

Remark

Oil pressure switch

3M ATD Part No. 8660 or equivalent

Semi-drying sealant

SPECIAL TOOLS
M1121000600363

Tool

Number

Name

Use

MB991610

Oil filter wrench

Removal and installation


of engine oil filter (When
using the oil filter of
MD356000)

MD998054

Oil pressure switch


wrench

Removal and installation


of oil pressure switch

MB991610

ON-VEHICLE SERVICE
ENGINE OIL CHECK
M1121000900320

1. Pull out the level gauge slowly and check that the
oil level is in the illustrated range.
2. Check that the oil is not excessively dirty, that
there is no coolant or petrol mixed in, and that it
has sufficient viscosity.

Drain plug

Drain plug
gasket

Oil pan side

ENGINE OIL REPLACEMENT

Oil pan

M1121001000494

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


temperature of the coolant reaches 80 C to 90
C.
2. Remove the engine oil filler cap.

CAUTION
Use care as oil could be hot.
3. Remove the drain plug to drain oil.

AC300837AB

4. Install a new drain plug gasket so that it faces in


the direction shown in the illustration, and then
tighten the drain plug to the specified torque.
Tightening torque: 39 5 Nm
NOTE: Install the drain plug gasket so it faces in
the direction shown in the illustration.

ENGINE LUBRICATION

12-4

ON-VEHICLE SERVICE

MB991610 or
commerciallyavailable tool

AC000093 AH

AC301513

5. Refill with specified quantity of oil.


Specified Engine Oil (ACEA and API
classification): ACEA A1, A2 or A3/API SG or
higher
Total quantity (Includes volume inside engine
oil filter):
4.3 L <4G63, 4G69 (A/T)>
4.6 L <4G69 (M/T)>

5. Use the respective tool in the following table to


remove the engine oil filter.
6. Clean the filter bracket side mounting surface.

6. Install the engine oil filler cap.


7. Check oil level.

ENGINE OIL FILTER REPLACEMENT

O-ring

M1121001100350

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


temperature of the coolant reaches 80 C to 90
C.
2. Remove the engine oil filler cap.

CAUTION
Use care as oil could be hot.
3. Remove the drain plug to drain oil.
4. Remove the under cover.

AC103250AD

7. Apply a small amount of engine oil to the O-ring of


the new oil filter.
8. Once the O-ring of the oil filter is touching the
flange, use the respective tool in the following
table to tighten to the specified torque.
9. Install the drain plug and refill the engine oil (Refer
to P.12-3).
10.Race the engine 23 times, and check to be sure
that no engine oil leaks from installation section of
the oil filter.

Number

Special tool

Tightening torque

MD356000

Oil filter wrench (MB991610)


or equivalent

Approximately 3/4 turn (14 2 Nm)

MD136466,
MD322508

Commercially- available tool

Approximately 3/4 turn (17 3 Nm)

ENGINE LUBRICATION

12-5

ON-VEHICLE SERVICE

OIL PRESSURE CHECK


M1121002300432

Standard value:
At idle: 29 kPa or more
At 3,500 r/min: 294 686 kPa
7. Remove the oil pressure gauge.

Cylinder block

Oil pressure switch

AK000197AF

1. Check engine oil quantity.


2. Remove the oil pressure switch terminal.

CAUTION

AKX00295AD

8. Apply the specified sealant to the thread of oil


pressure switch.
Specified sealant: 3M ATD Part No. 8660 or
equivalent

MD998054

CAUTION
MD998054

AKX00294 AD

Since sealant is applied to the thread of oil


pressure switch, take care not to damage the oil
pressure switch when removing it.
3. Use the special tool Oil pressure switch wrench
(MD998054) to remove the oil pressure switch.
4. Install the oil pressure gauge.
NOTE: Use an adapter of PT 1/8 thread.
5. Run the engine to warm it.
6. After the engine has been warmed up, check that
oil pressure is within the standard value.

AKX00294 AD

Do not start the engine within one hour after the


oil pressure switch has been installed.
9. Use the special tool Oil pressure switch wrench
(MD998054) to tighten the oil pressure switch to
the specified torque.
Tightening torque: 19 3 Nm
10.Install the oil pressure switch terminal.

ENGINE LUBRICATION

12-6

ENGINE OIL COOLER

ENGINE OIL COOLER


REMOVAL AND INSTALLATION
M1121001300116

Pre-removal Operation
Front Under Cover (LH) Removal (Refer to GROUP 51,
Under Cover P.51-19).

Post-installation Operation
Front Under Cover (LH) Installation (Refer to GROUP 51,
Under Cover P.51-19).
Engine Oil Refilling and Level Check (Refer to P.12-3).
5.0 1.0 Nm

12 2 Nm
12 2 Nm

27

26

45 5 Nm

21

12 2 Nm

13
24

17
14
2

45 5 Nm

48 7 Nm

20

22

33 2 Nm

12 2 Nm

23

12 2 Nm

11
15

4N

4N

10

25

19 N

12
12 2 Nm

16

9
10

12 2 Nm
48 7 Nm

18
12 2 Nm

6
AC309226AB

1.
2.
3.
4.
5.
6.
7.
8.

Engine oil cooler removal steps


Splash Shield Mounting Clips (LH)
(Refer to GROUP 51, Front Bumper
P.51-3).
Eye bolt
Gasket
Eye bolt
Gasket
Engine oil cooler assembly
Bracket
Bracket
Engine oil cooler

Engine oil cooler removal steps


9. Collar
10. Bush
Engine oil cooler hose removal
steps (Engine oil cooler side)
11. Engine oil cooler return hose
connection
1. Eye bolt
2. Gasket
12. Engine oil cooler return hose
13. Bolt

ENGINE LUBRICATION
ENGINE OIL COOLER

14.
3.
4.
15.

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

11.
14.
17.
21.
26.
27.

Engine oil cooler hose removal


steps (Engine oil cooler side)
Reserve tank assembly (Refer to
GROUP 14, Radiator P.14-29).
Engine oil cooler feed hose
connection
Eye bolt
Gasket
Engine oil cooler feed hose
Engine oil cooler hose removal
steps (Engine side)
Side under cover (RH) (Refer to
GROUP 51, Under cover P.51-3).
Clamp
Engine oil cooler return hose
connection
Eye bolt
Gasket
Engine oil cooler return hose
Engine oil cooler feed hose
connection
Eye bolt
Gasket
Engine oil cooler feed hose
Bracket
Engine oil cooler feed and return
tube removal steps
Front bumper beam (Refer to
GROUP 51, Front bumper assembly
P.51-3).
Engine oil cooler return hose
connection
Engine oil cooler feed hose
connection
Engine oil cooler return hose
connection
Engine oil cooler feed hose
connection
Engine oil cooler feed and return tube
Clamp

12-7

NOTES

13A-1

GROUP 13A

MULTIPORT FUEL
INJECTION (MFI)

00
11
12
13
14
15

CONTENTS

16
17

GENERAL INFORMATION . . . . . . . .

13A

ENGINE CONTROL RELAY CONTINUITY


CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A

SERVICE SPECIFICATIONS. . . . . . .

13A

FUEL PUMP RELAY CONTINUITY


CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A

22

SEALANT. . . . . . . . . . . . . . . . . . . . . .

13A

INTAKE AIR TEMPERATURE SENSOR


CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A

25

SPECIAL TOOLS. . . . . . . . . . . . . . . .

13A

ENGINE COOLANT TEMPERATURE


SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13A

26

TROUBLESHOOTING . . . . . . . . . . . .

13A

THROTTLE POSITION SENSOR CHECK . 13A

27

ON-VEHICLE SERVICE. . . . . . . . . . . 13A


THROTTLE BODY (THROTTLE VALVE
AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13A
THROTTLE POSITION SENSOR
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13A
BASIC IDLE SPEED ADJUSTMENT . . . . . 13A
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13A
FUEL PUMP CONNECTOR
DISCONNECTION (HOW TO REDUCE
PRESSURIZED FUEL LINES) . . . . . . . . . . 13A
FUEL PUMP OPERATION CHECK . . . . . . 13A
COMPONENT LOCATION . . . . . . . . . . . . . 13A

OXYGEN SENSOR CHECK . . . . . . . . . . . . 13A

21

INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A

31

IDLE SPEED CONTROL (ISC) SERVO


(STEPPER MOTOR) CHECK . . . . . . . . . . . 13A

32

INJECTOR . . . . . . . . . . . . . . . . . . . . . 13A

33

REMOVAL AND INSTALLATION . . . . . . . . 13A

34

THROTTLE BODY ASSEMBLY . . . . . 13A

35

REMOVAL AND INSTALLATION . . . . . . . . 13A

36

THROTTLE BODY ASSEMBLY


DISASSEMBLY AND REASSEMBLY . . . . . 13A

ENGINE ECU . . . . . . . . . . . . . . . . . . . 13A


REMOVAL AND INSTALLATION . . . . . . . . 13A

37
42
51
52
54
55

MULTIPORT FUEL INJECTION (MFI)

13A-2

GENERAL INFORMATION

GENERAL INFORMATION
M1131000100701

The Multipoint Fuel Injection System consists of sensors which detect the engine conditions, the engineECU which controls the system based on signals
from these sensors, and actuators which operate
under the control of the engine-ECU. The engineFUEL INJECTION CONTROL
The injector drive times and injection timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continuallychanging engine operation conditions.
A single injector is mounted at the intake port of each
cylinder. Fuel is sent under pressure from the fuel
tank by the fuel pump, with the pressure being regulated by the fuel pressure regulator. The fuel thus
regulated is distributed to each of the injectors.
Fuel injection is normally carried out once for each
cylinder for every two rotations of the crankshaft. The
firing order is 1-3-4-2. This is called sequential fuel
injection. The engine-ECU provides a richer air/fuel
mixture by carrying out "open-loop" control when the
IDLE AIR CONTROL
The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle
valve in accordance with changes in idling conditions
and engine load during idling. The engine-ECU
drives the idle speed control motor to keep the
engine running at the pre-set idle target speed in
accordance with the engine coolant temperature and

ECU carries out activities such as fuel injection control, idle speed control and ignition timing control. In
addition, the engine-ECU is equipped with several
diagnosis modes which simplify troubleshooting
when a problem develops.
engine is cold or operating under high load conditions in order to maintain engine performance. In
addition, when the engine is warm or operating under
normal conditions, the engine-ECU controls the
air/fuel mixture by using the oxygen sensor signal to
carry out "closed-loop" control in order to obtain the
theoretical air/fuel mixture ratio that provides the
maximum cleaning performance from the three way
catalyst.

air conditioner load. In addition, when the air conditioner switch is turned off and on while the engine is
idling, the idle speed control motor operates to adjust
the throttle valve bypass air amount in accordance
with the engine load conditions in order to avoid fluctuations in the engine speed.

IGNITION TIMING CONTROL


The power transistor located in the ignition primary
circuit turns ON and OFF to control the primary current flow to the ignition coil. This controls the ignition
timing in order to provide the optimum ignition timing
with respect to the engine operating conditions. The
ignition timing is determined by the engine-ECU from
the engine speed, intake air volume, engine coolant
temperature and atmospheric pressure.
SELF-DIAGNOSIS FUNCTION
When an abnormality is detected in one of the
sensors or actuators related to emission control,
the engine warning lamp (check engine lamp)
illuminates as a warning to the driver.
When an abnormality is detected in one of the
sensors or actuators, a diagnosis code corresponding to the abnormality is output.
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control

The RAM data inside the engine-ECU that is


related to the sensors and actuators can be read
by means of the MUT-II. In addition, the actuators
can be force-driven under certain circumstances.

Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running.

MULTIPORT FUEL INJECTION (MFI)


GENERAL INFORMATION

2. A/C Relay Control


Turns the compressor clutch of the A/C ON and OFF.
3. Fan Motor Control
The revolutions of the radiator fan and condenser fan
are controlled in response to the engine coolant
temperature and vehicle speed.
4. Purge Control Solenoid Valve Control

(Refer to 317, GROUP 17 - Engine And Emission


Control - Evaporative Emission Control System).
5. EGR Control Solenoid Valve Control
[Refer to 317, GROUP 17 - Engine And Emission Control - Exhaust Gas Recirculation (EGR)
System].

GENERAL SPECIFICATIONS
Items
Throttle body

Specifications
Throttle bore mm

60

Throttle position sensor

Variable resistor type

Idle speed control servo

Stepper motor type

Engine-ECU

Identification No.

E6T38971

Sensors

Air flow sensor

Karman vortex type

Barometric pressure Sensor

Semiconductor type

Intake air temperature sensor

Thermistor type

Engine coolant temperature

Thermistor type

Oxygen sensor

Zirconia type

Inhibitor switch

Contact switch type

Camshaft position sensor

Hall element type

Crank angle sensor

Hall element type

Detonation sensor

Piezoelectric type

Power steering fluid pressure switch

Contact switch type

Engine control relay type

Contact switch type

Fuel pump relay type

Contact switch type

Injector type and number

Electromagnetic type, 4

Injector identification mark

HDA 250E

EGR control solenoid valve

Duty cycle type solenoid valve

Purge control solenoid valve

Duty cycle type solenoid valve

Actuators

Fuel pressure Regulator pressure kPa


regulator

13A-3

329

MULTIPORT FUEL INJECTION (MFI)

13A-4

GENERAL INFORMATION

MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM


1
2
3
4

Oxygen sensor (front)


Oxygen sensor (rear)
Air flow sensor
Intake air temperature
sensor
5 Throttle position sensor
6 Camshaft position
sensor
7 Crank angle sensor
8 Barometric pressure
sensor
9 Engine coolant
temperature sensor
10 Detonation sensor

Power supply
Ignition switch-IG
Ignition switch-ST
A/C switch
A/C load signal
A/C pressure
sensor
Power steering
fluid pressure switch
Alternator FR
terminal
Vehicle speed
sensor

Engine control relay


Fuel pump relay
A/C compressor relay
Ignition coil
Fan controller
Engine warning lamp
Diagnosis output
Alternator G terminal
Oxygen sensor heater
Tachometer

4 Intake air temperature sensor


2 Idle speed control servo
3 Air flow sensor
(Stepper motor)
8 Barometric
5 Throttle position
pressure sensor
sensor

6 Camshaft position sensor

Air

Fuel pressure
regulator

To
fuel tank

1 Injector
2 Idle speed control
servo (Stepper motor)
3 EGR control solenoid
valve
4 Purge control solenoid
valve

Engine-ECU

From
fuel pump
EGR valve
Canister

1 Oxygen sensor
(front)
1 Injector
Catalytic
converter

9 Engine coolant
temperature sensor

3 EGR control
solenoid valve

10 Detonation sensor
7 Crank angle sensor
2 Oxygen sensor (rear)
Catalytic
converter

4 Purge control
solenoid valve

AK204338 AB

MULTIPORT FUEL INJECTION (MFI)

13A-5

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS
M1131000300459

Items

Specifications

Basic idle speed r/min

700 50

Throttle position sensor adjusting voltage mV

535 - 735

Throttle position sensor resistance kW

3.5 - 6.5

Idle speed control servo coil resistance (at 20C) W

28 - 33

Intake air temperature sensor -20C


resistance kW
0C

13 - 17

Engine coolant temperature


sensor resistance kW

5.3 - 6.7

20C

2.3 - 3.0

40C

1.0 - 1.5

60C

0.56 - 0.76

80C

0.30 - 0.42

-20C

14 - 17

0C

5.1 - 6.5

20C

2.1 - 2.7

40C

0.9 - 1.3

60C

0.48 - 0.68

80C

0.26 - 0.36

Oxygen sensor output voltage (at racing) V

0.6 - 1.0

Oxygen sensor heater


resistance (at 20C) W

front

4.5 - 8.0

rear

11 - 18

Fuel pressure kPa

Vacuum hose disconnection

330 - 350 at curb idle

Vacuum hose connection

Approximately. 270 at curb idle

Injector coil resistance (at 20C) W

10.5 - 13.5

SEALANT
M1131000500237

Item

Specified sealant

Remark

Engine coolant temperature sensor


Threaded portion

3M Nut Locking Part No. 4171 or equivalent

Drying sealant

MULTIPORT FUEL INJECTION (MFI)

13A-6

SPECIAL TOOLS

SPECIAL TOOLS
M1131000600342

Tool

Number

Name

Use

MB991502

MUT-II sub
assembly

Reading diagnosis code


MPI system inspection

MB991348

Test harness set

Measurement of voltage during


troubleshooting
Inspection using an oscilloscope

MB991709

Test harness

Measurement of voltage during


troubleshooting
Inspection using an oscilloscope
Adjusting of idle speed control servo

MD998478

Test harness (3pin, triangle)

Measurement of voltage during


Troubleshooting
Inspection using an oscilloscope

MB991536

Check harness
for throttle
position sensor
adjustment

Measurement of voltage during


Troubleshooting
Adjusting of throttle position sensor

MD998464

Test harness (4pin, square)

Measurement of voltage during


Troubleshooting
Inspection of oxygen sensor (front)

MB991658

Test harness

Measurement of voltage during


Troubleshooting
Inspection of oxygen sensor (rear)

B991502

MB991348

MB991536

MB991658

MULTIPORT FUEL INJECTION (MFI)


SPECIAL TOOLS

Tool

13A-7

Number

Name

Use

MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222

Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe

Check at the ECU terminals


A: Connector pin contact inspection
B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester connection

MD998709

Adaptor hose

Measurement of fuel pressure

MD998742

Hose adaptor

MB991637

Fuel pressure
gauge set

MB991223

MB991637

MULTIPORT FUEL INJECTION (MFI)

13A-8

TROUBLESHOOTING

Tool

Number

Name

Use

MD998706

Injector test set

Checking the spray condition of


injectors

MB991607

Injector test
harness

MD998741

Injector test
adaptor

MB991608

Clip

MD998706

MB991607

MD998741

MB991608

TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1131150000342

Refer to 300, GROUP 00 - How to Use Troubleshooting/Inspection Service Points.


NOTE: If the engine-ECU is replaced, the steering
lock cylinder and ignition key should be replaced
together with it.

DIAGNOSIS FUNCTION
M1131155500074

ENGINE WARNING LAMP (CHECK


ENGINE LAMP)

Engine warning lamp


(check engine lamp)

AK300251AB

If an abnormality occurs in any of the following items


related to the Multipoint Fuel Injection (MPI) system,
the engine warning lamp will illuminate.
If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

ENGINE WARNING LAMP INSPECTION ITEMS


Code No.
Diagnosis item

Engine-ECU

P0100

Air flow sensor system

P0105

Barometric pressure sensor system

P0110

Intake air temperature sensor system

P0115

Engine coolant temperature sensor system

P0120

Throttle position sensor system

P0125*

Feedback system monitor

P0130

Oxygen sensor (front) system <Sensor 1>

P0135

Oxygen sensor heater (front) system <Sensor 1>

P0136

Oxygen sensor (rear) system <Sensor 2>

P0141

Oxygen sensor heater (rear) system <Sensor 2>

P0170

Abnormal fuel system

P0201

No. 1 injector system

P0202

No. 2 injector system

P0203

No. 3 injector system

P0204

No. 4 injector system

P0300

Random cylinder mis-fire detection system

P0301*

No. 1 cylinder mis-fire detection system

P0302*

No. 2 cylinder mis-fire detection system

P0303*

No. 3 cylinder mis-fire detection system

P0304*

No. 4 cylinder mis-fire detection system

P0325

Detonation sensor system

P0335

Crank angle sensor system

P0340

Camshaft position sensor system

P0403

EGR control solenoid valve system

P0420

Catalyst deterioration system

P0443

Purge control solenoid valve system

P0500

Vehicle speed sensor system

P0505

Idle speed control system

P0551*

Power steering fluid pressure switch system

P1603*

Battery back-up line system

P1610

Immobilizer system

13A-9

MULTIPORT FUEL INJECTION (MFI)

13A-10

TROUBLESHOOTING

NOTE: .
If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between MUT-II and the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is
next turned on and the same malfunction is re-detected.However, for items marked with a "*" in the diagnosis code number column, the engine warning lamp illuminates only on the first detection of the malfunction.
After the engine warning lamp illuminates, it will be switched off under the following conditions.
When the engine-ECU monitored the power train malfunction three times* met set condition requirements, it detected no malfunction.
*: In this case, "one time" indicates from engine start to stop.
For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
Sensor 1 indicates, the sensor mounted at a position closest to the engine, and sensor 2 indicates the
sensor mounted at the position second closest to the engine.

METHOD OF READING AND ERASING


DIAGNOSIS CODES

INSPECTION USING MUT-II DATA LIST


AND ACTUATOR TESTING

Refer to 300, GROUP 00 - How to Use Troubleshooting/Inspection Service Points.

1. Carry out inspection by means of the data list and


the actuator test function, if there is an
abnormality, check and repair the chassis harness
and components.
2. After repairing, re-check using the MUT-II and
check that the abnormal input and output have
returned to normal as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II, and then start the engine
again and carry out a road test to confirm that the
problem has disappeared.

DIAGNOSIS USING DIAGNOSIS 2 CODES


1. Switch the diagnosis mode of the engine control
unit to DIAGNOSIS 2 mode using the MUT-II.
2. Carry out a road test.
3. Take a reading of the diagnosis code and repair
the problem location.
4. Turn the ignition switch to OFF and then back to
ON again.
NOTE: By turning the ignition switch to OFF, the
ENGINE-ECU will switch the diagnosis mode
from DIAGNOSIS 2 mode to DIAGNOSIS 1
mode.
5. Erase the diagnosis codes.

FREEZE FRAME DATA


When the engine-ECU detects a malfunction and
stores a diagnosis code, it also stores a current status of the engine. This function is called "Freeze
frame data". By analysing this "Freeze frame" data
with the MUT-II, an effective troubleshooting can be
performed.
The display items of freeze frame data are shown
below.

DISPLAY ITEM LIST


Item No.
Data

Unit

21

Engine coolant temperature sensor

22

Engine speed

r/min

24

Vehicle speed

km/h

80

Long-term fuel compensation (long-term fuel trim)

82

Short-term fuel compensation (short-term fuel trim)

MULTIPORT FUEL INJECTION (MFI)

13A-11

TROUBLESHOOTING

Item No.

Data

88

Fuel control condition

87

Unit
Open loop

OL

Closed loop

CL

Open loop owing to drive condition

OL-DRV.

Open loop owing to system malfunction

OL-SYS.

Closed loop based on one oxygen sensor

CL- H02S

Calculation load value

Diagnosis code during data recording

NOTE: If malfunctions have been detected in multiple systems, store one malfunction only, which has
been detected first.

READINESS TEST STATUS


The engine-ECU monitors the following main diagnosis items, judges if these items are in good condition
or not, and the stores its history. this history can be
read out by using MUT-II. (If the ECU has judged a
item before, the MUT-II displays "Complete").

In addition, if diagnosis codes are erased or the battery cable is disconnected, this history will also be
erased (the memory will be reset).
Catalyst: P0420
Oxygen sensor: P0130
Oxygen sensor heater: P0135, P0141

FAIL-SAFE FUNCTION REFERENCE TABLE


When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by
means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item

Control contents during malfunction

Air flow sensor

1. Uses the throttle position sensor signal and engine speed signal (crank angle
sensor signal) to take reading of the basic injector drive time and basic ignition
timing from the pre-set mapping.
2. Fixes the idle speed control servo in the appointed position so idle control is not
performed.

Intake air temperature


sensor

Controls as if the intake air temperature is 25C.

Barometric pressure
sensor

Controls as if the barometric pressure is 101 kPa.

Throttle position sensor No increase in fuel injection amount during acceleration due to the throttle position
sensor signal.
Engine coolant
temperature sensor

Controls as if the engine coolant temperature is 80C.

Camshaft position
sensor

Injectors fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the
ignition switch is turned to the "ON" position, the No. 1 cylinder top dead centre is
not detected at all)

Oxygen sensor (front)

Air/fuel ratio feedback control (closed loop control) is not performed.

Oxygen sensor (rear)

Performs the feedback control (closed loop control) of the air/fuel ratio by using
only the signal of the oxygen (front) installed on the front of the catalytic converter.

Detonation sensor

Fixes the ignition timing as that for regular gasoline.

MULTIPORT FUEL INJECTION (MFI)

13A-12

TROUBLESHOOTING

Malfunctioning item

Control contents during malfunction

Ignition coil
(incorporating power
transistor)

Cuts off the fuel supply to cylinders with an abnormal ignition.

Alternator FR terminal

Does not control the output of the alternator according to an electrical load. (works
as a normal alternator)

Misfiring

If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be
shut down.

INSPECTION CHART FOR DIAGNOSIS CODE


M1131151000624

Code No.

Diagnosis item

Reference page

P0100

Air flow sensor system

313A

P0105

Barometric pressure sensor system

313A

P0110

Intake air temperature sensor system

313A

P0115

Engine coolant temperature sensor system

313A

P0120

Throttle position sensor system

313A

P0125*

Feedback system monitor

313A

P0130

Oxygen sensor (front) system <Sensor 1>

313A

P0135

Oxygen sensor heater (front) system <Sensor 1>

313A

P0136

Oxygen sensor (rear) system <Sensor 2>

313A

P0141

Oxygen sensor heater (rear) system <Sensor 2>

313A

P0170

Abnormal fuel system

313A

P0201

No.1 Injector system

313A

P0202

No.2 Injector system

313A

P0203

No.3 Injector system

313A

P0204

No.4 Injector system

313A

P0300

Random cylinder mis-fire detection system

313A

P0301*

No.1 cylinder mis-fire detection system

313A

P0302*

No.2 cylinder mis-fire detection system

313A

P0303*

No.3 cylinder mis-fire detection system

313A

P0304*

No.4 cylinder mis-fire detection system

313A

P0325

Detonation sensor system

313A

P0335

Crank angle sensor system

313A

P0340

Camshaft position sensor system

313A

P0403

EGR control solenoid valve system

313A

P0420

Catalyst deterioration system

313A

P0443

Purge control solenoid valve system

313A

P0500

Vehicle speed sensor system

313A

P0505

Idle speed control system

313A

P0551*

Power steering fluid pressure switch system

313A

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-13

Code No.

Diagnosis item

Reference page

P0622

Alternator FR terminal system

313A

P1603*

Battery back-up line system

313A

P1610

Immobilizer system

313A

NOTE: .
Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit.
Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the engine
is started and the same malfunction is re-detected. However, for items marked with "*", the diagnosis
code is recorded on the first detection of the malfunction.
Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates the sensor mounted at the position second closest to the engine.

MULTIPORT FUEL INJECTION (MFI)

13A-14

TROUBLESHOOTING

INSPECTION PROCEDURE FOR


DIAGNOSIS CODES

Code No. P0100 Air Flow Sensor System

Air flow sensor circuit

Battery

W-B
W-B
3

4
B-17X

Engine control relay

4
B-08
Air flow sensor

1 2 3 4 5 6 7

G-W
20
J/C (1)
C-16

G-B

W-R

C-135

17

G-W
19

40

90

C-137

31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

C-134

71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

5V

1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300252 AB

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

OPERATION
Power is supplied to the air flow sensor (terminal
No. 4) from the engine control relay (terminal No.
1) and earthed to the engine-ECU (terminal No.
40) from the air flow sensor (terminal No. 5).
A power voltage of 5 V is applied to the air flow
sensor output terminal (terminal No. 3) from the
engine-ECU (terminal No. 90).
An air flow sensor filter reset signal is inputted to
the air flow sensor (terminal No. 7) from the
engine-ECU (terminal No. 19).
FUNCTION
Air flow sensor outputs a pulse signal proportional to the intake air flow rate.
The engine-ECU determines the basic injection
timing of the injector using the pulse signal output
from the air flow sensor and the engine speed
signal.
When the throttle position sensor output is low,
the engine-ECU causes the power transistor in
the unit to be ON to send an air flow sensor filter
reset signal to the air flow sensor. In response to
the reset signal, the air flow sensor resets the filter circuit to improve the ability of the air flow sensor to measure the air flow rate in the area where
the intake air flow rate is low.
TROUBLE JUDGMENT
Check Condition
Engine speed is 500 r/min or more.
Judgment Criterion
Sensor output frequency of 3.3 Hz or less for 2
seconds.
PROBABLE CAUSE
Failed air flow sensor
Open/short circuit in air flow sensor circuit or
loose connector contact
Failed engine-ECU

13A-15

DIAGNOSIS PROCEDURE
STEP 1. MUT-II data list
Refer to Data list reference table 313A.
a. Item 12: Air flow sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-08 air flow sensor
connector
Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 4 .

MULTIPORT FUEL INJECTION (MFI)

13A-16

TROUBLESHOOTING

STEP 4. Measure voltage at C-137 engine-ECU


connector.
CONNECTOR: C-137

STEP 5. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 90 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Go to Step 6 .

AK300254 AB

Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Q: Is the check result normal?


YES : Check and repair harness between B-08

(terminal No. 3) air flow sensor connector


and C-137 (terminal No. 90) engine-ECU
connector.
Check output line for open circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-17

TROUBLESHOOTING

STEP 6. Connector check: C-137 engine-ECU


connector.
CONNECTOR: C-137

STEP 7. Check harness between B-08 (terminal


No. 3) air flow sensor connector and C-137
(terminal No. 90) engine-ECU connector.
Connector: B-08

B-08 (B)
C-137
7 6 5 4 3 2 1

Harness side connector

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300253 AB

CONNECTOR: C-137

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.
C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for short circuit.


Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

STEP 8. MUT-II data list


Refer to Data list reference table 313A.
a. Item 12: Air flow sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

MULTIPORT FUEL INJECTION (MFI)

13A-18

TROUBLESHOOTING

STEP 9. Measure voltage at B-08 air flow sensor


connector.

STEP 10. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X

Connector: B-08

Relay boxs
triangle marks

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 4 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Go to Step 10 .

B-17X

Harness side
connector

AK300255 AB

Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Q: Is the check result normal?


YES : Check and repair harness between B-08

(terminal No. 4) air flow sensor connector


and B-17X (terminal No.1) engine control
relay connector.
Check power supply line for
open/short circuit.
NO : Repair.
STEP 11. Check at B-08 air flow sensor
connector.
Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Disconnect and measure at harness side.


Resistance between terminal No. 5 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 14 .
NO : Go to Step 12 .

MULTIPORT FUEL INJECTION (MFI)

13A-19

TROUBLESHOOTING

STEP 12. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

STEP 13. Check harness between B-08 (terminal


No. 5) air flow sensor connector and C-135
(terminal No. 40) engine-ECU connector.
Connector: B-08

C-135

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300253 AB

CONNECTOR: C-135

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 13 .
NO : Repair.
C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

NOTE: Before checking harness, check intermediate


connector C-16, and repair if necessary.
Check earthing line for open circuit and damage.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-20

TROUBLESHOOTING

STEP 14. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

STEP 16. Check harness between B-08 (terminal


No. 7) air flow sensor connector and C-134
(terminal No. 19) engine-ECU connector.
Connector: B-08

B-08 (B)
B-08 (B)
7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 7 and earth.
OK: 7 - 8 V

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

CONNECTOR: C-134

Q: Is the check result normal?


YES : Go to Step 17 .
NO : Go to Step 15 .

C-134

STEP 15. Connector check: C-134 engine-ECU


connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

CONNECTOR: C-134

Harness side connector


AK300257 AB

Check reset signal line for short circuit.


C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 16 .
NO : Repair.

Q: Is the check result normal?


YES : Replace air flow sensor.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-21

TROUBLESHOOTING

STEP 17. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

STEP 19. Check harness between B-08 (terminal


No. 7) air flow sensor connector and C-134
(terminal No. 19) engine-ECU connector.
Connector: B-08

B-08 (B)
B-08 (B)
7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness.
Transmission: Neutral
Voltage between terminal No. 7 and earth.
OK:
0 - 1 V (Engine: Idling)
6 - 9 V (Engine: 3,000 r/min)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

CONNECTOR: C-134

Q: Is the check result normal?


YES : Go to Step 20 .
NO : Go to Step 18 .

C-134

STEP 18. Connector check: C-134 engine-ECU


connector

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


CONNECTOR: C-134
AK300257 AB

Check reset signal line for open circuit and damage.

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 19 .
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-22

TROUBLESHOOTING

STEP 20. Measure output waveform at B-08 air


flow sensor connector (Use oscilloscope).
Connector: B-08

STEP 23. Check harness between B-08 (terminal


No. 4) air flow sensor connector and B-17X
(terminal No. 1) engine control relay connector.
Connector: B-08

B-08 (B)
B-08 (B)
7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness.
Engine: Idling
Transmission: Neutral
Voltage between terminal No. 3 and earth.
OK: Waveforms should be displayed on
inspection procedure using an oscilloscope
(Refer to 313A) and noise should not be
displayed in the waveform.

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Go to Step 21 .

AK300255 AB

Check power supply line for damage.

STEP 21. Replace air flow sensor.


After replacing the air flow sensor, re-check the
trouble symptoms.
Q: Is the check result normal?
YES : Go to Step 22 .
NO : Check end.

Q: Is the check result normal?


YES : Go to Step 24 .
NO : Repair.

STEP 24. Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

STEP 22. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300255 AB

AK300257 AB

Q: Is the check result normal?


YES : Go to Step 23 .
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 25 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-23

TROUBLESHOOTING

STEP 25. Check harness between B-08 (terminal


No. 3) air flow sensor connector and C-137
(terminal No. 90) engine-ECU connector.

STEP 26.Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

Connector: B-08

B-08 (B)

C-135

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

CONNECTOR: C-137

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Connector: B-08

C-137
B-08 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

7 6 5 4 3 2 1

Harness side connector

Harness side connector

AK300253 AB

AK300254 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 26 .
NO : Repair.

Q: Is the check result normal?


YES : Check intermediate connector C-16, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between B-08 (terminal No. 5) air
flow sensor connector and C-135 (terminal
No. 40) engine-ECU connector.
Check earthing line for damage.
No : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-24

TROUBLESHOOTING

Code No. P0105: Barometric Pressure Sensor System

Barometric pressure sensor circuit

B-08
Barometric pressure sensor
(Incorporated in air flow sensor)

1 2 3 4 5 6 7

2
B-W

20

Y-B

J/C (1)
C-16

G-W
17

B-W
81

85

40

C-135

C-137

31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

5V
Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300258 AB

OPERATION
A power voltage of 5 V is applied to the barometric pressure sensor power terminal (terminal No.
1) of the air flow sensor connector from the
engine-ECU (terminal No. 81) and earthed to the
engine-ECU (terminal No. 40) from the air flow
sensor (terminal No. 5).
The sensor signal is inputted to the engine-ECU
(terminal No. 85) from the barometric pressure
sensor output terminal (terminal No. 2) of the air
flow sensor connector.
FUNCTION
The barometric pressure sensor converts the barometric pressure into a voltage signal and inputs
the signal to the engine-ECU.

In response to the signal, the engine-ECU corrects the fuel injection amount, etc.
TROUBLE JUDGMENT
Check Condition
2 seconds later after the ignition switch has been
in "ON" position or the engine has started up.
The battery voltage is 8 V or more.
Judgment Criterion
The sensor output voltage is 4.5 V or more (Barometric pressure of above 114 kPa or equivalent)
for 2 seconds.
Or
The sensor output voltage is 0.2 V or less (Barometric pressure of below 53kpa or equivalent) for
2 seconds.

MULTIPORT FUEL INJECTION (MFI)

13A-25

TROUBLESHOOTING

PROBABLE CAUSE
Failed barometric pressure sensor
Open/short circuit in barometric pressure sensor
circuit or loose connector contact
Failed engine-ECU

STEP 3. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

DIAGNOSIS PROCEDURE
STEP 1. MUT-II data list
Refer to Data list reference table 313A.
a. Item 25: Barometric pressure sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-08 air flow sensor
connector

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 4 .

Connector: B-08

STEP 4. Measure voltage at C-137 engine-ECU


connector.
CONNECTOR: C-137
B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 81 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Go to Step 6 .

MULTIPORT FUEL INJECTION (MFI)

13A-26

TROUBLESHOOTING

STEP 5. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 6. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300254 AB

AK300253 AB

Q: Is the check result normal?


YES : Check and repair harness between B-08

(terminal No. 1) air flow sensor connector


and C-137 (terminal No. 81) engine-ECU
connector.
Check power supply line for open
circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-27

TROUBLESHOOTING

STEP 7. Check harness between B-08 (terminal


No. 1) air flow sensor connector and C-137
(terminal No. 81) engine-ECU connector.

STEP 9. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

Connector: B-08

B-08 (B)
B-08 (B)
7 6 5 4 3 2 1

Harness side connector

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

CONNECTOR: C-137

AK300253 AB

Disconnect connector, and measure at harness


side.
Voltage between terminal No. 5 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Go to Step 10 .

C-137

STEP 10. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check power supply line for short circuit.


Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

STEP 8. MUT-II data list


Refer to Data list reference table 313A.
a. Item No. 25: Barometric pressure sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-28

TROUBLESHOOTING

STEP 11. Check harness between B-08 (terminal


No. 5) air flow sensor connector and C-135
(terminal No. 40) engine-ECU connector.

STEP 12. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

Connector: B-08

B-08 (B)
B-08 (B)
7 6 5 4 3 2 1

Harness side connector

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

NOTE: Before checking harness, check intermediate


connector C-16, and repair if necessary.
Check earthing line for open circuit or damage.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

AK300253 AB

Use special tool test harness (MB991709) to connect only terminal No. 1, No. 2 and No. 5, and
then measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 14 .
NO : Go to Step 13 .

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 13. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

13A-29

STEP 14. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

B-08 (B)
C-137
7 6 5 4 3 2 1

Harness side connector


8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: B-08

Use special tool test harness (MB991709) to connect only terminal No. 1, No. 2 and No. 5, and
then measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 5 and earth.
OK: 0.5 V or less
Q: Is the check result normal?
YES : Go to Step 16 .
NO : Go to Step 15 .

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Q: Is the check result normal?


YES : Check and repair harness between B-08

(terminal No. 1) air flow sensor connector


and C-137 (terminal No. 81) engine-ECU
connector.
Check power supply line for damage.
NO : Repair.

AK300253 AB

MULTIPORT FUEL INJECTION (MFI)

13A-30

TROUBLESHOOTING

STEP 15. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

STEP 16. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

B-08 (B)
C-135
7 6 5 4 3 2 1

Harness side connector


38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Connector: B-08

AK300253 AB

Use special tool test harness (MB991709) to connect only terminal No. 1, No. 2 and No. 5, and
then measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 2 and earth.
OK:
Altitude 0m: 3.8 - 4.2 V
Altitude 600m: 3.5 - 3.9 V
Altitude 1,200m: 3.3 - 3.7 V
Altitude 1,800m: 3.0 - 3.4 V
Q: Is the check result normal?
YES : Go to Step 19 .
NO : Go to Step 17 .

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Q: Is the check result normal?


YES : Check intermediate connector C-16, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between B-08 (terminal No. 5) air
flow sensor connector and C-135 (terminal
No. 40) engine-ECU connector.
Check earthing line for damage.
NO : Repair.

STEP 17. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 18 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-31

TROUBLESHOOTING

STEP 18. Check harness between B-08 (terminal


No. 2) air flow sensor connector and C-137
(terminal No. 85) engine-ECU connector.

STEP 19. Measure voltage at C-137 engine-ECU


connector.
CONNECTOR: C-137

Connector: B-08

B-08 (B)
C-137
7 6 5 4 3 2 1

Harness side connector

AK300253 AB

CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 85 and earth.
OK:
Altitude 0m: 3.8 - 4.2 V
Altitude 600m: 3.5 - 3.9 V
Altitude 1,200m: 3.3 - 3.7 V
Altitude 1,800m: 3.0 - 3.4 V

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for short circuit and damage.


Q: Is the check result normal?
YES : Replace air flow sensor.
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 21 .
NO : Go to Step 20 .

MULTIPORT FUEL INJECTION (MFI)

13A-32

TROUBLESHOOTING

STEP 20. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 21. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.

Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300254 AB

AK300253 AB

Q: Is the check result normal?


YES : Check and repair harness between B-08

(terminal No. 2) air flow sensor connector


and C-137 (terminal No. 85) engine-ECU
connector.
Check output line for open circuit and
damage.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-33

TROUBLESHOOTING

Code No. P0110: Intake Air Temperature Sensor System

Intake air temperature sensor circuit

B-08
Intake air temperature sensor
(Incorporated in air flow sensor)

1 2 3 4 5 6 7

B-W

20
J/C (1)
C-16

Y-L

17
B-W

72

40
C-137

C-135

71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

5V
Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300259 AB

OPERATION
A power voltage of 5 V is applied to the intake air
temperature sensor output terminal (terminal No.
6) of the air flow sensor connector from the
engine-ECU (terminal No. 72)
The power voltage is earthed to the engine-ECU
(terminal No. 40) from the air flow sensor (terminal No. 5).
FUNCTION
The intake air temperature sensor converts the
intake air temperature into a voltage and inputs
the voltage signal to the engine-ECU.
In response to the signal, the engine-ECU corrects the fuel injection amount, etc.
The intake air temperature sensor is a kind of
resistor, which has characteristics to reduce its
resistance as the intake air temperature rises.
Therefore, the sensor output voltage varies with
the intake air temperature, and becomes lower as
the intake air temperature rises.

TROUBLE JUDGMENT
Check Condition
2 seconds later after the ignition switch has been
in "ON" position or the engine has started up.
Judgment Criterion
The sensor output voltage is 4.6 V or more
(intake air temperature of below -45C or equivalent) for 2 seconds.
Or
The sensor output voltage is 0.2 V or loss (intake
air temperature above 125C or equivalent) for 2
seconds.
PROBABLE CAUSE
Failed intake air temperature sensor
Open/short circuit in intake air temperature sensor circuit or loose connector contact
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-34

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 4. Measure voltage at B-08 air flow sensor


connector.

STEP 1. MUT-II data list


Refer to Data list reference table 313A.
a. Item 13: Intake air temperature sensor
OK: At ambient temperature (atmospheric
temperature) or equivalent.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-08 air flow sensor
connector

Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Disconnect connector, and measure at harness


side.
Voltage between terminal No. 5 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 5 .

Connector: B-08

STEP 5. Connector check: C-135 engine-ECU


connector

B-08 (B)

CONNECTOR: C-135
7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.
C-135

STEP 3. Check intake air temperature sensor


itself.
Check intake air temperature sensor itself (Refer
to 313A).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace air flow sensor.

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 6. Check harness between B-08 (terminal


No. 5) air flow sensor connector and C-135
(terminal No. 40) engine-ECU connector.
Connector: B-08

13A-35

STEP 7. MUT-II data list


Refer to Data list reference table 313A.
a. Item 13: Intake air temperature sensor
OK: At ambient temperature (atmospheric
temperature) or equivalent.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

CONNECTOR: C-135

STEP 8. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

C-135

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

NOTE: Before checking harness, check intermediate


connector C-16, and repair if necessary.
Check earthing line for open circuit and damage.
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Repair.

AK300253 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 6 and earth.
OK: 4.5 - 4.9 V
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Go to Step 9 .

MULTIPORT FUEL INJECTION (MFI)

13A-36

TROUBLESHOOTING

STEP 9. Measure voltage at C-137 engine-ECU


connector.
CONNECTOR: C-137

STEP 10. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Connector: B-08

Connector: B-08

B-08 (B)

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

7 6 5 4 3 2 1
AK300253 AB

Measure engine-ECU terminal voltage.


Disconnect B-08 air flow sensor connector.
Ignition switch: ON
Voltage between terminal No. 72 and earth.
OK: 4.5 - 4.9 V

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Go to Step 11 .

AK300254 AB

Harness side connector

AK300253 AB

Q: Is the check result normal?


YES : Check and repair harness between B-08

(terminal No. 6) air flow sensor connector


and C-137 (terminal No. 72) engine-ECU
connector.
Check output line for open circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-37

TROUBLESHOOTING

STEP 11. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 12. Check harness between B-08 (terminal


No. 6) air flow sensor connector and C-137
(terminal No. 72) engine-ECU connector.
Connector: B-08

B-08 (B)
C-137
7 6 5 4 3 2 1

Harness side connector

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300253 AB

CONNECTOR: C-137

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Repair.
C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for short circuit.


Q: Is the check result normal?
YES : Go to Step 7 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-38

TROUBLESHOOTING

STEP 13. Measure voltage at B-08 air flow sensor


connector.
Connector: B-08

STEP 15. Check harness between B-08 (terminal


No. 6) air flow sensor connector and C-137
(terminal No. 72) engine-ECU connector.
Connector: B-08

B-08 (B)
B-08 (B)
7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Use special tool test harness (MB991709) to connect only terminal No. 5 and No. 6, and then
measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 6 and earth.
OK:
Ambient temperature at -20C: 3.8 - 4.4 V
Ambient temperature at 0C: 3.2 - 3.8 V
Ambient temperature at 20C: 2.3 - 2.9 V
Ambient temperature at 40C: 1.5 - 2.1 V
Ambient temperature at 60C: 0.8 - 1.4 V
Ambient temperature at 80C: 0.4 - 1.0 V
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Go to Step 14 .

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

STEP 14. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 15 .
NO : Repair.

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 16 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 16. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Connector: B-08

B-08 (B)

7 6 5 4 3 2 1

Harness side connector

AK300253 AB

Q: Is the check result normal?


YES : Check intermediate connector C-16 and

repair if necessary. If intermediate


connector is normal, check and repair
harness between B-08 (terminal No. 5) air
flow sensor connector and C-135 (terminal
No. 40) engine-ECU connector.
Check earthing line for damage.
NO : Repair.

13A-39

MULTIPORT FUEL INJECTION (MFI)

13A-40

TROUBLESHOOTING

Code No. P0115: Engine Coolant Temperature Sensor System

Engine coolant temperature sensor circuit

B-108
(MU802406)
Engine coolant temperature sensor

1 2

BR

Y-G

92

83

C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

Engine-ECU
5V

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300260 AB

OPERATION
A power voltage of 5 V is applied to the engine
coolant temperature sensor output terminal (terminal No. 1) from the engine-ECU (terminal No.
83).
The power voltage is earthed to the engine-ECU
(terminal No. 92) from the engine coolant temperature sensor (terminal No. 2).
FUNCTION
The engine coolant temperature sensor converts
the engine coolant temperature into a voltage signal, and inputs the voltage to the engine-ECU.
In response to the signal, the engine-ECU controls the fuel infection amount and the fast idle
speed when the engine is cold state.

The engine coolant temperature sensor is a kind


of resistor, which has characteristics to reduce its
resistance as the engine coolant temperature
rises. Therefore, the sensor output voltage varies
with the engine coolant temperature, and
becomes lower as the engine coolant temperature rises.
TROUBLE JUDGMENT
Check Condition
2 seconds later after the ignition switch has been
in "ON" position or just after the engine has
started up.
Judgment Criterion
The sensor output voltage is 4.6 V or more (water
temperature of below -45C or equivalent) for 2
seconds.
Or
The sensor output voltage of 0.1 V or less (water
temperature of above 140C or equivalent) for 2
seconds.

MULTIPORT FUEL INJECTION (MFI)

13A-41

TROUBLESHOOTING

Check Condition
After the engine has started up.

STEP 3. Measure resistance at B-108 engine


coolant temperature sensor connector.

Judging Conditions
The sensor output voltage rises 1.6 V or more
(engine coolant temperature below 40C or
equivalent) from 1.6 V or less (engine coolant
temperature above 40C or equivalent).

Connector: B-108
2 1
Harness side
connector

PROBABLE CAUSE
Failed engine coolant temperature sensor
Open/short circuit in engine coolant temperature
sensor circuit or loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II data list
Refer to Data list reference table 313A.
a. Item 21: Engine coolant temperature sensor
OK:
Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
Engine hot state: At 80 - 120C
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-108 engine coolant
temperature sensor connector
Connector: B-108
2 1
Harness side
connector

B-108 (B)
AK300261 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

B-108 (B)
AK300261 AB

Disconnect connector, and measure at sensor


side.
Resistance between terminal No. 1 and No. 2.
OK:
Engine coolant temperature at -20C: 14 - 17
kW
Engine coolant temperature at 0C: 5.1 - 6.5
kW
Engine coolant temperature at 20C: 2.1 - 2.7
kW
Engine coolant temperature at 40C: 0.9 - 1.3
kW
Engine coolant temperature at 60C: 0.48 0.68 kW
Engine coolant temperature at 80C: 0.26 0.36 kW
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace engine coolant temperature

sensor.

MULTIPORT FUEL INJECTION (MFI)

13A-42

TROUBLESHOOTING

STEP 4. Measure voltage at B-108 engine coolant


temperature sensor connector.
Connector: B-108

STEP 5. Measure voltage at C-137 engine-ECU


connector.
CONNECTOR: C-137

2 1
Harness side
connector

B-108 (B)

C-137

AK300261 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: 4.5 - 4.9 V
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Go to Step 5 .

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: B-108
2 1
Harness side
connector

B-108 (B)
AK300261 AB

Measure engine-ECU terminal voltage.


Disconnect B-108 engine coolant temperature
sensor.
Ignition switch: ON
Voltage between terminal No. 83 and earth.
OK: 4.5 - 4.9 V
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 7 .

MULTIPORT FUEL INJECTION (MFI)

13A-43

TROUBLESHOOTING

STEP 6. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 7. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Connector: B-108
2 1
Harness side
connector

B-108 (B)
AK300261 AB

Q: Is the check result normal?


YES : Check and repair harness between B-108

(terminal No. 1) engine coolant temperature


sensor connector and C-137 (terminal No.
83) engine-ECU connector.
Check output line for open circuit.
NO : Repair.

AK300254 AB

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-44

TROUBLESHOOTING

STEP 8. Check harness between B-108 (terminal


No. 1) engine coolant temperature sensor
connector and C-137 (terminal No. 83) engineECU connector.

STEP 10. Measure voltage at B-108 engine


coolant temperature sensor connector.
Connector: B-108
2 1

Connector: B-108

Harness side
connector

2 1
Harness side
connector

B-108 (B)
AK300261 AB

B-108 (B)
AK300261 AB

CONNECTOR: C-137

Disconnect connector and measure at harness


side.
Voltage between terminal No. 2 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Go to Step 11 .

STEP 11. Connector check: C-137 engine-ECU


connector

C-137

Q: Is the check result normal?


CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for short circuit.


Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair.

STEP 9. MUT-II data list


Refer to Data list reference table 313A.
a. Item 21: Engine coolant temperature sensor
OK:
Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
Engine hot state: At 80 - 120 C
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

YES : Go to Step 12 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-45

TROUBLESHOOTING

STEP 12. Check harness between B-108 (terminal


No. 2) engine coolant temperature sensor
connector and C-137 (terminal No. 92) engineECU connector.

STEP 13. Measure voltage at B-108 engine


coolant temperature sensor connector.
Connector: B-108
2 1

Connector: B-108

Harness side
connector

2 1
Harness side
connector

B-108 (B)
AK300261 AB

B-108 (B)
AK300261 AB

CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair.

Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK:
Engine coolant temperature at -20C: 3.9 - 4.5
V
Engine coolant temperature at 0C: 3.2 - 3.8 V
Engine coolant temperature at 20C: 2.3 - 2.9
V
Engine coolant temperature at 40C: 1.3 - 1.9
V
Engine coolant temperature at 60C: 0.7 - 1.3
V
Engine coolant temperature at 80C: 0.3 - 0.9
V
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 14 .

MULTIPORT FUEL INJECTION (MFI)

13A-46

TROUBLESHOOTING

STEP 14. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 15. Check harness between B-108 (terminal


No. 1) engine coolant temperature sensor
connector and C-137 (terminal No. 83) engineECU connector.
Connector: B-108
2 1
Harness side
connector

C-137
B-108 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300261 AB

Harness side connector

CONNECTOR: C-137
AK300254 AB

Q: Is the check result normal?


YES : Go to Step 15 .
NO : Repair.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 16 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 16. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: B-108
2 1
Harness side
connector

B-108 (B)
AK300261 AB

Q: Is the check result normal?


YES : Check harness between B-108 (terminal

No. 2) engine coolant temperature sensor


connector and C-137 (terminal No. 92)
engine-ECU connector.
Check earthing line for damage.
NO : Repair.

13A-47

MULTIPORT FUEL INJECTION (MFI)

13A-48

TROUBLESHOOTING

Code No. P0120: Throttle Position Sensor System


Throttle position sensor circuit

B-06
(MU802724)
Throttle position sensor

1 2 3 4

Y-B

81

BR

84

92

C-137
Engine-ECU

71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

5V

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300262 AB

OPERATION
A power voltage of 5 V is applied to the throttle
position sensor (terminal No. 1) from the engineECU (terminal No. 81).
The power voltage is earthed to the engine-ECU
(terminal No. 92) from the throttle position sensor
(terminal No. 4).
The sensor signal is inputted to the engine-ECU
(terminal No. 84) from the throttle position sensor
output terminal (terminal No. 2).
FUNCTION
The throttle position sensor converts the opening
of the throttle valve into a voltage and inputs the
voltage signal to the engine-ECU.
In response to the signal, the engine-ECU checks
the opening of the throttle valve.

TROUBLE JUDGMENT
Check Condition
Ignition switch: ON
Or
Excluding 2 seconds after the ignition switch has
been in "ON" position or just after the engine has
started up.
Judgment Criteria
The sensor output voltage is 0.2 V or less for 2
seconds.
Or
When the engine speed is 1,000 r/min or less and
the charging efficiency is 40% or less, the throttle
position sensor output voltage is 4.4 V or more for
2 seconds.

MULTIPORT FUEL INJECTION (MFI)

13A-49

TROUBLESHOOTING

PROBABLE CAUSE
Failed throttle position sensor
Open/short circuit in throttle position sensor circuit or loose connector contact
Failed engine-ECU

STEP 4. Measure voltage at B-06 throttle position


sensor connector.
Connector: B-06
B-06 (B)

DIAGNOSIS PROCEDURE
STEP 1. MUT-II data list
Refer to Data list reference table 313A.
a. Item 14: Throttle position sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-06 throttle position
sensor connector

4 3 2 1
Harness side connector

AK300263 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Go to Step 5 .

Connector: B-06
B-06 (B)

STEP 5. Measure voltage at C-137 engine-ECU


connector.
CONNECTOR: C-137

4 3 2 1
Harness side connector

AK300263 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Check throttle position sensor itself.


Check throttle position sensor itself (Refer to
313A).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace throttle position sensor.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 81 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 7 .

MULTIPORT FUEL INJECTION (MFI)

13A-50

TROUBLESHOOTING

STEP 6. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 7. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.

Connector: B-06
B-06 (B)

4 3 2 1
Harness side connector

AK300254 AB

AK300263 AB

Q: Is the check result normal?


YES : Check and repair harness between B-06

(terminal No. 1) throttle position sensor


connector and C-137 (terminal No. 81)
engine-ECU connector.
Check power supply line for open
circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-51

TROUBLESHOOTING

STEP 8. Check harness between B-06 (terminal


No. 1) throttle position sensor connector and C137 (terminal No. 81) engine-ECU connector.

STEP 10. Measure resistance at B-06 throttle


position sensor connector.
Connector: B-06

Connector: B-06

B-06 (B)
B-06 (B)

4 3 2 1
Harness side connector

4 3 2 1
Harness side connector

AK300263 AB

CONNECTOR: C-137

AK300263 AB

Disconnect connector, and measure at harness


side.
Resistance between terminal No. 4 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Go to Step 11 .

C-137

STEP 11. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check power supply line for short circuit.


Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair.

STEP 9. MUT-II data list


Refer to Data list reference table 313A.
a. Item 14: Throttle position sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-52

TROUBLESHOOTING

STEP 12. Check harness between B-06 (terminal


No. 4) throttle position sensor connector and C137 (terminal No. 92) engine-ECU connector.

STEP 13. Measure voltage at B-06 throttle


position sensor connector.
Connector: B-06

Connector: B-06

B-06 (B)
B-06 (B)

4 3 2 1
Harness side connector

4 3 2 1
Harness side connector

AK300263 AB

CONNECTOR: C-137

Use special tool test harness (MB991536) to connect connector, and measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 15 .
NO : Go to Step 14 .

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair.

AK300263 AB

MULTIPORT FUEL INJECTION (MFI)

13A-53

TROUBLESHOOTING

STEP 14. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 15. Measure voltage at B-06 throttle


position sensor connector.
Connector: B-06
B-06 (B)

C-137

4 3 2 1
Harness side connector

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: B-06

4 3 2 1
Harness side connector

Use special tool test harness (MB991536) to connect connector, and measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 4 and earth.
OK: 0.5 V or less
Q: Is the check result normal?
YES : Go to Step 17 .
NO : Go to Step 16 .

B-06 (B)

AK300263 AB

Q: Is the check result normal?


YES : Check and repair harness between B-06

(terminal No. 1) throttle position sensor


connector and C-137 (terminal No. 81)
engine-ECU connector.
Check power supply line for damage.
NO : Repair.

AK300263 AB

MULTIPORT FUEL INJECTION (MFI)

13A-54

TROUBLESHOOTING

STEP 16. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 17. Measure voltage at B-06 throttle


position sensor connector.
Connector: B-06
B-06 (B)

C-137

4 3 2 1
Harness side connector

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: B-06
B-06 (B)

AK300263 AB

Use special tool test harness (MB991536) to connect connector, and measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 2 and earth.
OK:
Accelerator pedal fully released: 0.535 - 0.735
V
Accelerator pedal fully depressed: 4.5 - 5.0 V
Q: Is the check result normal?
YES : Go to Step 20 .
NO : Go to Step 18 .

4 3 2 1
Harness side connector

AK300263 AB

Q: Is the check result normal?


YES : Check and repair harness between B-06

(terminal No. 4) throttle position sensor


connector and C-137 (terminal No. 92)
engine-ECU connector.
Check earthing line for damage.
NO : Repair.

STEP 18. Adjust throttle position sensor


Adjust throttle position sensor (Refer to 313A
).
Q: Is the adjusted value normal?
YES : Go to Step 19 .
NO : Adjust throttle position sensor.

MULTIPORT FUEL INJECTION (MFI)

13A-55

TROUBLESHOOTING

STEP 19. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 20. Measure voltage at C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 84 and earth.
OK:
Accelerator pedal fully released: 0.535 - 0.735
V
Accelerator pedal fully depressed: 4.5 - 5.0 V

Connector: B-06
B-06 (B)

4 3 2 1
Harness side connector

AK300254 AB

AK300263 AB

Q: Is the check result normal?


YES : Check and repair harness between B-06

(terminal No. 2) throttle position sensor


connector and C-137 (terminal No. 84)
engine-ECU connector.
Check output line for short circuit and
damage.
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 22 .
NO : Go to Step 21 .

MULTIPORT FUEL INJECTION (MFI)

13A-56

TROUBLESHOOTING

STEP 21. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 22. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

Connector: B-06
B-06 (B)

4 3 2 1
Harness side connector

AK300254 AB

AK300263 AB

Q: Is the check result normal?


YES : Check and repair harness between B-06

(terminal No. 2) throttle position sensor


connector and C-137 (terminal No. 84)
engine-ECU connector.
Check output line for open circuit and
damage.
NO : Repair.

Code No. P0125: Feedback system monitor


OPERATION
Refer to P0201 injector circuit 313A.
Refer to P0202 injector circuit 313A.
Refer to P0203 injector circuit 313A.
Refer to P0204 injector circuit 313A.
Refer to P0130 Oxygen sensor (front) circuit
313A.
FUNCTION
The engine-ECU effects air-fuel ratio feedback
control in accordance with the signals from the
heater oxygen sensor (front).

If the heated oxygen sensor (front) has deteriorated, corrections will be made by the heated oxygen sensor (rear).
diagnosis code P0125 becomes stored in memory if a failure is detected in the above air/fuel
ratio feedback control system.
TROUBLE JUDGMENT
Check Conditions
The engine coolant temperature approximately.
82C or more.

MULTIPORT FUEL INJECTION (MFI)

13A-57

TROUBLESHOOTING

Within the range of air-fuel ratio feedback operation.


Not in low speed operation.
Judgment Criteria
The oxygen sensor output voltage is not deviated
from 0.5 V for 30 seconds.
PROBABLE CAUSE
Failed oxygen sensor (front)
Harness damage in oxygen sensor (front) circuit
or loose connector contact
Failed oxygen sensor (rear)
NOTE: When the oxygen sensor (front) begins to
deteriorate, the oxygen sensor output voltage will
deviate from the voltage when the sensor was new
(normally 0.5 volt at stoichiometric ratio). This deviation will be corrected by the oxygen sensor (rear).If
the oxygen sensor (rear) responds poorly because it
has deteriorated, it will improperly correct the oxygen
sensor (front). Thus, even when closed loop control
is being effected, the fluctuation of the oxygen sensor (front) output voltage decreases, without intersecting with 0.5 volt. As a result, there is a possibility
of diagnosis code P0125 becoming registered.
Failed fuel system
Failed exhaust system
Failed engine-ECU

STEP 3.Check for intake of air from intake hose


and inlet manifold.
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Repair.

STEP 4.Check for leakage of exhaust emission


from exhaust manifold.
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Repair.

STEP 5.Check throttle body (throttle valve


portion) for contamination.
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Clean throttle body (throttle valve portion)

(Refer to 313A).
STEP 6. Connector check: B-112 oxygen sensor
(front) connector, C-137 engine-ECU connector
Connector: B-112
Oxygen sensor (front)
B-112 (B)

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Is any other diagnosis code than P0170 output?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

2 1
4 3
Harness side connector
CONNECTOR: C-137

STEP 2.MUT-II data list


Refer to Data list reference table 313A.
a. Item 12: Air flow sensor
b. Item 21: Engine coolant temperature sensor
c. Item 25: Barometric pressure sensor
d. Item 69: Oxygen sensor (rear)
Q: Are the check results normal?
YES : Go to Step 3 .
NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an


abnormal data valve (Refer to Inspection
Chart for Diagnosis Codes 313A).

AK300264 AB

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-58

TROUBLESHOOTING

STEP 7. Check oxygen sensor (front) itself.


Check oxygen sensor (front) itself (Refer to
313A).

STEP 9. Connector check: Injector connector


Connector: B-01, B-02, B-04, B-05

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Replace oxygen sensor (front).

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

STEP 8. Check harness between B-112 oxygen


sensor (front) connector and C-137 engine-ECU
connector.
Connector: B-112
Oxygen sensor (front)
B-112 (B)

2 1
Harness side connector

a.
b.
c.
d.

AK300265 AB

B-01 (No.1 injector connector)


B-02 (No.2 injector connector)
B-04 (No.3 injector connector)
B-05 (No.4 injector connector)

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Repair.

2 1
4 3
Harness side connector

AK300264 AB

CONNECTOR: C-137

STEP 10. Check injector itself.


Check Injector itself (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Replace injector.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-59

TROUBLESHOOTING

STEP 11. Connector check: B-17X engine control


relay connector and B-134 engine-ECU
connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 12. Check harness between B-17X engine


control relay connector and injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

B-17X

Harness side
connector

Harness side
connector

AK300255 AB

AK300255 AB

Connector: B-01, B-02, B-04, B-05


CONNECTOR: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Repair.

2 1
Harness side connector

AK300265 AB

a. Check harness between B-17X (terminal No. 1)


engine control relay connector and B-01 (terminal
No. 1) No. 1 injector connector.
b. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-02 (terminal
No. 1) No. 2 injector connector.
c. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-04 (terminal
No. 1) No. 3 injector connector.
d. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-05 (terminal
No. 1) No. 4 injector connector.
Check power supply line for damage.
Q: Are the check results normal?
YES : Go to Step 13 .
NO : Repair

MULTIPORT FUEL INJECTION (MFI)

13A-60

TROUBLESHOOTING

STEP 13. Check harness between injector


connector and C-134 engine-ECU connector.

Q: Is the check result normal?


YES : Repair.
NO : Replace engine-ECU

Connector: B-01, B-02, B-04, B-05

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

2 1
Harness side connector

AK300265 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

a. Check harness between B-01 (terminal No. 2)


No. 1injector connector and C-134 (terminal No.
1) engine-ECU connector.
b. Check harness between B-02 (terminal No. 2)
No. 2 injector connector and C-134 (terminal No.
14) engine-ECU connector.
c. Check harness between B-04 (terminal No. 2)
No. 3 injector connector and C-134 (terminal No.
2) engine-ECU connector.
d. Check harness between B-05 (terminal No. 2)
No. 4 injector connector and C-134 (terminal No.
15) engine-ECU connector.
Q: Are the check results normal?
YES : Go to Step 14 .
NO : Repair

STEP 14. Measure fuel pressure.


Measure fuel pressure (Refer to 313A).

MULTIPORT FUEL INJECTION (MFI)

13A-61

TROUBLESHOOTING

Code No. P0130: Oxygen Sensor (Front) System <sensor 1>

Oxygen sensor (front) circuit

B-112
(MU802605)
Oxygen sensor (front)

1 2
3 4

From Engine control relay

To engine-ECU
B

2
B

W
92

J/C (2)
C-17

76
B

C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300266 AB

OPERATION
The sensor signal is inputted to the engine-ECU
(terminal No. 76) from the oxygen sensor output
terminal (terminal No. 4).
The oxygen sensor (terminal No. 2) is earthed
with engine-ECU (terminal No. 92).
FUNCTION
The oxygen sensor converts the concentration of
oxygen in the exhaust emission into a voltage
and inputs the signal to the engine-ECU.
When the air-fuel ratio is richer than the theoretical air-fuel ratio, the oxygen sensor outputs a voltage of about 1 V. When it is leaner than the
theoretical air-fuel ratio, it outputs a voltage of
about 0 V.
In response to the signal, the engine-ECU controls the fuel infection amount so that the air-fuel
ratio can be equivalent to the theoretical air-fuel
ratio.

TROUBLE JUDGMENT
Check Condition
Above 3 minutes later after the engine has
started up.
The engine coolant temperature approximately
82C or more.
The engine speed is 1,200 r/min or more.
The volumetric efficiency 25% or more.
The monitoring time is 5 seconds.
Judgment Criteria
When the oxygen sensor (front) output voltage is
0.2 V or less and a power voltage of 5 V is
applied to the oxygen sensor (front) in the
engine-ECU, the sensor output voltage is 4.5 V or
more.
Check Condition
The engine speed is 3,000 r/min or less.
During the air-fuel ratio feedback control

MULTIPORT FUEL INJECTION (MFI)

13A-62

TROUBLESHOOTING

Judgment Criteria
When the oxygen sensor (front) output frequency
is 6 or less for 10 seconds on the average.

STEP 3. Measure voltage at B-112 oxygen sensor


(front) connector.
Connector: B-112

PROBABLE CAUSE
Failed oxygen sensor
Open/short circuit in oxygen sensor (front) circuit
or loose connector contact
Failed engine-ECU

Oxygen sensor (front)


B-112 (B)

2 1
4 3

DIAGNOSIS PROCEDURE
STEP 1. MUT-II data list
Refer to Data list reference table 313A.
a. Item 11: Oxygen sensor (front)
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-112 oxygen sensor
(front) connector

Harness side connector

AK300264 AB

Disconnect connector, and measure at harness


side.
Resistance between terminal No. 2 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Go to Step 4 .

STEP 4. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

Connector: B-112
Oxygen sensor (front)
B-112 (B)

C-137

2 1
4 3
Harness side connector

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

AK300264 AB

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-63

TROUBLESHOOTING

STEP 5. Check harness between B-112 (terminal


No. 2) oxygen sensor (front) connector and C-137
(terminal No. 92) engine-ECU connector.
Connector: B-112
Oxygen sensor (front)
B-112 (B)

2 1
4 3

STEP 6. MUT-II data list


Refer to Data list reference table 313A.
a. Item 11: Oxygen sensor (front)
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.
STEP 7. Measure at B-112 oxygen sensor (front)
connector.

Harness side connector

AK300264 AB

Connector: B-112
CONNECTOR: C-137

Oxygen sensor (front)


B-112 (B)

2 1
4 3

C-137

Harness side connector

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Go to Step 6 .
NO : Repair.

AK300264 AB

Use special tool test harness (MD998464) to connect connector, and measure at pick-up harness.
Engine: After warm-up
Ignition switch: ON
Voltage between terminal No. 2 and earth.
OK: 0.5 V or less
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 8 .

MULTIPORT FUEL INJECTION (MFI)

13A-64

TROUBLESHOOTING

STEP 8. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 9. Measure voltage at B-112 oxygen sensor


(front) connector.
Connector: B-112
Oxygen sensor (front)
B-112 (B)

2 1
4 3

C-137

Harness side connector


8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: B-112
Oxygen sensor (front)
B-112 (B)

2 1
4 3
Harness side connector

AK300264 AB

Q: Is the check result normal?


YES : Check and repair harness between B-112

(terminal No. 2) oxygen sensor (front)


connector and C-137 (terminal No. 92)
engine-ECU connector.
Check earthing line for damage.
NO : Repair.

AK300264 AB

Use special tool test harness (MD998464) to connect connector, and measure at pick-up harness.
Engine: After warm-up
Voltage between terminal No. 4 and earth.
OK:
600 - 1,000 mV when 200 mV or lower abrupt
racing is done a few seconds after abrupt
deceleration from 4,000 r/min.
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Go to Step 10 .

STEP 10. Check oxygen sensor itself


Check oxygen sensor (front) itself (Refer to
313A).
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Replace oxygen (front) sensor.

MULTIPORT FUEL INJECTION (MFI)

13A-65

TROUBLESHOOTING

STEP 11. Connector check: C-137 engine-ECU


connector

STEP 12. Measure voltage at C-137 engine-ECU


connector.

CONNECTOR: C-137

CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Connector: B-112
Oxygen sensor (front)
B-112 (B)

2 1
4 3
Harness side connector

AK300264 AB

Q: Is the check result normal?


YES : Check and repair harness between B-112

(terminal No. 4) oxygen sensor (front)


connector and C-137 (terminal No. 76)
engine-ECU connector.
Check output line for damage.
NO : Repair.

AK300254 AB

Measure engine-ECU terminal voltage.


Transmission: Neutral
Engine: After warm-up
Voltage between terminal No. 76 and earth.
OK:
600 - 1,000 mV when 200 mV or lower abrupt
racing is done a few seconds after abrupt
deceleration from 4,000 r/min.

Q: Is the check result normal?


YES : Go to Step 14 .
NO : Go to Step 13 .

MULTIPORT FUEL INJECTION (MFI)

13A-66

TROUBLESHOOTING

STEP 13. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 14. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Connector: B-112
Oxygen sensor (front)
B-112 (B)

2 1
4 3
Harness side connector

AK300264 AB

Q: Is the check result normal?


YES : Check and repair harness between B-112

(terminal No. 4) oxygen sensor (front)


connector and C-137 (terminal No. 76)
engine-ECU connector.
Check output line for open circuit.
NO : Repair.

AK300254 AB

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-67

TROUBLESHOOTING

Code No. P0135: Oxygen Sensor Heater (Front) System <Sensor 1>

Oxygen sensor (front) heater circuit

Battery

W-B
W-B

B-17X

Oxygen sensor (front)


B-112
(MU8026053)

Engine
control
relay
1

1 2
3 4

2
1

To engine-ECU

Y-R
60
C-136
51 52 53 54 55 56
57 58 59 60 61 62

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300267 AB

OPERATION
Power is supplied to the heater power terminal
(terminal No. 1) of the oxygen sensor (front) connector from the engine control relay (terminal No.
1).
The heater (terminal No. 3) of the oxygen sensor
(front) connector is controlled by the power transistor in the engine-ECU (terminal No. 60).

FUNCTION
The power supply to the oxygen sensor heater
(front) is controlled by the ON/OFF control of the
power transistor in the engine-ECU.
Heating the oxygen sensor heater (front) enables
the oxygen sensor to provide good response
even when the exhaust emission temperature is
low.

MULTIPORT FUEL INJECTION (MFI)

13A-68

TROUBLESHOOTING

TROUBLE JUDGMENT
Check Conditions
The engine coolant temperature is approximately.
20C or higher.
The oxygen sensor heater (front) is in "ON" position.
The engine speed is 50 r/min or more.
The battery voltage is 11 - 16 V.
Judgment Criteria
The heater current of oxygen sensor heater
(front) is below 0.2 A or above 3.5 A for 1 second.
PROBABLE CAUSE
Failed oxygen sensor heater
Open/short circuit in oxygen sensor (front) circuit
or loose connector contact
Failed engine-ECU

STEP 2. Measure resistance at B-112 oxygen


sensor (front) connector.
Connector: B-112
Oxygen sensor (front)
B-112 (B)

2 1
4 3
Harness side connector

AK300264 AB

Disconnect connector, and measure at sensor


side.
Resistance between terminal No. 1 and No. 3.
OK: 4.5 - 8.0 W
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Replace oxygen sensor (front).

DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-112 oxygen sensor
(front) connector

STEP 3. Measure voltage at B-112 oxygen sensor


(front) connector.

Connector: B-112
Oxygen sensor (front)

Connector: B-112
Oxygen sensor (front)

B-112 (B)
B-112 (B)

2 1
4 3
Harness side connector

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

AK300264 AB

2 1
4 3
Harness side connector

AK300264 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Go to Step 4 .

MULTIPORT FUEL INJECTION (MFI)

13A-69

TROUBLESHOOTING

STEP 4. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X

CONNECTOR: C-136

B-17X

Relay boxs
triangle marks

STEP 5. Measure voltage at C-136 engine-ECU


connector.

C-136

Harness side
connector

AK300255 AB

56 55 54 53 52 51
62 61 60 59 58 57

Connector: B-112
Oxygen sensor (front)

Harness side connector

B-112 (B)

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 60 and earth.
OK: System voltage

2 1
4 3
Harness side connector

AK300268 AB

AK300264 AB

Q: Is the check result normal?


YES : Check and repair harness between B-112

(terminal No. 1) oxygen sensor connector


and B-17X (terminal No. 1) engine control
relay connector.
Check power supply line for
open/short circuit.
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Go to Step 6 .

STEP 6. Connector check: C-136 engine-ECU


connector
CONNECTOR: C-136

C-136

56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector


AK300268 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-70

TROUBLESHOOTING

STEP 7. Check harness between B-112 (terminal


No. 3) oxygen sensor (front) connector and C-136
(terminal No. 60) engine-ECU connector.

STEP 8. Connector check: C-136 engine-ECU


connector
CONNECTOR: C-136

Connector: B-112
Oxygen sensor (front)
B-112 (B)

C-136

2 1
4 3
Harness side connector

AK300264 AB

56 55 54 53 52 51
62 61 60 59 58 57

CONNECTOR: C-136

Harness side connector


AK300268 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.
C-136

STEP 9. Check harness between B-112 (terminal


No. 1) oxygen sensor (front) connector and B17X (terminal No. 1) engine control relay
connector.

56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector

Connector: B-112
Oxygen sensor (front)

AK300268 AB

Check earthing line for open/short circuit.

B-112 (B)

Q: Is the check result normal?


YES : Replace engine-ECU.
NO : Repair.
2 1
4 3
Harness side connector

AK300264 AB

CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

AK300255 AB

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 10. Check harness between B-112 (terminal


No. 3) oxygen sensor (front) connector and C-136
(terminal No. 60) engine-ECU connector.
Connector: B-112
Oxygen sensor (front)
B-112 (B)

2 1
4 3
Harness side connector

AK300264 AB

CONNECTOR: C-136

C-136

56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector


AK300268 AB

Check earthing line for damage.


Q: Is the check result normal?
YES : Go to Step 11 .
NO : Repair.

13A-71

STEP 11. Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

MULTIPORT FUEL INJECTION (MFI)

13A-72

TROUBLESHOOTING

Code No. P0136: Oxygen Sensor (Rear) System <Sensor 2>

Oxygen sensor (rear) circuit

C-18
(MU801688)

1 2
3 4

Oxygen sensor (rear)

From engine control relay

To engine-ECU

J/C (2)
C-17
92

75

B
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300269 AB

OPERATION
The sensor signal is inputted to the engine-ECU
(terminal No. 75) from the oxygen sensor (rear)
output terminal (terminal No. 4).
The oxygen sensor (rear) (terminal No. 3) is
earthed with engine-ECU (terminal No. 92).
FUNCTION
The oxygen sensor (rear) converts the concentration of oxygen in the exhaust emission into a voltage signal and inputs the voltage signal to the
engine-ECU.
When the air-fuel ratio is richer than the theoretical air-fuel ratio, the oxygen sensor (rear) outputs
a voltage of about 1 V. When it is leaner than the
theoretical air-fuel ratio, it outputs a voltage of
about 0 V.
In response to the signal, the engine-ECU controls the fuel infection amount so that the air-fuel
ratio can be equivalent to the theoretical air-fuel
ratio.

TROUBLE JUDGMENT
Check Conditions
Above 3 minutes later after the engine has
started up.
The engine coolant temperature is approximately.
82C or higher.
The engine speed is 1,200 r/min or more.
The volumetric efficiency is 25% or more.
The monitoring time is 5 seconds.
Judgment Criteria
When the oxygen sensor (rear) output voltage is
0.2 V or less and a power voltage of 5 V is
applied to the oxygen sensor (rear) in the engineECU, the sensor output voltage is 4.5 V or more.
PROBABLE CAUSE
Failed oxygen sensor
Open/short circuit in oxygen sensor (rear) circuit
or loose connector contact
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-73

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3. Measure voltage at C-18 oxygen sensor


(rear) connector.

STEP 1. MUT-II data list


Refer to Data list reference table 313A.
a. Item 59: Oxygen sensor (rear)

Connector: C-18
1 2
3 4

Q: Is the check result normal?


YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .

Harness side
connector
C-18

Oxygen sensor (rear)

STEP 2. Connector check: C-18 oxygen sensor


(rear) connector
Connector: C-18
1 2
3 4
Harness side
connector
C-18

Oxygen sensor (rear)

AK300270 AB

Disconnect connector, and measure at harness


side.
Resistance between terminal No. 3 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Go to Step 4 .

STEP 4. Connector check: C-137 engine-ECU


connector
AK300270 AB

CONNECTOR: C-137

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-74

TROUBLESHOOTING

STEP 5. Check harness between C-18 (terminal


No. 3) oxygen sensor (rear) connector and C-137
(terminal No. 92) engine-ECU connector.

STEP 6. MUT-II data list


Refer to Data list reference table 313A.
a. Item 59: Oxygen sensor (rear)
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

Connector: C-18
1 2
3 4
Harness side
connector

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

C-18

Oxygen sensor (rear)

STEP 7. Measure voltage at C-18 oxygen sensor


(rear) connector.
Connector: C-18
1 2
3 4
Harness side
connector

AK300270 AB

C-18

CONNECTOR: C-137

Oxygen sensor (rear)

C-137
AK300270 AB

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Go to Step 6 .
NO : Repair.

Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness.
Engine: After warm-up
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: 0.5 V or less
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 8 .

MULTIPORT FUEL INJECTION (MFI)

13A-75

TROUBLESHOOTING

STEP 8. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 9. Measure voltage at C-18 oxygen sensor


(rear) connector.
Connector: C-18
1 2
3 4
Harness side
connector
C-18

C-137
Oxygen sensor (rear)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: C-18
1 2
3 4
Harness side
connector
C-18

Oxygen sensor (rear)

AK300270 AB

Q: Is the check result normal?


YES : Check and repair harness between C-18

(terminal No. 3) oxygen sensor connector


and C-137 (terminal No. 92) engine-ECU
connector.
Check earthing line for damage.
NO : Repair.

AK300270 AB

Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness.
Engine: After warm-up
Voltage between terminal No. 4 and earth.
OK:
600 - 1,000 mV when 200 mV or lower abrupt
racing is done a few seconds after abrupt
deceleration from 4,000 r/min.
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Go to Step 10 .

STEP 10. Check oxygen sensor (rear) itself.


Check oxygen sensor (rear) itself (Refer to
313A).
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Replace oxygen (rear) sensor.

MULTIPORT FUEL INJECTION (MFI)

13A-76

TROUBLESHOOTING

STEP 11. Connector check: C-137 engine-ECU


connector

STEP 12. Measure voltage at C-137 engine-ECU


connector.

CONNECTOR: C-137

CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Connector: C-18
1 2
3 4
Harness side
connector
C-18

Oxygen sensor (rear)

AK300270 AB

Q: Is the check result normal?


YES : Check and repair harness between C-18

(terminal No. 4) oxygen sensor connector


and C-137 (terminal No. 75) engine-ECU
connector.
Check output line for damage.
NO : Repair.

AK300254 AB

Measure engine-ECU terminal voltage.


Transmission: Neutral
Engine: After warm-up
Voltage between terminal No. 75 and earth.
OK:
600 - 1,000 mV when 200 mV or lower abrupt
racing is done a few seconds after abrupt
deceleration from 4,000 r/min.

Q: Is the check result normal?


YES : Go to Step 14 .
NO : Go to Step 13 .

MULTIPORT FUEL INJECTION (MFI)

13A-77

TROUBLESHOOTING

STEP 13. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 14. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Connector: C-18
1 2
3 4
Harness side
connector
C-18

Oxygen sensor (rear)

AK300270 AB

Q: Is the check result normal?


YES : Check and repair harness between C-18

(terminal No. 4) oxygen sensor (rear)


connector and C-137 (terminal No. 75)
engine-ECU connector.
Check output line for open circuit.
NO : Repair.

AK300254 AB

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-78

TROUBLESHOOTING

Code No. P0141: Oxygen Sensor Heater (Rear) System <Sensor 2>

Oxygen sensor (rear) heater circuit

Battery

W-B
W-B

B-17X

Oxygen sensor (rear)


C-18
(MU801688)

Engine
control
relay
1

1 2
3 4

2
2

R
To engine-ECU

2
J/C (2)
C-17

Y-R

54
C-136
51 52 53 54 55 56
57 58 59 60 61 62

Engine-ECU
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300271 AB

OPERATION
Power is supplied to the heater power terminal
(terminal No. 2) of the oxygen sensor (rear) connector from the engine control relay (terminal No.
1).
The heater (terminal No. 1) of the oxygen sensor
(rear) connector is controlled by the power transistor in the engine-ECU (terminal No. 54).

FUNCTION
The power supply to the oxygen sensor heater
(rear) is controlled by the ON/OFF control of the
power transistor in the engine-ECU.
Heating the oxygen sensor heater (rear) enables
the oxygen sensor to provide good response
even when the exhaust emission temperature is
low.

MULTIPORT FUEL INJECTION (MFI)

13A-79

TROUBLESHOOTING

TROUBLE JUDGMENT
Judgment Criteria
The engine coolant temperature is approximately.
20 C or higher.
The oxygen sensor heater (rear) is in "ON" position.
The engine speed is 50 r/min or more.
The battery voltage is 11 - 16 V.
Judgment Criteria
The heater current of front oxygen sensor heater
(rear) is below 0.2 A or above 3.5 A for 1 second.

STEP 2. Measure resistance at C-18 oxygen


sensor (rear) connector.
Connector: C-18
1 2
3 4
Harness side
connector
C-18

Oxygen sensor (rear)

PROBABLE CAUSE
Failed oxygen sensor heater (rear)
Open/short circuit in oxygen sensor (rear) circuit
or loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-18 oxygen sensor
(rear) connector
Connector: C-18
1 2
3 4
Harness side
connector

AK300270 AB

Disconnect connector, and measure at sensor


side.
Resistance between terminal No. 1 and No. 2.
OK: 11 - 18 W
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Replace oxygen (rear) sensor.

STEP 3. Measure voltage at C-18 oxygen sensor


(rear) connector.
Connector: C-18

C-18

1 2
3 4

Oxygen sensor (rear)

Harness side
connector
C-18
AK300270 AB

Oxygen sensor (rear)

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.
AK300270 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 2 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Go to Step 4 .

MULTIPORT FUEL INJECTION (MFI)

13A-80

TROUBLESHOOTING

STEP 4. Connector check: B-17X engine control


relay connector
CONNECTOR: C-137

STEP 5. Measure voltage at C-136 engine-ECU


connector.
CONNECTOR: C-136

C-136

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector

Harness side connector


AK300254 AB

Connector: C-18
1 2
3 4
Harness side
connector
C-18

Oxygen sensor (rear)

AK300268 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 54 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 6 .

STEP 6. Connector check: C-136 engine-ECU


connector
CONNECTOR: C-136

AK300270 AB

Q: Is the check result normal?


YES : Check intermediate connector C-17, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between C-18 (terminal No. 2)
oxygen sensor (rear) connector and B-17X
(terminal No. 1) engine control relay
connector.
Check power supply line for
open/short circuit.
NO : Repair.

C-136

56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector


AK300268 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-81

TROUBLESHOOTING

STEP 7. Check harness between C-18 (terminal


No. 1) oxygen sensor connector and C-136
(terminal No. 54) engine-ECU connector.

STEP 8. Connector check: C-136 engine-ECU


connector
CONNECTOR: C-136

Connector: C-18
1 2
3 4
Harness side
connector
C-136

C-18

Oxygen sensor (rear)


56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector


AK300268 AB
AK300270 AB

CONNECTOR: C-136

C-136

56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector


AK300268 AB

Check earthing line for open/short circuit.


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

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-82

TROUBLESHOOTING

STEP 9. Check harness between C-18 (terminal


No. 2) oxygen sensor connector and B-17X
(terminal No. 1) engine control relay connector.
Connector: C-18

STEP 10. Check harness between C-18 (terminal


No. 1) oxygen sensor connector and C-136
(terminal No. 54) engine-ECU connector.
Connector: C-18

1 2
3 4

1 2
3 4

Harness side
connector
C-18

Harness side
connector
C-18

Oxygen sensor (rear)

Oxygen sensor (rear)

AK300270 AB

CONNECTOR: B-17X
Relay boxs
triangle marks

AK300270 AB

CONNECTOR: C-136

B-17X

Harness side
connector

C-136
AK300255 AB

NOTE: Before checking harness, check intermediate


connector C-17, and repair if necessary.
Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector


AK300268 AB

Check earthing line for damage.


Q: Is the check result normal?
YES : Go to Step 11 .
NO : Repair.

STEP 11. Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-83

Code No. P0170: Abnormal Fuel System


OPERATION
Refer to P0201 injector circuit 313A.
Refer to P0202 injector circuit 313A.
Refer to P0203 injector circuit 313A.
Refer to P0204 injector circuit 313A.
FUNCTION
If the fuel system goes out of order, the fuel correction value will become larger.
The engine-ECU checks whether the fuel correction value is within the standard limits.
TROUBLE JUDGMENT
Check Conditions
In learning air-fuel ratio
Judgment Criteria
The compensation value of fuel injection amount
is too low for 2 seconds or more.
Or
The compensation value of fuel injection amount
is too high for 2 seconds or more.
PROBABLE CAUSE
Failed fuel supply system
Failed oxygen sensor (front)
Failed intake air temperature sensor
Failed air flow sensor
Failed purge control solenoid valve
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Is any other diagnosis code than P0170 output?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

STEP 2. MUT-II data list


Refer to Data list reference table 313A.
a. Item 12: Air flow sensor
b. Item 13: Intake air temperature sensor
c. Item 21: Engine coolant temperature sensor
d. Item 22: Barometric pressure sensor
Q: Are the check results normal?
YES : Go to Step 3 .
NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an


abnormal data value (Refer to Inspection
Chart for Diagnosis Codes 313A).
STEP 3. Check for intake of air from intake hose
and inlet manifold.
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Repair.

STEP 4. Check for leakage of exhaust emission


from exhaust manifold.
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Repair.

STEP 5. Check throttle body (throttle valve


portion) for contamination.
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Clean throttle body (throttle valve portion)

(Refer to 313A).
STEP 6. MUT-II data list
Refer to Data list reference table 313A.
a. Item 11: Oxygen sensor (front).
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Check oxygen sensor (front) system (Refer

to313A, Code No. P0130).

MULTIPORT FUEL INJECTION (MFI)

13A-84

TROUBLESHOOTING

STEP 7. Connector Check: Injector connector


Connector: B-01, B-02, B-04, B-05

STEP 9. Connector check: B-17X engine control


relay connector and B-134 engine-ECU
connector
CONNECTOR: B-17X

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

2 1
Harness side connector

a.
b.
c.
d.

AK300265 AB

B-01 (No.1 injector connector).


B-02 (No.2 injector connector).
B-04 (No.3 injector connector).
B-05 (No.4 injector connector).

Relay boxs
triangle marks

B-17X

Harness side
connector

AK300255 AB

CONNECTOR: C-134

Q: Are the check results normal?


YES : Go to Step 8 .
NO : Replace.

STEP 8. Check injector itself.


Check Injector itself (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Replace injector.

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Replace.

MULTIPORT FUEL INJECTION (MFI)

13A-85

TROUBLESHOOTING

STEP 10. Check harness between B-17X engine


control relay connector and injector connector.
Connector: B-01, B-02, B-04, B-05

Connector: B-01, B-02, B-04, B-05

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

AK300265 AB

CONNECTOR: B-17X

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

2 1
Harness side connector

Relay boxs
triangle marks

STEP 11. Check harness between injector


connector and C-134 engine-ECU connector.

2 1
Harness side connector

AK300265 AB

CONNECTOR: C-134

B-17X

Harness side
connector

C-134
AK300255 AB

a. Check harness between B-17X (terminal No. 1)


engine control relay connector and B-01 (terminal
No. 1) No. 1 injector connector.
b. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-02 (terminal
No. 1) No. 2 injector connector.
c. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-04 (terminal
No. 1) No. 3 injector connector.
d. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-05 (terminal
No. 1) No. 4 injector connector.
Check power supply line for damage.
Q: Are the check results normal?
YES : Go to Step 11 .
NO : Replace.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

a. Check harness between B-01 (terminal No. 2)


No. 1injector connector and C-134 (terminal No.
1) engine-ECU connector.
b. Check harness between B-02 (terminal No. 2)
No. 2 injector connector and C-134 (terminal No.
14) engine-ECU connector.
c. Check harness between B-04 (terminal No. 2)
No. 3 injector connector and C-134 (terminal No.
2) engine-ECU connector.
d. Check harness between B-05 (terminal No. 2)
No. 4 injector connector and C-134 (terminal No.
15) engine-ECU connector.
Q: Are the check results normal?
YES : Go to Step 12 .
NO : Replace.

STEP 12. Check purge control solenoid valve


itself.
Check purge control solenoid valve itself (Refer to
GROUP 17 - Emission Control System - Evaporative Emission Control System 317).
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Replace purge control solenoid valve.

13A-86

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 13. Measure fuel pressure.


Measure fuel pressure (Refer to 313A).
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-87

TROUBLESHOOTING

Code No. P0201: No. 1 Injector System

Injector circuit
Battery

W-B
W-B
3

4
B-17X

Engine control relay

1
R

R
Injector
No. 1
B-01

R
1

1 2

Injector
No. 2

Injector
No. 4

B-04

B-05

1 2

1 2

1 2

Y-R

Injector
No. 3

B-02

Y-G

14

15

Engine-ECU

C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300272 AB

13A-88

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

OPERATION
Power is supplied to the injector (terminal No. 1)
from the engine control relay (terminal No. 1).
The engine-ECU (terminal No. 1) makes the
power transistor in the unit be in "ON" position,
and that makes currents go on the injector (terminal No. 2).
FUNCTION
The engine-ECU controls the power supply interval of the injector.
The fuel injection amount of the injector depends
on the power supply interval.
TROUBLE JUDGMENT
Check Conditions
The engine speed is 50 - 1,000 r/min.
The throttle position sensor output voltage is 1.15
V or less.
Injector not in forced drive (actuator test) mode
Judgment Criterion
No surge voltage of the injector coil is detected
for 2 seconds.
PROBABLE CAUSE
Failed No. 1 injector
Open/short circuit in injector circuit or loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II actuator test
Refer to Actuator test reference table list 313A
.
a. Item 01: No. 1 injector
OK: Idling state varies.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .

STEP 2. Connector check: B-01 No. 1 injector


connector
Connector: B-01

B-01 (GR)

2 1
Harness side connector

AK300265 AC

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Measure resistance at B-01 No. 1 injector


connector.
Connector: B-01

B-01 (GR)

2 1
Harness side connector

AK300265 AC

Disconnect connector, and measure at injector


side.
Resistance between terminal No. 1 and No. 2.
OK: 10.5 - 13.5 W
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace No. 1 injector.

MULTIPORT FUEL INJECTION (MFI)

13A-89

TROUBLESHOOTING

STEP 4. Measure voltage at B-01 No. 1 injector


connector.

STEP 5. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X

Connector: B-01

Relay boxs
triangle marks

B-17X

B-01 (GR)
2

2 1
Harness side connector

AK300265 AC

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage

Harness side
connector

AK300255 AB

Connector: B-01

B-01 (GR)

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Go to Step 5 .

2 1
Harness side connector

AK300265 AC

Q: Is the check result normal?


YES : Check and repair harness between B-17X

(terminal No. 1) engine control relay


connector and B-01 (terminal No. 1) No. 1
injector connector.
Check power supply line for
open/short circuit.
NO : Repair.
STEP 6. Connector check: B-17X engine control
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

AK300255 AB

MULTIPORT FUEL INJECTION (MFI)

13A-90

TROUBLESHOOTING

STEP 7. Check harness between B-17X (terminal


No. 1) engine control relay connector and B-01
(terminal No. 1) No. 1 injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 9. Check harness between B-01 (terminal


No. 2) No.1 injector connector and C-134
(terminal No. 1) engine-ECU connector.
Connector: B-01

B-17X
B-01 (GR)

3
M

Harness side
connector

AK300255 AB

2 1
Harness side connector

AK300265 AC

CONNECTOR: C-134

Connector: B-01

B-01 (GR)

C-134

2 1
Harness side connector

AK300265 AC

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

Harness side connector


AK300257 AB

STEP 8. Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Check output line for open/short circuit and damage.


Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 10. Measure signal waveform at C-134


engine-ECU connector (Use oscilloscope).
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Engine: Idling
Transmission: Neutral
Voltage between terminal No. 1 and earth.
OK: Waveforms should be display on
Inspection procedure using an oscilloscope
(Refer to 313A).
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

13A-91

MULTIPORT FUEL INJECTION (MFI)

13A-92

TROUBLESHOOTING

Code No. P0202: No. 2 Injector System

Injector circuit
Battery

W-B
W-B
3

4
B-17X

Engine control relay

1
R

R
Injector
No. 1
B-01

R
1

1 2

Injector
No. 2

Injector
No. 4

B-04

B-05

1 2

1 2

1 2

Y-R

Injector
No. 3

B-02

Y-G

14

15

Engine-ECU

C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300272 AB

MULTIPORT FUEL INJECTION (MFI)

13A-93

TROUBLESHOOTING

OPERATION
Power is supplied to the injector (terminal No. 1)
from the engine control relay (terminal No. 1).
The engine-ECU (terminal No. 14) makes the
power transistor in the unit be in "ON" position,
and that makes currents go on the injector (terminal No. 2).
FUNCTION
The engine-ECU controls the power supply interval of the injector.
The fuel injection amount of the injector depends
on the power supply interval.
TROUBLE JUDGMENT
Check Conditions
The engine speed is 50 - 1,000 r/mim.
The throttle position sensor output voltage 1.15 V
or less.
Injector not in forced drive (actuator test) mode
Judgment Criteria
No surge voltage of the injector coil is detected
for 2 seconds.
PROBABLE CAUSE
Failed No. 2 injector
Open/short circuit in No. 2 injector circuit or loose
connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II actuator test
Refer to Actuator test reference table list 313A
.
a. Item 02: No. 2 injector
OK: Idling state varies.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .

STEP 2. Connector check: B-02 No. 2 injector


connector
Connector: B-02

B-02 (GR)

2 1
Harness side connector

AK300265 AD

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Measure at resistance B-02 No. 2 injector


connector.
Connector: B-02

B-02 (GR)

2 1
Harness side connector

AK300265 AD

Disconnect connector, and measure at injector


side.
Resistance between terminal No. 1 and No. 2.
OK: 10.5 - 13.5 W
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace No. 2 injector.

MULTIPORT FUEL INJECTION (MFI)

13A-94

TROUBLESHOOTING

STEP 4. Measure voltage at B-02 No. 2 injector


connector.

STEP 5. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X

Connector: B-02

Relay boxs
triangle marks

B-17X

B-02 (GR)
2

2 1
Harness side connector

AK300265 AD

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage

Harness side
connector

AK300255 AB

Connector: B-02

B-02 (GR)

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Go to Step 5 .

2 1
Harness side connector

AK300265 AD

Q: Is the check result normal?


YES : Check and repair harness between B-17X

(terminal No. 1) engine control relay


connector and B-02 (terminal No. 1) No. 2
injector connector.
Check power supply line for
open/short circuit and damage.
NO : Repair.
STEP 6. Connector check: B-17X engine control
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

AK300255 AB

MULTIPORT FUEL INJECTION (MFI)

13A-95

TROUBLESHOOTING

STEP 7. Check harness between B-17X (terminal


No. 1) engine control relay connector and B-02
(terminal No. 1) No. 2 injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 9. Check harness between B-02 (terminal


No. 2) No. 2 injector connector and C-134
(terminal No. 14) engine-ECU connector.
Connector: B-02

B-17X
B-02 (GR)

3
M

Harness side
connector

AK300255 AB

2 1
Harness side connector

AK300265 AD

CONNECTOR: C-134

Connector: B-02

B-02 (GR)

C-134

2 1
Harness side connector

AK300265 AD

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

Harness side connector


AK300257 AB

STEP 8. Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Check output line for open/short circuit and damage.


Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-96

TROUBLESHOOTING

STEP 10. Measure signal waveform at C-134


engine-ECU connector (Use oscilloscope).
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Engine: Idling
Transmission: Neutral
Voltage between terminal No. 9 and earth.
OK: Waveform should be display on Inspection procedure using an oscilloscope (Refer
to 313A).
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

MULTIPORT FUEL INJECTION (MFI)

13A-97

TROUBLESHOOTING

Code No. P0203: No. 3 Injector System

Injector circuit
Battery

W-B
W-B
3

4
B-17X

Engine control relay

1
R

R
Injector
No. 1
B-01

R
1

1 2

Injector
No. 2

Injector
No. 4

B-04

B-05

1 2

1 2

1 2

Y-R

Injector
No. 3

B-02

Y-G

14

15

Engine-ECU

C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300272 AB

13A-98

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

OPERATION
Power is supplied to the injector (terminal No. 1)
from the engine control relay (terminal No. 1).
The engine-ECU (terminal No. 2) makes the
power transistor in the unit be in "ON" position,
and that makes currents go on the injector (terminal No. 2).
FUNCTION
The engine-ECU controls the power supply interval of the injector.
The fuel injection amount of the injector depends
on the power supply interval.
TROUBLE JUDGMENT
Check Conditions
The engine speed is 50 - 1,000 r/mim.
The throttle position sensor output voltage is 1.15
V or less.
Injector not in forced drive (actuator test) mode
Judgment Criteria
No surge voltage of the injector coil is detected
for 2 seconds.
PROBABLE CAUSE
Failed No. 3 injector
Open/short circuit in No. 3 injector circuit or loose
connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II actuator test
Refer to Actuator test reference table list 313A
.
a. Item 03: No. 3 injector
OK: Idling state varies.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .

STEP 2. Connector check: B-04 No. 3 injector


connector
Connector: B-04

B-04 (GR)

2 1
Harness side connector

AK300265 AE

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Measure resistance at B-04 No. 3 injector


connector.
Connector: B-04

B-04 (GR)

2 1
Harness side connector

AK300265 AE

Disconnect connector, and measure at injector


side.
Resistance between terminal No. 1 and No. 2.
OK: 10.5 - 13.5 W
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace No. 3 injector.

MULTIPORT FUEL INJECTION (MFI)

13A-99

TROUBLESHOOTING

STEP 4. Measure voltage at B-04 No. 3 injector


connector.

STEP 5. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X

Connector: B-04

Relay boxs
triangle marks

B-17X

B-04 (GR)
2

2 1
Harness side connector

AK300265 AE

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage

Harness side
connector

AK300255 AB

Connector: B-04

B-04 (GR)

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Go to Step 5 .

2 1
Harness side connector

AK300265 AE

Q: Is the check result normal?


YES : Check and repair harness between B-17X

(terminal No. 1) engine control relay


connector and B-04 (terminal No. 1) No. 3
injector connector.
Check power supply line for
open/short circuit.
NO : Repair.
STEP 6. Connector check: B-17X engine control
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

AK300255 AB

MULTIPORT FUEL INJECTION (MFI)

13A-100

TROUBLESHOOTING

STEP 7. Check harness between B-17X (terminal


No. 1) engine control relay connector and B-04
(terminal No. 1) No. 3 injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 9. Check harness between B-04 (terminal


No. 2) No. 3 injector connector and C-134
(terminal No. 2) engine-ECU connector.
Connector: B-04

B-17X
B-04 (GR)

3
M

Harness side
connector

AK300255 AB

2 1
Harness side connector

AK300265 AE

CONNECTOR: C-134

Connector: B-04

B-04 (GR)

C-134

2 1
Harness side connector

AK300265 AE

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

Harness side connector


AK300257 AB

STEP 8. Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Check output line for open/short circuit and damage.


Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 10. Measure signal waveform at C-134


engine-ECU connector (Use oscilloscope).
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Engine: Idling
Transmission: Neutral
Voltage between terminal No. 24 and earth.
OK: Waveform should be display on Inspection procedure using an oscilloscope (Refer
to 313A).
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

13A-101

MULTIPORT FUEL INJECTION (MFI)

13A-102

TROUBLESHOOTING

Code No. P0204: No. 4 Injector System

Injector circuit
Battery

W-B
W-B
3

4
B-17X

Engine control relay

1
R

R
Injector
No. 1
B-01

R
1

1 2

Injector
No. 2

Injector
No. 4

B-04

B-05

1 2

1 2

1 2

Y-R

Injector
No. 3

B-02

Y-G

14

15

Engine-ECU

C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300272 AB

MULTIPORT FUEL INJECTION (MFI)

13A-103

TROUBLESHOOTING

OPERATION
Power is supplied to the injector (terminal No. 1)
from the engine control relay (terminal No. 1).
The engine-ECU (terminal No. 15) makes the
power transistor in the unit be in "ON" position,
and that makes currents go on the injector (terminal No. 2).
FUNCTION
The engine-ECU controls the power supply interval of the injector.
The fuel injection amount of the injector depends
on the power supply interval.
TROUBLE JUDGMENT
Check Conditions
The engine speed is 50 - 1,000 r/mim.
The throttle position sensor output 1.15 V or less.
Injector not in forced drive (actuator test) mode
Judgment Criterion
No surge voltage of the injector coil is detected
for 2 seconds
PROBABLE CAUSE
Failed No. 4 injector
Open/short circuit in No. 4 injector circuit or loose
connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II actuator test
Refer to Actuator test reference table list 313A
.
a. Item 04: No. 4 injector
OK: Idling state varies.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .

STEP 2. Connector check: B-05 No. 4 injector


connector
Connector: B-05

B-05 (GR)

2 1
Harness side connector

AK300265 AF

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Measure resistance at B-05 No. 4 injector


connector.
Connector: B-05

B-05 (GR)

2 1
Harness side connector

AK300265 AF

Disconnect connector, and measure at injector


side.
Resistance between terminal No. 1 and No. 2.
OK: 10.5 - 13.5 W
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace No. 4 injector.

MULTIPORT FUEL INJECTION (MFI)

13A-104

TROUBLESHOOTING

STEP 4. Measure voltage at B-05 No. 4 injector


connector.

STEP 5. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X

Connector: B-05

Relay boxs
triangle marks

B-17X

B-05 (GR)
2

2 1
Harness side connector

AK300265 AF

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage

Harness side
connector

AK300255 AB

Connector: B-05

B-05 (GR)

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Go to Step 5 .

2 1
Harness side connector

AK300265 AF

Q: Is the check result normal?


YES : Check and repair harness between B-17X

(terminal No. 1) engine control relay


connector and B-05 (terminal No. 1) No. 4
injector connector.
Check power supply line for
open/short circuit and damage.
NO : Repair.
STEP 6. Connector check: B-17X engine control
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

Q: Is the check result normal?


YES : Go to Step 7.
NO : Repair.

AK300255 AB

MULTIPORT FUEL INJECTION (MFI)

13A-105

TROUBLESHOOTING

STEP 7. Check harness between B-17X (terminal


No. 1) engine control relay connector and B-05
(terminal No. 1) No. 4 injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 9. Check harness between B-05 (terminal


No. 2) No. 4 injector connector and C-134
(terminal No. 15) engine-ECU connector.
Connector: B-05

B-17X
B-05 (GR)

3
M

Harness side
connector

AK300255 AB

2 1
Harness side connector

AK300265 AF

CONNECTOR: C-134

Connector: B-05

B-05 (GR)

C-134

2 1
Harness side connector

AK300265 AF

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

Harness side connector


AK300257 AB

STEP 8. Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Check output line for open/short circuit and damage.


Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-106

TROUBLESHOOTING

STEP 10. Measure signal waveform at C-134


engine-ECU connector (Use oscilloscope).
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Engine: Idling
Transmission: Neutral
Voltage between terminal No. 2 and earth.
OK: Waveform should be display on Inspection procedure using an oscilloscope (Refer
to 313A).
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

Code No. P0300: Random cylinder mis-fire detected


OPERATION
Refer to P0201 injector circuit 313A.
Refer to P0202 injector circuit 313A.
Refer to P0203 injector circuit 313A.
Refer to P0204 injector circuit 313A.
FUNCTION
If a misfire occurs while the engine is running, the
engine speed changes for an instant.
The engine-ECU checks for such changes in
engine speed.
TROUBLE JUDGMENT
Check Conditions
5 seconds later after the engine has started up.
The engine speed is 500 - 4,500 r/min.
The engine coolant temperature is -10C or
higher.
The intake air temperature is -10C or higher.

The barometric pressure is 72 kPa or more.


The volumetric efficiency is 30 - 60%.
The adaptive learning has been completed with
the vane that generates the crankshaft position
signals.
During the engine operation except the shift
change or low speed driving and rapid acceleration and deceleration, also intermittent operation
of air compressor (A/C: within the 3 seconds after
changing to ON from OFF or to OFF from ON).
The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms.
Judgment Criteria
The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified
number (of 7.3 % on more than the two cylinders)
with the engine speed of 200 r/min.
Or

MULTIPORT FUEL INJECTION (MFI)

13A-107

TROUBLESHOOTING

The number of misfiring (that is 1.5 times the


emission standard limit) is beyond the specified
number (of 2 % on more than the two cylinders)
with the engine speed of 1000 r/min.
PROBABLE CAUSE
Ignition system related part(s) failed
Failed crank angle sensor
Incorrect air-fuel ratio
Low compression pressure
Failed coolant temperature sensor
Skipping of timing belt teeth.
EGR system and EGR valve failed
Failed engine-ECU

STEP 3.Check ignition coil spark.


Q: Is the check resuit normal?
YES : Go to Step 4 .
NO : Check ignition circuit system (Refer to

Inspection procedure 29 313A).


STEP 4.Connector check: Injector connector
Connector: B-01, B-02, B-04, B-05

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

DIAGNOSIS PROCEDURE
M

STEP 1.MUT-II data list


Item 22: Crank angle sensor
OK: Keep the engine speed constant to
make the pulse width of output waveform
constant.
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Check crank angle sensor system (Refer to

Code No. P0335 313A).


STEP 2.MUT-II data list
Refer to Data list reference table 313A.
a. Item 21: Engine coolant temperature sensor
b. Item 81: Long-term fuel compensation
c. Item 82: Short-term fuel compensation
Q: Are the check results normal?
YES : Go to Step 3 .
NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an


abnormal data valve (Refer to, Inspection
Chart for Diagnosis Codes 313A).

2 1
Harness side connector

a.
b.
c.
d.

AK300265 AB

B-01 (No.1 injector connector)


B-02 (No.2 injector connector)
B-04 (No.3 injector connector)
B-05 (No.4 injector connector)

Q: Are the check results normal?


YES : Go to Step 5 .
NO : Repair.

STEP 5.Check injector itself.


Check Injector itself (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Replace injector.

MULTIPORT FUEL INJECTION (MFI)

13A-108

TROUBLESHOOTING

STEP 6.Connector check: B-17X engine control


relay connector and B-134 engine-ECU
connector
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 7. Check harness between B-17X engine


control relay connector and injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

B-17X

Harness side
connector

Harness side
connector

AK300255 AB

AK300255 AB

Connector: B-01, B-02, B-04, B-05


CONNECTOR: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

2 1
Harness side connector

AK300265 AB

a. Check harness between B-17X (terminal No. 1)


engine control relay connector and B-01 (terminal
No. 1) No. 1 injector connector.
b. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-02 (terminal
No. 1) No. 2 injector connector.
c. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-04 (terminal
No. 1) No. 3 injector connector.
d. Check harness between B-17X (terminal No. 1)
engine control relay connector and B-05 (terminal
No. 1) No. 4 injector connector.
Check power supply line for damage.
Q: Are the check results normal?
YES : Go to Step 8 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 8. Check harness between injector


connector and C-134 engine-ECU connector.
Connector: B-01, B-02, B-04, B-05

B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)

13A-109

STEP 9. Measure fuel pressure.


Measure fuel pressure (Refer to fuel pressure
test 313A)
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

STEP 10. Check for intake of air from intake hose


and inlet manifold.
M

2 1
Harness side connector

AK300265 AB

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Repair.

CONNECTOR: C-134

STEP 11. Check for skipped timing belt teeth.


Q: Is the check result normal?
YES : Go to Step 12 .
NO : Repair.
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

a. Check harness between B-01 (terminal No. 2)


No. 1injector connector and C-134 (terminal No.
1) engine-ECU connector.
b. Check harness between B-02 (terminal No. 2)
No. 2 injector connector and C-134 (terminal No.
14) engine-ECU connector.
c. Check harness between B-04 (terminal No. 2)
No. 3 injector connector and C-134 (terminal No.
2) engine-ECU connector.
d. Check harness between B-05 (terminal No. 2)
No. 4 injector connector and C-134 (terminal No.
15) engine-ECU connector.
Check output line for damage.
Q: Are the check results normal?
YES : Go to Step 9 .
NO : Repair.

STEP 12. Exhaust gas recirculation system


check.
Exhaust gas recirculation system check [Refer to
GROUP 17 - Exhaust gas recirculation (EGR)
system 317].
Q: Is the check result normal?
YES : Replace engine-ECU
NO : Repair.

13A-110

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

Code No. P0301: No. 1 cylinder mis-fire detection system


OPERATION
Refer to P0201 injector circuit 313A.
FUNCTION
If a misfire occurs while the engine is running, the
engine speed changes for an instant.
The engine-ECU checks for such changes in
engine speed.
TROUBLE JUDGMENT
Check Conditions
5 seconds later after the engine has started up.
The engine speed is 500 - 4,500 r/min.
The engine coolant temperature is -10C or
higher.
The intake air temperature is -10C or higher.
The barometric pressure is 72 kPa or more.
The volumetric efficiency is 30 - 60 %.
The adaptive learning has been completed with
the vane that generates the crankshaft position
signals.
During the engine operation except the shift
change or low speed driving and rapid acceleration and deceleration, also intermittent operation
of air compressor (A/C: within the 3 seconds after
changing to ON from OFF or to OFF from ON).
The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms.
Judgment Criterion
The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified
number (of 7.3 % on more than the two cylinders)
with the engine speed of 200 r/min.
Or
The number of misfiring (that is 1.5 times the
emission standard limit) is beyond the specified
number (of 2 % on more than the two cylinders)
with the engine speed of 1,000 r/min.

PROBABLE CAUSE
Ignition system related part(s) failed
Low compression pressure
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1.Check ignition coil spark.
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Check ignition Circuit System (Refer to

Inspection procedure 29 313A)


STEP 2.Connector check: B-01 No.1 injector
connector
Connector: B-01

B-01 (GR)

2 1
Harness side connector

AK300265 AC

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3.Check No.1 injector itself.


Check Injector itself (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace No.1 injector.

MULTIPORT FUEL INJECTION (MFI)

13A-111

TROUBLESHOOTING

STEP 4.Connector check: B-17X engine control


relay connector and B-134 engine-ECU
connector
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 5.Check harness between B-17X (terminal


No. 1) engine control relay connector and B-01
(terminal No. 1) No.1 injector connector.
CONNECTOR: B-17X

B-17X

Relay boxs
triangle marks

Harness side
connector

AK300255 AB

CONNECTOR: C-134

B-17X

Harness side
connector

AK300255 AB

Connector: B-01

B-01 (GR)

C-134

2 1
Harness side connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Repair.

AK300265 AC

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 6 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-112

TROUBLESHOOTING

STEP 6. Check harness between B-01(terminal


No. 2) No.1 injector connector and C-134
(terminal No. 1) engine-ECU connector

STEP 7. Measure fuel pressure.


Measure fuel pressure (Refer to fuel pressure
test 313A).
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Repair.

Connector: B-01

B-01 (GR)

2 1
Harness side connector

AK300265 AC

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 7 .
NO : Repair.

Code No. P0302: No. 2 cylinder mis-fire detection system


OPERATION
Refer to P0202 injector circuit 313A.
FUNCTION
If a misfire occurs while the engine is running, the
engine speed changes for an instant.
The engine-ECU checks for such changes in
engine speed.
TROUBLE JUDGMENT
Check Conditions
5 seconds later after the engine has started up.
The engine speed is 500 - 4,500 r/min.
The engine coolant temperature is -10C or
higher.

The intake air temperature is -10C or higher.


The barometric pressure is 72 kPa or more.
The volumetric efficiency is 30 - 60 %.
The adaptive learning has been completed with
the vane that generates the crankshaft position
signals.
During the engine operation except the shift
change or low speed driving and rapid acceleration and deceleration, also intermittent operation
of air compressor (A/C: within the 3 seconds after
changing to ON from OFF or to OFF from ON).
The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms.

MULTIPORT FUEL INJECTION (MFI)

13A-113

TROUBLESHOOTING

Judgment Criterion
The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified
number (of 7.3 % on more than the two cylinders)
with the engine speed of 200 r/min.
Or
The number of misfiring (that is 1.5 times the
emission standard limit) is beyond the specified
number (of 2 % on more than the two cylinders)
with the engine speed of 1,000 r/min.
PROBABLE CAUSE
Ignition system related part(s) failed
Low compression pressure
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1.Check ignition coil spark.
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Check ignition circuit system (Refer to

STEP 3.Check No.2 injector itself.


Check Injector itself (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace No.2 injector.

STEP 4.Connector check: B-17X engine control


relay connector and B-134 engine-ECU
connector
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

AK300255 AB

CONNECTOR: C-134

Inspection procedure 29 313A).


STEP 2.Check connector: B-02 No.2 injector
connector
Connector: B-02

C-134

B-02 (GR)
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


M

2 1
Harness side connector

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

AK300257 AB
AK300265 AD

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-114

TROUBLESHOOTING

STEP 5.Check harness between B-17X (terminal


No. 1) engine control relay connector and B02(terminal No. 1) No.2 injector connector.

STEP 6. Check harness between B-02 (terminal


No. 2) No.2 injector connector and C-134
(terminal No. 14) engine-ECU connector

CONNECTOR: B-17X
Relay boxs
triangle marks

Connector: B-02

B-17X
B-02 (GR)

3
M

Harness side
connector

2 1
Harness side connector

AK300255 AB

AK300265 AD

CONNECTOR: C-134

Connector: B-02

B-02 (GR)

C-134

2 1
Harness side connector

AK300265 AD

Check power supply line for damage.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Repair.

Harness side connector


AK300257 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 7 .
NO : Repair.

STEP 7. Measure fuel pressure.


Measure fuel pressure (Refer to fuel pressure
test 313A)
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Repair.

Code No. P0303: No. 3 cylinder mis-fire detection system


OPERATION
Refer to P0203 injector circuit 313A.
FUNCTION
If a misfire occurs while the engine is running, the
engine speed changes for an instant.
The engine-ECU checks for such changes in
engine speed.

TROUBLE JUDGMENT
Check Conditions
5 seconds later after the engine has started up.
The engine speed is 500 - 4,500 r/min.
The engine coolant temperature is -10C or
higher.
The intake air temperature is -10C or higher.
The barometric pressure is 72 kPa or more.

MULTIPORT FUEL INJECTION (MFI)

13A-115

TROUBLESHOOTING

The volumetric efficiency is 30 - 60%.


The adaptive learning has been completed with
the vane that generates the crankshaft position
signals.
During the engine operation except the shift
change or low speed driving and rapid acceleration and deceleration, also intermittent operation
of air compressor (A/C: within the 3 seconds after
changing to ON from OFF or to OFF from ON).
The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms.
Judgment Criterion
The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified
number (of 7.3 % on more than the two cylinders)
with the engine speed of 200 r/min.
Or
The number of misfiring (that is 1.5 times the
emission standard limit) is beyond the specified
number (of 2 % on more than the two cylinders)
with the engine speed of 1,000 r/min.

STEP 3.Check No.3 injector itself.


Check Injector itself (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace No.3 injector.

STEP 4.Connector check: B-17X engine control


relay connector, B-134 engine-ECU connector
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

AK300255 AB

CONNECTOR: C-134

PROBABLE CAUSE
Ignition system related part(s) failed
Low compression pressure
Failed engine-ECU

DIAGNOSIS PROCEDURE

C-134

STEP 1.Check ignition coil spark.


Q: Is the check result normal?
YES : Go to Step 2 .
NO : Check ignition circuit system (Refer to

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

Inspection procedure 29 313A).


STEP 2.Connector check: B-04 No.3 injector
connector
Connector: B-04

B-04 (GR)

2 1
Harness side connector

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

AK300265 AE

AK300257 AB

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-116

TROUBLESHOOTING

STEP 5.Check harness between B-17X (terminal


No. 1) engine control relay connector and B-04
(terminal No. 1) No.3 injector connector.

STEP 6. Check harness between B-04 (terminal


No. 2) No.3 injector connector and C-134
(terminal No. 2) engine-ECU connector

CONNECTOR: B-17X
Relay boxs
triangle marks

Connector: B-04

B-17X
B-04 (GR)

3
M

Harness side
connector

2 1
Harness side connector

AK300255 AB

AK300265 AE

CONNECTOR: C-134

Connector: B-04

B-04 (GR)

C-134

2 1
Harness side connector

AK300265 AE

Check power supply line for damage.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Repair.

Harness side connector


AK300257 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 7 .
NO : Repair.

STEP 7. Measure fuel pressure.


Measure fuel pressure (Refer to fuel pressure
test 313A)
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Repair.

Code No. P0304: No. 4 cylinder mis-fire detection system


OPERATION
Refer to P0204 injector circuit 313A.
FUNCTION
If a misfire occurs while the engine is running, the
engine speed changes for an instant.
The engine-ECU checks for such changes in
engine speed.

TROUBLE JUDGMENT
Check Conditions
5 seconds later after the engine has started up.
The engine speed is 500 - 4,500 r/min.
The engine coolant temperature is -10C or
higher.
The intake air temperature is -10C or higher.
The barometric pressure is 72 kPa or more.

MULTIPORT FUEL INJECTION (MFI)

13A-117

TROUBLESHOOTING

The volumetric efficiency is 30 - 60%.


The adaptive learning has been completed with
the vane that generates the crankshaft position
signals.
During the engine operation except the shift
change or low speed driving and rapid acceleration and deceleration, also intermittent operation
of air compressor (A/C: within the 3 seconds after
changing to ON from OFF or to OFF from ON).
The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms.
Judgment Criterion
The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified
number (of 7.3 % on more than the two cylinders)
with the engine speed of 200 r/min.
Or
The number of misfiring (that is 1.5 times the
emission standard limit) is beyond the specified
number (of 2 % on more than the two cylinders)
with the engine speed of 1,000 r/min.

STEP 3.Check No.4 injector itself.


Check Injector itself (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace No.4 injector.

STEP 4.Connector check: B-17X engine control


relay connector and B-134 engine-ECU
connector
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

AK300255 AB

CONNECTOR: C-134

PROBABLE CAUSE
Ignition system related part(s) failed
Low compression pressure
Failed engine-ECU

DIAGNOSIS PROCEDURE
C-134

STEP 1.Check the ignition coil spark.


Q: Is the check result normal?
YES : Go to Step 2 .
NO : Check ignition Circuit System (Refer to

Inspection procedure 29 313A).

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

STEP 2.Connector check: B-05 No.4 injector


connector
Connector: B-05

B-05 (GR)

2 1
Harness side connector

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

AK300265 AF

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-118

TROUBLESHOOTING

STEP 5.Check harness between B-17X (terminal


No. 1) engine control relay connector and B-05
(terminal No. 1) No.4 injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 6. Check harness between B-05 (terminal


No. 2) No.4 injector connector and C-134
(terminal No. 15) engine-ECU connector.
Connector: B-05

B-17X
B-05 (GR)

3
M

Harness side
connector

AK300255 AB

2 1
Harness side connector

AK300265 AF

CONNECTOR: C-134

Connector: B-05

B-05 (GR)

C-134

2 1
Harness side connector

AK300265 AF

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 6 .
NO : Repair.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 7 .
NO : Repair.

STEP 7. Measure fuel pressure.


Measure fuel pressure (Refer to fuel pressure
test 313A)
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-119

TROUBLESHOOTING

Code No. P0325: Detonation Sensor System

Detonation sensor circuit

C-137
Engine-ECU

71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

78
W

B-103
(MU802661)

B
2

1 2

Detonation sensor

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet

O: Orange GR: Gray

AK300273 AB

OPERATION
The sensor signal is inputted to the engine-ECU
(terminal No. 78) from the detonation sensor (terminal No. 1).
FUNCTION
The detonation sensor detects the vibration of the
cylinder block caused by detonation waves, and
inputs a signal to the engine-ECU.
In response to the signal, the engine-ECU provides controls to retard the ignition timing when
the detonation occurs.

TROUBLE JUDGMENT
Check Condition
2 seconds later after the engine has started up.
Judgment Criteria
The change amount of the detonation sensor output voltage (the detonation sensor peak voltage
in every one third a turn of the crankshaft) is
below 0.08 V in 200 consecutive times.

MULTIPORT FUEL INJECTION (MFI)

13A-120

TROUBLESHOOTING

PROBABLE CAUSE
Failed detonation sensor
Open/short circuit in detonation sensor circuit or
loose connector contact
Failed engine-ECU

STEP 2. Measure resistance at B-103 detonation


sensor connector.
Connector: B-103
2 1

DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-103 detonation
sensor connector

Harness side
connector
B-103 (GR)

Connector: B-103
2 1
Harness side
connector
B-103 (GR)

Detonation sensor
Alternator
AK300274 AB

Disconnect connector, and measure at harness


side.
Resistance between terminal No. 2 and earth.
OK: 2 W or less

Detonation sensor
Alternator
AK300274 AB

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Check and repair harness between B-103

(terminal No. 2) detonation sensor


connector and body earth.
Check earthing line for open circuit
and damage.

MULTIPORT FUEL INJECTION (MFI)

13A-121

TROUBLESHOOTING

STEP 3. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 4. Check harness between B-103 (terminal


No. 1) detonation sensor connector and C-137
(terminal No.78) engine-ECU connector.
Connector: B-103
2 1
Harness side
connector
B-103 (GR)

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Repair.

Detonation sensor
Alternator
AK300274 AB

CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for open/short circuit and damage.


Q: Is the check result normal?
YES : Go to Step 5 .
NO : Repair.

STEP 5. Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Go to Step 6 .
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

13A-122

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 6. Replace detonation sensor.


After replacing the detonation sensor, re-check
the trouble symptoms.
Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Check end.

MULTIPORT FUEL INJECTION (MFI)

13A-123

TROUBLESHOOTING

Code No. P0335: Crank Angle Sensor System


Crank angle sensor circuit

Battery

W-B
W-B
3

4
B-17X
1

Engine control relay

R
B-29
(MU802603)

1 2
3

Crank angle sensor

1
B-W
18
J/C(1)
C-16

G-R
17

B-W
40

89
C-137

C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

5V

71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

Engine-ECU
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet

O: Orange GR: Gray

AK300275 AB

13A-124

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

OPERATION
Power is supplied to the crank angle sensor (terminal No. 3) from the engine control relay (terminal No. 1) and is earthed to the engine-ECU
(terminal No. 40) from the crank angle sensor
(terminal No. 1).
A power voltage of 5 V is applied to the crank
angle sensor output terminal (terminal No. 2)
from the engine-ECU (terminal No. 89).
FUNCTION
The crank angle sensor detects the crank angle
(position) and inputs a pulse signal to the engineECU.
In response to the signal, the engine-ECU controls the injector, etc.

DIAGNOSIS PROCEDURE
STEP 1. MUT-II data list
Refer to Data list reference table 313A.
a. Item 22: Crank angle sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-29 crank angle
sensor connector
Connector: B-29

TROUBLE JUDGMENT
Check Condition
Engine in cranking state.
Judgment Criterion
The sensor output voltage remains unchanged
(no pulse signal is inputted) for 2 seconds.

2 1
3
Harness side
connector

B-29 (B)

PROBABLE CAUSE
Failed crank angle sensor
Open/short circuit in crank angle sensor circuit or
loose connector contact
Failed engine-ECU

Crank angle sensor


AK300276 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-125

TROUBLESHOOTING

STEP 3. Measure voltage at B-29 crank angle


sensor connector.

STEP 4. Measure voltage at C-137 engine-ECU


connector.

Connector: B-29

CONNECTOR: C-137

2 1
3
Harness side
connector

B-29 (B)

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: B-29
2 1
3
Harness side
connector

Crank angle sensor


AK300276 AB

B-29 (B)

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 2 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 4 .

Crank angle sensor


AK300276 AB

Measure engine-ECU terminal voltage.


Disconnect B-29 crank angle sensor connector.
Ignition switch: ON
Voltage between terminal No. 89 and earth.
OK: 4.9 - 5.1 V

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Go to Step 6 .

MULTIPORT FUEL INJECTION (MFI)

13A-126

TROUBLESHOOTING

STEP 5. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 6. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

Connector: B-29
2 1
3
Harness side
connector

AK300254 AB

B-29 (B)

Crank angle sensor


AK300276 AB

Q: Is the check result normal?


YES : Check and repair harness between B-29

(terminal No. 2) crank angle sensor


connector and C-137 (terminal No. 89)
engine-ECU connector.
Check output line for open circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-127

TROUBLESHOOTING

STEP 7. Check harness between B-29 (terminal


No. 2) crank angle sensor connector and C-137
(terminal No. 89) engine-ECU connector.

STEP 8. MUT-II data list


Refer to Data list reference table 313A.
a. Item 22: Crank angle sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

Connector: B-29
2 1
3
Harness side
connector

B-29 (B)

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.
STEP 9. Measure voltage at B-29 crank angle
sensor connector.
Connector: B-29
2 1
3
Harness side
connector

B-29 (B)

Crank angle sensor


AK300276 AB

CONNECTOR: C-137

Crank angle sensor


C-137
AK300276 AB

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for short circuit.


Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Go to Step 10 .

MULTIPORT FUEL INJECTION (MFI)

13A-128

TROUBLESHOOTING

STEP 10. Connector check: B-17X engine control


relay connector

Connector: B-29

CONNECTOR: B-17X
Relay boxs
triangle marks

Harness side
connector

STEP 11. Measure resistance at B-29 crank angle


sensor connector.

B-17X
2 1
3
Harness side
connector

B-29 (B)

AK300255 AB

Connector: B-29
2 1
3
Harness side
connector

B-29 (B)

Crank angle sensor


AK300276 AB

Disconnect connector, and measure at harness


side.
Resistance between terminal No. 1 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 14 .
NO : Go to Step 12 .
Crank angle sensor
AK300276 AB

Q: Is the check result normal?


YES : Check and repair harness between B-29

STEP 12. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

(terminal No. 3) crank angle sensor


connector and B-17X (terminal No. 1)
engine control relay connector.
Check power supply line for
open/short circuit.
NO : Repair.

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 13 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-129

TROUBLESHOOTING

STEP 13. Check harness between B-29 (terminal


No. 1) crank angle sensor connector and C-135
(terminal No. 40) engine-ECU connector.

STEP 14. Measure output waveform at B-29 crank


angle sensor connector (Use oscilloscope).
Connector: B-29

Connector: B-29
2 1
3
Harness side
connector

B-29 (B)

2 1
3
Harness side
connector

B-29 (B)

Crank angle sensor


Crank angle sensor
AK300276 AB
AK300276 AB

CONNECTOR: C-135

C-135

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Go to Step 15 .

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

NOTE: Before checking harness, check intermediate


connector C-16, and repair if necessary.
Check earthing line for open circuit and damage.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

Use special tool test harness (MB998478) to connect connector, and measure at pick-up harness.
Engine: Idling
Transmission: Neutral
Voltage between terminal No. 2 and earth.
OK: Waveforms should be displayed on
Inspection procedure using an oscilloscope
(Refer to 313A), its maximum value
should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in
waveform.

MULTIPORT FUEL INJECTION (MFI)

13A-130

TROUBLESHOOTING

STEP 15. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

Connector: B-29

B-17X

Harness side
connector

STEP 16. Check harness between B-29 (terminal


No. 3) crank angle sensor connector and B-17X
(terminal No. 1) engine control relay connector.

2 1
3
Harness side
connector

B-29 (B)

AK300255 AB

Q: Is the check result normal?


YES : Go to Step 16 .
NO : Repair.

Crank angle sensor


AK300276 AB

CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

AK300255 AB

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 17 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-131

TROUBLESHOOTING

STEP 17. Connector check: C-135 and C-137


engine-ECU connectors
CONNECTOR: C-135, C-137

STEP 18. Check harness between B-29 (terminal


No. 2) crank angle sensor connector and C-137
(terminal No. 89) engine-ECU connector.
Connector: B-29
2 1
3
Harness side
connector

B-29 (B)

C-135
C-137

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

C-135 Harness side connector

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

C-137 Harness side connector


AK300277 AB

Q: Is the check result normal?


YES : Go to Step 18 .
NO : Repair.

Crank angle sensor


AK300276 AB

CONNECTOR: C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 19 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-132

TROUBLESHOOTING

STEP 19. Check harness between B-29 (terminal


No. 1) crank angle sensor connector and C-135
(terminal No. 40) engine-ECU connector.

STEP 20. Check the crankshaft sensing blade.

Connector: B-29

Q: Is the check result normal?


YES : Go to Step 21 .
NO : Replace the crankshaft sensing blade.

2 1
3
Harness side
connector

STEP 21: MUT-II data list


Refer to Data list reference table 313A.
a. Item 22: Crank angle sensor

B-29 (B)

Q: Is the check result normal?


YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace crank angle sensor.

Crank angle sensor


AK300276 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

NOTE: Before checking harness, check intermediate


connector C-16, and repair if necessary.
Check earthing line for damage.
Q: Is the check result normal?
YES : Go to Step 20 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-133

TROUBLESHOOTING

Code No. P0340: Camshaft Position Sensor System

Camshaft position sensor circuit

Battery

W-B
W-B
3

4
B-17X

Engine control relay

R
3

B-106
(MU802337)

Camshaft position sensor

1 2 3

1
B-W

19
J/C (1)
C-16

L-Y

17
B-W

40

88

C-135

C-137

31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

5V
Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300278 AB

OPERATION
Power is supplied to the camshaft position sensor
(terminal No. 3) from the engine control relay (terminal No. 1) and is earthed to the engine-ECU
(terminal No. 40) from the camshaft position sensor (terminal No. 1).

A power voltage of 5 V is applied to the camshaft


position sensor output terminal (terminal No. 2)
from the engine-ECU (terminal No. 88).
FUNCTION
The camshaft position sensor detects the top
dead center on the compression stroke of the No.
1 cylinder and inputs a pulse signal to the engineECU.

MULTIPORT FUEL INJECTION (MFI)

13A-134

TROUBLESHOOTING

TROUBLE JUDGMENT

STEP 2. Measure voltage at B-106 camshaft


position sensor connector.

Check Condition
After the engine has started up.

Connector: B-106

Judgment Criterion
The sensor output voltage remains unchanged
(no pulse signal is inputted) for 2 seconds.
PROBABLE CAUSE
Failed camshaft position sensor
Open/short circuit in camshaft position sensor circuit or loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-106 camshaft
position sensor connector
Connector: B-106
3 2 1
Harness side
connector

B-106 (B)

AK300279 AB

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

3 2 1
Harness side
connector

B-106 (B)

AK300279 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Go to Step 3 .

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 3. Connector check: B-17X engine control


relay connector

STEP 4. Measure voltage at B-106 camshaft


position sensor connector.
Connector: B-106

CONNECTOR: B-17X
Relay boxs
triangle marks

13A-135

B-17X
3 2 1
Harness side
connector

B-106 (B)

Harness side
connector

AK300255 AB

Connector: B-106
3 2 1
Harness side
connector

AK300279 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 2 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Go to Step 5 .

B-106 (B)

AK300279 AB

Q: Is the check result normal?


YES : Check and repair harness between B-106

(terminal No. 3) camshaft position sensor


connector and B-17X (terminal No. 1)
engine control relay connector.
Check power supply line for
open/short circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-136

TROUBLESHOOTING

STEP 5. Measure voltage at C-137 engine-ECU


connector.
CONNECTOR: C-137

STEP 6. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

Connector: B-106

Connector: B-106
3 2 1

3 2 1

Harness side
connector

Harness side
connector

B-106 (B)

B-106 (B)

AK300279 AB

Measure engine-ECU terminal voltage.


Disconnect B-106 camshaft position sensor connector.
Ignition switch: ON
Voltage between terminal No. 88 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 7 .

AK300254 AB

AK300279 AB

Q: Is the check result normal?


YES : Check and repair harness between B-106

(terminal No. 2) camshaft position sensor


connector and C-137 (terminal No. 88)
engine-ECU connector.
Check output line for open circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-137

TROUBLESHOOTING

STEP 7. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 8. Check harness between B-106 (terminal


No. 2) camshaft position sensor connector and
C-135 (terminal No. 56) engine-ECU connector.
Connector: B-106
3 2 1
Harness side
connector

C-137

B-106 (B)

AK300279 AB

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

CONNECTOR: C-135

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.
C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Check output line for short circuit.


Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair.

STEP 9. Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

MULTIPORT FUEL INJECTION (MFI)

13A-138

TROUBLESHOOTING

STEP 10. Measure resistance at B-106 camshaft


position sensor connector.
Connector: B-106

STEP 12. Check harness between B-106 (terminal


No. 1) camshaft position sensor connector and
C-135 (terminal No. 40) engine-ECU connector.
Connector: B-106

3 2 1
3 2 1

Harness side
connector

Harness side
connector

B-106 (B)
B-106 (B)
AK300279 AB

Disconnect connector, and measure at harness


side.
Resistance between terminal No. 1 and earth.
OK: 2 W or less

AK300279 AB

CONNECTOR: C-135

Q: Is the check result normal?


YES : Go to Step 13 .
NO : Go to Step 11 .
C-135

STEP 11. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

C-135

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Repair.

NOTE: Before checking harness, check intermediate


connector C-16, and repair if necessary.
Check earthing line for open circuit and damage.

MULTIPORT FUEL INJECTION (MFI)

13A-139

TROUBLESHOOTING

STEP 13. Measure output waveform at B-106


camshaft position sensor connector (Use
oscilloscope).
Connector: B-106

STEP 15. Check harness between B-106 (terminal


No. 3) camshaft position sensor connector and
B-17X (terminal No. 1) engine control relay
connector.
Connector: B-106

3 2 1
3 2 1

Harness side
connector

Harness side
connector

B-106 (B)
B-106 (B)
AK300279 AB

Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness.
Engine: Idling
Transmission: Neutral
Voltage between terminal No. 2 and earth.
OK: Waveforms should be displayed on
Inspection procedure using an oscilloscope
(Refer to 313A), its maximum value
should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in
waveform.
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 14 .

B-17X

Harness side
connector

Q: Is the check result normal?


YES : Go to Step 15 .
NO : Repair.

Relay boxs
triangle marks

B-17X

Harness side
connector

Q: Is the check result normal?


YES : Go to Step 16 .
NO : Repair.

CONNECTOR: B-17X

CONNECTOR: B-17X

AK300255 AB

Check power supply line for damage.

STEP 14. Connector check: B-17X engine control


relay connector.

Relay boxs
triangle marks

AK300279 AB

AK300255 AB

MULTIPORT FUEL INJECTION (MFI)

13A-140

TROUBLESHOOTING

STEP 16. Connector check: C-135 and C-137


engine-ECU connectors
CONNECTOR: C-135, C-137

STEP 17. Check harness between B-106 (terminal


No. 2) camshaft position sensor connector and
C-137 (terminal No. 88) engine-ECU connector.
Connector: B-106
3 2 1
Harness side
connector

C-135
C-137

B-106 (B)

AK300279 AB

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

C-135 Harness side connector

CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

C-137 Harness side connector


C-137

AK300277 AB

Q: Is the check result normal?


YES : Go to Step 17 .
NO : Repair.

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 18 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 18. Check harness between B-106 (terminal


No. 1) camshaft position sensor connector and
C-135 (terminal No. 40) engine-ECU connector.
Connector: B-106

13A-141

STEP 19. Check camshaft position sensing


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

3 2 1
Harness side
connector

Q: Does trouble symptom persist?


YES : Replace camshaft position sensor.
NO : Intermittent malfunction (Refer to GROUP

B-106 (B)

AK300279 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

NOTE: Before checking harness, check intermediate


connector C-16, and repair if necessary.
Check earthing line for damage.
Q: Is the check result normal?
YES : Go to Step 19 .
NO : Repair.

STEP 20. Check the trouble symptoms.

00 - How to Use
Troubleshooting/Inspection Service Points
300).

MULTIPORT FUEL INJECTION (MFI)

13A-142

TROUBLESHOOTING

Code No. P0403: EGR Control Solenoid Valve System

EGR control solenoid valve circuit

Battery

W-B
W-B
4

B-17X
1

Engine control relay

1
B-102
1 2

EGR control solenoid valve


2

76
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet

O: Orange GR: Gray

AK300280 AB

OPERATION
Power is supplied to the EGR control solenoid
valve (terminal No. 1) from the engine control
relay (terminal No. 1).

The engine-ECU (terminal No. 6) makes the


power transistor in the unit be in "ON", and that
makes currents go on the EGR control solenoid
valve (terminal No. 2).

MULTIPORT FUEL INJECTION (MFI)

13A-143

TROUBLESHOOTING

FUNCTION
In response to the signal from the engine-ECU,
the EGR control solenoid valve controls the operation of the EGR valve.

STEP 3. Measure resistance at B-102 EGR


control solenoid valve connector.
Connector: B-102

2 1
Harness side
connector

TROUBLE JUDGMENT
Check Conditions
Except the engine stalling
The battery voltage is 10 - 16 V.

B-102 (BR)

Judgment Criteria
If the off surge voltage from the motor coil is not
generated when the EGR valve control motor is
driven.
PROBABLE CAUSE
Failed EGR control solenoid valve
Open/short circuit in EGR control solenoid valve
circuit or loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II actuator test
Refer to Actuator test reference table 313A.
a. Item 10: EGR control solenoid valve
OK: Operating sound can be heard and the
valve vibrates.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-102 EGR control
solenoid valve connector
Connector: B-102

2 1
Harness side
connector

B-102 (BR)

AK300281 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

AK300281 AB

Disconnect connector, and measure at solenoid


valve side.
Resistance between terminal No. 1 and No. 2.
OK: 29 - 35 W (at 20C)
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace EGR control solenoid valve.

STEP 4. Measure voltage at B-102 EGR control


solenoid valve connector.
Connector: B-102

2 1
Harness side
connector

B-102 (BR)

AK300281 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 5 .

MULTIPORT FUEL INJECTION (MFI)

13A-144

TROUBLESHOOTING

STEP 5. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 6. Measure voltage at C-134 engine-ECU


connector.
CONNECTOR: C-134

B-17X

C-134

Harness side
connector

AK300255 AB

Connector: B-102

2 1
Harness side
connector

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

B-102 (BR)

AK300281 AB

Q: Is the check result normal?


YES : Check and repair harness between B-102

(terminal No. 1) EGR control solenoid valve


connector and B-17X (terminal No. 1)
engine control relay connector.
Check power supply line for
open/short circuit.
NO : Repair.

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 6 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 7 .

MULTIPORT FUEL INJECTION (MFI)

13A-145

TROUBLESHOOTING

STEP 7. Connector check: C-134 engine-ECU


connector

STEP 8. Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

Harness side connector


AK300257 AB

Connector: B-102

2 1
Harness side
connector

B-102 (BR)

AK300281 AB

Q: Is the check result normal?


YES : Check and repair harness between B-102

(terminal No. 2) EGR control solenoid valve


connector and C-134 (terminal No. 6)
engine-ECU connector.
Check output line for open/short
circuit.
NO : Repair.

AK300257 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-146

TROUBLESHOOTING

STEP 9. Check harness between B-102 (terminal


No. 2) EGR control solenoid valve connector and
C-134 (terminal No. 6) engine-ECU connector.
Connector: B-102

2 1

STEP 10. Check harness between B-102 (terminal


No. 1) EGR control solenoid valve connector and
B-17X (terminal No. 1) engine control relay
connector.
Connector: B-102

2 1

Harness side
connector

Harness side
connector

B-102 (BR)
B-102 (BR)
AK300281 AB
AK300281 AB

CONNECTOR: C-134
CONNECTOR: B-17X
Relay boxs
triangle marks

C-134

B-17X

Harness side
connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

AK300255 AB

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 11 .
NO : Repair.

STEP 11. MUT-II actuator test


Refer to actuator test reference table list 313A
.
Item 10: EGR control solenoid valve
OK: Operating sound can be heard and the
valve vibrates.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-147

Code No. P0420: Catalyst malfunction


FUNCTION
The signal from the heated oxygen sensor (rear)
differs from the heated oxygen sensor (front).
That is because the catalytic converter purifies
exhaust gas. When the catalytic converter has
deteriorated, the signal from the heated oxygen
sensor (front) becomes similar to the heated oxygen sensor (rear).
The engine-ECU compares the output of the front
and rear heated oxygen sensor signals.

STEP 2.MUT-II data list


Refer to Data list reference table 313A.
a. Item 11: Oxygen sensor (front)
b. Item 59: Oxygen sensor (rear)
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an


abnormal data valve (Refer to Inspection
Chart for Diagnosis Codes 313A).

TROUBLE JUDGMENT
Check Conditions
Engine speed: 3,000 r/min or less.
During the driving.
During the air-fuel ratio feedback control.
Judgment Criterion
When the output frequency ratio of the oxygen
sensor (rear) vs. The oxygen sensor (front) is 0.8
or more on the average for 12 seconds.
PROBABLE CAUSE
Catalytic converter deteriorated
Failed oxygen sensor (front)
Failed oxygen sensor (rear)
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1.Check for leakage of exhaust emission
from exhaust manifold.
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Repair.

STEP 3.MUT-II data list


a. Item 11: Oxygen sensor (front)
OK: 0 - 0.4 and 0.6 - 1.0 volt should alternate
15 times or more within 10 seconds (engine
speed at 2,000 r/min).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace the oxygen sensor (front).

STEP 4.Replace the oxygen sensor (rear).


After replacing the oxygen sensor (rear), recheck the trouble symptoms.
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Check end.

STEP 5.Replace the catalytic converter.


After replacing the catalytic converter, re-check
the trouble symptoms.
Q: Is the check result normal?
YES : Replacing engine-ECU.
NO : Check end.

MULTIPORT FUEL INJECTION (MFI)

13A-148

TROUBLESHOOTING

Code No. P0443: Purge Control Solenoid Valve System


Purge control solenoid valve circuit

Battery

W-B
W-B
4

B-17X
1

Engine control relay

B-101
(MU802779)

Purge control solenoid valve

1 2
1

BR

9
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet

O: Orange GR: Gray

AK300282 AB

OPERATION
Power is supplied to the purge control solenoid
valve (terminal No. 2) from the engine control
relay (terminal No. 1).

The engine-ECU (terminal No. 9) makes the


power transistor in the unit be in "ON" position,
and that makes currents go on the purge control
solenoid valve (terminal No. 1).

MULTIPORT FUEL INJECTION (MFI)

13A-149

TROUBLESHOOTING

FUNCTION
In response to a signal from the engine-ECU, the
purge control solenoid valve controls the flow rate
of the purge air to be introduced into the surge
tank.

STEP 3: Measure resistance at B-101 purge


control solenoid valve connector.
Connector: B-101
2 1
Harness side
connector

TROUBLE JUDGMENT
Check Conditions
Ignition switch: ON
The battery voltage is 10 V or more.
Judgment Criteria
The surge voltage (system voltage + 2 V) of solenoid coil is not detected when the purge control
solenoid valve is turned in OFF position from ON.
The battery voltage is 10 V or more.

B-101 (B)

AK300283AB

Disconnect connector, and measure at solenoid


valve side.
Resistance between terminal No. 1 and No. 2.
OK: 30 - 34 W (at 20C)

PROBABLE CAUSE
Failed purge control solenoid valve
Open/short circuit in purge control solenoid value
circuit or loose connector contact
Failed engine-ECU

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Replace purge control solenoid valve.

DIAGNOSIS PROCEDURE

STEP 4. Measure voltage at B-101 purge control


solenoid valve connector.

STEP 1. MUT-II actuator test


Item 08: Purge control solenoid valve
OK: Operating sound can be heard and the
valve vibrates
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-101 purge control
solenoid valve connector
Connector: B-101
2 1
Harness side
connector

B-101 (B)

AK300283AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

Connector: B-101
2 1
Harness side
connector

B-101 (B)

AK300283AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 2 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 5 .

MULTIPORT FUEL INJECTION (MFI)

13A-150

TROUBLESHOOTING

STEP 5. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 6. Measure voltage at C-134 engine-ECU


connector.
CONNECTOR: C-134

B-17X

C-134

Harness side
connector

AK300255 AB

Connector: B-101
2 1
Harness side
connector

B-101 (B)

AK300283AB

Q: Is the check result normal?


YES : Check and repair harness between B-101

(terminal No. 2) purge control solenoid valve


connector and B-17X (terminal No. 1)
engine control relay connector.
Check power line for open/short
circuit.
NO : Repair.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 9 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 7 .

MULTIPORT FUEL INJECTION (MFI)

13A-151

TROUBLESHOOTING

STEP 7. Connector check: C-134 engine-ECU


connector

STEP 8. Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

Harness side connector


AK300257 AB

Connector: B-101
2 1
Harness side
connector

B-101 (B)

AK300283AB

Q: Is the check result normal?


YES : Check and repair harness between B-101

(terminal No. 1) purge control solenoid valve


connector and C-134 (terminal No. 9)
engine-ECU connector.
Check output line for open and short
circuit.
NO : Repair.

AK300257 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-152

TROUBLESHOOTING

STEP 9. Check harness between B-101 (terminal


No. 1) purge control solenoid valve connector
and C-134 (terminal No. 9) engine-ECU
connector.
Connector: B-101

STEP 10. Check harness between B-101 (terminal


No. 2) purge control solenoid valve connector
and B-17X (terminal No. 1) engine control relay
connector.
Connector: B-101

2 1

2 1

Harness side
connector

Harness side
connector

B-101 (B)

B-101 (B)

AK300283AB

AK300283AB

CONNECTOR: B-17X

CONNECTOR: C-134

Relay boxs
triangle marks

C-134

B-17X

Harness side
connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

AK300255 AB

Check power line for damage.


Q: Is the check result normal?
YES : Go to Step 11 .
NO : Repair.

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

STEP 11. MUT-II actuator test


Item 08: purge control solenoid valve
OK: Operating sound can be heard and the
valve vibrates
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

MULTIPORT FUEL INJECTION (MFI)

13A-153

TROUBLESHOOTING

Code No. P0500: Vehicle speed sensor system

Vehicle speed sensor circuit

Ignition switch

Engine-ECU
C-137

C-303
1 2 3
4 5 6

LOCK

71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

ST
ACC
IG1 IG2

2
L-B

86

C-203
6
W-L
2 J/B
7.5A
C-202
11

3
J/C (1)
C-16

Meter and gauge

B-W

2
C-106
3
W-L

B-W
3

1
B-115
1 2 3

Vehicle speed sensor

2
B
8
J/C (2)
C-17
B

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet

O: Orange GR: Gray

AK300284 AB

OPERATION
A power voltage of 5 V is applied to the vehicle
speed sensor (terminal No. 3) from the engineECU (terminal No. 86).

FUNCTION
The vehicle speed sensor converts the vehicle
speed to the voltage, and then input it into the
engine-ECU

13A-154

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

TROUBLE JUDGMENT
Check Conditions
2 seconds later after the engine has started up.
Engine speed: 2,000 r/min or more.
Under the high load operation (The volumetric
efficiency is 40 - 75 %).
Judgment Criterion
The sensor output voltage remains unchanged
(no pulse signal is inputted) for 2 seconds.
PROBABLE CAUSE
Failed Vehicle speed sensor
Open/short circuit in vehicle speed sensor circuit
or loose connector contact
Failed engine-ECU

STEP 2.MUT-II data list


Refer to Data list reference table 313A.
a. Item 24: Vehicle speed sensor
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection


Service Points 300).
STEP 3.Check connector: C-137 engine-ECU
connector
CONNECTOR: C-137

DIAGNOSIS PROCEDURE
STEP 1.Check the speedometer
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Check the speedometer (Refer to GROUP

54A -Combination Meter Assembly and


Vehicle speed sensor - On-vehicle Service
354A).

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 4.Check harness between C-137 (terminal


No. 86) engine-ECU connector and B-115
(terminal No. 3) Vehicle speed sensor connector.
CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

CONNECTOR: B-115
3 2 1
Harness side
connector

AK300285AB

NOTE: Before checking harness, check intermediate


connector C-16, and repair if necessary.
Check output line for open circuit and damage.
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Repair.

STEP 5.Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replacing engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use Troubleshooting/Inspection


Service Points 300).

C-137

B-115 (B)

13A-155

MULTIPORT FUEL INJECTION (MFI)

13A-156

TROUBLESHOOTING

Code No. P0505: Idle Speed Control Servo System

Idle speed control servo circuit


Battery

W-B
W-B
3

B-17X
1

Engine control relay

R
2

B-105
1 2 3
4 5 6

Idle speed control servo

L-Y

Y-L

17

G-Y

18

C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300286 AB

MULTIPORT FUEL INJECTION (MFI)

13A-157

TROUBLESHOOTING

OPERATION
The power is supplied to the idle speed control
servo (terminal No. 2 and No. 5) from the engine
control relay (terminal No. 1).
The engine-ECU (terminal No. 4, No. 5, No. 17
and No. 18) makes power transistor in the unit be
in "ON" position in order, and that makes currents
go on the idle speed control servo (terminal No.
1, No. 3, No. 4 and No. 6).

Judgment Criteria
The actual idle speed is higher than the target
idle speed by 100 r/min or more for 10 seconds.

FUNCTION
The idle speed control servo opens and closes
the servo valve in response to a signal from the
engine-ECU to control the intake air flow rate during idling.

DIAGNOSIS PROCEDURE

TROUBLE JUDGMENT
Check conditions
The vehicle speed has reached 1.5 km/h or more
at least once.
During the closed-loop idle speed control.
Judgment Criteria
The actual idle speed is higher than the target
idle speed by 300 r/min or more for 10 seconds.
Check conditions
The vehicle speed has reached 1.5 km/h or more
at least once.
During the closed-loop idle speed control.
The highest ambient temperature at the last drive
is 45 C or less.
The engine coolant temperature is approximately.
82C or higher.
The battery voltage is 10 V or more.
The intake air temperature is -10C or higher.
Judgment Criteria
The actual idle speed is higher than the target
idle speed by 200 r/min or more for 10 seconds.
Check conditions
During the closed-loop idle speed control.
The engine coolant temperature is approximately.
82C or higher.
The battery voltage is 10 V or more.
The power steering switch is in OFF position.
The charging efficiency is 40 % or less.
The intake air temperature is -10C or higher.

PROBABLE CAUSE
Failed idle speed control servo
Open/short circuit in idle speed control servo circuit or loose connector contact
Failed engine-ECU

STEP 1. MUT-II Data List


Refer to Data list reference table 313A.
a. Item 45: Idle speed control position
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-105 idle speed
control servo connector
Connector: B-105
3

2 1

6 5 4
Harness side
connector

B-105 (B)
AK300287 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Check idle speed control servo itself.


Check idle speed control servo itself (Refer to
313A).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace idle speed control servo.

MULTIPORT FUEL INJECTION (MFI)

13A-158

TROUBLESHOOTING

STEP 4. Measure voltage at B-105 idle speed


control servo connector.
Connector: B-105

STEP 5. Check connector: B-17X engine control


relay connector
CONNECTOR: B-17X

2 1

6 5 4
Harness side
connector

B-105 (B)
AK300287 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 2 and earth, also
between terminal No. 5 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 5 .

Relay boxs
triangle marks

B-17X

Harness side
connector

AK300255 AB

Connector: B-105
3

2 1

6 5 4
Harness side
connector

B-105 (B)
AK300287 AB

Q: Is the check result normal?


YES : Check and repair harness between B-105

(terminal No. 2 or No. 5) idle speed control


servo connector and B-17X (terminal No. 1)
engine control relay connector.
Check power supply line for
open/short circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-159

TROUBLESHOOTING

STEP 6. Measure voltage at C-134 engine-ECU


connector.
CONNECTOR: C-134

Check power supply line for


open/short circuit.
STEP 7. Connector check: C-134 engine-ECU
connector
CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

Connector: B-105

AK300257 AB

2 1

6 5 4
Harness side
connector

B-105 (B)
AK300287 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 4 and earth,
between terminal No. 5 and earth, between terminal No. 17 and earth, also voltage between terminal No. 18 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Check and repair harness between B-105

idle speed control servo and C-134 engineECU.


1. Harness between idle speed control
servo terminal No. 1 and engineECU connector terminal No. 4
2. Harness between idle speed control
servo terminal No. 3 and engineECU connector terminal No. 17
3. Harness between idle speed control
servo terminal No. 4 and engineECU connector terminal No. 5
4. Harness between idle speed control
servo terminal No. 6 and engineECU connector terminal No. 18

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-160

TROUBLESHOOTING

STEP 8. Check harness between B-105 idle


speed control servo and C-134 engine-ECU.
Connector: B-105
3

2 1

STEP 9. Check harness between B-105 (terminal


No. 2 or No. 5) idle speed control servo
connector and B-17X (terminal No. 1) engine
control relay connector.
Connector: B-105

6 5 4
Harness side
connector

2 1

6 5 4
Harness side
connector

B-105 (B)
AK300287 AB

B-105 (B)
CONNECTOR: C-134

AK300287 AB

CONNECTOR: B-17X
Relay boxs
triangle marks

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side
connector

AK300255 AB

Check power supply line for damage.

Harness side connector


AK300257 AB

1. Harness between idle speed control servo terminal No. 1 and engine-ECU connector terminal
No. 4
2. Harness between idle speed control servo terminal No. 3 and engine-ECU connector terminal
No. 17
3. Harness between idle speed control servo terminal No. 4 and engine-ECU connector terminal
No. 5
4. Harness between idle speed control servo terminal No. 6 and engine-ECU connector terminal
No. 18
Check output line for damage.
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair.

B-17X

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Repair.

STEP 10. MUT-II Data List


Refer to Data list reference table 313A.
a. Item 45: Idle speed control position
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-161

Code No. P0551: Power Steering Fluid Pressure Switch System

Power steering pressure switch

C-135
Engine-ECU

31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

37

B-28
(MU801211)

1
Power steering pressure switch

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300288 AB

CONDITION
The battery voltage is applied to the power steering fluid pressure switch (terminal No. 1) from the
engine-ECU (terminal No. 37).
FUNCTION
It is detected whether a load is applied on the
power steering fluid pump by steering or not, and
the signal is inputted to the engine-ECU. When
the power steering fluid pressure switch "ON" signal (a large load on the power steering fluid
pump) is inputted, the engine-ECU provides the
idle-up control.
TROUBLE JUDGMENT
Check Conditions
The intake air temperature is -10C or higher.

The engine coolant temperature is approximately


30C or higher.
Repeat, 10 times or more, the *1 running and
stop also *2 running.
*1 running: engine speed of 2,500 r/min or more
(Vehicle speed of 50 km/h or more).
*2 running: Vehicle speed of 1.5 km/h or less.
Judgment Criteria
The power steering pressure switch remains in
ON position.
PROBABLE CAUSE
Failed power steering fluid pressure switch
Open/short circuit in power steering fluid pressure switch circuit or loose connector contact
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-162

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3. Measure voltage at C-135 engine-ECU


connector.

STEP 1. Connector check: B-28 power steering


fluid pressure switch connector

CONNECTOR: C-135

CONNECTOR: B-28

C-135

B-28 (B)
1
Harness side
connector

AK300289 AB

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

AK300256 AB

STEP 2. Measure voltage at B-28 power steering


fluid pressure switch connector.

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Go to Step 5 .

CONNECTOR: B-28

B-28 (B)
1
Harness side
connector

AK300289 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 3 .

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 37 and earth.
OK: System voltage

MULTIPORT FUEL INJECTION (MFI)

13A-163

TROUBLESHOOTING

STEP 4. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

STEP 5. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Repair.

CONNECTOR: B-28

B-28 (B)
1
Harness side
connector

AK300256 AB

AK300289 AB

Q: Is the check result normal?


YES : Check and repair harness between B-28

(terminal No. 1) power steering fluid


pressure switch connector and C-135
(terminal No. 37) engine-ECU connector.
Check output line for open circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-164

TROUBLESHOOTING

STEP 6. Check harness between B-28 (terminal


No. 1) power steering fluid pressure switch
connector and C-135 (terminal No. 37) engineECU connector.

STEP 8. Measure voltage at C-135 engine-ECU


connector.
CONNECTOR: C-135

CONNECTOR: B-28

B-28 (B)

C-135

1
Harness side
connector

AK300289 AB

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


CONNECTOR: C-135
AK300256 AB

C-135

Measure engine-ECU terminal voltage.


Engine: Idling
Voltage between terminal No. 37 and earth.
OK:
System voltage (Steering wheel: Stationary)
1 V or less (Steering wheel: Turned)
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Go to Step 9 .

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Check output line for short circuit.


Q: Is the check result normal?
YES : Go to Step 7 .
NO : Repair.

STEP 9. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

STEP 7. MUT-II Data List


Refer to Data list reference table 313A.
a. Item 27: Power steering fluid pressure switch

C-135

Q: Is the check result normal?


YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-165

TROUBLESHOOTING

STEP 10. Check harness between B-28 (terminal


No. 1) power steering fluid pressure switch
connector and C-135 (terminal No. 37) engineECU connector.

STEP 11. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

CONNECTOR: B-28

B-28 (B)

C-135

1
Harness side
connector

AK300289 AB

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


CONNECTOR: C-135
AK300256 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.
C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Check output line for damage.


Q: Is the check result normal?
YES : Replace power steering fluid pressure

switch.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-166

TROUBLESHOOTING

Code No. P0622: Alternator FR Terminal System

Alternator circuit

C-135
Engine-ECU

31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

41

Y-B

B-19
1

Y-B

B-30
(MU802046)
1 2 3 4

IC Voltage
regulator

Alternator

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet

O: Orange GR: Gray

AK300290 AB

OPERATION
The energized state of the alternator field coil is
inputted from the alternator (terminal No. 4) to the
engine-ECU (terminal No. 41).
FUNCTION
A signal of the power supply duty ratio for the
alternator field coil is inputted to the engine-ECU.
In response to the signal, the engine-ECU
detects the alternator output current and controls
the idling speed according to the output current
(electric load).

TROUBLE JUDGMENT
Check Condition
Engine speed is 50 r/min or more.
Judgment Criterion
Input voltage from alternator FR terminal is the
system voltage or more for 20 seconds.
PROBABLE CAUSE
Alternator FR terminal circuit open circuited
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-167

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3. Connector check: C-135 engine-ECU


connector

STEP 1. Connector check: B-19 intermediate


connector

CONNECTOR: B-19

CONNECTOR: B-19
B-19 (B)
B-19 (B)

Female side
connector

3 2 1
6 5 4
Female side
connector

3 2 1
6 5 4

AK300294 AB

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

STEP 2. Measure voltage at B-19 intermediate


connector.

AK300294 AB

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Repair.

STEP 4. Check harness between B-19 (terminal


No. 1) intermediate connector and C-135
(terminal No. 41) engine-ECU connector.
CONNECTOR: B-19

CONNECTOR: B-19
B-19 (B)
B-19 (B)
1 2 3
4 5 6

1 2 3
4 5 6
Male side
connector

Male side
connector
AK300295 AB

Disconnect connector, and measure at male connector side.


Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage

AK300295 AB

CONNECTOR: C-135

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Go to Step 3 .

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Check output line for short circuit.


Q: Is the check result normal?
YES : Go to Step 5 .
NO : Repair.

13A-168

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 5. Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
STEP 6. Measure voltage at B-19 intermediate
connector.

B-19 (B)

3 2 1
6 5 4

B-30 (GR)

4 3 2 1
AK300296 AB

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.

STEP 8. Check harness between B-30 (terminal


No. 4) alternator connector and B-19 (terminal
No. 1) intermediate connector.
AK300294 AB

Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 7 .

CONNECTOR: B-30

Harness side
connector

CONNECTOR: B-19

Female side
connector

STEP 7. Connector check: B-30 alternator


connector

CONNECTOR: B-30

B-30 (GR)

4 3 2 1
Harness side
connector

AK300296 AB

CONNECTOR: B-19

B-19 (B)

3 2 1
6 5 4
Female side
connector

AK300294 AB

Check output line for short circuit.


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

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 9. Measure voltage at B-19 intermediate


connector.
CONNECTOR: B-19

13A-169

STEP 11. Check harness between B-30 (terminal


No. 4) alternator connector and B-19 (terminal
No. 1) intermediate connector pin No. 1.
CONNECTOR: B-30

B-19 (B)
B-30 (GR)
3 2 1
6 5 4
Female side
connector

4 3 2 1
AK300294 AB

Use special tool test harness (MB991658) to connect connector, and measure at pick-up harness.
Engine: Idle after warm-up
Transmission: Neutral
Radiator fan: Inactive
Voltage between terminal No. 1 and earth.
OK: Switching the headlamps to ON from
OFF causes the voltage to fall.
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Go to Step 10 .

Harness side
connector
CONNECTOR: B-19

B-19 (B)

3 2 1
6 5 4
Female side
connector

Check output line for damage.


STEP 10. Connector check: B-30 alternator
connector
CONNECTOR: B-30

B-30 (GR)

4 3 2 1
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Repair.

AK300296 AB

AK300296 AB

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Repair.

AK300294 AB

MULTIPORT FUEL INJECTION (MFI)

13A-170

TROUBLESHOOTING

STEP 12. Check harness between B-19 (terminal


No. 1) intermediate connector and C-135
(terminal No. 41) engine-ECU connector.
CONNECTOR: B-19

Q: Same symptoms regenerated?


YES : Replace alternator.
NO : Intermittent malfunction (Refer to Group 00

- How to Use troubleshooting/Inspection


Service Points 300).
B-19 (B)

1 2 3
4 5 6
Male side
connector

AK300295 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Check output line for damage.


Q: Is the check result normal?
YES : Go to Step 13 .
NO : Repair.

STEP 13. Check trouble symptom.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-171

Code No. P1603: Battery Backup Line System

Battery backup circuit


Battey

9
20A

Relay box

W-B

A-14
5

W-B

80
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

Battery
backup

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet

O: Orange GR: Gray

AK300297 AB

OPERATION
Power is directly supplied to the engine-ECU (terminal No. 80) from the battery.

TROUBLE JUDGMENT

FUNCTION
The engine-ECU is check the open circuit of battery backup line.

Judgment Criterion
The battery backup line voltage 6 V or less.

Check Condition
Ignition switch: ON

PROBABLE CAUSE
Open/short circuit in battery backup line circuit or
loose connector contact
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-172

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3. Connector check: C-137 engine-ECU


connector

STEP 1 MUT-II self-diag code


Temporarily place the ignition switch in "LOCK"
(OFF) position, and 10 seconds after that, place it
in "ON" position again.

CONNECTOR: C-137

Q: Is the diagnosis code P1603 set?


YES : Go to Step 2 .
NO : Intermittent malfunction (Refer to GROUP

00 - How to use Troubleshooting/Inspection


Service Points 300).
STEP 2. Measure voltage at C-137 engine-ECU
connector.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

CONNECTOR: C-137
AK300254 AB

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Repair.

STEP 4. Check the trouble symptoms.

C-137

Q: Does trouble symptom persist?


YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

00 - How to Use
Troubleshooting/Inspection Service
Points300).

Harness side connector


AK300254 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 80 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Check intermediate connector A-14, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between battery and C-137
(terminal No. 80) engine-ECU connector.
Check power supply line for
open/short circuit.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-173

Code No. P1610: Immobilizer System

Immobilizer-ECU circuit

Signal
transmission
circuit

C-304-1

Immobilizer-ECU

1
2
3 4 5 6 7

C-304
(MU801547)

V
11

C-104

V
51
C-136
51 52 53 54 55 56
57 58 59 60 61 62

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300298 AB

OPERATION
The signals are sent and received between
engine-ECU (terminal No. 51) and immobilizerECU (terminal No. 7).
FUNCTION
Engine-ECU sends or receives the control signals to or from immobilizer-ECU to certify the
ignition key.
NOTE: .
If the registered ignition keys are close each
other when starting the engine, radio interference may cause this code to be displayed.
This code may be displayed when registering
the key encrypted code.

TROUBLE JUDGMENT
Check Condition
Ignition switch: ON
Judgment Criterion
Improper communication problems between the
engine-ECU and the immobilizer-ECU are
detected.
PROBABLE CAUSE
Open/short circuit in immobilizer system circuit or
loose connector contact
Failed immobilizer-ECU
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-174

TROUBLESHOOTING

DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-304 immobilizerECU connector and C-136 engine-ECU connector

STEP 2. Check harness between C-304 (terminal


No. 3) immobilizer-ECU connector and C-136
(terminal No. 51) engine-ECU connector.
Connector: C-304
Harness side
connector

Connector: C-304
Harness side
connector

1
2
76543

1
2
76543

C-304
C-304
AK203418 AC
AK203418 AC

CONNECTOR: C-136

CONNECTOR: C-136

C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57

56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector

Harness side connector

AK300268 AB
AK300268 AB

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

NOTE: Before checking harness, check intermediate


connector C-104, and repair if necessary.
Check output line for open/short circuit and damage.
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Repair.

STEP 3. Check the trouble symptoms.


Q: Is the check result normal?
YES : Go to Step 4 .
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
STEP 4. After replacing the immobilizer-ECU, recheck the trouble symptoms.
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Check end.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-175

INSPECTION CHART FOR TROUBLE SYMPTOMS


M1131151500522

Items

Trouble symptom

Inspection
procedure
No.

Communication
with MUT-II is
impossible

Communication with all system is not possible

Communication with engine-ECU only is not possible

Engine warning
lamp

The engine warning lamp does not illuminate right after the ignition switch 3
is turned the "ON" position
The engine warning lamp remains illuminating and never goes out

Starting

Starting impossible
(No initial combustion)

The starter is impossible to operate. 5

Starting impossible
(Starter operative but no initial
combustion)

The starter is operative and cranks


the engine, but none of initial
combustion is in the cylinders and
the engine is not started.

Starting impossible
The initial combustion occurs, but
(Initial combustion but no complete the engine stalls soon due to the
combustion)
incomplete combustion.

Improper idling

Engine stalls

Improper starting
(Long time to start)

It is long cranking to start the engine.

Unstable idling
(Rough idling, hunting)

The engine speed is not constant


8
and changeable during the idling.
Usually, the judgment can be based
on the movement of the tachometer
pointer, also on the vibration
transmitted to the steering wheel, sift
lever, vehicle body and so on.

Improper idling speed

The proper idling speed is not


satisfied.

Engine stalled during idling


(Die out)

The engine stalls during the idling in


no relation to the vehicle movement.

The engine stalls when starting the The engine stalls during the
car
operation, or when the accelerator
(Pass out)
pedal is depressed from the idling.
The engine stalls when
decelerating

The engine stalls at the deceleration. 10

MULTIPORT FUEL INJECTION (MFI)

13A-176

TROUBLESHOOTING

Items

Trouble symptom

Inspection
procedure
No.

Driving

Engine does not revolve up

The engine speed is not higher when 11


the accelerator pedal is depressed.

Hesitation, sag

The response of vehicle speed


12
(engine speed) is delayed when the
accelerator pedal is depressed, or
the vehicle speed (engine speed) is
temporarily dropped during the
acceleration. These phenomena are
called "hesitation" and the serious
hesitation is called "sag".

Poor acceleration

The engine cannot obtain the


acceleration corresponding to the
degree of throttle opening although
the engine is smooth at the constant
speed.

Stumble

The engine speed increase is


delayed when the accelerator pedal
is initially depressed at the starting.

Surge

The vehicle body is repeated to


vibrate jollity in the forward and
backward directions at the constant
speed or acceleration.

The feeling of impact or vibration


when accelerating

The large impact feeling occurs at


the acceleration.

13

The feeling of impact or vibration


when decelerating

The large impact feeling occurs at


the deceleration.

14

Knocking

Sharp sound like a hammer striking


on the cylinder walls during the
driving can be heard and wrongly
affects the driving.

15

Ignition timing offset

The basic ignition timing is deviated


from the datum value.

16

Stopping

Run on (Dieseling)

The engine continues to run after the 17


ignition switch is in "LOCK (OFF)"
position.

Exhaust gas

Odor, white smoke, black smoke,


high-concentration CO/HC during
idling

The exhaust gas is extremely rank


odor, white smoke or black smoke.
The concentration of CO & HC is
high during the idling.

18

Charging
performance

Battery rundown

The battery is soon rundown or the


charging ability of battery is small.

19

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-177

Items

Trouble symptom

Cooling
performance

Overheating

The temperature of engine cooling


water is extremely high.

20

Abnormal rotation of fan Motor

The fan motor is abnormally rotated


when the ignition switch is in "ON"
position in no relation to the engine
cooling water temperature.

21

Poor A/C Performance

The temperature of air cooling from


A/C is not efficient or very far from
the target temperature.

22

A/C performance

Inspection
procedure
No.

PROBLEM SYMPTOMS TABLE


Inspection Trouble symptom
procedure
No.

Reference
page

Communication with all system is not possible

313A

Communication with engine-ECU only is not possible

313A

The engine warning lamp does not illuminate right after the ignition switch is
turned the "ON" position

313A

The engine warning lamp remains illuminating and never goes out

313A

Starting impossible (No initial combustion)

313A

Starting impossible (Starter operative but no initial combustion)

313A

Starting impossible (Initial combustion but no complete combustion)

313A

Starting impossible (Long time to start)


8

Unstable idling (Rough idling, hunting)

313A

Improper idling speed (Too high or too low)


Engine stalls during idling (Die out)
9

The engine stalls when starting the car (pass out)

313A

10

The engine stalls when decelerating

313A

11

Engine does not revolve up

313A

12

Hesitation, sag

313A

Poor acceleration
Stumble
Surge
13

The feeling of impact or vibration when accelerating

313A

14

The feeling of impact or vibration when decelerating

313A

15

Knocking

313A

16

Ignition timing offset

313A

17

Run on (Dieseling)

313A

18

Odor, white smoke, black smoke, high-concentration CO/HC during idling

313A

19

Battery rundown

313A

20

Overheating

313A

MULTIPORT FUEL INJECTION (MFI)

13A-178

TROUBLESHOOTING

Inspection Trouble symptom


procedure
No.

Reference
page

21

Abnormal rotation of fan motor

313A

22

Poor A/C performance

313A

23

Engine-ECU power supply, engine control relay, ignition switch-IG1 system

313A

24

Fuel pump system

313A

25

Fan control relay system

313A

26

A/C switch system

313A

27

A/C compressor relay system

313A

28

A/C load signal system

313A

29

A/C pressure sensor system

313A

30

Ignition circuit system

313A

MULTIPORT FUEL INJECTION (MFI)

13A-179

TROUBLESHOOTING

SYMPTOM PROCEDURES

Inspection Procedure 1: Communication with All System is not Possible


Data link connector circuit

Fusible link (1)

C-116
15
R
C-204
1

15
15A

J/B

12
C-205

W-B

C-24

16

1 2 3 4 5 6 7 8
9 10 1112 13 14 1516

Data link connector


5

4
B

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300300 AB

OPERATION
Battery voltage is applied to diagnosis connector
(terminal No.16).
Diagnosis connector (terminals No. 4 and 5) are
earthed to the vehicle body.

COMMENT ON TROUBLE SYMPTOM


Failure is possibly caused by failed power supply
circuit or failed earthing circuit of diagnosis connector.
PROBABLE CAUSE
Failed diagnosis connector
Open/short circuit in diagnosis connector circuit
Failed MUT-II

MULTIPORT FUEL INJECTION (MFI)

13A-180

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3: Measure voltage at C-24 diagnosis


connector.

STEP 1: Check connector: C-24 diagnosis


connector

Connector: C-24

Connector: C-24

1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516

C-24 (B)

Harness side connector


AK203424 AE

Harness side connector


AK203424 AE

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

STEP 2: Measure resistance at C-24 diagnosis


connector.
Connector: C-24

1 2 3 4 5 6 7 8
9 10 1112 13 14 1516

C-24 (B)

Disconnect connector, and measure at the harness side.


Voltage between terminal No. 16 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Check intermediate connectors C-116, C-204

and C-205, and repair if necessary. If


connectors are normal, check and repair
harness between C-24 (terminal No. 16)
diagnosis connector and battery.
Check power supply line for
open/short circuit.
STEP 4: Replace MUT-II
After replacing the MUT-II, re-check the trouble
symptoms.

C-24 (B)

Harness side connector


AK203424 AE

Disconnect connector, and measure at harness


side.
Resistance between terminal No. 4 and earth,
also between terminal No. 5 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Check and repair harness between C-24

(terminal No. 4) diagnosis connector and


body earth, also between C-24 (terminal No.
5) diagnosis connector and body earth.
Check earthing line for open circuit
and damage.

Q: Does trouble symptom persist?


YES : Go to Step 5 .
NO : Check end

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 5: Check harness between C-24 (terminal


No. 6) diagnosis connector and battery.
Connector: C-24

1 2 3 4 5 6 7 8
9 10 1112 13 14 1516

C-24 (B)

Harness side connector


AK203424 AE

NOTE: Before checking harness, check intermediate


connectors C116, C-204 and C-205, and repair if
necessary.
Check power supply line for damage.
Q: Is the check result normal?
YES : Check and repair harness between C-24

(terminal No. 4 and No. 5) diagnosis


connector and body earth.
Check earthing line for damage.
NO : Repair.

13A-181

MULTIPORT FUEL INJECTION (MFI)

13A-182

TROUBLESHOOTING

Inspection Procedure 2: Communication with Engine-ECU only is not Possible.

Data link connector circuit

C-136
Engine-ECU

51 52 53 54 55 56
57 58 59 60 61 62

62
O-W

C-105
5

O-W

32

J/C (3)
C-02
29

O-L
C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516

Data link connector

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300301 AB

OPERATION
There is data communication between diagnosis
connector output terminal (terminal No. 7) and
engine-ECU (terminal No. 62).

DIAGNOSIS PROCEDURE

COMMENT ON TROUBLE SYMPTOM


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

Q: Is lamp illuminating for few seconds?


YES : Go to Step 2 .
NO : Check engine-ECU power supply, engine

PROBABLE CAUSE
Open/short circuit in engine-ECU power circuit
Between engine-ECU and diagnosis connector
for short circuit
Failed engine-ECU

STEP 1: Check engine warning lamp.


Ignition switch: OFF ON

control relay and ignition switch IG1 system


(Refer to Inspection Procedure 23 313A
).

MULTIPORT FUEL INJECTION (MFI)

13A-183

TROUBLESHOOTING

STEP 2: Connector check: C-136 engine-ECU


connector
CONNECTOR: C-136

STEP 3: Check harness between C-24 (terminal


No. 7) diagnosis connector and C-136 (terminal
No. 62) engine-ECU connector.
Connector: C-24

C-136

1 2 3 4 5 6 7 8
9 10 1112 13 14 1516

C-24 (B)

Harness side connector


AK203424 AE

56 55 54 53 52 51
62 61 60 59 58 57

CONNECTOR: C-136

Harness side connector


AK300268 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.
C-136

56 55 54 53 52 51
62 61 60 59 58 57

Harness side connector


AK300268 AB

NOTE: Before Checking harness, check intermediate connectors C-105 and C-02, and repair if necessary.
Check communication line for open/short circuit
and damage.
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Repair.

STEP 4: Check the trouble symptom.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

MULTIPORT FUEL INJECTION (MFI)

13A-184

TROUBLESHOOTING

Inspection Procedure 3: The Engine Warning Lamp Does not Illuminate Right after the Ignition Switch
is Turned The "ON" Position

Malfunction indicator lamp (Engine warning lamp) circuit

Ignition switch
C-303
LOCK

1 2 3
4 5 6

ST

ACC
IG1

IG2

2
L-B

C-203
6
2
7.5A

J/B

25
C-205

C-04

B-W

42

31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G

Malfunction indicator lamp


(Engine warning lamp)

C-05

1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122
G

14
R-W

7
C-105
R-W
36
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300302 AB

OPERATION
Battery voltage is applied to engine warning lamp
of combination meter connector (terminal No. 42)
from ignition switch.

Engine-ECU (terminal No. 36) makes power transistor in unit be in "ON" position, and that makes
currents go on engine warning lamp of combination meter connector (terminal No. 14).

MULTIPORT FUEL INJECTION (MFI)

13A-185

TROUBLESHOOTING

COMMENTS ON TROUBLE SYMPTOM


Engine-ECU turns on engine warning lamp for 5
seconds to check for burnt-out bulb immediately
after ignition switch is turned to ON.
If engine warning lamp is not lit just after turning
ignition switch to "ON" position, failure is possibly
caused by burn-out bulb, open/short circuit or
other faults.

STEP 3: Connector check: C-04 combination


meter connector
CONNECTOR: C-04
C-04

PROBABLE CAUSE
Engine warming lamp bulb burnt out
Failed ignition switch
Open/short circuit in engine warning lamp circuit
for or loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

Harness side connector

STEP 1: Check engine start-up.


Q: Is engine started?
YES : Go to Step 2 .
NO : Check engine-ECU power supply, engine

control relay and ignition switch IG1 system


(Refer to Inspection Procedure 23 313A
).
STEP 2: Check engine warning lamp for burntout bulb.

AK300303AB

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Repair

STEP 4: Measure voltage at C-04 combination


meter connector.
CONNECTOR: C-04
C-04

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Replace engine warning lamp.

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

Harness side connector


AK300303AB

Disconnect connector, and measure at the harness side.


Ignition switch: ON
Voltage between terminal No. 42 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 5 .

MULTIPORT FUEL INJECTION (MFI)

13A-186

TROUBLESHOOTING

STEP 5: Connector check: C-303 ignition switch


connector
CONNECTOR: C-303

STEP 6: Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

C-303
3 2 1
6 5 4
C-135

Harness side
connector
AK300304 AB

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

CONNECTOR: C-04

Harness side connector

C-04

AK300256 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

STEP 7: Measure voltage at C-135 engine-ECU


connector.
CONNECTOR: C-135

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

Harness side connector


AK300303AB

Q: Is the check result normal?


YES : Check intermediate connectors C-203 and

C-205, and repair if necessary. If


intermediate connectors are normal, check
and repair harness between C-04 (terminal
No. 42) combination meter connector and
C-303 (terminal No. 2) ignition switch
connector.
Check power supply line for
open/short circuit.
NO : Repair

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Disconnect connector, and measure at the harness side.


Ignition switch: ON
Voltage between terminal No. 36 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 8 .

MULTIPORT FUEL INJECTION (MFI)

13A-187

TROUBLESHOOTING

STEP 8: Check connector: C-05 combination


meter connector

STEP 9: Connector check: C-303 ignition switch


connector
CONNECTOR: C-303

CONNECTOR: C-05
C-05 (L)

C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Repair.

11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G

Harness side connector


AK300305 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Check intermediate connector C-105, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between C-05 (terminal No. 14)
combination meter connector and C-135
(terminal No. 36) engine-ECU connector.
Check output line for open/short
circuit.
NO : Repair

MULTIPORT FUEL INJECTION (MFI)

13A-188

TROUBLESHOOTING

STEP 10: Check harness between C-04 (terminal


No. 42) combination connector and C-303
(terminal No. 2) ignition switch connector.

STEP 11: Connector check: C-05 ignition switch


connector
CONNECTOR: C-05

CONNECTOR: C-04
C-05 (L)

C-04

11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

AK300305 AB

Harness side connector


AK300303AB

CONNECTOR: C-303

C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

NOTE: Before checking harness, check intermediate


connectors C-203 and C-205, and repair if necessary.
Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Repair.

Harness side connector

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 12: Check harness between C-05 (terminal


No. 14) combination connector and C-135
(terminal No. 36) engine-ECU connector.
CONNECTOR: C-05
C-05 (L)

11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G

Harness side connector


AK300305 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

NOTE: Before checking harness, check intermediate


connector C-105, and repair if necessary.
Check output line for damage.
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Repair.

13A-189

STEP 13: Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

MULTIPORT FUEL INJECTION (MFI)

13A-190

TROUBLESHOOTING

Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and never goes out

Malfunction indicator lamp (Engine warning lamp) circuit

Ignition switch
C-303
LOCK

1 2 3
4 5 6

ST

ACC
IG1

IG2

2
L-B

C-203
6
2
7.5A

J/B

25
C-205

C-04

B-W

42

31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G

Malfunction indicator lamp


(Engine warning lamp)

C-05

1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122
G

14
R-W

7
C-105
R-W
36
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300302 AB

OPERATION
Battery voltage is applied to engine warning lamp
(terminal No. 42) from ignition switch.

Engine-ECU (terminal No. 36) makes power transistor in unit be in "ON" position, and that makes
currents go on engine warning lamp (terminal No.
14).

MULTIPORT FUEL INJECTION (MFI)

13A-191

TROUBLESHOOTING

COMMENT ON TROUBLE SYMPTOM


Engine-ECU has detected failed sensor or failed
actuator. Or failure is possibly caused by short
circuit or other faults.

STEP 3: Measure voltage at C-135 engine-ECU


connector.
CONNECTOR: C-135

PROBABLE CAUSE
Short circuit in between engine warning lamp and
engine-ECU circuit.
Failed engine-ECU

DIAGNOSIS PROCEDURE

C-135

STEP 1: MUT-II self-diag code


Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A.)
NO : Go to Step 2 .

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

STEP 2: Connector check: C-135 engine-ECU


connector

CONNECTOR: C-05
C-05 (L)

CONNECTOR: C-135

C-135
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300305 AB

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair

Harness side connector

Disconnect connector, and measure at the harness side.


Ignition switch: ON
Voltage between terminal No. 36 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Check intermediate connector C-105, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between C-05 (terminal No. 14)
combination meter connector and C-135
(terminal No. 22) engine-ECU connector.
Check output line for short circuit.

13A-192

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 4: Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

Inspection Procedure 5: Starting impossible (No Initial Combustion)


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by failed starter itself
or failed related circuit.

STEP 3: Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

PROBABLE CAUSE
Failed battery
Failed starter motor
Open/short circuit in starter associated circuit or
loose connector contact

DIAGNOSIS PROCEDURE
STEP 1: Check battery voltage.
Measure battery voltage at cranking.
OK: 8 V or higher
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Check battery (Refer to GROUP 54A -

Battery - On-vehicle Service - Battery Test


354A).
STEP 2: MUT-II data list
Item 18: Cranking signal
OK:
ON (Ignition switch: ST)
OFF (Ignition switch: ON)
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 3 .

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-193

TROUBLESHOOTING

STEP 4: Measure voltage at C-137 engine-ECU


connector.

STEP 6: Check ignition switch.


CONNECTOR: C-137

CONNECTOR: C-137

C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

AK300254 AB

Disconnect connector, and measure at the harness side.


Ignition switch: ST
Voltage between terminal No. 71 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Go to Step 5 .

CONNECTOR: C-303

C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

STEP 5: Connector check: C-303 ignition switch


connector

Q: Is the check result normal?


YES : Check intermediate connectors C-106 and

CONNECTOR: C-303

C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Repair.

Check ignition switch (Refer to GROUP 54A Ignition Switch - Ignition Switch 354A).

B-19, and repair if necessary. If intermediate


connector are normal, check and repair
harness between C-137 (terminal No. 71)
inhibitor switch connector and C-303
(terminal No. 5) ignition switch connector.
Check power supply line for
open/short circuit.
NO : Replace ignition switch.

MULTIPORT FUEL INJECTION (MFI)

13A-194

TROUBLESHOOTING

STEP 7: Connector check: C-303 ignition switch


connector and B-26 starter connector

STEP 8: Check connector: B-26 starter connector


CONNECTOR: B-26

CONNECTOR: C-303

B-26 (B)

C-303
3 2 1
6 5 4

1
Harness side
connector

Harness side
connector

AK300306 AB

AK300304 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

CONNECTOR: B-26

STEP 9: Measure voltage at B-26 starter


connector.
B-26 (B)

CONNECTOR: B-26

1
Harness side
connector

AK300306 AB

Q: Is the check result normal?


YES : Check intermediate connectors C-106 and

B-19, and repair if necessary. If intermediate


connectors are normal, check and repair
harness between C-303 (terminal No. 5)
ignition switch connector and B-26 (terminal
No. 1) starter connector.
Check output line for short circuit.
NO : Repair.

B-26 (B)
1
Harness side
connector

AK300306 AB

Disconnect connector, and measure at the harness side.


Ignition switch: ST
Voltage between terminal No. 1 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Go to Step 10 .

MULTIPORT FUEL INJECTION (MFI)

13A-195

TROUBLESHOOTING

STEP 10: Connector check: C-303 ignition switch


connector
CONNECTOR: C-303

STEP 11: Connector check: B-25 starter


connector
CONNECTOR: B-25

C-303
3 2 1
6 5 4

B-25
1

Harness side
connector
AK300304 AB

AK300307 AB

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Repair.

CONNECTOR: B-26

STEP 12: Measure voltage at B-25 starter


connector.

B-26 (B)

CONNECTOR: B-25

1
Harness side
connector

Harness side
connector

AK300306 AB

Q: Is the check result normal?


YES : Check intermediate connectors B-19 and C-

106, and repair if necessary. If intermediate


connectors are normal, check and repair
harness between C-303 (terminal No. 5)
ignition switch connector and B-26 (terminal
No. 1) starter connector.
Check output line for open circuit and
damage.
NO : Repair.

B-25
1
Harness side
connector

AK300307 AB

Disconnect connector, and measure at the harness side.


Voltage between terminal No. 1 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Check and repair harness between B-25

(terminal No. 1) starter connector and


battery.
Check power supply line for
open/short circuit.

MULTIPORT FUEL INJECTION (MFI)

13A-196

TROUBLESHOOTING

STEP 13: Check harness between C-303 (terminal


No. 5) ignition switch connector and B-26
(terminal No. 1) starter connector.

STEP 14: Check harness between B-25 (terminal


No. 1) starter connector and battery.
CONNECTOR: B-25

CONNECTOR: C-303

C-303
3 2 1
6 5 4

B-25
1
Harness side
connector

Harness side
connector
AK300304 AB

AK300307 AB

Check power supply line for damage.


Q: Is the check result normal?
YES : Replace starter.
NO : Repair.

CONNECTOR: B-26

B-26 (B)
1
Harness side
connector

AK300306 AB

NOTE: Before checking harness, check intermediate


connectors B-19 and C-106, and repair if necessary.
Check output line for damage.
Q: Is the check result normal?
YES : Go to Step 14 .
NO : Repair.

Inspection Procedure 6: Starting impossible (Starter Operative but No Initial Combustion)


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by failed ignition circuit, failed fuel feed or other faults.
PROBABLE CAUSE
Failed battery
Timing belt broken
Failed idle speed control
Throttle valve fouled around
Failed ignition system
Failed fuel system
Failed immobilizer system
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1: Check battery voltage.
Measure battery voltage at cranking.
OK: 8 V or higher
Q: Is the check result normal?
YES : Go to STEP 2 .
NO : Check battery (Refer to GROUP 54 -

Battery - On-vehicle Service - Battery test


354A).

MULTIPORT FUEL INJECTION (MFI)

13A-197

TROUBLESHOOTING

STEP 2: Check engine warning lamp for burnt out


bulb.
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Check engine-ECU power supply, engine

control relay and ignition switch IG1 system


(Refer to Inspection Procedure 23 313A
).
STEP 3: MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis codes (Refer

to 313A)
NO : Go to Step 4 .

STEP 8: MUT-II DATA LIST


Item 18: Cranking signal
OK:
ON (Ignition switch: ST)
OFF (Ignition switch: ON)
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Go to Step 9 .

STEP 9: Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 4: MUT-II actuator test


Item 07: Fuel pump
OK: Operating sound of fuel pump can be
heard.

C-137

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Check fuel pump system (Refer to

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Inspection Procedure 24 313A)


STEP 5. Check timing belt for breakage.
Engine: Cranking
OK: Camshaft rotates.

Harness side connector


AK300254 AB

CONNECTOR: C-303

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Replace timing belt.

STEP 6. Check the engine start ability.


With depressing the accelerator pedal slightly,
and start the engine.
Q: Is the start ability good?
YES : Go to Step 7 .
NO : Go to Step 8 .

STEP 7: Check idling speed control for operating


sound.
Check idle speed control servo for operating
sound (Refer to 313A).
Q: Is the check result normal?
YES : Clean throttle body (throttle valve portion)

(Refer to 313A).
NO : Check idle speed control servo system

(Refer to code No. P0505 313A).

C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

Q: Is the check result normal?


YES : Check intermediate connectors B-19 and C-

106, and repair if necessary. If intermediate


connectors are normal, check and repair
harness between C-303 (terminal No. 5)
ignition switch connector and C-137
(terminal No. 71) engine-ECU connector.
Check output line for open/short
circuit.
NO : Repair.

13A-198

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 10: MUT-II DATA LIST


Refer to Data list reference table 313A.
a. Item 22: Crank angle sensor

STEP 12: Connector check: B-110 and B-111


ignition coil connectors
Connector: B-110, B-111

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Check crank angle sensor system (Refer to

Code No. P0335 313A).

B-111 (GR)

3 2 1
Harness side
connector

STEP 11: Check injector for operating sound.


Check injector for operating sound (Refer to
313A).
Q: Can operating sound be heard?
YES : Go to Step 12 .
NO : Check the injector system of the defective

cylinder.
(Refer to Code No. P0201: No. 1 injector
system 313A.)
(Refer to Code No. P0202: No. 2 injector
system 313A.)
(Refer to Code No. P0203: No. 3 injector
system 313A.)
(Refer to Code No. P0204: No. 4 injector
system 313A.)

B-110 (GR)
AK300308 AB

Q: Is the check result normal?


YES : Go to Step 13 .
NO : Repair.

STEP 13: Measure voltage at each of B-110 and


B-111 ignition coil connectors.
Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

B-110 (GR)
AK300308 AB

Disconnect connector, and measure at the harness side.


Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 15 .
NO : Go to Step 14 .

MULTIPORT FUEL INJECTION (MFI)

13A-199

TROUBLESHOOTING

STEP 14: Connector check: C-303 ignition switch


connector

STEP 15: Check ignition coil spark.


CONNECTOR: C-303

CONNECTOR: C-303

C-303
3 2 1
6 5 4

C-303
3 2 1
6 5 4

Harness side
connector

Harness side
connector

AK300304 AB
AK300304 AB

Connector: B-110, B-111


Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

B-111 (GR)

3 2 1
Harness side
connector

B-110 (GR)
B-110 (GR)

AK300308 AB

AK300308 AB

Q: Is the check result normal?


YES : Check intermediate connectors A-14, C-

116, C-203 and C-205, and repair if


necessary. Check and repair harness
between C-303 (terminal No. 2) ignition
switch connector and (terminal No. 1)
affected cylinders ignition coil connector.
Check power supply line for
open/short circuit.
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 16 .
NO : Check intermediate connectors A-14, C-116,

C-203 and C-205, and repair if necessary.


Check and repair harness between C-303
(terminal No. 2) ignition switch connector
and (terminal No. 1) affected cylinders
ignition coil connector.
Check power supply line for damage.
STEP 16: Replace engine-ECU
After replacing the engine-ECU, re-check the
trouble symptoms.
Q: Does trouble symptom persist?
YES : Check for foreign matters (water, kerosene,

etc.) in fuel and replace if necessary.


NO : Check end.

Inspection Procedure 7: Starting Impossible (Initial Combustion But no Complete Combustion),


Improper Starting (Long time to Start)
COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by poor ignition, incorrect air-fuel ratio at cranking, improper fuel pressure or other faults.
PROBABLE CAUSE
Failed battery
Failed ignition system
Failed fuel system

Air-fuel ratio control


Failed idle speed control system
Failed intake system
Failed exhaust gas cleaning system
Throttle valve fouled around
Timing belt not in place
Compression pressure improper
Failed engine-ECU

13A-200

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

DIAGNOSIS PROCEDURE
STEP 1: Check battery condition.
Q: Have the battery terminal been disconnected?
YES : After warm-up engine, idle for about 10

minutes.
NO : Go to Step 2 .

STEP 2: Check battery voltage.


Measure battery voltage at cranking.
OK: 8 V or higher
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Check battery (Refer to GROUP 54 -

Battery - On-vehicle Service - Battery Test


354A).
STEP 3: MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis codes (Refer

to 313A)
NO : Go to Step 4 .

STEP 4: MUT-II data list


Refer to Data list reference table 313A.
a. Item 13: Intake air temperature sensor
b. Item 21: Engine coolant temperature sensor
c. Item 25: Barometric pressure sensor
Q: Are the check results normal?
YES : Go to Step 5 .
NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an


abnormal data value (Refer to Inspection
Chart for Diagnosis Codes 313A).
STEP 5: Check start ability.
With depressing the accelerator pedal slightly,
and start the engine.
Q: Is the start ability good?
YES : Go to Step 6 .
NO : Go to Step 7 .

STEP 6: Check idle speed control servo for


operating sound.
Check idle speed control servo for operating
sound (Refer to 313A).
Q: Is the check result normal?
YES : Clean throttle body (throttle valve portion)

(Refer to 313A).
NO : Check idle speed control servo system

(Refer to Code No. P0505 313A).


STEP 7: MUT-II actuator test
Item 07: Fuel pump
OK: Operating sound of fuel pump can be
heard.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Check fuel pump system (Refer to

Inspection Procedure 24 313A).


STEP 8: Check air intake from intake hose and
inlet manifold.
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair.

STEP 9: Check injector for operating sound.


Check injector for operating sound at engine
cranking (Refer to 313A).
Q: Can operating sound be heard?
YES : Go to Step 10 .
NO : Check the injector system of the defective

cylinder.
(Refer to Code No. P0201: No.1 injector system
313A.)
(Refer to Code No. P0202: No.2 injector system
313A.)
(Refer to Code No. P0203: No.3 injector system
313A.)
(Refer to Code No. P0204: No.4 injector system
313A.)
STEP 10. Check timing marks of timing belt.
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Align timing marks.

MULTIPORT FUEL INJECTION (MFI)

13A-201

TROUBLESHOOTING

STEP 11: Measure voltage at C-134 engine-ECU


connector.
CONNECTOR: C-134

STEP 13: Connector check: B110 and B-111


ignition coil connectors
Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

C-134
B-110 (GR)
AK300308 AB

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

Q: Is the check result normal?


YES : Go to Step 14 .
NO : Repair.

AK300257 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 13 and earth, also
between terminal No. 26 and earth.
OK: 0.5 V or less

STEP 14: Check ignition coil spark.


Q: Is the check result normal?
YES : Go to Step 19 .
NO : Go to Step 15 .

STEP 15: Check spark plug.

Q: Is the check result normal?


YES : Go to Step 13 .
NO : Go to Step 12 .

Q: Is the check result normal?


YES : Go to Step 16 .
NO : Replace spark plug.

STEP 12: Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

STEP 16: Check spark plug cable itself.


Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).
Q: Is the check result normal?
YES : Go to Step 17 .
NO : Replace spark plug cable.

C-134

STEP 17: Check ignition coil itself.


Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Check and repair harness between C-134

(terminal No. 13 and No. 26) engine-ECU


connector and body earth.
Check earthing line for open circuit
and damage.
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 18 .
NO : Replace ignition coil.

MULTIPORT FUEL INJECTION (MFI)

13A-202

TROUBLESHOOTING

STEP 18: Check harness between terminal No. 2


of each cylinders ignition coil connector and
vehicle body earth.
Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

STEP 19: Check spray condition of injector.


Check each injector for spray condition (Refer to
313A).
Q: Is the check result normal?
YES : Go to Step 20 .
NO : Replace injector.

STEP 20: Check compression pressure.


Check compression pressure (Refer to GROUP
11A - On-vehicle Service 311A).
B-110 (GR)
AK300308 AB

Q: Is the check result normal?


YES : Go to Step 21 .
NO : Repair.

CONNECTOR: C-134

C-134

STEP 21: Check EGR control solenoid valve


itself.
Check EGR control solenoid valve itself [Refer to
GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317
].
Q: Is the check result normal?
YES : Go to Step 22 .
NO : Replace EGR control solenoid valve.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Check and repair harness between terminal

No. 3 of each cylinders ignition coil


connector and C-134 engine-ECU
connector.
Check signal line for open/short
circuit and damage.
NO : Repair.

STEP 22: Check EGR valve itself.


Check EGR valve itself [Refer to GROUP 17 Emission Control System - Exhaust Gas Recirculation (EGR) System 317].
Q: Is the check result normal?
YES : Go to Step 23 .
NO : Replace EGR valve.

STEP 23: Replace engine-ECU.


After replacing the engine-ECU, re-check the
trouble symptoms.
Q: Does trouble symptom persist?
YES : Check for foreign matters (water, kerosene,

etc.) in fuel and replace if necessary.


NO : Check end.

Inspection Procedure 8: Unstable idling (Rough idling, hunting), Improper idling speed (Too high or
too low), Engine stalls during idling (Die out)
COMMENT ON TROUBLE SYMPTOM
Probable causes can be widely found in ignition
system, air-fuel ratio control system, idle speed
control system, fuel system, etc. A sudden
engine stall is possibly caused by poor connector
contact.

PROBABLE CAUSE
Failed ignition system
Failed fuel system
Failed air-fuel ratio control system
Failed idle speed control system
Failed intake/exhaust system

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

Failed emission gas cleaning system


Throttle valve body fouled
Timing belt out of place
Compression pressure improper
Failed engine-ECU

DIAGNOSIS PROCEDURE

13A-203

STEP 5: Check idle speed control servo for


operating sound.
Check idle speed control servo for operating
sound (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Check idle speed control servo system

(Refer to Code No. P505 313A).


STEP 1: Check battery condition.
Q: Has the battery terminal been disconnected?
YES : After warm-up engine, idle for about 10

minutes.
NO : Go to Step 2 .

STEP 2: MUT-II self-diag code


Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 3 .
STEP 3: MUT-II data list
Refer to Data list reference table 313A.
a. Item 12: Air flow sensor
b. Item 13: Intake air temperature sensor
c. Item 14: Throttle position sensor
d. Item 21: Engine coolant temperature sensor
e. Item 25: Barometric pressure sensor
Q: Are the check results normal?
YES : Go to Step 4 .
NO : Perform the diagnosis code classified check

procedure for the sensor that has shown an


abnormal data value (Refer to Inspection
Chart for Diagnosis Codes 313A).
STEP 4: MUT-II data list
Refer to Data list reference table 313A.
a. Item 27: Power steering fluid pressure switch
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Check power steering fluid pressure switch

system (Refer to Code No. P0551 313A


).

STEP 6: Check throttle body (throttle valve


portion) for contamination.
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Clean throttle body (throttle valve portion)

(Refer to 313A).
STEP 7: Check air intake from intake hose and
inlet manifold.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

STEP 8: Check injector for operating sound.


Check injector for operating sound (Refer to
313A).
Q: Can operating sound be heard?
YES : Go to Step 9 .
NO : Check the injector system of the defective

cylinder.
(Refer to Code No. P0201: No. 1 injector
system 313A.)
(Refer to Code No. P0202: No. 2 injector
system 313A.)
(Refer to Code No. P0203: No. 3 injector
system 313A.)
(Refer to Code No. P0204: No. 4 injector
system 313A.)
STEP 9: Check timing marks of timing belt.
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Align timing marks.

STEP 10. MUT-II data list


Refer to Data list reference table 313A.
a. Item 11: Oxygen sensor (front)
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Check oxygen sensor (front) system (Refer

to Code No. P0130 313A).

MULTIPORT FUEL INJECTION (MFI)

13A-204

TROUBLESHOOTING

STEP 11: Measure voltage at C-134 engine-ECU


connector.

STEP 13. Measure voltage at C-135 engine-ECU


connector.

CONNECTOR: C-134

CONNECTOR: C-135

C-134

C-135

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Harness side connector


AK300257 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 13 and earth, also
between terminal No. 26 and earth.
OK: 0.5 V or less
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Go to Step 12 .

STEP 12: Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Check and repair harness between C-134

(terminal No. 13 and No. 26) engine-ECU


connector and body earth.
Check earthing line for open circuit
and damage.
NO : Repair.

AK300256 AB

Measure engine-ECU terminal voltage.


Engine: Idling after warm-up
Transmission: Neutral
Radiator fan: Not operating
Voltage between terminal No. 33 and earth.
OK: Switching the headlamps to ON from
OFF causes the voltage to increase by 0.2 3.5 V.

Q: Is the check result normal?


YES : Go to Step 16 .
NO : Go to Step 14 .

MULTIPORT FUEL INJECTION (MFI)

13A-205

TROUBLESHOOTING

STEP 14. Connector check: C-135 engine-ECU


connector and B-30 alternator connector
CONNECTOR: C-135

STEP 15. Check harness between C-135 (terminal


No. 33) engine-ECU connector and B-30 (terminal
No. 1) alternator connector.
CONNECTOR: C-135

C-135
C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Harness side connector


AK300256 AB
AK300256 AB

CONNECTOR: B-30
CONNECTOR: B-30

B-30 (GR)
B-30 (GR)
4 3 2 1
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 15 .
NO : Repair.

4 3 2 1
AK300296 AB

Harness side
connector

AK300296 AB

NOTE: Before checking harness, check intermediate


connector B-19, and repair if necessary.
Check output line for open/short circuit and damage.
Q: Is the check result normal?
YES : Go to Step 16 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-206

TROUBLESHOOTING

STEP 16. Measure voltage at C-135 engine-ECU


connector.
CONNECTOR: C-135

STEP 17. Connector check: C-135 engine-ECU


connector and B-30 alternator connector
CONNECTOR: C-135

C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Harness side connector


AK300256 AB

Measure engine-ECU terminal voltage.


Engine: Idling after warm-up
Transmission: Neutral
Radiator fan: Not operating
Voltage between terminal No. 33 and earth.
OK: Switching the headlamps to ON from
OFF causes the voltage to fall.

Q: Is the check result normal?


YES : Go to Step 20 .
NO : Go to Step 17 .

AK300256 AB

CONNECTOR: B-30

B-30 (GR)

4 3 2 1
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 18 .
NO : Repair.

AK300296 AB

MULTIPORT FUEL INJECTION (MFI)

13A-207

TROUBLESHOOTING

STEP 18. Check harness between C-135 (terminal


No. 54) engine-ECU connector and B-30 (terminal
No. 4) alternator connector.

STEP 20. Measure voltage at C-134 engine-ECU


connector.
CONNECTOR: C-134

CONNECTOR: C-135

C-134
C-135

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Harness side connector


AK300257 AB
AK300256 AB

CONNECTOR: B-30

B-30 (GR)

4 3 2 1
Harness side
connector

AK300296 AB

NOTE: Before checking harness, check intermediate


connector B-19, and repair if necessary.
Check output line for open/short circuit and damage.
Q: Is the check result normal?
YES : Go to Step 19 .
NO : Repair.

Measure engine-ECU terminal voltage.


Engine: Idling
A/C switch: ON (A/C compressor ON)
Voltage between terminal No. 24 and earth.
OK:
1 V or less (with outside air temperature sensor ambient temperature at 18C or higher
and A/C set for maximum air flow at minimum temperature)
System voltage (with A/C set for minimum air
flow at room temperature)

Q: Is the check result normal?


YES : Go to Step 21 .
NO : Check A/C load signal system (Refer to

Inspection Procedure 28 313A).


STEP 21. Connector check: B-110 and B-111
ignition coil connectors
Connector: B-110, B-111

STEP 19. Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace alternator.
NO : Intermittent malfunction (Refer to GROUP

B-111 (GR)

3 2 1
Harness side
connector

00 - How to Use
Troubleshooting/Inspection Service Points
300).

B-110 (GR)
AK300308 AB

Q: Is the check result normal?


YES : Go to Step 22 .
NO : Repair.

13A-208

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 22. Check ignition coil spark.


Q: Is the check result normal?
YES : Go to Step 27 .
NO : Go to Step 23 .

STEP 26. Check harness between terminal No. 2


of ignition coil connector of each cylinder and
body earth.
Connector: B-110, B-111

STEP 23. Check spark plug.


Q: Is the check result normal?
YES : Go to Step 24 .
NO : Replace spark plug.

STEP 24. Check individual spark plug cable


Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).

B-111 (GR)

3 2 1
Harness side
connector

B-110 (GR)
AK300308 AB

CONNECTOR: C-134

Q: Q: Is the check result normal?


YES : Go to Step 25 .
NO : Replace spark plug cable.

STEP 25. Check ignition coil itself.


Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).
Q: Is the check result normal?
YES : Go to Step 26 .
NO : Replace ignition coil.

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Check earthing line for open/short circuit and


damage.
Q: Is the check result normal?
YES : Check and repair harness between terminal

No. 3 of ignition coil connector of each


cylinder and C-134 engine-ECU
Check signal line for open/short and
damage.
NO : Repair.
STEP 27. Check injector for spray condition.
Check each injector for spray condition (Refer to
313A).
Q: Is the check result normal?
YES : Go to Step 28 .
NO : Replace injector.

STEP 28. Check compression pressure.


Check compression pressure (Refer to GROUP
11A - On-vehicle Service 311A).
Q: Is the check result normal?
YES : Go to Step 29 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 29. Check purge control solenoid valve


itself.
Check purge control solenoid valve itself (Refer to
GROUP 17 - Emission Control System - Evaporative Emission Control System 317)
Q: Is the check result normal?
YES : Go to Step 30 .
NO : Replace purge control solenoid valve.

STEP 30. Check EGR control solenoid valve


itself.
Check EGR control solenoid valve itself [Refer to
GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317
].
Q: Is the check result normal?
YES : Go to Step 31 .
NO : Replace EGR control solenoid valve.

13A-209

STEP 31. Check EGR control solenoid valve


itself.
Check EGR control solenoid valve itself [Refer to
GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317
].
Q: Is the check result normal?
YES : Go to Step 32 .
NO : Replace EGR valve.

STEP 32. MUT-II actuator test


Item 07: Fuel pump
OK: Operating sounds of fuel pump can be
heard.
Q: Is the check result normal?
YES : Go to Step 33 .
NO : Check fuel pump system (Refer to

inspection Procedure 24 313A).


STEP 33. Replace engine-ECU.
After engine-ECU is replaced, re-check for trouble symptom.
Q: Does trouble system persist?
YES : Check for foreign matters (water, kerosene,

etc.) in fuel and replace if necessary.


NO : Check end.

Inspection Procedure 9: The Engine Stalls when Starting the Car (Pass Out)
COMMENT ON TROUBLE SYMPTOM
Engine stall on starting is possibly caused by misfire due to failed spark plug, improper air-fuel
ratio at accelerator pedal depression or other
faults.
PROBABLE CAUSE
Failed ignition system
Failed intake system
Failed emission gas cleaning system
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

STEP 2. Check EGR control solenoid valve itself.


Check EGR control solenoid valve itself [Refer to
GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317
].
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Replace EGR control solenoid valve.

STEP 3. Check EGR valve itself.


Check EGR valve itself [Refer to GROUP 17 Emission Control System - Exhaust Gas Recirculation (EGR) System 317].
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace EGR valve.

MULTIPORT FUEL INJECTION (MFI)

13A-210

TROUBLESHOOTING

STEP 4. Check air intake from intake hose and


inlet manifold.
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Replace ignition coil.

STEP 5. Connector check: B-110 and B-111


ignition connectors.
Connector: B-110, B-111

B-111 (GR)

STEP 9. Check ignition coil itself.


Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).

3 2 1
Harness side
connector

STEP 10. Check harness between terminal No. 2


of ignition coil connector of each cylinder and
body earth.
Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

B-110 (GR)
AK300308 AB

B-110 (GR)

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Repair.

AK300308 AB

CONNECTOR: C-134

STEP 6. Check ignition coil spark.


Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Go to Step 7 .
C-134

STEP 7. Check spark plug.


Q: Is the check result normal?
YES : Go to Step 8 .
NO : Replace spark plug.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

STEP 8.Check spark plug cable itself.


Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Replace spark plug cable.

AK300257 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Check and repair harness between terminal

No. 3 of ignition coil connector of each


cylinder and C-134 engine-ECU.
Check signal line for open/short
circuit and damage.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-211

TROUBLESHOOTING

Inspection Procedure 10. The Engine Stalls when Decelerating


COMMENT ON TROUBLE SYMPTOM
Engine stall on deceleration is possibly caused
by insufficient air intake, improper air-fuel ratio
due to failed exhaust gas recirculation system or
other faults.
PROBABLE CAUSE
Failed idle speed control system
Failed ignition system
Failed emission control system
Throttle valve fouled
Failed engine-ECU

DIAGNOSIS PROCEDURE

STEP 5. Check EGR valve itself.


Check EGR valve itself [Refer to GROUP 17 Emission Control System - Exhaust Gas Recirculation (EGR) System 317].
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Replace EGR valve.

STEP 6. Check throttle body (throttle valve


portion) for contamination.
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Clean throttle body (throttle valve portion)

(Refer to 313A).
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

STEP 2. MUT-II data list


Refer to Data list reference table 313A.
a. Item 14: Throttle position sensor

STEP 7. Connector check: B-110 and B-111


ignition coil connectors
Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Check throttle position sensor system

B-110 (GR)

(Refer to Code No. P0120 313A).


STEP 3. MUT-II data list
Item 45: Idle speed control servo position
OK: Idle speed control servo drops to 0 - 2
Steps at deceleration (engine at 1,000 r/min
or higher).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Check idle speed control servo system

(Refer to Code No. P0505 313A).


STEP 4. Check EGR control solenoid valve itself.
Check EGR control solenoid valve itself [Refer to
GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317
].
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Replace EGR control solenoid valve.

AK300308 AB

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.

STEP 8. Check ignition coil spark.


Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Go to Step 9 .

STEP 9. Check spark plug.


Q: Is the check result normal?
YES : Go to Step 10 .
NO : Replace spark plug.

13A-212

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 10. Check spark plug cable itself.


Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).

STEP 12. Check harness between terminal No. 2


of ignition coil connector of each cylinder and
body earth.
Connector: B-110, B-111

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Replace spark plug cable.
B-111 (GR)

3 2 1
Harness side
connector

STEP 11. Check ignition coil itself.


Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).

B-110 (GR)

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Replace ignition coil.

AK300308 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Check and repair harness between terminal

No. 3 of ignition coil connector of each


cylinder and C-134 engine-ECU.
Check signal line for open/short
circuit and damage.
NO : Repair.

Inspection Procedure 11: Engine does not Revole Up


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by failed fuel system,
ignition system or other faults.

DIAGNOSIS PROCEDURE

PROBABLE CAUSE
Failed ignition system
Failed fuel system
Timing belt out of place
Failed engine-ECU

Q: Diagnosis code set?


YES : Inspection chart for diagnosis code (Refer

STEP 1. MUT-II self-diag code

to 313A).
NO : Go to Step 2 .

MULTIPORT FUEL INJECTION (MFI)

13A-213

TROUBLESHOOTING

STEP 2. Check timing marks of timing belt.


Q: Is the check result normal?
YES : Go to Step 3 .
NO : Align match marks.

STEP 8. Check harness between terminal No. 2 of


ignition coil connector of each cylinder and body
earth.
Connector: B-110, B-111

STEP 3. Connector check: B-110 and B-111


ignition coil connectors
B-111 (GR)

3 2 1
Harness side
connector

Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

B-110 (GR)
AK300308 AB

CONNECTOR: C-134
B-110 (GR)
AK300308 AB

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Repair

C-134

STEP 4. Check ignition coil spark.


Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 5 .

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

STEP 5. Check spark plug.


Q: Is the check result normal?
YES : Go to Step 6 .
NO : Replace spark plug.

STEP 6. Check spark plug cable itself.


Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Replace spark plug cable.

STEP 7. Check ignition coil itself.


Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Replace ignition coil.

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Check and repair harness between terminal

No. 3 of ignition coil connector of each


cylinder and C-134 engine-ECU.
Check signal line for open/short
circuit and damage.
NO : Repair
STEP 9. Measure fuel pressure.
Measure fuel pressure (Refer to 313A).
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Repair

13A-214

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

Inspection Procedure 12: Hesitation, sag,poor acceleration, stumble, surge


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by failed ignition system, improper air-fuel ratio, improper compression pressure or other faults.
PROBABLE CAUSE
Failed air-fuel ratio control system
Failed ignition system
Failed fuel system
Failed intake and exhaust system
Failed emission control system
Throttle valve fouled
Improper compression pressure
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .
STEP 2. Check injector for operating sound.
Check injector for operating sound (Refer to
313A).
Q: Can operating sound be heard?
YES : Go to Step 3 .
NO : Check the injector system of the defective

cylinder.
(Refer to code No. P0201: No. 1 injector system
313A).
(Refer to code No. P0202: No. 2 injector system
313A).
(Refer to code No. P0203: No. 3 injector system
313A).
(Refer to code No. P0204: No. 4 injector system
313A).

STEP 3. MUT-II data list


Refer to Data list reference table 313A.
a. Idem 13: Intake air temperature sensor
b. Item 14: Throttle position sensor
c. Item 21: Engine coolant temperature sensor
d. Item 25: Barometric pressure sensor
Q: Are the check results normal?
YES : Go to Step 4 .
NO : Perform the diagnosis code classified check

Procedure for the sensor that has shown an


abnormal data value (Refer to Inspection
Chart for Diagnosis Codes 313A).
STEP 4. Check purge control solenoid valve
itself.
Check purge control solenoid valve itself (Refer
to GROUP 17 - Emission Control System Evaporative Emission Control System 317).
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Replace purge control solenoid valve.

STEP 5. Check EGR control solenoid valve itself.


Check EGR control solenoid valve itself [Refer to
GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317
].
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Replace EGR control solenoid valve.

STEP 6. Check EGR valve itself.


Check EGR itself [Refer to GROUP 17 - Emission Control System - Exhaust Gas Recirculation
(EGR) System 317].
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Replace EGR valve.

STEP 7. MUT-II data list


Refer to Data list reference table 313A.
a. Item 11: Oxygen sensor (front)
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Check oxygen sensor system (Refer to

Code No. P0130 313A).

MULTIPORT FUEL INJECTION (MFI)

13A-215

TROUBLESHOOTING

STEP 8. Connector check: B-110 and B-111


ignition coil connectors
Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

STEP 13. Check harness between terminal No. 2


of ignition coil connector of each cylinder and
body earth.
Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

B-110 (GR)
B-110 (GR)

AK300308 AB

AK300308 AB

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair

CONNECTOR: C-134

STEP 9. Check ignition coil spark.


Q: Is the check result normal?
YES : Go to Step 14 .
NO : Go to Step 10 .

C-134

STEP 10. Check spark plug.


Q: Is the check result normal?
YES : Go to Step 11 .
NO : Replace spark plug.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

STEP 11. Check spark plug cable itself.


Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Replace spark plug cable.

STEP 12. Check ignition coil itself.


Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Replace ignition coil.

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Check and repair harness between terminal

No. 3 of ignition coil connector of each


cylinder and C-134 engine-ECU
Check signal line for open/short
circuit and damage.
NO : Repair.
STEP 14. Check throttle body (throttle valve
portion) for contamination.
Q: Is the check result normal?
YES : Go to Step 15 .
NO : Clean throttle body (throttle valve portion)

(Refer to 313A).
STEP 15. Measure fuel pressure.
Measure fuel pressure (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 16 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-216

TROUBLESHOOTING

STEP 16. Check compression pressure.


Check compression pressure (Refer to GROUP
11A - On-vehicle Service 311A).
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Repair.

Inspection Procedure 13. The Feeling of Impact or Vibration when Accelerating


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by failed ignition leak
with rise in spark plug-required voltage at acceleration.
PROBABLE CAUSE
Failed ignition system
Failed engine-ECU

Q: Is the check result normal?


YES : Replace engine-ECU.
NO : Go to Step 4 .

STEP 4. Check spark plug.


Q: Is the check result normal?
YES : Go to Step 5 .
NO : Replace spark plug.

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

STEP 2. Check connector: B-110 and B-111


ignition coil connectors
Connector: B-110, B-111

B-111 (GR)

STEP 3. Check ignition coil spark.

3 2 1
Harness side
connector

B-110 (GR)
AK300308 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 5. Check spark plug cable itself.


Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Replace spark plug cable.

STEP 6. Check ignition coil itself.


Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Replace ignition coil.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-217

STEP 7. Check harness between terminal No. 2 of


ignition coil connector of each cylinder and body
earth.
Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

B-110 (GR)
AK300308 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Check and repair harness between terminal

3 of ignition coil connector of each cylinder


and C-134 engine-ECU
Check signal line for open/short
circuit and damage.
NO : Repair.

Inspection Procedure 14: The feeling of impact or vibration when decelerating


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by insufficient air
intake due to failed idle speed control system.
PROBABLE CAUSE
Failed idle speed control system
Throttle valve body fouled
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

13A-218

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 2. Check idle speed control servo for


operating sound.
Check idle speed control servo for operating
sound (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Check idle speed control servo system

STEP 3. MUT-II data list


Refer to Data list reference table 313A.
a. Item 14: Throttle position sensor
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Check throttle position sensor system

(Refer to Code No. P0120 313A).

(Refer to Code No. P0505 313A).


STEP 4. Check throttle body (throttle valve)
contamination.
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Clean throttle body (throttle valve portion)

(Refer to 313A).

Inspection Procedure 15: Knocking


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by failed detonation
control, improper thermal value of spark plug or
other faults.
PROBABLE CAUSE
Defective detonation sensor
Failed detonation control system
Failed ignition system
Defective spark plug
Failed engine-ECU

STEP 2. Connector check: B-110 and B-111


ignition coil connectors
Connector: B-110, B-111

B-111 (GR)

3 2 1
Harness side
connector

B-110 (GR)

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

AK300308 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Check ignition coil spark.


Q: Is the check result normal?
YES : Check detonation sensor (Refer to Code

No. P0325 313A).


NO : Go to Step 4 .

STEP 4. Check spark plug.


Q: Is the check result normal?
YES : Go to Step 5 .
NO : Replace spark plug.

MULTIPORT FUEL INJECTION (MFI)

13A-219

TROUBLESHOOTING

STEP 5. Check spark plug cable itself.


Check spark plug cable itself (Refer to GROUP
16 -Ignition System - On-vehicle Service 316
).

STEP 7. Check harness between ignition coil


connector terminal No. 2 of each cylinder and
body earth.
Connector: B-110, B-111

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Replace spark plug cable.
B-111 (GR)

3 2 1
Harness side
connector

STEP 6. Check ignition coil itself.


Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Replace ignition coil.

B-110 (GR)
AK300308 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Check and repair harness between ignition

coil connector terminal No. 3 of each


cylinder and C-134 engine-ECU connector.
Check signal line for open circuit,
short circuit and damage.
NO : Repair.

Inspection Procedure 16: Ignition Timing Offset


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by failed crank angle
sensor, failed camshaft position sensor, improper
installed timing belt or other faults.
PROBABLE CAUSE
Failed crank angle sensor
Failed camshaft position sensor
Improperly installed timing belt
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

MULTIPORT FUEL INJECTION (MFI)

13A-220

TROUBLESHOOTING

STEP 2. Measure output waveforms of crank


angle sensor and camshaft position sensor (Use
oscilloscope).
Connector: B-29

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Go to Step 4 .

STEP 3. Check the trouble symptoms.

2 1
3
Harness side
connector

B-29 (B)

Q: Does trouble symptom persist?


YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
STEP 4. Check crank angle sensor and camshaft
position sensor mounted conditions.
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Repair.

STEP 5. Check timing marks of timing belt.


Crank angle sensor

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Align timing marks.

AK300276 AB

STEP 6. Check crank angle sensor vane.

Connector: B-106
3 2 1
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Replace crank angle sensor vane.

STEP 7. Check camshaft position sensing


cylinder.

B-106 (B)

AK300279 AB

Crank Angle Sensor


Use special tool test harness (MB998478) to connect B-29 crank angle sensor connector, and
measure at pick-up harness.
Engine: Idling
Transmission: Neutral
Voltage between terminal No. 2 and earth.
Camshaft Position Sensor
Use special tool test harness (MD991709) to connect B-106 camshaft position sensor connector,
and measure at pick-up harness.
Engine: Idling
Transmission: Neutral
Voltage between terminal No. 2 and earth.
OK: Output waveform timings of both sensors are the same as the check procedure
(Refer to 313A) using an oscilloscope.

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Replace camshaft position sensing cylinder.

STEP 8. Replace crank angle sensor.


After replacing the crank angle sensor, re-check
the trouble symptoms.
Q: Does trouble symptom persist?
YES : Go to Step 9 .
NO : Check end.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-221

STEP 9. Replace camshaft position sensor.


After replacing the camshaft position sensor, recheck the trouble symptoms.
Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

Inspection Procedure 17: Run on (Dieseling)


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by leakage from injector.
PROBABLE CAUSE
Failed injector
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. Check injector for spray condition.
Check each injector for spray condition (Refer to
313A).
Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Replace injector.

Inspection Procedure 18: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC during
Idling
COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by improper air-fuel
ratio, deteriorated catalyst, failed ignition system,
failed fuel system, failed compression pressure or
other faults.
PROBABLE CAUSE
Incorrect air/fuel ratio
Failed ignition system
Failed fuel system
Failed intake and exhaust system
Failed emission control system
Failed compression pressure
Failed catalytic converter
Failed engine-ECU

STEP 2. Check injector for operating sound.


Check injector for operating sound (Refer to
313A).
Q: Can operating sound be heard?
YES : Go to Step 3 .
NO : Check the injector system of the defective

cylinder.
(Refer to 313A, Code P0201: No. 1 injector
System)
(Refer to 313A, Code P0202: No. 2 injector
System)
(Refer to 313A, Code P0203: No. 3 injector
System)
(Refer to 313A, Code P0204: No. 4
injector System)

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

STEP 3. Check ignition timing.


Check ignition timing. (Refer to GROUP 11A On-vehicle Service 311A).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Check for offset ignition timing (Refer to

Inspection Procedure 16 313A).

13A-222

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 4. MUT-II Data List


Refer to Data list reference table 313A.
a. Item 12: Air flow sensor
b. Item 13: Intake air temperature sensor
c. Item 21: Engine coolant temperature sensor
d. Item 25: Barometric pressure sensor

STEP 10. Check EGR control solenoid valve


itself.
Check EGR control solenoid valve itself [Refer to
GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317
].

Q: Are the check results normal?


YES : Go to Step 5 .
NO : Perform the diagnosis code classified check

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Replace EGR control solenoid valve.

Procedure for the sensor that has shown an


abnormal data value (Refer to Inspection
Chart for Diagnosis Codes 313A).
STEP 5. Check air intake from intake hose and
inlet manifold.
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Repair.

STEP 6. Check for emission leakage from


exhaust manifold.
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Repair.

STEP 7. Check throttle body (throttle valve


portion) for contamination.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Clean throttle body (throttle valve portion)

(Refer to 313A).

STEP 11. Check EGR valve itself.


Check EGR valve itself [Refer to GROUP 17 Emission Control System - Exhaust Gas Recirculation (EGR) System 317].
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Replace EGR valve.

STEP 12. Measure fuel pressure.


Measure fuel pressure (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Repair.

STEP 13. Check positive crankcase ventilation


valve itself.
Check positive crankcase ventilation valve itself
(Refer to GROUP 17 - Emission Control System
- crankcase Emission Control System 317).
Q: Is the check result normal?
YES : Go to Step 14 .
NO : Replace positive crankcase ventilation

valve.

STEP 8. MUT-II data list


Refer to Data list reference table 313A.
a. Item 11: Oxygen sensor (front)

STEP 14. Check spark plug.

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Check oxygen sensor (front) system (Refer

Q: Is the check result normal?


YES : Go to Step 15 .
NO : Replace spark plug.

to Code No. P0130 313A).


STEP 9. Check Purge control solenoid valve
itself.
Check purge control solenoid valve itself (Refer
to GROUP 17 - Emission Control System Evaporative Emission Control System 317).
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Replace purge control solenoid valve.

STEP 15. Check spark plug cable itself.


Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).
Q: Is the check result normal?
YES : Go to Step 16 .
NO : Replace spark plug cable.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-223

STEP 16. Check ignition coil itself.


Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).

STEP 18. Check injector for spraying condition.


Check each injector for spray condition (Refer to
313A).

Q: Is the check result normal?


YES : Go to Step 17 .
NO : Replace ignition coil.

Q: Does trouble symptom persist?


YES : Go to Step 19 .
NO : Replace injector.

STEP 17. Check compression pressure.


Check compression pressure (Refer to GROUP
11A - On-vehicle Service 311A).

STEP 19. Replace catalytic converter.


After replacing the catalytic converter, re-check
the trouble symptoms.

Q: Is the check result normal?


YES : Go to Step 18 .
NO : Repair.

Q: Does trouble symptom persist?


YES : Replace engine-ECU.
NO : Check end

Inspection Procedure 19: Battery Rundown


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by failed alternator,
failed generation control circuit or other faults.

STEP 2. Connector check: B-19 intermediate


connector
CONNECTOR: B-19

PROBABLE CAUSE
Failed battery
Alternator G terminal short-circuited
Failed alternator
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. Check battery voltage.
Measure battery voltage during cranking.
OK: 8 V or more
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Check battery (Refer to GROUP 54 -

Battery - On-vehicle Service - Battery test


354A).

B-19 (B)

3 2 1
6 5 4
Female side
connector

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

AK300294 AB

13A-224

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 3. Measure voltage at B-19 intermediate


connector.

STEP 4. Connector check: C-303 ignition switch


connector
CONNECTOR: C-303

CONNECTOR: B-19

B-19 (B)
C-303
3 2 1
6 5 4

1 2 3
4 5 6
Male side
connector

Harness side
connector

Disconnect connector, and measure at male connector side.


Ignition switch: ON
Voltage between terminal No. 5 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Go to Step 4 .

AK300304 AB

AK300295 AB

CONNECTOR: B-19

B-19 (B)

1 2 3
4 5 6
Male side
connector

AK300295 AB

Q: Is the check result normal?


YES : Check intermediate connectors C-04, C-05,

C-105, C-203 and C-205, and repair if


necessary. If intermediate connectors are
normal, check and repair harness between
B-19 (terminal No. 5) intermediate
connector and C-303 (terminal No. 2)
ignition switch connector.
Check power supply line for
open/short circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-225

TROUBLESHOOTING

STEP 5. Measure voltage at B-19 intermediate


connector.
CONNECTOR: B-19

STEP 7. Check harness between B-19 (terminal


No. 4) intermediate connector and B-30 (terminal
No. 1) alternator connector.
CONNECTOR: B-19

B-19 (B)
B-19 (B)
3 2 1
6 5 4
Female side
connector

3 2 1
6 5 4
AK300294 AB

Disconnect connector, and measure at female


connector side.
Ignition switch: ON
Voltage between terminal No. 4 and earth.
OK: System voltage

Female side
connector

AK300294 AB

CONNECTOR: B-30

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Go to Step 6 .

B-30 (GR)

STEP 6. Connector check: B-30 alternator


connector

Harness side
connector

4 3 2 1

CONNECTOR: B-30

4 3 2 1
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

Check output line for short circuit.


Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

B-30 (GR)

AK300296 AB

AK300296 AB

13A-226

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 8. Check harness between B-19 (terminal


No. 5) intermediate connector and B-30 (terminal
No. 3) alternator connector.
CONNECTOR: B-19

STEP 9. Check harness between B-30 (terminal


No. 3) alternator connector and C-303 (terminal
No. 2) ignition switch connector.
CONNECTOR: B-30

B-19 (B)
B-30 (GR)
3 2 1
6 5 4
Female side
connector

4 3 2 1
AK300294 AB

Harness side
connector

AK300296 AB

CONNECTOR: C-303

CONNECTOR: B-30

B-30 (GR)

C-303
3 2 1
6 5 4

4 3 2 1
Harness side
connector

Harness side
connector

Check power supply line for open/short circuit.


Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair.

AK300304 AB

AK300296 AB

NOTE: Before checking harness, check intermediate


connectors C-04, C-05, C-105, C-203 and C-205 and
repair if necessary.
Check power supply line for damage.
Q: Is the check result normal?
YES : Replace alternator.
NO : Repair.

STEP 10. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-227

TROUBLESHOOTING

STEP 11. Measure voltage at C-135 engine-ECU


connector.

STEP 12. Measure voltage at C-135 engine-ECU


connector.

CONNECTOR: C-135

CONNECTOR: C-135

C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Harness side connector


AK300256 AB

CONNECTOR: B-19

B-19 (B)

1 2 3
4 5 6
Male side
connector

AK300295 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 33 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Check and repair harness between B-19

(terminal No. 4) intermediate connector and


C-135 (terminal No. 33) engine-ECU
connector.
Check output line for short circuit.

AK300256 AB

Measure engine-ECU terminal voltage.


Engine: Idling after warm-up
Transmission: Neutral
Radiator fan: Inactive
Voltage between terminal No. 8 and earth.
OK: Switching the headlamps to ON from
OFF causes the voltage to increase by 0.2 3.5 V.

Q: Is the check result normal?


YES : Go to Step 13 .
NO : Check alternator.

STEP 13. Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

13A-228

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

Inspection Procedure 20: Overheating


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by failed engine cooling system, failed fan controller, failed engine
coolant temperature sensor or other faults.
PROBABLE CAUSE
Insufficient or deteriorated engine coolant
Failed fan controller
Failed engine coolant temperature sensor
Failed thermostat
Failed water pump
Failed radiator core
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .
STEP 2. Check engine coolant
NOTE: If engine coolant level falls too early, check
for leaky spots, and repair if necessary.
Check engine coolant (Refer to GROUP 14 - Onvehicle Service 314).
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Replace or add engine coolant.

STEP 3. MUT-II actuator test


Item 21: Fan controller
OK: Fan motor rotating
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Check fan control relay system (Refer to

Inspection Procedure 25 313A).


STEP 4. MUT-II Data List
Item 21: Engine coolant temperature sensor
OK:
Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
Engine hot state: At 80 - 120C
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Check engine coolant temperature sensor

system (Refer to Code No. P0115 313A


).
STEP 5. Check thermostat.
Check thermostat (Refer to GROUP 14 - Thermostat 314).
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Replace thermostat.

STEP 6. Check water pump.


Check water pump.
Q: Is the check result normal?
YES : Replace radiator.
NO : Replace water pump.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-229

Inspection Procedure 21: Abnormal Rotation of Fan Motor

Fan controller (Radiator fan, A/C condensor fan) Circuit

5V

A-20
(MU802322)
1 2 3

Fan controller

2
L-W

7
A-14

L-W

21
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300309 AB

OPERATION
The control (duty) signal is inputted to the fan
controller (terminal No. 2) from the engine-ECU
(terminal No. 21).
FUNCTION
The engine-ECU inputs a duty signal suitable for
the engine coolant temperature, vehicle speed
and A/C switch position to the fan controller. In
response to the signal, the fan controller controls
the rotating speeds of the radiator fan and A/C
condenser fan (The fan speed becomes higher
as the average voltage of the terminal comes
nearer to 5V).

PROBABLE CAUSE
Failed fan controller
Open/short circuit in fan controller circuit or loose
connector contact
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-230

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3. Check the trouble symptoms.

STEP 1. Connector check: C-134 engine-ECU


connector

Q: Does trouble symptom persist?


YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

CONNECTOR: C-134

STEP 4. Measure voltage at C-134 engine-ECU


connector.
C-134

CONNECTOR: C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


C-134

AK300257 AB

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

STEP 2. Check at C-134 engine-ECU connector.


CONNECTOR: C-134

AK300257 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 21 and earth.
OK: 4.9 - 5.1 V
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

Q: Is the check result normal?


YES : Replace fan controller.
NO : Go to Step 5 .

STEP 5. Connector check: A-20 fan controller


connector
Connector: A-20

AK300257 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Short-circuit terminal No. 21 to earth.
OK: Fan motor stops rotating.
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Go to Step 4 .

A-20 (GR)

3 2 1
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Repair.

AK203423 AC

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-231

STEP 6. Check harness between A-20 (terminal


No. 2) fan controller connector and C-134
(terminal No. 21) engine-ECU connector.
Connector: A-20

A-20 (GR)

3 2 1
Harness side
connector

AK203423 AC

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

NOTE: Before checking harness, check intermediate


connector A-14, and repair if necessary.
Check output line for open circuit.
Q: Is the check result normal?
YES : Replace fan controller.
NO : Repair.

Inspection Procedure 22: Poor A/C Performance


COMMENT ON TROUBLE SYMPTOM
Failure is possibly caused by short /overcharged
A/C refrigerant, failed A/C control system, failed
fan control system or other faults.
PROBABLE CAUSE
Short or overcharged A/C refrigerant
Failed A/C compressor relay
Failed fan controller
Failed A/C-ECU

Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Diagnosis code set?
YES : Inspection chart for diagnosis code (Refer

to 313A).
NO : Go to Step 2 .

13A-232

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 2. A/C compressor magnet clutch


operation check.
Engine: Idling
A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more
Maximum Hot when temperature in cabin is 25C
or less
OK:
Magnet clutch active (when A/C is ON)
Magnet clutch inactive (when A/C is OFF)

STEP 4. MUT-II data list


Item 49: A/C relay
a. Engine: Running at idle
b. A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more.
Maximum Hot when temperature in cabin is
25C or less.
OK:
ON (when A/C is ON)
OFF (when A/C is OFF)

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Go to Step 3 .

Q: Is the check result normal?


YES : Check A/C system (Refer to GROUP 55A -

Troubleshooting 355A).
NO : Check A/C compressor relay (Refer to

STEP 3. MUT-II data list


Item 28: A/C switch
a. Engine: Idling
b. A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more
Maximum Hot when temperature in cabin is
25C or less
OK:
ON (when A/C is ON)
OFF (when A/C is OFF)
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Check A/C switch (Refer to Inspection

Procedure 26 313A).

inspection procedure 27 313A).


STEP 5. Check charged amount of A/C
refrigerant.
Check charged amount of A/C refrigerant (Refer
to GROUP 55A - On-vehicle Service 355A).
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Adjust charged amount of A/C refrigerant.

STEP 6. MUT-II actuator test


Item 21: Fan controller
OK: Fan motor rotates.
Q: Is the check result normal?
YES : Check A/C load signal system (Refer to

Inspection Procedure 28 313A).


NO : Check fan control relay system (Refer to

Inspection Procedure 25313A).

MULTIPORT FUEL INJECTION (MFI)

13A-233

TROUBLESHOOTING

Inspection Procedure 23: Engine-ECU Power Supply, Engine Control Relay, Ignition Switch-IG1
System
Power supply and ignition switch-IG circuit

Battery

9
20A

Relay box

Ignition switch

123
456

ACC

ST

W-B

C-303

LOCK

R
IG1

A-14
5

IG2

W-B

L-B
6

W-B

W-B
4

B-17X

8
7.5A

J/B

3
1
C-202

Engine
control
relay

L-B

R
C-106
10

J/C (2)
C-17

W-B

Y-G
9

L-B

10

R
12

25

38

80

82

Battery
backup

Power
source

C-134

C-135

1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

Engine-ECU

C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300310

AB

13A-234

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

OPERATION
The battery voltage is applied to the engine control relay (terminal No. 3 and 4).
The engine-ECU (terminal No. 38) makes the
power transistor in the unit be in "ON" position
and makes currents go on the engine control
relay coil, and that makes the relay be in "ON"
position.
When the engine control relay is in "ON" position,
the battery voltage is supplied to the engineECU, the sensor and the actuator from the
engine control relay (terminal No. 1).
FUNCTION
When the ignition switch ON signal is input to the
engine-ECU, the engine-ECU places the engine
control relay in the ON position. Accordingly, the
battery voltage is supplied to the engine-ECU,
sensor and actuator.
PROBABLE CAUSE
Failed engine control relay
Open/short circuit in engine control relay circuit or
loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE

STEP 2. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

Harness side
connector

AK300255 AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Check engine control relay.


Check engine control relay (Refer to 313A).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace engine control relay.

STEP 4. Measure voltage at B-17X engine control


relay connector.
CONNECTOR: B-17X

STEP 1. Check battery voltage.


Measure battery voltage during cranking.
OK: 8 V or more
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Check battery (Refer to GROUP 54 -

Battery - On-vehicle Service - Battery test


354A).

Relay boxs
triangle marks

Harness side
connector

B-17X

AK300255 AB

Remove relay, and measure at relay box side.


Voltage between terminal No. 3 and earth, also
between terminal No. 4 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Check intermediate connector A-14, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between B-17X (terminal No. 4)
engine control relay connector and battery.
Check power supply line for
open/short circuit.

MULTIPORT FUEL INJECTION (MFI)

13A-235

TROUBLESHOOTING

STEP 5. Measure voltage at C-134 engine-ECU


connector.

STEP 7. Measure voltage at C-137 engine-ECU


connector.
CONNECTOR: C-137

CONNECTOR: C-134

C-134

C-137

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300257 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 12 and earth, also
between terminal No. 25 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Check and repair C-134 engine-ECU

AK300254 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 82 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Go to Step 8 .

connector.
NO : Go to Step 6 .

STEP 8. Connector check: C-137 engine-ECU


connector

STEP 6. Connector check: C-137 engine-ECU


connector

CONNECTOR: C-137

CONNECTOR: C-137

C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 9 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-236

TROUBLESHOOTING

STEP 9. Check ignition switch.


Check ignition switch (Refer to GROUP 54A Ignition Switch - Ignition Switch 354A).
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Replace ignition switch.

STEP 11. Check harness between C-303 (terminal


No. 2) ignition switch connector and C-137
(terminal No. 82) engine-ECU connector.
CONNECTOR: C-303

STEP 10. Connector check: C-303 ignition switch


connector
CONNECTOR: C-303

C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

C-303

CONNECTOR: C-137

3 2 1
6 5 4
Harness side
connector
AK300304 AB

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Repair.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

NOTE: Before checking harness, check intermediate


connectors C-106, C-202 and C-203, and repair if
necessary.
Check output line for open/short circuit.
Q: Is the check result normal?
YES : Check and repair ignition switch IG1 power

supply line harness and connector.


Check power supply line for short
circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-237

TROUBLESHOOTING

STEP 12. Measure voltage at C-135 engine-ECU


connector.
CONNECTOR: C-135

STEP 13. Measure voltage at C-135 engine-ECU


connector.
CONNECTOR: C-135

C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Harness side connector


AK300256 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 38 and earth.
OK: 1 V or less

CONNECTOR: B-17X
Relay boxs
triangle marks

Harness side
connector

AK300256 AB

B-17X

Q: Is the check result normal?


YES : Go to Step 17 .
NO : Go to Step 14 .

AK300255 AB

Measure engine-ECU terminal voltage.


Ignition switch: OFF
Voltage between terminal No. 38 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 13 .
NO : Check and repair harness between B-17X

(terminal No. 2) engine control relay


connector and C-135 (terminal No. 38)
engine-ECU connector.
Check earthing line for open/short
circuit.

MULTIPORT FUEL INJECTION (MFI)

13A-238

TROUBLESHOOTING

STEP 14. Connector check: C-135 engine-ECU


connector, C-303 ignition switch connector
CONNECTOR: C-135

STEP 15. Check harness between C-303 (terminal


No. 2) ignition switch connector and C-137
(terminal No. 82) engine-ECU connector.
CONNECTOR: C-303

C-303
C-135

3 2 1
6 5 4
Harness side
connector
AK300304 AB

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

CONNECTOR: C-137

Harness side connector


AK300256 AB

CONNECTOR: C-303

C-137
C-303
3 2 1
6 5 4

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side
connector
AK300304 AB

Harness side connector


AK300254 AB

Q: Is the check result normal?


YES : Go to Step 15 .
NO : Repair.

NOTE: Before checking harness, check intermediate


connectors C-106, C-202 and C-203 and repair if
necessary.
Check output line for open/short circuit.
Q: Is the check result normal?
YES : Go to Step 16 .
NO : Repair.

STEP 16. Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).

MULTIPORT FUEL INJECTION (MFI)

13A-239

TROUBLESHOOTING

STEP 17. Check harness between B-17X


(terminal No. 1) engine control relay connector
and C-134 (terminal No. 12 and No. 25) engineECU connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

STEP 18. Check engine control relay output


power supply harness and connector for short
circuit.
Q: Is the check result normal?
YES : Go to Step 19 .
NO : Repair.

STEP 19. Check harness between B-17X


(terminal No. 3 and No. 4) engine control relay
connector and battery.
CONNECTOR: B-17X

Harness side
connector

AK300255 AB

Relay boxs
triangle marks

B-17X

CONNECTOR: C-134
2

Harness side
connector
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

NOTE: Before checking harness, check intermediate


connector C-17, and repair if necessary.
Check output line for open/short circuit and damage.
Q: Is the check result normal?
YES : Go to Step 18 .
NO : Repair.

AK300255 AB

NOTE: Before checking harness, check intermediate


connector A-14, and repair if necessary.
Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 20 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-240

TROUBLESHOOTING

STEP 20. Check harness between B-17X


(terminal No. 2) engine control relay connector
and C-135 (terminal No. 38) engine-ECU
connector.
CONNECTOR: B-17X
B-17X

Relay boxs
triangle marks

Harness side
connector

AK300255 AB

CONNECTOR: C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Check earthing line for damage.


Q: Is the check result normal?
YES : Go to Step 16 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-241

TROUBLESHOOTING

Inspection Procedure 24: Fuel Pump System

Fuel pump circuit


Battery
C-303

123
456

24
15A

L-B

C-202
2

4
C-213

1 2
3 4

1 2
3 4

OFF

Fuel
pump
relay (1)
C-215

C-203
6

ON

Ignition switch

ACC
IG2

C-116
41

C-215

ST
IG1

Reray box

LOCK

ON

OFF

Fuel
pump
relay (2)
C-213

C-209 1

C-205 11

8
7.5A
J/B

C-205
14

B-L
D-24 6

G
B-L
5
Fuel pump
D-16
(MU802058)

1 2 3
4 5

B
D-24 4
G
B
22

C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300311 AB

MULTIPORT FUEL INJECTION (MFI)

13A-242

TROUBLESHOOTING

OPERATION
The battery voltage is applied to the fuel pump
relay (1) (terminal No. 3) form the ignition switch
and is earthed to the vehicle body from the fuel
pump relay (1) (terminal No. 2).
The battery voltage is applied to the fuel pump
relay (1) (terminal No. 4) and to the fuel pump
relay (2) (terminal No. 1) from the fuel pump relay
(1) (terminal No. 1).
The battery voltage is applied to the fuel pump
relay (2) (terminal No. 3) from the ignition switch.
The engine-ECU (terminal No. 22) makes the
power transistor in the unit be in "ON" position
and makes currents go on the fuel pump relay (2)
coil, and that makes the relay be in "ON" position.
When the fuel pump relay (2) is in "ON" position,
the battery voltage is supplied to the fuel pump
(low pressure) from the fuel pump relay (2) (terminal No. 4).
FUNCTION
When the ignition switch ON signal is input to the
engine-ECU, the engine-ECU places the fuel
pump relay in the "ON" position. Accordingly, the
battery voltage is supplied to the fuel pump.
PROBABLE CAUSE
Failed fuel pump relay
Failed fuel pump
Open/short circuit in fuel pump drive circuit or
loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-215 fuel pump relay
(1) connector and C-213 fuel pump relay (2)
connector
CONNECTOR: C-213, C-215

Junction blocks
triangle marks

C-215
C-213

2 1
4 3
Harness side
connector

AK300312 AB

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

STEP 2. Check fuel pump relay.


Fuel pump relay, continuity check (Refer to
313A).
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Replace fuel pump relay.

STEP 3. Measure resistance at C-215 fuel pump


relay (1) connector.
CONNECTOR: C-215

Junction blocks
triangle marks

C-215
2 1
4 3
Harness side
connector

AK300313 AB

Remove relay, and measure at junction block


side.
Resistance between terminal No. 2 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Check intermediate connector C-205, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between C-215 (terminal No. 2)
fuel pump relay (1) connector and body
earth.
Check earthing line for open circuit
and damage.

MULTIPORT FUEL INJECTION (MFI)

13A-243

TROUBLESHOOTING

STEP 4. Measure voltage at C-215 fuel pump


relay (1) connector.
CONNECTOR: C-215

Junction blocks
triangle marks

STEP 5. Connector check: C-303 ignition switch


connector
CONNECTOR: C-303

C-215
2 1
4 3
Harness side
connector

C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

AK300313 AB

Remove relay, and measure at junction block


side.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 5 .

CONNECTOR: C-215

Junction blocks
triangle marks

C-215
2 1
4 3
Harness side
connector

AK300313 AB

Q: Is the check result normal?


YES : Check intermediate connector C-203, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between C-215 (terminal No. 3)
fuel pump relay (1) connector and C-303
(terminal No. 2) ignition switch connector.
Check power supply line for open
circuit and damage.
NO : Repair.

13A-244

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 6. Measure voltage at C-215 fuel pump


relay (1) connector.
CONNECTOR: C-215

Junction blocks
triangle marks

STEP 8. Connector check: C-303 ignition switch


connector
CONNECTOR: C-303

C-215
2 1
4 3
Harness side
connector

C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

AK300313 AB

Remove relay, and measure at junction block


side.
Voltage between terminal No. 4 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Check intermediate connectors C-116 and

C-202, and repair if necessary. If


intermediate connectors are normal, check
and repair harness between C-215 (terminal
No. 4) fuel pump relay (1) connector and
battery.
Check power supply line for
open/short circuit.
STEP 7. Measure voltage at C-213 fuel pump
relay (2) connector.
CONNECTOR: C-213

C-213

Junction blocks
triangle marks

2 1
4 3
Harness side
connector

AK300321 AB

Remove relay, and measure at junction block


side.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 8 .

CONNECTOR: C-213

C-213

Junction blocks
triangle marks

2 1
4 3
Harness side
connector

AK300321 AB

Q: Is the check result normal?


YES : Check intermediate connector C-203, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between C-303 (terminal No. 2)
ignition switch connector and C-213
(terminal No. 3) fuel pump relay (2)
connector.
Check power supply line for
open/short circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-245

TROUBLESHOOTING

STEP 9. Connector check: C-134 engine-ECU


connector

STEP 10. Measure voltage at C-134 engine-ECU


connector.
CONNECTOR: C-134

CONNECTOR: C-134

C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Repair.

AK300257 AB

CONNECTOR: C-213

C-213

Junction blocks
triangle marks

2 1
4 3
Harness side
connector

AK300321 AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 22 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Check intermediate connectors C-106 and

C-205, and repair if necessary. If


intermediate connectors are normal, check
and repair harness between C-213 (terminal
No. 2) fuel pump relay (2) connector and C134 (terminal No. 22) engine-ECU
connector.
Check earthing line for open/short
circuit.

13A-246

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 11. Connector check: D-16 fuel pump


connector
Connector: D-16

STEP 13. Check harness between C-213 (terminal


No. 4) fuel pump relay (2) connector and D-16
(terminal No. 5) fuel pump connector.
CONNECTOR: C-213

D-16 (GR)
3 2 1
5 4
Harness side
connector

Junction blocks
triangle marks

2 1
4 3
Harness side
connector

C-213

AK203431AC
AK300321 AB

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Repair.

Connector: D-16

STEP 12. Measure voltage at D-16 fuel pump


connector.
D-16 (GR)

Connector: D-16

3 2 1
5 4
Harness side
connector
D-16 (GR)

3 2 1
5 4
Harness side
connector

AK203431AC

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Using a jumper wire, connect C-134 (terminal No.
22) engine-ECU connector and earth.
Voltage between terminal No. 5 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 14 .
NO : Go to Step 13 .

AK203431AC

NOTE: Before checking harness, check intermediate


connectors D-209 and D-24, and repair if necessary.
Check output line for open/short circuit and damage.
Q: Is the check result normal?
YES : Replace engine-ECU.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-247

TROUBLESHOOTING

STEP 14. Measure resistance at D-16 fuel pump


connector.
Connector: D-16

STEP 16. Check harness between C-303 (terminal


No. 2) ignition switch connector and C-215
(terminal No. 3) fuel pump relay (1) connector.
CONNECTOR: C-303

D-16 (GR)
3 2 1
5 4
Harness side
connector

C-303
3 2 1
6 5 4

AK203431AC

Disconnect connector, and measure at harness


side.
Resistance between terminal No. 4 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 15 .
NO : Check intermediate connector D-24, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between D-16 (terminal No. 4) fuel
pump connector and body earth.
Check earthing line for open circuit
and damage.
STEP 15. Connector check: C-303 ignition switch
connector
CONNECTOR: C-303

C-303
3 2 1
6 5 4

Harness side
connector
AK300304 AB

CONNECTOR: C-215

C-215
2 1
4 3
Harness side
connector

AK300313 AB

NOTE: Before checking harness,check intermediate


connector C-203, and repair if necessary.
Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 17.
NO : Repair.

STEP 17. Check harness between battery and C215 (terminal No. 4) fuel pump relay (1)
connector.
CONNECTOR: C-215

Harness side
connector
AK300304 AB

Junction blocks
triangle marks

Junction blocks
triangle marks

C-215
2 1
4 3
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 16 .
NO : Repair.

AK300313 AB

NOTE: Before checking harness, check intermediate


connector C-202, and repair if necessary.
Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 18 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-248

TROUBLESHOOTING

STEP 18. Check harness between C-215 (terminal


No. 1) fuel pump relay (1) connector and C-213
(terminal No. 1) fuel pump relay (2) connector.
CONNECTOR: C-213, C-215

Junction blocks
triangle marks

STEP 20. Check harness between C-213 (terminal


No. 3) fuel pump relay (2) connector and C-134
(terminal No. 22) engine-ECU connector.
CONNECTOR: C-213

Junction blocks
triangle marks

C-215
C-213

2 1
4 3
Harness side
connector

2 1
4 3
Harness side
connector

C-213

AK300312 AB

Check power supply line for damage.

AK300321 AB

CONNECTOR: C-134

Q: Is the check result normal?


YES : Go to Step 19 .
NO : Repair.

STEP 19. Check harness between C-303 (terminal


No. 2) ignition switch connector and C-213
(terminal No. 3) fuel pump relay (2) connector.

C-134

CONNECTOR: C-303
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


C-303
AK300257 AB

3 2 1
6 5 4
Harness side
connector
AK300304 AB

CONNECTOR: C-213

C-213

Junction blocks
triangle marks

2 1
4 3
Harness side
connector

AK300321 AB

Check power supply line for damage.


Q: Is the check result normal?
YES : Go to Step 20 .
NO : Repair.

NOTE: Before checking harness, check intermediate


connectors C-106 and C-205, and repair if necessary.
Check earthing line for open/short circuit.
Q: Is the check result normal?
YES : Go to Step 21.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

STEP 21. Check harness between C-213 (terminal


No. 3) fuel pump relay (2) connector and D-16
(terminal No.5) fuel pump connector.
CONNECTOR: C-213

Junction blocks
triangle marks

2 1
4 3
Harness side
connector

C-213

AK300321 AB

CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

NOTE: Before checking harness, check intermediate


connectors D-24 and C-205, and repair if necessary.
Check output line for open/short circuit.
Q: Is the check result normal?
YES : Replace fuel pump.
NO : Repair.

13A-249

MULTIPORT FUEL INJECTION (MFI)

13A-250

TROUBLESHOOTING

Inspection Procedure 25: Fan Control Relay System

Fan control relay Circuit


Battery
W

9
20A
W-B
A-14
5
W-B

W-B
3

4
B-17X

Engine control relay

1
Engine control system

R
To engine-ECU

Fusible link (2)

J/C (2)
C-17

R
A-14
11

L-W
R

4
A-10X

Fan control relay

4
2

3
B

L
3

A-20
(MU802322)
1 2 3

Smoothing
circuit

Fan controller

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet

O: Orange GR: Gray


AK300323 AB

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

OPERATION
The battery voltage is applied to the fan control
relay (terminal No. 1) from the engine control
relay (terminal No. 1) and is earthed to the vehicle body from the fan control relay (terminal No.
3).
The battery voltage is applied to the fan control
relay (terminal No. 4).
When the fan control relay is in "ON" position, the
battery voltage is supplied to the fan controller
(terminal No. 3) from the fan control relay (terminal No. 2).
FUNCTION
When the engine control relay is in "ON" position,
the fan control relay is also simultaneously
placed in "ON" position. Accordingly, the battery
voltage is supplied to the fan controller.
PROBABLE CAUSE
Failed fan control relay
Failed fan controller
Failed radiator fan motor
Failed condenser fan motor
Open/short circuit in fan control relay circuit or
loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. Connector check: A-10X fan control
relay connector
CONNECTOR: A-10X

STEP 2. Check fan control relay.


Check fan control relay (Refer to GROUP 14 On-vehicle Service 314).
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Replace fan control relay.

STEP 3. Measure resistance at A-10X fan control


relay connector.
CONNECTOR: A-10X

A-10X

1
4
Harness side
connector

Remove relay and measure at relay box side.


Resistance between terminal No. 3 and earth.
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Check and repair harness between A-10X

(terminal No. 3) fan control relay connector


and body earth.
Check earthing line for open circuit
and damage.

CONNECTOR: A-10X

A-10X

4
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

AK300324 AB

STEP 4. Measure voltage at A-10X fan control


relay connector.
A-10X

13A-251

AK300324 AB

1
4
Harness side
connector

AK300324 AB

Remove relay and measure at relay box side.


Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 5 .

MULTIPORT FUEL INJECTION (MFI)

13A-252

TROUBLESHOOTING

STEP 5. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

STEP 6. Measure voltage at A-10X fan control


relay connector.
CONNECTOR: A-10X

B-17X
A-10X

Harness side
connector

AK300255 AB

A-10X

4
Harness side
connector

1
4
Harness side
connector

AK300324 AB

Remove relay, and measure at relay box side.


Voltage between terminal No. 4 and earth
OK: System voltage

CONNECTOR: A-10X

AK300324 AB

Q: Is the check result normal?


YES : Check intermediate connectors A-14 and C-

17, and repair if necessary. If intermediate


connectors are normal, check and repair
harness between B-17X (terminal No. 1)
engine control relay connector and A-10X
(terminal No. 1) fan control relay connector.
Check power supply line for
open/short circuit.
NO : Repair.

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Check and repair harness between battery

and A-10X (terminal No. 4) fan control relay


connector.
Check power supply line for
open/short circuit.
STEP 7. Connector check: A-20 fan controller
connector
Connector: A-20

A-20 (GR)

3 2 1
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.

AK203423 AC

MULTIPORT FUEL INJECTION (MFI)

13A-253

TROUBLESHOOTING

STEP 8. Measure voltage at A-20 fan controller


connector.

STEP 10. Connector check: B-17X engine control


relay connector
CONNECTOR: B-17X

Connector: A-20

Relay boxs
triangle marks

B-17X

A-20 (GR)

3 2 1
Harness side
connector

AK203423 AC

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Go to Step 9 .

STEP 9. Check harness between A-10X (terminal


No. 2) fan control relay connector and A-20
(terminal No. 3) fan controller connector.

Harness side
connector

AK300255 AB

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Repair.

STEP 11. Check harness between B-17X


(terminal No. 1) engine control relay connector
and A-10X (terminal No. 1) fan control relay
connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

B-17X

CONNECTOR: A-10X

A-10X

1
4
Harness side
connector

Harness side
connector

AK300255 AB

CONNECTOR: A-10X

AK300324 AB

A-10X
Connector: A-20
3

1
4
Harness side
connector

A-20 (GR)

3 2 1
Harness side
connector

AK300324 AB

NOTE: Before checking harness, check intermediate


connectors A-14 and C-17, and repair if necessary.
Check power supply line for damage.
AK203423 AC

Check output line for open/short circuit.


Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair.

Q: Is the check result normal?


YES : Check and repair harness between A-10X

(terminal No. 3) fan control relay connector


and body earth.
Check earthing line for damage.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-254

TROUBLESHOOTING

STEP 12. Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

STEP 14. MUT-II actuator test


Item 21: Fan controller
OK: Fan motor rotates.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

C-134

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.
STEP 15. Measure voltage at C-134 engine-ECU
connector.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

CONNECTOR: C-134

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 13 .
NO : Repair.

C-134

STEP 13. Fan motor drive test.


CONNECTOR: C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Disconnect C-134 engine-ECU connector.


Ignition switch: ON
OK: Fan motor rotates.
Q: Is the check result normal?
YES : Go to Step 14 .
NO : Go to Step 15 .

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 21 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 16 .
NO : Go to Step 18 .

MULTIPORT FUEL INJECTION (MFI)

13A-255

TROUBLESHOOTING

STEP 16. Check harness between A-10X


(terminal No. 4) fan control relay connector and
battery.
CONNECTOR: A-10X

STEP 18. Check harness between A-20 (terminal


No. 2) fan controller connector and C-134
(terminal No. 21) engine-ECU connector.
Connector: A-20

A-10X
A-20 (GR)
3

1
4
Harness side
connector

AK300324 AB

Check power supply line for damage.

3 2 1
Harness side
connector

AK203423 AC

CONNECTOR: C-134

Q: Is the check result normal?


YES : Go to Step 17 .
NO : Repair.

STEP 17. Check harness between A-10X


(terminal No. 2) fan control relay connector and
A-20 (terminal No. 3) fan controller connector.

C-134

CONNECTOR: A-10X
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

A-10X

Harness side connector


AK300257 AB

1
4
Harness side
connector

AK300324 AB

Q: Is the check result normal?


YES : Replace fan motor and fan controller.
NO : Repair.

Connector: A-20

A-20 (GR)

3 2 1
Harness side
connector

NOTE: Before checking harness, check intermediate


connector A-14, and repair if necessary.
Check output line for short circuit.

AK203423 AC

Check output line for damage.


Q: Is the check result normal?
YES : Replace fan motor and fan controller.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-256

TROUBLESHOOTING

Inspection Procedure 26: A/C Switch System

A/C Switch circuit

C-06
A/C-ECU

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

4 <Manual A/C>
34 <Auto A/C>
G-B
C-104
7
G-B
45
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300325 AB

OPERATION
The battery voltage is applied to the engine-ECU
(terminal No. 45) from the A/C-ECU (terminal No.
4) <Manual A/C> or A/C-ECU (terminal No. 34)
<Auto A/C>.
FUNCTION
When the A/C switch is in "ON" position, A/C
switch ON signal is inputted to the engine-ECU
from the A/C-ECU. In response to the signal, the
engine-ECU controls the A/C compressor relay.

PROBABLE CAUSE
Failed A/C
Failed A/C system
Open/short circuit in A/C circuit or loose connector contact
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-257

TROUBLESHOOTING

DIAGNOSIS PROCEDURE
STEP 1. Measure voltage at C-135 engine-ECU
connector.
CONNECTOR: C-135

STEP 2. Measure voltage at C-06 A/C-ECU


connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C>.
Connector: C-06
<Manual A/C>

C-06 (B)

C-135

8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

Harness side
connector

AK300326 AB

Connector: C-26
<Auto A/C>

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Measure engine-ECU terminal voltage.


Engine: Running at idle
A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more
Maximum Hot when temperature in cabin is 25C
or less
Voltage between terminal No. 45 and earth.
OK:
System voltage (when A/C is ON)
0.5 V or less (when A/C is OFF)
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 2 .

28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29

C-26 (B)

Harness side
connector

AK300327AB

Measure engine-ECU terminal voltage.


Engine: Idling
A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more
Maximum Hot when temperature in cabin is 25C
or less
Voltage between terminal No. 4 and earth <Manual A/C>
Voltage between terminal No. 34 and earth <Auto
A/C>
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Go to Step 3 .

MULTIPORT FUEL INJECTION (MFI)

13A-258

TROUBLESHOOTING

STEP 3. Connector check: C-06 A/C-ECU


connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C> C-135 engine-ECU
connector
Connector: C-06
<Manual A/C>

STEP 4. Check harness between C-06 A/C-ECU


connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C> and C-135 (terminal No.
45) engine-ECU connector.
Connector: C-06
<Manual A/C>

C-06 (B)

C-06 (B)

8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

Harness side
connector

AK300326 AB

Connector: C-26
<Auto A/C>

28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29

Harness side
connector

AK300326 AB

Connector: C-26
<Auto A/C>

28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29

C-26 (B)

Harness side
connector

AK300327AB

CONNECTOR: C-135

C-26 (B)

Harness side
connector

AK300327AB

CONNECTOR: C-135

C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 4 .
NO : Repair.

AK300256 AB

NOTE: Before checking harness, check intermediate


connector C-104, and repair if necessary.
Check output line for short circuit.
Q: Is the check result normal?
YES : Check A/C system (Refer to GROUP 55A -

Troubleshooting 355A).
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-259

TROUBLESHOOTING

STEP 5. Connector check: C-06 A/C-ECU


connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C> and C-135 engine-ECU
connector

STEP 6. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

Connector: C-06
<Manual A/C>

C-06 (B)
C-135
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

Harness side
connector

AK300326 AB

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Connector: C-26
<Auto A/C>

AK300256 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29

C-26 (B)

Harness side
connector

AK300327AB

CONNECTOR: C-135

C-135

STEP 7. MUT-II data list


Item 28: A/C switch
a. Engine: Idling
b. A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more.
Maximum Hot when temperature in cabin is
25C or less.
OK:
ON (when A/C is ON)
OFF (when A/C is OFF)
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Check intermediate connector C-104, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between C-06 (terminal No. 4) or
C-26 (terminal No. 34) A/C-ECU connector
and C-135 (terminal No. 45) engine-ECU
connector.
Check output line for open circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-260

TROUBLESHOOTING

Inspection Procedure 27: A/C Compressor Relay System

A/C compressor relay Circuit


Ignition switch
C-303
1 2 3
4 5 6

LOCK

ST
IG1

ACC
IG2

4
L-R
Battery

C-203
2
5 J/B
7.5A

10
10A

C-205
16

Relay box

L-R
B-R

C-106
11

A-14
9

B-R

L-R
3

4
B-18X

A/C compressor relay

A/C-ECU

B-W
1

8
Engine-ECU

A/C compressor
assembly
B-27
(MU802653)

A/C refrigerant
temperature
switch

Magnetic
clutch

C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet

O: Orange GR: Gray


AK300328 AB

MULTIPORT FUEL INJECTION (MFI)

13A-261

TROUBLESHOOTING

OPERATION
The battery voltage is applied to the A/C compressor relay (terminal No. 4).
The battery voltage is applied to the A/C compressor relay (terminal No. 3) from the ignition
switch. The engine-ECU (terminal No. 8) makes
the power transistor in the unit be in "ON" position and makes currents go on the A/C compressor relay coil, and that makes the relay be in "ON"
position.
When the A/C compressor is in "ON" position, the
battery voltage is supplied to the A/C compressor
(terminal No. 1) from the A/C compressor relay
(terminal No. 1).
FUNCTION
When the A/C switch "ON" signal is input to the
engine-ECU, the engine-ECU places the A/C
compressor relay in the "ON" position. Accordingly, the battery voltage supplied to the A/C compressor operates the magnet clutch.
PROBABLE CAUSE
Failed A/C compressor relay
Failed A/C compressor magnet clutch
Open/short circuit in A/C compressor relay circuit
or loose connector contact
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-18X A/C
compressor relay connector
CONNECTOR: B-18X
Relay boxs
triangle marks

B-18X

Harness side
connector

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Repair.

AK300329 AB

STEP 2. A/C compressor relay check.


Check A/C compressor relay (Refer to GROUP
55A - On-vehicle Service 355A).
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Replace A/C compressor relay.

STEP 3. Measure voltage at B-18X A/C


compressor relay connector.
CONNECTOR: B-18X
Relay boxs
triangle marks

B-18X

Harness side
connector

AK300329 AB

Remove relay, and measure at relay box side.


Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 5 .
NO : Go to Step 4 .

MULTIPORT FUEL INJECTION (MFI)

13A-262

TROUBLESHOOTING

STEP 4. Connector check: C-303 ignition switch


connector

STEP 5. Measure voltage at B-18X A/C


compressor relay connector.
CONNECTOR: B-18X

CONNECTOR: C-303

Relay boxs
triangle marks

B-18X

C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

Harness side
connector

Harness side
connector

AK300329 AB

Remove relay, and measure at relay box side.


Voltage between terminal No. 4 and earth.
OK: System voltage

CONNECTOR: B-18X
Relay boxs
triangle marks

B-18X

Q: Is the check result normal?


YES : Go to Step 6 .
NO : Check intermediate connector A-14, and

AK300329 AB

Q: Is the check result normal?


YES : Check intermediate connectors C-106, C-

202 <Auto A/C>, C-203 and C-205 <Manual


A/C>, and repair if necessary. If
intermediate connectors are normal, check
and repair harness between B-18X
(terminal No. 3) A/C compressor relay
connector and C-303 (terminal No. 4)
ignition switch connector.
Check power supply line for
open/short circuit.
NO : Repair.

repair if necessary. If intermediate


connector is normal, check and repair
harness between B-18X (terminal No. 4)
A/C compressor relay connector and
battery.
Check power supply line for
open/short circuit.
STEP 6. Connector check: B-27 A/C compressor
connector
CONNECTOR: B-27

B-27 (B)
1
Harness side
connector

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

AK300330 AB

MULTIPORT FUEL INJECTION (MFI)

13A-263

TROUBLESHOOTING

STEP 7. Measure voltage at B-27 A/C compressor


connector.

STEP 8. Measure voltage at C-134 engine-ECU


connector.
CONNECTOR: C-134

CONNECTOR: B-27

B-27 (B)
C-134

1
Harness side
connector

AK300330 AB

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

CONNECTOR: B-18X
Relay boxs
triangle marks

B-18X

Harness side connector


AK300257 AB

Harness side
connector

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 8 and earth.
OK: System voltage
AK300329 AB

Disconnect connector, and measure at harness


side.
Remove B-18X (terminal No. 1 and No. 4) A/C
compressor relay and short-circuit of harness
side connector.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: System voltage

Q: Is the check result normal?


YES : Go to Step 12 .
NO : Go to Step 9 .

STEP 9. Connector check: C-134 engine-ECU


connector
CONNECTOR: C-134

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Check and repair harness between B-27

(terminal No. 1) A/C compressor connector


and B-18X (terminal No. 1) A/C compressor
relay connector.
Check output line for open/short
circuit.

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 10 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-264

TROUBLESHOOTING

STEP 10. Check harness between B-18X


(terminal No. 2) A/C compressor relay connector
and C-134 (terminal No. 8) engine-ECU
connector.
CONNECTOR: B-18X
Relay boxs
triangle marks

B-18X

STEP 11. MUT-II Data List


Item 49: A/C relay
a. Engine: Idling
b. A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more
Maximum Hot when temperature in cabin is
25C or less
OK:
ON (when A/C is ON)
OFF (when A/C is OFF)
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

Harness side
connector

AK300329 AB

CONNECTOR: C-134

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.
STEP 12. Connector check: C-134 engine-ECU
connector

C-134

CONNECTOR: C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


C-134
AK300257 AB

Check earthing line for open circuit and damage.


Q: Is the check result normal?
YES : Go to Step 11 .
NO : Repair.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 13 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-265

TROUBLESHOOTING

STEP 13. Check harness between B-18X


(terminal No. 2) A/C compressor relay connector
and C-134 (terminal No. 8) engine-ECU
connector.

STEP 15. Check harness between C-303 (terminal


No. 4) ignition switch connector and B-18X
(terminal No. 3) A/C compressor relay connector.
CONNECTOR: C-303

CONNECTOR: B-18X
Relay boxs
triangle marks

B-18X

C-303
2

3 2 1
6 5 4
Harness side
connector
AK300304 AB

Harness side
connector

AK300329 AB

CONNECTOR: B-18X
CONNECTOR: C-134

Relay boxs
triangle marks

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Check earthing line for damage.


Q: Is the check result normal?
YES : Go to Step 14 .
NO : Repair.

STEP 14. Connector check: C-303 ignition switch


connector
CONNECTOR: C-303

Harness side
connector

3 2 1
6 5 4

AK300329 AB

NOTE: Before checking harness, check intermediate


connectors C-106, C-202 <Auto A/C>, C-203 and C205 <Manual A/C>, and repair if necessary.
Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 16 .
NO : Repair.

STEP 16. Check harness between battery and B18X (terminal No. 4) A/C compressor relay
connector.
CONNECTOR: B-18X
Relay boxs
triangle marks

C-303

B-18X

Harness side
connector

Harness side
connector
AK300304 AB

Q: Is the check result normal?


YES : Go to Step 15 .
NO : Repair.

B-18X

AK300329 AB

NOTE: Before checking harness, check intermediate


connector A-14, and repair if necessary.
Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 17 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-266

TROUBLESHOOTING

STEP 17. Check harness between B-18X


(terminal No. 1) A/C compressor relay connector
and B-27 (terminal No. 1) A/C compressor relay
connector.
CONNECTOR: B-18X
Relay boxs
triangle marks

B-18X

Harness side
connector

AK300329 AB

CONNECTOR: B-27

B-27 (B)
1
Harness side
connector

AK300330 AB

Check output line for damage.


Q: Is the check result normal?
YES : Replace A/C compressor magnet clutch.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)


TROUBLESHOOTING

13A-267

Inspection Procedure 28: A/C Load Signal System

A/C load signal circuit

C-06
A/C-ECU

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

5 <Manual A/C>
32 <Auto A/C>
L-W
C-106
6
L-W
24
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300338 AB

OPERATION
The A/C load signal is inputted to the engineECU (terminal No. 24) from the A/C-ECU (terminal No. 5). <Manual A/C> or (terminal No. 32)
<Auto A/C>
FUNCTION
The magnitude of the A/C compressor load is
detected and input to the engine-ECU. The
engine-ECU provides A/C idle up control according to the A/C compressor load condition.

PROBABLE CAUSE
Failed A/C-ECU
Open/short circuit in A/C load signal circuit or
loose connector contact
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-268

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 2. Connector check: C-134 engine-ECU


connector

STEP 1. Measure voltage at C-134 engine-ECU


connector.

CONNECTOR: C-134

CONNECTOR: C-134

C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Harness side connector


AK300257 AB

Measure engine-ECU terminal voltage.


Engine: Idling
A/C switch: ON (A/C compressor in driven state)
Voltage between terminal No. 24 and earth
OK:
1 V or less (when the temperate around the
atmospheric air temperature sensor is 18C
or more, and the A/C is set to the lowest temperature and the maximum air flow rate)
System voltage (when the A/C is set to the
temperature in the cabin and the minimum
air flow rate)

Q: Is the check result normal?


YES : Go to Step 2 .
NO : Go to Step 4 .

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

STEP 3. Check the trouble symptoms.


Q: Does trouble symptom persist?
YES : Replace engine-ECU.
NO : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
STEP 4. Connector check: C-134 engine-ECU
connector
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

Q: Is the check result normal?


YES : Go to Step 5 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-269

TROUBLESHOOTING

STEP 5. Measure voltage at C-06 A/C-ECU


connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C>.
Connector: C-06
<Manual A/C>

STEP 6. Connector Check: C-06 A/C-ECU


connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C>
Connector: C-06
<Manual A/C>

C-06 (B)

C-06 (B)

8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

Harness side
connector

AK300326 AB

Connector: C-26
<Auto A/C>

28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29

Harness side
connector

AK300326 AB

Connector: C-26
<Auto A/C>

28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29

C-26 (B)

Harness side
connector

AK300327AB

Measure A/C-ECU terminal voltage.


Engine: Idling
A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more
Maximum Hot when temperature in cabin is 25C
or less
Voltage between terminal No. 5 and earth <Manual A/C>
Voltage between terminal No. 32 and earth <Auto
A/C>
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 6 .

C-26 (B)

Harness side
connector

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

AK300327AB

MULTIPORT FUEL INJECTION (MFI)

13A-270

TROUBLESHOOTING

STEP 7. Check harness between C-06 (terminal


No. 5) or C-26 (terminal No. 32) A/C-ECU
connector and C-134 (terminal No. 24) engineECU connector.
Connector: C-06
<Manual A/C>

STEP 8. Check connector: C-06 A/C-ECU


connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C>
Connector: C-06
<Manual A/C>

C-06 (B)
C-06 (B)

8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

Harness side
connector

Harness side
connector

AK300326 AB

Connector: C-26
<Auto A/C>

28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29

Connector: C-26
<Auto A/C>

28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29

C-26 (B)

Harness side
connector

C-26 (B)

Harness side
connector

AK300326 AB

AK300327AB

AK300327AB

CONNECTOR: C-134
CONNECTOR: C-134

C-134
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

Harness side connector


AK300257 AB

AK300257 AB

NOTE: Before checking harness, check intermediate


connector C-104, and repair if necessary.
Check output line for short circuit.
Q: Is the check result normal?
YES : Check A/C system (Refer to GROUP 55A -

Troubleshooting 355A).
NO : Repair.

Q: Is the check result normal?


YES : Check intermediate connector C-104, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between C-06 (terminal No. 5) or
C-26 (terminal No. 32) A/C-ECU connector
and C-134 (terminal No. 24) engine-ECU
connector.
Check output line for open circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-271

TROUBLESHOOTING

Inspection Procedure 29: A/C Pressure Sensor System

A/C Pressure sensor circuit

A-02
(MU802509)

A/C Pressure sensor

1 2 3
3

1
BR

G-Y

G-R
C-116
5

17

A-14
17

BR

G-R
C-105
21

C-104
4

G-Y

81

A/C-ECU

G-R

BR
92

42

C-135

C-137

31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46

71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192

5V

Engine-ECU

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300339 AB

OPERATION
A power voltage of 5 V is applied to the A/C pressure sensor power terminal (terminal No. 3) from
the engine-ECU (terminal No. 81) and is earthed
to the engine-ECU (terminal No. 92) from the A/C
pressure sensor (terminal No. 1).
The sensor signal is inputted to the engine-ECU
(terminal No. 42) from the A/C pressure sensor
output terminal (terminal No. 2).

FUNCTION
The A/C pressure sensor detects the A/C refrigerant pressure and inputs the pressure signal to
the engine-ECU. The engine-ECU uses the signal for ON/OFF control of the magnet clutch of
the A/C compressor.
PROBABLE CAUSE
Failed A/C pressure sensor
Open/short circuit in A/C pressure sensor circuit
or loose connector contact
Failed engine-ECU

MULTIPORT FUEL INJECTION (MFI)

13A-272

TROUBLESHOOTING

DIAGNOSIS PROCEDURE

STEP 3. Measure voltage at A-02 A/C pressure


sensor connector.

STEP 1. MUT-II Data List

Connector: A-02

Connector: A-02

A-02 (B)
A-02 (B)
3 2 1
Harness side
connector

3 2 1
Harness side
connector
AK300340AB

Refer to Data list reference table 313A.


a. Item 3A: A/C pressure sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: A-02 A/C pressure
sensor connector

AK300340AB

Disconnect connector, and measure at harness


side.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Go to Step 4 .

STEP 4. Measure voltage at C-137 engine-ECU


connector.
CONNECTOR: C-137

Connector: A-02

A-02 (B)
C-137

3 2 1
Harness side
connector
AK300340AB

Q: Is the check result normal?


YES : Go to Step 3 .
NO : Repair.

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Measure engine-ECU terminal voltage.


Ignition switch: ON
Voltage between terminal No. 81 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 6 .
NO : Go to Step 5 .

MULTIPORT FUEL INJECTION (MFI)

13A-273

TROUBLESHOOTING

STEP 5. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

STEP 6. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

C-137

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

Harness side connector


AK300254 AB

AK300254 AB

Q: Is the check result normal?


YES : Go to Step 7 .
NO : Repair.

Connector: A-02

A-02 (B)

3 2 1
Harness side
connector
AK300340AB

Q: Is the check result normal?


YES : Check intermediate connector A-14, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between A-02 (terminal No. 3) A/C
pressure sensor connector and C-137
(terminal No. 81) engine-ECU connector.
Check power line for open circuit.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-274

TROUBLESHOOTING

STEP 7. Check harness between A-02 (terminal


No. 3) A/C pressure sensor connector and C-137
(terminal No. 81) engine-ECU connector.

STEP 9. Measure resistance at A-02 A/C pressure


sensor connector.
Connector: A-02

Connector: A-02

A-02 (B)
A-02 (B)
3 2 1
Harness side
connector

3 2 1
Harness side
connector
AK300340AB

CONNECTOR: C-137

AK300340AB

Disconnect connector, and measure at harness


side.
Resistance between terminal No. 1 and earth
OK: 2 W or less
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Go to Step 10 .

C-137

STEP 10. Connector check: C-137 engine-ECU


connector
CONNECTOR: C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

NOTE: Before checking harness, check intermediate


connector A-14, and repair if necessary.
Check power line for short circuit.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector

STEP 8. MUT-II Data List


Refer to Data list reference table 313A.
a. Item 3A: A/C pressure sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP

00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Replace engine-ECU.

AK300254 AB

Q: Is the check result normal?


YES : Go to Step 11 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-275

TROUBLESHOOTING

STEP 11. Check harness between A-02 (terminal


No. 1) A/C pressure sensor connector and C-137
(terminal No. 92) engine-ECU connector.

STEP 12. Measure voltage at A-02 A/C pressure


sensor connector.
Connector: A-02

Connector: A-02

A-02 (B)
A-02 (B)
3 2 1
Harness side
connector

3 2 1
Harness side
connector
AK300340AB

CONNECTOR: C-137

AK300340AB

Use special tool test harness (MB991348) to connect connector, and measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: 4.9 - 5.1 V
Q: Is the check result normal?
YES : Go to Step 14 .
NO : Go to Step 13 .

C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

NOTE: Before checking harness, check intermediate


connectors C-105 and C-116, and repair if necessary.
Check earthing line for open circuit or damage.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-276

TROUBLESHOOTING

STEP 13. Connector check: C-137 engine-ECU


connector

STEP 14. Measure voltage at A-02 A/C pressure


sensor connector.
Connector: A-02

CONNECTOR: C-137

A-02 (B)

3 2 1
Harness side
connector

C-137

AK300340AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: A-02

Use special tool test harness (MB991348) to connect connector, and measure at pick-up harness.
Ignition switch: ON
Voltage between terminal No. 1 and earth.
OK: 0.5 or less
Q: Is the check result normal?
YES : Go to Step 16 .
NO : Go to Step 15 .

A-02 (B)

3 2 1
Harness side
connector
AK300340AB

Q: Is the check result normal?


YES : Check intermediate connector A-14, and

repair if necessary. If intermediate


connector is normal, check and repair
harness between A-02 (terminal No. 3) A/C
pressure sensor connector and C-137
(terminal No. 81) engine-ECU connector.
Check power line for damage.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-277

TROUBLESHOOTING

STEP 15. Connector check: C-137 engine-ECU


connector

STEP 16. Measure voltage at A-02 A/C pressure


sensor connector.
Connector: A-02

CONNECTOR: C-137

A-02 (B)

3 2 1
Harness side
connector

C-137

AK300340AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

Harness side connector


AK300254 AB

Connector: A-02

Use special tool test harness (MB991348) to connect connector, and measure at pick-up harness.
Engine: Running at idle
A/C switch: ON
Voltage between terminal No. 2 and earth.
OK:
1.8 - 2.0 V (A/C refrigerant pressure: 1 kPa)
3.23 - 3.57 V (A/C refrigerant pressure: 2 kPa)
Q: Is the check result normal?
YES : Go to Step 19 .
NO : Go to Step 17 .

A-02 (B)

3 2 1
Harness side
connector
AK300340AB

Q: Is the check result normal?


YES : Check intermediate connectors C-105 and

STEP 17. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

C-116, and repair if necessary. If


intermediate connectors are normal, check
and repair harness between A-02 (terminal
No. 1) A/C pressure sensor connector and
C-137 (terminal No. 92) engine-ECU
connector.
Check earthing line for damage.
NO : Repair.

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector


AK300256 AB

Q: Is the check result normal?


YES : Go to Step 18 .
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-278

TROUBLESHOOTING

STEP 18. Check harness between A-02 (terminal


No. 2) A/C pressure sensor connector and C-135
(terminal No. 42) engine-A/T-ECU connector.

STEP 19. Measure voltage at C-135 engine-ECU


connector.
CONNECTOR: C-135

Connector: A-02

A-02 (B)
C-135

3 2 1
Harness side
connector
AK300340AB

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

CONNECTOR: C-135

Harness side connector


AK300256 AB

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Measure engine-ECU terminal voltage.


Engine: Running at idle
A/C switch: ON
Voltage between terminal No. 42 and earth.
OK:
1.8 - 2.0 V (A/C refrigerant pressure: 1 kPa)
3.23 - 3.57 V (A/C refrigerant pressure: 2 kPa)

Q: Is the check result normal?


YES : Go to Step 21 .
NO : Go to Step 20 .

Harness side connector


AK300256 AB

NOTE: Before checking harness, check intermediate


connectors C-105 and C-116, and repair if necessary.
Check output line for short circuit and damage.
Q: Is the check result normal?
YES : Replace A/C pressure sensor.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-279

TROUBLESHOOTING

STEP 20. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

STEP 21. Connector check: C-135 engine-ECU


connector
CONNECTOR: C-135

C-135

C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

Harness side connector

Harness side connector


AK300256 AB

AK300256 AB

Q: Is the check result normal?


YES : Go to Step 8 .
NO : Repair.

Connector: A-02

A-02 (B)

3 2 1
Harness side
connector
AK300340AB

Q: Is the check result normal?


YES : Check intermediate connectors C-105 and

C-116, and repair if necessary. If


intermediate connectors are normal, check
and repair harness between A-02 (terminal
No. 2) A/C pressure sensor connector and
C-135 (terminal No. 42) engine-ECU
connector.
Check power line for open circuit and
damage.
NO : Repair.

MULTIPORT FUEL INJECTION (MFI)

13A-280

TROUBLESHOOTING

Inspection Procedure 30: Ignition Circuit System

Ignition circuit
Ignition switch
C-303
1 2 3
4 5 6

LOCK

ST
IG1

ACC
IG2

L-B

C-203
6
1
10A

J/B

10
C-205
C-116
26

A-14
16
W

Ignition coil 1
B-110

Ignition coil 2
B-111

1 2 3

1 2 3
3

Spark
plug

B-107
Capacitor

B
W-L

B-L

B
10

23

C-134
Engine-ECU

1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26

Wire colour code


B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300341 AB

MULTIPORT FUEL INJECTION (MFI)

13A-281

TROUBLESHOOTING

OPERATION
The battery voltage is applied to the ignition coil
(terminal No. 1) from the ignition switch and is
earthed to the vehicle body from the ignition coil
(terminal No. 2).
A power voltage of 12 V is applied to the ignition
coil output termin