Mitsubishi Lancer Evo IX.

15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATION . . . . . . . . 15-2 REMOVAL AND INSTALLATION . . . . . . . . 15-5
SERVICE SPECIFICATIONS. . . . . . . 15-2 INTERCOOLER . . . . . . . . . . . . . . . . . 15-6

REMOVAL AND INSTALLATION . . . . . . . . 15-6
SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-2
INLET MANIFOLD . . . . . . . . . . . . . . . 15-7
ON-VEHICLE SERVICE. . . . . . . . . . . 15-2 REMOVAL AND INSTALLATION . . . . . . . . 15-7
TURBOCHARGER SUPERCHARGING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-9
PRESSURE CHECK. . . . . . . . . . . . . . . . . . 15-2
SUPERCHARGING PRESSURE CONTROL EXHAUST MANIFOLD AND
SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . 15-3 TURBOCHARGER . . . . . . . . . . . . . . . 15-10
WASTE GATE ACTUATOR CHECK . . . . . 15-3 REMOVAL AND INSTALLATION . . . . . . . . 15-10
WASTE GATE SOLENOID VALVE CHECK 15-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-12
AIR BY-PASS VALVE CHECK . . . . . . . . . . 15-4
INLET MANIFOLD VACUUM CHECK . . . . 15-4 EXHAUST PIPE AND MAIN MUFFLER 15-13
AIR CLEANER . . . . . . . . . . . . . . . . . . 15-5
15-2 INTAKE AND EXHAUST
GENERAL INFORMATION
GENERAL INFORMATION
M1151000100480
SUPERCHARGING PRESSURE CON-

TROL
By controlling the duty of the waste gate solenoid
valve, the waste gate actuator functions to control
the supercharging pressure. This allows a super-
charged pressure matching the engine operation
state to be attained. Control is carried out to prevent
excessive supercharging and thereby prevent engine
damage.
SERVICE SPECIFICATIONS
M1151000300699
Item Standard value Limit

Turbocharger supercharging pressure 96 − 121 −
(waste gate solenoid valve not operating) kPa
Initial activation pressure of waste gate actuator Approximately 100 −
(at the stroke of approximately 1 mm) kPa
Waste gate solenoid valve coil resistance (at 20°C) Ω 29 − 35 −
Initial activation pressure of air bypass valve kPa Approximately 59 −
Manifold distortion of the installation surface mm 0.15 or less 0.20
SPECIAL TOOL
M1151000600463
Tool Number Name Use

MD998770 Oxygen sensor wrench Removal and installation of
oxygen sensor
ON-VEHICLE SERVICE
TURBOCHARGER SUPERCHARGING
PRESSURE CHECK Plug
M1151001000282
CAUTION Vacuum
Two persons should be in the vehicle when the terminal
test is conducted; the person in the passenger
seat should read the indications shown by the
pressure meter.
Waste gate
actuator AK305234 AB
INTAKE AND EXHAUST
ON-VEHICLE SERVICE
15-3
1. Disconnect the hose (black) from the vacuum 4. Applying a negative pressure with the hand
terminal, and connect the plug to the hose. vacuum pump, check tightness both when the
Connect a pressure gauge to the vacuum terminal hose end is closed and when it is open.
nipple. Engine state Hose end Normal state
2. Drive at full-throttle acceleration in second gear
Stop Opened Negative
and then measure the supercharging pressure
(Ignition switch: ON) pressure leaks.
when the engine speed in about 3,000 r/min.
Standard value: 96 − 121 kPa Closed Negative
pressure is
3. If the supercharging pressure deviates from the maintained.
standard value, check the following items for
Idling (after Negative
possible cause.
warm-up) pressure leaks.
• Malfunction of the waste gate actuator
• Leakage of supercharging pressure NOTE: If this check indicates an abnormal condi-
• Malfunction of the turbocharger tion, the turbocharger waste gate actuator, turbo-
4. When the indicated supercharging is more than charger waste gate solenoid or hose is broken.
standard value, supercharging control may be
faulty, therefore check the followings. WASTE GATE ACTUATOR CHECK
M1151001200178
• Malfunction of the waste gate actuator
• Malfunction of waste gate valve
• Disconnection or cracks of the waste gate actua-
tor rubber hose
SUPERCHARGING PRESSURE
CONTROL SYSTEM CHECK
M1151001100160
Vacuum
AK200367
terminal Three-way joint
1. Connect a manual pump (pressure-application
Boost hose
type) to nipple.
CAUTION
In order to avoid damage to the diaphragm, do
not apply a pressure of 117 kPa or higher.
Waste gate
actuator 2. While gradually applying pressure, check the
AK305236 AB
pressure that begins to activate (approximately 1
1. Disconnect the hose (black) from the vacuum mm stroke) the waste gate actuator rod.
terminal, and connect a three-way joint between Standard value: Approximately 100 kPa
the hose and the vacuum terminal.
3. If there is a significant deviation from the standard
2. Connect a hand vacuum pump to the three-way value, check the actuator or the waste gate valve,
joint. replace actuator or turbocharger assembly if
3. Disconnect the hose from the turbocharger waste necessary.
gate actuator control boost nipple and plug the
nipple.
ON-VEHICLE SERVICE
WASTE GATE SOLENOID VALVE CHECK Measure the resistance between solenoid valve ter-
M1151001300131 minals
OPERATION CHECK Standard value: 29 − 35 Ω (at 20°C)
A
AIR BY-PASS VALVE CHECK
B M1151001600121
Battery
AK200441AC
1. Connect a hand vacuum pump to the solenoid

valve nipple A. AK200443
2. Using a jumper wire, connect between the

1. Remove the air bypass valve.
solenoid valve terminal and battery terminal.
2. Connect the hand vacuum pump to the nipple of
3. Connecting and disconnecting the jumper wire at
the air bypass valve.
the battery negative terminal to apply a negative
pressure, check tightness. 3. Apply a negative pressure of approximately 54
kPa, and check that air tightness is maintained.
Jumper wire B nipple Normal condition 4. Also check operation of the valve.
condition
Standard value:
Connected Opened Negative pressure
leaks. Negative pressure Valve operation
Closed Negative pressure is Approximately 59 kPa It starts opening
held.
Disconnected Opened Negative pressure is INLET MANIFOLD VACUUM CHECK
M1151001800192
held. Refer to GROUP 11A − On-vehicle Service
P.11A-12.
COIL RESISTANCE CHECK
AK200442
INTAKE AND EXHAUST
AIR CLEANER
15-5
AIR CLEANER
REMOVAL AND INSTALLATION
M1151002100594
CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following pre-
cautions.
1. Avoid any shock or load to these parts when removing and installing them.
2. Engage the case hinges securely when assembling these parts.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws
11
12 6*
7 2
4.0 ± 1.0 N·m 3
8* 9.0 ± 1.0 N·m
4.0 ± 1.0 N·m

13
4.0 ± 1.0 N·m
9.0 ± 1.0 N·m N 5 9.0 ± 1.0 N·m
9.0 ± 1.0 N·m

9.0 ± 1.0 N·m
9
10
AC210412 AB
Removal steps Removal steps (Continued)

1. Intake air duct 8. Air cleaner housing
2. Battery 9. Air cleaner bracket
3. Air cleaner assembly 10. Waste gate solenoid valve
4. Airflow sensor assembly 11. Air pipe C, air by-pass hose and air
5. Gasket by-pass valve
6. Air cleaner housing cover 12. Vacuum hose connection
7. Air cleaner element 13. Air intake hose
INTERCOOLER
INTERCOOLER
M1151002400045
Pre-removal and Post-installation Operation

• Intake Air Duct and Air Cleaner Assembly Removal and
Installation (Refer to P.15-5).
6.0 ± 1.0 N·m 6.0 ± 1.0 N·m

12 ± 1 N·m
6.0 ± 1.0 N·m

6.0 ± 1.0 N·m
11 6.0 ± 1.0 N·m
5 4
7 1
6.0 ± 1.0 N·m
3
12 ± 1 N·m
6.0 ± 1.0 N·m 2 12 ± 1 N·m
6
6.0 ± 1.0 N·m
8
12 ± 1 N·m
13
6.0 ± 1.0 N·m
12 12 ± 1 N·m 9
10
6.0 ± 1.0 N·m
AC210413 AB

1. Vacuum hose connection • Front bumper assembly (Refer to
2. Air by-pass valve GROUP 51, Front Bumper
3. Air by-pass hose Assembly P.51-2).
4. Air hose E 8. Air pipe B
5. Air pipe C 9. Bracket
6. Air hose D 10. Air hose C
• Under cover (Refer to GROUP 51, 11. Air pipe A
Front Bumper Assembly P.51-2). 12. Air hose B
7. Air hose A 13. Intercooler assembly
INTAKE AND EXHAUST
INLET MANIFOLD
15-7
INLET MANIFOLD
M1151003001601
Pre-removal Operation Post-installation Operation

• Fuel Discharge Prevention (Refer to GROUP 13A, • Front Exhaust Pipe Installation (Refer to P.15-13).
On-vehicle Service P.13A-398). • Crossmember Bar Installation (Refer to GROUP 32,
• Under Cover Removal (Refer to GROUP 51, Front Engine Roll Stopper, Centremember P.32-7).
Bumper P.51-2). • Throttle Body Installation (Refer to GROUP 13A, Throttle
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle Body P.13A-413).
Service P.14-15). • Strut Tower Bar Installation (Refer to GROUP 42, Strut
• Intake Air Duct Removal (Refer to P.15-5). Tower Bar P.42-9).
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Intake Air Duct Installation (Refer to P.15-5).
Tower Bar P.42-9). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Throttle Body Removal (Refer to GROUP 13A, Throttle Service P.14-15).
Body P.13A-413). • Under Cover Installation (Refer to GROUP 51, Front
• Crossmember Bar Removal (Refer to GROUP 32, Engine Bumper P.51-2).
Roll Stopper, Centremember P.32-7). • Accelerator Cable Adjustment (Refer to GROUP 17,
• Front Exhaust Pipe Removal (Refer to P.15-13). On-vehicle Service P.17-2).
2 1 3.0 ± 0.5 N·m

5.0 ± 1.0 N·m
6
5 10
11 ± 1 N·m
4
3
10
N7
N 4
(Engine oil)
8 N 9
11
13 ± 1 N·m
13
12 N
14 (Engine oil)
AC310728 AB

1. Rocker cover centre cover 9. Insulators
2. Control wiring harness connection 10. Insulators
3. Vacuum hose connection 11. Oil level gauge and guide assembly
4. Vacuum hoses connection 12. O-ring
5. Fuel return hose connection 13. Brake booster vacuum hose
>>A<< 6. Fuel high-pressure hose connection connection
>>A<< 7. O-ring 14. Purge hoses connection
<<A>> 8. Delivery pipe, fuel injector, fuel return
pipe and fuel pressure regulator
assembly
INLET MANIFOLD
11 ± 1 N·m
20 ± 2 N·m
26
N 24
36 ± 6 N·m
20 ± 2 N·m
23 31 N
25
21
19
11 ± 1 N·m
17
21 30
18
27 9.0 ± 1.0 N·m
29
11 ± 1 N·m 16 15
28
11 ± 1 N·m 36 ± 6 N·m
20 ± 2 N·m
22 ± 4 N·m
22 24 ± 4 N·m
21
20
31 ± 3 N·m
11 ± 1 N·m
AC504960AB

15. Detonation sensor connector 22. Inlet manifold stay
16. Purge control solenoid valve 23. EGR valve
17. Vacuum hose 24. EGR valve gasket
18. Fuel pressure solenoid valve 25. Earth cable connection
19. PCV hose 26. Harness connection
• Alternator (Refer to GROUP 16, 27. Crank angle sensor connector
Charging System − Alternator 28. Harness bracket
Assembly P.16-12). 29. Alternator brace stay
20. EGR solenoid valve connector 30. Inlet manifold
21. EGR solenoid valve, vacuum pipe 31. Inlet manifold gasket
and hose assembly
INTAKE AND EXHAUST
INLET MANIFOLD
15-9
REMOVAL SERVICE POINT Be careful not to damage the O-ring. After
<<A>> DELIVERY PIPE, FUEL INJEC- installing, check that the fuel high-pressure hose
turns smoothly.
TOR, FUEL RETURN PIPE AND FUEL
3. If the fuel high-pressure hose does not turn
PRESSURE REGULATOR ASSEMBLY smoothly, the O-ring may be trapped. Remove the
REMOVAL fuel high-pressure hose, re-install the fuel
CAUTION high-pressure hose into the delivery pipe and
Be careful not to drop the fuel injector when the check again.
delivery pipe is removed. 4. Tighten the fuel high-pressure hose to the
The delivery pipe must be removed with the fuel specified torque.
injector, fuel return pipe and fuel pressure regulator Tightening torque: 5.0 ± 1.0 N⋅m
attached.
INSPECTION
INSTALLATION SERVICE POINT M1151003100694
Check the following points; replace the part if a prob-
>>A<< O-RING/ FUEL HIGH-PRESSURE lem is found.
HOSE INSTALLATION Inlet Manifold Check
CAUTION 1. Check for damage or cracking of any part.
Do not let the engine oil get into the delivery 2. Clogging of the negative pressure (vacuum) outlet
pipe, or it will be damaged. port, or clogging of the exhaust gas recirculation
1. Apply a drop of new engine oil to the O-ring. passages.
2. Turn the fuel high-pressure hose to the right and 3. Using a straight edge and feeler gauge, check for
left to install to the delivery pipe. distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
EXHAUST MANIFOLD AND TURBOCHARGER

M1151008900060

• Under Cover Removal (Refer to GROUP 51, Front • Front Exhaust Pipe Installation (Refer to P.15-13).
Bumper P.51-2). • Crossmember Bar Installation (Refer to GROUP 32,
• Radiator Removal (Refer to GROUP 14, Radiator Engine Roll Stopper, Centremember P.32-7).
P.14-24). • Air Pipe A, Air Pipe B, Air Pipe C, Air Hose A and Air Hose
• Air Intake Hose Removal (Refer to P.15-5). D Installation (Refer to P.15-6).
• Air Pipe A, Air Pipe B, Air Pipe C, Air Hose A and Air Hose • Air Intake Hose installation (Refer to P.15-5).
D Removal (Refer to P.15-6). • Radiator Installation (Refer to GROUP 14, Radiator
• Crossmember Bar Removal (Refer to GROUP 32, Engine P.14-24).
Roll Stopper, Centremember P.32-7). • Under Cover Installation (Refer to GROUP 51, Front
• Front Exhaust Pipe Removal (Refer to P.15-13). Bumper P.51-2).
23 ± 3 N·m
64 ± 5 N·m
25 N
1
24
23 ± 3 N·m 29 ± 3 N·m
49 ± 5 N·m
14 ± 1 N·m 17 ± 2 N·m
3 N 18 8N
31 ± 2 N·m
17
19 49 ± 5 N·m
7
N 20 11 ± 1 N·m
2 21
44 ± 5 N·m N8 10 ± 1 N·m
4
59 ± 5 N·m
15
N 11 42 ± 7 N·m
5N
N 14 42 ± 7 N·m
9 12
16 13 6
N 23
N 10
10 ± 1 N·m
35 ± 6 N·m
22
9.0 ± 1.0 N·m 19 ± 1 N·m
14 ± 1 N·m
AC210648 AB

1. Exhaust manifold cover 5. Gaskets
<<A>> >>D<< 2. Oxygen sensor (Front) 6. Turbocharger water return hose
3. Turbocharger heat protector connection
4. Turbocharger water feed pipe <> 7. Turbocharger oil feed pipe
connection 8. Gaskets
INTAKE AND EXHAUST
15-11
Removal steps (Continued) Removal steps (Continued)
• Starter motor (Refer to GROUP 16, 17. Turbocharger and exhaust fitting
Starting System − Starter Motor assembly
Assembly P.16-20). 18. Turbocharger gasket
9. Turbocharger oil return pipe >>A<< 19. Turbocharger assembly
>>C<< 10. Turbocharger oil return pipe gasket 20. Exhaust fitting gasket
11. Turbocharger oil return pipe gasket 21. Exhaust fitting assembly
12. Vacuum hose connection 22. Turbocharger water return pipe and
13. Air outlet fitting hose assembly
>>B<< 14. Air outlet fitting gasket 23. Gaskets
15. Vacuum hose connection 24. Exhaust manifold
16. Exhaust fitting bracket 25. Exhaust manifold gasket
REMOVAL SERVICE POINTS

<<A>> OXYGEN SENSOR (FRONT) INSTALLATION SERVICE POINTS
REMOVAL >>A<< TURBOCHARGER ASSEMBLY
INSTALLATION
MD998770
ACX02426 AB
AC210649AB
Use special tool oxygen sensor wrench (MD998770)
to remove the oxygen sensor (front). 1. Clean the oil pipe and water pipe fitting, the inside
of eye bolts, and individual pipe for clogs.
<> TURBOCHARGER OIL FEED PIPE CAUTION
REMOVAL Take care not to allow foreign objects to get into
the turbocharger assembly.
CAUTION
Take care not to allow foreign objects to get into 2. Clean or use compressed air to remove any
the oil passage hole of the turbocharger assem- carbon particles stuck to the oil passage of the
bly after the turbocharger oil feed pipe is turbocharger assembly.
removed. 3. Refill new engine oil at the oil feed pipe fitting hole
of the turbocharger assembly.
>>B<< AIR OUTLET FITTING GASKET Use special tool oxygen sensor wrench (MD998770)
INSTALLATION to install the oxygen sensor (front).
Turbocharger INSPECTION
assembly M1151009400013
Protrusion
Check the following points; replace the part if a prob-
lem is found.
Exhaust Manifold Check
1. Check for damage or cracking of any part.
2. Using a straight edge and a feeler gauge, check
View A for distortion of the cylinder head installation
A surface.
AC210650 AB
Install the gasket so that its protrusion faces in the Limit: 0.20 mm
direction shown in the illustration.
Turbocharger Assembly Check
>>C<< TURBOCHARGER OIL RETURN
PIPE GASKET INSTALLATION
Turbocharger Compressor wheel
oil return pipe
AC210683AB
Turbocharger oil return
pipe gasket protrusion 1. Visually check the turbine wheel and the
AC210682AB
compressor wheel for cracking or other damage.
Install the gasket so that its protrusion faces in the 2. Check whether the turbine wheel and the
direction shown in the illustration. compressor wheel can be easily turned by hand.
3. Check for oil leakage from the turbocharger
>>D<< OXYGEN SENSOR (FRONT) assembly.
INSTALLATION 4. Check whether or not the turbocharger waste gate
regulating valve remains open. If any problem is
found, replace the part after disassembly.
MD998770
ACX02426 AB
INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER
15-13
EXHAUST PIPE AND MAIN MUFFLER
M1151008700390
5
13 ± 2 N·m
1
5
13 ± 2 N·m
11 49 ± 10 N·m 2 N 3
N 9
8
45 ± 5 N·m
59 ± 10 N·m 6
4 N
7 10 N
11
13 ± 2 N·m
50 ± 5 N·m
AC310642AB
Exhaust main muffler removal Front exhaust pipe removal steps

steps • Under cover (Refer to GROUP 51,
1. Exhaust main muffler Front Bumper Assembly P.51-2).
3. Exhaust pipe gasket • Crossmember bar (Refer to GROUP
5. Exhaust muffler hangers 32, Engine Roll Stopper,
Centre exhaust pipe removal steps Centremember P.32-7).
2. Centre exhaust pipe 7. Springs
3. Exhaust pipe gasket 8. Front exhaust pipe
4. Exhaust pipe gasket 9. Seal ring
6. Exhaust pipe hanger 10. Exhaust pipe gasket
11. Exhaust pipe hangers
NOTES
16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . . 16-2 IGNITION SYSTEM . . . . . . . . . 16-26
GENERAL INFORMATION . . . . . . 16-2 GENERAL INFORMATION . . . . . . 16-26
SERVICE SPECIFICATIONS. . . . . 16-3 SERVICE SPECIFICATIONS . . . . . 16-27
SPECIAL TOOL . . . . . . . . . . . . . . . 16-4 SPECIAL TOOL . . . . . . . . . . . . . . . 16-28
ON-VEHICLE SERVICE. . . . . . . . . 16-5 ON-VEHICLE SERVICE . . . . . . . . . 16-28

ALTERNATOR OUTPUT LINE VOLTAGE IGNITION COIL (WITH BUILT-IN POWER
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-5 TRANSISTOR) CHECK . . . . . . . . . . . . . 16-28
OUTPUT CURRENT TEST . . . . . . . . . . 16-6 IGNITION COIL RELAY CHECK
REGULATED VOLTAGE TEST. . . . . . . 16-8 <RH DRIVE VEHICLES> . . . . . . . . . . . . 16-28
WAVEFORM CHECK USING SPARK PLUG CABLE CHECK . . . . . . . 16-29
AN OSCILLOSCOPE. . . . . . . . . . . . . . . 16-9 SPARK PLUG CHECK AND CLEANING 16-29
CAMSHAFT POSITION SENSOR CHECK 16-30
ALTERNATOR ASSEMBLY . . . . . 16-12 CRANK ANGLE SENSOR CHECK . . . . 16-30
DETONATION SENSOR CHECK . . . . . 16-30
REMOVAL AND INSTALLATION . . . . . 16-12
IGNITION SECONDARY VOLTAGE
DISASSEMBLY AND REASSEMBLY . . 16-15
WAVEFORM CHECK USING
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-17
AN OSCILLOSCOPE . . . . . . . . . . . . . . . 16-30
STARTING SYSTEM . . . . . . . . . 16-18 IGNITION COIL. . . . . . . . . . . . . . . . 16-34

REMOVAL AND INSTALLATION. . . . . . 16-34
GENERAL INFORMATION . . . . . . 16-18
CAMSHAFT POSITION SENSOR . 16-35
SERVICE SPECIFICATIONS. . . . . 16-19 REMOVAL AND INSTALLATION. . . . . . 16-35
STARTER MOTOR ASSEMBLY . . 16-20 CRANK ANGLE SENSOR . . . . . . . 16-36

REMOVAL AND INSTALLATION . . . . . 16-20 REMOVAL AND INSTALLATION. . . . . . 16-36
STARTER MOTOR ASSEMBLY DETONATION SENSOR . . . . . . . . 16-37

INSPECTION . . . . . . . . . . . . . . . . . 16-20 REMOVAL AND INSTALLATION. . . . . . 16-37
DISASSEMBLY AND REASSEMBLY . . 16-22
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-24
16-2 ENGINE ELECTRICAL
CHARGING SYSTEM
CHARGING SYSTEM
GENERAL INFORMATION
M1161000100652
The charging system uses the alternator output to The average output voltage fluctuates slightly with
keep the battery charged at a constant level under the alternator load condition.
various electrical loads. When the ignition switch is turned on, current flows in
OPERATION the field coil and initial excitation of the field coil
occurs.
Voltage When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field cur-
Approximately rent increases and it falls as the field current
14.4 V decreases. When the battery voltage (alternator "S"
terminal voltage) reaches a regulated voltage of
approximately 14.4 V, the field current is cut off.
Time
When the battery voltage drops below the regulated
AK400075AB voltage, the voltage regulator regulates the output
Rotation of the excited field coil generates AC volt- voltage to a constant level by controlling the field cur-
age in the stator. rent.
This alternating current is rectified through diodes to In addition, when the field current is constant, the
DC voltage having a waveform shown in the illustra- alternator output voltage rises as the engine speed
tion. increases.
SYSTEM DIAGRAM
Alternator
Stator coil
Engine-ECU
Field coil S
L
+
Voltage
regulator FR Ignition switch
Charge Battery
warning lamp
–
AK304222 AB
ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
ALTERNATOR SPECIFICATIONS
Item Specifications
Type Battery voltage sensing
Rated output V/A 12/90
Voltage regulator Electronic built-in type
M1161000300407

Alternator output line voltage drop (at 30 A) V − maximum 0.3
Regulated voltage ambient −20°C 14.2 − 15.4 −
temperature at voltage regulator V 20°C 13.9 − 14.9 −
60°C 13.4 − 14.6 −
80°C 13.1 − 14.5 −
Output current − 70 % of normal output current
CHARGING SYSTEM
SPECIAL TOOL
M1161000600356

MB991502 M.U.T.-II sub assembly • Checking the idle speed
B991502
MB991955 M.U.T.-III sub assembly • Checking the idle speed

A A: • A: Vehicle CAUTION
MB991824 communication M.U.T.-III main harness B
B: interface (V.C.I.) (MB991911) should be used.
MB991827 • B: M.U.T.-III USB M.U.T.-III main harness A should
MB991824 C: cable not be used for this vehicle.
B MB991910 • C: M.U.T.-III main
D: harness A (Vehicles
MB991911 with CAN
E: communication
MB991827 MB991825 system)
F: • D: M.U.T.-III main
C
MB991826 harness B (Vehicles
DO NOT USE without CAN
communication
system)
MB991910
• E: M.U.T.-III
D measurement adapter
• F: M.U.T.-III trigger
harness
MB991911
MB991825
MB991826
MB991955
MB991519 Alternator test harness Checking the alternator

("S" terminal voltage)
ENGINE ELECTRICAL
CHARGING SYSTEM
16-5
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

M1161000900681
Ammeter (clamp-type)
Alternator
Voltmeter (digital-type)
Battery
"B" terminal
AK203361AE
This test determines whether the wiring from the 6. Reconnect the negative battery cable.
alternator "B" terminal to the battery (+) terminal 7. Connect the M.U.T.-II/III.
(including the fusible link) is in a good condition or
8. Leave the hood open.
not.
9. Start the engine.
1. Always be sure to check the following before the
test. 10.With the engine running at 2,500 r/min, turn the
• Alternator installation headlamps and other lamps on and off to adjust
• Drive belt tension the alternator load so that the value displayed on
(Refer to GROUP 11A − On-vehicle Service the ammeter is slightly above 30 A.
P.11A-7.) Adjust the engine speed by gradually decreasing
• Fusible link it until the value displayed on the ammeter is 30
• Abnormal noise from the alternator while the A. Take a reading of the value displayed on the
engine is running. voltmeter at this time.
2. Turn the ignition switch to the "LOCK" (OFF) Limit: maximum 0.3 V
position. NOTE: When the alternator output is high and the
3. Disconnect the negative battery cable. value displayed on the ammeter does not
4. Connect a clamp-type DC test ammeter with a decrease until 30 A, set the value to 40 A. Read
range of 0 − 100 A to the alternator "B" terminal the value displayed on the voltmeter at this time.
output wire. When the value range is 40 A, the limit is maxi-
NOTE: The way of disconnecting the alternator mum 0.4 V.
output wire and of connecting the ammeter is pos- 11.If the value displayed on the voltmeter is above
sibly not found the problem that the output current the limit value, there is probably a malfunction in
is dropping due to the insufficient connection the alternator output wire, so check the wiring
between terminal "B" and the output wire. between the alternator "B" terminal and the
5. Connect a digital-type voltmeter between the battery (+) terminal (including fusible link).
alternator "B" terminal and the battery (+) If a terminal is not sufficiently tight or if the
terminal. [Connect the (+) lead of the voltmeter to harness has become discoloured due to
the "B" terminal, and then connect the (-) lead of overheating, repair and then test again.
the voltmeter to the battery (+) cable].
CHARGING SYSTEM
12.After the test, run the engine at idle. 15.Disconnect the negative battery cable.
13.Turn off all lamps and the ignition switch. 16.Disconnect the ammeter and voltmeter.
14.Remove the M.U.T.-II/III. 17.Connect the negative battery cable.
OUTPUT CURRENT TEST

M1161001000692
Load
Ammeter
Voltmeter (clamp-type)
– +
Charge warning
Ignition switch lamp
B
FR
L
S
G
Alternator
+ Engine-ECU
Battery
AK401826 AD
This test determines whether the alternator output 2. Turn the ignition switch to the "LOCK" (OFF)
current is normal. position.
1. Before the test, always be sure to check the 3. Disconnect the negative battery cable.
following.
CAUTION
• Alternator installation
Never use clips but tighten bolts and nuts to con-
• Battery (Refer to GROUP 54A − Battery −
nect the line. Otherwise loose connections (e.g.
On-vehicle Service P.54A-5).
using clips) will lead to a serious accident
NOTE: The battery should be slightly discharged. because of high current.
The load needed by a fully-charged battery is
4. Connect a clamp-type DC test ammeter with a
insufficient for an accurate test.
range of 0 − 100 A to the alternator "B" terminal
• Drive belt tension
output wire.
(Refer to GROUP 11A − On-vehicle Service
P.11A-7.) NOTE: The way of disconnecting the alternator
• Fusible link output wire and of connecting the ammeter is pos-
sibly not found the problem that the output current
• Abnormal noise from the alternator while the
is dropping due to the insufficient connection
engine is running.
between terminal "B" and the output wire.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-7
5. Connect a voltmeter with a range of 0 − 20 V NOTE: .
between the alternator "B" terminal and the earth • For the nominal current output, refer to the
[Connect the (+) lead of the voltmeter to the "B" Alternator Specifications.
terminal, and then connect the (-) lead of the • Because the current from the battery will soon
voltmeter to the earth]. drop after the engine is started, the above step
6. Connect the negative battery cable. should be carried out as quickly as possible in
order to obtain the maximum current output
7. Connect the M.U.T.-II/III.
value.
8. Leave the hood open. • The current output value will depend on the
9. Check that the reading on the voltmeter is equal electrical load and the temperature of the
to the battery voltage. alternator body.
NOTE: If the voltage is 0 V, the cause is probably • If the electrical load is small while testing, the
an open circuit in the wire or fusible link between specified level of current may not be output
the alternator "B" terminal and the battery (+) ter- even though the alternator is normal. In such
minal. cases, increase the electrical load by leaving
10.Turn the lamp switch on to turn on headlamps and the headlamps turned on for some time to dis-
then start the engine. charge the battery or by using the lighting sys-
tem in another vehicle, and then test again.
11.Immediately after setting the headlamps to high
• The specified level of current also may not be
beam and turning the heater blower switch to the
output if the temperature of the alternator body
high revolution position, increase the engine
or the ambient temperature is too high. In such
speed to 2,500 r/min and read the maximum
cases, cool the alternator and then test again.
current output value displayed on the ammeter.
12.The reading on the ammeter should be above the
Limit: 70% of normal current output
limit value. If the reading is below the limit value
and the alternator output wire is normal, remove
the alternator from the engine and check the
alternator.
13.Run the engine at idle after the test.
14.Turn the ignition switch to the "LOCK" (OFF)
position.
15.Remove the M.U.T.-II/III.
16.Disconnect the negative battery cable.
17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.
CHARGING SYSTEM
REGULATED VOLTAGE TEST

M1161001100871
Load
Ammeter (clamp-type)
MB991519
Ignition switch Charge warning lamp
Blue
B
FR
L Alternator
S
G
+ Black
Engine-ECU
Yellow Red
Battery
Voltmeter (digital-type)
+ –
AK401827AC
This test determines whether the voltage regulator is 5. Connect a clamp-type DC test ammeter with a
correctly controlling the alternator output voltage. range of 0 − 100 A to the alternator "B" terminal
1. Always be sure to check the following before the output wire.
test. NOTE: The way of disconnecting the alternator
• Alternator installation output wire and of connecting the ammeter is pos-
• Check that the battery installed in the vehicle is sibly not found the problem that the output current
fully charged. is dropping due to the insufficient connection
(Refer to GROUP 54A − Battery − On-vehicle Serv- between terminal "B" and the output wire.
ice − Charging P.54A-4). 6. Reconnect the negative battery cable.
• Drive belt tension
(Refer to GROUP 11A − On-vehicle Service 7. Connect the M.U.T.-II/III.
P.11A-7.) 8. Turn the ignition switch to the "ON" position and
• Fusible link check that the reading on the voltmeter is equal to
• Abnormal noise from the alternator while the the battery voltage.
engine is running NOTE: If the voltage is 0 V, the cause is probably
2. Turn the ignition switch to the "LOCK" (OFF) an open circuit in the wire or fusible link between
position. the alternator "S" terminal and the battery (+) ter-
minal.
3. Disconnect the negative battery cable.
9. Turn all lamps and accessories off.
4. Use the special tool Alternator test harness
(MB991519) to connect a digital voltmeter 10.Start the engine.
between the alternator "S" terminal and earth 11.Increase the engine speed to 2,500 r/min.
[Connect the (+) lead of the voltmeter to the "S" 12.Read the value displayed on the voltmeter when
terminal, and then connect the (-) lead of the the alternator output current alternator becomes
voltmeter to a secure earth or to the battery (-) 10 A or less.
terminal].
ENGINE ELECTRICAL
CHARGING SYSTEM
16-9
13.If the voltage reading conforms to the value in the 16.Remove the M.U.T.-II/III.
voltage regulation, then the voltage regulator is 17.Disconnect the negative battery cable.
operating normally. 18.Disconnect the ammeter and voltmeter.
If the voltage is not within the standard value, 19.Connect the alternator output wire to the
there is a malfunction of the voltage regulator or of alternator "B" terminal.
the alternator. 20.Remove the special tool, and return the connector
14.After the test, lower the engine speed to the idle to the original condition.
speed. 21.Connect the negative battery cable.
15.Turn the ignition switch to the "LOCK" (OFF)
position.
Voltage Regulation Table
Standard value:
Inspection terminal Voltage regulator ambient Voltage V
temperature °C
Terminal "S" −20 14.2 − 15.4
20 13.9 − 14.9
60 13.4 − 14.6
80 13.1 − 14.5
WAVEFORM CHECK USING AN OSCILLOSCOPE

M1161001200209
MEASUREMENT METHOD Connect the oscilloscope special patterns pick-up to

the alternator "B" terminal.
Alternator
CH1
"B" terminal AK100002 AC

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

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

can undulate as shown in the illustration. This wave-
form is produced when the regulator operates
according to fluctuations in the alternator load (cur-
rent), and is normal for the alternator. In addition,
ENGINE ELECTRICAL
CHARGING SYSTEM
16-11
EXAMPLE OF ABNORMAL WAVEFORMS
NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not oper-
ating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveform Problem cause
Example 1 Open diode
AKX00191
Example 2 Short in diode
AKX00192
Example 3 Broken wire in

stator coil
AKX00193
Example 4 Short in stator

coil
AKX00194
CHARGING SYSTEM
ALTERNATOR ASSEMBLY
M1161001401358
CAUTION
If the vehicle is equipped with the Brembo™ disc brake, during maintenance, take care not to contact
the caliper with tool or parts, because the caliper paint will be scratched.
• Under Cover Removal (Refer to GROUP 51, Front • Front Exhaust Pipe Assembly Installation (Refer to
Bumper P.51-2). GROUP 15, Exhaust Pipe and Main Muffler P.15-13).
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Crossmember Bar Installation (Refer to GROUP 32,
Tower Bar P.42-9). Engine Roll Stopper and Centremember P.32-7).
• Crossmember Bar Removal (Refer to GROUP 32, Engine • Strut Tower Bar Installation (Refer to GROUP 42, Strut
Roll Stopper and Centremember P.32-7). Tower Bar P.42-9).
• Front Exhaust Pipe Assembly Removal (Refer to GROUP • Drive Belt Tension Check (Refer to GROUP 11A, On-vehi-
15, Exhaust Pipe and Main Muffler P.15-13). cle Service − Drive Belt Tension Check P.11A-7).
• Under Cover Installation (Refer to GROUP 51, Front
Bumper P.51-2).
ENGINE ELECTRICAL
CHARGING SYSTEM
16-13
5.0 ± 1.0 N·m
3
1 2
5.0 ± 1.0 N·m
11 ± 1 N·m
11 7
6 4
13 ± 1 N·m 9 10
5
17
22 ± 4 N·m
8 9.0 ± 1.0 N·m

20 ± 2 N·m
9.0 ± 1.0 N·m
18
24 ± 4 N·m
(Engine oil)
14
N 12
16
44 ± 10 N·m
8.8 ± 1.0 N·m
15
13
AC406359AB

1. Fuel injector connectors 10. Purge control solenoid valve
2. Accelerator cable connection 11. Oil level gauge and guide assembly
<<A>> 3. Fuel injector, delivery pipe, fuel 12. O-ring
return pipe and fuel pressure <> 13. Drive belt
regulator assembly 14. Alternator connector and terminal
4. Insulators • Engine front mounting bracket
5. Insulators (Refer to GROUP 32, Engine
6. Fuel pressure solenoid valve Mounting P.32-4).
connector <<C>> 15. Alternator
7. Fuel pressure solenoid valve 16. Water pump pulley
8. Detonation sensor connector 17. Crank angle sensor connector
9. Purge control solenoid valve 18. Alternator bracket
connector
CHARGING SYSTEM
REMOVAL SERVICE POINTS 1. Securely insert the spindle handle or ratchet

<<A>> FUEL INJECTOR, DELIVERY PIPE, handle with a 12.7 mm insertion angle into the jig
hole of the auto-tensioner.
FUEL RETURN PIPE AND FUEL PRES-
2. Rotate the auto-tensioner anti-clockwise and align
SURE REGULATOR ASSEMBLY hole A with hole B.
REMOVAL
CAUTION
After loosening the delivery pipe mounting bolts, To reuse the drive belt, draw an arrow indicating
move the fuel injector, delivery pipe, fuel return pipe the rotating direction (clockwise) on the back of
and the fuel pressure regulator as an assembly aside the belt using chalk, etc.
in order to make room for the alternator removal.
<> 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
Auto-
tensioner
L-shaped
hexagon
wrench
AC210998AB
3. Insert an L-shaped hexagon wrench, etc. into the

hole to fix and then remove the drive belt.
Hole B
Hole A
<<C>> ALTERNATOR REMOVAL
AC210996 AB
Raise the engine with a floor jack and remove the
alternator upward from the engine room.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-15
DISASSEMBLY AND REASSEMBLY
M1161001600199
1
4
3
5
7 6
12
10
9
8
14
13
11
AK202845 AB
Disassembly steps Disassembly steps (Continued)

<<A>> 1. Front bracket assembly <<C>> 8. Stator
<> 2. Alternator pulley 9. Plate
>>B<< 3. Rotor <<C>> >>A<< 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Rubber packing
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
CHARGING SYSTEM
DISASSEMBLY SERVICE POINTS CAUTION

<<A>> FRONT BRACKET ASSEMBLY • Use a 180 − 250 W soldering iron, and finish
REMOVAL unsoldering within four seconds. Diodes will
be damaged by heat if unsoldering time is too
long.
• Avoid applying undue force to the diode
leads.
1. Unsolder the stator leads from the main diode of
the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the
regulator assembly, undo the soldered points on
the rectifier assembly.
AK202718
REASSEMBLY SERVICE POINTS
CAUTION >>A<< REGULATOR ASSEMBLY INSTAL-
Do not insert the screwdriver blades too deep.
LATION
Doing so could damage the stator coil.
Insert the blades of screwdrivers between the front
bracket assembly and stator core, and pry and sepa-
rate them with the screwdrivers.
Wire
<> ALTERNATOR PULLEY REMOVAL
AK202779 AB
Rear bracket
Brush
AK202714
CAUTION Wire
Perform operation carefully not to damage the
rotor.
Clamp the rotor in a vise with the pulley facing up to AK202830 AB
remove the pulley.
After installing the regulator assembly, insert a piece
of wire through the hole in the rear bracket while
<<C>> STATOR / REGULATOR pressing the brush to keep the brush against move-
ASSEMBLY REMOVAL ment.
Rectifier Solder NOTE: Holding the brush with the wire facilities
assembly installation of the rotor.
Solder
AK202778 AB
ENGINE ELECTRICAL
CHARGING SYSTEM
16-17
>>B<< ROTOR INSTALLATION 3. If continuity is present, replace the rotor.
STATOR
Wire
AK202779 AB
Remove the brush holding wire after the rotor has

been installed. AK202716
INSPECTION 1. Check the continuity between coil leads.

M1161001700129
If there is no continuity, replace the stator.
ROTOR
AK202717
AK202735
2. Check the continuity between coil and core.
1. Measure the resistance between the two slip rings
If there is no continuity, replace the stator.
of the rotor coil to check the continuity between
them.
RECTIFIER ASSEBMLY
Replace the rotor if the resistance is not within the
standard value range.
Standard value: 3 − 5 Ω
2. Check the continuity between the slip rings and
core.
AK202803
1. Check the condition of the (+) heat sink by

checking continuity between the (+) heat sink and
each of the stator coil lead connecting terminals.
AK202736 If continuity is present for both terminals, the
diode is shorted. Replace the rectifier assembly.
STARTING SYSTEM
BRUSH
Protrusion
length
AK202802
AK202808 AB
2. Check the condition of the (−) heat sink by
checking continuity between the (−) heat sink and 1. Measure the length of the protrusion of the brush.
each of the stator coil lead connecting terminals. Replace the brush if the protrusion length is
If continuity is present in both directions, the diode shorter than the limit.
is shorted. Replace the rectifier assembly. Limit: 2 mm minimum
2. Unsolder the lead of the brush. The brush will
come out, becoming ready for removal.
Solder
AK202804
3. Check the condition of the diode trio by testing

continuity of each of the three diodes using a AK202834 AB
circuit tester connected to both sides of the diode.

3. Install a new brush by pushing it into the holder as
Connect in a polarity and then reverse the polarity
shown in the drawing and soldering the lead.
for each test.
If continuity exists or no continuity exists for both
polarities, the diode is defective. Replace the
rectifier assembly if any of the diodes is defective.
STARTING SYSTEM
GENERAL INFORMATION
M1162000100309
If the ignition switch is turned to the "START" posi- When the ignition switch is returned to the "ON" posi-
tion, current flows in the pull-in and holding coils pro- tion after starting the engine, the starter clutch is dis-
vided inside magnetic switch, attracting the plunger, engaged from the ring gear.
When the plunger is attracted, the lever connected to An overrunning clutch is provided between the pinion
the plunger is actuated to engage the starter clutch. and the armature shaft, to prevent damage to the
On the other hand, attracting the plunger will turn on starter.
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
ENGINE ELECTRICAL
STARTING SYSTEM
16-19
SYSTEM DIAGRAM
Holding coil Plunger
Pull-in coil
Lever
B Overrunning clutch
Ignition switch M
Pinion gear
S
+ Armature
Battery
Brush
Yoke
AK202970 AB
STARTER MOTOR SPECIFICATIONS

Item Specifications
Type Reduction drive with planetary gear
Rated output kW/V 1.2/12
No. of pinion teeth 8
M1162000300080

Pinion gap mm 0.5 − 2.0 −
Commutator run-out mm 0.05 0.1
Commutator diameter mm 29.4 28.8
Undercut depth mm 0.5 0.2
STARTING SYSTEM
STARTER MOTOR ASSEMBLY

M1162001000781

• Under Cover Removal and Installation (Refer to GROUP
51, Front Bumper P.51-2).
• Crossmember Bar Removal and Installation (Refer to
GROUP 32, Engine Roll Stopper and Centremember
P.32-7).
• Front Exhaust Pipe Assembly Removal and Installation
(Refer to GROUP 15, Exhaust Pipe and Main Muffler
P.15-13).
3
13 ± 2 N·m
30 ± 3 N·m
4.9 ± 1.0 N·m 2
30 ± 3 N·m
4.9 ± 1.0 N·m
AC210296 AB

1. Starter cover 2. Starter connector and terminal
3. Starter assembly
STARTER MOTOR ASSEMBLY INSPECTION

M1162001100249
PINION GAP ADJUSTMENT 1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
Switch
2. Connect a 12-volt battery between the S-terminal
and M-terminal.
B
CAUTION
S M This test must be performed quickly (in less than
Battery
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move
Starter Wire
motor out.
AKX01239 AF
ENGINE ELECTRICAL
STARTING SYSTEM
16-21
MAGNETIC SWITCH HOLD-IN TEST
Stopper
S M Battery
Pinion
Starter
Pinion gap motor
AKX00198 AC
Wire
4. Check the pinion-to-stopper clearance (pinion AKX01245 AF
gap) with a feeler gauge.

1. Disconnect the field coil wire from the M-terminal
Standard value: 0.5 − 2.0 mm of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
2. Connect a 12-volt battery between the S-terminal
and body.
3. Manually pull out the pinion as far as the pinion
stopper position.
4. If the pinion remains out, everything is in order. If
AKX00199
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
5. If the pinion gap is out of specification, adjust by
adding or removing gasket(s) between the FREE RUNNING TEST
magnetic switch and front bracket.
Carbon-pile
MAGNETIC SWITCH PULL-IN TEST B
rheostat
Ammeter
S M A
B Battery
Starter V
motor Voltmeter
S M Battery
AKX01247AF
Starter Wire
motor 1. Place the starter motor in a vise equipped with
AKX01243 AF
soft jaws and connect a fully-charged 12-volt
battery to the starter motor as follows:
1. Disconnect the field coil wire from the M-terminal
2. Connect a test ammeter (100-ampere scale) and
of the magnetic switch.
carbon pile rheostat in series between the positive
CAUTION battery terminal and starter motor terminal.
This test must be performed quickly (in less than 3. Connect a voltmeter (15-volt scale) across the
10 seconds) to prevent the coil from burning. starter motor.
2. Connect a 12-volt battery between the S-terminal 4. Rotate the rheostat to full-resistance position.
and M-terminal. 5. Connect the battery cable from the negative
3. If the pinion moves out, the pull-in coil is good. If it battery terminal to the starter motor body.
doesn't, replace the magnetic switch. 6. Adjust the rheostat until the battery positive
voltage shown on the voltmeter is 11 V.
STARTING SYSTEM
7. Confirm that the maximum amperage is within the 1. Disconnect the field coil wire from the M-terminal
specifications and that the starter motor turns of the magnetic switch.
smoothly and freely. CAUTION
Current: maximum 95 Amps This test must be performed quickly (in less than
MAGNETIC SWITCH RETURN TEST
2. Connect a 12-volt battery between the M-terminal
and body.
WARNING
B Be careful not to get your fingers caught
when pulling out the pinion.
S M Battery
3. Pull the pinion out and release. If the pinion
quickly returns to its original position, everything is
Starter operating properly. If it doesn't, replace the
motor
Wire magnetic switch.
AKX01249AF

M1162001200246
2
11
14 12
10
13
19
5.8 ± 1.6 N·m
5.8 ± 1.6 N·m
1 18 4
5
17
16
15
3
8
21 3.4 ± 1.0 N·m
7
9
6
AK304626AB
ENGINE ELECTRICAL
STARTING SYSTEM
16-23
1. Screw 10. Packing A
<<A>> 2. Magnetic switch 11. Packing B
3. Screw 12. Plate
4. Bolt 13. Planetary gear
5. Rear bracket 14. Lever
6. Brush holder <> >>A<< 15. Snap ring
7. Rear bearing <> >>A<< 16. Stop ring
8. Armature 17. Overrunning clutch
9. Yoke assembly 18. Internal gear
19. Planetary gear shaft
20. Front bracket
DISASSEMBLY SERVICE POINTS

<<A>> MAGNETIC SWITCH REMOVAL 1. Apply a long socket wrench of an appropriate size
to the stop ring and strike the wrench to drive out
B terminal S terminal the stop ring toward the pinion gear side.
Snap ring
Field coil Snap ring
M terminal lead pliers Pinion gear
Overrunning
clutch
AK202890 AB
CAUTION AK202791 AB
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the mag- 2. Remove the snap ring with snap ring pliers, then
netic switch. remove the stop ring and overrunning clutch.
<> SNAP RING/STOP RING REMOVAL STARTER MOTOR PARTS CLEANING

Never clean in a solvent such starter motor parts as
the magnetic switch, brush holder, and armature.
Socket wrench
If they are soaked in a solvent, their insulation
could be impaired. When these parts require
Stop ring Pinion Gear cleaning, wipe off contamination with cloth.
Overrunning 1. Never soak the drive unit in a solvent. If it is
clutch washed in a solvent, the grease having been
packed in the overrunning clutch at the factory will
be washed out. Wipe the drive unit with cloth if it
requires cleaning.
AK202790 AB
STARTING SYSTEM
REASSEMBLY SERVICE POINTS

>>A<< STOP RING/SNAP RING INSTAL- Undercut
Segment
LATION Mica
Overrunning Stop ring

clutch AK202711 AB
Stop ring
3. Measure the depth of the undercut between
segments.
Snap ring AK202911 AB Standard value: 0.5 mm
Use a suitable puller to pull the stop ring until it gets Limit: 0.2 mm
over the snap ring.
BRUSH HOLDER
INSPECTION
M1162001300180
COMMUTATOR
AK202897
Push the brush into the brush holder to make sure

AK202712 that the spring is working on the brush.
If the spring is not working, replace the brush holder.
1. Support the armature with a pair of V block and
turn it to measure the runout of the surface not OVERRUNNING CLUTCH
rubbed by the brushes using a dial gauge.
Limit: 0.1 mm
Free
Lock
AK202710 AB
1. Make sure that the pinion cannot be turned

AK202715 counterclockwise and can be turned clockwise
freely.
2. Measure the diameter of the commutator. 2. Check the pinion for abnormal ware and damage.
Standard value: 29.4 mm
Limit: 28.8 mm
ENGINE ELECTRICAL
STARTING SYSTEM
16-25
BRUSHES
Brush
height
AK202734
AK202846 AB
4. Check the insulation between commutator
1. Check the commutator contacting surface of each segments and armature coils. The armature coils
brush for abnormal roughness. Also check the are properly insulated if no continuity is present.
height of the brush. Replace the brush holder if
the height is lower than the limit.
Limit: 7.0 mm
2. When the contact surface of the brush is rectified
or the brush holder is replaced, recondition the
contact surface with sandpaper wrapped around
the commutator.
ARMATURE COIL AK202713

1. Check the armature coil for short circuit as
follows: 5. Check continuity between a segment and another.
There is no open circuit in the tested coil if there is
Growler continuity.
MAGNETIC SWITCH
AK202733 AB
2. Set the armature in a growler.

M terminal
CAUTION
Clean the surface of the armature thoroughly AK202891 AB
before performing the test.
3. While holding a thin strip of iron against the 1. Coil open circuit test
armature in parallel with its axis, turn the armature • Check that there is continuity between the M ter-
slowly. The armature is normal if the iron strip is minal and body A.
not attracted to the armature or it does not vibrate. • If there is no continuity, replace the magnetic
switch.
IGNITION SYSTEM
B terminal B terminal
M terminal M terminal
AK202892 AB AK202893 AB
2. Contact fusion check 3. Switch contact check

• Check that there is no continuity between the B • Push the indicated end of the magnetic switch
terminal and M terminal. with a strong force to close the internal contacts.
• If there is continuity, replace the magnetic switch. Without releasing the switch end, check that
there is continuity between the B terminal and M
terminal.
• If there is no continuity, replace the magnetic
switch.
IGNITION SYSTEM
GENERAL INFORMATION
M1163000100614
This system is equipped with two ignition coils (A and The engine-ECU turns the two power transistors
B) with built-in power transistors for the No. 1 and inside the ignition coils alternately on and off. This
No. 4 cylinders and the No. 2 and No. 3 cylinders causes the primary currents in the ignition coils to be
respectively. alternately interrupted and allowed to flow to fire the
Interruption of the primary current flowing in the pri- cylinders in the order 1-3-4-2.
mary side of ignition coil A generates a high voltage The engine-ECU determines which ignition coil
in the secondary side of ignition coil A. The high volt- should be controlled by means of the signals from
age thus generated is applied to the spark plugs of the camshaft position sensor which is incorporated in
No. 1 and No. 4 cylinders to generate sparks. At the the camshaft and from the crank angle sensor which
time that the sparks are generated at both spark is incorporated in the crankshaft. It also detects the
plugs, if one cylinder is at the compression stroke, crankshaft position in order to provide ignition at the
the other cylinder is at the exhaust stroke, so that most appropriate timing in response to the engine
ignition of the compressed air/fuel mixture occurs operation conditions. It also detects the crankshaft
only for the cylinder which is at the compression position in order to provide ignition at the most
stroke. appropriate timing in response to the engine opera-
In the same way, when the primary current flowing in tion conditions.
ignition coil B is interrupted, the high voltage thus When the engine is cold or operated at high alti-
generated is applied to the spark plugs of No. 2 and tudes, the ignition timing is slightly advanced to pro-
No. 3 cylinders. vide optimum performance.
ENGINE ELECTRICAL
IGNITION SYSTEM
16-27
SYSTEM DIAGRAM
Air flow sensor

Intake air temperature
sensor
Engine coolant Ignition

temperature sensor switch
Ignition coil B Ignition coil A
Camshaft position
sensor
Crank angle sensor Engine-ECU
Barometric pressure
Battery
sensor
Detonation sensor Spark plug
Vehicle speed
sensor
Cylinder No. 2 3 4 1
Ignition switch-ST
AK101074 AH
IGNITION COIL SPECIFICATION

Item Specification
Type Molded 2-coil
SPARK PLUG SPECIFICATIONS

Item Specifications
NGK ILFR7H
M1163000300403
IGNITION COIL
Item Standard value
Secondary coil resistance kΩ 8.5 − 11.5
SPARK PLUG
Spark plug gap mm 0.5 − 0.6 0.75
SPARK PLUG CABLE

Resistance kΩ − Maximum 19
IGNITION SYSTEM
SPECIAL TOOL
M1163000600288

MD998773 Detonation sensor Detonation sensor
wrench removal and installation
ON-VEHICLE SERVICE
IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK

M1163001200614
Check by the following procedure, and replace if CAUTION
there is a malfunction. This test must be performed quickly (in less than
SECONDARY COIL RESISTANCE CHECK 10 seconds) to prevent coil from burning and
power transistor from breakage.
1.5 V power supply Continuity between 1 −
between 2 − 3 2
When current is flowing Continuity
When current is not
flowing No continuity
IGNITION COIL RELAY CHECK <RH

AKX01264
DRIVE VEHICLES>
M1163006500029
Measure the resistance between the high-voltage CAUTION
terminals of the ignition coil. The top and bottom of the ignition coil relay are
Standard value: 8.5 − 11.5 kΩ difficult to identify. The triangle mark on the relay
surface should be uppermost.
PRIMARY COIL AND POWER TRANSIS-
TOR CONTINUITY CHECK
NOTE: .
•
1.5 V
– + 1 2 3 AC311402AB
1. Removal the ignition coil relay.
AK501917 AB
An analogue-type circuit tester should be used.

• Connect the negative (-) prove of the circuit tester
to terminal No. 1.
ENGINE ELECTRICAL
IGNITION SYSTEM
16-29
3. Check the continuity between ignition coil relay
Relay connector terminals 1 and 4 while alternately
side connecting and disconnecting the jumper leads
from the battery terminals.
Jumper leads Continuity between
terminals 1 and 4
Connected Less than 2 Ω
Disconnected Open circuit
AC311403 AB 4. If there is a malfunction, replace the ignition coil
relay.
2. Use the jumper leads to connect ignition coil relay
terminal 3 to the negative battery terminal and
terminal 2 to the positive battery terminal.
SPARK PLUG CABLE CHECK

M1163001400157
Measure the resistance of the all spark plug cables.
1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Maximum 19 kΩ
AKX00382
SPARK PLUG CHECK AND CLEANING

M1163004300728
CAUTION CAUTION
When pulling off the spark plug cable from the • Do not attempt to adjust the gap of the iridium
plug always hold the cable cap, not the cable. plug.
1. Remove the spark plug cables and ignition coils. • Always use a plug cleaner and finish cleaning
2. Remove the spark plugs. within 20 seconds. Do not use wire brushes.
Otherwise, the iridium and platinum tip may
be damaged.
Iridium tip
Platinum tip
AK501797AB
3. Check the plug gap and replace if the limit is

exceeded.
Standard value: 0.5 − 0.6mm
Limit: 0.75 mm
IGNITION SYSTEM
CAUTION 5. Install the spark plugs.

Be careful not to allow foreign matter in cylin- 6. Install the spark plug cables and ignition coils.
ders.
4. Clean the engine plug holes.
CAMSHAFT POSITION SENSOR CHECK

M1163004400305
Check the camshaft position sensor system if (Refer to GROUP 13A − Troubleshooting − Inspec-
self-diagnosis code, No. P0340 is shown. tion procedure for diagnosis code P.13A-166.)
CRANK ANGLE SENSOR CHECK

M1163004500368
Check the crank angle sensor system if self-diagno- (Refer to GROUP 13A − Troubleshooting − Inspec-
sis code, No. P0335 is shown. tion procedure for diagnosis code P.13A-155.)
DETONATION SENSOR CHECK

M1163002900070
Check the detonation sensor system if self-diagnosis (Refer to GROUP 13A − Troubleshooting − Inspec-
code, No. P0325 is shown. tion procedure for diagnosis code P.13A-151.)
IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN OSCILLOSCOPE

M1163001700288
MEASUREMENT METHOD 2. Clamp the spark plug cable with the trigger
1. Clamp the spark plug cable (No. 1 cylinder or No. pickup.
3 cylinder) with the secondary pickup. NOTE: Clamp the trigger pickup to the same
NOTE: . spark plug cable clamped by the secondary
• Because of the two-cylinder simultaneous igni- pickup.
tion system, the waveforms for two cylinders in
each group appear during waveform observa-
tion (No. 1 cylinder - No. 4 cylinder, No. 2 cyl-
inder - No. 3 cylinder). However, waveform
observation is only applicable for the cylinder
with the spark plug cable clamped by the sec-
ondary pickup.
• Identifying which cylinder waveform is dis-
played can be difficult. For reference, remem-
ber that the waveform of the cylinder attached
to the secondary pickup will be displayed as
stable.
ENGINE ELECTRICAL
IGNITION SYSTEM
16-31
STANDARD WAVEFORM
Observation Conditions
Function Secondary
Pattern height High (or Low)
Pattern selector Raster
Engine revolutions Curb idle speed
Spark line (point A)

kV
Ignition voltage
(point D)
Secondary
ignition voltage
wave pattern
Wave damping reduction section (point B)
Dwell section
Point C
Time
AKX00278AC
IGNITION SYSTEM
Observation Conditions (The only change from above condition is the pattern selector.)
Pattern selector Display
kV
NO. 2 cylinder
NO. 1 cylinder NO. 3 cylinder NO. 4 cylinder ignition noise
ignition noise
Secondary ignition
voltage wave pattern Time
0
2 Neutral section
AKX01275 AD
WAVEFORM OBSERVATION POINTS

Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal
waveform examples, 1, 2, 3 and 4).
Spark line Plug gap Condition of Compression Concentration Ignition Spark plug
electrode force of air mixture timing cable
Length Long Small Normal Low Rich Advanced Leak
Short Large Large wear High Lean Retarded High
resistance
Height High Large Large wear High Lean Retarded High
resistance
Low Small Normal Low Rich Advanced Leak
Slope Large Plug is fouled − − − −
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Coil and condenser
3 or more Normal
Except above Abnormal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations Coil
5 − 6 or higher Normal
Except above Abnormal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition Plug gap Condition of Compression Concentration Ignition Spark plug
voltage electrode force of air mixture timing cable
High Large Large wear High Lean Retarded High
resistance
Low Small Normal Low Rich Advanced Leak
ENGINE ELECTRICAL
IGNITION SYSTEM
16-33
EXAMPLES OF ABNORMAL WAVE- Example 3
FORMS • Wave characteristics
Spark line is low and long, and is sloping. How-
ever, there is almost no spark line distortion.
• Cause of problem
Spark plug gap is fouled.
AKX00280
Example 1
• Wave characteristics
Spark line is high and short. AKX00283
Example 4
Spark plug gap is too large.
Spark line is high and short.
Difficult to distinguish between this and abnormal
waveform example 1.
Spark plug cable is nearly falling off (Causing a
dual ignition).
AKX00281
Example 2
Spark line is low and long, and is sloping.
Also, the second half of the spark line is distorted.
This could be a result of misfiring.
• Cause of problem AKX00284
Spark plug gap is too small.

Example 5
No waves in wave damping section.
Layer short in ignition coil.
AKX00282
IGNITION SYSTEM
IGNITION COIL
M1163004000909

• Rocker Cover Centre Cover Removal and Installation
(Refer to GROUP 11A, Camshaft and Valve Stem Seal
P.11A-17).
10 ± 2 N·m
1
2
4
1
4 3
25 ± 4 N·m
AC210297 AB

1. Ignition coil connectors 4. Ignition coils
2. Spark plug cable No. 1 5. Spark plugs
3. Spark plug cable No. 3
ENGINE ELECTRICAL
IGNITION SYSTEM
16-35
CAMSHAFT POSITION SENSOR
M1163003400829
10.5 ± 0.5 N·m 5

4 6N
N 3
2
1
10.5 ± 0.5 N·m
AC407255
AC505000 AB
Removal steps <exhaust side> Removal steps <inlet side>

1. Camshaft position sensor 4. Camshaft position sensor
connector connector
2. Camshaft position sensor 5. Camshaft position sensor
3. O-ring 6. O-ring
IGNITION SYSTEM
CRANK ANGLE SENSOR

M1163004800143
CAUTION
the caliper with tool or parts, because the caliper paint will be scratched.
• Timing Belt Removal and Installation (Refer to GROUP
11A,Timing Belt P.11A-36).
• Radiator Reserve Tank Assembly Removal and Installa-
tion (Refer to GROUP 14, Radiator P.14-24).
12 ± 2 N·m
22 ± 4 N·m
22 ± 4 N·m 2
12 ± 2 N·m
5
1 22 ± 4 N·m
8.8 ± 1.0 N·m 40 ± 5 N·m

3
4 49 ± 9 N·m
49 ± 9 N·m
AC210409AB

1. Power steering pressure switch <<A>> 3. Power steering oil pump, bracket
connector and oil reservoir assembly
2. Power steering oil pump heat 4. Power steering oil pump bracket
protector 5. Crank angle sensor connector
6. Crank angle sensor
ENGINE ELECTRICAL
IGNITION SYSTEM
16-37
REMOVAL SERVICE POINT Remove the power steering oil pump, bracket and oil
reservoir assembly with the hoses attached from the
<<A>> POWER STEERING OIL PUMP,
power steering oil pump bracket.
BRACKET AND OIL RESERVOIR ASSEM-
BLY REMOVAL
NOTE: Tie the removed power steering oil pump,
bracket and oil reservoir assembly with a rope and
set aside where they cannot hinder the removal of
the power steering oil pump bracket.
DETONATION SENSOR
M1163002800664

• Inlet Manifold Stay Removal and Installation (Refer to
GROUP 15, Inlet Manifold P.15-7).
Inlet manifold stay

23 ± 2 N·m
1
2
AC210411AB
Removal steps INSTALLATION SERVICE POINT

1. Detonation sensor connector
>>A<< DETONATION SENSOR INSTALLA-
<<A>> >>A<< 2. Detonation sensor
TION
REMOVAL SERVICE POINT
Detonation sensor
<<A>> DETONATION SENSOR REMOVAL
Detonation sensor
MD998773
AC100807AB
MD998773
Use special tool detonation sensor wrench
AC100807AB
(MD998773) to install the detonation sensor.
Use special tool detonation sensor wrench

(MD998773) to remove the detonation sensor.
NOTES
17-1
GROUP 17
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL . . . . . . . . . . 17-2 COMPONENT LOCATION (CRANKCASE

EMISSION CONTROL SYSTEM) . . . . . 17-8
POSITIVE CRANKCASE VENTILATION
GENERAL INFORMATION . . . . . . 17-2 SYSTEM CHECK . . . . . . . . . . . . . . . . . . 17-8
POSITIVE CRANKCASE VENTILATION
SERVICE SPECIFICATIONS. . . . . 17-2 (PCV) VALVE CHECK . . . . . . . . . . . . . . 17-9
ON-VEHICLE SERVICE. . . . . . . . . 17-2 EVAPORATIVE EMISSION CONTROL

ACCELERATOR CABLE CHECK AND SYSTEM . . . . . . . . . . . . . . . . . . . . . 17-9
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 17-2 GENERAL INFORMATION (EVAPORATIVE
COMPONENT LOCATION (EVAPORATIVE
ACCELERATOR CABLE AND PEDAL 17-3
PURGE CONTROL SYSTEM CHECK. . 17-10
PURGE PORT VACUUM CHECK . . . . . 17-11
EMISSION CONTROL MPI . . . . 17-4 PURGE CONTROL SOLENOID VALVE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-11
GENERAL INFORMATION . . . . . . 17-4 CHECK VALVE CHECK. . . . . . . . . . . . . 17-12
FUEL VAPOUR CANISTER REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . . 17-12
EMISSION CONTROL DEVICE
REFERENCE
TABLE . . . . . . . . . . . . . . . . . . . . . . 17-5 EXHAUST GAS RECIRCULATION
(EGR) SYSTEM . . . . . . . . . . . . . . . 17-13
SERVICE SPECIFICATIONS. . . . . 17-5 GENERAL INFORMATION
(EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-13
SPECIAL TOOL . . . . . . . . . . . . . . . 17-5 COMPONENT LOCATION
(EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-14
VACUUM HOSE. . . . . . . . . . . . . . . 17-6 EGR SYSTEM CHECK . . . . . . . . . . . . . 17-14
VACUUM HOSE PIPING DIAGRAM . . . 17-6 EGR VALVE CHECK . . . . . . . . . . . . . . . 17-15
VACUUM CIRCUIT DIAGRAM . . . . . . . 17-7 EGR PORT VACUUM CHECK. . . . . . . . 17-15
VACUUM HOSE CHECK. . . . . . . . . . . . 17-7 EGR CONTROL SOLENOID VALVE
VACUUM HOSE INSTALLATION . . . . . 17-7 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-15
EGR VALVE REMOVAL AND
CRANKCASE EMISSION CONTROL INSTALLATION . . . . . . . . . . . . . . . . . . . 17-16
SYSTEM. . . . . . . . . . . . . . . . . . . . . 17-8
GENERAL INFORMATION (CRANKCASE
CATALYTIC CONVERTER . . . . . . 17-17
EMISSION CONTROL SYSTEM) . . . . . 17-8 REMOVAL AND INSTALLATION. . . . . . 17-17
17-2 ENGINE AND EMISSION CONTROL
ENGINE CONTROL
ENGINE CONTROL
GENERAL INFORMATION SERVICE SPECIFICATIONS
M1171000100341 M1171000300185
A cable-type accelerator mechanical sus-
pended-type pedal has been adopted.
Item Standard value
Accelerator cable play mm 1−2
Engine idle speed r/min 800 ± 50
ON-VEHICLE SERVICE Adjusting bolts
ACCELERATOR CABLE CHECK AND

ADJUSTMENT
M1171000900488 Plate 5.0 ± 1.0 N·m
1. Turn off air conditioner and all lamps. Inspect and
adjust at no load.
2. Start engine and allow to idle unit it reaches
normal operating temperature.
3. Confirm the idle speed is at standard value. AC210289AB
AC210289
Standard value: 800 ± 50 r/min 7. If there is too much slack or no slack, adjust the
4. Stop the engine [ignition switch in the ''LOCK'' cable as follows:
(OFF) position]. (1) Loosen the adjusting bolts to release the
5. Confirm there are no sharp bends in the cable.
accelerator cable. (2) Move the plate until the inner cable play is at
6. Check the inner cable for correct slack. the standard value, and then tighten the
Standard value: 1 − 2 mm adjusting bolts to specified torque.
Tightening torque: 5.0 ± 1.0 N⋅m
ENGINE AND EMISSION CONTROL
ENGINE CONTROL
17-3
ACCELERATOR CABLE AND PEDAL
M1171001200608
Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-2).
<L.H. drive vehicles>
5.0 ± 1.0 N·m

11 ± 1 N·m
10
5.0 ± 1.0 N·m
9
11 12 ± 2 N·m
1 8
4N
2
6
<R.H. drive vehicles>
6 7
5.0 ± 1.0 N·m
12
10 1 3 N
11
8
6
6 5
2 3N
N 4 9
7
12 ± 2 N·m
12 AC505002 AB
Accelerator pedal removal steps Accelerator pedal removal steps

>>B<< 1. Inner cable connection (Accelerator 6. Bushing
pedal side) 7. Spring
2. Accelerator pedal assembly 8. Stopper
>>A<< 3. Accelerator pedal pad 9. Accelerator pedal bracket
4. Push-on spring nut
5. Accelerator pedal arm assembly
EMISSION CONTROL <MPI>
Accelerator cable removal steps

>>B<< 1. Inner cable connection (Accelerator
pedal side)
10. Inner cable connection (Throttle lever
side)
11. Accelerator cable assembly
Accelerator pedal stopper removal
12. Accelerator pedal stopper
INSTALLATION SERVICE POINTS >>B<< INNER CABLE INSTALLATION

>>A<< ACCELERATOR PEDAL PAD Plastic bushing
INSTALLATION Rubber dumper
Warm the peg of the accelerator pedal pad with a
dryer before installing the pad.
NOTE: If it is difficult to fit, apply soapy water to the
peg lightly.
Accelerator
pedal arm
Accelerator
cable AC210048 AB
Securely fit the plastic bushing on the inner cable of

the accelerator cable to the accelerator pedal arm as
shown.

GENERAL INFORMATION • Crankcase emission control system
M1173000100541 • Evaporative emission control system
The emission control system consists of the following • Exhaust emission control system
subsystems:
Items Name Specification
Crankcase emission control Positive crankcase ventilation Variable flow type (Purpose: HC
system (PCV) valve reduction)
Evaporative emission control Canister Equipped
system Purge control solenoid valve Duty cycle type solenoid valve
Check valve Equipped
(Purpose: HC reduction)
Exhaust emission control system Air-fuel ratio control device - MPI Oxygen sensor feedback type
system (Purpose: CO, HC, NOx reduction)
Exhaust gas recirculation system Equipped
• EGR valve Single type
• EGR control solenoid valve Duty cycle type solenoid valve
(Purpose: NOx reduction)
Catalytic converter Monolith type (Purpose: CO, HC,
NOx reduction)
17-5
EMISSION CONTROL DEVICE
REFERENCE TABLE
M1173006600180
Related parts Crankcase Evaporative Air/fuel ratio Catalytic Exhaust gas

emission emission control converter recirculation
control control system system
system system
PCV valve ×
Purge control solenoid valve ×
Check valve ×
MPI system component × ×
Catalytic converter ×
EGR valve ×
EGR control solenoid valve ×
M1173000300448
Items Standard value

Purge control solenoid valve coil resistance (at 20°C) Ω 30 − 34
EGR control solenoid valve coil resistance (at 20°C) Ω 29 − 35
SPECIAL TOOL
M1173000600256

MD998770 Oxygen sensor wrench Removal and installation of
oxygen sensor
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
M1173000900796
Canister
From
fuel tank
Check valve
Fuel pressure
control solenoid
Purge control valve
solenoid valve EGR control
Fuel pressure solenoid valve
regulator From
fuel pump
To fuel
tank
PCV
valve
EGR
valve
Injector
Air inlet
Catalytic converter Catalytic converter

Oxygen sensor (front) Oxygen sensor (rear)
AK501844 AB
17-7
VACUUM CIRCUIT DIAGRAM
M1173007100586
Inlet manifold Throttle body
To
combustion From
chamber air
cleaner
Y
Fuel pressure control
solenoid valve
B B W
G
B
Y EGR valve
L Air by-pass valve
EGR control
solenoid valve
Y B
R
Fuel
pressure Waste gate actuator
regulator
R
Canister
Check valve Waste gate
solenoid valve B
B B
Brown
Purge control
solenoid valve
Air cleaner
W
Vacuum hose colour
B: Black
G: Green
L: Light blue
R: Red
W: White
Y: Yellow
AK501843 AB
VACUUM HOSE CHECK VACUUM HOSE INSTALLATION

M1173007300193 M1173007200141
1. Using the piping diagram as a guide, check to be 1. When connecting the vacuum hoses, they should
sure that the vacuum hoses are correctly be securely inserted onto the nipples.
connected. 2. Connect the hoses correctly, using the vacuum
2. Check the connection condition of the vacuum hose piping diagram as a guide.
hoses, (removed, loose, etc.) and check to be
sure that there are no bends or damage.
CRANKCASE EMISSION CONTROL The air becomes mixed with the blow-by gases
inside the crankcase.
SYSTEM The blow-by gas inside the crankcase is drawn into
the inlet manifold through the positive crankcase
GENERAL INFORMATION (CRANKCASE
ventilation (PCV) valve.
EMISSION CONTROL SYSTEM) The PCV valve lifts the plunger according to the inlet
M1173005000691
manifold vacuum so as to regulate the flow of
The crankcase emission control system prevents
blow-by gas properly.
blow-by gases from escaping inside the crankcase
In other words, the blow-by gas flow is regulated dur-
into the atmosphere.
ing low load engine operation to maintain engine sta-
Fresh air is sent from the air cleaner into the crank-
bility, while the flow is increased during high load
case through the breather hose.
operation to improve the ventilation performance.
SYSTEM DIAGRAM
Ventilation hose
PCV valve
Breather hose
AK501845 AB
COMPONENT LOCATION (CRANKCASE POSITIVE CRANKCASE VENTILATION

EMISSION CONTROL SYSTEM) SYSTEM CHECK
M1173007400297 M1173001100373
1. Remove the ventilation hose from the PCV valve.
2. Remove the PCV valve from the rocker cover.
3. Reinstall the PCV valve at the ventilation hose.
4. Start the engine and run at idle.
PCV valve
AK304227AB
17-9
1. Insert a thin rod into the PCV valve from the side
shown in the illustration (rocker cover installation
side), and move the rod back and forth to check
that the plunger moves.
2. If the plunger does not move, there is a clogging
in the PCV valve. In this case, clean or replace
the PCV valve.
PCV valve EVAPORATIVE EMISSION CONTROL

AK300021AC SYSTEM
5. Place a finger at the opening of the PCV valve GENERAL INFORMATION (EVAPORATIVE
and check that vacuum of the inlet manifold is felt.
EMISSION CONTROL SYSTEM)
NOTE: At this moment, the plunger in the PCV M1173005100717
valve moves back and forth. The evaporative emission control system prevents
6. If vacuum is not felt, clean the PCV valve or fuel vapors generated in the fuel tank from escaping
replace it. into the atmosphere.
Fuel vapors from the fuel tank flow through the fuel
POSITIVE CRANKCASE VENTILATION tank pressure control valve and vapor pipe/hose to
(PCV) VALVE CHECK be stored temporarily in the canister.
M1173001200336 When driving the vehicle, fuel vapors stored in the
canister flow through the purge solenoid and purge
port and go into the inlet manifold to be sent to the
PCV valve
combustion chamber.
When the engine coolant temperature is low or when
the inlet air quantity is small (when the engine is at
idle, for example), the engine control unit turns the
purge solenoid off to shut off the fuel vapor flow to
the inlet manifold.
This does not only insure the driveability when the
engine is cold or running under low load but also sta-
AK300022 AC
bilize the emission level.
SYSTEM DIAGRAM
Throttle body
Engine-ECU
Canister Check valve
From
fuel Air flow sensor
tank
OFF
Engine coolant
Purge temperature sensor
control
ON solenoid
Engine
valve control Intake air
relay temperature sensor
Barometric pressure sensor
Battery
AK401830AB
COMPONENT LOCATION (EVAPORATIVE 1. Disconnect the vacuum hose (red stripe) from
EMISSION CONTROL SYSTEM) throttle body and connect it to a hand vacuum
M1173007500302 pump.
2. Plug the nipple from which the vacuum hose was
removed.
3. When the engine is cold or hot, apply negative
pressure of 53 kPa, and check the condition of the
negative pressure.
Purge control When engine is cold
solenoid valve (Engine coolant temperature: 40°C or less)
Engine condition Normal condition
AK304229AB At idle Negative pressure is
3,000 r/min maintained.
PURGE CONTROL SYSTEM CHECK
M1173001400664 When engine is hot
(Engine coolant temperature: 80°C or higher)
Throttle body Engine condition Normal condition
At idle Negative pressure is
maintained.
3,000 r/min (within 3 minutes Negative pressure
after engine starts) will leak.
Red stripe
AK304230AB
17-11
PURGE PORT VACUUM CHECK
M1173001500252 A
Throttle body
Red stripe
Battery
AK100012 AC
AK304231AB 1. Disconnect the vacuum hose from the solenoid

valve.
1. Disconnect the vacuum hose (red stripe) from the
2. Disconnect the harness connector.
throttle body and connect a hand vacuum pump to
the nipple. 3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
2. Plug the vacuum hose (red stripe).
4. Check airtightness by applying negative pressure
with voltage applied directly from the battery to the
purge control solenoid valve and without applying
voltage.
Battery voltage Normal condition
Vac-
uum Applied Negative pressure
leaks
Not applied Negative pressure
Engine speed (r/min)
maintained
AK100011AC

4. Check that a fairly constant negative pressure is
generated regardless of the engine speed.
5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.
PURGE CONTROL SOLENOID VALVE

CHECK
M1173001700405 AK100013
NOTE: When disconnecting the vacuum hose,

5. Measure the resistance between the terminals of
always make a mark so that it can be reconnected at
the solenoid valve.
original position.
Standard value: 30 − 34 Ω (at 20°C)
CHECK VALVE CHECK

M1173006200085
Connect a hand vacuum pump to the check valve,
apply negative pressure and check the airtightness.
Connect nipple colour Normal condition
Black Negative pressure
leaks
Brown Negative pressure
is maintained
AK200373
FUEL VAPOUR CANISTER REMOVAL AND INSTALLATION

M1173004200186

• Air Pipe C, Air Hose D Removal (Refer to GROUP 15, • Air Cleaner Assembly Installation (Refer to GROUP 15,
Intercooler P.15-6). Air Cleaner P.15-5).
• Battery and Battery Tray Removal • Battery and Battery Tray Installation
• Air Cleaner Assembly Removal (Refer to GROUP 15, Air • Air Pipe C, Air Hose D Installation (Refer to GROUP 15,
Cleaner P.15-5). Intercooler P.15-6).
3 1
2
4
5 8
AC310639 AB

1. Emission vacuum hose connection 5. Fuel vapour control line clamp
2. Fuel vapour control line hose 6. Fuel vapour canister
3. Fuel vapour control check valve 7. Fuel high-pressure hose clamp
4. Fuel vapour control line hose 8. Fuel vapour canister bracket
17-13
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL INFORMATION (EGR SYSTEM) The EGR flow rate is controlled by the EGR valve so
M1173005200684 as not to decrease the driveability.
The exhaust gas recirculation (EGR) system lowers
the nitrogen oxide (NOx) emission level. OPERATION
When the air/fuel mixture combustion temperature is The EGR valve is being closed and does not recircu-
high, a large quantity of NOx is generated in the late exhaust gases under one of the following condi-
combustion chamber. tions.
Therefore, this system recirculates part of emission Otherwise, the EGR valve is opened and recirculates
gas from the exhaust port of the cylinder head to the exhaust gases.
combustion chamber through the inlet manifold to • The engine coolant temperature is low.
decrease the air/fuel mixture combustion tempera- • The engine is at idle.
ture, resulting in reduction of NOx. • The throttle valve is widely opened.
SYSTEM DIAGRAM
Engine-ECU
Barometric
pressure sensor
EGR control
Solenoid valve Air flow sensor
OFF Engine coolant

temperature sensor
ON Crank angle sensor
Engine
EGR valve control
relay
Battery
AK501846 AB
COMPONENT LOCATION (EGR SYSTEM) 1. Disconnect the vacuum hose (Green stripe) from
M1173007600309 the EGR valve, and then connect a hand vacuum
pump via the three-way terminal.
2. When the engine is hot or cold, check the
condition of vacuum by racing the engine.
When engine is cold
(Engine coolant temperature: 20°C or less)
Throttle valve Normal vacuum
EGR control
condition
solenoid valve Open quickly No vacuum will
AK304234AB generate (the same
as barometric
pressure.)
When engine is hot
EGR valve (Engine coolant temperature: 80°C or higher)
Throttle valve Normal vacuum
condition
Open quickly It will momentarily
rise over 13 kPa
AK304235AB
3. Disconnect the three-way terminal.
EGR SYSTEM CHECK

M1173002600393
Three-way terminal Green stripe
EGR control
Green stripe solenoid valve AK304237AB
4. Connect the hand vacuum pump to the EGR

EGR control
solenoid valve AK304236AB
valve nipple (Green stripe).
5. Check whether the engine stalls or the idling is
unstable when a vacuum of 27 kPa or higher is
applied during idling.
17-15
EGR VALVE CHECK 2. Plug the vacuum hose (White stripe).
M1173002800308
1. Remove the EGR valve and inspect for sticking,
carbon deposits, etc. If found, clean with a
suitable solvent so that the valve seats correctly.
2. Connect a hand vacuum pump to the EGR valve.
Vac-
3. Apply negative pressure of 67 kPa, and check uum
that the negative pressure is maintained.
Engine speed (r/min)

AK100011AC

4. Check that a fairly constant vacuum is generated
regardless of the engine speed.
5. If no vacuum is generated, the port is probably
blocked and should be cleaned.
AKX00348
EGR CONTROL SOLENOID VALVE
4. Apply negative pressure and check the passage CHECK
of air by blowing through one side of the EGR M1173003100368
passage. NOTE: When disconnecting the vacuum hose,
Vacuum Passage of air always make a mark so that it can be reconnected at
original position.
5.3 kPa or less Air is not blown out
27 kPa or more Air is blown out B
5. Replace the gasket, and tighten to the specified
torque. A
Tightening torque: 20 ± 2 N⋅m
EGR PORT VACUUM CHECK C

M1173002900242 Battery
Throttle body
AK100015 AF
1. Disconnect the vacuum hose from the solenoid

valve.
3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
White stripe
4. Check air tightness by applying negative pressure
AK304238 AB with voltage applied directly from the battery to the
1. Disconnect the vacuum hose (White stripe) from EGR control solenoid valve and without applying
the throttle body EGR vacuum nipple and connect voltage.
a hand vacuum pump to the nipple.
Battery voltage Nipple Normal

condition condition
Applied Both nipples Negative
open pressure
leaks
Nipple "B" closed Negative
pressure
maintained
Not applied Both nipples Negative AK304447
open pressure
leaks 5. Measure the resistance between the terminals of
the solenoid valve.
Nipple "C" Negative
closed pressure Standard value: 29 − 35 Ω (at 20°C)
maintained
EGR VALVE REMOVAL AND INSTALLATION

M1173010500272
6.0 ± 1.0 N·m
6.0 ± 1.0 N·m
20 ± 2 N·m
4N
2
AC210292 AB

<<A>> >>A<< • Strut tower bar 2. Vacuum hose connection
1. Intercooler air hose E 3. EGR valve
4. EGR valve gasket
17-17
REMOVAL SERVICE POINT INSTALLATION SERVICE POINT
<<A>> STRUT TOWER BAR REMOVAL >>A<< STRUT TOWER BAR INSTALLA-
1. Remove the strut tower bar. (Refer to GROUP 42, TION
Strut Tower Bar P.42-9). 1. Remove the nuts that are temporarily securing the
2. After removing the strut tower bar, install the top strut assembly.
of the strut assembly temporarily with the strut 2. Install the strut tower bar. (Refer to GROUP 42,
tower bar mounting nuts. Strut Tower Bar P.42-9).
CATALYTIC CONVERTER
M1173003900472
44 ± 5 N·m
13 ± 2 N·m
49 ± 10 N·m
1 7 N
N 4
6 59 ± 10 N·m
5 N
2 13 ± 2 N·m
50 ± 5 N·m
AC310641 AB

<<A>> >>A<< 1. Oxygen sensor (Rear) 5. Gasket
2. Spring 6. Catalytic converter
3. Front exhaust pipe 7. Gasket
4. Seal ring

<<A>> OXYGEN SENSOR (REAR) >>A<< OXYGEN SENSOR (REAR)
REMOVAL INSTALLATION
MD998770 MD998770
ACX02426 AB ACX02426 AB
Use special tool oxygen sensor wrench (MD998770) Use special tool oxygen sensor wrench (MD998770)
to remove the oxygen sensor (rear). to install the oxygen sensor (rear).
42-1
GROUP 42
BODY
CONTENTS
HOOD. . . . . . . . . . . . . . . . . . . . . 42-3 WINDOW REPAIR . . . . . . . . . . . . . 42-10
ON-VEHICLE SERVICE. . . . . . . . . 42-3 WINDSHIELD . . . . . . . . . . . . . . . . . 42-12

ADJUSTMENT OF CLEARANCE AROUND REMOVAL AND INSTALLATION. . . . . . 42-12
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF ALIGNMENT OF HOOD REAR WINDOW GLASS . . . . . . . . 42-17
STEPPED PORTION AND HOOD STRIKER 42-3 REMOVAL AND INSTALLATION. . . . . . 42-17
ADJUSTMENT OF HOOD HEIGHT . . . 42-3
HOOD. . . . . . . . . . . . . . . . . . . . . . . 42-4
DOOR . . . . . . . . . . . . . . . . . . . . 42-20
SERVICE SPECIFICATIONS . . . . . 42-20
FENDER. . . . . . . . . . . . . . . . . . . 42-5
SEALANT . . . . . . . . . . . . . . . . . . . . 42-20
SPECIAL TOOL . . . . . . . . . . . . . . . 42-5

SPECIAL TOOLS . . . . . . . . . . . . . . 42-21
FENDER. . . . . . . . . . . . . . . . . . . . . 42-6
TROUBLESHOOTING . . . . . . . . . . 42-22
ON-VEHICLE SERVICE . . . . . . . . . 42-22

FUEL FILLER LID . . . . . . . . . . . 42-8 DOOR FIT ADJUSTMENT . . . . . . . . . . . 42-22
DOOR WINDOW GLASS ADJUSTMENT 42-23
REMOVAL AND INSTALLATION . 42-8 GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT. . . . . . . . . . . . . . . . 42-23
POWER WINDOW OPERATING
STRUT TOWER BAR . . . . . . . . 42-9 CURRENT CHECK . . . . . . . . . . . . . . . . 42-24
POWER WINDOW RELAY CHECK. . . . 42-24
CIRCUIT BREAKER (INCORPORATED
REMOVAL AND INSTALLATION . 42-9
IN THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-24
WINDOW GLASS . . . . . . . . . . . 42-9 POWER WINDOW CHECK . . . . . . . . . . 42-24
CENTRAL DOOR LOCKING SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-25
ADHESIVE . . . . . . . . . . . . . . . . . . . 42-9 DOOR OUTSIDE HANDLE PLAY CHECK 42-25
DOOR INSIDE HANDLE PLAY
SPECIAL TOOLS. . . . . . . . . . . . . . 42-10 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 42-25
Continued on next page

42-2
DOOR ASSEMBLY . . . . . . . . . . . . 42-26 TRUNK LID HEIGHT ADJUSTMENT. . . 42-36

INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-27 TRUNK LID . . . . . . . . . . . . . . . . . . . 42-37
REMOVAL AND INSTALLATION. . . . . . 42-37
DOOR GLASS AND REGULATOR 42-27 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-39
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-29
KEYLESS ENTRY SYSTEM . . 42-39
DOOR HANDLE AND LATCH. . . . 42-30
REMOVAL AND INSTALLATION . . . . . 42-30 SERVICE SPECIFICATIONS . . . . . 42-39
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-31
SPECIAL TOOLS . . . . . . . . . . . . . . 42-40
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP 42-33 TROUBLESHOOTING . . . . . . . . . . 42-41
ON-VEHICLE SERVICE . . . . . . . . . 42-41
TRUNK LID . . . . . . . . . . . . . . . . 42-35 KEYLESS ENTRY SYSTEM CHECK. . . 42-41
KEYLESS ENTRY SYSTEM TIMER LOCK
FUNCTION INSPECTION . . . . . . . . . . . 42-41
SPECIAL TOOL . . . . . . . . . . . . . . . 42-35 ENABLING/DISABLING THE ANSWERBACK
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . 42-41
ON-VEHICLE SERVICE. . . . . . . . . 42-35 HOW TO REGISTER SECRET CODE . 42-43
TRUNK LID ADJUSTMENT. . . . . . . . . . 42-35
ADJUSTMENT OF CLEARANCE AROUND TRANSMITTER. . . . . . . . . . . . . . . . 42-46
TRUNK LID . . . . . . . . . . . . . . . . . . . . . . 42-36 TRANSMITTER . . . . . . . . . . . . . . . . . . . 42-46
TRUNK LID STRIKER ADJUSTMENT . 42-36 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-47
BODY
HOOD
42-3
HOOD
ON-VEHICLE SERVICE ADJUSTMENT OF HOOD HEIGHT
M1421007400123
ADJUSTMENT OF CLEARANCE AROUND

HOOD A
M1421007200129
Y0215AU
Section A – A
Hood
AC005945
ADJUSTMENT OF ALIGNMENT OF HOOD

STEPPED PORTION AND HOOD
17 mm
STRIKER
M1421007300126
Hood bumper X0424CA

AC005948AB
Rotate the hood bumper by using arrow mark on the

hood bumper as a guide to adjust the hood height. If
the hood bumper is rotated just one turn, the hood
height changes by approximately 3 mm.
AC005947
42-4 BODY
HOOD
HOOD
M1421001600419
CAUTION
Use the special bolts when securing the hinge to the hood. They have special coating for anti-corro-
sion.
Section A – A Section B – B Section C – C

A B
10 11 10 11
10
A B
11 Clip A Clip B Clip C

C
14 14 14 14
11
Note
AC211580
: Clip A positions 12
: Clip B positions 17
: Clip C positions
14
21 ± 4 N·m
11 ± 2 N·m
15 16
1 11 ± 2 N·m
13
8
3 11
4
10 9
6 7
1
2
3
9.0 ± 2.0 N·m 8
5
4 AC311076 AB
Removal Hood lock release cable removal steps

1. Hood bumper (Continued)
Hood lock release cable removal 3. Hood latch
steps 4. Hood lock release handle
• Front bumper assembly (Refer to 5. Hood lock release cable
GROUP 51, Front Bumper Assembly Hood and hood hinge removal steps
P.51-2). 6. Hood weatherstrip <Right side>
• Splash shield (Refer to P.42-6). 7. Hood weatherstrip <Left side>
2. Hood latch cover 8. Headlamp weatherstrip
BODY
FENDER
42-5
Hood and hood hinge removal steps Hood and hood hinge removal steps
• Washer hose (Refer to GROUP 51, 12. Hood outlet garnish
Windshield Wiper and Washer 13. Hood hinge bolt (Hood side)
P.51-23). 14. Hood
9. Hood support rod 15. Shim
10. Hood heat protector panel 16. Hood hinge
11. Hood heat protector 17. Hood weather strip
FENDER
SPECIAL TOOL
M1421000600256

MB990784 Ornament remover Side turn-signal lamp removal
MB990784
42-6 BODY
FENDER
FENDER
M1421001900409
CAUTION
Use the special fasteners to secure the fender. They have special coating for anti-corrosion.
• Front Bumper Assembly Removal and Installation (Refer
to GROUP 51, Front Bumper Assembly P.51-2).
• Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper and Washer P.51-20).
• Side Air Dam Removal and Installation (Refer to GROUP
51, Side Air Dam P.51-8).
AC211637 AB

1. Splash shield 4. Fender
<<A>> >>A<< 2. Side turn-signal lamp 5. Front fender bracket
3. Delta garnish (Refer to GROUP 51,
Garnish and Moulding P.51-10).
BODY
FENDER
42-7
<<A>> SIDE TURN-SIGNAL LAMP >>A<< SIDE TURN-SIGNAL LAMP
Front of vehicle
Side turn-signal lamp Hook
Claw
Fender
Fender
MB990784
AC005980AD : Front of vehicle AC005719 AB
Use special tool ornament remover (MB990784) to Engage the claw with the fender, and install the side
prize out the tab from the fender, and remove the turn-signal lamp.
side turn-signal lamp.
42-8 BODY
FUEL FILLER LID
FUEL FILLER LID

M1421002500277

• Rear Seat Removal and Installation (Refer to GROUP
52A, Rear Seat P.52A-20.)
• Front Scuff Plate (Driver's Seat Side), Rear Scuff Plate
(Driver's Side), Centre Pillar Lower Trim (Driver's Side),
Quarter Trim (Driver's Side) Removal and Installation
(Refer to GROUP 52A, Trims P.52A-10.)
W0570AQ
18M0109
Fuel filler lid height and clearance
adjustment
4
5
1
3
2 5.0 ± 1.0 N·m
AC005973
AC005996 AC

1. Fuel filler lid panel assembly 4. Fuel filler lid lock release cable
2. Clip 5. Fuel filler lid lock release handle
3. Fuel filler lid hook assembly
BODY
STRUT TOWER BAR
42-9
STRUT TOWER BAR
M1421005600132
N 44 ± 5 N·m
Plate
Strut tower bar
Plate
AC211421 AB
WINDOW GLASS
ADHESIVE
M1422000500111
Item Specified adhesive

Windshield 3M ATD Part No.8609 Super Fast Urethane Auto Glass
Rear window glass Sealant or equivalent
3M ATD Part No.8608 Super Fast Urethane Primer or
equivalent
42-10 BODY
WINDOW GLASS
SPECIAL TOOLS
M1422000600293

MB990480 Glass holder Removal and installation of window glass
MB990480
MB990784 Ornament remover Removal of rear window lower moulding
MB990784
WINDOW REPAIR ITEMS

M1422005600038
The windshield and rear window glass are attached
by an urethane-base adhesive to the window frame.
This adhesive provides improved glass holding and
sealing, and also gives body openings a greater
structural strength.
Name Remark
Adhesive 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer 3M ATD Part No.8608 Super Fast Urethane Primer or equivalent
Spacers Available as service part
Dam Available as service part
Anti-rust solvent (or Tectyl For rust prevention
506T.Valvoline Oil Company)
Isopropyl alcohol For grease removal from bonded surface
Steel piano wire Dia. × length... 0.6mm × 1m For cutting adhesive
Glass adhesive knife For cutting adhesive
Adhesive gun For pressing-out adhesive
HANDLING OF AUTO WINDOW SEALER BODY PINCH-WELD FLANGE SERVICING

Keep the sealant in a cool place, not exposed to the Before servicing the body pinch-weld flange, remove
direct rays of the sun. Do not place any heavy article old adhesive completely. If the flange requires paint-
on the sealant nor press it, otherwise it will become ing, bake it after painting is completed.
deformed. Avoid storing the sealant for more than 6
months, because it will lose its sealing effect.
BODY
WINDOW GLASS
42-11
WINDOW GLASS INSTALLATION
Window glass installation procedure
Body side Window glass side
Reusing the glass Replace the glass
Cleaning of adhesion surface Cleaning of adhesion surface

Cleaning of adhesion surface Completely cut off all of the residual
Cut off the residual adhesive until the Clean off any dirt adhering to the adhesion
adhesive. Clean the adhesive surface surface with isopropyl alcohol, and let dry
thickness is less than 2 mm. Clean the with isopropyl alcohol, and let dry for
adhesion surface with isopropyl alcohol, for 3 minutes or more.
3 minutes or more.
and let dry for 3 minutes or more.
Gluing of window dam and window spacer

Attaching of dual lock fastener
Glue the window dam and window spacer to the glass, following the standard position
Attach the dual lock fastener to set the
all the way around the inside edge of the glass.
positions for the glass to be installed.
Application of primer
Do not apply primer on residual adhesive as doing so may affect adhesion. apply enough primer on adhesion surface evenly taking
care not to apply it on the residual adhesive. after applying primer, let it dry for 3 minutes or more.
Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.
Installing the glass

After applying the adhesive, lightly press the glass evenly so that it adheres
completely.
Cleaning
After removing excess adhesive from the body or glass with a spatula, etc.
Clean off with isopropyl alcohol.
Checking for water leaks

Carry out a shower test to check that no water leaks through.
AC306636 AD
42-12 BODY
WINDOW GLASS
WINDSHIELD
• Front Deck Garnish Removal and Installation (Refer to
GROUP 51,Windshield Wiper and Washer P.51-20).
• Roof Drip Moulding Removal and Installation (Refer to
GROUP 51, Garnish and Moulding P.51-10).
• Inside Rear View Mirror Removal and Installation (Refer
to GROUP 52A, Inside Rear View Mirror P.52A-18).
• Front Pillar Trim Removal and Installation (Refer to
GROUP 52A, Trims P.52A-10).
• Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-17).
4 N
N3
2N
N5
3N
N6 5N
Y0495AU
A Units: mm
Section A – A Section B – B
A B
B Seal line
Seal line centre centre
1
Ceramic line
Seal line
1
C Primer
16 X0111AU
X0112AU
C Primer 13
Ceramic line Section C – C

1
Apply the primer and Seal line
adhesive along the centre
fictitious lines (seal line)
between each of Primer
the marks.
Mark
16
Seal line Y0496AU
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
AC006003 AC
BODY
WINDOW GLASS
42-13
Removal steps CAUTION
<<A>> >>B<< 1. Windshield
>>A<< 2. Windshield moulding
>>A<< 3. Window dam
>>A<< 4. Glass stopper
>>A<< 5. Spacer
>>A<< 6. Windshield spacer

<<A>> WINDSHIELD REMOVAL
1. To protect the body (paint surface), apply cloth AC002060
tape to all body areas around the installed
windshield. Glass adhesive knife
2. Make mating marks on the windshield and body.
AC207478 AD
Inserting the glass adhesive knife too deeply into

ACX00474 AB windshield adhesive may damage windshield.
3. Using piano wire. 4. Using glass adhesive knife
(1) Using a sharp-point drill, make a hole in the Keep glass adhesive knife at right angles with the
windshield adhesive. windshield edge, and put the blade at windshield
(2) Pass the piano wire from the inside of the edge and surface. Then cut away adhesive along
vehicle through the hole. the windshield edge.
CAUTION MB990480
Do not let the piano wire touch the edge of the
windshield.
(3) Pull the piano wire alternately from the inside
and outside along the windshield to cut the
adhesive.
ACX00475AB
5. Use special tool glass holder (MB990480) to

remove the windshield.
42-14 BODY
WINDOW GLASS
CAUTION CAUTION
Allow the cleaned area to dry for at least three
•
minutes. Do not touch any surface that has been

cleaned.
8. When reusing the windshield, remove the
adhesive still adhering to the windshield, and
clean with isopropyl alcohol.
9. Clean the body side in the same way.
INSTALLATION SERVICE POINTS

ACX00476 AB
>>A<< WINDSHIELD
Be careful not to remove more adhesive than is
SPACER/SPACER/GLASS STOPPER/WIN-
necessary.
• Be careful also not to damage the paintwork
DOW DAM/WINDSHIELD MOULDING
on the body surface with the knife. If the INSTALLATION
paintwork is damaged, repair the damaged CAUTION
area with repair paint or anti-rust agent. Leave the degreased parts for 3 or more minutes
6. Use a knife to cut away the remaining adhesive so to dry well, before starting on the next step. Do
that the thickness is within 2 mm around the entire not touch the degreased parts.
circumference of the body flange. 1. Use isopropyl alcohol to degrease the inside and
7. Finish the flange surfaces so that they are outside of the windshield and the body flanges.
smooth.
BODY
WINDOW GLASS
42-15
Glass stopper, spacer, windshield spacer and window dam installation position
Align the window

Glass stopper Glass end line dam and with the
seal line mark.
17.5 mm Align the glass Mark

stopper end with
the ceramic notch.
Seal line 13 mm
Ceramic line
Ceramic line
Windshield
Glass end line
Window dam Y0628AU
Section A – A
Seal line 14 mm
centre
Windshield spacer
Y0497AU
Align the spacer Section B – B
and with glass
end line
B
A
B 14 mm
A 10138AU
Align the windshield Spacer
spacer end with the
ceramic notch. 10139AU
AC006029AB
2. The inner side of the windshield is curved, CAUTION

therefore, make a point to assemble the glass • The primer strengthens the adhesive, so be
stopper and windshield spacer without any lifting sure to apply it evenly around the entire cir-
and assemble in the position shown in the Figure cumference. However, a too thick application
of the instructions. will weaken the adhesive.
3. Install the windshield moulding. • Do not touch the coated surface.
• Do not apply the primer on the remaining
>>B<<WINDSHIELD INSTALLATION adhesive because of weakening the adhesive.
1. When replacing the windshield, temporarily set
2. Soak a sponge in the primer, and apply evenly to
the windshield against the body, and place a
the windshield in the specified places. If the
mating mark on the windshield and body.
adhesive does not remain on the body flange
surface because of the panel replacement on the
body side, apply evenly to the body side in the
specified places.
3. Allow the windshield to dry for at least three
minutes after applying primer.
42-16 BODY
WINDOW GLASS
6. Use a spatula or similar tool to remove any

excessive adhesive. Clean the surface with
isopropyl alcohol. Avoid moving the vehicle until
the adhesive sets.
7. Bond the windshield to the body, and install the
roof drip moulding quickly before the adhesive
10 mm cures (Refer to GROUP51, Garnish and Moulding
15 mm P.51-10).
CAUTION
• Do not move the vehicle unless absolutely
ACX00480 AB
4. Fill a sealant gun with adhesive. Then apply the necessary.

adhesive evenly around the windshield within 30 • When testing for water leakage, do not pinch
minutes after applying the primer. the end of the hose to spray the water.
NOTE: Cut the tip of the sealant gun nozzle into a 8. Wait 30 minutes or more, and then test for water
V shape to simplify adhesive application. leakage.
5. Align the mating marks on the windshield and the
body, and lightly press the windshield evenly so
that it adheres completely.
BODY
WINDOW GLASS
42-17
REAR WINDOW GLASS
M1422001600155

• Roof Drip Moulding Removal and Installation (Refer to
GROUP 51, Garnish and Moulding P.51-10).
• High-mounted Stop Lamp Assembly Removal and Instal-
lation <Rear Shelf Mounted Type> (Refer to GROUP 54A,
High Mount Stop lamp P.54A-69).
• Rear Pillar Trim and Rear Shelf Trim Removal and Instal-
lation (Refer to GROUP 52A, Trims P.52A-10).
• Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-17).
N 10
7 Section A – A
7
N8 1
1
N2
6
N9 Y0564AU
N3
A 2N
4N
3N
3N 2N
A
2N 5N Y0500AU
N4
B Apply the primer and Section B – B

adhesive along the
fictitious lines (seal line) Seal line
between each of centre
B the marks.
Ceramic line 16 mm
7
Primer Y0502AU
Y0501AU
Mark
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
AC006056 AB

<<A>> >>B<< 1. Rear window lower moulding 4. Grommet B
2. Clip 5. Grommet C
3. Grommet A 6. Connecting the harness connector
42-18 BODY
WINDOW GLASS
Removal steps (Continued) INSTALLATION SERVICE POINTS

<> >>A<< 7. Rear window glass
>>A<< 8. Rear window upper moulding >>A<< GLASS STOPPER/WINDOW
>>A<< 9. Window dam DAM/REAR WINDOW UPPER MOULD-
>>A<< 10. Glass stopper ING/REAR WINDOW GLASS INSTALLA-
REMOVAL SERVICE POINTS TION
1. When replacing the rear window glass,
<<A>> REAR WINDOW LOWER MOULD- temporarily set the rear window glass against the
ING REMOVAL body, and place a mating mark on the rear
CAUTION window glass and body.
If the drip moulding has become warped, it CAUTION
should not be reused. Leave the degreased parts for 3 or more minutes
to dry well, before starting on the next step. Do
not touch the degreased parts.
2. Use isopropyl alcohol to degrease the inside and
outside of the rear window glass and the body
MB990784
flanges.
CAUTION
• The primer strengthens the adhesive, so be
sure to apply it evenly around the entire cir-
cumference. However, a too thick application
AC006073AB
will weaken the adhesive.
Use special tool ornament remover (MB990784) to • Do not touch the coated surface.
lever out the moulding.
3. Soak a sponge in the primer, and apply evenly to
the rear window glass and the body in the
<> REAR WINDOW GLASS REMOVAL specified places.
Remove the rear window glass using the same pro-
4. Allow the rear window glass to dry for at least 3
cedure as for the windshield (Refer to P.42-12).
minutes after applying primer.
BODY
WINDOW GLASS
42-19
Glass stopper and window dam installation position

Align the window
Glass end line dam end with
Glass stopper the ceramic notch.
18 mm Align the glass Mark

stopper end with
the ceramic notch.
Seal line 19 mm
Ceramic line
Rear window
glass
Ceramic
line
Y0629AU
Window dam
Section A - A
19 mm Window dam
Y0630AU
A
AC006075 AB
5. Install the glass stopper and window dam to the >>B<< REAR WINDOW LOWER
specified positions so that there are no adrift or MOULDING INSTALLATION
bent surfaces inside the rear window glass. Install the clips to the rear window lower moulding,
6. Install the rear window upper moulding. and then fix the rear window moulding to the vehicle
7. Install the glass in the same manner as the body.
windshield. (Refer to P.42-12).
42-20 BODY
DOOR
DOOR
M1423000300206
Item Standard value

Power window operation current (Power supply voltage 14.5 ± 0.5 V, at 25 °C) A 5±1
Door outside handle play mm Front door 2.3
Rear door 0 - 3.3 (target value:
1.3)
Door inside handle play mm Front door 10.4 ± 9.6
Rear door 10 ± 9.6
SEALANT
M1423000500095
Item Specified sealant

Door waterproof film 3M ATD Part No.8633 or equivalent
BODY
DOOR
42-21
SPECIAL TOOLS
M1423000600627

MB990480 Window glass holder Removal of power window regulator
assembly
MB990480
MB990900 or Door hinge adjusting Door alignment

MB991164 wrench
MB990900
MB990925 Bearing and oil seal Door striker adjustment

A
A: MB990939 installer set
A: Brass bar
MB990925AF
MB990211 Sliding hammer
MB990211
MB990241 Axle shaft puller

A: MB990243 A: Body puller
A
MB990241AE
A
MB991223 Harness set Terminal voltage measurement
A: MB991219 A: Test harness A: For checking connector pin
B: MB991220 B: LED harness contact pressure
C: MB991221 C: LED harness adapter B: For checking power supply circuit
B D: MB991222 D: Probe C: For checking power supply circuit
D: For connecting a locally sourced
tester
C
D DO NOT USE
MB991223 AZ
MB992006 Extra fine probe Continuity check and voltage

measurement at harness wire or
connector
MB992006
42-22 BODY
DOOR
TROUBLESHOOTING NOTE:
M1423000700312 Weld point Washer
The door system is controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to GROUP
54B, Troubleshooting P.54B-13 or GROUP 54C,
Troubleshooting P.54C-4.
Bolts
ON-VEHICLE SERVICE
DOOR FIT ADJUSTMENT Weld point Washer
M1423001100313 Door hinge AC206498 AF
CAUTION If the door hinge mounting bolt washers are
• Attach protection tape to the fender and door welded, grind off the welding according to the pro-
edges where the hinge is installed. cedure below beforehand.
• Do not rotate special tool door adjusting .
wrench (MB991164) with a torque of over 98
1. Remove the door hinge (Refer to P.42-26).
N⋅m.
2. Use a chisel or grinder to release the door
hinge mounting bolt washers, which are
welded to the door hinge.
3. On completion, paint the affected area with a
suitable touch-in brush to prevent corrosion.
MB990900 4. Install the door hinge (Refer to P.42-26).
or
MB991164 3. When the door is stiff to lock and unlock
AC000592 AB
1. Use the special tool door adjusting wrench

(MB990900 or MB991164) to loosen the hinge
mounting bolts on the body side, and then adjust
MB990939
the clearance around the door so that it is uniform
on all sides. Temporary
bolts Striker
2. If a door is not flush with its surrounding panels, AC006109AB
loosen the door-side door hinge mounting bolts
and obtain the flushness by moving the door. (1) Adjustment by using the striker (toward the
inside of the vehicle and vertical direction)
Install temporary bolts instead of the striker
mounting bolts, and use special tool brass bar
(MB990939) and a hammer to tap the bolt to
the desired direction.
MB990211
MB990243
Striker
AC006110 AB
(2) Adjustment by using the striker (toward the

outside of the vehicle)
BODY
DOOR
42-23
Use special tools slide hammer (MB990211) GLASS SLIDING MECHANISM CHECK
and body puller (MB990243) to pull the striker AND ADJUSTMENT
toward the outside of the vehicle. M1429000900154
If the window glass automatically starts moving
downwards at the wrong time while it is being raised,
Shim
carry out the following adjustment or replacement
Striker
procedures.
1. Remove the door trim assembly (Refer to GROUP
52A, Door trim P.52A-12).
2. Remove the waterproof film (Refer to P.42-33).
3. Remove the window regulator assembly from the
door window glass, and then raise and lower the
AC006111AB door window glass by hand to check the operation
(3) Adjustment by using shims (forward and force.
rearward) NOTE: Insert a cushion or similar object to pre-
Increase or decrease the number of shims so vent damage to the glass if it should happen to fall
that the striker engages with the door latch down.
properly.
Runchannel Door
DOOR WINDOW GLASS ADJUSTMENT sash
M1423001000394
Check that the door glass moves while contacting
the door glass channel when it is raised and lowered
fully. If not, adjust the door window according to the
following procedures. Lower
sash
52A, Door trim P.52A-12).
AC003777AB
2. Remove the waterproof film (Refer to P.42-33).
3. Loosen the door glass mounting screw via the 4. If the door window glass does not move up and
adjusting hole with the door window glass fully down smoothly, check or repair the following
closed, then lower the window glass a little. points.
• Check the installation condition of the runchan-
<Front> <Rear>
nel.
• Repair any twisting in the door sash.
• Check the installation condition of the lower sash
or the centre sash.
NOTE: The lower sash cannot normally be
Adjusting
Adjusting hole adjusted, but it may be possible to adjust the sash
hole
span slightly within the range allowed by manu-
facturing tolerances by pushing the lower sash
Y0238AU Y0239AU outwards while re-installing it.
AC006112 AB
5. If repair or adjustment is not possible, replace the
4. Fully close the door window glass again and door assembly.
tighten the door glass mounting screw firmly via
the adjusting hole.
42-24 BODY
DOOR
POWER WINDOW OPERATING CURRENT BATTERY Tester Specified

CHECK VOLTAGE connection condition
M1429001100269
Not applied 4−5 Open circuit
• Connect Less than 2
terminal No. 3 ohms
and the
negative
battery
terminal.
• Connect
terminal No. 1
and the
AC006115AB
positive battery
1. Remove the power window fuse and connect an terminal.
ammeter as shown in the illustration.
2. When the power window switch is pressed to the CIRCUIT BREAKER (INCORPORATED IN
“UP” position, a large amount of current flows at THE POWER WINDOW MOTOR)
the time the window starts to close and when it is INSPECTION
fully closed, so measure the operation current in M1429001000273
the interval between these two points. 1. Pull the power window switch to the UP position
Standard value (A): 5 ± 1A (Power supply to fully close the door window glass, and keep
voltage 14.5 ± 0.5V, 25°C) pulling the switch for 10 additional seconds.
3. If the operation current is outside the standard 2. Release the power window switch from the UP
value, refer to P.42-23. position and immediately press it to the DOWN
position. The condition of the circuit breaker is
POWER WINDOW RELAY CHECK good if the door window glass starts to move
M1429001800202 downwards within 60 seconds.
POWER WINDOW CHECK

M1429004400203
Check the system as described below. If the system
does not work, carry out troubleshooting. Refer to
Junction block
(front view) GROUP 54B, Troubleshooting P.54B-13 or GROUP
54C, Troubleshooting P.54C-4.
• Operate the power window switch of each seat to
check that the power window works.
• Turn on the power window lock switch of the
power window main switch, and operate the front
Power window relay
passenger's and rear power window sub switches
to check that the power windows do not work.
Power window
relay
• Turn on the power window lock switch of the
power window main switch, and operate the
5 1 2 3 power window main switch to check that each
4 4 power window operates.
1 3 5
AC305140 AB
BODY
DOOR
42-25
CENTRAL DOOR LOCKING SYSTEM DOOR INSIDE HANDLE PLAY
INSPECTION ADJUSTMENT
M1427001100207 M1423001500292
Check that the central door locking system works by Section A – A
operating the key cylinders (driver’s and passenger’s
door) and the inside lock knob (driver’s door). Carry A
A
out troubleshooting if the system does not activate.
B
Refer to GROUP 54B, Troubleshooting P.54B-13 or
GROUP 54C, Troubleshooting P.54C-4.
DOOR OUTSIDE HANDLE PLAY CHECK

M1423001600404
Y0705AU
AC006114 AB
1. Check that the door inside handle play is within

the standard value range.
A Standard value (B):
Front door: 10.4 ± 9.6 mm
Rear door: 10 ± 9.6 mm
2. If the door inside handle play is outside the
standard value range.
AC006113AB
1. Check that the door outside handle play is within 52A, Door trim P.52A-12).
the standard value range. 4. Remove the waterproof film (Refer to P.42-33).
Standard value (A):
Front door: 2.3 mm Inner cable Clip
Rear door: 0 − 3.3 mm (target value: 1.3 mm)
2. If the door outside handle play is not within the Outer cable end
standard value range, check the door outside
handle or the door latch assembly. Replace, if
necessary.
Door inside handle

Inside handle rod AC100404 AB
5. Adjust the door inside handle play with the outer

cable end connecting the door inside handle and
inside lock cable.
42-26 BODY
DOOR
DOOR ASSEMBLY
M1423002200283
• Door Fit Adjustment (Refer to P.42-22.)
<FRONT DOOR>
4 1
7 8
27 ± 5 N·m 5
11 ± 2 N·m
1
21 ± 4 N·m
2 3 9 10
1.5 ± 0.5 N·m
27 ± 5 N·m 11 ± 2 N·m Y0652AU
6 <REAR DOOR>
21 ± 4 N·m 11 ± 2 N·m
4
27 ± 5 N·m
5, 6 5
7 8
1
1.5 ± 0.5 N·m
21 ± 4 N·m
2
27 ± 5 N·m
ACX00503 3 9 10
21 ± 4 N·m 11 ± 2 N·m Y0655AU
6 AC006125AB
Removal Striker removal steps

1. Damper mail >>A<< 7. Striker
Door assembly removal steps 8. Striker shim
2. Harness connector Door switch removal steps
3. Door check connecting bolt 9. Door switch cap
4. Door assembly 10. Door switch
5. Door upper hinge
6. Door lower hinge
BODY
DOOR
42-27
INSTALLATION SERVICE POINT INSPECTION
M1423006000322
>>A<< STRIKER INSTALLATION DOOR SWITCH CHECK
Striker centre Latch centre
+1.5 mm 2 3
1
-1.5 mm
Striker
Latch
AC305098AB
AC211414 AC
Align the centre of the striker and latch within ±1.5
mm, and install. Switch Tester Specified
position connection condition
Released (ON) 1 − switch body, Less than 2
2 − switch body, ohms
3 − switch body
Depressed 1 − switch body, Open circuit
(OFF) 2 − switch body,
3 − switch body
DOOR GLASS AND REGULATOR

M1429001300467
• Door Window Glass Adjustment (Refer to P.42-23).
<FRONT DOOR> <REAR DOOR>

4 5 6
1
1
2
2
AC212124 AB
42-28 BODY
DOOR
<FRONT DOOR> View A
7
C C C C
B
B
B B
C C C C
A
7 Section B - B Section C - C
7 7
Door trim
Door trim
NOTE Clip Claw
: Clip positions
: Claw positions AC305108 AB
<REAR DOOR>
View D
F F F
F
E E
E E
F
F F F
7
D
7 Section E - E Section F - F
7 7
Door trim Door trim

Clip Claw
NOTE
: Clip positions
: Claw positions AC305109 AB
Door window regulator assembly Stationary window glass removal

removal steps steps
• Door trim assembly (Refer to GROUP • Window glass runchannel (Refer to
52A, Door Trim P.52A-12). P.42-33).
• Waterproof film (Refer to P.42-33). • Door beltline inner weatherstrip
<<A>> >>B<< 1. Window regulator assembly (Refer to P.42-33).
<<A>> >>B<< 2. Power window motor assembly 3. Door window glass
Door window glass removal steps <> >>A<< 4. Centre sash upper
• Window glass runchannel (Refer to 5. Stationary window glass
P.42-33). 6. Stationary window weatherstrip
3. Door window glass Power window switch removal steps
7. Power window switch panel assembly
BODY
DOOR
42-29
REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS
<<A>> WINDOW REGULATOR ASSEM- >>A<< CENTRE SASH UPPER INSTALLA-
BLY/POWER WINDOW MOTOR ASSEM- TION
BLY REMOVAL Securely insert the centre sash upper into the win-
1. Remove the door window glass installation bolts. dow rear sash (door).
CAUTION >>B<< POWER WINDOW MOTOR
If film or others are adhered to the door window
ASSEMBLY INSTALLATION/WINDOW
glass, attach special tool window glass holder
(MB990480) to the outside of the glass to prevent REGULATOR ASSEMBLY
the film from peeling off. <FRONT DOOR>
MB990480 1
4
7
3
2
6
5
<REAR DOOR> Y1536AU

AC100009AB
2. Lift the door window glass, and attach special tool

window glass holder (MB990480) to the glass as
shown to prevent the glass from falling. 1
4 6
3. Remove the window regulator assembly and
power window motor assembly 3
2 5
<> CENTRE SASH UPPER REMOVAL
Y1476AU
AC100010AB
When installing the window regulator assembly,

tighten the bolts in the order shown in the illustration.
INSPECTION
M1429001400282
Door outer
opening How to make the power window switch learn the
weatherstrip fully closed position of the power window
Door centre How to make the power window switch learn the
sash AC000602AB fully closed position when the power window
1. Remove the door outer opening weatherstrip from switch is removed, or the power window regula-
the centre sash upper only. tor assembly is removed or replaced
1. If the anti-trap function (safety mechanism) is
2. Remove the centre sash upper mounting screws,
activated consecutively three times or more, the
and then remove the centre sash upper from the
fully closed position that the power window switch
door panel.
has learned will be erased (initialised).
2. Operate the power window switch and fully open
the door window glass.
42-30 BODY
DOOR
CAUTION How to make the power window switch learn the

The anti-trap function does not work until the fully closed position when the power window
power window switch completes learning the switch is replaced with a new one
fully closed position (It is because the anti-trap CAUTION
function is reset). The anti-trap function does not work until the
3. Operate the power window switch and fully close power window switch completes learning the
the door window glass. The power window fully closed position (It is because the anti-trap
activates for 0.7 seconds and stops automatically function is reset).
when the power window switch is pressed once. Operate the power window main switch to fully close
Repeat this operation until the door window glass the door window glass by one-shot up action so that
fully closes and release the switch once. Then, the power window switch will complete learning (Ini-
hold the power window switch to the fully closed tialisation is not needed).
side again for one second so that the power NOTE: When the power window sub switch of each
window switch completes learning the fully closed seat is replaced, operate the power window main
position. switch to fully close the applicable power window by
NOTE: If the power window switch is operated to one-shot up action (It is because the power window
open the door window glass while the switch is sub switch does not have one-shot up/down func-
learning, learning will be cancelled. If this hap- tion).
pens, return to step 2.
DOOR HANDLE AND LATCH

M1423004600458

• Door Trim Removal (Refer to GROUP 52A, Door trim • Door Inside Handle Play Check (Refer to P.42-25).
P.52A-12). • Door Outside Handle Play Check (Refer to P.42-25).
• Door Trim Installation (Refer to GROUP 52A, Door trim
P.52A-12).
<FRONT DOOR> <REAR DOOR>
3 2
7
N
6 9.0 ± 2.0 N·m
9.0 ± 2.0 N·m
N 8
5
8 5
1
1 4
5.0 ± 1.0 N·m 4
9
9
5.0 ± 1.0 N·m
AC300270 AB
BODY
DOOR
42-31
Door handle and door latch assembly Door handle and door latch assembly
removal steps removal steps (Continued)
>>C<< 1. Door inside handle 5. Door latch assembly
• Waterproof film (Refer to P.42-33). 6. Inside lock cable (Front door)
2. Door outside handle 7. Inside lock rod (Rear door)
3. Door lock key cylinder 8. Inside handle rod
>>B<< 4. Lower sash Door check removal steps
• Waterproof film (Refer to P.42-33).
>>A<< 9. Door check

>>A<< DOOR CHECK INSTALLATION 1. Install the inside lock cable to the door inside
handle as follows:
(1) Install the inner cable end in the inside lock
cable to the clip in the door inside handle.
Identification mark
(2) Turn the inside lock knob to the door lock
position.
(3) Install the outer cable end to the door inside
handle securely.
(4) Install the clip to the inner cable.
2. Install the inside handle rod to the door inside
ACX00541AB handle.
Install the door check so that the identification mark 3. Install the door inside handle to the door.
faces upwards.
INSPECTION
Item Identification M1423004700541
mark FRONT DOOR LOCK ACTUATOR CHECK
Front Door Left door 39L
Front door <Left side>
Right door 39R Lock Unlock
Rear Door Left door 40L

Right door 40R
View A
>>B<< LOWER SASH INSTALLATION
Securely insert the rear lower sash into the window Lever
1 2 3
rear sash. 4 5 6
>>C<< DOOR INSIDE HANDLE A
<Right side>
INSTALLATION Unlock Lock
Inner cable Clip
Outer cable end

View B
Lever
1 2 3
4 5 6
Door inside handle B AC305111 AB

Inside handle rod AC100404 AB
42-32 BODY
DOOR
ACTUATOR OPERATION CHECK REAR DOOR LOCK ACTUATOR CHECK

Lever Battery connection Lever
Rear door
position operation <Left side> Unlock
At the • Connect terminal The lever Lock
"LOCK" No.4 and the moves from the
position negative battery "LOCK"
terminal. position to the
• Connect terminal "UNLOCK" View A
No.6 and the position. Lever
positive battery 1 2 3
terminal. 4 5 6
At the • Connect terminal The lever A
Lock
"UNLOCK" No.6 and the moves from the <Right side>
position negative battery "UNLOCK"
Unlock
• Connect terminal "LOCK"
No.4 and the position.
positive battery View B
terminal.
Lever 1 2 3
ACTUATOR SWITCH CHECK <LH DRIVE VEHI- 4 5 6
CLES (DRIVER’S SIDE)>
Lever position Tester Specified B
AC305112 AB
connection condition
At the "LOCK" 1−2 Less than 2 ACTUATOR OPERATION CHECK
position ohms Lever Battery connection Lever
position operation
At the "UNLOCK" 1−3 Less than 2
position ohms At the • Connect terminal The lever
"LOCK" No.4 and the moves from the
ACTUATOR SWITCH CHECK <RH DRIVE VEHI- position negative battery "LOCK"
CLES (DRIVER’S SIDE)> terminal. position to the
Lever position Tester Specified • Connect terminal "UNLOCK"
connection condition No.6 and the position.
At the "LOCK" 2−3 Less than 2 positive battery
position ohms terminal.
At the "UNLOCK" 1−3 Less than 2 At the • Connect terminal The lever
position ohms "UNLOCK" No.6 and the moves from the
position negative battery "UNLOCK"
• Connect terminal "LOCK"
No.4 and the position.
positive battery
terminal.
BODY
DOOR
42-33
DOOR LOCK KEY CYLINDER SWITCH Switch Tester Specified
CHECK <PASSENGER’S SIDE> position connection condition
LOCK 1−2 Less than 2
ohms
NEUTRAL 1 − 2, 2 − 3 Open circuit
(OFF)
UNLOCK 2−3 Less than 2
ohms
1 2 3
AC101318
WINDOW GLASS RUNCHANNEL AND

DOOR OPENING WEATHERSTRIP
M1423003100449
<FRONT DOOR>
6 5 3
: Sectional view of
clip position
4
A 2
: Sectional view of
clip position
1 Section A – A
<Front door>
6
1
Door
Sealant: 3M ATD Part No.8633 or equivalent

AC304409AB
42-34 BODY
DOOR
Waterproof film removal steps Door window glass runchannel

• Front door trim (Refer to GROUP removal
52A, Door trim P.52A-12). 4. Door window glass runchannel
• Speaker (Refer to GROUP 54A, Door beltline inner weatherstrip
Speaker P.54A-78). removal steps
1. Waterproof film • Front door trim (Refer to GROUP
Door inner opening weatherstrip 52A, Door trim P.52A-12).
removal steps 5. Door beltline inner weatherstrip
• Scuff plate, centre pillar lower trim Door beltline moulding removal steps
and cowl side trim (Refer to GROUP • Door mirror assembly (Refer to
52A, Trims P.52A-10). GROUP 51, Door mirror P.51-35).
2. Door inner opening weatherstrip • Door window glass (Refer to
(Body side) P.42-27).
Door outer opening weatherstrip 6. Door beltline moulding
removal steps
• Front door check mounting bolt (Door
side) (Refer to P.42-26).
<<A>> >>A<< 3. Door outer opening weatherstrip
<REAR DOOR>
: Sectional view of
clip position
6
4
A
5
A
: Sectional view of
3 2 clip position
B B Section A – A
1
7
Door
<Rear door>
Section B – B
Door
1
4
3
Sealant: 3M ATD Part No.8633 or equivalent
AC304418AB
BODY
TRUNK LID
42-35
Waterproof film removal steps Door outer opening weatherstrip
• Rear door trim (Refer to GROUP 52A, removal steps (Continued)
Door trim P.52A-12). <<A>> >>A<< 4. Door outer opening weatherstrip
1. Waterproof film Door window glass runchannel
Door inner opening weatherstrip removal
removal steps 5. Door window glass runchannel
• Scuff plate, centre pillar lower trim Door beltline inner weatherstrip
and cowl side trim (Refer to GROUP removal steps
52A, Trims P.52A-10). • Rear door trim (Refer to GROUP 52A,
2. Door inner opening weatherstrip Door trim P.52A-12).
(Body side) • Centre sash upper (Refer to P.42-27).
Door outer opening weatherstrip 6. Door beltline inner weatherstrip
removal steps Door beltline moulding removal steps
• Rear door check mounting bolt (Door • Door window glass (Refer to
side) (Refer to P.42-26). P.42-27).
3. Retainer weatherstrip • Stationary glass (Refer to P.42-27).
7. Door beltline moulding

<<A>> DOOR OUTER OPENING WEATH- Make a fabricated tool as shown in the illustration to
ERSTRIP REMOVAL remove the door weatherstrip.
Fabricated
INSTALLATION SERVICE POINT
15 mm
4 mm
tool >>A<< DOOR OUTER OPENING WEATH-
ERSTRIP INSTALLATION
8 mm The clip colour identifies the left and right weather-
strips so be sure to use the colours so as to install
Thickness:
1 mm correctly.
Applicable side Identification colour
Right door Pink
ACX00555AB
Left door Natural (White)
TRUNK LID
SPECIAL TOOL
M1421000600245

MB991244 Torsion bar remover and Removal and installation of
installer trunk lid torsion bar
MB991244
ON-VEHICLE SERVICE P.42-36) and trunk lid hinges (refer to P.42-36).

2. If the clearance around the trunk lid panel
TRUNK LID ADJUSTMENT assembly is uniform, but locking and unlocking of
M1421001000042
the trunk lid is difficult, make adjustments to the
1. If the clearance around the trunk lid panel trunk lid bumpers (refer to P.42-36) and trunk lid
assembly is not uniform and locking and striker (refer to P.42-36).
unlocking of the trunk lid is difficult, make
adjustments to the trunk lid bumpers (refer to
42-36 BODY
TRUNK LID
TRUNK LID STRIKER ADJUSTMENT

Trunk lid panel M1421008200036
assembly
Trunk lid striker
A A
A A
AC202324
Side outer panel

AC202898 AB
Section A – A
After checking the trunk lid release cable for proper
Trunk lid panel assembly
routing, loosen the trunk lid striker mounting bolts.
Change the position of the trunk lid striker relative to
Side outer panel
the trunk lid latch assembly so that trunk lid locking
and unlocking effort is correct.
TRUNK LID HEIGHT ADJUSTMENT

M1421008300066
AC202325
AC202913 AB Trunk lid panel assembly
3. If there is a difference in height between the side

outer panels and the side edges of the trunk lid
panel assembly, check the trunk lid hinges and, if A
necessary, replace them
A
4. If the clearance around the trunk lid panel
assembly is not uniform, and the trunk lid can be
locked and unlocked smoothly, make adjustments
Trunk lid bumper
to the trunk lid bumpers (refer to P.42-36) and
trunk lid hinges (Refer to P.42-36). Section A – A
5. If the locking and unlocking of the trunk lid still is Trunk lid bumper
difficult after making the above adjustments,
adjust the trunk lid striker (Refer to P.42-36).
ADJUSTMENT OF CLEARANCE AROUND 14 mm

TRUNK LID
M1421008100039 Trunk lid panel
assembly
Trunk lid hinge
AC207187AD
Turn each trunk lid bumper until the height shown in

the drawing is reached. If the trunk lid panel height
on one side is different from that on the other side
(even after the trunk lid bumpers have been adjusted
Trunk lid panel to the height indicated in the drawing), turn the trunk
assembly lid bumper(s) slightly to make fine adjustments to the
AC202897 AB trunk lid panel height
Loosen the trunk lid panel assembly mounting bolts NOTE: When the bumper is new, one full turn of the
and move the trunk lid panel assembly to make the trunk lid bumper changes the height approximately 3
clearance around the trunk lid uniform. mm. Turn it clockwise to reduce height. Turn it anti-
clockwise to increase height
BODY
TRUNK LID
42-37
TRUNK LID
M1421002200243
11 Section A – A
5
9
15 mm
10
AC308423
Section B – B
A 5
A
B 14 mm
6
12 B Y0636AU
8
5
1
2
3
7
8.8 ± 2.0 N·m
AC006098
4 AC310064 AB
Trunk lid weatherstrip removal steps Trunk lid striker removal steps
• Rear end trim (Refer to GROUP 52A, • Rear end trim (Refer to GROUP 52A,
Trims P.52A-10). Trims P.52A-10).
>>B<< 1. Trunk lid weatherstrip 4. Trunk lid striker
Trunk lid release cable and trunk lid Trunk lid panel removal steps
release handle removal steps 5. Trunk lid bumper
• Trunk rear side trim (Refer to GROUP 6. Trunk lid lock cylinder
52A, Trims P.52A-10). 7. Trunk lid latch assembly
• Rear seat (Refer to GROUP 52A, 8. Trunk lid hinge mounting bolt
Rear Seat Assembly P.52A-20). 9. Trunk lid panel assembly
• Centre pillar lower trim (Refer to Trunk lid latch removal
GROUP 52A, Trims P.52A-10). 7. Trunk lid latch assembly
• Cowl side trim (Refer to GROUP 52A, Trunk lid hinge removal steps
Trims P.52A-10). • Rear shelf trim (Refer to GROUP
• Accelerator pedal stopper (Refer to 52A, Trims P.52A-10).
GROUP 17, Accelerator Pedal • Rear seat (Refer to GROUP 52A,
P.17-3). Rear Seat Assembly P.52A-20).
2. Trunk lid release handle 9. Trunk lid panel assembly
3. Trunk lid release cable <<A>> >>A<< 10. Trunk lid torsion bar <RH>
<<A>> >>A<< 11. Trunk lid torsion bar <LH>
12. Trunk lid hinge
42-38 BODY
TRUNK LID
Grease application area
6 7
AC305143 AB
REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS

<<A>> TRUNK LID TORSION BAR >>A<< TRUNK LID TORSION BAR
Trunk lid torsion bar <RH> Trunk lid torsion bar <LH>
Colour mark
Trunk lid torsion bar <RH>
A
MB991244 F
Trunk lid torsion bar <LH> Trunk lid hinge <LH>
AC205068 AB
1. Attach the special tool torsion bar remover and B

installer (MB991244) to the illustrated portion of
the trunk lid torsion bar <RH> on the right hand of
the vehicle, then use the tool to detach the trunk
lid torsion bar <RH> from the trunk lid hinge <LH>
2. Remove the trunk lid torsion bar <LH> in the
Trunk lid torsion bar <LH>
same way as the trunk lid torsion bar <RH>. Hole
View F
Trunk lid hinge <RH>
E D C
A
Trunk lid torsion bar

<LH> B
MB991244 AC305282 AB
Install the trunk lid torsion bars using the following

procedure.
BODY
KEYLESS ENTRY SYSTEM
42-39
CAUTION >>B<< TRUNK LID WEATHERSTRIP
Install the trunk lid torsion bar <LH> before the INSTALLATION
trunk lid torsion bar <RH>. If the sequence is
reversed, the trunk lid torsion bar <LH> will not
be able to be installed because the special tool
torsion bar remover and installer (MB991244) will
interfere with the trunk lid torsion bar <RH> dur-
ing installation of the trunk lid torsion bar <LH>.
1. Identify the LH and RH torsion bars by the colour
mark made at the centre of each torsion bar. Marking
section
Trunk lid torsion bar Mark colour Joint
section
LH Green AC006104AB
Install the trunk lid weatherstrip so that the marking

RH Yellow
and the joint are aligned with the body centre line,
2. Insert the left end of the trunk lid torsion bar <LH>
in the hole in the trunk lid hinge <LH>. INSPECTION
M1421004800133
3. Press portion A of the trunk lid torsion bar <LH>
right end against point A on the trunk lid hinge TRUNK LID LATCH SWITCH CONTINUITY
<RH> as shown in View F in the drawing. CHECK
4. Twist the portion B of the trunk lid torsion bar
<LH> right end using the special tool torsion bar
remover and installer (MB991244) until it is
moved from point B and pressed against point C
of the trunk lid hinge <RH> as shown in View F.
Then force the portion into point D.
5. Twist the portion A of the trunk lid torsion bar
<LH> right end until it reaches point E on the trunk
lid hinge <RH> as shown in View F. Trunk lid latch assembly
6. Attach the trunk lid torsion bar <RH> to the trunk AC305142 AB
lid hinge <LH> using the same method as the

Switch position Tester Specified
trunk lid torsion bar <LH>.
ON (Latch open) 1 − Earth Less than 2
ohms
OFF (Latch shut) Open circuit

M1428000300148
Item Standard value

Voltage of transmitter battery V 2.5 − 3.2
42-40 BODY
SPECIAL TOOLS
M1428000600462

MB991502 M.U.T.-II Encrypted code registration
sub-assembly
B991502
MB991529 Diagnosis code check

harness
MB991529
MB991955 M.U.T.-III Encrypted code registration

A A: MB991824 sub-assembly CAUTION
B: MB991827 A: Vehicle M.U.T.-III main harness B
C: MB991910 communication (MB991911) should be used.
D: MB991911 interface (V.C.I.) M.U.T.-III main harness A
MB991824
E: MB991825 B: M.U.T.-III USB should not be used for this
B F: MB991826 cable vehicle.
C: M.U.T.-III main
harness A
(applicable to
MB991827 vehicles with CAN
communication)
C
D: M.U.T.-III main
DO NOT USE harness B
(applicable to
MB991910
vehicles without
CAN
D communication)
E: M.U.T.-III
measurement
adapter
MB991911
F: M.U.T.-III trigger
harness
E
MB991825
MB991826
MB991955
BODY
42-41
TROUBLESHOOTING ENABLING/DISABLING THE
M1428000700287
ANSWERBACK FUNCTION
The keyless entry system is controlled by the Smart M1428003200355
Wiring System (SWS). For troubleshooting, refer to If the keyless entry system locks or unlocks the
GROUP 54B, Troubleshooting P.54B-13 or GROUP doors, the room lamp flashes or illuminates, the haz-
54C, Troubleshooting P.54C-4. ard warning lamp flashes (hazard answerback func-
tion). The hazard answerback function can be
ON-VEHICLE SERVICE enabled or disabled according to the following proce-
dure:
KEYLESS ENTRY SYSTEM CHECK
M1428001400137
Check the system as described below. If the system ENABLING/DISABLING THE HAZARD
does not work, carry out troubleshooting. Refer to ANSWERBACK FUNCTION
GROUP 54B, Troubleshooting P.54B-13 or GROUP The hazard answerback function can be enabled or
54C, Troubleshooting P.54C-4. disabled by one of the two following procedures.
• Operate the transmitter to check that the doors <WHEN USING THE TRANSMITTER
can be locked and unlocked.
• Operate the transmitter to check that the answer-
AFTER DIAGNOSIS CONNECTOR (1) IS
back function works in response to doors lock- EARTHED>
ing/unlocking. 1. Enter the hazard answerback customize mode by
NOTE: The adjustment function allows you to performing one of the following steps. If the
change the answerback setting as follows. Prior ETACS-ECU enters the customize mode, its
to that check, confirm which setting is activated. buzzer will sound once.
. (1) Turn the ignition switch to “LOCK”(OFF)
• The hazard warning lamp flashes twice when position.
locked and once when unlocked. The room (2) Turn off the hazard warning lamp switch.
lamp flashes twice when locked and illumi- CAUTION
nates for 15 seconds when unlocked. Before connecting or disconnecting the earth,
• The hazard warning lamp do not flash when turn the ignition switch to the "LOCK" (OFF)
locked and flash once when unlocked. The position.
room lamp flashes twice when locked and illu-
Steering shaft
minates for 15 seconds when unlocked. Diagnosis
connector
• The hazard warning lamp flashes twice when
locked and do not flash when unlocked. The
room lamp flashes twice when locked and illu-
minates for 15 seconds when unlocked.
MB991529
• The hazard warning lamp do not flash when
both locked and unlocked. The room lamp
flashes twice when locked and illuminates for
15 seconds when unlocked.
AC305133AB
KEYLESS ENTRY SYSTEM TIMER LOCK (3) Connect the diagnosis connector to the
FUNCTION INSPECTION special tool diagnosis code check harness
M1428004000183 (MB991529).
Push the transmitter unlock button and check to see
(4) Close the driver's side door.
that the doors lock within 30 seconds. If it doesn't,
(5) Keep the windshield washer switch on for at
then execute troubleshooting remedies. Refer to
least ten seconds. Then the ETACS-ECU
GROUP 54B, Troubleshooting P.54B-13 or GROUP
buzzer will sound once.
54C, Troubleshooting P.54C-4.
2. If the transmitter “LOCK” button is pushed
consecutively twice (within two seconds), the
ETACS-ECU buzzer will sound, indicating that the
hazard answerback function can be enabled or
disabled when the doors are locked.
42-42 BODY
• Enable the hazard answerback function CAUTION

when the doors are locked: The Before connecting or disconnecting the M.U.T.-II,
ETACS-ECU buzzer will sound once. turn the ignition switch to the "LOCK" (OFF)
• Disable the hazard answerback function position.
when the doors are locked: The
ETACS-ECU buzzer will sound twice. Steering shaft
16-Pin
3. If the transmitter “UNLOCK” button is pushed
consecutively twice (within two seconds), the
ETACS-ECU buzzer will sound, indicating that the
hazard answerback function can be enabled or
disabled when the doors are unlocked.
• Enable the hazard answerback function
when the doors are unlocked: The MB991502
ETACS-ECU buzzer will sound once. AC304777AC
• Disable the hazard answerback function
(3) Connect the M.U.T.-II to the diagnosis
when the doors are unlocked: The
connector.
ETACS-ECU buzzer will sound twice.
(4) Close the driver's side door.
4. Exit the hazard answerback customize mode by (5) Keep the windshield washer switch on for at
observing one of the following steps. least ten seconds. Then the ETACS-ECU
(1) Disconnect diagnosis connector terminal (1) buzzer will sound once.
form the earth.
2. If the transmitter “LOCK” button is pushed
(2) Turn the ignition switch to position other then consecutively twice (within two seconds), the
“LOCK”(OFF), or remove the ignition key. ETACS-ECU buzzer will sound, indicating that the
(3) Open the driver's side door. hazard answerback function can be enabled or
(4) Any other warning buzzer output occurs. disabled when the doors are locked.
NOTE: If any operation is not done for at least three • Enable the hazard answerback function
minutes after the ETACS-ECU has entered the cus- when the doors are locked: The
tomize mode, the hazard answerback customize ETACS-ECU buzzer will sound once.
mode will be canceled automatically. • Disable the hazard answerback function
<WHEN THE TRANSMITTER IS USED ETACS-ECU buzzer will sound twice.
AFTER CONNECTING M.U.T.-II TO THE 3. If the transmitter “UNLOCK” button is pushed
DIAGNOSIS CONNECTOR> consecutively twice (within two seconds), the
1. Enter the hazard answerback customize mode by ETACS-ECU buzzer will sound, indicating that the
performing one of the following steps. If the hazard answerback function can be enabled or
ETACS-ECU enters the customize mode, its disabled when the doors are unlocked.
buzzer will sound once. • Enable the hazard answerback function
(1) Turn the ignition switch to “LOCK”(OFF) when the doors are unlocked: The
position. ETACS-ECU buzzer will sound once.
(2) Turn off the hazard warning lamp switch. • Disable the hazard answerback function
4. Exit the hazard answerback customize mode by
observing one of the following steps.
(1) Disconnect M.U.T.-II from the diagnosis
connector.
(2) Turn the ignition switch to position other then
“LOCK”(OFF), or remove the ignition key.
(3) Open the driver's side door.
(4) Any other warning buzzer output occurs.
BODY
42-43
NOTE: If any operation is not done for at least three 2. If the transmitter “LOCK” button is pushed
minutes after the ETACS-ECU has entered the cus- consecutively twice (within two seconds), the
tomize mode, the hazard answerback customize ETACS-ECU buzzer will sound, indicating that the
mode will be canceled automatically. hazard answerback function can be enabled or
disabled when the doors are locked.
<WHEN THE TRANSMITTER IS USED • Enable the hazard answerback function
AFTER CONNECTING SPECIAL TOOL when the doors are locked: The
V.C.I. (MB991824) TO THE DIAGNOSIS ETACS-ECU buzzer will sound once.
CONNECTOR> • Disable the hazard answerback function
1. Enter the hazard answerback customize mode by
performing one of the following steps. If the
ETACS-ECU enters the customize mode, its 3. If the transmitter “UNLOCK” button is pushed
buzzer will sound once. consecutively twice (within two seconds), the
(1) Turn the ignition switch to “LOCK”(OFF) ETACS-ECU buzzer will sound, indicating that the
position. hazard answerback function can be enabled or
(2) Turn off the hazard warning lamp switch. disabled when the doors are unlocked.
CAUTION • Enable the hazard answerback function
Before connecting or disconnecting the V.C.I.,
ETACS-ECU buzzer will sound once.
turn the ignition switch to the "LOCK" (OFF)
• Disable the hazard answerback function
position.
AC211686 ETACS-ECU buzzer will sound twice.
4. Exit the hazard answerback customize mode by
observing one of the following steps.
(1) Disconnect V.C.I. from the diagnosis
connector.
(2) Turn the ignition switch to position other then
“LOCK”(OFF), or remove the ignition key.
16-Pin (3) Open the driver's side door.
(4) Any other warning buzzer output occurs.
NOTE: If any operation is not done for at least three
minutes after the ETACS-ECU has entered the cus-
tomize mode, the hazard answerback customize
MB991911
mode will be canceled automatically.
HOW TO REGISTER SECRET CODE

M1428001000667
Each individual secret code is registered inside the
transmitter, and so it is necessary to resister these
codes with the EEPROM inside the receiver in the
MB991824 following cases.
AC309970 AC
• When the transmitter or ETACS-ECU is replaced
(3) Connect the V.C.I. to the diagnosis connector.
• If more transmitters are to be used
(4) Turn the V.C.I. power switch to the "ON" • If it appears that a problem is occurring because
position. of faulty registration of a code.
(5) Close the driver's side door. A maximum of four different codes can be stored in
(6) Keep the windshield washer switch on for at the EEPROM memory (four different transmitters can
least ten seconds. Then the ETACS-ECU be used). When the code for the first transmitter is
buzzer will sound once. registered, the previously registered codes for all
transmitters are cleared. Therefore, if you are using
four transmitters or are adding more transmitters, the
codes for all transmitters must be registered at the
same time.
42-44 BODY
WHEN THE SPECIAL TOOL DIAGNOSIS 6. Once the program is saved, it will operate once
CODE CHECK HARNESS (MB991529) IS with the all doors lock and unlock operations.
USED 7. If you are using two or more transmitters or have
added a second transmitter, the next transmitter
1. Check that the doors lock normally when the key
should be registered within one minute after
is used.
registering the code for the previous transmitter.
2. Insert the ignition key. The registration procedure is common for all the
CAUTION transmitters.
Before connecting or disconnecting the earth, 8. Registration mode will be cancelled under the
turn the ignition switch to the "LOCK" (OFF) following conditions:
position. • When the secret code for four transmitters has
Steering shaft Diagnosis
been registered;
connector • When passing one minute after finishing the reg-
istration of all transmitters;
• When the diagnosis connector is disconnected
from earth;
MB991529 • When the key is removed from the key cylinder;
• When no secret codes have been registered for
more then one minute after the registration mode
is entered;
AC305133AB 9. After the registration is completed, remove the
ignition key and close all the doors, and then
3. Connect the diagnosis connector to the special check that the keyless entry system operates
tool diagnosis code check harness (MB991529). normally.
NOTE: This will connect terminal (1) of the diag-
nosis connector to earth, and the system will be in WHEN THE M.U.T.-II IS USED
secret code registration standby mode. 1. Check that the doors lock normally when the key
is used.
Ground connected 2. Insert the ignition key.
CAUTION
Within 10 seconds Before connecting or disconnecting the M.U.T.-II,
turn the ignition switch to the "LOCK" (OFF)
position.
1 2 3 4 5 6
Hazard ON Steering shaft
warning 16-Pin
switch OFF
ACX00571 AG
4. Press the hazard warning lamp switch six times

within 10 seconds.
NOTE: Once the process is completed six times,
then it will operate with all doors lock and unlock
operations once and then go to the save mode. MB991502
AC304777AC
NOTE: The hazard warning lamp switch is turned
on and off alternately whenever it is pushed. 3. Connect the M.U.T.-II to the diagnosis connector.
5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will
register the code.
BODY
42-45
2. Insert the ignition key.
M.U.T.-II connected CAUTION
Before connecting or disconnecting the V.C.I.,
Within 10 seconds turn the ignition switch to the "LOCK" (OFF)
position.
AC211686
1 2 3 4 5 6
Hazard ON
warning
switch OFF
ACX00571 AB
4. Press the hazard warning switch six times within

10 seconds.
NOTE: Once the process is completed six times, 16-Pin
then it will operate with all doors lock and unlock
operations once and then go to the save mode.
NOTE: The hazard warning lamp switch is turned
on and off alternately whenever it is pushed.
5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will MB991911
register the code.
6. Once the program is saved, it will operate once
with the all doors lock and unlock operations.
7. If you are using two or more transmitters or have
added a second transmitter, the next transmitter MB991824
should be registered within one minute after AC309970 AC
registering the code for the previous transmitter. 3. Connect the V.C.I. to the diagnosis connector.
The registration procedure is common for all the
transmitters.
V.C.I. connected
8. Registration mode will be cancelled under the
following conditions: Within 10 seconds
• When the secret code for four transmitters has
been registered;
• When passing one minute after finishing the reg-
istration of all transmitters; Hazard 1 2 3 4 5 6
warning ON
• When the M.U.T.-II is disconnected from the diag- lamp
OFF
nosis connector; switch
• When the key is removed from the key cylinder; ACX00571 AQ
• When no secret codes have been registered for 4. Press the hazard warning lamp switch six times
more then one minute after the registration mode within 10 seconds.
is entered;
NOTE: Once the process is completed six times,
9. After the registration is completed, remove the then it will operate with all doors lock and unlock
ignition key and close all the doors, and then operations once and then go to the save mode.
check that the keyless entry system operates
normally. NOTE: The hazard warning lamp switch is turned
on and off alternately whenever it is pushed.
WHEN THE SPECIAL TOOL V.C.I. 5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will
(MB991824) IS USED
register the code.
1. Check that the doors lock normally when the key
6. Once the program is saved, it will operate once
is used.
with the all doors lock and unlock operations.
42-46 BODY
7. If you are using two or more transmitters or have TRANSMITTER

added a second transmitter, the next transmitter
should be registered within one minute after TRANSMITTER
registering the code for the previous transmitter. M1428002800086
The registration procedure is common for all the DISASSEMBLY SERVICE POINT
transmitters. BATTERY REMOVAL
8. Registration mode will be cancelled under the
CAUTION
following conditions:
Do not allow water or dust to enter the inside of
• When the secret code for four transmitters has
the transmitter when it is open. Also, do not
been registered;
touch the precision electronic device.
• When passing one minute after finishing the reg-
istration of all transmitters;
• When the V.C.I. is disconnected from the diagno- Transmitter assembly
sis connector;
• When the key is removed from the key cylinder;
• When no secret codes have been registered for
more then one minute after the registration mode
is entered;
9. After the registration is completed, remove the
ignition key and close all the doors, and then Case
check that the keyless entry system operates
normally.
Master key
AC303199
Transmitter assembly
Case side
Battery
AC304118
Master key side
AC304142AB
Since the battery is incorporated into the transmitter

assembly, disassemble the transmitter assembly to
remove the battery.
BODY
42-47
ASSEMBLY SERVICE POINT 1. Install a new battery to the transmitter assembly
BATTERY INSTALLATION with its (+) side facing towards the case side.
Battery required for replacement: Coin type
CAUTION battery CR1616
Do not allow water or dust to enter the inside of
the transmitter when it is open. Also, do not 2. Check the transmitter operation.
touch the precision electronic device.
INSPECTION
M1428003800067
Transmitter assembly TRANSMITTER BATTERY CHECK
Case
AC004486
Master key Measure the voltage of the battery. If the voltage of

the battery is not within the standard value, replace
the battery.
AC303199 Standard value: 2.5 − 3.2 V
Transmitter assembly
-
(–) (+)
Case side
Battery
AC304118
Master key side
AC304142AD
NOTES
51-1
GROUP 51
EXTERIOR
CONTENTS
FRONT BUMPER ASSEMBLY . . . . . 51-2 WINDSHIELD WIPER AND WASHER 51-18

ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-2 SERVICE SPECIFICATION . . . . . . . . . . . . 51-18
REMOVAL AND INSTALLATION . . . . . . . . 51-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 51-18
DISASSEMBLY AND REASSEMBLY. . . . . 51-3 TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-19
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-19
REAR BUMPER ASSEMBLY . . . . . . 51-5 WINDSHIELD INTERMITTENT WIPER
REMOVAL AND INSTALLATION . . . . . . . . 51-5 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-19
DISASSEMBLY AND REASSEMBLY. . . . . 51-6 WINDSHIELD WIPER . . . . . . . . . . . . . . . . . 51-20
SIDE AIR DAM . . . . . . . . . . . . . . . . . . 51-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-21
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-8 WINDSHIELD WASHER . . . . . . . . . . . . . . . 51-23
REMOVAL AND INSTALLATION . . . . . . . . 51-8 REMOVAL AND INSTALLATION . . . . . . . . 51-23
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-24
GARNISHES AND MOULDINGS. . . . 51-10
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . 51-10 MARK . . . . . . . . . . . . . . . . . . . . . . . . . 51-25
REMOVAL AND INSTALLATION . . . . . . . . 51-10 REMOVAL AND INSTALLATION . . . . . . . . 51-25
DOOR SASH TAPE . . . . . . . . . . . . . . 51-12 DOOR MIRROR . . . . . . . . . . . . . . . . . 51-27

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . 51-12 SERVICE SPECIFICATION . . . . . . . . . . . . 51-27
DOOR SASH TAPE . . . . . . . . . . . . . . . . . . 51-12 SPECIAL TOOL. . . . . . . . . . . . . . . . . . . . . . 51-27
REMOVAL AND INSTALLATION . . . . . . . . 51-12 TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-27
DIAGNOSIS TROUBLESHOOTING FLOW 51-27
REAR SPOILER. . . . . . . . . . . . . . . . . 51-16 TROUBLE SYMPTOM CHART . . . . . . . . . . 51-27
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-16 SYMPTOM PROCEDURES . . . . . . . . . . . . 51-28
REMOVAL AND INSTALLATION . . . . . . . . 51-16 DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . 51-35
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-36
51-2 EXTERIOR
FRONT BUMPER ASSEMBLY

ADHESIVE
M1511000501195
Item Specification
Front three-diamond mark Double-sided tape: Generic products
0.8 mm thickness

M1511001401113
AC407353
7
A
C
A
5
C
Section A – A
6
1
3 6 Clip
B Section B – B
4
4
B
B 1, 2 Clip
Section C – C
B Fender
Clip
B
6
2
B
AC504541AB

1. Side under cover 5. Splash shield mounting clips
2. Centre under cover • Water spray hose connection
3. Under cover centre bracket 6. Front bumper assembly
4. Front under cover 7. Front bumper stay assembly
EXTERIOR
51-3
M1511001601117
AC407316
View A B Section B – B
10
1
Screw
1 10
B B Hook
A 11
Double-sided tape: Generic products
0.8 mm thickness
AC504538
12
8
18
19
7N 20
N 13 21
22
15
C 9
13 N
5 14
C
15
16 N 17
Section C – C
21
4
5
Clip 12
6
AC309968
N2
3
AC504539AB

1. Front three-diamond mark 12. Front bumper upper support
2. Front bumper nut 13. Clip B
3. Front licence plate garnish 14. Air intake cover
4. Front bumper cover A 15. Front bumper net
5. Front bumper cover B <<A>> >>A<< 16. Rivets
6. Air dam skirt panel 17. Bumper side net (LH)
7. Clip A 18. Oil cooler duct (RH)
8. Front bumper centre net 19. Bumper side net (RH)
9. Front bumper lower plate 20. Front bumper side plate
10. Grille side cover 21. Front bumper upper reinforcement
11. Front bumper upper plate 22. Front bumper face
51-4 EXTERIOR
DISASSEMBLY SERVICE POINT ASSEMBLY SERVICE POINT

<<A>> RIVETS REMOVAL >>A<< RIVETS ASSEMBLY
Drill Rivet tool
Front bumper
face
Bumper face Rivet
Front bumper
side plate Front bumper face
AC100411AB
Use a drill (4.0 mm) to make a hole in the rivet to Portion A

1
break it, and then remove the rivet. Rivet
3 Rivet tool
Flange
4
Rivet
AC305178AC
Use the rivet tool shown in the illustration to attach

the rivet by the following procedures.
1. Insert the rivet into the front bumper face and front
bumper side plate.
2. Place the rivet tool over portion A of the rivet.
3. While pushing the flange surface of the rivet with
the rivet tool, press the handle of the tool.
4. The thin part of portion A is cut out and the rivet is
held in position.
EXTERIOR
REAR BUMPER ASSEMBLY
51-5
M1511001901011

• Rear Combination Lamp Removal and Installation (Refer
to GROUP 54A, Rear Combination Lamp P.54A-67.)
• Rear End Trim Removal and Installation (Refer to
GROUP 52A, Trims P.52A-10.)
• Trunk Room Side Trim Lid Removal and Installation
(Refer to GROUP 52A, Trims P.52A-10.)
Section A – A 3
Clip
Splash shield A
AC504546AB

1. Splash shield mounting screw 2. Rear bumper bracket
3. Rear bumper assembly
51-6 EXTERIOR

M1511002100639
AC407263
8
7
6N
5N
9
N1
10
N 2 3
AC504547AB

<<A>> >>A<< 1. Rivets A 5. Clip A
<<A>> >>A<< 2. Rivets B 6. Clip B
• Licence plate lamp assembly 7. Licence plate lamp bracket
3. Rear bumper face support side 8. Rear bumper reinforcement
reinforcement 9. Rear bumper side plate
4. Rear bumper under cover 10. Rear bumper face
EXTERIOR
51-7
DISASSEMBLY SERVICE POINT ASSEMBLY SERVICE POINT
<<A>> RIVETS A AND B REMOVAL >>A<< RIVETS A AND B ASSEMBLY
Drill Rivet tool
Rear bumper
face
Bumper face Rivet
Y0412AU
Rear bumper
side plate Rear bumper face
AC100411AB
Portion A
Use a drill (4.0 mm) to make a hole in the rivet to 1
break it, and then remove the rivet. Rivet
2
3 Rivet tool
Flange
Rivet 18E0192
AC005876AE
Use the rivet tool shown in the illustration to attach

the rivet by the following procedures.
1. Insert the rivet into the rear bumper face and rear
bumper side plate.
2. Place the rivet tool over portion A of the rivet.
3. While pushing the flange surface of the rivet with
the rivet tool, press the handle of the tool.
4. The thin part of portion A is cut out and the rivet is
held in position.
51-8 EXTERIOR
SIDE AIR DAM
SIDE AIR DAM

ADHESIVE
M1511000500932
Item Specification
Side air dam Double-sided tape: General products
5 mm width and 1.2 mm thickness

M1511005500153
Section A – A
Clip
1
Adhesive tape: double-sided tape [ 5 mm width and 1.2 mm thickness ] AC310080 AB
REMOVAL
<<A>> >>A<< 1. Side air dam
EXTERIOR
SIDE AIR DAM
51-9
<<A>> SIDE AIR DAM REMOVAL
Gently lift and remove the side air dam. If there is
any double-sided tape remaining on the side air dam,
remove according to the following instructions.
<Remove double-sided tape remaining on the body
surface>
AC304145
Double-sided tape 1. Scrape off the double-sided tape on the side air
dam with a resin spatula as possible.
2. Wipe the side sill garnish surface and clean it with
a rag moistened with isopropyl alcohol.
Protection tape 3. Remove only a small portion of the residual
adhesive.
AC304143 AB
4. Adhere the double-sided tape as specified on the
1. Attach protection tape all the way along the edges side air dam.
of the double-sided tape which is still adhering to
the body. INSTALLATION SERVICE POINT
>>A<< SIDE AIR DAM INSTALLATION.
Double-sided tape
Backing paper
AC304144 AB Adhesive tape
2. Scrape off the double-sided tape with a resin AC310126 AB

spatula as possible.
1. Tear off the double-sided tape backing paper.
3. Peel off the protection tape.
4. Wipe the body surface and clean it with a rag NOTE: If you attach the adhesive tape to the edge
moistened with isopropyl alcohol. of the backing paper, it will be easy to tear off.
2. Install the side air dam.
<Remove double-sided tape remaining on side air NOTE: If the double-sided tape is difficult to affix
dam and adhere double-sided tape (when re-using in cold temperature, etc., warm the bonding sur-
side air dam)> faces of the body and side air dam to about 40 −
60°C before affixing the tape.
3. Firmly press in the side air dam.
51-10 EXTERIOR
GARNISHES AND MOULDINGS

SPECIAL TOOL
M1511000601136

MB990449 Window moulding remover Removal of drip moulding
MB990449

M1511004400238
Section A – A Section B – B Section C – C Section D – D
2 2 2
2
Clip Clip
Clip Clip
Y0622AU Y0623AU W0740AU Y0624AU
Section E – E Section F – F
2 N 6 Clip
E
1
C
2
D
Clip E
Y0729AU W0772AQ
N5 C N 9 D
N 10
B
N4 B 8N
N3
A
N 7
F
1
AC310124 AB
Removal Roof drip moulding removal steps

1. Delta outer garnish >>B<< 6. Rear drip moulding clip
Roof drip moulding removal steps >>A<< 7. Drip moulding clip A
<<A>> >>C<< 2. Roof drip moulding >>A<< 8. Drip moulding clip B
>>B<< 3. Front drip moulding clip A >>A<< 9. Drip moulding clip C
>>B<< 4. Front drip moulding clip B 10. Roof drip moulding clip
>>B<< 5. Front drip moulding clip C
EXTERIOR
51-11
<<A>> ROOF DRIP MOULDING REMOVAL
Front pillar outer
CAUTION
If the moulding has become warped, it should not
be reused.
Portion B
Portion A
AC003629AD
2. After installing the clip to the front pillar outer in

alignment with its portion A, cut from portion B.
MB990449
AC003626AB
>>B<< REAR DRIP MOULDING
CLIP/FRONT DRIP MOULDING CLIP
Use special tool window moulding remover C/FRONT DRIP MOULDING CLIP
(MB990449) to pry out the moulding. B/FRONT DRIP MOULDING CLIP A
INSTALLATION SERVICE POINTS INSTALLATION
The front drip moulding clips A, B, C and rear drip
moulding clip differ according to where they are
>>A<< DRIP MOULDING CLIP C/DRIP used, so check the identification colour before instal-
MOULDING CLIP B/DRIP MOULDING lation.
CLIP A INSTALLATION Applicable location Identification colour
1. The drip moulding clips A, B and C differ Front drip moulding clip A Orange
according to where they are used, so check the
identification colour before installation. Front drip moulding clip B Purple
Applicable location Identification colour Front drip moulding clip C Blue
Drip moulding clip A Yellow Rear drip moulding clip Grey
Drip moulding clip B Blue >>C<< ROOF DRIP MOULDING

Drip moulding clip C Milky white INSTALLATION
Install the clips to the roof drip moulding before
installing the moulding to the vehicle body.
51-12 EXTERIOR
DOOR SASH TAPE
DOOR SASH TAPE

SPECIAL TOOL
M1511000601664

MB990528 Stripe tape spatula Installation of door sash tape
MB990528
DOOR SASH TAPE

M1511024100176

• Door Trim Assembly Removal and Installation (Refer to
GROUP 52A P.52A-12).
• Door Beltline Weatherstrip Inner Removal and Installation
(Refer to GROUP 42 P.42-33).
• Door Opening Weatherstrip Outer Removal and Installa-
tion (Refer to GROUP 42 P.42-33).
• Door Window Glass Runchannel Removal and Installation
(Refer to GROUP 42 P.42-33).
• Door Beltline Moulding Removal and Installation (Refer to
GROUP 42 P.42-33).
Y1897AU
3N
N 2 4N
N 1
AC403531 AB
Removal steps <<A>> >>A<< 3. Rear door sash tape upper

<<A>> >>A<< 1. Front door sash tape upper <<A>> >>A<< 4. Rear door sash tape front
<<A>> >>A<< 2. Front door sash tape rear
EXTERIOR
DOOR SASH TAPE
51-13
•
<Pushing direction>
<<A>> DOOR SASH TAPES REMOVAL
CAUTION 3 to 7 cm/sec. 40 to 50˚
Pay attention to keep from getting burned by hot
door panel or tapes. MB990528
10 to 20 mm
1. Use a hair drier to warm the tape.
2. Peel the tip of the tape with your finger, and then Door sash tape
peel off the tape parallel to the application
surface. Backing paper
INSTALLATION SERVICE POINT <Pulling direction>
>>A<< DOOR SASH TAPES INSTALLA- 3 to 7 cm/sec.

TION
10 to 20 mm
CAUTION MB990528
30 to 45˚
• The ambient temperature should be 20 to
30°C. Ensure that the working area is clean. Door sash tape
Ideally, the tape application should be done at
ambient temperature of 25°C. Backing paper
• If ambient temperature is less than 15°C, heat AC303428 AB
the tape and application surface to a tempera-
Use the special tool stripe tape spatula
ture of 20 to 30°C. If ambient temperature is
(MB990528) to apply the tape with a steady
35°C or higher, cool down them. The adhesive
pace and pressure. If you do not apply the
property of the tape is deteriorated at low
tape with a steady pace or pressure, or abort
temperature, so the tape may come adrift eas-
the application, a shallow groove (lateral
ily. Meanwhile, it gets softened at hot temper-
groove called as "Shock line") may be
ature.
present on the tape surface. Meanwhile, if you
• When beginning to apply the tape, pay partic- apply it too quickly, air bubbles may be
ular attention. If the end of the tape cannot be formed under the tape.
applied to the specified position with an accu-
racy of less than 1 mm, it may cause the poor 1. Wrap a soft cloth (synthetic fibre) around the tip of
appearance or adhesion. the special tool.
2. Use isopropyl alcohol to degrease the tape
application surface.
3. Wipe away dirt from the tape.
51-14 EXTERIOR
DOOR SASH TAPE
Tape overlap: Tape overlap:

3.0 mm 3.0 mm 3.5 mm
3.5 mm RH only
3.5 mm 3.5 mm
Tape perforate-
Tape perforate- Backing paper line
line cut-line
Rear door sash

Front door sash tape upper
tape rear
Front door sash Rear door sash

tape upper tape front
Backing paper
Backing paper RH only RH only cut-line
cut-line
3.5 mm 3.5 mm
Tape perforate-
5.0 line
mm 7.0
mm
: Tape locating points

: T-stud for door opening weatherstrip attaching locations (5 pieces in all). AC403580AC
4. Apply the door sash tapes according to the NOTE: .

procedures shown below. • Align the front door sash tape upper at the
(1) Align a tape with specified application position. rear end.
If necessary, use a magnet to secure it. • Align the rear door sash tape upper at the
front end.
• Align the front door sash tape rear/rear
door sash tape front at the upper end.
EXTERIOR
DOOR SASH TAPE
51-15
(2) As for the front/rear door sash tape upper, peel (5) As for the front door sash tape rear/rear door
off the backing paper under the tape by the sash tape front, peel off the application tape in
backing paper cut-line and apply the tape the direction of 180° from bottom to top.
temporarily. (6) Remove unnecessary part of the tape at tape
perforate-line.
Backing paper
60˚
120˚
Door sash tape MB990528
Hemming part
AC303110AB
(3) Peel off the backing paper and cut it as AC303415AB
necessary. (7) Press the folded area of the tape at 3 steps

securely(60°, 120° and holding), rolling in
toward the vehicle inside direction.
MB990528
Tape pasting onto corner
Door sash (viewed from inside)
tape A section
Backing paper
AC402197AD
(4) While peeling off the remaining backing paper,

press the tape by a special tool (MB990528). AC303443AE
NOTE: . (8) As for the front door sash tape rear/rear door
• Apply the front door sash tape upper from sash tape front, roll in the A section of the tape
rear to front. upper corner toward the vehicle inside with
• Apply the rear door sash tape upper from your palm securely.
front to rear.
• Apply the front door sash tape rear/rear
door sash tape front from top to bottom.
51-16 EXTERIOR
REAR SPOILER
REAR SPOILER
ADHESIVE
M1511000500512
Item Specification
Rear spoiler assembly <Type A> Double-sided tape: Generic products
3 mm thickness
Rear spoiler assembly <Type B> Double-sided tape: Generic products
1.6 mm thickness

M1511006100211
<TYPE A>
4
2
3
1
Adhesive tape affixed location
4
3 3
Double-sided tape: Generic products, 3 mm thickness

AC310062AC

Trunk lid bumper (Refer to GROUP
• 4. Rear spoiler
42, Trunk Lid P.42-37). • High-mounted stop lamp (Refer to
1. Cap GROUP 54A, High-mounted Stop
<<A>> >>A<< 2. Rear spoiler assembly Lamp P.54A-69).
3. Gasket
EXTERIOR
REAR SPOILER
51-17
<Type B>
5.2 ± 0.2 N·m

5.2 ± 0.2 N·m
1
5.2 ± 0.2 N·m
1 5.2 ± 0.2 N·m
Adhesive tape affixed location
Double-sided tape: Generic products, 1.6 mm thickness

AC504553AB
Removal steps INSTALLATION SERVICE POINT

• Trunk lid bumper (Refer to GROUP >>A<< REAR SPOILER ASSEMBLY
42, Trunk Lid P.42-37).
1. Cap INSTALLATION
<<A>> >>A<< 2. Rear spoiler assembly Install by the same procedure as described in SIDE
AIR DAM INSTALLATION (Refer to P.51-8).
<<A>> REAR SPOILER ASSEMBLY
REMOVAL
Remove by the same procedure as described in
SIDE AIR DAM REMOVAL (Refer to P.51-8).
51-18 EXTERIOR
WINDSHIELD WIPER AND WASHER

SERVICE SPECIFICATION
M1511000300422
Item Standard value

Stop position of the windshield wiper arm/blade assembly (Distance between the 69 ± 5
edge of the wiper blade and the end of the deck garnish) mm
SPECIAL TOOLS
M1511000601783

MB991502 M.U.T.-II sub Check the windshield intermittent
assembly wiper interval
B991502
MB991955 M.U.T.-III Check the windshield intermittent

A A: MB991824 sub-assembly wiper interval
B: MB991827 A: Vehicle CAUTION
C: MB991910 Communication M.U.T.-III main harness B
D: MB991911 Interface (V. C. I.) (MB991911) should be used.
MB991824
E: MB991825 B: M.U.T.-III USB M.U.T.-III main harness A
B F: MB991826 cable should not be used for this
C: M.U.T.-III main vehicle.
harness A
(Vehicles with CAN
MB991827 communication
system)
C
D: M.U.T.-III main
(Vehicles without
MB991910
CAN
communication
D system)
E: M.U.T.-III
measurement
adapter
MB991911
harness
E
MB991825
MB991826
MB991955
EXTERIOR
51-19
MB991529 Diagnosis code check Input signal check by using a
harness voltmeter
MB991529
MB991223 Harness set Continuity check and voltage

a
a. MB991219 a. Check harness measurement at harness wire or
b. MB991220 b. LED harness connector
c. MB991221 c. LED harness a. For checking connector pin
d. MB991222 adapter contact pressure
b
d. Probe b. For checking power supply
circuit
c. For checking power supply
circuit
c
d. For connecting a locally
sourced tester
d
DO NOT USE
MB991223BA

connector
MB992006
TROUBLESHOOTING ON-VEHICLE SERVICE

M1511000700323
The windshield wiper and washer are controlled by WINDSHIELD INTERMITTENT WIPER
the Smart Wiring System (SWS). For troubleshoot-
ing, refer to GROUP 54B, Troubleshooting P.54B-13
INSPECTION
M1511021900054
or GROUP 54C, Troubleshooting P.54C-4. 1. If the windshield intermittent wiper interval
NOTE: Even when the ETACS-ECU has failed, the adjusting knob is operated, the wiper interval
windshield wiper can work at low speed as fail-safe should change.
mode. (Normally, the windshield wiper operates 2. Holding the windshield intermittent wiper interval
when the ignition switch is at the "ACC" position. But, adjusting knob, input the simulated vehicle speed
if it enters the fail-safe mode, the wiper can operate with M.U.T.-II / III and check that the wiper interval
only when the ignition switch is at the "ON" position.) changes as the vehicle speed changes.
3. If not, carry out the troubleshooting (Refer to
GROUP 54B, Troubleshooting P.54B-13 or
GROUP 54C, Troubleshooting P.54C-4).
51-20 EXTERIOR
WINDSHIELD WIPER
M1511007900209
View A Section A – A
6 7
B
6, 7
A B
Note Clip (A)

:Indicates the clip (A) locations. :Indicates the clip (B) locations.
Section B – B
1
2 3, 4
3
5
Clip (B)
4
A
1
2
4
6
27 ± 3 N·m
8
8.9 ± 1.9 N·m
7.4 ± 1.4 N·m

7
AC211876AF
Wiper blade assembly removal steps Windshield wiper motor and link
>>B<< 1. Wiper blade assembly assembly removal steps (Continued)
>>A<< 2. Wiper blade 5. Hood weather strip
Windshield wiper motor and link 6. Front deck garnish (Passenger's side)
assembly removal steps 7. Front deck garnish (Driver's side)
3. Cover <<A>> 8. Windshield wiper motor assembly
4. Wiper arm 9. Link assembly
EXTERIOR
51-21
NOTE: For removal and installation of the wiper and >>B<< WIPER BLADE ASSEMBLY
washer switch, refer to GROUP 54A, Column switch INSTALLATION
P.54A-73.

<<A>> WINDSHIELD WIPER MOTOR
ASSEMBLY REMOVAL A A
1. Remove the windshield wiper motor assembly
mounting bolts.
CAUTION
Front deck garnish terminal
Be careful not to damage the windshield glass AC000427AD
when removing the windshield wiper motor
assembly. Install the wiper blade at the specified position
(standard value).
Windshield wiper
motor assembly Standard value: (A) 69 ± 5 mm
INSPECTION
M1511008000209
FRONT WIPER MOTOR CHECK

Inspect the windshield wiper motor by removing the
Link assembly harness connector with the motor attached to the
connection vehicle.
Flat-tipped screwdriver
AC310927AB
WIPER MOTOR AT LOW OR HIGH SPEED
2. Use the flat-tipped screwdriver to disengage the OPERATION
link between the windshield wiper motor assembly
and the link assembly.

>>A<< WIPER BLADE INSTALLATION
Backing Section A – A 1 2 3
Wiper blade 4 5
Wiper
blade Backing
Check operation
A
A 1 2 3
4 5
Backing Low speed

AC101090AD
CAUTION
Ensure that the backings are bent in the shown 1 2 3
4 5
direction, and then install the backings to the
wiper blade. High speed
AC310929 AB
Connect the battery to the windshield wiper motor to

inspect the operation of motor rotation in low or high
speed.
51-22 EXTERIOR
WIPER MOTOR AT STOP POSITION Switch position Tester Specified

OPERATION connection condition
OFF 6 − 11, 6 − 10, Open circuit
6 − 9, 6 − 8, 6
−7
Windshield mist 6 − 11 Less than 2
wiper switch ohms
Windshield 6 − 10
1 2 3
4 5 intermittent wiper
switch
Windshield 6−9
Stop position check low-speed wiper
switch
1 2 3
Windshield 6−8
4 5 high-speed wiper
switch
(A) Low speed
Windshield 6−7
washer switch
1 2 3
4 5
WINDSHIELD INTERMITTENT WIPER
(B) Automatic stop
AC310930 AB
VOLUME CHECK
1. Connect the battery to the windshield wiper motor
to rotate the motor in a low speed as shown in the
illustration (A) and disconnect the battery during
rotation to stop the motor.
2. Connect between the terminals and the battery as
shown in the illustration (B) and confirm whether
the motor stops at the automatic stop position
after rotating in a low speed.
1
WINDSHIELD WIPER AND WINDSHIELD 2
WASHER SWITCH CHECK 3
4
5
1 6
2 7
3 8
4 9
5 10
6 11
7
8
9 AC201004
10
11
Check that the resistance varies between 0 and 1 kΩ
AC000417 when the windshield intermittent volume is turned
Check continuity between the switch terminals. from FAST to SLOW after measuring resistance
between connector terminals 3 and 6 at the column
switch.
EXTERIOR
51-23
WINDSHIELD WASHER
M1511008200407
5.0 ± 1.0 N·m
2 5
AC310066 AB
Washer hose removal steps Windshield washer nozzle removal
• Splash shield <Right side> (Refer to steps
GROUP 42, Fender P.42-6). • Connection of washer hose
• Cowl side trim, front scuff plate, 2. Windshield washer nozzle
centre pillar trim, lower, rear scuff Washer tank and washer motor
plate (Refer to GROUP 52A, Trim removal steps
P.52A-10). • Rear end trim, trunk side trim (Refer
• Rear seat (Refer to GROUP 52A, to GROUP 52A, Trim P.52A-10).
Seat P.52A-20). • Connection of front washer hose
1. Front washer hose 3. Washer tank assembly
4. Washer tank bracket
5. Front washer motor
51-24 EXTERIOR
NOTE: For removal and installation of the wiper and 1. Remove the washer tank assembly with the
washer switch, refer to GROUP 54A, Column switch washer hose attached. Then fill the washer tank
P.54A-73. with water.
2. Check to see that the water is vigorously
INSPECTION sprayed. When connecting the positive battery
M1511008300200
terminal to terminal number 2 and terminal
FRONT WASHER MOTOR CHECK number 1 to the negative battery terminal.
WINDSHIELD WASHER FLUID EJECTION

CHECK
1
Move the nozzle to adjust the position so that the
2
spray is in the area shown in the illustration.
CAUTION
On RH drive vehicles, the illustration is symmet-
rical.
AC211378
Units: mm
25 25
90 110
25
130 25 90
50
50
25 50
25 40
25 25
35 75 25 85
<Right> <Left>
440 430
220 220
Ceramic line terminal
Windshield washer
Windshield washer nozzle perpendicular
nozzle perpendicular
600
Windshield washer nozzle

AC309919 AB
EXTERIOR
MARK
51-25
MARK
M1511011801424
1
3
AC504528AC
Removal Removal (Continued)

1. Front three-diamond mark (Refer to >>A<< 3. LANCER mark
P.51-3). >>A<< 4. Evolution mark
>>A<< 2. Rear three-diamond mark
51-26 EXTERIOR
MARK

>>A<< MARK APPLICATION Attach each mark to the position shown in the
1. Installation position illustration.
Rear three-diamond mark
Trunk lid press line

84 ± 1 mm
Centre line of vehicle

AC309915AF
LANCER mark, Evolution mark
Trunk lid end line
48 ± 1 mm
41 ± 1 mm
12 ± 1 mm
35 ± 1 mm
Trunk lid end line
AC210731AE
2. Installation procedure CAUTION

(1) Use 3M ATD Part number 8906 or equivalent When attaching the marks, the ambient tempera-
to clean the mark installation surfaces on the ture should be 20 − 38°C and the air should be
body. completely free of dust. If the ancient tempera-
ture is lower than 20°C, the marks and the places
on the vehicle body where the marks are to be
attached should be heated to 20 − 38°C.
(2) Peel off the protection sheet on the back of the
marks to paste it on the installation position.
EXTERIOR
DOOR MIRROR
51-27
DOOR MIRROR
SERVICE SPECIFICATION
M1511000300347
Item Standard value

Heated door mirror operation current Ω 5.9 − 7.8
SPECIAL TOOL
M1511000601103

MB990784 Ornament remover Removal of remote controlled
mirror switch
MB990784
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1511014600169
Refer to GROUP 00 − How to Use Troubleshoot-
ing/Inspection Service Points P.00-5.
TROUBLE SYMPTOM CHART

M1511015000245
Symptom Inspection Reference

procedure page
All heated door mirrors do not operate 1 P.51-28
Right or left heated door mirror does not operate 2 P.51-29
51-28 EXTERIOR
DOOR MIRROR
SYMPTOM PROCEDURES
Inspection Procedure 1: All Heated Door Mirrors do not Operate
Heated door mirror circuit
REAR WINDOW
DEFOGGER RELAY
REAR WINDOW
DEFOGGER
REMOTE REMOTE
CONTROLLED CONTROLLED
MIRROR (LH) MIRROR MIRROR MIRROR (RH)
HEATER HEATER
NOTE
LH drive vehicles
RH drive vehicles
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
COMMENTS ON TROUBLE SYMPTOM DIAGNOSIS PROCEDURE

The heated door mirrors should works for approxi-
mately 11 minutes when the rear defogger switch is STEP 1. Check the rear window defogger.
turned on. If the mirror heater does not work for the Check that the rear window defogger system should
specified period, the defogger relay circuit (heated work normally.
door mirror power supply circuit) may be defective.
Q: Is the check result normal?
PROBABLE CAUSE YES : Go to Step 2.
• Damaged harness wire and connector NO : Troubleshoot the rear window defogger
(Refer to GROUP 55, Troubleshooting
P.55-63).
EXTERIOR
DOOR MIRROR
51-29
STEP 2. Connector check: C-214 junction block
YES : Intermittent malfunction (Refer to GROUP
connector
00 − How to Cope with Intermittent
Connector: C-214 Malfunction P.00-5).
Junction block (Front view)
NO : Repair the defective connector.
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC304913 AC
Inspection Procedure 2: Right or Left Heated Door Mirror does not Operate
Heated door mirror circuit
REAR WINDOW
DEFOGGER RELAY
REAR WINDOW
DEFOGGER
REMOTE REMOTE
MIRROR (LH) MIRROR MIRROR MIRROR (RH)
HEATER HEATER
NOTE
LH drive vehicles
RH drive vehicles
Wire colour code

51-30 EXTERIOR
DOOR MIRROR
COMMENTS ON TROUBLE SYMPTOM STEP 3. Check the door mirror assembly (RH).
If either of the heated door mirrors does not work, the Check that the heater element of the door mirror
door mirror assembly may be defective. assembly (RH) is in good condition (Refer to
P.51-36).
PROBABLE CAUSES
• Malfunction of the door mirror assembly Q: Is the check result normal?
• Damaged harness wires and connectors YES : Go to Step 4.
NO : Replace the door mirror assembly (RH).
DIAGNOSIS PROCEDURE
STEP 4. Resistance measurement at the E-10
door mirror assembly (RH) connector.
STEP 1. Verify the operation of each heated door
mirror. Connector: E-10
Q: Which door mirror does not heat?

Door mirror (RH) : Go to Step 2.
Door mirror (LH) : Go to Step 9.
STEP 2. Connector check: E-10 door mirror Harness side

assembly (RH) connector
Connector: E-10
AC304817 AC
(1) Disconnect the connector, and measure at the

wiring harness side.
Harness side
Connector E-10
(harness side)
AC304817 AC

YES : Go to Step 3.
AC304821 AC
(2) Resistance between E-10 door mirror assembly

connector terminal No.4 and body earth
OK: 2 Ω or less
YES : Go to Step 6.
NO : Go to Step 5.
EXTERIOR
DOOR MIRROR
51-31
STEP 5. Check the wiring harness between E-10 (2) Rear window defogger switch: ON
door mirror assembly (RH) connector terminal Connector: E-10
No.4 and body earth.
Connector: E-10
Harness side
Harness side
AC304817 AC

AC304817 AC wiring harness side.
• Check the earth wires for open circuit.
NOTE:
Connector: C-110
Connector E-10
(harness side)
AC304826 AC
(4) Voltage between E-10 door mirror assembly

AC304819 AC connector terminal No.1 and body earth
Prior to the wiring harness inspection, check interme- OK: System voltage
diate connector C-110 and repair if necessary.
Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP
YES : Intermittent malfunction (Refer to GROUP 00 − How to Cope with Intermittent
00 − How to Cope with Intermittent Malfunction P.00-5).
Malfunction P.00-5). NO : Go to Step 7.
NO : Repair the wiring harness.

STEP 6. Voltage measurement at the E-10 door connector
mirror assembly (RH) connector.
Connector: C-214
(1) Turn the ignition switch to the ON position. Junction block (Front view)
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC304913 AD

YES : Go to Step 8.
51-32 EXTERIOR
DOOR MIRROR
STEP 8. Check the wiring harness between E-10 STEP 9. Connector check: E-03 door mirror
door mirror assembly (RH) connector terminal assembly (LH) connector
No.1 and C-214 junction block connector
Connector: E-03
terminal No.3.
Connector: E-10
Harness side
Harness side
AC304818 AC
AC304817 AC Q: Is the check result normal?

YES : Go to Step 10.
Connector: C-214 NO : Repair the defective connector.
STEP 10. Check the door mirror assembly (LH).
Check that the heater element of the door mirror
assembly (LH) is in good condition (Refer to
P.51-36).
Harness side Q: Is the check result normal?
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 NO : Replace the door mirror assembly (LH).
AC304913 AD
STEP 11. Resistance measurement at the E-03
• Check the power supply line for open circuit. door mirror assembly (LH) connector.
NOTE: Connector: E-03
Connector: C-110
Harness side
AC304818 AC
AC304819 AC
Prior to the wiring harness inspection, check interme- wiring harness side.
00 − How to Cope with Intermittent Connector E-03
(harness side)
Malfunction P.00-5).
AC310825 AB
(2) Resistance between E-03 door mirror assembly

OK: 2 Ω or less
EXTERIOR
DOOR MIRROR
51-33
STEP 14. Measure the voltage at the E-03 door
NO : Go to Step 12.
mirror assembly (LH) connector.
(1) Turn the ignition switch to the ON position.
STEP 12. Check the wiring harness between E-03 (2) Rear window defogger switch: ON
door mirror assembly (LH) connector terminal
Connector: E-03
Connector: E-03
Harness side
Harness side
AC304818 AC

AC304818 AC
NOTE:
Connector: C-17
Connector E-03
(harness side)
AC304828 AC
(4) Voltage between E-03 door mirror assembly

AC304820 AC
Prior to the wiring harness inspection, check interme-
OK: System voltage
Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP
Malfunction P.00-5). NO : Go to Step 15.

connector
Connector: C-214
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC304913 AD

51-34 EXTERIOR
DOOR MIRROR

STEP 15. Check the wiring harness between E-03
door mirror assembly (LH) connector terminal
No.1 and C-214 junction block connector
terminal No.3. NO : Repair the wiring harness.
Connector: E-03
Harness side
AC304818 AC
Connector: C-214
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC304913 AD
• Check the power supply line for open circuit.

NOTE:
Connector: C-17
AC304820 AC

EXTERIOR
DOOR MIRROR
51-35
DOOR MIRROR
M1511006400461
8
5 4
7
6
Section A – A
Claw 1
3
2
A
Note A
: Claw positions 1
AC304733 AC
Door mirror removal steps Remote controlled mirror switch

1. Cover removal steps
2. Delta inner cover 7. Instrument panel ornament (Refer to
3. Harness connector GROUP 52A, Instrument Panel
4. Door mirror assembly P.52A-2).
5. Door mirror body assembly 8. Remote controlled mirror switch
<<A>> >>A<< 6. Mirror
51-36 EXTERIOR
DOOR MIRROR

<<A>> MIRROR REMOVAL >>A<< MIRROR INSTALLATION
Section A – A Section A – A
Flat-tipped Mirror Flat-tipped
screwdriver Mirror
screwdriver
Pivot Plate Pivot plate
A A A A
A A A A
Protective
tape
Notch
00007256 00007258
AC000441AB AC000442 AB
Push the top of the mirror with your hand to tilt it and While supporting the clip position on the underside of
attach the protective tape as shown in the illustration. the pivot plate with a flat-tipped screwdriver, press
Then insert a flat-tipped screwdriver in between the the clip at the front of the mirror to engage the bottom
notch at the rear of the mirror and the pivot plate, and of the mirror.
disengage the bottom of the mirror.
INSPECTION
M1511006500372
ELECTRIC REMOTE CONTROL MIRROR Battery connection Direction

OPERATION CHECK operation
• Connect terminal 5 to the negative Mirror
battery terminal. glass
• Connect terminal 7 to the positive should face
battery terminal. upward
1 2 3
4 5 6 7
battery terminal. downward
AC202548
Check that the mirror moves as described in the • Connect terminal 6 to the positive should face
table when each terminal is connected to the battery. battery terminal. to the right
battery terminal. to the left
EXTERIOR
DOOR MIRROR
51-37
DOOR MIRROR CONTROL SWITCH CON- HEATED DOOR MIRROR CHECK
TINUITY CHECK CAUTION
When relocating the car between locations with
extremely different temperatures (warm and
cold), leave the car in the location for a while to
adapt to the temperature prior to checking it.
1 2 3 4
5 6 7 8 9 10 11
AC005970
Switch position Tester Specified 1 2 3

connection condition 4 5 6 7
OFF 9 − 2, 9 − 3, 9 − 6, Open circuit AC202548

9 − 10, 9 − 11, 1 − The resistance value between door mirror connector
2, 1 − 3, 1 − 6, 1 − terminals 1 and 4 should meet the standard value
10, 1 − 11 with the ambient temperature at a steady 25°C.
Left side OFF 9 − 6, 9 − 10, 9 − Open circuit Standard value: 5.9 − 7.8 Ω
11, 1 − 6, 1 − 10,
1 − 11
Up 1 − 6, 9 − 11 Less than 2
Down 1 − 11, 6 − 9 ohms
Right 1 − 6, 9 − 10
Left 1 − 10, 6 − 9
Right OFF 9 − 2, 9 − 3, 9 − 6, Open circuit
side 1 − 2, 1 − 3, 1 − 6
Up 1 − 6, 3 − 9 Less than 2
Down 1 − 3, 6 − 9 ohms
Right 1 − 6, 2 − 9
Left 1 − 2, 6 − 9
NOTES
13A-1
GROUP 13A
MULTIPORT FUEL
INJECTION (MPI)
CONTENTS
GENERAL INFORMATION . . . . . . . . 13A-2 FUEL PUMP OPERATION CHECK . . . . . . 13A-399

COMPONENT LOCATION . . . . . . . . . . . . . 13A-400
SERVICE SPECIFICATIONS. . . . . . . 13A-5 ENGINE CONTROL RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-401
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13A-6 FUEL PUMP RELAY CONTINUITY CHECK 13A-402
FUEL PUMP RESISTOR CHECK . . . . . . . . 13A-403
TROUBLESHOOTING . . . . . . . . . . . . 13A-9 INTAKE AIR TEMPERATURE SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-403
DIAGNOSIS TROUBLESHOOTING FLOW 13A-9
ENGINE COOLANT TEMPERATURE
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 13A-9
SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13A-403
INSPECTION CHART FOR DIAGNOSIS
THROTTLE POSITION SENSOR CHECK . 13A-404
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-17
OXYGEN SENSOR CHECK . . . . . . . . . . . . 13A-404
INSPECTION PROCEDURE FOR DIAGNOSIS
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-19 INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A-406
INSPECTION CHART FOR TROUBLE INJECTOR RESISTOR CHECK . . . . . . . . . 13A-407
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13A-233 IDLE SPEED CONTROL SERVO
SYMPTOM PROCEDURES . . . . . . . . . . . . 13A-237 (STEPPER MOTOR) CHECK . . . . . . . . . . . 13A-408
DATA LIST REFERENCE TABLE . . . . . . . 13A-372 FUEL PRESSURE SOLENOID VALVE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-409
ACTUATOR TEST REFERENCE TABLE. . 13A-378
OIL FEEDER CONTROL VALVE CHECK. . 13A-410
CHECK AT THE ENGINE-ECU
TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . 13A-379
INSPECTION PROCEDURE USING INJECTOR . . . . . . . . . . . . . . . . . . . . . 13A-411
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13A-385 REMOVAL AND INSTALLATION . . . . . . . . 13A-411
ON-VEHICLE SERVICE. . . . . . . . . . . 13A-395 THROTTLE BODY ASSEMBLY . . . . . 13A-413

THROTTLE BODY (THROTTLE VALVE REMOVAL AND INSTALLATION . . . . . . . . 13A-413
AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13A-395
THROTTLE POSITION SENSOR ENGINE CONTROL RESISTOR,
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13A-395 RELAY . . . . . . . . . . . . . . . . . . . . . . . . 13A-415
BASIC IDLE SPEED ADJUSTMENT . . . . . 13A-396 REMOVAL AND INSTALLATION . . . . . . . . 13A-415
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13A-396
FUEL PUMP CONNECTOR DISCONNECTION ENGINE-ECU . . . . . . . . . . . . . . . . . . . 13A-416
(HOW TO REDUCE PRESSURIZED FUEL
REMOVAL AND INSTALLATION . . . . . . . . 13A-416
LINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-398
13A-2 MULTIPORT FUEL INJECTION (MPI)
GENERAL INFORMATION
GENERAL INFORMATION
M1131000102428
The Multipoint Fuel Injection System consists of sen- engine-ECU carries out activities such as fuel injec-
sors which detect the engine conditions, the tion control, idle speed control and ignition timing
engine-ECU which controls the system based on sig- control. In addition, the engine-ECU is equipped with
nals from these sensors, and actuators which oper- several diagnosis modes which simplify trouble-
ate under the control of the engine-ECU. The shooting when a problem develops.
FUEL INJECTION CONTROL
The injector drive times and injector timing are con- engine is cold or operating under high load condi-
trolled so that the optimum air/fuel mixture is sup- tions in order to maintain engine performance. In
plied to the engine to correspond to the addition, when the engine is warm or operating under
continually-changing engine operation conditions. normal conditions, the engine-ECU controls the
A single injector is mounted at the intake port of each air/fuel mixture by using the oxygen sensor signal to
cylinder. Fuel is sent under pressure from the fuel carry out "closed-loop" control in order to obtain the
tank by the fuel pump, with the pressure being regu- theoretical air/fuel mixture ratio that provides the
lated by the fuel pressure regulator. The fuel thus maximum cleaning performance from the three way
regulated is distributed to each of the injectors. catalyst.
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 SPEED CONTROL

The idle speed is kept at the optimum speed by con- air conditioner load. In addition, when the air condi-
trolling the amount of air that bypasses the throttle tioner switch is turned off and on while the engine is
valve in accordance with changes in idling conditions idling, the idle speed control motor operates to adjust
and engine load during idling. The engine-ECU the throttle valve bypass air amount in accordance
drives the idle speed control motor to keep the with the engine load conditions in order to avoid fluc-
engine running at the pre-set idle target speed in tuations in the engine speed.
accordance with the engine coolant temperature and
IGNITION TIMING CONTROL

The power transistor located in the ignition primary
circuit turns ON and OFF to control the primary cur-
rent 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 • The RAM data inside the engine-ECU that is
sensors or actuators related to emission control, related to the sensors and actuators can be read
the engine warning lamp (check engine lamp) by means of the M.U.T.-II/III. In addition, the actu-
illuminates as a warning to the driver. ators can be force-driven under certain circum-
• When an abnormality is detected in one of the stances.
sensors or actuators, a diagnosis code corre-
sponding to the abnormality is output.
MULTIPORT FUEL INJECTION (MPI)
GENERAL INFORMATION
13A-3
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control 4. Fan Motor Control
Turns the fuel pump relay ON so that current is sup- The revolutions of the radiator fan and condenser fan
plied to the fuel pump while the engine is crank- are controlled in response to the engine coolant
ing or running. temperature and vehicle speed.
2. A/C Relay Control 5. Purge Control Solenoid Valve Control
Turns the compressor clutch of the A/C ON and OFF. (Refer to GROUP 17 − Engine And Emission Control
3. Oil feeder control valve control − Evaporative Emission Control System P.17-9).
The engine-ECU effects duty cycle control on the 6. EGR Control Solenoid Valve Control
engine oil feeder control valve, in accordance (Refer to GROUP 17 − Engine And Emission Control
with the engine speed. This regulates the supply − Exhaust Gas Recirculation (EGR) System
of engine oil to the intake rocker starft, which P.17-13).
switches the cams.
GENERAL SPECIFICATIONS
Items Specifications
Throttle body Throttle bore mm 60
Throttle position sensor Variable resistor type
Idle speed control servo Stepper motor type
Engine-ECU Identification No. E6T46983
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
Vehicle speed sensor Magnetic resistive element type
Intake camshaft position sensor Hall element type
Exhaust camshaft position sensor Hall element type
Crank angle sensor Hall element type
Detonation sensor Piezoelectric type
Power steering fluid pressure switch Contact switch type
Actuators Engine control relay type Contact switch type
Fuel pump relay type Contact switch type
Injector type and number Electromagnetic type, 4
Injector identification mark MDL 560P
Oil feeder control valve Duty cycle type solenoid valve
EGR control solenoid valve Duty cycle type solenoid valve
Purge control solenoid valve Duty cycle type solenoid valve
Fuel pressure control solenoid valve ON/OFF type solenoid valve
Waste gate solenoid valve Duty cycle type solenoid valve
Fuel pressure Regulator pressure kPa 294
regulator
GENERAL INFORMATION
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM
1 Oxygen sensor (front) Power supply Engine- 1 Injector Engine control relay
2 Oxygen sensor (rear) Ignition switch-IG ECU 2 Idle speed control Fuel pump relay 2
3 Air flow sensor Ignition switch-ST servo (Stepper Fuel pump relay 3
4 Intake air temperature A/C switch motor) A/C relay
sensor A/C load signal 3 Fuel pressure Ignition coil
5 Throttle position Power steering control solenoid Fan controller
sensor fluid pressure valve Condenser fan relay(High)
6 Intake camshaft switch 4 Waste gate Condenser fan relay(Low)
position sensor Alternator FR solenoid valve Engine warning lamp
7 Exhaust camshaft terminal 5 EGR control Diagnosis output
position sensor Clutch switch solenoid valve Alternator G terminal
8 Crank angle sensor Transmission oil 6 Purge control Air flow sensor reset
9 Barometric pressure temperature sensor solenoid valve signal
sensor Vehicle speed 7 Oil feeder control Oxygen sensor heater
10 Engine coolant sensor valve (Front)
temperature sensor Oxygen sensor heater
11 Detonation sensor (Rear)
Tachometer
Transmission oil
temperature warning lamp
Canister 5 Throttle position sensor

2 Idle speed control servo
By-pass valve (Stepper motor)
Check valve
6 Purge control 5 EGR

solenoid valve 3 Fuel pressure control control
Fuel pressure solenoid valve solenoid
regulator valve
From fuel pump
3 Air flow sensor To fuel tank
9 Barometric 7 Oil feeder
pressure sensor control valve
7 Exhaust camshaft
position sensor 6 Intake camshaft
position sensor
4 Intake air EGR
temperature 1 Oxygen valve
sensor sensor (front) 1 Injector
10 Engine coolant temperature sensor

Air 8 Crank angle sensor
inlet
11 Detonation sensor
Waste gate actuator
4 Waste gate solenoid valve 2 Oxygen sensor (rear)
Catalytic converter Catalytic converter

AK501871AB
13A-5
M1131000301452
Items Specifications
Basic idle speed r/min 800 ± 50
Throttle position sensor adjusting voltage mV 535 − 735
Throttle position sensor resistance kΩ 3.5 − 6.5
Idle speed control servo coil resistance (at 20°C) Ω 28 − 33
Intake air temperature sensor −20°C 13 − 17
resistance kΩ 0°C 5.3 − 6.7
20°C 2.3 − 3.0
40°C 1.0 − 1.5
60°C 0.56 − 0.76
80°C 0.30 − 0.42
Engine coolant temperature −20°C 14 − 17
sensor resistance kΩ 0°C 5.1 − 6.5
20°C 2.1 − 2.7
40°C 0.9 − 1.3
60°C 0.48 − 0.68
80°C 0.26 − 0.36
Oxygen sensor output voltage (at racing) V 0.6 − 1.0
Oxygen sensor heater Front 4.5 − 8.0
resistance (at 20°C) Ω Rear 11 − 18
Fuel pressure kPa Vacuum hose disconnection 289 − 309 at curb idle
Vacuum hose connection Approximately 230 at curb idle
Fuel pressure control solenoid valve resistance (at 20°C) Ω 28 − 36
Fuel pump resistance Ω 0.45 − 0.65
Injector coil restance (at 20°C) Ω 2−3
Injector fuel leakage rate Drop/minute 1 or less
Resistor (for injector) resistance (at 20°C) Ω 5.8 − 6.2
Oil feeder control valve (at 20°C) Ω 6.9 − 7.2
SPECIAL TOOLS
SPECIAL TOOLS
M1131000601583

MB991502 M.U.T.-II sub assembly • Reading diagnosis code
• MPI system inspection
• Measurement of fuel pressure
B991502
MB991955 M.U.T.-III sub assembly • Reading diagnosis code

A A: MB991824 A: Vehicle communication • MPI system inspection
B: MB991827 interface (V.C.I.) • Measurement of fuel pressure
C: MB991910 B: M.U.T.-III USB cable CAUTION
D: MB991911 C: M.U.T.-III main harness If you connect M.U.T.-III main
MB991824
E: MB991825 A (Vehicles with CAN harness A to a vehicle without
B F: MB991826 communication system) CAN communication system to
D: M.U.T.-III main harness use the M.U.T.-III, a pulse signal
B (Vehicles without CAN may interfere with the
communication system) simulated vehicle speed lines,
MB991827 E: M.U.T.-III measurement thus causing the M.U.T.-III
C
adapter inoperative. Therefore, use the
F: M.U.T.-III trigger harness M.U.T.-III main harness B
DO NOT USE
(MB991911) instead.
MB991910
MB991911
MB991825
MB991826
MB991955
MB991348 Test harness set • Inspection using an

oscilloscope
MB991348
SPECIAL TOOLS
13A-7
MB991709 Test harness • Measurement of voltage
during troubleshooting
• Inspection using an
oscilloscope
• Check of idle control servo
MD998478 Test harness (3-pin, triangle) • Measurement of voltage

during Troubleshooting
• Inspection using an
oscilloscope
MD991536 Check harness for throttle • Measurement of voltage

position sensor adjustment during Troubleshooting
• Adjusting of throttle position
sensor
MB991536
MD998464 Test harness (4-pin, square) • Measurement of voltage

• Inspection of oxygen sensor
(front)
MB991658 Test harness • Measurement of voltage

• Inspection of oxygen sensor
(rear)
MB991658
MB991223 Harness set • Check at the ECU terminals

A: MB991219 A: Test harness A: Connector pin contact
B: MB991220 B: LED harness inspection
C: MB991221 C: LED harness adapter B: Power circuit inspection
D: MB991222 D: Probe C: Power circuit inspection
D: Commercial tester
connection
MB991223
SPECIAL TOOLS

MD998709 Adaptor hose Measurement of fuel pressure
MD998742 Hose adaptor
MB991637 Fuel pressure gauge set
MB991637
MB991981 Fuel pressure gauge set
MB991981
MD998706 Injector test set Checking the spray condition of

injectors
MD998706
MB991607 Injector test harness
MB991607
MD998741 Injector test adaptor
MD998741
MB991976 Clip
MB991976
TROUBLESHOOTING
13A-9
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1131150001572
Refer to P.00-5, GROUP 00 − How to Use Trouble- DIAGNOSIS FUNCTION
shooting/Inspection Service Points. M1131155501527
NOTE: If the engine-ECU is replaced, the steering ENGINE WARNING LAMP (CHECK
lock cylinder and ignition key should be replaced ENGINE LAMP)
together with it.
<L.H.drive vehicles>
Engine warning lamp

(check engine lamp)
<R.H.drive vehicles>
Engine warning lamp

(check engine lamp)
AK501993AB
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 illumi-
nates while the engine is running, check the diagno-
sis code output.
TROUBLESHOOTING
ENGINE WARNING LAMP INSPECTION ITEMS

Code No. Diagnosis item
− Engine-ECU
P0090 Fuel pressure control valve system
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
P0135 Oxygen sensor heater (front) system
P0136 Oxygen sensor (rear) system
P0141 Oxygen sensor heater (rear) system
P0170 Abnormal fuel system
P0201 No. 1 injector system
P0234 Turbocharger wastegate system malfunction
P0243 Waste gate solenoid valve system
P0300 Random cylinder misfire detection system
P0301* No. 1 cylinder misfire detection system
P0325 Detonation sensor system
P0335 Crank angle sensor system
P0340 Exhaust camshaft position sensor system
P0403 EGR control solenoid valve system
P0421 Warm up catalyst malfunction
P0443 Purge control solenoid valve system
P0500 Vehicle speed sensor system
P0505 Idle speed control system
P0551* Power steering fluid pressure switch system
P0710 Transmission oil temperature sensor system
P1012 Intake camshaft position sensor system
P1021 Oil feeder control valve system
P1603* Battery back-up line system
TROUBLESHOOTING
13A-11
NOTE: .
• If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between M.U.T.-II/III 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 diag-
nosis code number column, the engine warning lamp illuminates only on the first detection of the malfunc-
tion.
• 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 require-
ments, 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 INSPECTION USING M.U.T.-II/III DATA

DIAGNOSIS CODES LIST AND ACTUATOR TESTING
Refer to P.00-5, GROUP 00 − How to Use Trouble- 1. Carry out inspection by means of the data list and
shooting/Inspection Service Points. the actuator test function, if there is an
abnormality, check and repair the chassis harness
DIAGNOSIS USING DIAGNOSIS 2 MODE and components.
1. Switch the diagnosis mode of the engine control 2. After repairing, re-check using the M.U.T.-II/III and
unit to DIAGNOSIS 2 mode using the M.U.T.-II/III. check that the abnormal input and output have
2. Carry out a road test. returned to normal as a result of the repairs.
3. Take a reading of the diagnosis code and repair 3. Erase the diagnosis code memory.
the problem location. 4. Remove the M.U.T.-II/III, and then start the engine
4. Turn the ignition switch to "LOCK" (OFF) position again and carry out a road test to confirm that the
and then back to "ON" position again. problem has disappeared.
NOTE: By turning the ignition switch to "LOCK"
(OFF) position, the ENGINE-ECU will switch the FREEZE FRAME DATA
diagnosis mode from DIAGNOSIS 2 mode to When the engine-ECU detects a malfunction and
DIAGNOSIS 1 mode. stores a diagnosis code, it also stores a current sta-
5. Erase the diagnosis codes. tus of the engine. This function is called "Freeze
frame data". By analyzing this "Freeze frame" data
with the M.U.T.-II/III, an effective troubleshooting can
be performed.
The display items of freeze frame data are shown
below.
TROUBLESHOOTING
DISPLAY ITEM LIST

Item No. Data Unit
21 Engine coolant temperature sensor °C
22 Engine speed r/min.
24 Vehicle speed km/h
81 Long-term fuel compensation (long-term fuel trim) %
82 Short-term fuel compensation (short-term fuel trim) %
88 Fuel control condition Open loop OL
Closed loop CL
Open loop due to drive condition OL-DRV.
Open loop due to system malfunction OL-SYS.
Closed loop based on one oxygen sensor CL- HO2S
87 Calculation load value %
− Diagnosis code during data recording −
NOTE: If malfunctions have been detected in multi-
ple systems, store one malfunction only, which has
been detected first.
DRIVE CYCLE
By carrying out the test drive in the following three drive cycle patterns, the all monitoring can be accom-
plished for the diagnosis codes that is required by the vehicle driving to identify the fault. In other words,
doing such a drive allows to regenerate any kind of trouble which involves illuminating the engine warning
lamp (check engine lamp) and to verify the repair procedure has eliminated the trouble [the engine warning
lamp (check engine lamp) is no longer illuminated].
CAUTION
Two technicians should always be in the vehicle when carrying out a test drive.
NOTE: Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the diag-
nosis code if it has been output.
DRIVE CYCLE PATTERN LIST
Procedure Monitor item Diagnosis code
1 Catalytic converter monitor P0421
2 Oxygen sensor (front) monitor P0130
3 Other monitor P0136, P0201, P0202,
P0203, P0204, P0300,
P0301, P0302, P0303,
P0304, P0325, P0500,
P0551
TROUBLESHOOTING
13A-13
Procedure 1
Catalytic converter monitor
Diagnosis P0421
code No.
Drive cycle One trip monitor [from start to ignition switch to "LOCK" (OFF) position] will be completed
pattern while traveling with the following drive cycle pattern. It will take 16 minutes or more.
6 minutes or more
90 km/h or more 10 minutes or more

(3)
(4) 55 - 80 km/h
Vehicle
speed (2) (5,6)
Stopping and braking

permitted
(1) (7)
Time
Engine Start Ignition switch :

"LOCK" (OFF)
position
AK301815 AB
Inspection • Atmospheric temperature: −10°C or more

condition
Test 1. Engine: start
procedure 2. Accelerate until the vehicle speed is 90 km/h or more.
3. Travel for 6 minutes or more while keeping the vehicle speed at 90 km/h or more.
4. Decelerate until the vehicle speed is within 80 km/h or less.
5. While traveling at 55 − 80 km/h for 10 minutes or more, fully close the throttle at least
once in 2 minutes and decelerate for 10 seconds or more.
• Do not repeat deceleration too often.
• Vehicle speed may go below 55 km/h after the deceleration.
• Stopping and braking are permitted. (If stopped or drive at 55 km/h or less for more
than 5 minutes the monitoring may be stopped. In this case please restart monitoring
from the beginning.)
6. After completing the above deceleration, bring the vehicle speed back to 55 − 80 km/h
and keep it in the range until starting the deceleration again.
• Repeat the above deceleration at least 5 times.
7. Return the vehicle to the shop, then turn the ignition switch to "LOCK" (OFF) position.
TROUBLESHOOTING
Procedure 2
Oxygen sensor (front) monitor
Diagnosis P0130
code No.
16 minutes or more
55 - 80 km/h
(3)
Vehicle
speed (2) Stopping and braking
permitted
(1) (4)
Time

"LOCK" (OFF)
position
AK301816AB
Inspection • Engine coolant temperature: After engine warm up

conditions • Atmospheric temperature: −10°C or more
procedure 2. Accelerate until the vehicle speed is 55 − 80 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at
55 − 80km/h and travel for 16 minutes or more.
• Stopping and braking during this operation are permitted.
4. Return the vehicle to the shop, then turn the ignition switch to "LOCK" (OFF) position.
TROUBLESHOOTING
13A-15
Procedure 3
Other monitor
Diagnosis P0136, P0201, P0202, P0203, P0204, P0300, P0301, P0302, P0303, P0304, P0325,
code No. P0500, P0551
16 minutes or more
55 km/h or more
(3)
Vehicle (2) 5 minutes or more

speed Engine: Idling
Transmission: Neutral
(1) (4) (5)

Time

"LOCK" (OFF)
position
AK301817AB
Inspection • Engine coolant temperature: After engine warm up

conditions • Atmospheric temperature: −10°C or more
procedure 2. Accelerate until the vehicle speed is 55 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at
55 km/h and travel for 16 minutes or more.
4. Return the vehicle to the shop.
5. After stopping the vehicle, continue idling for 5 minutes, and then turn the ignition switch
to "LOCK" (OFF) position.
READINESS TEST STATUS In addition, if diagnosis codes are erased or the bat-
The engine-ECU monitors the following main diagno- tery cable is disconnected, this history will also be
sis items, judges if these items are in good condition erased (the memory will be reset).
or not, and the stores its history. This history can be • Catalyst: P0421
read out by using M.U.T.-II/III. (If the ECU has judged • Oxygen sensor: P0130
a item before, the M.U.T.-II/III displays "Complete"). • Oxygen sensor heater: P0135, P0141
TROUBLESHOOTING
FAIL-SAFE FUNCTION REFERENCE TABLE

When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by
means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item Control contents during malfunction

Air flow sensor 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 Controls as if the intake air temperature is 25°C.
sensor
Barometric pressure Controls as if the barometric pressure is 101 kPa.
sensor
Throttle position sensor No increase in fuel injection amount during acceleration due to the throttle position
sensor signal.
Engine coolant Controls as if the engine coolant temperature is 80°C.
temperature sensor
Intake camshaft Turns the oil feeder control valve OFF, and sets the valve timing to the most
position sensor retarded angle.
Exhaust camshaft 1. Injects fuel simultaneously into all cylinders (provided that the TDC of the No. 1
position sensor cylinder is not detected even once after the ignition switch has been turned
"ON").
2. Cuts the supply of fuel 4 seconds after detecting a failure (provided that the TDC
of the No. 1 cylinder is not detected even once after the ignition switch has been
turned "ON").
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.
Ignition coil Cuts off the fuel supply to cylinders with an abnormal ignition.
(incorporating power
transistor)
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.
TROUBLESHOOTING
13A-17
INSPECTION CHART FOR DIAGNOSIS CODE
M1131151001962
Code No. Diagnosis item Reference page

P0090 Fuel pressure control solenoid valve system P.13A-19
P0100 Air flow sensor system P.13A-24
P0105 Barometric pressure sensor system P.13A-35
P0110 Intake air temperature sensor system P.13A-45
P0115 Engine coolant temperature sensor system P.13A-52
P0120 Throttle position sensor system P.13A-60
P0125* Feedback system monitor P.13A-70
P0130 Oxygen sensor (front) system P.13A-75
P0135 Oxygen sensor heater (front) system P.13A-82
P0136 Oxygen sensor (rear) system P.13A-88
P0141 Oxygen sensor heater (rear) system P.13A-95
P0170 Abnormal fuel system P.13A-101
P0201 No. 1 Injector system P.13A-105
P0234 Turbocharger wastegate system malfunction P.13A-129
P0243 Waste gate solenoid valve system P.13A-130
P0300 Random cylinder misfire detection system P.13A-135
P0301* No. 1 cylinder misfire detection system P.13A-139
P0325 Detonation sensor system P.13A-151
P0335 Crank angle sensor system P.13A-155
P0340 Exhaust camshaft position sensor system P.13A-166
P0403 EGR control solenoid valve system P.13A-175
P0421 Warm up catalyst malfunction P.13A-180
P0443 Purge control solenoid valve system P.13A-182
P0500 Vehicle speed sensor system P.13A-187
P0505 Idle speed control system P.13A-190
P0513 Immobilizer system P.13A-195
P0551* Power steering fluid pressure switch system P.13A-197
P0622 Alternator FR terminal system P.13A-203
P0710 Transmission oil temperature sensor system P.13A-208
TROUBLESHOOTING
Code No. Diagnosis item Reference page

P1012 Intake camshaft position system P.13A-216
P1021 Oil feeder control valve system P.13A-225
P1603* Battery back-up line system P.13A-230
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 sen-
sor mounted at the position second closest to the engine.
TROUBLESHOOTING
13A-19
INSPECTION PROCEDURE FOR
DIAGNOSIS CODES
Code No. P0090: Fuel Pressure Control Solenoid Valve System
Fuel pressure control solenoid valve circuit
Battery
B-Y 6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
Engine control relay
3 4
4 3
To engine-ECU
R-Y
B-28 1
(MU802722)
1 2 Fuel pressure control solenoid valve
W-B
48
C-119
(MU803782)
41 42 43 44 45 46 47
48 49 50 51 52 53 54 55 56 57 58 59 Engine-ECU
60 61 62 63 64 65 66 67 68
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
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 PU: Purple
AK501799 AB
TROUBLESHOOTING
OPERATION STEP 2. Connector check: B-28 fuel pressure

• Power is supplied from the engine control relay control solenoid valve connector
(terminal No. 4) to the fuel pressure control sole-
Connector : B-28
noid valve (terminal No. 1).
2 1
• The engine-ECU (terminal No. 48) causes the
Harness side
power transistor in the unit to be ON to supply connector
power to the fuel pressure control solenoid valve
(terminal No. 2).
FUNCTION
B-28(B)
• In response to a signal from the engine-ECU, the
fuel pressure control solenoid valve switches the
AK305002AB
pressure to be introduced into the fuel pressure
regulator between the intake manifold negative Q: Is the check result normal?
pressure and atmospheric pressure. YES : Go to Step 3 .
NO : Repair or replace the connector.
TROUBLE JUDGMENT
Check Condition STEP 3. Perform resistance measurement at B-28
• Battery voltage is 10 V or more. fuel pressure control solenoid valve connector.
Judgment Criterion Connector : B-28
• Surge voltage cannot be detected within 1 sec- 2 1
onds from the time when the fuel pressure control Harness side
solenoid valve has changed from ON to OFF. connector
PROBABLE CAUSES
• Failed fuel pressure control solenoid valve
• Open/short circuit in fuel pressure control sole- B-28(B)
noid valve circuit or loose connector contact
• Failed engine-ECU AK305002AB
• Disconnect connector, and measure at solenoid

DIAGNOSIS PROCEDURE valve side.
• Resistance between terminal No. 1 and No. 2.
STEP 1. M.U.T.-II/III actuator test OK: 28 − 36 Ω (at 20°C)
• Item No. 09: Fuel pressure control solenoid valve
OK: Operating sound can be heard and the YES : Go to Step 4 .
valve vibrates. NO : Replace the fuel pressure control solenoid
Q: Is the check result normal? valve.
00 − How to Use
Troubleshooting/Inspection Service Points)
P.00-5.
NO : Go to Step 2 .
TROUBLESHOOTING
13A-21
STEP 4. Perform voltage measurement at B-28
YES : Check and repair harness between B-28
fuel pressure control solenoid valve connector.
(terminal No. 1) fuel pressure control
Connector : B-28 solenoid valve connector and B-12X
2 1 (terminal No. 4) engine control relay
Harness side connector.
connector
• Check power supply line for
open/short circuit.
B-28(B)
STEP 6. Perform voltage measurement at C-119
engine-ECU connector.
AK305002AB
• Disconnect connector, and measure at harness Connector: C-119

side. <L. H. drive vehicles>
• Ignition switch: "ON"
• Voltage between terminal No. 1 and earth.
OK: System voltage
YES : Go to Step 6 .
NO : Go to Step 5 .
STEP 5. Connector check: B-12X engine control C-119 (GR)

relay connector <R. H. drive vehicles>
Connector : B-12X Relay box’s
triangle marks
2 1
B-12X
4 3
Harness side
connector C-119 (GR)
47 46 45 44 43 42 41
AK305003 AB 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
Connector : B-28 Harness side connector

AK501994 AB
2 1
Harness side • Disconnect connector, and measure at harness
connector side.
OK: System voltage
B-28(B)
AK305002AB
NO : Go to Step 7 .
TROUBLESHOOTING

STEP 7. Connector check: C-119 engine-ECU
connector
(terminal No. 2) fuel pressure control
Connector: C-119 solenoid valve connector and C-119
<L. H. drive vehicles>
(terminal No. 48) engine-ECU connector.
• Check output line for open/short
circuit.

connector
Connector: C-119
C-119 (GR) <L. H. drive vehicles>
<R. H. drive vehicles>
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
Harness side connector
AK501994 AB
Connector : B-28
2 1
Harness side
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
B-28(B) AK501994 AB
AK305002AB Q: Is the check result normal?

TROUBLESHOOTING
13A-23
STEP 9. Check harness between B-28 (terminal STEP 10. Check harness between B-28 (terminal
No. 2) fuel pressure control solenoid valve No. 1) fuel pressure control solenoid valve
connector and C-119 (terminal No. 48) connector and B-12X (terminal No. 4) engine
engine-ECU connector. control relay connector.
Connector : B-28 Connector : B-28
2 1 2 1
Harness side Harness side
connector connector
B-28(B) B-28(B)
AK305002AB AK305002AB
Connector: C-119 Connector : B-12X Relay box’s

triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
C-119 (GR) • Check power supply line for damage.

<R. H. drive vehicles> Q: Is the check result normal?
NO : Repair the damaged harness wire.
STEP 11. M.U.T.-II/III actuator test

• Item No. 09: Fuel pressure control solenoid valve
OK: Operating sound can be heard and the
valve vibrates.
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 YES : Intermittent malfunction (Refer to GROUP
68 67 66 65 64 63 62 61 60 00 − How to Use
Harness side connector Troubleshooting/Inspection Service Points
AK501994 AB
P.00-5).
• Check output line for damage. NO : Replace the engine-ECU.
TROUBLESHOOTING
Code No. P0100: Air Flow Sensor System
Air flow sensor circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
To engine-ECU
R-Y
4
B-105
(MU802552)
1 2 3 4 5 6 7 Air flow sensor
7 5 3
L-B B W-B
C-121 19 34 61 C-119
(MU803783) (MU803782)
1 2 3 4 5 6 7 8 41 42 43 44 45 46 47
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 48 49 50 51 52 53 54 55 56 57 58 59
24 25 26 27 28 29 30 3132 33 34 35 60 61 62 63 64 65 66 67 68
5V
Engine-ECU
NOTE
Wire colour code
AK501800 AB
TROUBLESHOOTING
13A-25
OPERATION DIAGNOSIS PROCEDURE
• Power is supplied to the air flow sensor (terminal
No. 4) from the engine control relay (terminal No. STEP 1. M.U.T.-II/III data list
4) and earthed to the engine-ECU (terminal No. • Refer to Data List Reference Table P.13A-372.
34) from the air flow sensor (terminal No. 5).
a. Item No. 12: Air flow sensor
• A power voltage of 5 V is applied to the air flow
sensor output terminal (terminal No. 3) from the Q: Is the check result normal?
engine-ECU (terminal No. 61). YES : Intermittent malfunction (Refer to GROUP
• An air flow sensor filter reset signal is inputted to 00 − How to Use
the air flow sensor (terminal No. 7) from the Troubleshooting/Inspection Service Points
engine-ECU (terminal No. 19). P.00-5).
NO : Go to Step 2 .
FUNCTION
• Air flow sensor outputs a pulse signal propor- STEP 2. Connector check: B-105 air flow sensor
tional to the intake air flow rate. connector
• The engine-ECU determines the basic injection
timing of the injector using the pulse signal output Connector : B-105
from the air flow sensor and the engine speed
signal. B-105(B)
• 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 fil- 7 6 5 4 3 2 1
ter circuit to improve the ability of the air flow sen- Harness side
connector
sor to measure the air flow rate in the area where AK305005AB
the intake air flow rate is low.

TROUBLE JUDGMENT NO : Repair or replace the connector.
Check Condition
• Engine speed of 500 r/min. or more. STEP 3. Perform voltage measurement at B-105
Judgment Criterion air flow sensor connector.
• The sensor output frequency of 3.3 Hz or more Connector : B-105
for 2 seconds.
B-105(B)
PROBABLE CAUSES
• Failed air flow sensor
• Open/short circuit in air flow sensor circuit or
loose connector contact
• Failed engine-ECU 7 6 5 4 3 2 1
Harness side
connector AK305005AB
• Disconnect connector, and measure at harness

side.
OK: 4.9 − 5.1 V
NO : Go to Step 4 .
TROUBLESHOOTING
STEP 4. Perform voltage measurement at C-119 STEP 5. Connector check: C-119 engine-ECU
engine-ECU connector. connector
Connector: C-119 Connector: C-119
<L. H. drive vehicles> <L. H. drive vehicles>
C-119 (GR) C-119 (GR)
<R. H. drive vehicles> <R. H. drive vehicles>
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
Harness side connector Harness side connector
AK501994 AB AK501994 AB
• Measure engine-ECU terminal voltage. Connector : B-105

• Voltage between terminal No. 61 and earth. B-105(B)
OK: 4.9 − 5.1 V
NO : Go to Step 6 .
7 6 5 4 3 2 1
Harness side

(terminal No. 3) air flow sensor connector
and C-119 (terminal No. 61) engine-ECU
connector.
• Check output line for open circuit.
TROUBLESHOOTING
13A-27
STEP 6. Connector check: C-119 engine-ECU STEP 7. Check harness between B-105 (terminal
connector No. 3) air flow sensor connector and C-119
Connector: C-119
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side
C-119 (GR)
<R. H. drive vehicles> Connector: C-119

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 C-119 (GR)
68 67 66 65 64 63 62 61 60
Harness side connector <R. H. drive vehicles>
AK501994 AB

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
• Check output line for short circuit.

TROUBLESHOOTING
STEP 8. M.U.T.-II/III data list STEP 10. Connector check: B-12X engine control
• Refer to Data List Reference Table P.13A-372. relay connector
a. Item No. 12: Air flow sensor Connector : B-12X Relay box’s
triangle marks
00 − How to Use
Troubleshooting/Inspection Service Points B-12X
2 1
P.00-5). 4 3
NO : Replace the engine-ECU. Harness side
connector

AK305003 AB
air flow sensor connector.
B-105(B) B-105(B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1
connector connector AK305005AB
AK305005AB
• Disconnect connector, and measure at harness Q: Is the check result normal?

side. YES : Check and repair harness between B-105
• Ignition switch: "ON" (terminal No. 4) air flow sensor connector
• Voltage between terminal No. 4 and earth. and B-12X (terminal No. 4) engine control
OK: System voltage relay connector.
open/short circuit.
NO : Go to Step 10 .
STEP 11. Perform resistance measurement at

B-105 air flow sensor connector.
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side
• Disconnect and measure at harness side.

• Resistance between terminal No. 5 and earth.
OK: 2 Ω or less
TROUBLESHOOTING
13A-29
Connector: C-121
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
• Check earthing line for open circuit and damage.

TROUBLESHOOTING
STEP 14. Perform voltage measurement at B-105 STEP 16. Check harness between B-105 (terminal
air flow sensor connector. No. 7) air flow sensor connector and C-121
Connector : B-105
Connector : B-105
B-105(B)
B-105(B)
7 6 5 4 3 2 1
Harness side 7 6 5 4 3 2 1
connector AK305005AB Harness side
connector
• Use special tool test harness (MB991709) to con- AK305005AB
nect connector, and measure at pick-up harness.

Connector: C-121
• Voltage between terminal No. 7 and earth. <L. H. drive vehicles>
OK: 6 − 9 V

connector
C-121 (GR)
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1
C-121 (GR)
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
• Check reset signal line for short circuit.

YES : Replace the air flow sensor.
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
13A-31
STEP 17. Perform voltage measurement at B-105 STEP 18. Connector check: C-121 engine-ECU
air flow sensor connector. connector
Connector : B-105 Connector: C-121
B-105(B)
7 6 5 4 3 2 1
Harness side
• Use special tool test harness (MB991709) to con- C-121 (GR)

• Transmission: Neutral
OK:
0 − 1 V (Engine: Idling)
6 − 9 V (Engine: 3,000 r/min.)
NO : Go to Step 18 . C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
STEP 19. Check harness between B-105 (terminal STEP 20. Perform output wave pattern
No. 7) air flow sensor connector and C-121 measurement at B-105 air flow sensor connector
(terminal No. 19) engine-ECU connector. (Using an oscilloscope).
B-105(B) B-105(B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1
connector AK305005AB connector AK305005AB
• Use special tool test harness (MB991709) to con-

Connector: C-121
<L. H. drive vehicles> • Engine: Idling
OK: Waveforms should be displayed on
inspection procedure using an oscilloscope
(Refer to P.13A-385) and noise should not be
displayed in the waveform.
C-121 (GR)
STEP 21. Replace the air flow sensor.

• After replacing the air flow sensor, re-check the
trouble symptoms.
NO : The check is end.
C-121 (GR)
8 7 6 5 4 3 2 1 STEP 22. Connector check: B-12X engine control

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
relay connector
Harness side connector Connector : B-12X Relay box’s
AK501995 AB
triangle marks
• Check reset signal line for open circuit and dam-
age.
2 1
Q: Is the check result normal? B-12X
YES : Go to Step 8 . 4 3
NO : Repair the damaged harness wire. Harness side
connector
AK305003 AB

TROUBLESHOOTING
13A-33
STEP 23. Check harness between B-105 (terminal STEP 24. Connector check: C-119 engine-ECU
No. 4) air flow sensor connector and B-12X connector
(terminal No. 4) engine control relay connector.
Connector: C-119
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side
C-119 (GR)
Connector : B-12X Relay box’s <R. H. drive vehicles>

triangle marks
2 1
B-12X
4 3
Harness side
connector
C-119 (GR)
AK305003 AB
47 46 45 44 43 42 41
• Check power supply line for damage. 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
Q: Is the check result normal? Harness side connector
YES : Go to Step 24 . AK501994 AB

TROUBLESHOOTING
No. 3) air flow sensor connector and C-119 connector
Connector: C-121
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side
C-121 (GR)
Connector: C-119 <R. H. drive vehicles>

C-121 (GR)
8 7 6 5 4 3 2 1
C-119 (GR) 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
<R. H. drive vehicles> Harness side connector

AK501995 AB
Connector : B-105
B-105(B)
C-119 (GR)
47 46 45 44 43 42 41 7 6 5 4 3 2 1
59 58 57 56 55 54 53 52 51 50 49 48
Harness side
68 67 66 65 64 63 62 61 60
AK501994 AB
• Check output line for damage. YES : Check and repair harness between B-105
Q: Is the check result normal? (terminal No. 5) air flow sensor connector
YES : Go to Step 26 . and C-121 (terminal No. 34) engine-ECU
NO : Repair the damaged harness wire. connector.
• Check earthing line for damage.
No : Repair or replace the connector.
TROUBLESHOOTING
13A-35
Code No. P105: Barometric Pressure Sensor System
Barometric pressure sensor circuit
B-105
(MU802552)
Barometric pressure sensor
1 2 3 4 5 6 7 (Incorporated in air flow sensor)
1 2 5
GR Y-L B
42 51 34 C-121
C-119
(MU803782) (MU803783)
41 42 43 44 45 46 47 1 2 3 4 5 6 7 8
48 49 50 51 52 53 54 55 56 57 58 59 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
60 61 62 63 64 65 66 67 68 24 25 26 27 28 29 30 3132 33 34 35
5V
Engine-ECU
Wire colour code
AK501801 AB
OPERATION TROUBLE JUDGMENT

• A power voltage of 5 V is applied to the baromet- Check Condition
ric pressure sensor power terminal (terminal No. • 2 seconds after the ignition switch has been
1) of the air flow sensor connector from the placed in the "ON" position or the engine has
engine-ECU (terminal No. 42) and earthed to the started up.
engine-ECU (terminal No. 34) from the air flow
sensor (terminal No. 5). Judgment Criterion
• The sensor signal is inputted to the engine-ECU • The sensor output voltage of 4.5 V or more (Baro-
metric pressure above 114 kPa or equivalent) for
(terminal No. 51) from the barometric pressure 2 seconds.
sensor output terminal (terminal No. 2) of the air or
flow sensor connector. • The sensor output voltage 0.2 V or less (Baro-
metric pressure below 53 kPa or equivalent) for 2
FUNCTION seconds.
• The barometric pressure sensor converts the bar- PROBABLE CAUSES
ometric pressure into a voltage signal and inputs • Failed barometric pressure sensor
the signal to the engine-ECU. • Open/short circuit in barometric pressure sensor
• In response to the signal, the engine-ECU cor- circuit or loose connector contact
rects the fuel injection amount, etc. • Failed engine-ECU
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 4. Perform voltage measurement at C-119

STEP 1. M.U.T.-II/III data list Connector: C-119
• Refer to Data List Reference Table P.13A-372.
a. Item No. 25: Barometric pressure sensor
00 − How to Use
Troubleshooting/Inspection Service Points
P.00-5).
NO : Go to Step 2 .
C-119 (GR)
STEP 2. Connector check: B-105 air flow sensor
connector <R. H. drive vehicles>
Connector : B-105
B-105(B)
C-119 (GR)
7 6 5 4 3 2 1
Harness side 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
Q: Is the check result normal? AK501994 AB
• Measure engine-ECU terminal voltage.
STEP 3. Perform voltage measurement at B-105 OK: 4.9 − 5.1 V
Connector : B-105 YES : Go to Step 5 .
NO : Go to Step 6 .
B-105(B)
7 6 5 4 3 2 1
Harness side

side.
OK: 4.9 − 5.1 V
NO : Go to Step 4 .
TROUBLESHOOTING
13A-37
STEP 5. Connector check: C-119 engine-ECU STEP 6. Connector check: C-119 engine-ECU
connector connector
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB
Connector : B-105 Q: Is the check result normal?

B-105(B) NO : Repair or replace the connector.
7 6 5 4 3 2 1
Harness side

connector.
• Check power supply line for open
circuit.
TROUBLESHOOTING
STEP 7. Check harness between B-105 (terminal STEP 8. M.U.T.-II/III data list
No. 1) air flow sensor connector and C-119 • Refer to Data List Reference Table P.13A-372.
(terminal No. 42) engine-ECU connector. a. Item No. 25: Barometric pressure sensor
B-105(B) 00 − How to Use
P.00-5).
NO : Replace the engine-ECU.
7 6 5 4 3 2 1
Harness side
connector B-105 air flow sensor connector.
AK305005AB
Connector : B-105
Connector: C-119
<L. H. drive vehicles> B-105(B)
7 6 5 4 3 2 1
Harness side

C-119 (GR) side.
<R. H. drive vehicles> • Resistance between terminal No. 5 and earth.
OK: 2 Ω or less
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
• Check power supply line for short circuit.

TROUBLESHOOTING
13A-39
Connector: C-119
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side
C-119 (GR)

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 C-119 (GR)
68 67 66 65 64 63 62 61 60
AK501994 AB

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
• Check earthing line for open circuit or damage.

TROUBLESHOOTING
B-105(B)
7 6 5 4 3 2 1
Harness side

nect only terminal No. 1, No. 2 and No. 5, and
then measure at pick-up harness.
OK: 4.9 − 5.1 V
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side

connector.
• Check power supply line for damage.
TROUBLESHOOTING
13A-41
B-105(B)
7 6 5 4 3 2 1
Harness side

OK: 0.5 V or less
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side

connector.
TROUBLESHOOTING
B-105(B)
7 6 5 4 3 2 1
Harness side

OK:
Altitude 0 m: 3.8 − 4.2 V
Altitude 600 m: 3.5 − 3.9 V
Altitude 1,200 m: 3.3 − 3.7 V
Altitude 1,800 m: 3.0 − 3.4 V C-119 (GR)
Q: Is the check result normal? 47 46 45 44 43 42 41
YES : Go to Step 19 . 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
13A-43
STEP 18. Check harness between B-105 (terminal STEP 19. Perform voltage measurement at C-119
No. 2) air flow sensor connector and C-119 engine-ECU connector.
Connector: C-119
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side
C-119 (GR)

C-119 (GR)
47 46 45 44 43 42 41
C-119 (GR) 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60

AK501994 AB

OK:
Altitude 0 m: 3.8 − 4.2 V
Altitude 600 m: 3.5 − 3.9 V
C-119 (GR) Altitude 1,200 m: 3.3 − 3.7 V
47 46 45 44 43 42 41 Altitude 1,800 m: 3.0 − 3.4 V
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 Q: Is the check result normal?
Harness side connector YES : Go to Step 21 .
AK501994 AB NO : Go to Step 20 .
• Check output line for short circuit and damage.
YES : Replace the air flow sensor.
TROUBLESHOOTING
connector connector
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB

7 6 5 4 3 2 1
Harness side

connector.
• Check output line for open circuit and
damage.
TROUBLESHOOTING
13A-45
Code No. P0110: Intake Air Temperature Sensor System
Intake air temperature sensor circuit
B-105
(MU802552)
1 2 3 4 5 6 7 Intake air temperature sensor

(Incorporated in air flow sensor)
5 6
B R-L
34 62
C-121 C-119
(MU803783) (MU803782)
1 2 3 4 5 6 7 8 41 42 43 44 45 46 47
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 48 49 50 51 52 53 54 55 56 57 58 59
24 25 26 27 28 29 30 3132 33 34 35 60 61 62 63 64 65 66 67 68
5V
Engine-ECU
Wire colour code
AK501802 AB
OPERATION • The intake air temperature sensor is a kind of

• A power voltage of 5 V is applied to the intake air resistor, which has characteristics to reduce its
temperature sensor output terminal (terminal No. resistance as the intake air temperature rises.
6) of the air flow sensor connector from the Therefore, the sensor output voltage varies with
engine-ECU (terminal No. 62) the intake air temperature, and becomes lower as
• The power voltage is earthed to the engine-ECU the intake air temperature rises.
(terminal No. 34) from the air flow sensor (termi-
nal No. 5). TROUBLE JUDGMENT
Check Condition
FUNCTION • 2 seconds later after the ignition switch has been
• The intake air temperature sensor converts the in "ON" position or the engine has started up.
intake air temperature into a voltage and inputs
the voltage signal to the engine-ECU. Judgment Criterion
• In response to the signal, the engine-ECU cor- • The sensor output voltage of 4.6 V or more
rects the fuel injection amount, etc. (intake air temperature below −45°C or equiva-
lent) for 2 seconds.
or
• The sensor output voltage of 0.2 V or loss (intake
air temperature above 125 °C or equivalent) for 2
seconds.
TROUBLESHOOTING
PROBABLE CAUSES STEP 4. Perform resistance measurement at

• Failed intake air temperature sensor B-105 air flow sensor connector.
• Open/short circuit in intake air temperature sen-
Connector : B-105
sor circuit or loose connector contact
• Failed engine-ECU
B-105(B)
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list

• Item No. 13: Intake air temperature sensor 7 6 5 4 3 2 1
OK: At ambient temperature or equivalent. Harness side
YES : Intermittent malfunction (Refer to GROUP • Disconnect connector, and measure at harness
00 − How to Use side.
Troubleshooting/Inspection Service Points • Resistance between terminal No. 5 and earth.
P.00-5). OK: 2 Ω or less
NO : Go to Step 2 . Q: Is the check result normal?
STEP 2. Connector check: B-105 air flow sensor NO : Go to Step 5 .
connector
Connector : B-105 STEP 5. Connector check: C-121 engine-ECU
connector
B-105(B)
Connector: C-121
7 6 5 4 3 2 1
Harness side

NO : Repair or replace the connector. C-121 (GR)
STEP 3. Check intake air temperature sensor
itself.
• Check intake air temperature sensor itself (Refer
to P.13A-403).
NO : Replace the air flow sensor.
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
13A-47
No. 5) air flow sensor connector and C-121 • Item No. 13: Intake air temperature sensor
(terminal No. 34) engine-ECU connector. OK: At ambient temperature or equivalent.
P.00-5).
7 6 5 4 3 2 1
Harness side
Connector : B-105
Connector: C-121
<L. H. drive vehicles> B-105(B)
7 6 5 4 3 2 1
Harness side

C-121 (GR) side.
<R. H. drive vehicles> • Ignition switch: "ON"
OK: 4.5 − 4.9 V
NO : Go to Step 9 .
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB
B-105(B) B-105(B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1
• Measure engine-ECU terminal voltage. Q: Is the check result normal?

• Disconnect B-105 air flow sensor connector. YES : Check and repair harness between B-105
• Ignition switch: "ON" (terminal No. 6) air flow sensor connector
• Voltage between terminal No. 62 and earth. and C-119 (terminal No. 62) engine-ECU
OK: 4.5 − 4.9 V connector.
Q: Is the check result normal? • Check output line for open circuit.
YES : Go to Step 10 . NO : Repair or replace the connector.
TROUBLESHOOTING
13A-49
Connector: C-119
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side
C-119 (GR)

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 C-119 (GR)
68 67 66 65 64 63 62 61 60
AK501994 AB

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
B-105(B)
7 6 5 4 3 2 1
Harness side

nect only terminal No. 5 and No. 6, and then
measure at pick-up harness.
OK:
Ambient temperature at −20°C: 3.8 − 4.4 V
Ambient temperature at 0°C: 3.2 − 3.8 V
Ambient temperature at 40°C: 1.5 − 2.1 V C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
TROUBLESHOOTING
13A-51
No. 6) air flow sensor connector and C-119 connector
Connector: C-121
Connector : B-105
B-105(B)
7 6 5 4 3 2 1
Harness side
C-121 (GR)

C-121 (GR)
8 7 6 5 4 3 2 1
C-119 (GR) 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24

AK501995 AB
Connector : B-105
B-105(B)
C-119 (GR)
47 46 45 44 43 42 41 7 6 5 4 3 2 1
59 58 57 56 55 54 53 52 51 50 49 48
Harness side
68 67 66 65 64 63 62 61 60
AK501994 AB
• Check output line for damage. YES : Check and repair harness between B-105
Q: Is the check result normal? (terminal No. 5) air flow sensor connector
YES : Go to Step 16 . and C-121 (terminal No. 34) engine-ECU
NO : Repair the damaged harness wire. connector.
TROUBLESHOOTING
Code No. P0115: Engine Coolant Temperature Sensor System
Engine coolant temperature sensor circuit
B-107
(MU802406)
1 2 Engine coolant temperature sensor
2 1
B Y-W
49 44
C-119
(MU803782)
41 42 43 44 45 46 47
48 49 50 51 52 53 54 55 56 57 58 59 Engine-ECU
60 61 62 63 64 65 66 67 68
5V
Wire colour code

AK501803 AB
OPERATION • The engine coolant temperature sensor is a kind

• A power voltage of 5 V is applied to the engine of resistor, which has characteristics to reduce its
coolant temperature sensor output terminal (ter- resistance as the engine coolant temperature
minal No. 1) from the engine-ECU (terminal No. rises. Therefore, the sensor output voltage varies
44). with the engine coolant temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the engine coolant tempera-
(terminal No. 49) from the engine coolant temper- ture rises.
ature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION Check Condition
• The engine coolant temperature sensor converts • 2 seconds later after the ignition switch has been
the engine coolant temperature into a voltage sig- in "ON" position or the engine has started up.
nal, and inputs the voltage to the engine-ECU.
• In response to the signal, the engine-ECU con- Judgment Criteria
trols the fuel infection amount and the fast idle • The sensor output voltage of 4.6 V or more
speed when the engine is cold state. (engine coolant temperature of −45°C or equiva-
lent) for 2 seconds,
or
• The sensor output voltage of 0.1 V or less
(engine coolant temperature of 140°C or more, or
equivalent) for 2 seconds.
TROUBLESHOOTING
13A-53
Check Conditions STEP 3. Perform resistance measurement at
• Ignition switch: "ON" B-107 engine coolant temperature sensor
• Engine speed of 50 r/min. or more connector.
Judging Conditions Connector : B-107
• The sensor output voltage rises 1.6 V or more
(engine coolant temperature below 40°C or
equivalent) from 1.6 V or less (engine coolant
temperature above 40°C or equivalent).
• Thereafter, the sensor output voltage is 1.6 V or
more for 5 minutes. B-107(B)
2 1
PROBABLE CAUSES Harness side
• Failed engine coolant temperature sensor connector AK305008AB
• Open/short circuit in engine coolant temperature
sensor circuit or loose connector contact • Disconnect connector, and measure at sensor
• Failed engine-ECU side.
DIAGNOSIS PROCEDURE OK:
Engine coolant temperature at −20°C: 14 − 17
kΩ
STEP 1. M.U.T.-II/III data list Engine coolant temperature at 0°C: 5.1 − 6.5
• Item No. 21: Engine coolant temperature sensor kΩ
OK: Engine coolant temperature at 20°C: 2.1 − 2.7
Engine cold state: At ambient temperature or kΩ
equivalent. Engine coolant temperature at 40°C: 0.9 − 1.3
Engine hot state: At 80 − 120°C kΩ
Q: Is the check result normal? Engine coolant temperature at 60°C: 0.48 −
YES : Intermittent malfunction (Refer to GROUP 0.68 kΩ
00 − How to Use Engine coolant temperature at 80°C: 0.26 −
Troubleshooting/Inspection Service Points 0.36 kΩ
P.00-5). Q: Is the check result normal?
NO : Go to Step 2 . YES : Go to Step 4 .
NO : Replace the engine coolant temperature
STEP 2. Connector check: B-107 engine coolant sensor.
temperature sensor connector
Connector : B-107
B-107(B)
2 1
Harness side

TROUBLESHOOTING
STEP 4. Perform voltage measurement at B-107 STEP 5. Perform voltage measurement at C-119
engine coolant temperature sensor connector. engine-ECU connector.
B-107(B)
2 1
Harness side
• Disconnect connector, and measure at harness C-119 (GR)

side.
OK: 4.5 − 4.9 V
NO : Go to Step 5 .
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
Connector : B-107
B-107(B)
2 1
Harness side

• Disconnect B-107 engine coolant temperature
sensor.
OK: 4.5 − 4.9 V
NO : Go to Step 7 .
TROUBLESHOOTING
13A-55
connector connector
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB

B-107(B)
2 1
Harness side

(terminal No. 1) engine coolant temperature
sensor connector and C-119 (terminal No.
44) engine-ECU connector.
TROUBLESHOOTING
No. 1) engine coolant temperature sensor • Item No. 21: Engine coolant temperature sensor
connector and C-119 (terminal No. 44) OK:
engine-ECU connector. Engine cold state: At ambient temperature or
Connector : B-107 equivalent.
Engine hot state: At 80 − 120°C
00 − How to Use
B-107(B)
P.00-5).
2 1
Harness side
Connector: C-119 B-107 engine coolant temperature sensor
connector.
Connector : B-107
B-107(B)
2 1
C-119 (GR) Harness side
• Disconnect connector and measure at harness
side.
OK: 2 Ω or less
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
13A-57
connector No. 2) engine coolant temperature sensor
connector and C-119 (terminal No. 49)
Connector: C-119
Connector : B-107
B-107(B)
2 1
Harness side
C-119 (GR)

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 C-119 (GR)
68 67 66 65 64 63 62 61 60
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
engine coolant temperature sensor connector. connector
B-107(B)
2 1
Harness side

OK:
Engine coolant temperature at −20°C: 3.9 − 4.5
V
Engine coolant temperature at 0°C: 3.2 − 3.8 V
Engine coolant temperature at 20°C: 2.3 − 2.9
V C-119 (GR)
47 46 45 44 43 42 41
V 59 58 57 56 55 54 53 52 51 50 49 48
Engine coolant temperature at 60°C: 0.7 − 1.3 68 67 66 65 64 63 62 61 60
V Harness side connector

AK501994 AB
V Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 15 .
TROUBLESHOOTING
13A-59
No. 1) engine coolant temperature sensor connector
Connector: C-119
Connector : B-107
B-107(B)
2 1
Harness side C-119 (GR)
Connector: C-119
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
Connector : B-107
B-107(B)
C-119 (GR) 2 1
47 46 45 44 43 42 41 Harness side
59 58 57 56 55 54 53 52 51 50 49 48 connector AK305008AB
68 67 66 65 64 63 62 61 60
Harness side connector Q: Is the check result normal?
AK501994 AB
YES : Check harness between B-107 (terminal
• Check output line for damage. No. 2) engine coolant temperature sensor
Q: Is the check result normal? connector and C-119 (terminal No. 49)
YES : Go to Step 16 . engine-ECU connector.
NO : Repair the damaged harness wire. • Check earthing line for damage.
TROUBLESHOOTING
Code No. P0120: Throttle Position Sensor System
Throttle position sensor circuit
B-03
(MU802724)
1 2 3 4 Throttle position sensor
1 2 4
GR G B
42 78 49
C-119 C-117
(MU803782) (MU803783)
41 42 43 44 45 46 47 71 72 73 74 75 76 77
48 49 50 51 52 53 54 55 56 57 58 59 78 79 80 81 82 83 84 85 86 87 88 89 90
60 61 62 63 64 65 66 67 68 91 92 93 94 95 96 97 98 99 100
5V
Engine-ECU
Wire colour code
AK501804 AB

• The power voltage of 5 V is applied to the throttle
Check Condition
position sensor (terminal No. 1) from the
• Ignition switch: "ON" (Exclude 2 seconds after the
engine-ECU (terminal No. 42).
ignition switch has been in "ON" position or just
• The power voltage is earthed to the engine-ECU
after the engine has started up.)
(terminal No. 49) from the throttle position sensor
(terminal No. 4). Judgment Criterion
• The sensor signal is inputted to the engine-ECU • The sensor output voltage is 0.2 V or less for 2
(terminal No. 78) from the throttle position sensor seconds.
output terminal (terminal No. 2). Check Conditions
• Engine speed of 1,000 r/min. or less.
FUNCTION
• Volumetric efficiency 60% or less.
• The throttle position sensor converts the opening
of the throttle valve into a voltage and inputs the Judgment Criterion
voltage signal to the engine-ECU. • The sensor output voltage is 2.0 V or more for 2
• In response to the signal, the engine-ECU checks seconds.
the opening of the throttle valve.
TROUBLESHOOTING
13A-61
PROBABLE CAUSES STEP 3. Check throttle position sensor itself.
• Failed throttle position sensor • Check throttle position sensor itself (Refer to
• Open/short circuit in throttle position sensor cir- P.13A-404).
cuit or loose connector contact
• Failed engine-ECU Q: Is the check result normal?
NO : Replace the throttle position sensor.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list throttle position sensor connector.
a. Item No. 14: Throttle position sensor Connector : B-03
Q: Is the check result normal? B-03(B)

00 − How to Use
P.00-5).
NO : Go to Step 2 . 4 3 2 1
Harness side
STEP 2. Connector check: B-03 throttle position connector AK305010 AB
sensor connector • Disconnect connector, and measure at harness

Connector : B-03 side.
B-03(B) • Voltage between terminal No. 1 and earth.
OK: 4.9 − 5.1 V
NO : Go to Step 5 .
4 3 2 1
Harness side
connector AK305010 AB

TROUBLESHOOTING
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB
• Measure engine-ECU terminal voltage. Connector : B-03

• Voltage between terminal No. 42 and earth. B-03(B)
OK: 4.9 − 5.1 V
NO : Go to Step 7 .
4 3 2 1
Harness side

(terminal No. 1) throttle position sensor
• Check power supply line for open
circuit.
TROUBLESHOOTING
13A-63
connector No. 1) throttle position sensor connector and
C-119 (terminal No. 42) engine-ECU connector.
Connector: C-119
Connector : B-03
B-03(B)
4 3 2 1
Harness side
C-119 (GR)

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 C-119 (GR)
68 67 66 65 64 63 62 61 60
AK501994 AB

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
• Check power supply line for short circuit.

TROUBLESHOOTING
STEP 9. M.U.T.-II/III data list STEP 11. Connector check: C-119 engine-ECU
• Refer to Data List Reference Table P.13A-372. connector
a. Item No. 14: Throttle position sensor
Connector: C-119
Q: Is the check result normal? <L. H. drive vehicles>
00 − How to Use
P.00-5).

B-03 throttle position sensor connector.
C-119 (GR)
Connector : B-03
B-03(B)
4 3 2 1
Harness side
connector AK305010 AB C-119 (GR)
• Disconnect connector, and measure at harness 47 46 45 44 43 42 41

59 58 57 56 55 54 53 52 51 50 49 48
side. 68 67 66 65 64 63 62 61 60
• Resistance between terminal No. 4 and earth. Harness side connector
OK: 2 Ω or less
AK501994 AB
Q: Is the check result normal? Q: Is the check result normal?

YES : Go to Step 13 . YES : Go to Step 12 .
NO : Go to Step 11 . NO : Repair or replace the connector.
TROUBLESHOOTING
13A-65
STEP 12. Check harness between B-03 (terminal STEP 13. Perform voltage measurement at B-03
No. 4) throttle position sensor connector and throttle position sensor connector.
C-119 (terminal No. 49) engine-ECU connector. Connector : B-03
Connector : B-03
B-03(B)
B-03(B)
4 3 2 1
4 3 2 1 Harness side
Harness side connector AK305010 AB
Connector: C-119
<L. H. drive vehicles> • Voltage between terminal No. 1 and earth.
OK: 4.9 − 5.1 V
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
STEP 14. Connector check: C-119 engine-ECU STEP 15. Perform voltage measurement at B-03
connector throttle position sensor connector.
Connector: C-119 Connector : B-03

B-03(B)
4 3 2 1
Harness side
C-119 (GR) • Use special tool test harness (MB991536) to con-

OK: 0.5 V or less
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
Connector : B-03
B-03(B)
4 3 2 1
Harness side

TROUBLESHOOTING
13A-67
STEP 16. Connector check: C-119 engine-ECU STEP 17. Perform voltage measurement at B-03
connector throttle position sensor connector.

B-03(B)
4 3 2 1
Harness side
C-119 (GR) • Use special tool test harness (MB991536) to con-

OK:
Accelerator pedal fully released: 0.536 − 0.735
V
Accelerator pedal fully depressed: 4.5 − 5.0 V
C-119 (GR) YES : Go to Step 20 .
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
Harness side connector STEP 18. Adjust throttle position sensor
AK501994 AB • Adjust throttle position sensor (Refer to
Connector : B-03
P.13A-395).
Q: Is the adjusted value normal?
B-03(B) YES : Go to Step 19 .
NO : Adjust throttle position sensor.
4 3 2 1
Harness side

TROUBLESHOOTING
STEP 19. Connector check: C-117 engine-ECU STEP 20. Perform voltage measurement at C-117
connector engine-ECU connector
C-117 (GR) C-117 (GR)
C-117 (GR) C-117 (GR)

77 76 75 74 73 72 71 77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78 90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91 100 99 98 97 96 95 94 93 92 91
AK501996 AB AK501996 AB
Connector : B-03
B-03(B)
OK:
Accelerator pedal fully released: 0.536 − 0.735
V
Accelerator pedal fully depressed: 4.5 − 5.0 V
4 3 2 1 Q: Is the check result normal?
Harness side YES : Go to Step 22 .
connector AK305010 AB NO : Go to Step 21 .

• Check output line for short circuit and
damage.
TROUBLESHOOTING
13A-69
connector connector
C-117 (GR) C-117 (GR)
C-117 (GR) C-117 (GR)

77 76 75 74 73 72 71 77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78 90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91 100 99 98 97 96 95 94 93 92 91
AK501996 AB AK501996 AB

4 3 2 1
Harness side

damage.
TROUBLESHOOTING
Code No. P0125: Feedback system monitor
OPERATION • Failed fuel system

• Refer to P0201 injector circuit P.13A-105. • Failed exhaust system
Refer to P0202 injector circuit P.13A-111. • Failed engine-ECU
Refer to P0203 injector circuit P.13A-117.
Refer to P0204 injector circuit P.13A-123. DIAGNOSIS PROCEDURE
• Refer to P0130 Oxygen sensor (front) circuit
P.13A-75. STEP 1. M.U.T.-II/III diagnosis code
FUNCTION Q: Is any other diagnosis code than P0125 output?
YES : Inspection chart for diagnosis code (Refer
• The engine-ECU effects air-fuel ratio feedback
to P.13A-17).
control in accordance with the signals from the
NO : Go to Step 2 .
oxygen sensor (front).
• If the heated oxygen sensor (front) has deterio-
rated, corrections will be made by the oxygen STEP 2. M.U.T.-II/III data list
sensor (rear). • Refer to Data List Reference Table P.13A-372.
• Diagnosis code P0125 becomes stored in mem- a. Item No. 12: Air flow sensor
ory if a failure is detected in the above air-fuel b. Item No. 21: Engine coolant temperature sensor
ratio feedback control system. c. Item No. 25: Barometric pressure sensor
d. Item No. 59: Oxygen sensor (rear)
TROUBLE JUDGMENT
Q: Are the check results normal?
Check Conditions YES : Go to Step 3 .
• The engine coolant temperature is approximately NO : Perform the diagnosis code classified check
76°C or more. procedure for the sensor that has shown an
• Within the range of air-fuel ratio feedback opera- abnormal data valve (Refer to Inspection
tion. Chart for Diagnosis Codes P.13A-17).
• Not in slowing down operation.
Judgment Criterion STEP 3. Check for intake of air from intake hose
• The oxygen sensor output voltage is not deviated and inlet manifold.
from 0.5 V for 30 seconds.
PROBABLE CAUSES
NO : Repair.
• Failed oxygen sensor (front)
• Harness damage in oxygen sensor (front) circuit
or loose connector contact STEP 4. Check for leakage of exhaust emission
• Failed oxygen sensor (rear) from exhaust manifold.
NOTE: When the oxygen sensor (front) begins to Q: Is the check result normal?
deteriorate, the oxygen sensor output voltage will YES : Go to Step 5 .
deviate from the voltage when the sensor was new NO : Repair.
(normally 0.5 volt at stoichiometric ratio). This devia-
tion will be corrected by the oxygen sensor (rear). If STEP 5. Check throttle body (throttle valve
the oxygen sensor (rear) responds poorly because it portion) for contamination.
has deteriorated, it will improperly correct the oxygen
sensor (front). Thus, even when closed loop control Q: Is the check result normal?
is being effected, the fluctuation of the oxygen sen- YES : Go to Step 6 .
NO : Clean throttle body (throttle valve portion)
sor (front) output voltage decreases, without inter-
(Refer to P.13A-395).
secting with 0.5 volt. As a result, there is a possibility
of diagnosis code P0125 becoming registered.
TROUBLESHOOTING
13A-71
STEP 6. Connector check: B-113 oxygen sensor Connector: C-117, C-119
(front) connector, C-117 and C-119 engine-ECU
connector
Connector : B-113
C-117 (GR)
C-119 (GR)
Oxygen sensor(front)
2 1 C-117 (GR) C-119 (GR)

B-113(B)
4 3
77 76 75 74 73 72 71
Harness side 90 89 88 87 86 85 84 83 82 81 80 79 78
connector 100 99 98 97 96 95 94 93 92 91
AK305011AB
C-117 Harness side connector
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501997 AB

STEP 7. Check oxygen sensor (front) itself.

• Check oxygen sensor (front) itself (Refer to
P.13A-404).
NO : Replace the oxygen sensor (front).
TROUBLESHOOTING
STEP 8. Check harness between B-113 oxygen STEP 9. Connector check: Injector connector
sensor (front) connector and C-117 engine-ECU Connector : B-17,B-18,B-20,B-22
connector.
Connector : B-113
B-22(B) B-20(B) B-18(B) B-17(B)
2 1
Oxygen sensor(front) Harness side connector AK305012 AB
a. B-22 (No. 1 injector connector)

b. B-20 (No. 2 injector connector)
c. B-18 (No. 3 injector connector)
d. B-17 (No. 4 injector connector)
2 1
4 3
B-113(B) STEP 10. Check injector itself.
Harness side • Check Injector itself (Refer to P.13A-406).
connector
Connector: C-117 NO : Replace the injector.
C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB
• Check output line for damage.
TROUBLESHOOTING
13A-73
STEP 11. Connector check: B-12X engine control STEP 12. Check harness between B-12X engine
relay connector and C-119 engine-ECU control relay connector and injector connector.
connector.
Relay box’s triangle marks
Connector : B-12X
triangle marks
2 1
B-12X
2 1 4 3
B-12X
4 3 Harness side
connector
AK305003 AB
AK305003 AB
Connector : B-17,B-18,B-20,B-22
Connector: C-119
B-22(B) B-20(B) B-18(B) B-17(B)
2 1
NOTE: Before checking harness, check intermediate

C-119 (GR) connector C-105, and repair if necessary.
<R. H. drive vehicles> a. Check harness between B-12X (terminal No. 4)
engine control relay connector and B-22 (terminal
No. 1) No. 1 injector connector.
b. Check harness between B-12X (terminal No. 4)
c. Check harness between B-12X (terminal No. 4)
C-119 (GR) No. 1) No. 3 injector connector.
47 46 45 44 43 42 41 d. Check harness between B-12X (terminal No. 4)
59 58 57 56 55 54 53 52 51 50 49 48 engine control relay connector and B-17 (terminal
68 67 66 65 64 63 62 61 60
AK501994 AB • Check power supply line for damage.
Q: Is the check result normal? Q: Are the check results normal?

NO : Repair or replace the connector. NO : Repair the damaged harness wire.
TROUBLESHOOTING

STEP 13. Check harness between injector
connector and C-121 engine-ECU connector. NO : Repair the damaged harness wire.
STEP 14. Fuel pressure measurement.

• Fuel pressure measurement (Refer to
B-22(B) B-20(B) B-18(B) B-17(B) P.13A-396).
YES : Replace the engine-ECU.
NO : Repair.
2 1
Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
a. Check harness between B-22 (terminal No. 2)

No. 1 injector connector and C-121 (terminal No.
b. Check harness between B-20 (terminal No. 2)
c. Check harness between B-18 (terminal No. 2)
d. Check harness between B-17 (terminal No. 2)
TROUBLESHOOTING
13A-75
Code No. P0130: Oxygen Sensor (front) System
Oxygen sensor (front) circuit
B-113
MU802605
1 2
3 4 Oxygen sensor (front)
1 3 2 4
From Engine control relay
To engine-ECU
B W
C-119 49 71 C-117
(MU803782) (MU803783)
41 42 43 44 45 46 47 71 72 73 74 75 76 77
48 49 50 51 52 53 54 55 56 57 58 59 78 79 80 81 82 83 84 85 86 87 88 89 90
60 61 62 63 64 65 66 67 68 91 92 93 94 95 96 97 98 99 100
Engine-ECU
Wire colour code
AK501805 AB

• The sensor signal is inputted to the engine-ECU
Check Conditions
(terminal No. 71) from the oxygen sensor (front)
• After 3 or more minutes from when the engine
output terminal (terminal No. 4).
has started up.
• The oxygen sensor (front) (terminal No. 2) is
• Engine coolant temperature approximately 80°C
earthed with engine-ECU (terminal No. 49).
or more.
FUNCTION • Volumetric efficiency 25% or more.
• Engine speed of 1,200 r/min. or more.
• The oxygen sensor (front) converts the concen-
tration of oxygen in the exhaust emission into a Judgment Criterion
voltage and inputs the signal to the engine-ECU. • When the oxygen sensor (front) output voltage is
• When the air-fuel ratio is richer than the theoreti- 0.2 V or less, and a power voltage of 5 V is
cal air-fuel ratio, the oxygen sensor (front) out- applied to the oxygen sensor (front) in the
puts a voltage of about 1 V. When it is leaner than engine-ECU, the sensor output voltage is 4.5 V or
the theoretical air-fuel ratio, it outputs a voltage of more.
about 0 V.
• In response to the signal, the engine-ECU con- PROBABLE CAUSES
trols the fuel infection amount so that the air-fuel • Failed oxygen sensor (front)
ratio can be equivalent to the theoretical air-fuel • Open/short circuit in oxygen sensor (front) circuit
ratio. or loose connector contact
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Perform resistance measurement at

B-113 oxygen sensor (front) connector
STEP 1. M.U.T.-II/III data list Connector : B-113
a. Item No. 11: Oxygen sensor (front)
00 − How to Use
P.00-5). Oxygen sensor(front)
NO : Go to Step 2 .
STEP 2. Connector check: B-113 oxygen sensor

(front) connector
Connector : B-113
2 1
B-113(B)
4 3
Harness side
connector
AK305011AB
side.
OK: 2 Ω or less
NO : Go to Step 4 .
2 1
B-113(B)
4 3
Harness side
connector
AK305011AB

TROUBLESHOOTING
13A-77
connector No. 2) oxygen sensor connector and C-119
Connector: C-119
Connector : B-113
C-119 (GR)
2 1
B-113(B)
4 3
connector
AK305011AB
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 Connector: C-119
AK501994 AB <L. H. drive vehicles>

C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
TROUBLESHOOTING

Connector: C-119
00 − How to Use
P.00-5).

oxygen sensor (front) connector.
C-119 (GR)
Connector : B-113
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
Connector : B-113
2 1
B-113(B)
4 3
Harness side
connector
AK305011AB
• Use special tool test harness (MD998464) to con-

nect connector, and measure at pick-up harness. Oxygen sensor(front)
• Engine: After warm-up
OK: 0.5 V or less
NO : Go to Step 8 .
2 1
B-113(B)
4 3
Harness side
connector
AK305011AB
TROUBLESHOOTING
13A-79
connector
(terminal No. 2) oxygen sensor (front)
connector and C-119 (terminal No. 49) Connector: C-117
engine-ECU connector. <L. H. drive vehicles>

oxygen sensor (front) connector.
Connector : B-113
C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB
2 1
B-113(B)
4 3 Connector : B-113
Harness side
connector
AK305011AB

OK: Oxygen sensor(front)
600 − 1,000 mV when 200 mV or lower abrupt
racing is done a few seconds after abrupt
deceleration from 4,000 r/min.
STEP 10. Check oxygen sensor (front) itself

2 1
• Check oxygen sensor itself (Refer to P.13A-404). B-113(B)
4 3
Q: Is the check result normal? Harness side
YES : Go to Step 11 . connector
AK305011AB
TROUBLESHOOTING

connector

Connector: C-117
C-117 (GR)
C-117 (GR)
<R. H. drive vehicles> C-117 (GR)

77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB
Connector : B-113
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB
• Measure engine-ECU terminal voltage. Oxygen sensor(front)

OK:
2 1
YES : Go to Step 14 . B-113(B)
NO : Go to Step 13 . 4 3
Harness side
connector
AK305011AB
TROUBLESHOOTING
13A-81
connector
C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB

TROUBLESHOOTING
Code No. P0135: Oxygen Sensor Heater (front) System
Oxygen sensor heater (front) circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2 Oxygen sensor (front) B-113
B-12X
MU802605
1 2 Engine
control
3 4 relay 1 2
3 4
4 3
To engine-ECU 1 3 2 4
To engine-ECU
R-Y
L-R
3
C-121
(MU803783)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
Engine-ECU
NOTE
Wire colour code
AK501806 AB
OPERATION • The heater (terminal No. 3) of the oxygen sensor

• Power is supplied to the heater power terminal (front) connector is controlled by the power tran-
(terminal No. 1) of the oxygen sensor (front) con- sistor in the engine-ECU (terminal No. 3).
nector from the engine control relay (terminal No.
4).
TROUBLESHOOTING
13A-83
FUNCTION DIAGNOSIS PROCEDURE
• The power supply to the oxygen sensor heater
(front) is controlled by the ON/OFF control of the STEP 1. Connector check: B-113 oxygen sensor
power transistor in the engine-ECU. (front) connector
• Heating the oxygen sensor heater (front) enables
the oxygen sensor to provide good response Connector : B-113
even when the exhaust emission temperature is
low.
TROUBLE JUDGMENT
Check Conditions
• The engine coolant temperature is 20°C or
higher.
• The oxygen sensor heater: (front) is ON.
• The engine speed of 50 r/min. or more.
• A/C relay: OFF
• Radiator fan: OFF
• The system voltage is 11 − 16 V.
Judging Criterion
• The heater current of oxygen sensor heater
(front) 0.2 A or less or 3.5 A or more for 4 sec-
2 1
onds. B-113(B)
4 3
PROBABLE CAUSES Harness side

connector
• Failed oxygen sensor heater (front) AK305011AB
• Open/short circuit in oxygen sensor heater (front) Q: Is the check result normal?
circuit or loose connector contact YES : Go to Step 2 .
• Failed engine-ECU NO : Repair or replace the connector.
STEP 2. Perform resistance measurement at • Disconnect connector, and measure at sensor

B-113 oxygen sensor (front) connector. side.
Connector : B-113
OK: 4.5 − 8.0 Ω
2 1
B-113(B)
4 3
Harness side
connector
AK305011AB
TROUBLESHOOTING
STEP 3. Perform voltage measurement at B-113 STEP 4. Connector check: B-12X engine control
oxygen sensor (front) connector. relay connector
Connector : B-113 Connector : B-12X Relay box’s
triangle marks
2 1
B-12X
4 3
Harness side
Oxygen sensor(front) connector
AK305003 AB
Connector : B-113
2 1
B-113(B)
4 3 Oxygen sensor(front)
Harness side
connector
AK305011AB

side.
OK: System voltage
YES : Go to Step 5 . 2 1
B-113(B)
NO : Go to Step 4 . 4 3
Harness side
connector
AK305011AB

connector and B-12X (terminal No. 4)
engine control relay connector.
open/short circuit.
TROUBLESHOOTING
13A-85
C-121 (GR) C-121 (GR)

C-121 (GR) C-121 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB AK501995 AB

• Ignition switch: "ON" YES : Go to Step 7 .
• Voltage between terminal No. 3 and earth. NO : Repair or replace the connector.
OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING

STEP 7. Check harness between B-113 (terminal
No. 3) oxygen sensor connector and C-121 NO : Repair the damaged harness wire.
Connector : B-113
connector
Connector: C-121
C-121 (GR)
2 1
B-113(B)
4 3
Harness side
connector
AK305011AB
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
• Check earthing line for open/short circuit.

TROUBLESHOOTING
13A-87
No. 1) oxygen sensor (front) connector and No. 3) oxygen sensor (front) connector and C-121
B-12X (terminal No. 4) engine control relay (terminal No. 3) engine-ECU connector.
connector. Connector : B-113
Connector : B-113
2 1
2 1 B-113(B)
4 3
B-113(B) Harness side
4 3
AK305011AB
connector
AK305011AB
Connector: C-121
triangle marks <L. H. drive vehicles>
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING

STEP 11. Check the trouble symptoms.
NO : Repair the damaged harness wire. Q: Does trouble symptom persist?
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
P.00-5).
Code No. P0136: Oxygen Sensor (rear) System
Oxygen sensor (rear) circuit
C-137
MU801446
1 2 3 4 Oxygen sensor (rear)
3 4 2 1
From engine control relay
To engine-ECU
B W
C-119 49 73 C-117
(MU803782) (MU803783)
41 42 43 44 45 46 47 71 72 73 74 75 76 77
48 49 50 51 52 53 54 55 56 57 58 59 78 79 80 81 82 83 84 85 86 87 88 89 90
60 61 62 63 64 65 66 67 68 91 92 93 94 95 96 97 98 99 100
Engine-ECU
Wire colour code

AK501807AB
OPERATION FUNCTION
• The sensor signal is inputted to the engine-ECU • The oxygen sensor (rear) converts the concentra-
(terminal No. 73) from the oxygen sensor (rear) tion of oxygen in the exhaust emission into a volt-
output terminal (terminal No. 1). age signal and inputs the voltage signal to the
• The oxygen sensor (rear) (terminal No. 2) is engine-ECU.
earthed with engine-ECU (terminal No. 49).
TROUBLESHOOTING
13A-89
• When the air-fuel ratio is richer than the theoreti- STEP 2. Connector check: C-137 oxygen sensor
cal air-fuel ratio, the oxygen sensor (rear) outputs (rear) connector
a voltage of about 1 V. When it is leaner than the
theoretical air-fuel ratio, it outputs a voltage of Connector : C-137
about 0 V.
C-137
• In response to the signal, the engine-ECU con-
trols the fuel infection amount so that the air-fuel
ratio can be equivalent to the theoretical air-fuel
ratio.
Oxygen sensor(rear)
TROUBLE JUDGMENT 4 3 2 1
Harness side
Check Conditions connector AK305013AB
• Above 3 minutes later after the engine has
started up. Q: Is the check result normal?
• The engine coolant temperature is 80°C or YES : Go to Step 3 .
higher. NO : Repair or replace the connector.
• The volumetric efficiency is 25% or more.
• The engine speed is 1,200 r/min. or more. STEP 3. Perform resistance measurement at
Judgment Criterion C-137 oxygen sensor (rear) connector.
• When the oxygen sensor (rear) output voltage is Connector : C-137
0.2 V or less, and a power voltage of 5 V is
applied to the oxygen sensor (rear) in the C-137
engine-ECU, the sensor output voltage is 4.5 V or
more.
PROBABLE CAUSES Oxygen sensor(rear)

• Failed oxygen sensor (rear) 4 3 2 1
• Open/short circuit in oxygen sensor (rear) circuit Harness side
or loose connector contact connector AK305013AB
DIAGNOSIS PROCEDURE side.
OK: 2 Ω or less
• Refer to Data List Reference Table P.13A-372. Q: Is the check result normal?
a. Item No. 59: Oxygen sensor (rear)
NO : Go to Step 4 .
00 − How to Use
P.00-5).
NO : Go to Step 2 .
TROUBLESHOOTING
STEP 4. Connector check: C-119 engine-ECU STEP 5. Check harness between C-137 (terminal
connector No. 2) oxygen sensor (rear) connector and C-119
Connector: C-119
Connector : C-137
C-137
Oxygen sensor(rear)
4 3 2 1
Harness side
C-119 (GR)

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 C-119 (GR)
68 67 66 65 64 63 62 61 60
AK501994 AB

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
13A-91
a. Item No. 59: Oxygen sensor (rear)
Connector: C-119
00 − How to Use
P.00-5).

oxygen sensor (rear) connector.
C-119 (GR)
Connector : C-137
C-137
Oxygen sensor(rear)
4 3 2 1
Harness side
connector AK305013AB C-119 (GR)
• Use special tool test harness (MB991658) to con- 47 46 45 44 43 42 41

59 58 57 56 55 54 53 52 51 50 49 48
nect connector, and measure at pick-up harness. 68 67 66 65 64 63 62 61 60
• Engine: After warm-up Harness side connector
• Ignition switch: "ON" AK501994 AB

Connector : C-137
OK: 0.5 V or less
Q: Is the check result normal? C-137
NO : Go to Step 8 .
Oxygen sensor(rear)
4 3 2 1
Harness side

YES : Check and repair harness between C-137
(terminal No. 2) oxygen sensor (rear)
TROUBLESHOOTING
oxygen sensor (rear) connector. connector
Connector : C-137 Connector: C-117
C-137 <L. H. drive vehicles>
Oxygen sensor(rear)
4 3 2 1
Harness side

OK:
YES : Go to Step 12 . C-117 (GR)
NO : Go to Step 10 . 77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
STEP 10. Check oxygen sensor (rear) itself Harness side connector
• Check oxygen sensor (rear) itself (Refer to AK501996 AB
P.13A-404). Connector : C-137

YES : Go to Step 11 . C-137
NO : Replace the oxygen (rear) sensor.
Oxygen sensor(rear)
4 3 2 1
Harness side

TROUBLESHOOTING
13A-93
C-117 (GR) C-117 (GR)
C-117 (GR) C-117 (GR)

77 76 75 74 73 72 71 77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78 90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91 100 99 98 97 96 95 94 93 92 91
AK501996 AB AK501996 AB
• Measure engine-ECU terminal voltage. Connector : C-137

• Engine: After warm-up C-137
OK:
racing is done a few seconds after abrupt Oxygen sensor(rear)
deceleration from 4,000 r/min. 4 3 2 1
connector
YES : Go to Step 14 . AK305013AB
TROUBLESHOOTING

connector
Connector: C-117
C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB

TROUBLESHOOTING
13A-95
Code No. P0141: Oxygen Sensor Heater (rear) System
Oxygen sensor heater (rear) circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2 Oxygen sensor (rear)
B-12X C-137
MU801446
1 2 Engine
control
3 4 relay
1 2 3 4
4 3
To engine-ECU 3 4 2 1
R-Y
To engine-ECU
28
R-Y
J/C (6)
C-105
29
L-Y
26
C-121
(MU803783)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
Engine-ECU
NOTE
Wire colour code
AK501808 AB
OPERATION • The heater (terminal No. 4) of the oxygen sensor

• Power is supplied to the heater power terminal (rear) connector is controlled by the power tran-
(terminal No. 3) of the oxygen sensor (rear) con- sistor in the engine-ECU (terminal No. 26).
nector from the engine control relay (terminal No.
4).
TROUBLESHOOTING
FUNCTION STEP 2. Perform resistance measurement at

• The power supply to the oxygen sensor heater C-137 oxygen sensor (rear) connector.
(rear) is controlled by the ON/OFF control of the
Connector : C-137
power transistor in the engine-ECU.
• Heating the oxygen sensor heater (rear) enables C-137
the oxygen sensor to provide good response
even when the exhaust emission temperature is
low.
Oxygen sensor(rear)
TROUBLE JUDGMENT
4 3 2 1
Check Conditions Harness side
• The engine coolant temperature is 20°C or connector AK305013AB
higher.
• Disconnect connector, and measure at sensor
• The oxygen sensor heater (rear) is ON.
side.
• The engine speed is 50 r/min. or more.
• A/C relay: OFF
• Radiator fan: OFF OK: 11 − 18 Ω
• The system voltage is 11 − 16 V. Q: Is the check result normal?
Judgment Criterion
NO : Replace the oxygen (rear) sensor.
• The heater current of oxygen sensor (rear) heater
0.2 A or less or 3.5 A or more for 4 seconds.
PROBABLE CAUSES oxygen sensor (rear) connector.
• Failed oxygen sensor heater (rear) Connector : C-137
• Open/short circuit in oxygen sensor (rear) circuit
or loose connector contact C-137
DIAGNOSIS PROCEDURE
Oxygen sensor(rear)
4 3 2 1
STEP 1. Connector check: C-137 oxygen sensor
(rear) connector Harness side
Connector : C-137
C-137 side.
OK: System voltage
Oxygen sensor(rear)
4 3 2 1
Harness side NO : Go to Step 4 .

TROUBLESHOOTING
13A-97
STEP 4. Connector check: B-12X engine control STEP 5. Perform voltage measurement at C-121
relay connector engine-ECU connector.
Connector : B-12X Relay box’s Connector: C-121
triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
Connector : C-137 C-121 (GR)

C-137
Oxygen sensor(rear)
4 3 2 1
Harness side
Q: Is the check result normal? 8 7 6 5 4 3 2 1

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
YES : Check intermediate connector C-105, and 35 34 33 32 31 30 29 28 27 26 25 24
repair if necessary. If intermediate Harness side connector
connector are normal, check and repair AK501995 AB
harness between C-137 (terminal No. 3) • Measure engine-ECU terminal voltage.

oxygen sensor (rear) connector and B-12X • Ignition switch: "ON"
(terminal No. 4) engine control relay • Voltage between terminal No. 26 and earth.
connector. OK: System voltage
open/short circuit.
NO : Go to Step 6 .
TROUBLESHOOTING
connector No. 4) oxygen sensor connector and C-121
Connector: C-121
Connector : C-137
C-137
Oxygen sensor(rear)
4 3 2 1
Harness side
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
13A-99
connector No. 3) oxygen sensor (rear) connector and B-12X
Connector: C-121
Connector : C-137
C-137
Oxygen sensor(rear)
4 3 2 1
Harness side
C-121 (GR)
<R. H. drive vehicles> Connector : B-12X Relay box’s
triangle marks
2 1
B-12X
4 3
Harness side
connector
C-121 (GR)
AK305003 AB
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 NOTE: Before checking harness, check intermediate
Harness side connector connector C-105, and repair if necessary.
AK501995 AB • Check power supply line for damage.
NO : Repair or replace the connector. NO : Repair the damaged harness wire.
TROUBLESHOOTING
STEP 10. Check harness between C-137 (terminal STEP 11. Check the trouble symptoms.
No. 4) oxygen sensor (rear) connector and C-121 Q: Does trouble symptom persist?
(terminal No. 26) engine-ECU connector. YES : Replace the engine-ECU.
Connector : C-137 NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
C-137 Troubleshooting/Inspection Service Points
P.00-5).
Oxygen sensor(rear)
4 3 2 1
Harness side
Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
13A-101
Code No. P0170: Abnormal Fuel System
OPERATION STEP 2. M.U.T.-II/III data list

• Refer to P0201 injector circuit P.13A-105. • Refer to Data List Reference Table P.13A-372.
• Refer to P0202 injector circuit P.13A-111. a. Item No. 12: Air flow sensor
• Refer to P0203 injector circuit P.13A-117. b. Item No. 13: Intake air temperature sensor
• Refer to P0204 injector circuit P.13A-123.
c. Item No. 21: Engine coolant temperature sen-
FUNCTION sor
• If the fuel system goes out of order, the fuel cor- d. Item No. 22: Barometric pressure sensor
rection value will become larger. Q: Are the check results normal?
• The engine-ECU checks whether the fuel correc- YES : Go to Step 3 .
tion value is within the standard limits. NO : Perform the diagnosis code classified check
procedure for the sensor that has shown an
TROUBLE JUDGMENT abnormal data value (Refer to Inspection
Chart for Diagnosis Codes P.13A-17).
Check Condition
• In learning air-fuel ratio
STEP 3. Check for intake of air from intake hose
Judgment Criteria and intake manifold.
• Fuel injection amount correction value remains
unusually low for more than 5 seconds. Q: Is the check result normal?
or YES : Go to Step 4 .
• Fuel injection amount correction value remains NO : Repair.
unusually high for more than 5 seconds.
STEP 4. Check for leakage of exhaust emission
PROBABLE CAUSES from exhaust manifold.
• Failed fuel supply system
• Failed oxygen sensor (front)
• Failed intake air temperature sensor NO : Repair.
• Failed air flow sensor
• Failed purge control solenoid valve
• Failed engine-ECU STEP 5. Check throttle body (throttle valve
portion) for contamination.
DIAGNOSIS PROCEDURE Q: Is the check result normal?
STEP 1. M.U.T.-II/III diagnosis code
Q: Is any other diagnosis code than P0170 output?
YES : Inspection Chart for Diagnosis Code (Refer
to P.13A-17). STEP 6. M.U.T.-II/III data list
NO : Go to Step 2 . • Refer to Data List Reference Table P.13A-372.
NO : Check oxygen sensor (front) system (Refer
to Code No. P0130 P.13A-75).
TROUBLESHOOTING
STEP 7. Connector Check: Injector connector STEP 9. Connector check: B-12X engine control
relay connector and C-119 engine-ECU
connector
triangle marks
B-22(B) B-20(B) B-18(B) B-17(B)
2 1
B-12X
4 3
2 1 Harness side
Harness side connector AK305012 AB connector
a. B-22 (No. 1 injector connector).

AK305003 AB
b. B-20 (No. 2 injector connector).
c. B-18 (No. 3 injector connector). Connector: C-119
d. B-17 (No. 4 injector connector). <L. H. drive vehicles>
STEP 8. Check injector itself.

• Check Injector itself (Refer to P.13A-406).
NO : Replace the injector.
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
13A-103
STEP 10. Check harness between B-12X engine STEP 11. Check harness between injector
control relay connector and injector connector. connector and C-121 engine-ECU connector.
Connector : B-12X Relay box’s Connector : B-17,B-18,B-20,B-22
triangle marks
2 1 B-22(B) B-20(B) B-18(B) B-17(B)

B-12X
4 3
Harness side
connector
2 1
AK305003 AB Harness side connector AK305012 AB
Connector : B-17,B-18,B-20,B-22 Connector: C-121

B-22(B) B-20(B) B-18(B) B-17(B)
2 1
NOTE: Before checking harness, check intermediate C-121 (GR)

connector C-105, and repair if necessary. <R. H. drive vehicles>
a. Check harness between B-12X (terminal No. 4)
b. Check harness between B-12X (terminal No. 4)
c. Check harness between B-12X (terminal No. 4)
engine control relay connector and B-18 (terminal C-121 (GR)
No. 1) No. 3 injector connector. 8 7 6 5 4 3 2 1
d. Check harness between B-12X (terminal No. 4) 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
No. 1) No. 4 injector connector. AK501995 AB
Q: Are the check results normal? No. 1 injector connector and C-121 (terminal No.
YES : Go to Step 11 . 1) engine-ECU connector.
NO : Repair the damaged harness wire. b. Check harness between B-20 (terminal No. 2)
TROUBLESHOOTING
STEP 12. Check purge control solenoid valve STEP 13. Fuel pressure measurement
itself. • Fuel pressure measurement (Refer to
• Check purge control solenoid valve itself (Refer P.13A-396).
to GROUP 17 − Emission Control System −
Evaporative Emission Control System P.17-11).
Q: Is the check result normal? NO : Repair.
NO : Replace the purge control solenoid valve.
TROUBLESHOOTING
13A-105
Code No. P0201: No. 1 Injector System
Injector circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
R-Y
28 To engine-ECU
J/C (6)
C-105
29
R-Y
B-119 3
MU802607 Injector resistor
1 2 3
4 5 6
1 4 5 6
R R-W R-L R-B
1 1 1 1
Injector Injector Injector Injector
No.1 No.2 No.3 No.4
B-22 B-20 B-18 B-17
MU802722 (MU802722) (MU802722) (MU802722)
1 2 1 2 1 2 1 2
2 2 2 2
O W-R G R
1 9 24 2
C-121
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
NOTE
*1: L.H. drive vehicles Engine-ECU
Wire colour code
AK501809AB
TROUBLESHOOTING
OPERATION STEP 2. Connector check: B-22 No. 1 injector

• Power is supplied to the injector (terminal No. 1) connector
from the engine control relay (terminal No. 4) via
Connector : B-22
the injector resistor.
• 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 (termi- B-22(B)
nal No. 2).
FUNCTION
• The engine-ECU controls the power supply inter-
2 1
val of the injector.
• The fuel injection amount of the injector depends AK305012 AC
on the power supply interval. Q: Is the check result normal?

Check Conditions
• The engine speed is 50 − 1,000 r/min. STEP 3. Perform resistance measurement at B-22
• The throttle position sensor output voltage is 1.15 No. 1 injector connector.
V or less.
Connector : B-22
• Injector not in forced drive (actuator test) mode.
Judgment Criterion
• No surge voltage of the injector detected for 2
seconds. B-22(B)
PROBABLE CAUSES
• Failed No. 1 injector
• Open/short circuit in injector circuit or loose con- 2 1
nector contact Harness side connector AK305012 AC
• Failed engine-ECU • Disconnect connector, and measure at injector
side.
DIAGNOSIS PROCEDURE • Resistance between terminal No. 1 and No. 2.
OK: 2 − 3 Ω
• Item No. 01: No. 1 injector YES : Go to Step 4 .
OK: Idling state varies. NO : Replace the No. 1 injector.
00 − How to Use
P.00-5).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-107
No. 1 injector connector. No. 1) injector resistor connector and B-22
Connector : B-22
(terminal No. 1) No. 1 injector connector.
Connector : B-119
B-22(B)
2 1
Harness side connector AK305012 AC
B-119(B)
side.
OK: System voltage
NO : Go to Step 5 . 3 2 1
6 5 4
Harness side
STEP 5. Connector check: B-12X engine control connector AK305016AB
relay connector
Connector : B-12X Relay box’s Connector : B-22
triangle marks
2 1 B-22(B)
B-12X
4 3
Harness side
connector
2 1
AK305003 AB Harness side connector AK305012 AC
Q: Is the check result normal? Connector : B-12X Relay box’s

YES : Go to Step 6 . triangle marks
2 1
STEP 6. Check injector resistor itself. B-12X
• Check injector resistor itself (Refer to 4 3
P.13A-407). Harness side
connector
NO : Replace the injector resistor.
• Check power supply line for open/short circuit.
TROUBLESHOOTING

YES : Check intermediate connector C-105, and
No. 3) injector resistor connector and B-12X
repair if necessary. If intermediate
connector are normal, check and repair
harness between B-119 (terminal No. 3) Connector : B-119
injector resistor connector and B-12X <L.H.drive vehicles>
(terminal No. 4) engine control relay
connector.
open/short circuit.
STEP 8. Check harness between B-119 (terminal B-119(B)

No. 1) injector resistor connector and B-22
(terminal No. 1) No. 1 injector connector. <R.H.drive vehicles>
Connector : B-119
B-119(B)
3 2 1
6 5 4
Harness side
B-119(B)
<R.H.drive vehicles> triangle marks
2 1
B-12X
B-119(B) 4 3
Harness side
3 2 1 connector
6 5 4
Harness side AK305003 AB
Connector : B-22 connector C-105, and repair if necessary.
B-22(B) NO : Repair the damaged harness wire.
2 1

TROUBLESHOOTING
13A-109
connector No. 2) No. 1 injector connector and C-121
Connector: C-121
Connector : B-22
B-22(B)
2 1
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
• Check output line for open/short circuit and dam-

age.
TROUBLESHOOTING
STEP 12. Perform signal wave pattern

measurement at C-121 engine-ECU connector
(Using an oscilloscope).
Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
• Engine: Idling
OK: Waveforms should be display on
Inspection procedure using an oscilloscope
00 − How to Use
P.00-5).
TROUBLESHOOTING
13A-111
Injector circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
R-Y
28 To engine-ECU
J/C (6)
C-105
29
R-Y
B-119 3
1 2 3
4 5 6
1 4 5 6
R R-W R-L R-B
1 1 1 1
No.1 No.2 No.3 No.4
B-22 B-20 B-18 B-17
MU802722 (MU802722) (MU802722) (MU802722)
1 2 1 2 1 2 1 2
2 2 2 2
O W-R G R
1 9 24 2
C-121
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501809AB
TROUBLESHOOTING

Connector : B-20
nal No. 2).
FUNCTION
2 1
• The fuel injection amount of the injector depends AK305012 AD

Check Conditions
• The engine speed is 50 − 1,000 r/min. STEP 3. Perform resistance measurement B-20
V or less.
Connector : B-20
Judgment Criterion
seconds. B-20(B)
PROBABLE CAUSES
• Open/short circuit in No. 2 injector circuit or loose 2 1
connector contact Harness side connector AK305012 AD
side.
OK: 2 − 3 Ω
00 − How to Use
P.00-5).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-113
Connector : B-20
Connector : B-119
B-20(B)
2 1
Harness side connector AK305012 AD
B-119(B)
side.
OK: System voltage
6 5 4
Harness side
relay connector
triangle marks
2 1 B-20(B)
B-12X
4 3
Harness side
connector
2 1
AK305003 AB Harness side connector AK305012 AD

2 1
• Check injector resistor itself (Refer to P.13A-407) 4 3
Harness side
Q: Is the check result normal? connector
AK305003 AB

TROUBLESHOOTING

connector.
open/short circuit.

Connector : B-119
B-119(B)
3 2 1
6 5 4
Harness side
B-119(B)
2 1
B-12X
B-119(B) 4 3
Harness side
3 2 1 connector
6 5 4
2 1

TROUBLESHOOTING
13A-115
Connector: C-121
Connector : B-20
B-20(B)
2 1
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
• Check output line for open/short circuit or dam-

age.
TROUBLESHOOTING

Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
• Engine: Idling
OK: Waveform should be display on Inspec-
tion procedure using an oscilloscope (Refer
to P.13A-385).
00 − How to Use
P.00-5).
TROUBLESHOOTING
13A-117
Injector circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
R-Y
28 To engine-ECU
J/C (6)
C-105
29
R-Y
B-119 3
1 2 3
4 5 6
1 4 5 6
R R-W R-L R-B
1 1 1 1
No.1 No.2 No.3 No.4
B-22 B-20 B-18 B-17
MU802722 (MU802722) (MU802722) (MU802722)
1 2 1 2 1 2 1 2
2 2 2 2
O W-R G R
1 9 24 2
C-121
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501809AB
TROUBLESHOOTING

Connector : B-18
nal No. 2).
FUNCTION
2 1
• The fuel injection amount of the injector depends AK305012 AE

Check Conditions
V or less.
Connector : B-18
Judgment Criterion
seconds. B-18(B)
PROBABLE CAUSES
connector contact Harness side connector AK305012 AE
side.
OK: 2 − 3 Ω
00 − How to Use
P.00-5).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-119
Connector : B-18
Connector : B-119
B-18(B)
2 1
Harness side connector AK305012 AE
B-119(B)
side.
OK: System voltage
6 5 4
Harness side
relay connector
triangle marks
2 1 B-18(B)
B-12X
4 3
Harness side
connector
2 1
AK305003 AB Harness side connector AK305012 AE

2 1
connector
TROUBLESHOOTING

connector.
open/short circuit.

Connector : B-119
B-119(B)
3 2 1
6 5 4
Harness side
B-119(B)
2 1
B-12X
B-119(B) 4 3
Harness side
3 2 1 connector
6 5 4
2 1

TROUBLESHOOTING
13A-121
Connector: C-121
Connector : B-18
B-18(B)
2 1
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

age.
TROUBLESHOOTING

Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
• Engine: Idling
to P.13A-385).
00 − How to Use
P.00-5).
TROUBLESHOOTING
13A-123
Injector circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
R-Y
28 To engine-ECU
J/C (6)
C-105
29
R-Y
B-119 3
1 2 3
4 5 6
1 4 5 6
R R-W R-L R-B
1 1 1 1
No.1 No.2 No.3 No.4
B-22 B-20 B-18 B-17
MU802722 (MU802722) (MU802722) (MU802722)
1 2 1 2 1 2 1 2
2 2 2 2
O W-R G R
1 9 24 2
C-121
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501809AB
TROUBLESHOOTING

Connector : B-17
nal No. 2).
FUNCTION
2 1
• The fuel injection amount of the injector depends AK305012 AF

Check Conditions
V or less.
Connector : B-17
Judgment Criterion
seconds. B-17(B)
PROBABLE CAUSES
connector contact Harness side connector AK305012 AF
side.
OK: 2 − 3 Ω
00 − How to Use
P.00-5).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-125
No. 4 injector connector No. 6) injector resistor connector and B-17
Connector : B-17
Connector : B-119
B-17(B)
2 1
Harness side connector AK305012 AF
B-119(B)
side.
OK: System voltage
6 5 4
Harness side
relay connector
triangle marks
2 1 B-17(B)
B-12X
4 3
Harness side
connector
2 1
AK305003 AB Harness side connector AK305012 AF

2 1
connector
TROUBLESHOOTING

connector.
open/short circuit.

Connector : B-119
B-119(B)
3 2 1
6 5 4
Harness side
B-119(B)
2 1
B-12X
B-119(B) 4 3
Harness side
3 2 1 connector
6 5 4
2 1

TROUBLESHOOTING
13A-127
Connector: C-121
Connector : B-17
B-17(B)
2 1
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

age.
TROUBLESHOOTING

Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
• Engine: Idling
to P.13A-385).
00 − How to Use
P.00-5).
TROUBLESHOOTING
13A-129
Code No. P0234: Turbocharger Wastegate System Malfunction
FUNCTION DIAGNOSIS PROCEDURE

• The engine-ECU checks that the engine is not
overcharged by always monitoring intake air vol- STEP 1. Check turbocharger supercharging
ume. pressure.
• The engine-ECU protects the engine by shutting • Check turbocharger supercharging pressure
off fuel when an overcharged condition is (Refer to GROUP 15 − On-vehicle Service − Tur-
detected. bocharger Supercharging Pressure P.15-2).
TROUBLE JUDGMENT Q: Is the check result normal?
Check Condition NO : Repair or replace.
• Waste gate solenoid valve is normal.
Judgment Criterion STEP 2. Check supercharging pressure control
• The volumetric efficiency continues to be the sta- system.
tus having more than the specified valve for the • Check supercharging pressure control system
stipulated period. (Refer to GROUP 15 − On-vehicle Service −
Supercharging Pressure Control System P.15-3).
PROBABLE CAUSES
• Failed turbocharger wastages actuator
• Failed supercharging pressure control system
NO : Repair or replace.
STEP 3. M.U.T.-II/III diagnosis code.

• Reconfirmation of diagnosis code.
Q: Is the diagnosis code?
00 − How to Use
P.00-5).
TROUBLESHOOTING
Code No. P0243: Waste Gate Solenoid Valve System
Waste gate solenoid valve circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
B-12X 1 2
1 2
3 4
4 3
R-Y
To engine-ECU
1
B-26
Waste gate solenoid valve
1 2
LG
41
C-119
(MU801824)
41 42 43 44 45 46 47 Engine-ECU
48 49 50 51 52 53 54 55 56 57 58 59
60 61 62 63 64 65 66 67 68
NOTE
Wire colour code
AK501810AB
OPERATION FUNCTION
• Power is supplied from the engine control relay • In response to a signal from the engine-ECU, the
(terminal No. 4) to the waste gate solenoid valve waste gate solenoid valve controls the turbo
(terminal No. 1). charge pressure to be introduced into the waste
• The engine-ECU (terminal No. 41) causes the gate actuator of the turbo charger.
power transistor in the unit to be ON to supply
power to the waste gate solenoid valve (terminal TROUBLE JUDGMENT
No. 2).
Check Condition
• Battery voltage is 10 V or more.
TROUBLESHOOTING
13A-131
Judgment Criterion STEP 3. Perform resistance measurement at B-26
• Surge voltage cannot be detected within 1 sec- waste gate solenoid valve connector.
onds from the time when the waste gate solenoid
valve has changed from ON to OFF. Connector : B-26
PROBABLE CAUSES
• Failed waste gate solenoid valve B-26(GR)
• Open/short circuit in waste gate solenoid valve
sensor circuit or loose connector contact
2 1
DIAGNOSIS PROCEDURE Harness side

• Disconnect connector, and measure at solenoid

valve side.
• Item No. 12: Waste gate solenoid valve
OK: 29 − 35 Ω (at 20°C)
valve vibrates.
NO : Replace the waste gate solenoid valve.
00 − How to Use
P.00-5). STEP 4. Perform voltage measurement at B-26
NO : Go to Step 2 . waste gate solenoid valve connector.
Connector : B-26
STEP 2. Connector check: B-26 waste gate
solenoid valve connector
B-26(GR)
Connector : B-26
B-26(GR) 2 1
Harness side
2 1 • Disconnect connector, and measure at harness

Harness side side.
connector AK305018 AB • Ignition switch: "ON"
Q: Is the check result normal? OK: System voltage
NO : Repair or replace the connector. Q: Is the check result normal?
NO : Go to Step 5 .
TROUBLESHOOTING
triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
C-119 (GR)
Connector : B-26
B-26(GR)
2 1
Harness side
47 46 45 44 43 42 41
Q: Is the check result normal? 59 58 57 56 55 54 53 52 51 50 49 48
YES : Check and repair harness between B-26 68 67 66 65 64 63 62 61 60
(terminal No. 1) waste gate solenoid valve Harness side connector
connector and B-12X (terminal No. 4) AK501994 AB
engine control relay connector. • Disconnect connector, and measure at harness

• Check power supply line for side.
open/short circuit. • Ignition switch: "ON"
NO : Repair or replace the connector. • Voltage between terminal No. 41 and earth.
OK: System voltage
NO : Go to Step 7 .
TROUBLESHOOTING
13A-133
connector connector
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB

B-26(GR)
2 1
Harness side

(terminal No. 2) waste gate solenoid valve
circuit.
TROUBLESHOOTING
No. 2) waste gate solenoid valve connector and No. 1) waste gate solenoid valve connector and
C-119 (terminal No. 41) engine-ECU connector. B-12X (terminal No. 4) engine control relay
Connector : B-26
connector.
Connector : B-26
B-26(GR)
B-26(GR)
2 1
Harness side 2 1
connector AK305018 AB Harness side
Connector: C-119
<L. H. drive vehicles> triangle marks
2 1
B-12X
4 3
Harness side
connector
C-119 (GR) AK305003 AB


C-119 (GR)
valve vibrates.
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 Q: Is the check result normal?
68 67 66 65 64 63 62 61 60 YES : Intermittent malfunction (Refer to GROUP
Harness side connector 00 − How to Use
AK501994 AB
• Check output line for damage. P.00-5).
Q: Is the check result normal? NO : Replace the engine-ECU.
TROUBLESHOOTING
13A-135
Code No. P0300: Random Cylinder Misfire Detected
OPERATION • Incorrect air-fuel ratio

• Refer to P0201 injector circuit P.13A-105. • Low compression pressure
• Refer to P0202 injector circuit P.13A-111. • Failed coolant temperature sensor
• Refer to P0203 injector circuit P.13A-117. • Skipping of timing belt teeth.
• Refer to P0204 injector circuit P.13A-123. • EGR system and EGR valve failed
FUNCTION
• If a misfire occurs while the engine is running, the DIAGNOSIS PROCEDURE
engine speed changes for an instant.
• The engine-ECU checks for such changes in STEP 1. M.U.T.-II/III data list
engine speed. • Item No. 22: Crank angle sensor
TROUBLE JUDGMENT OK: Keep the engine speed constant to make
the pulse width of output waveform con-
Check Conditions stant.
• The engine speed is 500 − 6,500 r/min.
• The engine coolant temperature is −10°C or
higher. NO : Check crank angle sensor system (Refer to
• The barometric pressure is 76 kPa or more. Code No. P0335 P.13A-155).
• The volumetric efficiency is 30 − 55%.
• The adaptive learning has been completed with
the vane that generates the crankshaft position STEP 2. M.U.T.-II/III data list
signals. • Refer to Data List Reference Table P.13A-372.
• During the engine operation except the shift a. Item No. 21: Engine coolant temperature sensor
change or low speed driving and rapid accelera- b. Item No. 81: Long-term fuel compensation
tion and deceleration, also intermittent operation c. Item No. 82: Short-term fuel compensation
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 −0.06 NO : Perform the diagnosis code classified check
V/10ms to 0.06 V/10ms. procedure for the sensor that has shown an
Judgment Criteria abnormal data valve (Refer to, Inspection
• Misfire has occurred more frequently than Chart for Diagnosis Codes P.13A-17).
allowed during the last 200 revolutions (When the
catalyst temperature is higher than 950°C). STEP 3. Check ignition coil spark.
or
• Misfire has occurred in 15 or more of the last Q: Is the check result normal?
1,000 revolutions (corresponding to 1.5 times the YES : Go to Step 4 .
limit of emission standard). NO : Check ignition circuit system (Refer to
Inspection procedure 30 <L.H. drive
PROBABLE CAUSES vehicles>P.13A-356 or Inspection
• Ignition system related part(s) failed procedure 31 <R.H. drive
• Failed crank angle sensor vehicles>P.13A-363).
TROUBLESHOOTING
STEP 4. Connector check: Injector connector STEP 6. Connector check: C-121 engine-ECU
connector
Connector: C-121
B-22(B) B-20(B) B-18(B) B-17(B)
2 1
a. B-22 (No. 1 injector connector)

b. B-20 (No. 2 injector connector) C-121 (GR)
c. B-18 (No. 3 injector connector) <R. H. drive vehicles>
d. B-17 (No. 4 injector connector)
STEP 5. Check injector itself.

• Check Injector itself (Refer to P.13A-406). C-121 (GR)
YES : Go to Step 6 . 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
NO : Replace the injector. 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
13A-137
STEP 7. Check harness between injector
connector and C-121 engine-ECU connector. NO : Repair the damaged harness wire.
STEP 8. Check injector resistor itself.

• Check injector resistor itself (Refer to
B-22(B) B-20(B) B-18(B) B-17(B) P.13A-407).
2 1
Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
STEP 9. Connector check: B-119 injector resistor STEP 10. Check harness between B-119 injector
connector and C-121 engine-ECU connector resistor connector and injector connector.
<L.H.drive vehicles> <L.H.drive vehicles>
B-119(B) B-119(B)
<R.H.drive vehicles> <R.H.drive vehicles>
B-119(B) B-119(B)
3 2 1 3 2 1
6 5 4 6 5 4
Connector: C-121 Connector : B-17,B-18,B-20,B-22
B-22(B) B-20(B) B-18(B) B-17(B)
2 1
C-121 (GR) a. Check harness between B-119 (terminal No. 1)

injector resistor connector and B-22 (terminal No.
1) No. 1 injector connector.
C-121 (GR) d. Check harness between B-119 (terminal No. 6)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 1) No. 4 injector connector.
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB Q: Are the check results normal?
Q: Is the check result normal? NO : Repair the damaged harness wire.
TROUBLESHOOTING
13A-139
STEP 11. Fuel pressure measurement. STEP 13. Check for skipped timing belt teeth.
• Fuel pressure measurement (Refer to fuel pres- Q: Is the check result normal?
sure test P.13A-396). YES : Go to Step 14 .
Q: Is the check result normal? NO : Repair.
NO : Repair.
STEP 14. Exhaust gas recirculation system
check.
STEP 12. Check for intake of air from intake hose • Exhaust gas recirculation system check (Refer to
and inlet manifold. GROUP 17 − Exhaust gas recirculation (EGR)
system P.17-14).
YES : Go to Step 13 . Q: Is the check result normal?
NO : Repair. YES : Replace the engine-ECU
NO : Repair.
Code No. P0301: No. 1 Cylinder Misfire Detection System
OPERATION PROBABLE CAUSES

• Refer to P0201 injector circuit P.13A-105. • Ignition system related part(s) failed
• Low compression pressure
FUNCTION • Failed engine-ECU
• If a misfire occurs while the engine is running, the
engine speed changes for an instant. DIAGNOSIS PROCEDURE
• The engine-ECU checks for such changes in
engine speed.
STEP 1. Check ignition coil spark.
TROUBLE JUDGMENT Q: Is the check result normal?
Check Conditions NO : Check ignition Circuit System (Refer to
• The engine speed is 500 − 6,500 r/min. Inspection procedure 30 <L.H. drive
• The engine coolant temperature is −10°C or vehicles>P.13A-356 or Inspection
higher. procedure 31 <R.H. drive
• The barometric pressure is 76 kPa or more. vehicles>P.13A-363).
the vane that generates the crankshaft position STEP 2. Connector check: B-22 No. 1 injector
signals. connector
• During the engine operation except the shift Connector : B-22
change or low speed driving and rapid accelera-
tion 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). B-22(B)
• The throttle deviation is within the range of −0.06
V/10ms to 0.06 V/10ms.
Judgment Criteria
• Misfire has occurred more frequently than 2 1
allowed during the last 200 revolutions (When the AK305012 AC
catalyst temperature is higher than 950°C).

or YES : Go to Step 3 .
• Misfire has occurred in 15 or more of the last NO : Repair or replace the connector.
1,000 revolutions (corresponding to 1.5 times the
limit of emission standard).
TROUBLESHOOTING
STEP 3. Check No. 1 injector itself. STEP 5. Check harness between B-22 (terminal
• Check Injector itself (Refer to P.13A-406). No. 2) No. 1 injector connector and C-121
(terminal No. 1) engine-ECU connector
YES : Go to Step 4 . Connector : B-22
NO : Replace the No. 1 injector.

B-22(B)
connector
Connector: C-121
2 1
Connector: C-121
C-121 (GR)
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1
YES : Go to Step 5 . 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
NO : Repair or replace the connector. 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB


P.13A-407).
TROUBLESHOOTING
13A-141
STEP 7. Connector check: B-119 injector resistor STEP 8. Check harness between B-119 (terminal
connector and C-121 engine-ECU connector No. 1) injector resistor connector and B-22
Connector : B-119
(terminal No. 1) No.1 injector connector.
<L.H.drive vehicles> Connector : B-119
B-119(B)
B-119(B)
B-119(B)
B-119(B)
3 2 1
6 5 4 3 2 1
Harness side 6 5 4
Connector: C-121
Connector : B-22
B-22(B)
2 1
C-121 (GR)

• Fuel pressure measurement (Refer to fuel pres-
sure test P.13A-396).
C-121 (GR) Q: Is the check result normal?
8 7 6 5 4 3 2 1 NO : Repair.
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING

FUNCTION
• If a misfire occurs while the engine is running, the Q: Is the check result normal?
engine speed changes for an instant. YES : Go to Step 2 .
• The engine-ECU checks for such changes in NO : Check ignition circuit system (Refer to
engine speed. Inspection procedure 30 <L.H. drive
vehicles>P.13A-356 or Inspection
TROUBLE JUDGMENT procedure 31 <R.H. drive
vehicles>P.13A-363).
Check Conditions
• The engine coolant temperature is −10°C or STEP 2. Connector check: B-20 No. 2 injector
higher. connector
• The barometric pressure is 76 kPa or more. Connector : B-20
the vane that generates the crankshaft position
signals. B-20(B)
• During the engine operation except the shift
of air compressor (A/C: within the 3 seconds after 2 1
changing to ON from OFF or to OFF from ON). Harness side connector AK305012 AD
V/10ms to 0.06 V/10ms. Q: Is the check result normal?
Judgment Criteria NO : Repair or replace the connector.
• Misfire has occurred more frequently than
catalyst temperature is higher than 950°C). STEP 3. Check No. 2 injector itself.
or • Check Injector itself (Refer to P.13A-406).
limit of emission standard). NO : Replace the No. 2 injector.
PROBABLE CAUSES
• Ignition system related part(s) failed
TROUBLESHOOTING
13A-143
Connector: C-121
Connector : B-20
B-20(B)
2 1
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB


P.13A-407).
TROUBLESHOOTING
Connector : B-119
B-119(B)
B-119(B)
B-119(B)
B-119(B)
3 2 1
6 5 4 3 2 1
Harness side 6 5 4
Connector: C-121
Connector : B-20
B-20(B)
2 1
C-121 (GR)

C-121 (GR)
8 7 6 5 4 3 2 1 YES : Replace the engine-ECU.
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 NO : Repair.
AK501995 AB

TROUBLESHOOTING
13A-145

FUNCTION
• The engine-ECU checks for such changes in NO : Check ignition circuit system (Refer to
Check Conditions
higher. connector
signals. B-18(B)
changing to ON from OFF or to OFF from ON). Harness side connector AK305012 AE
PROBABLE CAUSES
TROUBLESHOOTING
Connector: C-121
Connector : B-18
B-18(B)
2 1
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB


P.13A-407).
TROUBLESHOOTING
13A-147
Connector : B-119
B-119(B)
B-119(B)
B-119(B)
B-119(B)
3 2 1
6 5 4 3 2 1
Harness side 6 5 4
Connector: C-121
Connector : B-18
B-18(B)
2 1
C-121 (GR)

C-121 (GR)
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 NO : Repair.
AK501995 AB

TROUBLESHOOTING

STEP 1. Check the ignition coil spark.
FUNCTION
• The engine-ECU checks for such changes in NO : Check ignition Circuit System (Refer to
Check Conditions
higher. connector
signals. B-17(B)
changing to ON from OFF or to OFF from ON). Harness side connector AK305012 AF
PROBABLE CAUSES
TROUBLESHOOTING
13A-149
Connector: C-121
Connector : B-17
B-17(B)
2 1
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB


P.13A-407).
TROUBLESHOOTING
Connector : B-119
B-119(B)
B-119(B)
B-119(B)
B-119(B)
3 2 1
6 5 4 3 2 1
Harness side 6 5 4
Connector: C-121
Connector : B-18
B-18(B)
2 1
C-121 (GR)

C-121 (GR)
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 NO : Repair.
AK501995 AB

TROUBLESHOOTING
13A-151
Code No. P0325: Detonation Sensor System
Detonation sensor circuit
C-117
(MU803783)
71 72 73 74 75 76 77
78 79 80 81 82 83 84 85 86 87 88 89 90 Engine-ECU
91 92 93 94 95 96 97 98 99 100
91
B B
B-108
MU802661
2 1 1 2
Detonation sensor
Wire colour code

AK501811AB

• The sensor signal is inputted to the engine-ECU
Check Conditions
(terminal No. 91) from the detonation sensor (ter-
minal No. 1).
• Excluding for 2 seconds after ignition switch is set
FUNCTION to "ON" position or 2 seconds after engine start is
completed.
• The detonation sensor detects the vibration of the
• The engine speed is 2,000 r/min. or more.
cylinder block caused by detonation waves, and
• The volumetric efficiency is 30% or more.
inputs a signal to the engine-ECU.
• In response to the signal, the engine-ECU pro- Judgment Criterion
vides controls to retard the ignition timing when • The change amount of the detonation sensor out-
the detonation occurs. put voltage (the detonation sensor peak voltage
in every half a turn of the crankshaft) is below
0.06 V or less in 200 consecutive times.
TROUBLESHOOTING
PROBABLE CAUSES STEP 2. Perform resistance measurement at

• Failed detonation sensor B-108 detonation sensor connector.
• Open/short circuit in detonation sensor circuit or
Connector : B-108
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-108 detonation

sensor connector
Connector : B-108 Detonation sensor
Detonation sensor B-108(GR)

2 1
Harness side

side.
B-108(GR) OK: 2 Ω or less
2 1 Q: Is the check result normal?
Harness side
connector NO : Check and repair harness between B-108
AK305019AB
(terminal No. 2) detonation sensor
Q: Is the check result normal? connector and body earth.
YES : Go to Step 2 . • Check earthing line for open circuit
NO : Repair or replace the connector. and damage.
TROUBLESHOOTING
13A-153
connector
Connector: C-117
C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB

TROUBLESHOOTING

No. 1) detonation sensor connector and C-117 NO : Repair the damaged harness wire.
Connector : B-108
Q: Does trouble symptom persist?
00 − How to Use
P.00-5).
Detonation sensor
STEP 6. Replace the detonation sensor.
• After replacing the detonation sensor, re-check
the trouble symptoms.
B-108(GR)
2 1
Harness side
Connector: C-117
C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB

age.
TROUBLESHOOTING
13A-155
Code No. P0335: Crank Angle Sensor System
Crank angle sensor circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
B-12X 1 2
1 2
3 4
4 3
R-Y To engine-ECU
3
B-117
MU802603
1 2
Crank angle sensor
3
1 2
B BR-G
34 43
C-121 C-119
(MU803783) (MU803782)
1 2 3 4 5 6 7 8 41 42 43 44 45 46 47
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 48 49 50 51 52 53 54 55 56 57 58 59
24 25 26 27 28 29 30 3132 33 34 35 60 61 62 63 64 65 66 67 68
5V
Engine-ECU
NOTE
Wire colour code
AK501812 AB
OPERATION • A power voltage of 5 V is applied to the crank

• Power is supplied to the crank angle sensor (ter- angle sensor output terminal (terminal No. 2)
minal No. 3) from the engine control relay (termi- from the engine-ECU (terminal No. 43).
nal No. 4) and is earthed to the engine-ECU
(terminal No. 34) from the crank angle sensor
(terminal No. 1).
TROUBLESHOOTING
FUNCTION STEP 2. Connector check: B-117 crank angle

• The crank angle sensor detects the crank angle sensor connector
(position) and inputs a pulse signal to the
Connector : B-117
engine-ECU.
• In response to the signal, the engine-ECU con-
trols the injector, etc.
TROUBLE JUDGMENT
Check Condition
• Engine in cranking state.
Crank angle sensor
Judgment Criterion
• The sensor output voltage remains unchanged
(no pulse signal is inputted) for 2 seconds.
PROBABLE CAUSES
• Failed crank angle sensor B-117(B)
• Open/short circuit in crank angle sensor circuit or
• Failed engine-ECU 2 1
3
connector
AK305020AB

a. Item No. 22: Crank angle sensor NO : Repair or replace the connector.
00 − How to Use
P.00-5).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-157
crank angle sensor connector. engine-ECU connector.
Crank angle sensor
C-119 (GR)

B-117(B)
2 1
3
Harness side
connector
AK305020AB C-119 (GR)
• Disconnect connector, and measure at harness 47 46 45 44 43 42 41
side. 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
• Ignition switch: "ON" Harness side connector
• Voltage between terminal No. 2 and earth. AK501994 AB
OK: 4.9 − 5.1 V Connector : B-117

NO : Go to Step 4 .
Crank angle sensor
B-117(B)
2 1
3
Harness side
connector
AK305020AB
• Disconnect B-117 crank angle sensor connector.
OK: 4.9 − 5.1 V
TROUBLESHOOTING

YES : Go to Step 5 . YES : Check and repair harness between B-117
NO : Go to Step 6 . (terminal No. 2) crank angle sensor
STEP 5. Connector check: C-119 engine-ECU engine-ECU connector.
connector • Check output line for open circuit.
Connector: C-119
<L. H. drive vehicles> STEP 6. Connector check: C-119 engine-ECU
connector
Connector: C-119
C-119 (GR)
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
Harness side connector C-119 (GR)
AK501994 AB
47 46 45 44 43 42 41
Connector : B-117 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

Crank angle sensor
B-117(B)
2 1
3
Harness side
connector
AK305020AB
TROUBLESHOOTING
13A-159
No. 2) crank angle sensor connector and C-119 NO : Repair the damaged harness wire.
Connector : B-117
a. Item No. 22: Crank angle sensor
00 − How to Use
Crank angle sensor
P.00-5).

crank angle sensor connector.
B-117(B)
Connector : B-117
2 1
3
Harness side
connector
AK305020AB
Crank angle sensor

Connector: C-119
B-117(B)
2 1
C-119 (GR) 3
Harness side
<R. H. drive vehicles> connector
AK305020AB

side.
OK: System voltage
C-119 (GR) YES : Go to Step 11 .
47 46 45 44 43 42 41 NO : Go to Step 10 .
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
STEP 10. Connector check: B-12X engine control STEP 11. Perform resistance measurement at
relay connector B-117 crank angle sensor connector.
triangle marks
2 1
B-12X
4 3
Harness side
connector
Crank angle sensor
AK305003 AB
Connector : B-117
B-117(B)
2 1
3
Crank angle sensor
Harness side
connector
AK305020AB

side.
B-117(B)
OK: 2 Ω or less
2 1 NO : Go to Step 12 .
3
Harness side
connector
AK305020AB

(terminal No. 3) crank angle sensor
connector and B-12X (terminal No. 4)
open/short circuit.
TROUBLESHOOTING
13A-161
connector No. 1) crank angle sensor connector and C-121
Connector: C-121
Connector : B-117
Crank angle sensor
C-121 (GR)
B-117(B)
2 1
3
connector
AK305020AB
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 Connector: C-119
AK501995 AB <L. H. drive vehicles>

C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING

STEP 15. Connector check: B-12X engine control
relay connector
triangle marks
STEP 14. Perform output wave pattern
measurement at B-117 crank angle sensor
connector (Using an oscilloscope). 2 1
B-12X
Connector : B-117 4 3
Harness side
connector
AK305003 AB

Crank angle sensor NO : Repair or replace the connector.
B-117(B)
2 1
3
Harness side
connector
AK305020AB

• Engine: Idling
OK: Waveforms should be displayed on
(Refer to P.13A-385), 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.
TROUBLESHOOTING
13A-163
STEP 16. Check harness between B-117 (terminal STEP 17. Connector check: C-119 and C-121
No. 3) crank angle sensor connector and B-12X engine-ECU connectors
Connector: C-119, C-121
Connector : B-117
Crank angle sensor
C-119 (GR) C-121 (GR)
B-117(B)
2 1
3 C-121 (GR)
connector
AK305020AB
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
Connector : B-12X Relay box’s 68 67 66 65 64 63 62 61 60
triangle marks
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
2 1 35 34 33 32 31 30 29 28 27 26 25 24
B-12X
4 3 C-121 Harness side connector

connector
AK305003 AB YES : Go to Step 18 .
TROUBLESHOOTING
No. 2) crank angle sensor connector and C-119 No. 1) crank angle sensor connector and C-121
(terminal No. 43) engine-ECU connector. (terminal No. 34) engine-ECU connector.
Crank angle sensor Crank angle sensor
B-117(B) B-117(B)
2 1 2 1
3 3
connector connector
AK305020AB AK305020AB

C-119 (GR) C-121 (GR)

C-119 (GR) C-121 (GR)
47 46 45 44 43 42 41 8 7 6 5 4 3 2 1
59 58 57 56 55 54 53 52 51 50 49 48 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
68 67 66 65 64 63 62 61 60 35 34 33 32 31 30 29 28 27 26 25 24
AK501994 AB AK501995 AB
• Check output line for damage. • Check earthing line for damage.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
TROUBLESHOOTING
13A-165
STEP 20. Check the crankshaft sensing blade STEP 21: M.U.T.-II/III data list
YES : Go to Step 21 . a. Item No. 22: Crank angle sensor
NO : Replace the crankshaft sensing blade. Q: Is the check result normal?
00 − How to Use
P.00-5).
NO : Replace the crank angle sensor.
TROUBLESHOOTING
Code No. P0340: Exhaust Camshaft Position Sensor System
Exhaust camshaft position sensor circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
R-Y
To engine-ECU
3
B-106
MU802337
1 2 3 Exhaust camshaft position sensor
1 2
B L-R
34 50
C-121 C-119
(MU803783) (MU803782)
1 2 3 4 5 6 7 8 41 42 43 44 45 46 47
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 48 49 50 51 52 53 54 55 56 57 58 59
24 25 26 27 28 29 30 3132 33 34 35 60 61 62 63 64 65 66 67 68
5V
Engine-ECU
NOTE
Wire colour code
AK501813 AB
OPERATION camshaft position sensor (terminal No. 1).

• Power is supplied to the exhaust camshaft posi- • A power voltage of 5 V is applied to the exhaust
tion sensor (terminal No. 3) from the engine con- camshaft position sensor output terminal (termi-
trol relay (terminal No. 4) and is earthed to the nal No. 2) from the engine-ECU (terminal No. 50).
engine-ECU (terminal No. 34) from the exhaust
TROUBLESHOOTING
13A-167
FUNCTION STEP 2. Perform voltage measurement at B-106
• The exhaust camshaft position sensor detects exhaust camshaft position sensor connector.
the top dead center on the compression stroke of
the No. 1 cylinder and inputs a pulse signal to the Connector: B-106
engine-ECU. 3 2 1
Harness side
TROUBLE JUDGMENT B-106 (B) connector
Check Conditions
• Engine speed of 50 r/min. or more.
Judgment Criterion
• The sensor output voltage remains unchanged AK501999 AB
(no pulse signal is inputted) for 2 seconds. • Disconnect connector, and measure at harness
side.
PROBABLE CAUSES • Ignition switch: "ON"
• Failed exhaust camshaft position sensor • Voltage between terminal No. 3 and earth.
• Open/short circuit in exhaust camshaft position OK: System voltage
NO : Go to Step 3 .
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-106 exhaust

camshaft position sensor connector
Connector: B-106
3 2 1
Harness side
B-106 (B) connector
AK501999 AB

TROUBLESHOOTING
STEP 3. Connector check: B-12X engine control STEP 4. Perform voltage measurement at B-106
relay connector exhaust camshaft position sensor connector.
Connector : B-12X Relay box’s Connector: B-106
triangle marks
3 2 1
Harness side
B-106 (B) connector
2 1
B-12X
4 3
Harness side
connector
AK305003 AB AK501999 AB

Connector: B-106
side.
3 2 1 • Ignition switch: "ON"
Harness side • Voltage between terminal No. 2 and earth.
connector
B-106 (B) OK: 4.9 − 5.1 V
NO : Go to Step 5 .
AK501999 AB

(terminal No. 3) exhaust camshaft position
sensor connector and B-12X (terminal No.
4) engine control relay connector.
open/short circuit.
TROUBLESHOOTING
13A-169
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB
Connector: B-106 Connector: B-106

3 2 1 3 2 1
B-106 (B) connector B-106 (B) connector
AK501999 AB AK501999 AB

• Disconnect B-106 exhaust camshaft position sen- YES : Check and repair harness between B-106
sor connector. (terminal No. 2) exhaust camshaft position
• Ignition switch: "ON" sensor connector and C-119 (terminal No.
• Voltage between terminal No. 50 and earth. 50) engine-ECU connector.
OK: 4.9 − 5.1 V • Check output line for open circuit.
Q: Is the check result normal? NO : Repair or replace the connector.
NO : Go to Step 7 .
TROUBLESHOOTING
connector No. 2) camshaft position sensor connector and
Connector: C-119
Connector: B-106
3 2 1
Harness side
B-106 (B) connector
AK501999 AB
C-119 (GR)

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 C-119 (GR)
68 67 66 65 64 63 62 61 60
AK501994 AB

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB


00 − How to Use
P.00-5).
TROUBLESHOOTING
13A-171
STEP 10. Perform resistance measurement at STEP 12. Check harness between B-106 (terminal
B-106 exhaust camshaft position sensor No. 1) camshaft position sensor connector and
connector. C-121 (terminal No. 34) engine-ECU connector.
3 2 1 3 2 1
AK501999 AB AK501999 AB

Connector: C-121
side.
• Resistance between terminal No. 1 and earth. <L. H. drive vehicles>
OK: 2 Ω or less

connector
C-121 (GR)
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1
C-121 (GR)
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
STEP 13. Perform output wave pattern STEP 15. Check harness between B-106 (terminal
measurement at B-106 exhaust camshaft No. 3) exhaust camshaft position sensor
position sensor connector (Using an connector and B-12X (terminal No. 4) engine
oscilloscope). control relay connector.
3 2 1 3 2 1
AK501999 AB AK501999 AB

nect connector, and measure at pick-up harness. triangle marks
• Engine: Idling
• Voltage between terminal No. 2 and earth. 2 1
B-12X
OK: Waveforms should be displayed on 4 3
Harness side
(Refer to P.13A-385), its maximum value connector
should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in AK305003 AB
waveform.

relay connector.
triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB

TROUBLESHOOTING
13A-173
STEP 16. Connector check: C-119 and C-121 STEP 17. Check harness between B-106 (terminal
engine-ECU connectors No. 2) exhaust camshaft position sensor
Connector: B-106
3 2 1
Harness side
B-106 (B) connector
C-119 (GR) C-121 (GR)

AK501999 AB
Connector: C-119
C-121 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 C-119 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501998 AB

47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
STEP 18. Check harness between B-106 (terminal STEP 19. Check the exhaust camshaft position
No. 1) exhaust camshaft position sensor sensing cylinder.
connector and C-121 (terminal No. 34) Q: Is the check result normal?
engine-ECU connector. YES : Go to Step 20 .
Connector: B-106 NO : Replace the exhaust camshaft position
sensing cylinder.
3 2 1
Harness side
B-106 (B) connector STEP 20. Check the trouble symptoms.
YES : Replace the exhaust camshaft position
sensor.
AK501999 AB
00 − How to Use
Connector: C-121 P.00-5).
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
13A-175
Code No. P0403: Exhaust Gas Recirculation (EGR) Control Solenoid Valve
EGR control solenoid valve circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
R-Y To engine-ECU
B-14
2
R-Y
1
B-101
1 2 EGR control solenoid valve
2
G-O
G-O
6
C-121
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Engine-ECU
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501814 AB
TROUBLESHOOTING
OPERATION STEP 2. Connector check: B-101 EGR control

• Power is supplied to the EGR control solenoid solenoid valve connector
valve (terminal No. 1) from the engine control
Connector : B-101
relay (terminal No. 4). 2 1
• The engine-ECU (terminal No. 6) makes the Harness side
power transistor in the unit be in "ON", and that connector
makes currents go on the EGR control solenoid
valve (terminal No. 2).
B-101(BR)
FUNCTION
• In response to the signal from the engine-ECU,
the EGR control solenoid valve controls the oper-
AK305024 AB
ation of the EGR valve.
TROUBLE JUDGMENT YES : Go to Step 3 .
Check Condition NO : Repair or replace the connector.
• The battery voltage is 10 V or more.
Judgment Criterion STEP 3. Perform resistance measurement at
• When the EGR control solenoid valve is turned to B-101 EGR control solenoid valve connector.
"LOCK" (OFF) position from "ON" position, none Connector : B-101
2 1
of solenoid coil surge voltage (system voltage of
+2 V) is detected. Harness side
connector
PROBABLE CAUSES
• Failed EGR control solenoid valve
• Open/short circuit in EGR control solenoid valve B-101(BR)
circuit or loose connector contact
AK305024 AB
DIAGNOSIS PROCEDURE • Disconnect connector, and measure at solenoid
valve side.
STEP 1. M.U.T.-II/III actuator test • Resistance between terminal No. 1 and No. 2.
• Item No. 10: EGR control solenoid valve OK: 29 − 35 Ω (at 20°C)
OK: Operating sound can be heard and the Q: Is the check result normal?
valve vibrates. YES : Go to Step 4 .
Q: Is the check result normal? NO : Replace the EGR control solenoid valve.
00 − How to Use
P.00-5).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-177
EGR control solenoid valve connector. relay connector
2 1 triangle marks
Harness side
connector
2 1
B-12X
4 3
B-101(BR)
Harness side
connector
AK305024 AB AK305003 AB
• Disconnect connector, and measure at harness Connector : B-101

side. 2 1
• Ignition switch: "ON" Harness side
• Voltage between terminal No. 1 and earth. connector
OK: System voltage
B-101(BR)
NO : Go to Step 5 .
AK305024 AB

YES : Check intermediate connector B-14, and
connector is normal, check and repair
harness between B-101 (terminal No. 1)
EGR control solenoid valve connector and
B-12X (terminal No. 4) engine control relay
connector.
open/short circuit.
TROUBLESHOOTING
C-121 (GR) C-121 (GR)

C-121 (GR) C-121 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB AK501995 AB
• Disconnect connector, and measure at harness Connector : B-101

side. 2 1
• Ignition switch: "ON" Harness side
• Voltage between terminal No. 6 and earth. connector
OK: System voltage
B-101(BR)
NO : Go to Step 7 .
AK305024 AB

EGR control solenoid valve connector and
C-121 (terminal No. 6) engine-ECU
connector.
circuit.
TROUBLESHOOTING
13A-179
connector No. 2) EGR control solenoid valve connector and
Connector: C-121
Connector : B-101
<L. H. drive vehicles> 2 1
Harness side
connector
B-101(BR)
AK305024 AB
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

connector B-14, and repair if necessary.
TROUBLESHOOTING
STEP 10. Check harness between B-101 (terminal STEP 11. M.U.T.-II /III actuator test
No. 1) EGR control solenoid valve connector and • Item No. 10: EGR control solenoid valve
B-12X (terminal No. 4) engine control relay OK: Operating sound can be heard and the
connector. valve vibrates.
2 1
Harness side
connector 00 − How to Use
P.00-5).
B-101(BR)
AK305024 AB

triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB

connector B-14, and repair if necessary.
Code No. P0421: Warm up Catalyst Malfunction
FUNCTION • 3 seconds or longer has elapsed after the

• The signal from the oxygen sensor (rear) differs above-mentioned conditions have been met.
from the oxygen sensor (front). That is because • Engine running, intake air temperature is −10°C
the catalytic converter purifies exhaust gas. or higher.
When the catalytic converter has deteriorated, • Under the closed-loop control.
the signal from the oxygen sensor (front) • Vehicle speed is 1.5 km/h or more.
becomes similar to the oxygen sensor (rear). • The engine-ECU monitors for this condition for 7
• The engine-ECU compares the output of the front cycles of 10 seconds each during the drive cycle.
and rear oxygen sensor signals. • Short-term fuel trim is higher than −25% or lower
than +25%.
TROUBLE JUDGMENT • Accumulated air flow sensor output is 2,931 g or
higher.
Check Conditions
• The engine speed is 3,000 r/min. or less. Judgment Criterion
• The accelerator pedal is fully depressed. • The oxygen sensor (rear) signal frequency
• Airflow sensor output is 8 gm/s or higher. divided by oxygen sensor (front) signal frequency
= 0.8 or more.
TROUBLESHOOTING
13A-181
PROBABLE CAUSES STEP 3. M.U.T.-II/III data list
• Catalytic converter deteriorated • Item No. 11: Oxygen sensor (front)
• Failed oxygen sensor (front) OK: 0 − 0.4 and 0.6 − 1.0 volt should alternate
• Failed oxygen sensor (rear) 15 times or more within 10 seconds (engine
• Failed engine-ECU speed at 2,000 r/min.).
STEP 1. Check for leakage of exhaust emission
from exhaust manifold.
STEP 4. Replace the oxygen sensor (rear).
Q: Is the check result normal? • After replacing the oxygen sensor (rear),
YES : Go to Step 2 . re-check the trouble symptoms.
NO : Repair.
YES : The check is end.
STEP 2. M.U.T.-II/III data list NO : Go to Step 5 .
STEP 5. Replace the catalytic converter.
b. Item No. 59: Oxygen sensor (rear) • After replacing the catalytic converter, re-check
Q: Is the check result normal? the trouble symptoms.
NO : Perform the diagnosis code classified check YES : The check is end.
procedure for the sensor that has shown an NO : Replace the engine-ECU.
abnormal data valve (Refer to Inspection
TROUBLESHOOTING
Code No. P0443: Purge Control Solenoid Valve System
Purge control solenoid valve circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
To engine-ECU
R-Y
B-02 2
MU802779
1 2 Purge control solenoid valve
Y-G
C-121 16
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Engine-ECU
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501815 AB
OPERATION • The engine-ECU (terminal No. 16) makes the

• Power is supplied to the purge control solenoid power transistor in the unit be in "ON" position,
valve (terminal No. 2) from the engine control and that makes currents go on the purge control
relay (terminal No. 4). solenoid valve (terminal No. 1).
TROUBLESHOOTING
13A-183
FUNCTION STEP 3. Perform resistance measurement at B-02
• In response to a signal from the engine-ECU, the purge control solenoid valve connector.
purge control solenoid valve controls the flow rate
Connector : B-02
of the purge air to be introduced into the surge
tank.
TROUBLE JUDGMENT
Check Conditions
• The battery voltage is 10 V or more. 2 1
B-02(B)
Judgment Criterion Harness side
connector
• The surge voltage (system voltage +2 V) of sole- AK305025AB
noid coil is not detected when the purge control • Disconnect connector, and measure at solenoid
solenoid valve is turned to OFF from ON. valve side.
PROBABLE CAUSES OK: 30 − 34 Ω (at 20°C)
• Failed purge control solenoid valve
• Open/short circuit in purge control solenoid value Q: Is the check result normal?
circuit or loose connector contact
DIAGNOSIS PROCEDURE STEP 4. Perform voltage measurement at B-02

purge control solenoid valve connector.
STEP 1. M.U.T.-II/III actuator test Connector : B-02
• Item No. 08: Purge control solenoid valve
valve vibrates
00 − How to Use 2 1
Troubleshooting/Inspection Service Points Harness side
B-02(B)
P.00-5). connector AK305025AB
NO : Go to Step 2 .
side.
STEP 2. Connector check: B-02 purge control • Ignition switch: "ON"
solenoid valve connector • Voltage between terminal No. 2 and earth.
Connector : B-02 OK: System voltage
NO : Go to Step 5 .
2 1
B-02(B)
Harness side

TROUBLESHOOTING
relay connector. engine-ECU connector.
triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
Connector : B-02 C-121 (GR)

2 1
B-02(B)
Harness side

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
YES : Check and repair harness between B-02 35 34 33 32 31 30 29 28 27 26 25 24
(terminal No. 2) purge control solenoid valve Harness side connector
connector and B-12X (terminal No. 4) AK501995 AB
engine control relay connector. • Disconnect connector, and measure at harness

• Check power line for open/short side.
circuit. • Ignition switch: "ON"
NO : Repair or replace the connector. • Voltage between terminal No. 16 and earth.
OK: System voltage
NO : Go to Step 7 .
TROUBLESHOOTING
13A-185
connector connector
C-121 (GR) C-121 (GR)

C-121 (GR) C-121 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB AK501995 AB

2 1
B-02(B)
Harness side

(terminal No. 1) purge control solenoid valve
circuit.
TROUBLESHOOTING
No. 1) purge control solenoid valve connector No. 2) purge control solenoid valve connector
and C-121 (terminal No. 16) engine-ECU and B-12X (terminal No. 4) engine control relay
connector. connector.
2 1 2 1
B-02(B) B-02(B)
Connector: C-121 Connector : B-12X Relay box’s

triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
C-121 (GR) • Check power supply line for damage.


• Item No. 08: purge control solenoid valve
C-121 (GR)
valve vibrates.
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 YES : Intermittent malfunction (Refer to GROUP
35 34 33 32 31 30 29 28 27 26 25 24 00 − How to Use
Harness side connector Troubleshooting/Inspection Service Points
AK501995 AB
P.00-5).
• Check output line for damage. NO : Replace the engine-ECU.
TROUBLESHOOTING
13A-187
Code No. P0500: Vehicle Speed Sensor System
Vehicle speed sensor circuit
Ignition
switch Engine-ECU
C-208 5V C-117
R LOCK (MU803783)
1 2 3
4 5 6 ST ACC 71 72 73 74 75 76 77
IG1 IG2
78 79 80 81 82 83 84 85 86 87 88 89 90
91 92 93 94 95 96 97 98 99 100
2
B-W 80
C-211
6
2
J/B
7.5A B-Y
25 C-124
C-214 17 (*1)
B-W*1 or
C-124
O*2 25 (*2) B-R
18 (*1)
Meter and gauge
or
16 (*2)
B-W
B-27 B-27
6 8
B-W B-Y
1 3
B-04
(MU802723)
Vehicle speed sensor
1 2 3
7
B
B-27
5
B B
NOTE
Wire colour code
AK501816 AB
TROUBLESHOOTING
OPERATION STEP 2. M.U.T.-II/III data list

• A power voltage of 5 V is applied to the vehicle • Refer to Data List Reference Table P.13A-372.
speed sensor (terminal No. 3) from the a. Item No. 24: Vehicle speed sensor
FUNCTION NO : Intermittent malfunction (Refer to GROUP
00 - How to Use Troubleshooting/Inspection
• The vehicle speed sensor converts the vehicle
Service Points P.00-5).
speed to the voltage, and then input it into the
engine-ECU.
TROUBLE JUDGMENT connector
Check Conditions Connector: C-117
• 2 seconds later after the engine has started up. <L. H. drive vehicles>
• The engine speed is 2,000 − 4,000 r/min.
Judgment Criterion
• The sensor output voltage remains unchanged
(no pulse signal is inputted) for 2 seconds.
PROBABLE CAUSES
• Failed Vehicle speed sensor
C-117 (GR)
• Open/short circuit in vehicle speed sensor circuit
or loose connector contact <R. H. drive vehicles>
DIAGNOSIS PROCEDURE
STEP 1. Check the speedometer

C-117 (GR)
NO : Check the speedometer (Refer to GROUP
54A −Combination Meter Assembly − 77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
On-vehicle Service P.54A-53). 100 99 98 97 96 95 94 93 92 91
AK501996 AB

TROUBLESHOOTING
13A-189
STEP 4. Check harness between C-117 (terminal STEP 5. Check the trouble symptoms.
No. 80) engine-ECU connector and B-04 (terminal Q: Does trouble symptom persist?
No. 3) vehicle speed sensor connector. YES : Replace the engine-ECU.
Connector: C-117 NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
P.00-5).
C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB
Connector : B-04
3 2 1
Harness side
connector
B-04(B)
Transmission assembly AK305027AB

connectors B-27 and C-124, and repair if necessary.
• Check output line for open circuit and damage.
TROUBLESHOOTING
Code No P0505: Idle Speed Control Servo System
Idle speed control servo circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
To engine-ECU
R-Y
R-Y R-Y
B-104 2 5
1 2 3
Idle speed control
4 5 6 servo
1 3 4 6
Y-L Y R-G LG
14 28 15 29
C-121
(MU803784)
1 2 3 4 5 6 7 8
Engine-ECU
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501817AB
TROUBLESHOOTING
13A-191
OPERATION Judgment Criterion
• The power is supplied to the idle speed control • Actual idle speed has continued to be higher than
servo (terminal No. 2 and No. 5) from the engine the target idle speed by 100 r/min. or more for 10
control relay (terminal No. 4). seconds.
• The engine-ECU (terminal No. 14, No. 15, No. 28
and No. 29) makes power transistor in the unit be PROBABLE CAUSES
in "ON" position in order, and that makes currents • Failed idle speed control servo
go on the idle speed control servo (terminal No. • Open/short circuit in idle speed control servo cir-
1, No. 3, No. 4 and No. 6). cuit or loose connector contact
FUNCTION
• The idle speed control servo opens and closes DIAGNOSIS PROCEDURE
the servo valve in response to a signal from the
engine-ECU to control the intake air flow rate dur- STEP 1. M.U.T.-II/III data list
ing idling. • Refer to Data List Reference Table P.13A-372.
a. Item No. 45: Idle speed control servo
TROUBLE JUDGMENT
Check Conditions YES : Intermittent malfunction (Refer to GROUP
• Vehicle speed has reached 1.5 km/h at least 00 − How to Use
once. Troubleshooting/Inspection Service Points
• Under the closed loop idle speed control.
P.00-5).
Judgment Criterion NO : Go to Step 2 .
• Actual idle speed has continued to be higher than
the target idle speed by 300 r/min. or more for 10 STEP 2. Connector check: B-104 idle speed
seconds. control servo connector
Check Conditions Connector : B-104
• Vehicle speed has reached 1.5 km/h at least
3 2 1
once.
6 5 4
• During idle speed closed loop control.
Harness side
• The highest temperature at the last drive is 45°C connector
or less.
• Engine coolant temperature is approximately B-104 (B)
80°C or less.
• Battery voltage is 10 V or more.
• The barometric pressure is 76 kPa or higher. AK305029AB
• Intake air temperature is −10°C or more.
Judgment Criterion
• Actual idle speed has continued to be higher than NO : Repair or replace the connector.
the target idle speed by 200 r/min. or more for 10
seconds.
STEP 3. Check idle speed control servo itself.
Check Conditions • Check idle speed control servo itself (Refer to
• During idle speed closed loop control.
P.13A-408).
• Engine coolant temperature is approximately
80°C or less. Q: Is the check result normal?
• Battery voltage is 10 V or more. YES : Go to Step 4 .
• Power steering fluid pressure switch is off. NO : Replace the idle speed control servo.
• Volumetric efficiency is 40% or lower.
• The barometric pressure is 76 kPa or higher.
• Intake air temperature is −10°C or more.
TROUBLESHOOTING
idle speed control servo connector. relay connector
triangle marks
3 2 1
6 5 4
Harness side
connector 2 1
B-12X
4 3
B-104 (B)
Harness side
connector
AK305029AB AK305003 AB

Connector : B-104
side.
3 2 1
• Voltage between terminal No. 2 and earth, also 6 5 4
between terminal No. 5 and earth. Harness side
connector
OK: System voltage
B-104 (B)
NO : Go to Step 5 .
AK305029AB

(terminal No. 2 or No. 5) idle speed control
servo connector and B-12X (terminal No. 4)
open/short circuit.
TROUBLESHOOTING
13A-193
STEP 6. Perform voltage measurement at C-121 1. Harness between idle speed control
engine-ECU connector. servo terminal No. 1 and
engine-ECU connector terminal No.
Connector: C-121 14
<L. H. drive vehicles> 2. Harness between idle speed control
servo terminal No. 3 and
28
3. Harness between idle speed control
servo terminal No. 4 and
15
4. Harness between idle speed control
C-121 (GR) servo terminal No. 6 and
<R. H. drive vehicles> engine-ECU connector terminal No.
29
open/short circuit.

connector
C-121 (GR) Connector: C-121
8 7 6 5 4 3 2 1 <L. H. drive vehicles>

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
Connector : B-104
3 2 1
6 5 4
Harness side
B-104 (B) <R. H. drive vehicles>
AK305029AB

side.
• Voltage between terminal No. 14 and earth, C-121 (GR)
between terminal No. 15 and earth, between ter-
8 7 6 5 4 3 2 1
minal No. 28 and earth, also voltage between ter- 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
minal No. 29 and earth. 35 34 33 32 31 30 29 28 27 26 25 24
OK: System voltage AK501995 AB

NO : Check and repair harness between B-104
idle speed control servo and C-121
engine-ECU.
TROUBLESHOOTING

STEP 8. Check harness between B-104 idle
speed control servo and C-121 engine-ECU NO : Repair the damaged harness wire.
connector.
Connector : B-104
3 2 1 No. 2 or No. 5) idle speed control servo
6 5 4 connector and B-12X (terminal No. 4) engine
Harness side control relay connector.
connector
Connector : B-104
B-104 (B) 3 2 1
6 5 4
Harness side
AK305029AB connector
Connector: C-121 B-104 (B)
AK305029AB

triangle marks
2 1
B-12X
4 3
C-121 (GR)
Harness side
<R. H. drive vehicles> connector
AK305003 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 • Refer to Data List Reference Table P.13A-372.
35 34 33 32 31 30 29 28 27 26 25 24
a. Item No. 45: Idle speed control servo
AK501995 AB
1. Harness between idle speed control servo termi- YES : Intermittent malfunction (Refer to GROUP
nal No. 1 and engine-ECU connector terminal 00 − How to Use
No. 14 Troubleshooting/Inspection Service Points
2. Harness between idle speed control servo termi- P.00-5).
nal No. 3 and engine-ECU connector terminal NO : Replace the engine-ECU.
No. 28
3. Harness between idle speed control servo termi-
nal No. 4 and engine-ECU connector terminal
No. 15
4. Harness between idle speed control servo termi-
nal No. 6 and engine-ECU connector terminal
No. 29
TROUBLESHOOTING
13A-195
Code No. P0513: Immobilizer System
Immobilizer system circuit
C-207-1
Immobilizer-ECU
1 2 3 4
C-207
C-207-1 3 MU801547
1 2
3 4 5 6 7
7
GR
C-124
21
R-W
98
C-117
(MU803783)
71 72 73 74 75 76 77
78 79 80 81 82 83 84 85 86 87 88 89 90
Engine-ECU
91 92 93 94 95 96 97 98 99 100
Wire colour code

AK501818 AB

• The signals are sent and received between
Check Condition
engine-ECU (terminal No. 98) and immobi-
lizer-ECU (terminal No. 7).
Judgment Criterion
FUNCTION • When the communication error between the
• Engine-ECU sends or receives the control sig- engine-ECU and the immobilizer-ECU continues
nals to or from immobilizer-ECU to certify the for 2 seconds or more.
ignition key.
NOTE: .
PROBABLE CAUSES
• If the registered ignition keys are close each • Open/short circuit in immobilizer system circuit or
other when starting the engine, radio interfer- loose connector contact
ence may cause this code to be displayed. • Failed immobilizer-ECU
• This code may be displayed when registering • Failed engine-ECU
the key encrypted code.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Check harness between C-207 (terminal

No. 7) immobilizer-ECU connector and C-117
STEP 1. Connector check: C-207 (terminal No. 98) engine-ECU connector.
immobilizer-ECU connector and C-117 Connector : C-207 2 1
engine-ECU connector 7 6 5 4 3
Connector : C-207 Harness side
2 1 connector
7 6 5 4 3
Harness side
connector
C-207
AK305030 AB
C-207
AK305030 AB
Connector: C-117
Connector: C-117
C-117 (GR)

C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
C-117 (GR) 100 99 98 97 96 95 94 93 92 91
77 76 75 74 73 72 71 Harness side connector
90 89 88 87 86 85 84 83 82 81 80 79 78 AK501996 AB
100 99 98 97 96 95 94 93 92 91
Harness side connector NOTE: Before checking harness, check intermediate
AK501996 AB
connector C-124, and repair if necessary.
YES : Go to Step 2 . age.
TROUBLESHOOTING
13A-197
STEP 3. Check the trouble symptoms. STEP 4. Replace the immobilizer-ECU.
• After replacing the immobilizer-ECU, re-check the
YES : Go to Step 4 . trouble symptoms.
NO : Intermittent malfunction (Refer to GROUP Q: Does trouble symptom persist?
00 − How to Use YES : Replace the engine-ECU.
Troubleshooting/Inspection Service Points NO : The check is end.
P.00-5).
Code No. P0551: Power Steering Fluid Pressure Switch System
Power steering fluid pressure switch circuit
C-119
(MU803782)
41 42 43 44 45 46 47
48 49 50 51 52 53 54 55 56 57 58 59
Engine-ECU
60 61 62 63 64 65 66 67 68
54
R-W
5 <A-13> (*1) or
15 <C-31> (*2)
R-W
1
A-40
1 Power steering fluid

pressure switch
NOTE
Wire colour code
AK501819AB
CONDITION
• The battery voltage is applied to the power steer-
ing fluid pressure switch (terminal No. 1) from the
TROUBLESHOOTING
FUNCTION STEP 1. Connector check: A-40 power steering

• It is detected whether a load is applied on the fluid pressure switch connector
power steering fluid pump by steering or not, and
the signal is inputted to the engine-ECU. When Connector: A-40
the power steering fluid pressure switch "ON" sig- A-40 (B)
nal (a large load on the power steering fluid
pump) is inputted, the engine-ECU provides the
idle-up control.
TROUBLE JUDGMENT
1
Check Conditions Harness side
• The engine coolant temperature is 30°C or connector AK502001AB
higher.
• Drive for 4 seconds or more with the vehicle Q: Is the check result normal?
speed is 50 km/h or more. Stop the vehicle (vehi- YES : Go to Step 2 .
cle speed is 1.5 km/h or less). Repeat 10 times is NO : Repair or replace the connector.
more.
Judgment Criterion STEP 2. Perform voltage measurement at A-40
• The power steering fluid pressure switch remains power steering fluid pressure switch connector.
in "ON" position. Connector: A-40
PROBABLE CAUSES A-40 (B)
• Failed power steering fluid pressure switch

• Open/short circuit in power steering fluid pres-
sure switch circuit or loose connector contact
1
connector
NOTE: . AK502001AB
*1: L.H. drive vehicles • Disconnect connector, and measure at harness

*2: R.H. drive vehicles side.
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
13A-199
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB

Connector: A-40
• Voltage between terminal No. 54 and earth. A-40 (B)
OK: System voltage

NO : Go to Step 5 .
1
Harness side

YES : Check intermediate connector A-13*1 or
C-31*2, and repair if necessary. If
intermediate connector is normal, check and
repair harness between A-40 (terminal No.
1) power steering fluid pressure switch
TROUBLESHOOTING
STEP 5. Connector check: C-119 engine-ECU STEP 6. Check harness between A-40 (terminal
connector No. 1) power steering fluid pressure switch
Connector: C-119
Connector: A-40
A-40 (B)
1
Connector: C-119
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

connector A-13*1 or C-31*2, and repair if necessary.
TROUBLESHOOTING
13A-201
a. Item No. 27: Power steering fluid pressure
Connector: C-119
switch
00 − How to Use
P.00-5).

engine-ECU connector. C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
C-119 (GR) 68 67 66 65 64 63 62 61 60

AK501994 AB

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

• Engine: Idling
OK:
System voltage (Steering wheel: Stationary)
1 V or less (Steering wheel: Turned)
NO : Go to Step 9 .
TROUBLESHOOTING
STEP 10. Check harness between A-40 (terminal STEP 11. Connector check: C-119 engine-ECU
No. 1) power steering fluid pressure switch connector
Connector: C-119
Connector: A-40
A-40 (B)
1
Connector: C-119
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

YES : Replace the power steering fluid pressure
switch.
TROUBLESHOOTING
13A-203
Code No. P0622: Alternator FR Terminal System
Alternator FR terminal circuit
C-119
(MU803782)
41 42 43 44 45 46 47
Engine-ECU
48 49 50 51 52 53 54 55 56 57 58 59
60 61 62 63 64 65 66 67 68
52
B-14
5
4
B-25
(MU802066)
M
IC Voltage Alternator
1 2 3 4 regulator
Wire colour code

R: Red P: Pink V: Violet
AK501820 AB

• The energized state of the alternator field coil is
Check Condition
inputted from the alternator (terminal No. 4) to the
• Engine speed is 50 r/min. or more.
Judgment Criterion
FUNCTION • Input voltage from alternator FR terminal is the
• A signal of the power supply duty ratio for the system voltage or more for 20 seconds.
alternator field coil is inputted to the engine-ECU.
• In response to the signal, the engine-ECU PROBABLE CAUSES
detects the alternator output current and controls • Open circuit in alternator FR terminal circuit
the idling speed according to the output current • Failed engine-ECU
(electric load).
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Connector check: C-119 engine-ECU

connector
STEP 1. Connector check: B-14 intermediate Connector: C-119
connector
Connector : B-14
B-14(B)
5 4 3 2 1
10 9 8 7 6
Female side C-119 (GR)
connector AK305035AC

intermediate connector.
Connector : B-14 C-119 (GR)
B-14(B)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
1 2 3 4 5 Q: Is the check result normal?

6 7 8 9 10 YES : Go to Step 4 .
Male side NO : Repair or replace the connector.
• Disconnect connector, and measure at male con-

nector side.
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
13A-205
STEP 4. Check harness between B-14 (terminal STEP 5. Check the trouble symptoms.
No. 5) intermediate connector and C-119 Q: Does trouble symptom persist?
(terminal No. 52) engine-ECU connector. YES : Replace the engine-ECU.
Connector : B-14 NO : Intermittent malfunction (Refer to GROUP
P.00-5).

5 4 3 2 1
intermediate connector.
10 9 8 7 6
Female side Connector : B-14
connector AK305035AC B-14(B)
Connector: C-119
5 4 3 2 1
10 9 8 7 6
Female side

C-119 (GR) • Voltage between terminal No. 5 and earth.
<R. H. drive vehicles> OK: System voltage
NO : Go to Step 7 .
STEP 7. Connector check: B-25 alternator

connector
C-119 (GR) Connector : B-25
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

M
Q: Is the check result normal? 4 3 2 1
YES : Go to Step 5 . Harness side B-25(GR)
NO : Repair the damaged harness wire. connector AK305036 AB

TROUBLESHOOTING
STEP 8. Check harness between B-25 (terminal STEP 9. Perform voltage measurement at B-14
No. 4) alternator connector and B-14 (terminal intermediate connector.
No. 5) intermediate connector. Connector : B-14
Connector : B-25 B-14(B)
5 4 3 2 1
M 10 9 8 7 6
4 3 2 1 Female side
Harness side B-25(GR) connector AK305035AC
Connector : B-14
B-14(B) • Engine: Idle after warm-up
• Radiator fan: Inactive
OK: Switching the headlamps to ON from
5 4 3 2 1 OFF causes the voltage to fall.
10 9 8 7 6 Q: Is the check result normal?
Female side YES : Go to Step 5 .
connector AK305035AC NO : Go to Step 10 .
Q: Is the check result normal? STEP 10. Connector check: B-25 alternator
YES : Replace the alternator. connector
NO : Repair the damaged harness wire. Connector : B-25
M
4 3 2 1
Harness side B-25(GR)

TROUBLESHOOTING
13A-207
No. 4) alternator connector and B-14 (terminal No. 5) intermediate connector and C-119
No. 5) intermediate connector. (terminal No. 52) engine-ECU connector.
B-14(B)
M 1 2 3 4 5
4 3 2 1 6 7 8 9 10
Male side
connector AK305036 AB connector AK401753 AB

B-14(B)
5 4 3 2 1
10 9 8 7 6
Female side
• Check output line for damage. C-119 (GR)
Q: Is the check result normal? <R. H. drive vehicles>

C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB


YES : Replace the alternator.
NO : Intermittent malfunction (Refer to Group 00
− How to Use troubleshooting/Inspection
TROUBLESHOOTING
Code No. P0710: Transmisson Oil Temperature Sensor System
Transmission oil temperature sensor circuit
B-30
(MU802406)
1 2 Transmission oil temperature sensor
2 1
B G-R
B-27
1 2
B G-R
49 96
C-119 C-117
(MU803782) (MU803783)
41 42 43 44 45 46 47 71 72 73 74 75 76 77
48 49 50 51 52 53 54 55 56 57 58 59 78 79 80 81 82 83 84 85 86 87 88 89 90
60 61 62 63 64 65 66 67 68 91 92 93 94 95 96 97 98 99 100
5V
Engine-ECU
Wire colour code
AK501821 AB
OPERATION • The transmission oil temperature sensor is a kind

• A power voltage of 5 V is applied to the transmis- of resistor, which has characteristics to reduce its
sion oil temperature sensor output terminal (ter- resistance as the transmission oil temperature
minal No. 1) from the engine-ECU (terminal No. rises. Therefore, the sensor output voltage varies
96). with the transmission oil temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the transmission oil tempera-
(terminal No. 49) from the transmission oil tem- ture rises.
perature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION Check Conditions
• The transmission oil temperature sensor converts • 2 seconds later after the ignition switch has been
the transmission oil temperature into a voltage in "ON" position or the engine has started up.
signal, and inputs the voltage to the engine-ECU. • The engine coolant temperature of 82°C or more.
• The engine-ECU controls the boost pressure,
based on this signal. Judgment Criteria
• The sensor output voltage of 4.8 V or more
(transmission oil temperature of −40°C or equiva-
lent) for 2 seconds,
or
TROUBLESHOOTING
13A-209
• The sensor output voltage of 0.1 V or less (trans- STEP 2. Perform resistance measurement at B-30
mission oil temperature of 150°C or more, or transmission oil temperature sensor connector.
equivalent) for 2 seconds.
Connector: B-30
PROBABLE CAUSES
• Failed transmission oil temperature sensor
• Open/short circuit in transmission oil temperature
B-30 (B)
DIAGNOSIS PROCEDURE 2 1
Harness side
STEP 1. Connector check: B-30 transmission oil
• Disconnect connector, and measure at sensor
temperature sensor connector
side.
Connector: B-30 • Resistance between terminal No. 1 and No. 2.
OK:
Transmission oil temperature at −20°C: 14 − 17
kΩ
Transmission oil temperature at 0°C: 5.1 − 6.5
B-30 (B)
kΩ
2 1
kΩ
Harness side Transmission oil temperature at 40°C: 0.9 − 1.3
kΩ
Q: Is the check result normal? Transmission oil temperature at 60°C: 0.48 −
YES : Go to Step 3 . 0.68 kΩ
NO : Repair or replace the connector. Transmission oil temperature at 80°C: 0.26 −
0.36 kΩ
NO : Replace the transmission oil temperature
sensor.
TROUBLESHOOTING
transmission oil temperature sensor connector. engine-ECU connector.
Connector: B-30 Connector: C-117
B-30 (B)
2 1
Harness side
• Disconnect connector, and measure at harness C-117 (GR)

side.
OK: 4.5 − 4.9 V
NO : Go to Step 4 .
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB

• Disconnect B-30 transmission oil temperature
sensor.
OK: 4.5 − 4.9 V
NO : Go to Step 6 .
TROUBLESHOOTING
13A-211
connector connector
C-117 (GR) C-117 (GR)
C-117 (GR) C-117 (GR)

77 76 75 74 73 72 71 77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78 90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91 100 99 98 97 96 95 94 93 92 91
AK501996 AB AK501996 AB
Connector: B-30 Q: Is the check result normal?

B-30 (B)
2 1
Harness side

transmission oil temperature sensor
TROUBLESHOOTING
No. 1) transmission oil temperature sensor Q: Does trouble symptom persist?
connector and C-117 (terminal No. 96) YES : Replace the engine-ECU.
engine-ECU connector. NO : Intermittent malfunction (Refer to GROUP
Connector: B-30 00 − How to Use
P.00-5).
STEP 9. Perform resistance measurement at B-30

B-30 (B)
transmission oil temperature sensor connector.
2 1 Connector: B-30
Harness side
Connector: C-117
B-30 (B)
2 1
Harness side
• Disconnect connector and measure at harness

side.
OK: 2 Ω or less
C-117 (GR)
<R. H. drive vehicles> YES : Go to Step 12 .
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB
NOTE: Before checking harness, checking interme-

diate connector B-27, and repair if necessary.
TROUBLESHOOTING
13A-213
connector No. 2) transmission oil temperature sensor
Connector: C-119
Connector: B-30
B-30 (B)
2 1
Connector: C-119
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
NOTE: Before checking harness, checking interme-

diate connector B-27, and repair if necessary.
TROUBLESHOOTING
transmission oil temperature sensor connector. connector
B-30 (B)
2 1
Harness side

OK:
Transmission oil temperature at −20°C: 3.9 −
4.5 V
V
V C-117 (GR)
V 77 76 75 74 73 72 71
Transmission oil temperature at 60°C: 0.7 − 1.3 90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
V
Transmission oil temperature at 80°C: 0.3 − 0.9 AK501996 AB
V
Q: Is the check result normal? Connector: B-30
B-30 (B)
2 1
Harness side

connector is normal, check harness
between B-30 (terminal No. 1) transmission
oil temperature sensor connector and C-117
TROUBLESHOOTING
13A-215
STEP 14. Connector check: C-117 and C-119
engine-ECU connector
C-117 (GR)
C-119 (GR)
C-117 (GR) C-119 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501997 AB

TROUBLESHOOTING
Code No. P1012: Intake Camshaft Position Sensor System
Intake camshaft position sensor circuit
Battery
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2
3 4
4 3
R-Y
To engine-ECU
3
B-124
MU802337
1 2 3 Intake camshaft position sensor
1 2
B L-R
34 53
C-121 C-119
(MU803783) (MU803782)
1 2 3 4 5 6 7 8 41 42 43 44 45 46 47
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 48 49 50 51 52 53 54 55 56 57 58 59
24 25 26 27 28 29 30 3132 33 34 35 60 61 62 63 64 65 66 67 68
5V
Engine-ECU
NOTE
Wire colour code
AK501813 AC
OPERATION camshaft position sensor (terminal No. 1).

• Power is supplied to the intake camshaft position • A power voltage of 5 V is applied to the intake
sensor (terminal No. 3) from the engine control camshaft position sensor output terminal (termi-
relay (terminal No. 4) and is earthed to the nal No. 2) from the engine-ECU (terminal No. 53).
engine-ECU (terminal No. 34) from the intake
TROUBLESHOOTING
13A-217
FUNCTION STEP 2. Perform voltage measurement at B-124
• The intake camshaft position sensor detects the intake camshaft position sensor connector.
top dead center on the compression stroke of the
No. 1 cylinder and inputs a pulse signal to the Connector: B-124
engine-ECU.
TROUBLE JUDGMENT
Check Condition
• Engine: During the engine cranking and the driv- B-124 (B)
ing. 3 2 1
Judgment Criterion Harness side

connector
• The sensor output voltage remains unchanged AK502002 AB
(no pulse signal is inputted) for 4 seconds. • Disconnect connector, and measure at harness
side.
PROBABLE CAUSE • Ignition switch: "ON"
• Failed intake camshaft position sensor • Voltage between terminal No. 3 and earth.
• Open/short circuit in intake camshaft position OK: System voltage
NO : Go to Step 3 .
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-124 intake camshaft

position sensor connector
Connector: B-124
B-124 (B)
3 2 1
Harness side

TROUBLESHOOTING
STEP 3. Connector check: B-12X engine control STEP 4. Perform voltage measurement at B-124
relay connector intake camshaft position sensor connector.
Connector : B-12X Relay box’s Connector: B-124
triangle marks
2 1
B-12X
4 3
Harness side B-124 (B)
connector 3 2 1
Harness side
AK305003 AB connector AK502002 AB

Connector: B-124
side.
OK: 4.9 − 5.1 V
B-124 (B) YES : Go to Step 10 .
3 2 1 NO : Go to Step 5 .
Harness side

(terminal No. 3) intake camshaft position
sensor connector and B-12X (terminal No.
4) engine control relay connector.
open/short circuit.
TROUBLESHOOTING
13A-219
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB
B-124 (B) B-124 (B)

3 2 1 3 2 1

• Disconnect B-124 intake camshaft position sen- YES : Check and repair harness between B-124
sor connector. (terminal No. 2) intake camshaft position
• Ignition switch: "ON" sensor connector and C-119 (terminal No.
• Voltage between terminal No. 53 and earth. 53) engine-ECU connector.
OK: 4.9 − 5.1 V • Check output line for open circuit.
Q: Is the check result normal? NO : Repair or replace the connector.
NO : Go to Step 7 .
TROUBLESHOOTING
connector No. 2) intake camshaft position sensor connector
Connector: C-119
connector.
Connector: B-124
B-124 (B)
3 2 1

Connector: C-119
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
C-119 (GR)
AK501994 AB
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB


00 − How to Use
P.00-5).
TROUBLESHOOTING
13A-221
STEP 10. Perform resistance measurement at STEP 12. Check harness between B-124 (terminal
B-124 intake camshaft position sensor No. 1) intake camshaft position sensor connector
connector. and C-121 (terminal No. 34) engine-ECU
connector.
Connector: B-124
Connector: B-124
B-124 (B)
3 2 1 B-124 (B)
Harness side 3 2 1
connector
• Disconnect connector, and measure at harness AK502002 AB
side.
Connector: C-121
OK: 2 Ω or less

connector
Connector: C-121
C-121 (GR)
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
<R. H. drive vehicles> 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
STEP 13. Perform output wave pattern STEP 15. Check harness between B-124 (terminal
measurement at B-124 intake camshaft position No. 3) intake camshaft position sensor connector
sensor connector (Using an oscilloscope). and B-12X (terminal No. 4) engine control relay
connector.
Connector: B-124
Connector: B-124
B-124 (B)
3 2 1 B-124 (B)
Harness side 3 2 1
connector
• Use special tool test harness (MB991709) to con- AK502002 AB

• Engine: Idling triangle marks
OK: Waveforms should be displayed on 2 1
B-12X
Inspection procedure using an oscilloscope 4 3
(Refer to P.13A-385), its maximum value
Harness side
should be 4.8 V or more, and its minimum connector
value should be 0.6 V or less with no noise in
waveform. AK305003 AB
Q: Is the check result normal? • Check power supply line for damage.
NO : Go to Step 14 . Q: Is the check result normal?
relay connector.
triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB

TROUBLESHOOTING
13A-223
STEP 16. Connector check: C-119 and C-121 STEP 17. Check harness between B-124 (terminal
engine-ECU connectors No. 2) intake camshaft position sensor connector
connector.
Connector: B-124
B-124 (B)
3 2 1
C-119 (GR) C-121 (GR) Harness side

Connector: C-119
C-121 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 C-119 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501998 AB

47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
STEP 18. Check harness between B-124 (terminal STEP 19. Check the intake camshaft position
No. 1) intake camshaft position sensor connector sensing cylinder.
and C-121 (terminal No. 34) engine-ECU Q: Is the check result normal?
connector. YES : Go to Step 20 .
Connector: B-124 NO : Replace the intake camshaft position
sensing cylinder.

B-124 (B) YES : Replace the intake camshaft position
3 2 1 sensor.
Harness side
00 − How to Use
Connector: C-121 P.00-5).
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
13A-225
Code No. P1021: Oil Feeder Control Valve System
Oil feeder control valve circuit
Battery
B-Y 6 <A-13> (*1) or

13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2 Engine
control
3 4 relay
4 3
R-Y To engine-ECU
28
J/C (6)
C-105
33
R-Y
B-123 1
MU802779
1 2 Oil feeder control

valve
P-B
C-121 32
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Engine-ECU
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501822 AB
TROUBLESHOOTING
OPERATION STEP 2. Perform resistance measurement at

• Power is supplied to the oil feeder control valve B-123 oil feeder control valve connector.
(terminal No. 1) from the engine control relay (ter-
minal No. 4). Connector: B-123
power transistor in the unit be in ON position, and
that makes currents go on the oil feeder control
valve (terminal No. 2). B-123 (B)
FUNCTION
2 1
• The oil feeder control valve controls the phase
angle of the intake camshaft by the signal from Harness side
the engine-ECU.
• Disconnect connector, and measure at control
TROUBLE JUDGMENT valve side.
Check Condition
• The oil feeder control valve does not operate. OK: 6.9 − 7.9 Ω (at 20°C)
Judgment Criterion Q: Is the check result normal?

• The oil feeder control valve drive terminal voltage
NO : Replace the oil feeder control valve.
of the engine-ECU is not normal for 4 seconds or
more.
PROBABLE CAUSE oil feeder control valve connector.
• Failed oil feeder control valve Connector: B-123
• Open/short circuit in oil feeder control valve cir-
cuit or loose connector contact
B-123 (B)
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-123 oil feeder 2 1

control valve connector Harness side
Connector: B-123
side.
• Ignition switch: ON
B-123 (B)
OK: System voltage
2 1 YES : Go to Step 5 .
Harness side NO : Go to Step 4 .

TROUBLESHOOTING
13A-227
triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
Connector: B-123 C-121 (GR)

B-123 (B)
2 1
Harness side

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
YES : Check intermediate connector C-105, and 35 34 33 32 31 30 29 28 27 26 25 24
repair if necessary. If intermediate Harness side connector
connector is normal, check and repair AK501995 AB
harness between B-123 (terminal No. 1) oil • Disconnect connector, and measure at harness
feeder control valve connector and B-12X side.
(terminal No. 4) engine control relay • Ignition switch: ON
connector. • Voltage between terminal No. 32 and earth.
• Check power line for open/short OK: System voltage
circuit.
NO : Go to Step 6 .
TROUBLESHOOTING
connector connector
C-121 (GR) C-121 (GR)

C-121 (GR) C-121 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB AK501995 AB
Connector: B-123 Q: Is the check result normal?

B-123 (B)
2 1
Harness side

(terminal No. 2) oil feeder control valve
circuit.
TROUBLESHOOTING
13A-229
No. 2) oil feeder control valve connector and No. 1) oil feeder control valve connector and
C-121 (terminal No. 32) engine-ECU connector. B-12X (terminal No. 4) engine control relay
connector.
Connector: B-123
Connector: B-123
B-123 (B)
B-123 (B)
2 1
Harness side 2 1
Connector: C-121
<L. H. drive vehicles> triangle marks
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
C-121 (GR)
<R. H. drive vehicles> NOTE: Before checking harness, check intermediate
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 YES : Replace the engine-ECU.
35 34 33 32 31 30 29 28 27 26 25 24 NO : Intermittent malfunction (Refer to GROUP
Harness side connector 00 − How to Use
AK501995 AB
• Check output line for damage. P.00-5).
TROUBLESHOOTING
Code No. P1603: Battery Back-up Line System
Battery back-up circuit
Battery
W W
Relay box 8
20A
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
R-B
60
C-119
(MU803782)
41 42 43 44 45 46 47 Back-up
48 49 50 51 52 53 54 55 56 57 58 59 power supply Engine-ECU
60 61 62 63 64 65 66 67 68
NOTE
Wire colour code
R: Red P: Pink V: Violet
AK501823 AB

• Power is directly supplied to the engine-ECU (ter-
Check Condition
minal No. 60) from the battery.
FUNCTION Judgment Criterion
• The engine-ECU is check the open circuit of bat- • The battery back-up line voltage 6 V or less.
tery back-up line.
TROUBLESHOOTING
13A-231
PROBABLE CAUSES STEP 2. Perform voltage measurement at C-119
• Open/short circuit in battery back-up line circuit or engine-ECU connector.
• Failed engine-ECU Connector: C-119
DIAGNOSIS PROCEDURE

• Temporarily place the ignition switch in "LOCK"
(OFF) position, and 10 seconds after that, place it
in "ON" position again.
Q: Is the diagnosis code P1603 set?
00 − How to use Troubleshooting/Inspection
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

side.
OK: System voltage
NO : Check intermediate connector A-13, <L.H.
drive vehicles> or C-31 <R.H. drive
vehicles>, and repair if necessary. If
repair harness between battery and C-119
open/short circuit.
TROUBLESHOOTING
STEP 3. Connector check: C-119 engine-ECU STEP 4. Check the trouble symptoms.
connector Q: Does trouble symptom persist?
Connector: C-119 YES : Replace the engine-ECU.
00 − How to Use
P.00-5).
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
13A-233
INSPECTION CHART FOR TROUBLE SYMPTOMS
M1131151501655
Items Trouble symptom Inspection

procedure
No.
Communication Communication with all system is not possible 1
with M.U.T.-II/III is Communication with engine-ECU only is not possible 2
impossible
Engine warning The engine warning lamp does not illuminate right after the ignition switch 3
lamp is turned to the "ON" position
The engine warning lamp remains illuminating and never goes out 4
Starting Starting impossible The starter is impossible to operate. 5
(starter inoperative)
Starting impossible The starter is operative and cranks 6
(Starter operative but no initial the engine, but none of initial
combustion) combustion is in the cylinders and
the engine is not started.
Starting impossible The initial combustion occurs, but 7
(Initial combustion but no complete the engine stalls soon due to the
combustion) incomplete combustion.
Improper starting It is long cranking to start the engine.
(Long time to start)
Improper idling Unstable idling The engine speed is not constant 8
(Rough idling, hunting) 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 The engine stalls during the idling in
(Die out) no relation to the vehicle movement.
Engine stalls The engine stalls when starting the The engine stalls during the 9
car operation, or when the accelerator
(Pass out) pedal is depressed from the idling.
The engine stalls when The engine stalls at the deceleration. 10
decelerating
TROUBLESHOOTING

procedure
No.
Driving 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 The large impact feeling occurs at 13
when accelerating the acceleration.
The feeling of impact or vibration The large impact feeling occurs at 14
when decelerating the deceleration.
Knocking Sharp sound like a hammer striking 15
on the cylinder walls during the
driving can be heard and wrongly
affects the driving.
Ignition timing offset The basic ignition timing is deviated 16
from the datum value.
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, The exhaust gas is extremely rank 18
high-concentration CO/HC during odor, white smoke or black smoke.
idling The concentration of CO & HC is
high during the idling.
Charging Battery rundown The battery is soon rundown or the 19
performance charging ability of battery is small.
Cooling Overheating The temperature of engine cooling 20
performance water is extremely high.
Abnormal rotation of fan Motor The fan motor is abnormally rotated 21
when the ignition switch is in "ON"
position in no relation to the engine
cooling water temperature.
TROUBLESHOOTING
13A-235
procedure
No.
A/C performance Poor A/C Performance The temperature of air cooling from 22
A/C is not efficient or very far from
the target temperature.
PROBLEM SYMPTOMS TABLE
Inspection Trouble symptom Reference
procedure page
No.
1 Communication with all system is not possible P.13A-237
2 Communication with engine-ECU only is not possible P.13A-240
3 The engine warning lamp does not illuminate right after the ignition switch is P.13A-243
turned "ON" position
4 The engine warning lamp remains illuminating and never goes out P.13A-252
5 Starting impossible (No initial combustion) P.13A-255
6 Starting impossible (Starter operative but no initial combustion) P.13A-262
7 Starting impossible (Initial combustion but no complete combustion) P.13A-264
Starting impossible (Long time to start)
8 Unstable idling (Rough idling, hunting) P.13A-268
Improper idling speed (Too high or too low)
Engine stalls during idling (Die out)
9 The engine stalls when starting the car (pass out) P.13A-275
10 The engine stalls when decelerating P.13A-277
11 Engine does not revolve up P.13A-279
12 Hesitation, sag P.13A-281
Poor acceleration
Stumble
Surge
13 The feeling of impact or vibration when accelerating P.13A-283
14 The feeling of impact or vibration when decelerating P.13A-285
15 Knocking P.13A-285
16 Ignition timing offset P.13A-287
17 Run on (Dieseling) P.13A-288
18 Odor, white smoke, black smoke, high-concentration CO/HC during idling P.13A-289
19 Battery rundown P.13A-291
20 Overheating P.13A-296
21 Abnormal rotation of fan motor P.13A-297
22 Poor A/C performance P.13A-300
23 Engine-ECU power supply, engine control relay, ignition switch-IG1 system P.13A-302
24 Fuel pump system P.13A-313
TROUBLESHOOTING
Inspection Trouble symptom Reference

procedure page
No.
25 Radiator fan control relay system P.13A-324
26 Condenser fan control relay system P.13A-330
27 A/C switch system P.13A-341
28 A/C compressor relay system P.13A-344
29 A/C load signal system P.13A-352
30 Ignition circuit system <L.H. drive vehicles> P.13A-356
31 Ignition circuit system <R.H. drive vehicles> P.13A-363
TROUBLESHOOTING
13A-237
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with All System is not Possible
Diagnosis connector circuit
Fusible link (1)
W-R
C-126
1
W-R
C-211
1
15 J/B
15A
12
C-214
G-R (*1) or
W (*2)
C-14 16
1 2 3 4 5 6 7 8
Diagnosis connector
9 10 1112 13 14 1516
4 5
B B
NOTE
Wire colour code
AK305249 AC
OPERATION COMMENTS ON TROUBLE SYMPTOM

• Battery voltage is applied to diagnosis connector • Failure is possibly caused by failed power supply
(terminal No.16). circuit or failed earthing circuit of diagnosis con-
• Diagnosis connector (terminals No. 4 and 5) are nector.
earthed to the vehicle body.
TROUBLESHOOTING
PROBABLE CAUSES STEP 3. Perform voltage measurement at C-14

• Failed diagnosis connector diagnosis connector.
• Open/short circuit in diagnosis connector circuit.
• Failed M.U.T.-II/III Connector: C-14
C-14 (B)
DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-14 diagnosis

connector 1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Connector: C-14
AK203591AD
C-14 (B)
• Disconnect connector, and measure at the har-
ness side.
1 2 3 4 5 6 7 8 OK: System voltage
9 10 1112 13 14 1516
Harness side connector YES : Go to Step 4 .
AK203591AD
NO : Check intermediate connectors C-126, C-211
Q: Is the check result normal? and C-214, and repair if necessary. If
YES : Go to Step 2 . connectors are normal, check and repair
NO : Repair or replace the connector. harness between C-14 (terminal No. 16)
diagnosis connector and battery.
STEP 2. Perform resistance measurement at C-14
open/short circuit.
diagnosis connector.
Connector: C-14
STEP 4. Replace M.U.T.-II/III.
C-14 (B)
• After replacing the M.U.T.-II/III, re-check the trou-
ble symptoms.
1 2 3 4 5 6 7 8 NO : The check is end.
9 10 1112 13 14 1516

AK203591AD

side.
• Resistance between terminal No. 4 and earth,
also between terminal No. 5 and earth.
OK: 2 Ω or less
NO : Check and repair harness between C-14
(terminal No. 4) diagnosis connector and
body earth, also between C-14 (terminal No.
5) diagnosis connector and body earth.
• Check earthing line for open circuit
and damage.
TROUBLESHOOTING
13A-239
STEP 5. Check harness between C-14 (terminal
No. 16) diagnosis connector and battery.
Connector: C-14
C-14 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516

AK203591AD

connectors C-126, C-211 and C-214, and repair if
necessary.
(terminal No. 4 and No. 5) diagnosis
connector and body earth.
TROUBLESHOOTING
Inspection Procedure 2: Communication with Engine-ECU only is not Possible.
Diagnosis connector circuit
C-117
(MU803783)
71 72 73 74 75 76 77
78 79 80 81 82 83 84 85 86 87 88 89 90 Engine-ECU
91 92 93 94 95 96 97 98 99 100
85
*1 *2
O
20
J/C (6)
C-105 O
19
O
23
C-124
9 (*1) or 14 (*2)
J/C (2) <C-101> (*1) or <C-23> (*2)
10 (*1) or 15 (*2)
O
C-14 7
1 2 3 4 5 6 7 8
Diagnosis connector
9 10 1112 13 14 1516
NOTE
Wire colour code

AK501824 AB
OPERATION COMMENTS ON TROUBLE SYMPTOM

• There is data communication between diagnosis • Failure is possibly caused by failed power supply
connector output terminal (terminal No. 7) and circuit or failed earthing circuit of engine-ECU.
TROUBLESHOOTING
13A-241
PROBABLE CAUSES STEP 2. Connector check: C-117 engine-ECU
• Open/short circuit in engine-ECU power circuit connector
• Short circuit in diagnosis connector circuit
• Failed engine-ECU Connector: C-117
DIAGNOSIS PROCEDURE
NOTE: .
STEP 1. Check engine warning lamp.

• Ignition switch: OFF → ON
C-117 (GR)
Q: Is lamp illuminating for few seconds?
YES : Go to Step 2 . <R. H. drive vehicles>
NO : Check engine-ECU power supply, engine
control relay and ignition switch IG1 system
(Refer to Inspection Procedure 23
P.13A-302).
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB

TROUBLESHOOTING
STEP 3. Check harness between C-14 (terminal STEP 4. Check the trouble symptom.
No. 7) diagnosis connector and C-117 (terminal Q: Does trouble symptom persist?
No. 85) engine-ECU connector. YES : Replace the engine-ECU.
Connector: C-14 NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
C-14 (B) Troubleshooting/Inspection Service Points
P.00-5).
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516

AK203591AD
Connector: C-117
C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB
NOTE: Before Checking harness, check intermedi-

ate connectors C-105*1, C-124 and C-101*1 or
C-23*2, and repair if necessary.
• Check communication line for open/short circuit
and damage.
TROUBLESHOOTING
13A-243
Inspection Procedure 3: The Engine Warning Lamp does not Illuminate Right after the Ignition Switch
is Turned to the "ON" Position
Engine warning lamp (check engine lamp) circuit
Ignition switch
C-208
R LOCK
1 2 3 ST ACC
4 5 6 IG1 IG2
B-W
C-211
6
2 J/B
7.5A
25
C-214
*1 *2
Y-R
19
J/C (4)
C-23 O
17
Y-R
9
C-01
engine
Check
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Engine warning lamp (check engine lamp)
17
W-L
C-124
9
W-L
22
C-121
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Engine-ECU
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501825 AB
TROUBLESHOOTING
OPERATION STEP 3. Connector check: C-01 combination

• Battery voltage is applied to engine warning lamp meter connector
of combination meter connector (terminal No. 9)
from ignition switch. Connector: C-01
• Engine-ECU (terminal No. 22) makes power tran- <L. H. drive vehicles>
sistor in unit be in "ON" position, and that makes
currents go on engine warning lamp of combina- C-01
tion meter connector (terminal No. 17).
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.
PROBABLE CAUSES
• Engine warming lamp bulb burnt out C-01
• Failed ignition switch
• Open/short circuit in engine warning lamp circuit
or loose connector contact
DIAGNOSIS PROCEDURE
STEP 1. Check engine start-up.

Q: Is engine started?
YES : Go to Step 2 . 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Check engine-ECU power supply, engine Harness side connector

control relay and ignition switch IG1 system AK301236 AC
P.13A-302). Q: Is the check result normal?
STEP 2. Check engine warning lamp for
burnt-out bulb.
NO : Replace the engine warning lamp.
TROUBLESHOOTING
13A-245
combination meter connector.
Connector: C-01
C-01
C-01
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AK301236 AC

ness side.
OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
STEP 5. Connector check: C-208 ignition switch Connector: C-01

connector <L. H. drive vehicles>
Connector: C-208
<L. H. drive vehicles> C-01
C-208

C-01
C-208
3 2 1
6 5 4 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AK305251AB
AK301236 AC

YES : Check intermediate connectors C-23 <L.H.
drive vehicles> or C-214 and C-211, and
connectors are normal, check and repair
harness between C-01 (terminal No. 9)
combination meter connector and C-208
(terminal No. 2) ignition switch connector.
open/short circuit.
TROUBLESHOOTING
13A-247
connector engine-ECU connector.
C-121 (GR) C-121 (GR)

C-121 (GR) C-121 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB AK501995 AB

YES : Go to Step 7 . ness side.
NO : Repair or replace the connector. • Ignition switch: "ON"
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING
STEP 8. Connector check: C-01 combination Connector: C-121

meter connector
Connector: C-01
C-01
C-121 (GR)
C-01
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side connector combination meter connector and C-121
AK301236 AC (terminal No. 22) engine-ECU connector.
circuit.
TROUBLESHOOTING
13A-249
STEP 9. Connector check: C-208 ignition switch
connector
Connector: C-208
C-208
C-208
3 2 1
6 5 4
AK305251AB

TROUBLESHOOTING
STEP 10. Check harness between C-01 (terminal Connector: C-208

No. 9) combination connector and C-208 <L. H. drive vehicles>
Connector: C-01
C-208
C-01
C-208
C-01
3 2 1
6 5 4
AK305251AB

connectors C-23 <L.H. drive vehicles>, C-211and
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-214, and repair if necessary.
AK301236 AC
TROUBLESHOOTING
13A-251
No. 17) combination connector and C-121
Connector: C-01
C-01
C-121 (GR)
C-121 (GR)
C-01
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AK301236 AC
00 − How to Use
P.00-5).
TROUBLESHOOTING
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and never goes out
Engine warning lamp (check engine lamp) circuit
Ignition switch
C-208
R LOCK
1 2 3 ST ACC
4 5 6 IG1 IG2
B-W
C-211
6
2 J/B
7.5A
25
C-214
*1 *2
Y-R
19
J/C (4)
C-23 O
17
Y-R
9
C-01
engine
Check
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Engine warning lamp (check engine lamp)
17
W-L
C-124
9
W-L
22
C-121
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Engine-ECU
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501825 AB
TROUBLESHOOTING
13A-253
OPERATION STEP 2. Connector check: C-121 engine-ECU
• Battery voltage is applied to engine warning lamp connector
(terminal No. 9) from ignition switch.
• Engine-ECU (terminal No. 22) makes power tran- Connector: C-121
sistor in unit be in "ON" position, and that makes <L. H. drive vehicles>
currents go on engine warning lamp (terminal No.
17).

• Engine-ECU has detected failed sensor or failed
actuator. Or failure is possibly caused by short
circuit or other faults.
PROBABLE CAUSES C-121 (GR)

• Short circuit in between engine warning lamp and
engine-ECU circuit.
DIAGNOSIS PROCEDURE

Q: Diagnosis code set? C-121 (GR)
to P.13A-17). 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
NO : Go to Step 2 . 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
STEP 3. Perform voltage measurement at C-121 Connector: C-01

Connector: C-121
<L. H. drive vehicles> C-01
C-121 (GR)
C-01
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

AK301236 AC

ness side.
OK: System voltage
NO : Check intermediate connector C-124, and
combination meter connector and C-121

00 − How to Use
P.00-5).
TROUBLESHOOTING
13A-255
Inspection Procedure 5: Starting Impossible (No Initial Combustion)
Starter circuit
Ignition switch
C-208
LOCK
ACC
R IG2 1 2 3
ST IG1
4 5 6
Battery
5
B-Y
C-123
7
B-R
B-L
B-R
B-14 B-R
3
B-R
B-19 B-21
1 1 68
Starter C-119
B-21 (MU803782)
B-19 (MU801211)
ON 41 42 43 44 45 46 47
OFF
1 1 48 49 50 51 52 53 54 55 56 57 58 59
M 60 61 62 63 64 65 66 67 68
Engine-ECU
Wire colour code

AK501826 AB
OPERATION COMMENT ON TROUBLE SYMPTOM

• If the ignition switch is turned to "START" posi- • Failure is possibly caused by failed starter itself
tion, battery voltage is applied to starter (terminal or failed related circuit.
No. 1).
• If the ignition switch is turned to "START" posi- PROBABLE CAUSES
tion, battery voltage is applied to engine-ECU • Failed battery
(terminal No. 68) from ignition switch. Because of • Failed starter motor
this, engine-ECU detects that the engine is • Open/short circuit in starter associated circuit or
cranked. loose connector contact
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 4. Perform voltage measurement at C-119

STEP 1. Check battery voltage. Connector: C-119
• Measure battery voltage at cranking.
OK: 8 V or higher
NO : Check battery (Refer to GROUP 54A −
Battery − On-vehicle Service − Battery Test
P.54A-5).
STEP 2. M.U.T.-II/III data list C-119 (GR)

• Item No. 18: Cranking signal
OK: <R. H. drive vehicles>
ON (Ignition switch: ST)
OFF (Ignition switch: ON)
NO : Go to Step 3 .
STEP 3. Connector check: C-119 engine-ECU C-119 (GR)

connector 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
Connector: C-119 68 67 66 65 64 63 62 61 60
<L. H. drive vehicles> Harness side connector

AK501994 AB

ness side.
• Ignition switch: ST
OK: System voltage
C-119 (GR)
NO : Go to Step 5 .
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
13A-257
connector
Connector: C-208
C-208
C-208
3 2 1
6 5 4
AK305251AB

TROUBLESHOOTING
STEP 6. Check ignition switch. Connector: C-208
Connector: C-119 <L. H. drive vehicles>
C-208
C-119 (GR)
C-208
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
3 2 1
6 5 4
AK501994 AB Harness side connector
AK305251AB
• Check ignition switch (Refer to GROUP 54A −

Ignition Switch − Ignition Switch − Inspection
P.54A-30).
YES : Check intermediate connectors C-123, and
inhibitor switch connector and C-208
open/short circuit.
NO : Replace the ignition switch.
TROUBLESHOOTING
13A-259
STEP 7. Connector check: C-208 ignition switch STEP 8. Connector check: B-21 starter connector
connector and B-21 starter connector Connector: B-21
Connector: C-208
1
<L. H. drive vehicles> B-21(B) Harness side
connector
C-208
AK305254 AB

starter connector.
Connector: B-21
C-208
1
connector
3 2 1
6 5 4
AK305251AB • Disconnect connector, and measure at the har-
Connector: B-21 ness side.
• Ignition switch: ST
1 • Voltage between terminal No. 1 and earth.
B-21(B) Harness side OK: System voltage
connector
AK305254 AB

YES : Check intermediate connectors C-123 and
B-14, and repair if necessary. If intermediate
ignition switch connector and B-21 (terminal
No. 1) starter connector.
TROUBLESHOOTING
STEP 10. Connector check: C-208 ignition switch STEP 11. Connector check: B-19 starter
connector connector
Connector: C-208 Connector: B-19
1
Harness side
connector
C-208
B-19 (B)
AK502004 AB

<R. H. drive vehicles> NO : Repair or replace the connector.

starter connector.
C-208
Connector: B-19
1
Harness side
connector
3 2 1
6 5 4
Harness side connector B-19 (B)
AK305251AB AK502004 AB
Connector: B-21 • Disconnect connector, and measure at the har-

ness side.
1 • Voltage between terminal No. 1 and earth.
B-21(B) Harness side OK: System voltage
connector
(terminal No. 1) starter connector and
battery.
AK305254 AB • Check power supply line for
open/short circuit.
YES : Check intermediate connectors B-14 and
C-123, and repair if necessary. If
intermediate connectors are normal, check
and repair harness between C-208 (terminal
No. 5) ignition switch connector and B-21
(terminal No. 1) starter connector.
damage.
TROUBLESHOOTING
13A-261
STEP 13. Check harness between C-208 (terminal STEP 14. Check harness between B-19 (terminal
No. 5) ignition switch connector and B-21 No. 1) starter connector and battery.
(terminal No. 1) starter connector.
Connector: B-19
Connector: C-208 1
Harness side
<L. H. drive vehicles> connector
C-208
B-19 (B)
AK502004 AB

YES : Replace the starter.
<R. H. drive vehicles> NO : Repair the damaged harness wire.
C-208
3 2 1
6 5 4
AK305251AB
Connector: B-21
1
connector
AK305254 AB

connectors B-14 and C-123, and repair if necessary.
TROUBLESHOOTING
Inspection Procedure 6: Starting impossible (Starter Operative but No Initial Combustion)
OPERATION STEP 4. M.U.T.-II/III actuator test

• Refer to inspection procedure, ignition circuit sys- • Item No. 07: Fuel pump
tem <L. H. drive vehicles>P.13A-356 or ignition OK: Operating sound of fuel pump can be
circuit system <R. H. drive vehicles>P.13A-363 heard.
COMMENTS ON TROUBLE SYMPTOM Q: Is the check result normal?
• Failure is possibly caused by failed ignition cir- YES : Go to Step 5 .
cuit, failed fuel feed or other faults. NO : Check fuel pump system (Refer to
Inspection Procedure 24 P.13A-313).
PROBABLE CAUSES
• Failed battery STEP 5. Check timing belt for breakage.
• Timing belt broken • Engine: Cranking
• Failed idle speed control OK: Camshaft rotates.
• Throttle valve fouled around
• Failed ignition system Q: Is the check result normal?
• Failed fuel system YES : Go to Step 6 .
NO : Replace the timing belt.
• Failed immobilizer system
STEP 6. Check the engine start ability.
DIAGNOSIS PROCEDURE • With depressing the accelerator pedal slightly,
and start the engine.
STEP 1. Check battery voltage. Q: Is the start ability good?
• Measure battery voltage at cranking. YES : Go to Step 7 .
NO : Go to Step 8 .
OK: 8 V or higher
STEP 7. Check idling speed control for operating
NO : Check battery (Refer to GROUP 54A − sound.
Battery − On-vehicle Service − Battery test • Check idle speed control servo for operating
sound (Refer to P.13A-408).
P.54A-5).
YES : Clean throttle body (throttle valve portion)
STEP 2. Check engine warning lamp for burnt out
bulb NO : Check idle speed control servo system
Q: Is the check result normal? (Refer to code No. P0505 P.13A-190).
NO : Check engine-ECU power supply, engine
control relay and ignition switch IG1 system
• Item No. 18: Cranking signal
P.13A-302). OK:
ON (Ignition switch: ST)
OFF (Ignition switch: ON)
Q: Diagnosis code set? YES : Go to Step 10 .
YES : Inspection chart for diagnosis codes (Refer NO : Go to Step 9 .
to P.13A-17).
NO : Go to Step 4 .
TROUBLESHOOTING
13A-263
STEP 9. Connector check: C-119 engine-ECU Connector: C-208
connector <L. H. drive vehicles>
Connector: C-119
C-208
C-119 (GR) <R. H. drive vehicles>
C-208
C-119 (GR)
47 46 45 44 43 42 41 3 2 1
59 58 57 56 55 54 53 52 51 50 49 48
6 5 4
68 67 66 65 64 63 62 61 60
AK501994 AB AK305251AB

ignition switch connector and C-119
circuit.

a. Item No. 22: Crank angle sensor
NO : Check crank angle sensor system (Refer to
Code No. P0335 P.13A-155).
TROUBLESHOOTING
STEP 11. Check injector for operating sound. STEP 12. Check ignition coil spark
• Check injector for operating sound (Refer to Q: Is the check result normal?
P.13A-406). YES : Go to Step 13 .
Q: Can operating sound be heard? NO : Check ignition circuit system (refer to
YES : Go to Step 12 . inspection procedure 30 <L. H. drive
NO : Check the injector system of the defective vehicles>P.13A-356 or inspection
cylinder procedure 31 <R. H. drive
(Refer to Code No. 0201: No. 1 injector system vehicles>P.13A-363).
P.13A-105).
(Refer to Code No. 0202: No. 2 injector system STEP 13. Replace the engine-ECU.
P.13A-111). • After replacing the engine-ECU, re-check the
(Refer to Code No. 0203: No. 3 injector system trouble symptoms.
P.13A-117). Q: Does trouble symptom persist?
(Refer to Code No. 0204: No. 4 injector system YES : Check for foreign matters (water, kerosene,
P.13A-123). etc.) in fuel and replace if necessary.
Inspection Procedure 7: Starting Impossible (Initial Combustion but no Complete Combustion),

Starting (Long Time to Start)
COMMENTS ON TROUBLE SYMPTOM STEP 2. Check battery voltage.

• Failure is possibly caused by poor ignition, incor- • Measure battery voltage at cranking.
rect air-fuel ratio at cranking, improper fuel pres- OK: 8 V or higher
sure or other faults.
PROBABLE CAUSES YES : Go to Step 3 .
• Failed battery NO : Check battery (Refer to GROUP 54A −
• Failed ignition system Battery − On-vehicle Service − Battery Test
• Failed fuel system P.54A-5).
• Failed air-fuel ratio control system
• Failed idle speed control system STEP 3. M.U.T.-II/III diagnosis code
• Failed intake system
• Failed exhaust gas cleaning system Q: Diagnosis code set?
YES : Inspection chart for diagnosis codes (Refer
• Throttle valve fouled around
to P.13A-17).
• Timing belt not in place
NO : Go to Step 4 .
• Compression pressure improper
DIAGNOSIS PROCEDURE • Refer to Data List Reference Table P.13A-372.
a. Item No. 13: Intake air temperature sensor
b. Item No. 21: Engine coolant temperature sen-
STEP 1. Check battery condition.
sor
Q: Have the battery terminal been disconnected? c. Item No. 25: Barometric pressure sensor
YES : After warm-up engine, idle for about 10
minutes. Q: Are the check results normal?
NO : Perform the diagnosis code classified check
procedure for the sensor that has shown an
abnormal data value (Refer to Inspection
TROUBLESHOOTING
13A-265
STEP 5. Check start ability. STEP 10. Check timing marks of timing belt.
• With depressing the accelerator pedal slightly, Q: Is the check result normal?
and start the engine. YES : Go to Step 11 .
Q: Is the start ability good? NO : Align timing marks.
NO : Go to Step 7 .
STEP 6. Check idle speed control servo for
Connector: C-119
operating sound.
• Check idle speed control servo for operating <L. H. drive vehicles>
YES : Clean throttle body (throttle valve portion)
NO : Check idle speed control servo system
(Refer to Code No. P0505 P.13A-190).
STEP 7. M.U.T.-II/III actuator test C-119 (GR)

• Refer to Actuator Test Reference Table
P.13A-378.
a. Item No. 07: Fuel pump
OK: Operating sound of fuel pump can be
heard.
NO : Check fuel pump system (Refer to
Inspection Procedure 24 P.13A-313). C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
STEP 8. Check air intake from intake hose and 68 67 66 65 64 63 62 61 60
intake manifold. Harness side connector
AK501994 AB
NO : Repair. • Voltage between terminal No. 46 and earth also
between terminal No. 58 and earth.
OK: System voltage
STEP 9. Check injector for operating sound.
• Check injector for operating sound at engine Q: Is the check result normal?
cranking (Refer to P.13A-406). YES : Go to Step 13 .
Q: Can operating sound be heard?
NO : Check the injector system of the defective
cylinder
(Refer to Code No. 0201: No. 1 injector system
P.13A-105).
P.13A-111).
P.13A-117).
P.13A-123).
TROUBLESHOOTING
STEP 12. Connector check: C-119 engine-ECU STEP 13. Connector check: B-103 and B-114
connector ignition coil connectors.
Connector: C-119 Connector : B-103, B-114
3 2 1
<L. H. drive vehicles> Harness side
connector
B-114(GR)
B-103(GR)
AK305047AB
C-119 (GR)
<R. H. drive vehicles> YES : Go to Step 14 .

C-119 (GR)
STEP 15. Check spark plug.
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB NO : Replace the spark plug.

YES : Check and repair harness between C-119 STEP 16. Check spark plug cable itself.
(terminal No. 46 and No. 58) engine-ECU • Check spark plug cable itself (Refer to GROUP
connector and body earth. 16 − Ignition System − On-vehicle Service
• Check earth line for open circuit and P.16-29).
damage. Q: Is the check result normal?
NO : Repair or replace the connector. YES : Go to Step 17 .
NO : Replace the spark plug cable.
STEP 17. Check ignition coil itself.

• Check ignition coil itself (Refer to GROUP 16 −
Ignition System − On-vehicle Service P.16-28).
NO : Replace the ignition coil.
TROUBLESHOOTING
13A-267
STEP 18. Check harness between ignition coil STEP 19. Check spray condition of injector.
connector terminal No. 2 of each cylinder and • Check each injector for spray condition (Refer to
body earth. P.13A-406).
Connector : B-103, B-114 Q: Is the check result normal?
3 2 1 YES : Go to Step 20 .
Harness side NO : Replace the injector.
connector
B-114(GR)
STEP 20. Check compression pressure.
• Check compression pressure (Refer to GROUP
11A − On-vehicle Service P.11A-11).
B-103(GR)
AK305047AB YES : Go to Step 21 .
NO : Repair.
Connector: C-121
<L. H. drive vehicles> 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
P.17-15).
NO : Replace the EGR control solenoid valve.
C-121 (GR)
STEP 22. Check EGR valve itself.
• Check EGR valve itself (Refer to GROUP 17 −
Emission Control System − Exhaust Gas Recir-
culation (EGR) System P.17-15).
NO : Replace the EGR valve.
C-121 (GR)
8 7 6 5 4 3 2 1 STEP 23. Replace the engine-ECU.

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 • After replacing the engine-ECU, re-check the
35 34 33 32 31 30 29 28 27 26 25 24
trouble symptoms.
AK501995 AB
• Check earthing line for open circuit and damage. YES : Check for foreign matters (water, kerosene,
etc.) in fuel and replace if necessary.
YES : Check and repair harness between ignition
coil connector terminal No. 3 of each
cylinder and C-121 engine-ECU connector.
• Check signal line for open/short
circuit and damage.
TROUBLESHOOTING
Inspection Procedure 8: Unstable Idling (Rough Idling, hunting), Improper Idling Speed (Too High or
too Low), Engine Stalls During Idling (Die Out)
COMMENTS ON TROUBLE SYMPTOM STEP 4. M.U.T.-II/III data list

• Probable causes can be widely found in ignition • Refer to Data List Reference Table P.13A-372.
system, air-fuel ratio control system, idle speed a. Item 27: Power steering fluid pressure switch
control system, fuel system, etc. A sudden
engine stall is possibly caused by poor connector Q: Is the check result normal?
contact. YES : Go to Step 5 .
NO : Check power steering fluid pressure switch
PROBABLE CAUSES system (Refer to Code No. P0551
• Failed ignition system P.13A-197).
• Failed fuel system
• Failed air-fuel ratio control system STEP 5. Check idle speed control servo for
• Failed idle speed control system operating sound.
• Failed intake/exhaust system • Check idle speed control servo for operating
• Failed emission gas cleaning system sound (Refer to P.13A-408).
• Throttle valve body fouled
• Timing belt out of place
• Compression pressure improper NO : Check idle speed control servo system
• Failed engine-ECU (Refer to Code No. P0505 P.13A-190).
DIAGNOSIS PROCEDURE
STEP 6. Check throttle body (throttle valve
portion) for contamination.
STEP 1. Check battery condition.
Q: Has the battery terminal been disconnected? YES : Go to Step 7 .
YES : After warm-up engine, idle for about 10 NO : Clean throttle body (throttle valve portion)
minutes. (Refer to P.13A-395).
NO : Go to Step 2 .
STEP 7. Check air intake from intake hose and

STEP 2. M.U.T.-II/III diagnosis code intake manifold.
Q: Diagnosis code set? Q: Is the check result normal?
YES : Inspection chart for diagnosis code (Refer YES : Go to Step 8 .
to P.13A-17). NO : Repair.
NO : Go to Step 3 .
STEP 8. Check injector for operating sound.

STEP 3. M.U.T.-II/III data list • Check injector for operating sound (Refer to
• Refer to Data List Reference Table P.13A-372. P.13A-406).
a. Item No. 12: Air flow sensor
Q: Can operating sound be heard?
b. Item No. 13: Intake air temperature sensor
c. Item No. 14: Throttle position sensor NO : Check the injector system of the defective
d. Item No. 21: Engine coolant temperature sen- cylinder.
sor (Refer to Code No. P0201: No. 1 injector
e. Item No. 25: Barometric pressure sensor system P.13A-105).
Q: Are the check results normal? (Refer to Code No. P0202: No. 2 injector
YES : Go to Step 4 . system P.13A-111).
NO : Perform the diagnosis code classified check (Refer to Code No. P0203: No. 3 injector
Procedure for the sensor that has shown an system P.13A-117).
abnormal data value (Refer to Inspection (Refer to Code No. P0204: No. 4 injector
Chart for Diagnosis Codes P.13A-17). system P.13A-123).
TROUBLESHOOTING
13A-269
STEP 9. Check timing marks of timing belt. STEP 12. Connector check: C-119 engine-ECU
connector
YES : Go to Step 10 . Connector: C-119
NO : Align timing marks.

NO : Check the oxygen sensor (front) system
C-119 (GR)
STEP 11. Perform voltage measurement at C-119 <R. H. drive vehicles>

engine-ECU.
Connector: C-119
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB
C-119 (GR)
(terminal No. 46 and No. 58) engine-ECU
and damage.
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

• Voltage between terminal No. 46 and earth, also
OK: 0.5 V or less
TROUBLESHOOTING
engine-ECU connector. connector and B-25 alternator connector.
C-121 (GR) C-121 (GR)

C-121 (GR) C-121 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB AK501995 AB

Connector : B-25
• Engine: Idling after warm-up
• Radiator fan: Not operating
OK: Switching the head lamps to ON from
OFF causes the voltage to increase by 0.2 − M
3.5 V. 4 3 2 1
B-25(GR)
connector
TROUBLESHOOTING
13A-271
STEP 15. Check harness between C-121 (terminal STEP 16. Perform voltage measurement at C-121
No. 8) engine-ECU connector and B-25 (terminal engine-ECU connector.
No. 1) alternator connector.
Connector: C-121
C-121 (GR)
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
35 34 33 32 31 30 29 28 27 26 25 24
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 Harness side connector
AK501995 AB
AK501995 AB
• Engine: Idling after warm-up
Connector : B-25
• Radiator fan: Not operating
OFF causes the voltage to fall.
M Q: Is the check result normal?
4 3 2 1 YES : Go to Step 20 .
Harness side B-25(GR) NO : Go to Step 17 .

connector B-14 and repair if necessary.
age.
TROUBLESHOOTING
connector and B-25 alternator connector. No. 52) engine-ECU connector and B-25 (terminal
No. 4) alternator connector.
Connector: C-119
<L. H. drive vehicles> Connector: C-119
C-119 (GR)
C-119 (GR)
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
47 46 45 44 43 42 41
68 67 66 65 64 63 62 61 60
59 58 57 56 55 54 53 52 51 50 49 48
Harness side connector 68 67 66 65 64 63 62 61 60
AK501994 AB
AK501994 AB
Connector : B-25
Connector : B-25
M
4 3 2 1 M
Harness side B-25(GR) 4 3 2 1
connector AK305036 AB Harness side B-25(GR)
YES : Go to Step 18 . NOTE: Before checking harness, check intermediate
NO : Repair or replace the connector. connector B-14, and repair if necessary.
age.
TROUBLESHOOTING
13A-273
STEP 19. Check the trouble symptoms. STEP 21. Connector check: B-103 and B-114
ignition coil connectors.
YES : Replace the alternator. Connector : B-103, B-114
NO : Intermittent malfunction (Refer to GROUP 3 2 1
00 − How to Use Harness side
connector
P.00-5). B-114(GR)
STEP 20. Perform voltage measure at C-119

B-103(GR)
Connector: C-119 AK305047AB


C-119 (GR)
<R. H. drive vehicles> STEP 23. Check spark plug.

NO : Replace the spark plug.
STEP 24. Check spark plug cable.

• Check spark plug cable itself (Refer to GROUP
C-119 (GR) 16 − Ignition System − On-vehicle Service
P.16-29).
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB NO : Replace the spark plug cable.
• Engine: Idling STEP 25. Check ignition coil itself.
• A/C switch: ON (A/C compressor ON) • Check ignition coil itself (Refer to GROUP 16 −
• Voltage between terminal No. 65 and earth. Ignition System − On-vehicle Service P.16-28).
OK: Q: Is the check result normal?
1 V or less (with outside air temperature sen- YES : Go to Step 26 .
sor ambient temperature at 18°C or higher NO : Replace the ignition coil.
and A/C set for maximum air flow at mini-
mum temperature)
System voltage (with A/C set for minimum air
flow at room temperature)
NO : Check A/C load signal system (Refer to
TROUBLESHOOTING
STEP 26. Check harness between ignition coil STEP 27. Check injector for spray condition.
connector terminal No. 2 of each cylinder and • Check each injector for spray condition (Refer to
Harness side NO : Replace the injector.
connector
B-114(GR)
B-103(GR)
AK305047AB YES : Go to Step 29 .
NO : Repair.
Connector: C-121
<L. H. drive vehicles> STEP 29. Check purge control solenoid valve
itself.
• Check purge control solenoid valve itself (Refer
to GROUP 17 − Emission Control System −
C-121 (GR)
STEP 30. Check EGR control solenoid valve
<R. H. drive vehicles> itself.
P.17-15).
C-121 (GR) NO : Replace the EGR control solenoid valve.
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 STEP 31. Check EGR valve itself.
35 34 33 32 31 30 29 28 27 26
25 24
AK501995 AB Emission Control System − Exhaust Gas Recir-
• Check earthing line for open/short circuit and
damage. Q: Is the check result normal?
cylinder and C-121 engine-ECU. STEP 32. M.U.T.-II/III actuator test
• Check signal line for open/short and • Item No. 07: Fuel pump
damage. OK: Operating sounds of fuel pump can be
NO : Repair the damaged harness wire. heard.
NO : Check fuel pump system (Refer to
inspection Procedure 24 P.13A-313).
TROUBLESHOOTING
13A-275
STEP 33. Replace the engine-ECU
• After engine-ECU is replaced, re-check for trou-
ble symptoms.
Q: Does trouble system persist?
YES : Check for foreign matters (water, kerosene,
etc.) in fuel and replace if necessary.
Inspection Procedure 9: The Engine Stalls when Starting the Car (Pass Out)
COMMENT ON TROUBLE SYMPTOM STEP 4. Check air intake from intake hose and
• Engine stall on starting is possibly caused by mis- intake manifold.
fire due to failed spark plug, improper air-fuel
ratio at accelerator pedal depression or other
faults.
PROBABLE CAUSES
• Failed ignition system STEP 5. Connector check: B-103 and B-114
• Failed intake system ignition connectors
• Failed emission gas cleaning system Connector : B-103, B-114
• Failed engine-ECU 3 2 1
Harness side
DIAGNOSIS PROCEDURE connector
B-114(GR)

Q: Diagnosis code set? B-103(GR)
to P.13A-17). AK305047AB
NO : Go to Step 2 .
STEP 2. Check EGR control solenoid valve itself. YES : Go to Step 6 .
Exhaust Gas Recirculation (EGR) System STEP 6. Check ignition coil spark.
P.17-15). Q: Is the check result normal?
Q: Is the check result normal? YES : Replace the engine-ECU.
YES : Go to Step 3 . NO : Go to Step 7 .
STEP 3. Check EGR valve itself. Q: Is the check result normal?
• Check EGR valve itself (Refer to GROUP 17 − YES : Go to Step 8 .
Emission Control System − Exhaust Gas Recir- NO : Replace the spark plug.
TROUBLESHOOTING
STEP 8.Check spark plug cable itself. STEP 10. Check harness between ignition coil
• Check spark plug cable itself (Refer to GROUP connector terminal No. 2 of each cylinder and
16 − Ignition System − On-vehicle Service body earth.
P.16-29). Connector : B-103, B-114
Q: Is the check result normal? 3 2 1
YES : Go to Step 9 . Harness side
connector
B-114(GR)

B-103(GR)
Q: Is the check result normal? AK305047AB
NO : Replace the ignition coil. Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

circuit and damage.
TROUBLESHOOTING
13A-277
Inspection Procedure 10: The Engine Stalls when Decelerating
COMMENT ON TROUBLE SYMPTOM STEP 5. Check EGR valve itself.

• Engine stall on deceleration is possibly caused by • Check EGR valve itself (Refer to GROUP 17 −
insufficient air intake, improper air-fuel ratio due Emission Control System − Exhaust Gas Recir-
to failed exhaust gas recirculation system or culation (EGR) System P.17-15).
other faults.
• Failed idle speed system
• Failed ignition system
• Failed emission control system STEP 6. Check throttle body (throttle valve
• Throttle valve fouled portion) for contamination.
DIAGNOSIS PROCEDURE NO : Clean throttle body (throttle valve portion)
Q: Diagnosis code set?
STEP 7. Connector check: B-103 and B-114
YES : Inspection chart for diagnosis code (Refer ignition coil connectors
to P.13A-17). Connector : B-103, B-114
Harness side
connector
B-114(GR)
a. Item No. 14: Throttle position sensor
Q: Is the check result normal? B-103(GR)
NO : Check throttle position sensor system AK305047AB
• Item No. 45: Idle speed control servo position
OK: Idle speed control servo drops to 0 − 2
steps at deceleration (engine at 1,000 r/min STEP 8. Check ignition coil spark.
or higher). Q: Is the check result normal?
NO : Go to Step 9 .
(Refer to Code No. P0505 P.13A-190). STEP 9. Check spark plug.
STEP 4. Check EGR control solenoid valve itself. YES : Go to Step 10 .
• Check EGR control solenoid valve itself (Refer to NO : Replace the spark plug.
P.17-15).
TROUBLESHOOTING
STEP 10. Check spark plug cable itself. STEP 12. Check harness between ignition coil
• Check spark plug cable itself (Refer to GROUP connector terminal No. 2 of each cylinder and
16 − Ignition System − On-vehicle Service body earth.
P.16-29). Connector : B-103, B-114
connector
B-114(GR)

B-103(GR)
Q: Is the check result normal? AK305047AB
NO : Replace the ignition coil. Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

circuit and damage.
TROUBLESHOOTING
13A-279
Inspection Procedure 11: Engine does not Revole Up
COMMENTS ON TROUBLE SYMPTOM STEP 4. Check ignition coil spark.

• Failure is possibly caused by failed fuel system,
ignition system or other faults.
NO : Go to Step 5 .
PROBABLE CAUSES
• Failed fuel system STEP 5. Check spark plug.
• Timing belt out of place Q: Is the check result normal?
• Failed engine-ECU YES : Go to Step 6 .
DIAGNOSIS PROCEDURE
STEP 6. Check spark plug cable itself.
STEP 1. M.U.T.-II/III diagnosis code • Check spark plug cable itself (Refer to GROUP
16 − Ignition System − On-vehicle Service
YES : Inspection chart for diagnosis code (Refer P.16-29).
to P.13A-17). Q: Is the check result normal?
STEP 2. Check timing marks of timing belt.
Q: Is the check result normal? STEP 7. Check ignition coil itself.
YES : Go to Step 3 . • Check ignition coil itself (Refer to GROUP 16 −
NO : Align match marks. Ignition System − On-vehicle Service P.16-28).
STEP 3. Connector check: B-103 and B-114 YES : Go to Step 8 .
ignition coil connectors NO : Replace the ignition coil.
Connector : B-103, B-114

3 2 1
Harness side
connector
B-114(GR)
B-103(GR)
AK305047AB

TROUBLESHOOTING
STEP 8. Check harness between ignition coil STEP 9. Fuel pressure measurement.
connector terminal No. 2 of each cylinder and • Fuel pressure measurement (Refer to
3 2 1 YES : Replace the engine-ECU.
Harness side NO : Repair.
connector
B-114(GR)
B-103(GR)
AK305047AB
Connector: C-121
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

circuit and damage.
TROUBLESHOOTING
13A-281
Inspection Procedure 12: Hesitation, Sag,Poor Acceleration, Stumble or Surge
COMMENTS ON TROUBLE SYMPTOM STEP 3. M.U.T.-II/III data list

• Failure is possibly caused by failed ignition sys- • Refer to Data List Reference Table P.13A-372.
tem, improper air-fuel ratio, improper compres- a. Item No. 13: Intake air temperature sensor
sion pressure or other faults. b. Item No. 14: Throttle position sensor
PROBABLE CAUSES c. Item No. 21: Engine coolant temperature sen-
sor
• Failed air-fuel ratio control system
• Failed ignition system d. Item No. 25: Barometric pressure sensor
• Failed fuel system Q: Are the check results normal?
• Failed intake and exhaust system YES : Go to Step 4 .
• Failed emission control system NO : Perform the diagnosis code classified check
• Failed turbocharger system procedure for the sensor that has shown an
• Throttle valve fouled abnormal data value (Refer to Inspection
• Improper compression pressure Chart for Diagnosis Codes P.13A-17).
STEP 4. Check Purge control solenoid valve
DIAGNOSIS PROCEDURE itself.
• Check Purge control solenoid valve itself (Refer
STEP 1. M.U.T.-II/III diagnosis code to GROUP 17 − Emission Control System −
YES : Inspection chart for diagnosis code (Refer Q: Is the check result normal?
to P.13A-17). YES : Go to Step 5 .
NO : Go to Step 2 . NO : Replace the purge control solenoid valve.
STEP 2. Check injector for operating sound. STEP 5. Check EGR control solenoid valve itself.
• Check injector for operating sound (Refer to • Check EGR control solenoid valve itself (Refer to
P.13A-406). GROUP 17 − Emission Control System −
Exhaust Gas Recirculation (EGR) Sys-
Q: Can operating sound be heard? temP.17-15).
NO : Check the injector system of the defective Q: Is the check result normal?
cylinder. YES : Go to Step 6 .
(Refer to code No. P0201: No. 1 injector system NO : Replace the EGR control solenoid valve.
P.13A-105).
(Refer to code No. P0202: No. 2 injector system STEP 6. Check EGR valve itself.
P.13A-111). • Check EGR valve itself (Refer to GROUP 17 −
(Refer to code No. P0203: No. 3 injector system Emission Control System − Exhaust Gas Recir-
P.13A-117). culation (EGR) System P.17-15).
(Refer to code No. P0204: No. 4 injector system Q: Is the check result normal?
P.13A-123). YES : Go to Step 7 .

NO : Check oxygen sensor (front) system (Refer
to Code No. P0130 P.13A-75).
TROUBLESHOOTING
STEP 8. Connector check: B-103 and B-114 STEP 13. Check harness between ignition coil
ignition coil connectors connector terminal No. 2 of each cylinder and
body earth.
3 2 1 Connector : B-103, B-114
Harness side 3 2 1
connector Harness side
B-114(GR) connector
B-114(GR)
B-103(GR)
B-103(GR)
AK305047AB
AK305047AB


Q: Is the check result normal? C-121 (GR)

P.16-29).
C-121 (GR)
NO : Replace the spark plug cable. 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
STEP 12. Check ignition coil itself. Harness side connector
AK501995 AB
Ignition System − On-vehicle Service P.16-28). • Check earthing line for open circuit and damage.
YES : Go to Step 13 . YES : Check and repair harness between ignition
NO : Replace the ignition coil. coil connector terminal No. 3 of each
• Check signal line for open or short
circuit or damage.
TROUBLESHOOTING
13A-283
STEP 14. Check throttle body (throttle valve STEP 17. Check supercharging pressure control
portion) for contamination. system.
• Check supercharging pressure control system
YES : Go to Step 15 . (Refer to GROUP 15 −Intake Exhaust
NO : Clean throttle body (throttle valve portion) −On-vehicle Service P.15-3).
(Refer to P.13A-395). Q: Is the check result normal?
STEP 15. M.U.T.-II/III actuator test. NO : Repair.
OK: Operating sound is audible on actua- STEP 18. M.U.T.-II/III actuator test.
tion. • Item No. 09: Fuel pressure control solenoid valve
Q: Is the check result normal? OK: Operating sound is audible on actua-
YES : Go to Step 16 . tion.
NO : Check waste gate solenoid valve system Q: Is the check result normal?
(Refer to Code No. P0243 P.13A-130). YES : Go to Step 19 .
NO : Check fuel pressure control solenoid valve
STEP 16. Check turbo charger supercharging system (Refer to Code No. P0443
pressure. P.13A-182).
• Check turbo charger output pressure (Refer to
GROUP 15 −Intake Exhaust −On-vehicle Service STEP 19.Fuel pressure measurement.
P.15-2). • Fuel pressure measurement (Refer to
Q: Is the check result normal? P.13A-396).
NO : Repair. YES : Go to Step 20 .
NO : Repair.

NO : Repair.
Inspection Procedure 13: The Feeling of Impact or Vibration when Accelerating
COMMENT ON TROUBLE SYMPTOM DIAGNOSIS PROCEDURE

• Failure is possibly caused by failed ignition leak
with rise in spark plug-required voltage at accel- STEP 1. M.U.T.-II/III diagnosis code
eration.
PROBABLE CAUSES YES : Inspection chart for diagnosis code (Refer
• Failed ignition system to P.13A-17).
• Failed engine-ECU NO : Go to Step 2 .
TROUBLESHOOTING
STEP 2. Connector check: B-103 and B-114 STEP 7. Check harness between ignition coil
ignition coil connectors connector terminal No. 2 of each cylinder and
body earth.
3 2 1 Connector : B-103, B-114
Harness side 3 2 1
B-114(GR) connector
B-114(GR)
B-103(GR)
B-103(GR)
AK305047AB
AK305047AB

NO : Go to Step 4 .


P.16-29).
C-121 (GR)
NO : Replace the spark plug cable. 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
STEP 6. Check ignition coil itself. Harness side connector
AK501995 AB
Ignition System − On-vehicle Service P.16-28). • Check earthing line for open circuit and damage.
YES : Go to Step 7 . YES : Check and repair harness between ignition
NO : Replace the ignition coil. coil connector terminal No. 3 of each
circuit and damage.
TROUBLESHOOTING
13A-285
Inspection Procedure 14: The Feeling of Impact or Vibration when Decelerating
COMMENT ON TROUBLE SYMPTOM STEP 2. Check idle speed control servo for
• Failure is possibly caused by insufficient air operating sound.
intake due to failed idle speed control system. • Check idle speed control servo for operating
PROBABLE CAUSES
• Failed idle speed system
• Throttle valve body fouled
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code a. Item No. 14: Throttle position sensor
to P.13A-17). NO : Check throttle position sensor system
NO : Go to Step 2 .
STEP 4. Check throttle body (throttle valve

portion) contamination.
Inspection Procedure 15: Knocking
COMMENT ON TROUBLE SYMPTOM STEP 2. Connector check: B-103 and B-114

• Failure is possibly caused by failed detonation ignition coil connectors
control, improper thermal value of spark plug or
other faults.
3 2 1
Harness side
PROBABLE CAUSES connector
• Defective detonation sensor B-114(GR)
• Failed detonation control system
• Defective spark plug
B-103(GR)
DIAGNOSIS PROCEDURE AK305047AB

STEP 1. M.U.T.-II/III diagnosis code YES : Go to Step 3 .
to P.13A-17).
NO : Go to Step 2 .
TROUBLESHOOTING
STEP 3. Check ignition coil spark. STEP 7. Check harness between ignition coil
connector terminal No. 2 of each cylinder and
YES : Check detonation sensor (Refer to Code body earth.
No. P0325 P.13A-151). Connector : B-103, B-114
Harness side
connector
B-114(GR)
NO : Replace the spark plug. B-103(GR)
STEP 5. Check spark plug cable itself. AK305047AB

16 −Ignition System − On-vehicle Service Connector: C-121
P.16-29). <L. H. drive vehicles>

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

circuit and damage.
TROUBLESHOOTING
13A-287
Inspection Procedure 16: Ignition Timing Offset
COMMENT ON TROUBLE SYMPTOM STEP 2. Perform output wave pattern

• Failure is possibly caused by failed crank angle measurement of crank angle sensor and exhaust
sensor, failed exhaust camshaft position sensor, camshaft position sensor (Using an
improper installed timing belt or other faults. oscilloscope).
PROBABLE CAUSE Connector : B-117
• Failed crank angle sensor

• Failed exhaust camshaft position sensor
• Improperly installed timing belt
DIAGNOSIS PROCEDURE
Crank angle sensor

to P.13A-17).
NO : Go to Step 2 . B-117(B)
2 1
3
Harness side
connector
AK305020AB
Connector: B-106
3 2 1
Harness side
B-106 (B) connector
AK501999 AB
Crank Angle Sensor

nect B-117 crank angle sensor connector, and
measure at pick-up harness.
• Engine: Idling
Exhaust camshaft Position Sensor
nect B-106 exhaust camshaft position sensor
connector, and measure at pick-up harness.
• Engine: Idling
TROUBLESHOOTING
OK: Output waveform timings of both sen- STEP 6. Check crank angle sensor vane.
sors are the same as the check procedure
(Refer to P.13A-385) using an oscilloscope. Q: Is the check result normal?
Q: Is the check result normal? NO : Replace the crank angle sensor vane.
NO : Go to Step 4 .
STEP 7. Check exhaust camshaft position
sensing cylinder.
Q: Does trouble symptom persist? YES : Go to Step 8 .
YES : Replace the engine-ECU. NO : Replace the exhaust camshaft position
sensing cylinder.
00 − How to Use
P.00-5). STEP 8. Replace crank angle sensor.
• After replacing the crank angle sensor, re-check
the trouble symptoms.
STEP 4. Check crank angle sensor and exhaust
camshaft position sensor mounted conditions. Q: Does trouble symptom persist?
Q: Is the check result normal? NO : The check is end.
NO : Repair.
STEP 9. Replace exhaust camshaft position
sensor.
STEP 5. Check timing marks of timing belt. • After replacing the exhaust camshaft position
Q: Is the check result normal? sensor, re-check the trouble symptoms.
YES : Go to Step 6 . Q: Does trouble symptom persist?
NO : Align timing marks. YES : Replace the engine-ECU.
00 − How to Use
P.00-5).
Inspection Procedure 17: Run on (Dieseling)
COMMENT ON TROUBLE SYMPTOM DIAGNOSIS PROCEDURE

• Failure is possibly caused by leakage from injec-
tor. STEP 1. Check injector for spray condition.
• Check each injector for spray condition (Refer to
PROBABLE CAUSES
P.13A-406).
• Failed injector
• Failed engine-ECU Q: Does trouble symptom persist?
TROUBLESHOOTING
13A-289
Inspection Procedure 18: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC During
Idling
COMMENT ON TROUBLE SYMPTOM STEP 4. M.U.T.-II/III data list

• Failure is possibly caused by improper air-fuel • Refer to Data List Reference Table P.13A-372.
ratio, deteriorated catalyst, failed ignition system, a. Item No. 12: Air flow sensor
failed fuel system, failed compression pressure or b. Item No. 13: Intake air temperature sensor
other faults.
c. Item No. 21: Engine coolant temperature sen-
PROBABLE CAUSES sor
• Failed air-fuel control system d. Item No. 25: Barometric pressure sensor
• Failed ignition system Q: Are the check results normal?
• Failed fuel system YES : Go to Step 5 .
• Failed intake and exhaust system NO : Perform the diagnosis code classified check
• Failed emission control system procedure for the sensor that has shown an
• Failed compression pressure abnormal data value (Refer to Inspection
• Failed catalytic converter Chart for Diagnosis Codes P.13A-17).
STEP 5. Check air intake from intake hose and
DIAGNOSIS PROCEDURE intake manifold.
STEP 1. M.U.T.-II/III diagnosis code YES : Go to Step 6 .
Q: Diagnosis code set? NO : Repair.
to P.13A-17). STEP 6. Check for emission leakage from
NO : Go to Step 2 . exhaust manifold.
STEP 2. Check injector for operating sound. YES : Go to Step 7 .
• Check injector for operating sound (Refer to NO : Repair.
P.13A-406).
Q: Can operating sound be heard? STEP 7. Check throttle body (throttle valve
YES : Go to Step 3 . portion) for contamination.
NO : Check the injector system of the defective
cylinder. YES : Go to Step 8 .
(Refer to Code No. P0201: No. 1 injector NO : Clean throttle body (throttle valve portion)
system P.13A-105). (Refer to P.13A-395).
(Refer to Code No. P0202: No. 2 injector
system P.13A-111).
(Refer to Code No. P0203: No. 3 injector STEP 8. M.U.T.-II/III data list
system P.13A-117). • Refer to Data List Reference Table P.13A-372.
(Refer to Code No. P0204: No. 4 injector a. Item No. 11: Oxygen sensor (front)
system P.13A-123). Q: Is the check result normal?
STEP 3. Check ignition timing. NO : Check oxygen sensor (front) system (Refer
• Check ignition timing (Refer to GROUP 11A − to Code No. P0130 P.13A-75).
On-vehicle Service P.11A-9).
NO : Check for offset ignition timing (Refer to
TROUBLESHOOTING
STEP 9. Check Purge control solenoid valve STEP 14. Check spark plug.
itself. Q: Is the check result normal?
• Check Purge control solenoid valve itself (Refer YES : Go to Step 15 .
to GROUP 17 − Emission Control System − NO : Replace the spark plug.
Q: Is the check result normal? STEP 15. Check spark plug cable itself.
YES : Go to Step 10 . • Check spark plug cable itself (Refer to GROUP
P.16-29).
STEP 10. Check EGR control solenoid valve
itself.
• Check the EGR control solenoid valve itself NO : Replace the spark plug cable.
(Refer to GROUP 17 − Emission Control System
− Exhaust Gas Recirculation (EGR) System
P.17-15). STEP 16. Check ignition coil itself.
Q: Is the check result normal? Ignition System − On-vehicle Service P.16-28).
NO : Replace the EGR control solenoid valve. Q: Is the check result normal?
STEP 11. Check EGR valve itself.
Emission Control System − Exhaust Gas Recir- STEP 17. Check compression pressure.
culation (EGR) System P.17-15). • Check compression pressure (Refer to GROUP
NO : Replace the EGR valve. YES : Go to Step 18 .
NO : Repair.

• Fuel pressure measurement (Refer to STEP 18. Check injector for spraying condition.
• Check each injector for spray condition (Refer to
P.13A-396).
P.13A-406).
YES : Go to Step 13 . Q: Does trouble symptom persist?
NO : Repair. YES : Go to Step 19 .
STEP 13. Check positive crankcase ventilation

valve itself. STEP 19. Replace catalytic converter.
• Check positive crankcase ventilation valve itself • After replacing the catalytic converter re-check
(Refer to GROUP 17 − Emission Control System the trouble symptoms.
− Evaporative Emission Control System P.17-9). Q: Does trouble symptom persist?
Q: Is the check result normal? NO : The check is end.
NO : Replace the positive crankcase ventilation
valve.
TROUBLESHOOTING
13A-291
Inspection Procedure 19: Battery Rundown
COMMENT ON TROUBLE SYMPTOM STEP 3. Perform voltage measurement at B-14

• Failure is possibly caused by failed alternator, intermediate connector.
failed generation control circuit or other faults.
Connector : B-14
PROBABLE CAUSES B-14(B)
• Failed battery
• Alternator G terminal short-circuit
• Failed alternator
1 2 3 4 5
DIAGNOSIS PROCEDURE 6 7 8 9 10
Male side
STEP 1. Check battery voltage. • Disconnect connector, and measure at male con-
• Measure battery voltage during cranking. nector side.
OK: 8 V or more • Ignition switch: "ON"
Q: Is the check result normal? • Voltage between terminal No. 9 and earth.
YES : Go to Step 2 . OK: System voltage
NO : Check battery (Refer to GROUP 54A −
Battery − On-vehicle Service − Battery test YES : Go to Step 5 .
P.54A-5). NO : Go to Step 4 .
STEP 2. Connector check: B-14 intermediate

connector
Connector : B-14
B-14(B)
5 4 3 2 1
10 9 8 7 6
Female side

TROUBLESHOOTING
STEP 4. Connector check: C-208 ignition switch STEP 5. Perform voltage measurement at B-14
connector intermediate connector.
B-14(B)
C-208 5 4 3 2 1
10 9 8 7 6
Female side
• Disconnect connector, and measure at female

connector side.
<R. H. drive vehicles> • Ignition switch: "ON"
OK: System voltage
C-208 YES : Go to Step 10 .
NO : Go to Step 6 .
STEP 6. Connector check: B-25 alternator

connector
Connector : B-25
3 2 1
6 5 4
AK305251AB
Connector : B-14
M
B-14(B)
4 3 2 1

1 2 3 4 5 YES : Go to Step 7 .
6 7 8 9 10 NO : Repair or replace the connector.
Male side

YES : Check intermediate connectors C-01, C-23
<L.H. drive vehicles>, C-124, C-211 and
and repair harness between B-14 (terminal
No. 9) intermediate connector and C-208
open/short circuit.
TROUBLESHOOTING
13A-293
No. 10) intermediate connector and B-25 No. 9) intermediate connector and B-25 (terminal
(terminal No. 1) alternator connector. No. 3) alternator connector.
B-14(B) B-14(B)
5 4 3 2 1 5 4 3 2 1
10 9 8 7 6 10 9 8 7 6
Female side Female side
connector AK305035AC connector AK305035AC
M M
4 3 2 1 4 3 2 1
Harness side B-25(GR) Harness side B-25(GR)
• Check output line for short circuit. • Check power supply line for open/short circuit.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
TROUBLESHOOTING
No. 3) alternator connector and C-208 (terminal connector
No. 2) ignition switch connector.
Connector: C-121
Connector : B-25
M
4 3 2 1
C-121 (GR)
C-208
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

C-208
3 2 1
6 5 4
AK305251AB

connectors C-01, C-23 <L.H. drive vehicles>, C-124,
C-211 and C-214, and repair if necessary.
YES : Replace the alternator.
TROUBLESHOOTING
13A-295
STEP 11. Perform voltage measurement at C-121 STEP 12. Perform voltage measurement at C-121
engine-ECU connector. engine-ECU connector.
C-121 (GR) C-121 (GR)

C-121 (GR) C-121 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB AK501995 AB
Connector : B-14
B-14(B) • Engine: Idling after warm-up
• Radiator fan: Inactive
1 2 3 4 5
OFF causes the voltage to increase by 0.2 −
6 7 8 9 10
3.5 V.
Male side Q: Is the check result normal?
connector AK401753 AB YES : Go to Step 13 .
• Disconnect connector, and measure at harness NO : Replace the alternator.
side.
• Ignition switch: "ON" STEP 13. Check the trouble symptoms.
OK: System voltage YES : Replace the engine-ECU.
Q: Is the check result normal? NO : Intermittent malfunction (Refer to GROUP
YES : Go to Step 12 . 00 − How to Use
NO : Check and repair harness between B-14 Troubleshooting/Inspection Service Points
(terminal No. 10) intermediate connector P.00-5).
connector.
TROUBLESHOOTING
Inspection Procedure 20: Overheating
COMMENT ON TROUBLE SYMPTOM STEP 3. M.U.T.-II/III actuator test

• Failure is possibly caused by failed engine cool- • Item No. 21: Fan controller
ing system, failed fan controller, failed engine OK: Fan motor rotating
coolant temperature sensor or other faults.
• Insufficient or deteriorated engine coolant NO : Check radiator fan control relay system
• Failed fan controller (Refer to Inspection Procedure 25
• Failed engine coolant temperature sensor P.13A-324).
• Failed thermostat
• Failed water pump STEP 4. M.U.T.-II/III data list
• Failed radiator core • Item No. 21: Engine coolant temperature sensor
OK:
Engine cold state: At ambient temperature
DIAGNOSIS PROCEDURE (atmospheric temperature) or equivalent.
Engine hot state: At 80 − 120 °C
STEP 1. M.U.T.-II/III diagnosis code Q: Is the check result normal?
Q: Diagnosis code set? YES : Go to Step 5 .
YES : Inspection chart for diagnosis code (Refer NO : Check engine coolant temperature sensor
to P.13A-17). system (Refer to Code No. P0115
NO : Go to Step 2 . P.13A-52).
STEP 2. Check engine coolant. STEP 5. Check thermostat.

NOTE: If engine coolant level falls too early, check • Check thermostat (Refer to GROUP 14 − Ther-
for leaky spots, and repair if necessary. mostat P.14-19).
• Check engine coolant (Refer to GROUP 14 − Q: Is the check result normal?
On-vehicle Service P.14-15). YES : Go to Step 6 .
Q: Is the check result normal? NO : Replace the thermostat.
NO : Replace or add engine coolant. STEP 6. Check water pump.
• Check water pump.
YES : Replace the radiator.
NO : Replace the water pump.
TROUBLESHOOTING
13A-297
Inspection Procedure 21: Abnormal Rotation of Fan Motor
Fan controller circuit
5V
A-17
(MU802322)
Fan controller
1 2 3
L
A-13 (*1)
2
C-31 (*2)
14
18
C-121
(MU803784)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Engine-ECU
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501827AB

• The control (duty) signal is inputted to the fan • Failed fan controller
controller (terminal No. 2) from the engine-ECU • Open/short circuit in fan controller circuit or loose
(terminal No. 18). connector contact
FUNCTION
• The engine-ECU inputs a duty signal suitable for DIAGNOSIS PROCEDURE
the engine coolant temperature, vehicle speed NOTE: .
and A/C switch position to the fan controller. In *1: L.H. drive vehicles
response to the signal, the fan controller controls *2: R.H. drive vehicles
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 5 V.)
TROUBLESHOOTING
STEP 1. Connector check: C-121 engine-ECU STEP 2. Check at C-121 engine-ECU connector.
connector
Connector: C-121
C-121 (GR)
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
35 34 33 32 31 30 29 28 27 26 25 24
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 Harness side connector
AK501995 AB
AK501995 AB
side.
YES : Go to Step 2 . • Ignition switch: "ON"
NO : Repair or replace the connector. • Short-circuit terminal No. 18 to earth.
OK: Fan motor stops rotating.
NO : Go to Step 4 .

00 − How to Use
P.00-5).
TROUBLESHOOTING
13A-299
STEP 4. Perform voltage measurement at C-121 STEP 6. Check harness between A-17 (terminal
engine-ECU connector. No. 2) fan controller connector and C-121
Connector: C-121
Connector: A-17
A-17 (GR)
3 2 1
AK305256 AB
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 C-121 (GR)
AK501995 AB

side.
OK: 4.9 − 5.1 V
YES : Replace the fan controller.
NO : Go to Step 5 . 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
STEP 5. Connector check: A-17 fan controller Harness side connector
AK501995 AB
connector
Connector: A-17
connector A-13*1 or 31*2, and repair if necessary.
YES : Replace the fan controller.
A-17 (GR) NO : Repair the damaged harness wire.
3 2 1
AK305256 AB

TROUBLESHOOTING
Inspection Procedure 22: Poor A/C Performance
COMMENT ON TROUBLE SYMPTOM STEP 3. M.U.T.-II/III data list

• Failure is possibly caused by short /overcharged • Item No. 28: A/C switch
A/C refrigerant, failed A/C control system, failed a. Engine: Idling
fan control system or other faults. b. A/C set temperature:
Maximum Cool when temperature in cabin is
PROBABLE CAUSES
25°C or more
• Short or overcharged A/C refrigerant Maximum Hot when temperature in cabin is
• Failed A/C compressor 25°C or less
• Failed fan controller
• Failed A/C-ECU OK:
• Failed engine-ECU ON (when A/C is ON)
OFF (when A/C is OFF)
NO : Check A/C switch (Refer to Inspection
STEP 1. M.U.T.-II/III diagnosis code Procedure 27 P.13A-341).
to P.13A-17).
• Item No. 49: A/C relay
NO : Go to Step 2 .
a. Engine: Idling
b. A/C set temperature:
STEP 2. A/C compressor magnet clutch Maximum Hot when temperature in cabin is
operation check. 25°C or less
• Engine: Idling Maximum Cool when temperature in cabin is
• A/C set temperature: 25°C or more
OK:
25°C or more
ON (when A/C is ON)
Maximum Hot when temperature in cabin is 25°C
or less
OK: Q: Is the check result normal?
Magnet clutch active (when A/C is ON) YES : Check A/C system (Refer to GROUP 55 −
Magnet clutch inactive (when A/C is OFF) Troubleshooting P.55-29).
NO : Check A/C compressor relay (Refer to
Q: Is the check result normal? Inspection procedure 28 P.13A-344).
NO : Go to Step 3 .
TROUBLESHOOTING
13A-301
STEP 5. Check charged amount of A/C STEP 6. M.U.T.-II/III actuator test
refrigerant. • Item No. 21: Fan controller
• Check charged amount of A/C refrigerant (Refer OK: Fan motor rotates.
to GROUP 55 − On-vehicle Service P.55-104).
Q: Is the check result normal? YES : Check A/C load signal system (Refer to
YES : Go to Step 6 . Inspection Procedure 29 P.13A-352).
NO : Adjust charged amount of A/C refrigerant. NO : Check radiator fan control relay system
P.13A-324).
TROUBLESHOOTING
Inspection Procedure 23: Engine-ECU Power Supply, Engine Control Relay, Ignition Switch-IG1
System
Power supply and ignition switch-IG circuit
Battery
W W
8
Relay box
20A Ignition switch
C-208
LOCK
R
1 2 3
ST ACC
B-Y IG1 IG2 4 5 6
6 <A-13> (*1) or
13 <C-31> (*2) 2
B-W
C-211
6
B-Y B-Y 8
J/B
7.5A
B-12X 1 2
1
Engine C-210
1 2
control
3 4 relay
L (*1) or
B-W (*2)
4 3
R-Y
C-123
4
28
J/C (6)
C-105 R R-B
B 30 31 B-R
R-Y R-Y
B B
58 46 47 59 57 60 99
Power Back-up
supply power supply Engine-ECU
C-119 C-117
(MU803782) (MU803783)
41 42 43 44 45 46 47 71 72 73 74 75 76 77
48 49 50 51 52 53 54 55 56 57 58 59 78 79 80 81 82 83 84 85 86 87 88 89 90
60 61 62 63 64 65 66 67 68 91 92 93 94 95 96 97 98 99 100
NOTE
Wire colour code
AK501828 AB
TROUBLESHOOTING
13A-303
OPERATION STEP 2. Connector check: B-12X engine control
• The battery voltage is applied to the engine con- relay connector
trol relay (terminal No. 1 and No. 4).
• The engine-ECU (terminal No. 57) makes the Connector : B-12X Relay box’s
triangle marks
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" 2 1
position. B-12X
• When the engine control relay is in "ON" position, 4 3
the battery voltage is supplied to the Harness side
connector
engine-ECU, the sensor and the actuator from
the engine control relay (terminal No. 4).
• The engine-ECU (terminal No. 46, No. 58) is AK305003 AB
grounded to the vehicle body. Q: Is the check result normal?

FUNCTION NO : Repair or replace the connector.
• 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 STEP 3. Check engine control relay.
battery voltage is supplied to the engine-ECU, • Check engine control relay (Refer to P.13A-401).
sensor and actuator. Q: Is the check result normal?
PROBABLE CAUSES NO : Replace the engine control relay.
• Failed engine control relay
• Open/short circuit in engine control relay circuit or STEP 4. Perform voltage measurement at B-12X
loose connector contact engine control relay connector.
triangle marks
DIAGNOSIS PROCEDURE
NOTE: .
*1: L.H. drive vehicles 2 1
B-12X
*2: R.H. drive vehicles 4 3
Harness side
STEP 1. Check battery voltage. connector
• Measure battery voltage during cranking.
OK: 8 V or more AK305003 AB

• Remove relay, and measure at relay box side.
YES : Go to Step 2 . • Voltage between terminal No. 1 and earth, also
NO : Check battery (Refer to GROUP 54A − between terminal No. 2 and earth.
Battery − On-vehicle Service − Battery test OK: System voltage
P.54A-5). Q: Is the check result normal?
NO : Check intermediate connector A-13*1 or
repair harness between B-12X (terminal No.
1, No. 2) engine control relay connector and
battery.
open/short circuit.
TROUBLESHOOTING
connector engine-ECU connector.
C-117 (GR) C-117 (GR)
C-117 (GR) C-117 (GR)

77 76 75 74 73 72 71 77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78 90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91 100 99 98 97 96 95 94 93 92 91
AK501996 AB AK501996 AB

YES : Go to Step 6 . side.
NO : Repair or replace the connector. • Ignition switch: "ON"
OK: System voltage
NO : Go to Step 7 .
TROUBLESHOOTING
13A-305
connector
Connector: C-208
C-208
C-208
3 2 1
6 5 4
AK305251AB

TROUBLESHOOTING
STEP 8. Check ignition switch. Connector: C-208
C-208
C-117 (GR)
C-208
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
3 2 1
6 5 4
AK501996 AB Harness side connector
AK305251AB

Ignition Switch − Ignition Switch − Inspection
P.54A-30).
YES : • Check intermediate connectors C-123,
C-210 and C-211, then repair if
necessary. If intermediate connectors
are normal, check and repair harness
between C-117(terminal No. 99)
engine-ECU connector and C-208
(terminal No. 2) ignition switch
connector.
open/short circuit.
TROUBLESHOOTING
13A-307
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB

side. YES : Go to Step 11 .
• Voltage between terminal No. 60 and earth. NO : Repair or replace the connector.
OK: System voltage
NO : • Check intermediate connector A-13*1 or
C-31*2 and repair if necessary. If
intermediate connector is normal, check
and repair harness between C-119
and battery.
• Check power supply line for short
circuit.
TROUBLESHOOTING
STEP 11. Perform resistance measurement at STEP 12. Connector check: C-119 engine-ECU
C-119 engine-ECU connector. connector
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB

• Resistance between terminal No. 46 and earth, NO : Repair or replace the connector.
and No. 58 and earth.
OK: 2 Ω or less
(terminal No. 46 and No. 58) engine-ECU
and damage.
TROUBLESHOOTING
13A-309
engine-ECU connector. engine-ECU connector.
C-119 (GR) C-119 (GR)
C-119 (GR) C-119 (GR)
47 46 45 44 43 42 41 47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48 59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 68 67 66 65 64 63 62 61 60
AK501994 AB AK501994 AB
Connector : B-12X Relay box’s Connector : B-12X Relay box’s

triangle marks triangle marks
2 1 2 1
B-12X B-12X
4 3 4 3
connector connector
AK305003 AB AK305003 AB
side.
side.
• Using jumper wire, connect C-119 (terminal No.
57) engine-ECU connector and earth.
OK: System voltage • Voltage between terminal No. 47 and earth, and
Q: Is the check result normal? No. 59 and earth.
YES : Go to Step 14 . OK: System voltage
NO : Check and repair harness between B-12X
(terminal No. 3) engine control relay YES : Go to Step 15 .
connector and C-119 (terminal No. 57) NO : Check intermediate connector C-105 and
engine-ECU connector. repair if necessary. If intermediate
• Check earthing line for open/short connector is normal, check and repair
circuit. harness between C-119 (terminal No. 47
and No. 59) engine-ECU connector and
B-12X (terminal No. 4) engine control relay
connector.
TROUBLESHOOTING

No. 2) ignition switch connector and C-117
Connector: C-208
C-208
C-117 (GR)
C-117 (GR)
C-208
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB

3 2 1
connectors C-123, C-210 and C-211, and repair if
6 5 4 necessary.
Harness side connector • Check power supply line for damage.
TROUBLESHOOTING
13A-311
STEP 16. Check harness between B-12X STEP 17. Check harness between B-12X
(terminal No. 1, No. 2) engine control relay (terminal No. 3) engine control relay connector
connector and battery. and C-119 (terminal No. 57) engine-ECU
connector.
triangle marks Relay box’s
Connector : B-12X
triangle marks
2 1
B-12X
4 3 2 1
B-12X
Harness side 4 3
connector
AK305003 AB
AK305003 AB
connector A-13*1 or C-31*2, and repair if necessary. Connector: C-119
• Check power supply line for damage. <L. H. drive vehicles>
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
STEP 18. Check harness between B-12X STEP 19. Check the trouble symptoms.
(terminal No. 4) engine control relay connector Q: Does trouble symptom persist?
and C-119 (terminal No. 47 and No. 59) YES : Replace the engine-ECU.
engine-ECU connector. NO : Intermittent malfunction (Refer to GROUP
Connector : B-12X Relay box’s 00 − How to Use
triangle marks Troubleshooting/Inspection Service Points
P.00-5).
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
Connector: C-119
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
AK501994 AB

TROUBLESHOOTING
13A-313
Inspection Procedure 24: Fuel Pump System
Fuel pump circuit

Battery
W W
C-208
R LOCK Ignition
Relay 1 2 3 ST ACC switch
15 IG1 IG2
15A box 4 5 6
2
GR
C-129
1 (*1) or 12 (*2)
B-W
W
C-210 C-211
2 6
4 3 1 3
C-223 C-221 8
1 2 1 2 7.5A
J/B
3 4 OFF ON 3 4 OFF ON
Fuel pump 1 2 Fuel pump 4 2

relay (1) relay (2)
11 13 14
B C-214 C-214 C-214
BR (*1)
or
B (*2)
R-W 1 C-123
V
1 R-W R-W
B-121 B-120 2 4
MU802601
Fuel pump 1 2 Fuel pump
resistor 3 4 ON OFF relay (3)
1 2
1 3
2 R C-123
2
R
C-123
5
W
D-12
(MU802058) 5 R-B
Fuel pump D-33
1 C-113 (*1) W V
1 2 3 M and fuel
4 5 gauge unit or
C-112 (*2)
4 1
B
D-34 W
4
55 21
B C-119 C-121
(MU803782) (MU803784)
41 42 43 44 45 46 47 1 2 3 4 5 6 7 8
48 49 50 51 52 53 54 55 56 57 58 59 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
60 61 62 63 64 65 66 67 68 24 25 26 27 28 29 30 3132 33 34 35
NOTE
*2: R.H. drive vehicles Engine-ECU
Wire colour code
AK501829 AB
TROUBLESHOOTING

• The battery voltage is applied to the fuel pump NOTE: .
relay (1) (terminal No. 3) form the ignition switch. *1: L.H. drive vehicles
• When the ignition switch is turned to the "ON" *2: R.H. drive vehicles
position, the battery voltage is applied to the fuel
pump relay (2) (terminal No. 1) from the fuel
pump relay 1 (terminal No. 1). STEP 1. M.U.T.-II/III actuator test
• Battery voltage is applied to the fuel pump relay • Refer to Actuator Test Reference Table
(2) (terminal No. 3) from the ignition switch. P.13A-378.
• During cranking and while the engine is running, a. Item No. 07: Fuel pump
the engine-ECU turns ON the power transistor in Q: Is the check result normal?
the engine-ECU in order to earth the coil of the YES : Go to Step 2 .
fuel pump relay (2). Consequently, the fuel pump NO : Go to Step 3 .
relay 2 turns ON, and the fuel pump relay (2) (ter-
minal No. 4) supplies the battery voltage to the
fuel pump and the fuel pump circuit resistor.
• Refer to Actuator Test Reference Table
• While the engine operates with a low load, the
engine-ECU turns ON the power transistor in the P.13A-378.
engine-ECU in order to earth the coil of the fuel a. Item No. 13: Fuel pump 3
pump relay (3). Consequently, the fuel pump Q: Is the check result normal?
relay (3) turns OFF, and the fuel pump resistor YES : Intermittent malfunction (Refer to GROUP
(terminal No. 2) supplies the battery voltage to 00 − How to Use
the fuel pump (terminal No. 5). Troubleshooting/Inspection Service Points
• While the engine operates with a high load, the P.00-5.)
engine-ECU turns OFF the power transistor in NO : Go to Step 18 .
the engine-ECU, causing the fuel pump relay (3)
to turn ON. Consequently, the fuel pump relay (3)
(terminal No. 1) supplies power directly to the fuel STEP 3. Connector check: C-223 fuel pump relay
pump (terminal No. 5). (1) connector and C-221 fuel pump relay (2)
connector.
FUNCTION Connector: C-221, C-223
• The engine-ECU turns the fuel pump relay ON Junction block’s
triangle marks
during cranking and engine operation, and sup- C-223
plies the drive power to the fuel pump. C-221
• When operating with a low load, the engine-ECU 2 1
supplies power to the fuel pump via the resistor. 4 3
When operating with a high load, power is directly Harness side
connector
supplied and the fuel pump fuel discharge
amount is increased.
AK305258 AB
PROBABLE CAUSES
• Failed fuel pump relay Q: Is the check result normal?
• Failed fuel pump YES : Go to Step 4 .
• Failed fuel pump resistor
• Open/short circuit in fuel pump drive circuit or
TROUBLESHOOTING
13A-315
STEP 4. Connector check: B-121 fuel pump STEP 7. Perform voltage measurement at C-223
resistor connector. fuel pump relay (1) connector.
<L. H. drive vehicles> Junction block’s
triangle marks
C-223
2 1
B-121(B) 4 3
Harness side
connector
AK305260 AB
• Remove relay, and measure at junction block

side.
B-121(B)
OK: System voltage
NO : Check intermediate connector C-129 and
C-210 and repair if necessary. If
repair harness between C-223 (terminal No.
2 1 4) fuel pump relay (1) connector and battery.
Harness side connector AK305259 AB • Check power supply line for
open/short circuit.
NO : Repair or replace the connector. STEP 8. Perform voltage measurement at C-223
fuel pump relay (1) connector.
STEP 5. Check fuel pump relay (1) and fuel pump Connector: C-223
relay (2). Junction block’s
triangle marks
• Fuel pump relay (1) and fuel pump relay (2), con- C-223
tinuity check (Refer to P.13A-402).
2 1
Q: Is the check result normal? 4 3
NO : Replace the fuel pump relay. connector
STEP 6. Check fuel pump resistor. AK305260 AB

• Check fuel pump resistor (Refer to P.13A-403).
Q: Is the check result normal? side.
YES : Go to Step 7 . • Ignition switch: "ON"
NO : Replace the fuel pump resistor. • Voltage between terminal No. 3 and earth.
OK: System voltage
NO : Go to Step 9 .
TROUBLESHOOTING
STEP 9. Check harness between C-223 (terminal STEP 10. Perform resistance measurement at
No. 3) fuel pump relay (1) connector and C-208 C-223 fuel pump relay (1) connector.
(terminal No. 2) ignition switch connector. Connector: C-223
Connector: C-223 Junction block’s
Junction block’s triangle marks
C-223
triangle marks
C-223
2 1
2 1 4 3
4 3 Harness side
connector
AK305260 AB
AK305260 AB
Connector: C-208 side.
OK: 2Ω or less
C-208
connector normal, check and repair harness
between C-223 (terminal No. 2) fuel pump
relay (1) connector and body earth.
and damage.
C-208
3 2 1
6 5 4
AK305251AB

connector C-211 repair if necessary.
YES : Check ignition switch (Refer to GROUP 54
− Ignition switch − Ignition switch −
Inspection P.54A-30).
TROUBLESHOOTING
13A-317
fuel pump relay (2) connector. engine-ECU connector.
Junction block’s
triangle marks <L. H. drive vehicles>
C-221
2 1
4 3
Harness side
connector
AK305261AB
Connector: C-223 C-121 (GR)

Junction block’s <R. H. drive vehicles>
triangle marks
C-223
2 1
4 3
Harness side
connector
AK305260 AB C-121 (GR)
• Remove relay, and measure at junction block 8 7 6 5 4 3 2 1

side. 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
• Ignition switch: "ON" Harness side connector
• Voltage between terminal No. 1 and earth and AK501995 AB
No. 3 and earth.
Connector: C-221
OK: System voltage Junction block’s
triangle marks
C-221
NO : Check and repair harness between C-223 2 1
(terminal No. 1 and No. 3) fuel pump relay 4 3
(1) connector and C-221 (terminal No. 1 and Harness side
No. 3) fuel pump relay (2) connector. connector
open/short circuit. AK305261AB
side.
OK: System voltage
intermediate connector normal, check and
repair harness between C-221 (terminal No.
2) fuel pump relay (2) connector and C-121
• Check earthing line for open/short
circuit.
TROUBLESHOOTING
STEP 13. Perform voltage measurement at C-121 STEP 14. Perform voltage measurement at B-121
engine-ECU connector. fuel pump resistor connector.
B-121(B)

B-121(B)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 2 1
35 34 33 32 31 30 29 28 27 26 25 24 Harness side connector AK305259 AB
AK501995 AB
Connector: C-221
• Disconnect connector, and measure at harness Junction block’s
side. triangle marks
C-221
• Voltage between terminal No. 21 and earth. 2 1
OK: Fuel pump operates (Operation sounds 4 3
are heard) Harness side
connector
NO : Replace the engine-ECU. AK305261AB

side.
OK: System voltage
NO : Check intermediate connectors C-123,
intermediate connector are normal, check
and repair harness between C-221 (terminal
No. 4) fuel pump relay (2) connector and
B-121 (terminal No. 1) fuel pump resistor
connector.
open/short circuit.
TROUBLESHOOTING
13A-319
STEP 15. Check connector: D-12 fuel pump STEP 16. Perform voltage measurement at D-12
connector. fuel pump connector.
Connector: D-12 Connector: D-12
3 2 1 3 2 1
5 4 5 4
connector connector
D-12 (GR) D-12 (GR)
AK203611 AD AK203611 AD
Q: Is the check result normal? Connector: B-121

YES : Go to Step 16 . <L. H. drive vehicles>
B-121(B)
B-121(B)
2 1

side.
OK: System voltage
NO : Check intermediate connectors C-113*1,
C-112*2 C-123 and D-33, and repair if
necessary. If intermediate connector are
normal, check and repair harness between
B-121 (terminal No. 2) fuel pump resistor
connector and D-12 (terminal No. 5) fuel
pump connector.
open/short circuit.
TROUBLESHOOTING
STEP 17. Perform resistance measurement at STEP 18. Check connector: B-120 fuel pump
D-12 fuel pump connector. relay (3) connector.
Connector: D-12 Connector: B-120
3 2 1
5 4 <L. H. drive vehicles>
Harness side
connector
D-12 (GR)
B-120
AK203611 AD

side.
OK: 2Ω or less
YES : Replace fuel pump.
NO : Check intermediate connector D-34, and
connector is normal, check and repair B-120
harness between D-12 (terminal No. 4) fuel Junction block’s
pump connector and body earth. triangle marks
and damage. 2 1
4 3

STEP 19. Check fuel pump relay (3).

• Fuel pump relay (3) continuity check (Refer to
P.13A-402).
NO : Replace the fuel pump relay (3).
TROUBLESHOOTING
13A-321
STEP 20. Perform voltage measurement at B-120 • Remove relay, and measure at junction block
fuel pump relay (3) connector. side.
Connector: B-120 • Voltage between terminal No. 2 and earth, and
<L. H. drive vehicles> No. 4 and earth.
OK: System voltage
B-120
harness between B-120 (terminal No. 2 and
No. 4) fuel pump relay (3) connector and
<R. H. drive vehicles> B-121 (terminal No. 1) fuel pump resistor
connector.

connector.
Connector: C-119
B-120
Junction block’s
triangle marks
2 1
4 3
Connector: B-121
<L. H. drive vehicles> C-119 (GR)
B-121(B)
<R. H. drive vehicles> C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60
B-121(B)
AK501994 AB

YES : Go to Stop 22 .
2 1
TROUBLESHOOTING
STEP 22. Perform voltage measurement at C-119 Connector: B-120

Connector: C-119
B-120
C-119 (GR)
B-120
Junction block’s
triangle marks
C-119 (GR)
2 1
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
4 3
68 67 66 65 64 63 62 61 60 Harness side connector AK305262 AB
AK501994 AB • Disconnect connector, and measure at harness
side.
• Disconnect C-121 (terminal No. 21) engine-ECU
connector and earth.
OK: System voltage
(terminal No.55) engine-ECU connector and
B-120 (terminal No.3) fuel pump relay (3)
connector.
and damage.
TROUBLESHOOTING
13A-323
STEP 23. Check harness between B-120 (terminal Connector: B-121
No. 2 and No. 4) fuel pump relay (3) connector <L. H. drive vehicles>
and B-121 (terminal No. 1) fuel pump resistor
connector.
NOTE: Before checking harness, check intermediate B-121(B)
Connector: B-120
B-120
B-121(B)
2 1

B-120 NO : Repair the damaged harness wire.
Junction block’s
triangle marks
2 1
4 3
TROUBLESHOOTING
Inspection Procedure 25: Radiator Fan Control Relay System
Radiator fan control relay circuit
Battery
W W
8
Relay relay
20A
B-Y
6 <A-13> (*1) or
13 <C-31> (*2)
B-Y B-Y
1 2
B-12X
1 2 Engine control relay

3 4
4 3
3
R-Y
A-17 28 To engine-ECU
(MU802322) Fan
Fan control Fusible link (2) J/C (6)
controller
circuit C-105
1 2 3
2
33 Engine control system
L
A-13 R-Y
2 (*1) or 1 (*2) B-W A-13 (*1)
3
L-B C-31 (*2)
31 12
R-Y
4 1 Radiator
fan control relay
Engine-ECU A-09X
2
1 3
4
C-121
(MU803784) 2 3
1 2 3 4 5 6 7 8 L B
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501830 AB
TROUBLESHOOTING
13A-325
OPERATION STEP 2. Check radiator fan control relay.
• The battery voltage is applied to the fan control • Check radiator fan control relay (Refer to
relay (terminal No. 1) form the engine control GROUP 14 − On-vehicle Service P.14-17).
relay (terminal No. 4) and is earthed to the vehi-
cle body from the radiator fan control relay (termi-
nal No. 3).
NO : Replace the fan control relay.
• The battery voltage is applied to the radiator fan
control relay (terminal No. 4).
• When the radiator fan control relay is in "ON" STEP 3. Perform resistance measurement at
position, the battery voltage is supplied to the fan A-09X radiator fan control relay connector.
controller (terminal No.3) from the radiator fan Connector: A-09X
control relay (terminal No. 2). 2
3 1
FUNCTION 4
Harness side
• When the engine control relay turns "ON", the connector
radiator fan control relay turns "ON" simultane-
ously, and power is supplied to the fan controller.
The radiator fan motor is driven when the fan
motor drive signal is input to the fan controller A-09X
from the engine-ECU. AK305263 AB
PROBABLE CAUSES • Remove relay, and measure at relay box side.

• Failed radiator fan control relay • Resistance between terminal No.3 and earth.
• Failed fan controller OK: 2Ω or less
• Failed radiator fan motor Q: Is the check result normal?
• Failed engine-ECU YES : Go to Step 4 .
NO : Check and repair harness between A-09X
DIAGNOSIS PROCEDURE (terminal No. 3) radiator fan control relay
NOTE: . connector and body earth.
*1: L.H. drive vehicles • Check and earthing line for open
*2: R.H. drive vehicles circuit and damage.
STEP 1. Connector check: A-09X radiator fan STEP 4. Perform voltage measurement at A-09X
control relay connector. radiator fan control relay connector.
Connector: A-09X Connector: A-09X

2 2
3 1 3 1
4 4
connector connector
A-09X A-09X
AK305263 AB
AK305263 AB
Q: Is the check result normal? • Ignition switch: "ON"
OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
STEP 5. Connector check: B-12X engine control STEP 6. Perform voltage measurement at A-09X
relay connector. radiator fan control relay connector.
Connector : B-12X Relay box’s Connector: A-09X
triangle marks 2
3 1
4
Harness side
2 1 connector
B-12X
4 3
Harness side
connector
A-09X
AK305003 AB AK305263 AB

Connector: A-09X
2
3 1
4
OK: System voltage
connector
NO : Check and repair harness between battery
and A-09X (terminal No. 4) radiator fan
A-09X control relay connector.
AK305263 AB open/short circuit.
YES : Check intermediate connectors A-13*1 or STEP 7. Connector check: A-17 fan controller
2
C-31* and C-105, and repair if necessary. If connector
intermediate connectors are normal, check Connector: A-17
and repair harness between B-12X (terminal
No. 4) engine control relay connector and
A-09X (terminal No. 1) radiator fan control
relay connector.
• Check power supply line for A-17 (GR)
open/short circuit.
3 2 1
AK305256 AB

TROUBLESHOOTING
13A-327
STEP 8. Perform voltage measurement at A-17 STEP 10. Connector check: B-12X engine control
fan controller connector. relay connector
Connector: A-17 Connector : B-12X Relay box’s
triangle marks
2 1
B-12X
A-17 (GR) 4 3
Harness side
connector
3 2 1
AK305256 AB AK305003 AB

• Ignition switch: "ON" NO : Repair or replace the connector.
OK: System voltage
STEP 11. Check harness between B-12X (terminal
Q: Is the check result normal? No. 4) engine control relay connector and A-09X
YES : Go to Step 12 . (terminal No. 1) radiator fan control relay
NO : Go to Step 9 . connector.
STEP 9. Check harness between A-09X (terminal triangle marks
No. 2) radiator fan control relay connector and
A-17 (terminal No. 3) fan controller connector.
2 1
Connector: A-09X B-12X
2 4 3
3 1
4 Harness side
connector
AK305003 AB
Connector: A-09X
A-09X 2
3 1
AK305263 AB
4
Harness side
connector
Connector: A-17
A-09X
A-17 (GR) AK305263 AB

3 2 1 connectors A-13*1 or C-31*2 and C-105, and repair if
AK305256 AB
necessary.
• Check output line for open/short circuit.
Q: Is the check result normal? YES : Check and repair harness between A-09X
YES : Go to Step 10 . (terminal No. 3) radiator fan control relay
NO : Repair the damaged harness wire. connector and body earth.
TROUBLESHOOTING
STEP 12. Connector check: C-121 engine-ECU STEP 14. M.U.T.-II/III actuator test
connector • Item No. 21: Fan controller
Connector: C-121 OK: Radiator fan motor rotates
<L. H. drive vehicles> Q: Is the check result normal?
00 − How to Use
P.00-5.)

C-121 (GR)
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
C-121 (GR)
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

STEP 13. Check radiator fan motor drive.

C-121 (GR)
• Disconnect C-121 engine-ECU connector.
• Ignition switch: "ON" 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
OK: Radiator fan motor rotates at a high 35 34 33 32 31 30 29 28 27 26 25 24
speed Harness side connector
AK501995 AB
YES : Go to Step 14 . • Disconnect connector, and measure at harness
NO : Go to Step 15 . side.
OK: 4.9 − 5.1 V
TROUBLESHOOTING
13A-329
STEP 16. Check harness between A-09X STEP 18. Check harness between A-17 (terminal
(terminal No. 4) radiator fan control relay No. 2) fan controller connector and C-121
connector and battery. (terminal No. 18) engine-ECU connector.
Connector: A-09X Connector: A-17
2
3 1
4
Harness side
connector
A-17 (GR)
A-09X 3 2 1
AK305263 AB AK305256 AB

Connector: C-121
STEP 17. Check harness between A-09X

(terminal No. 2) radiator fan control relay
connector and A-17 (terminal No. 3) fan
controller connector.
Connector: A-09X
2 C-121 (GR)
3 1
4 <R. H. drive vehicles>
Harness side
connector
A-09X
AK305263 AB
C-121 (GR)
Connector: A-17
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
A-17 (GR) NOTE: Before checking harness, check intermediate

connectors A-13*1 or C-31*2 and repair if necessary.
3 2 1 • Check output line for short circuit.
AK305256 AB Q: Is the check result normal?
YES : Replace the radiator fan motor and fan
• Check output line for damage. controller.
Q: Is the check result normal? NO : Repair the damaged harness wire.
YES : Replace the radiator fan motor and fan
controller.
TROUBLESHOOTING
Inspection Procedure 26: Condenser Fan Relay System
Condenser fan relay system

Ignition switch
C-208
R LOCK
ST ACC 1 2 3
IG1 IG2
Battery 4 5 6
W W 4
L-B
C-211
2
25 11 5
30A 30A J/B
7.5A
13
W-B C-210
17 (*1) or 10 (*2)
B-R B-R J/B (2)

C-101
16*1
W-B 10*2
C-129
W-B 2
W-B
A-07X 4 2 A-06X 4 2
1 2 Condenser 1 2 Condenser
fan relay fan relay (low)
3 4 (high) 3 4
1 3 1 3
B-Y G-R W
L
A-34
MU802601 1 2 G-R
1 2
1<A-29> (*1) 5<A-29> (*1)
Condenser
A-35 fan motor
MU802661
7<C-31> (*2) 16<C-31> (*2)
1 2 2
C-121 30 31
B (MU803784)
1 2 3 4 5 6 7 8
Engine-ECU
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
NOTE
Wire colour code
AK501831 AB
TROUBLESHOOTING
13A-331
OPERATION STEP 3. Connector check: A-06X condenser fan
• The battery voltage is applied on the engine-ECU relay (low) connector.
(terminal No. 31) form the condenser fan control
Connector: A-06X Relay box's
relay (low). triangle marks
• The battery is applied on the engine-ECU (termi-
nal No. 30) from the condenser fan control relay
(high). 2 1
4 3
A-06X
FUNCTION Harness side
• The engine-ECU condenser fan control relay connector
turns "ON" with the signal from the engine-ECU,
and power is supplied to the condenser fan
motor. AK305265 AB

• Failed condenser fan relay (high) NO : Repair or replace the connector.
• Failed condenser fan relay (low)
• Failed condenser fan motor
• Open/short circuit in condenser fan control relay STEP 4. Check condenser fan relay (low).
circuit or loose connector contact • Check condenser fan relay (low) (Refer to
• Failed engine-ECU GROUP 55 − On-vehicle Service P.55-107).
DIAGNOSIS PROCEDURE YES : Go to Step 5 .
NO : Replace the condenser fan relay (low).
NOTE: .
*2: R.H. drive vehicles STEP 5. Perform voltage measurement at A-06X
condenser fan relay (low) connector.
STEP 1. Check condenser fan motor. Connector: A-06X Relay box's
• Check condenser fan motor (Refer to GROUP 55 triangle marks
− Heater, Air conditioner and Ventilation

−Condenser and condenser fan motor − Inspec- 2 1
tion P.55-127). 4 3
A-06X
YES : Go to Step 2 . connector
NO : Replace the condenser fan motor.
AK305265 AB
STEP 2. M.U.T.-II/III actuator test • Remove relay, and measure at relay box side.
• Item No. 38: Condenser fan (low) • Ignition switch: "ON"
OK: Condenser fan motor rotates (low) • Voltage between terminal No. 2 and earth.
NO : Go to Step 6 .
TROUBLESHOOTING
STEP 6. Connector check: C-208 ignition switch STEP 7. Check ignition switch.
connector.
Connector: C-208 triangle marks

2 1
4 3
A-06X
Harness side
connector
C-208
AK305265 AB
Connector: C-208
C-208
C-208

3 2 1
6 5 4
AK305251AB C-208

3 2 1
6 5 4
AK305251AB
Ignition switch − Ignition switch − Inspection
P.54A-30).
YES : Check intermediate connectors C-101,
C-129, C-210 and C-211, and repair if
necessary. If intermediate connectors are
A-06X (terminal No. 2) condenser fan relay
(low) connector and C-208 (terminal No. 4)
ignition switch connector.
• Check power supply for open circuit
and damage.
TROUBLESHOOTING
13A-333
STEP 8. Perform voltage measurement at A-06X STEP 9. Perform voltage measurement at C-121
condenser fan relay (low) connector. engine-ECU connector.
Connector: A-06X Relay box's Connector: C-121
triangle marks
2 1
4 3
A-06X
Harness side
connector
AK305265 AB
• Remove relay, and measure at relay box side. C-121 (GR)

OK: System voltage
YES : Check and repair harness between battery
and A-08X (terminal No. 4) condenser fan
relay connector.
and damage.
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

OK: System voltage
TROUBLESHOOTING
STEP 10. Connector check: C-121 engine-ECU STEP 11. Perform voltage measurement at A-34
connector. condenser fan motor connector.
Connector: C-121 Connector: A-34
2 1
Harness side
connector
A-34(B)
AK305266 AB
C-121 (GR) Connector: A-06X Relay box's

triangle marks
2 1
4 3
A-06X
Harness side
connector
C-121 (GR) AK305265 AB
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 Connector: C-121
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

triangle marks
2 1
4 3
A-06X
Harness side
AK305265 AB

YES : Check intermediate connectors A-29*1 or
and repair harness between A-06X (terminal C-121 (GR)
No. 3) condenser fan relay (low) connector
and C-121 (terminal No. 31) engine-ECU 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
connector. 35 34 33 32 31 30 29 28 27 26 25 24
• Check power supply for open circuit Harness side connector
and damage. AK501995 AB
NO : Repair or replace the connector. • Disconnect connector, and measure at harness

side.
• Disconnect C-121 engine-ECU connector, and
earth terminal No. 31.
TROUBLESHOOTING
13A-335
• Voltage between terminal No. 2 and earth. STEP 13. Check harness between A-06X
OK: System voltage (terminal No. 3) condenser fan relay (low)
NO : Check and repair harness between A-06X Connector: A-06X Relay box's
(terminal No. 3) condenser fan relay (low) triangle marks
engine-ECU connector. 2 1
• Check power supply for open circuit.
4 3
A-06X
Harness side
STEP 12. Connector check: A-34 condenser fan connector
motor connector.
Connector: A-34
AK305265 AB
2 1
Harness side Connector: C-121
connector
A-34(B)
AK305266 AB

C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
STEP 14. M.U.T.-II/III actuator test STEP 16. Check condenser fan relay (high).
• Item No. 38: Condenser fan (high) • Check condenser fan relay (high) (Refer to
OK: Condenser fan motor rotates (high GROUP 55 − On-vehicle Service P.55-107).
speed) Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 17 .
YES : Replace the engine-ECU. NO : Replace the condenser fan relay (high).
STEP 17. Perform voltage measurement at A-07X
STEP 15. Connector check: A-07X condenser fan condenser fan relay (high) connector.
relay (high) connector. Connector: A-07X Relay box’s
triangle marks
Connector: A-07X Relay box’s
triangle marks
2 1
2 1 A-07X 4 3
A-07X 4 3 Harness side
connector
Harness side
connector
AK305267AB
AK305267AB • Remove relay, and measure at relay box side.

Q: Is the check result normal? • Voltage between terminal No. 2 and earth.
NO : Repair or replace the connector. OK: System voltage
TROUBLESHOOTING
13A-337
STEP 18. Connector check: C-208 ignition switch STEP 19. Check ignition switch.
connector. Connector: A-07X Relay box’s
Connector: C-208 triangle marks

2 1
A-07X 4 3
Harness side
C-208 connector
AK305267AB
Connector: C-208
C-208
C-208

3 2 1
6 5 4
AK305251AB C-208

3 2 1
6 5 4
AK305251AB
• Check ignition switch (Refer to GROUP 54 − igni-

tion switch P.54A-30).
YES : Check intermediate connectors C-101,
C-129, C-210 and C-211 and repair if
A-07X (terminal No. 2) condenser fan relay
(high) connector and C-208 (terminal No. 4)
and damage.
TROUBLESHOOTING
STEP 20. Perform voltage measurement at A-07X STEP 21. Perform voltage measurement at C-121
condenser fan relay (high) connector. engine-ECU connector.
Connector: A-07X Relay box’s Connector: C-121
triangle marks
2 1
A-07X 4 3
Harness side
connector
AK305267AB
• Remove relay, and measure at relay box side. C-121 (GR)

OK: System voltage
YES : Check and repair harness between battery
and A-07X (terminal No. 4) condenser fan
relay (high) connector.
and damage.
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

OK: System voltage
TROUBLESHOOTING
13A-339
STEP 22. Connector check: C-121 engine-ECU STEP 23. Perform voltage measurement at A-34
connector. condenser fan motor connector.
Connector: C-121 Connector: A-34
2 1
Harness side
connector
A-34(B)
AK305266 AB
C-121 (GR) Connector: A-07X Relay box’s

triangle marks
2 1
A-07X 4 3
Harness side
connector
C-121 (GR) AK305267AB
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 Connector: C-121
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB
Connector: A-07X Relay box’s

triangle marks
2 1
A-07X 4 3
connector
AK305267AB

YES : Check intermediate connectors A-29*1 or
and repair harness between A-07X (terminal C-121 (GR)
No. 3) condenser fan relay (high) connector
and C-121 (terminal No. 30) engine-ECU 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
connector. 35 34 33 32 31 30 29 28 27 26 25 24
• Check power supply for open circuit Harness side connector
and damage. AK501995 AB
NO : Repair or replace the connector. • Disconnect connector, and measure at harness

side.
• Disconnect C-121 engine-ECU connector, and
earth terminal No. 30.
TROUBLESHOOTING
• Voltage between terminal No. 2 and earth. STEP 25. Check harness between A-07X
OK: System voltage (terminal No. 3) condenser fan relay (high)
NO : Check intermediate connectors A-29*1 or Connector: A-07X Relay box’s
C-31*2, and repair if necessary. If triangle marks
and repair harness between A-07X (terminal
No. 3) condenser fan relay (high) connector 2 1
and C-121 (terminal No. 30) engine-ECU A-07X 4 3
connector. Harness side
• Check power supply for open circuit connector
and damage.
AK305267AB
STEP 24. Connector check: A-34 condenser fan

Connector: C-121
motor connector.
Connector: A-34
2 1
Harness side
connector
A-34(B)
C-121 (GR)
AK305266 AB
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
13A-341
STEP 26. Connector check: A-35 condenser fan STEP 27. Perform resistance measurement at
motor connector. A-35 condenser fan motor connector.
Connector: A-35 Connector: A-35
2 1 2 1
connector connector
A-35(GR) A-35(GR)
AK305443 AB AK305443 AB

YES : Go to Step 27 . side.
NO : Repair or replace the connector. • Resistance between terminal No. 2 and earth.
OK: 2 Ω or less
Inspection Procedure 27: A/C Switch System
A/C Switch circuit
A/C-ECU
C-117 83
(MU803783)
71 72 73 74 75 76 77
78 79 80 81 82 83 84 85 86 87 88 89 90 Engine-ECU
91 92 93 94 95 96 97 98 99 100
Wire colour code

AK501832 AB
TROUBLESHOOTING

• The battery voltage is applied to the engine-ECU
(terminal No. 83) from the A/C-ECU (terminal No. STEP 1. Perform voltage measurement at C-117
1). engine-ECU connector.
FUNCTION Connector: C-117
• When the A/C switch is in "ON" position, A/C <L. H. drive vehicles>
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 CAUSES
• Failed A/C
• Failed A/C system
• Open/short circuit in A/C circuit or loose connec-
tor contact C-117 (GR)
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB

• Engine: Idling
• A/C set temperature:
25°C or more
Maximum Hot when temperature in cabin is 25°C
or less
OK:
System voltage (when A/C is ON)
0.5 V or less (when A/C is OFF)
NO : Check A/C system (Refer to GROUP 55 −
Troubleshooting − Check Chart for Trouble
Symptoms P.55-29)
TROUBLESHOOTING
13A-343
STEP 2. Connector check: C-117 engine-ECU STEP 3. M.U.T.-II/III data list
connector • Item No. 28: A/C switch
a. Engine: Idling
Connector: C-117
b. A/C set temperature:
25°C or more
Maximum Hot when temperature in cabin is
25°C or less
OK:
ON (when A/C is ON)
C-117 (GR) YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
P.00-5).
C-117 (GR)
77 76 75 74 73 72 71
90 89 88 87 86 85 84 83 82 81 80 79 78
100 99 98 97 96 95 94 93 92 91
AK501996 AB

TROUBLESHOOTING
Inspection Procedure 28: A/C Compressor Relay System
A/C compressor relay Circuit
Ignition switch
C-208
R LOCK
1 2 3 ST ACC
4 5 6 IG1 IG2
L-B
C-211
2
5
Battery J/B
7.5A
W W 13
C-210
W-B
17 (*1) or 11 (*2)
9 Relay box J/C (2)

C-101
10A
14 (*1) or 8 (*2)
L-G
C-31 (*2) W-B
4 3<C-124> (*1) or
A-29 (*1) 1<C-122> (*2)
6 W-B
L-G
1 2
B-13X
1 2 A/C compressor relay

3 4
4 3
B-Y
A-13 (*1)
1 P
C-31 (*2)
6
B-Y
1 20
A/C compressor
assembly C-121
A/C refrigerant (MU803784)
A-36 temperature
MU802653 switch 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
1
Magnetic
NOTE clutch
*2: R.H. drive vehicles Engine-ECU
Wire colour code
AK501833 AB
TROUBLESHOOTING
13A-345
OPERATION STEP 1. Connector check: B-13X A/C
• The battery voltage is applied to the A/C com- compressor relay connector
pressor relay (terminal No. 1).
Connector: B-13X
• The battery voltage is applied to the A/C com- Relay box’s
triangle marks
pressor relay (terminal No. 2) from the ignition
switch. The engine-ECU (terminal No. 20) makes
the power transistor in the unit be in "ON" posi- B-13X 2 1
tion and makes currents go on the A/C compres-
sor relay coil, and that makes the relay be in "ON" 4 3
position. Harness side
connector
• When the A/C compressor is in "ON" position, the
battery voltage is supplied to the A/C compressor
(terminal No. 4) from the A/C compressor relay AK305270AB
assembly (terminal No. 1). Q: Is the check result normal?

FUNCTION NO : Repair or replace the connector.
• 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. Accord- STEP 2. A/C compressor relay check.
ingly, the battery voltage supplied to the A/C com- • Check A/C compressor relay (Refer to GROUP
pressor operates the magnet clutch. 55 − On-vehicle Service − Power Relay Check
P.55-107).
PROBABLE CAUSES Q: Is the check result normal?
• Failed A/C compressor relay YES : Go to Step 3 .
• Failed A/C compressor magnet clutch NO : Replace the A/C compressor relay.
• Open/short circuit in A/C compressor relay circuit
or loose connector contact STEP 3. Perform voltage measurement at B-13X
• Failed engine-ECU A/C compressor relay connector.
DIAGNOSIS PROCEDURE Connector: B-13X Relay box’s
triangle marks
NOTE: .
*2: R.H. drive vehicles B-13X 2 1
4 3
Harness side
connector
AK305270AB

OK: System voltage
NO : Go to Step 4 .
TROUBLESHOOTING
STEP 4. Connector check: C-208 ignition switch STEP 5. Perform voltage measurement at B-13X
connector A/C compressor relay connector.
Connector: C-208 Connector: B-13X Relay box’s
triangle marks
B-13X 2 1
4 3
C-208
Harness side
connector
AK305270AB

<R. H. drive vehicles> OK: System voltage
NO : Check intermediate connector A-29*1or
C-208 C-31*2, and repair if necessary. If
repair harness between B-13X (terminal No.
1) A/C compressor relay connector and
battery.
open/short circuit.
3 2 1
6 5 4
Harness side connector STEP 6. Connector check: A-36 A/C compressor
AK305251AB assembly connector
Connector: B-13X Relay box’s Connector: A-36 1

triangle marks Harness side
connector
B-13X 2 1
4 3
Harness side
connector
A-36 (B)
AK502005 AB
AK305270AB

YES : Check intermediate connectors C-124*1or YES : Go to Step 7 .
C-122*2, C-210 and C-211, and repair if
B-13X (terminal No. 2) A/C compressor
relay connector and C-208 (terminal No. 4)
open/short circuit.
TROUBLESHOOTING
13A-347
STEP 7. Perform voltage measurement at A-36 STEP 8. Perform voltage measurement at C-121
A/C compressor assembly connector. engine-ECU connector.
Connector: A-36 1 Connector: C-121
Harness side <L. H. drive vehicles>
connector
A-36 (B)
AK502005 AB
Connector: B-13X C-121 (GR)

Relay box’s
triangle marks <R. H. drive vehicles>
B-13X 2 1
4 3
Harness side
connector
AK305270AB C-121 (GR)
• Disconnect connector, and measure at harness 8 7 6 5 4 3 2 1

side. 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
• Remove B-13X (terminal No. 1 and No. 4) A/C Harness side connector
compressor relay and short-circuit of harness AK501995 AB
side connector. • Disconnect connector, and measure at harness
• Ignition switch: "ON" side.
• Voltage between terminal No. 1 and earth. • Ignition switch: "ON"
OK: System voltage • Voltage between terminal No. 20 and earth.
NO : Check intermediate connector A-13*1 or YES : Go to Step 12 .
C-31*2, and repair if necessary. If NO : Go to Step 9 .
repair harness between A-36 (terminal No.
1) A/C compressor assembly connector and
B-13X (terminal No. 4) A/C compressor
relay connector.
circuit.
TROUBLESHOOTING
STEP 9. Connector check: C-121 engine-ECU STEP 10. Check harness between B-13X
connector (terminal No. 3) A/C compressor relay connector
Connector: C-121
connector.
Connector: B-13X Relay box’s
triangle marks
B-13X 2 1
4 3
Harness side
connector
C-121 (GR)
AK305270AB
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
Harness side connector C-121 (GR)
AK501995 AB
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
13A-349
STEP 11. M.U.T.-II/III data list STEP 13. Check harness between B-13X
• Item No. 49: A/C relay (terminal No. 3) A/C compressor relay connector
a. Engine: Idling and C-121 (terminal No. 20) engine-ECU
b. A/C set temperature: connector.
Maximum Cool when temperature in cabin is Connector: B-13X Relay box’s
25°C or more triangle marks
Maximum Hot when temperature in cabin is
25°C or less
B-13X
OK: 2 1
ON (when A/C is ON) 4 3
OFF (when A/C is OFF) Harness side
connector
00 − How to Use AK305270AB

Connector: C-121
P.00-5).
NO : Replace the engine-ECU. <L. H. drive vehicles>

connector
Connector: C-121
C-121 (GR)
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

C-121 (GR)
8 7 6 5 4 3 2 1 YES : Go to Step 14 .
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK501995 AB

TROUBLESHOOTING
STEP 14. Connector check: C-208 ignition switch STEP 15. Check harness between C-208 (terminal
connector No. 4) ignition switch connector and B-13X
Connector: C-208 (terminal No. 2) A/C compressor relay connector.
Connector: C-208
C-208
C-208

C-208
C-208
3 2 1
6 5 4 3 2 1
Harness side connector 6 5 4
AK305251AB Harness side connector
AK305251AB
YES : Go to Step 15 . Connector: B-13X Relay box’s
NO : Repair or replace the connector. triangle marks
B-13X 2 1
4 3
Harness side
connector
AK305270AB

connectors C-124*1or C-122*2, C-210 and C-211,
and repair if necessary.
TROUBLESHOOTING
13A-351
STEP 16. Check harness between battery and STEP 17. Check harness between B-13X
B-13X (terminal No. 1) A/C compressor relay (terminal No. 4) A/C compressor relay connector
connector. and A-36 (terminal No. 1) A/C compressor
Connector: B-13X
assembly connector.
Relay box’s
triangle marks Connector: B-13X Relay box’s
triangle marks
B-13X 2 1
B-13X 2 1
4 3
Harness side 4 3
connector
AK305270AB
AK305270AB
connector A-29*1or C-31*2, and repair if necessary. Connector: A-36 1
• Check power supply line for damage. Harness side
connector
A-36 (B)
AK502005 AB

connector A-13*1or C-31*2, and repair if necessary.
YES : Replace the A/C compressor magnet clutch.
TROUBLESHOOTING
Inspection Procedure 29: A/C Load Signal System
A/C load signal circuit
C-37
(MU801584)
21 22 23 24 25 26 27 28 A/C-ECU
29 30 31 32 33 34 35 36
32
G-Y
5<C-124> (*1) or 4<C-122> (*2)
G-Y
65
C-119
(MU803782)
41 42 43 44 45 46 47
48 49 50 51 52 53 54 55 56 57 58 59 Engine-ECU
60 61 62 63 64 65 66 67 68
NOTE
Wire colour code
AK501834 AB

• The A/C load signal is inputted to the • Failed A/C-ECU
engine-ECU (terminal No. 65) from the A/C-ECU • Open/short circuit in A/C load signal circuit or
(terminal No. 32). loose connector contact
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 accord-
ing to the A/C compressor load condition.
TROUBLESHOOTING
13A-353
DIAGNOSIS PROCEDURE STEP 2. Connector check: C-121 engine-ECU
connector
STEP 1. Perform voltage measurement at C-121 Connector: C-121
Connector: C-121
C-121 (GR)
C-121 (GR)
C-121 (GR)
8 7 6 5 4 3 2 1
C-121 (GR) 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
8 7 6 5 4 3 2 1 Harness side connector
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 AK501995 AB
35 34 33 32 31 30 29 28 27 26 25 24
Harness side connector Q: Is the check result normal?
AK501995 AB
• Measure engine-ECU terminal voltage. NO : Repair or replace the connector.
• Engine: Idling
• A/C switch: ON (A/C compressor in driven state)
• Voltage between terminal No. 65 and earth
OK: Q: Does trouble symptom persist?
1 V or less (when the A/C is under low load)
System voltage (when the A/C is under high
00 − How to Use
load)
Q: Is the check result normal? P.00-5).
NO : Go to Step 4 .
TROUBLESHOOTING
connector A/C-ECU connector.
Connector: C-121 Connector: C-37 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
<L. H. drive vehicles> Harness side
connector
C-37 (B)
AK502007 AB
C-121 (GR) • Measure A/C-ECU terminal voltage.

• Engine: Idling
• A/C switch: ON (A/C compressor in driven state)
• Voltage between terminal No. 32 and earth
OK: System voltage (when the A/C is under
high load)
NO : Go to Step 6 .
C-121 (GR)
8 7 6 5 4 3 2 1 STEP 6. Connector Check: C-37 A/C-ECU

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 connector
Harness side connector Connector: C-37
AK501995 AB 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29

connector
C-37 (B)
AK502007 AB

TROUBLESHOOTING
13A-355
STEP 7. Check harness between C-37 (terminal STEP 8. Connector check: C-37 A/C-ECU
No. 32) A/C-ECU connector and C-119 (terminal connector
No. 65) engine-ECU connector.
Connector: C-37 28 27 26 25 24 23 22 21
Connector: C-37 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
36 35 34 33 32 31 30 29 Harness side
connector
C-37 (B)
C-37 (B) AK502007 AB
AK502007 AB
Connector: C-119
C-119 (GR)
C-119 (GR)
C-119 (GR)
C-119 (GR)
47 46 45 44 43 42 41
59 58 57 56 55 54 53 52 51 50 49 48
47 46 45 44 43 42 41
68 67 66 65 64 63 62 61 60
59 58 57 56 55 54 53 52 51 50 49 48
68 67 66 65 64 63 62 61 60 Harness side connector
AK501994 AB
AK501994 AB
NOTE: Before checking harness, check intermediate YES : Check intermediate connector C-124*1 or
connector C-124*1 or C-122*2, and repair if neces- C-122*2, and repair if necessary. If
sary. intermediate connector is normal, check and
• Check output line for short circuit. repair harness between C-37 (terminal No.
Q: Is the check result normal? 32) A/C-ECU connector and C-119 (terminal
YES : Check Air conditioner (Refer to GROUP 55 No. 65) engine-ECU connector.
− Troubleshooting − Check Chart For • Check output line for open circuit.
Trouble Symptoms P.55-29).
TROUBLESHOOTING
Inspection Procedure 30: Ignition Circuit System <L. H. drive vehicles>
Ignition circuit
Ignition switch
C-208
R LOCK
1 2 3
ST
4 5 6 ACC
IG1 IG2
2
B-W
C-211
6
1
J/B
10 A
10
C-214
Y-G
C-129
18
W
A-29
4
W-R W-R
Ignition coil 1 1 1 Ignition coil 2

B-103 B-114
(MU802064) (MU802064)
1 2 3 1 2 3
3 2 Spark 2 3
plug
B B
B-Y B-G
B B
11 12
C-121
(MU803784)
1 2 3 4 5 6 7 8
Engine-ECU 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
Wire colour code

AK501836 AB
TROUBLESHOOTING
13A-357
OPERATION STEP 3. Connector check: B-103 and B-114
• The battery voltage is applied to the ignition coil ignition coil connectors
(terminal No. 1) from the ignition switch and is
earthed to the vehicle body from the ignition coil
3 2 1
(terminal No. 2). Harness side
• A power voltage of 12 V is applied to the ignition connector
coil output terminal (terminal No. 3) from the B-114(GR)
engine-ECU (terminal No. 11 and No. 12).
FUNCTION
B-103(GR)
• When the engine-ECU makes the power transis-
tor in the unit be in "OFF" position, the battery
AK305047AB
voltage in the unit is applied to the power transis-
tor unit, and that makes the power transistor unit Q: Is the check result normal?
be in "ON" position. The engine-ECU makes the YES : Go to Step 4 .
power transistor in the unit be in "ON", and that NO : Repair or replace the connector.
makes the power transistor unit be in "OFF" posi-
tion.
the power transistor unit is in "ON" position. The
primary current is going to the ignition coil. When
the power transistor unit is in "OFF" position, the Q: Is the check result normal?
primary current is interrupted and high voltage is YES : Go to Step 5 .
generated in the secondary coil. NO : Replace the ignition coil.
PROBABLE CAUSES STEP 5. Perform voltage measurement at B-103

• Failed ignition coil and B-114 ignition coil connectors.
• Failed spark plug
• Failed spark plug cable
3 2 1
• Open/short circuit in ignition primary circuit or
Harness side
loose connector contact connector
• Failed engine-ECU B-114(GR)
DIAGNOSIS PROCEDURE
B-103(GR)
• Check spark plug cable itself (Refer to GROUP AK305047AB
16 − Ignition System − On-vehicle Service • Disconnect connector, and measure at harness
P.16-29). side.
Q: Is the check result normal? • Ignition switch: "ON"
YES : Go to Step 2 . • Voltage between terminal No. 1 and earth.
NO : Replace the spark plug cable. OK: System voltage
STEP 2. Check spark plug. YES : Go to Step 7 .
Q: Is the check result normal? NO : Go to Step 6 .
TROUBLESHOOTING
STEP 6. Connector check: C-208 ignition switch STEP 7. Perform voltage measurement at B-103
connector and B-114 ignition coil connectors.
Connector: C-208 Connector : B-103, B-114
3 2 1
Harness side
connector
C-208 B-114(GR)
3 2 1
6 5 4 B-103(GR)
Harness side
connector AK305446 AB AK305047AB

3 2 1
side.
Harness side • Engine: Cranking
connector • Voltage between terminal No. 3 and earth.
B-114(GR) OK: 0.5 − 4.0 V
B-103(GR) NO : Go to Step 8 .
AK305047AB

YES : Check intermediate connectors A-29,
C-129, C-211 and C-214, and repair if
C-208 (terminal No. 2) ignition switch
connector and B-114 (terminal No. 1)
ignition coil connector, also between C-208
(terminal No. 2) ignition switch connector
and B-103 (terminal No. 1) ignition coil
connector.
open/short circuit.
TROUBLESHOOTING
13A-359
C-121 (GR) C-121 (GR)

8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 35 34 33 32 31 30 29 28 27 26 25 24
AK502032 AB AK502032 AB
Connector : B-103, B-114 Connector : B-103, B-114

3 2 1 3 2 1
connector connector
B-114(GR) B-114(GR)
B-103(GR) B-103(GR)
AK305047AB AK305047AB

• Disconnect B-103 and B-114 ignition coil connec- YES : Check and repair harness between B-114
tors. (terminal No. 3) ignition coil connector and
• Engine: Cranking C-121 (terminal No. 12) engine-ECU
• Voltage between terminal No. 11 and earth, also connector, also between B-103 (terminal
between terminal No. 12 and earth. No. 3) ignition coil connector and C-121
OK: 0.5 − 4.0 V (terminal No. 11) engine-ECU connector.
Q: Is the check result normal? • Check output line for open circuit.
TROUBLESHOOTING
connector No. 3) ignition coil connector and C-121 (terminal
No. 12) engine-ECU connector, also between
Connector: C-121
B-103 (terminal No. 3) ignition coil connector and
3 2 1
Harness side
connector
B-114(GR)
C-121 (GR)
B-103(GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK305047AB
AK502032 AB
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK502032 AB


00 − How to Use
P.00-5).
TROUBLESHOOTING
13A-361
STEP 13. Perform resistance measurement at STEP 14. Check harness between C-208 (terminal
B-103 and B-114 ignition coil connectors. No. 2) ignition switch connector and B-103
(terminal No. 1) ignition coil connector, also
3 2 1 between C-208 (terminal No. 2) ignition switch
Harness side connector and B-114 (terminal No. 1) ignition coil
connector connector.
B-114(GR) Connector: C-208
B-103(GR)
C-208
AK305047AB
• Disconnect connector, and measure at harness 3 2 1

side. 6 5 4
• Resistance between terminal No. 2 and earth. Harness side
OK: 2 Ω or less
Q: Is the check result normal? Connector : B-103, B-114
YES : Go to Step 14 . 3 2 1
NO : Check and repair harness between B-103 Harness side
connector
(terminal No. 2) ignition coil connector and
B-114(GR)
body earth, also between B-114 (terminal
No. 2) ignition coil connector and body
earth.
• Check earthing line for open circuit B-103(GR)
and damage.
AK305047AB

connectors A-29, C-129, C-211 and C-214, and
repair if necessary.
TROUBLESHOOTING

No. 3) ignition coil connector and C-121 (terminal
3 2 1
Harness side
connector
B-114(GR)
B-103(GR)
AK305047AB
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK502032 AB

TROUBLESHOOTING
13A-363
Inspection Procedure 31: Ignition Circuit System <R. H. drive vehicles>
Ignition circuit
Ignition switch
C-208
R LOCK
ST
ACC 1 2 3
IG1 IG2
4 5 6
Battery
2
W W
B-W
C-211
6
Relay 8 1
J/B
box 20A 10A
10
B-Y C-214
B-R
C-31 C-123
Engine 13
control 9
system B-Y W
1 2
B-10X
1 2 Ignition
coil relay
3 4 OFF ON
4 3
B
W-R
B B
W-R W-R
Ignition coil 1 1 1 Ignition coil 2

B-103 B-114
(MU802064) (MU802064)
1 2 3 1 2 3
3 2 Spark 2 3
plug
B B
B-Y B-G
B
11 12
C-121
(MU803784)
1 2 3 4 5 6 7 8
Engine-ECU 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 3132 33 34 35
Wire colour code

AK501855 AB
TROUBLESHOOTING
OPERATION STEP 2. Check spark plug.

• The battery voltage is applied to the ignition coil
relay (terminal No. 2) from the ignition switch and
is earthed to the vehicle body from the ignition
coil relay (terminal No. 3).
• The battery voltage is applied to the ignition coil
relay (terminal No. 1) from the battery and is STEP 3. Connector check: B-103 and B-114
earthed to the vehicle body from the ignition coil ignition coil connectors
(terminal No. 2). Connector : B-103, B-114
• A power voltage of 12 V is applied to the ignition 3 2 1
coil output terminal (terminal No. 3) from the Harness side
engine-ECU (terminal No. 11 and No. 12). connector
B-114(GR)
FUNCTION
• When the engine-ECU makes the power transis-
tor in the unit be in "OFF" position, the battery B-103(GR)
voltage in the unit is applied to the power transis-
tor unit, and that makes the power transistor unit AK305047AB
be in "ON" position. The engine-ECU makes the
power transistor in the unit be in "ON", and that Q: Is the check result normal?
makes the power transistor unit be in "OFF" posi- YES : Go to Step 4 .
tion. NO : Repair or replace the connector.
the power transistor unit is in "ON" position. The STEP 4. Check ignition coil itself.
primary current is going to the ignition coil. When • Check ignition coil itself (Refer to GROUP 16 −
the power transistor unit is in "OFF" position, the Ignition System − On-vehicle Service P.16-28).
primary current is interrupted and high voltage is
generated in the secondary coil. Q: Is the check result normal?
PROBABLE CAUSES NO : Replace the ignition coil.
• Failed ignition coil
• Failed ignition coil relay STEP 5. Perform voltage measurement at B-103
• Failed spark plug and B-114 ignition coil connectors.
• Failed spark plug cable Connector : B-103, B-114
• Open/short circuit in ignition primary circuit or 3 2 1
loose connector contact Harness side
• Failed engine-ECU connector
B-114(GR)
DIAGNOSIS PROCEDURE
B-103(GR)
16 − Ignition System − On-vehicle Service AK305047AB
P.16-29). • Disconnect connector, and measure at harness

side.
NO : Replace the spark plug cable. • Voltage between terminal No. 1 and earth.
OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING
13A-365
STEP 6. Connector check: B-10X ignition coil STEP 9. Connector check: C-208 ignition switch
relay connector connector
Connector: B-10X Relay box's Connector: C-208
triangle marks
3 2 1
6 5 4
Harness side
2 1 connector
C-208
4 3
B-10X(B)
Harness side
connector
AK305279 AB AK305448 AB
Q: Is the check result normal? Connector: B-10X Relay box's

2 1
STEP 7. Check ignition coil relay.
4 3
• Check ignition coil relay (Refer to GROUP 16 − B-10X(B)
Ignition System − On-vehicle Service P.16-28). Harness side
connector
AK305279 AB
NO : Replace the ignition coil relay.
STEP 8. Perform voltage measurement at B-10X YES : Check intermediate connectors C-123,
ignition coil relay connector. C-211 and C-214, and repair if necessary. If
Connector: B-10X Relay box's and repair harness between C-208 (terminal
triangle marks
No. 2) ignition switch connector and B-10X
(terminal No. 2) ignition coil relay connector.
2 1 • Check power supply line for
open/short circuit.
4 3
B-10X(B) NO : Repair or replace the connector.
Harness side
connector
AK305279 AB

OK: System voltage
NO : Go to Step 9 .
TROUBLESHOOTING
STEP 10. Perform resistance measurement at STEP 11. Perform voltage measurement at B-10X
B-10X connector. ignition coil relay connector.
Connector: B-10X Relay box's Connector: B-10X Relay box's
triangle marks triangle marks
2 1 2 1
4 3 4 3
B-10X(B) B-10X(B)
connector connector
AK305279 AB AK305279 AB
• Remove relay, and measure at relay box side. Connector : B-103, B-114
• Resistance between terminal No. 3 and earth. 3 2 1
OK: 2 Ω or less Harness side
connector
B-114(GR)
NO : Check and repair harness between B-10X
(terminal No. 3) ignition coil relay connector
and body earth. B-103(GR)
and damage. AK305047AB

OK: System voltage
YES : Check and repair harness between B-10X
(terminal No. 4) ignition coil relay connector
and B-103 (terminal No. 1) ignition coil
connector, also between B-10X (terminal
No. 4) ignition coil relay connector and
B-114 (terminal No. 1) ignition coil
connector.
open/short circuit.
harness between B-10X (terminal No. 1)
ignition coil relay connector and battery.
open/short circuit.
TROUBLESHOOTING
13A-367
and B-114 ignition coil connectors. engine-ECU connector.
Connector : B-103, B-114 Connector: C-121
3 2 1
Harness side
connector
B-114(GR)
B-103(GR)
AK305047AB C-121 (GR)
• Disconnect connector, and measure at harness 8 7 6 5 4 3 2 1

side. 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
• Engine: Cranking Harness side connector
• Voltage between terminal No. 3 and earth. AK502033 AB
OK: 0.5 − 4.0 V Connector : B-103, B-114

connector
B-114(GR)
B-103(GR)
AK305047AB

• Disconnect B-103 and B-114 ignition coil connec-
tors.
• Engine: Cranking
• Voltage between terminal No. 11 and earth, also
OK: 0.5 − 4.0 V
TROUBLESHOOTING
connector connector
C-121 (GR) C-121 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24 35 34 33 32 31 30 29 28 27 26 25 24
AK502033 AB AK502033 AB

Harness side NO : Repair or replace the connector.
connector
B-114(GR)
B-103(GR)
AK305047AB

(terminal No. 3) ignition coil connector and
C-121 (terminal No. 12) engine-ECU
connector, also between B-103 (terminal
No. 3) ignition coil connector and C-121
TROUBLESHOOTING
13A-369
No. 3) ignition coil connector and C-121 (terminal Q: Does trouble symptom persist?
No. 12) engine-ECU connector, also between YES : Replace the engine-ECU.
B-103 (terminal No. 3) ignition coil connector and NO : Intermittent malfunction (Refer to GROUP
C-121 (terminal No. 11) engine-ECU connector. 00 − How to Use
Connector : B-103, B-114 Troubleshooting/Inspection Service Points
3 2 1 P.00-5).
Harness side
connector
B-114(GR) STEP 18. Perform resistance measurement at
B-103 and B-114 ignition coil connectors.
B-103(GR) 3 2 1
Harness side
connector
AK305047AB
B-114(GR)
Connector: C-121
B-103(GR)
AK305047AB

side.
C-121 (GR) OK: 2 Ω or less
8 7 6 5 4 3 2 1 Q: Is the check result normal?
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 YES : Go to Step 19 .
35 34 33 32 31 30 29 28 27 26 25 24
AK502033 AB (terminal No. 2) ignition coil connector and
body earth, also between B-114 (terminal
No. 2) ignition coil connector and body
Q: Is the check result normal? earth.
YES : Go to Step 17 . • Check earthing line for open circuit
NO : Repair the damaged harness wire. and damage.
TROUBLESHOOTING
STEP 19. Check harness between C-208 (terminal STEP 20. Check harness between battery and
No. 2) ignition switch connector and B-10X B-10X (terminal No. 1) ignition coil relay
(terminal No. 2) ignition coil relay connector. connector.
Connector: C-208 Connector: B-10X Relay box's
triangle marks
3 2 1
6 5 4
Harness side
connector 2 1
C-208
4 3
B-10X(B)
Harness side
connector
AK305448 AB AK305279 AB
Connector: B-10X Relay box's NOTE: Before checking harness, check intermediate
triangle marks connector C-31 and repair if necessary.
2 1 Q: Is the check result normal?

B-10X(B)
4 3 NO : Repair the damaged harness wire.
Harness side
connector
STEP 21. Check harness between B-10X
(terminal No. 4) ignition coil relay connector and
AK305279 AB
B-103 (terminal No. 1) ignition coil connector,
NOTE: Before checking harness, check intermediate also between B-10X (terminal No. 4) ignition coil
connectors C-123, C-211 and C-214, and repair if relay connector and B-114 (terminal No. 1)
necessary. ignition coil connector.
• Check power supply line for damage. Connector: B-10X Relay box's
Q: Is the check result normal? triangle marks
2 1
4 3
B-10X(B)
Harness side
connector
AK305279 AB

3 2 1
Harness side
connector
B-114(GR)
B-103(GR)
AK305047AB

TROUBLESHOOTING
13A-371
No. 3) ignition coil connector and C-121 (terminal
3 2 1
Harness side
connector
B-114(GR)
B-103(GR)
AK305047AB
Connector: C-121
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34 33 32 31 30 29 28 27 26 25 24
AK502033 AB

TROUBLESHOOTING
DATA LIST REFERENCE TABLE

M1131152002117
Item Inspection Inspection condition Normal condition Inspection Reference

No. item procedure page
No.
11 Oxygen Engine: After Excessive deceleration 200 mV or less Code No. P.13A-7
sensor warm-up (leaner by from 4,000 r/min P0130 5
deceleration, richer At excessive 600 − 1,000 mV
by acceleration) acceleration
Engine: After Idle operation 400 mV or less
warm-up (using 2,500 r/min ⇔ 600 − 1,000
oxygen sensor, mV (altered)
check air-fuel ratio
as well as control
status by
engine-ECU.
12 Air flow • Engine coolant Idle operation 17 − 43 Hz − −
sensor *1 temperature: 80 2,500 r/min 40 − 100 Hz
−95°C
Acceleration According to
• Lamps, electric
acceleration,
cooling fan and
frequency is
all accessories:
amplified.
OFF
• Transmission:
Neutral
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13A-4
temperature "ON" or engine −20°C P0110 5
sensor running Intake air temperature: 0°C
0°C
Intake air temperature: 20°C
20°C
40°C
Intake air temperature: 80° C
80°C
14 Throttle Ignition switch: Release accelerator 535 − 735 mV Code No. P.13A-6
position "ON" pedal fully P0120 0
sensor Depress accelerator Increased
pedal gradually according to
accelerator pedal
stroke
Depress accelerator 4,500 − 5,000
pedal fully mV
16 Power Ignition switch: "ON" System voltage Procedure P.13A-3
supply No. 23 02
voltage
18 Cranking Ignition switch: Engine: Stopped OFF Procedure P.13A-3
signal "ON" Engine: Cranking ON No. 23 02
(ignition
switch-ST)
TROUBLESHOOTING
13A-373
No.
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13A-5
coolant "ON" or engine −20°C P0115 2
temperature running Coolant temperature: 0°C
sensor 0°C
Coolant temperature: 20°C
20°C
40°C
80°C
22 Crank angle • Engine: Compare engine speed Matched − −
sensor Cranking on tachometer with the
• Tachometer: value displayed on
Connected M.U.T.-II/III
Engine: Idle Coolant temperature: 1,200 − 1,400
operation −20°C r/min
Coolant temperature: 1,200 − 1,400
0°C r/min
20°C r/min
40°C r/min
Coolant temperature: 750 − 950 r/min
80°C
25 Barometric Ignition switch: Altitude: 0 m 101 kPa Code P.13A-3
pressure "ON" Altitude: 600 m 95 kPa No.P0105 5
sensor
Altitude: 1,200 m 88 kPa
Altitude: 1,800 m 81 kPa
27 Power Engine: Idle Steering wheel: Not OFF Code P.13A-1
steering fluid operation operated No.P0551 97
pressure Steering wheel: ON
switch Operated
28 A/C switch Engine: Idle AC switch: OFF OFF Procedure P.13A-3
AC A/C OFF No. 27 41
switch: compressor is
ON not driven
A/C ON
compressor is
driven
34 Air flow Engine: After Idle operation ON Code No. P.13A-2
sensor reset engine warm-up 3,000 r/min OFF P0100 4
signal
TROUBLESHOOTING

No.
37 Volumetric • Engine coolant Idle operation 15 − 35% − −
efficiency temperature: 80 2,500 r/min 15 − 35%
−95°C
Excessive acceleration According to
• Lamps, electric
acceleration,
cooling fan and
volumetric
all accessories:
efficiency is
OFF
increased.
41 Injectors *2 Engine: Cranking Coolant temperature: 18 − 307 ms − −
0°C (all cylinders in
simultaneous injecting
operation)
Coolant temperature: 7.0 − 12 ms
20°C
Coolant temperature: 2.9 − 4.9 ms
80°C
Injectors *3 • Engine coolant Idle operation 1.5 − 2.7 ms
temperature: 80 2,500 r/min 1.2 − 2.4 ms
−95°C
Excessive acceleration Increased
• Lamps, electric
cooling fan and
all accessories:
OFF
• Transmission:
Neutral
44 Ignition • Engine: After Idle operation 0 − 10° BTDC − −
advance warm-up 2,500 r/m 20 − 40° BTDC
• Install timing
light (for use to
measure actual
ignition timing)
45 Idle speed • Engine coolant A/C switch: OFF 2 − 25 steps − −
control temperature: 80 A/C switch: OFF → ON Increased 10 −
(stepper −95°C 70 steps
motor) servo • Lighting, electric
position *4 cooling fan and
accessories:
OFF
• Transmission:
Neutral
• Engine: Idle
operation (When
A/C switch is
ON, A/C
compressor
must be ON)
TROUBLESHOOTING
13A-375
No.
49 A/C relay Engine: After A/C switch: OFF OFF Procedure P.13A-3
warm-up, idle A/C A/C OFF No. 28 44
operation after switch: compressor is
warm-up ON not driven
A/C ON
compressor is
driven
59 Oxygen Engine: After At excessive 0 mV or less ⇔ Code P.13A-8
sensor warm-up acceleration 600 − 1,000 mV No.P0136 8
(rear) (altered)
7E Variable Engine: After Idling without load 0 − 5°CA − −
valve timing warm-up 2,500 r/min without any 8 − 12°CA
phase angle load
12 Air flow • Engine coolant Idle operation 19 − 6.7 gm/s − −
*5 sensor temperature: 80 2,500 r/min 7.9 − 12.1 gm/s
−95°C
Acceleration According to
• Lamps, electric
acceleration,
cooling fan and
frequency is
all accessories:
amplified.
OFF
• Transmission:
Neutral
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13A-4
*5 temperature "ON" or engine −20°C P0110 5
sensor running Intake air temperature: 0°C
0°C
20°C
40°C
Intake air temperature: 80° C
80°C
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13A-5
*5 coolant "ON" or engine −20°C P0115 2
temperature running Coolant temperature: 0°C
sensor 0°C
20°C
40°C
80°C
TROUBLESHOOTING

No.
22 Crank angle • Engine: Compare engine speed Matched − −
*5 sensor Cranking on tachometer with the
• Tachometer: value displayed on
Connected M.U.T.-II/III
Engine: Idle Coolant temperature: 1,200 − 1,400
operation −20°C r/min
0°C r/min
20°C r/min
40°C r/min
Coolant temperature: 750 − 950 r/min
80°C
24 Vehicle Drive 40 km/h Approximately 40 Code No. P.13A-1
*5 speed km/h P0500 87
sensor
81 Long-term Engine: After warm-up 2,500 r/min without −12.5 to 12.5% Code No. P.13A-1
*5 fuel any load (during closed loop) P0170 01
compensati
on
82 Shot-term Engine: After warm-up 2,500 r/min without −20 to 20% Code No. P.13A-1
*5 fuel any load (during closed loop) P0170 01
compensati
on
87 Calculation Engine: After Idle operation 15 − 35% − −
*5 load value warm-up 2,500 r/min 15 − 35%
88 Fuel control Engine: After 2,500 r/min Closed loop − −
*5 condition warm-up Acceleration Open loop −drive
condition
8A Throttle Ignition switch: Set to Idle position 0 − 1% Code No. P.13A-6
*5 position "ON" Release accelerator Increased P0120 0
sensor pedal gradually according to
(Throttle accelerator pedal
opening stroke
angle)
Release accelerator 80 − 100%
pedal fully
TROUBLESHOOTING
13A-377
No.
A1 Oxygen Engine: After Excessive deceleration 0.2 V or less Code No. P.13A-7
*5 sensor warm-up (leaner by from 4,000 r/min P0130 5
deceleration, richer At excessive 0.6 − 1 V
by acceleration) acceleration
Engine: After Idle operation 0.2 V or less
warm-up (using 2,500 r/min 0.6 − 1 V
oxygen sensor,
check air-fuel ratio
as well as control
status by
engine-ECU.
A2 Oxygen Engine: After At excessive 0 V or less ⇔ 0.6 Code P.13A-8
*5 sensor warm-up acceleration − 1 V (altered) No.P0136 8
(rear)
NOTE: .
*1: On the new vehicle (mileage: 500 km or less), air flow sensor output frequency may be higher by
approximately 10%.
*2: Injector drive time ranges shown are when power voltage is 11 V and the cranking speed is 250 r/min.
or less.
*3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approximately 10%.
*4: On the new vehicle (mileage: 500 km or less), the number of steps of stepper motor may be larger by
approximately 30 steps.
*5: When service data in check mode is selected, the data is not displayed.
TROUBLESHOOTING
ACTUATOR TEST REFERENCE TABLE

M1131152501324
Item Inspection Drive content Inspection conditions Normal Code No. Reference
No. item condition /Inspection page
procedure
No.
01 Injector Cut off No. 1 Engine: After warm-up, Engine is Code No. P.13A-10
injector idle operation (Cut off changed P0201 5
02 Cut off No. 2 injectors sequentially to (becomes Code No. P.13A-11
injector check for a cylinder that unstable or P0202 1
does not change engine in stalled)
03 Cut off No. 3 idle status. Code No. P.13A-11
injector P0203 7
04 Cut off No. 4 Code No. P.13A-12
injector P0204 3
07 Fuel pump Drive fuel pump Ignition Hold return Pulse is felt Procedure P.13A-31
to circulate fuel switch: "ON" hose with No. 24 3
fingers to
feel pulse of
fuel flowing
Check for Operating
pump noise audible
operating
noise near
fuel tank
08 Purge Switch solenoid Ignition switch: "LOCK" When the valve Code No. P.13A-18
control valve from OFF (OFF) is actuated, P0443 2
solenoid to ON operating noise
valve is audible
09 Fuel Switch solenoid Ignition switch: "ON" When the valve Code No. P.13A-19
pressure valve from OFF is actuated, P0090
control to ON operating noise
solenoid is audible
valve
10 EGR control Switch solenoid Ignition switch: "ON" When the valve Code No. P.13A-17
solenoid valve from OFF is actuated, P0403 5
valve to ON operating noise
is audible.
12 Waste gate Switch solenoid Ignition switch: "ON" When the valve Code No. P.13A-13
solenoid valve from OFF is actuated, P0243 0
valve to ON operating noise
is audible
13 Fuel pump Fuel pump Relay Ignition switch: "ON" Sound of Procedure P.13A-31
relay 3 3 turns from OFF Operation is No. 24 3
to ON heard
17 Basic ignition Switch • Engine: Idle operation 5° BTDC − −
timing engine-ECU to • Install timing light
ignition timing
adjusting mode
TROUBLESHOOTING
13A-379
Item Inspection Drive content Inspection conditions Normal Code No. Reference
No. item condition /Inspection page
procedure
No.
21 Fan Actuate fan • Ignition switch: "ON" Fan motor is Procedure P.13A-32
controller motor • A/C switch: ON rotated No. 25 4
37 Condenser Condenser fan Ignition switch: "ON" Fan motor Procedure P.13A-33
fan (high) motor is driven. rotates at high No. 26 0
speed
38 Condenser Condenser fan Ignition switch: "ON" Fan motor
fan (low) motor is driven. rotates at low
speed
CHECK AT THE ENGINE-ECU NOTE: .

TERMINALS 1. Make the voltage measurement with the
M1131153500744 engine-ECU connector connected.
TERMINAL VOLTAGE CHECK CHART 2. You may find it convenient to pull out the
engine-ECU to make it easier to reach the
Needle-nosed wire probe connector terminals.
3. The checks can be carried out off the order
given in the chart.
CAUTION
Short-circuiting the positive (+) probe between a
connector terminal and earth could damage the
vehicle wiring, the sensor, engine-ECU or all of
them. Be careful to prevent this!
AK201749AB 3. If voltmeter shows any division from standard
value, check the corresponding sensor, actuator
1. Connect a needle-nosed wire probe to a voltmeter
and related electrical wiring, then repair or
probe.
replace.
2. Insert the needle-nosed wire probe into each of
4. After repair or replacement, recheck with the
the engine-ECU connector terminals from the wire
voltmeter to confirm that the repair has corrected
side, and measure the voltage while referring to
the problem.
the check chart.
TROUBLESHOOTING
Engine-ECU Connector Terminal Arrangement

Terminal Check item Check condition (Engine condition) Normal condition
No.
1 No. 1 injector While engine is idling after having warmed From 11 − 14 V,
9 No. 2 injector up, suddenly depress the accelerator pedal. momentarily drops slightly
24 No. 3 injector
2 No. 4 injector
3 Oxygen sensor Engine: Idling after warming up 1 V or less
heater (front) Engine r/min: 5,000 r/min System voltage
6 EGR control Ignition switch: "ON" System Voltage
solenoid valve While engine is idling, suddenly depress the From system voltage,
accelerator pedal. momentarily drops
8 Alternator G terminal • Engine: Warm, idle (radiator fan: OFF) Voltage increases by 0.2 −
• Headlamp: OFF → ON 3.5 V
• Stop lamp: OFF → ON
• Rear defogger switch: OFF → ON
11 Ignition coil − No. 1, Engine r/min: 3,000 r/min 0.3 − 3.0 V
No. 4
12 Ignition coil − No. 2,
No. 3
14 Stepper motor coil • Engine: Soon after the warmed up engine System voltage ⇔ 1V or
<A1> is started less (Changes repeatedly)
28 Stepper motor coil • A/C switch: OFF → ON (A/C compressor
<A2> is operating)
• Headlight switch: OFF → ON
15 Stepper motor coil
<B1>
29 Stepper motor coil
<B2>
16 Purge control Ignition switch: "ON" System voltage
solenoid valve Running at 3,500 r/min while engine is 1 V or less
warming up after having been started.
18 Fan controller Radiator fan is not operating 0 − 0.3 V
Radiator fan is operating 0.7 V or more
19 Air flow sensor reset Engine: Idle speed 0−1V
signal Engine r/min: 3,000 r/min 6−9V
20 A/C relay • Engine: Idle speed System voltage or
• A/C switch: OFF → ON (A/C compressor Momentarily 6 V or more
is operating) → 1 V or less
21 Fuel pump relay 2 Ignition switch: "ON" System voltage
Engine: Idle speed 1 V or less
22 Engine warning lamp Ignition switch: "LOCK" (OFF) → "ON" 1 V or less → System
voltage (After several
seconds have elapsed)
26 Oxygen sensor Engine: Idling after warming up 1 V or less
heater (rear) Engine: Racing System voltage
TROUBLESHOOTING
13A-381
No.
30 Condenser fan Fan inactive state (Engine coolant System voltage
motor relay (high) temperature: 90°C or less)
Fan high-speed rotation state (Engine 1 V or less
coolant temperature: 105°C or less)
31 Condenser fan Fan inactive state (Engine coolant System voltage
motor relay (low) temperature: 90°C or less)
Fan low-speed rotation state (Engine coolant 1 V or less
temperature: 95 − 100°C or less)
33 Oil feeder control Ignition switch: "ON" System voltage
valve High-load running 4.0 − 10 V
41 Waste gate solenoid Ignition switch: "ON" System voltage
valve Engine: After warm-up, idle operation (When 1 V or less
using premium gasoline)
42 Sensor impressed Ignition switch: "ON" 4.9 − 5.1 V
voltage
43 Crank angle sensor Engine: Cranking 0.4 − 4.0 V
Engine: Idling speed 1.5 − 2.5 V
44 Engine coolant Ignition switch: "ON" When engine coolant 3.9 − 4.5 V
temperature sensor temperature is −20°C
When engine coolant 3.2 − 3.8 V
temperature is 0°C
temperature is 20°C
45 Tachometer signal Engine r/min: 3,000 r/min 0.3 − 3.0 V
47 Power supply Ignition switch: "ON" System voltage
59
48 Fuel pressure Ignition switch: "ON" System voltage
control solenoid Engine: Cranking → Idle operation (within 1 V or less → System
valve approximately 2 minutes or less) voltage
50 Exhaust camshaft Engine: Cranking 0.4 − 3.0 V
position sensor Engine: Idling 1.5 − 3.0 V
51 Barometric pressure Ignition switch: "ON" Altitude: 0 m 3.8 − 4.2 V
sensor Altitude: 600 m 3.5 − 3.9 V
Altitude: 1,200 m 3.3 − 3.7 V
Altitude: 1,800 m 3.0 − 3.4 V
TROUBLESHOOTING

No.
52 Alternator FR • Engine: Warm, idle (radiator fan: OFF) Voltage decreases
terminal • Headlamp: OFF → ON
• Stop lamp: OFF → ON
• Rear defogger switch: OFF → ON
53 Intake camshaft Engine: Cranking 0.4 − 3.0 V
position sensor Engine: Idling 1.5 − 3.0 V
54 Power steering fluid Engine: Idling after When steering wheel System voltage
pressure switch warming up is stationary
When steering wheel 1 V or less
is turned
55 Fuel pump relay 3 While engine is idling, suddenly depress the Temporarily rises slightly
accelerator pedal. from 1 V or less.
57 Control relay (Power Ignition switch: "LOCK" (OFF) System voltage
supply) Ignition switch: "ON" 1 V or less
60 Backup power Ignition switch: "LOCK" (OFF) System voltage
supply
61 Air flow sensor Engine: Idle speed 2.2 − 3.2 V
Engine r/min: 2,500 r/min
62 Intake air Ignition switch: "ON" When intake air 3.8 − 4.4 V
When intake air 3.2 − 3.8 V
temperature is 0°C
65 A/C load signal Refer to GROUP 55 - Troubleshooting (Inspection at the Automatic
compressor - ECU Terminal)
68 Ignition switch-ST Engine: Cranking 8 V or more
71 Oxygen sensor Engine: Running at 2,500 r/min after warmed 0 ⇔ 0.8 V (Changes
(front) up (Check using a digital type voltmeter) repeatedly)
73 Oxygen sensor Engine: Idling after warmed up (Check using 0 ⇔ 0.6 V (Changes
(rear) a digital type voltmeter) repeatedly)
78 Throttle position Ignition switch: "ON" Set throttle valve to 0.535 − 0.735 V
sensor idle Position
Fully open throttle 4.4 − 5.3 V
valve
80 Vehicle speed • Ignition switch: "ON" 0 ⇔ 5 V Changes
sensor • Move the vehicle forword slowly repeatedly
TROUBLESHOOTING
13A-383
No.
83 A/C switch Engine: Idle speed Turn the A/C switch 0.5 V or less
OFF
Turn the A/C switch System voltage
ON (A/C compressor
is operating)
96 Transmission oil Ignition switch: "ON" Transmission oil 3.9 − 4.5 V
Transmission oil 3.2 − 3.8 V
temperature is 0°C
99 Ignition switch-IG Ignition switch: "ON" System voltage
CHECK CHART FOR RESISTANCE AND CAUTION

CONTINUITY BETWEEN TERMINALS If the terminals that should be checked are mis-
1. Turn the ignition switch to "LOCK" (OFF) position. taken, or if connector terminals are not correctly
shorted to earth, damage may be caused to the
2. Disconnect the engine-ECU connector.
vehicle wiring, sensors, engine-ECU and/or ohm-
3. Measure the resistance and check for continuity meter. Be careful to prevent this!
between the terminals of the engine-ECU
4. If the ohmmeter shows any deviation from the
harness-side connector while referring to the
standard value, check the corresponding sensor,
check chart.
actuator and related electrical wiring, and the
NOTE: . repair or replace.
1. When measuring resistance and checking 5. After repair or replacement, recheck with the
continuity, a harness for checking contact pin ohmmeter to confirm that the repair or
pressure should be used instead of inserting a replacement has corrected the problem.
test probe.
2. Checking need not be carried out in the order
given in the chart.
TROUBLESHOOTING
Engine-ECU Harness Side Connector Terminal Arrangement

Terminal Inspection item Normal condition (Check condition)
No.
1 − 47 No. 1 injector 2 − 3 Ω (At 20°C)
9 − 47 No. 2 injector
47 − 48 Fuel pressure control solenoid valve 28 − 36 Ω (At 20°C)
14 − 47 Stepper motor coil (A1) 26 − 33 Ω (At 20°C)
28 − 47 Stepper motor coil (A2)
15 − 47 Stepper motor coil (B1)
29 − 47 Stepper motor coil (B2)
6 − 47 EGR control solenoid valve 29 − 35 Ω (At 20°C)
16 − 47 Purge control solenoid valve 30 − 34 Ω (At 20°C)
41 − 47 Waste gate solenoid valve 29 − 35 Ω (At 20°C)
3 − 47 Oxygen sensor heater (rear) 11 − 18 Ω (At 20°C)
26 − 47 Oxygen sensor heater (front) 4.5 − 8.0 Ω (At 20°C)
33 − 47 Oil feeder control valve 6.9 − 7.9 Ω (At 20°C)
46 − Body ECU earth Continuity (2 Ω or less)
earth
58 − Body
earth
42 − 62 Intake air temperature sensor 13 − 17 kΩ (When intake air temperature is −20°C)
5.3 − 6.7 kΩ (When intake air temperature is 0°C)
42 − 44 Engine coolant temperature sensor 14 − 17 kΩ (When coolant temperature is −20°C)
5.1 − 6.5 kΩ (When coolant temperature is 0°C)
TROUBLESHOOTING
13A-385
Terminal Inspection item Normal condition (Check condition)
No.
42 − 96 Transmission oil temperature sensor 14 − 17 kΩ (When transmission oil temperature is
−20°C)
5.1 − 6.5 kΩ (When transmission oil temperature is
0°C)
20°C)
40°C)
60°C)
80°C)
INSPECTION PROCEDURE USING AIR FLOW SENSOR (AFS)

OSCILLOSCOPE Measurement Method
M1131154501483
The output signals of the sensors and the conditions
Oscilloscope
of the actuation signals of the actuators can be
inspected visually by observing the waveforms on 1 2 3 4 5 6 7
the oscilloscope.
Special
patterns
pickup
AK000786 AE
1. Disconnect the air flow sensor connector, and

connect the special tool test harness (MB991709)
in between (All terminals should be connected).
2. Connect the oscilloscope special patterns pickup
to air flow sensor connector terminal No. 3.
Alternate Method (Test harness not available)

1. Connect the oscilloscope special patterns pickup Standard Wave Pattern
to engine-ECU terminal No. 61.
Observation conditions
Function Special patterns
Pattern height Low
Engine speed Idle
TROUBLESHOOTING
Standard wave pattern

(V)
10 The time (cycle time) T is reduced when
T the amount of intake air increases.
T1 T2 Times T1 and T2 are equal.
Time
0
AK202334 AC
Observation conditions (from conditions above engine is increased by racing.)

(V)
10
T
Time
0
AK202335 AB
Wave Pattern Observation Points • Example 1

Check that cycle time T becomes shorter and the fre- Cause of problem
quency increases when the engine speed is Sensor interface malfunction
increased. Wave pattern characteristics
Rectangular wave pattern is output even when
Examples of Abnormal Wave Patterns the engine is not started.
• Example 2
Cause of problem
Damaged rectifier or vortex generation column
Wave pattern characteristics
Unstable wave pattern with non-uniform fre-
quency. However, when an ignition leak
occurs during acceleration, the wave pattern
will be distorted temporarily, even if the air
flow sensor is normal.
AKX01597
TROUBLESHOOTING
13A-387
INTAKE CAMSHAFT POSITION SENSOR 1. Disconnect the camshaft position sensor
Measurement Method connector and connect the special tool test
harness (MB991709) in between (All terminals
Intake camshaft should be connected).
position sensor Oscilloscope
connector 2. Connect the oscilloscope special pattern pickup to
1 2 3
Special patterns camshaft position sensor terminal No. 2.
pick-up
3. To check the state of the intake camshaft position
sensor output signal, observe its synchronicity
with the crankshaft position sensor output signal.
1 2
3 Crank angle
sensor connector
AK000840AD
Alternate Method (Test harness not available)

to engine-ECU terminal No. 53 (When checking
the camshaft position sensor signal wave pattern).
Standard Wave Pattern
Observation condition
Pattern height Low
Engine speed Idle

2 engine revolutions (1 camshaft revolution)
(V)
at retard angle
at advance angle
Crank angle sensor 4

output wave pattern
0
T phase angle
Intake camshaft 4
position sensor
output wave pattern
0 (Time)
AK403888 AC
TROUBLESHOOTING
Wave Pattern Observation Points Wave pattern characteristics

For the engine at 2,500 r/min, make sure that the Wave pattern is displaced to the left or right.
time difference "T", between the output waveform of
the crank angle sensor and that of the intake cam- EXHAUST CAMSHAFT POSITION SEN-
shaft position sensor, is shorter on the rising edge. SOR AND CRANK ANGLE SENSOR
Examples of Abnormal Wave Patterns Measurement Method
•
Exhaust camshaft
position sensor Oscilloscope
connector
1 2 3
Special patterns
pick-up
1 2
3 Crank angle
sensor connector
AKX01597 AK000840AE
Example 1 1. Disconnect the exhaust camshaft position sensor

connector and connect the special tool test
Cause of problem
harness (MB991709) in between (All terminals
Sensor interface malfunction
should be connected).
2. Connect the oscilloscope special pattern pickup to
Rectangular wave pattern is output even when
exhaust camshaft position sensor terminal No. 2.
the engine is not started.
•
3. Disconnect the crank angle sensor connector and
connect the special tool test harness (MD998478)
in between.
to crank angle sensor terminal No. 2.
Alternate Method (Test harness not

available)
AKX01602 to engine-ECU terminal No. 50 (When checking
the exhaust camshaft position sensor signal wave
Example 2
pattern).
Cause of problem
Loose timing belt
Failure of the fuel pump camshaft
the crank angle sensor signal wave pattern).
TROUBLESHOOTING
13A-389
Pattern height Low
Engine speed Idle
Standard Wave Pattern 2 engine revolutions

(V) (1 camshaft revolution)
The time (cycle time)
75˚ BTDC T is reduced when the
5˚ BTDC
engine speed increases
Crank angle
sensor output
wave pattern
Camshaft position
sensor output
wave pattern
Time
0
TDC: Top dead centre No.1 TDC No.3 TDC No.4 TDC No.2 TDC
AK202336 AB
Wave Pattern Observation Points Wave pattern characteristics

Check that cycle time T becomes shorter and the fre- Rectangular wave pattern is output even when
quency increases when the engine speed is the engine is not started.
•
increased.
Examples of Abnormal Wave Patterns

•
AKX01602
Example 2
Cause of problem
AKX01597
Loose timing belt
Example 1 Abnormality in sensor disk
Cause of problem Wave pattern characteristics
Sensor interface malfunction Wave pattern is displaced to the left or right.
TROUBLESHOOTING
INJECTOR 2. Connect the oscilloscope special patterns pickup

Measurement Method to terminal No. 2 of the injector connector.

Oscilloscope
available)
1 2
to engine-ECU terminal No. 1 (When checking the
No. 1 cylinder).
Special 2. Connect the oscilloscope special patterns pickup
patterns
pickup to engine-ECU terminal No. 9 (When checking the
No. 2 cylinder).
AK101807AC
1. Disconnect the injector connector, and then the No. 3 cylinder).
connect the special tool test harness (MB991348) 4. Connect the oscilloscope special patterns pickup
in between (All terminals should be connected). to engine-ECU terminal No. 2 (When checking the
No. 4 cylinder).
Pattern height Variable
Variable knob Adjust while viewing the
wave pattern
Engine speed Idle
(V) Point A.
Solenoid back
50 electromotive
force
(Approx.7×10V)
Point B
Injector drive
time
Time
Power
voltage
0 Drive signal: ON Drive signal: OFF
AK202347AB
TROUBLESHOOTING
13A-391
Wave Pattern Observation Points 1. Disconnect the idle speed control servo
Point A: Height of solenoid back electromotive force connector, and connect the special tool test
harness (MB991709) in between.
Contrast with standard Probable cause
wave pattern 2. Connect the oscilloscope special patterns pickup
to the idle speed control servoside connector
Solenoid coil back Short in the injector terminal No. 1, No. 3, No. 4 and No. 6
electromotive force is solenoid respectively.
low or doesn't appear at
all. Alternate Method (Test harness not
Point B: Injector drive time
•
available)
to engine-ECU terminal No. 14, connection
terminal No. 28, connection terminal No. 15, and
connection terminal No. 29 respectively.

When idling
When racing AKX01605AE Pattern height High
The injector drive time will be synchronized with the Pattern selector Display
M.U.T.-II/III tester display. Engine condition When the engine coolant
• When the engine is suddenly raced, the drive temperature is 20°C or
time will be greatly extended at first, but the drive below, turn the ignition
time will soon match the engine speed. switch from "LOCK"
(OFF) position to ON
IDLE SPEED CONTROL (ISC) SERVO (without starting the
(STEPPER MOTOR) engine).
Measurement Method While the engine is
idling, turn the A/C
switch to ON.
Oscilloscope
Immediately after
1 2 3 starting the warm
4 5 6 engine.
Special
patterns
pickup
AK201856AB
TROUBLESHOOTING
(V) The wave pattern

appears for an
instant, but soon Point B
Point A
disappears. Coilreverse electromotive Induced electromotive force
30 force (Approx.3x10V)
from the motor turning
Stepper 20
motor
control
signal
wave 10
pattern
Time
AK201857 AB
Wave pattern Observation Points

Check that the standard wave pattern appears when Example 1
the stepper motor is operating. Cause of problem
Point A: Presence or absence of induced electromo- Motor is malfunctioning. (Motor is not operating.)
tive force from the motor turning (Refer to the abnor-
mal wave pattern).
Induced electromotive force from the motor turn-
Contrast with standard wave Probable ing does not appear.
pattern cause •
Induced electromotive force does Motor is Open

not appear or is extremely small. malfunctioning circuit
side
Point B: Height of coil reverse electromotive force
Contrast with standard wave Probable
pattern cause
Coil reverse electromotive force Short in the
does not appear or is extremely coil Normal
side
small. AKX01609AF
Example 2
Examples of Abnormal Wave Pattern
Open circuit in the line between the stepper
motor and the engine-ECU.
Current is not supplied to the motor coil on the
open circuit side (Voltage does not drop to 0
V).
Furthermore, the induced electromotive force
waveform at the normal side is slightly differ-
ent from the normal waveform.
AKX01608AE
TROUBLESHOOTING
13A-393
IGNITION COIL AND POWER TRANSIS- 1. Disconnect the ignition coil connector, and
TOR connect the special tool test harness (MB991348)
in between (All terminals should be connected).
Measurement Method
to terminal No. 3 of each ignition coil connector in
Oscilloscope
turn.
1 2 3
available)
Special 1. Connect the oscilloscope special patterns pickup
patterns to engine-ECU terminal No. 11 (No. 1 − No. 4),
pickup
CH1 connection terminal No. 12 (No. 2 − No.3)
respectively.
AK201750 AB
Pattern height Low
Engine r/min Approximately 1,200
r/min

(V)
6 T
5˚ BTDC
4 75˚ BTDC
Crank angle Compression top dead center
sensor output 2
wave pattern
0
Power transistor T1
2 Ignition period
control signal
wave pattern
0
OFF ON
Dwell section
T : Revolution time corresponding to a crank angle of 180˚

T1 : Time computed by the engine-ECU
: Spark advance angle
AK204435 AC
TROUBLESHOOTING
Wave Pattern Observation Points Example 1

Point: Condition of wave pattern build-up section and Wave pattern during engine cranking
maximum voltage (Refer to abnormal wave pattern Cause of problem
examples 1 and 2). Open-circuit in ignition primary circuit
Condition of wave pattern Probable cause Wave pattern characteristics
build-up section and maximum Top-right part of the build-up section cannot be
voltage seen, and voltage value is approximately 2 V
too low.
Rises from approximately 2 V Normal •
to approximately 4.5 V at the

Normal wave pattern
top-right
VB
2 V rectangular wave Open-circuit in
ignition primary
circuit
Rectangular wave at power Power transistor
voltage malfunction
Examples of Abnormal Wave Patterns AKX01613AD

•
Example 2
Wave pattern during engine cranking
Normal wave pattern
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor
2V is ON.
AKX01612AD
ON-VEHICLE SERVICE
13A-395
ON-VEHICLE SERVICE
THROTTLE BODY (THROTTLE VALVE
AREA) CLEANING
M1131001000990
1. Remove the air intake hose from the throttle body. Throttle position
sensor
2. Spray cleaning fluid on a clean cloth.
CAUTION
• Do not spray the cleaning fluid directly to the
MB991536
throttle valve.
• Make sure the cleaning fluid does not enter
the motor from the bypass line. Also make AK201752AB
sure it does not enter the sensor through the (1) Disconnect the throttle position sensor
shaft. connector and connect the special tool test
• Be careful not to rub off the molybden applied harness (MB991536) between the
around the throttle valve shaft. disconnected connector taking care not to
confuse the terminal to be connected.
(2) Connect digital voltmeter between the terminal
No. 2 (special tool’s yellow clip on the sensor
15 mm output) and the terminal No. 4 (special tool’s
red clip on the sensor earth) of the throttle
15 mm position sensor connector.
2. Turn the ignition switch to "ON" position (but do
not start the engine).
Areas on throttle valve to 3. Check the output voltage of the throttle position
apply molybdenum disulfide AK000833AD sensor.
Standard value: 535 − 735 mV
3. Wipe off the dirt around the throttle valve with the
cloth sprayed with cleaning fluid.
4. Attach the air intake hose.
5. Adjust the basic idle speed (Refer to P.13A-396).
THROTTLE POSITION SENSOR

ADJUSTMENT
M1131001100801
1 2 3 4
AK304569AB
Throttle Equipment
position sensor side connector
4. If not within the standard value, loosen the throttle
position sensor mounting bolts. Then rotate the
sensor body to adjust.
5. Turn the ignition switch to "LOCK" (OFF) position.
6. Remove the M.U.T.-II/III. If the M.U.T.-II/III is not
AK304568AB used, remove the special tool, and then connect
the throttle position sensor connector.
1. Connect the M.U.T.-II/III to the diagnosis 7. If a diagnosis code is displayed, erase the
connector. diagnosis code by using the M.U.T.-II/III or
When not using the M.U.T.-II/III, proceed as disconnect the negative battery cable from the
follows. battery terminal and then leave it for at least 10
seconds. After that, reconnect the battery cable,
and then let the engine run at idle for
approximately 10 minutes.
ON-VEHICLE SERVICE
BASIC IDLE SPEED ADJUSTMENT 6. If not within the standard value range, turn the
M1131001800888 speed adjusting screw (SAS) to make the
CAUTION necessary adjustment.
• The standard idling speed has been adjusted NOTE: If the idling speed is higher than the stand-
by the speed adjusting screw (SAS) by the ard value range even when the SAS is fully
manufacturer, and there should usually be no closed, check whether or not there is any indica-
need for readjustment. tion that the fixed SAS has been moved. If there is
• If the adjustment has been changed by mis- an indication that it has been moved, adjust the
take, the idle speed may become too high or fixed SAS.
the idle speed may drop too low when loads 7. Press the M.U.T.-II/III clear key, and release the
from components such as the A/C are placed idle speed control servo from the Actuator test
on the engine. If this occurs, adjust by the fol- mode.
lowing procedure.
NOTE: Unless the idle speed control servo is
• The adjustment, if made, should be made
released, the Actuator test mode will continue 27
after first confirming that the spark plugs, the
minutes.
injectors, the idle speed control servo, the
compression pressure, etc., are all normal. 8. Turn the ignition switch to "LOCK" (OFF) position.
1. Before inspection and adjustment, set the vehicle 9. Disconnect the M.U.T.-II/III.
to the pre-inspection condition. 10.Start the engine again and let it run at idle speed
2. Connect the M.U.T.-II/III to the diagnosis for about 10 minutes; check that the idling
connector (16-pin). condition is normal.
NOTE: When the M.U.T.-II/III is connected, the
FUEL PRESSURE TEST
diagnosis control terminal should be earthed. M1131001901286
3. Start the engine and run at idle. 1. Release residual pressure from the fuel pipe line
4. Select the item No. 30 of the M.U.T.-II/III Actuator to prevent fuel gush out (Refer to P.13A-398).
test. CAUTION
NOTE: This holds the idle speed control servo at Cover the hose connection with rags to prevent
the basic step to adjust the basic idle speed. splash of fuel that could be caused by some
5. Check the idle speed. residual pressure in the fuel pipe line.
Standard value:
800 ± 50 r/min
High-pressure
NOTE: . fuel hose
• The engine speed may be 20 to 100 r/min
lower than indicated above for a new vehicle
[driven approximately 500 km or less], but no
adjustment is necessary.
• If the engine stalls or the engine speed is low
even though the vehicle has been driven
approximately 500 km or more, it is probable AK304571AB
that deposits are adhered to the throttle valve, 2. Disconnect the high-pressure fuel hose at the
so clean it (Refer to P.13A-395). delivery pipe side.
Speed adjust screw
AK304570 AB
ON-VEHICLE SERVICE
13A-397
Fuel pressure
MB 991637 gauge set
Gasket O-ring or gasket
MD 998709 MD 998709
Delivery
Delivery pipe
pipe MD 998742 MD 998742
High-pressure High-pressure
fuel hose fuel hose
AKX01458AG AKX01457AF
4. Install the assembled fuel pressure measurement

MB 991981 tools between the fuel rail and fuel high-pressure
hose.
Gasket CAUTION
MD 998709 To prevent damage to the M.U.T.-II/III, always turn
the ignition switch to the "LOCK" (OFF) position
Delivery before connecting or disconnecting the
pipe MD 998742 M.U.T.-II/III.
High-pressure
fuel hose 5. Connect the M.U.T.-II/III to the diagnosis
connector.
AK305430AB
6. Turn the ignition switch to "ON" position (But do
3. Assemble the fuel pressure measurement tools not start the engine).
as follows. 7. Select "Item No. 07" from the M.U.T.-II/III Actuator
test to drive the fuel pump. Check that there are
<When using the fuel pressure gauge set (special
no fuel leaks from any parts.
tool)>
a. Remove the union joint and bolt from the special 8. Finish the actuator test or turn the ignition switch
tool adaptor hose (MD998709) and attach the to "LOCK" (OFF) position.
special tool hose adaptor (MD998742) to the 9. Start the engine and run at idle.
adaptor hose. 10.Measure fuel pressure while the engine is running
b. Via a gasket, install the special tool fuel pressure at idle.
gauge set (MB991637 or MB991981) into the Standard value: Approximately 230 kPa
special tool that has already assembled as
described in (a) above.
<When using the fuel pressure gauge>
a. Remove the union joint and bolt from special tool Fuel pressure
adaptor hose (MD998709) and attach the special regulator
tool hose adaptor (MD998742) to the adaptor
hose.
b. Via a suitable O-ring or gasket, install the fuel
pressure gauge to the special tool that has
already assembled as described in (a) above. Vacuum hose
AK304572AB
11.Disconnect the vacuum hose from the fuel

pressure regulator and measure fuel pressure
with the hose end closed by a finger.
Standard value: 289 − 309 kPa
12.Check to see that fuel pressure at idle does not
drop even after the engine has been raced
several times.
ON-VEHICLE SERVICE
13.Racing the engine repeatedly, hold the fuel return 14.If any of fuel pressure measured in steps 10 to 13
hose lightly with fingers to feel that fuel pressure is out of specification, troubleshoot and repair
is present in the return hose. according to the table below.
NOTE: If the fuel flow rate is low, there will be no
fuel pressure in the return hose.
Symptom Probable cause Remedy
• Fuel pressure too low Clogged fuel filter Replace fuel filter
• Fuel pressure drops after racing Fuel leaking to return side due to Replace fuel pressure regulator
• No fuel pressure in fuel return poor fuel regulator valve seating or
hose settled spring
Low fuel pump delivery pressure Replace fuel pump
Fuel pressure too high Binding valve in fuel pressure Replace fuel pressure regulator
regulator
Clogged fuel return hose or pipe Clean or replace hose or pipe
Same fuel pressure when vacuum Damaged vacuum hose or Replace vacuum hose or clean
hose is connected and when Clogged nipple nipple
disconnected
15.Stop the engine and check change of fuel
pressure gauge reading. Normal if the reading
does not drop within 2 minutes. If it does, observe
the rate of drop and troubleshoot and repair
according to the table below.
Symptom Probable cause Remedy
Fuel pressure drops gradually after Leaky injector Replace injector
engine is stopped Leaky fuel regulator valve seat Replace fuel pressure regulator
Fuel pressure drops sharply Check valve in fuel pump is held Replace fuel pump
immediately after engine is open
stopped
16.Release residual pressure from the fuel pipe line FUEL PUMP CONNECTOR
(Refer to P.13A-398). DISCONNECTION (HOW TO REDUCE
CAUTION PRESSURIZED FUEL LINES)
Cover the hose connection with rags to prevent M1131000900718
splash of fuel that could be caused by some WARNING

residual pressure in the fuel pipe line. When removing the fuel pipe, etc., release
17.Remove the fuel pressure gauge and special tool fuel pressure to prevent fuel spray.
from the delivery pipe. 1. Remove the rear seat assembly (Refer to GROUP
18.Replace the O-ring at the end of the fuel high 52A − Rear Seat Assembly P.52A-20).
pressure hose with a new one. Furthermore, 2. Remove the protector.
apply engine oil to the new O-ring before Y0915AU
Y2015AU
replacement. Fuel pump module connector
19.Fit the fuel high pressure hose over the delivery

pipe and tighten the bolt to specified toque.
20.Check for any fuel leaks by following the
procedure in step 7.
21.Disconnect the M.U.T.-II/III.
AC208407AB
ON-VEHICLE SERVICE
13A-399
3. Disconnect the fuel pump module connector.
4. After starting the engine and letting it run until it 1 2 3

stops naturally, turn the ignition switch to the 4 5
"LOCK" (OFF) position.
5. Connect the fuel pump module connector.
6. Install the protector and rear seat assembly (Refer
to GROUP 52A − Rear Seat Assembly P.52A-20).
FUEL PUMP OPERATION CHECK AC208409

M1131002000818
CAUTION 2. If the fuel pump will not operate, check by using

the following procedure. If normal, check the fuel
<When using the M.U.T.-II>
pump drive circuit.
(1) Turn the ignition switch to the "LOCK" (OFF)
position.
16-pin (2) Remove the rear seat assembly (Refer to
GROUP 52A − Rear Seat Assembly
P.52A-20).
(3) Remove the protector.
M.U.T.-II (4) Disconnect the fuel pump module connector.
AC207179AD (5) When the fuel pump drive connector is
attached directly to the battery, check if the
<When using the M.U.T.-III> sound of the fuel pump operation can be
heard.
NOTE: As the fuel pump is an in-tank type, the
16-pin
fuel pump sound is hard to hear. Remove the
fuel tank filler tube cap and check from the tank
inlet.
(6) Check for fuel pressure by pinching the fuel
hose with fingertips.
(7) Connect the fuel pump module connector.
MB991911 (8) Install the protector and rear seat assembly
(Refer to GROUP 52A − Rear Seat Assembly
MB991824 P.52A-20).
MB991827 AC210056AG
To prevent damage to the M.U.T.-II/III, always turn

the ignition switch to the "LOCK" (OFF) position
before connecting or disconnecting the
M.U.T.-II/III.
1. Check the operating of the fuel pump by using the
M.U.T.-II/III to force-drive the fuel pump.
ON-VEHICLE SERVICE
COMPONENT LOCATION
M1131002101573
Name Symbol Name Symbol
A/C relay I Fuel pump resistor <L.H. drive D

vehicles>
<R.H. H
drive
vehicles>
A/C switch X Idle speed control servo (stepper motor) F
Air flow sensor (with intake air R Ignition coil (integrated power transister) M
temperature sensor and barometric
pressure sensor)
Crank angle sensor A Ignition coil relay <R.H. drive vehicles> I
Injector E
Detonation sensor N Oil feeder control solenoid valve B
Diagnosis connector W Oxygen sensor (front) K
EGR control solenoid valve L Oxygen sensor (rear) T
Engine control relay I Power steering fluid pressure switch J
Engine coolant temperature sensor O Purge control solenoid valve G
Engine-ECU Y Injector resistor <L.H. drive D
vehicles>
<R.H. H
drive
vehicles>
Engine warming lamp (check engine V Intake camshaft position sensor N
lamp)
Exhaust camshaft position sensor N Throttle position sensor F
Fan control relay I Transmission oil temperature sensor Q
Fuel pressure control solenoid valve C Vehicle speed sensor P
Fuel pump relay (1) and (2) U Waste gate solenoid valve S
Fuel pump relay (3) <L.H. drive D
vehicles>
<R.H. H
drive
vehicles>
ON-VEHICLE SERVICE
13A-401
A B C D E F G H I
U V W X Y

J K L M N O P Q R S
Y X W V U
AK304573AC
ENGINE CONTROL RELAY CONTINUITY Tester Battery Normal State

CHECK Connection Voltage
M1131050000754
Terminal
Relay box’s
triangle marks
2−3 No Voltage Continuity
1−4 No Voltage No continuity
Voltage Continuity
1 2 (Connect
Engine control 3 4 positive (+)
relay terminal of
Equipment side
connector battery to
terminal No. 2
AK304574 AB and negative (−)
terminal of
battery to
terminal No. 3.)
ON-VEHICLE SERVICE
FUEL PUMP RELAY CONTINUITY CHECK

M1131033000762 <L. H. drive vehicles>
Junction block's
Fuel pump relay (1) triangle marks
1 2
3 4
Fuel pump relay (2) Equipment Fuel pump relay(3)
side connector
AK304575 AB
Fuel pump relay (1) and (2)
Tester Battery Normal State
Connection Voltage
Terminal
2−3 No Voltage No continuity Fuel pump relay(3)
Voltage Continuity Junction block's
triangle marks
(Connect
positive (+)
terminal of 1 2
battery to 3 4
terminal No. 1 Equipment side connector AK304576AB
and negative (−)
terminal of Fuel pump relay (3)
battery to Tester Battery Normal State
terminal No. 4.) Connection Voltage
Terminal
1−2 No Voltage No continuity
Voltage Continuity
(Connect
positive (+)
terminal of
battery to
terminal No. 2
and negative (−)
terminal of
battery to
terminal No. 1.)
ON-VEHICLE SERVICE
13A-403
FUEL PUMP RESISTOR CHECK 1.0 − 1.5 kΩ (at 40°C)
M1131052700049 0.56 − 0.76 kΩ (at 60°C)
0.30 − 0.42 kΩ (at 80°C)
Fuel pump resistor Intake air temperature

connector sensor
Fuel pump resistor

AKX01621AD
Fuel pump 3. Measure resistance while heating the sensor
resistor
connector using a hair drier.
Normal condition:
Temperature (°C) Resistance (kΩ)
Fuel pump resistor Higher Smaller
4. If the value deviates from the standard value or
the resistance remains unchanged, replace the air
flow sensor assembly.
1 2
Equipment side connector AK304577AB
ENGINE COOLANT TEMPERATURE
SENSOR CHECK
1. Disconnect the fuel pump resistor connector. M1131003101060
2. Measure the resistance between terminals. CAUTION

Standard value: 0.45 − 0.65 Ω Be careful not to touch the connector (resin sec-
tion) with the tool when removing and installing.
3. If the resistance is out of specification, replace the
fuel pump resistor.
1 2
INTAKE AIR TEMPERATURE SENSOR Equipment side
CHECK connector
M1131002801118
Engine coolant
1 2 3 4 5 6 7 sensor
Equipment side
connector
AK304579 AB
1. Remove the engine coolant temperature sensor.

Air flow sensor
AK304578AB
1. Disconnect the air flow sensor connector.

2. Measure resistance between terminals No. 5 and
No. 6.
Standard value:
13 − 17 kΩ (at −20°C)
AKX01622
5.3 − 6.7 kΩ (at 0°C)
2.3 − 3.0 kΩ (at 20°C)
ON-VEHICLE SERVICE
2. With temperature sensing portion of engine 3. Measure the resistance between the throttle
coolant temperature sensor immersed in hot position sensor side connector terminal No. 2 and
water, check resistance. terminal No. 4.
Standard value: Normal condition:
14 − 17 kΩ (at −20°C) Throttle valve slowly Changes smoothly in
5.1 − 6.5 kΩ (at 0°C) open until fully open from proportion to the opening
2.1 − 2.7 kΩ (at 20°C) the idle position angle of the throttle valve
0.9 − 1.3 kΩ (at 40°C)
4. If the resistance is outside the standard value, or if
0.48 − 0.68 kΩ (at 60°C)
it doesn’t change smoothly, replace the throttle
0.26 − 0.36 kΩ (at 80°C)
position sensor.
3. If the resistance deviates from the standard value NOTE: For the throttle position sensor adjustment
greatly, replace the sensor. procedure, refer to P.13A-395.
OXYGEN SENSOR CHECK

M1131005001434
Oxygen sensor (front)
Oxygen sensor (front)
AKX01623AD
4. Apply sealant to threaded portion.

Specified sealant:
3M NUT Locking Part No. 4171 or equivalent
5. Install the engine coolant temperature sensor and
tighten it to the specified torque.
THROTTLE POSITION SENSOR CHECK

M1131003200796 1 2
3 4
1 2 3 4 Equipment side Oxygen sensor (front)
connector connector
Throttle Equipment
position sensor side connector
AK304581 AB
1. Disconnect the oxygen sensor connector and

connect the special tool test harness (MD998464)
to the connector on the oxygen sensor side.
2. Make sure that there is continuity (4.5 − 8.0 Ω at
AK304568AB
20°C) between terminal No. 1 (red clip of special
1. Disconnect the throttle position sensor connector. tool) and No. 3 (blue clip of special tool) on the
oxygen sensor connector.
2. Measure the resistance between the throttle
position sensor side connector terminal No. 1 and 3. If there is no continuity, replace the oxygen
terminal No. 4. sensor.
4. Warm up the engine until engine coolant is 80°C
Standard value: 3.5 − 6.5 kΩ
or higher.
5. Perform a tracing for 5 minutes or more with the
engine speed of 4,500 r/min.
ON-VEHICLE SERVICE
13A-405
Oxygen sensor (rear)
Oxygen Oxygen sensor (rear)

Black sensor 1 2 3 4 connector
equipment
side connector Equipment side
connector
White
Oxygen sensor (rear)

MD998464 AK305450 AB
6. Connect a digital voltage meter between terminal AK304582 AB
No. 2 (black clip of special tool) and No. 4 (white 1. Disconnect the oxygen sensor connector and
clip of special tool). connect the special tool test harness (MB991658)
7. While repeatedly racing the engine, measure the to the connector on the oxygen sensor side.
oxygen sensor output voltage. 2. Make sure that there is continuity (11 − 18 Ω at
Standard value: 20°C) between terminal No. 3 and No. 4 on the
Engine Oxygen Remarks oxygen sensor connector.
sensor 3. If there is no continuity, replace the oxygen
output sensor.
voltage 4. Warm up the engine until engine coolant is 80°C
When 0.6 − 1.0 V If you make the air-fuel or higher.
racing the ratio rich by racing the 5. Perform a tracing for 5 minutes or more with the
engine engine repeatedly, a engine speed of 4,500 r/min.
normal oxygen sensor
will output a voltage of
0.6 − 1.0 V.
CAUTION
• Be very careful when connecting the jumper
wire; incorrect connection can damage the Oxygen sensor
oxygen sensor.
• Be careful the heater is broken when voltage
of beyond 8 V is applied to the oxygen sensor
heater. MB991658 AK301808 AB
NOTE: If the sufficiently high temperature (of
approximate 400°C or more) is not reached 6. Connect a digital voltage meter between terminal
although the oxygen sensor is normal, the output No. 1 and No. 2.
voltage would be possibly low although the rich 7. While repeatedly racing the engine, measure the
air-fuel ratio. Therefore, if the output voltage is oxygen sensor output voltage.
low, use a jumper wire to connect the terminal No. Standard value:
1 (red clip of special tool) and the terminal No. 3 Engine Oxygen Remarks
(blue clip of special tool) of the oxygen sensor sensor
with a (+) terminal and (−) terminal of 8 V power output
supply respectively, then check again. voltage
8. If the sensor is defective, replace the oxygen When 0.6 − 1.0 V If you make the air-fuel
sensor. racing the ratio rich by racing the
NOTE: For removal and installation of the oxygen engine engine repeatedly, a
sensor, refer to GROUP 15 − Exhaust Manifold normal oxygen sensor
and turbocharger. P.15-10. will output a voltage of
0.6 − 1.0 V.
ON-VEHICLE SERVICE
CAUTION Measurement of Resistance between Ter-

• Be very careful when connecting the jumper minals
wire; incorrect connection can damage the 1. Disconnect the injector connector.
oxygen sensor.
2. Measure the resistance between terminals.
• Be careful the heater is broken when voltage
Standard value: 2 − 3 Ω (at 20°C)
of beyond 12 V is applied to the oxygen sen-
sor heater. 3. Connect the injector connector.
NOTE: If the sufficiently high temperature (of
approximately 400°C or more) is not reached Check the Injection Condition
although the oxygen sensor is normal, the output 1. Following the steps below, bleed out the residual
voltage would be possibly low although the rich pressure within the fuel pipe line to prevent flow of
air-fuel ratio. Therefore, if the output voltage is the fuel (Refer to P.13A-398).
low, use a jumper wire to connect the terminal No. 2. Remove the injector.
3 and the terminal No. 4 of the oxygen sensor with
a (+) terminal and (−) terminal of 12 V power sup- Fuel pressure
regulator
ply respectively, then check again.
8. If the sensor is defective, replace the oxygen
MD998741
sensor. High-pressure
fuel hose
NOTE: For removal and installation of the oxygen MD998706
sensor, refer to GROUP 15 − Exhaust Pipe and MB991607 Return hose
Main Muffler P.15-13.
MB991976
INJECTOR CHECK
M1131005201267 Battery Injector
Check the Operation Sound AK301464 AC
3. Assemble the following special tools as shown in

1 2 Fig.
Equipment side • Injector test set (MD998706)
connector • Injector test harness (MB991607)
• Injector test adaptor (MD998741)
• Injector test holder assembly (MB991976)
4. Connect the M.U.T.-II/III to the diagnosis
connector.
Injector 5. Turn the ignition switch to "ON" position (But do
AK304583 AB
not start the engine).
1. Use a stethoscope to listen to the operation sound 6. Select "Item No. 07" from the M.U.T.-II/III actuator
(clicking) of the injectors while the engine is idling test to drive the fuel pump.
or cranking.
Fuel pressure
CAUTION regulator
Beware that the operation sounds of other injec-
tors can be heard even if the injector that is being
inspected might not be operating. High-pressure
fuel hose
2. Verify that the operation sound increases with the
engine speed. Return hose
NOTE: If the operating sound cannot be heard,
inspect the injector actuation circuit.
Injector
Battery
AK301465AC
7. Activate the injector and check the atomized

spray condition of the fuel.
ON-VEHICLE SERVICE
13A-407
The condition can be considered satisfactory INJECTOR RESISTOR CHECK
unless it is extremely poor. M1131052800046
8. Stop the actuation of the injector, and check for <L. H. drive vehicles>
leakage from the injector’s nozzle.
Standard value: 1 drop or less per minute
9. Without the fuel pump operation, operate the
injector to draw the fuel out.
10.If the spraying is extremely poor or the fuel
leakage from the injector nozzle deviates from the
standard value, replace the injector. Injector resistor
11.Disconnect the M.U.T.-II/III.
Injector resistor
1 2 3
4 5 6
Equipment side
Injector resistor
connector
1 2 3
4 5 6
AK202415AC
1. Disconnect the injector resistor connector.

ON-VEHICLE SERVICE
2. Measure the resistance between terminals.

Measurement terminals Resistance
1−3 5.8 − 6.2 Ω (At 20°C)
4−3
5−3
6−3
3. If the resistance is out of specification, replace the Check the Coil resistance
injector resistor.
IDLE SPEED CONTROL SERVO

(STEPPER MOTOR) CHECK
M1131005400804
Check the Operation Sound
1 2 3
1 2 3
4 5 6 4 5 6
Equipment side
connector
Idle speed
control servo
1 2 3
AK304586 AB 4 5 6
1. Check that the engine coolant temperature is

20°C or below.
NOTE: Disconnecting the engine coolant temper-
ature sensor connector and connecting the har-
AKX01561AE
ness-side of the connector to another engine
coolant temperature sensor that is at 20°C or 1. Disconnect the idle speed control servo
below is also okay. connector.
2. Check that the operation sound of the stepper 2. Measure the resistance between terminal No. 2
motor can be heard after the ignition is switched and either terminal No. 1 or terminal No. 3 of the
"ON" position (but without starting the engine). connector at the idle speed control servo side.
3. If the operation sound cannot be heard, check the Standard value: 28 − 33 Ω (at 20°C)
stepper motor’s activation circuit.
3. Measure the resistance between terminal No. 5
If the circuit is normal, it is probable that there is a and either terminal No. 6 or terminal No. 4 of the
malfunction of the stepper motor or of the connector at the idle speed control servo side.
engine-ECU. Standard value: 28 − 33 Ω (at 20°C)
ON-VEHICLE SERVICE
13A-409
Operation Check FUEL PRESSURE SOLENOID VALVE
CHECK
M1131005800114
OPERATION CHECK
1 2 Fuel pressure
Equipment side solenoid valve
connector
AKX01626
1. Remove the throttle body.

2. Remove the stepper motor. AK304587AB
3. Connect the special tool Test harness
(MB991709) to the idle speed control servo 1. Remove the vacuum hose from the solenoid
connector. valve.
4. Connect the positive (+) terminal of a power 2. Disconnect the harness connector.
supply (approximately 6 V) to the terminals No. 2
B nipple
and No. 5.
5. With the idle speed control servo as shown in the
illustration, connect the negative (−) terminal of
the power supply to each clip as described in the
following steps, and check whether or not a
vibrating feeling (a feeling of very slight vibration
of the stepper motor) is generated as a result of
the activation of the stepper motor. Battery
(1) Connect the negative (−) terminal of the power AK202416 AC
supply to the red and black clip.
3. Connect a hand vacuum pump to the solenoid
(2) Connect the negative (−) terminal of the power
valve’s A nipple.
supply to the blue and black clip.
(3) Connect the negative (−) terminal of the power 4. Connect the solenoid valve terminal and battery
supply to the blue and yellow clip. terminal with a jumper wire.
(4) Connect the negative (−) terminal of the power 5. Disconnect the jumper wire between the battery’s
supply to the red and yellow clip. (−) terminals, apply a negative pressure, and
inspect the tightness.
(5) Connect the negative (−) terminal of the power
supply to the red and black clip. Standard valve:
(6) Repeat the tests in sequence from (5) to (1). Battery voltage B nipple Normal
condition
6. If, as a result of these tests, vibration is detected,
the stepper motor can be considered to be No applied Open Vacuum leak
normal. Close Vacuum
maintained
Applied Open Vacuum
maintained
ON-VEHICLE SERVICE
COIL RESISTANCE CHECK 1. Disconnect the oil feeder control valve connector.
CAUTION
To prevent the coil from burning, keep the dura-
tion of the voltage application as short as possi-
ble.
2. Apply battery voltage to the terminals of the
connector at the oil feeder control valve, and
make sure the oil feeder control valve makes a
clicking sound.
AK304596 MEASUREMENT OF RESISTANCE

BETWEEN TERMINALS
1. Measure the resistance between the terminals of
the solenoid valve. 1. Disconnect the oil feeder control valve connector.
Standard value: 28 − 36 Ω (at 20°C) 2. Measure the resistance between the terminals of
the connector at the oil feeder control valve.
OIL FEEDER CONTROL VALVE CHECK Standard value: 6.9 − 7.9 Ω (at 20°C)
M1131053800072
3. If resistance is outside the standard value, replace
OPERATION CHECK
the oil feeder control valve.
1 2
Equipment side
connector
Oil feeder
control valve
AK502034 AB
INJECTOR
13A-411
INJECTOR
M1131007100854

• Fuel Discharge Prevention (Refer to P.13A-398). • Air Hose E, Air By-pass Hose, Air Pipe C Installation
• Strut Tower Bar Removal (Refer to GROUP 42, Strut (Refer to GROUP 15, Intercooler P.15-6).
Tower Bar P.42-9). • Strut Tower Bar Installation (Refer to GROUP 42, Strut
• Air Hose E, Air By-pass Hose, Air Pipe C Removal (Refer Tower Bar P.42-9).
to GROUP 15, Intercooler P.15-6). • Fuel Leakage Check
5.0 ± 1.0 N·m 2 10

5
3
4N
12
15 N 3,7
10
13
9 O-ring
11
11 ± 1 N·m 6 12 N
5.0 ± 1.0 N·m
15 N
5
N8 14 N
7
8.9 ± 1.9 N·m O-ring 13
1
Engine oil
AC210060AD

1. Accelerator cable assembly 8. O-ring
connection (Throttle body side) 9. Fuel return pipe
2. Control wiring harness connection <<A>> 10. Delivery pipe
>>A<< 3. Fuel high-pressure hose 11. Insulators
connection 12. Insulators
4. O-ring <<A>> >>A<< 13 Injectors
5. Fuel return hoses connection 14. O-ring
6. Vacuum hose connection 15. Grommets
>>A<< 7. Fuel pressure regulator
INJECTOR
REMOVAL SERVICE POINT 2. Turn the injector to the right and left to install to
<<A>> DELIVERY PIPE/INJECTORS the delivery pipe. Repeat for fuel pressure
regulator and fuel high-pressure hose. Be careful
REMOVAL not to damage the O-ring. After installing, check
CAUTION that the item turns smoothly.
Do not drop the injector. 3. If it does not turn smoothly, the O-ring may be
Remove the delivery pipe with the injectors attached pinched, remove the item, re-install it into the
to it. delivery pipe and check again.
4. Tighten the fuel pressure regulator and fuel
INSTALLATION SERVICE POINT high-pressure hose to the specified torque.
>>A<< INJECTORS/FUEL PRESSURE Tightening torque:
REGULATOR/FUEL HIGH-PRESSURE 8.9 ± 1.9 N⋅m <Fuel pressure regulator>
HOSE INSTALLATION 5.0 ± 1.0 N⋅m <Fuel high-pressure hose>
CAUTION
Do not let the engine oil get into the delivery pipe
will be damaged.
1. Apply a drop of new engine oil to the O-ring.
THROTTLE BODY ASSEMBLY
13A-413
M1131007700759

• Under Cover Removal (Refer to GROUP 51, Front • Air Hose E, Air By-pass Hose, Air Pipe C Installation
Bumper P.51-2). (Refer to GROUP 15, Intercooler P.15-6).
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Strut Tower Bar Installation Refer to GROUP 42, Strut
Service − Engine Coolant Replacement P.14-15). Tower Bar P.42-9).
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Tower Bar P.42-9). Service − Engine Coolant Replacement P.14-15).
• Air Hose E, Air By-pass Hose, Air Pipe C Removal (Refer • Under Cover Installation (Refer to GROUP 51, Front
to GROUP 15, Intercooler P.15-6). Bumper P.51-2).
• Accelerator Cable Adjustment (Refer to GROUP 17,
On-vehicle Service − Accelerator Cable Check and
Adjustment P.17-2).
5.0 ± 1.0 N·m
19 ± 3 N·m
1
4
7N
2
5 5
AC310860AB

1. Accelerator cable connection 5. Water hoses connection
2. Throttle position sensor connector 6. Throttle body
3. Idle speed control servo connector >>A<< 7. Throttle body gasket
4. Vacuum hoses connection
INSTALLATION SERVICE POINT Install the throttle body gasket as shown in the illus-
tration.
>>A<<THROTTLE BODY GASKET
INSTALLATION
CAUTION
Poor idling etc. may result if the throttle body
gasket is installed incorrectly.
Up
Towards front
of vehicle AC200313AB
ENGINE CONTROL RESISTOR, RELAY
13A-415
ENGINE CONTROL RESISTOR, RELAY
M1131034600024

• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Harness Connector Connection
Tower Bar P.42-9). • Strut Tower Bar Installation (Refer to GROUP 42, Strut
• Harness Connector Disconnection Tower Bar P.42-9).
5.0 ± 1.0 N·m
Electric pump relay

5.0 ± 1.0 N·m

3
1
5.0 ± 1.0 N·m
2.5 ± 0.5 N·m

2
5.0 ± 1.0 N·m
4
5.0 ± 1.0 N·m
2 3
5.0 ± 1.0 N·m
2.5 ± 0.5 N·m
Electric pump relay 4
5.0 ± 1.0 N·m

1
AC310757 AB

• Electric pump relay (Refer to 2. Injector resistor
GROUP 22A, Sensor, Switch and 3. Bracket
Relay P.22A-168). 4. Fuel pump resistor
1. Fuel pump relay
ENGINE-ECU
ENGINE-ECU
M1131033800230
CAUTION
When the engine-ECU is replaced, always refer to GROUP 54A, General Information − Immobilizer
System − Encrypted Code Registration Criteria Table P.54A-6.
• Glove Box Assembly Removal and Installation (Refer to
GROUP 52A, Instrument Panel P.52A-2).
• Harness Cover Removal and Installation (Refer to
5.0 ± 1.0 N·m

1
AC505253AB
Removal steps
1. Engine-ECU connectors
2. Engine-ECU
13-1
GROUP 13
FUEL
CONTENTS
MULTIPORT FUEL INJECTION (MPI) . . . . . . . . . . . . . . . . . . . . 13A
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B

NOTES
35-1
GROUP 35
SERVICE BRAKES
CONTENTS
SERVICE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A
ANTI-SKID BRAKING SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . 35B

NOTES
35A-1
GROUP 35A
SERVICE BRAKES
CONTENTS
GENERAL INFORMATION . . . . . . . . 35A-2 BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A-14

SERVICE SPECIFICATIONS. . . . . . . 35A-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-15
LUBRICANTS . . . . . . . . . . . . . . . . . . 35A-4 MASTER CYLINDER ASSEMBLY

AND BRAKE BOOSTER . . . . . . . . . . 35A-16
SEALANT. . . . . . . . . . . . . . . . . . . . . . 35A-4 REMOVAL AND INSTALLATION . . . . . . . . 35A-16
MASTER CYLINDER . . . . . . . . . . . . . . . . . 35A-18
SPECIAL TOOLS. . . . . . . . . . . . . . . . 35A-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-18
ON-VEHICLE SERVICE. . . . . . . . . . . 35A-5 FRONT DISC BRAKE ASSEMBLY . . 35A-19

BRAKE PEDAL CHECK AND ADJUSTMENT 35A-5 REMOVAL AND INSTALLATION . . . . . . . . 35A-19
BRAKE BOOSTER OPERATING TEST . . . 35A-6 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-19
CHECK VALVE OPERATION CHECK . . . . 35A-7 DISASSEMBLY AND REASSEMBLY . . . . . 35A-20
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 35A-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-21
BRAKE FLUID LEVEL SENSOR CHECK. . 35A-8
FRONT DISC BRAKE PAD CHECK AND REAR DISC BRAKE ASSEMBLY . . . 35A-22
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 35A-8 REMOVAL AND INSTALLATION . . . . . . . . 35A-22
DISC BRAKE ROTOR CHECK. . . . . . . . . . 35A-10 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-22
BRAKE DISC THICKNESS CHECK . . . . . . 35A-11 DISASSEMBLY AND REASSEMBLY . . . . . 35A-23
BRAKE DISC RUN-OUT CHECK AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-24
CORRECTION . . . . . . . . . . . . . . . . . . . . . . 35A-12
35A-2 SERVICE BRAKES
GENERAL INFORMATION
GENERAL INFORMATION
M1351000100536
CAUTION
Take care not to contact the parts or tools to the
caliper because the paint of caliper will be
scratched.
Top components such as Brembo™ brakes, EBD and
sports ABS improve braking power and braking sta-
bility.
CONSTRUCTION DIAGRAM
Brake booster assembly
Brake modulator hydraulic unit

(integrated with ABS-ECU)
10064AU
Rear disc brake

Brake master
cylinder assembly Parking brake
Front disc brake

AC211387AD
SERVICE BRAKES
35A-3
SPECIFICATIONS
Item Specification
Master Type Tandem type
cylinder I.D. mm 26.9
Brake Type Vacuum type, tandem
booster Effective dia. of power 205 + 230
cylinder mm
Boosting ratio 4.5 (Brake pedal depressing force: 230 N)
Rear wheel hydraulic control method Electronic brake-force distribution (EBD)
Front brakes Type 4-opposed piston, ventilated disc
Disc effective dia. × 263 × 32
thickness mm
Wheel cylinder I.D. mm 40.0 × 2, 46.0 × 2
Pad thickness mm 10.0
Clearance adjustment Automatic
Rear brakes Type 2-opposed piston, ventilated disc
Disc effective dia. × 252 × 22
thickness mm
Wheel cylinder I.D. mm 40.0 × 2
Pad thickness mm 9.0
Clearance adjustment Automatic
M1351000300574

Brake pedal height mm 169.1 − 172.1 −
Brake pedal free play mm 3−8 −
Brake pedal to floorboard clearance mm 90 or more −
Front disc brake pad thickness mm 10.0 Minimum 2.0
Front disc brake disc thickness mm 32.0 Minimum 29.8
Front disc brake disc run-out mm − 0.03
Front disc brake drag force N 69 or less −
Rear disc brake pad thickness mm 9.0 Minimum 2.0
Rear disc brake disc thickness mm 22.0 Minimum 20.4
Rear disc brake disc run-out mm − 0.03
Rear disc brake drag force N 69 or less −
Front wheel bearing axial play mm − 0.05
Rear wheel bearing axial play mm − 0.05
Brake booster push rod protruding amount mm 8.98 − 9.23 −
LUBRICANTS
LUBRICANTS
M1351000400504
Item Specified lubricant

Brake fluid DOT3 or DOT4
Pad assembly Repair kit grease
SEALANT
M1351000500415
Item Specified sealant Remark

Fitting 3M ATD Part No.8661 or equivalent Semi-drying sealant
SPECIAL TOOLS
M1351000600434

MB991568 Push rod adjusting Adjustment of the brake booster
socket push rod protrusion amount
MB990964 Brake tool set • Pushing-in of the disc brake

A A: MB990520 A: Disc brake piston
B
B: MB990619 piston expander • Installation of the drum brake
B: Installer wheel cylinder piston cup
MB990964
MB990998 Front hub remover Provisional holding of the wheel

and installer bearing
MB990998
SERVICE BRAKES
ON-VEHICLE SERVICE
35A-5
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND NOTE: When the clevis is turned 180 degrees,
ADJUSTMENT the pedal height is changed approximately 2.4
M1351000900510 mm.
BRAKE PEDAL HEIGHT (5) Install the brake booster (Refer to P.35A-16).
1. Turn up the carpet, etc. under the brake pedal. (6) Measure the brake pedal height, and ensure
that the measured value is within the specified
value. When it is out of the specified value,
repeat Step (3) - (6).
Stopper
A
AC006215AB
2. Measure the brake pedal height as illustrated.

Stopper
Standard value (A): 169.1 − 172.1 mm [From
the surface of melting sheet (floorboard) to
the face of pedal pad]
3. If the brake pedal height is not within the standard
value, follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch by turning it
approximately 1/4 turn anticlockwise.
(3) Remove the brake booster (Refer to 0.5 - 1.0 mm
P.35A-16).
NOTE: With the master cylinder and brake AC309282AE
pipe connected, remove the brake booster
(7) Insert the stop lamp switch until its threaded
only.
part touches the stopper. Then lock the stop
lamp switch by turning it approximately 1/4
turn clockwise, and confirm that the clearance
between the switch plunger and the stopper is
as shown.
Clevis
CAUTION
Check that the stop lamp does not illuminate
when the brake pedal is not depressed.
(8) Connect the connector at the stop lamp
AC006217AB
switch.
4. Return the carpet, etc.
(4) Adjust the brake pedal height by turning the
clevis.
ON-VEHICLE SERVICE
BRAKE PEDAL FREE PLAY Standard value (C): 90 mm or more [From the
surface of the floorboard to the face of pedal
pad]
3. If the clearance is outside the standard value,
check for air trapped in the brake line and
thickness of the disc brake pad. And then bleed
the air and replace the disc brake pad as required.
4. Return the carpet etc. to its original position.
B BRAKE BOOSTER OPERATING TEST

M1351001000435
AC006219AB
1. For simple checking of the brake booster
1. With the engine stopped, depress the brake pedal operation, carry out the following tests:
two or three times, After eliminating the vacuum in Good No good
the power brake booster, press the pedal down by
hand, and confirm that the amount of movement
before resistance is met (the free play) is within
the standard value.
Standard value (B): 3 − 8 mm
2. If the brake pedal play is not within the standard
value, check the following, and adjust or replace if
necessary:
AC000870 AB
• Excessive play between the brake pedal and the
clevis pin, or between the clevis pin and the (1) Run the engine for one or two minutes, and
brake booster operating rod then stop it. If the pedal depresses fully the
• Brake pedal height first time but gradually becomes higher when
• Installation position of the stop lamp switch, etc. depressed succeeding times, the booster is
operating properly. If the pedal height remains
CLEARANCE BETWEEN BRAKE PEDAL unchanged, the booster is defective. Go to
AND FLOORBOARD step 2.
1. Turn up the carpet, etc. under the brake pedal. When engine
When engine
is stopped is started
AC000871AB
C
AC006220AB (2) With the engine stopped, step on the brake
pedal several times. Then step on the brake
2. Start the engine, depress the brake pedal with pedal and start the engine. If the pedal moves
approximately 500 N of force, and measure the downward slightly, the booster is in good
clearance between the brake pedal and the condition. If there is no change, the booster is
floorboard. defective. Go to step 3.
SERVICE BRAKES
ON-VEHICLE SERVICE
35A-7
2. Check the operation of the check valve by using a
Good No good vacuum pump.
Vacuum pump Accept/reject criteria
connection
Connection at the brake A negative pressure
booster side (A) (vacuum) is created and
held.
Connection at the intake A negative pressure
AC000872 AB manifold side (B) (vacuum) is not created.
(3) With the engine running, step on the brake BLEEDING

pedal and then stop the engine. Hold the M1351001400552
pedal depressed for 30 seconds. If the pedal CAUTION
height does not change, the booster is in good Use only brake fluid DOT 3 or DOT 4. Never mix
condition, if the pedal rises, the booster is the specified brake fluid with other fluid as it will
defective. affect the braking performance significantly.
2. If the above three tests are okay, the booster is MASTER CYLINDER BLEEDING
OK. If one of the above three tests is not okay, the
The master cylinder has no check valve, so if bleed-
check valve, vacuum hose, or booster is
ing is carried out by the following procedure, bleed-
defective. Check the check valve operation (Refer
ing of air from the brake pipeline will become easier
to P.35A-7), vacuum hose for leaks, high volume
(When brake fluid is not contained in the master cyl-
engine vacuum applied to booster. Repair or
inder).
replace as necessary. If these are OK, replace the
booster and repeat this test starting at Step 1. 1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
CHECK VALVE OPERATION CHECK
M1351009000462
CAUTION
The check valve should not be removed from the
vacuum hose.
1. Remove the vacuum hose (Refer to P.35A-16).
CAUTION
If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.
AC000876
Valve Spring
3. Have another person cover the master cylinder
A B
outlet with a finger.
Intake manifold 4. With the outlet still closed, release the brake
side pedal.
(does not hold)
Booster side 5. Repeat steps 2 − 4 three or four times to fill the
(holds)
inside of the master cylinder with brake fluid.
AC000873AE
ON-VEHICLE SERVICE
DISC BRAKE BLEEDING Start the engine and bleed the air in the sequence
shown in the figure.
CAUTION
Take care not to contact the parts or tools to the BRAKE FLUID LEVEL SENSOR CHECK
caliper because the paint of caliper will be M1351009100447
scratched. And if there is brake fluid on the cali-
per, wipe it off quickly.
Air bleeder screw
;
AC006224AB
The brake fluid level sensor is in good condition if

AC211983 AB
there is no continuity when the float surface is above
Connect a vinyl tube to the outer end of the air "MIN" and if there is continuity when the float surface
bleeder screw to bleed the circuit of air. Then, con- is below "MIN".
nect the vinyl tube to the inner end and bleed the cir-
cuit of air. Except for these, the conventional FRONT DISC BRAKE PAD CHECK AND
procedures shall be followed. After the circuit has REPLACEMENT
been bled of air, tighten both air bleeder screws M1351002300484
securely. NOTE:
When new When worn
BRAKE LINE BLEEDING
Pad
CAUTION
Be sure to filter/strain the brake fluid being
added to the master cylinder reservoir tank.
Debris may damage the hydraulic unit.
Brake
disc
Wear indicator
4 1
AC000879 AB
The brake pads have indicators that contact the

brake disc when the brake pad thickness becomes 2
mm, and emit a squealing sound to warn the driver.
2 3
AC211984 AB
CAUTION
scratched. And if there is brake fluid on the

caliper, wipe it off quickly.
• Whenever a pad must be replaced, replace
both LH and RH wheel pads as a set to pre-
vent the vehicle from pulling to one side when
braking.
• If there is a significant difference in the thick-
nesses of the pads on the left and right sides,
check moving parts.
Front
Pads
Pads
Rear
AC211985 AB
;
SERVICE BRAKES
ON-VEHICLE SERVICE
• Take care not to contact the parts or tools to

the caliper because the paint of caliper will be
AC211987
(2) Remove the pad from the caliper.

35A-9
(3) To measure brake drag force after new pads

have been installed, use a spring scale to
measure the turning sliding resistance of the
hub with the pads removed.
MB990520
1. Check the brake pad thickness through the caliper

body check port.
AC211988 AB
Standard value:
<Front> 10.0 mm (4) Clean the piston and, using special tool piston
<Rear> 9.0 mm expander (MB990520), push the piston into
Minimum limit: 2.0 mm the cylinder.
Front Rear
AC211989 AB
AC211986
(5) Apply repair kit grease to the portions of the

2. When the thickness is less than the limit, always pads indicated. At this time, make sure that
replace the pads at an axle set. the grease will not be applied to any other
(1) Holding the cross spring with one hand, pull surfaces.
the pin out of the caliper. (6) Mount the pads to the caliper so that its side
with the wear indicator is on the outside of the
vehicle. With the rear pads, ensure that the
arrow on the pad faces in the same direction
as the brake disc turns when the vehicle
moves forward.
ON-VEHICLE SERVICE
(8) Using a spring scale, measure the turning

Pins sliding resistance of the hub in the forward
Cross direction.
spring
(9) Find the brake disc drag force [the difference
in measurements taken in step(3) and in
step(8)].
Standard value: 69 N or less
(10)If that drag force exceeds the standard value,
AC211990 AB
disassemble the caliper assembly. Then check
the piston for contamination or rust, and
(7) Holding the cross spring with one hand, fit pins confirm if the piston or the piston seal is
in the caliper. deteriorated.
DISC BRAKE ROTOR CHECK

M1351002900408
CAUTION
Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.
Before turning the brake disc, the following condi-
tions should be checked.
Inspection item Remark
Scratches, rust, saturated lining materials and wear • If the vehicle is not driven for a long period of
time, sections of the discs that are not in contact
with the pads will become rusty, causing noise
and shuddering.
• If grooves and scratches resulting from excessive
disc wear are not removed prior to installing a new
pad assembly, there will be inadequate contact
between the disc and the lining (pad) until the
pads conform to the disc.
Run-out Excessive run-out of the discs will increase the pedal
depression resistance due to piston kick-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause
pedal pulsation, shuddering and surging.
Inset or warping (flatness) Overheating and improper handling while servicing
will cause warping or distortion.
SERVICE BRAKES
ON-VEHICLE SERVICE
35A-11
BRAKE DISC THICKNESS CHECK CAUTION
M1351002400469
• After a new brake disc is installed, always
CAUTION grind the brake disc with on-the-car type
Take care not to contact the parts or tools to the brake lathe. If this step is not carried out, the
caliper because the paint of caliper will be brake disc run-out exceeds the specified
scratched. And if there is brake fluid on the cali- value, resulting in judder.
per, wipe it off quickly. •
M12 flat washer
ACX00668AB
1. Using a micrometer, measure disc thickness at

eight positions, approximately 45 degrees apart
and 10 mm from the outer edge of the disc. M12 flat washer
Standard value:
<Front> 32.0 mm
<Rear> 22.0 mm
Minimum limit:
<Front> 29.8 mm
<Rear> 20.4 mm
AC006226 AB
NOTE: Thickness variation (at least 8 positions)
should not be more than 0.015 mm. When the on-the-car type lathe is used, first
install a M12 flat washer on the stud bolt in
the brake disc side according to the figure,
and then install the adapter. If the adapter is
installed with M12 flat washer not seated, the
brake disc rotor may be deformed, resulting
in inaccurate grinding.
• Grind the brake disc with all wheel nuts diag-
onally and equally tightened to the specified
torque 100 N⋅m. When all numbers of wheel
nuts are not used, or the tightening torque is
excessive or not equal, the brake disc rotor or
drum may be deformed, resulting in judder.
2. If the disc thickness is less than the limits, replace
it with a new one. If thickness variation exceeds
the specification, turn rotor with an on-the-car type
brake lathe ("Accuturn-8750" or equivalent).
If the calculated final thickness after turning the
rotor is less than the standard value, replace the
disc.
ON-VEHICLE SERVICE
BRAKE DISC RUN-OUT CHECK AND 4. If the brake disc run-out exceeds the limit, correct
CORRECTION it as follows:
M1351009400534 (1) Chalk phase marks on the wheel stud and the
CAUTION brake disc, which run-out is excessive as
Take care not to contact the parts or tools to the shown.
caliper because the paint of caliper will be <Front>
1. Remove the brake assembly, and then hold it with
wire.
2. Temporarily install the disc with the hub nut.
AC102438 AC
<Rear>
ACX00669AB
3. Place a dial gauge approximately 5 mm from the

outer circumference of the brake disc, and
measure the run-out of the disc.
AC205869AC
Limit: 0.03 mm
(2) Remove the brake disc. Then place a dial
gauge as shown, and measure the axial play
by pushing and pulling the wheel hub.
Chalk marks Limit: 0.05 mm
(3) If the axial play exceeds the limit, disassemble
the hub and knuckle assembly to check each
part.
(4) If the axial play does not exceed the limit,
dephase the brake disc and secure it. Then
AC210711AB recheck the brake disc run-out.
SERVICE BRAKES
ON-VEHICLE SERVICE
35A-13
CAUTION 5. If the run-out cannot be corrected by changing the
• After a new brake disc is installed, always phase of the brake disc, replace the brake disc or
grind the brake disc with on-the-car type grind it with the on-the-car type brake lathe
brake lathe. If this step is not carried out, the ("Accuturn-8750" or equivalent).
brake disc run-out exceeds the specified
value, resulting in judder.
•
M12 flat washer
M12 flat washer
AC006226 AB
When the on-the-car type lathe is used, first

install a M12 flat washer on the stud bolt in
the brake disc side according to the figure,
and then install the adapter. If the adapter is
installed with M12 flat washer not seated, the
brake disc rotor may be deformed, resulting
in inaccurate grinding.
• Grind the brake disc with all wheel nuts diag-
onally and equally tightened to the specified
torque 100 N⋅m. When all numbers of wheel
nuts are not used, or the tightening torque is
excessive or not equal, the brake disc rotor or
drum may be deformed, resulting in judder.
BRAKE PEDAL
BRAKE PEDAL
M1351003400473
• Brake Pedal Adjustment (Refer to P.35A-5).
12 ± 2 N·m
3 1
2
5
7
14 ± 3 N·m
4
6
AC211554 AB

1. Harness connector 5. Brake booster pin
2. Stoplamp switch 6. Brake pin assembly
3. Brake pedal clip 7. Brake pedal pad
4. Brake pedal stopper >>A<< 8. Brake pedal assembly
SERVICE BRAKES
BRAKE PEDAL
35A-15
M1351003500254
>>A<< BRAKE PEDAL ASSEMBLY STOPLAMP SWITCH CHECK
INSTALLATION
B B
No continuity Continuity
A A
4 mm
AC006235AB
AC006234 AB
Tighten the brake booster mounting nuts (A), and 1. Connect an ohmmeter between the stop lamp
then the brake pedal assembly mounting bolts (B). switch connector terminals.
NOTE: The brake pedal assembly cannot be posi- 2. There should be no continuity between the
tioned correctly if the brake pedal assembly mount- terminals when the plunger is pushed in as
ing bolts (B) are tightened first, as their holes are shown. There should be continuity when it is
oblong holes. released.
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

M1351003700537

• Brake Fluid Draining • Brake Pedal Adjustment (Refer to P.35A-5).
• Air Intake Hose and Air Cleaner Removal (Refer to • Air Intake Hose and Air Cleaner Installation (Refer to
GROUP 15, Air Cleaner P.15-5). GROUP 15, Air Cleaner P.15-5).
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Strut Tower Bar Removal (Refer to GROUP 42, Strut
Tower Bar P.42-9). Tower Bar P.42-9).
• Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-7).
4
2
3
11
15 ± 2 N·m
12
8
1 10
5
6 9
22 ± 3 N·m
10 ± 2 N·m
14 ± 3 N·m
5
15 ± 2 N·m
AC310837AB
7 7
13
16 ± 1 N·m
13
13 16 ± 1 N·m
3M ATD part No. 8661 or equivalent
Master cylinder removal steps Brake booster removal steps

1. Clutch hose connection >>B<< • Push rod protrusion amount check
2. Brake fluid level indicator switch and adjustment
connector >>A<< 7. Brake booster vacuum hose
3. Brake fluid reservoir cap (With built-in check valve)
4. Brake fluid level indicator switch 8. Brake booster pin
5. Brake tube connection 9. Brake booster pin assembly
6. Brake master cylinder assembly 10. Clevis
Brake booster removal steps • Remove A/C liquid pipe B from the
retaining clip (Refer to GROUP 55,
1. Clutch hose connection
Refrigerant Line P.55-128).
2. Brake fluid level indicator switch
11. Brake booster assembly
connector
12. Brake booster body seal
5. Brake tube connection
6. Brake master cylinder assembly
SERVICE BRAKES
35A-17
Fitting removal steps 1. Measure dimension (A).
>>A<< 7. Brake booster vacuum hose
Standard value (A): 8.98 − 9.23 mm
(With built-in check valve)
13. Brake booster vacuum hose fitting NOTE: When a negative pressure of 66.7 kPa is
applied to the brake booster, the push rod should
INSTALLATION SERVICE POINTS protrude 10.27 - 10.53 mm.
>>A<< BRAKE BOOSTER VACUUM HOSE
CONNECTION
Insert the brake booster vacuum hose to the brake
booster assembly with its paint mark facing upward,
and then secure the hose by using the hose clip.
>>B<< PUSH ROD PROTRUSION

Rod spline
AMOUNT CHECK AND ADJUSTMENT
Angle-nose pliers
MB991568
Measuring distance A AC006238AB
2. If the protrusion amount is not within the standard

value range, adjust the push rod length by turning
the push rod. Use special tool push rod adjusting
socket (MB991568) to turn the push rod while
holding the rod spline with angle-nose pliers.
Block gauge
AC006237AB
MASTER CYLINDER
M1351004200449

7
1
3 8
4
9
2
N 7 Master cylinder kit
5 10
8 N
6
3 9 N
10 9 8
AC006239 AB Brake fluid: DOT 3 or DOT 4

1. Brake fluid reservoir cap 9. Secondary piston assembly
2. Brake fluid reservoir filter 10. Master cylinder body
3. Brake master cylinder pin
4. Brake fluid reservoir INSPECTION
M1351004300338
5. Brake master cylinder to reservoir
• Check the inner surface of master cylinder body
seal
6. Brake master cylinder pin
for rust or pitting.
7. Piston retainer • Check the primary and secondary pistons for
8. Primary piston assembly rust, scoring, wear or damage.
• Check the diaphragm for cracks and wear.
SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY
35A-19
M1351006000526
CAUTION
Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
And if there is brake fluid on the caliper, wipe it off quickly.
• Brake Fluid Draining • Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-7).
108 ± 10 N·m
30 ± 5 N·m 1
N 2
AC211991 AB
Removal steps 2. If that drag force exceeds the standard value,

1. Brake hose connection disassemble the caliper assembly. Then check
2. Gasket the piston for contamination or rust, and confirm if
>>A<< 3. Brake caliper assembly the piston or the piston seal is deteriorated.
4. Brake disc
INSPECTION
INSTALLATION SERVICE POINT M1351006100341
>>A<< BRAKE CALIPER ASSEMBLY BRAKE DISC CHECK

Disc wear (Refer to P.35A-11).
INSTALLATION Disc run-out (Refer to P.35A-12).
1. Find the drag force of the disc brake (Refer to
P.35A-8).
Standard value: 69 N or less

M1351006200586
CAUTION
6 7N
6 9N
8
10
4
3 14 ± 2 N·m
5
1
Grease: Repair kit grease

2
AC211994 AB
6
7 9
6 8
10 5 5
9
7
7
9
1
Brake caliper kit Seal and boot repair kit Shim set
3 4
2
1
3
1
2
4
Clip set Pad set

SERVICE BRAKES
35A-21
Disassembly steps <> PISTON SEAL REMOVAL
1. Pin
CAUTION
2. Pad anti-squeak spring
3. Pad and wear indicator assembly
To prevent damage to inner cylinder, do not use a
4. Pad assembly flat-tipped screwdriver or other tool.
5. Shim 1. Remove the piston seal with finger tip.
6. Caliper bleeder 2. Clean the piston surface and inner cylinder with
<<A>> 7. Piston boot alcohol or brake fluid DOT 3 or DOT 4.
<<A>> 8. Piston
<> 9. Piston seal INSPECTION
10. Caliper body M1351006300431
• Check the cylinder for wear, damage or rust.
DISASSEMBLY SERVICE POINTS • Check the piston surface for wear, damage or
CAUTION rust.
Take care not to contact the parts or tools to the • Check the caliper body for wear.
caliper because the paint of caliper will be • Check the pad for damage or adhesion of grease,
scratched. And if there is brake fluid on the cali- check the backing metal for damage.
per, wipe it off quickly. PAD WEAR CHECK
When disassembling the disc brakes, disassemble
WARNING
both sides (left and right) as a set.
• Always replace both brake pads on each
<<A>> PISTON BOOT/PISTON REMOVAL wheel as a set (both front wheels or both
CAUTION rear wheels). Failure to do so will result in
Do not remove one piston completely before try- uneven braking, which may cause unrelia-
ing to remove the other piston, because it will ble brake operation.
become impossible to remove other pistons. • If there is significant difference in the
thickness of the pads on the left and right
Wood block sides, check the moving parts.
AC212148AB
Remove the pistons by pumping in air slowly from

the brake hose connection. Be sure to use a wood ACX00690
block and adjust the height of the four pistons so that Measure thickness at the thinnest, most worn area of
the pistons protrude evenly. the pad. Replace the pad assembly if pad thickness
is less than the limit value.
Minimum limit: 2.0 mm
REAR DISC BRAKE ASSEMBLY

M1351007000411
CAUTION
• Brake Fluid Draining • Brake Fluid Filling and Air Bleeding (Refer to P.35A-7).
54 ± 5 N·m 1
15 ± 2 N·m
2N
3
4
AC403344AB
Removal steps Standard value: 69 N or less

1. Brake hose connection 2. If that drag force exceeds the standard value,
2. Gasket disassemble the caliper assembly. Then check
>>A<< 3. Brake caliper assembly
the piston for contamination or rust, and confirm if
4. Brake disc
the piston or the piston seal is deteriorated.
INSPECTION
>>A<< BRAKE CALIPER ASSEMBLY M1351007100300
INSTALLATION BRAKE DISC CHECK

1. Find the drag force of the disc brake (Refer to Disc wear: Refer to P.35A-11.
P.35A-8). Disc run-out: Refer to P.35A-12.
SERVICE BRAKES
35A-23
M1351007200374
CAUTION
14 ± 2 N·m 5 4
6 2
3
5
10
N 7 Grease: Repair kit grease
N 9
8 AC211995 AB
6 10 2
8 9
9 7
7 6
1 5
7
9 5
Brake caliper kit Seal and boot repair kit Shim set
3 4 4
1
3
2
1
2
Clip set Pad set

1. Pin 6. Caliper bleeder
2. Pad anti-squeak spring <<A>> 7. Piston boot
3. Pad and wear indicator assembly <<A>> 8. Piston
4. Pad assembly <> 9. Piston seal
5. Shim 10. Caliper body
DISASSEMBLY SERVICE POINTS INSPECTION

M1351007300296
CAUTION • Check the cylinder for wear, damage or rust.
Take care not to contact the parts or tools to the • Check the piston surface for wear, damage or
caliper because the paint of caliper will be rust.
scratched. And if there is brake fluid on the cali- • Check the caliper body for wear.
per, wipe it off quickly. • Check the pad for damage or adhesion of grease,
When disassembling the disc brakes, disassemble check the backing metal for damage.
both sides (left and right) as a set.
PAD WEAR CHECK
<<A>> PISTON BOOT/PISTON REMOVAL
WARNING
• Always replace both brake pads on each
Wooden plate wheel as a set (both front wheels or both
rear wheels). Failure to do so will result in
uneven braking, which may cause unrelia-
ble brake operation.
• If there is significant difference in the
thickness of the pads on the left and right
sides, check the moving parts.
AC212149AB
Remove the pistons by pumping in air slowly from

the brake hose connection. Be sure to use a wood
plate and adjust the height of the two pistons while
so that the pistons protrude evenly.
<> PISTON SEAL REMOVAL

CAUTION
To prevent damage to inner cylinder, do not use a
ACX00690
flat-tipped screwdriver or other tool.
1. Remove the piston seal with finger tip. Measure thickness at the thinnest, most worn area of
the pad. Replace the pad assembly if pad thickness
2. Clean the piston surface and inner cylinder with is less than the limit value.
alcohol or brake fluid DOT 3 or DOT 4.
35B-1
GROUP 35B
ANTI-SKID
BRAKING SYSTEM
(ABS)
CONTENTS
GENERAL INFORMATION . . . . . . . . 35B-2 HYDRAULIC UNIT . . . . . . . . . . . . . . . 35B-143

REMOVAL AND INSTALLATION . . . . . . . . 35B-143
SERVICE SPECIFICATIONS. . . . . . . 35B-3
ABS SENSOR. . . . . . . . . . . . . . . . . . . 35B-146
SPECIAL TOOLS. . . . . . . . . . . . . . . . 35B-4 REMOVAL AND INSTALLATION . . . . . . . . 35B-146
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35B-147
TROUBLESHOOTING . . . . . . . . . . . . 35B-5
G-SENSOR . . . . . . . . . . . . . . . . . . . . . 35B-148
ON-VEHICLE SERVICE. . . . . . . . . . . 35B-138 REMOVAL AND INSTALLATION . . . . . . . . 35B-148
WHEEL SPEED SENSOR OUTPUT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35B-149
VOLTAGE MEASUREMENT . . . . . . . . . . . 35B-138
HYDRAULIC UNIT CHECK . . . . . . . . . . . . 35B-140 STEERING WHEEL SENSOR*. . . . . . 35B-150
IN THE EVENT OF A DISCHARGED REMOVAL AND INSTALLATION . . . . . . . . 35B-150
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . 35B-142
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
• Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger
(from rendering the SRS inoperative).
• Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.
• MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any
SRS-related component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, and interconnecting
wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance)
are indicated in the table of contents by an asterisk (*).
35B-2 ANTI-SKID BRAKING SYSTEM (ABS)
GENERAL INFORMATION
GENERAL INFORMATION
M1352000100584
Top components such as Brembo™ brakes, EBD and
sports ABS improve braking power and braking sta-
bility.
SPORTS ABS
• 4-wheel independent control optimises the brake • The steering wheel sensor, lateral G-sensor and
force to each wheel to achieve a balance of longitudinal G-sensor accurately monitor driving
improved braking force and braking stability. conditions and optimise ABS control to match the
• A steering wheel sensor was added to monitor specific driving conditions.
the steering angle status. Braking force is altered
in response to the steering status to improve the
quality of steering when cornering.
EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION SYSTEM)

• Rear brake power is electronically controlled to • Effective use of rear wheel brake force reduces
optimise performance in accordance with road temperature build-up in the front brakes under
and load conditions and to ensure optimal distri- hard braking conditions.
bution of braking force between the front and rear • Independent control of the left and right rear
brakes. brakes when braking during cornering achieves a
• Rear brake fluid pressure control employs a balance of improved vehicle stability and braking
brake modulator hydraulic unit solenoid valve that force.
made it possible to eliminate the pressure control
valves (proportioning valves).
SPECIFICATIONS
Item Specification
ABS control method 4-sensor, 4-channel
Number of rotor teeth Front 43
Rear 43
Wheel speed sensor Type Magnet coil type
Gap between sensor and Front 0.85 (Non-adjustable type)
rotor mm Rear 0.60 (Non-adjustable type)
ANTI-SKID BRAKING SYSTEM (ABS)
35B-3
<L.H. drive vehicles> <R.H. drive vehicles>
ABS warning lamp ABS warning lamp Parking brake switch
Steering wheel sensor
Hydraulic unit and Brake

modulator (ABS-ECU)
Wheel speed sensor

Lateral G-sensor
Diagnosis connector Longitudinal G-sensor
Stop lamp switch Wheel speed sensor AC310670 AC
M1352000300685
Item Standard value

Wheel speed sensor internal resistance kΩ 1.24 − 1.64
G-sensor output voltage V Stationary Vehicles 2.4 − 2.6
Arrow facing downward 3.4 − 3.6
SPECIAL TOOLS
SPECIAL TOOLS
M1352000600794

MB991502 M.U.T.-II sub assembly Checking the ABS
(Diagnosis display using
the M.U.T.-II)
B991502
MB991955 M.U.T.-III sub-assembly Checking the ABS

A A: MB991824 A: Vehicle communication (Diagnosis display using
B: MB991827 interface (V. C. I). the M.U.T.-III)
C: MB991910 B: M.U.T.-III USB cable CAUTION
D: MB991911 C: M.U.T.-III main M.U.T.-III main harness
MB991824 E: MB991825 harness A (Vehicles with B (MB991911) should be
B F: MB991826 CAN communication used. M.U.T.-III main
system) harness A should not
D: M.U.T.-III main be used for this vehicle.
harness B (Vehicles
MB991827 without CAN
communication system)
C
E: M.U.T.-III
DO NOT USE measurement adapter
harness
MB991910
MB991911
MB991825
MB991826
MB991955
MB991529 Diagnosis code check Checking the ABS

harness (Diagnosis display using
the ABS warning lamp)
MB991529
TROUBLESHOOTING
35B-5
MB991348 Test harness set Checking the G-sensor
MB991348
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC NOTES WITH REGARD TO DIAGNOSIS
M1352012600207
TROUBLESHOOTING 1. The ABS is a system which controls the brake
M1352011100641
Refer to GROUP 00, How to Use Troubleshoot- pressure by means of the operation of the ECU.
ing/Inspection Service Points P.00-5. Accordingly, the following symptoms may occur at
times, but these are a sign of normal ABS
operation, and do not indicate a malfunction.
Phenomenon Explanation of phenomenon
When the engine starts, a knocking sound can be heard coming This sound occurs as a result of system
from the engine compartment. operation checking, and is not a
malfunction.
• Sound of the motor inside the ABS hydraulic unit operation. This is the sound of normal system
(whine) operation, and is not a malfunction.
• Sound is the generated along with vibration of the brake
pedal. (scraping)
• When ABS operates, sound is generated from the vehicle
chassis due to repeated brake application and release.
(Thump: suspension; squeak: tyres)
Shocks are felt if the brake pedal is depressed when driving at This is due to system operation checking
low speed. (starting-of check when the vehicle speed
reaches a certain number of km/h) and is
not a malfunction.
2. For road surfaces such as snow-covered roads 3. Diagnosis detection condition can vary depending
and gravel roads, the braking distance for on the diagnosis code. Make sure that checking
vehicles with ABS can sometimes be longer than requirements listed in the "Comment" are satisfied
that for other vehicles. Accordingly, advise the when checking the trouble symptom again.
customer to drive safely on such roads by
lowering the vehicle speed and not being too
overconfident.
TROUBLESHOOTING
ABS WARNING LAMP INSPECTION 3. When the ignition switch is turned from the
M1352012000249 "START" position back to the "ON" position, the
<L.H. drive vehicles> ABS warning lamp illuminates for approximately 3
seconds and then switches off.
NOTE: The ABS waning lamp may remain on until
the vehicle reaches a speed of several km/h. This
is limited to cases where diagnosis code Nos. 21
to 24, 41 to 44, or 53 to 55 have been recorded
because of a previous problem occurring. In this
case, the ABS-ECU keeps the warning lamp illu-
minated until the problem corresponding to that
<R.H. drive vehicles> diagnosis code can be detected.
4. If the illumination is other than the above, check
the diagnosis codes.
DIAGNOSIS FUNCTION
M1352011200819
READING DIAGNOSIS CODES

WHEN USING THE M.U.T.-II/III
Refer to GROUP 00, How to Use Troubleshoot-
Approx. 3 s Approx. 3 s WHEN USING THE ABS WARNING LAMP
1. Turn the ignition switch to the "LOCK" (OFF)
ABS Illuminated position.
warning
lamp Not
illuminated Diagnosis connector
START
Ignition
ON
switch
ACC
MB991529
AC311051 AB 1 2 3 4 5 6 7 8
Check that the ABS warning lamp illuminates as fol-

9 10 11 12 13 14 15 16
lows. AC211895AB
1. When the ignition switch is turned to the "ON" 2. Use special tool diagnosis code check harness
position, the ABS warning lamp illuminates for (MB991529) to earth terminal number 1
approximately 3 seconds and then switches off. (diagnosis control terminal) of the diagnosis
2. When the ignition switch is turned to the "START" connector.
position, the ABS warning lamp remains 3. Turn the ignition switch to the "ON" position.
illuminated.
TROUBLESHOOTING
35B-7
4. Read out a diagnosis code by observing how the
warning lamp flashes.
ABS warning lamp
ABS warning lamp

AC311052 AB
When the diagnosis code No.24 is set When no diagnosis code is set
0.5 sec. 0.25 sec.

1.5 secs.
0.5 sec.
Illuminated
Illuminated
Switched Switched
off off
Pause Tens Place Units
ACX01778 AD
time signal division signal
3 secs. 2 secs.
ACX01777 AD
5. Turn the ignition switch to the "LOCK" (OFF) 6. Disconnect special tool diagnosis code check
position. harness (MB991529).
TROUBLESHOOTING
ERASING DIAGNOSIS CODES

WHEN USING THE M.U.T.-II/III Diagnosis connector
WHEN NOT USING THE M.U.T.-II/III MB991529

NOTE: If the ABS-ECU functions have stopped due
to the fail-safe function, the diagnosis code cannot
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
be erased.
AC211895AB
position. 2. Use special tool diagnosis code check harness
(MB991529) to earth terminal number 1 of the
diagnosis connector.
ON
Ignition switch
OFF(OFF)
ON
Stop lamp switch
OFF
ON
ABS warning lamp
OFF
3 seconds
ABS-ECU memory
Within Within Within

1 1
Within Within Within Within Within Within Within Within
1 1 1 1 1 1 1 1
1
3 seconds seconds seconds seconds seconds seconds seconds seconds seconds seconds seconds
seconds
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
Erasing of ABS-ECU
diagnosis codes complete.
AC000937AD
3. Depress the brake pedal and hold it. 6. Turn the ignition switch to the "LOCK" (OFF)
4. Turn the ignition switch to the "ON" position. position.
5. After turning the ignition switch to the "ON", 7. Disconnect special tool diagnosis code check
release the pedal within three seconds. Repeat harness (MB991529).
this process of pressing and releasing the brake
pedal 10 continuous times.
TROUBLESHOOTING
35B-9
CODE
M1352011300797
Follow the inspection chart that is appropriate for the diagnosis code.
Diagnosis code Inspection item Reference page

No.
11 Front right wheel speed sensor (Open circuit or short-circuit) <LH drive vehicle>
12 Front left wheel speed sensor (Open circuit or short-circuit) P.35B-11, <RH drive
vehicle> P.35B-47
13 Rear right wheel speed sensor (Open circuit or short-circuit)
14 Rear left wheel speed sensor (Open circuit or short-circuit)
16 ABS-ECU power supply system (abnormal voltage drop or <LH drive vehicle>
rise) P.35B-19, <RH drive
vehicle> P.35B-55
21 Front right wheel speed sensor system <LH drive vehicle>
22 Front left wheel speed sensor system P.35B-11, <RH drive
vehicle> P.35B-47
23 Rear right wheel speed sensor system
24 Rear left wheel speed sensor system
32 Longitudinal G-sensor system <LH drive vehicle>
P.35B-22, <RH drive
vehicle> P.35B-58
41 Front right solenoid valve system <LH drive vehicle>
42 Front left solenoid valve system P.35B-29, <RH drive
vehicle> P.35B-65
43 Rear right solenoid valve system
44 Rear left solenoid valve system
51 Valve relay ON problem Replace the brake
modulator hydraulic unit
(Integrated with
ABS-ECU).
52 Valve relay problem (stays off) <LH drive vehicle>
53 Motor relay problem (stays off) P.35B-29, <RH drive
vehicle> P.35B-65
54 Motor relay ON problem Replace the brake
(Integrated with
ABS-ECU).
55 Motor system (seized pump motor) <LH drive vehicle>
P.35B-29, <RH drive
vehicle> P.35B-65
63 ABS-ECU abnormality Replace the brake
(Integrated with
ABS-ECU).
71 Lateral G-sensor system <LH drive vehicle>
P.35B-32, <RH drive
vehicle> P.35B-68
TROUBLESHOOTING
Diagnosis code Inspection item Reference page

No.
81 Steering wheel sensor (ST-1) system <LH drive vehicle>
82 Steering wheel sensor (ST-2) system P.35B-39, <RH drive
vehicle> P.35B-75
83 Steering wheel sensor (ST-N) system
NOTE: diagnosis code No.16, 52, 63
.
• Code No.16 is cleared from the memory by turning the ignition switch to the "ACC" position. When the
system is properly reset, this code is also cleared from the memory.
• Code No.52 and 63 are cleared from the memory by turning the ignition switch to the "ACC" position.
TROUBLESHOOTING
35B-11
DIAGNOSTIC TROUBLE CODE
PROCEDURES <L.H. drive vehicle>
Code No.11: Front Right Wheel Speed Sensor (Open Circuit or Short Circuit)
Code No.12: Front Left Wheel Speed Sensor (Open Circuit or Short Circuit)
Code No.13: Rear Right Wheel Speed Sensor (Open Circuit or Short Circuit)
Code No.14: Rear Left Wheel Speed Sensor (Open Circuit or Short Circuit)
Code No.21: Front Right Wheel Speed Sensor System
Code No.22: Front Left Wheel Speed Sensor System
Code No.23: Rear Right Wheel Speed Sensor System
Code No.24: Rear Left Wheel Speed Sensor System
Wheel Speed Sensor Circuit
ABS-ECU
(FRONT: LH) (FRONT: RH) (REAR: LH) (REAR: RH)
WHEEL SPEED SENSOR

Wire colour code
OPERATION • The amount of voltage generated at each wheel

• A toothed wheel speed rotor generates a voltage is determined by the clearance between the
pulse as it moves across the pickup field of each wheel speed rotor teeth and the wheel speed
wheel speed sensor. sensor, and by the speed of rotation.
TROUBLESHOOTING
• The wheel speed sensors transmit the frequency DIAGNOSIS

of the voltage pulses and the amount of voltage
generated by each pulse to the ABS-ECU.
• The hydraulic unit modulates the amount of brak- STEP 1. M.U.T.-II/III data list.
ing force individually applied to each wheel cylin- CAUTION
der. To prevent damage to M.U.T.-II/III, always turn the
ignition switch to the "LOOK" (OFF) position
DIAGNOSIS CODE SET CONDITIONS before connecting or disconnecting M.U.T.-II/III.
• Diagnosis codes 11, 12, 13, 14 are set when sig- <Using the M.U.T.-II>
nal is not input due to breakage of the wires of
one or more of the four wheel speed sensors.
• Diagnosis codes 21, 22, 23, 24 are set in the fol-
lowing cases: 16-PIN
• Open circuit is not found but no input is
received by one or more of the four wheel
speed sensors at 10 km/h or more.
• Sensor output drops due to a malfunctioning M.U.T.-II
wheel speed sensor or warped wheel speed
AC207179AB
rotor.
<Using the M.U.T.-III>
PROBABLE CAUSES
The most likely causes for these diagnosis codes to
set are:
16-PIN
Diagnosis codes 11, 12, 13, 14
• Malfunction of the wheel speed sensor
• Damaged wiring harness or connector
• Malfunction of the brake modulator hydraulic unit
Diagnosis codes 21, 22, 23, 24 MB991911
MB991824
• Malfunction of the wheel speed rotor
• Malfunction of the wheel bearing
• Excessive clearance between the wheel speed
sensor and wheel speed rotor
MB991827 AC210056AC
(1) Connect M.U.T.-II/III as shown in the illustration.

(2) Start the engine.
(3) Set M.U.T.-II/III to the data reading mode, and
TROUBLESHOOTING
35B-13
check the data list items by driving the vehicle. STEP 4. Check wheel speed sensor circuit.
• Item 11 (diagnosis code 11 or 21 is set): Front Resistance measurement at the ABS-ECU
right wheel speed sensor connector B-118.
• Item 12 (diagnosis code 12 or 22 is set): Front
left wheel speed sensor Connector: B-118
• Item 13 (diagnosis code 13 or 23 is set): Rear
right wheel speed sensor
• Item 14 (diagnosis code 14 or 24 is set): Rear B-118 (B)
left wheel speed sensor
OK: The reading on the speedometer
nearly matches the indication on
M.U.T.-II/III, when driving.
position.
Q: Is the wheel speed sensor input normal? Connector B-118
YES : This malfunction is intermittent. Refer to (harness side)
GROUP 00, How to Use
Troubleshooting/Inspection Service Points − 12 11 10 9 8 7 6 5 4 3
22 21 20 19 18 17 16 15 14 13
2 1
How to Cope With Intermittent Malfunction 34 33 32 31 30 29 28 27 26 25 24 23
P.00-5.
NO : Go to Step 2.
STEP 2. Check the wheel speed sensor

installation. AC212153AB
Q: Is the wheel speed sensor bolted securely in place (1) Disconnect the connector B-118 and measure at
at the front knuckle or the rear knuckle? the harness side.
YES : Go to Step 3. (2) Measure the resistance between the ABS-ECU
NO : Install it properly (Refer to P.35B-146). Then connector terminals.
go to Step 15 . • If diagnosis code 11 or 21 is set: between ter-
minals 29 and 30
• If diagnosis code 12 or 22 is set: between ter-
STEP 3. Inspect the wheel speed sensor and/or
minals 22 and 31
wheel speed rotor.
Refer to P.35B-147.
minals 8 and 9
Check items: • If diagnosis code 14 or 24 is set: between ter-
• Wheel speed sensor internal resistance: 1.24 − minals 6 and 7
1.64 kΩ Standard Value: 1.24 − 1.64 kΩ
• Insulation between the wheel speed sensor body
and the connector terminals Q: Is the resistance within the standard value?
• Toothed wheel speed rotor check
NO <The resistance between terminals 22 and 31 is
Q: Is the wheel speed sensor or wheel speed rotor not within the standard value.> : Go to Step 5.
damaged? NO <The resistance between terminals 29 and 30 is
YES : Replace it (Refer to P.35B-146). Then go to not within the standard value.> : Go to Step 7.
Step 15. NO <The resistance between terminals 6 and 7 is
NO : Go to Step 4. not within the standard value.> : Go to Step 9.
not within the standard value.> : Go to Step 11.
TROUBLESHOOTING
STEP 5. Check the following connectors. STEP 6. Check the following harness wires.
• •
B-118 (B) B-118 (B)
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23 34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD AC211901AD
ABS-ECU connector B-118

• Connector: A-03
Connector: A-29
A-03 (B)
A-29 (B)
1 2 3 4
Harness side
5 6 7 8 2 1
AC211899AC
AC211262 AX
The wire between ABS-ECU connector B-118 (termi-
Intermediate connector A-29 nal 22) and front wheel speed sensor (LH) con-
•
nector A-03 (terminal 2)

Connector: A-03
• The wire between ABS-ECU connector B-118
(terminal 31) and front wheel speed sensor (LH)
connector A-03 (terminal 1)
Q: Is any harness wire damaged?
A-03 (B)
YES : Repair or replace it and then go to Step 15.
NO : Go to Step 15.
Harness side
2 1
AC211899AC
Front wheel speed sensor (LH) connector A-03

Check the connectors for loose, corroded or dam-
aged terminals, or terminals pushed back in the con-
nector.
Q: Are the connectors and terminals in good
condition?
YES : Go to Step 6.
NO : Repair it and then go to Step 15.
TROUBLESHOOTING
35B-15
• •
B-118 (B) B-118 (B)
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23 34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD AC211901AD
ABS-ECU connector B-118 Connector: A-27

•
Connector: C-111
A-27 (B)
Harness side
5 4 3 2 1
13121110 9 8 7 6 Harness side
2 1
AC211900AC
AC211266 BN
nal 29) and front wheel speed sensor (RH) con-
Connector: C-122
(terminal 30) and front wheel speed sensor (RH)
NO : Go to Step 15.
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 AC211265 DD
Intermediate connectors C-111, C-122

•
Connector: A-27
A-27 (B)
Harness side
2 1
AC211900AC
Front wheel speed sensor (RH) connector A-27

nector.
condition?
YES : Go to Step 8.
TROUBLESHOOTING
• •
B-118 (B) B-118 (B)
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23 34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD AC211901AD
ABS-ECU connector B-118 Connector: D-13

•
Connector: C-113
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
2524 23 22 21 20 19 18 17 16 1514
D-13 (B)
Harness side
1 2
AC211902AE
AC211266 BO
nal 6) and rear wheel speed sensor (LH) connec-
Connector: C-122
tor D-13 (terminal 1)
(terminal 7) and rear wheel speed sensor (LH)
connector D-13 (terminal 2)
NO : Go to Step 15.
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 AC211265 DD
Connectors: D-13, D-34
D-34
D-13 (B)
Connector D-13 Connector D-34

(Harness side) 1 2 3
1 2 4 5 6 7 8
AC211902AD
Intermediate connectors C-113, C-122, D-34

• Rear wheel speed sensor (LH) connector D-13
nector.
condition?
TROUBLESHOOTING
35B-17
STEP 11. Check the following connectors. STEP 12. Check the following harness wires:
• •
B-118 (B) B-118 (B)
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23 34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD AC211901AD

•
D-06 (B)
Connector: C-113
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
2524 23 22 21 20 19 18 17 16 1514
Harness side
1 2
AC211902AG
AC211266 BO
nal 8) and rear wheel speed sensor (RH) connec-
Connector: C-122
(terminal 9) and rear wheel speed sensor (RH)
NO : Go to Step 15.
C-122 (L)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 AC211265 DD STEP 13. Measure the wheel speed sensor
output voltage.
D-06 (B) Refer to P.35B-138.
Output Voltage:
• When measured with a voltmeter: 42 mV or more
D-34
• When measured with an oscilloscope (maximum
voltage): 120 mV or more
Connector D-06 Connector D-34 Q: Does the voltage meet the specification?
(Harness side) 1 2 3 YES : Replace the brake modulator hydraulic unit
1 2 4 5 6 7 8
(integrated with ABS-ECU) (Refer to
AC211902AF
P.35B-143). Then go to Step 15.
Intermediate connectors C-113, C-122, D-34 NO : Go to Step 14.
• Rear wheel speed sensor (RH) connector D-06
nector.
condition?
TROUBLESHOOTING
STEP 14. Check the wheel bearing. STEP 15. Check whether the diagnosis code is
Refer to GROUP 26, On-vehicle Service − Wheel reset.
Bearing Axial Play Check <Front>P.26-6 or GROUP <Using the M.U.T.-II>
27, On-vehicle Service − Wheel Bearing Axial Play
Check <Rear>P.27-30. If play on the wheel bearing
is not within the limit, replace the wheel bearing.
Limit: 0.05 mm 16-PIN
Q: Is play on the wheel bearing within the standard

value?
YES : Go to Step 15. M.U.T.-II
NO : Replace it and then go to Step 15.
AC207179AB
16-PIN
MB991911
MB991824
MB991827 AC210056AC
Check again if the diagnosis code is set.

(1) Turn the ignition switch to the "ON" position.
(2) Erase the diagnosis code.
position.
(5) Check if the diagnosis code is set.
position.
Q: Do the diagnosis codes 11, 12, 13, 14, 21, 22, 23 or
24 reset?
YES : Go to Step 1.
NO : The procedure is complete.
TROUBLESHOOTING
35B-19
Code No.16: ABS-ECU Power Supply System (abnormal voltage drop or rise)
Power Supply Circuit
IGNITION
SWITCH (IG2)
ABS-ECU
POWER
SUPPLY
Wire colour code

OPERATION DIAGNOSIS
The ABS-ECU power is supplied to the ABS-ECU
(terminal 10) from the ignition switch (IG2) through STEP 1. Check the battery.
the multi-purpose fuse number 12 in the junction Refer to GROUP 54A, Battery − On-vehicle Service
block. − Battery Test P.54A-5.
DIAGNOSIS CODE SET CONDITIONS Q: Is the battery damaged?
Output is provided when ABS-ECU power supply YES : Charge or replace the battery and then go
voltage drops below or rises above the normal value. to Step 5.
NO : Go to Step 2.
Output is not provided if power supply voltage
returns to normal voltage.
STEP 2. Check the charging system.
PROBABLE CAUSES Refer to GROUP 16, Charging System − On-vehicles
The most likely causes for this diagnosis code to set Service P.16-5.
are: Q: Is the charging system damaged?
• Malfunction of battery YES : Repair the Charging System and then go to
• Damaged wiring harness and connector Step 5.
• Malfunction of brake modulator hydraulic unit and NO : Go to Step 3.
ABS-ECU
TROUBLESHOOTING

STEP 3. Check the following connectors.
•
condition?
Connector: B-118 YES : Go to Step 4.
B-118 (B) STEP 4. Check the following harness wire.

Connector: B-118
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 B-118 (B)
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

• Harness side
Connector: C-124
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector: C-211
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 2122 23 24 25
AC211265 AR
Intermediate connector C-124 Harness side

•
2 1
Connectors: C-210, C-211 Junction block 6 5 4 3
(Front view) AC211269 AL
C-211 The wire between ABS-ECU connector B-118 (termi-

nal 10) and junction block connector C-211 (terminal
2)
Q: Is the harness wire damaged?
C-210 YES : Repair or replace it and then go to Step 5.
NO : Go to Step 5.
Junction block
(Front view)
Connector C-210
(Harness side)
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Connector C-211
(Harness side)
2 1
6 5 4 3
AC212152 AC
Junction block connectors C-210, C-211

nector.
TROUBLESHOOTING
35B-21
STEP 5. Check whether the diagnosis code is (2) Erase the diagnosis code.
reset. (3) Turn the ignition switch to the "LOCK" (OFF)
position.
<Using the M.U.T.-II> (4) Turn the ignition switch to the "ON" position.
16-PIN position.
Q: Does diagnosis code No.16 reset?
YES : Start over at Step 1.
M.U.T.-II
AC207179AB
16-PIN
MB991911
MB991824
MB991827 AC210056AC

TROUBLESHOOTING
Code No.32: Longitudinal G-Sensor System
Longitudinal G-Sensor Circuit
IGNITION
SWITCH (IG2)
G-SENSOR
(LONGITUDINAL)
ABS-ECU
Wire colour code

OPERATION • If the G-sensor output power does not change

The G-sensor detects the acceleration level in the (G-sensor output fastening).
forward/reverse direction of the vehicle, converts the
signals into voltage signals and then sends that sig- PROBABLE CAUSES
nal to the ABS-ECU. The most likely causes for this diagnosis code to set
are:
DIAGNOSIS CODE SET CONDITIONS • Malfunction of the G-sensor
This code is set in the following case. • Damaged wiring harness and connector
• When the G-sensor output is 0.5 V or lower or • Malfunction of the brake modulator hydraulic unit
4.5 V or higher (disconnected G-sensor or G-sen- (integrated with ABS-ECU)
sor short circuit)
TROUBLESHOOTING
35B-23
DIAGNOSIS (2) Start the engine.
(3) Set M.U.T.-II/III to data reading mode for following
STEP 1.M.U.T.-II/III data list. item.
• Item 32: Longitudinal G-sensor
CAUTION
OK:
To prevent damage to M.U.T.-II/III, always turn the
When vehicle is stationary (level): 2.4 −
2.6 V
before connecting or disconnecting M.U.T.-II/III.
When vehicle is being driven: 1.0 − 4.0 V
<Using the M.U.T.-II>
Q: Is the longitudinal G-sensor input normal?
YES : This malfunction is intermittent. Refer to
16-PIN Troubleshooting/Inspection Service Points −
How to Cope With Intermittent Malfunction
P.00-5.
NO : Go to Step 2.
M.U.T.-II
AC207179AB STEP 2. Check the power supply circuit. Voltage

measurement at longitudinal G-sensor connector
<Using the M.U.T.-III> D-38.
Connector: D-38
16-PIN
D-38 (B)
MB991911
MB991824
Connector D-38
(Harness side)
3 2 1
MB991827 AC210056AC

AC212253AB
(1) Disconnect connector D-38, and check at the

harness side.
(3) Measure the voltage between terminal 1 and
earth.
OK: System voltage
YES : Go to Step 3.
NO : Go to Step 4.
TROUBLESHOOTING
STEP 3. Check the earth circuit. Resistance STEP 4. Check the following connectors.
measurement at longitudinal G-sensor
•
Connector: D-38
connector D-38.
Connector: D-38
D-38 (B)
Harness side
D-38 (B) 3 2 1
AC208854AE
Longitudinal G-sensor connector D-38

•
Connectors: C-211, C-214
C-211
Connector D-38
(Harness side)
AD
3 2 1
C-214
Junction block Connector C-211

AC212253AC (Harness side)
(Front view)
(1) Disconnect connector D-38, and check at the 2 1
harness side. 6 5 4 3
(2) Measure the resistance between terminal 3 and Connector C-214

earth. (Harness side)
OK: 2 ohms or less
Q: Is the resistance 2 ohms or less. 14 13 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 8. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
NO : Go to Step 6.
AC212152AD

nector.
condition?
YES : Go to Step 5.
TROUBLESHOOTING
35B-25
STEP 5. Check the following harness wire. STEP 6. Check the following connectors.
• •
D-38 (B) D-38 (B)

3 2 1 3 2 1
AC208854AE AC208854AE

Connector: C-211 •
Connector: C-124
Harness side
2 1
Junction block 6 5 4 3
(Front view) 1 2 3 4 5 6 7 8 9 10 11 12 13
AC211269 AL
14 15 16 17 18 19 20 2122 23 24 25
AC211265 AR
The wire between longitudinal G-sensor connector
D-38 (terminal 1) and junction block connector Intermediate connector C-124
C-211 (terminal 2)
•
Connector: B-118
NO : Go to Step 11.
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

nector.
condition?
YES : Go to Step 7.
TROUBLESHOOTING
STEP 7. Check the following harness wire. STEP 8. Check longitudinal G-sensor output
voltage.
•
Connector: D-38
Label
D-38 (B) MB991348

Harness side
3 2 1
AC208854AE
Connector: B-118 Connector: D-38

(Harness side)
B-118 (B) Label
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD
The wire between longitudinal G-sensor connector AC103662AG

D-38 (terminal 3) and ABS-ECU connector B-118 (1) Disconnect connector D-38, and then connect
(terminal 15) special tool harness set (MB991348) between
Q: Is the harness wire damaged? terminals of the disconnected connectors.
YES : Repair or replace it and then go to Step 11. (2) Turn the ignition switch to the "ON" position.
NO : Go to Step 11. (3) Measure the voltage between terminal 2 and
earth.
OK:
When the longitudinal G-sensor is placed
on a level plane: 2.4 − 2.6 volts
with its label positioned as shown: 3.4 −
3.6 volts
Q: Is the longitudinal G-sensor output voltage
normal?
YES : Go to Step 9.
NO : Replace the longitudinal G-sensor (Refer to
TROUBLESHOOTING
35B-27
STEP 9. Check the following connectors. STEP 10. Check the following harness wire.
• •
D-38 (B) D-38 (B)

3 2 1 3 2 1
AC208854AE AC208854AE
Longitudinal G-sensor connector D-38 Connector: B-118

•
Connector: C-122
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
C-122 (L) 34 33 32 31 30 29 28 27 26 25 24 23
1 2 3 4 5 6 7 8 9 10 11 AC211901AD
12 13 14 15 16 17 18 19 20 21 22 AC211265 DD
Intermediate connector C-122 D-38 (terminal 2) and ABS-ECU connector B-118
Connector: B-118
•
(terminal 25)
NO : Replace the brake modulator hydraulic unit
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

nector.
condition?
TROUBLESHOOTING
position.
16-PIN position.
M.U.T.-II
AC207179AB
16-PIN
MB991911
MB991824
MB991827 AC210056AC

TROUBLESHOOTING
35B-29
Code No.41: Front Right Solenoid Valve inside Hydraulic Unit

Code No.42: Front Left Solenoid Valve inside Hydraulic Unit
Code No.43: Rear Right Solenoid Valve inside Hydraulic Unit
Code No.44: Rear Left Solenoid Valve inside Hydraulic Unit
Code No.52: Valve Relay Problem (Stays off)
Code No.53: Motor Relay Problem (Stays off)
Code No.55: Motor System (Seized Pump Motor)
Solenoid Valve and Motor Power Supply Circuit

FUSIBLE
LINK 3
HYDRAULIC UNIT
MOTOR SOLENOID VALVE
SOLENOID MOTOR
VALVE POWER POWER
SUPPLY SUPPLY
ABS-ECU
Wire colour code

B : Black LG : Light green G : Green L : Blue
W : White Y : Yellow SB : Sky blue BR : Brown
O : Orange GR : Gray R : Red P : Pink V : Violet

Power is continuously supplied to the ABS-ECU The most likely causes for these diagnosis codes to
through fusible link number 3 to operate the solenoid set are:
valve and motor. • Damaged wiring harness or connector
DIAGNOSIS CODE SET CONDITIONS (integrated with ABS-ECU)
These codes are displayed if the power supply circuit
of solenoid valve or motor is open or shorted.
TROUBLESHOOTING
DIAGNOSIS STEP 2. Check the following connectors.

•
Connector: B-118
STEP 1. Check the solenoid valve or motor power
supply circuit. Voltage measurement at ABS-ECU
connector B-118.
B-118 (B)
Connector: B-118
Harness side
B-118 (B) 12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

•
Connector: A-12
A-12 (B)
Connector B-118
(Harness side)
12 11 10 9 8 7 6 5 4 3 2 1 1 2
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211262AY
Intermediate connector A-12

Check the connectors, for loose, corroded or dam-
AC212153AD
nector.
(1) Disconnect ABS-ECU connector B-118 and
measure at the harness side. Q: Are the connectors and terminals in good
(2) Measure the voltage between terminal 11 and condition?
YES : Go to Step 3.
earth, and 33 and earth.
OK: System voltage
YES : Replace the brake modulator hydraulic unit
NO : Go to Step 2.
TROUBLESHOOTING
35B-31
STEP 3. Check the following harness wires. STEP 4. Check whether the diagnosis code is
reset.
•
Fusible link: No.3

No.3 16-PIN
M.U.T.-II
AC208825 AL
AC207179AB
Connector: B-118
B-118 (B)
16-PIN
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD
The wire between fusible link No.3 and ABS-ECU

connector B-118 (terminal 11) MB991911
• The wire between fusible link No.3 and ABS-ECU

NO : Go to Step 4.
MB991827 AC210056AC

position.
position.
Q: Do diagnosis codes 41, 42, 43, 44, 52, 53 or 55
reset?
YES : Return to Step 1.
TROUBLESHOOTING
Code No.71: Lateral G-Sensor System
Lateral G-Sensor Circuit
IGNITION
SWITCH (IG2)
G-SENSOR
(LATERAL)
ABS-ECU
Wire colour code

OPERATION • If the lateral G-sensor output power does not

The lateral G-sensor detects the acceleration level in change (lateral G-sensor output fastening).
the left/right direction of the vehicle, converts the sig-
nals into voltage signals and then sends that signal PROBABLE CAUSES
to the ABS-ECU. The most likely causes for diagnosis code to set are:
• Malfunction of the lateral G-sensor
DIAGNOSIS CODE SET CONDITIONS • Damaged wiring harness and connector
This code is set in the following cases: • Malfunction of the brake modulator hydraulic unit
• When the G-sensor output is 0.5 V or lower or (integrated with ABS-ECU)
4.5 V or higher (disconnected lateral G-sensor or
lateral G-sensor short circuit)
TROUBLESHOOTING
35B-33
item.
STEP 1.M.U.T.-II/III data list. • Item 71: Lateral G-sensor
CAUTION OK:
To prevent damage to M.U.T.-II/III, always turn the When vehicle is stationary (level): 2.4 − 2.6
ignition switch to the "LOOK" (OFF) position V
before connecting or disconnecting M.U.T.-II/III. When vehicle is being driven: 1.0 − 4.0 V
<Using the M.U.T.-II> Q: Is the lateral G-sensor input normal?
P.00-5.
NO : Go to Step 2.
M.U.T.-II
AC207179AB
STEP 2. Check the power supply circuit. Voltage
measurement at lateral G-sensor connector D-37.
Connector: D-37
16-PIN
D-37 (B)
MB991911
MB991824
Connector D-37
(Harness side)
3 2 1
MB991827 AC210056AC
AC212253AD
harness side.
earth.
OK: System voltage
YES : Go to Step 3.
NO : Go to Step 4.
TROUBLESHOOTING
•
Connector: D-37
Connector: D-37
D-37 (B)
D-37 (B)
Harness side
3 2 1
AC208854AF
Lateral G-sensor connector D-37

•
Connector D-37 C-211

(Harness side)
AD
3 2 1
C-214
AC212253AE
(1) Disconnect connector D-37, and check at the (Front view) (Harness side)
harness side. 2 1
(2) Measure the resistance between terminal 3 and 6 5 4 3
earth. Connector C-214

OK: 2 ohms or less (Harness side)
Q: Is the resistance 2 ohms or less?

YES : Go to Step 8. 14 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Go to Step 6. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC212152AD

nector.
condition?
YES : Go to Step 5.
TROUBLESHOOTING
35B-35
•
D-37 (B) D-37 (B)
3 2 1 3 2 1
AC208854AF AC208854AF

Connector: C-211 •
Connector: C-122
Harness side
2 1
C-122 (L)
(Front view) AC211269 AL 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 AC211265 DD
The wire between lateral G-sensor connector D-37
(terminal 1) and junction block connector C-211 (ter- Intermediate connector C-122
minal 2)
•
Connector: B-118
NO : Go to Step 11.
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

nector.
condition?
YES : Go to Step 7.
TROUBLESHOOTING
STEP 7. Check the following harness wire. STEP 8. Check lateral G-sensor output voltage.
Connector: D-37
Label
MB991348
D-37 (B)
Harness side
3 2 1
AC208854AF
Connector: D-37 (Harness side)
Connector: B-118
Label
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD
AC103662AP
The wire between lateral G-sensor connector D-37 (1) Disconnect connector D-37, and then connect
(terminal 3) and ABS-ECU connector B-118 (terminal special tool harness set (MB991348) between
24) terminals of the disconnected connectors.
Q: Is the harness wire damaged? (2) Turn the ignition switch to the "ON" position.
YES : Repair or replace it and then go to Step 11. (3) Measure the voltage between terminal 2 and
NO : Go to Step 11. earth.
OK:
When the lateral G-sensor is placed on a
level plane: 2.4 − 2.6 volts
When the lateral G-sensor is placed with its
label positioned as shown: 3.4 − 3.6 volts
Q: Is the lateral G-sensor output voltage normal?
YES : Go to Step 9.
NO : Replace the lateral G-sensor (Refer to
TROUBLESHOOTING
35B-37
•
D-37 (B) D-37 (B)
3 2 1 3 2 1
AC208854AF AC208854AF
Lateral G-sensor connector D-37 Connector: B-118

•
Connector: C-122
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
C-122 (L) 34 33 32 31 30 29 28 27 26 25 24 23
1 2 3 4 5 6 7 8 9 10 11 AC211901AD
12 13 14 15 16 17 18 19 20 21 22 AC211265 DD
Intermediate connector C-122 (terminal 2) and ABS-ECU connector B-118 (terminal
Connector: B-118
•
14)
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

nector.
condition?
TROUBLESHOOTING
position.
16-PIN position.
M.U.T.-II
AC207179AB
16-PIN
MB991911
MB991824
MB991827 AC210056AC

TROUBLESHOOTING
35B-39
Code No.81: Steering Wheel Sensor (ST-1) System

Code No.83: Steering Wheel Sensor (ST-N) System
Steering Wheel Sensor Circuit

IGNITION
SWITCH (IG2)
ABS-ECU
STEERING
WHEEL
SENSOR
ST-1 ST-2 ST-N
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
OPERATION DIAGNOSIS CODE SET CONDITIONS

The steering wheel sensor monitors the steering Diagnosis code No.81 (ST-1), No.82 (ST-2) and
angle and sends the ST-1, ST-2 and ST-N signals. No.83 (ST-N) are set if there is a fault in the steering
The ABS-ECU calculates the steering angle by read- wheel sensor, an open circuit or short circuit in the
ing the signals from the steering wheel sensor. signal lines, or the internal circuit in the hydraulic unit
and ABS-ECU is defective.
TROUBLESHOOTING
PROBABLE CAUSES (2) Start the engine.

The most likely causes for these diagnosis codes to (3) Set M.U.T.-II/III to data reading mode for following
set are: items.
• Malfunction of the steering wheel sensor • Item 74: Steering wheel (ST−N)
• Damaged wiring harness and connector • Item 75: Steering wheel (ST−1)
• Malfunction of the brake modulator hydraulic unit • Item 76: Steering wheel (ST−2)
(integrated with ABS-ECU) OK:
DIAGNOSIS Item Check item Checking Display

No. requirement
74 Steering Steering: Neutral ON
STEP 1. M.U.T.-II/III data list. wheel sensor position and
CAUTION (ST-N) position near by
To prevent damage to M.U.T.-II/III, always turn the ± 360°
Steering: Except OFF
for above
75 Steering Steering: Turn Display
wheel sensor laterally slowly. ON and
(ST-1) OFF
16-PIN 76 Steering alternately
wheel sensor
(ST-2)
M.U.T.-II Q: Is the steering wheel sensor input normal?
AC207179AB GROUP 00, How to Use
Troubleshooting/Inspection Service Points −
P.00-5.
NO : Go to Step 2.
16-PIN
MB991911
MB991824
MB991827 AC210056AC

TROUBLESHOOTING
35B-41
STEP 2. Check the power supply circuit. Voltage STEP 3. Check the earth circuit. Resistance
measurement at steering wheel sensor measurement at steering wheel sensor
connector C-230. connector C-230.
Connector C-230 Connector C-230

(Harness side) (Harness side)
1 1
5 4 3 2 5 4 3 2
AC212249AB AC212249AC
(1) Disconnect connector C-230, and check at the (1) Disconnect connector C-230, and check at the
harness side. harness side.
(2) Turn the ignition switch to the "ON" position. (2) Measure the resistance between terminal 3 and
(3) Measure the voltage between terminal 2 and earth.
earth. OK: 2 ohms or less
OK: System voltage Q: Is the resistance 2 ohms or less?
Q: Is the check result normal? YES : Go to Step 8.
YES : Go to Step 3. NO : Go to Step 6.
NO : Go to Step 4.
TROUBLESHOOTING

•
condition?
Connector: C-230 YES : Go to Step 5.
STEP 5. Check the following harness wire.

Connector: C-230
Harness side
1
5 4 3 2
AC211267AL
Steering wheel sensor connector C-230

•
Connectors: C-210, C-211 Harness side

1
5 4 3 2
AC211267AL
C-211
Connector: C-211
C-210
Junction block Harness side

(Front view) 2 1
Connector C-210 (Front view) AC211269 AL

(Harness side)
The wire between steering wheel sensor connector
6 5 4 3 2 1
14 13 12 11 10 9 8 7 C-230 (terminal 2) and junction block connector
C-211 (terminal 2)
Connector C-211
(Harness side)
2 1
6 5 4 3 NO : Go to Step 11.
AC212152 AC

•
Connector: C-101
C-101 (L)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 AC211265DE
Joint connector C-101

nector.
TROUBLESHOOTING
35B-43
•

1 1
5 4 3 2 5 4 3 2
AC211267AL AC211267AL

• Earth
Connector: C-06
1 2 3 4 5 6 7 8 9 10 11
C-06 (GR)
12 13 14 15 16 17 18 19 20 21 22
No.3
AC211266BP

nector.
condition?
YES : Go to Step 7.
NO : Repair it and then go to Step 11. AC211896 AB
TROUBLESHOOTING
Earth STEP 8. Check steering wheel sensor output

voltage.
Connector: C-230
Connector C-230
(Harness side)
1
5 4 3 2
NO.14
AC211898AB
C-230 (terminal 3) and earth (No.3, No.14)
Q: Is any harness wire damaged? AC212249AD
NO : Go to Step 11. (1) Connect steering wheel sensor connector C-230.
Variations in voltage when turning the
steering wheel
Voltage
2.7 - 4.4 V
0.8 - 2.1 V
Time
AC211894 AB
(3) Measure the voltage, by backprobing, between

terminal 1 and earth, terminal 4 and earth, and
terminal 5 and earth.
OK: The voltage should measure as indi-
cated in the figure.
Q: Is the steering wheel sensor output voltage
normal?
YES : Go to Step 9.
NO : Replace the steering wheel sensor (Refer to
TROUBLESHOOTING
35B-45
• •

1 1
5 4 3 2 5 4 3 2
AC211267AL AC211267AL
Steering wheel sensor connector C-230 Connector: B-118

•
Connector: C-122
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
C-122 (L) 34 33 32 31 30 29 28 27 26 25 24 23
1 2 3 4 5 6 7 8 9 10 11 AC211901AD
12 13 14 15 16 17 18 19 20 21 22 AC211265 DD
If diagnosis code No.81 (ST-1) is set: The wire
Intermediate connector C-122 between steering wheel sensor connector C-230
Connector: B-118
•
(terminal 5) and ABS-ECU connector B-118 (ter-

minal 26)
• If diagnosis code No.82 (ST-2) is set: The wire
between steering wheel sensor connector C-230
B-118 (B) (terminal 4) and ABS-ECU connector B-118 (ter-
minal 17)
• If diagnosis code No.83 (ST-N) is set: The wire
Harness side
12 11 10 9 8 7 6 5 4 3 2 1 (terminal 1) and ABS-ECU connector B-118 (ter-
34
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23 minal 4)
AC211901AD
ABS-ECU connector B-118 Q: Is any harness wire damaged?

nector.
condition?
TROUBLESHOOTING
position.
16-PIN position.
Q: Does diagnosis code No.81, 82 and/or 83 reset?
M.U.T.-II
AC207179AB
16-PIN
MB991911
MB991824
MB991827 AC210056AC

TROUBLESHOOTING
35B-47
PROCEDURES <R.H. drive vehicle>
Code No.11: Front Right Wheel Speed Sensor (Open Circuit or Short Circuit)
Code No.12: Front Left Wheel Speed Sensor (Open Circuit or Short Circuit)
Code No.13: Rear Right Wheel Speed Sensor (Open Circuit or Short Circuit)
Code No.14: Rear Left Wheel Speed Sensor (Open Circuit or Short Circuit)
Code No.21: Front Right Wheel Speed Sensor System
Code No.22: Front Left Wheel Speed Sensor System
Code No.23: Rear Right Wheel Speed Sensor System
Code No.24: Rear Left Wheel Speed Sensor System
Wheel Speed Sensor Circuit
ABS-ECU
Wire colour code

(FRONT: LH) (FRONT: RH) (REAR: LH) (REAR: RH) G : Green L : Blue
WHEEL SPEED SENSOR R : Red P : Pink V : Violet
OPERATION • The amount of voltage generated at each wheel

• A toothed wheel speed rotor generates a voltage is determined by the clearance between the
pulse as it moves across the pickup field of each wheel speed rotor teeth and the wheel speed
wheel speed sensor. sensor, and by the speed of rotation.
• The wheel speed sensors transmit the frequency
of the voltage pulses and the amount of voltage
generated by each pulse to the ABS-ECU.
TROUBLESHOOTING
• The hydraulic unit modulates the amount of brak- DIAGNOSIS

ing force individually applied to each wheel cylin-
der.
DIAGNOSIS CODE SET CONDITIONS CAUTION
• Diagnosis codes 11, 12, 13, 14 are set when sig- To prevent damage to M.U.T.-II/III, always turn the
nal is not input due to breakage of the wires of ignition switch to the "LOOK" (OFF) position
one or more of the four wheel speed sensors. before connecting or disconnecting M.U.T.-II/III.
• Diagnosis codes 21, 22, 23, 24 are set in the fol-
lowing cases:
Steering shaft
• Open circuit is not found but no input is
received by one or more of the four wheel
speed sensors at 10 km/h (6 mph) or more.
• Sensor output drops due to a malfunctioning
wheel speed sensor or warped wheel speed
rotor.
MB991502
PROBABLE CAUSES AC311157AB
The most likely causes for these diagnosis codes to
set are: <Using the M.U.T.-III>
16-PIN
(integrated with ABS-ECU) MB991911
• Malfunction of the wheel speed rotor
MB991824
• Malfunction of the wheel bearing
• Excessive clearance between the wheel speed
sensor and wheel speed rotor
MB991827 AC311153AB

(3) Set M.U.T.-II/III to the data reading mode, and
TROUBLESHOOTING
35B-49
check the data list items by driving the vehicle. STEP 4. Check wheel speed sensor circuit.
• Item 11 (diagnosis code 11 or 21 is set): Front Resistance measurement at the ABS-ECU
right wheel speed sensor connector B-118.
• Item 12 (diagnosis code 12 or 22 is set): Front
left wheel speed sensor Connector: B-118
right wheel speed sensor
left wheel speed sensor
OK: The reading on the speedometer
nearly matches the indication on
M.U.T.-II/III, when driving. B-118 (B)
position.
Q: Is the wheel speed sensor input normal?
YES : This malfunction is intermittent. Refer to Connector B-118
GROUP 00, How to Use (harness side)
How to Cope With Intermittent Malfunction 12 11 10 9 8 7 6 5 4 3
22 21 20 19 18 17 16 15 14 13
2 1
P.00-5. 34 33 32 31 30 29 28 27 26 25 24 23
NO : Go to Step 2.
STEP 2. Check the wheel speed sensor

installation. AC311124 AB
Q: Is the wheel speed sensor bolted securely in place (1) Disconnect the connector B-118 and measure at
at the front knuckle or the rear knuckle? the harness side.
YES : Go to Step 3. (2) Measure the resistance between the ABS-ECU
NO : Install it properly (Refer to P.35B-146). Then connector terminals.
go to Step 15 . • If diagnosis code 11 or 21 is set: between ter-
minals 29 and 30
STEP 3. Inspect the wheel speed sensor and/or
minals 22 and 31
wheel speed rotor.
Refer to P.35B-147.
minals 8 and 9
Check items: • If diagnosis code 14 or 24 is set: between ter-
• Wheel speed sensor internal resistance: 1.24 − minals 6 and 7
1.64 kΩ Standard Value: 1.24 − 1.64 kΩ
• Insulation between the wheel speed sensor body
and the connector terminals Q: Is the resistance within the standard value?
• Toothed wheel speed rotor check
Q: Is the wheel speed sensor or wheel speed rotor not within the standard value.> : Go to Step 5.
damaged? NO <The resistance between terminals 29 and 30 is
YES : Replace it (Refer to P.35B-146). Then go to not within the standard value.> : Go to Step 7.
Step 15 . NO <The resistance between terminals 6 and 7 is
NO : Go to Step 4. not within the standard value.> : Go to Step 9.
not within the standard value.> : Go to Step 11.
TROUBLESHOOTING
• •
B-118 (B) B-118 (B)

12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23 34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB AC311127AB

• Connector: A-03
Connector: C-31
A-03 (B)
C-31 Harness side

2 1
AC211899AC
AC311160AB
Intermediate connector C-31 nal 22) and front wheel speed sensor (LH) con-
•
Connector: A-03
(terminal 31) and front wheel speed sensor (LH)
A-03 (B)
NO : Go to Step 15.
Harness side
2 1
AC211899AC
Front wheel speed sensor (LH) connector A-03

nector.
condition?
YES : Go to Step 6.
TROUBLESHOOTING
35B-51
• •
B-118 (B) B-118 (B)

12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23 34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB AC311127AB

• Connector: A-03
Connector: C-111
A-03 (B)
C-111
Harness side
2 1
AC211899AC
AC311161AB
nal 29) and front wheel speed sensor (RH) con-
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11 • The wire between ABS-ECU connector B-118
12 13 14 15 16 17 18 19 20 21 22
(terminal 30) and front wheel speed sensor (RH)
C-122 (L) NO : Go to Step 15.
AC311160AC
Intermediate connectors C-111, C-122

•
Connector: A-27
A-27 (B)
Harness side
2 1
AC211900AC
Front wheel speed sensor (RH) connector A-27

nector.
condition?
YES : Go to Step 8.
TROUBLESHOOTING
•
STEP 9. Check the following connectors. Connector: D-13 Harness side

•
Connector: B-118 1 2
B-118 (B)
Harness side D-13
12 11 10 9 8 7 6 5 4 3 2 1 AC311163AB
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB Rear wheel speed sensor (LH) connector D-13
ABS-ECU connector B-118 Check the connectors for loose, corroded or dam-
• aged terminals, or terminals pushed back in the con-
Connector: C-112 nector.
condition?
C-112 (RG)
STEP 10. Check the following harness wires.
•
Connector: B-118
AC311161AC
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
C-122 (L)
Connector: D-13 Harness side
AC311160AC
1 2
Connector: D-34
D-13
D-34
AC311163AB

AC311162AB nal 6) and rear wheel speed sensor (LH) connec-
(terminal 7) and rear wheel speed sensor (LH)
NO : Go to Step 15.
TROUBLESHOOTING
35B-53
•
STEP 11. Check the following connectors. Connector: D-06 Harness side
•
1 2
Connector: B-118
D-06 (B)
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1 AC311163AC
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB Rear wheel speed sensor (RH) connector D-06
ABS-ECU connector B-118 Check the connectors for loose, corroded or dam-
• aged terminals, or terminals pushed back in the con-
Connector: C-112 nector.
condition?
C-112 (RG)
STEP 12. Check the following harness wires:
•
Connector: B-118
AC311161AC
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
C-122 (L)
Connector: D-06 Harness side
AC311160AC
1 2
Connector: D-34
D-06 (B)
D-34
AC311163AC

AC311162AB nal 8) and rear wheel speed sensor (RH) connec-
(terminal 9) and rear wheel speed sensor (RH)
NO : Go to Step 15.
TROUBLESHOOTING
STEP 13. Measure the wheel speed sensor STEP 15. Check whether the diagnosis code is
output voltage. reset.
Refer to P.35B-138.
Output Voltage: Steering shaft
• When measured with a voltmeter: 42 mV or more
• When measured with an oscilloscope (maximum
voltage): 120 mV or more
Q: Does the voltage meet the specification?
(integrated with ABS-ECU) (Refer to MB991502
AC311157AB
NO : Go to Step 14.
STEP 14. Check the wheel bearing.
Refer to GROUP 26, On-vehicle Service − Wheel
Bearing End Play Check <Front>P.26-6 or GROUP
27, On-vehicle Service − Wheel Bearing End Play 16-PIN
Check <Rear>P.27-30. If play on the wheel bearing
is not within the limit, replace the wheel bearing.
Limit: 0.05 mm (0.002 inch)
Q: Is play on the wheel bearing within the standard
value?
MB991911
NO : Replace it and then go to Step 15.
MB991824
MB991827 AC311153AB

position.
position.
Q: Do the diagnosis codes 11, 12, 13, 14, 21, 22, 23 or
24 reset?
YES : Go to Step 1.
TROUBLESHOOTING
35B-55
Code No.16: ABS-ECU Power Supply System (abnormal voltage drop or rise)
Power Supply Circuit
IGNITION
SWITCH (IG2)
ABS-ECU Wire colour code

POWER G : Green L : Blue
SUPPLY W : White Y : Yellow
OPERATION DIAGNOSIS
The ABS-ECU power is supplied to the ABS-ECU
(terminal 10) from the ignition switch (IG2) through STEP 1. Check the battery.
the multi-purpose fuse number 12 in the junction Refer to GROUP 54A, Battery − On-vehicle Service
block. − Battery Test P.54A-5.
DIAGNOSIS CODE SET CONDITIONS Q: Is the battery damaged?
Output is provided when ABS-ECU power supply YES : Charge or replace the battery and then go
voltage drops below or rises above the normal value. to Step 5.
NO : Go to Step 2.
Output is not provided if power supply voltage
returns to normal voltage.
STEP 2. Check the charging system.
PROBABLE CAUSES Refer to GROUP 16, Charging System − On-vehicles
The most likely causes for this diagnosis code to set Service P.16-5.
are: Q: Is the charging system damaged?
• Malfunction of battery YES : Repair the Charging System and then go to
• Damaged wiring harness and connector Step 5.
• Malfunction of brake modulator hydraulic unit and NO : Go to Step 3.
ABS-ECU
TROUBLESHOOTING

•
condition?

B-118 (B) Connector: B-118
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
B-118 (B)
• Harness side
Connector: C-122
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
1 2 3 4 5 6 7 8 9 10 11 34 33 32 31 30 29 28 27 26 25 24 23
12 13 14 15 16 17 18 19 20 21 22 AC311127AB
Connector: C-211
C-122 (L)
AC311160AC
Harness side
Intermediate connector C-122 2 1
•
(Front view)
AC311165AB

C-211 nal 10) and junction block connector C-211 (terminal
C-210 2)
NO : Go to Step 5.
Junction block
(Front view)

(Harness side) (Harness side)
6 5 4 3 2 1 2 1
14 13 12 11 10 9 8 7 6 5 4 3
AC311164AB

nector.
TROUBLESHOOTING
35B-57
position.
Steering shaft (5) Check if the diagnosis code is set.
position.
MB991502
AC311157AB
16-PIN
MB991911
MB991824
MB991827 AC311153AB

TROUBLESHOOTING
Code No.32: Longitudinal G-Sensor System
Longitudinal G-Sensor Circuit

IGNITION
SWITCH (IG2)
G-SENSOR
(LONGITUDINAL)
Wire colour code

G : Green L : Blue
W : White Y : Yellow ABS-ECU
OPERATION • If the G-sensor output power does not change

The G-sensor detects the acceleration level in the (G-sensor output fastening).
forward/reverse direction of the vehicle, converts the
signals into voltage signals and then sends that sig- PROBABLE CAUSES
nal to the ABS-ECU. The most likely causes for this diagnosis code to set
are:
DIAGNOSIS CODE SET CONDITIONS • Malfunction of the G-sensor
This code is set in the following case. • Damaged wiring harness and connector
• When the G-sensor output is 0.5 V or lower or • Malfunction of the brake modulator hydraulic unit
4.5 V or higher (disconnected G-sensor or G-sen- (integrated with ABS-ECU)
sor short circuit)
TROUBLESHOOTING
35B-59
DIAGNOSIS (3) Set M.U.T.-II/III to data reading mode for following
item.
STEP 1. M.U.T.-II/III data list. • Item No.32: Longitudinal G-sensor
OK:
CAUTION
When vehicle is stationary (level): 2.4 − 2.6
V
Q: Is the longitudinal G-sensor input normal?
Steering shaft GROUP 00, How to Use
P.00-5.
NO : Go to Step 2.
MB991502
AC311157AB measurement at longitudinal G-sensor connector
D-38.
Connector: D-38
16-PIN
D-38 (B)
MB991911
MB991824
Connector D-38
(Harness side)
3 2 1
MB991827 AC311153AB
AC311166AB
(2) Start the engine. (1) Disconnect connector D-38, and check at the
harness side.
earth.
OK: System voltage
YES : Go to Step 3.
NO : Go to Step 4.
TROUBLESHOOTING
measurement at longitudinal G-sensor connector
•
Connector: D-38
D-38.
Connector: D-38
D-38 (B) Harness side
3 2 1
D-38 (B) AC311167AB

•
Connector D-38
C-211
(Harness side)
AD
3 2 1
C-214
Connector C-211
AC311166AC (Harness side)
(1) Disconnect connector D-38, and check at the Junction block 2 1
6 5 4 3
harness side. (Front view)
(2) Measure the resistance between terminal 3 and Connector C-214
earth. (Harness side)
OK: 2 ohms or less
14 13 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 8. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
NO : Go to Step 6.
AC311164AC

nector.
condition?
YES : Go to Step 5.
TROUBLESHOOTING
35B-61
•
D-38 (B) Harness side D-38 (B) Harness side
3 2 1 3 2 1
AC311167AB AC311167AB
Connector: C-211
•
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Harness side
2 1
C-122 (L)
(Front view)
AC311165AB
AC311160AC
D-38 (terminal 1) and junction block connector C-211 Intermediate connector C-122
(terminal 2)
•
Connector: B-118
NO : Go to Step 11.
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB

nector.
condition?
YES : Go to Step 7.
TROUBLESHOOTING
STEP 7. Check the following harness wire. STEP 8. Check longitudinal G-sensor output
Connector: D-38
voltage.
Label
MB991348
D-38 (B) Harness side
3 2 1
AC311167AB
Connector: B-118 Connector: D-38

(Harness side)
Label
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
The wire between longitudinal G-sensor connector AC103662AG

D-38 (terminal 3) and ABS-ECU connector B-118 (1) Disconnect connector D-38, and then connect
(terminal 15) special tool harness set (MB991348) between
Q: Is the harness wire damaged? terminals of the disconnected connectors.
YES : Repair or replace it and then go to Step 11. (2) Turn the ignition switch to the "ON" position.
NO : Go to Step 11. (3) Measure the voltage between terminal 2 and
earth.
OK:
on a level plane: 2.4 − 2.6 volts
with its label positioned as shown: 3.4 −
3.6 volts
Q: Is the longitudinal G-sensor output voltage
normal?
YES : Go to Step 9.
NO : Replace the longitudinal G-sensor (Refer to
TROUBLESHOOTING
35B-63
•
D-38 (B) Harness side D-38 (B) Harness side
3 2 1 3 2 1
AC311167AB AC311167AB
Longitudinal G-sensor connector D-38 Connector: B-118

•
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
C-122 (L) 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
AC311160AC
Intermediate connector C-122 D-38 (terminal 2) and ABS-ECU connector B-118
(terminal 25)
•
Connector: B-118
B-118 (B) P.35B-143). Then go to Step 11.
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB

nector.
condition?
TROUBLESHOOTING
position.
position.
MB991502
AC311157AB
16-PIN
MB991911
MB991824
MB991827 AC311153AB

TROUBLESHOOTING
35B-65
Code No.41: Front Right Solenoid Valve inside Hydraulic Unit

Code No.42: Front Left Solenoid Valve inside Hydraulic Unit
Code No.43: Rear Right Solenoid Valve inside Hydraulic Unit
Code No.44: Rear Left Solenoid Valve inside Hydraulic Unit
Code No.52: Valve Relay Problem (Stays off)
Code No.53: Motor Relay Problem (Stays off)
Code No.55: Motor System (Seized Pump Motor)
Solenoid Valve and Motor Power Supply Circuit

FUSIBLE
LINK 3
HYDRAULIC UNIT
SOLENOID MOTOR
VALVE POWER POWER
SUPPLY SUPPLY
ABS-ECU
Wire colour code


Power is continuously supplied to the ABS-ECU The most likely causes for these diagnosis codes to
through fusible link number 3 to operate the solenoid set are:
valve and motor. • Damaged wiring harness or connector
DIAGNOSIS CODE SET CONDITIONS (integrated with ABS-ECU)
These codes are displayed if the power supply circuit
of solenoid valve or motor is open or shorted.
TROUBLESHOOTING

•
Connector: B-118
STEP 1. Check the solenoid valve or motor power
supply circuit. Voltage measurement at ABS-ECU
connector B-118.
Connector: B-118
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB

•
B-118 (B) Connector: A-12
A-12 (B) 1 2
Connector B-118
(Harness side)
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311169AB
Intermediate connector A-12

Check the connectors, for loose, corroded or dam-
AC311168AB
nector.
measure at the harness side. Q: Are the connectors and terminals in good
condition?
YES : Go to Step 3.
earth, and 33 and earth.
OK: System voltage
NO : Go to Step 2.
TROUBLESHOOTING
35B-67
reset.
•
Fusible link: No.3

Steering shaft
No.3
MB991502
AC208825 AL
AC311157AB
Connector: B-118
B-118 (B) 16-PIN

Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
The wire between fusible link No.3 and ABS-ECU

connector B-118 (terminal 11)
• The wire between fusible link No.3 and ABS-ECU MB991911

NO : Go to Step 4.
MB991827 AC311153AB

position.
position.
Q: Do diagnosis codes 41, 42, 43, 44, 52, 53 or 55
reset?
TROUBLESHOOTING
Code No.71: Lateral G-Sensor System
Lateral G-Sensor Circuit

IGNITION
SWITCH (IG2)
G-SENSOR
(LATERAL)
Wire colour code

G : Green L : Blue
W : White Y : Yellow ABS-ECU
OPERATION • If the lateral G-sensor output power does not

The lateral G-sensor detects the acceleration level in change (lateral G-sensor output fastening).
the left/right direction of the vehicle, converts the sig-
nals into voltage signals and then sends that signal PROBABLE CAUSES
to the ABS-ECU. The most likely causes for diagnosis code to set are:
DIAGNOSIS CODE SET CONDITIONS • Damaged wiring harness and connector
This code is set in the following cases: • Malfunction of the brake modulator hydraulic unit
• When the G-sensor output is 0.5 V or lower or (integrated with ABS-ECU)
4.5 V or higher (disconnected lateral G-sensor or
lateral G-sensor short circuit)
TROUBLESHOOTING
35B-69
item.
STEP 1. M.U.T.-II/III data list • Item No.71: Lateral G-sensor
CAUTION OK:
To prevent damage to M.U.T.-II/III, always turn the When vehicle is stationary (level): 2.4 − 2.6
ignition switch to the "LOOK" (OFF) position V
before connecting or disconnecting M.U.T.-II/III. When vehicle is being driven: 1.0 − 4.0 V
<Using the M.U.T.-II> Q: Is the lateral G-sensor input normal?
Steering shaft YES : This malfunction is intermittent. Refer to
P.00-5.
NO : Go to Step 2.
MB991502
AC311157AB
<Using the M.U.T.-III> Connector: D-37
16-PIN
D-37 (B)
MB991911
MB991824
Connector D-37
(Harness side)
3 2 1
MB991827 AC311153AB
AC311166AD
harness side.
earth.
OK: System voltage
YES : Go to Step 3.
NO : Go to Step 4.
TROUBLESHOOTING
•
Connector: D-37
Connector: D-37
D-37 (B)
D-37 (B)
Harness side
3 2 1 AC311167AC

•
Connector D-37
(Harness side)
AD C-211
3 2 1
C-214
AC311166AE
Connector C-211
(1) Disconnect connector D-37, and check at the (Harness side)
harness side. Junction block 2 1
6 5 4 3
(2) Measure the resistance between terminal 3 and (Front view)
OK: 2 ohms or less (Harness side)

14 13 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 8.
NO : Go to Step 6. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC311164AC

nector.
condition?
YES : Go to Step 5.
TROUBLESHOOTING
35B-71
•
D-37 (B) D-37 (B)
3 2 1 AC311167AC 3 2 1 AC311167AC
Connector: C-211
•
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Harness side
2 1
C-122 (L)
(Front view)
AC311165AB
AC311160AC
(terminal 1) and junction block connector C-211 (ter- Intermediate connector C-122
minal 2)
•
Connector: B-118
NO : Go to Step 11.
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB

nector.
condition?
YES : Go to Step 7.
TROUBLESHOOTING
STEP 7. Check the following harness wire. STEP 8. Check lateral G-sensor output voltage.
Connector: D-37
Label
MB991348
D-37 (B)
Harness side
3 2 1 AC311167AC
Connector: D-37 (Harness side)
Connector: B-118
Label
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB AC103662AP
The wire between lateral G-sensor connector D-37 (1) Disconnect connector D-37, and then connect
(terminal 3) and ABS-ECU connector B-118 (terminal special tool harness set (MB991348) between
24) terminals of the disconnected connectors.
YES : Repair or replace it and then go to Step 11. (3) Measure the voltage between terminal 2 and
NO : Go to Step 11. earth.
OK:
When the lateral G-sensor is placed on a
level plane: 2.4 − 2.6 volts
When the lateral G-sensor is placed with its
label positioned as shown: 3.4 − 3.6 volts
Q: Is the lateral G-sensor output voltage normal?
YES : Go to Step 9.
NO : Replace the lateral G-sensor (Refer to
TROUBLESHOOTING
35B-73
•
D-37 (B) D-37 (B)
3 2 1 AC311167AC 3 2 1 AC311167AC
Lateral G-sensor connector D-37 Connector: B-118

•
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
C-122 (L) 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
AC311160AC
Intermediate connector C-122 (terminal 2) and ABS-ECU connector B-118 (terminal
14)
•
Connector: B-118
B-118 (B) P.35B-143). Then go to Step 11.
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB

nector.
condition?
TROUBLESHOOTING
position.
position.
MB991502
AC311157AB
16-PIN
MB991911
MB991824
MB991827 AC311153AB

TROUBLESHOOTING
35B-75

Code No.83: Steering Wheel Sensor (ST-N) System

IGNITION
SWITCH (IG2)
ABS-ECU
STEERING
WHEEL
SENSOR
ST-1 ST-2 ST-N
Wire colour code


The steering wheel sensor monitors the steering Diagnosis code No.81 (ST-1), No.82 (ST-2) and
angle and sends the ST-1, ST-2 and ST-N signals. No.83 (ST-N) are set if there is a fault in the steering
The ABS-ECU calculates the steering angle by read- wheel sensor, an open circuit or short circuit in the
ing the signals from the steering wheel sensor. signal lines, or the internal circuit in the hydraulic unit
and ABS-ECU is defective.
TROUBLESHOOTING
PROBABLE CAUSES (2) Start the engine.

The most likely causes for these diagnosis codes to (3) Set M.U.T.-II/III to data reading mode for following
set are: items.
• Malfunction of the steering wheel sensor • Item No.74: Steering wheel (ST−N)
• Damaged wiring harness and connector • Item No.75: Steering wheel (ST−1)
• Malfunction of the brake modulator hydraulic unit • Item No.76: Steering wheel (ST−2)
(integrated with ABS-ECU) OK:
DIAGNOSIS Item Check item Checking Display

No. requirement
74 Steering Steering: Neutral ON
STEP 1. M.U.T.-II/III data list. wheel sensor position and
CAUTION (ST-N) position near by
To prevent damage to M.U.T.-II/III, always turn the ± 360°
for above
<Using the M.U.T.-II> 75 Steering Steering: Turn Display
Steering shaft wheel sensor laterally slowly. ON and
(ST-1) OFF
76 Steering alternately
wheel sensor
(ST-2)
MB991502 Q: Is the steering wheel sensor input normal?
AC311157AB GROUP 00, How to Use
P.00-5.
NO : Go to Step 2.
16-PIN
MB991911
MB991824
MB991827 AC311153AB

TROUBLESHOOTING
35B-77
STEP 2. Check the power supply circuit. Voltage STEP 3. Check the earth circuit. Resistance
measurement at steering wheel sensor measurement at steering wheel sensor
Connector C-230
Connector C-230 (Harness side)
(Harness side)
1
1 5 4 3 2
5 4 3 2
AC311195AB AC311195AC
(1) Disconnect connector C-230, and check at the (1) Disconnect connector C-230, and check at the
harness side. harness side.
(2) Turn the ignition switch to the "ON" position. (2) Measure the resistance between terminal 3 and
(3) Measure the voltage between terminal 2 and earth.
earth. OK: 2 ohms or less
OK: System voltage Q: Is the resistance 2 ohms or less?
NO : Go to Step 4.
TROUBLESHOOTING

•
condition?
Harness side STEP 5. Check the following harness wire.

1
5 4 3 2 Connector: C-230
Harness side
AC311196AB 1
5 4 3 2
•
AC311196AB
C-211
Connector: C-211
C-210
Harness side
2 1
(Front view) AC311165AB

C-230 (terminal 2) and junction block connector
(Harness side) (Harness side) C-211 (terminal 2)
6 5 4 3 2 1 2 1 Q: Is the harness wire damaged?
14 13 12 11 10 9 8 7 6 5 4 3
NO : Go to Step 11.
AC311164AB

•
Connector: C-101
C-101 (L)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
AC311161AE

nector.
TROUBLESHOOTING
35B-79
•

1 1
5 4 3 2 5 4 3 2
AC311196AB AC311196AB
Steering wheel sensor connector C-230 Earth

•
Connector: C-06
C-06 (GR)
Windshield
wiper arm
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
AC311161AF

nector.
condition?
YES : Go to Step 7.
AC311200AB

C-230 (terminal 3) and earth
NO : Go to Step 11.
TROUBLESHOOTING
STEP 8. Check steering wheel sensor output STEP 9. Check the following connectors.
voltage.
•
Connector: C-230
Connector: C-230
Harness side
1
5 4 3 2
AC311196AB

•
Connector: C-138
Connector C-230
(Harness side)
1
5 4 3 2
C-138
AC311160AE
AC311195AD
Intermediate connector C-138
(1) Connect steering wheel sensor connector C-230. •
(2) Turn the ignition switch to the "ON" position. Connector: B-118
Variations in voltage when turning the

steering wheel
Voltage
B-118 (B)
2.7 - 4.4 V
Harness side
0.8 - 2.1 V 12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
Time
AC211894 AB ABS-ECU connector B-118
(3) Measure the voltage, by backprobing, between
terminal 1 and earth, terminal 4 and earth, and
nector.
terminal 5 and earth.
OK: The voltage should measure as indi- Q: Are the connectors and terminals in good
condition?
cated in the figure.
Q: Is the steering wheel sensor output voltage NO : Repair it and then go to Step 11.
normal?
YES : Go to Step 9.
TROUBLESHOOTING
35B-81
reset.
•
Connector: C-230
Steering shaft
Harness side
1
5 4 3 2
MB991502
AC311196AB
AC311157AB
Connector: B-118
B-118 (B) 16-PIN

Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
If diagnosis code No.81 (ST-1) is set: The wire

(terminal 5) and ABS-ECU connector B-118 (ter- MB991911
minal 26) MB991824
• If diagnosis code No.82 (ST-2) is set: The wire
minal 17)
• If diagnosis code No.83 (ST-N) is set: The wire
MB991827 AC311153AB
minal 4)
position.
position.
Q: Does diagnosis code No.81, 82 and/or 83 reset?
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE NOTE: During ABS operation, the brake pedal may
SYMPTOMS vibrate a little or may not be able to be pressed. Such
M1352011400750 conditions are due to intermittent changes in hydrau-
NOTE: If steering movements are made when driv- lic pressure inside the brake line to prevent the
ing at high speed, or when driving on road surfaces wheels from locking. This is normal.
with low frictional resistance, or when passing over
bumps, the ABS may operate although sudden brak-
ing is not being applied. Because of this, when get-
ting information from the customer, check if the
problem occurred while driving under such condi-
tions as these.
Trouble symptoms Inspection procedure Reference page
No.
Communication between the M.U.T.-II/III and all the 1 <LH drive vehicle>
system is not possible. P.35B-83, <RH drive
vehicle> P.35B-109
Communication between the M.U.T.-II/III and the 2 <LH drive vehicle>
ABS-ECU is not possible. P.35B-87, <RH drive
vehicle> P.35B-113
When the ignition key is turned to the "ON" position 3 <LH drive vehicle>
(Engine stopped), the ABS warning lamp does not P.35B-92, <RH drive
illuminate. vehicle> P.35B-118
The ABS warning lamp remains illuminated after the 4 <LH drive vehicle>
engine is started. P.35B-97, <RH drive
vehicle> P.35B-123
In the inspection with the M.U.T.-II/III data list, the 5 <LH drive vehicle>
parking brake switch is not turned ON or turned OFF. P.35B-99, <RH drive
vehicle> P.35B-125
The neutral position learning of the steering wheel 6 <LH drive vehicle>
sensor is not detected. P.35B-103, <RH drive
vehicle> P.35B-129
Faulty ABS operation 7 <LH drive vehicle>
P.35B-108, <RH drive
vehicle> P.35B-134
TROUBLESHOOTING
35B-83
TROUBLE SYMPTOMS <L.H. drive
vehicle>
INSPECTION PROCEDURE 1: Communication between the M.U.T.-II/III and all the Systems is Not
Possible.
Diagnosis Connector Power Supply and Earth Circuit

FUSIBLE
LINK 1
DIAGNOSIS
CONNECTOR
FRONT SIDE
Wire colour code


A battery positive voltage is applied on the diagnosis The cause is probably a defect in power supply cir-
connector power terminal (terminal 16). The earth cuit or the earth circuit.
terminals (terminal 4, 5) are earthed to the vehicle
body. PROBABLE CAUSES
The most likely causes for this case are:
• Malfunction of the diagnosis connector
TROUBLESHOOTING

•
Connector: C-14
measurement at diagnosis connector C-14.
Connector: C-14
C-14(B)
AC100188AG
C-14(B) Diagnosis connector C-14

•
C-212 (B)
Diagnosis connector
C-214
Connector C-212
AC212151AB (harness side)
Measure the voltage between terminal 16 and earth. 1
OK: System voltage Connector C-214

(harness side)
YES : Go to Step 4. 14 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Go to Step 2.
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC212152 AB

•
Connector: C-126
Harness side C-126

3 2 1
AC211265DG

nector.
TROUBLESHOOTING
35B-85
STEP 4. Check the earth circuit. Resistance
condition?
YES : Go to Step 3. measuremen at diagnosis connector C-14.
NO : Repair it and then go to Step 7. Connector: C-14

Connector: C-14
C-14(B)
C-14(B)
AC100188AG
Connector: C-212
C-212 (B)
Diagnosis connector
AC212151AC
Harness side Measure the resistance between terminal 4 and

1 earth, and terminal 5 and earth.
AC211269 BR
OK: 2 ohms or less
The wire between diagnosis connector C-14 (termi- Q: Is the resistance 2 ohms or less?
nal 16) and junction block connector C-212 (terminal YES : Replace the M.U.T.-II and then go to Step 7.
1) NO : Go to Step 5.
YES : Repair or replace it and then go to Step 7. STEP 5. Check the following connector.
NO : Go to Step 7. •
Connector: C-14
C-14(B)
AC100188AG
Diagnosis connector C-14

Check the connector, for loose, corroded or dam-
nector.
Q: Are the connector and terminals in good
condition?
YES : Go to Step 6.
TROUBLESHOOTING
STEP 6. Check the following harness wires. STEP 7. Retest the system.
•
Connector: C-14 Q: Does the M.U.T.-II/III communicate with the whole

system?
YES : The procedure is complete.
NO : Return to Step 1.
C-14(B)
AC100188AG
Earth
No.7
AC211897AC
The wire between diagnosis connector C-14 (termi-

nal 4) and earth (No.7)
• The wire between diagnosis connector C-14 (ter-
minal 5) and earth (No.7)
NO : Go to Step 7.
TROUBLESHOOTING
35B-87
INSPECTION PROCEDURE 2: Communication between the M.U.T.-II/III and the ABS-ECU is not
possible.
ABS-ECU Power Supply /Earth and Diagnosis Connector Circuit

IGNITION
SWITCH (IG2)
ABS-ECU
POWER
SUPPLY
DIAGNOSIS
CONNECTOR FRONT SIDE
Wire colour code

TROUBLESHOOTING
OPERATION DIAGNOSIS
• The diagnosis code is set by the ABS-ECU (ter-
minal 2) to the diagnostic output terminal (termi- STEP 1. Check the power supply circuit. Voltage
nal 7) of the diagnosis connector. measurement at ABS-ECU connector B-118.
• When the diagnosis connector's diagnosis test
mode control terminal (terminal 1) is earthed, the Connector: B-118
ABS-ECU will go into diagnosis mode.
COMMENT ON TROUBLE SYMPTOM

B-118 (B)
When communication with the M.U.T.-II/III is not pos-
sible, the cause is probably an open circuit in the
ABS-ECU power circuit or an open circuit in the diag-
nostic output circuit.
PROBABLE CAUSES
• Blown fuse Connector B-118
• Damaged wiring harness or connector (harness side)
11 10 9 8 7 6 5 4 3 2 1
(Integrated with ABS-ECU)
12
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC212153AC

measure at the harness side.
earth.
OK: System voltage
YES : Go to Step 4.
NO : Go to Step 2.
TROUBLESHOOTING
35B-89
•
condition?
B-118 (B) STEP 3. Check the following harness wire.

Connector: C-211
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

•
Harness side
2 1
C-211
Connector: B-118
C-210 B-118 (B)

(Front view)
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
Connector C-210 AC211901AD
(Harness side)
The wire between junction block connector C-211
6 5 4 3 2 1
14 13 12 11 10 9 8 7 (terminal 2) and ABS-ECU connector B-118 (terminal
10)
Connector C-211
(Harness side)
2 1
6 5 4 3 NO : Go to Step 9.
AC212152 AC

•
Connector: C-124
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 2122 23 24 25
AC211265 AR

nector.
TROUBLESHOOTING
STEP 4. Check the earth circuit. Resistance STEP 6. Check the following harness wires.
measurement at ABS-ECU connector B-118.
•
Connector: B-118
Connector: B-118
B-118 (B)
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Earth
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
Connector B-118
(harness side)
AC212153AE
Measure the resistance between terminal 12 and

earth, and terminal 34 and earth.
OK: 2 ohms or less
YES : Go to Step 7.
NO : Go to Step 5. NO.14
AC211898AC
STEP 5. Check the following connector.
• The wire between ABS-ECU connector B-118 (termi-
Connector: B-118 nal 12) and earth (No.14)
(terminal 34) and earth (No.14)
B-118 (B) Q: Is any harness wire damaged?
NO : Go to Step 9.
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

nector.
condition?
YES : Go to Step 6.
TROUBLESHOOTING
35B-91
•
condition?
STEP 8. Check the following harness wires.

•
Connector: B-118
C-14(B)
B-118 (B)
AC100188AG

• Harness side
Connectors: C-23, C-101, C-105, C-124
12 11 10 9 8 7 6 5 4 3 2 1
C-101 (L) 34
22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
AC211901AD
Connector: C-14
C-23 (B) C-124
C-105
C-14(B)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 AC100188AG
2324 25 2627 28 2930 31 32 33 12 13 14 15 16 17 18 19 20 21 22

Connector C-124 Connector C-101 nal 2) and diagnosis connector C-14 (terminal 7)
1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11
14 15 16 17 18 19 20 2122 23 24 25 12 13 14 15 16 17 18 19 20 21 22 (terminal 5) and diagnosis connector C-14 (termi-
nal 1)
AC212218 AB
Joint connectors C-23, C-101, C-105 NO : Replace the brake modulator hydraulic unit
• Intermediate connector C-124 (integrated with ABS-ECU) (Refer to
•

Connector: B-118
STEP 9. Retest the system.

B-118 (B) Q: Does the M.U.T.-II/III communicate with the ABS
system?
Harness side NO : Return to Step 1.
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

nector.
TROUBLESHOOTING
INSPECTION PROCEDURE 3: When the Ignition Key is Turned to the "ON" position (Engine Stopped),
the ABS Warning Lamp does not Illuminate.
ABS Warning Lamp Circuit

IGNITION
SWITCH (IG1)
COMBINATION
METER
ABS-ECU
Wire colour code

OPERATION • The ABS-ECU illuminates the ABS warning lamp

• The ABS warning lamp power is supplied from for 3 seconds while running self-check. This lamp
the ignition switch. The ABS-ECU earths the cir- is illuminated for 3 seconds upon start-up or
cuit to illuminate the lamp. when the ignition switch is turned to the "ON"
position with engine stopped.
TROUBLESHOOTING
35B-93
• When the ABS-ECU connector is disconnected, (2) Turn the ignition switch to the "ON" position.
the circuit is earthed to illuminate the lamp. Q: Does the ABS warning lamp illuminate?
• The ABS-ECU controls the continuity to the ABS YES : Replace the brake modulator hydraulic unit
warning lamp by turning the power transistor in (integrated with ABS-ECU) (Refer to
the unit "OFF" and "ON," respectively.
NO : Go to Step 2.
The cause may be an open circuit in the ABS warn-
ing lamp power supply circuit, a blown ABS warning STEP 2. Check the power supply circuit. Voltage
lamp bulb, or a short circuit to earth between the measurement at combination meter connector
ABS warning lamp and the ABS-ECU. C-01.
Connector: C-01
PROBABLE CAUSES
• Blown fuse
• Burnt out ABS warning lamp bulb
DIAGNOSIS
STEP 1. Check the ABS warning lamp circuit at Connector C-01

ABS-ECU connector B-118. (harness side)
Connector: B-118 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-118 (B)
Harness side AC212218 AC
12 11 10 9 8 7 6 5 4 3
22 21 20 19 18 17 16 15 14 13
2 1 (1) Disconnect combination meter connector C-01
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD and measure at the harness side.
(1) Disconnect ABS-ECU connector B-118.
earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 3.
TROUBLESHOOTING

•
condition?
Connectors: C-01, C-23 YES : Go to Step 4.
C-01 NO : Repair it and then go to Step 10.

C-23 (B) Connector: C-211
Connector C-01 Harness side

(harness side) 2 1
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector C-23 Connector: C-01

C-01
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
AC212218AE
Combination meter connector C-01

•
Connectors: C-211, C-214 Harness side

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC211265DF
C-211
(terminal 6) and combination meter connector C-01
(terminal 9)
C-214 Q: Is the harness wire damaged?
NO : Go to Step 10.

(Front view) (Harness side)
2 1
6 5 4 3
Connector C-214
(Harness side)
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC212152AD

• Joint connector C-23
nector.
TROUBLESHOOTING
35B-95
STEP 5. Check the earth circuit. Resistance STEP 7. Check the following harness wire.
measurement at combination meter connector
Connector: C-02
C-02.
Connector: C-02
C-02 (L)
Harness side
515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC211265 AI
Earth
Connector C-02
(harness side)
515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 No.7
AC212218AD
(1) Disconnect combination meter connector C-02

and measure at the harness side.
(2) Measure the resistance between terminal 48 and
earth.
OK: 2 ohms or less
YES : Go to Step 8. AC211897AB
NO : Go to Step 6. The wire between combination meter connector C-02

(terminal 48) and earth (No.7)
STEP 6. Check the following connector. Q: Is the harness wire damaged?
•
Connector: C-02
NO : Go to Step 10.
Harness side
515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC211265 AI

Check the connector for loose, corroded or damaged
terminals, or terminals pushed back in the connector.
condition?
YES : Go to Step 7.
TROUBLESHOOTING
•

C-01 C-01

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC211265DF AC211265DF
Combination meter connector C-01 Connector: B-118

•
Connector: C-122
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
C-122 (L) 34 33 32 31 30 29 28 27 26 25 24 23
1 2 3 4 5 6 7 8 9 10 11 AC211901AD
12 13 14 15 16 17 18 19 20 21 22 AC211265 DD
The wire between combination meter connector C-01
Intermediate connector C-122 (terminal 13) and ABS-ECU connector B-118 (termi-
Connector: B-118
•
nal 27)
NO : Replace the combination meter (Refer to
B-118 (B)
GROUP 54A, Combination Meter Assembly
P.54A-58). Then go to Step 10.
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD Q: Does the ABS warning lamp illuminate for 3
seconds when the ignition switch is turned to the
ABS-ECU connector B-118 "ON" position with engine stopped or upon
Check the connectors for loose, corroded or dam- start-up?
aged terminals, or terminals pushed back in the con- YES : The procedure is complete.
nector. NO : Return to Step 1.
condition?
YES : Go to Step 9.
TROUBLESHOOTING
35B-97
INSPECTION PROCEDURE 4: The ABS Warning Lamp Remains Illuminated after the Engine is
Started.
NOTE: This diagnosis procedure is limited to cases where communication with the M.U.T.-II is possible
(ABS-ECU power supply is normal) and no diagnosis code is set.
ABS WARNING LAMP CIRCUIT DIAGNOSIS
Refer to P.35B-92.
CIRCUIT OPERATION •
Refer to P.35B-92. Connectors: C-01, C-122

C-01
The cause is probably the ABS-ECU malfunction.
PROBABLE CAUSES
• Damaged wiring harness or connector C-122 (L)
Connector C-01
(harness side)
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector C-122
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
AC212218AF

• Intermediate connector C-122
•
Connector: B-118
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

nector.
condition?
YES : Go to Step 2.
TROUBLESHOOTING
STEP 2. Check the following harness wire. STEP 3. Check the ABS warning lamp circuit at
ABS-ECU connector B-118.
Connector: C-01
C-01 Connector: B-118
B-118 (B)
Harness side
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC211265DF
Connector: B-118
Connector B-118
(harness side)
B-118 (B)
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD
The wire between combination meter connector C-01 AC212153AF

(terminal 13) and ABS-ECU connector B-118 (termi-
nal 27)
check at the harness side connector.
YES : Repair or replace it and then go to Step 4. (3) Earth terminal 27 and check the ABS warning
NO : Go to Step 3. lamp.
Q: Does the ABS warning lamp go off?

Q: Does the ABS warning lamp turn off in 3 seconds
after start-up?
TROUBLESHOOTING
35B-99
INSPECTION PROCEDURE 5: In the Inspection with the M.U.T.-II/III Data List, the Parking Brake
Switch is not Turned ON or Turned OFF.
Parking Brake Switch Circuit

ABS-ECU
Wire colour code

B : Black LG : Light green PARKING
G : Green L : Blue BRAKE
W : White Y : Yellow SWITCH

The ABS-ECU monitors the parking brake switch to The most likely causes for this case are:
optimise the ABS control. • Damaged wiring harness or connector
• Malfunction of the parking brake switch
COMMENT ON TROUBLE SYMPTOM • Malfunction of the brake modulator hydraulic unit
The cause may be an open or a short circuit between (integrated with ABS-ECU)
the parking brake switch and the ABS-ECU.
TROUBLESHOOTING

item.
• Item No.29: Parking brake switch
STEP 1. M.U.T.-II/III data list.
OK:
CAUTION
To prevent damage to M.U.T.-II/III, always turn the Checking requirement Display
ignition switch to the "LOOK" (OFF) position Pull the parking brake lever ON
Release the parking brake lever OFF
Q: Is the parking brake switch input normal?
P.00-5.
NO : Go to Step 2.
M.U.T.-II
AC207179AB STEP 2. Check the parking brake switch circuit at

Connector: B-118
16-PIN B-118 (B)
MB991911
Connector B-118
MB991824
(harness side)
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
MB991827 AC210056AC
(1) Connect M.U.T.-II/III as shown in the illustration. AC212153AG
(2) Start the engine. (1) Disconnect ABS-ECU connector B-118 and
TROUBLESHOOTING
35B-101
(2) Check for continuity between terminal 1 and STEP 4. Check the following connectors.
earth with pulling or releasing the parking brake •
lever. Connector: B-118
OK: If the parking brake lever is pulled,

there should be no continuity, and if the
parking brake lever is released, there B-118 (B)
should be continuity (less than 2 ohms).
Q: Does continuity exist when the parking brake lever Harness side
is released, and dose continuity not exist when the
parking brake lever is pulled? 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 3.
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD
NO : Go to Step 4.
•
STEP 3. Check the following connector. Connectors: C-23, C-124

•
Connector: B-118
B-118 (B) C-23 (B)
C-124
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD Connector C-23
ABS-ECU connector B-118 1 2 3 4 5 6 7 8 9 10 11
Check the connector for loose, corroded or damaged 12 13 14 15 16 17 18 19 20 21 22
Q: Are the connector and terminals in good Connector C-124
condition?
YES : Replace the brake modulator hydraulic unit 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 2122 23 24 25
NO : Go to Step 6. AC212218 AG

• Joint connector C-23
•
Connector: D-28
D-28 (B)
Harness side
1
AC211902AH
Parking brake switch connector D-28

nector.
TROUBLESHOOTING

STEP 6. Check whether the diagnosis code is
condition?
YES : Go to Step 5. reset.
NO : Repair it and then go to Step 6. Q: Does the parking brake switch turn ON/OFF
normally in the inspection by M.U.T.-II/III data list?
Connector: D-28
D-28 (B)
Harness side
1
AC211902AH
Connector: B-118
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD
The wire between parking brake switch connector

D-28 (terminal 1) and ABS-ECU connector B-118
(terminal 1)
NO : Replace the parking brake switch (Refer to
GROUP 36, Parking Brake Lever P.36-4).
Then go to Step 6.
TROUBLESHOOTING
35B-103
INSPECTION PROCEDURE 6: The Neutral Position Learning of the Steering Wheel Sensor is not
Detected.

IGNITION
SWITCH (IG2)
ABS-ECU
STEERING
WHEEL
SENSOR
ST-1 ST-2 ST-N
Wire colour code

G : Green L : Blue
CIRCUIT OPERATION COMMENT ON TROUBLE SYMPTOM

The ABS system detects the neutral position learning The diagnosis is difficult because it depends on driv-
of the steering wheel sensor by the signal from the ing condition and road surface, if the diagnosis code
stop lamp. has not been set, carry out the following checks
(refer to TROUBLESHOOTING HINTS).
TROUBLESHOOTING
PROBABLE CAUSES STEP 3. M.U.T.-II/III data list.

CAUTION
• Malfunction of the stop lamp switch system
• Tyres are not all the same diameter
• Malfunction of suspension
• Malfunction of the steering wheel sensor installa- <Using the M.U.T.-II>
tion
(integrated with ABS-ECU) 16-PIN
DIAGNOSIS
STEP 1. Check the front tyres. M.U.T.-II
Q: Are the tyre diameters different? AC207179AB

YES : Replace the appropriate tyre and then go to
Step 13. <Using the M.U.T.-III>
NO : Go to Step 2.
STEP 2. Check the front suspension. 16-PIN

Q: Is the front suspension abnormal?
YES : Repair the front suspension and then go to
Step 13.
NO : Go to Step 3.
MB991911
MB991824
MB991827 AC210056AC

TROUBLESHOOTING
35B-105
(3) Set M.U.T.-II/III to data reading mode for following (2) Turn the ignition switch to the "ON" position.
item. Variations in voltage when turning the
• Item No.37: Steering wheel sensor neutral steering wheel
position learning Voltage
OK:
2.7 - 4.4 V
Checking requirement Display
After driving straight at vehicle ON
0.8 - 2.1 V
speed over than 10 km/h
Before driving with ignition switch OFF Time
ON AC211894 AB
Q: Is the steering wheel sensor straight ahead (3) Measure the voltage, by backprobing, between
position learning input normal? terminal 1 and earth, terminal 4 and earth, and
YES : Go to Step 5. terminal 5 and earth.
NO : Confirm the steering wheel sensor is OK: The voltage should measure as indi-
correctly installed. Then go to Step 4. cated in the figure.
STEP 4. Check for steering wheel sensor output normal?
voltage. YES : Go to Step 13.
Connector: C-230
P.35B-150). and then go to Step 13.
STEP 5. Check the stop lamp.

Q: Does the stop lamp turn on and off normally?
YES : Go to Step 9.
NO : Go to Step 6.
STEP 6. Check the stop lamp switch installation

condition.
Q: Is the stop lamp switch installed correctly?
Connector C-230 YES : Check the stop lamp switch (Refer to
(Harness side)
GROUP 35A, Brake pedal P.35A-15). Then
1
5 4 3 2
go to Step 7.
NO : Repair the installation of the stop lamp
switch (Refer to GROUP 35A, On-vehicle
Service - Brake pedal Check and
Adjustment P.35A-5). Then go to Step 13.
AC212249AD
(1) Connect steering wheel sensor connector C-230.

TROUBLESHOOTING
• •
Connectors: C-102, C-129 Fuse: No.10
No.10
C-102
C-129
AC208825AN
Connector C-102 Connector: C-102

(harness side)
2 1
4 3
Connector C-129 C-102
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 2122 23 24 25 Harness side
2 1
4 3
AC212218AH AC211265DH
Intermediate connectors C-129 The wire between relay box in engine compartment
• Stop lamp switch connector C-102 (fuse No.10) and stop lamp switch connector
Check the connectors for loose, corroded or dam- C-102 (terminal 2)
aged terminals, or terminals pushed back in the con- • The wire between stop lamp switch connector
nector. C-102 (terminal 1) and stop lamps
Q: Are the connectors and terminals in good Q: Is any harness wire damaged?
condition? YES : Repair or replace it and then go to Step 13.
TROUBLESHOOTING
35B-107
STEP 9. Check the stop lamp switch circuit. STEP 10. Check the following connectors.
Measure the voltage at ABS-ECU connector
•
Connector: B-118
B-118.
Connector: B-118
B-118 (B)
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD

•
Connectors: C-102, C-105, C-124
Connector B-118
(harness side)
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23 C-124
C-102
C-105
AC212153AH
(1) Disconnect ABS-ECU connector B-118 and Connector C-102 Connector C-105
measure at the harness side. (harness side)
(2) Depress the brake pedal to turn on the stop lamp
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
2 1 2324 25 2627 28 2930 31 32 33
switch. 4 3
OK: System voltage 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 2122 23 24 25
Q: IIs the check result normal?
YES : Go to Step 12. AC212218AI
NO : Go to Step 10. Joint connector C-105

• Stop lamp switch connector C-102
nector.
condition?
TROUBLESHOOTING
STEP 11. Check the following harness wire. STEP 12. Check the following connector.
•
B-118 (B)
C-102
Harness side
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
2 1 22 21 20 19 18 17 16 15 14 13
4 3 34 33 32 31 30 29 28 27 26 25 24 23
AC211265DH AC211901AD
Connector: B-118
B-118 (B)
condition?
Harness side (integrated with ABS-ECU) (Refer to
12 11 10 9 8 7 6 5 4 3
22 21 20 19 18 17 16 15 14 13
2 1
34 33 32 31 30 29 28 27 26 25 24 23
AC211901AD
The wire between stop lamp switch connector C-102 STEP 13. Retest the system.
(terminal 1) and ABS-ECU connector B-118 (terminal Q: Is the neutral position learning of the steering
19) wheel sensor detected by the ABS system?
Q: Is the harness wire damaged? YES : The procedure is complete.
YES : Repair or replace it and then go to Step 13. NO : Return to Step 1.
NO : Go to Step 13.
INSPECTION PROCEDURE 7: Faulty ABS Operation
COMMENT ON TROUBLE SYMPTOM DIAGNOSIS

(COMMENT) Check the brake modulator hydraulic unit (Refer to
The cause depends on driving and road surface con- P.35B-140). If the brake modulator hydraulic unit
ditions, so diagnosis may be difficult. However, if no (integrated with ABS-ECU) is malfunctioning, replace
diagnosis code is set, carry out the following inspec- it. Then check that the malfunction symptom is elimi-
tion. nated.
PROBABLE CAUSES
The most likely cause for this case is:
TROUBLESHOOTING
35B-109
TROUBLE SYMPTOMS <R.H. drive
vehicle>
INSPECTION PROCEDURE 1: Communication between the M.U.T.-II/III and all the Systems is Not
Possible.
Diagnosis Connector Power Supply and Earth Circuit

FUSIBLE
LINK 1
DIAGNOSIS
CONNECTOR
FRONT SIDE
Wire colour code


A battery positive voltage is applied on the diagnosis The cause is probably a defect in power supply cir-
connector power terminal (terminal 16). The earth cuit or the earth circuit.
terminals (terminal 4, 5) are earthed to the vehicle
body. PROBABLE CAUSES
• Malfunction of the diagnosis connector
TROUBLESHOOTING

•
Connector: C-14
measurement at diagnosis connector C-14.
Connector: C-14
C-14(B)
AC311202 AB
C-14(B) Diagnosis connector C-14

•
C-212 (B)
Diagnosis connector
C-214
Connector C-212
AC311203AB (harness side)
Junction block
Measure the voltage between terminal 16 and earth. (Front view) 1
OK: System voltage Connector C-214

(harness side)
YES : Go to Step 4. 14 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Go to Step 2.
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC311164AD

•
Connector: C-126
Harness side
3 2 1
C-126
AC311160AF

nector.
TROUBLESHOOTING
35B-111
condition?
YES : Go to Step 3. measurement at diagnosis connector C-14.
NO : Repair it and then go to Step 7. Connector: C-14

Connector: C-14
C-14(B)
C-14(B)
AC311202 AB
Connector: C-212
C-212 (B)
Diagnosis connector
AC311203AC
Harness side
Junction block
(Front view)
1
AC311165AC
OK: 2 ohms or less
nal 16) and junction block connector C-212 (terminal YES : Replace the M.U.T.-II/III and then go to Step
1) 7.
Q: Is the harness wire damaged? NO : Go to Step 5.
NO : Go to Step 7.
STEP 5. Check the following connector.
•
Connector: C-14
C-14(B)
AC311202 AB

nector.
condition?
YES : Go to Step 6.
TROUBLESHOOTING
STEP 6. Check the following harness wires. STEP 7. Retest the system.
•
Connector: C-14 Q: Does the M.U.T.-II/III communicate with the whole

system?
C-14(B)
AC311202 AB
Earth
Windshield
wiper arm
AC311200AB

nal 4) and earth
• The wire between diagnosis connector C-14 (ter-
minal 5) and earth
NO : Go to Step 7.
TROUBLESHOOTING
35B-113
INSPECTION PROCEDURE 2: Communication between the M.U.T.-II/III and the ABS-ECU is not
possible.
ABS-ECU Power Supply /Earth and Diagnosis Connector Circuit
IGNITION
SWITCH (IG2)
ABS-ECU
POWER
SUPPLY
Wire colour code

G : Green L : Blue DIAGNOSIS
W : White Y : Yellow CONNECTOR FRONT SIDE
OPERATION • When the diagnosis connector's diagnosis test

• The diagnosis code is set by the ABS-ECU (ter- mode control terminal (terminal 1) is earthed, the
minal 2) to the diagnostic output terminal (termi- ABS-ECU will go into diagnosis mode.
nal 7) of the diagnosis connector.
TROUBLESHOOTING
COMMENT ON TROUBLE SYMPTOM STEP 2. Check the following connectors.

When communication with the M.U.T.-II/III is not pos- •
Connector: B-118
sible, the cause is probably an open circuit in the
ABS-ECU power circuit or an open circuit in the diag-
nostic output circuit.
PROBABLE CAUSES
B-118 (B)
• Blown fuse Harness side
• Damaged wiring harness or connector 12 11 10 9 8 7 6 5 4 3 2 1
• Malfunction of the brake modulator hydraulic unit 34

22 21 20 19 18 17 16 15 14 13
33 32 31 30 29 28 27 26 25 24 23
(Integrated with ABS-ECU) AC311127AB

DIAGNOSIS
•

measurement at ABS-ECU connector B-118. C-211
Connector: B-118 C-210
B-118 (B) Junction block

(Front view)

Connector B-118 (Harness side) (Harness side)
(harness side) 6 5 4 3 2 1 2 1
14 13 12 11 10 9 8 7 6 5 4 3
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311164AB

•
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11
AC311168AC 12 13 14 15 16 17 18 19 20 21 22

earth. C-122 (L)
OK: System voltage

AC311160AC
YES : Go to Step 4.
NO : Go to Step 2.
nector.
TROUBLESHOOTING
35B-115
condition?
YES : Go to Step 3. measurement at ABS-ECU connector B-118.
NO : Repair it and then go to Step 9. Connector: B-118

Connector: C-211
B-118 (B)
Harness side
2 1
(Front view)
AC311165AB
12 11 10 9 8 7 6 5 4 3 2 1
Connector: B-118 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
Connector B-118
(harness side)
B-118 (B)
AC311168AD
Harness side
11 10
12 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB OK: 2 ohms or less
The wire between junction block connector C-211 Q: Is the resistance 2 ohms or less?
(terminal 2) and ABS-ECU connector B-118 (terminal YES : Go to Step 7.
10) NO : Go to Step 5.
YES : Repair or replace it and then go to Step 9. STEP 5. Check the following connector.
NO : Go to Step 9. •
Connector: B-118
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB

nector.
condition?
YES : Go to Step 6.
TROUBLESHOOTING
STEP 6. Check the following harness wires. STEP 7. Check the following connectors.
• •
B-118 (B)
Harness side C-14(B)
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB AC311202 AB

Earth •
Connector: C-23
C-23 (B)
AC311161AG
Connectors: C-21, C-105, C-122, C-124
C-21
C-105 C-124
AC311204 AB
C-122 (L)
nal 12) and earth
(terminal 34) and earth Connector C-21 Connector C-105
Q: Is any harness wire damaged? 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
YES : Repair or replace it and then go to Step 9. 2324 25 2627 28 2930 31 32 33
NO : Go to Step 9.
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13
12 13 14 15 16 17 18 19 20 21 22 14 15 16 17 18 19 20 2122 23 24 25
AC311205AB
Joint connectors C-21, C-23, C-105

• Intermediate connectors C-122, C-124
TROUBLESHOOTING
35B-117
•
Connector: B-118 STEP 8. Check the following harness wires.

•
Connector: B-118
B-118 (B)
Harness side B-118 (B)
12 11 10 9 8 7 6 5 4 3 2 1 Harness side
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB 12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
ABS-ECU connector B-118 34 33 32 31 30 29 28 27 26 25 24 23

AC311127AB
aged terminals, or terminals pushed back in the con- Connector: C-14
nector.
condition?
YES : Go to Step 8.
C-14(B)
AC311202 AB

nal 2) and diagnosis connector C-14 (terminal 7)
(terminal 5) and diagnosis connector C-14 (termi-
nal 1)

Q: Does the M.U.T.-II/III communicate with the ABS
system?
TROUBLESHOOTING
INSPECTION PROCEDURE 3: When the Ignition Key is Turned to the "ON" position (Engine Stopped),
the ABS Warning Lamp does not Illuminate.
ABS Warning Lamp Circuit
IGNITION
SWITCH (IG1)
COMBINATION
METER
ABS-ECU
Wire colour code

OPERATION • The ABS-ECU illuminates the ABS warning lamp

• The ABS warning lamp power is supplied from for 3 seconds while running self-check. This lamp
the ignition switch. The ABS-ECU earths the cir- is illuminated for 3 seconds upon start-up or
cuit to illuminate the lamp. when the ignition switch is turned to the "ON"
position with engine stopped.
TROUBLESHOOTING
35B-119
• When the ABS-ECU connector is disconnected, (2) Turn the ignition switch to the "ON" position.
the circuit is earthed to illuminate the lamp. Q: Does the ABS warning lamp illuminate?
• The ABS-ECU controls the continuity to the ABS YES : Replace the brake modulator hydraulic unit
warning lamp by turning the power transistor in (integrated with ABS-ECU) (Refer to
the unit "OFF" and "ON," respectively.
NO : Go to Step 2.
The cause may be an open circuit in the ABS warn-
ing lamp power supply circuit, a blown ABS warning STEP 2. Check the power supply circuit. Voltage
lamp bulb, or a short circuit to earth between the measurement at combination meter connector
ABS warning lamp and the ABS-ECU. C-01.
Connector: C-01
PROBABLE CAUSES
• Blown fuse
• Burnt out ABS warning lamp bulb
DIAGNOSIS
STEP 1. Check the ABS warning lamp circuit at

ABS-ECU connector B-118. Connector C-01
(harness side)
Connector: B-118
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-118 (B)
Harness side AC311206AB
12 11 10 9 8 7 6 5 4 3
22 21 20 19 18 17 16 15 14 13
2 1 (1) Disconnect combination meter connector C-01
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
(1) Disconnect ABS-ECU connector B-118.
earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 3.
TROUBLESHOOTING
•
Harness side
Connector C-01 (harness side) 2 1
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
(Front view)
AC311161AD AC311165AB

• Connector: C-01
C-211
Connector C-01 (harness side)

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC311161AD
C-214
Connector C-211
(Harness side)
(terminal 6) and combination meter connector C-01
(terminal 9)
Junction block 2 1
(Front view)
6 5 4 3
Connector C-214
(Harness side) NO : Go to Step 10.
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC311164AC

nector.
condition?
YES : Go to Step 4.
TROUBLESHOOTING
35B-121
STEP 5. Check the earth circuit. Resistance STEP 7. Check the following harness wire.
measurement at combination meter connector
Connector: C-02
C-02. C-02 (L)
Connector: C-02
C-02 (L)

515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC311161AH
Earth
Connector C-02
(harness side)
515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
Windshield
wiper arm
AC311206AC
(1) Disconnect combination meter connector C-02

earth.
OK: 2 ohms or less
YES : Go to Step 8.
NO : Go to Step 6. AC311200AB

STEP 6. Check the following connector. (terminal 48) and earth (No.7)
•
Connector: C-02 Q: Is the harness wire damaged?

C-02 (L)
NO : Go to Step 10.

515049 48 4746 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC311161AH

condition?
YES : Go to Step 7.
TROUBLESHOOTING
•
Connector C-01 (harness side) Connector C-01 (harness side)

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC311161AD AC311161AD
Combination meter connector C-01 Connector: B-118

•
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
C-122 (L) 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
AC311160AC
Intermediate connector C-122 (terminal 13) and ABS-ECU connector B-118 (termi-
nal 27)
•
Connector: B-118
B-118 (B) P.54A-56). Then go to Step 10.
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB Q: Does the ABS warning lamp illuminate for 3
seconds when the ignition switch is turned to the
ABS-ECU connector B-118 "ON" position with engine stopped or upon
Check the connectors for loose, corroded or dam- start-up?
aged terminals, or terminals pushed back in the con- YES : The procedure is complete.
nector. NO : Return to Step 1.
condition?
YES : Go to Step 9.
TROUBLESHOOTING
35B-123
INSPECTION PROCEDURE 4: The ABS Warning Lamp Remains Illuminated after the Engine is
Started.
NOTE: This diagnosis procedure is limited to cases where communication with the M.U.T.-II/III is possible
(ABS-ECU power supply is normal) and no diagnosis code is set.
ABS WARNING LAMP CIRCUIT DIAGNOSIS
Refer to P.35B-118.
CIRCUIT OPERATION •
Refer to P.35B-118. Connector: C-01

The cause is probably the ABS-ECU malfunction.
PROBABLE CAUSES
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
(integrated with ABS-ECU) AC311161AD

•
Connector: C-122
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
C-122 (L)
AC311160AC

•
Connector: B-118
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB

nector.
condition?
YES : Go to Step 2.
TROUBLESHOOTING
STEP 2. Check the following harness wire. STEP 3. Check the ABS warning lamp circuit at
Connector: C-01
Connector: B-118

B-118 (B)
21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC311161AD
Connector: B-118
Connector B-118
(harness side)
12 11 10 9 8 7 6 5 4 3 2 1
B-118 (B) 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
The wire between combination meter connector C-01 AC311168 AE

(terminal 13) and ABS-ECU connector B-118 (termi-
nal 27)
check at the harness side connector.
YES : Repair or replace it and then go to Step 4. (3) Earth terminal 27 and check the ABS warning
NO : Go to Step 3. lamp.
Q: Does the ABS warning lamp go off?

Q: Does the ABS warning lamp turn off in 3 seconds
after start-up?
TROUBLESHOOTING
35B-125
INSPECTION PROCEDURE 5: In the Inspection with the M.U.T.-II/III Data List, the Parking Brake
Switch is not Turned ON or Turned OFF.
Parking Brake Switch Circuit

ABS-ECU
Wire colour code PARKING

B : Black LG : Light green BRAKE
G : Green L : Blue SWITCH

The ABS-ECU monitors the parking brake switch to The most likely causes for this case are:
optimise the ABS control. • Damaged wiring harness or connector
• Malfunction of the parking brake switch
The cause may be an open or a short circuit between (integrated with ABS-ECU)
the parking brake switch and the ABS-ECU.
TROUBLESHOOTING

item.
• Item No.29: Parking brake switch
STEP 1. M.U.T.-II/III data list.
OK:
CAUTION
To prevent damage to M.U.T.-II/III, always turn the Checking requirement Display
ignition switch to the "LOOK" (OFF) position Pull the parking brake lever ON
Release the parking brake lever OFF
Q: Is the parking brake switch input normal?
Steering shaft
P.00-5.
NO : Go to Step 2.
MB991502
AC311157AB STEP 2. Check the parking brake switch circuit.

Resistance measurement at ABS-ECU connector
<Using the M.U.T.-III> B-118.
Connector: B-118
16-PIN
B-118 (B)
MB991911
MB991824
Connector B-118
(harness side)
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
MB991827 AC311153AB

(2) Start the engine. AC311168AF

TROUBLESHOOTING
35B-127
(2) Check for continuity between terminal 1 and STEP 4. Check the following connectors.
earth with pulling or releasing the parking brake •
lever. Connector: B-118
OK: If the parking brake lever is pulled,

there should be no continuity, and if the
parking brake lever is released, there
should be continuity (less than 2 ohms). B-118 (B)
Q: Does continuity exist when the parking brake lever Harness side
is released, and dose continuity not exist when the
parking brake lever is pulled? 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 3.
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
NO : Go to Step 4.
•
STEP 3. Check the following connector. Connector: C-122

•
Connector: B-118 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B-118 (B)
C-122 (L)
Harness side
AC311160AC
12 11 10 9 8 7 6 5 4 3 2 1

22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB •

condition? D-28 (B)
Harness side
1
NO : Go to Step 6.
AC311162AC
Parking brake switch connector D-28

nector.
condition?
YES : Go to Step 5.
TROUBLESHOOTING
STEP 5. Check the following harness wire. STEP 6. Check whether the diagnosis code is
reset.
Connector: D-28
Q: Does the parking brake switch turn ON/OFF
normally in the inspection by M.U.T.-II/III data list?
D-28 (B)
Harness side
1
AC311162AC
Connector: B-118
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
The wire between parking brake switch connector

D-28 (terminal 1) and ABS-ECU connector B-118
(terminal 1)
NO : Replace the parking brake switch (Refer to
GROUP 36, Parking Brake Lever P.36-4).
Then go to Step 6.
TROUBLESHOOTING
35B-129
INSPECTION PROCEDURE 6: The Neutral Position Learning of the Steering Wheel Sensor is not
Detected.

IGNITION
SWITCH (IG2)
ABS-ECU
STEERING
WHEEL
SENSOR
ST-1 ST-2 ST-N
Wire colour code

G : Green L : Blue
CIRCUIT OPERATION COMMENT ON TROUBLE SYMPTOM

The ABS system detects the neutral position learning The diagnosis is difficult because it depends on driv-
of the steering wheel sensor by the signal from the ing condition and road surface, if the diagnosis code
stop lamp. has not been set, carry out the following checks
(refer to TROUBLESHOOTING HINTS).
TROUBLESHOOTING
PROBABLE CAUSES STEP 3. M.U.T.-II/III data list.

CAUTION
• Malfunction of the stop lamp switch system
• Tyres are not all the same diameter
• Malfunction of suspension
• Malfunction of the steering wheel sensor installa- <Using the M.U.T.-II>
tion Steering shaft
DIAGNOSIS
MB991502
STEP 1. Check the front tyres.
Q: Are the tyre diameters different? AC311157AB
YES : Replace the appropriate tyre and then go to
Step 13. <Using the M.U.T.-III>
NO : Go to Step 2.
STEP 2. Check the front suspension. 16-PIN

Q: Is the front suspension abnormal?
YES : Repair the front suspension and then go to
Step 13.
NO : Go to Step 3.
MB991911
MB991824
MB991827 AC311153AB

TROUBLESHOOTING
35B-131
(3) Set M.U.T.-II/III to data reading mode for following (2) Turn the ignition switch to the "ON" position.
item. Variations in voltage when turning the
• Item No.37: Steering wheel sensor neutral steering wheel
position learning Voltage
OK:
2.7 - 4.4 V
Checking requirement Display
After driving straight at vehicle ON
0.8 - 2.1 V
speed over than 10 km/h
Before driving with ignition switch OFF Time
ON AC211894 AB
Q: Is the steering wheel sensor straight ahead (3) Measure the voltage, by backprobing, between
position learning input normal? terminal 1 and earth, terminal 4 and earth, and
YES : Go to Step 5. terminal 5 and earth.
NO : Confirm the steering wheel sensor is OK: The voltage should measure as indi-
correctly installed. Then go to Step 4. cated in the figure.
STEP 4. Check for steering wheel sensor output normal?
voltage. YES : Go to Step 13.
Connector: C-230
P.35B-150). and then go to Step 13.
STEP 5. Check the stop lamp.

Q: Does the stop lamp turn on and off normally?
YES : Go to Step 9.
NO : Go to Step 6.
STEP 6. Check the stop lamp switch installation

condition.
Q: Is the stop lamp switch installed correctly?
Connector C-230 YES : Check the stop lamp switch (Refer to
(Harness side) GROUP 35A, Brake pedal P.35A-15). Then
1 go to Step 7.
5 4 3 2 NO : Repair the installation of the stop lamp
switch (Refer to GROUP 35A, On-vehicle
Service − Brake pedal Check and
Adjustment P.35A-5). Then go to Step 13.
AC311195AD
(1) Connect steering wheel sensor connector C-230.

TROUBLESHOOTING
• •
Connector: C-129 Fuse: No.10

1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 2122 23 24 25
No.10
AC311160AG AC208825AN
Intermediate connectors C-129

• Connector: C-102
Connector: C-102
2 1
2 1 4 3
4 3
AC311161AI
AC311161AI
The wire between relay box in engine compartment
Stop lamp switch connector C-102 (fuse No.10) and stop lamp switch connector
Check the connectors for loose, corroded or dam- C-102 (terminal 2)
aged terminals, or terminals pushed back in the con- • The wire between stop lamp switch connector
nector. C-102 (terminal 1) and stop lamps
Q: Are the connectors and terminals in good Q: Is any harness wire damaged?
condition? YES : Repair or replace it and then go to Step 13.
TROUBLESHOOTING
35B-133
STEP 9. Check the stop lamp switch circuit. STEP 10. Check the following connectors.
Voltage measurement at ABS-ECU connector
•
Connector: B-118
B-118.
Connector: B-118
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
B-118 (B) 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB

•
Connector B-118
(harness side)
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 C-124
34 33 32 31 30 29 28 27 26 25 24 23
C-105
AC311168AG
(1) Disconnect ABS-ECU connector B-118 and Connector C-105

measure at the harness side. 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
(2) Depress the brake pedal to turn on the stop lamp 2324 25 2627 28 2930 31 32 33
switch.
(3) Measure the voltage between terminal 19 and Connector C-124
earth. 1 2 3 4 5 6 7 8 9 10 11 12 13
OK: System voltage 14 15 16 17 18 19 20 2122 23 24 25

YES : Go to Step 12. AC311207AB
NO : Go to Step 10. Joint connector C-105

•
Connector: C-102
2 1
4 3
AC311161AI
Stop lamp switch connector C-102

TROUBLESHOOTING
Check the connectors for loose, corroded or dam- STEP 12. Check the following connector.
aged terminals, or terminals pushed back in the con- •
nector. Connector: B-118

condition?
B-118 (B)
Harness side
12 11 10 9 8 7 6 5 4 3 2 1
Connector: C-102 22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB

2 1
4 3
condition?
AC311161AI
Connector: B-118 NO : Repair it and then go to Step 13.

Q: Is the neutral position learning of the steering
B-118 (B)
wheel sensor detected by the ABS system?
Harness side NO : Return to Step 1.
12 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13
34 33 32 31 30 29 28 27 26 25 24 23
AC311127AB
The wire between stop lamp switch connector C-102

(terminal 1) and ABS-ECU connector B-118 (terminal
19)
NO : Go to Step 13.
INSPECTION PROCEDURE 7: Faulty ABS Operation

(COMMENT)
The cause depends on driving and road surface con-
DIAGNOSIS
ditions, so diagnosis may be difficult. However, if no Check the brake modulator hydraulic unit (Refer to
diagnosis code is set, carry out the following inspec- P.35B-140). If the brake modulator hydraulic unit
tion. (integrated with ABS-ECU) is malfunctioning, replace
it. Then check that the malfunction symptom is elimi-
PROBABLE CAUSES nated.
The most likely cause for this case is:
TROUBLESHOOTING
35B-135
M1352011500702
The following items can be read by the M.U.T.-II/III
from the ABS-ECU input data.
M.U.T.-II/III Item Check item Checking requirements Normal valve
display No.
FR SNSR 11 Front-right wheel speed Drive the vehicle Vehicle speeds
sensor displayed on the
FL SNSR 12 Front-left wheel speed speedometer
sensor and M.U.T.-II/III
are identical.
RR SNSR 13 Rear-right wheel speed
sensor
RL SNSR 14 Rear-left wheel speed
sensor
BATT. 21 ABS-ECU power supply Ignition switch: ON 10 − 16 V
VOLTAGE voltage
PARKING 29 Parking brake switch Pull the parking brake lever. ON
SW Release the parking brake lever. OFF
GS 32 Longitudinal G-sensor When vehicle stops. 2.4 − 2.6 V
(STRAIGHT) When vehicle is driven. 1.0 − 4.0 V
STOP LAMP 36 Stop lamp switch Depress the brake pedal. ON
SW Release the brake pedal. OFF
ST-N 37 Steering wheel sensor After driving straight at vehicle speed ON
MEMORY neutral position learning over 10 km/h.
Before driving with ignition switch ON. OFF
GS 71 Lateral G-sensor When vehicle stops. 2.4 − 2.6 V
(LATERAL) When vehicle is driven. 1.0 − 4.0 V
ST-N 74 Steering wheel sensor Ignition switch: ON Steering: Neutral ON
(ST-N) position and fully
turned
for the above
ST-1 75 Steering wheel sensor Ignition switch: ON Steering: Turn Display ON and
(ST-1) slowly. OFF alternately
ST-2 76 Steering wheel sensor
(ST-2)
ST ANGLE 86 Steering degree • Ignition switch: Steering: Turn 90° + 90°
ON to the right.
• Steering wheel Steering: Neutral OFF
sensor neutral
position Steering: Turn 90° - 90°
learning is to the left.
finished
(service data
item No.37
displays ON).
TROUBLESHOOTING
ACTUATOR TEST REFERENCE TABLE No. Item

M1352011600709
The M.U.T.-II/III activates the following actuators for 01 Solenoid valve for Solenoid valves
testing. front-left wheel and pump motors
NOTE: If the ABS-ECU runs down, actuator testing 02 Solenoid valve for in the hydraulic
cannot be carried out. front-right wheel unit (simple
inspection mode)
NOTE: Actuator testing is only possible when the 03 Solenoid valve for
vehicle is stationary. rear-left wheel
ACTUATOR TEST SPECIFICATIONS 04 Solenoid valve for
rear-right wheel
Activation pattern
Start of End of
activation activation
Solenoid A
valve
B 1s
C 2s
0.05 s 0.01 s
Pump ON
motor OFF
NOTE
A: Hydraulic pressure increases
B: Hydraulic pressure holds
C: Hydraulic pressure decreases
AC100172 AG
CHECK AT ABS-ECU
M1352011800695
Use the following steps to remove the connector
cover of the ABS-ECU and then measure the termi-
nal voltage.
AC211694AB
2. Push up and unlock the hooks of the ABS-ECU

Lock lever connector as shown in the illustration, then
AC211555AB
remove the connector cover.
1. Move the lock lever of the ABS-ECU connector as
shown in the illustration, and then disconnect the
ABS-ECU as connector.
TROUBLESHOOTING
35B-137
TERMINAL VOLTAGE CHECK CHART
AC211716
1. Measure the voltages between terminals (12) NOTE: Do not measure terminal voltage for approxi-
(earth terminal) and each respective terminal. mately three seconds after the ignition switch is
2. The terminal layout is shown in the illustration. turned "ON." The ABS-ECU performs the initial
check during that period.
Terminal No. Check item Checking requirements Normal condition
1 Parking brake switch Pull the parking brake lever. 1 V or less
Release the parking brake lever. System voltage
2 M.U.T.-II/III When the M.U.T.-II/III is connected Serial
communication
with M.U.T.-II/III
When the M.U.T.-II/III is not connected 1 V or less
4 Steering wheel Ignition Steering wheel: Neutral 0.8 − 2.1 V
sensor (ST-N) switch: "ON" position and fully turned.
Steering wheel: Except for the 2.7 − 4.4 V
above
5 Diagnosis When the M.U.T.-II/III is connected Approximately 0 V
changeover input When the M.U.T.-II/III is not connected System voltage
10 ABS-ECU power Ignition switch: "ON" System voltage
supply Ignition switch: "START" or "ACC" Approximately 0 V
11 Solenoid valve power Always System voltage
supply
14 Lateral G-sensor Ignition switch: "ON" 2.4 − 2.6 V
input (horizontal
position)
15 Longitudinal Always 0V
G-sensor earth
17 Steering wheel Ignition Steering wheel: Turned Variation in the
sensor (ST-2) switch: "ON" voltage value 0.8 −
2.1 V and 2.7 − 4.4
V
19 Stop lamp monitor Ignition Stop lamp switch: "ON" System voltage
input switch: "ON" Stop lamp switch: "OFF" 1 V or less
24 Lateral G-sensor Always 0V
earth
25 Longitudinal Ignition switch: "ON" 2.4 − 2.6 V
G-sensor input (horizontal
position)
ON-VEHICLE SERVICE
Terminal No. Check item Checking requirements Normal condition

26 Steering wheel Ignition Steering wheel: Turned Variation in the
sensor (ST-1) switch: "ON" voltage value 0.8 −
2.1 V and 2.7 − 4.4
V
27 ABS-ECU warning Ignition When the lamp off 1 V or less
lamp transistor output switch: "ON" When the lamp is illuminated 7 V or more
33 Motor power supply Always System voltage
RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR

TERMINALS
AC211717
1. Turn the ignition switch to the "LOCK" (OFF) 2. Check the resistance and continuity between the
position and disconnect the ABS-ECU connectors terminals indicated in the table below.
before checking resistance and continuity. 3. The terminal layout is shown in the illustration.
ABS-ECU terminal No. Signal Normal condition
6−7 Rear-left wheel speed sensor 1.24 − 1.64 kΩ
8−9 Rear-right wheel speed sensor 1.24 − 1.64 kΩ
22 − 31 Front-left wheel speed sensor 1.24 − 1.64 kΩ
29 − 30 Front-right wheel speed sensor 1.24 − 1.64 kΩ
12 − body earth Earth Less than 2 ohms
34 − body earth Earth Less than 2 ohms
ON-VEHICLE SERVICE
WHEEL SPEED SENSOR OUTPUT 1. Move the lock lever of the ABS-ECU connector as
VOLTAGE MEASUREMENT shown, and then disconnect the ABS-ECU
M1352001600612 connector.
Lift up the vehicle and release the parking brake.
Lock lever AC211694AB

AC211555AB
2. Push up and unlock the hooks of the ABS-ECU
connector as shown in the illustration, then
remove the connector cover.
ON-VEHICLE SERVICE
35B-139
• Faulty wheel speed sensor
NOTE: Check the connection of the wheel speed
sensor harness and connector before using the
oscilloscope.
When turned by hand

AC211695AB
3. Manually turn the wheel to be measured 1/2 to 1

turn/second. Measure the output voltage with a
voltmeter or oscilloscope.
NOTE: The output waveform is low when the
wheel speed is low. Similarly, it will be higher as
the wheel speed increases. Waveform may also When idling (5 − 6 km/h), with 1st gear
be observed by driving the vehicle.
Terminal No.
Front left Front right Rear left Rear right
22 29 6 8 [10.0 ms/DIV IV/DIV]
31 30 7 9
Output voltage:
• Minimal voltmeter reading: 42 mV AC000949 AF
• Maximum voltmeter reading: 300 mV

• Minimal oscilloscope reading: 120 mV 4. To observe the waveform with an oscilloscope:
• Maximum oscilloscope reading: 600 mV • Front Wheels: Shift into low gear and drive the
wheels.
Probable causes of low output voltage • Rear Wheels: Turn the wheels manually at a con-
• Wheel speed sensor pole piece-to-wheel speed stant speed.
rotor clearance too large
POINTS IN WAVEFORM MEASUREMENT
Symptom Probable causes Remedy
Too small or zero waveform Faulty wheel speed sensor or Replace wheel speed sensor
amplitude excessive gap between it and the
wheel speed rotor
Waveform amplitude fluctuates Axle hub eccentric or with large Replace hub assembly
excessively (This is no problem if runout
the minimum amplitude is 100 mV Faulty ABS-ECU earth Repair harness wires
or more)
Noisy or disturbed waveform Open circuit in wheel speed sensor Replace wheel speed sensor
Open circuit in harness Repair harness wire
Incorrectly mounted wheel speed Mount wheel speed sensor
sensor correctly
Wheel speed rotor with missing or Replace wheel speed rotor
damaged teeth
NOTE: The wheel speed sensor cable moves in relation to motion of the front or rear suspension. Therefore,
it is likely that it has an open circuit only when driving on rough roads but it functions normally when driving on
smooth roads. It is recommended to observe sensor output voltage waveform also under special conditions,
such as driving on a rough road.
ON-VEHICLE SERVICE
HYDRAULIC UNIT CHECK CAUTION

M1352001700642
To prevent damage to the M.U.T.-II/III, always turn
CAUTION the ignition switch to the "LOOK" (OFF) position
• The roller of the braking force tester and the before connecting or disconnecting the
tyre should be dry during testing. M.U.T.-II/III.
• When testing the front brakes, apply the park-
ing brake. When testing the rear brakes, stop
the front wheels with chocks.
1. Jack up the vehicle. Then support the vehicle with
rigid racks at the specified jack-up points or place 16-PIN
the front or rear wheels on the rollers of the
braking force tester.
2. Release the parking brake, and feel the drag force
(drag torque) on each road wheel. When using M.U.T.-II
the braking force tester, take a reading of the AC207179AB
brake drag force.
3. Turn the ignition switch to the "LOCK" (OFF) <Using the M.U.T.-III>
position.
16-PIN
MB991911
MB991824
MB991827 AC210056AC
4. Connect the M.U.T.-II/III as shown in the

illustration.
5. After checking that the shift lever is in neutral,
start the engine.
6. Use the M.U.T.-II/III to force-drive the actuator.
For the M.U.T.-II/III, follow the steps below.
(1) Select "Interactive Diagnosis" from the start-up
screen.
(2) Select "System select."
(3) Choose "ABS" from the "CHASSIS" tab.
(4) Select "Actuator Test" from "ABS" screen
ON-VEHICLE SERVICE
35B-141
(5) Choose an appropriate item for hydraulic unit NOTE: When the ABS has been interrupted by
check. the fail-safe function, the M.U.T.-II/III actuator
NOTE: The ABS system will switch to the testing cannot be used.
M.U.T.-II/III mode and the ABS warning lamp
will illuminate.
Depressed
Pedal
operation M.U.T.-II/III actuator test
Released (Item No.01, 02, 03, 04) start
Increase in pressure
Solenoid 2 seconds
valve Steady pressure
position
Reduction in pressure 1 seconds
Lock
Checking
the brake
force 3 seconds
Drag force when the
pedal is free Approx. 0.05 second
AC000954AH
7. Turn the wheel by hand and check the change in

braking force when the brake pedal is depressed.
When using the braking force tester, depress the
brake pedal until the braking force is at the
following values, and check that the braking force
changes to the reading taken in step 2. The result
should be as shown in the diagram above.
Front wheel 785 − 981 N
Rear wheel 588 − 784 N
ON-VEHICLE SERVICE
8. If the result of inspection is abnormal, repair

according to the Diagnosis Table below.
Diagnosis Table
M.U.T.-II/III Display Operation Inspection result Judgment Probable cause Remedy
01 FR VALVE • Depress brake pedal Brake force is Normal − −

02 FL VALVE to lock wheel. released for
03 RR VALVE • Using the M.U.T.-II/III, three seconds
04 RL VALVE select the wheel to be after wheels
checked and force the have been
actuator to operate. locked.
• Turn the selected Wheel does not Abnorm Clogged brake Check and clean
wheel manually to lock when brake al line other than brake line
check the change of pedal is hydraulic unit
brake force. depressed. Clogged Replace
hydraulic circuit hydraulic unit
in hydraulic unit assembly
Brake force is Incorrect Connect correctly
not released hydraulic unit
brake tube
connection
Hydraulic unit Replace
solenoid valve hydraulic unit
not functioning assembly
correctly
9. After inspection, disconnect the M.U.T.-II/III IN THE EVENT OF A DISCHARGED
immediately after turning the ignition switch to the BATTERY
"LOCK" (OFF) position. M1352003500600
WARNING
If the ABS is not operating, the vehicle pos-
ture will be unstable during braking, Do not
drive the vehicle with the ABS-ECU connec-
tor disconnected or with the ABS not operat-
ing for any other reason.
If the engine is started using a booster cable when
the battery is completely flat, and the vehicle is then
driven without waiting for the battery to be recharged,
the engine may misfire and it may not be possible to
drive the vehicle. This is because the ABS consumes
a large amount of current when carrying out its initial
checks. If this happens, recharge the battery fully.
HYDRAULIC UNIT
35B-143
HYDRAULIC UNIT
M1352008600549
NOTE: The ABS-ECU is integrated in the hydraulic unit.
<LH DRIVE VEHICLES>
• Brake Fluid Draining • Brake Fluid Filling
• Bake Line Bleeding (Refer to P.35A-7).
• Hydraulic Unit Check (Refer to P.35B-140).
2
15 ± 2 N·m
2 3
1
2
2
25 ± 6 N·m
25 ± 6 N·m
AC100173 AC

<<A>> 1. ABS-ECU harness connector <> 3. Brake modulator hydraulic unit
>>A<< 2. Brake tube connection (hydraulic unit and ABS-ECU)
4. Brake hydraulic unit bracket
NOTE: The ABS-ECU is integrated in the hydraulic unit.

HYDRAULIC UNIT
<RH DRIVE VEHICLES>

• Brake Fluid Draining • Brake Fluid Filling
• Air Intake Hose and Air Cleaner Removal • Bake Line Bleeding (Refer to P.35A-7).
• Hydraulic Unit Check (Refer to P.35B-140).
• Air Intake Hose and Air Cleaner Installation
2
15 ± 2 N·m
3
1 2
2
25 ± 6 N·m 2
4
25 ± 6 N·m
AC311045AB

<<A>> 1. ABS-ECU harness connector <> 3. Brake modulator hydraulic unit
>>A<< 2. Brake tube connection (hydraulic unit and ABS-ECU)
4. Brake hydraulic unit bracket
HYDRAULIC UNIT
35B-145
REMOVAL SERVICE POINTS INSTALLATION SERVICE POINT
<<A>> ABS-ECU HARNESS CONNECTOR >>A<< BRAKE TUBE CONNECTION
DISCONNECTION
2 3
4
5
6
AC100240AB
Lock lever
AC211555AB Connect the tubes to the hydraulic unit assembly as
Move the lock lever of the ABS-ECU connector as shown in the illustration.
shown in the illustration, and then disconnect the 1. From the master cylinder (secondary)
harness connector. 2. To the front brake (LH)
3. To the rear brake (RH)
<> BRAKE MODULATOR HYDRAULIC 4. To the rear brake (LH)
UNIT (HYDRAULIC UNIT AND ABS-ECU) 5. To the front brake (RH)
REMOVAL 6. From the master cylinder (primary)
WARNING
The hydraulic unit is heavy. Use care when
removing it.
CAUTION
• The hydraulic unit cannot be disassembled.
Never loosen its nuts or bolts.
• Do not drop or shock the hydraulic unit.
• Do not turn the hydraulic unit upside down or
lay it on its side.
ABS SENSOR
ABS SENSOR
M1352020700061
• Wheel Speed Sensor Output Voltage Measurement
(Refer to P.35B-138).
3 4
<Front>
1
<Rear>
AC211696AB
Front wheel speed sensor Rear wheel speed sensor

removal steps removal steps
<<A>> 1. Front wheel speed sensor <<A>> >>A<< 3. Rear wheel speed sensor
2. Front wheel speed rotor (Refer to 4. Rear wheel speed rotor (Refer to
GROUP 26, Drive Shaft Assembly GROUP 27, Drive Shaft Assembly
P.26-11). P.27-36).
NOTE: The wheel speed rotors are integrated with
the drive shaft and cannot be disassembled.
ABS SENSOR
35B-147
REMOVAL SERVICE POINT NOTE: The projection can become magnetized
due to the magnet inside the wheel speed sensor,
<<A>> FRONT WHEEL SPEED SEN-
causing foreign material to easily adhere to it. The
SOR/REAR WHEEL SPEED SENSOR projection may not be able to correctly sense the
REMOVAL wheel rotation speed if foreign matter is on it or if it
CAUTION is damaged.
<Front> <Rear>
<Front> <Rear>
AC100242 AB AC211699AB
Be careful when handling the projection at the tip 2. Measure the resistance between the wheel speed
of the wheel speed sensor and the toothed edge sensor terminals.
of the wheel speed rotor so as not to damage Standard value: 1.24 − 1.64 kΩ
them by contacting other parts.
3. If the internal resistance of the wheel speed
INSTALLATION SERVICE POINT sensor is not within the standard value, replace it
with a new wheel speed sensor.
>>A<< REAR WHEEL SPEED SENSOR
INSTALLATION
Rear wheel speed sensor
ACX01120 AB
Parking brake cable

AC211698AB
4. Remove all connections from the speed sensor.
The circuit should be open between terminals (1)
Install the rear wheel speed sensor, crossing with the and (2) and the body of the wheel speed sensor. If
parking brake cable as shown. the circuit is not open, replace with a new wheel
speed sensor.
INSPECTION
M1352020800057 5. Check the wheel speed sensor cable for
WHEEL SPEED SENSOR CHECK breakage, damage or disconnection. Replace with
a new one if a problem is found.
1. Check whether any metallic foreign material has
adhered to the projection at the wheel speed NOTE: When checking for cable damage, remove
sensor tip. Remove any foreign material. Also the cable clamp part from the body and then gen-
check whether the pole piece is damaged. tly bend and pull the cable near the clamp.
Replace it with a new one if it is damaged.
G-SENSOR
TOOTHED WHEEL SPEED ROTOR Check whether the wheel speed rotor teeth are bro-
CHECK ken or deformed. Replace the EBJ assembly of the
driveshaft, respectively, if the teeth are damaged or
deformed.
AC000965
G-SENSOR
M1352010100369
CAUTION
Do not drop or apply a shock on the G-sensor.
• Rear Console Assembly Removal and Installation (Refer
to GROUP 52A, Rear Floor Console Assembly P.52A-8).
Parking brake lever
2
Rear of the vehicle Y2056AU
AC211700 AB
>>B<< 1. Lateral G-sensor

>>A<< 2. Longitudinal G-sensor
G-SENSOR
35B-149
INSTALLATION SERVICE POINTS 1. Disconnect the G-sensor connector and connect
>>A<< LONGITUDINAL G-SENSOR special tool test harness set (MB991348),
between terminals of the disconnected connector.
INSTALLATION
2. With the ignition switch turned to the "ON"
The arrow mark on the G-sensor must point to front
position, read the voltage between terminals
of the vehicle.
number 2 and number 3.
>>B<< LATERAL G-SENSOR Standard Value: 2.4 − 2.6 V
INSTALLATION 3. With special tool test harness set (MB991348)
The arrow mark on the G-sensor must point to the connected, rotate so that the arrow points straight
parking brake lever. down. Read output voltage between terminals
number 2 and number 3.
INSPECTION Standard Value: 3.4 − 3.6 V
M1352018000098
LATERAL/LONGITUDINAL G-SENSOR 4. If the voltage deviates from the standard value,

and nothing is wrong with the power supply wire
CHECK and earth wire, replace the G-sensor.
Label
MB991348
Connector: D-37/D-38
(Harness side)
Label
AC103662AG
STEERING WHEEL SENSOR
STEERING WHEEL SENSOR

M1352009500039
CAUTION
• Before removing the steering wheel and air bag module assembly, be sure to refer to GROUP 52B,
Service Precautions (P.52B-3) and Driver’s, Front Passenger’s Air Bag Module and Clock Spring
(P.52B-110).
• Make sure no oil adheres to the steering wheel sensor because a photointerruptors are mounted
on the steering wheel sensor.
• Steering Wheel Removal and Installation (Refer to
GROUP 37, Steering Wheel P.37-13).
• Column Cover, Clock Spring and Column Switch Assem-
bly Removal and Installation (Refer to GROUP 37, Steer-
ing Shaft P.37-15).
AC311019AB
36-1
GROUP 36
PARKING BRAKES
CONTENTS
GENERAL INFORMATION . . . . . . . . 36-2 PARKING BRAKE LEVER . . . . . . . . . 36-4

SERVICE SPECIFICATIONS. . . . . . . 36-2
PARKING BRAKE CABLE. . . . . . . . . 36-5
LUBRICANTS . . . . . . . . . . . . . . . . . . 36-2 REMOVAL AND INSTALLATION . . . . . . . . 36-5
ON-VEHICLE SERVICE. . . . . . . . . . . 36-3 PARKING BRAKE LINING AND DRUM 36-6

PARKING BRAKE LEVER STROKE CHECK REMOVAL AND INSTALLATION . . . . . . . . 36-6
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 36-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 36-7
PARKING BRAKE SWITCH CHECK . . . . . 36-3
LINING RUNNING-IN . . . . . . . . . . . . . . . . . 36-3
36-2 PARKING BRAKES
GENERAL INFORMATION
GENERAL INFORMATION
M1361000100418
The parking brake is of a mechanical control type CONSTRUCTION DIAGRAM
acting on the rear wheels. A lever is used to apply
the parking brake.
AC211553AB
M1361000300490

Parking brake lever stroke (Operation force: Approximately 5 − 7 notches −
200 N)
Rear brake lining thickness mm 2.8 Minimum 1.0
Rear drum inside diameter mm 168.0 169.0
LUBRICANTS
M1361000400367
Item Specified lubricant

Backing plate Brake grease SAE J310, NLGI No.1
Shoe and lining assembly
Adjuster
PARKING BRAKES
ON-VEHICLE SERVICE
36-3
ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE
CHECK AND ADJUSTMENT
M1361000900447
1. Pull the parking brake lever with a force of
approximately 200 N and count the number of
notches.
Standard value: 5 − 7 notches
2. If the parking brake lever stroke is not the
standard value, adjust as described below.
AC006198AB
(1) Remove the rear floor console assembly
(Refer to GROUP 52A, Rear Floor Console 3. Check for continuity between the parking brake
P.52A-8). switch terminal and the switch mounting bolt.
When parking brake lever is pulled Less than 2
Cable rod ohms
Adjusting nut When parking brake lever is Open circuit
released
LINING RUNNING-IN
M1361001100336
Pull
AC006190
(2) Loosen the adjusting nut to move it to the Spring balance

cable rod end so that the cable will be free.
(3) Depress the brake pedal repeatedly until the
lever has no change in its stroke.
NOTE: Depressing the brake pedal repeatedly Approximately
40 mm
adjusts shoe clearance correctly.
AC212035AB
CAUTION
If the parking brake lever stroke is below the Carry out running-in by the following procedure when
standard value and the braking is too firm, the replacing the parking brake linings or the rear brake
rear brakes may drag. disc rotors, or when brake performance is insuffi-
(4) Turn the adjusting nut to adjust the parking cient.
brake lever stroke to the standard value. After CAUTION
adjusting, check that there is no space Carry out running-in a place with good visibility,
between the adjusting nut and the parking and pay careful attention to safety.
brake lever. Check that the adjusting nut is 1. Adjust the parking brake stroke to the standard
secured with the nut holder. value.
(5) After adjusting the parking brake lever stroke, Standard value (Operation force: Approxi-
jack up the rear end of the vehicle, and then mately 200 N): 5 - 7 notches
release the parking brake and turn the rear
2. Hook a spring balance onto the centre of the
wheels to check that the rear brakes are not parking brake lever grip and pull it with a force of
dragging. 100 − 150 N in a direction perpendicular to the
handle.
PARKING BRAKE SWITCH CHECK 3. Drive the vehicle at a constant speed of 35 − 50
M1361003300488
km/h for 100 meters.
1. Remove the rear floor console assembly (Refer to 4. Release the parking brake and let the brakes cool
GROUP 52A, Rear Floor Console P.52A-8). for 5 - 10 minutes.
2. Remove the front seat assembly (RH) (Refer to 5. Repeat the procedure in steps 2 to 4, four or five
GROUP 52A, Front Seat P.52A-18). times.
36-4 PARKING BRAKES
PARKING BRAKE LEVER
PARKING BRAKE LEVER

M1361001300426

Rear Floor Console Assembly and Rear Console Bracket • Parking Brake Lever Stroke Adjustment (Refer to P.36-3).
Removal (Refer to GROUP 52A, Rear Floor Console • Rear Floor Console Assembly and Rear Console Bracket
P.52A-8). Installation (Refer to GROUP 52A, Rear Floor Console
P.52A-8).
2
AC212036 AB
Section A - A Section B - B
Ratchet pawl
A
Ratchet plate
B
A ABC
B
AC212037AB

1. Adjusting nut 4. Parking brake lever assembly
2. Parking brake switch connector 5. Parking brake switch
3. Parking brake cable connection
PARKING BRAKES
PARKING BRAKE CABLE
36-5
PARKING BRAKE CABLE
M1361001900644
CAUTION
During maintenance, take care not to contact the parts or tools to the caliper because the paint of cal-
iper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly.
• Rear Floor Console Assembly and Rear Console Bracket • Parking Brake Lever Stroke adjustment (Refer to P.36-3).
Removal (Refer to GROUP 52A, Rear Floor Console • Rear Seat Cushion Installation (Refer to GROUP 52A,
P.52A-8). Rear Seat P.52A-20).
• Rear Seat Cushion Assembly Removal (Refer to GROUP • Rear Floor Console Assembly and Rear Console Bracket
52A, Rear Seat P.52A-20). Installation (Refer to GROUP 52A, Rear Floor Console
P.52A-8).
1 AC212038 AB

• Shoe and lining assembly (Refer to • Parking brake cable connection
P.36-6). (Refer to P.36-4).
1. Parking brake cable
36-6 PARKING BRAKES
PARKING BRAKE LINING AND DRUM

M1361002500401
CAUTION
During maintenance, take care not to contact the parts or tools to the caliper because the paint of cal-
118 ± 19 N·m
54 ± 5 N·m
14 1
12
11
3
10 6
13 7
11
9
4 2
8 5
11
Specified grease: Brake grease SAE J310, NLGI No.1
AC212051 AB

<<A>> 1. Rear disc brake caliper assembly 9. Rear brake shoe hold-down spring
2. Rear brake disc 10. Parking brake cable clip
>>B<< 3. Rear brake shoe return spring 11. Rear brake shoe assembly
4. Rear brake shoe auto adjuster spring 12. Rear hub assembly (Refer to GROUP
>>A<< 5. Rear brake shoe slack adjuster 27, Rear Hub Assembly P.27-32).
6. Parking brake operating lever strut 13. Rear brake backing plate
7. Rear brake shoe-to-strut spring 14. Rear brake pin
8. Rear brake shoe spring cup
PARKING BRAKES
36-7
REMOVAL SERVICE POINT Install the rear brake shoe return springs in the order
shown in the illustration.
<<A>> REAR DISC BRAKE CALIPER
NOTE: The figure shows the left wheel; for the right
ASSEMBLY REMOVAL
wheel, the position is symmetrical.
CAUTION
Take care not to contact the parts or tools to the INSPECTION
M1361002600334
caliper because the paint of caliper will be
scratched. And if there is brake fluid on the cali- BRAKE LINING AND BRAKE DRUM
per, wipe it off quickly. CHECK
Remove the rear brake caliper assembly and support
it with a wire or similar material.

>>A<< REAR BRAKE SHOE SLACK
ADJUSTER INSTALLATION
AC212066
1. Measure the thickness of the brake lining at

several places.
Shoe adjusting bolt Standard value: 2.8 mm
Limit: 1.0 mm
AC212064 AB
2. If the thickness of the brake lining has worn down
to the limit value or more, replace the rear brake
Install the rear brake adjuster so that the shoe shoe assemblies on both sides of the vehicle.
adjusting bolt of left hand wheel is attached towards
the rear of the vehicle, and the shoe adjusting bolt of
right hand wheel is towards the front of the vehicle.
>>B<< REAR BRAKE SHOE RETURN

SPRING INSTALLATION
AC212064AB
Rear of
vehicle
3. Measure the inside diameter of the brake disc in
two places or more.
1 2 Limit: 169.0 mm
Paint
AC212065 AB 4. If the inside of the brake disc has worn down to
the limit value or more, or if it is excessively worn
on one side, replace the brake disc.
NOTES
55-1
GROUP 55
HEATER, AIR
CONDITIONER AND
VENTILATION
CONTENTS
SERVICE SPECIFICATIONS. . . . . . . 55-3 COMPRESSOR NOISE CHECK . . . . . . . . . 55-106

POWER RELAY CHECK. . . . . . . . . . . . . . . 55-107
LUBRICANTS . . . . . . . . . . . . . . . . . . 55-3 IDLE-UP OPERATION CHECK. . . . . . . . . . 55-107
CLEAN AIR FILTER REPLACEMENT
SPECIAL TOOLS. . . . . . . . . . . . . . . . 55-3 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55-108
TROUBLESHOOTING . . . . . . . . . . . . 55-5 HEATER CONTROL ASSEMBLY AND

DIAGNOSIS TROUBLESHOOTING FLOW 55-5 A/C SWITCH . . . . . . . . . . . . . . . . . . . . 55-108
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 55-5 REMOVAL AND INSTALLATION . . . . . . . . 55-108
DIAGNOSIS CODE CHART . . . . . . . . . . . . 55-5
HEATER UNIT, HEATER CORE,
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 55-6 BLOWER ASSEMBLY AND
TROUBLE SYMPTOM CHART. . . . . . . . . . 55-29 EVAPORATOR UNIT . . . . . . . . . . . . . 55-109
SYMPTOM PROCEDURES . . . . . . . . . . . . 55-29 REMOVAL AND INSTALLATION . . . . . . . . 55-109
DATA LIST REFERENCE TABLE . . . . . . . 55-100 HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . . 55-110
ACTUATOR TEST TABLE . . . . . . . . . . . . . 55-101 DISASSEMBLY AND REASSEMBLY <LHD> 55-110
CHECK AT ENGINE-A/T ECU TERMINALS 55-101 DISASSEMBLY AND REASSEMBLY <RHD> 55-111
CHECK AT A/C-ECU TERMINALS. . . . . . . 55-102 BLOWER ASSEMBLY. . . . . . . . . . . . . . . . . 55-112
DISASSEMBLY AND REASSEMBLY . . . . . 55-112
ON-VEHICLE SERVICE. . . . . . . . . . . 55-104
MAGNETIC CLUTCH TEST . . . . . . . . . . . . 55-104 MODE SELECTION DAMPER CONTROL
COMPRESSOR DRIVE BELT
MOTOR, AIR MIXING DAMPER CONTROL
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 55-104 MOTOR, OUTSIDE/INSIDE AIR
DUAL PRESSURE SWITCH CHECK . . . . . 55-104 SELECTION DAMPER CONTROL
CHARGING AND DISCHARGING . . . . . . . 55-104
MOTOR AND BLOWER MOTOR . . . . 55-113
REFILLING OF OIL IN THE A/C SYSTEM . 55-104
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-114
PERFORMANCE TEST . . . . . . . . . . . . . . . 55-104
REFRIGERANT LEAK REPAIR
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55-105 Continued on next page
55-2
SENSORS . . . . . . . . . . . . . . . . . . . . . 55-116 DISASSEMBLY AND REASSEMBLY . . . . . 55-124

REMOVAL AND INSTALLATION . . . . . . . . 55-116 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-125
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-117
CONDENSER AND CONDENSER
EVAPORATOR ASSEMBLY . . . . . . . 55-118 FAN MOTOR. . . . . . . . . . . . . . . . . . . . 55-126
REMOVAL AND INSTALLATION <LHD> . . 55-118 REMOVAL AND INSTALLATION . . . . . . . . 55-126
REMOVAL AND INSTALLATION <RHD> . 55-119 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-127
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-120
REFRIGERANT LINE . . . . . . . . . . . . . 55-128
OUTSIDE THERMO SENSOR . . . . . . 55-121 REMOVAL AND INSTALLATION <LHD> . . 55-128
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-121 REMOVAL AND INSTALLATION <RHD> . . 55-129
COMPRESSOR ASSEMBLY AND DUCTS . . . . . . . . . . . . . . . . . . . . . . . . 55-130

TENSION PULLEY. . . . . . . . . . . . . . . 55-122 REMOVAL AND INSTALLATION . . . . . . . . 55-130
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-123 VENTILATORS . . . . . . . . . . . . . . . . . . 55-131
HEATER, AIR CONDITIONER AND VENTILATION
55-3
M1552000300515
Item Standard value

Idle speed r/min 850 ± 50
Idle-up speed r/min 850 ± 50
Air gap (magnetic clutch) mm 0.3 − 0.5
Resistance value for air mixing damper control motor and potentiometer kΩ Approximately 0.65 − 5.35
Resistance value for mode selection damper control motor and Approximately 0.65 − 5.35
potentiometer kΩ
A/C refrigerant temperature switch operating Being turned off 150
temperature °C Being turned on 120
LUBRICANTS
M1552000400396
Item Specified lubricant Quantity

Compressor refrigerant unit lubricant SUN PAG 56 120 mL
Each connection of refrigerant line SUN PAG 56 As required
Refrigerant R134a (HFC-134a) 480 − 520 g
SPECIAL TOOLS
M1552000600505

MB991367 Special spanner Armature mounting nut of
compressor removal and
installation
B991367
MB991386 Pin
MB991502 M.U.T.-II sub-assembly Automatic A/C check
B991502
55-4 HEATER, AIR CONDITIONER AND VENTILATION
SPECIAL TOOLS

MB991955 M.U.T.-III sub-assembly Automatic A/C check
A A: MB991824 A: Vehicle CAUTION
B: MB991827 Communication M.U.T.-III main harness B
C: MB991910 Interface (V. C. I.) (MB991911) should be
D: MB991911 B: M.U.T.-III USB cable used. M.U.T.-III main
MB991824 E: MB991825 C: M.U.T.-III main harness A should not be
B F: MB991826 harness A (Vehicles with used for this vehicle.
CAN communication
system)
D: M.U.T.-III main
MB991827 harness B (Vehicles
without CAN
C
communication system)
DO NOT USE E: M.U.T.-III
measurement adapter
MB991910
harness
D
MB991911
MB991825
MB991826
MB991955

a
a. MB991219 a. Check harness measurement at harness wire
b. MB991220 b. LED harness or connector
c. MB991221 c. LED harness adapter a. For checking connector
d. MB991222 d. Probe pin contact pressure
b b. For checking power supply
circuit
circuit
c d. For connecting a locally
sourced tester
d
DO NOT USE
MB991223BA
TROUBLESHOOTING
55-5
measurement at harness wire
or connector
MB992006
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW DIAGNOSIS FUNCTION
M1554004700102 M1554004800176
Refer to GROUP 00, How to Use Troubleshoot- How to read diagnosis code
ing/Inspection Service Points P.00-5. Connect the M.U.T.-II/III to the 16-pin diagnosis con-
nector to read diagnosis code (Refer to GROUP 00,
How to Use Troubleshooting/Inspection Service
Points P.00-5).
How to erase diagnosis code

DIAGNOSIS CODE CHART

M1554004900537
Code No. Diagnostic item Reference page

11 Interior temperature senor system (open circuit) P.55-6
12 Interior temperature sensor system (short circuit)
13 Outside thermo sensor system (open circuit) P.55-8
14 Outside thermo sensor system (short circuit)
15 Heater water temperature sensor system (open circuit) P.55-11
16 Heater water temperature sensor system (short circuit)
21 Air thermo sensor system (open circuit) P.55-14
22 Air thermo sensor system (short circuit)
31 Air mixing damper control motor and potentiometer sensor system P.55-17
32 Mode selection damper control motor and potentiometer sensor P.55-20
system
41 Air mixing damper control motor and potentiometer activating P.55-23
system
42 Mode selection damper control motor and potentiometer activating P.55-26
system
TROUBLESHOOTING

PROCEDURES
Code No.11, 12: Interior Temperature Sensor System
Interior Temperature Sensor Circuit
A/C-ECU
INTERIOR
TEMPERATURE
SENSOR
Wire colour code

BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple

This code is set when the interior temperature sensor
circuit is open (Code No.11) or is short (Code No.12). STEP 1. Check the interior temperature sensor.
Refer to P.55-117.
PROBABLE CAUSES
• Malfunction of the interior temperature sensor Q: Is the check result normal?
• Damaged the wiring harness or connectors YES : Go to Step 2.
• Malfunction of the automatic A/C control panel NO : Replace the interior temperature sensor.
(A/C-ECU)
TROUBLESHOOTING
55-7
STEP 2. Connector check: C-36 A/C-ECU STEP 3. Check the wiring harness between C-36
connector and C-142 interior temperature sensor A/C-ECU connector (terminals 1 and 20) and
connector C-142 interior temperature sensor connector
(terminals 2 and 1).
Connector: C-36, C-142 <LHD>
C-142 (B)
C-36 (B) C-142 (B)
C-36 (B)
Harness side
C-36 Harness side
C-36
C-142
C-142
AC504641AC
AC504641AC
Connector: C-36 <RHD>
Harness side
Harness side
C-36 (B)
C-36 (B)
AC504618AJ
AC504618AJ
Harness side
Harness side
C-142 (B)
C-142 (B)
AC504625AD
AC504625AD
YES : Go to Step 3. • Check the sensor signal line and earth line for
NO : Repair the connector. open or short circuit.
YES : Replace the automatic A/C control panel
(A/C-ECU)
TROUBLESHOOTING
Code No.13, 14: Outside Thermo Sensor System
Outside Thermo Sensor Circuit
A/C-ECU
OUTSIDE
THERMO
SENSOR
Wire colour code


This code is set when the outside thermo sensor cir-
cuit is open (Code No.13) or is short (Code No.14). STEP 1. Check the outside thermo sensor.
Refer to P.55-121.
PROBABLE CAUSES
• Malfunction of the outside thermo sensor Q: Is the check result normal?
• Damaged the wiring harness and connectors YES : Go to Step 2.
• Malfunction of the automatic A/C control panel NO : Replace the outside thermo sensor.
(A/C-ECU)
TROUBLESHOOTING
55-9
STEP 2. Connector check: A-44 outside thermo STEP 3. Check the wiring harness between A-44
sensor connector and C-36 A/C-ECU connector outside thermo sensor connector (terminals 1
Connector: A-44
and 2) and C-36 A/C-ECU connector (terminals 20
and 7).
Connector: A-44
Harness side
Harness side
A-44 (BR)
A-44 (BR)
AC504656AB
Connector: C-36 <LHD> AC504656AB
Connector: C-36 <LHD>
Harness side
C-36 (B)
Harness side
AC504622AB C-36 (B)

AC504622AB
Harness side
Harness side
C-36 (B)
C-36 (B)
AC504618AJ
Q: Is the check result normal? AC504618AJ

YES : Go to Step 3.
NO : Repair the connector.
TROUBLESHOOTING
NOTE:
AC504618AK
AC504622AE

diate connector C-145 <LH drive vehicles> or C-129
<RH drive vehicles>, and repair if necessary.
• Check the sensor signal line and earth line for
open or short circuit.
(A/C-ECU)
TROUBLESHOOTING
55-11
Code No.15, 16: Heater Water Temperature Sensor System
Heater Water Temperature Sensor Circuit
HEATER WATER
TEMPERATURE
SENSOR
A/C-ECU
Wire colour code


This code is set when the heater water temperature
sensor circuit is open (Code No.15) or is short (Code STEP 1. Check the heater water temperature
No.16). sensor.
Refer to P.55-117.
PROBABLE CAUSES
• Malfunction of the heater water temperature sen- Q: Is the check result normal?
sor YES : Go to Step 2.
• Damaged the wiring harness or connectors NO : Replace the heater water temperature
• Malfunction of the automatic A/C control panel sensor.
(A/C-ECU)
TROUBLESHOOTING
connector and C-32 heater water temperature A/C-ECU connector (terminals 4 and 20) and C-32
connector heater water temperature sensor connector
(terminals 2 and 1).
Harness side
Harness side
AC504617AJ
AC504617AJ
Connector: C-32, C-36 <RHD>
C-32
C-36 (B) C-32
C-36 (B)
Harness side
C-32 Harness side
C-32
C-36
C-36
AC504624AE
AC504624AE
Harness side
C-36 (B)
Harness side
C-36 (B)
AC504622AB
AC504622AB
YES : Go to Step 3.
TROUBLESHOOTING
55-13
NOTE:
AC504617AF
AC504618AF

diate connector C-10, and repair if necessary.
• Check the sensor signal line and earth line for
(A/C-ECU)
TROUBLESHOOTING
Code No.21, 22: Air Thermo Sensor System
<LHD>
Air Thermo Sensor Circuit
AIR THERMO
SENSOR
A/C-ECU
Wire colour code

<RHD>
Air Thermo Sensor Circuit
HEATER WATER AIR THERMO

TEMPERATURE SENSOR
SENSOR
A/C-ECU
Wire colour code

TROUBLESHOOTING
55-15
COMMENTS ON TROUBLE SYMPTOM STEP 2. Connector check: C-36 A/C-ECU
This code is set when the air thermo sensor circuit is connector and C-35 air thermo sensor connector
open (Code No.21) or is short (Code No.22).
PROBABLE CAUSES
• Malfunction of the air thermo sensor
Harness side
• Damaged the wiring harness or connectors
• Malfunction of the automatic A/C control panel
(A/C-ECU)
DIAGNOSIS PROCEDURE
AC504617AD
STEP 1. Check the air thermo sensor.
Refer to P.55-120. Connectors: C-35, C-36 <RHD>

YES : Go to Step 2.
NO : Replace the air thermo sensor.
C-36 (B)
C-35
Harness side
C-35
C-36
AC504624AC
Harness side
C-36 (B)
AC504622AB

YES : Go to Step 3.
TROUBLESHOOTING
STEP 3. Check the wiring harness between C-36 NOTE:

A/C-ECU connector (terminals 8 and 20) and C-35
air thermo sensor connector (terminals 1 and 2).
Harness side
AC504617AF

AC504617AD
Connectors: C-35, C-36 <RHD>
C-36 (B) AC504618AF

C-35
Harness side
Harness side
C-35
C-36
AC504618AL

diate connector C-10 and heater water temperature
AC504624AC sensor connector C-32 <RH drive vehicles>, and
Connector: C-36 <LHD> • Check the sensor signal line and earth line for
(A/C-ECU)
Harness side
C-36 (B)
AC504622AB
TROUBLESHOOTING
55-17
Code No.31: Air Mixing Damper Control Motor Potentiometer System
<LHD>
Air Mixing Damper Control Motor Potentiometer Circuit
AIR MIXING DAMPER

CONTROL MOTOR AND
POTENTIOMETER
A/C-ECU
Wire colour code

<RHD>
Air Mixing Damper Control Motor Potentiometer Circuit
AIR MIXING DAMPER

CONTROL MOTOR AND
POTENTIOMETER
A/C-ECU
Wire colour code

TROUBLESHOOTING

This code is set when the air mixing damper control connector and C-144 air mixing damper control
motor potentiometer does not send any signal to the motor and potentiometer connector
A/C-ECU due to short or open circuit.
PROBABLE CAUSES
• Malfunction of the air mixing damper control
motor and potentiometer
(A/C-ECU) Harness side
C-36 (B)
DIAGNOSIS PROCEDURE
AC504622AB
STEP 1. Check the air mixing damper control Connectors: C-36, C-144 <RHD>
motor and potentiometer.
Refer to P.55-114.
YES : Go to Step 2.
NO : Replace the air mixing damper control C-144 C-36 (B)
Harness side
C-36
C-144
AC504624AI
Harness side
AC504617AL

YES : Go to Step 3.
TROUBLESHOOTING
55-19
STEP 3. Check the wiring harness between C-36 Connectors: C-10, C-144 <LHD>
A/C-ECU connector (terminals 10, 5 and 20) and
C-144 air mixing damper control motor and
C-144
potentiometer connector (terminals 2, 5 and 6).
C-10
C-10
Harness side
C-36 (B)
AC504622AB
Connectors: C-10, C-32, C-36, C-144 <RHD>

Harness side
C-144
C-32
C-10 AC504701AC
C-144 C-36 (B)
NOTE: Prior to the wiring harness inspection, check
intermediate connector C-10, and heater water tem-
Harness side
perature sensor connector C-32 <RH drive vehi-
C-10 C-32 cles>, and repair if necessary.
• Check the potentiometer power supply, earth and
signal line for open or short circuit.
Harness side Harness side (A/C-ECU).
C-36 C-144 NO : Repair the wiring harness.
AC504624AQ
TROUBLESHOOTING
Code No.32: Mode Selection Damper Control Motor Potentiometer System
<LHD>
Mode Selection Damper Control Motor Potentiometer Circuit
MODE SELECTION
DAMPER CONTROL
MOTOR AND
POTENTIOMETER
A/C-ECU
Wire colour code

<RHD>
Mode Selection Damper Control Motor Potentiometer Circuit
MODE SELECTION
DAMPER CONTROL
MOTOR AND
POTENTIOMETER HEATER WATER
TEMPERATURE SENSOR
A/C-ECU
Wire colour code

TROUBLESHOOTING
55-21
This code is set when the mode selection damper connector and C-143 mode selection damper
control motor potentiometer does not send any sig- control motor and potentiometer connector
nal to the A/C-ECU due to short or open circuit.
PROBABLE CAUSES
• Malfunction of the mode selection damper control
(A/C-ECU)
• Damaged the wiring harness or connectors Harness side
C-36 (B)
DIAGNOSIS PROCEDURE
AC504622AB
STEP 1. Check the mode selection damper Connectors: C-36, C-143 <RHD>
control motor and potentiometer. C-143
Refer to P.55-114.
YES : Go to Step 2.
NO : Replace the mode selection damper control C-36 (B)
Harness side
C-36
C-143
AC504624AK
Harness side
AC504617AM

YES : Go to Step 3.
TROUBLESHOOTING
A/C-ECU connector (terminals 10, 6 and 20) and
C-143 mode selection damper control motor and
potentiometer connector (terminals 2, 5 and 6). C-143
C-10
C-10
Harness side
C-36 (B)
AC504622AB
Connectors: C-10, C-32, C-36, C-143 <RHD> Harness side

C-143
C-143
C-10 C-32 AC504701AD

C-36 (B)
intermediate connector C-10 and heater water tem-
Harness side perature sensor connector C-32 <RH drive vehi-
C-10
C-32 cles>, and repair if necessary.
• Check the potentiometer power supply, earth and
signal line for open or short circuit.
Harness side Harness side YES : Malfunction of the automatic A/C control
C-36 C-143 panel (A/C-ECU)
AC504624AR
TROUBLESHOOTING
55-23
Code No.41: Air Mixing Damper Control Motor System
Air Mixing Damper Control Motor Circuit
AIR MIXING DAMPER CONTROL

MOTOR AND POTENTIOMETER
A/C-ECU
MOTOR
DRIVE CIRCUIT
Wire colour code


This code is set when the air mixing damper cannot
be rotated to the preset opening angle. STEP 1. Check the air mixing damper control
PROBABLE CAUSES
Refer to P.55-114.
• Malfunction of the air mixing damper control
motor and potentiometer Q: Is the check result normal?
• Malfunction of the automatic A/C control panel YES : Go to Step 2.
(A/C-ECU) NO : Replace the air mixing damper control
• Damaged the wiring harness or connectors motor and potentiometer.
TROUBLESHOOTING

STEP 2. Connector check: C-37 A/C-ECU
YES : Go to Step 3.
connector and C-144 air mixing damper control NO : Repair the connector.
motor and potentiometer connector
Harness side
C-37 (B)
AC504622AC
C-144 C-37 (B)
Harness side
C-37
C-144
AC504624AM
Harness side
AC504617AL
TROUBLESHOOTING
55-25
A/C-ECU connector (terminals 22 and 25) and
C-144 air mixing damper control motor and
C-144
potentiometer connector (terminals 3 and 1).
C-10
Harness side
C-10
C-37 (B)
AC504622AC
Connectors: C-10, C-37, C-144 <RHD>

Harness side
C-144
C-10 AC504701AC
C-144 C-37 (B)
intermediate connector C-10, and repair if necessary.
• Check the motor activating lines for open or short
C-10 circuit.
YES : Malfunction of the automatic A/C control
panel (A/C-ECU)
C-37 C-144
AC504624AN
TROUBLESHOOTING
Code No.42: Mode Selection Damper Control Motor and Potentiometer Activating System
Mode Selection Damper Control Motor and Potentiometer Circuit
MODE SELECTION DAMPER CONTROL

MOTOR AND POTENTIOMETER
A/C-ECU
MOTOR
DRIVE CIRCUIT
Wire colour code


This code is set when the mode selection damper
cannot be rotated to the preset opening angle. STEP 1. Check the mode selection damper
control motor and potentiometer.
PROBABLE CAUSES
Refer to P.55-114.
• Malfunction of the mode selection damper control
motor and potentiometer Q: Is the check result normal?
• Malfunction of the automatic A/C control panel YES : Go to Step 2.
(A/C-ECU) NO : Replace the mode selection damper control
• Damaged the wiring harness or connectors motor and potentiometer.
TROUBLESHOOTING
55-27
STEP 2. Connector check: C-37 A/C-ECU
YES : Go to Step 3.
connector and C-143 mode selection damper NO : Repair the connector.
control motor and potentiometer connector
Harness side
C-37 (B)
AC504622AC
C-143
C-37 (B)
Harness side
C-37
C-143
AC504624AO
Harness side
AC504617AM
TROUBLESHOOTING
C-143 mode selection damper control motor and
potentiometer connector (terminals 3 and 1). C-143
C-10
Harness side
C-10
C-37 (B)
AC504622AC
Connectors: C-10, C-37, C-143 <RHD> Harness side

C-143
C-143
C-10 AC504701AD
C-37 (B)
C-10 circuit.
(A/C-ECU).
C-37 C-143
AC504624AP
TROUBLESHOOTING
55-29
M1554005000571
Symptom Inspection Reference page

procedure number
Communication with the M.U.T.-II/III is not possible. 1 P.55-29
When the A/C is operating, temperature inside the 2 P.55-32
passenger compartment does not decrease (cool air is
not emitted).
A/C outlet air temperature cannot be set. 3 P.55-41
The blower does not work. 4 P.55-42
The blower air volume cannot be changed. 5 P.55-54
When sunlight intensity changes, blower air 6 P.55-56
temperature does not change.
The outside/inside air changeover is impossible. 7 P.55-58
Rear window defogger function does not operate. 8 P.55-63
Malfunction of the A/C-ECU power supply system. 9 P.55-73
A/C compressor power supply system. 10 P.55-79
Condenser fan does not operate. 11 P.55-86
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with the M.U.T.-II/III is not Possible.
Diagnosis Connector Circuit
A/C-ECU
<LHD>
<RHD>
DIAGNOSIS
CONNECTOR
FRONT SIDE
Wire colour code

TROUBLESHOOTING

If communication with all other systems is not possi- connector and C-14 diagnosis connector
ble, there is a high possibility that there is a malfunc-
tion of the diagnosis line. If only the A/C system can Connector: C-14, C-36 <LHD>
not communicate with the M.U.T.-II/III, the diagnosis
line between the A/C-ECU and the diagnosis con-
nector may be defective.
PROBABLE CAUSES
C-36 (B)
C-14
(A/C-ECU)

C-14
STEP 1. Check the communication with other
systems.
Q: Is the communication with the other systems C-36
possible using the M.U.T.-II/III?
YES : Go to Step 2.
NO : Check the diagnosis line using the
M.U.T.-II/III, and repair if necessary.
AC504641AD
STEP 2. Check operations of the A/C, rear Connector: C-14 <RHD>

window defogger and outside/inside air selection
damper control motor.
Q: Does the A/C, rear window defogger or Harness side
outside/inside air selection damper control motor
operate?
YES : Go to Step 3.
NO : Refer to Inspection procedure 9
"Malfunction of the A/C-ECU power supply C-14 (B)
system P.55-73." AC504625AE
Harness side
C-36 (B)
AC504618AJ

YES : Go to Step 4.
TROUBLESHOOTING
55-31
A/C-ECU connector (terminal 17 and 18) and C-14
diagnosis connector (terminal 11 and 1).
AC504618AM
C-36 (B)
C-14 Connector: C-23 <LHD>
Harness side
C-14
C-23 (B)
C-36
AC504622AG
Prior to the wiring harness inspection, check joint

connector C-23 <LH drive vehicles> or C-21 <RH
AC504641AD drive vehicles> , and repair if necessary.
• Check the communication lines for open or short
Connector: C-14 <RHD> circuit.
Harness side
(A/C-ECU).
C-14 (B)
AC504625AE
Harness side
C-36 (B)
AC504618AJ
TROUBLESHOOTING
Inspection Procedure 2: When the A/C is Operating, Temperature Inside the Passenger Compartment
does not Decrease (Cool Air is not Emitted).
A/C-ECU System Circuit
ENGINE-ECU
LOW- DUAL
PRESSURE PRESSURE
SIDE SWITCH
HIGH-
PRESSURE
SIDE
A/C-ECU
Wire colour code

B : Black
LG : Light green
G : Green
L: Blue
W : White
Y: Yellow
SB : Sky blue BLOWER LINER
BR : Brown CONTROLLER
O : Orange
GR : Grey
R : Red AIR THERMO
P : Pink SENSOR
V : Violet
PU: Purple
TROUBLESHOOTING
55-33
COMMENTS ON TROUBLE SYMPTOM STEP 4. Connector check: A-36 A/C compressor
If cool air is not distributed when the A/C switch is on, connector and C-121 engine-ECU connector
the air thermo sensor or the A/C compressor relay
Connector: A-36
system may be defective.
PROBABLE CAUSES
• Improper amount of refrigerant Harness side
• Malfunction of the air thermo sensor
• Malfunction of the dual pressure switch
• Malfunction of the A/C compressor relay
• Malfunction of the A/C refrigerant temperature
switch A-36 (B)
• Malfunction of the magnetic clutch AC504616AB
• Malfunction of the manual air conditioner control Connector: C-121 <LHD>

panel (A/C-ECU)
Harness side
• Malfunction of the engine-ECU
DIAGNOSIS PROCEDURE C-121 (GR)
STEP 1. Check the rear window defogger and

operation. AC504617AB
Q: Do the rear window defogger and outside/inside air Connector: C-121 <RHD>
selection damper control motor work normally? Harness side
YES : Go to Step 2.
"Malfunction of the A/C-ECU power supply
C-121 (GR)
system P.55-73 ."
STEP 2. Check the blower motor operation.

Q: Does the blower motor work normally?
AC504618AB
YES : Go to Step 3.
NO : Refer to Inspection procedure 4 "The blower Q: Is the check result normal?
does not work P.55-42." YES : Go to Step 5.
STEP 3. Check the A/C compressor.
Check the A/C compressor for compressor oil leaks.
Q: Is the check result satisfactory?
YES : Go to Step 4.
NO : Replace the A/C compressor or the
expansion valve.
TROUBLESHOOTING
STEP 5. Voltage measurement at the A-36 A/C (3) Turn the ignition switch to the "ON" position.
compressor connector.
Connector: A-36
Connector A-36
(Harness side)
Harness side 1
AC301541GC
A-36 (B) AC504616AB (4) Measure the voltage between terminal 1 and
(1) Disconnect the connector, and measure at the body earth.
wiring harness side. OK: System voltage
Connector: C-121 <LHD> Q: Is the check result normal?
Harness side YES : Go to Step 6.
NO : Refer to Inspection procedure 10 "A/C
Compressor power supply system P.55-79."
C-121 (GR)
AC504617AB

Harness side
C-121 (GR)
AC504618AB
Connector C-121
(Harness side)
AC504619AB
(2) Disconnect engine-ECU connector C-121, and

earth terminal 20.
TROUBLESHOOTING
55-35
connector and C-34 blower liner controller blower liner controller connector terminal No.5
connector and C-36 A/C-ECU connector terminal No.2.
Connector: C-34 <LHD> Connector: C-34 <LHD>
AC504617AC AC504617AC
Connectors: C-34, C-36 <RHD> Connectors: C-34, C-36 <RHD>
C-36 (B) C-36 (B)

C-34 C-34

C-34 C-34
C-36 C-36
AC504624AB AC504624AB

C-36 (B) C-36 (B)
AC504622AB AC504622AB

YES : Go to Step 7. YES : Go to Step 8.
NO : Repair the connector. NO : Repair the wiring harness.
TROUBLESHOOTING
STEP 8. Connector check: A-25 dual pressure STEP 11. Check the wiring harness between C-35
switch connector air thermo sensor connector (terminals 4 and 5)
Connector: A-25
and C-36 A/C-ECU connector (terminals 8 and
10).
A-25 (BR) Connector: C-35 <LHD>
Harness side
Harness side
AC504616AC
Q: Is the check result normal? AC504617AD

YES : Go to Step 9.
NO : Repair the connector. Connectors: C-35, C-36 <RHD>
STEP 9. Check the dual pressure switch

operation.
Refer to P.55-104.
Q: Is the dual pressure switch operating properly? C-36 (B)
YES : Go to Step 10. C-35
NO : Replace the dual pressure switch.
STEP 10. Connector check: C-35 air thermo Harness side

sensor connector C-35
Harness side C-36
AC504624AC
AC504617AD
Harness side
Harness side
C-36 (B)
AC504622AB
AC504618AD

TROUBLESHOOTING
55-37
NOTE: STEP 12. Check the wiring harness between A-25
dual pressure switch connector terminal No.1
and C-37 A/C-ECU connector terminal No.34.
Connector: A-25
A-25 (BR)
Harness side
AC504617AF

AC504616AC
Harness side
AC504618AF
C-37 (B)
• Check the air thermo sensor output and earth line AC504622AC
for open or short circuit. Connector: C-37 <RHD>

C-37 (B)
AC504618AE
TROUBLESHOOTING
NOTE: STEP 13. Connector check: C-117 engine-ECU

connector
Harness side
C-117 (GR)
AC504617AE

AC504617AG
Connector: C-117
Harness side
AC504625AB
C-117 (GR)
AC504618AY
• Check the dual pressure switch output line for Q: Is the check result normal?
open or short circuit. YES : Go to Step 14.
Q: Is the check result normal? NO : Repair the connector.
TROUBLESHOOTING
55-39
STEP 14. Check the wiring harness between Connector: C-117, C-122 <RHD>
C-117 engine-ECU connector terminal No.83 and
A-25 dual pressure switch connector terminal
No.2.
C-117 (GR)
Connector: A-25
A-25 (BR)
C-122
Harness side
C-117
Harness side
AC504616AC

C-122
C-117 (GR)
AC504624AS
NOTE:
C-111
C-111
C-117
AC504701AE
AC504622AD

diate connector C-111 and C-124 <LH drive vehi-
cles> or C-122 <RH drive vehicles>, and repair if
necessary.
• Check the communication line for open or short
circuit.
TROUBLESHOOTING
STEP 15. Connector check: C-119 engine-ECU STEP 16. Check the wiring harness between
connector C-119 engine-ECU connectors terminal No.65
and C-37 A/C-ECU connector terminal No.32.
Harness side
C-119 (GR)
Harness side
C-37 (B)
AC504617AH
AC504622AC
Harness side Connector: C-37 <RHD>
Harness side
C-119 (GR)
C-37 (B)
AC504618AI
AC504618AE
YES : Go to Step 16. Connector: C-119 <LHD>
Harness side
C-119 (GR)
AC504617AH

Harness side
C-119 (GR)
AC504618AI
TROUBLESHOOTING
55-41
NOTE: STEP 17. Check the magnetic clutch operation.
Refer to P.55-123.
Q: Can the sound of the magnetic clutch (click) be
heard?
NO : Replace the compressor magnet clutch.
C-122 (L) STEP 18. Check the refrigerant temperature

switch.
AC504618AH Refer to P.55-125.
Connector: C-124 <LHD> Q: Is the refrigerant temperature switch operating
properly?
NO : Replace the refrigerant temperature switch.
STEP 19. Check the air thermo sensor.

Refer to P.55-120.
Q: Is the air thermo sensor in good condition?
AC504622AD
NO : Replace the air thermo sensor.
diate connector C-124 <LH drive vehicles> or C-122 STEP 20. Check the refrigerant level.
<RH drive vehicles>, and repair if necessary. Refer to P.55-104.
circuit. Q: Is the refrigerant level correct?
Q: Is the check result normal? NO : Correct the refrigerant level (Refer to
P.55-104).
STEP 21. Replace the A/C-ECU.

Check that the air conditioner works normally.
Inspection Procedure 3: A/C Outlet Air Temperature cannot be set.

When the blower air temperature can not be
changed even if the preset temperature is changed, M.U.T.-II/III diagnosis code
the sensors, the air mixing damper control motor and
potentiometer or the A/C-ECU may be defective. Q: Is the diagnosis code set?
YES : Refer to diagnosis code chart P.55-5.
PROBABLE CAUSE NO : Replace the automatic A/C control panel
• Malfunction of the A/C-ECU (A/C-ECU).
TROUBLESHOOTING
Inspection Procedure 4: The Blower does not work.
Blower Circuit
FUSIBLE IGNITION
LINK 1 SWITCH (IG2)
BLOWER
RELAY
<RHD> <LHD>
BLOWER MOTOR
(BLOWER
LINEAR
CONTROLLER)
A/C-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 : Grey R : Red P : Pink V : Violet PU : Purple

If the blower motor does not operate, the blower
motor circuit system may be defective. STEP 1. M.U.T.-II/III actuator test
Carry out the actuator test. (Refer to P.55-101)
PROBABLE CAUSES
• Item 01, 02, 03, 04: Blower motor
• Malfunction of the blower motor (blower linear
controller). Q: Does the blower motor work normally?
• Malfunction of the automatic A/C control panel YES : Replace the automatic A/C control panel
(A/C-ECU) (A/C-ECU).
• Damaged the wiring harness or connectors NO : Go to Step 2.
TROUBLESHOOTING
55-43
STEP 2. Voltage measurement at the C-34 blower STEP 3. Check the blower relay.
linear controller connector. Refer to GROUP 55A, On-vehicle Service − Power
relay check P.55-107.
Q: Is the blower relay in good condition?
YES : Go to Step 4.
Harness side NO : Replace the blower relay.
STEP 4. Voltage measurement at C-216 blower

relay connector.
AC504617AC
Harness side
Junction block side
AC504692AB

AC504618AC

Junction block side
Connector C-34
(Harness side)
AC504694AB
(1) Remove the relay, and measure at the junction

block side.
AC301541JY Connector C-216

(Junction block side)
body earth.
OK: System voltage
NO : Go to Step 3.
AC301541JZ
(3) Voltage between terminal 1 and body earth.

OK: System voltage
YES : Go to Step 7.
NO : Go to Step 5.
TROUBLESHOOTING
STEP 5. Connector check: C-216 blower relay Connector: C-211, C-216 <RHD>
connector
C-211
Junction block side

C-216
Harness side
AC504692AB
C-211
Junction block side

C-216
Junction block side

AC504635AC
AC504694AB
junction block connector C-211, and repair if neces-
Q: Is the check result normal? sary.
YES : Go to Step 6. • Check the blower relay power supply line for
NO : Repair the connector. open circuit.
STEP 6. Check the wiring harness between C-216 YES : The trouble can be an intermittent
blower relay connector terminal No.1 and the malfunction (Refer to GROUP 00, How to
ignition switch (IG2). Cope with Intermittent Malfunction P.00-5).
C-211
C-216
Harness side
C-211
Junction block side

C-216
AC504633AC
TROUBLESHOOTING
55-45
STEP 7. Measure the voltage at C-216 blower STEP 8. Connector check: C-216 blower relay
relay connector. connector
Junction block (Front view) Junction block (Front view)
Junction block side Junction block side
AC504692AB AC504692AB
Connector: C-216 <RHD> Connector: C-216 <RHD>

AC504694AB AC504694AB
(1) Remove the relay, and measure at the junction Q: Is the check result normal?
block side. YES : Go to Step 9.
Connector C-216
AC301541KA

OK: System voltage
NO : Go to Step 8.
TROUBLESHOOTING

blower relay connector terminal No.5 and fusible
link (1).
Connectors: C-212, C-216 <LHD>
Junction block (Front view) Harness side
C-212 (B)
AC504622AH

C-216
Harness side
Harness side
C-212
Junction block side

C-216 AC504618AN

diate connectors C-126 and junction block connector
AC504633AD C-212, and repair if necessary.
• Check the blower relay power supply line for
Connectors: C-212, C-216 <RHD> open circuit.
Junction block (Front view) Q: Is the check result normal?
YES : The trouble can be an intermittent
C-212 (B)
malfunction (Refer to GROUP 00, How to
Cope with Intermittent Malfunction P.00-5).
C-216
Harness side
C-212
Junction block side

C-216
AC504635AD
TROUBLESHOOTING
55-47
STEP 10. Resistance measurement at C-216 STEP 11. Connector check: C-216 blower relay
blower relay connector. connector
AC504692AB AC504692AB

AC504694AB AC504694AB
(1) Remove the relay, and measure at the junction Q: Is the check result normal?
block side. YES : Go to Step 12.
Connector C-216
AC301541KB

body earth
OK: 2Ω or less
NO : Go to Step 11.
TROUBLESHOOTING
STEP 12. Check the wiring harness between Connector: C-36 <RHD>
C-216 blower relay connector terminal No.3 and
Harness side
body earth.

C-36 (B)
AC504618AJ
C-214 NOTE: Prior to the wiring harness inspection, check

C-216
junction block connector C-214 and joint connector
C-36 <RH drive vehicles>, and repair if necessary.
• Check the blower relay earth wires for open cir-
Harness side
C-214 cuit.
Junction block side NO : Repair the wiring harness.
C-216
AC504633AE
C-214
C-216
Harness side
C-214
Junction block side

C-216
AC504635AE
TROUBLESHOOTING
55-49
STEP 13. Connector check: C-216 blower relay
connector and C-34 blower linear controller NO : Repair the connector.
connector
Harness side
AC504617AC
Harness side
AC504618AC
Junction block side
AC504692AB

Junction block side
AC504694AB
TROUBLESHOOTING
STEP 14. Check the wiring harness between Connector: C-34 <LHD>
C-216 blower relay connector terminal No.4 and
C-34 blower linear controller connector terminal
Harness side
No.6.
C-211 AC504617AC
Harness side
C-216
Harness side
C-211
AC504618AC
Junction block side
C-216
sary.
AC504633AC
• Check the blower linear controller power supply
line for open circuit.
Connector: C-211, C-216 <RHD> Q: Is the check result normal?
C-211 Cope with Intermittent Malfunction P.00-5).
C-216
Harness side
C-211
Junction block side

C-216
AC504635AC
TROUBLESHOOTING
55-51
STEP 15. Resistance measurement at the C-34 STEP 16. Connector check: C-34 blower liner
blower linear controller connector. controller
AC504617AC AC504617AC
AC504618AC AC504618AC
(1) Disconnect the connector, and measure at the Q: Is the check result normal?
wiring harness side. YES : Go to Step 17.
Connector C-34
(Harness side)
AC301541KC
(2) Continuity between terminal 3 and body earth

OK: 2Ω or less
NO : Go to Step 16.
TROUBLESHOOTING
STEP 17. Check the wiring harness between C-34 STEP 18. Connector check: C-36 A/C-ECU
blower linear controller connector terminal No.3 connector and C-34 blower linear controller
and body earth. connector
AC504617AC AC504617AC
Connector: C-34 <RHD> Connectors: C-34, C-36 <RHD>
Harness side
C-36 (B)
C-34
AC504618AC
• Check the blower linear controller earth line for Harness side
open circuit. C-34
Cope with Intermittent Malfunction P.00-5). C-36
AC504624AB
Harness side
C-36 (B)
AC504622AB

TROUBLESHOOTING
55-53
STEP 19. Check the wiring harness between C-36
YES : Replace the A/C control panel (A/C-ECU) or
A/C-ECU connector terminal No.2 and C-34
the blower motor (blower linear controller).
blower linear controller connector terminal No.5. NO : Repair the wiring harness.
Harness side
AC504617AC
C-36 (B)
C-34
Harness side
C-34
C-36
AC504624AB
Harness side
C-36 (B)
AC504622AB

circuit.
TROUBLESHOOTING
Inspection Procedure 5: The Blower Air Volume cannot be changed.
Blower Motor Circuit
BLOWER
RELAY
BLOWER MOTOR
(BLOWER
LINEAR
CONTROLLER)
A/C-ECU
Wire colour code

If the blower air volume can not be changed when
the blower switch is operated, the circuit between STEP 1. M.U.T.-II/III actuator test
blower motor (blower linear controller) and A/C-ECU Carry out the actuator test.
may be defective. • Items 01, 02, 03, 04: Blower motor
POSSIBLE CAUSES Q: Does the blower motor work normally?
• Blower motor (blower linear controller) YES : Replace the automatic A/C control panel
• Damaged the wiring harness or connectors (A/C-ECU)
• Malfunction of the automatic A/C control panel NO : Go to Step 2.
(A/C-ECU)
TROUBLESHOOTING
55-55
connector and C-34 blower linear controller A/C-ECU connector terminal No.2 and C-34
connector blower linear controller connector terminal No.5.
AC504617AC AC504617AC
Connectors: C-34, C-36 <RHD> Connectors: C-34, C-36 <RHD>
C-36 (B) C-36 (B)

C-34 C-34

C-34 C-34
C-36 C-36
AC504624AB AC504624AB

C-36 (B) C-36 (B)
AC504622AB AC504622AB

YES : Go to Step 3. circuit.
NO : Repair the connector. Q: Is the check result normal?
(A/C-ECU) or the blower motor (blower
linear controller).
TROUBLESHOOTING
Inspection Procedure 6: When sunlight intensity changes, blower air temperature does not Change.
Photo Sensor Circuit
A/C-ECU
PHOTO SENSOR
Wire colour code

CIRCUIT OPERATION STEP 2. M.U.T.-II/III diagnosis code

When the blower air temperature can not be On completion, check that the diagnosis code is not
changed even if the preset temperature is changed, reset.
the sensors may be defective.
PROBABLE CAUSES YES : Go to Step 3.
NO : Carry the diagnosis code procedures. Refer
• Malfunction of the photo sensor
to P.55-5.
• Malfunction of the A/C-ECU
DIAGNOSIS PROCEDURE • Item 25: Photo sensor
OK: Check that the volume of insolation takes
inverse proportion with the M.U.T.-II/III displayed
STEP 1. Check the rear window defogger and voltage.
operation. Q: Is the check result normal?
Q: Do the rear window defogger and outside/inside air (A/C-ECU).
selection damper control motor work normally? NO : Go to Step 4.
YES : Go to Step 2.
"Malfunction of the A/C-ECU power supply
system P.55-73."
TROUBLESHOOTING
55-57
connector and C-141 photo sensor connector. photo sensor connector (terminal 1, 2) and C-36
A/C-ECU connector (terminal 19, 9).
C-141
C-141
C-36 (B)
C-36 (B)
Harness side
C-36 Harness side
C-36
C-141
C-141
AC504641AE
AC504641AE
Harness side
Harness side
C-36 (B)
C-36 (B)
AC504618AJ
AC504618AJ
Harness side
Harness side
AC504625AG
AC504625AG
YES : Go to Step 5. • Check the photo sensor signal lines for open or
NO : Repair or replace the connector. short circuit.
YES : Replace the Photo sensor.
TROUBLESHOOTING
Inspection Procedure 7: The outside/inside air changeover is impossible.
Outside/Inside Air Selection Damper Control Motor Circuit
A/C-ECU IGNITION
MOTOR DRIVE
SWITCH (IG2)
CIRCUIT
OUTSIDE/INSIDE AIR
SELECTION DAMPER
CONTROL MOTOR
Wire colour code


When inside air cannot be changed to outside air
vice versa even if its changeover switch is on, the STEP 1. M.U.T.-II/III actuator test
outside/inside air selection damper control motor Carry out the actuator test. (Refer to P.55-101)
system may be defective. • Item 13, 14: outside/inside air selection damper
control motor
PROBABLE CAUSES
• Malfunction of the outside/inside air selection Q: Does the blower motor work normally?
damper control motor YES : Replace the automatic A/C control panel
• Damaged the wiring harness or connectors (A/C-ECU)
• Malfunction of the automatic A/C control panel NO : Go to Step 2.
(A/C-ECU)
TROUBLESHOOTING
55-59
STEP 2. Measure the voltage at C-07 STEP 3. Connector check: C-07 outside/inside air
outside/inside air selection damper control motor selection damper control motor connector
connector. Connector: C-07 <LHD>
Harness side
Harness side
AC504617AK
AC504617AK
Harness side
Harness side
AC504618AO
AC504618AO
(1) Disconnect the connector, and measure at the YES : Go to Step 4.
wiring harness side. NO : Repair the connector.
Connector C-07
(Harness side)
AC301541KD

body earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 3.
TROUBLESHOOTING

connector terminal No.7 and the ignition switch C-101 (L)
(IG2).
C-07
AC504622AI
C-10
C-07
Harness side
C-101 (L)
C-10 AC504625AF

AC504701AB
Connectors: C-07, C-10 <RHD> C-211
C-07
C-210
C-10
Harness side
C-210
C-07
Harness side
C-211
C-10
AC504633AF
AC504624AF
TROUBLESHOOTING
55-61
Connectors: C-210, C-211 <RHD> STEP 6. Connector check: C-37 A/C-ECU
connector and C-07 outside/inside air selection
Junction block (Front view) damper control motor connector
C-211
Harness side
C-210
Harness side
C-210
AC504617AK
C-211 C-07
AC504635AF C-37 (B)

diate connector C-10, joint connector C-101 and
junction block connectors C-210 and C-211, and Harness side
C-07
• Check the motor power supply line for open cir-
cuit.
C-37
STEP 5. Check the outside/inside air selection AC504624AG

damper control motor
Refer to P.55-114. Connector: C-37 <LHD>

YES : Go to Step 6.
NO : Replace the outside/inside air selection
damper control motor. Harness side
C-37 (B)
AC504622AC

YES : Go to Step 7.
TROUBLESHOOTING
STEP 7. Check the wiring harness between C-37 Connector: C-37 <LHD>
C-07 outside/inside air selection damper control
motor connector (terminals 6 and 4).
Connectors: C-07, C-10 <LHD> Harness side
C-07 C-37 (B)
AC504622AC
C-10
circuit.
C-07
(A/C-ECU).
C-10
AC504701AB
Connectors: C-07, C-10, C-37 <RHD>
C-07
C-10
C-37 (B)
C-07 C-10
Harness side
C-37
Harness side
AC504624AH
TROUBLESHOOTING
55-63
Inspection Procedure 8: Rear Window Defogger function does not operate.
Rear Window Defogger Circuit
IGNITION FUSIBLE
SWITCH (IG2) LINK 1
REAR WINDOW
DEFOGGER
RELAY
REAR WINDOW
DEFOGGER
A/C-ECU
Wire colour code

CIRCUIT OPERATION DIAGNOSIS PROCEDURE

If the rear window defogger does not operate when
the rear window defogger switch is turned on, the STEP 1. Check the A/C and outside/inside air
rear window defogger relay system may be defec- selection damper control motor operation.
tive.
Q: Do the A/C and outside/inside air selection damper
PROBABLE CAUSES control motor work normally?
• Malfunction of the A/C-ECU YES : Go to Step 2.
• Malfunction of the rear window defogger relay
• Damaged the wiring harness or connectors "Malfunction of the A/C-ECU power supply
• Malfunction of the rear window defogger system P.55-73."
TROUBLESHOOTING
STEP 2. Voltage measurement at F-16 rear STEP 3. Check the rear window defogger relay
window defogger connector. continuity.
Connector: F-16 <LHD>
Refer to P.55-107.
Q: Is the rear window defogger relay in good
condition?
Harness side YES : Go to Step 4.
NO : Replace the rear window defogger relay.
STEP 4. Voltage measurement at C-215 rear

window defogger relay connector.
AC504707AB

Connector: F-16 <RHD>
Junction block side

Harness side
AC504692AC
AC504709AB
(2) Turn the rear window defogger switch to the "ON"
position.
Junction block side
Connector F-16
(Harness side)
AC504694AC

block side.
Connector C-215
AC301541KE

body earth.
OK: System voltage
NO : Go to Step 3. AC301541KF

body earth.
OK: System voltage
YES : Go to Step 7.
NO : Go to Step 5.
TROUBLESHOOTING
55-65
STEP 5. Connector check: C-215 rear window STEP 6. Check the wiring harness between C-215
defogger relay connector rear window defogger relay connector terminal
No.5 and the fusible link (1).
Junction block side C-212 (B)
AC504692AC C-215

Harness side
C-212

C-215
AC504694AC
Q: Is the check result normal? AC504633AG
YES : Go to Step 6.
C-212 (B)
C-215
Harness side
C-212
Junction block side

C-215
AC504635AG
TROUBLESHOOTING
NOTE: STEP 7. Voltage measurement at C-215 rear

window defogger relay connector.

Harness side
Junction block side
AC504622AH
Connector: C-126 <RHD> AC504692AC
Harness side Connector: C-215 <RHD>

Junction block side

AC504618AN

AC504694AC
diate connectors C-126 and junction block connector
C-212, and repair if necessary. (1) Remove the relay, and measure at the junction
• Check the rear window defogger relay power block side.
supply line for open or short circuit. (2) Turn the ignition switch to the "ON" position.
Connector C-215
malfunction (Refer to GROUP 00, How to (Junction block side)
AC301541KG

OK: System voltage
NO : Go to Step 8.
TROUBLESHOOTING
55-67
STEP 8. Connector check: C-215 rear window Connectors: C-211, C-215 <RHD>
defogger relay connector
C-211
Junction block side C-215
AC504692AC Harness side

C-211
Junction block side

C-215
Junction block side

AC504635AH
AC504694AC
Q: Is the check result normal? sary.
YES : Go to Step 9. • Check the rear window defogger power supply
NO : Repair the connector. line for open circuit.
STEP 9. Check the wiring harness between C-215 Q: Is the check result normal?
rear window defogger relay connector No.1 and YES : The trouble can be an intermittent
ignition switch (IG2). malfunction (Refer to GROUP 00, How to
Connectors: C-211, C-215 <LHD> NO : Repair the wiring harness.
C-211
C-215
Harness side
C-211
Junction block side

C-215
AC504633AH
TROUBLESHOOTING
STEP 10. Connector check: C-215 rear window STEP 11. Check the wiring harness between rear
defogger relay connector and C-36 A/C-ECU window defogger relay connector C-215 No.3 and
connector A/C-ECU connector C-36 No.16.

C-36 (B) C-36 (B)
AC504622AB AC504622AB
C-36 (B) C-36 (B)
AC504618AJ AC504618AJ
Connector: C-215 <LHD> Connectors: C-214, C-215 <LHD>

Junction block side
C-214
C-215
AC504692AC
Connector: C-215 <RHD> Harness side

Junction block (Front view) C-214

C-215
AC504694AC
AC504633AI

TROUBLESHOOTING
55-69
Connectors: C-214, C-215 <RHD> STEP 12. Connector check: C-215 rear window
defogger relay connector and F-16 rear window
Junction block (Front view) defogger connector
C-214
C-215
Junction block side
Harness side
C-214
AC504692AC

Junction block side

C-215
AC504635AI Junction block side

junction block connector C-214, and repair if neces- AC504694AC
sary.
• Check the rear window defogger relay line for Connector: F-16 <LHD>
YES : Go to Step 12. Harness side
AC504707AB
Harness side
AC504709AB

TROUBLESHOOTING
STEP 13. Check the wiring harness between Connector: F-16 <LHD>
C-215 rear window defogger relay connector
terminal No.4 and F-16 rear window defogger
connector terminal No.1. Harness side
AC504707AB
C-215
Harness side
C-217
Junction block side
C-215
AC504709AB

C-217
sary.
AC504633AK
• Check the rear window defogger power supply
line for open or short circuit.
Connectors: C-215, C-217 <RHD> Q: Is the check result normal?
(A/C-ECU).
C-215
C-217
Junction block side

C-215
C-217
AC504635AK
TROUBLESHOOTING
55-71
STEP 14. Resistance measurement at F-06 rear STEP 15. Connector check: F-06 rear window
window defogger connector. defogger connector
Connector: F-06 <LHD> Connector: F-06 <LHD>
F-06 (B) F-06 (B)
AC504707AC AC504707AC
Connector: F-06 <RHD> Connector: F-06 <RHD>
F-06 (B) F-06 (B)
AC504709AC AC504709AC
Connector F-06
(Harness side)
AC301541KH
(2) Continuity between terminal 1 and body earth.

OK: 2 ohm or less
NO : Go to Step 15.
TROUBLESHOOTING
STEP 16. Check the wiring harness between F-06 STEP 17. Check the rear window defogger.
rear window defogger connector terminal No.1 Refer to P.54A-80.
and earth. Q: Does the rear window defogger work normally?
Connector: F-06 <LHD> YES : The trouble can be an intermittent
F-06 (B) Cope with Intermittent Malfunction P.00-5).
NO : Repair the rear window defogger.
Harness side
AC504707AC
F-06 (B)
Harness side
AC504709AC
• Check the rear window defogger earth line for

NO : Repair or replace the wiring harness.
TROUBLESHOOTING
55-73
Inspection Procedure 9: Malfunction of the A/C-ECU power supply system.
A/C-ECU Power Supply Circuit
IGNITION
SWITCH (IG2) BATTERY
RELAY
BOX
A/C-ECU
BATTERY
BACK-UP
<LHD> <RHD>
Wire colour code

CIRCUIT OPERATION PROBABLE CAUSES

The A/C-ECU power system may be defective if the • Damaged the wiring harness or connectors
A/C, defogger, and outside/inside air selection • Malfunction of the A/C-ECU
damper motor all do not operate normally.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Connector check: C-37 A/C-ECU

connector
STEP 1. Voltage measurement at A/C-ECU Connector: C-37 <LHD>
connector C-37.
Harness side
Harness side
C-37 (B)
C-37 (B) AC504622AC

AC504622AC
Harness side
Harness side
C-37 (B)
C-37 (B)
AC504618AE

AC504618AE
YES : Go to Step 3.
(1) Disconnect the connector, and measure at the NO : Repair the connector.
STEP 3. Check the wiring harness between C-37
A/C-ECU connector terminal No.28 and the
ignition switch (IG2).
Connector C-37
(Harness side) Connector: C-37 <LHD>
Harness side
AC301541JV C-37 (B)

body earth. AC504622AC
OK: System voltage

Harness side
YES : Go to Step 4.
NO : Go to Step 2.
C-37 (B)
AC504618AE
TROUBLESHOOTING
55-75
NOTE: STEP 4. Resistance measurement at C-37
A/C-ECU connector.
Junction block (Front view) Connector: C-37 <LHD>
C-211
Harness side
C-214
C-37 (B)
Harness side AC504622AC

C-211
Harness side
C-214
C-37 (B)
AC504633AB
AC504618AE
C-211
block side.
Connector C-37
(Harness side)
C-214
Harness side
C-211
AC301541JW
(2) Continuity between terminal 27 and body earth.

C-214 OK: 2 ohm or less
YES : Go to Step 7.
NO : Go to Step 5.
AC504635AB
Prior to the wiring harness inspection, check junction

block connectors C-214 and C-211, and repair if nec-
essary.
• Check the A/C-ECU power supply line for open or
short circuit.
TROUBLESHOOTING
STEP 5. Connector check: C-37 A/C-ECU NOTE:

connector
Connector: C-37 <LHD> C-06 (GR)
Harness side
C-37 (B) AC504617AI
AC504622AC

Harness side
C-06 (GR)
C-37 (B)
AC504625AC

AC504618AE
connector C-06 <LH drive vehicles>, and repair if
Q: Is the check result normal? necessary.
YES : Go to Step 6. • Check the A/C-ECU earth line for open or short
NO : Repair the connector. circuit.
STEP 6. Check the wiring harness between C-37 YES : Replace the automatic A/C control panel
A/C-ECU connector terminal No.27 and the earth. (A/C-ECU).
Harness side
C-37 (B)
AC504622AC

Harness side
C-37 (B)
AC504618AE
TROUBLESHOOTING
55-77
STEP 7. Voltage measurement at C-36 A/C-ECU STEP 8. Connector check: C-36 A/C-ECU
connector. connector

C-36 (B) C-36 (B)
AC504622AB AC504622AB
C-36 (B) C-36 (B)
AC504618AJ AC504618AJ
Connector C-36
(Harness side) STEP 9. Check the wiring harness between C-36
A/C-ECU connector terminal No.3 and battery.
AC301541JX

earth. Harness side
C-36 (B)
OK: System voltage
AC504622AB
YES : Replace the automatic A/C control panel Connector: C-36 <RHD>
(A/C-ECU).
NO : Go to Step 8. Harness side
C-36 (B)
AC504618AJ
TROUBLESHOOTING
NOTE: Q: Is the check result normal?

Connectors: C-05, C-129 <LHD> YES : The trouble can be an intermittent
C-05 (GR) NO : Repair the wiring harness.
C-129
C-05
C-129
AC504641AB
C-05 (GR)
C-129
C-05
C-129
AC504624AD
diate connector C-129 and joint connector C-05, and
• Check the A/C-ECU power supply (battery
back-up) line for open or short circuit.
TROUBLESHOOTING
55-79
Inspection Procedure 10: A/C Compressor power supply system.
A/C Compressor Circuit
IGNITION
BATTERY SWITCH (IG2)
RELAY
BOX
A/C
COMPRESSOR
RELAY
A/C
COMPRESSOR
A/C
REFRIGERANT
TEMPERATURE ENGINE-ECU
SWITCH
MAGNETIC
CLUTCH
Wire colour code

COMMENTS ON TROUBLE SYMPTOM POSSIBLE CAUSES

If the power is not supplied to the A/C compressor, • Malfunction of the A/C compressor relay
the A/C compressor circuit system may be defective. • Damaged the wiring harness or connectors
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Voltage measurement at B-13X A/C

compressor relay connector.
STEP 1. Connector check: B-13X A/C Connector: B-13X
compressor relay connector
Connector: B-13X
Relay box side
2 1
Relay box side 4 3
2 1
Front of
4 3 vehicle
AC504760AB
Front of
vehicle (1) Remove the relay, and measure at the relay box
AC504760AB side.
YES : Go to Step 2.
NO : Repair the connector. Connector B-13X
(Relay box side)
STEP 2. Check the A/C compressor relay
continuity.
Refer to P.55-107.
Q: Is the A/C compressor relay in good condition?
Front of
YES : Go to Step 3.
vehicle
NO : Replace the A/C compressor relay.
AC301541KI

body earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.
TROUBLESHOOTING
55-81
STEP 4. Check the wiring harness between B-13X Connector: C-122 <RHD>
A/C compressor relay connector terminal No.2
and the ignition switch (IG2).
Connector: B-13X
Relay box side

C-122 (L)
2 1
4 3 AC504618AH
Front of Connectors: C-210, C-211 <LHD>

vehicle
AC504760AB Junction block (Front view)
NOTE:
Connector: C-101, C-124 <LHD> C-211
C-101 (L)
C-210
C-124 Harness side

C-210
C-101
Harness side
C-211
C-124
AC504633AF
AC504641AF
C-101 (L)
AC504625AF
TROUBLESHOOTING
Connectors: C-210, C-211 <RHD> STEP 5. Voltage measurement at B-13X A/C

compressor relay connector.
Connector: B-13X
C-211
Relay box side
C-210 2 1
4 3
Front of
Harness side vehicle
AC504760AB
C-210
block side.
C-211
Connector B-13X
(Relay box side)
AC504635AF

diate connector C-124 <LH drive vehicles>, C-122 Front of
<RH drive vehicles>, joint connector C-101, junction vehicle
block connectors C-210 and C-211, and repair if nec- AC301541KJ
essary. (2) Measure the voltage between terminal 1 and

• Check the A/C compressor relay power supply body earth.
line for open circuit. OK: System voltage
YES : The trouble can be an intermittent YES : Go to Step 7.
malfunction (Refer to GROUP 00, How to NO : Go to Step 6.
TROUBLESHOOTING
55-83
STEP 6. Check the wiring harness between B-13X STEP 7. Connector check: A-36 A/C compressor
A/C compressor relay connector terminal No.1 connector
and the battery. Connector: A-36
Connector: B-13X
Harness side
Relay box side
2 1
4 3
Front of
A-36 (B)
vehicle AC504616AB
AC504760AB
NOTE: YES : Go to Step 8.
Connector: A-29 <LHD> NO : Repair the connector.
A-29 (B)
AC504656AC
Harness side
AC504618AP

diate connector A-29 <LHD> or C-31 <RHD>, and
• Check the A/C compressor relay power supply
TROUBLESHOOTING

STEP 8. Check the wiring harness between B-13X
YES : Go to Step 9.
A/C compressor relay connector terminal No.4 NO : Repair the wiring harness.
and A-36 A/C compressor connector terminal
No.1.
Connector: A-36
connector
Harness side
Harness side
C-121 (GR)
A-36 (B) AC504616AB
Connector: B-13X AC504617AB
Relay box side Harness side
2 1
4 3
C-121 (GR)
Front of
vehicle
AC504760AB
NOTE: AC504618AB
Connector: A-13 <LHD>
A-13 (B)
AC504656AD
Harness side
AC504618AP

• Check the A/C compressor power supply line for
open circuit.
TROUBLESHOOTING
55-85
STEP 11. Check the wiring harness between
C-121 engine-ECU connector terminal No.20 and
B-13X A/C compressor relay connector terminal
No.3. NO : Repair the wiring harness.
Connector: B-13X
Relay box side
2 1
4 3
Front of
vehicle
AC504760AB

Harness side
C-121 (GR)
AC504617AB

Harness side
C-121 (GR)
AC504618AB
• Check the A/C compressor relay earth line for

TROUBLESHOOTING
Inspection Procedure 11: Condenser Fan does not Operate.
Condenser Fan Motor Circuit

IGNITION
RELAY
BOX
CONDENSER CONDENSER
FAN RELAY (HI) FAN RELAY (LO)
NOTE
: LH drive vehicles
: RH drive vehicles
CONDENSER
FAN MOTOR
ENGINE-ECU
Wire colour code

TROUBLESHOOTING
55-87
CIRCUIT OPERATION DIAGNOSIS PROCEDURE
If the condenser fan motor does not operate, the
condenser fan relay circuit system or the earth sys- STEP 1. Connector check: A-34 condenser fan
tem of the condenser fan motor is suspected. motor connector and C-121 engine-ECU
connector
PROBABLE CAUSES
• Malfunction of the condenser fan relay (HI) Connector: A-34 <LHD>
• Malfunction of the condenser fan relay (LO)
• Malfunction of the condenser fan motor
• Malfunction of the engine-ECU
• Damaged the wiring harness or connectors Harness side
A-34 (B)
AC310431AG
Connector: A-34 <RHD>
Harness side
A-34 (B)
AC310433 AF

Harness side
C-121 (GR)
AC504617AB

Harness side
C-121 (GR)
AC504618AB

YES : Go to Step 2.
TROUBLESHOOTING
STEP 2. Voltage measurement at A-34 condenser (2) Turn the ignition switch to the "ON" position.
fan motor connector. Connector: C-121 <LHD>
Connector: A-34 <LHD> Harness side
C-121 (GR)
Harness side
A-34 (B)
AC504617AB
AC310431AG Connector: C-121 <RHD>
Connector: A-34 <RHD> Harness side
C-121 (GR)
Harness side
A-34 (B)
AC504618AB
AC310433 AF Connector: C-121

(1) Remove the relay, and measure at the relay box (Harness side)
side.
AC504964AB

earth terminal 30.
Connector: A-34
(Harness side)
AC310507AI

body earth.
OK: System voltage
NO : Go to Step 3.
TROUBLESHOOTING
55-89
STEP 3. Connector check: A-07X condenser fan STEP 5. Voltage measurement at A-07X
relay (HI) connector condenser fan relay (HI) connector.
Relay box side Relay box side
AC311017AB AC311017AB

(1) Remove the relay, and measure at the relay box
YES : Go to Step 4. side.
NO : Repair the connector. (2) Turn the ignition switch to the "ON" position.
Connector: A-07X
STEP 4. Check the condenser fan relay (HI) (Relay box side)
continuity.
Refer to P.55-107.
Q: Is the condenser fan relay (HI) in good condition?
YES : Go to Step 5.
NO : Replace the condenser fan relay (HI). 2 1
4 3
AC310507AJ

body earth.
OK: System voltage
YES : Go to Step 7.
NO : Go to Step 6.
TROUBLESHOOTING
STEP 6. Check the wiring harness between A-07X Connector: C-129 <RHD>
condenser fan relay (HI) connector terminal No.2
and the ignition switch (IG2).
Connector: A-07X
AC310454 AV
Relay box side
Junction block (front view)
AC311017AB
C-211
NOTE:
C-101 (L) C-210
C-129 Harness side

C-210
6 5 4 3 2 1
14 13 12 11 10 9 8 7
C-101
Harness side
C-211
2 1
6 5 4 3
C-129 AC310449AF
AC310447AG
C-101 (L)
AC310456 AQ
TROUBLESHOOTING
55-91
Connectors: C-210, C-211 <RHD> STEP 7. Voltage measurement at A-07X

Junction block (front view) C-211 condenser fan relay (HI) connector.
Connector: A-07X
C-210
Relay box side
Harness side
AC311017AB
C-210
6 5 4 3 2 1 side.
14 13 12 11 10 9 8 7
Harness side Connector: A-07X

(Relay box side)
C-211
2 1
6 5 4 3 2 1
AC310459AF 4 3

diate connector C-129, joint connector C-101, junc-
tion block connectors C-210 and C-211, and repair if
necessary. AC310507AK
• Check the condenser fan relay (HI) power supply (2) Measure the voltage between terminal 4 and
line for open circuit. body earth.
malfunction (Refer to GROUP 00, How to YES : Go to Step 9.
Cope with Intermittent Malfunction P.00-5). NO : Go to Step 8.
TROUBLESHOOTING
STEP 8. Check the wiring harness between A-07X STEP 9. Check the wiring harness between A-07X
condenser fan relay (HI) connector terminal No.4 condenser fan relay (HI) connector terminal No.3
and the battery. and C-121 engine-ECU connector terminal No.30.
Relay box side Relay box side
AC311017AB AC311017AB
• Check the condenser fan relay (HI) power supply Connector: C-121 <LHD>
Harness side
Cope with Intermittent Malfunction P.00-5). C-121 (GR)
AC504617AB
C-121 (GR)
C-31
C-31
Harness side
C-121
AC504624AT
TROUBLESHOOTING
55-93
NOTE: STEP 11. Voltage measurement at A-34
condenser fan motor connector.
A-29 (B) Harness side

1 2 3 4
5 6 7 8
A-34 (B)
AC310542 AB

diate connector A-29 <LHD> or C-31 <RHD>, and AC310431AG
repair if necessary. Connector: A-34 <RHD>

• Check the condenser fan relay (HI) earth line for
A-34 (B)
STEP 10. Check the wiring harness between
A-07X condenser fan relay (HI) connector
terminal No.1 and A-34 condenser fan motor AC310433 AF
connector terminal No.1. (1) Remove the relay, and measure at the relay box
side.
Connector: A-07X
Relay box side
AC311017AB
• Check the condenser fan motor power supply line

for open circuit.
TROUBLESHOOTING
(2) Turn the ignition switch to the "ON" position. STEP 12. Connector check: A-06X condenser fan
Connector: C-121 <LHD> relay (LO) connector
Harness side Connector: A-06X
C-121 (GR)
Relay box side

AC504617AB
Connector: C-121 <RHD> AC311017AC

C-121 (GR)
STEP 13. Check the condenser fan relay (LO)

continuity.
Refer to P.55-107.
AC504618AB Q: Is the condenser fan relay (LO) in good condition?
Connector: C-121
NO : Replace the condenser fan relay (LO).
(Harness side)
STEP 14. Voltage measurement at A-06X

condenser fan relay (LO) connector.
Connector: A-06X
AC504964AB

earth terminal 31. Relay box side
Connector: A-34
(Harness side) AC311017AC

side.
AC310507AL

body earth.
OK: System voltage
NO : Go to Step 12.
TROUBLESHOOTING
55-95
(2) Turn the ignition switch to the "ON" position. STEP 15. Check the wiring harness between
A-06X condenser fan relay (LO) connector
Connector: A-06X
(Relay box side)
terminal No.2 and C-129 intermediate connector
terminal No.2.
Connector: A-06X
2 1
4 3
AC310507AM
Relay box side
body earth.
OK: System voltage AC311017AC
Q: Is the check result normal? Connector: C-129

YES : Go to Step 16. <LHD>
NO : Go to Step 15.
AC310446AI
Connector: C-129
<RHD>
AC310454AJ
• Check the condenser fan relay (LO) power sup-

ply line for open circuit.
TROUBLESHOOTING
STEP 16. Voltage measurement at A-06X STEP 17. Check the wiring harness between
condenser fan relay (LO) connector. A-06X condenser fan relay (LO) connector
terminal No.4 and the battery.
Connector: A-06X
Connector: A-06X
Relay box side

Relay box side
AC311017AC
(1) Remove the relay, and measure at the relay box AC311017AC
side. • Check the condenser fan relay (HI) power supply

Connector: A-06X Q: Is the check result normal?
(Relay box side) YES : The trouble can be an intermittent
2 1 Cope with Intermittent Malfunction P.00-5).
4 3 NO : Repair the wiring harness.
AC310507AN

body earth.
OK: System voltage
NO : Go to Step 17.
TROUBLESHOOTING
55-97
STEP 18. Check the wiring harness between NOTE:
A-06X condenser fan relay (LO) connector
terminal No.3 and C-121 engine-ECU connector
terminal No.31.
Connector: A-06X
A-29 (B)
1 2 3 4
5 6 7 8
AC310542 AB
Relay box side Prior to the wiring harness inspection, check interme-
AC311017AC
• Check the condenser fan relay (HI) earth line for
Connector: C-121 <LHD> open or short circuit.
C-121 (GR)
AC504617AB
C-121 (GR)
C-31
C-31
Harness side
C-121
AC504624AT
TROUBLESHOOTING
STEP 19. Check the wiring harness between STEP 20. Connector check: A-35 condenser fan
A-06X condenser fan relay (LO) connector motor connector
terminal No.1 and A-34 condenser fan motor
connector terminal No.2.
Connector: A-06X
Harness side
Relay box side A-35 (GR)

AC310431AH
AC311017AC
Harness side
Harness side
A-35 (GR)
A-34 (B)
AC310433 AG
AC310431AG
Connector: A-34 <RHD> NO : Repair the connector.
Harness side
A-34 (B)
AC310433 AF
• Check the condenser fan motor power supply line

for open circuit.
TROUBLESHOOTING
55-99
STEP 21. Resistance measurement at A-35 STEP 22. Check the wiring harness between A-35
condenser fan motor connector. condenser fan motor connector terminal No.1
and earth.
Harness side
Harness side
A-35 (GR)
AC310431AH A-35 (GR)
AC310431AH
Harness side
Harness side
A-35 (GR)
AC310433 AG A-35 (GR)
(1) Disconnect the connector, and measure at the AC310433 AG
wiring harness side. • Check the condenser fan motor earth line for
open circuit.
Connector: A-35
(Harness side)
AC310506AO
AC310506
(2) Measure the resistance value between terminal 1

and earth.
OK: 2 ohms or less
NO : Go to Step 22.
TROUBLESHOOTING

M1554005100341
Item No. Check items Inspection conditions Normal condition

11 Interior temperature sensor Turn the ignition switch to Room temperature is the
the ON position. same as M.U.T.-II/III
displayed temperature.
13 Outside thermo sensor Turn the ignition switch to Outside temperature is the
displayed temperature.
15 Heater water temperature Turn the ignition switch to Heater core wall surface
sensor the ON position. temperature is the same as
M.U.T.-II/III displayed
temperature.
21 Air thermo sensor Turn the ignition switch to Evaporator outlet temperate
the ON position. is the same as M.U.T.-II/III
displayed temperature
25 Photo sensor • Turn the ignition switch to The volume of insolation
the ON position. takes inverse proportion with
• Change the volume of the M.U.T.-II/III displayed
insolation. voltage.
31 Air mixing damper control • Turn the ignition switch to Opening angle: approximately
motor and potentiometer the ON position. 100%
• Door position: MAX HOT
• Turn the ignition switch to Opening angle: approximately
the ON position. 0%
• Door position: MAX
COOL
32 Mode selection damper • Turn the ignition switch to Opening angle: approximately
control motor and the ON position. 0%
potentiometer • Damper position: FACE
the ON position. 60%
• Damper position: FOOT
• Damper position:
FOOT/DEF
• Damper position: DEF
42 A/C pressure sensor Turn the ignition switch to A/C refrigerant pressure is the
displayed pressure.
TROUBLESHOOTING
55-101
ACTUATOR TEST TABLE
M1554005200315
Item No. Check items Drive content

01 Blower motor Stop
02 Low speed
03 Middle speed
04 High speed
05 Air mixing damper control motor Open angle: Approximately 0% (MAX COOL)
06 Opening angle: approximately 50%
07 Open angle: Approximately 100% (MAX HOT)
08 Mode selection damper control motor FACE
09 FOOT
10 DEF
11 Compressor output OFF
12 ON
13 Outside/inside air selection damper Outside air
14 control motor Inside air
38 Idle-up OFF (A/C high pressure)
39 ON (A/C low pressure)
CHECK AT ENGINE-A/T ECU TERMINALS

M1554005400289
<C-121> <C-119> <C-117>

41 42 43 44 45 46 47 71 72 73 74 75 76 77
4849 50 51 52 53 54 55 5657 58 59 78 79 80 81 82 83 84 85 8687 88 89 90
60 61 62 63 64 65 66 67 68 91 92 93 94 95 96 97 98 99 100
AC504605AB
Terminal Check items Check conditions Normal conditions

No.
20 Output to A/C compressor A/C compressor relay: OFF System voltage
A/C compressor relay: ON 0V
30 Condenser fan motor relay Fan inactive state (Engine coolant System voltage
(HI) temperature: 90°C or less
Fan high-speed rotation state (Engine 1 V or less
coolant temperature: 105°C or less
31 Condenser fan motor relay Fan inactive state (Engine coolant System voltage
(LOW) temperature: 90°C or less)
Fan low-speed rotation state (Engine 1 V or less
coolant temperature: 95 − 100°C or less)
83 Input from A/C-ECU (A/C1) When the A/C is in operation (When the air System voltage
thermo sensor detects 3°C or more).
65 Input from A/C-ECU (A/C2) When the A/C is under low load System voltage
TROUBLESHOOTING
CHECK AT A/C-ECU TERMINALS

M1554005400290
<C-36> <C-37>
1 2 3 4 5 6 7 8 9 10 21 2223 24 25 26 27 28
11 12 13 14 15 16 17 18 19 20 29 30 31 32 33 34 35 36
AC300196 AC

No.
1 Interior temperature sensor Sensor temperature: 25°C (4kΩ) 2.1− 2.7V
2 Output to blower pulse controller When the blower is operating. 0 − 2.5V (Effective
alternating voltage)
3 Back-up power supply Always System voltage
4 Input from heater water temperature Sensor temperature: 25°C (4kΩ) 2.1 − 2.7V
sensor
5 Input from air mixing damper control When the damper flaps is moving to 4.1 − 4.6 V
motor potentiometer the MAX HOT position.
6 Input from mode selection damper When the damper is moved to the 4.1 − 4.6 V
control motor potentiometer DEF position.
7 Input from the outside thermo sensor Sensor temperature: 25°C (4kΩ) 2.1 − 2.7 V
8 Input from the air thermo sensor Sensor temperature: 25°C (4kΩ) 2.1 − 2.7 V
9 Photo sensor (-) Brightness is 0 lux 4.9 − 5.1 V
Brightness is 100,000 lux or more Approximately 0 V
10 Potentiometer power supply Always 5V
11 Input from the A/C pressure sensor 2.6 MPa 3.9 V
12 − 15 - - -
16 Rear defogger When the rear defogger is operating. 2.0 V or less
When the rear defogger is stopped System voltage
17 Diagnosis set Ignition switch: ON A voltmeter needle
fluctuates between
0 and 12 V.
18 Input from diagnosis Ignition switch: ON Approximately 5 V
19 Photo sensor (+) Always 0V
20 Sensors and potentiometers earth Always 0V
21 Air outlet changeover damper motor When the damper is moved to the 10 V
(FACE) FACE position.
When the damper is moved to the Faint voltage (0.5
DEF position. V)
22 Air mix damper motor (MAX COOL) When the damper flaps is moving to 10 V
the MAX COOL position.
When the damper flaps is moving to Faint voltage (0.5
the MAX HOT position. V)
TROUBLESHOOTING
55-103
No.
23 Outside/inside air selection damper When the damper is moved to the 10 V (When the
control motor (outside) inside air recirculation position motor is stopped)
When the damper is moved to the 2.0 V or less
outside air inside air intake position
24 Mode selection damper control motor When the damper is moved to the Faint voltage (0.5
and potentiometer (DEF) FACE position. V)
When the damper is moved to the 10 V
DEF position.
25 Air mixing damper control motor and When the damper flaps is moving to Faint voltage (0.5
potentiometer (MAX HOT) the MAX COOL position. V)
When the damper flaps is moving to 10 V
the MAX HOT position.
26 outside/inside air selection damper When the damper is moved to the 2.0 V or less
control motor (inside) inside air recirculation position
When the damper is moved to the 10 V (When the
outside air inside air intake position motor is stopped)
27 Earth Always Continuity exists.
28 IG2 power supply Ignition switch: ON System voltage
29 Illumination earth Always Continuity exists.
30 ILL power supply Lighting switch: ON System voltage
31 - - -
32 Input from the engine-A/T-ECU When the A/C is under low load System voltage
(A/C2)
33 Input from the compressor relay Compressor: ON System voltage
34 Input from the engine-A/T-ECU When the A/C is stopped 0V
(A/C1) When the A/C is operating (When the System voltage
compressor is operating)
35 - - -
36 ACC power supply Ignition switch: ACC System voltage
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
MAGNETIC CLUTCH TEST 1. Remove the dual pressure switch connector and
M1552008500483 connect the high/low pressure side terminals
1. Disconnect the magnetic clutch connector to the located on the harness side as shown in the
magnetic clutch. illustration.
Magnetic clutch connector 2. Install a gauge manifold to the high-pressure side
service valve of the refrigerant line (Refer to
P.55-128, P.55-129).
3. When the high/low pressure sides of the dual
pressure switch are at operation pressure (ON)
the resistance should less than two ohms
between the terminals. If open circuit, replace the
switch.
CHARGING AND DISCHARGING

AC005671AC M1552022200044
Use the refrigerant recovery unit to discharge refrig-
2. Connect positive battery voltage directly to the erant gas front the system.
connector for the magnetic clutch.
NOTE: Refer to the Refrigerant Recovery and Recy-
3. If the magnetic clutch is normal, there will be a cling Unit instruction Manual for operation of the unit.
"click." If the pulley and armature do not make
contact ("click"), there is a malfunction. REFILLING OF OIL IN THE A/C SYSTEM
M1552020000066
COMPRESSOR DRIVE BELT Too little oil will provide inadequate compressor lubri-
ADJUSTMENT cation and cause a compressor failure. Too much oil
M1552001000409 will increase discharge air temperature.
Refer to GROUP 11A, On-vehicle Service − Drive When a compressor is installed at the factory, it con-
Belt Tension Check P.11A-7. tains 120 mL of compressor oil. While the A/C sys-
tem is in operation, the oil is carried through the
DUAL PRESSURE SWITCH CHECK entire system by the refrigerant. Some of this oil will
M1552010400375
be trapped and retained in various parts of the sys-
High/Low
tem.
Pressure Side When the following system components are
changed, it is necessary to add oil to the system to
replace the oil being removed with the component.
Compressor oil: SUN PAG 56
Quantity
Evaporator: 60 mL
Condenser: 15 mL
Flexible suction hose: 10 mL
Receiver: 10 mL
PERFORMANCE TEST
Low-pressure side High-pressure side M1552001400429
210 ± 25 2060 ± 200 1. The vehicles to be tested should be in a place that
230 ± 20 2650 ± 200
is not in direct sunlight.
ON ON
OFF OFF
(kPa)
AC001368 AD
ON-VEHICLE SERVICE
55-105
NOTE: The high-pressure service valve is on the
A/C pipe and the low-pressure service valve is on
Low-pressure High-pressure the suction hose.
valve valve
5. Connect the quick joint (for low-pressure) to the
low-pressure service valve and connect the quick
joint (for high-pressure) to the high-pressure
service valve.
Gauge manifold 7. Set the A/C controls as follows:
Charging
• A/C switch: A/C − ON position
hose (red)
• Mode selection: FACE position
Charging
hose (blue) • Temperature control: MAXIMUM COOLING posi-
A tion
Adaptor valve • Air selection: RECIRCULATION position
(for low- Sleeve • Blower switch: "4" (Fast) position
pressure)
Adaptor valve 8. Keep engine speed to idling speed with A/C clutch
(for high- engaged.
Low- High- pressure)
pressure pressure 9. Engine should be warmed up with doors and all
service
valve
service windows opened.
valve
Thermometer
AC001388 AB
2. Close the high and low-pressure valve of the

gauge manifold.
3. Connect the charging hose (blue) to the
low-pressure valve and connect the charging
hose (red) to the high-pressure valve of the gauge
manifold.
CAUTION AC304576 AB
• To connect the quick joint, press section A
firmly against the service valve until a click is 10.Insert a thermometer in the centre air outlet and
heard. operate the engine for 20 minutes.
• When connecting, run your hand along the NOTE: If the clutch cycles, take the reading before
hose while pressing to ensure that there are the clutch disengages.
no bends in the hose. 11.Note the discharge air temperature.
4. Install the quick joint (for low-pressure) to the
charging hose (blue), and connect the quick joint
(for high-pressure) to the charging hose (red).
PERFORMANCE TEMPERATURE CHART
Garage ambient temperature °C 20 25 30 35
Discharge air temperature °C 8.0 − 11.0 12.0 − 16.0 17.0 − 21.0 22.5 − 27.5
Compressor high pressure kPa 740 − 840 950 − 1,050 1,160 − 1,300 1,360 − 1,550
Compressor low pressure kPa 150 − 190 190 − 240 240 − 300 300 − 375
REFRIGERANT LEAK REPAIR 2. Charge the system with approximately 480 − 520
PROCEDURE g of refrigerant.
M1552001500385 3. Check for leaks.
LOST CHARGE 4. Discharge the system.
If the system has lost all charge due to a leak: 5. Repair leaks.
1. Evacuate the system (Refer to P.55-104).
ON-VEHICLE SERVICE
CAUTION On standard plumbing fittings with O-rings, these

Replacement filter-drier units must be sealed O-rings are not reusable.
while in storage. The drier used in these units will
saturate water quickly upon exposure to the
COMPRESSOR NOISE CHECK
M1552008700379
atmosphere. When installing a drier, have all You must first know the conditions when the noise
tools and supplies ready for quick assembly to occurs. These conditions are: weather, vehicle
avoid keeping the system open any longer than speed, in gear or neutral, engine temperature or any
necessary. other special conditions.
6. Replace receiver drier. Noises that develop during A/C operation can often
7. Evacuate and charge system. be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
LOW CHARGE caused by loose bolts, nuts, mounting brackets, or a
If the system has not lost all of its refrigerant charge; loose clutch assembly. Verify accessory drive belt
locate and repair all leaks. If it is necessary to tension (power steering or alternator).
increase the system pressure to find the leak Improper accessory drive belt tension can cause a
(because of an especially low charge) add refriger- misleading noise when the compressor is engaged
ant. If it is possible to repair the leak without dis- and little or no noise when the compressor is disen-
charging the refrigerant system, use the procedure gaged.
for correcting low refrigerant level. Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
HANDLING TUBING AND FITTINGS belts can develop unusual noises that are often mis-
taken for mechanical problems within the compres-
Kinks in the refrigerant tubing or sharp bends in the
sor.
refrigerant hose lines will greatly reduce the capacity
of the entire system. High pressures are produced in ADJUSTMENT
the system when it is operating. Extreme care must 1. Select a quiet area for testing. Duplicate
be exercised to make sure that all connections are conditions as much as possible. Switch the
pressure tight. Dirt and moisture can enter the sys- compressor on and off several times to clearly
tem when it is opened for repair or replacement of identify compressor noise. To duplicate high
lines or components. The following precautions must ambient conditions (high head pressure), restrict
be observed. The system must be completely dis- air flow through the condenser. Install a manifold
charged before opening any fitting of connection in gauge set to make sure discharge pressure
the refrigeration system. Open fittings with caution doesn't exceed 2,070 kPa.
even after the system has been discharged. If any 2. Tighten all compressor mounting bolts, clutch
pressure is noticed as a fitting is loosened, allow mounting bolt, and compressor drive belt. Check
trapped pressure to bleed off very slowly. to assure clutch coil is tight (no rotation or
Never attempt to rebend formed lines to fit. Use the wobble).
correct line for the installation you are servicing. A 3. Check refrigerant hoses for rubbing or
good rule for the flexible hose lines is keep the radius interference that can cause unusual noises.
of all bends at least 10 times the diameter of the
hose. 4. Check refrigerant charge (Refer to P.55-104).
Sharper bends will reduce the flow of refrigerant. The 5. Recheck compressor noise as in Step 1.
flexible hose lines should be routed so that they are 6. If noise still exists, loosen compressor mounting
at least 80 mm from the exhaust manifold. It is good bolts and retighten. Repeat Step 1.
practice to inspect all flexible hose lines at least once 7. If noise continues, replace compressor and repeat
a year to make sure they are in good condition and Step 1.
properly routed.
ON-VEHICLE SERVICE
55-107
POWER RELAY CHECK A/C COMPRESSOR RELAY, CON-
M1552008800428
DENSER FAN RELAY (LO) AND (HI) CON-
BLOWER RELAY CONTINUITY CHECK
TINUITY CHECK
Blower relay
A/C compressor relay
Condenser fan relay (HI)
Condenser fan relay (LO)
1 2 3 5
4 1 2 1
4 X 4
5 1 3 3 4
2 3
Front of
vehicle
AC310514AB
AC310515AB
Battery voltage Tester Specified

connection condition Battery voltage Tester Specified
• Connect 4−5 Less than 2
terminal 3 to ohms • Connect 1−4 Less than 2
the positive terminal 2 to ohms
battery the positive
terminal battery
• Connect terminal
terminal 1 to • Connect
the negative terminal 3 to
battery the negative
terminal battery
terminal
IDLE-UP OPERATION CHECK

M1552001600683
1. Before inspection and adjustment, set vehicle in Standard value: 850 ± 50 r/min
the following condition: 3. When the A/C is running after turning the A/C
• Engine coolant temperature: 80 − 90 °C switch to ON, and the blower switch to the 3(MH)
• Lamps, electric cooling fan and accessories: Set or 4(HI) position, check to be sure that the idle up
to OFF speed is at the standard value.
Standard value: 850 ± 50 r/min
• Steering wheel: Straightforward
NOTE: It is not necessary to make an adjustment,
2. Check whether or not the idle speed is the
because the idling speed is automatically
standard value. Refer to GROUP 13A, On-vehicle
adjusted by the ISC system. If, however, a devia-
Service − Basic Idle Speed Adjustment
tion from the standard value occurs for some rea-
P.13A-396. son, check the ISC system.
HEATER CONTROL ASSEMBLY AND A/C SWITCH
CLEAN AIR FILTER REPLACEMENT

PROCEDURE
M1552020100096
1. Remove the glove box (Refer to GROUP 52A,
Instrument Panel P.52A-2).
Clean air filter

AC309643AC
2. Remove the two screws as shown, and replace

the clean air filter.
3. Install the glove box.
HEATER CONTROL ASSEMBLY AND A/C SWITCH

M1552002400659
1
2
4 5
5
4 2
2
AC504841AB

1. Centre lower case (Refer to 3. Automatic A/C control panel
GROUP 52A, Instrument panel (A/C-ECU)
assembly P.52A-2) 4. Bracket
2. Knob
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
55-109
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND
EVAPORATOR UNIT
M1552011600521

• Refrigerant draining and Refilling (Refer to Charging and
Discharging P.55-104).
• Engine coolant Draining and Refilling (Refer to GROUP
14, On vehicles service P.14-15).
• Instrument Panel Removal and Installation (Refer to
• Air cleaner cover and air flow sensor assembly Removal
and Installation (Refer to GROUP 15, Air cleaner P.15-5).
• Rear console assembly Removal and Installation (Refer
to GROUP 52A, Rear console assembly P.52A-8).
• Front floor console assembly Removal and Installation
(Refer to GROUP 52A, Front floor console assembly
P.52A-7).
• Front seat assembly Removal and Installation (Refer to
GROUP 52A, Front seat assembly P.52A-18).
-Pipe coupling
2 12 ± 2 N·m
5
7
9
6, 7 O-ring
A/C compressor oil: 3
SUN PAG 56
6
1 8N
44 ± 10 N·m
44 ± 10 N·m
AC304861AC

1. Front deck crossmember 4. Blower assembly
2. Centre duct 5. Heater hose connection
3. Intake duct <<A>> 6. Flexible suction hose connection
• Foot duct (RH), Rear heater duct A <<A>> 7. Liquid pipe B connection
(RH) upper side (Refer to 8. O-ring
P.55-130). 9. Heater unit
REMOVAL SERVICE POINT HEATER UNIT

<<A>> FLEXIBLE SUCTION HOSE/LIQUID
PIPE B DISCONNECTION
<LHD>
CAUTION M1551005400503
As the compressor oil and receiver are highly
moisture absorbent, use a non-porous material
to plug the hose and nipples.
To prevent the entry of dust or other foreign bodies,
plug the dismantled hose and the nipples of the
expansion valves.
2 1
-Pipe coupling
3
12
6, 9 O-ring
A/C compressor oil:
11 SUN PAG 56
4 5
16
10 6 8
13 7N
14
9
15
AC504612 AB

1. Foot duct (LH) 8. Evaporator cover
2. Air mixing damper control motor 9. Evaporator
and potentiometer 10. Air thermo sensor clip
3. Mode selection damper control 11. Air thermo sensor
motor and potentiometer 12. Heater water temperature sensor
4. Heater core 13. Aspirator
5. Expansion valve 14. Aspirator hose
6. Joint 15. Harness
7. O-ring 16. Heater case
55-111
<RHD>
M1551005400514
-Pipe coupling 1
15
17 16
13
2
6 O-ring 14
A/C compressor oil:
SUN PAG 56 10
4
11
7
9
8
5
12
3 AC504713AB

1. Foot duct (RH) 11. Aspirator hose
2. Foot duct (LH) 12. Harness
3. Evaporator cover 13. Air mixing damper control motor
4. Heater core and potentiometer
5. Expansion valve 14. Mode selection damper control
6. Evaporator motor and potentiometer
7. O-ring 15. Heater water temperature sensor
8. Air thermo sensor clip clip
9. Air thermo sensor 16. Heater water temperature sensor
10. Aspirator 17. Heater case
BLOWER ASSEMBLY
M1551005500287
3
4
AC504715AB

1. Joint duct 3. Blower motor
2. Outside/inside air selection damper 4. Air filter
control motor 5. Blower case
MODE SELECTION DAMPER CONTROL MOTOR, AIR MIXING DAMPER CONTROL MOTOR, OUTSIDE/INSIDE
55-113
MODE SELECTION DAMPER CONTROL MOTOR, AIR
MIXING DAMPER CONTROL MOTOR, OUTSIDE/INSIDE AIR
SELECTION DAMPER CONTROL MOTOR AND BLOWER
MOTOR
M1554019900016
4
AC504716AB
Blower motor removal step REMOVAL SERVICE POINT

• Front passenger's side under cover
<<A>> BLOWER MOTOR AND MODE
<<A>> 1. Blower motor
Air mixing damper control motor SELECTION DANPER CONTROL MOTOR
and potentiometer removal step AND POTENTIOMETER REMOVAL
2. Air mixing damper control motor
NOTE:
and potentiometer
Mode selection damper control
removal step
<<A>> 3. Mode selection damper control
Outside/inside air selection
damper control motor removal
step
• Glove box (Refer to GROUP 52A,
Instrument Panel P.52A-2). AC304916
• Engine-ECU (Refer to GROUP
13A, Engine-ECU P.13A-416).
Use of commercially available offset screw driver is
4. Outside/inside air selection damper recommended.
control motor
MODE SELECTION DAMPER CONTROL MOTOR, AIR MIXING DAMPER CONTROL MOTOR,
INSPECTION MODE SELECTION DAMPER CONTROL

M1551006300491
MOTOR AND POTENTIOMETER CHECK
CHECK THE AIR MIXING DAMPER CON-
TROL MOTOR AND POTENTIOMETER <L.H. drive vehicles>
MAX. COOL FACE

position position
MAX HOT position DEF position
1 2
3 4 5 6
AC301519AG
1 2
3 4 5 6
AC301517AG <R.H. drive vehicles>
1 2 DEF position
<R.H. drive vehicles> 3 4 5 6
1 2
3 4 5 6
FACE
position
MAX. COOL
position
AC504718AB
MAX HOT position AC504717AB MODE SELECTION DAMPER CONTROL MOTOR

CHECK
CHECK THE AIR MIXING DAMPER CONTROL Battery Battery Lever operation
MOTOR connection connection
Battery Battery Lever operation (+) terminal (-) terminal
connection connection
1 3 Rotate to the DEF
(+) terminal (-) terminal
position.
1 3 Rotate to the HOT
3 1 Rotate to the FACE
position.
position.
3 1 Rotate to the COOL
Potentiometer check
position.
When the resistances between terminals 2 and 5 as
Potentiometer check well as terminals 5 and 6 are measured at the mode
When the resistances between terminals 2 and 5 as selection damper control motor check, the resistance
well as terminals 5 and 6 are measured at the air value should change gradually within the standard
mixing damper motor check, the resistance value value.
should change gradually within the standard value. Standard value: Approximately 0.65 − 5.35
Standard value: Approximately 0.65 − 5.35 kΩ
kΩ
MODE SELECTION DAMPER CONTROL MOTOR, AIR MIXING DAMPER CONTROL MOTOR, OUTSIDE/INSIDE
55-115
OUTSIDE/INSIDE AIR SELECTION BLOWER MOTOR CHECK
DAMPER CONTROL MOTOR CHECK Execute actuator test item No.01 to 04 by using
M.U.T.-II/III with the vehicle body, and check that the
CAUTION
blower motor works normally. (Refer to P.55-101).
Inside air
Outside air AC100625AE
Cut off the battery voltage when the damper is in

the outside/inside air position.
Lever position Battery Lever
connection operation
At the inside • Connect The lever
position terminal 7 to moves from the
the positive inside position
battery to the outside
terminal position
• Connect
terminal 4 to
the negative
battery
terminal
At the outside • Connect The lever
position terminal 7 to moves from the
the positive outside position
battery to the inside
terminal position
• Connect
terminal 6 to
the negative
battery
terminal
SENSORS
SENSORS
M1554001900196
2
1
AC504729AB
Interior temperature sensor Heater water temperature sensor

removal steps removal steps
1. Interior temperature sensor • Foot duct <front passenger's side>
(Refer to GROUP 55, Ventilator
P.55-131).
2. Heater water temperature sensor
Photo sensor removal steps
<<A>> 3. Photo sensor
SENSORS
55-117
REMOVAL SERVICE POINT Check to see that the resistance shown in the graph
is almost satisfied when measuring the resistance
<<A>> PHOTO SENSOR REMOVAL
between the terminals under two or more different
Photo sensor connector temperature conditions.
HEATER WATER TEMPERATURE SEN-

SOR CHECK
Resistance
(k ) 20
String
15
AC504803AB 10
1. Remove the photo sensor together with the 5

defroster nozzle.
2. Suspend the connector with a string to avoid the 0
-10 0 20 40 60 80
connector drops behind the instrument panel. Temperature (˚C) AC503134 AB
INSPECTION Check to see that the resistance shown in the graph

M1552014302150 is almost satisfied when measuring the resistance
INTERIOR TEMPERATURE SENSOR between the terminals under two or more different
CHECK temperature conditions.
Resistance PHOTO SENSOR CHECK

(k ) 20
Check that the blower rotation comes down if the
15 photo sensor is covered with hands, when the auto-
matic A/C is operating (in summer sunbeam). If not
10 the rotation comes down, replace the photo sensor.
5
0
-10 0 20 40 60 80
Temperature (˚C) AC503134 AB
EVAPORATOR ASSEMBLY
EVAPORATOR ASSEMBLY
REMOVAL AND INSTALLATION <LHD>
M1552003600496

discharging P.55-104).
• Air cleaner and air cleaner air flow sensor assembly
Removal and Installation (Refer to GROUP 15, Air
cleaner P.15-5).
-Pipe coupling
1, 2, 4, 7 O-ring
2 A/C compressor oil:
SUN PAG 56
12 ± 2 N·m
1
10 4
3 8
9 8
5
AC504937AB

<<A>> 1. Flexible suction hose connection 9. Air thermo sensor clip
<<A>> 2. Liquid pipe B connection 10. Air thermo sensor
3. Expansion valve
4. Joint REMOVAL SERVICE POINT
• Glove box (Refer to GROUP 52A,
<<A>> FLEXIBLE SUCTION HOSE/LIQUID
• Engine-ECU (Refer to GROUP PIPE B DISCONNECTION
13A, Engine-ECU P.13A-416). CAUTION
5. Joint duct As the compressor oil and receiver are highly
• Foot duct (RH), Rear heater duct A
(RH) upper side (Refer to
P.55-130).
6. Evaporator cover
7. Evaporator plug the dismantled hose and the nipples of the
8. O-ring expansion valves.
EVAPORATOR ASSEMBLY
55-119
REMOVAL AND INSTALLATION <RHD>
M1552003600504

discharging P.55-104).
• Air cleaner and air cleaner air flow sensor assembly
Removal and Installation (Refer to GROUP 15, Air
cleaner P.15-5).
-Pipe coupling
1, 2, 6 O-ring
A/C compressor oil:
SUN PAG 56
2
12 ± 2 N·m
3
7
1
7 9
8
6
5
4 AC304886AC

<<A>> 1. Flexible suction hose connection • Foot duct (RH), Rear heater duct A
<<A>> 2. Liquid pipe B connection (RH) upper side (Refer to
3. Expansion valve P.55-130).
• Glove box (Refer to GROUP 52A, 5. Evaporator cover
Instrument Panel P.52A-2). <> 6. Evaporator
• Engine-ECU (Refer to GROUP 7. O-ring
13A, Engine-ECU P.13A-416). 8. Air thermo sensor clip
4. Joint duct 9. Air thermo sensor
EVAPORATOR ASSEMBLY
REMOVAL SERVICE POINT INSPECTION

M1552014302161
<<A>> FLEXIBLE SUCTION HOSE/LIQUID AIR THERMO SENSOR INSPECTION
PIPE B DISCONNECTION
CAUTION
plug the dismantled hose and the nipples of the
expansion valves.
<> EVAPORATOR REMOVAL

Resistance
(k ) 25
Dashboard pad 20
15
10
5
0
-10 0 10 20 30 40
Blower unit Temperature (˚C)
AC305312 AB
AC103376 AB
CAUTION Measure the resistance between connector terminals

Do not cut the upper side of the pad. 4 and 5 under at least two different temperatures.
1. When removing the evaporator, cut and fold back The resistance values should generally match those
the dashboard pad as in the diagram (The thick- in the graph.
ness of the pad interferes with the removal of the NOTE: The temperature at the check should not
evaporator). exceed the range in the graph.
2. Remove the evaporator.
OUTSIDE THERMO SENSOR
55-121
OUTSIDE THERMO SENSOR
INSPECTION Check to see that the resistance shown in the graph
M1552014302138 is almost satisfied when measuring the resistance
between the sensor terminals under two or more dif-
ferent temperature conditions.
Outside
thermo sensor
AC212287AF
Resistance
(k ) 50
40
30
20
10
0
-30 -20 0 20 40 60
Temperature (˚C) AC103489AB
COMPRESSOR ASSEMBLY AND TENSION PULLEY

M1552004100535

• Refrigerant Discharging (Refer to P.55-104). • Drive Belt Tension Adjustment (Refer to GROUP 11A,
On-vehicles Service − Drive Belt Tension Check P.11A-7).
• Refrigerant Charging (Refer to P.55-104).
-Pipe coupling
6
5
3N
1, 2
3N
A/C compressor oil: 2
SUN PAG 56
25 ± 4 N·m
1
4
AC310766AB

<<A>> 1. Flexible suction hose connection <> 4. Drive belt
<<A>> 2. Flexible discharge hose connection <<C>> >>A<< 5. A/C compressor
3. O-ring 6. A/C compressor bracket

<<A>> FLEXIBLE SUCTION HOSE/FLEXI- <> DRIVE BELT REMOVAL
BLE DISCHARGE HOSE DISCONNEC- The following operations will be needed due to the
TION serpentine drive system with the alternator drive belt
auto tensioner.
CAUTION
plug the dismantled hoses and compressor nipples.
55-123
Alternator drive belt 1. Measure the amount (X mL) of oil within the
auto tensioner removed compressor.
2. Drain (from the new compressor) the amount of
oil calculated according to the following formula,
and then install the new compressor.
New compressor oil amount = 120 mL
Hole B
120 mL−X mL = Y mL
NOTE: Y mL indicates the amount of oil in the
Hole A AC107640AD
refrigerant line, the condenser, the evaporator,
etc.
Alternator drive belt NOTE: When replacing the following parts at the
auto tensioner same times as the compressor, subtract the rated
oil amount of the each part from Y mL and dis-
charge from the new compressor.
Quantity:
• Evaporator: 60 mL
• Condenser: 15 mL
L-shaped • Suction hose: 10 mL
hexagon • Receiver: 10 mL
wrench AC107641AC
1. Securely insert the spindle handle or ratchet INSPECTION

M1552014301834
handle with a 12.7 mm insertion angle into the jig
COMPRESSOR MAGNETIC CLUTCH
hole of the alternator drive belt auto tensioner,
and turn the alternator drive belt auto tensioner OPERATION CHECK
anti-clockwise until it hits the stopper. Magnetic clutch connector
CAUTION
To reuse the alternator drive belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the alternator drive belt using chalk.
2. Align hole A with hole B, insert an L-shaped
hexagon wrench, etc. to fix and then remove the
alternator drive belt.
<<C>> A/C COMPRESSOR REMOVAL AC005671AK

Take care not to spill any compressor oil when
removing the compressor. Connect the compressor connector terminal to the
battery positive (+) terminal and earth the battery’s
INSTALLATION SERVICE POINT negative (−) terminal to the compressor unit. At that
time, the magnetic clutch should make a definite
>>A<< A/C COMPRESSOR INSTALLA- operating sound.
TION
If a new compressor is installed, first adjust the
amount of oil according to the procedures described
below, and then install the compressor.

M1552004600808
9 3N
2
8
7
6
11 1
5
10
N 4
16 ± 1 N·m
AC100630 AB
Cooling temperature switch Magnetic clutch disassembly

disassembly steps <<A>> >>C<< 4. Self-locking nut
1. Snap ring 5. Armature
2. Refrigerant temperature switch >>B<< 6. Snap ring
3. O-ring 7. Rotor
Magnetic clutch disassembly 8. Snap ring
>>D<< • Air gap adjustment >>A<< 9. Field core
10. Shim
11. A/C compressor
DISASSEMBLY SERVICE POINT

<<A>> SELF-LOCKING NUT REMOVAL Use the special tools to remove the self-locking nut.
• Special spanner (MB991367)
• Pin (MB991386)
MB991386
MB991367
AC100633AB
55-125
REASSEMBLY SERVICE POINTS >>D<< AIR GAP ADJUSTMENT
>>A<< FIELD CORE
Thickness
gauge
Field core projection
Compressor
unit pin hole AC100637AB
AC100634 AB Apply voltage from the battery to the magnetic clutch

Line up the pin hole on the compressor unit with the and check that the clutch air gap is inside the stand-
field core projection and attach. ard value. If outside the standard value, use a shim
to adjust the gap.
>>B<< SNAP RING INSTALLATION Standard value: 0.3 − 0.5 mm
Snap ring Rotor Clutch coil INSPECTION

M1552014301340
REFRIGERANT TEMPERATURE SWITCH

CAUTION
Do not heat more than necessary.
Tapered part
AC001412 AB
Using snap ring pliers, fit the snap ring so that the
snap ring’s tapered part is on the outside. Thermometer
>>C<< SELF-LOCKING NUT

Engine oil
INSTALLATION
AC100787 AB
MB991386
1. Dip the metal part of the cooling temperature
switch into engine oil and increase the oil
MB991367 temperature using a gas burner or similar.
120˚C 150˚C
Continuity
AC100633AB No continuity
Use the special tools to install the self-locking nut.
• Special spanner (MB991367) Oil temperature
• Pin (MB991386)
AC100810 AD
2. When the oil temperature reaches the standard

value, check that voltage is supplied between the
terminals.
CONDENSER AND CONDENSER FAN MOTOR
Standard value: NOTE: When the oil temperature is 150°C or

more and there is no continuity, the resistance will
Item Temperature not be 2Ω or lower until the oil temperature
Less than 2 Slightly below 150°C reduces to 120°C or less.
ohms
No continuity 150°C or more

M1552006700674

• Refrigerant Draining and Refilling (Refer to P.55-104).
• Front Bumper Removal and Installation (Refer to GROUP
51 P.51-2).
4.9 ± 0.9 N·m

-Pipe coupling 12 ± 2 N·m
6
5
N 10
5, 6 10 N
A/C compressor oil:
SUN PAG 56
2 7
3
4 1 N 10
9 8 AC211410AC
Fan shroud assembly removal Condenser removal steps

steps <> 5. Flexible discharge hose connection
<<A>> 1. Fan shroud assembly <> 6. Liquid pipe A connection
2. Fan >>A<< 7. Condenser
3. Fan motor 8. Clamp
4. Fan shroud 9. Receiver
10. O ring
55-127
M1552014301351
<<A>> FAN SHROUD ASSEMBLY CONDENSER FAN MOTOR CHECK
REMOVAL
A-34
1 2
1 2
A-35
AC211409AC
AC211409AC
BATTERY CONNECTION CONDENSER
1. Remove the intercooler mounting bolts/nuts and FAN MOTOR
pull the intercooler forward. OPERATION
2. Move the fan motor/shroud assembly upward for • Connect connector A-34 Condenser fan
removal. terminal 2 to the positive motor LO
battery terminal operation
<> FLEXIBLE DISCHARGE • Connect connector A-35
HOSE/LIQUID PIPE A DISCONNECTION terminal 2 to the negative
CAUTION battery terminal
As the compressor oil and receiver are highly • Connect connector A-34 Condenser fan
moisture absorbent, use a non-porous material terminal 1 to the positive motor HI
to plug the hose and nipples. battery terminal operation
To prevent the entry of dust or other foreign material, • Connect connector A-35
plug the dismantled hose and condenser assembly terminal 2 to the negative
nipples. battery terminal

>>A<< CONDENSER INSTALLATION
When replacing the condenser, refill it with a speci-
fied amount of compressor oil and install it to the
vehicle.
Compressor oil: SUN PAG 56
Quantity: 15 cm3 (0.5 floz)
REFRIGERANT LINE
REFRIGERANT LINE
REMOVAL AND INSTALLATION <LHD>
M1552006401063

• Air Cleaner Removal and Installation (Refer to GROUP
15, Air cleaner P.15-5).
• Radiator Grille Removal and Installation (Refer to
GROUP 51, Front bumper P.51-2).
13 ± 1 N·m
6
High-pressure
side service valve 8N
1 8 N
2 Low-pressure side 7
4.9 ± 0.9 N·m service valve
12 ± 2 N·m 8 N
5 12 ± 2 N·m
4
8N
25 ± 4 N·m
8N
3 -Pipe coupling
O-ring
1, 2, 3,
5, 6 O-ring 6
A/C compressor oil: SUN PAG 56
AC304553AE
Removal steps REMOVAL SERVICE POINT

<<A>> 1. Dual pressure switch
<<A>> HOSE/PIPE DISCONNECTION
<<A>> 2. Liquid pipe A
<<A>> 3. Flexible discharge hose CAUTION
4. Expansion valve cover As the compressor oil and receiver are highly
<<A>> >>A<< 5. Flexible suction hose moisture absorbent, use a non-porous material
<<A>> 6. Liquid pipe B to plug the hose and nipples.
7. Expansion valve cover To prevent the entry of other foreign bodies, plug the
8. O-ring condenser, compressor, and expansion valve nip-
ples.
REFRIGERANT LINE
55-129
INSTALLATION SERVICE POINT Compressor oil: SUN PAG 56
>>A<< FLEXIBLE SUCTION HOSE Quantity: Suction hose: 10 cm3
INSTALLATION
When replacing the suction hose, refill them with a
specified amount of compressor oil, and then install
them.
REMOVAL AND INSTALLATION <RHD>

M1552006401074

• Air Cleaner Removal and Installation (Refer to GROUP
15, Air cleaner P.15-5).
• Radiator Grille Removal and Installation (Refer to
GROUP 51, Front bumper P.51-2).
13 ± 1 N·m
8N 6
Low-pressure side
High-pressure
service valve
Side Service Valve
1
4.9 ± 0.9 N·m
8N
2
5 7
12 ± 2 N·m
8N
8N 4 12 ± 2 N·m
25 ± 4 N·m
3 8N
-Pipe coupling
O-ring
1, 2, 3,
5, 6 O-ring 6
A/C compressor oil: SUN PAG 56
AC304554 AB

<<A>> 1. Dual pressure switch <<A>> >>A<< 5. Flexible suction hose
<<A>> 2. Liquid pipe A <<A>> 6. Liquid pipe B
<<A>> 3. Flexible discharge hose 7. Expansion valve cover
4. Expansion valve cover 8. O-ring
DUCTS

<<A>> HOSE/PIPE DISCONNECTION >>A<< FLEXIBLE SUCTION HOSE
CAUTION INSTALLATION
As the compressor oil and receiver are highly When replacing the suction hose, refill them with a
moisture absorbent, use a non-porous material specified amount of compressor oil, and then install
to plug the hose and nipples. them.
To prevent the entry of other foreign bodies, plug the Compressor oil: SUN PAG 56
condenser, compressor, and expansion valve nip- Quantity: Suction hose: 10 cm3
ples.
DUCTS
M1553001000134
Cross-section A-A 4
Clip 5
Instrument panel 4
1 3
2
6
A 1
3
9
10
11 8
13
12
AC304890 AB
Air Outlet Removal steps Defroster nozzle and Distribution

1. Centre Air Outlet Panel duct Removal steps
2. Centre Air Outlet • Instrument Panel (Refer to 52A,
3. Side Air Outlet Instrument Panel P.52A-2).
4. Side defroster duct
VENTILATORS
55-131
Defroster nozzle and Distribution Foot duct Removal steps
duct Removal steps (Continued) 9. Foot duct (LH)
5. Defroster nozzle Rear heater duct Removal steps
6. Distribution duct • Front floor console (Refer to
Foot duct Removal steps GROUP 52A, Front floor console
• Console cover and Glove box assembly P.52A-7).
(Refer to GROUP 52A, Instrument • Front seat (Refer to GROUP 52A -
panel P.52A-2). Front seat assembly P.52A-18).
7. Foot duct (RH) • Floor carpet and Floor pads
8. Rear heater duct A (RH) upper side 10. Rear heater duct A (LH)
• Under cover (Refer to GROUP 11. Left -hand rear heater duct B
52A, Instrument panel P.52A-2). 12. Right-hand rear heater duct B
13. Rear heater duct A (RH) lower side
VENTILATORS
M1553001600523
Cross-Section A – A Cross-Section B – B A
A
1 A
Claw A
Claw
B
1 B
AC211528 AD
Rear ventilation duct removal

steps
• Rear bumper assembly (Refer to
GROUP 51, Rear bumper P.51-5).
1. Rear ventilation duct
NOTES
31-1
GROUP 31
WHEEL AND TYRE

CONTENTS
GENERAL INFORMATION . . . . . . . . 31-2 ON-VEHICLE SERVICE . . . . . . . . . . . 31-7

TYRE INFLATION PRESSURE CHECK . . . 31-7
SERVICE SPECIFICATIONS. . . . . . . 31-2 TYRE WEAR CHECK . . . . . . . . . . . . . . . . . 31-7
WHEEL RUNOUT CHECK . . . . . . . . . . . . . 31-7
TROUBLESHOOTING . . . . . . . . . . . . 31-3
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 31-3 WHEEL AND TYRE . . . . . . . . . . . . . . 31-7
WHEEL BALANCE ACCURACY . . . . . . . . 31-4 INSTALLATION SERVICE POINT . . . . . . . 31-7
31-2 WHEEL AND TYRE
GENERAL INFORMATION
GENERAL INFORMATION
M1311000100134
The wheels and tyres of the following specifications SPECIFICATIONS
have been established. ROAD WHEEL AND TYRE
Item Specification
Wheel Type Aluminium type
Size 17 × 8JJ
Amount of wheel offset mm 38
Pitch circle diameter (PCD) mm 114.3
Tyre Size 235/45R17 93W
SPARE WHEEL AND TYRE
Item Specification
Spare wheel Type Steel type
Size 17 × 4T
Amount of wheel offset mm 30
Pitch circle diameter (PCD) mm 114.3
Spare tyre Size T125/70D17 98M
NOTE: PCD indicates the pitch circle diameter of the wheel installation holes.
M1311000300473
Item Limit
Tread depth of tyre mm Minimum 1.6
Wheel runout (Radial runout) mm 1.0 or less
Wheel runout (Lateral runout) mm 1.0 or less
WHEEL AND TYRE
TROUBLESHOOTING
31-3
TROUBLESHOOTING
DIAGNOSIS
M1311000700523
Symptom Probable cause Remedy Reference page

Rapid wear Under-inflation Adjust the tyre For tyre inflation
at shoulders or lack of pressure. pressure, refer to
rotation the label on the
driver's side centre
pillar.
ACX00923AB
ACX00924 AB
Rapid wear Over-inflation

at centre or lack of
rotation
ACX00925AB
ACX00926AB
Cracked Under-inflation Adjust the tyre For tyre inflation

treads pressure. pressure, refer to
the label on the
driver's side centre
pillar.
ACX00927AB
Wear on one Excessive Check the camber. Refer to GROUP

side camber 33, On-vehicle
service − Front
wheel alignment
check and
ACX00928 AB
adjustment P.33-4.
ACX00929 AB
Feathered Incorrect toe-in Adjust the toe-in.

edge
ACX00930AB
ACX00931AB
Bald spots Unbalanced Balance the wheels. P.31-4

wheel
ACX00932AB
ACX00933 AB
31-4 WHEEL AND TYRE
TROUBLESHOOTING
Symptom Probable cause Remedy Reference page

Scalloped Lack of rotation of tyres or worn Rotate the tyres, and Refer to GROUP
wear or out-of-alignment suspension check the front 33, On-vehicle
suspension service − Front
alignment. wheel alignment
check and
ACX00934
adjustment P.33-4.
WHEEL BALANCE ACCURACY 2. Off-the-car wheel balancers must be calibrated

M1311001700582 periodically to ensure good balancing results. An
PURPOSE inaccurately calibrated balancer could cause
This section contains tips and procedures for achiev- unnecessary replacement of tyres, shocks,
ing accurate wheel balance. Steering wheel vibration suspension components, or steering components.
and/or body shake can result if any of these proce- Check your balancer's calibration approximately
dures are not carefully observed. every 100 balances. Your wheel balancer's instruc-
1. Wheels and tyres must be properly mounted on a tion manual should include calibration procedures. If
balancer in order to achieve correct balance. the calibration procedures specifically for your bal-
Centering the wheel on the shaft of the balancer is ancer are missing, use the generic steps in this sec-
essential for proper mounting. tion for zero calibration, static balance, and dynamic
balance checks. The wheel balancer calibration
checks are also described in the flowchart (Refer to
P.31-6).
PROCEDURE <BALANCING TIPS>
Clamping cup
Hub/shaft assembly
Wing nut
Spring plate
Wheel mounting cone AC000041AB
Standard passenger car wheel
1. Confirm that the balancer's cone and the wheel 5. When installing wheel weights, hammer them at a
mounting cone are undamaged and free of dirt straight (not diagonal) angle.
and rust.
2. On this vehicle, the wheel's centre hole on the <CONFIRMING PROPER BALANCE>
hub side has a chamfered edge. Use a 1. After balancing the wheel, loosen the wing nut
back-mounting cone on your wheel balancer to and turn the wheel 180° against the balancer's
centre the wheel on the balancer shaft. hub. Then re-tighten the wing nut and check the
3. Install a wheel mounting cone. The appropriate balance again. Repeat wheel balance if
size cone for this vehicle is 67.0 mm. necessary.
4. Before balancing the wheel, remove any wheel 2. Turn the wheel again 180° against the balancer's
weights from both sides. Also check both sides for hub. If the wheel becomes out-of-balance each
any damage. time it is turned against the balancer's hub, the
wheel balancer may require calibration.
WHEEL AND TYRE
TROUBLESHOOTING
31-5
<WHEEL BALANCER CALIBRATION 4. <<Static Balance Check>> Attach a 5 g weight to
CHECKS> the outer rim. Recheck the balancer. The balancer
should detect 5 ± 2 g of imbalance 170 to 190°
1. Mount an undamaged original-equipment alloy
away from the 5 g weight.
rim and tyre assembly (wheel) onto your
• If the imbalance is within specification, the static
off-the-car wheel balancer. Balance the wheel.
balance calibration is correct. Go to Step 5 to
2. <<Zero Calibration Check>> Loosen the balancer check the dynamic balance.
wing nut, rotate the wheel a half-turn (180°), and • If the imbalance is out of specification, the bal-
retighten the nut. Recheck the balance. ancer requires calibration. Contact the balancer
• If the imbalance is 5 g or less, the zero calibration manufacturer for calibration by their repair repre-
is OK. Rebalance the wheel, then go to Step 4 to sentative.
check static balance.
5. <<Dynamic Balance Check>> Attach a 5 g weight
• If the imbalance is more than 5 g, go to Step 3.
to the inner rim at 180° opposite the 5 g weight
3. Loosen the balancer wing nut, rotate the wheel that was added in Step 4. Recheck the balance.
1/4 turn (90°), and retighten the nut. Recheck the The balancer should detect 5 ± 2 g of imbalance
wheel balance. 170 to 190° away from both the inner and outer 5
• If the imbalance is 5 g or less, the wheel may not g weights.
be centred on the balancer, or the balancing • If the imbalance is within specification, the
cones, the cup, and/or wing nut are damaged, dynamic balance calibration is correct. The bal-
dirty, or inappropriate for the wheel. You may ancer calibration checks are complete.
need to refer to the balancer manufacturer's • If the imbalance is out of specification, the bal-
instructions to verify the correct attachments. ancer requires calibration. Contact the balancer
After making the necessary corrections, recheck manufacturer for calibration by their repair repre-
the wheel balance. If OK, then go to Step 4. sentative.
• If the imbalance is more than 5 g, the balancer
requires calibration. Contact the balancer manu-
facturer for calibration by their repair representa-
tive.
31-6 WHEEL AND TYRE
TROUBLESHOOTING
WHEEL BALANCER CALIBRATION

CHECKING FLOW CHART
Balance wheel.
ZERO CALIBRATION
Rotate wheel 1/2 turn. CHECK
Imbalance = 5 g or less Imbalance = more than 5 g
Rebalance wheel.
Rotate wheel 1/4 turn.
Imbalance = 5 g or less Imbalance = more than 5 g
Verify wheel is properly centred.

Verify cones, cup, and wing nut are clean,
undamaged, and appropriate for wheel.
Make necessary corrections, then recheck
wheel balance.
STATIC BALANCE
Attach a 5 g weight to the outer rim.
CHECK
Is the imbalance 5 ± 2 g at 170 – 190˚ away from the
5 g weight?
YES NO
DYNAMIC BALANCE
Attach a 5 g weight to the inner rim at 180˚ opposite CHECK
the weight on the outer rim.
Is the imbalance 5 ± 2 g at 170 – 190˚ away from
both 5 g weights?
YES NO
Balancer does not require Balancer requires calibration.

calibration. Contact balancer manufacturer.
AC502720AB
WHEEL AND TYRE
ON-VEHICLE SERVICE
31-7
ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK WHEEL RUNOUT CHECK
M1311000900419 M1311001100461
NOTE: For information on tyre inflation pressure,
refer to the label attached to the centre pillar on the
driver's side.
Radial
TYRE WEAR CHECK
M1311001000442
Measure the tread depth of the tyres.
If the remaining tread depth is less than the minimum
limit, replace the tyre. Lateral
ACX00651AB
NOTE: When the tread depth of the tyres is reduced Jack up the vehicle so that the wheels are clear of
to 1.6 mm or less, wear indicators will appear. the floor. While slowly turning the wheel, measure
wheel runout with a dial indicator.
Limit:
Radial runout; 1.0 mm or less
Lateral runout; 1.0 mm or less
If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TYRE

INSTALLATION SERVICE POINT Tightening torque: 98 ± 10 N⋅m
M1311001300379
Tighten the wheel nuts to the specified torque.
NOTES
33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 33-2 DISASSEMBLY AND ASSEMBLY . . . . . . . 33-7

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-9
SERVICE SPECIFICATIONS. . . . . . . 33-3
LOWER ARM . . . . . . . . . . . . . . . . . . . 33-10
SPECIAL TOOLS. . . . . . . . . . . . . . . . 33-3 REMOVAL AND INSTALLATION . . . . . . . . 33-10
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-11
ON-VEHICLE SERVICE. . . . . . . . . . . 33-4 BALL JOINT DUST COVER REPLACEMENT 33-12
FRONT WHEEL ALIGNMENT CHECK AND LOWER ARM PILLOW BALL BUSHING
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 33-4 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-12
LOWER ARM BALL JOINT AXIAL PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-5 STABILIZER BAR* . . . . . . . . . . . . . . . 33-14
BALL JOINT DUST COVER CHECK . . . . . 33-5 REMOVAL AND INSTALLATION . . . . . . . . 33-14
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-16
STRUT ASSEMBLY. . . . . . . . . . . . . . 33-6
REMOVAL AND INSTALLATION . . . . . . . . 33-6 CROSSMEMBER BAR . . . . . . . . . . . . 33-17
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 33-6 REMOVAL AND INSTALLATION . . . . . . . . 33-17
WARNING
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
passenger (from rendering the SRS inoperative).
NOTE
33-2 FRONT SUSPENSION
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1332000100311
A MacPherson strut independent suspension-type
suspension is used for the front suspension. Aggres-
sive use of special components that include Mitsubi-
shi Motor’s own inverted struts and forged aluminium
parts reduces weight to create a suspension that
gives superior performance made with competition
use in mind.
Coil spring
Strut insulator
Stabilizer link
(pillow ball bushing)
Stabilizer bar
Lower arm bushing
(pillow ball bushing)
Strut (inverted strut)
Lower arm assembly

(forged aluminium)
Front axle No.1

crossmember Front axle
crossmember bar
AC211383AC
SPECIFICATIONS
COIL SPRING
Item Specification
Wire diameter mm 14
Average diameter mm 155
Free length mm 286
FRONT SUSPENSION
33-3
M1332000300735
Item Specification
Toe-in mm 0±2
Steering angle Inner wheel 31°45' ± 1°30'
Outer wheel (reference) 27°15'
Camber (selectable from 2 options) −1°00' ± 0°30'* or −2°00’ ± 0°30’ (Left/right
deviation within 30')
Caster 3°55' ± 0°30' (Left/right deviation within 30')
Kingpin inclination 13°45' ± 1°30'
Lower arm ball joint starting torque N⋅m 0.5 − 3.4
Lower arm pillow ball bushing starting torque N⋅m 0.5 − 3.0
Stabilizer link ball joint turning torque N⋅m 1.7 − 3.2
NOTE: *: Default factory setting
SPECIAL TOOLS
M1332000600532

A: MB991237 A: Spring compressor Coil spring compression
B: MB991238 body
A B: Arm set
B MB991237
A MB991680 Wrench set Strut assembly

B A: MB991681 A: Wrench disassembly and
B: MB991682 B: Socket reassembly
MB991680
MB991006 Preload socket Lower arm ball joint

starting torque
measurement
MB991006
MB990326 Preload socket Lower arm ball bushing

starting torque
measurement
MB990326
MB990800 Ball joint dust cover Lower arm ball joint dust
installer cover press-in
MB990800
ON-VEHICLE SERVICE

MB990651 Bar Lower arm pillow ball
bushing removal and
press-fitting
MB990883
MB991816 Bushing remover &

installer base
MB991576 Base
MB991576
MB991897 or MB992011 Ball joint remover Knuckle and tie rod end
ball joint disconnection
NOTE: Steering linkage
puller (MB990635 or
AC106827 MB991113) is also
available to disconnect
knuckle and tie rod end
ball joint.
ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND 1. Adjust the toe-in by undoing the clip and lock nut,
ADJUSTMENT and turning the left and right tie rod turnbuckles by
M1331000900875 the same amount (in opposite directions).
Measure wheel alignment with alignment equipment NOTE: The toe will move out as the left turnbuckle
on a level surface. The front suspension, steering is turned toward the front of the vehicle and the
system, wheels, and tires should be serviced to nor- right turnbuckle is turned toward the rear of the
mal condition before measuring wheel alignment. vehicle.
TOE-IN 2. Install the clip and tighten the lock nut to the
Standard value: 0 ± 2 mm specified torque.
Lock nut
3. Confirm that the toe-in is at the standard value.
Clip 4. Use a turning radius gauge to check that the
steering angle is at the standard value.
Standard value:
Inner wheel 31°45' ± 1°30'
Outer wheel (for 27°15'
reference)
AC006074 AD
FRONT SUSPENSION
ON-VEHICLE SERVICE
33-5
CAMBER, CASTER AND KINGPIN Select the camber by the installation direction of the
INCLINATION arrow of the connecting bolt of the strut assembly
and the knuckle.
Standard value: • −1°00' ± 0°30': Install the bolt turning the arrow in
Item Specification the direction of inside the vehicle.
Camber (Selectable from −1°00' ± 0°30'*1 or • −2°00' ± 0°30': Install the bolt turning the arrow in
2 options) the direction of outside the vehicle.
−2°00' ± 0°30'*1
Caster 3°55' ± 0°30'*1 LOWER ARM BALL JOINT AXIAL PLAY
Kingpin inclination 13°45' ± 1°30'
CHECK
M1332010900051
NOTE: . 1. Raise the vehicle.

1. *1: Difference between right and left wheels must 2. Remove the stabilizer bar from the lower arm
be less than 30' assembly.
2. Caster and kingpin inclination are preset at the 3. Move the lower arm up and down with your hands
factory and cannot be adjusted. to check for excessive play in the axial direction of
the ball joint. If there is excessive play, replace the
SELECTION THE CAMBER lower arm assembly.
<Camber: –1˚00'> <Camber: –2˚00'> BALL JOINT DUST COVER CHECK

M1332008600398
1. Press the dust cover with your finger to check that
there are no cracks or damage in the dust cover.
2. If the dust cover is cracked or damaged, replace
the lower arm assembly.
NOTE: If the dust cover is cracked or damaged, it
is possible that there may also be damage to the
ball joint.
AC505096 AE
STRUT ASSEMBLY
STRUT ASSEMBLY
M1332001100422
• Front Wheel Alignment Check and Adjustment (Refer to
P.33-4).
44 ± 5 N·m
2
1
5
3
167 ± 9 N·m
AC310743 AB
Removal steps INSPECTION

1. Front wheel speed sensor harness M1332001200300
bracket • Check for oil leaks from the strut assembly.

2. Brake hose bracket • Check the strut assembly for damage or defor-
3. Knuckle connection mation.
4. Strut mounting nut
5. Strut assembly
FRONT SUSPENSION
STRUT ASSEMBLY
33-7
DISASSEMBLY AND ASSEMBLY
M1332001300620
1
3
60 ± 10 N·m
7 2
5
8
9
AC310745AB

1. Strut cover 6. Strut cover
<<A>>>>A<<2. Strut nut 7. Coil spring
3. Strut insulator 8. Spring lower pad
4. Spring upper seat <> 9. Front suspension strut
5. Strut damper
STRUT ASSEMBLY
DISASSEMBLY SERVICE POINTS WARNING

<<A>> STRUT NUT REMOVAL Do not use an impact wrench to remove the
strut nut.
CAUTION
• Do not tighten the bolt of special tool spring • Vibration of the impact wrench will cause
compressor body (MB991237) too tight. Spe- special tools (MB991237 and MB991238)
cial tool spring compressor body (MB991237) to slip and cause personal injury.
will be broken if the allowable tightening • Vibration of the impact wrench will cause
torque of 74 N⋅m is exceed. the valve inside the strut to drop out.
• Install special tool arm set (MB991238) evenly,
and so that the maximum length will be
attained within the installation range. MB991682
• Do not use an impact wrench to tighten the
bolt of special tool spring compressor body MB991681
(MB991237), otherwise the special tool will
break.
AC006091 AB
MB991238 MB991237
2. Use following special tools to secure the strut, and
then remove the self-locking nut.
• Wrench (MB991681)
• Socket (MB991682)
<> FRONT SUSPENSION STRUT

AC001085AB
REMOVAL
1. Use following special tools to compress the coil WARNING
spring. Wear goggles when drilling to protect your
• Spring compressor body (MB991237) eyes from flying metal debris.
• Arm set (MB991238)
AC001087
The gas must be discharged from the front suspen-

sion strut assembly before discarding it. Place the
strut horizontally with its piston rod extended. Then
drill a hole of approximately 3 mm in diameter at the
location shown in the illustration and discharge the
gas.
FRONT SUSPENSION
STRUT ASSEMBLY
33-9
ASSEMBLY SERVICE POINTS CAUTION
>>A<< STRUT NUT INSTALLATION Do not use an impact wrench to tighten the strut
1. Ensure that the bearing is seated correctly. nut, otherwise the strut nut will be damaged.
Vibration of the impact wrench will cause the
valve inside the strut to dropout.
MB991238 MB991237
MB991682
MB991681
AC001085AB
2. Install following special tools to the strut assembly AC211766AB
same as its removal. 6. Using following special tools, tighten the strut nut
• Spring compressor body (MB991237) to 60 ± 10 N⋅m.
• Arm set (MB991238) • Wrench (MB991681)
CAUTION • Socket (MB991682)
Do not use an impact wrench to tighten the bolt
of special tool spring compressor body
(MB991237), otherwise the special tool will break.
3. While the coil spring is being compressed by the
special tools, temporarily tighten the strut nut.
Rod AC211769
7. After tightening the strut nut, fill the multi purpose

grease to the bearing part of strut insulator.
INSPECTION
AC310747AB M1332001400229
• Check the strut bearing for wear or rust.
4. Align the hole in the strut spring lower seat with • Check the rubber parts for damage or deteriora-
the hole in the upper spring seat. tion.
NOTE: Using a rod as shown facilitates the align- • Check the coil spring for deformation, deteriora-
ment. tion or damage.
5. Correctly align both ends of the coil spring with • Check the front suspension strut for deformation.
the grooves in the spring seat, and then loosen
the special tools.
LOWER ARM
LOWER ARM
M1332001600405
CAUTION
• During maintenance, take care not to contact the parts or tools to the caliper because the paint of
caliper will be scratched. And if there is brake fluid on the caliper, wipe off quickly.
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.
• Check the Dust Cover for Cracks or Damage by Pushing
it with Your Finger.
P.33-4).
5
39 ± 5 N·m
39 ± 5 N·m
1
4
3 186 ± 10 N·m* 2
3
167 ± 9 N·m 108 ± 10 N·m AC310744AB

1. Stabilizer link nut 4. Stabilizer bar bracket
2. Lower arm and knuckle connection 5. Lower arm assembly
<<A>> 3. Lower arm and crossmember
connection
FRONT SUSPENSION
LOWER ARM
33-11
REMOVAL SERVICE POINT 2. When the measured value exceeds the standard
<<A>> LOWER ARM AND CROSSMEM- value, replace the lower arm assembly.
BER DISCONNECTION 3. When the measured value is lower than the
standard value, check that the lower arm ball joint
Piece of wood turns smoothly without excessive play. If there is
no excessive play, the ball joint can be reused.
PILLOW BALL BUSHING STARTING

TORQUE CHECK
Mounting bolt Pillow ball joint

Garage jack AC006133AE
As for the L.H. lower arm assembly, withdraw the

lower arm bolt (front) with the transmission lift up by
using a transmission jack.
INSPECTION
M1332001700491
LOWER ARM BALL JOINT STARTING Pillow ball

TORQUE CHECK bushing
MB990326
AC504614AB
Ball joint
1. Insert the bolt to the lower arm pillow ball bushing.
In the opposite direction, insert the washer then
install the nut. After rotating the inner sleeve
(contained washer) several times, measure the
starting torque of the lower arm pillow ball bushing
MB991006 using special tool preload socket (MB990326).
Standard value: 0.5 − 3.0 N⋅m
2. When the measured value exceeds the standard
value, replace the pillow ball bushing.
Ball joint 3. When the measured value is lower than the
standard value, check that the lower arm pillow
AC504613AB
ball bushing turns smoothly without excessive
play. If there is no excessive play, the pillow ball
1. After shaking the lower arm ball joint stud several bushing can be reused.
times, use special tool preload socket
(MB991006) to measure the starting torque of the
ball joint.
LOWER ARM
LOWER ARM BALL JOINT DUST COVER Replace the bushing as follows:
CHECK
1. Check the dust cover for cracks or damage by
pushing it with your finger.
MB990651
the lower arm.
MB991576
NOTE: Cracks or damage to the dust cover may
cause damage to the ball joint. When it is dam-
aged during service work, replace the dust cover.
BALL JOINT DUST COVER Lower arm

assembly
REPLACEMENT
M1332008200312
If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Remove the dust cover.
2. Apply multipurpose grease to the lip and inside of
the dust cover.
MB990800
MB991816
Dust cover AC504563 AB
1. Use following special tools to drive out the

bushing.
• Bar (MB990651)
• Base (MB991576)
AC006135 AB
• Bushing remover & installer base (MB991816)
3. Using special tool ball joint remover and installer
(MB990800), press the dust cover until it contacts Marking
the lower arm assembly.
4. Press the dust cover with your finger to check that 60˚
LOWER ARM PILLOW BALL BUSHING

REPLACEMENT
M1332008100564
AC504565 AB
Pillow ball
bushing
2. Set the bushing to the lower arm assembly so that
the bushing marking and the opening are as
shown in the illustration.
AC504566AB
FRONT SUSPENSION
LOWER ARM
33-13
3. Use special tools to press in the bushing until its
outer tube is flush with the lower arm assembly
surface.
MB990651
MB991576
Outer tube
Lower arm
assembly
MB991816
AC504564 AB
STABILIZER BAR
STABILIZER BAR
M1332004000662
CAUTION
• Before removing the steering wheel and air bag module assembly, refer to GROUP 52B − Service
Precautions (P.52B-3) and Driver’s, Front Passenger’s Air Bag Module(s) and Clock Spring
(P.52B-110). Also, put the front wheels in straight-ahead position. Failure to do so may damage the
SRS clock spring and render the SRS air bag inoperative, which results serious driver injury.
• During maintenance, take care not to contact the parts or tools to the caliper because the paint of
caliper will be scratched. And if there is brake fluid on the caliper, wipe off quickly.
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.
• Steering Wheel - Driver’s Air Bag Module Assembly • Front Exhaust Pipe Installation (Refer to GROUP 15,
Removal (Refer to GROUP 37, Steering Wheel P.37-13). Exhaust Pipe and Main Muffler P.15-13).
• Clock Spring Removal (Refer to GROUP 52B, Driver’s, • Front Axle No.1 Crossmember Assembly Installation
Front Passenger’s Air Bag Module(s) and Clock Spring (Refer to GROUP 32, Crossmember P.32-10).
P.52B-110). • Front Axle Crossmember Bar Installation (Refer to
• Front Axle Crossmember Bar Removal (Refer to P.33-17).
P.33-17). • Clock Spring Installation (Refer to GROUP 52B, Driver’s,
• Front Axle No.1 Crossmember Assembly Removal (Refer Front Passenger’s Air Bag Module(s) and Clock Spring
to GROUP 32, Crossmember P.32-10). P.52B-110).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Steering Wheel - Driver’s Air Bag Module Assembly
Exhaust Pipe and Main Muffler P.15-13). Installation (Refer to GROUP 37, Steering Wheel
P.37-13).
• Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
• Checking Steering Wheel Position with Wheels Straight
Ahead
P.33-4).
FRONT SUSPENSION
STABILIZER BAR
33-15
6
5
18 ± 2 N·m
21 ± 4 N·m
10 8
9
39 ± 5 N·m
4
3 1
N 25 ± 5 N·m
39 ± 5 N·m
7
52 ± 7 N·m*
AC310741AB
49 ± 10 N·m
167 ± 9 N·m 108 ± 10 N·m

1. Stabilizer link 6. Steering gear and joint
2. Stabilizer bar bracket connection bolt
3. Lower arm and knuckle 7. Rear roll stopper connection
connection bolt
<<A>> 4. Tie rod end knuckle <> >>A<< 8. Stabilizer bracket
connection <> >>A<< 9. Stabilizer bushing
5. Steering shaft cover <> >>A<< 10. Stabilizer bar
STABILIZER BAR

<<A>> TIE ROD END AND KNUCKLE DIS-
CONNECTION Piece of wood
CAUTION
• Do not remove the nut from ball joint. Loosen
it and use special tool ball joint remover
(MB991897 or MB992011) to avoid possible
damage to ball joint threads.
Transmission
• Hang special tool ball joint remover jack AC102600 AD
(MB991897 or MB992011) with a cord to pre-
vent it from falling. 1. Use a transmission jack to hold the crossmember,
remove the crossmember mounting nuts and
Cord bolts.
CAUTION
Be careful not to lower the crossmember exces-
sively. The power steering return hose bracket
Nut MB991897 may deform if the crossmember is lowered too
or much.
MB992011
2. Lower the crossmember until the fixture, the
Bolt bushing and the stabilizer bar can be removed.
Ball joint AC208247AJ

1. Install special tool ball joint remover (MB991897
or MB992011) as shown in the figure. >>A<< STABILIZER BAR/STABILIZER
BUSHING/STABILIZER
Bolt
BRACKET/INSTALLATION
Outside of vehicle
Parallel
Identification mark
Knob Good
Bad AC106821AB
2. Turn the bolt and knob as necessary to make the Stabilizer bushing (LH)
Stabilizer bracket (LH)
jaws of special tool ball joint remover (MB991897 AC006141AJ
or MB992011) parallel, tighten the bolt by hand Align the stabilizer bar identification mark with the
and confirm that the jaws are still parallel. right end of the bushing (LH).
NOTE: When adjusting the jaws in parallel, make
sure the knob is in the position shown in the fig- INSPECTION
M1332002000321
ure. • Check the stabilizer bushings for wear and deteri-
3. Tighten the bolt with a wrench to disconnect the oration.
tie rod end. • Check the stabilizer bar for deterioration or dam-
age.
<> STABILIZER • Check all bolts for condition and straightness.
BRACKET/STABILIZER
BUSHING/STABILIZER BAR REMOVAL
Carry out the following operations to ensure working
space in order to remove the fixture, the bushing and
the stabilizer bar.
FRONT SUSPENSION
CROSSMEMBER BAR
33-17
STABILIZER LINK BALL JOINT TURNING Standard value: 1.7 − 3.2 N⋅m
TORQUE CHECK 2. When the measured value exceeds the standard
value, replace the stabilizer link.
MB990326 3. When the measured value is lower than the
standard value, check that the ball joint turns
smoothly without excessive play. If so, it is
possible to re-use that ball joint.
STABILIZER LINK BALL JOINT DUST

COVER CHECK
AC001129 AB pushing it with your finger.
1. After shaking the ball joint stud several times, 2. If the dust cover is cracked or damaged, replace
install the nut to the stud and use special tool the stabilizer link.
preload socket (MB990326) to measure the NOTE: Cracks or damage of the dust cover may
turning torque of the ball joint. cause damage to the ball joint.
CROSSMEMBER BAR
M1332016100086
49 ± 10 N·m
Front axle crossmember bar

AC310742 AB
NOTES
34-1
GROUP 34
REAR SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . . 34-2 REMOVAL AND INSTALLATION . . . . . . . . 34-10

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-11
SERVICE SPECIFICATIONS. . . . . . . 34-3 TRAILING ARM BALL JOINT DUST COVER
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-11
SPECIAL TOOLS. . . . . . . . . . . . . . . . 34-3
LOWER ARM ASSEMBLY AND ASSIST
ON-VEHICLE SERVICE. . . . . . . . . . . 34-4 LINK . . . . . . . . . . . . . . . . . . . . . . . . . . 34-12
REAR WHEEL ALIGNMENT CHECK AND REMOVAL AND INSTALLATION . . . . . . . . 34-12
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 34-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-14
BALL JOINT DUST COVER INSPECTION 34-4 ASSIST LINK BALL JOINT DUST COVER
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-15
REAR SUSPENSION ASSEMBLY . . 34-5
REMOVAL AND INSTALLATION . . . . . . . . 34-5 SHOCK ABSORBER ASSEMBLY . . . 34-16
UPPER ARM ASSEMBLY . . . . . . . . . 34-7 DISASSEMBLY AND ASSEMBLY . . . . . . . 34-17
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 34-8 STABILIZER BAR. . . . . . . . . . . . . . . . 34-20
UPPER ARM BALL JOINT DUST COVER REMOVAL AND INSTALLATION . . . . . . . . 34-20
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-21
STABILIZER BAR LINK BALL JOINT DUST
TRAILING ARM . . . . . . . . . . . . . . . . . 34-10 COVER REPLACEMENT . . . . . . . . . . . . . . 34-22
34-2 REAR SUSPENSION
GENERAL INFORMATION
GENERAL INFORMATION
M1341000100706
A trailing arm type multi-link suspension is used for points and use of aluminium parts for the suspension
the rear suspension. In contrast to the trailing arm arms and crossmember reduces weight. In addition,
multi-link system used on the Lancer, the Lancer use of ball joints on the suspension arms reduce fric-
Evolution uses a newly developed multi-link system tion and creates a suspension system that exhibits
built on a double wishbone base to achieve superior superior stroke characteristics that respond well
handling stability. Optimum design of the suspension under all driving conditions.
Coil spring
Shock absorber Stabilizer bar
Upper arm assembly Crossmember

(forged aluminium) (forged aluminium)
Differential support
Stabilizer bar link member
Assist link Differential
(forged aluminium) support arm
Assist link
control bar
Trailing arm assembly Lower arm assembly
(forged aluminium ) (forged aluminium)
AC211385AC
SPECIFICATION
COIL SPRING
Item Standard Option
Wire diameter mm 12 12
Average diameter mm 88 88
Free length mm 287 277
REAR SUSPENSION
34-3
M1341000300722
Item Standard value

Toe-in mm 3±2
Camber −1°00' ± 0°30' (Difference between
right and left within 30')
Thrust angle 0°00' ± 0°09'
Upper arm ball joint starting torque N⋅m 0.5 − 2.5
Trailing arm ball joint starting torque N⋅m 0.5 − 2.5
Assist link ball joint starting torque N⋅m 0.5 − 2.5
Assist link slide bushing starting torque N⋅m 0.5 − 2.0
Lower arm pillow ball bushing starting torque N⋅m 0.5 − 3.0
Stabilizer bar link ball joint turning torque N⋅m 1.7 − 3.1
SPECIAL TOOLS
M1341000600626

MB991897 or MB992011 Ball joint remover Ball joint and Knuckle
disconnection
NOTE: Steering linkage
puller (MB990635 or
AC106827
MB991113) is also
available to disconnect
ball joint and Knuckle.
MB990326 Preload socket • Ball joints and side
bushing starting
torque measurement
• Pillow ball bushing
turning torque
MB990326
measurement
MB990800 Ball joint dust cover Ball joint dust cover
installer press-fitting
MB990800
A: MB991237 A: Spring compressor Coil spring removal and

B: MB991239 body installation
B: Arm set
A
B MB991237
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
REAR WHEEL ALIGNMENT CHECK AND If camber and/or toe-in is not within the standard
ADJUSTMENT value, adjust by following procedures.
M1341011000725
The rear suspension, wheels and tires should be
Camber adjusting bolt
serviced to normal condition prior to
measurement of wheel alignment.
1. Measure the wheel alignment with the vehicle
parked on a level surface.
TOE-IN
Standard value: 3 ± 2 mm Lower arm
If toe-in is not within the standard value, adjust by fol- AC310762 AB
lowing procedures.
1. Be sure to adjust the camber before making toe 1. Carry out camber adjustment by turning the
adjustment. camber adjusting bolt (lower arm to rear
crossmember mounting bolt).
Left wheel: Turning clockwise (+) camber
Right wheel: Turning clockwise (−) camber
NOTE: The scale has gradations of approximately
Assist link 14’
2. After adjusting the camber, the toe should be
adjusted.
Toe adjusting bolt
BALL JOINT DUST COVER INSPECTION
AC310761AB M1341012800326
Check the toe control arm assembly and the stabi-
2. Carry out adjustment by turning the toe adjusting lizer bar link assembly ball joint dust cover as fol-
bolt (assist link mounting bolt which is located on lows.
the inner side of the body). 1. Check dust covers for cracks or damage by
Left wheel: Turning clockwise (+) toe-in pushing it with your finger.
Right wheel: Turning clockwise (−) toe-in 2. If a dust cover is cracked or damaged, replace the
NOTE: The scale has gradations of approximately toe suspension arms or the stabilizer bar link
3.3 mm (single side toe angle equivalent to 19’). assembly.
NOTE: Cracks or damage to the dust cover may
CAMBER cause damage to the ball joint.
Standard value:
−1°00’ ± 0°30’ (difference between right and
left wheel: less than 30’)
REAR SUSPENSION
REAR SUSPENSION ASSEMBLY
34-5
M1341001000199
CAUTION
• During maintenance, take care not to contact the parts or tools to the caliper, because the paint of
caliper will be scratched. And contact the parts or tools to the caliper, wipe out quickly.
• *:To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.
• Centre Exhaust Pipe Removal (Refer to GROUP 15, • Centre Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-13). Exhaust Pipe and Main Muffler P.15-13).
• Parking Brake Lever Stroke Check (Refer to
GROUP36-On-vehicle Service − Parking Brake Lever
Stroke Check and Adjustment P.36-3).
• Wheel Alignment Check And Adjustment (Refer to
P.34-4).
3
44 ± 5 N·m
4N
1
32 ± 2 N·m 64 ± 4 N·m*
49 ± 5 N·m 24 ± 4 N·m
3
10
9
15
7
2
12
11
147 ± 9 N·m* 6 5
13
13 14 N 54 ± 5 N·m
88 ± 5 N·m
120 ± 10 N·m 13
8
93 ± 15 N·m*
88 ± 5 N·m AC310772AB

1. Fuel filler cap <> >>B<< 9. Propeller shaft connection
2. Protector 10. Upper arm mounting bolt
3. Bolt 11. Trailing arm mounting bolt
4. Shock absorber mounting nut 12. Assist link mounting bolt
<<A>> 5. Brake caliper assembly <<C>> >>A<< 13. Crossmember mounting bolt
6. Rear ABS sensor 14. Differential support assembly
7. Brake disc mounting nut
8. Parking brake cable end 15. Rear suspension assembly
REMOVAL SERVICE POINTS Tighten the bolt by following the order shown in the
illustration. The sort and size of each bolt is different,
<<A>> BRAKE CALIPER ASSEMBLY
so tighten by following the table below.
REMOVAL
NOTE: In order to maintain accuracy and for ease of
CAUTION installing, the attachment hall diameter of the cross-
Take care not to contact the parts or tools to the member is different on forward/rearward. Follow the
caliper because the paint of caliper will be tightening order of the mounting bolts.
No. Sort of bolt Size of bolt
(Screw diameter
Remove the brake caliper assembly and support with
× Length) mm
wire.
1,2,3 Flange bolt (with washer) 12 × 105
<> PROPELLER SHAFT 4 Bolt (with spring washer 12 × 152
DISCONNECTION and washer)
1. Mark the mating mark on the companion flange of 5 Flange bolt (with washer) 12 × 70
the differential carrier and the flange yoke of the
propeller shaft. >>B<< PROPELLER SHAFT
2. Remove the propeller shaft mounting bolt and nut. CONNECTION
<<C>> CROSSMEMBER MOUNTING CAUTION
If there is oil or grease on the thread of the
BOLT REMOVAL
mounting bolt or nut, they will loosen. So after
Support the differential case with a garage jack or
wiping off oil or grease from the threads, tighten
transmission jack, then remove the crossmember
the mounting bolt.
mounting bolt.
Install the differential carrier and propeller shaft by
aligning the mating marks.
>>A<< CROSSMEMBER MOUNTING
BOLT INSTALLATION
3 3
1 4 4 2
5 5
AC211967AB
REAR SUSPENSION
UPPER ARM ASSEMBLY
34-7
UPPER ARM ASSEMBLY
M1341003600335
CAUTION
caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
*1
• : To prevent bushings from breakage, the parts indicated by *1 should be temporarily tightened,
• Press the dust cover with your finger to check that there
are no cracks or damage in the dust cover.
• Wheel Alignment Check and Adjustment (Refer to
P.34-4).
3
5
6
64 ± 4 N·m*¹ 1
7
24 ± 4 N·m
39 ± 5 N·m
2
4
49 ± 5 N·m
4
81 ± 6 N·m
AC310782AB

1. Fuel filler cap*2 6. Upper arm stopper
2. 7. Upper arm assembly
Protector*2
3. NOTE: Install/remove the parts with the mark "*2"
Bolt*2
when installing/removing the LH side upper arm
<<A>> 4. Upper arm assembly and knuckle
connection
assembly.
5. Upper arm assembly mounting bolt
UPPER ARM ASSEMBLY

M1341015500186
<<A>> UPPER ARM BALL JOINT AND UPPER ARM BALL JOINT STARTING
KNUCKLE DISCONNECTION TORQUE CHECK
CAUTION
MB990326
• Hang special tool ball joint remover
vent it from falling.
Cord ACX00716 AB
1. After shaking the upper arm ball joint stud several

Ball joint times, use special tool preload socket
Bolt (MB990326) to measure the starting torque of the
ball joint.
MB991897 Standard value: 0.5 − 2.5 N⋅m
or
Nut MB992011 2. When the measured value exceeds the standard
AC106820 AE value, replace the upper arm assembly.
3. When the measured value is lower than the
1. Install the special tool ball joint remover
(MB991897 or MB992011) as shown in the figure.
smoothly without excessive play. If there is no
excessive play, the ball joint can be reused.
Bolt
UPPER ARM BALL JOINT DUST COVER
Parallel CHECK
Knob Good pushing it with your finger.
the upper arm assembly.
Bad AC106821AB NOTE: Cracks or damage of the dust cover may
2. Turn the bolt and knob as necessary to make the aged during service work, replace the dust cover.
jaws of the special tool ball joint remover
(MB991897 or MB992011) parallel, tighten the UPPER ARM BALL JOINT DUST COVER
bolt by hand and confirm that the jaws are still REPLACEMENT
parallel. M1341010900413
NOTE: When adjusting the jaws in parallel, make Only when the dust cover is damaged accidentally
sure the knob is in the position shown in the fig- during service work, replace the dust cover as fol-
ure. lows:
3. Tighten the bolt with a wrench to disconnect the 1. Remove the dust cover.
upper arm assembly and the knuckle.
REAR SUSPENSION
UPPER ARM ASSEMBLY
34-9
3. Using the special tool ball joint remover and
installer (MB990800), punch the dust cover until it
MB990800 contacts the snap ring.
AC212031AB
2. Fill the multipurpose grease in the dust cover and

lubricate the lip. (Amount of filling grease in the
dust cover: approximately 7 g).
TRAILING ARM
TRAILING ARM
M1341002200743
CAUTION
• *: To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
P.34-4).
81 ± 6 N·m
5 N
147 ± 9 N·m*
4 2
5
4
AC310784 AB

1. Parking brake cable bolt 3. Trailing arm assembly mounting bolt
<<A>> 2. Trailing arm assembly and knuckle 4. Trailing arm bushing stopper
connection 5. Trailing arm assembly
REAR SUSPENSION
TRAILING ARM
34-11
M1341002300289
<<A>> TRAILING ARM ASSEMBLY AND BALL JOINT STARTING TORQUE CHECK
KNUCKLE DISCONNECTION
CAUTION
• Do not remove the nut from ball joint. Loosen MB990326
ACX00716 AB
Cord
1. After shaking the ball joint stud several times, use
special tool preload socket (MB990326) to
Ball joint measure the starting torque of the ball joint.
Bolt
MB991897
or value, replace the trailing arm assembly.
Nut MB992011 3. When the measured value is lower than the
AC106820 AE standard value, check that the ball joint turns
smoothly without excessive play. If there is no
1. Install the special tool ball joint remover
excessive play, the ball joint can be reused.
(MB991897 or MB992011) as shown in the figure.
DUST COVER CHECK
Bolt 1. Check the dust cover for cracks or damage by
Parallel 2. If the dust cover is cracked or damaged, replace
the trailing arm assembly.
Knob Good NOTE: Cracks or damage to the dust cover may
Bad AC106821AB
TRAILING ARM BALL JOINT DUST
2. Turn the bolt and knob as necessary to make the COVER REPLACEMENT
jaws of the special tool ball joint remover M1341010900424
(MB991897 or MB992011) parallel, tighten the Only when the dust cover is damaged accidentally
bolt by hand and confirm that the jaws are still during service work, replace the dust cover as fol-
parallel. lows:
1. Remove the dust cover.
sure the knob is in the position shown in the fig-
ure.
3. Tighten the bolt with a wrench to disconnect the MB990800
trailing arm assembly and the knuckle.
AC212031AB
LOWER ARM ASSEMBLY AND ASSIST LINK
2. Fill the multipurpose grease in the dust cover and 3. Using special tool ball joint remover and installer
lubricate the lip (Amount of filling grease in the (MB990800), punch the dust cover until it contacts
dust cover: approximately 7 g). the snap ring.

M1341017100065
CAUTION
• *: To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
P.34-4).
93 ± 15 N·m*
6
5 6
4
81 ± 6 N·m
2
N 93 ± 15 N·m*
3 2
N
N
88 ± 10 N·m*
88 ± 10 N·m*
1
AC310785AB
Lower arm assembly removal Assist link removal steps

steps <> 4. Assist link and knuckle connection
1. Lower arm assembly to shock <<C>> 5. Assist link mounting bolt
absorber connecting bolt 6. Assist link assembly
<<A>> 2. Lower arm assembly mounting bolt
>>A<< 3. Lower arm assembly
REAR SUSPENSION
34-13
REMOVAL SERVICE POINTS 2. Turn the bolt and knob as necessary to make the
<<A>> LOWER ARM ASSEMBLY MOUNT- jaws of special tool ball joint remover (MB991897
or MB992011) parallel, tighten the bolt by hand
ING BOLT REMOVAL and confirm that the jaws are still parallel.
Mating marks sure the knob is in the position shown in the fig-
ure.
3. Tighten the bolt with a wrench to disconnect the
assist link assembly and the knuckle.
<<C>> ASSIST LINK MOUNTING BOLT

REMOVAL
AC310794 AB
Mating marks
Make mating marks on the lower arm and the
decentering cam bolt, then remove the lower arm
and the decentering cam bolt.
<> ASSIST LINK AND KNUCKLE

DISCONNECTION
CAUTION Eccentric
cam bolt
• Do not remove the nut from ball joint. Loosen AC310795 AB
it and use special tool ball joint remover Make mating marks on the assist link and the
(MB991897 or MB992011) to avoid possible decentering cam bolt, then remove the toe control
damage to ball joint threads. arm and the decentering cam bolt.
(MB991897 or MB992011) with a cord to pre- INSTALLATION SERVICE POINT
>>A<< LOWER ARM ASSEMBLY INSTAL-
Cord LATION
With red marking: RH side

Ball joint lower arm assembly
Bolt
MB991897
or With countersunk Ø10mm:
Nut MB992011 LH side lower arm assembly
AC106820 AE
1. Install special tool ball joint remover (MB991897 AC310797AB

or MB992011) as shown in the figure.
Check the identification mark, install the lower arm
assembly.
Bolt
Parallel
Knob Good
Bad AC106821AB
INSPECTION 3. When the measured value is lower than the

M1341017200051 standard value, check that the assist link slide
ASSIST LINK BALL JOINT STARTING bushing turns smoothly without excessive play. If
TORQUE CHECK there is no excessive play, the slide bushing can
be reused.
ASSIST LINK BALL JOINT DUST COVER

MB990326
CHECK
the trailing arm assembly.
ACX00716 AB
NOTE: Cracks or damage of the dust cover may
1. After shaking the assist link ball joint stud several aged during service work, replace the dust cover.
times, measure the starting torque of the assist
link ball joint by using special tool preload socket LOWER ARM PILLOW BALL BUSHING
(MB990326). STARTING TORQUE CHECK
value, replace the assist link.
3. When the measured value is lower than the
standard value, check that the assist link ball joint
turns smoothly without excessive play. If there is
no excessive play, the ball joint can be reused.
ASSIST LINK SLIDE BUSHING STARTING

TORQUE CHECK
Pillow ball bushing
MB990326
MB990326
AC212117AB
AC310798AB
1. After inserting the bolt to the assist link slide bush
and attaching the washer in the opposite 1. Insert the bolt to the lower arm pillow ball bushing,
direction, install the nut. After rotating the inner in the opposite direction, insert the washer then
sleeve (include the washer) several times, install the nut. After rotating the inner sleeve
measure the starting torque of the assist link slide (contained washer) several times, measure the
bushing by using special tool preload socket starting torque of the lower arm below ball
(MB990326). bushing using special tool preload socket
(MB990326).
value, replace the assist link. 2. When the measured value exceeds the standard
value, replace the lower arm assembly.
REAR SUSPENSION
34-15
3. When the measured value is lower than the Only when the dust cover is damaged accidentally
standard value, check that the lower arm pillow during service work, replace the dust cover as fol-
ball bushing turns smoothly without excessive lows:
play. If there is no excessive play, the pillow ball 1. Remove the dust cover.
bushing can be reused. 2. Fill the multipurpose grease in the dust cover and
lubricate the lip (Amount of filling grease in the
ASSIST LINK BALL JOINT DUST COVER dust cover: approximately 7 g).
REPLACEMENT 3. Using special tool ball joint remover and installer
M1341017300058
(MB990800), punch the dust cover until it contacts
the snap ring.
MB990800
AC212031AB
SHOCK ABSORBER ASSEMBLY

M1341002500391
CAUTION
*
• : To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
• Trunk Room Side Trim Removal and Installation (Refer to
GROUP 52A, Trims P.52A-10).
1N
44 ± 5 N·m
2
N
88 ± 10 N·m*
AC310799AB

1. Coil spring nut 2. Coil spring bolt
3. Shock absorber assembly
REAR SUSPENSION
34-17
DISASSEMBLY AND ASSEMBLY
M1341005300363
25 ± 5 N·m 1N
2
3
9
4
7
5
6
11
8
10
12
AC310801AB

<<A>> >>D<< 1. Coil spring nut 7. Coil spring collar
2. Coil spring washer 8. Shock absorber cup
3. Coil spring bushing 9. Shock absorber cover
>>C<< 4. Shock absorber insulator 10. Shock absorber damper
>>B<< 5. Spring upper pad >>A<< 11 Coil spring
6. Coil spring bushing 12 Shock absorber assembly
DISASSEMBLY SERVICE POINT ASSEMBLY SERVICE POINTS

<<A>> COIL SPRING NUT REMOVAL >>A<< COIL SPRING INSTALLATION
CAUTION CAUTION
• Install special tools spring compressor body Do not use an impact wrench, as it will cause the
(MB991237) and arm set (MB991239) evenly, bolt of the special tool spring compressor body
and so that the maximum length will be (MB991237) to be seized.
attained within the installation range.
• Do not use an impact wrench, as it will cause
the bolt of special tool spring compressor MB991237
body (MB991237) to be seized.
MB991237
MB991239
AC001070 AB
1. Use special tools spring compressor body

(MB991237) and arm set (MB991239) to
MB991239
AC001070 AB
compress the coil spring, and install it to the
spring seat of the shock absorber.
1. Use special tools spring compressor body
(MB991237) and arm set (MB991239) to
compress the coil spring.
WARNING
To prevent the piston rod lock nut inside the
shock absorber from loosening, do not use
an impact wrench when the coil spring nut is
loosened. Spring seat
stepped section
AC006176AB
Piston rod 2. Align the end of the coil spring with the stepped
section of the spring seat of the shock absorber.
>>B<< SPRING UPPER PAD

INSTALLATION
AC310802 AB Spring upper pad

stepped section
2. Holding the piston rod, remove the coil spring nut.
AC310803AB
Align the stepped section of the spring upper pad

with the end of the coil spring, and install the spring
upper pad.
REAR SUSPENSION
34-19
>>C<< SHOCK ABSORBER INSULATOR Install the shock absorber insulator so that the lower
INSTALLATION bushing inner pipe of the shock absorber and the line
between the shock absorber insulator mounting bolts
are straight when looking from above.
Lower bushing
inner pipe >>D<< COIL SPRING NUT INSTALLATION
CAUTION
To prevent the piston rod lock nut inside the
shock absorber from loosening, do not use an
Shock
impact wrench when the coil spring nut is tight-
absorber
insulator ened.
mounting Spring upper 1. Provisionally tighten the coil spring nut.
bolt pad stepped
section
MB991237
Lower bushing
Spring seat inner pipe
stepped section MB991239
AC001070 AB
2. After removing special tools spring compressor

AC310805AB
body (MB991237) and arm set (MB991239),
tighten the coil spring nut to 25 ± 5 N⋅m.
STABILIZER BAR
STABILIZER BAR
M1341003000322
CAUTION
During maintenance, take care not to contact the parts or tools to the caliper, because the paint of cal-
3
2
39 ± 5 N·m 4
39 ± 5 N·m
3
24 ± 4 N·m
39 ± 5 N·m
2 AC310809AB

1. Stabilizer nut >>A<< 4. Stabilizer bushing
2. Stabilizer bar link >>A<< 5. Stabilizer bar
>>A<< 3. Stabilizer bar bracket
REAR SUSPENSION
STABILIZER BAR
34-21
M1341001400368
>>A<< STABILIZER BAR/STABILIZER STABILIZER BAR LINK BALL JOINT
BUSHING/STABILIZER BAR BRACKET TURNING TORQUE CHECK
INSTALLATION
MB990326
AC212145AB
Approx. 10mm
1. After shaking the stabilizer bar link ball joint stud
several times, install the stabilizer nut to the stud
and use special tool preload socket (MB990326)
to measure the turning torque of the stabilizer bar
link ball joint.
B Standard value: 1.7 − 3.1 N⋅m
value, replace the stabilizer bar link.
B 3. When the measured value is lower than the
A smoothly without excessive play. If so, it is
possible to reuse that ball joint.
AC310811AB STABILIZER BAR LINK BALL JOINT

DUST COVER CHECK
Align the stabilizer bar until the identification colour of
the stabilizer bar is out of the dimension shown as 1. Check the dust cover for cracks or damage by
the illustration from the stabilizer bush to the vehicle pushing it with your finger.
centre. After tightening the stabilizer bracket mount- 2. If the dust cover is cracked or damaged, replace
ing bolt A, tighten mounting bolt B. the stabilizer bar link.
NOTE: Cracks or damage of the dust cover may
cause damage of the ball joint. When it is dam-
STABILIZER BAR
STABILIZER BAR LINK BALL JOINT 2. Apply multipurpose grease to the inside of the
DUST COVER REPLACEMENT dust cover.
M1341010900338 3. Wrap plastic tape around the stabilizer bar link
Only when the dust cover is damaged accidentally stud, and then install the dust cover to the
during service work, replace the dust cover as fol- stabilizer bar link.
lows:
Clip ring end
(possible on
opposite direction)
90º
Clip ring AC310812 AB

AC006188AB
4. Secure the dust cover by the clip ring. Then install

1. Remove the clip ring and the dust cover.
the clip ring end in order to position it 90 degrees
from the axis of the link.
AC212251AB
21A-1
GROUP 21A
CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . . 21A-2 CLUTCH SWITCH CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21A-4
SERVICE SPECIFICATIONS. . . . . . . 21A-2
CLUTCH PEDAL. . . . . . . . . . . . . . . . . 21A-5
LUBRICANTS . . . . . . . . . . . . . . . . . . 21A-2 REMOVAL AND INSTALLATION . . . . . . . . 21A-5
ON-VEHICLE SERVICE. . . . . . . . . . . 21A-3 CLUTCH CONTROL . . . . . . . . . . . . . . 21A-7

CLUTCH PEDAL CHECK AND REMOVAL AND INSTALLATION . . . . . . . . 21A-7
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21A-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-8
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . 21A-4 DISASSEMBLY AND REASSEMBLY . . . . . 21A-9
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-10
21A-2 CLUTCH
GENERAL INFORMATION
GENERAL INFORMATION
M1211000100223
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control. The
clutch shares a brake fluid reservoir with the brake
system.
M1211000300357
Item Standard value

Clutch pedal height mm LH drive vehicles 203.8 ± 2
Clutch pedal height mm RH drive vehicles 198.7 ± 2
Clutch pedal clevis pin play mm 1−3
Clutch pedal free play mm 4 − 13
Distance between the clutch pedal and the clutch pedal LH drive vehicles 114.3 or more
stopper when the clutch pedal is released mm
Distance between the clutch pedal and the dash pad when the RH drive vehicles 95 or more
clutch pedal is released mm
LUBRICANTS
M1211000400194
Item Specified lubricant Quantity

Clutch fluid Brake Fluid DOT 3 or DOT 4 As required
Pushrod assembly Rubber grease As required
Boot Rubber grease As required
Release cylinder push rod MITSUBISHI genuine grease Part As required
No.0101011
CLUTCH
ON-VEHICLE SERVICE
21A-3
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND CAUTION
ADJUSTMENT Do not push in the master cylinder pushrod at
M1211000900401 this time, otherwise the clutch will not operate
Clutch pedal height properly.
<LH drive vehicles>
3. If the clutch pedal height and clutch pedal clevis
pin play are not within the standard value, loosen
the setting nut to adjust the clutch pedal height
and clevis pin play to the standard value.
A
Clutch pedal free play
Clutch pedal stopper
<RH drive vehicles>
A
C
AC100355 AC
Carpet <LH drive vehicles>
Dash pad
AC310574 AB
D
1. Measure the clutch pedal height.
Standard value (A): 203.8 ± 2 mm <LH drive
vehicles>, 198.7 ± 2 mm <RH drive vehicles> Clutch pedal
stopper
Clutch pedal clevis pin play
<RH drive vehicles>
AC100355 AB
Dash pad
2. Measure the clutch pedal clevis pin play.
AC310575AD
Standard value (B): 1 − 3 mm
4. After completing the adjustments, confirm that the
clutch pedal free play (measured at the face of the
Setting nut pedal pad) and the distance between the clutch
pedal (the face of the pedal pad) and the clutch
pedal stopper or dash pad when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 4 − 13 mm
Standard value (D): 114.3 mm or more <LH
Clutch pedal
drive vehicles>, 95 mm or more <RH drive
13 ± 2 N·m
vehicles>
AC100356 AB
21A-4 CLUTCH
ON-VEHICLE SERVICE
5. If the clutch pedal free play and the distance 4. Check that the brake fluid reservoir level stays
between the clutch pedal and the clutch pedal between "MAX" and "MIN" marks throughout the
stopper or dash pad when the clutch is clutch bleeding process.
disengaged do not agree with the standard
values, it is probably the result of either air in the CLUTCH SWITCH CHECK AND
hydraulic system or a faulty master cylinder, ADJUSTMENT
release cylinder or clutch. Bleed the air, or M1211001100185
disassemble and inspect the master cylinder, 1. Adjust the clutch pedal.
release cylinder or clutch.
CLUTCH BLEEDING
M1211001400216
CAUTION
Use the specified brake fluid. Do not mix brake
fluids.
Specified fluid: Brake fluid DOT 3 or DOT 4
AC310580
2. Connect an ohmmeter to the clutch switch

connector, and then check for continuity when the
clutch pedal is fully depressed and when it is
released outward.
Tester Pedal position Specified
AC211514 AB 1-2 Fully depressed Open circuit
1. Connect a hose with a bottle to the bleeder screw. Released Less than 2
ohms
2. Open the bleed nipple.
3. If the continuity is incorrect, replace the clutch
CAUTION switch.
For bleeding, never "pump" the clutch pedal.
This may cause an oil leak at the clutch cylinder.
3. Depress the clutch pedal slowly. Open the bleeder
screw to let air and brake fluid out. Close the
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.
CLUTCH
CLUTCH PEDAL
21A-5
CLUTCH PEDAL
M1211001600340
Clutch Pedal Adjustment (Refer to P.21A-3).
<LH drive vehicles>

15
16
6
4
12 ± 2 N·m
10 9
7
12 ± 2 N·m
5 14
<RH drive vehicles> 8 11
2 13
1 12 ± 2 N·m
15 N 3
12
16 8
12 ± 2 N·m
9
5 10
12 ± 2 N·m
4
12 ± 2 N·m 7
13
14 12
AC310323AC

• Instrument panel under cover 6. Clevis pin
(Refer to GROUP 52A, Instrument 7. Clutch master cylinder mounting
panel P.52A-2). nut
1. Clutch pedal position switch 8. Clutch pedal assembly mounting
2. Clutch pedal position switch bolt
harness >>A<< 9. Clutch switch
3. Clip 10. Nut
4. Stopper 11. Stopper
5. Snap pin 12. Pedal pad
21A-6 CLUTCH
CLUTCH PEDAL
Removal steps (Continued) INSTALLATION SERVICE POINT

13. Pedal stopper
14. Clutch pedal assembly >>A<< CLUTCH SWITCH INSTALLATION
15. Turn over spring
Clutch switch
16. Bushing
Clutch pedal 0.5 – 1.5 mm
AC309757AB
Install the clutch switch at the specified dimension

when the clutch pedal is released.
CLUTCH
CLUTCH CONTROL
21A-7
CLUTCH CONTROL
M1211001900396

• Clutch Fluid Draining • Strut Tower Bar Removal (Refer to GROUP42, Strut
• Strut Tower Bar Removal (Refer to GROUP42, Strut Tower Bar P.42-9 ).
Tower Bar P.42-9 ). • Clutch Fluid Supplying
• Clutch Line Bleeding (Refer to P.21A-4).
• Clutch Pedal Adjustment (Refer to P.21A-3).
<LH drive vehicles>
Release fork
15 ± 2 N·m
10
Release cylinder
11 push rod
Specified grease:
MITSUBISHI genuine grease
PART No. 0101011 or equivalent
1
4
12 ± 2 N·m
10
18 ± 3 N·m 30 ± 4 N·m
2
12 ± 2 N·m
N 3 6 5 7 8
9
11
AC211515 AD
Clutch master cylinder removal Clutch release cylinder removal

steps steps
1. Clevis pin assembly 10. Clutch pipe
2. Eye bolt 11. Clutch release cylinder
3. Gasket Clutch line removal steps
4. Reservoir hose 9. Clutch hose
5. Clevis pin and pushrod assembly 10. Clutch pipe
connecting part
6. Clutch master cylinder
7. Sealer
8. Retainer plate
21A-8 CLUTCH
CLUTCH CONTROL
<RH drive vehicles>
1
Release fork
3 12 ± 2 N·m
Release cylinder
push rod
7
Specified grease:
MITSUBISHI genuine grease 4 5
PART No. 0101011 or equivalent 8
6
15 ± 2 N·m 18 ± 3 N·m 2
6, 8
9
7
AC310343 AB
Clutch master cylinder removal Clutch line removal steps

steps 8. Clutch pipe
1. Clevis pin assembly 9. Clutch hose
2. Clutch pipe connection
3. Reservoir hose INSPECTION
M1211002000169
4. Clutch master cylinder
• Check the master cylinder or clutch hose for fluid
5. Sealer
Clutch release cylinder removal
leakage.
steps • Check the clutch hose or tube for cracks or clog-
6. Clutch pipe ging.
7. Clutch release cylinder
CLUTCH
CLUTCH CONTROL
21A-9
M1211002100315
CLUTCH MASTER CYLINDER
CAUTION
Do not disassemble the piston assembly.
13 ± 2 N·m
7 6
7 3
4 N
5 1 N
2N
8 5
<LH drive vehicles>

8
<RH drive vehicles>
4
1 2
2
3
4
Clutch fluid:
Piston repair kit Brake fluid DOT3 OR DOT4 Grease: Rubber grease
AC310349AD

1. Piston stopper ring 5. Spring pin
2. Piston assembly 6. Reservoir tank
>>A<< 3. Pushrod assembly 7. Seal
4. Boot 8. Master cylinder body
21A-10 CLUTCH
CLUTCH CONTROL
REASSEMBLY SERVICE POINT Set the length of the pushrod assembly to the dimen-
sion shown to make the adjustment of the clutch
>>A<< PUSHROD ASSEMBLY INSTALLA-
pedal easier.
TION
INSPECTION
M1211002200163
• Check inside the cylinder body for rust and scars.
• Check the piston for rust and scars.
• Check the pipe connection for clogging.
103 ± 0.5 mm
AC001144 AG
22A-1
GROUP 22A
MANUAL
TRANSMISSION (FF)
CONTENTS
GENERAL INFORMATION . . . . . . . . 22A-3 TROUBLESHOOTING <M/T>. . . . . . . 22A-148

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 22A-148
SERVICE SPECIFICATIONS. . . . . . . 22A-3 TROUBLESHOOTING STRATEGY . . . . . . 22A-148
SYMPTOM CHART . . . . . . . . . . . . . . . . . . . 22A-148
LUBRICANTS . . . . . . . . . . . . . . . . . . 22A-3 SYMPTOM PROCEDURES . . . . . . . . . . . . 22A-149
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22A-4 ON-VEHICLE SERVICE . . . . . . . . . . . 22A-151

TRANSMISSION OIL CHECK . . . . . . . . . . . 22A-151
TROUBLESHOOTING <ACD> . . . . . 22A-7 TRANSMISSION OIL REPLACEMENT. . . . 22A-152
TROUBLESHOOTING STRATEGY . . . . . . 22A-7 TRANSFER OIL CHECK . . . . . . . . . . . . . . . 22A-152
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 22A-7 TRANSFER OIL REPLACEMENT . . . . . . . 22A-152
INSPECTION CHART FOR DIAGNOSIS FLUID CHECK. . . . . . . . . . . . . . . . . . . . . . . 22A-152
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A-8
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 22A-153
DIAGNOSIS TROUBLE CODE
ACD OPERATION CHECK . . . . . . . . . . . . . 22A-153
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 22A-9
HYDRAULIC PRESSURE CHECK . . . . . . . 22A-154
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 22A-118
WHEEL SPEED SENSOR OUTPUT
SYMPTOM PROCEDURES . . . . . . . . . . . . 22A-119
VOLTAGE MEASUREMENT. . . . . . . . . . . . 22A-154
DATA LIST REFERENCE TABLE . . . . . . . 22A-142
OIL TEMPERATURE SENSOR CHECK . . . 22A-156
ACTUATOR TEST JUDGEMENT VALUE . 22A-145
CHECK AT 4WD-ECU TERMINALS. . . . . . 22A-146
WARNING
NOTE
22A-2
TRANSMISSION CONTROL . . . . . . . 22A-157 4WD-ECU . . . . . . . . . . . . . . . . . . . . . . 22A-167

REMOVAL AND INSTALLATION . . . . . . . . 22A-157 REMOVAL AND INSTALLATION . . . . . . . . 22A-167
SELECT CABLE (SHIFT LEVER SIDE)
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 22A-159 SENSOR, SWITCH AND RELAY* . . . 22A-168
TRANSFER ASSEMBLY* . . . . . . . . . 22A-160 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 22A-169
AIR DUCT . . . . . . . . . . . . . . . . . . . . . . 22A-170
TRANSMISSION ASSEMBLY . . . . . . 22A-163 REMOVAL AND INSTALLATION . . . . . . . . 22A-170
MANUAL TRANSMISSION (FF)
GENERAL INFORMATION
22A-3
GENERAL INFORMATION
M1221000100848
Item Specification
Transmission model W6MAA
Transmission type 6-speed forward, 1-speed reverse constant mesh
Gear ratio 1st 2.909
2nd 1.944
3rd 1.434
4th 1.100
5th 0.868
6th 0.693
Reverse 2.707
Final deceleration ratio 4.583
Speedometer gear ratio Not applicable
Front differential Helical gear LSD
Transfer Deceleration ratio 3.307
Limited slip differential Hydraulic multi plate clutch <ACD>
M1221000300132
Item Standard value

Hydraulic unit generation oil pressure MPa 1.0 − 1.6
Oil temperature sensor resistance kΩ At 20°C 2.31 − 2.59
At 110°C 0.145 − 0.146
LUBRICANTS
M1221000400430
Item Specified lubricant Quantity L

Transmission oil DIA QUEEN SUPER MULTI GEAR 75W-85W (GL-4) or exact equivalent 2.2
Transfer oil Dia Queen LSD gear oil 0.6
Fluid DIA QUEEN ATF SP III 1.0
22A-4 MANUAL TRANSMISSION (FF)
SPECIAL TOOLS
SPECIAL TOOLS
M1221000600832

MB991955 M.U.T.-III sub-assembly Checking the ACD (Diagnosis
A
A: MB991824 A: Vehicle communication display by using the M.U.T.-III)
B: MB991827 interface (V. C. I.)
C: MB991910 B: M.U.T.-III USB cable
MB991824
D: MB991911 C: M.U.T.-III main harness A
E: MB991825 (Vehicles with CAN
B F: MB991826 communication system)
D: M.U.T.-III main harness B
(Vehicles without CAN
MB991827 communication system)
E: M.U.T.-III measurement
C
adapter
DO NOT USE F: M.U.T.-III trigger harness
MB991910
MB991911
MB991825
MB991826
MB991955
MB991502 M.U.T.-II Sub assembly Diagnosis code checking
B991502
MB991529 Diagnosis code checking

harness
MB991529
SPECIAL TOOLS
22A-5
A
MB991223 Harness set Check at the ECU terminals
A: MB991219 A: Test harness A: Connector pin contact
B: MB991220 B: LED harness inspection
C: MB991221 C: LED harness adapter B: Power circuit inspection
B
D: MB991222 D: Probe C: Power circuit inspection
connection
D DO NOT USE
MB991223 AZ

connector
MB992006
MB991348 Test harness set G-sensor check
MB991348
MD998330 Oil pressure gauge (3.0 Hydraulic pressure

(including MPa) measurement
MD998331)
AC103525
MB991705 Adapter
MB991705
SPECIAL TOOLS

MB991454 Engine hanger balancer When the engine hanger is used:
Supporting the engine assembly
during removal and installation of
the transmission assembly
B991454
NOTE: Special tool MB991454 is
MB991895 Engine hanger a part of engine hanger
attachment set MB991453.
MB991895
MB991928 Engine hanger

Slide bracket (HI) A: MB991929 A: Joint (50) ×2
B: MB991930 B: Joint (90) ×2
E C: MB991931 C: Joint (140) ×2
D: MB991932 D: Foot (standard) ×4
F E: MB991933 E: Foot (short) ×2
A
D F: MB991934 F: Chain and hook assembly
B
C
B991928
TROUBLESHOOTING <ACD>
22A-7
TROUBLESHOOTING STRATEGY If a malfunction occurs in the ACD, all of the ACD
M1221007000604 mode indicator lamps (tarmac, gravel, and snow) will
Refer to GROUP 00 - How to Use Troubleshoot- illuminate.
ing/Inspection Service Points P.00-5. If all of the ACD mode indicator lamps (tarmac,
NOTE: Before starting the troubleshooting proce- gravel, and snow) are illuminating, check for diagno-
dure, make sure that the following items have been sis code.
checked okay.
• Is the appropriate steering wheel installed at the METHOD OF READING THE DIAGNOSIS
centre of the steering column shaft correctly?
• Are the tyre, wheel size, specifications, air pres-
CODE
sure, balance, and wear state normal? Use the M.U.T.-II/III to read the diagnosis code.
• Is the wheel alignment normal? (Refer to GROUP 00 − How to Use Troubleshoot-
• Has the engine, suspension, etc. been remod- ing/Inspection Service Points P.00-5).
eled in such a way that it will affect the ACD and
AYC systems? METHOD OF ERASING THE DIAGNOSIS
CODE
DIAGNOSIS FUNCTION Use the M.U.T.-II/III to erase the diagnosis code.
M1221007700012
(Refer to GROUP 00 − How to Use Troubleshoot-
ACD MODE INDICATOR LAMP SYSTEM ing/Inspection Service Points P.00-5).
ACD mode indicator lamp

AC311095AB

CODES
M1221007800019
Diagnosis Diagnosis items Reference page

code No.
12 Power supply voltage (valve power open circuit or short circuit P.22A-9
supply) system
13 Fail-safe relay system (inside open circuit or short circuit P.22A-14
4WD-ECU)
21 Wheel speed sensor system <FR> open circuit or short circuit P.22A-14
22 Wheel speed sensor system <FL> open circuit or short circuit P.22A-14
23 Wheel speed sensor system <RR> open circuit or short circuit P.22A-14
24 Wheel speed sensor system <RL> open circuit or short circuit P.22A-14
25 Wrong-diameter tyre P.22A-18
26 Wheel speed sensor system faulty output signal P.22A-19
31 Steering wheel sensor system <ST-1, open circuit or short circuit P.22A-20
ST-2, ST-N>
32 Steering wheel sensor system <ST-N> short circuit P.22A-29
33 fixed P.22A-29
34 Steering wheel sensor system <ST-1, short circuit or output fixed P.22A-33
ST-2>
41 TPS system open circuit or short circuit P.22A-37
42 short circuit P.22A-37
45 Pressure sensor system open circuit or short circuit P.22A-41
46 open earth P.22A-46
47 abnormal power supply P.22A-49
51 Longitudinal G-sensor system open circuit or short circuit P.22A-53
52 abnormal sensor P.22A-62
56 Lateral G-sensor system open circuit or short circuit P.22A-68
57 abnormal sensor P.22A-77
61 Stop lamp switch system open circuit P.22A-83
62 ACD mode switch system stuck P.22A-88
63 Parking brake switch system short circuit or not returned P.22A-94
to original position
65 ABS monitor system open circuit or defective P.22A-99
ABS
71 Proportional valve system <AYC> open circuit or short circuit Refer to GROUP 27 −
Diagnostic Trouble
Code Chart P.27-9
72 Directional control valve system open circuit or short circuit Refer to GROUP 27 −
<Right> Diagnostic Trouble
Code Chart P.27-9
22A-9
Diagnosis Diagnosis items Reference page
code No.
73 Directional control valve system <Left> open circuit or short circuit Refer to GROUP 27 −
Diagnostic Trouble
Code Chart P.27-9
74 Proportional valve system <ACD> open circuit or short circuit P.22A-105
81 Electric pump relay system open circuit or short circuit P.22A-109
82 electric pump malfunction P.22A-113
or pressure sensor defect
84 AYC control error Refer to GROUP 27 −
Diagnostic Trouble
Code Chart P.27-9
85 ACD control error −
NOTE: Code No.85 is not a code number set due to
malfunction, but a code number output when control
for the 4WD-ECU to protect the ACD is stopped in
excessive driving. ACD control can be recovered by
turning the ignition switch ON to OFF to ON.
DIAGNOSIS TROUBLE CODE PROCEDURES
Code No.12 Power supply voltage (valve power supply) system
Power supply circuit <LH drive vehicles>
IGNITION
SWITCH (IG2)
4WD-ECU
POWER
SOURCE
Wire colour code

Power supply circuit <RH drive vehicles>
IGNITION
SWITCH (IG2)
4WD-ECU
POWER
SOURCE
Wire colour code

OPERATION Or code No.12 is set when the battery voltage drops.

The 4WD-ECU (terminal 13) is energized through
the fuse by the ignition switch (IG2). PROBABLE CAUSES
• Damaged harness wires and connectors
DIAGNOSIS CODE SET CONDITIONS • Malfunction of the battery
The power supply circuit opens or short-circuits if the • Malfunction of the 4WD-ECU
power supply voltage of the 4WD-ECU is below 9 V
or above 18 V.
22A-11
DIAGNOSIS STEP 3. Measure the voltage at 4WD-ECU
connector C-25.
STEP 1. Check the battery. (1) Turn the ignition switch to the ON position.
Refer to GROUP 54A, Battery − On-vehicle Service Connector: C-25
− Battery Test P.54A-5. 4WD-ECU
Q: Is the battery damaged? <LH drive vehicles>
YES : Charge or replace the battery.
NO : Go to Step 2.
C-25 (Y)
Rear console
assembly
Item 10: Battery voltage (Refer to Data List Refer-
<RH drive vehicles>
ence Table P.22A-142).
Malfunction P.00-5). 4WD-ECU
NO : Go to Step 3.
C-25 (Y)
Harness side
AC311002AB
(2) Measure the voltage between 4WD-ECU

connector C-25 terminal No.13 and earth.
OK: System voltage
YES : Go to Step 7.
NO : Go to Step 4.
STEP 4. Connectors check: C-25 4WD-ECU Connector: C-138 <RH drive vehicles>
connector, C-124 intermediate connector, C-210
J/B connector <LH drive vehicles> or C-25
4WD-ECU connector, C-138 intermediate
connector, C-214 J/B connector <RH drive
vehicles>.
Connector: C-25
4WD-ECU C-138
<LH drive vehicles> AC311016AB
Connector: C-214 Junction block (front view)

<RH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles> C-214
Junction
block side
4WD-ECU AC310458AO
C-25 (Y) Check for the contact with terminals.
YES : Go to Step 5.
Harness side
AC311002AB
Connector: C-124 <LH drive vehicles>
C-124
AC311015AB
C-210
Junction block side
AC310448AS
22A-13
STEP 5. Check the harness between 4WD-ECU STEP 6. M.U.T.-II/III data list
connector C-25 terminal No.13 and J/B connector Item 10: Battery voltage (Refer to Data List Refer-
C-210 terminal No.8 <LH drive vehicles> or J/B ence Table P.22A-142).
connector C-214 terminal No.16 <RH drive Q: Is the check result normal?
vehicles>. YES : Intermittent malfunction (Refer to GROUP
Connector: C-25 00 − How to Cope with Intermittent
4WD-ECU
NO : Replace the 4WD-ECU.
<LH drive vehicles>
STEP 7. Connector check: C-25 4WD-ECU

C-25 (Y) connector.
Rear console
assembly Connector: C-25
<RH drive vehicles> 4WD-ECU

<LH drive vehicles>
C-25 (Y)
4WD-ECU Rear console
assembly
C-25 (Y)
<RH drive vehicles>
Harness side
4WD-ECU
AC311002AB
C-25 (Y)
Harness side
AC311002AB
C-210
Junction block side
Check for the contact with terminals.
YES : Go to Step 6.
AC310448AS
<RH drive vehicles>
C-214
Junction
block side
AC310458AO
Check the power supply line for short or open circuit.

YES : Go to Step 6.
Code No.13 Fail-safe relay system (inside 4WD-ECU)

The power supplied from the ignition switch will be • Malfunction of the 4WD-ECU
distributed to each section inside the ECU through
the fail-safe relay (incorporated in the ECU). DIAGNOSIS
DIAGNOSIS CODE SET CONDITIONS
Replace the 4WD-ECU.
Code No.13 will be set as the open circuit or short
circuit of the fail-safe relay when the voltage is above Q: Is the malfunction eliminated?
6 V during fail-safe relay OFF or when the voltage is YES : The inspection is complete.
below 6 V during ON. NO : If no malfunction is not found an intermittent
malfunction is suspected. (Refer to GROUP
Code No.21, 22, 23, 24 Wheel speed sensor system
ABS-ECU signal line system circuit
ABS-ECU
4WD-ECU
Wire colour code


• The ABS-ECU detects the speed of each wheel A diagnosis code corresponding to the open circuit or
according to the pulse signals from each wheel short circuit of the wheel speed sensor is set when
speed sensor. one wheel speed sensor has detected a vehicle
• The 4WD-ECU receives the wheel speed sensor speed of above 15 km/h, but any one of the remain-
signals through the ABS-ECU. ing three wheel speed sensors could not detect the
vehicle speed.
22A-15
PROBABLE CAUSES STEP 3. Measure the voltage at 4WD-ECU
• Malfunction of the wheel speed sensor connector C-25.
• Damaged harness wires and connectors (1) Turn the ignition switch to the ON position.
• Malfunction of the ABS-ECU
• Malfunction of the 4WD-ECU Connector: C-25
4WD-ECU
DIAGNOSIS <LH drive vehicles>

C-25 (Y)
Q: Are ABS diagnosis codes 11, 12, 13, 14, 21, 22, 23, Rear console
24 set? assembly
YES : Refer to GROUP 35B − Check Chart for <RH drive vehicles>
Diagnosis Codes P.35B-9.
NO : Go to Step 2.

4WD-ECU
• Item 01: Wheel speed sensor <FR>
• Item 02: Wheel speed sensor <FL> C-25 (Y)
• Item 03: Wheel speed sensor <RR>
• Item 04: Wheel speed sensor <RL>
Check the above data list (Refer to data list reference
table P.22A-142).
Harness side
Q: Is the check result normal? AC311002AB
00 − How to Cope with Intermittent (2) Measure the voltage between the following
Malfunction P.00-5). terminals of 4WD-ECU connector C-25 and earth
NO : Go to Step 3. while turning the relevant tyre of the terminal
being measured one-half to one turn per second.
• Terminal No.9 <FR>
• Terminal No.6 <FL>
• Terminal No.7 <RR>
• Terminal No.8 <RL>
OK: 0 ⇔ 5 V flushing
YES : Go to Step 7.
NO : Go to Step 4.

STEP 4. Connectors check: B-118 ABS-ECU
YES : Go to Step 5.
connector, C-25 4WD-ECU connector. NO : Repair the defective connector.
Connector: B-118
<LH drive vehicles>
B-118
(B)
<RH drive vehicles>

B-118
(GR)
B-118
Harness side
AC311020 AB
Connector: C-25
4WD-ECU
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Harness side
AC311002AB

22A-17
STEP 5. Check the harness between ABS-ECU Check the output line for short or open circuit.
connector B-118 (terminal No.9, 6, 7, 8) and Q: Is the check result normal?
4WD-ECU connector C-25 (terminal No.18, 32, 21, YES : Go to Step 6.
20). NO : Repair the wiring harness.
Connector: B-118
<LH drive vehicles> STEP 6. M.U.T.-II/III data list
B-118 • Item 02: Wheel speed sensor <FL>
(B) • Item 03: Wheel speed sensor <RR>
table P.22A-142).
<RH drive vehicles> Malfunction P.00-5).
B-118 NO : Replace the 4WD-ECU.
(GR)
STEP 7. Connector check: C-25 4WD-ECU

connector.
Connector: C-25
4WD-ECU
<LH drive vehicles>
B-118
C-25 (Y)
Rear console
assembly
Harness side <RH drive vehicles>
AC311020 AB
Connector: C-25
4WD-ECU
<LH drive vehicles> 4WD-ECU
C-25 (Y)
C-25 (Y)
Rear console
assembly
<RH drive vehicles> Harness side
AC311002AB

4WD-ECU YES : Go to Step 6.
C-25 (Y) NO : Repair the defective connector.
Harness side
AC311002AB
Code No.25 Wrong-diameter tyre
ABS SIGNAL LINE SYSTEM CIRCUIT STEP 2. M.U.T.-II/III diagnosis code

Refer to P.22A-14.
Q: Are ABS diagnosis codes 11, 12, 13, 14, 21, 22, 23,
OPERATION 24 set?
YES : Refer to GROUP 35B − Check Chart for
The 4WD-ECU receives each wheel speed sensor
signal through the ABS-ECU to detect the tyre condi- NO : Go to Step 3.
tions.
DIAGNOSIS CODE SET CONDITIONS STEP 3. M.U.T.-II/III diagnosis code

Code No.25 is set as wrong-diameter tyre when one Q: Are ACD diagnosis codes 21, 22, 23, 24 set?
of the four vehicle speeds is outside the range of YES : Refer to diagnosis code 21, 22, 23, 24
specified values in respect to the average of the four Wheel Speed Sensor System P.22A-14.
vehicle speed sensors, when the vehicle speed is NO : Go to Step 4.
above 20 km/h with the steering wheel in the straight
ahead position. However the warning lamp does not
light up.
PROBABLE CAUSES • Item 02: Wheel speed sensor <FL>
• Malfunction of the tyre
table P.22A-142).
• Malfunction of the 4WD-ECU Q: Is the check result normal?
DIAGNOSIS 00 − How to Cope with Intermittent
STEP 1. Check the tyre.
Check the tyre pressure, size and brand.
YES : Go to Step 2.
NO : Adjust or replace the tyre.
22A-19
Code No.26 Wheel speed sensor system (faulty output signal)
ABS SIGNAL LINE SYSTEM CIRCUIT STEP 2. M.U.T.-II/III diagnosis code

Refer to P.22A-14.
Q: Are ABS diagnosis codes 11, 12, 13, 14, 21, 22, 23,
OPERATION 24 set?
YES : Refer to GROUP 35B − Check Chart for
The 4WD-ECU receives each wheel speed sensor
signal through the ABS-ECU to detect the conditions NO : Go to Step 3.
of the wheel speed sensors.
DIAGNOSIS CODE SET CONDITIONS STEP 3. M.U.T.-II/III diagnosis code

Code No.26 is set as output signal error of the wheel Q: Are ACD diagnosis codes 21, 22, 23, 24 set?
speed sensor when one wheel speed is outside the YES : Refer to diagnosis code 21, 22, 23, 24
specified range at the vehicle speed of above 20 Wheel Speed Sensor System P.22A-14.
km/h. However, warning lamp will light up. NO : Go to Step 4.
PROBABLE CAUSES
• Malfunction of the tyre
• Item 02: Wheel speed sensor <FL>
• Malfunction of the 4WD-ECU
table P.22A-142).
DIAGNOSIS
STEP 1. Check the tyre. 00 − How to Cope with Intermittent
Check the tyre pressure, size and brand. Malfunction P.00-5).
Q: Is the check result normal? NO : Replace the 4WD-ECU.
YES : Go to Step 2.
NO : Adjust or replace the tyre.
Code No.31 Steering wheel sensor system <ST-1, ST-2, ST-N>
Steering wheel sensor system circuit <LH drive vehicles>

IGNITION
SWITCH (IG2)
4WD-ECU
STEERING
WHEEL
SENSOR
Wire colour code

22A-21
Steering wheel sensor system circuit <RH drive vehicles>

IGNITION
SWITCH (IG2)
4WD-ECU
STEERING
WHEEL
SENSOR
Wire colour code


The steering wheel sensor detects the neutral posi- • Malfunction of the steering wheel sensor
tion and steering angle of the steering wheel by the • Damaged harness wires and connectors
photointerruptor (ST-1, ST-2 or ST-N), and sends • Malfunction of the 4WD-ECU
them to the 4WD-ECU.
DIAGNOSIS
Code No.31 is set when open circuit or short circuit
of the steering wheel sensor output line (ST-1, ST-2,
or ST-N) occurs. Q: Are ABS diagnosis codes 81, 82, 83 set?
YES : Go to Step 8.
NO : Go to Step 2.
STEP 2. M.U.T.-II/III data list STEP 4. Connector check: C-26 4WD-ECU

• Item 21: Steering wheel sensor voltage <ST-1> connector.
• Item 22: Steering wheel sensor voltage <ST-2>
Connector: C-26
• Item 23: Steering wheel sensor voltage <ST-N>
Check the above data list (Refer to data list reference 4WD-ECU
table P.22A-142). <LH drive vehicles>

00 − How to Cope with Intermittent C-26 (Y)
Rear console
Malfunction P.00-5). assembly
NO : Go to Step 3.
<RH drive vehicles>
STEP 3. Measure the voltage at 4WD-ECU

connector C-26.
4WD-ECU
Connector: C-26
C-26 (Y)
4WD-ECU
<LH drive vehicles>
Harness side
C-26 (Y)
Rear console
AC311002AC
assembly
<RH drive vehicles>
YES : Go to Step 5.
4WD-ECU STEP 5. M.U.T.-II/III data list

C-26 (Y) • Item 21: Steering wheel sensor voltage <ST-1>
• Item 23: Steering wheel sensor voltage <ST-N>
table P.22A-142).
Harness side
AC311002AC
(2) Measure the voltage between the following 00 − How to Cope with Intermittent
terminals of 4WD-ECU connector C-26 and earth Malfunction P.00-5).
while turning the steering wheel. NO : Replace the 4WD-ECU.
• Terminal No.33 <ST-1>
• Terminal No.34 <ST-2>
• Terminal No.44 <ST-N>
OK: Approximately 1.5 ⇔ 3.5 V flushing
YES : Go to Step 4.
NO : Go to Step 6.
22A-23
STEP 6. Connectors check: C-26 4WD-ECU STEP 7. Check the harness between 4WD-ECU
connector, C-122 intermediate connector <LH connector C-26 (terminal No.33, 34, 44) and
drive vehicles> or C-26 4WD-ECU connector, intermediate connector C-122 (terminal No.12, 1,
C-138 intermediate connector <RH drive 2) <LH drive vehicles> or intermediate connector
vehicles>. C-138 (terminal No.5, 2, 1) <RH drive vehicles>.
4WD-ECU 4WD-ECU
<LH drive vehicles> <LH drive vehicles>
C-26 (Y) C-26 (Y)

Rear console Rear console
assembly assembly
<RH drive vehicles> <RH drive vehicles>
4WD-ECU 4WD-ECU
C-26 (Y) C-26 (Y)

AC311002AC AC311002AC
Connector: C-122 <LH drive vehicles> Connector: C-122 <LH drive vehicles>
C-122 C-122
AC311015AC AC311015AC
Connector: C-138 <RH drive vehicles> Connector: C-138 <RH drive vehicles>
C-138 C-138
AC311016AB AC311016AB
Check for the contact with terminals. Check the output line for open circuit.
NO : Repair the defective connector. NO : Repair the wiring harness.
STEP 8. M.U.T.-II/III data list STEP 9. Measure the voltage at steering wheel
• Item 21: Steering wheel sensor voltage <ST-1> sensor connector C-230.
Connector: C-230
• Item 23: Steering wheel sensor voltage <ST-N> <LH drive vehicles>
table P.22A-142).
YES : Intermittent malfunction (Refer to GROUP C-230
NO : Go to Step 9. <RH drive vehicles>
C-230
Harness side
AC311035AB
(1) Disconnect the steering wheel sensor connector

C-230, and measure the voltage between
terminal No.2 and earth at the wiring harness
side.
OK: System voltage
NO : Go to Step 10.
22A-25
STEP 10. Connectors check: C-101 J/C (2), C-210 Connector: C-230
<LH drive vehicles>
J/B connector, C-230 steering wheel sensor
connector.
C-230
C-101 (L)
<RH drive vehicles>
AC311015AE
Connector: C-101 <RH drive vehicles>
C-230
Harness side
C-101 (L)
AC311035AB

AC311037AB
Connector: C-210 <LH drive vehicles> NO : Repair the defective connector.
C-210
Junction block side
AC310448AS

<RH drive vehicles>
C-210
Junction
block side
AC310458AP
STEP 11. Check the harness between J/B STEP 12. Measure the resistance at steering
connector C-210 terminal No.13 and steering wheel sensor connector C-230.
wheel sensor connector C-230 terminal No.2.
Connector: C-230
<LH drive vehicles>
C-230
C-210
Junction block side
<RH drive vehicles>
AC310448AS

<RH drive vehicles>
C-210
C-230
Junction
block side Harness side
AC311035AB
AC310458AP
(1) Disconnect the steering wheel sensor connector
Connector: C-230 C-230, and measure the resistance between
<LH drive vehicles>
terminal No.3 and earth at the wiring harness
side.
OK: 2 Ω or less
C-230
NO : Go to Step 13.
<RH drive vehicles>
C-230
Harness side
AC311035AB

YES : The inspection is complete.
22A-27
STEP 13. Connectors check: C-06 J/C (3), C-230 STEP 14. Check the harness between steering
steering wheel sensor connector. wheel sensor connector C-230 terminal No.3 and
body earth.
Connector: C-230
<LH drive vehicles>
C-06 (GR)
C-230
AC311039AB <RH drive vehicles>

C-06 (GR)
C-230
Harness side
AC311037AC
AC311035AB
Connector: C-230
<LH drive vehicles>
Check the earth line for open circuit.
YES : The inspection is complete.
C-230
<RH drive vehicles>
C-230
Harness side
AC311035AB

STEP 15. Connectors check: C-230 steering STEP 16. Check the harness between steering
wheel sensor connector, C-122 intermediate wheel sensor connector C-230 (terminal No.5, 4,
connector <LH drive vehicles> or C-138 1) and intermediate connector C-122 (terminal
intermediate connector <RH drive vehicles>. No.12, 1, 2) <LH drive vehicles> or intermediate
connector C-138 (terminal No.5, 2, 1) <RH drive
Connector: C-230
<LH drive vehicles> vehicles>.
Connector: C-230
<LH drive vehicles>
C-230
C-230
<RH drive vehicles>
<RH drive vehicles>
C-230
Harness side C-230
AC311035AB Harness side
Connector: C-122 <LH drive vehicles> AC311035AB
C-122
C-122
AC311015AC
Connector: C-138 <RH drive vehicles> AC311015AC
C-138
AC311016AB
C-138
AC311016AB
YES : Go to Step 16. Check the output line for short or open circuit.
NO : Repair the defective connector. Q: Is the check result normal?
YES : Replace the steering wheel sensor.
22A-29
Code No.32, 33 Steering wheel sensor system <ST-N>
STEERING WHEEL SENSOR SYSTEM STEP 2. Measure the voltage at 4WD-ECU

CIRCUIT connector C-26.
Refer to P.22A-20. (1) Turn the ignition switch to the ON position.
Connector: C-26
OPERATION
Refer to P.22A-20. 4WD-ECU
<LH drive vehicles>
• Code No.32 is set when the steering wheel sen-
sor ST-N has been detected at the neutral posi- C-26 (Y)
Rear console
tion in a state where the steering wheel has been
assembly
determined to have changed above 40° from
<RH drive vehicles>
steering wheel sensor ST-1 and ST-2.
• Code No.33 is set when the steering wheel sen-
sor ST-N has been detected at the neutral posi-
tion in a state where the steering wheel has been
determined to have changed above 400° from
4WD-ECU
steering wheel sensor ST-1 and ST-2.
C-26 (Y)
PROBABLE CAUSES
• Malfunction of the steering wheel sensor
• Malfunction of the 4WD-ECU Harness side
DIAGNOSIS AC311002AC

connector C-26 terminal 44 and earth while
STEP 1. M.U.T.-II/III data list turning the steering wheel.
Item 52: Steering wheel sensor <ST-N> (Refer to
OK: Approximately 1.5 ⇔ 3.5 V flushing
data list reference table P.22A-142).
YES : Go to Step 3.
NO : Go to Step 5.
NO : Go to Step 2.
STEP 3. Connector check: C-26 4WD-ECU STEP 4. M.U.T.-II/III data list

connector. Item 52: Steering wheel sensor <ST-N> (Refer to
Connector: C-26
4WD-ECU Q: Is the check result normal?
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

YES : Go to Step 4.
22A-31
STEP 5. Connectors check: C-26 4WD-ECU Connector: C-230
<LH drive vehicles>
steering wheel sensor connector <LH drive
vehicles> or C-26 4WD-ECU connector, C-138
intermediate connector, C-230 steering wheel
sensor connector <RH drive vehicles>. C-230
Connector: C-26
4WD-ECU
<RH drive vehicles>
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
C-230
Harness side
4WD-ECU
AC311035AB
C-26 (Y)
YES : Go to Step 6.
Harness side
AC311002AC
C-122
AC311015AC
C-138
AC311016AB
STEP 6. Check the harness between 4WD-ECU STEP 7. Replace the steering wheel sensor and
connector C-26 terminal No.44 and steering then recheck the diagnosis code.
wheel sensor connector C-230 terminal No.1. (1) Replace the steering wheel sensor.
(2) Test drive the vehicle.
Connector: C-26
(3) Check the diagnosis code.
4WD-ECU
<LH drive vehicles>
Q: Is the diagnosis code set?
YES : Go to Step 4.
NO : The inspection is complete.
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC
Connector: C-230
<LH drive vehicles>
C-230
<RH drive vehicles>
C-230
Harness side
AC311035AB
Check the output line for open circuit.

YES : Go to Step 7.
22A-33
Code No.34 Steering wheel sensor system <ST-1, ST-2>
STEERING WHEEL SENSOR SYSTEM STEP 2. Measure the voltage at 4WD-ECU

CIRCUIT connector C-26.
Refer to P.22A-20. (1) Turn the ignition switch to the ON position.
Connector: C-26
OPERATION
Refer to P.22A-20. 4WD-ECU
<LH drive vehicles>
Code No.34 is set when no change in the steering
wheel sensor signal at a vehicle speed of above 15 C-26 (Y)
Rear console
km/h is detected for a total of more than 15 minutes
assembly
<ST-1, ST-2>, and turning is detected during this
<RH drive vehicles>
time.
PROBABLE CAUSES
• Malfunction of the steering wheel sensor
4WD-ECU
C-26 (Y)
DIAGNOSIS

• Item 53: Steering wheel sensor <ST-1> Harness side
• Item 54: Steering wheel sensor <ST-2> AC311002AC
Check the above data list (Refer to data list reference (2) Measure the voltage between the following
table P.22A-142). terminals of 4WD-ECU connector C-26 and earth
Q: Is the check result normal? while turning the steering wheel.
YES : Intermittent malfunction (Refer to GROUP • Terminal No.33 <ST-1>
00 − How to Cope with Intermittent • Terminal No.34 <ST-2>
Malfunction P.00-5). OK: Approximately 1.5 ⇔ 3.5 V flushing
NO : Go to Step 2.
YES : Go to Step 3.
NO : Go to Step 5.

connector. • Item 53: Steering wheel sensor <ST-1>
• Item 54: Steering wheel sensor <ST-2>
Connector: C-26
4WD-ECU table P.22A-142).
<LH drive vehicles>
C-26 (Y)
Rear console Malfunction P.00-5).
assembly NO : Replace the 4WD-ECU.
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

YES : Go to Step 4.
22A-35
STEP 5. Connectors check: C-26 4WD-ECU Connector: C-230
<LH drive vehicles>
steering wheel sensor connector <LH drive
vehicles> or C-26 4WD-ECU connector, C-138
intermediate connector, C-230 steering wheel
sensor connector <RH drive vehicles>. C-230
Connector: C-26
4WD-ECU
<RH drive vehicles>
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
C-230
Harness side
4WD-ECU
AC311035AB
C-26 (Y)
YES : Go to Step 6.
Harness side
AC311002AC
C-122
AC311015AC
C-138
AC311016AB
STEP 6. Check the harness between 4WD-ECU STEP 7. Replace the steering wheel sensor and
connector C-26 (terminal No.33, 34) and steering then recheck the diagnosis code.
wheel sensor connector C-230 (terminal No.5, 4). (1) Replace the steering wheel sensor.
Connector: C-26
4WD-ECU
<LH drive vehicles>
YES : Go to Step 4.
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC
Connector: C-230
<LH drive vehicles>
C-230
<RH drive vehicles>
C-230
Harness side
AC311035AB

YES : Go to Step 7.
22A-37
Code No.41, 42 Throttle position sensor system
Throttle position sensor system circuit
THROTTLE
POSITION
SENSOR
<LH DRIVE VEHICLES> OR

<RH DRIVE VEHICLES>
4WD-ECU
Wire colour code

OPERATION DIAGNOSIS
The 4WD-ECU receives a change in the output volt-
age from the throttle position sensor to determine the STEP 1. M.U.T.-II/III diagnosis code
accelerator pedal opening angle.
Q: Is MPI diagnosis code P0120 set?
DIAGNOSIS CODE SET CONDITIONS YES : Refer to GROUP 13A − Inspection Chart for
• Code No.41 is set as excessively small output Diagnosis Codes P.13A-60.
when the TPS output is below 0.2 V In the idling NO : Go to Step 2.
state.
• Code No.42 is set as excessively large output STEP 2. M.U.T.-II/III data list
when the TPS output is more than 4.8 V for more Item 13: Throttle position sensor voltage (Refer to
than 2 minutes continuously below a vehicle data list reference table P.22A-142).
speed of 10 km/h.
PROBABLE CAUSES
• Malfunction of the throttle position sensor
• Damaged harness wires and connectors NO : Go to Step 3.
STEP 3. Measure the voltage at 4WD-ECU STEP 4. Connector check: C-26 4WD-ECU
connector C-26. connector.
Connector: C-26
Connector: C-26 4WD-ECU
4WD-ECU <LH drive vehicles>
<LH drive vehicles>
C-26 (Y)
Rear console
C-26 (Y) assembly
Rear console
assembly <RH drive vehicles>
<RH drive vehicles>
4WD-ECU
4WD-ECU
C-26 (Y)
C-26 (Y)
Harness side
AC311002AC Check for the contact with terminals.
(2) Measure the voltage between 4WD-ECU Q: Is the check result normal?
connector C-26 terminal No.39 and earth. YES : Go to Step 5.
OK: NO : Repair the defective connector.
Accelerator pedal fully released: 0.535 −
0.735 V
Accelerator pedal fully depressed: 4.5 − 5.0
Item 13: Throttle position sensor voltage (Refer to
V
YES : Go to Step 4.
NO : Go to Step 6.
STEP 6. Check throttle position sensor.

Check throttle position sensor (Refer to P.13A-404).
YES : Go to Step 7.
NO : Repair or replace throttle position sensor.
22A-39
STEP 7. Connectors check: B-03 throttle position
YES : Go to Step 8.
sensor connector, C-26 4WD-ECU connector, NO : Repair the defective connector.
C-105 J/C (6).
Connector: B-03
<LH drive vehicles>
B-03 (B)
<RH drive vehicles>

B-03 (B)
B-03
Sensor side
AC311020 AC
Connector: C-26
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC


STEP 8. Check the harness between throttle
YES : Go to Step 5.
position sensor connector B-03 terminal No.2 NO : Repair the wiring harness.
and 4WD-ECU connector C-26 terminal No.39.
Connector: B-03
<LH drive vehicles>
B-03 (B)
<RH drive vehicles>

B-03 (B)
B-03
Sensor side
AC311020 AC
Connector: C-26
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

22A-41
Code No.45 Pressure sensor system (open circuit or short circuit)
Pressure sensor system circuit <LH drive vehicles>
4WD-ECU
Wire colour code

B : Black LG : Light green PRESSURE
G : Green L : Blue SENSOR
Pressure sensor system circuit <RH drive vehicles>
4WD-ECU
Wire colour code

B : Black LG : Light green PRESSURE
G : Green L : Blue SENSOR
OPERATION DIAGNOSIS
The 4WD-ECU receives accumulator pressure infor-
mation from the pressure sensor to control the elec- STEP 1. M.U.T.-II/III data list
tric pump. Item 18: Pressure sensor (Refer to data list reference
table P.22A-142).
Code No.45 is set when the output signal from the Q: Is the check result normal?
pressure sensor is below 0.2 V. YES : Intermittent malfunction (Refer to GROUP
PROBABLE CAUSES Malfunction P.00-5).
• Malfunction of the pressure sensor NO : Go to Step 2.
• Malfunction of the 4WD-ECU STEP 2. Measure the voltage at 4WD-ECU
connector C-26.
22A-43
Connector: C-26 STEP 3. Connector check: C-26 4WD-ECU

4WD-ECU connector.
<LH drive vehicles> Connector: C-26
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles> C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
4WD-ECU
C-26 (Y)
Harness side
AC311002AC
(2) Measure the voltage between 4WD-ECU Harness side

connector C-26 terminal No.32 and earth. AC311002AC
OK: 0.5 − 1.5 V Check for the contact with terminals.

NO : Go to Step 5. NO : Repair the defective connector.

Item 18: Pressure sensor (Refer to data list reference
table P.22A-142).
STEP 5. Connectors check: C-26 4WD-ECU Connector: C-134 <LH drive vehicles>
connector, C-122, C-134, F-21 intermediate
connector, F-26 pressure sensor connector.
Connector: C-26
4WD-ECU
<LH drive vehicles>
C-134 (B)
AC311015AG
C-26 (Y)
Rear console
assembly Connector: C-134 <RH drive vehicles>
<RH drive vehicles>
4WD-ECU
C-26 (Y)
C-134 (GR) AC311016AD
Connector: F-21, F-26

Harness side
F-21
AC311002AC
F-26
F-26 (B)
Sensor side
F-21 (B)
AC311042AB
C-122
AC311015AC YES : Go to Step 6.
C-122 (L)
AC311016AE
22A-45
STEP 6. Check the harness between 4WD-ECU
YES : Replace the pressure sensor.
connector C-26 (terminal No.43, 32) and pressure NO : Repair the wiring harness.
sensor connector F-26 (terminal No.1, 2).
Connector: C-26
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC
Connector: F-26
F-26
F-26 (B)
Sensor side
AC311042AC
Check the power supply line, output line for short or

open circuit.
Code No.46 Pressure sensor system (open earth)
PRESSURE SENSOR SYSTEM CIRCUIT STEP 2. Connector check: F-26 pressure sensor
Refer to P.22A-41. connector.
OPERATION Connector: F-26
Refer to P.22A-41.

Code No.46 is set when the output signal from the
pressure sensor is above 2.0 V. F-26
F-26 (B)
PROBABLE CAUSES
Sensor side
• Malfunction of the pressure sensor
• Damaged harness wires and connectors AC311042AC
• Malfunction of the 4WD-ECU Check for the contact with terminals.

DIAGNOSIS YES : Replace the pressure sensor.
STEP 1. Measure the voltage at pressure sensor
connector F-26.
Connector: F-26
F-26
F-26 (B)
Sensor side
AC311042AC
Disconnect the pressure sensor connector, and

measure the resistance between terminal 3 and body
earth at the harness side.
OK: 2 Ω or less
YES : Go to Step 2.
NO : Go to Step 3.
22A-47
connector, F-26 pressure sensor connector <LH
drive vehicles> or C-25 4WD-ECU connector,
C-134, C-138, F-21 intermediate connector, F-26
pressure sensor connector <RH drive vehicles>.
Connector: C-25
4WD-ECU
<LH drive vehicles> C-134 (GR) AC311016AD

C-25 (Y)
Rear console
assembly
<RH drive vehicles>
C-138
4WD-ECU AC311016AB
C-25 (Y)
F-21
Harness side
AC311002AB
F-26
Connector: C-122 <LH drive vehicles> F-26 (B)
Sensor side
F-21 (B)
AC311042AB

C-122 YES : Go to Step 4.
AC311015AC
C-134 (B)
AC311015AG

YES : Replace the 4WD-ECU.
connector C-25 terminal No.10 and pressure NO : Repair the wiring harness.
sensor connector F-26 terminal No.3.
Connector: C-25
4WD-ECU
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Harness side
AC311002AB
Connector: F-26
F-26
F-26 (B)
Sensor side
AC311042AC
Check the power supply line, output line, earth line

for short or open circuit.
22A-49
Code No.47 Pressure sensor system (abnormal power supply)
PRESSURE SENSOR SYSTEM CIRCUIT STEP 2. Measure the voltage at 4WD-ECU

Refer to P.22A-41. connector C-26.
OPERATION
Refer to P.22A-41. Connector: C-26
4WD-ECU
DIAGNOSIS CODE SET CONDITIONS <LH drive vehicles>
Code No.47 is set when the pressure sensor power
supply voltage is above 4.0V during pressure sensor
power OFF or less than 4.0V during pressure sensor
C-26 (Y)
power ON. Rear console
assembly
PROBABLE CAUSES <RH drive vehicles>
• Malfunction of the pressure sensor
DIAGNOSIS 4WD-ECU
C-26 (Y)
Item 19: Pressure sensor power supply (Refer to
YES : Intermittent malfunction (Refer to GROUP AC311002AC
00 − How to Cope with Intermittent (2) Measure the voltage between 4WD-ECU
Malfunction P.00-5). connector C-26 terminal No.43 and earth.
NO : Go to Step 2.
OK: 5 V
YES : Go to Step 3.
NO : Go to Step 5.

connector. Item 19: Pressure sensor power supply (Refer to
Connector: C-26
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

YES : Go to Step 4.
22A-51
connector, F-26 pressure sensor connector.
Connector: C-26
4WD-ECU
<LH drive vehicles>
C-134 (B)
AC311015AG
C-26 (Y)
Rear console
<RH drive vehicles>
4WD-ECU
C-26 (Y)
C-134 (GR) AC311016AD

Harness side
F-21
AC311002AC
F-26
F-26 (B)
Sensor side
F-21 (B)
AC311042AB
C-122
AC311015AC YES : Go to Step 6.
C-122 (L)
AC311016AE

YES : Replace the pressure sensor.
connector C-26 terminal No.43 and pressure NO : Repair the wiring harness.
sensor connector F-26 terminal No.1.
Connector: C-26
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC
Connector: F-26
F-26
F-26 (B)
Sensor side
AC311042AC

22A-53
Code No.51 Longitudinal G-sensor system (open circuit or short circuit)
G-sensor (longitudinal) system circuit <LH drive vehicles>

IGNITION
SWITCH (IG2)
G-SENSOR
(LONGITUDINAL)
4WD-ECU ABS-ECU
Wire colour code

G-sensor (longitudinal) system circuit <RH drive vehicles>

IGNITION
SWITCH (IG2)
G-SENSOR
(LONGITUDINAL)
4WD-ECU ABS-ECU
Wire colour code

OPERATION DIAGNOSIS
The 4WD-ECU receives the acceleration level in the
forward/reverse direction of the vehicle from the lon- STEP 1. M.U.T.-II/III data list
gitudinal G-sensor. Item 14: Longitudinal G-sensor voltage (Refer to data
list reference table P.22A-142).
Code No.51 is set when the output signal of the lon- Q: Is the check result normal?
gitudinal G-sensor is less than 0.5 V or above 4.5 V. YES : Intermittent malfunction (Refer to GROUP
• Malfunction of the longitudinal G-sensor NO : Go to Step 2.
22A-55
STEP 2. Measure the voltage at longitudinal STEP 3. Connector check: C-211, C-214 J/B
G-sensor connector D-38. connector, D-38 longitudinal G-sensor connector.
Connector: D-38 Connector: C-211, C-214 <LH drive vehicles>
<LH drive vehicles> Junction block (front view)
C-211
C-211
C-214
C-214
D-38 (B)
AC310448AW
Connector: C-211, Junction block (front view)

<RH drive vehicles> C-214 <RH drive vehicles> C-211
C-211
C-214
D-38 (B)
C-214
AC310458AS
Sensor side
Connector: D-38
AC311048 AB
<LH drive vehicles>
(1) Disconnect the longitudinal G-sensor connector,
and measure the voltage between terminal No.1
and earth.
OK: System voltage
YES : Go to Step 7. D-38 (B)
NO : Go to Step 3.
<RH drive vehicles>
D-38 (B)
Sensor side
AC311048 AB

YES : Go to Step 4.
STEP 4. Check the harness between J/B STEP 5. Replace the longitudinal G-sensor and
connector C-214 terminal No.26 and longitudinal then recheck the diagnosis code.
G-sensor connector D-38 terminal No.1. (1) Replace the longitudinal G-sensor.
Connector: C-214 <LH drive vehicles> (2) Test drive the vehicle.
Junction block (front view) Q: Is the diagnosis code set?
YES : Go to Step 6.
Junction block side
C-214
Item 14: Longitudinal G-sensor voltage (Refer to data
AC310448AU
Connector: C-214 Junction block (front view) YES : Intermittent malfunction (Refer to GROUP
<RH drive vehicles> 00 − How to Cope with Intermittent
C-214
Junction STEP 7. Measure the resistance at longitudinal
block side
G-sensor connector D-38.
Connector: D-38
<LH drive vehicles>
AC310458AO
Connector: D-38
<LH drive vehicles>
D-38 (B)
D-38 (B) <RH drive vehicles>
<RH drive vehicles>
D-38 (B)
D-38 (B)
Sensor side
AC311048 AB
Sensor side Disconnect the longitudinal G-sensor connector, and

measure the resistance between terminal No.3 and
AC311048 AB earth.
Check the power supply line for short or open circuit. OK: 2 Ω or less
NO : Repair the wiring harness. NO : Go to Step 8.
22A-57
STEP 8. Connector check: B-118 ABS-ECU Connector: C-122 <RH drive vehicles>
connector, C-124 intermediate connector, D-38
longitudinal G-sensor connector <LH drive
vehicles> or B-118 ABS-ECU connector, C-122
intermediate connector, D-38 longitudinal
G-sensor connector <RH drive vehicles>.
Connector: B-118
C-122 (L)
<LH drive vehicles>
AC311016AE
B-118
(B)
Connector: D-38
<LH drive vehicles>
<RH drive vehicles>

B-118
(GR) D-38 (B)
<RH drive vehicles>
D-38 (B)
B-118
Sensor side
Harness side
AC311020 AB
AC311048 AB
Connector: C-124 <LH drive vehicles> Check for the contact with terminals.
YES : Go to Step 9.
C-124
AC311015AB
STEP 9. Check the harness between ABS-ECU Connector: D-38

connector B-118 terminal No.15 and longitudinal <LH drive vehicles>
G-sensor connector D-38 terminal No.3.
Connector: B-118
<LH drive vehicles>
B-118
(B)
D-38 (B)
<RH drive vehicles>
<RH drive vehicles>

B-118
D-38 (B)
(GR)
Sensor side
AC311048 AB

B-118
Harness side
AC311020 AB STEP 10. Replace the longitudinal G-sensor and
then recheck the diagnosis code.
(1) Replace the longitudinal G-sensor.

Item 14: Longitudinal G-sensor voltage (Refer to data
NO : Refer to GROUP 35B − Inspection Chart for
Diagnosis Code P.35B-9.
22A-59
STEP 12. Measure the voltage at longitudinal (3) Measure the voltage between terminal No.2 and
G-sensor connector D-38. earth.
OK:
Label
V
MB991348 YES : Go to Step 13.
NO : Replace the G-sensor.
Connector: D-38
(Harness side)
Label
AC103662AL
(1) Disconnect the longitudinal G-sensor connector,

and connect special tool harness set (MB991348)
between the disconnected connectors.
STEP 13. Connectors check: B-118 ABS-ECU Connector: C-122 <LH drive vehicles>
connector, C-25 4WD-ECU connector, C-122
G-sensor connector.
Connector: B-118
<LH drive vehicles> C-122
B-118
(B)
AC311015AC
<RH drive vehicles>

B-118
(GR)
C-122 (L)
AC311016AE
Connector: D-38
<LH drive vehicles>
B-118
Harness side
AC311020 AB
D-38 (B)
Connector: C-25
4WD-ECU <RH drive vehicles>
<LH drive vehicles>
C-25 (Y) D-38 (B)

Rear console
assembly
<RH drive vehicles>
Sensor side
AC311048 AB
4WD-ECU
C-25 (Y) Q: Is the check result normal?
Harness side
AC311002AB
22A-61
connector C-25 terminal No.23 and longitudinal NO : Repair the wiring harness.
Connector: C-25
4WD-ECU
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Harness side
AC311002AB
Connector: D-38
<LH drive vehicles>
D-38 (B)
<RH drive vehicles>
D-38 (B)
Sensor side
AC311048 AB
Check the output line for short or open circuit.


Connector: B-118
<LH drive vehicles>
B-118
(B)
D-38 (B)
<RH drive vehicles>
<RH drive vehicles>

B-118
D-38 (B)
(GR)
Sensor side
AC311048 AB
Check the output line for short circuit.

B-118
YES : Go to Step 6.
Harness side
AC311020 AB
Code No.52 Longitudinal G-sensor system (abnormal sensor)
G-SENSOR (LONGITUDINAL) SYSTEM • Damaged harness wires and connectors

CIRCUIT • Malfunction of the ABS-ECU
Refer to P.22A-53.
OPERATION DIAGNOSIS
Refer to P.22A-53.
DIAGNOSIS CODE SET CONDITIONS Item 14: Longitudinal G-sensor voltage (Refer to data
Code No.52 is set when the G-sensor has exceeded list reference table P.22A-142).
the specified value in a state where the ABS and
brake are not operating above the vehicle speed of
10 km/h.
PROBABLE CAUSES
NO : Go to Step 2.
• Malfunction of the longitudinal G-sensor
22A-63
STEP 2. Measure the voltage at longitudinal STEP 3. Measure the voltage at 4WD-ECU
G-sensor connector D-38. connector C-25.
Connector: C-25
Label
4WD-ECU
<LH drive vehicles>
MB991348
C-25 (Y)
Rear console
assembly
Connector: D-38
(Harness side) <RH drive vehicles>
Label
4WD-ECU
C-25 (Y)
AC103662AL Harness side
(1) Disconnect the longitudinal G-sensor connector, AC311002AB
and connect special tool harness set (MB991348) (2) Measure the voltage between 4WD-ECU
between the disconnected connectors. connector C-25 terminal No.23 and earth.
(2) Turn the ignition switch to the ON position. OK: 2.4 − 2.6 V (when the vehicle is in
(3) Measure the voltage between terminal No.2 and horizontal state)
earth.
OK:
YES : Go to Step 4.
When vehicle is stationary (level): 2.4 − 2.6 NO : Go to Step 6.
V
YES : Go to Step 3.

connector. Item 14: Longitudinal G-sensor voltage (Refer to data
Connector: C-25
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Harness side
AC311002AB

YES : Go to Step 5.
22A-65
G-sensor connector.
Connector: B-118
B-118
(B)
AC311015AC
<RH drive vehicles>

B-118
(GR)
C-122 (L)
AC311016AE
Connector: D-38
<LH drive vehicles>
B-118
Harness side
AC311020 AB
D-38 (B)
Connector: C-25
<LH drive vehicles>
C-25 (Y) D-38 (B)

Rear console
assembly
<RH drive vehicles>
Sensor side
AC311048 AB
4WD-ECU
YES : Go to Step 7.
Harness side
AC311002AB

YES : Go to Step 8.
connector C-25 terminal No.23 and longitudinal NO : Repair the wiring harness.
Connector: C-25
4WD-ECU
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Harness side
AC311002AB
Connector: D-38
<LH drive vehicles>
D-38 (B)
<RH drive vehicles>
D-38 (B)
Sensor side
AC311048 AB

22A-67
Connector: B-118
<LH drive vehicles>
B-118
(B)
D-38 (B)
<RH drive vehicles>
<RH drive vehicles>

B-118
D-38 (B)
(GR)
Sensor side
AC311048 AB

B-118
YES : Go to Step 5.
Harness side
AC311020 AB
Code No.56 Lateral G-sensor system (open circuit or short circuit)
G-sensor (lateral) system circuit <LH drive vehicles>

IGNITION
SWITCH (IG2)
G-SENSOR
(LATERAL)
4WD-ECU ABS-ECU
Wire colour code

22A-69
G-sensor (lateral) system circuit <RH drive vehicles>

IGNITION
SWITCH (IG2)
G-SENSOR
(LATERAL)
4WD-ECU ABS-ECU
Wire colour code

OPERATION DIAGNOSIS
The 4WD-ECU receives the acceleration level of the
vehicle in the right/left direction from the lateral G STEP 1. M.U.T.-II/III data list
sensor. Item 15: Lateral G-sensor voltage (Refer to data list
reference table P.22A-142).
Code No.56 is set when the output signal of the lat- Q: Is the check result normal?
eral G sensor is below 0.5 V or above 4.5 V. YES : Intermittent malfunction (Refer to GROUP
• Malfunction of the lateral G-sensor NO : Go to Step 2.
• Malfunction of the ABS-EC
STEP 2. Measure the voltage at lateral G-sensor STEP 3. Connector check: C-211, C-214 J/B
connector D-37. connector, D-37 lateral G-sensor connector.
Connector: D-37 Connector: C-211, C-214 <LH drive vehicles>
<LH drive vehicles> Junction block (front view)
C-211
C-211
C-214
C-214
D-37 (B) AC310448AW

<RH drive vehicles> C-214 <RH drive vehicles> C-211
C-211
C-214
C-214
Sensor side D-37 (B) AC310458AS
Connector: D-37
AC311048 AC
<LH drive vehicles>
(1) Disconnect the lateral G-sensor connector, and
measure the voltage between terminal No.1 and
earth.
OK: System voltage
YES : Go to Step 7. D-37 (B)
NO : Go to Step 3.
<RH drive vehicles>
Sensor side D-37 (B)
AC311048 AC

YES : Go to Step 4.
22A-71
STEP 4. Check the harness between J/B STEP 5. Replace the lateral G-sensor and then
connector C-214 terminal No.26 and lateral recheck the diagnosis code.
G-sensor connector D-37 terminal No.1. (1) Replace the lateral G-sensor.
Connector: C-214 <LH drive vehicles> (2) Test drive the vehicle.
Junction block (front view) Q: Is the diagnosis code set?
YES : Go to Step 6.
Junction block side
C-214
Item 15: Lateral G-sensor voltage (Refer to data list
AC310448AU
Connector: C-214 Junction block (front view) YES : Intermittent malfunction (Refer to GROUP
<RH drive vehicles> 00 − How to Cope with Intermittent
C-214
Junction STEP 7. Measure the resistance at lateral
block side
G-sensor connector D-37.
Connector: D-37
<LH drive vehicles>
AC310458AO
Connector: D-37
<LH drive vehicles>
D-37 (B)
D-37 (B) <RH drive vehicles>
<RH drive vehicles>
AC311048 AC
D-37 (B)
Sensor side Disconnect the lateral G-sensor connector, and
AC311048 AC earth.
Check the power supply line for short or open circuit. OK: 2 Ω or less
NO : Repair the wiring harness. NO : Go to Step 8.
STEP 8. Connector check: B-118 ABS-ECU Connector: D-37

connector, C-122 intermediate connector, D-37 <LH drive vehicles>
lateral G-sensor connector.
Connector: B-118
<LH drive vehicles>
B-118
(B)
D-37 (B)
<RH drive vehicles>
<RH drive vehicles>

B-118
(GR)
AC311048 AC

B-118
YES : Go to Step 9.
Harness side
AC311020 AB
C-122
AC311015AC
C-122 (L)
AC311016AE
22A-73
connector B-118 terminal No.24 and lateral <LH drive vehicles>
Connector: B-118
<LH drive vehicles>
B-118
(B)
D-37 (B)
<RH drive vehicles>
<RH drive vehicles>

B-118
(GR)
AC311048 AC

B-118
Harness side
AC311020 AB STEP 10. Replace the lateral G-sensor and then
recheck the diagnosis code.
(1) Replace the lateral G-sensor.

Item 15: Lateral G-sensor voltage (Refer to data list
NO : Refer to GROUP 35B − Inspection Chart for
Diagnosis Code P.35B-9.
STEP 12. Measure the voltage at lateral G-sensor (3) Measure the voltage between terminal No.2 and
connector D-37. earth.
OK:
Label
V
MB991348 YES : Go to Step 13.
Connector: D-37
(Harness side)
Label
AC103662AM
(1) Disconnect the lateral G-sensor connector, and

connect special tool harness set (MB991348)
22A-75
intermediate connector, D-37 lateral G-sensor
connector.
Connector: B-118
B-118
(B)
AC311015AC
<RH drive vehicles>

B-118
(GR)
C-122 (L)
AC311016AE
Connector: D-37
<LH drive vehicles>
B-118
Harness side
AC311020 AB D-37 (B)
Connector: C-25
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
AC311048 AC
4WD-ECU
Harness side
AC311002AB

connector C-25 terminal No.11 and lateral NO : Repair the wiring harness.
Connector: C-25
4WD-ECU
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Harness side
AC311002AB
Connector: D-37
<LH drive vehicles>
D-37 (B)
<RH drive vehicles>
AC311048 AC

22A-77
Connector: B-118
<LH drive vehicles>
B-118
(B)
D-37 (B)
<RH drive vehicles>
<RH drive vehicles>

B-118
(GR)
AC311048 AC

B-118
YES : Go to Step 6.
Harness side
AC311020 AB
Code No.57 Lateral G-sensor system (abnormal sensor)
G-SENSOR (LATERAL) SYSTEM CIRCUIT • Malfunction of the ABS-ECU

Refer to P.22A-53. • Malfunction of the 4WD-ECU
OPERATION DIAGNOSIS
Refer to P.22A-53.
DIAGNOSIS CODE SET CONDITIONS Item 15: Lateral G-sensor voltage (Refer to data list
Code No.57 is set when the G-sensor has exceeded reference table P.22A-142).
the specified value in a state where the ABS and
brake are not operating above the vehicle speed of Q: Is the check result normal?
10 km/h. YES : Intermittent malfunction (Refer to GROUP
NO : Go to Step 2.
STEP 2. Measure the voltage at lateral G-sensor STEP 3. Measure the voltage at 4WD-ECU
connector D-37. connector C-25.
Connector: D-37
<LH drive vehicles> Connector: C-25
4WD-ECU
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
D-37 (B)
<RH drive vehicles>
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Sensor side D-37 (B) Harness side

AC311002AB
AC311048 AC
(1) Disconnect the lateral G-sensor connector, and connector C-25 terminal No.11 and earth.
connect special tool harness set (MB991348)
OK: 2.4 − 2.6 V (when the vehicle is in
horizontal state)
(3) Measure the voltage between terminal No.2 and Q: Is the check result normal?
earth. YES : Go to Step 4.
NO : Go to Step 6.
OK:
V
YES : Go to Step 3.
22A-79
connector. Item 15: Lateral G-sensor voltage (Refer to data list
Connector: C-25
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Harness side
AC311002AB

YES : Go to Step 5.
intermediate connector, D-37 lateral G-sensor
connector.
Connector: B-118
B-118
(B)
AC311015AC
<RH drive vehicles>

B-118
(GR)
C-122 (L)
AC311016AE
Connector: D-37
<LH drive vehicles>
B-118
Harness side
AC311020 AB D-37 (B)
Connector: C-25
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
AC311048 AC
4WD-ECU
YES : Go to Step 7.
Harness side
AC311002AB
22A-81
YES : Go to Step 8.
connector C-25 terminal No.11 and lateral NO : Repair the wiring harness.
Connector: C-25
4WD-ECU
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Harness side
AC311002AB
Connector: D-37
<LH drive vehicles>
D-37 (B)
<RH drive vehicles>
AC311048 AC


Connector: B-118
<LH drive vehicles>
B-118
(B)
D-37 (B)
<RH drive vehicles>
<RH drive vehicles>

B-118
(GR)
AC311048 AC

B-118
YES : Go to Step 5.
Harness side
AC311020 AB
22A-83
Code No.61 Stop lamp switch system
Stop lamp switch system circuit
BATTERY
RELAY
BOX
STOP LAMP SWITCH

<RH DRIVE VEHICLES>

<RH DRIVE VEHICLES>
4WD-ECU
Wire colour code


The stop lamp switch judges whether the brake • Malfunction of brake pedal
pedal is depressed or released, and sends the infor- • Malfunction of stop lamp switch
mation to the 4WD-ECU. • Damaged harness wires and connectors
Code No.61 is set when the stop lamp switch is ON
for more than 15 minutes when the vehicle speed is
above 15 km/h.
DIAGNOSIS STEP 5. Connector check: C-102 stop lamp

switch connector
STEP 1. Check that the stop lamps illuminate and Connector: C-102
extinguish normally. C-102
The stop lamps should illuminate when the brake
pedal is depressed, and extinguish when released.
2 1
NO : Go to Step 2.
STEP 2. Check the brake pedal height. Brake pedal

AC309520AC
Refer to GROUP 35A − On-vehicle Service, Brake
Pedal Check and Adjustment P.35A-5. Check for the contact with terminals.
NO : Adjust the brake pedal height. NO : Repair the defective connector.
STEP 3. Check the stop lamp switch. STEP 6. Measure the voltage at stop lamp switch
Refer to GROUP 35A − Brake Pedal and Stop Lamp connector C-102.
Switch Continuity Check P.35A-15.
Connector: C-102
YES : Go to Step 4.
NO : Replace the stop lamp switch.
2 1
4 3
STEP 4. M.U.T.-II/III data list Harness side

Item 56: Stop lamp switch (Refer to data list refer-
ence table P.22A-142).
Brake pedal
Q: Is the check result normal? AC309520AC
Disconnect the stop lamp switch connector, and
measure the voltage between terminal No.2 and
earth at the harness side.
NO : Go to Step 5.
OK: System voltage
YES : Go to Step 7.
NO : Go to Step 12.
22A-85
STEP 7. Measure the voltage at 4WD-ECU STEP 8. Connector check: C-26 4WD-ECU
connector C-26. connector
(1) Connect the stop lamp switch connector C-102.
Connector: C-26
<LH drive vehicles>
C-26 (Y)
Rear console
C-26 (Y) assembly
Rear console
<RH drive vehicles>
4WD-ECU
4WD-ECU
C-26 (Y)
C-26 (Y)
Harness side
AC311002AC Check for the contact with terminals.
(2) Measure the voltage between 4WD-ECU Q: Is the check result normal?
connector C-26 terminal No.38 and earth. YES : Go to Step 9.
OK: NO : Repair the defective connector.
Brake pedal depressed: System voltage
Brake pedal not depressed: 1 V or less
Q: Is the check result normal? Item 56: Stop lamp switch (Refer to data list refer-
YES : Go to Step 8. ence table P.22A-142).
NO : Go to Step 10.
connector, C-105 J/C (6), C-124 intermediate
connector.
Connector: C-26
4WD-ECU
C-124
<LH drive vehicles>
AC311015AB
C-26 (Y)
Rear console
<RH drive vehicles>
4WD-ECU
C-124
C-26 (Y)
AC311016AF

AC311002AC
C-105
AC311015AF
C-105
AC311016AC
22A-87
STEP 11. Check the harness between stop lamp STEP 12. Connector check: C-129 intermediate
switch connector C-102 terminal No.1 and connector
4WD-ECU connector C-26 terminal No.38. Connector: C-129 <LH drive vehicles>
Connector: C-102
C-102
2 1
4 3
Harness side C-129
AC311015AH
Brake pedal
AC309520AC
Connector: C-26
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
C-129 AC311016AG
<RH drive vehicles>
4WD-ECU
C-26 (Y)
STEP 13. Check the harness between stop lamp
switch connector C-102 terminal No.2 and
battery.
Connector: C-102
Harness side
C-102
AC311002AC

2 1

Brake pedal
AC309520AC

YES : Go to Step 9.
Code No.62 ACD mode changeover switch system
ACD mode changeover switch system circuit <LH drive vehicles>

IGNITION
SWITCH(IG1)
ACD MODE
CHANGEOVER
SWITCH
4WD-ECU
Wire colour code

22A-89
ACD mode changeover switch system circuit <RH drive vehicles>

IGNITION
SWITCH(IG1)
ACD MODE
CHANGEOVER
SWITCH
4WD-ECU
Wire colour code

OPERATION DIAGNOSIS
The 4WD-ECU receives a control mode (tarmac,
gravel, snow) from the ACD mode changeover STEP 1. M.U.T.-II/III data list
switch. Item 63: ACD mode changeover switch (Refer to
Code No.62 is set when the ACD mode changeover Q: Is the check result normal?
switch is ON for more than 60 seconds. YES : Intermittent malfunction (Refer to GROUP
• Malfunction of the ACD mode changeover switch NO : Go to Step 2.
• Malfunction of the 4WD-ECU STEP 2. Check the ACD mode changeover
switch.
Refer to P.22A-169.
YES : Go to Step 3.
NO : Replace the ACD mode changeover switch.
STEP 3. Measure the voltage at ACD mode STEP 4. Connectors check: C-23 J/C (4), C-135
changeover switch connector C-135. ACD mode changeover switch connector, C-211,
C-214 J/B connector <LH drive vehicles> or
C-135 ACD mode changeover switch connector,
C-210, C-211 J/B connector <RH drive vehicles>.
C-135 Connector: C-23 <LH drive vehicles>
C-23 (B)
AC311015AI

AC311015AK

C-135
C-135
AC311037AD
(1) Disconnect the ACD mode changeover switch

connector, and measure the voltage between
terminal No.2 and earth. AC311015AI
(2) Turn the ignition switch to the ON position. Connector: C-135 <RH drive vehicles>
OK: System voltage
YES : Go to Step 7. C-135
NO : Go to Step 4.
AC311037AD
Connector: C-211, C-214 <LH drive vehicles>

C-211
C-211
C-214
C-214
AC310448AW
22A-91
Connector: C-210, Junction block (front view) STEP 6. M.U.T.-II/III data list
C-211 <RH drive vehicles> C-211 Item 63: ACD mode changeover switch (Refer to
C-211 data list reference table P.22A-142).
C-210
C-210 Malfunction P.00-5).
AC310458AT
Check for the contact with terminals. connector C-26.
Q: Is the check result normal? (1) Turn the ignition switch to the ON position.
YES : Go to Step 5.
Connector: C-26
4WD-ECU
<LH drive vehicles>
STEP 5. Check the harness between ACD mode
changeover switch connector C-135 terminal
No.2 and ignition switch.
C-26 (Y)
Connector: C-135 <LH drive vehicles> Rear console
assembly
<RH drive vehicles>
C-135
4WD-ECU
C-26 (Y)
AC311015AI
Harness side
AC311002AC
C-135
OK: System voltage
AC311037AD YES : Go to Step 10.
Check the power supply line for short or open circuit. NO : Go to Step 8.

YES : Go to Step 6.
ACD mode changeover switch connector <LH
drive vehicles> or C-26 4WD-ECU connector, C-135
C-138 intermediate connector, C-135 ACD mode
changeover switch connector <RH drive
vehicles>.
Connector: C-26
4WD-ECU AC311015AI
<LH drive vehicles>
C-26 (Y)
Rear console
assembly C-135
<RH drive vehicles>
AC311037AD
4WD-ECU
C-26 (Y)
YES : Go to Step 9.
Harness side
AC311002AC
C-122
AC311015AC
C-138
AC311016AB
22A-93
STEP 9. Check the harness between 4WD-ECU STEP 10. Connector check: C-26 4WD-ECU
connector C-26 terminal No.47 and ACD mode connector.
changeover switch connector C-135 terminal
Connector: C-26
No.1.
4WD-ECU
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
C-26 (Y)
Rear console <RH drive vehicles>
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
4WD-ECU
C-26 (Y)
Harness side
AC311002AC
Harness side
AC311002AC
Connector: C-135 <LH drive vehicles> YES : Go to Step 6.
C-135
AC311015AI
C-135
AC311037AD

YES : Go to Step 6.
Code No.63 Parking brake switch system
Parking brake switch system circuit <LH drive vehicles>
ABS-ECU
4WD-ECU PARKING BRAKE SWITCH
Wire colour code

Parking brake switch system circuit <RH drive vehicles>
ABS-ECU
4WD-ECU PARKING BRAKE SWITCH
Wire colour code

22A-95
OPERATION connector C-26 terminal No.37 and earth.
The 4WD-ECU receives a signal from the parking OK:
brake switch whether the parking brake lever is Release the parking brake lever: System
pulled or released. voltage
Pull the parking brake lever: 1 V or less
Code No.63 is set when the parking brake switch is YES : Go to Step 3.
ON for more than 15 minutes with the vehicle speed NO : Go to Step 5.
above 15 km/h.
PROBABLE CAUSES STEP 3. Connector check: C-26 4WD-ECU

• Malfunction of parking brake switch connector.
• Damaged harness wires and connectors Connector: C-26
• Malfunction of the ABS-ECU 4WD-ECU
<LH drive vehicles>
DIAGNOSIS
C-26 (Y)
STEP 1. M.U.T.-II/III data list Rear console
assembly
Item 62: Parking brake switch (Refer to data list ref-
erence table P.22A-142). <RH drive vehicles>

NO : Go to Step 2.
C-26 (Y)

connector C-26.
Harness side
Connector: C-26
AC311002AC
4WD-ECU
<LH drive vehicles>
YES : Go to Step 4.
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
Item 62: Parking brake switch (Refer to data list ref-
erence table P.22A-142).
4WD-ECU 00 − How to Cope with Intermittent
C-26 (Y) NO : Replace the 4WD-ECU.
Harness side
AC311002AC

STEP 5. Connectors check: B-118 ABS-ECU Connector: C-26

connector, C-23 J/C (4), C-26 4WD-ECU 4WD-ECU
connector, C-124 intermediate connector, D-28 <LH drive vehicles>
parking brake switch connector <LH drive
vehicles> or B-118 ABS-ECU connector, C-26
connector, D-28 parking brake switch connector C-26 (Y)
Rear console
<RH drive vehicles>. assembly
Connector: B-118 <RH drive vehicles>
<LH drive vehicles>
B-118
(B)
4WD-ECU
C-26 (Y)
<RH drive vehicles> Harness side

AC311002AC
B-118
(GR)
C-124
B-118
AC311015AB

Harness side
AC311020 AB
C-122 (L)
C-23 (B)
AC311016AE
AC311015AK
22A-97
Connector: D-28 STEP 6. Check the harness between 4WD-ECU
<LH drive vehicles> connector C-26 terminal No.37 and parking brake
switch connector D-28 terminal No.1.
Connector: C-26
D-28 (B) 4WD-ECU

<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles> <RH drive vehicles>
D-28 (B)
4WD-ECU
C-26 (Y)
Switch side
AC311048 AD
Harness side
Check for the contact with terminals. AC311002AC
YES : Go to Step 6. Connector: D-28
<LH drive vehicles>
D-28 (B)
<RH drive vehicles>
D-28 (B)
Switch side
AC311048 AD

YES : Go to Step 7.

connector B-118 terminal No.1 and parking brake <LH drive vehicles>
switch connector D-28 terminal No.1.
Connector: B-118
<LH drive vehicles>
D-28 (B)
B-118
(B)
<RH drive vehicles>
<RH drive vehicles>

B-118 D-28 (B)
(GR)
Switch side
AC311048 AD

B-118
YES : Go to Step 4.
Harness side
AC311020 AB
22A-99
Code No.65 ABS monitor system
ABS monitor system circuit
ABS-ECU
4WD-ECU
Wire colour code

OPERATION DIAGNOSIS
The 4WD-ECU receives ABS operation condition
from the ABS-ECU. STEP 1. M.U.T.-II/III data list
Item 61: ABS monitor
Code No.65 is set when ABS is detected to be oper- OK:
ating for more than 1 minute continuously. 1. Disconnect ABS-ECU connector B-118:
ON
PROBABLE CAUSES 2. Connect ABS-ECU connector B-118: OFF
• Damaged harness wires and connectors Q: Is the check result normal?
• Malfunction of the ABS-ECU YES : Intermittent malfunction (Refer to GROUP
• Malfunction of the 4WD-ECU 00 − How to Cope with Intermittent
NO <When 1. is abnormal> : Go to Step 2.
NO <When 2. is abnormal> : Go to Step 4.

STEP 2. Connectors check: B-118 ABS-ECU
YES : Go to Step 3.
connector, C-26 4WD-ECU connector. NO : Repair the defective connector.
Connector: B-118
<LH drive vehicles>
B-118
(B)
<RH drive vehicles>

B-118
(GR)
B-118
Harness side
AC311020 AB
Connector: C-26
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

22A-101
STEP 3. Check the harness between ABS-ECU
YES : Replace the ABS-ECU.
connector B-118 terminal No.3 and 4WD-ECU NO : Repair the wiring harness.
connector C-26 terminal No.48.
Connector: B-118
<LH drive vehicles> connector C-26.
B-118
(B)
Connector: C-26
4WD-ECU
<LH drive vehicles>
<RH drive vehicles> C-26 (Y)

Rear console
B-118 assembly
(GR) <RH drive vehicles>
4WD-ECU
C-26 (Y)
B-118
Harness side
AC311020 AB
Connector: C-26 OK: System voltage
<LH drive vehicles> YES : Go to Step 5.
NO : Go to Step 7.
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

STEP 5. Connector check: C-26 4WD-ECU STEP 7. Connectors check: B-118 ABS-ECU
connector. connector, C-26 4WD-ECU connector.
<LH drive vehicles>
B-118
(B)
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
<RH drive vehicles>

B-118
4WD-ECU (GR)
C-26 (Y)
Harness side
AC311002AC
B-118
YES : Go to Step 6.
NO : Repair the defective connector. Harness side
AC311020 AB
STEP 6. M.U.T.-II/III data list Connector: C-26

Item 61: ABS monitor
4WD-ECU
OK:
<LH drive vehicles>
Connect ABS-ECU connector B-118: OFF
C-26 (Y)
00 − How to Cope with Intermittent Rear console
Malfunction P.00-5). assembly
NO : Replace the 4WD-ECU. <RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

22A-103
Connector: C-26
YES : Go to Step 8.
NO : Repair the defective connector. 4WD-ECU
<LH drive vehicles>
STEP 8. Check the harness between ABS-ECU

connector B-118 terminal No.3 and 4WD-ECU
connector C-26 terminal No.48. C-26 (Y)
Rear console
Connector: B-118 assembly
<LH drive vehicles> <RH drive vehicles>
B-118
(B)
4WD-ECU
C-26 (Y)
<RH drive vehicles>

B-118 Harness side
(GR) AC311002AC

YES : Go to Step 9.
B-118
Harness side
AC311020 AB

STEP 9. Measure the voltage at ABS-ECU
connector B-118. NO : Replace the ABS-ECU.
(2) Execute ABS actuator test (item 05: ABS signal).
Connector: B-118
<LH drive vehicles>
B-118
(B)
<RH drive vehicles>

B-118
(GR)
B-118
Harness side
AC311020 AB
(3) Measure the voltage between ABS-ECU

connector B-118 terminal No.3 and earth.
OK: The voltage remains 1 V or less dur-
ing the actuator test (for 10 seconds) and
becomes system voltage.
22A-105
Code No.74 Proportional valve system <ACD>
Proportioning valve <ACD> system circuit
4WD-ECU

<RH DRIVE VEHICLES>
PROPORTIONING VALVE
(FOR ACD CONTROL)
Wire colour code

OPERATION • Malfunction of the 4WD-ECU

The proportional valve (ACD) controls the hydraulic
pressure to activate the ACD hydraulic multi plate DIAGNOSIS
clutch according to signal from the 4WD-ECU.
DIAGNOSIS CODE SET CONDITIONS Item 11: Proportional valve current <ACD> (Refer to
Code No.74 is set when open circuit or short circuit data list reference table P.22A-142).
of the control circuit of the proportional valve has
occurred. Q: Is the check result normal?
PROBABLE CAUSES 00 − How to Cope with Intermittent
• Malfunction of proportional valve Malfunction P.00-5).
NO : Go to Step 2.
STEP 2. Measure the resistance at proportional STEP 4. Connectors check: F-21 intermediate
valve connector F-24. connector, F-24 proportional valve connector.
Connector: F-24 Connector: F-21, F-24
F-21
F-24 F-24
F-24 (B) Valve side F-24 (B) Valve side

F-21 (B)
AC311042AD AC311042AE
Disconnect the proportional valve connector, and Check for the contact with terminals.
measure the resistance between terminal No.2 and Q: Is the check result normal?
No.3. YES : Go to Step 5.
OK: 4.7 Ω or less NO : Repair the defective connector.
YES : Go to Step 3. STEP 5. Check the harness between proportional
NO : Replace the hydraulic unit. valve connector F-24 terminal No.2 and earth.
Connector: F-24
STEP 3. Measure the resistance at proportional
valve connector F-24.
Connector: F-24
F-24
F-24 (B) Valve side

F-24
AC311042AD

F-24 (B) Valve side
AC311042AD
YES : Go to Step 6.
Disconnect the proportional valve connector, and NO : Repair the wiring harness.
earth.
OK: 2 Ω or less Item 11: Proportional valve current <ACD> (Refer to
Q: Is the check result normal? data list reference table P.22A-142).
YES : Go to Step 7. Q: Is the check result normal?
NO : Go to Step 4. YES : Intermittent malfunction (Refer to GROUP
22A-107
connector, F-24 proportional valve connector
<LH drive vehicles> or C-25 4WD-ECU connector,
C-134, C-138, F-21 intermediate connector, F-24
proportional valve connector <RH drive
vehicles>.
Connector: C-25
4WD-ECU C-134 (GR) AC311016AD
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
C-138
AC311016AB
4WD-ECU
C-25 (Y) Connector: F-21, F-24
F-21
Harness side
F-24
AC311002AB
Connector: C-124 <LH drive vehicles> F-24 (B) Valve side

F-21 (B)
AC311042AE

YES : Go to Step 8.
C-124
AC311015AB
C-134 (B)
AC311015AG

YES : Go to Step 6.
connector C-25 terminal No.1 and proportional NO : Repair the wiring harness.
valve connector F-24 terminal No.3.
Connector: C-25
4WD-ECU
<LH drive vehicles>
C-25 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
Harness side
AC311002AB
Connector: F-24
F-24
F-24 (B) Valve side

AC311042AD

22A-109
Code No.81 Electric pump relay system (open circuit or short circuit)
Electric pump relay system circuit <LH drive vehicles>
4WD-ECU
FUSIBLE
LINK 27
ELECTRIC
PUMP RELAY
ELECTRIC
PUMP
Wire colour code

Electric pump relay system circuit <RH drive vehicles>
4WD-ECU
FUSIBLE
LINK 27
ELECTRIC
PUMP RELAY
ELECTRIC
PUMP
Wire colour code

OPERATION DIAGNOSIS
The electric pump relay provides power to activate
the electric pump according to the signal from the STEP 1. M.U.T.-II/III actuator test
4WD-ECU. Item 04: Electric pump drive
DIAGNOSIS CODE SET CONDITIONS OK: Operating sound can be heard.
Code No.81 is set when the coil circuit of the electric Q: Is the check result normal?
pump relay has open circuit or short circuit. YES : Intermittent malfunction (Refer to GROUP
• Malfunction of electric pump relay NO : Go to Step 2.
• Malfunction of the 4WD-ECU STEP 2. Check the electric pump relay.
Refer to P.22A-169.
YES : Go to Step 3.
NO : Replace the electric pump relay.
22A-111
STEP 3. Measure the resistance at electric pump STEP 4. Connector check: B-122 electric pump
relay connector B-122. relay connector.
<LH drive vehicles> <LH drive vehicles>
B-122 B-122
<RH drive vehicles> B-122 <RH drive vehicles> B-122
B-122 B-122
Relay side Relay side
AC311020 AD AC311020 AD
Disconnect the electric pump relay connector, and Check for the contact with terminals.
measure the resistance between terminal No.1 and Q: Is the check result normal?
earth. YES : Go to Step 5.
OK: 2 Ω or less NO : Repair the defective connector.
YES : Go to Step 7.
NO : Go to Step 4.
STEP 5. Check the harness between electric STEP 7. Connectors check: B-122 electric pump
pump relay connector B-122 terminal No.1 and relay connector, C-25 4WD-ECU connector.
earth.
Connector: B-122
Connector: B-122 <LH drive vehicles>
B-122
<LH drive vehicles>
B-122
<RH drive vehicles> B-122

B-122
B-122
Relay side
Relay side
AC311020 AD
AC311020 AD
Connector: C-25
4WD-ECU
Q: Is the check result normal? <LH drive vehicles>
YES : Go to Step 6.
C-25 (Y)
STEP 6. M.U.T.-II/III actuator test Rear console
Item 04: Electric pump drive assembly
OK: Operating sound can be heard. <RH drive vehicles>

C-25 (Y)
Harness side
AC311002AB

22A-113
Connector: C-25
YES : Go to Step 8.
NO : Repair the defective connector. 4WD-ECU
<LH drive vehicles>
STEP 8. Check the harness between electric

pump relay connector B-122 terminal No.2 and
4WD-ECU connector C-25 terminal No.16. C-25 (Y)
Rear console
Connector: B-122 assembly
<LH drive vehicles> <RH drive vehicles>
B-122
4WD-ECU
C-25 (Y)

Harness side
AC311002AB

YES : Go to Step 6.
B-122
Relay side
AC311020 AD
Code No.82 Electric pump relay system (electric pump malfunction or pressure sensor defect)
ELECTRIC PUMP RELAY SYSTEM PROBABLE CAUSES

CIRCUIT • Insufficient fluid
Refer to P.22A-109. • Malfunction of the pressure sensor
• Malfunction of the electric pump relay
OPERATION • Malfunction of the hydraulic unit
Refer to P.22A-109. • Damaged harness wires and connectors
Code No.82 is set when the pressure sensor does
not reach the specified value even if the 4WD-ECU
has output the electric pump motor drive command.
DIAGNOSIS STEP 6. Measure the voltage at electric pump

relay connector B-122.
STEP 1. Check the fluid. Connector: B-122
Check that the right amount of fluid is in the reservoir <LH drive vehicles>
tank. B-122

YES : Go to Step 3.
NO : Go to Step 2.
STEP 2. Check the fluid leaks.

Check that the fluid is not leaking.
YES : Add the fluid. <RH drive vehicles> B-122
NO : Repair the leaking part and add the fluid.

Q: Are diagnosis codes 45, 46, 47 set?
YES <diagnosis code 45 is set> : Refer to
diagnosis code 45: Pressure sensor system
(open circuit or short circuit) P.22A-41.
diagnosis code 46: Pressure sensor system B-122
(open earth) P.22A-46.
diagnosis code 47: Pressure sensor system Relay side
(abnormal power supply) P.22A-49.
NO : Go to Step 4.
AC311020 AD
Disconnect the electric pump relay connector, and

STEP 4. M.U.T.-II/III diagnosis code measure the voltage between terminal No.4 and
Q: Are diagnosis code 81 set? earth at the harness side.
YES : Refer to diagnosis code 81: Electric pump OK: System voltage
relay system P.22A-109.
NO : Go to Step 5. Q: Is the check result normal?
NO : Go to Step 7.
Item 04: Electric pump drive
OK: Operating sound can be heard.
NO : Go to Step 6.
22A-115
STEP 7. Connector check: B-122 electric pump STEP 8. Check the harness between electric
relay connector pump relay connector B-122 terminal No.4 and
fusible link No.27.
Connector: B-122
<LH drive vehicles> Connector: B-122
B-122
<LH drive vehicles>
B-122

B-122
B-122
Relay side
Relay side
AC311020 AD
Check for the contact with terminals. AC311020 AD

NO : Repair the defective connector. YES : Go to Step 9.

Item 04: Electric pump drive
OK: Operating sound can be heard.
STEP 10. Connectors check: B-122 electric pump Connector: C-30 <RH drive vehicles>
relay connector, C-28, C-138 intermediate
connector, F-20 electric pump connector <LH
drive vehicles> or B-122 electric pump relay
connector, C-30 intermediate connector, F-20
electric pump connector <RH drive vehicles>.
Connector: B-122
B-122 C-30 (GR)
AC311016AH
Connector: F-20
F-20 (B)
F-20

Pump side
AC311042AF

B-122
Relay side
AC311020 AD
C-28 C-28
C-138
C-138 AC311015AL
22A-117
STEP 11. Check the harness between electric
YES : Go to Step 9.
pump relay connector B-122 terminal No.3 and NO : Repair the wiring harness.
earth.
Connector: B-122
<LH drive vehicles>
B-122
B-122
Relay side
AC311020 AD

SYMPTOM CHART
M1221007100593
Trouble symptom Inspection Reference page

procedure No.
No communication possible between M.U.T.-II/III and all systems 1 P.22A-119
No communication possible between M.U.T.-II/III and 4WD-ECU 2 P.22A-124
ACD mode indicator lamp does not light up when the ignition 3 P.22A-132
switch is set to "ON" (engine is stopped)
More than two ACD mode indicator lamps remain lit even after the 4 P.22A-138
engine is started
The ACD does not operate (no diagnostic code) 5 P.22A-141
The AYC does not operate (no diagnostic code) 6 Refer to GROUP 27
− Symptom Chart
P.27-23.
The rear tyre sounds when turning at low speed corners (vehicle 7 Refer to GROUP 27
slows down) − Symptom Chart
P.27-23.
Noise is produced from the torque transfer differential during 8 Refer to GROUP 27
turning − Symptom Chart
P.27-23.
22A-119
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: No communication possible between M.U.T.-II/III and all systems
Diagnosis connector circuit <LH drive vehicles>

IGNITION FUSIBLE
SWITCH (IG2) LINK 1
4WD-ECU
POWER
SOURCE
Wire colour code

G : Green L : Blue
DIAGNOSIS
CONNECTOR
Diagnosis connector circuit <RH drive vehicles>

IGNITION FUSIBLE
SWITCH (IG2) LINK 1
4WD-ECU
POWER
SOURCE
Wire colour code

G : Green L : Blue
DIAGNOSIS
CONNECTOR

The M.U.T.-II/III is energised by connecting the diag- • Malfunction of diagnosis connector
nosis connector. • Damaged harness wires and connectors
The diagnosis connector power supply circuit, earth
circuit, or M.U.T.-II/III may be faulty.
22A-121
DIAGNOSIS STEP 2. Connectors check: C-14 diagnosis
connector, C-126 intermediate connector, C-212,
STEP 1. Measure the voltage at diagnosis C-214 J/B connector.
connector C-14. Connector: C-14 <LH drive vehicles>
C-14 C-14 (B)

C-14 C-14 (B)
AC311015AM
AC311015AM
C-14
C-14
C-14 (B)
C-14 (B) AC311037AE
AC311037AE
Measure the voltage between diagnosis connector
C-14 terminal No.16 and earth.
OK: System voltage
YES : Go to Step 4.
NO : Go to Step 2.
C-126
AC311015AN
C-126
C-126
AC311016AI
Connector: C-212, C-214 <LH drive vehicles> STEP 3. Check the harness between diagnosis
connector C-14 terminal No.16 and fusible link
No.1.
C-212 (B)
C-212 Connector: C-14 <LH drive vehicles>
C-214
C-214
AC310448AV
C-14 C-14 (B)

C-214 <RH drive vehicles>
C-212 (B)
C-212 AC311015AM

C-214
C-214
C-14
AC310458AR

C-14 (B)
YES : Go to Step 3. AC311037AE
NO : Repair the defective connector. Check the power supply line for short or open circuit.
22A-123
STEP 4. Measure the resistance at diagnosis STEP 5. Connector check: C-14 diagnosis
connector C-14. connector.
Connector: C-14 <LH drive vehicles> Connector: C-14 <LH drive vehicles>
C-14 C-14 (B) C-14 C-14 (B)
AC311015AM AC311015AM
Connector: C-14 <RH drive vehicles> Connector: C-14 <RH drive vehicles>
C-14 C-14
C-14 (B) C-14 (B)

AC311037AE AC311037AE
Measure the resistance between terminal No.4, No.5 Check for the contact with terminals.
and earth. Q: Is the check result normal?
OK: 2 Ω or less YES : Go to Step 6.
Q: Is the check result normal? NO : Repair the defective connector.
YES : Replace the M.U.T.-II/III.
NO : Go to Step 5.
STEP 6. Check the harness between diagnosis

connector C-14 terminal No.4, No.5 and earth.
C-14 C-14 (B)
AC311015AM
C-14
C-14 (B)
AC311037AE

INSPECTION PROCEDURE 2: No Communication possible between M.U.T.-II/III and 4WD-ECU
DIAGNOSIS CONNECTOR CIRCUIT COMMENTS ON TROUBLE SYMPTOM

Refer to P.22A-119. The diagnostic output circuit, 4WD-ECU power sup-
ply circuit, earth circuit, or 4WD-ECU may be faulty.
OPERATION
The M.U.T.-II/III will be able to communicate with the PROBABLE CAUSES
4WD-ECU by connecting the diagnosis connector. • Damaged harness wires and connectors
22A-125
DIAGNOSIS Connector: C-26
4WD-ECU
STEP 1. Measure the harness resistance between <LH drive vehicles>
diagnosis connector C-14 and 4WD-ECU
connector C-26.
•
Connector: C-14 <LH drive vehicles> C-26 (Y)

Rear console
assembly
<RH drive vehicles>
C-14 C-14 (B)

4WD-ECU
AC311015AM C-26 (Y)
Harness side
AC311002AC
C-14
Measure the resistance between connector C-14 ter-
minal No.1 and connector C-26 terminal No.46.
• Measure the resistance between connector C-14
C-14 (B) terminal No.7 and connector C-26 terminal
AC311037AE No.35.
OK: 2 Ω or less
YES : Go to Step 4.
NO : Go to Step 2.
STEP 2. Connectors check: C-14 diagnosis Connector: C-21, C-105, C-122, C-124
connector, C-23 J/C (4), C-26 4WD-ECU <RH drive vehicles>
connector, C-101 J/C (2), C-105 J/C (6), C-124 C-21
intermediate connector <LH drive vehicles> or
C-14 diagnosis connector, C-21 J/C (5), C-23 J/C
(4), C-26 4WD-ECU connector, C-105 J/C (6), C-124
C-122, C-124 intermediate connector <RH drive
vehicles>.
C-105
Connector: C-14, C-23, C-101, C-105, C-124 C-122 (L)
<LH drive vehicles>
C-101 (L)
C-21 C-105
C-105
C-23 (B) C-122
C-124
C-14 (B)
C-124
C-14 C-23, C-101
AC311089AB
Connector: C-26
C-105 C-124
4WD-ECU
<LH drive vehicles>
AC311087AB
C-26 (Y)
Rear console
Connector: C-14, 23 <RH drive vehicles> assembly
<RH drive vehicles>
C-23 (B)
4WD-ECU
C-26 (Y)
C-14 (B)
C-14 C-23 Harness side

AC311002AC
AC311088 AB
YES : Go to Step 3.
22A-127
STEP 3. Check the harness between diagnosis STEP 4. Measure the voltage at 4WD-ECU
connector C-14 (terminal No.1, 7) and 4WD-ECU connector C-25.
connector C-26 (terminal No.46, 35). (1) Turn the ignition switch to the ON position.
Connector: C-14 <LH drive vehicles> Connector: C-25
4WD-ECU
<LH drive vehicles>
C-25 (Y)
Rear console
C-14 C-14 (B) assembly
<RH drive vehicles>
AC311015AM
4WD-ECU
C-25 (Y)
C-14
C-14 (B)
Harness side
AC311037AE
AC311002AB
Connector: C-26 (2) Measure the voltage between 4WD-ECU

4WD-ECU connector C-25 terminal No.13 and earth.
<LH drive vehicles> OK: System voltage
YES : Go to Step 7.
C-26 (Y) NO : Go to Step 5.
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

STEP 5. Connectors check: C-25 4WD-ECU Connector: C-210, C-211 <LH drive vehicles>
connector, C-124 intermediate connector, C-210, Junction block (front view)
C-211 J/B connector <LH drive vehicles> or C-25 C-211
connector, C-211, C-214 J/B connector <RH drive C-210
vehicles>.
C-210
Connector: C-25
C-211
4WD-ECU
<LH drive vehicles> AC310448AX

C-214 <RH drive vehicles> C-211
C-25 (Y)
Rear console C-211
assembly
C-214
4WD-ECU AC310458AS
C-25 (Y) Check for the contact with terminals.
YES : Go to Step 6.
Harness side
AC311002AB
C-124
AC311015AB
C-138
AC311016AB
22A-129
STEP 6. Check the harness between 4WD-ECU STEP 7. Measure the resistance at 4WD-ECU
connector C-25 terminal No.13 and ignition connectors C-25, C-26.
switch.
•

<LH drive vehicles>
C-25 (Y) C-26 (Y)

C-25 (Y) Rear console
Rear console
assembly
<RH drive vehicles>
4WD-ECU
4WD-ECU C-25 (Y)
C-26 (Y)
C-25 (Y)
C-25 C-26

Harness side AC311002AD
AC311002AB Measure the resistance between 4WD-ECU connec-
Check the power supply line for short or open circuit. tor C-25 terminal No.26 and earth.
• Measure the resistance between 4WD-ECU con-
YES : Intermittent malfunction (Refer to GROUP nector C-26 terminal No.42 and earth.
00 − How to Cope with Intermittent OK: 2 Ω or less
Malfunction P.00-5). Q: Is the check result normal?
NO : Repair the wiring harness. YES : Go to Step 10.
NO : Go to Step 8.
STEP 8. Connectors check: C-25, C-26 4WD-ECU STEP 9. Check the harness between 4WD-ECU
connector. connector C-25 terminal No.26, C-26 terminal
No.42 and earth.
4WD-ECU Connector: C-25, C-26
<LH drive vehicles> 4WD-ECU
<LH drive vehicles>
C-25 (Y) C-26 (Y)

Rear console C-25 (Y) C-26 (Y)
assembly Rear console
<RH drive vehicles> assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y) 4WD-ECU
C-26 (Y)
C-25 (Y)
C-26 (Y)
C-25 C-26
C-25 C-26

AC311002AD
Check for the contact with terminals. AC311002AD

NO : Repair the defective connector. YES : Intermittent malfunction (Refer to GROUP
22A-131
STEP 10. Connectors check: C-25, C-26
YES : Repair the 4WD-ECU.
4WD-ECU connector. NO : Repair the defective connector.
4WD-ECU
<LH drive vehicles>
C-25 (Y) C-26 (Y)

Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-25 (Y)
C-26 (Y)
C-25 C-26

AC311002AD

INSPECTION PROCEDURE 3: ACD mode indicator lamp does not light up when the ignition switch is
set to "ON" (engine is stopped)
ACD mode indicator lamp system circuit <LH drive vehicles>

IGNITION
SWITCH (IG1)
COMBINATION
METER
DRIVE CIRCUIT
Wire colour code

B : Black LG : Light green 4WD-ECU
G : Green L : Blue
22A-133
ACD mode indicator lamp system circuit <RH drive vehicles>

IGNITION
SWITCH (IG1)
COMBINATION
METER
DRIVE CIRCUIT
Wire colour code 4WD-ECU

G : Green L : Blue

The 4WD-ECU displays a control mode (tarmac, • Damaged harness wires and connectors
gravel, snow) on the ACD mode indicator lamp on • Malfunction of the ACD mode indicator lamp
the combination meter. assembly
The ACD mode indicator lamp circuit or 4WD-ECU
may be faulty.
DIAGNOSIS STEP 2. Connectors check: C-01 combination

meter connector, C-23 J/C (4), C-211, C-214 J/B
STEP 1. Measure the voltage at combination connector <LH drive vehicles> or C-01
meter connector C-01. combination meter connector, C-211, C-214 J/B
connector <RH drive vehicles>.
C-01
C-01
C-01
C-01
AC311015AO
AC311015AO
C-01
C-01
C-01
C-01
AC311037AG
AC311037AG
(1) Disconnect the combination meter connector,
and measure the voltage between terminal No.9 Connector: C-23 <LH drive vehicles>
and earth.
OK: System voltage
YES : Go to Step 4. C-23 (B)
NO : Go to Step 2.
AC311015AK

C-211
C-211
C-214
C-214
AC310448AW
22A-135
Connector: C-211, Junction block (front view) STEP 4. Check the ACD mode indicator lamp
C-214 <RH drive vehicles> C-211 illumination.
C-211
Connector: C-26
C-214 4WD-ECU
<LH drive vehicles>
C-214
C-26 (Y)
Rear console
AC310458AS
assembly
Check for the contact with terminals. <RH drive vehicles>
YES : Go to Step 3.
4WD-ECU
STEP 3. Check the harness between combination
meter connector C-01 terminal No.9 and ignition C-26 (Y)
switch.
Harness side
AC311002AC
C-01 (1) Disconnect the 4WD-ECU connector C-26, and

check the harness side.
C-01 (3) Connect terminal No.40,51,52 to body earth.
AC311015AO OK: The indicator lamp illuminates.
YES : Go to Step 7.
C-01 NO : Go to Step 5.
C-01
AC311037AG

STEP 5. Connectors check: C-01 combination Connector: C-122 <LH drive vehicles>
meter connector, C-26 4WD-ECU connector,
C-122 intermediate connector <LH drive
vehicles> or C-01 combination meter connector,
C-26 4WD-ECU connector, C-138 intermediate
C-122
AC311015AC

C-01
C-01
AC311015AO

C-01 C-138
AC311016AB

YES : Go to Step 6.
C-01 NO : Repair the defective connector.
AC311037AG
Connector: C-26
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC
22A-137
STEP 6. Check the harness between combination STEP 7. Connector check: C-26 4WD-ECU
meter connector C-01 (terminal No.10, 14, 15) and connector.
4WD-ECU connector C-26 (terminal No.40, 52,
Connector: C-26
51).
4WD-ECU
<LH drive vehicles>
C-26 (Y)
Rear console
C-01 assembly
<RH drive vehicles>
C-01
AC311015AO

4WD-ECU
C-01
C-26 (Y)
Harness side
C-01
AC311002AC
AC311037AG
Connector: C-26 YES : Replace the 4WD-ECU.
4WD-ECU NO : Repair the defective connector.
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

YES : Replace the ACD mode indicator lamp
assembly.
INSPECTION PROCEDURE 4: More than two ACD mode indicator lamps remain lit even after the
engine is started
ACD MODE INDICATOR LAMP SYSTEM DIAGNOSIS

CIRCUIT
Refer to P.22A-132. STEP 1. Check the ACD mode indicator lamp
illumination.
OPERATION
Refer to P.22A-132. Connector: C-26
4WD-ECU
COMMENTS ON TROUBLE SYMPTOM <LH drive vehicles>
The output circuit of the ACD mode indicator lamp
may be faulty.
PROBABLE CAUSES C-26 (Y)

Rear console
• Damaged harness wires and connectors assembly
• Malfunction of the ACD mode indicator lamp <RH drive vehicles>
assembly
4WD-ECU
C-26 (Y)
Harness side
AC311002AC
(1) Disconnect the 4WD-ECU connector C-26.

(3) Check that the ACD mode indicator lamp does
not illuminate.
OK: The indicator lamp does not illumi-
nate.
NO : Go to Step 2.
22A-139
STEP 2. Connectors check: C-01 combination Connector: C-122 <LH drive vehicles>
meter connector, C-26 4WD-ECU connector,
C-122 intermediate connector <LH drive
vehicles> or C-01 combination meter connector,
C-26 4WD-ECU connector, C-138 intermediate
C-122
AC311015AC

C-01
C-01
AC311015AO

C-01 C-138
AC311016AB

YES : Go to Step 3.
C-01 NO : Repair the defective connector.
AC311037AG
STEP 3. Check the harness between combination
Connector: C-26 meter connector C-01 (terminal No.10, 14, 15) and
4WD-ECU connector C-26 (terminal No.40, 52,
4WD-ECU
51).
<LH drive vehicles>
C-26 (Y)
Rear console
assembly
C-01
AC311015AO
4WD-ECU
C-26 (Y)
C-01
Harness side
AC311002AC
C-01
AC311037AG

Connector: C-26
YES : Replace the ACD mode indicator lamp
4WD-ECU assembly.
<LH drive vehicles> NO : Repair the wiring harness.
C-26 (Y)
Rear console
assembly
<RH drive vehicles>
4WD-ECU
C-26 (Y)
Harness side
AC311002AC

22A-141
INSPECTION PROCEDURE 5: The ACD does not operate (no diagnosis code)
COMMENTS ON TROUBLE SYMPTOM STEP 4. Check the fluid leaks.

Insufficient operating oil, oil leakage, faulty opera- Check that the fluid is not leaking.
tions of the oil pressure unit, and faulty operations of
the ACD transfer may be suspected.
YES : Add the fluid.
NO : Repair the leaking part and add the fluid.
PROBABLE CAUSES
• Leakage of transfer oil
• Insufficient transfer oil STEP 5. Check the ACD operation.
• Leakage of oil pressure line Refer to P.22A-153.
• Insufficient fluid Q: Is the check result normal?
• Malfunction of the hydraulic unit YES : The inspection is complete.
• Malfunction of the ACD transfer NO : Go to Step 6.
DIAGNOSIS
STEP 6. Check the fluid pressure.
Refer to P.22A-154.
STEP 1. Check the transfer oil. Q: Is the check result normal?
Refer to P.22A-152. YES : Go to Step 7.
Q: Is the check result normal? NO : Go to Step 8.
YES : Go to Step 3.
NO : Go to Step 2.
STEP 7. Check the hydraulic pressure line.
Check that the hydraulic pressure line is not contam-
STEP 2. Check the transfer oil leaks. inated with foreign materials.
Check that the transfer oil is not leaking. Q: Is the check result normal?
Q: Is the check result normal? YES : Replace the ACD transfer.
YES : Add the transfer oil. NO : Repair.
NO : Repair the leaking part and add the transfer
oil. STEP 8. Perform air bleeding.
Refer to P.22A-153.
STEP 3. Check the fluid. Q: Is the check result normal?
Refer to P.22A-152. YES : The procedure is complete.
Q: Is the check result normal? NO : Replace the hydraulic pressure unit.
YES : Go to Step 5.
NO : Go to Step 4.

M1221011200010
Item Check item Check condition Normal

No. condition
01 Wheel speed sensor Execute actual driving. The speed meter
<FR> display and
02 Wheel speed sensor M.U.T.-II/III
<FL> display match.
03 Wheel speed sensor
<RR>
<RL>
<FR> (0.2 km/h)
<FL> (0.2 km/h)
<RR> (0.2 km/h)
<RL> (0.2 km/h)
09 Vehicle speed
10 Battery voltage Ignition switch: ON System voltage
11 Proportional valve During ACD operation 50 − 1,000 mA
current <ACD>
12 Proportional valve During AYC operation 50 − 1,000 mA
current <AYC>
13 TPS voltage • Ignition switch: ON Accelerator pedal: Full 535 − 735 mV
• Engine: Stopped closed
Accelerator pedal: Press Gradually rises
from the above
value
Accelerator pedal: Full 4,500 − 5,000
throttle mV
14 Longitudinal G-sensor Ignition switch: ON Vehicle stopped (horizontal) 2.4 − 2.6 V
voltage state
Actual driving The displayed
value increases
and decreases
mainly around
2.5 V.
15 Lateral G-sensor Ignition switch: ON Vehicle stopped (horizontal) 2.4 − 2.6 V
voltage state
Perform actual driving The displayed
value increases
and decreases
mainly around
2.5 V.
22A-143
No. condition
16 Steering operation Ignition switch: ON Steering wheel: Steer by 90 R90 deg
angle degrees to the right
Steering wheel: Steer by 90 L90 deg
degrees to the left
17 Steering angle Ignition switch: ON Steering wheel: No steering 0 deg/s
velocity Steering wheel: Steer The display
changes
according to the
revolution
speed.
18 Pressure sensor During electric pump motor operations 1.0 − 1.6 MPa
19 Pressure sensor Ignition switch: ON Approx.5 V
power supply
20 Valve power supply Ignition switch: ON System voltage
21 Steering wheel Ignition switch: ON Steering wheel: Turn 1 − 2 V and 2.5 −
sensor voltage 4.5 V are
<ST-1> displayed
alternately.
22 Steering wheel Ignition switch: ON Steering wheel: Turn 1 − 2 V and 2.5 −
sensor voltage 4.5 V are
<ST-2> displayed
alternately.
23 Steering wheel Ignition switch: ON Steering wheel: Neutral 1−2V
sensor voltage Steering wheel: Turn 2.5 − 4.5 V
<ST-N>
51 Idle switch Ignition switch: ON Accelerator pedal: Full ON
closed
Accelerator pedal: Press OFF
52 Steering wheel Ignition switch: ON steering wheel: Neutral ON
sensor <ST-N> Steering wheel: Turn from OFF
the neutral position
53 Steering wheel Ignition switch: ON Steering wheel: Turn slowly ON and OFF are
sensor <ST-1> displayed
alternately.
54 Steering wheel Ignition switch: ON Steering wheel: Turn slowly ON and OFF are
sensor <ST-2> displayed
alternately
55 Steering wheel Perform actual driving Steering wheel sensor ON
sensor learning neutral position learning
<ST-N> executed
Steering wheel sensor OFF
neutral position learning
un-executed
56 Stop lamp switch • Ignition switch: ON Brake pedal: Depress ON
• Engine: Stopped Brake pedal: Release OFF

No. condition
57 Motor monitor Electric pump motor is currently operating ON
Electric pump motor is currently not operating OFF
58 Oil pressure state Electric pump motor is currently operating LOW
Electric pump motor is currently not operating HIGH
59 Directional valve AYC clutch right side is currently operating ON
<Right> AYC clutch right side is currently not operating OFF
60 Directional valve AYC clutch left side is currently operating ON
<Left> AYC clutch left side is currently not operating OFF
61 ABS monitor ABS is currently operating ON
ABS is currently not operating OFF
62 Parking brake switch • Ignition switch: ON Parking brake lever: Pull ON
• Engine: Stopped Parking brake lever: OFF
Release
63 ACD mode switch • Ignition switch: ON ACD mode switch: Press ON
• Engine: Stopped ACD mode switch: Release OFF
22A-145
ACTUATOR TEST JUDGEMENT VALUE
M1221011300017
Item Check item Test description Normal state

No.
01 Bleeding <ACD> Input current to the proportional valve Make sure no air leaks from the
according to the steering angle, and bleeder screw on the transfer.
operate the proportional valve for five
minutes.
02 Bleeding <AYC> Input current to the proportional valve Make sure no air leaks from the
according to the steering angle, and bleeder screw on the torque transfer
operate the directional valve for five differential.
minutes.
03 Check the oil Operate the directional valve to the left Check that the oil volume of the
volume and right for 20 seconds. reservoir tank is appropriate.
04 Electric pump drive Operate the electric pump for 5 seconds. Operation sounds of the electric
pump can be heard.
05 Check the Operate the proportional valve <ACD> Generate the tight corner braking
operations of the and supply the maximum oil pressure to phenomenon.
ACD the multi plate clutch.
06 Check clutch Operate the direction valve and supply When the wheels are lifted, speed
operations <Left> the maximum oil pressure to the left difference will occur between the
clutch. rear left and right wheels.
07 Check clutch Operate the direction valve and supply When the wheels are lifted, speed
operations <Right> the maximum oil pressure to the right difference will occur between the
clutch. rear left and right wheels.
08 Control OFF Turn OFF the electric pump relay, and In actual driving, there is difference
turn OFF the control of the ACD and between control ON and OFF.
AYC.
1. The actuator test can be executed only when all • When any one of the wheel speed sensor input is
the following conditions are satisfied. detected to be above 20 km/h. (excluding Item
• All wheel speed sensor inputs below 20 km/h. No.08 "Control OFF").
• No system malfunction detected. • When system malfunction is detected. (excluding
• Steering angle is within ±30 degrees from the diagnostic code No.82, 84, and 85).
neutral position. • When the forced drive time is exceeded.
2. When the actuator test corresponds to one of the • When the M.U.T.-II/III is removed.
following conditions, forced driving will be cleared. • When the Clear key of the M.U.T.-II/III is oper-
ated.
CHECK AT 4WD-ECU TERMINALS

M1221011400014
C-25 C-26
AC310529AB
Terminal Check item Check condition Normal state

No.
1 Proportional Operate the Proportional While executing the System voltage
valve <ACD> valve in the actuator test actuator test
(Item No.01). <ACD> After completing the 1 V or less
actuator test
3 Proportional Operate the Proportional While executing the System voltage
valve <AYC> valve in the actuator test actuator test
(Item No.02). <AYC> After completing the 1 V or less
actuator test
6 Wheel speed Vehicle is stopping 1 V or less
sensor <FL> Moving forward slowly 0 ⇔ 5 V flushing
sensor <RR> Moving forward slowly 0 ⇔ 5 V flushing
sensor <RL> Moving forward slowly 0 ⇔ 5 V flushing
sensor <FR> Moving forward slowly 0 ⇔ 5 V flushing
10 Pressure sensor Any time 1 V or less
earth
11 Lateral G-sensor Ignition switch: ON Vehicle horizontal state 2.4 − 2.6 V
13 4WD-ECU Ignition switch: OFF 0V
power supply Ignition switch: ON System voltage
14 Directional valve Operate the directional While executing the System voltage
<Right> valve <right> in the actuator test
actuator test (Item No.07) After completing the 1 V or less
actuator test
15 Directional valve Operate the directional While executing the System voltage
<Left> valve <left> in the actuator test
actuator test (Item No.06) After completing the 1 V or less
actuator test
16 Electric pump When the electric pump motor is not operating 0V
relay power While the electric pump motor is operating System voltage
supply
23 Longitudinal Ignition switch: ON Vehicle horizontal state 2.4 − 2.6 V
G-sensor
26 ECU earth Any time 1 V or less
22A-147
No.
31 ECU backup Any time System voltage
power supply
32 Pressure sensor Ignition switch: ON 0.5 − 1.5 V
33 Steering wheel Ignition switch: ON Steering wheel: Turn 1 − 2 V ⇔ 2.5 − 4.5 V
sensor <ST-1> slowly flushing
34 Steering wheel Ignition switch: ON Steering wheel: Turn 1 − 2 V ⇔ 2.5 − 4.5 V
sensor <ST-2> slowly flushing
36 Idle switch Ignition switch: ON Accelerator pedal: Full 1 V or less
closed
Accelerator pedal: 4.5 − 5.0 V
Depress
37 Parking brake Ignition switch: ON Parking brake lever: Pull 1 V or less
switch Parking brake lever: System voltage
Release
38 Stop lamp switch Ignition switch: ON Brake pedal: Depress System voltage
Brake pedal: Release 1 V or less
39 TPS Ignition switch: ON Accelerator pedal: Full 0.5 − 0.7 V
closed
Accelerator pedal: Full 4.5 − 5.5 V
throttle
40 ACD mode Ignition switch: ON ACD mode indicator lamp 0 V
indicator lamp position: TARMAC
<TARMAC> ACD mode indicator lamp Approx.10.5 V
position: Except for
above
42 ECU earth Any time 1 V or less
43 Pressure sensor Ignition switch: OFF 1 V or less
power supply Ignition switch: ON Approx.5.0 V
44 Steering wheel Ignition switch: ON Steering wheel: Neutral 1−2V
sensor <ST-N> Steering wheel: Turn from 2.5 − 4.5 V
the neutral position
47 ACD mode Ignition switch: ON Switch: Press System voltage
switch Switch: Release 0V
48 ABS monitor With ABS not active System voltage
With ABS active 1.5 V or less
indicator lamp position: SNOW
<SNOW> ACD mode indicator lamp Approx.10.5 V
above
TROUBLESHOOTING <M/T>

No.
indicator lamp position: GRAVEL
<GRAVEL> ACD mode indicator lamp Approx.10.5 V
above
INTRODUCTION TROUBLESHOOTING STRATEGY
M1221006900701 M1221007000626
The manual transmission can exhibit any of the fol- Use these steps to plan your diagnostic strategy. If
lowing symptoms: noise or vibration is generated, oil you follow them carefully, you will be sure that you
leaks, shifting gears is hard or troublesome, or the have exhausted most of the possible ways to find a
transmission jumps out of gear. manual transmission fault.
The causes of these symptoms could come from: 1. Gather information from the customer.
incorrect mounting, the oil level may be low, or a 2. Verify that the condition described by the
component of the transmission may be faulty. customer exists.
3. Find the malfunction by following the Symptom
Chart.
4. Verify malfunction is eliminated.
SYMPTOM CHART
M1221007100612

procedure No.
Noise, vibration 1 P.22A-149
Oil leaks 2 P.22A-150
Hard shifting 3 P.22A-150
Jumps out of gear 4 P.22A-151
22A-149
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Noise, vibration
DIAGNOSIS STEP 4. Check for the specified oil.

Q: Is the specified oil DIA QUEEN SUPER MULTI
STEP 1. Check the idle speed. GEAR 75W−85W (GL−4) or exact equivalent?
YES : Go to Step 5.
Q: Does the idle speed meet the standard values?
YES : Go to Step 2. NO : If in doubt, replace the oil. Refer to
NO : Refer to GROUP 11A − On-vehicle Service, P.22A-152. Then go to Step 7.
Idle Speed Check P.11A-10.
STEP 5. Remove the transmission. Check the
STEP 2. Check whether the transmission and axial play of the input and output shafts.
engine mount is loose or damaged. Q: Does the axial play of the input and output shafts
Q: Are the transmission and engine mount loose or meet the standard value?
damaged? YES : Go to Step 6.
YES : Tighten or replace the part. Then go to Step NO : Adjust the axial play of the input and output
7. shafts. Then go to Step 7.
NO : Go to Step 3.
STEP 6. Disassemble the transmission. Check
STEP 3. Check that the oil level is up to the lower the gears for wear and damage.
edge of the filler plug hole. Q: Are the gears worn or damaged?
YES : Replace the gears. Go to Step 7.
NO : Go to Step 7.
Filler plug hole
STEP 7. Retest the systems.
Q: Is the noise or vibration still there?
Transmission oil Filler plug
AC102278AO
Q: Is the oil level up to the lower edge of the filler plug

hole?
YES : Go to Step 4.
NO : Refill DIA QUEEN SUPER MULTI GEAR
75W−85W (GL−4) or exact equivalent. Then
go to Step 7.
INSPECTION PROCEDURE 2: Oil leaks
DIAGNOSIS STEP 2. Visual check at the clutch housing.

Q: Do oil leaks appear around the joint between the
STEP 1. Visual check. engine and the clutch housing?
Raise the vehicle, and check for oil leaks. If oil leak is YES : Remove the transmission. Check the input
difficult to locate, steam clean the transmission and shaft oil seal, and replace if necessary.
drive the vehicle for at 10 minutes. Then check the Then go to Step 4.
leak again. NO : Go to Step 3.
Q: Is the oil leak(s) found?
YES : Go to Step 2. STEP 3. Check the oil seal or O-ring for damage.
NO : Check for the oil leaks around the engine.
Q: Is the oil seal or O-ring damaged?
Then go to Step 4.
YES : Replace the oil seal or the O-ring. Then go
to Step 4.
NO : Go to Step 4.

Q: Is the oil still leaking?
INSPECTION PROCEDURE 3: Hard shifting
DIAGNOSIS STEP 4. Remove and disassemble the

transmission. Check the control housing.
STEP 1. Check the transmission control Q: Is the control housing in good condition?
Q: Are the shift cable and the select cable in good YES : Go to Step 5.
condition? NO : Repair or replace the control housing. Refer
YES : Go to Step 2. to GROUP 22B − Transmission P.22B-11.
NO : Repair or replace the shift cable and the Then go to Step 7.
select cable. Refer to P.22A-157. Then go
to Step 7. STEP 5. Check for poor meshing of worn
synchronizer ring and gear cone.
STEP 2. Check the transmission oil. Q: Is poor meshing or worn synchronizer ring and
Q: Is the oil dirty? gear cone found?
YES : Replace the oil. Refer to P.22A-152. Then YES : Repair or replace the synchronizer ring and
go to Step 7. gear cone. Then go to Step 7.
NO : Go to Step 3. NO : Go to Step 6.
STEP 3. Check the clutch system. STEP 6. Check the synchronizer spring for
weakness.
Q: Is the clutch system normal?
YES : Go to Step 4. Q: Is the synchronizer spring weak?
NO : Repair or replace the clutch system. Refer YES : Replace the synchronizer spring. Then go
to GROUP 21B − Clutch P.21B-3. Then go to Step 7.
to Step 7. NO : Go to Step 7.
ON-VEHICLE SERVICE
22A-151
Q: Is the shifting of the gears still hard?
INSPECTION PROCEDURE 4: Jumps out of gear
DIAGNOSIS STEP 4. Check the gear shift forks for wear.

Q: Is the gear shift forks worn?
STEP 1. Check the transmission control YES : Replace the gear shift fork. Refer to
Q: Are the shift cable and the select cable in good GROUP 22B − Transmission P.22B-11.
condition? Then go to Step 6.
NO : Repair or replace the shift cable and the
select cable. Refer to P.22A-157. Then go STEP 5. Check the clearance.
to Step 6.
Q: Is the clearance between the synchronizer hub and
sleeve excessive?
STEP 2. Remove and disassemble the YES : Replace the synchronizer hub or sleeve.
transmission. Check the poppet spring for Refer to GROUP 22B − Input Shaft
breakage. P.22B-24. Then go to Step 6.
Q: Is the poppet spring broken? NO : Go to Step 6.
YES : Replace the poppet spring. Refer to
GROUP 22B − Transmission P.22B-11. STEP 6. Retest the system.
Then go to Step 6.
NO : Go to Step 3. Q: Does the transmission still jump out of gear?
STEP 3. Check the control housing.
Q: Is the control housing in good condition?
YES : Go to Step 4.
NO : Repair or replace the control housing. Refer
to GROUP 22B − Transmission P.22B-11.
Then go to Step 6.
ON-VEHICLE SERVICE
TRANSMISSION OIL CHECK 1. Remove the oil filler plug.
M1221000900491
2. Oil level should be at the lower portion of the filler
plug hole.
3. Check that the transmission oil is not noticeably
Filler plug hole dirty, and that it has a suitable viscosity.
4. Tighten the filler plug to the specified torque.
Transmission oil Filler plug
AC210553 AB
ON-VEHICLE SERVICE
TRANSMISSION OIL REPLACEMENT TRANSFER OIL REPLACEMENT

M1221001000565 M1221001200138
Filler plug
Filler plug
Oil pan
Drain plug
Drain plug
AC504941AB AC310836AF
1. Remove oil filler plug and oil drain plug. 1. Remove oil filler plug and oil drain plug.
2. Drain oil. 2. Drain oil.
3. Tighten the oil drain plug to the specified torque. 3. Tighten the oil drain plug to the specified torque.
Tightening torque: 35 ± 4 N⋅m Tightening torque: 32 ± 2 N⋅m
4. Fill with specified oil till the level comes to the 4. Fill with specified oil till the level comes to the
lower portion of oil filler plug hole. lower portion of oil filler plug hole.
Specified transmission oil: DIA QUEEN Specified transfer oil: Dia Quieen LSD gear oil
SUPER MULTI GEAR 75W−85W (GL−4) or Quantity: 0.6 L
exact equivalent 5. Tighten the oil filler plug to the specified torque.
Quantity: 2.2 L
5. Tighten the oil filler plug to the specified torque.
Tightening torque: 35 ± 4 N⋅m FLUID CHECK
M1221011500033
TRANSFER OIL CHECK 1. Remove the maintenance lid located in the

M1221001100120 luggage compartment.
2. <Not using M.U.T.-II/III>
• If the vehicle has been run, leave it for 90 min. or
Filler plug hole more in an ordinary temperature (10°C − 30°C) to
allow the accumulator internal pressure to drop.
NOTE: If the ambient temperature is 10°C or less,
allow more time to leave the vehicle to stand idle.
3. <Using M.U.T.-II/III>
Transfer oil Filler plug
CAUTION
AC210553AC Turn the ignition switch to the LOCK (OFF) posi-
tion before connecting or disconnecting the
1. Remove the oil filler plug. M.U.T.-II/III.
2. Oil level should be at the lower portion of the filler • Set the M.U.T.-II/III to the 16-pin diagnosis con-
plug hole. nector.
3. Check that the transfer oil is not noticeably dirty, • Turn ON the ignition switch, perform M.U.T.-II/III
and that it has a suitable viscosity. actuator test (Item No.03), forcibly drive the
hydraulic unit and remove the pressure in the
4. Tighten the filler plug to the specified torque.
accumulator.
ON-VEHICLE SERVICE
22A-153
NOTE: . NOTE: .
• In the actuator test (Item No.03: Oil Level • The actuator test (Item No.01: Bleeding Mode)
Check Mode), the directional valve of the will be performed for 5 minutes, after which it
hydraulic unit is moved to the left and right for will be cleared automatically. Drive can also be
20 times, and then the differential is cleared cleared during forced driving using the clear
automatically. Drive can also be cleared forci- key of the M.U.T.-II/III.
bly using the clear key of the M.U.T.-II/III. • If the hydraulic unit function has been stopped
• If the function has been stopped by fail-safe, by fail-safe, the hydraulic unit cannot be forci-
the hydraulic unit cannot be cleared forcibly. bly driven.
Front exhaust pipe
Bleeder screw
AC310841AB AC310843AB
4. Check that the fluid level in the oil reservoir is in 6. Remove the cap of the bleeder screw on the
the range between MAX and MIN. transfer, and connect the vinyl hose.
5. If the fluid level is lower than MIN, add the CAUTION
specified fluid. During bleeding, replenish the fluid so that some
Specified fluid: DIA QUEEN ATF SP III always remains in the oil reservoir.
6. Reinstall the maintenance lid. 7. Slowly turn the steering wheel to the left or right
from the neutral state. Loosen the bleeder screw,
BLEEDING and check that air is discharged together with the
M1221011600018
fluid.
CAUTION 8. After the air is discharged, tighten the bleeder
If bleeding is not performed completely, noise screw, and return the steering wheel to the neutral
may be produced from the hydraulic unit, or the state.
durability of the pump, etc. may drop.
9. Repeat steps 6 and 7 several 2 to 3 times, and
1. Lift up the vehicle.
after checking that no more air mixes in, tighten
CAUTION the bleeder screw at the specified torque.
Turn the ignition switch to the "LOCK"(OFF) Tightening torque: 5 ± 1 N⋅m
position before connecting or disconnecting the
M.U.T.-II/III. 10.After bleeding, check the fluid level. (Refer to
P.22A-152).
2. Set the M.U.T.-II/III to the 16-pin diagnosis
connector. 11.If the hydraulic pressure unit is removed, bleed
the AYC (Refer to GROUP 27 − On-vehicle
3. Turn the ignition switch to the ON position. Service P.27-28).
4. Set the steering wheel in the straight-ahead
position. ACD OPERATION CHECK
M1221011700037
5. Perform the M.U.T.-II/III actuator test (Item
No.01), and forcibly drive the hydraulic unit. CAUTION
Turn the ignition switch to the "LOCK" (OFF)
position before connecting or disconnecting the
M.U.T.-II/III.
1. Set the M.U.T.-II/III to the 16-pin diagnosis
connector.
ON-VEHICLE SERVICE
3. Set the steering wheel to the neutral position, and NOTE: .

carry out the actuator test (Item No.05) using • The actuator test (Item No.05 ACD Operation
M.U.T.-II/III. Then, activate the transfer forcibly. Check Mode) is performed for 1 minute, after
NOTE: . which it will be cleared automatically. Drive
• The actuator test (Item No.05: ACD Operation can also be cleared during forced driving using
Check Mode) is performed for 1 minute, after the clear key of the M.U.T.-II/III.
which it will be cleared automatically. Drive • If the hydraulic unit function has been stopped
can also be cleared during forced driving using by fail-safe, the hydraulic unit cannot be forci-
the clear key of the M.U.T.-II/III. bly driven.
• If the hydraulic unit function has been stopped CAUTION
by fail-safe, the transfer cannot be forcibly While the oil pressure is checked, add fluid as
driven. necessary to ensure that it is left in the oil reser-
4. Turn the steering wheel 180° or more to the right voir during the entire procedure.
or left, and drive the vehicle at 20 km/h or less to 6. Check that the generated oil pressure of the
check that tight corner braking phenomenon. hydraulic unit satisfies the standard value.
NOTE: . Standard value: 1.0 − 1.6 MPa
• The occurrence level of the body vibration and
7. If the measured value exceeds the standard
noise depends on the condition of tyres and
value, replace the hydraulic unit.
roads.
• If tight corner braking does not occur, check 8. Connect the hydraulic unit and transfer connector
the hydraulic pressure because the system assembly, and tighten the flare nut at the specified
may be defective. torque.
Tightening torque:
HYDRAULIC PRESSURE CHECK 34 ± 5 N⋅m (when screw is dry)
M1221011800034
26 ± 4 N⋅m (when screw is applied with oil)
1. Lift up the vehicle.
9. Supply the specified fluid up to the MAX level of
CAUTION the oil reservoir, and bleed the oil pressure pipes.
Turn the ignition switch to the LOCK (OFF) posi-
• Specified fluid: DIA QUEEN ATF SP III
tion before connecting or disconnecting the
• Quantity: 1.0 L
M.U.T.-II/III.
2. Set the M.U.T.-II/III to the 16-pin diagnosis WHEEL SPEED SENSOR OUTPUT
connector. VOLTAGE MEASUREMENT
M1221011900019
MB991705
Lift the vehicle, and release the parking brake.
CAUTION
Insert the probe from the harness of the connec-
tor. Inserting in the terminal side may cause con-
tact fault.
1. Disconnect the 4WD-ECU connector, and
measure at the connector of the harness.
MD998330 AC310844AC
3. Disconnect the hydraulic unit and transfer

connector assembly, and connect the special tool
to the hydraulic unit.
4. Turn the ignition switch to ON.
5. Perform the M.U.T.-II/III actuator test (Item
No.05), and forcibly drive the hydraulic unit.
AC310852AB
ON-VEHICLE SERVICE
22A-155
2. Rotate the measured wheel by about 1/2 to 1 INSPECTION PROCEDURE USING
rotations/second, and check the output voltage OSCILLOSCOPE
between the following terminals using a circuit
tester (AC mV range) or oscilloscope. When rotated with the hand
Front left Front right Rear left Rear right
Terminal Terminal Terminal Terminal
No.6 and No.9 and No.8 and No.7 and
No.19 No.22 No.21 No.20
Output voltage:
Above 70 mV when measured with the circuit
tester
Above 200 mVP-P when measured with the
oscilloscope
When idling (5 - 6 km/h) 1st gear
3. If the output voltage is lower than the above
values, the following reasons may be suspected.
Check or replace the wheel speed sensor.
• Excessive clearance between the ball piece of
the wheel speed sensor and ABS rotor
• Wheel speed sensor fault
10.0 ms/DIV
1 V/DIV
AC310853 AB
After checking the connected state of the harness of

the wheel speed sensor and connector, and measure
the output voltage waveform of each wheel speed
sensor on the oscilloscope as follows.
Start the engine, shift the transmission to the 1st
gear to rotate the driving wheel, and rotate the
non-driving wheel at constant velocity with the hand.
NOTE: .
• It is also possible to actually drive the vehicle and
observe the waveform.
• The output voltage is low if the wheel speed is
low and gradually increases as the speed
increases.
CAUTION
As the wheel speed sensor cable follows the
movement of the front or rear suspension, it will
change considerably on poor condition roads.
Therefore, also observe the output voltage wave-
form of the wheel speed sensor with the sensor
harness vibrated to simulate special conditions
such as driving in poor road conditions.
ON-VEHICLE SERVICE
<WAVEFORM OBSERVATION POINTS>

Phenomenon Probable cause Solution
Waveform amplitude is too small or Wheel speed sensor fault Replace the sensor
not output at all
Excessive waveform amplitude Excessive vibration or Replace the hub
(However allowed if above the concentricity of the axle hub
minimum amplitude of 100 mV) 4WD-ECU earth fault Correct
Noise in the waveform or waveform Open circuit of the sensor Replace the sensor
is abnormal Open circuit of the harness Replace the harness
Wheel speed sensor installation Correct the installation of the
fault sensor
Chipping or flattening of the ABS Replace the ABS rotor
rotor
OIL TEMPERATURE SENSOR CHECK

M1221006700020
Oil temperature sensor
N
Filler plug Transmission oil
AC504890AB
AC504940AB 2. Measure the resistance between terminals 1 and

2 of the oil temperature sensor connector.
1. Remove the oil temperature sensor.
Standard value:
Oil temperature (°C) Resistance value (kΩ)
20 2.31 − 2.59
110 0.145 − 0.146
3. If the resistance is not within the standard value,
replace the oil temperature sensor.
4. Install the oil temperature sensor, and tighten it to
the specified torque.
TRANSMISSION CONTROL
22A-157
M1221003800783
WARNING
• Be careful not to subject the SRS-ECU to any shocks during removal and installation of
the shift cable and select cable assembly.
• Do not disassemble the shift lever assembly except the distance piece and bushing.
(non-supply parts)
• Never use mineral grease for the shift lever assembly moving area. If mineral grease is
used, the plastic parts can be damaged.
Pre-removal Operation
• Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-5).
• Air Pipe C, Air Hose D Removal (Refer to GROUP 15 −
Intercooler P.15-6).
• Battery and Battery Tray Removal
6 10
12 ± 2 N·m 2
7
8
6.0 ± 1.5 N·m
N 9
3 1
4
12 ± 2 N·m
5
11
13
12 AC211367AC
Shift cable and select cable Shift lever assembly removal

assembly removal steps steps
1. Shift knob 1. Shift knob
• Front floor console (Refer to • Front floor console (Refer to
GROUP 52A P.52A-7). GROUP 52A P.52A-7).
2. Front floor console bracket 2. Front floor console bracket
>>C<< 3. Select cable connection (Shift >>C<< 3. Select cable connection (Shift
lever side) lever side)
4. Shift cable connection (Shift lever 4. Shift cable connection (Shift lever
side) side)
5. Clip (Shift lever side) 5. Clip (Shift lever side)
6. Snap pin 11. Shift lever assembly
7. Shift cable connection 12. Distance piece
(Transmission side) 13. Bushing
<<A>> >>B<< 8. Select cable connection
(Transmission side)
<> >>A<< 9. Clip
10. Shift cable and Select cable
assembly
REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS

<<A>> SELECT CABLE CONNECTION >>A<< CLIP INSTALLATION
(TRANSMISSION SIDE) REMOVAL CAUTION
1
New clip
2
Cable bracket
Select cable AC211243AC
Set the clip of the select cable as shown in figure 1 Gear shift cable, Select cable
and 2, and disconnect the select cable.
<> CLIP REMOVAL

Clip Gear shift cable,
Claws
select cable
AC210558AE
Insert thoroughly the clip, shift cable and select

cable until they click in place.
AC310871AC 1. After installing the new clip to the cable bracket of
the transmission, install the shift cable and select
Push up the claws of the clip using a screwdriver,
cable to the cable bracket.
etc., and then remove the clip from the bracket
together with the cables. NOTE: The clip is reversible.
2. Move the shift lever to all positions and check that
the operation is smooth.
>>B<< SELECT CABLE CONNECTION

(TRANSMISION SIDE) INSTALLATION
CAUTION
Check that the clip is securely installed.
Select cable
Clip
AC402309 AC
1. Install the clip of the select cable as shown in the

illustration.
22A-159
2. Move the shift lever to all positions and check that 2. Remove the select cable from the select lever.
the operation is smooth. 3. Move the shift lever until it hits the stopper at the
6th gear side.
>>C<< SELECT CABLE CONNECTION 4. Release the shift lever to place it to the neutral
(SHIFT LEVER SIDE) INSTALLATION position.
5th gear, 6th gear direction Select cable

Lock clip
Neutral position
Fixing clip
Select lever AC211247AD
AC211351AC
1. Move the shift lever until it contacts the 5-speed or 5. Move the lock clip of the select cable towards the
6-speed stopper to stabilize the shift cable at the arrowed direction in the figure, and pull the fixing
shift lever. clip.
2. Release the shift lever, and install the select cable 6. Install the select cable to the select lever, taking
(at the shift lever side) to the select lever while the care not to move the shift lever from the neutral
lever is at the neutral position. position.
3. Check that the shift cable (shift lever side) and the
select cable (shift lever side) are installed
securely, and move the shift lever to all shift
positions.
4. If the shift lever cannot be moved to the shift
positions, adjustment the select cable. Lock clip
Fixing clip
SELECT CABLE (SHIFT LEVER SIDE)
ADJUSTMENT
M1221013300013 AC211248AD
Place the shift lever to the neutral position .
1. Remove the front floor console. 7. Pulling the select cable slightly towards the cabin
side, press in the fixing clip of the select cable.
5th gear, 6th gear direction Then, return the lock clip back to the original
state.
Neutral position 8. Move the shift lever to all shift positions.
NOTE: If the shift lever cannot be moved to each
position or is difficult to move, repeat from step 3
to step 9.
9. Install the front floor console.
Select lever
AC211351AC
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
M1221003200178
CAUTION
• Always refer to GROUP 52B − Service Precautions and Airbag Modules and Clock Spring before
removing the steering wheel and airbag module assembly.
• If the Brembo brake caliper is used, be careful not to hit parts and tools against the caliper when
servicing because the paint of the caliper may delaminate.
• *: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
• Steering Wheel Removal and Installation (Refer to
GROUP 37 − Steering Wheel P.37-13).
• Under Cover Removal and Installation (Refer to GROUP
51 − Front Bumper P.51-2).
• Steering Shaft Cover Removal and Installation (Refer to
GROUP 37 − Steering Clumn shaft P.37-15).
• Steering Gear and Joint Connection Removal and Instal-
lation (Refer to GROUP 37 − Steering Clumn shaft
P.37-15).
• Front Axle Crossmember Bar Removal and Installation
(Refer to GROUP 32 − Engine Roll Stopper, Centermem-
ber P.32-7).
• Front Exhaust Pipe Removal and Installation (Refer to
GROUP 15 − Exhaust Pipe and Main Muffler P.15-13).
• Propeller Shaft Removal and Installation (Refer to
GROUP 25 Propeller Shaft P.25-3).
• Output shaft Removal and Installation (Refer to GROUP
26 − Drive Shaft Assembly P.26-11).
• Transmission Oil Draining and Supplying (Refer to
P.22A-152).
• Transfer Oil Draining and Supplying (Refer to P.22A-152).
• Bleeding and Hydraulic Pressure Check <ACD> (Refer to
P.22A-153, P.22A-154). <after installation only>
• Power Steering Fluid Refilling and Bleeding (Refer to
GROUP 37 − On-vehicle Service P.37-10) <Only after
Installation>.
TRANSFER ASSEMBLY
22A-161
44 ± 5 N·m
N 5 4
69 ± 9 N·m
N 7
7N 69 ± 9 N·m
2
54 ± 5 N·m*
54 ± 5 N·m*
1
3
69 ± 10 N·m 49 ± 10 N·m
167 ± 9 N·m
69 ± 10 N·m
167 ± 9 N·m
AC211381AC

1. Centremember assembly <<A>> 3. Front axle No.1 crossmember
• Power steering return hose and assembly
steering gear connection 4. Pressure hose connection
• Power steering pressure hose and 5. Gasket
steering gear connection <> 6. Transfer assembly
2. Rear roll stopper connecting bolt 7. O-ring
TRANSFER ASSEMBLY

<<A>> FRONT AXLE NO.1 CROSSMEM- <> TRANSFER ASSEMBLY REMOVAL
BER ASSEMBLY REMOVAL
Transfer assembly
Front axle No.1
crossmember assembly
Transmission jack AC211733AC

Transmission jack
AC211732AC Support the transfer assembly with a transmission
jack, and remove the transfer mounting bolts and the
Support the front axle No.1 crossmember assembly
transfer assembly.
with a transmission jack, and remove the crossmem-
ber mounting bolts and the front axle No.1 cross-
member assembly.
TRANSMISSION ASSEMBLY
22A-163
M1221002700590
CAUTION
• If the Brembo brake caliper is used, be careful not to hit parts and tools against the caliper when
servicing because the paint of the caliper may delaminate.
• *: Indicates parts which should be initially tightened, and then fully tightened after placing the
• Transfer Assembly Removal and Installation (Refer to
P.22A-160).
• Battery and Battery Tray Removal and Installation.
• Strut Tower Bar Removal and Installation (Refer to
GROUP 42 − Strut Tower Bar P.42-9).
• Strut assembly mounting bolt temporary Installation
<Pre-removal only>
• Air duct, Air Cleaner Assembly and Air Intake Hose
Removal and Installation (Refer to GROUP 15 − Air
Cleaner ).
• Air By-pass Hose, Air Hose E, Air Pipe C and Air Hose D
Removal and Installation (Refer to GROUP 15 P.15-6).
• Starter Assembly Removal and Installation (Refer to
GROUP 16 P.16-20).
4
18 ± 3 N·m
5
18 ± 3 N·m
6 7
AC211629AC

1. Main harness clamp connection 5. Shift cable connection
2. Back-up lamp switch connector <<A>> 6. Select cable connection
connection 7. Control cable assembly and
3. Vehicle speed sensor connector bracket
connection 8. Clutch release cylinder and clutch
4. Snap pin oil pipe
9 10 48 ± 5 N·m 8.8 ± 1.0 N·m

47 ± 7 N·m* 10
9 9
48 ± 5 N·m
15 48 ± 5 N·m
48 ± 5 N·m
12
13
11 12 82 ± 7 N·m*
15
48 ± 5 N·m
16 26 ± 5 N·m
14
9.0 ± 1.0 N·m
AC211628AC

9. Transmission assembly upper part <<C>> • Engine assembly supporting
coupling bolt • Raise the vehicle.
10. Harness clump 14. Bell housing cover
<> 11. Transmission mounting insulator <<D>> • Clutch release bearing separation
assembly 15. Transmission assembly lower part
>>A<< 12. Transmission mounting insulator coupling bolt
stopper 16. Transmission assembly
13. Transmission mounting insulator

<<A>> SELECT CABLE CONNECTION <> TRANSMISSION MOUNTING
REMOVAL INSULATOR ASSEMBLY REMOVAL
1 Engine and transmission assembly
Garage jack
Select cable AC211243AC AC211722AC
Set the clip of the select cable as shown in figure 1 Jack up and support the engine and transmission
and 2, and disconnect the select cable. assembly, and remove the transmission mounting
insulator assembly.
22A-165
<<C>> ENGINE ASSEMBLY SUPPORTING NOTE: Adjust the engine hanger balance by
sliding the slide bracket (HI).
MB991895 (3) Set special tool MB991454 to hold the engine
and transmission assembly.
<<D>> CLUTCH RELEASE BEARING

SEPARATION
MB991454
1. Remove the service hole cover of the clutch
housing.
AC211734AC
CAUTION
• Do not insert the flat-tipped driver before
1. <Engine hanger (special tool MB991895) is used> pressing the release fork towards direction A.
(1) Set special tool MB991895 to the strut • Do not insert the flat-tipped driver between
mounting nuts and the radiator support upper the wedge collar and the wave spring.
insulator mounting bolts, which are located in Release fork
the engine compartment, as shown. B A
(2) Set special tool MB991454 to hold the engine
and transmission assembly.
Slide bracket (HI)
Front side
Service hole
Joint (90)
(MB991930) Release
bearing
Foot (Standard)
(MB991932) AC209516AB
2. <Engine hanger (special tool MB991928) is used>

(1) Assemble the engine hanger (special tool
MB991928). Set the following parts to the
Wedge collar
base hanger. Refer to CAUTION 2.
• Slide bracket (HI) AC211679AD
• Foot (standard) (MB991932)

2. Insert the flat-tipped driver between the release
• Joint (90) (MB991930)
bearing and wedge collar while slightly pressing
MB991928 Slide bracket (HI) the release fork towards direction A by hand.
MB991934
CAUTION
If the driver cannot be turned slightly (the release
bearing cannot be disconnected), remove the
flat-tipped driver and press the release fork sev-
MB991932
eral times towards direction A, then retry again. If
MB991930
MB991527 the release bearing is pried off forcibly, it may be
MB991454 MB991932 damaged.
AC211735AC 3. Disconnect the release bearing with the wedge
collar while prying off slightly by the flat-tipped
(2) Set the engine hanger (special tool driver (turn the driver's handle 90°).
MB991928) to the strut mounting nuts and the
radiator support upper insulator mounting NOTE: When the release bearing is discon-
bolts, which are located in the engine nected, the release fork is moved to the direction
compartment, as shown. B fully by the return spring.
INSTALLATION SERVICE POINT Install so that the arrow on the transmission mount-
ing insulator stopper faces the top of the vehicle.
>>A<< TRANSMISSION MOUNTING INSU-
LATOR STOPPER INSTALLATION
Engine side Transmission
mounting
insulator
stopper
Transmission
mounting
insulator
AC310943 AC
4WD-ECU
22A-167
4WD-ECU
M1221012100016

• Cowl Side Trim <RH> Removal and Installation. (Refer to
GROUP 52A - Trims P.52A-10). <LH drive vehicles>
• Front Floor Console Removal and Installation. (Refer to
GROUP 52A P.52A-7). <RH drive vehicles>
<LH drive vehicles>
4WD-ECU
4.9 ± 0.9 N·m
<RH drive vehicles>
4.9 ± 0.9 N·m
4WD-ECU
AC310944AB
SENSOR, SWITCH AND RELAY

M1221012300043
WARNING
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Serv-
ice Precautions (P.52B-3) and Air Bag Module and Clock Spring (P.52B-110).
Parking brake lever

1
3
AC311353 AC
Steering wheel sensor removal Electric pump relay removal

steps 4. Electric pump relay
• Column cover (Refer to GROUP 37 ACD mode changeover switch
− Steering Shaft P.37-15). removal steps
<<A>> 1. Steering wheel sensor • Instrument panel ornament (Refer to
G-sensor removal steps GROUP 52A − Instrument Panel
• Front floor console (Refer to Assembly P.52A-2).
GROUP 52A P.52A-7). 5. ACD mode changeover switch
2. Longitudinal G-sensor
3. Lateral G-sensor
NOTE: For details on the wheel speed sensor, refer to GROUP 35B − On-vehicle Service P.35B-138.
22A-169
REMOVAL SERVICE POINT 1. Using a jumper wire, connect a battery (+) to
<<A>> STEERING WHEEL SENSOR terminal No.2 of the electric pump relay and
battery (-) to terminal No.1.
REMOVAL
2. While intermittently disconnecting the jumper wire
CAUTION at the battery side, check for continuity between
Make sure no oil adheres to the steering wheel terminals No.3 and No.4 of the electric pump
sensor because a photocoupler is used. relay.
Jumper wire Continuity between No.3 − No.4
Connected Less than 2 ohms
Disconnected Open circuit
ACD MODE CHANGEOVER SWITCH

CONTINUITY CHECK
AC310946AC
Remove the steering wheel sensor from the column

switch.
INSPECTION
M1221008000016
ELECTRIC PUMP RELAY CONTINUITY

CHECK AC311214AB
ACD mode ACD mode Continuity

changeover switch changeover
terminal switch
No.1 − No.2 ON Less than 2
ohms
OFF Open circuit
No.3 − No.4 − Less than 2
ohms
AC311213AB
AIR DUCT
AIR DUCT
M1221013400010

Front Under Cover Removal and Installation (Refer to
GROUP 51, Front Bumper Assembly P.51-2.)
11 ± 2 N·m
AC504974 AB
Removal steps REMOVAL SERVICE POINT

<<A>> 1. Air duct
<<A>> AIR DUCT REMOVAL
Turn the splash shield up to the position where the
air duct mounting bolts can be removed.
52B-1
GROUP 52B
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS
GENERAL INFORMATION . . . . . . . . 52B-2 SRS CONTROL UNIT (SRS-ECU) . . . 52B-109

SERVICE PRECAUTIONS. . . . . . . . . 52B-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B-110
SPECIAL TOOLS. . . . . . . . . . . . . . . . 52B-6 DRIVER'S AND PASSENGER'S (FRONT)

AIR BAG MODULES AND CLOCK
TEST EQUIPMENTS . . . . . . . . . . . . . 52B-8 SPRING. . . . . . . . . . . . . . . . . . . . . . . . 52B-110
TROUBLESHOOTING . . . . . . . . . . . . 52B-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B-115
POST-COLLISION DIAGNOSIS . . . . 52B-102 SEAT BELTS WITH PRE-

TENSIONER . . . . . . . . . . . . . . . . . . . . 52B-117
INDIVIDUAL COMPONENT REMOVAL AND INSTALLATION . . . . . . . . 52B-117
SERVICE . . . . . . . . . . . . . . . . . . . . . . 52B-105 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 52B-119
WARNING/CAUTION LABELS . . . . . 52B-106 AIR BAG MODULE AND SEAT BELT

PRE-TENSIONER DISPOSAL
FRONT IMPACT SENSORS . . . . . . . 52B-107 PROCEDURES . . . . . . . . . . . . . . . . . . 52B-120
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 52B-108
WARNING
• Carefully read and observe the information in the SERVICE PRECAUTIONS prior to any service.
• For information concerning troubleshooting or maintenance, always observe the procedures in the
Troubleshooting section.
• If any SRS components are removed or replaced in connection with any service procedures, be sure to follow the
procedures in the INDIVIDUAL COMPONENT SERVICE section for the comportments involved.
• If you have any questions about the SRS, please contact your local distributor.
52B-2 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
GENERAL INFORMATION
GENERAL INFORMATION
M1524000100558
The Supplemental Restraint System (SRS) and seat monitors the system and has a safing G-sensor and
belt with pre-tensioner is designed to supplement the analogue G-sensor. The warning lamp on the instru-
driver's and front passenger's seat belts to help ment panel indicates the operational status of the
reduce the risk or severity of injury to the driver and SRS. The clock spring is installed in the steering col-
front passenger by activating and deploying both umn. The seat belt pre-tensioner is built into the
front air bags in certain frontal collisions. driver's and passenger's front seat belt retractor. The
The SRS consist of two air bag modules, SRS air front impact sensor is assembled on the headlamp
bag control unit (SRS-ECU), two front impact sen- support panel to monitor collision upon frontal
sors, SRS warning lamp, clock spring and seat belt impact.
pre-tensioner. Front air bags are located in the centre Only authorized service personnel should do work on
of the steering wheel and above the glove box. Each or around the SRS components. Those service per-
air bag is made up of a folded air bag and an inflator sonnel should read this manual carefully before start-
unit. The SRS-ECU under the front floor console ing any such work.
Seat belt with

pre-tensioner
SRS warning lamp

AC310070
Diagnosis connector
Driver's air bag Passenger's (front)
module air bag module
Clock spring
SRS-ECU AC208855
AC304668
Front impact sensor
AC310783 AB
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SERVICE PRECAUTIONS
52B-3
SERVICE PRECAUTIONS
M1524000300596
DANGER CAUTION
In order to avoid injury to yourself or others
from accidental deployment of the air bag
SRS-ECU connector
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION
Do not use any electrical test equipment on or
near SRS components, except those specified on
P.52B-8.
AC300634 AB
CAUTION
Never Attempt to Repair the Following Compo-
nents:
1. SRS air bag control unit (SRS-ECU)
2. Clock spring
3. Driver's and front passenger's (front) air bag
modules
4. Front impact sensor
5. 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 pro-
cedures in this manual, starting at page P.52B-105.
SERVICE PRECAUTIONS
Do not attempt to repair the wiring harness con-

nectors of the SRS. If a defective wiring harness
is found, repair or replace it by referring to the
table below.
SRS-ECU terminal No. Destination of harness Remedy
1, 2 Instrument panel wiring harness → Correct or replace each wiring
Front wiring harness (RH) → Front harness.
impact sensor (RH)
Front wiring harness (LH) → Front harness.
impact sensor (LH)
7 Instrument panel wiring harness→ Correct or replace the instrument
Earth panel wiring harness.
8 Instrument panel wiring harness → Correct or replace the instrument
SRS warning lamp panel wiring harness.
9, 10 Instrument panel wiring harness → Correct or replace the instrument
Passenger's (front) air bag module panel wiring harness.
11, 12 Instrument panel wiring harness → Correct or replace instrument panel
Clock spring → Driver's air bag wiring harness. Replace the clock
module spring.
Junction block (fuse No.3) panel wiring harness.
Diagnosis connector panel wiring harness.
27, 28 Floor wiring harness (RH) → Connect or replace the floor wiring
Passenger's (front) seat belt harness.
pre-tensioner <LH drive vehicles>
Floor wiring harness (LH) →
Passenger's (front) seat belt
pre-tensioner <RH drive vehicles>
29, 30 Floor wiring harness (LH) → Driver's Connect or replace the floor wiring
seat belt pre-tensioner <LH drive harness.
vehicles> Floor wiring harness (RH)
→ Driver's seat belt pre-tensioner
<RH drive vehicles>
SERVICE PRECAUTIONS
52B-5
DANGER CAUTION
Insulating tape SRS-harness connector

Battery
MB992006
Battery cable
AC300580AB
After disconnecting the battery cable, wait 60

seconds or more before proceeding with the SRS-ECU harness connector
(rear side)
following work. In addition, insulate the neg-
ative battery terminal with a tape. The con-
denser 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 AC006195 AH
after the battery cables are disconnected. If checks are carried out by using the SRS-ECU
CAUTION harness connector, observe the following proce-
The SRS components and seat belt with pre-ten- dures: Insert the special tool extra fine probe
sioner should not be subjected to heat, so (MB992006) into connector from harness side
remove the front impact sensors, SRS-ECU, (rear side), and connect the tester to this probe. If
driver’s and passenger’s (front) air bag modules, any tool than special tool is used, damage to the
clock spring, and seat belt pre-tensioner before harness and other components will result. Never
drying or baking the vehicle after painting. insert the probe directly to the terminals from the
• Front impact sensors, SRS-ECU, air bag mod- front of the connector. The terminals are plated
ules, clock spring: 93°C or more to increase their conductivity, so that if they are
• Seat belt with pre-tensioner: 90°C or more touched directly by the probe, the plating may
break, which will cause drops in reliability.
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.
SPECIAL TOOLS
SPECIAL TOOLS
M1524000700549
Tool No. Name Use

MB991865 Dummy resistor SRS air bag and seat belt with
pre-tensioner circuit check
MB991865
MB991866 Resistor harness SRS air bag circuit check
MB991866
MB991884 Resistor harness (For Seat belt with pre-tensioner and

Pre-tensioner) curtain air bag circuit check
MB991884
MB686560 SRS air bag adapter • Deployment of passenger's

harness (front) air bag module inside
the vehicle
MB686560
• Deployment of passenger's
(front) air bag module outside
the vehicle
MB991885 Pre-tensioner adapter • Deployment of seat belt with
harness pre-tensioner and curtain air
bag inside the vehicle
MB991885
• Deployment of seat belt with
pre-tensioner and curtain air
bag outside the vehicle
MB990784 Ornament remover Removal of cover.
MB990784
MB991502 M.U.T.-II sub assembly • Reading and erasing

diagnosis code
• Reading trouble period
B991502 • Reading erase times
SPECIAL TOOLS
52B-7
Tool No. Name Use
A
MB991955 M.U.T.-III sub-assembly Checking diagnosis code
A: MB991824 A: Vehicle CAUTION
B: MB991827 communication M.U.T.-III main harness B
C: MB991910 interface (V. C. I.) (MB991911) should be used.
MB991824
D: MB991911 B: M.U.T.-III USB cable M.U.T.-III main harness A
B E: MB991825 C: M.U.T.-III main should not be used for this
F: MB991826 harness A (Vehicles vehicle.
with CAN
C system)
DO NOT USE D: M.U.T.-III main
harness B (Vehicles
MB991910 without CAN
D communication
system)
E: M.U.T.-III measure
MB991911
adapter
E harness
MB991825
MB991826
MB991955
A MB991223 Harness set Checking the continuity and

A: MB991219 A: Check harness measuring the voltage at the
B: MB991220 B: LED harness SRS-ECU harness connector
C: MB991221 C: LED harness
B
D: MB991222 adapter
D: Probe
D DO NOT USE
MB991223 AZ

connector
MB992006
TEST EQUIPMENTS
TEST EQUIPMENTS
M1524000800290
Tool Name Use

Digital multi-meter Checking SRS electrical circuitry (Use
multi-meter for which the maximum test
current is 2 mA or less at minimum range
of resistance measurement
AC300683
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW SRS WARNING LAMP CHECK
M1524003100386 M1524004300446
ing/Inspection Service PointsP.00-5.
DIAGNOSIS FUNCTION
M1524003200361
DIAGNOSIS CODES CHECK

CAUTION
Turn off the ignition switch before connecting or
disconnecting the M.U.T.-II/III.
Connect the M.U.T.-II/III to the diagnosis connector SRS warning lamp AC311044 AB
(16-pin) under the instrument under cover, then
check diagnosis codes (Refer to GROUP 00 − How 1. Check that the SRS warning lamp comes on
to Use Troubleshooting/Inspection Service when the ignition switch is turned ON.
PointsP.00-5). 2. Check that the SRS warning lamp illuminates for
about 7 seconds and then goes out.
ERASING DIAGNOSIS CODE 3. If this is not the cause, check the diagnosis codes.
CAUTION
Turn off the ignition switch before connecting or
disconnecting the M.U.T.-II/III.
Connect the M.U.T.-II/III to the diagnosis connector
and erase the diagnosis code.
TROUBLESHOOTING
52B-9
CHECK CHART FOR DIAGNOSIS CODES
M1524003300885
Inspect according to the inspection chart that is
appropriate for the diagnosis code.
Code No. Diagnosis item Reference Page
1A Front impact sensor (LH) circuit short P.52B-11
1B Front impact sensor (LH) circuit open P.52B-11
1C Front impact sensor (LH) short-circuited to power supply P.52B-11
1D Front impact sensor (LH) short-circuited to earth P.52B-11
2A Front impact sensor (RH) circuit short P.52B-11
2B Front impact sensor (RH) circuit open P.52B-11
2C Front impact sensor (RH) short-circuited to power supply P.52B-11
2D Front impact sensor (RH) short-circuited to earth P.52B-11
14 Analogue G-sensor malfunction P.52B-15
15 Safing G-sensor (for frontal collision) short-circuited P.52B-15
16 Safing G-sensor (for frontal collision) open-circuited P.52B-15
21*2 Driver's air bag module (squib) system (short-circuited P.52B-17
between terminals of the squib circuit)
22*2 Driver's air bag module (squib) system (open-circuited in the P.52B-21
squib circuit)
24*2 Passenger's (front) air bag module (squib) system P.52B-24
(short-circuited between terminals of the squib circuit)
25*2 Passenger's (front) air bag module (squib) system P.52B-27
(open-circuited in the squib circuit)
26*2 Driver's seat belt pre-tensioner (squib) system P.52B-29
(short-circuited between terminals of the squib circuit)
27*2 Driver's seat belt pre-tensioner (squib) system P.52B-34
28*2 Passenger's (front) seat belt pre-tensioner (squib) system P.52B-38
(short-circuit between terminals of the squib circuit)
29*2 Passenger's (front) seat belt pre-tensioner (squib) system P.52B-43
31 SRS-ECU capacitor circuit voltage too high P.52B-15
32 SRS-ECU capacitor circuit voltage too low P.52B-15
34*1 SRS-ECU connector lock out of order P.52B-47
35 Ignition of the air bag completed P.52B-49
39 Air bag deployed simultaneously P.52B-49
41*1 Power supply voltage (IG1 (A) voltage) drops abnormally. P.52B-50
42*1 Power supply voltage (IG1 (B) voltage) drops abnormally. P.52B-55
43*1 SRS warning lamp circuit Lamp does not illuminate P.52B-60
open-circuited Lamp does not switch off P.52B-64
44*1 SRS warning lamp circuit malfunction P.52B-67
TROUBLESHOOTING
Code No. Diagnosis item Reference Page

45 SRS-ECU non-volatile memory (EEPROM) and A/D P.52B-15
converter system
46*1 Improper installed of SRS-ECU P.52B-68
51 Driver's air bag squib activating circuit short-circuited P.52B-15
52 Driver's air bag squib activating circuit open-circuited P.52B-15
54 Passenger's (front) air bag squib activating circuit P.52B-15
short-circuited
55 Passenger's (front) air bag squib activating circuit P.52B-15
open-circuited
56 Driver’s seat belt pre-tensioner activating circuit short- P.52B-15
circuited
57 Driver’s seat belt pre-tensioner activating circuit open- P.52B-15
circuited
58 Passenger’s (front) seat belt pre-tensioner activating circuit P.52B-15
short- circuited
59 Passenger’s (front) seat belt pre-tensioner activating circuit P.52B-15
open- circuited
61 Driver's air bag module (squib) system (short-circuited to the P.52B-69
power supply)
62 Driver's air bag module (squib) system (short-circuited to the P.52B-72
earth)
64 Passenger's (front) air bag module (squib) system P.52B-75
(short-circuited to the power supply)
65 Passenger's (front) air bag module (squib) system P.52B-77
(short-circuited to the earth)
66 Driver's seat belt pre-tensioner (squib) system P.52B-79
(short-circuited to the power the supply)
67 Driver's seat belt pre-tensioner (squib) system P.52B-83
68 Passenger's (front) seat belt pre-tensioner (squib) system P.52B-87
(short-circuited to the power supply)
69 Passenger's (front) seat belt pre-tensioner (squib) system P.52B-91
NOTE: .
1. *1: If the vehicle condition returns to normal, the diagnosis code will be automatically erased, and the SRS
warning lamp will return to normal.
2. *2: However, if no diagnosis code resets, the SRS warning lamp will be switched off (The diagnosis code
will be retained).
3. If the vehicle has a discharged battery, it will store the diagnosis code 41 or 42. When these diagnosis
codes are read, check the battery.
TROUBLESHOOTING
52B-11
PROCEDURES
Code No.1A Front impact sensor (LH) circuit short

Code No.1B Front impact sensor (LH) circuit open
Code No.1C Front impact sensor (LH) short-circuited to power supply
Code No.1D Front impact sensor (LH) short-circuited to earth
Code No.2A Front impact sensor (RH) circuit short
Code No.2B Front impact sensor (RH) circuit open
Code No.2C Front impact sensor (RH) short-circuited to power supply
Code No.2D Front impact sensor (RH) short-circuited to earth
Front Impact Sensor Circuit
SRS-ECU
MICROCOMPUTER
INTERFACE CIRCUIT
NOTE
: LH drive vehicles
: RH drive vehicles
FRONT IMPACT FRONT IMPACT

SENSOR (LH) SENSOR (RH)
Wire colour code

OPERATION • SRS-ECU judges how severe a collision is by

• When the left and right front impact sensors detecting signals from the front impact sensors
detect a collision, the switches inside the sensors and the front air bag analogue G-sensor. If the
turn ON. impact is over a predetermined level, the
SRS-ECU sends an ignition signal. At this time, if
the front air bag safing G-sensor is on, the SRS
air bag will inflate.
TROUBLESHOOTING
DIAGNOSIS CODE SET CONDITIONS The most likely causes for these codes to be set are
These diagnosis codes are set if these are abnormal shown in the table below:
resistance between the input terminals of the front
impact sensors.
Code No. Trouble causes
1A • Left front impact sensor or its wiring shorted
1B • Left front impact sensor or wiring open circuit
1C • Short to the power supply in the left front impact sensor harness
1D • Short to body earth in the left front impact sensor harness
2A • Right front impact sensor or its wiring shorted
2B • Right front impact sensor or wiring open circuit
2C • Short to the power supply in the right front impact sensor harness
2D • Short to body earth in the right front impact sensor harness
PROBABLE CAUSE DIAGNOSIS

• Front impact sensor failed
• Malfunction of the SRS-ECU Step 1. Check the front impact sensor.
Refer to P.52B-108.
YES : Go to Step 2.
NO : Replace the front impact sensor (Refer to
P.52B-107).
TROUBLESHOOTING
52B-13
Step 2. Resistance measurement at the SRS-ECU C-12 Harness side
connector C-12. (Rear View)
Connector: C-12
1 2 3 4
C-12 (Y) 5 6 7 8 9 10 11 12
Harness side 13 14 15 16 17 18 19 20
connector
(rear view)
AC103372 AI
SRS-ECU
• Continuity between terminals 1, 2, 3, 4 and
AC101950AJ body earth
(1) Disconnect SRS-ECU connector C-12. OK: No continuity
CAUTION Q: Is the check result satisfactory?
YES : Go to Step 3.
AC100338
C-12 HarnessAC103684
side NO : Go to Step 4.
(Rear View)
Step 3. Voltage measurement at the SRS-ECU
1 2 3 4
5 6 7 8 9 101112
connector C-12.
1314151617181920
Connector: C-12
C-12 (Y)
AC103683AK Harness side
connector
AC100338 (rear view)
C-12 Harness side
(Rear View) SRS-ECU
1 2 3 4 AC101950AJ
5 6 7 8 9 101112
1314151617181920
(1) Disconnect SRS-ECU connector C-12.
CAUTION
C-12 Harness side
(Rear View)
AC103684 AK
Do not insert a test probe into the terminal from

its front side directly as the connector contact 1 2 3 4
pressure may be weakened. 5 6 7 8 9 10 11 12
(2) Take the measurements below at harness-side 13 14 15 16 17 18 19 20
connector C-12.
• Resistance between terminals 1 and 2 as well AC210613AB
as 3 and 4. Do not insert a test probe into the terminal from
NG: 2 ohms or less (short circuit) or 2 its front side directly as the connector contact
megaohms or more (open circuit) pressure may be weakened.
(2) Take the measurements below at harness-side
connector C-12.
• Voltage between terminals 1, 2, 3, 4 and body
earth
OK: 0V
YES : Go to Step 5.
NO : Go to Step 4.
TROUBLESHOOTING
Step 4. Check the wiring harness between the Connector: A-33 <RHD>
right front impact sensor connector A-37
(terminals 1 and 2) and SRS-ECU connector C-12
Harness side
(terminals 1 and 2) as well as between left front
(front view)
impact sensor connector A-33 (terminals 1 and 2)
and SRS-ECU connector C-12 (terminals 3 and 4). 2 1

A-33 (Y)
AC310475AD
Harness side NOTE:

(front view) A-37 (Y) Connector: C-111
2 1 <LHD>
AC310431AF
Harness side AC310452AW

(front view) A-37 (Y)
2 1 Connector: C-111
<RHD>
AC310433 AE
Connector: C-12
C-12 (Y) AC310456 AT

Harness side
connector Connector: C-129 <LHD>
(rear view)
SRS-ECU
AC101950AJ
Connectors: A-33 <LHD>
Harness side
(front view) AC310446 BD
A-33 (Y) 2 1
AC310542 AE
TROUBLESHOOTING
52B-15
Connector: C-129 <RHD> Step 5. Check whether the diagnosis code is
reset.
position.
Q: Is diagnosis code 1A, 1B, 1C, 1D, 2A, 2B, 2C or 2D
AC310454 AV set?
Prior to the wiring harness inspection, check interme- YES : Replace the SRS-ECU (Refer to
diate connectors C-111 and C-129, and repair if nec- P.52B-109).
essary. NO : The procedure is complete. (If no
• Check the front impact sensor output line for malfunctions are found in all steps, an
open or short circuit. intermittent malfunction is suspected. Refer
to GROUP 00 − How to Use
YES : Go to Step 4. Troubleshooting/Inspection Service Points
NO : Repair the wiring harness. P.00-5).
Code No.14: Analogue G-sensor malfunction

Code No.15: Safing G-sensor (for frontal collision) short-circuited
Code No.16: Safing G-sensor (for frontal collision) open-circuited
Code No.31: SRS-ECU capacitor circuit voltage too high
Code No.32: SRS-ECU capacitor circuit voltage too low
Code No.45: SRS-ECU non-volatile memory (EEPROM) and A/D converter system
Code No.51: Driver's air bag squib activating circuit short-circuited
Code No.52: Driver's air bag squib activating circuit open-circuited
Code No.54: Passenger's (front) air bag squib activating circuit short-circuited
Code No.55: Passenger's (front) air bag squib activating circuit open-circuited
Code No.56: Driver’s seat belt pre-tensioner activating circuit short-circuited
Code No.57: Driver’s seat belt pre-tensioner activating circuit open-circuited
Code No.58: Passenger’s (front) seat belt pre-tensioner activating circuit short-circuited
Code No.59: Passenger’s (front) seat belt pre-tensioner activating circuit open-circuited
TROUBLESHOOTING

These diagnosis codes are set when a fault is
detected in the SRS-ECU. The most likely causes for
this code to be set are shown in the table below:
Code No. Part/Circuit integral to Trouble causes
SRS-ECU
14 Analog G-sensor • When the analog G-sensor is not operating
• When the characteristics of the analog G-sensor are
abnormal
• When the output from the analog G-sensor is
abnormal
15 Safing G-sensor (for frontal • Short circuit in the safing G-sensor
16 collision) • Open circuit in the safing G-sensor
31 Capacitor circuit • Voltage at the capacitor terminal is higher than the
specified value for five seconds or more
32 • Voltage at the capacitor terminal is lower than the
specified value for five seconds or more (This is not
detected if diagnosis code No.41 or 42 indicating
battery positive voltage drop has been output).
45 Non-volatile memory (EEPROM) • When the non-volatile memory (EEPROM) and A/D
and A/D converter converter system are abnormal
51 Driver's air bag module (squib • Short circuit in the squib ignition drive circuit
52 ignition drive circuit) • Open circuit in the squib ignition drive circuit
54 Passenger's (front) air bag • Short circuit in the squib ignition drive circuit
55 module (squib ignition drive • Open circuit in the squib ignition drive circuit
circuit)
56 Driver’s seat belt pre-tensioner • Short circuit in the squib ignition drive circuit
57 (squib ignition drive circuit) • Open circuit in the squib ignition drive circuit
58 Passenger’s (front) seat belt • Short circuit in the squib ignition drive circuit
59 pre-tensioner (squib ignition drive • Open circuit in the squib ignition drive circuit
circuit)
PROBABLE CAUSE DIAGNOSIS PROCEDURE

Malfunction of the SRS-ECU Replace the SRS-ECU (Refer to P.52B-109).
TROUBLESHOOTING
52B-17
Code No.21: Driver's air bag module (squib) system (short-circuited between terminals of the squib
circuit)
Driver's Air Bag Module (Squib) Circuit
SRS-ECU
MICROCOMPUTER
AIR BAG
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
CLOCK CONNECTOR
SPRING LOCK
SWITCH
NOTE
: CONNECTOR
COUPLED: ON
AIR BAG MODULE CONNECTOR CONNECTOR
(SQUIB) LOCK UNCOUPLED: OFF
(DRIVER'S SIDE) SWITCH : LH drive vehicles
: RH drive vehicles
Wire colour code


• The SRS-ECU judges how severe a collision is • Improper engaged connector or defective short
by detecting signals from the front impact sensors spring*
and the front air bag analogue G-sensor. If the • Short circuit in the clock spring
impact is over a predetermined level, the • Short circuit between the driver's air bag module
SRS-ECU outputs an ignition signal. At this time, (squib) circuit terminals
if the front air bag safing G-sensor is on, the SRS • Damaged connector(s)
air bag will inflate. • Malfunction of the SRS-ECU
• The ignition signal is input to the air bag module NOTE: *: The squib circuit connectors integrate a
via the clock spring to inflate the air bag. "short" spring (which prevents the air bag from
deploying unintentionally due to static electricity by
DIAGNOSIS CODE SET CONDITIONS shorting the positive wire to the earth wire in the
This diagnosis code is set if one driver's air bag squib circuit when the connectors are disconnected).
squib wire shorted to the other. However, if no diag- Therefore, if connector C-12, C-205 or C-201 is dam-
nosis code resets, the SRS warning lamp will be aged or improperly engaged, the short spring may
switched off (diagnosis code will be retained). not be released when the connector is connected.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Connector lock check: SRS-ECU

connector C-12 clock spring connector C-205
STEP 1.M.U.T.-II/III diagnosis code and driver’s air bag module connector C-201.
(M.U.T.-II/III diagnosis code)
CAUTION
(1) Disconnect the negative battery terminal.
ignition switch to the "LOCK" (OFF) position Connector: C-12
(2) Check if the diagnosis code is set. C-12 (Y)
(3) Turn the ignition switch to the "LOOK" (OFF) Harness side
position. connector
(rear view)
Q: Is diagnosis code 34 set?
YES : Go to Step 2. SRS-ECU
NO : Go to Step 3.
AC101950AJ
STEP 2. Connector lock check: SRS-ECU Connectors: C-201, C-205

connector C-12 (M.U.T.-II/III diagnosis code) <LHD>
C-201 Harness side
connector (rear view)
Connector: C-12 C-201
C-205 Harness side

C-12 (Y) connector (rear view) C-205 (Y)
Harness side
connector
AC310479 AF
(rear view)
SRS-ECU Connectors: C-201, C-205

<RHD> C-201 Harness side
AC101950AJ connector (rear view)
(2) Disconnect connectors C-12 and then reconnect
them. C-205 (Y) C-201
(3) Connect the negative battery terminal.
C-205 Harness side
(4) Erase the diagnosis code memory, and check the connector (rear view)
diagnosis code.
YES : Go to Step 4. AC310481AF
NO : The procedure is complete. It is assumed (2) Disconnect connectors C-12, C-205 and C-201,
that diagnosis code 21 set as connector and then reconnect them.
C-12 was engaged improperly. (3) Connect the negative battery terminal.
(4) Erase the diagnosis code memory, and check the
diagnosis code.
YES : Go to Step 4.
NO : The procedure is complete. It is assumed
that diagnosis code 21 set as connector
C-12, C-205 or C-201 was engaged
improperly.
TROUBLESHOOTING
52B-19
STEP 4. Check the diagnosis code by connecting
YES : Go to Step 5.
a dummy resistor. (M.U.T.-II/III diagnosis code) NO : Replace the driver's air bag module (Refer
(1) Disconnect the negative battery terminal. to P.52B-110).

Steering a dummy resistor. (M.U.T.-II/III diagnosis code)
wheel
Harness side
connector
(rear view)
AC304700
C-205 (Y)
C-201 Air bag
module connector
AC310479 AG

A Harness side
connector
(rear view)
AC105823
AC305145AE
C-205 (Y)
(2) By sliding the A section (in the figure) of air bag
module connector C-201 in the arrow direction,
disconnect the connector.
MB991865 MB991866 AC310481AG
(Dummy resistor : 3 ) (Resistor harness)
(2) Disconnect the clock spring connector C-205.
MB991865 (Dummy
resistor : 3 ) MB991866
(Resistor harness)
C-201 Air bag

module
connector
AC300945AE
(3) Connect special tool dummy resistor (MB991865)
C-205 Clock spring
to special tool resistor harness (MB991866). (Rear view) connector
AC300949AC
CAUTION
Do not insert a test probe into the terminal from (3) Connect special tool dummy resistor (MB991865)
its front side directly as the connector contact to special tool resistor harness (MB991866).
pressure may be weakened. CAUTION
(4) Insert special tool (MB991866) into clock spring Do not insert a test probe into the terminal from
side air bag module connector C-201 by its front side directly as the connector contact
backprobing. pressure may be weakened.
(5) Connect the negative battery terminal. (4) Insert special tool (MB991866) into clock spring
(6) Erase the diagnosis code memory, and check the harness side connector C-205 (terminal No.3 and
diagnosis code. 4) by backprobing.
diagnosis code.
TROUBLESHOOTING
Q: Is diagnosis code 21 set? CAUTION

YES : Go to Step 6.
NO : Replace the clock spring (Refer to
P.52B-110). C-12 Harness side
(front view)
Terminal
Section
STEP 6. Resistance measurement at the
A-A Cable tie
SRS-ECU connector C-12. A
Connector: C-12
A
Short spring
C-12 (Y) 4 mm or more AC100391BG
Harness side
connector Insert an insulator such as a cable tie to a depth
(rear view) of 4 mm or more, otherwise the short spring will
not be released.
SRS-ECU
(3) Insert a cable tie [3 mm wide, 0.5 mm thick]
AC101950AJ between terminals 11, 12 and the short spring to
release the short spring.
CAUTION
Harness side
connector C-12 Harness side
(rear view) (rear view)
C-205 (Y)
AC310479 AG
Connector: C-205 <RHD> AQ
Harness side Do not insert a test probe into the terminal from
connector
(rear view)
its front side directly as the connector contact
pressure may be weakened.
C-205 (Y) (4) Resistance measurement between C-12 harness
side connector terminals 11 and 12.
OK: Open circuit
AC310481AG YES : Go to Step 7.
NO : Repair the harness wires between
SRS-ECU connector C-12 (terminal No.11
DANGER and 12 and clock spring connector C-205
To prevents the air bag from deploying unin- (terminal No.3 and 4).
tentionally, disconnect the clock spring con-
nector C-205 to short the squib circuit.
reset.
YES : Replace the SRS-ECU (Refer to
P.52B-109).
NO : An intermittent malfunction is suspected
(Refer to GROUP 00 − How to Use
P.00-5).
TROUBLESHOOTING
52B-21
Code No.22: Driver's air bag module (squib) system (open-circuited in the squib circuit)
SRS-ECU
MICROCOMPUTER
AIR BAG
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
CLOCK CONNECTOR
SPRING LOCK
SWITCH
NOTE
: CONNECTOR
COUPLED: ON
: RH drive vehicles
Wire colour code


• The SRS-ECU judges how severe a collision is • Open circuit in the clock spring
by detecting signals from the front impact sensors • Open circuit due to improper neutral position of
and the front air bag analogue G-sensor. If the the clock spring
impact is over a predetermined level, the • Open circuit in the driver's air bag module (squib)
SRS-ECU outputs an ignition signal. At this time, circuit
if the front air bag safing G-sensor is on, the SRS • Disengaged driver's air bag module (squib) con-
air bag will inflate. nector
• The ignition signal is input to the air bag module • Improper connector contact
via the clock spring to inflate the air bag. • Malfunction of the SRS-ECU

This diagnosis code is set if driver’s air bag squib
wire(s) are open-circuited. However, if no diagnosis
code resets, the SRS warning lamp will be switched
off (diagnosis code will be retained).
TROUBLESHOOTING
DIAGNOSIS PROCEDURE Q: Is diagnosis code 22 set?

YES : Go to Step 2.
NO : Replace the driver's air bag module (Refer
STEP 1. Check the diagnosis code by connecting to P.52B-110).
a dummy resistor. (M.U.T.-II/III diagnosis code)
Steering
wheel Connector: C-205 <LHD>
Harness side
connector
(rear view)
C-205 (Y)
AC304700
AC310479 AG
C-201 Air bag
module connector Connector: C-205 <RHD>
Harness side
connector
(rear view)
A
C-205 (Y)
AC105823
AC305145AE

module connector C-201 in the arrow direction, AC310481AG
disconnect the connector. (2) Disconnect the clock spring connector C-205.
MB991865 MB991866 MB991865 (Dummy
(Dummy resistor : 3 ) (Resistor harness) MB991866
resistor : 3 )
(Resistor harness)
C-201 Air bag

module
connector C-205 Clock spring
(Rear view) connector
AC300945AE AC300949AC
(3) Connect special tool dummy resistor (MB991865) (3) Connect special tool dummy resistor (MB991865)
to special tool resistor harness (MB991866). to special tool resistor harness (MB991866).
CAUTION CAUTION
Do not insert a test probe into the terminal from Do not insert a test probe into the terminal from
its front side directly as the connector contact its front side directly as the connector contact
pressure may be weakened. pressure may be weakened.
(4) Insert special tool (MB991866) into clock spring (4) Insert special tool (MB991866) into clock spring
side air bag module connector C-201 by harness side connector C-205 (terminal No.3 and
backprobing. 4) by backprobing.
(5) Connect the negative battery terminal. (5) Connect the negative battery terminal.
(6) Erase the diagnosis code memory, and check the (6) Erase the diagnosis code memory, and check the
diagnosis code. diagnosis code.
TROUBLESHOOTING
52B-23
YES : Go to Step 3.
C-12 Harness C-205 Harness
P.52B-110). side connector side connector
(rear view) (rear view)
STEP 3. Resistance measurement between the 1 2 3 4

1 2 3 4
SRS-ECU connector C-12 (terminal No.11 and 12) 5 6 7 8 9 10 11 12
and the clock spring connector C-205 (terminal 13 14 15 16 17 18 19 20
No.3 and 4)
Connector: C-12
AC200924 AJ

C-12 (Y) its front side directly as the connector contact
Harness side pressure may be weakened.
connector (2) Resistance measurement between the following
(rear view)
terminals.
SRS-ECU • SRS-ECU connector C-12 terminal No.11 and
the clock spring connector C-205 terminal
AC101950AJ
No.3
• SRS-ECU connector C-12 terminal No.12 and
the clock spring connector C-205 terminal
No.4
Harness side
connector OK: Less than 2 Ω
(rear view) Q: Are the check results normal?
YES : Go to Step 4.
C-205 (Y) SRS-ECU connector C-12 (terminal No.11
and 12) and clock spring connector C-205
AC310479 AG (terminal No.3 and 4).
Harness side STEP 4. Check whether the diagnosis code is
connector reset.
(rear view)
C-205 (Y) YES : Replace the SRS-ECU (Refer to
P.52B-109).
AC310481AG P.00-5).
(1) Disconnect SRS-ECU connector C-12 and clock
spring connector C-205.
TROUBLESHOOTING
Code No.24: Passenger's (front) air bag module (squib) system (short-circuited between terminals of
the squib circuit)
Passenger's (Front) Air Bag Module (Squib) Circuit
SRS-ECU NOTE
: CONNECTOR
COUPLED: ON
MICROCOMPUTER CONNECTOR
UNCOUPLED: OFF
: LH drive vehicles
: RH drive vehicles
AIR BAG DRIVE
CIRCUIT
CONNECTOR
LOCK
SWITCH
Wire colour code

B : Black LG : Light green CONNECTOR AIR BAG MODULE
G : Green L : Blue LOCK (SQUIB)
W : White Y : Yellow SWITCH (PASSENGER'S SIDE)
OPERATION NOTE: *: The squib circuit connectors integrate a

• The SRS-ECU judges how severe a collision is "short" spring (which prevents the air bag from
by detecting signals from the front impact sensors deploying unintentionally due to static electricity by
and the front air bag analogue G-sensor. If the shorting the positive wire to the earth wire in the
impact is over a predetermined level, the squib circuit when the connectors are discon-
SRS-ECU outputs an ignition signal. At this time, nected).Therefore, if connector C-12 or C-106 is
if the front air bag safing G-sensor is on, the SRS damaged or improperly engaged, the short spring
air bag will inflate. may not be released when the connector is con-
• The ignition signal is input to the air bag module nected.
to inflate the air bag.
DIAGNOSIS PROCEDURE
This diagnosis code is set if one passenger’s (front) STEP 1. M.U.T.-II/III diagnosis code
air bag squib wire shorted to the other. However, if no
CAUTION
diagnosis code resets, the SRS warning lamp will be
switched off (diagnosis code will be retained).
ignition switch to the "LOCK" (OFF) position
PROBABLE CAUSES before connecting or disconnecting M.U.T.-II/III.
• Improper engaged connector or defective short
spring*
(3) Turn the ignition switch to the "LOOK" (OFF)
• Short circuit between the passenger's (front) air
position.
bag module (squib) circuit terminals
• Damaged connector(s) Q: Is diagnosis code 34 set?
• Malfunction of the SRS-ECU YES : Go to Step 2.
NO : Go to Step 3.
TROUBLESHOOTING
52B-25
STEP 2. Connector lock check: SRS-ECU (3) Connect the negative battery terminal.
connector C-12. (M.U.T.-II/III diagnosis code) (4) Erase the diagnosis code memory, and check the
(1) Disconnect the negative battery terminal. diagnosis code.
Connector: C-12
YES : Go to Step 4.
C-12 (Y) C-12, or C-106 was engaged improperly.
Harness side
connector
(rear view) STEP 4. Check the diagnosis code by connecting
SRS-ECU
AC101950AJ
Connector: C-106 Glove box striker
(2) Disconnect the connectors C-12 and then
reconnect them.
(4) Erase the diagnosis code memory, and check the C-106 (R)
diagnosis code.
Harness side
Q: Is diagnosis code 24 set? connector (rear view)
YES : Go to Step 4.
NO : The procedure is complete. It is assumed 1 2
that diagnosis code 24 set as connector AC100985 AQ
C-12 was engaged improperly. (2) Disconnect passenger’s (front) air bag module
connector C-106.
STEP 3. Connector lock check: SRS-ECU MB991865
connector C-12 and passenger’s (front) air bag (Dummy resistor: 3 )
module connector C-106. (M.U.T.-II/III diagnosis C-106 Harness side
code) connector
Connector: C-12 MB991866
(Resistor harness)
C-106 Passenger's (front)

C-12 (Y) air bag module connector AC300956AL
Harness side
connector (3) Connect special tool dummy resistor (MB991865)
(rear view) to special tool resistor harness (MB991866).
SRS-ECU CAUTION
AC101950AJ its front side directly as the connector contact
Connector: C-106 Glove box striker (4) Disconnect the passenger's (front) air bag
module connector C-106 and insert special tool
(MB991866) into the harness side connector by
backprobing.
C-106 (R) (5) Connect the negative battery terminal.
Harness side
connector (rear view) diagnosis code.
1 2
AC100985 AQ YES : Go to Step 5.
NO : Replace the passenger's (front) air bag
(2) Disconnect connectors C-12 and C-106, and then
module (Refer to P.52B-110).
reconnect them.
TROUBLESHOOTING
STEP 5. Resistance measurement at SRS-ECU CAUTION

connector C-12. C-12
Connector: C-12 Harness side connector
(rear view)
1 2 3 4
C-12 (Y) 5 6 7 8 9 10 11 12
Harness side 13 14 15 16 17 18 19 20
connector
(rear view)
SRS-ECU
AC006044 AQ
AC101950AJ Do not insert a test probe into the terminal from

(1) Disconnect SRS-ECU connector C-12. its front side directly as the connector contact
Connector: C-106 Glove box striker (5) Resistance measurement between C-12 harness
OK: Open circuit
C-106 (R) Q: Is the check result normal?
YES : Go to Step 6.
Harness side NO : Repair the harness wires between
connector (rear view) SRS-ECU connector C-12 (terminal No.9
and 10) and passenger’s (front) air bag
1 2
AC100985 AQ module connector C-106 (terminal No.2 and
(2) Disconnect passenger’s (front) air bag module 1).
connector C-106.
DANGER STEP 6. Check whether the diagnosis code is
To prevents the air bag from deploying unin- reset.
tentionally, disconnect the passenger’s Q: Is diagnosis code 24 set?
(front) air bag module connector C-106 to YES : Replace the SRS-ECU (Refer
short the squib circuit. toP.52B-109).
(3) Disconnect the passenger's (front) air bag NO : An intermittent malfunction is suspected
module connector C-106. (Refer to GROUP 00 − How to Use
CAUTION
P.00-5).
C-12
(front view)
Terminal
Section
A-A Cable tie
A
4 mm or more Short spring AC006036 AV
Insert an insulator such as a cable tie to a depth

of 4 mm or more, otherwise the short spring will
not be released.
between terminals 9, 10 and the short spring to
TROUBLESHOOTING
52B-27
Code No.25: Passenger's (front) air bag module (squib) system (open-circuited in the squib circuit)
SRS-ECU NOTE
: CONNECTOR
COUPLED: ON
UNCOUPLED: OFF
: LH drive vehicles
: RH drive vehicles
AIR BAG DRIVE
CIRCUIT
CONNECTOR
LOCK
SWITCH
Wire colour code


• The SRS-ECU judges how severe a collision is This diagnosis code is set if passenger’s (front) air
by detecting signals from the front impact sensors bag squib wire(s) are open-circuited. However, if no
and the front air bag analogue G-sensor. If the diagnosis code resets, the SRS warning lamp will be
impact is over a predetermined level, the switched off (diagnosis code will be retained).
SRS-ECU outputs an ignition signal. At this time,
if the front air bag safing G-sensor is on, the SRS PROBABLE CAUSES
air bag will inflate. • Open circuit in the passenger's (front) air bag
• The ignition signal is input to the air bag module module (squib) circuit
to inflate the air bag. • Improper connector contact
• Malfunction of the SRS-ECU
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Resistance measurement between

SRS-ECU connector C-12 (terminal No9 and 10)
STEP 1. Check the diagnosis code by connecting and the passenger's (front) air bag module
a dummy resistor. (M.U.T.-II/III diagnosis code) connector C-106 (terminal No.2 and 1)
(1) Disconnect the negative battery terminal. Connector: C-106 Glove box striker
Connector: C-106 Glove box striker
C-106 (R)
C-106 (R)
Harness side
Harness side
1 2
AC100985 AQ
1 2
AC100985 AQ (1) Disconnect passenger’s (front) air bag module
(2) Disconnect passenger’s (front) air bag module connector C-106.
connector C-106. Connector: C-12
MB991865
(Dummy resistor: 3 )
C-106 Harness side C-12 (Y)

connector
(rear view)
MB991866
(Resistor harness) SRS-ECU
AC101950AJ
air bag module connector AC300956AL (2) Disconnect SRS-ECU connector C-12 and
(3) Connect special tool dummy resistor (MB991865) passenger's (front) air bag module connector
to special tool resistor harness (MB991866). C-106.
CAUTION CAUTION
Do not insert a test probe into the terminal from C-12 C-106 Harness side connector
its front side directly as the connector contact Harness side (rear view)
pressure may be weakened. connector
(4) Disconnect the passenger's (front) air bag (rear view) 1 2
module connector C-106, and insert special tool
1 2 3 4
(MB991866) into the harness side connector by 5 6 7 8 9 10 11 12
backprobing. 13 14 15 16 17 18 19 20
diagnosis code. AC203891AG
Q: Is diagnosis code 25 set? Do not insert a test probe into the terminal from
YES : Go to Step 2. its front side directly as the connector contact
NO : Replace the passenger's (front) air bag pressure may be weakened.
TROUBLESHOOTING
52B-29
(3) Resistance measurement between the following STEP 3. Check whether the diagnosis code is
terminals. reset.
the passenger’s (front) air bag module con- Q: Is diagnosis code 25 set?
nector C-106 terminal No.1 YES : Replace the SRS-ECU (Refer
• SRS-ECU connector C-12 terminal No.9 and toP.52B-109).
the passenger’s (front) air bag module con- NO : An intermittent malfunction is suspected
nector C-106 terminal No.2 (Refer to GROUP 00 − How to Use
OK: Less than 2 Ω
P.00-5).
YES : Go to Step 3.
and 9 and passenger’s (front) air bag
module connector C-106 (terminal No.1 and
2).
Code No.26: Driver's seat belt pre-tensioner (squib) system (short-circuited between terminals of the
squib circuit)
Driver's Seat Belt Pre-Tensioner (Squib) (LHD)
SRS-ECU
MICROCOMPUTER
AIR BAG DRIVE CIRCUIT
NOTE
CONNECTOR : CONNECTOR
COUPLED: ON
LOCK CONNECTOR
SWITCH UNCOUPLED: OFF
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(LH) SWITCH
Wire colour code

TROUBLESHOOTING
Driver's Seat Belt Pre-Tensioner (Squib) (RHD)
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(RH) SWITCH
Wire colour code


The SRS-ECU judges how severe a collision is by • Improper engaged connector or defective short
detecting signals from the front impact sensors and spring*
the front air bag analogue G-sensor. If the impact is • Short circuit between the driver's seat belt
over a predetermined level, the SRS-ECU outputs an pre-tensioner (squib) circuit terminals
ignition signal. At this time, if the front air bag safing • Damaged connector(s)
G-sensor is on, the seat belt pre-tensioner will • Malfunction of the SRS-ECU
deploy. NOTE: *: The squib circuit connectors integrate a
"short" spring (which prevents the air bag from
DIAGNOSIS CODE SET CONDITIONS deploying unintentionally due to static electricity by
This diagnosis code is set if one driver’s seat belt shorting the positive wire to the earth wire in the
pre-tensioner squib wire shorted to the other. How- squib circuit when the connectors are disconnected).
ever, if no diagnosis code resets, the SRS warning Therefore, if connector C-13, D-16 <LHD>, or D-03
lamp will be switched off (diagnosis code will be <RHD> is damaged or improperly engaged, the short
retained). spring may not be released when the connector is
connected.
TROUBLESHOOTING
52B-31
connector C-13 and driver’s seat belt
STEP 1. M.U.T.-II/III diagnosis code pre-tensioner connector D-16 <LHD> or D-03
<RHD> (M.U.T.-II/III diagnosis code)
CAUTION
ignition switch to the "LOCK" (OFF) position Connector: C-13
(2) Check if the diagnosis code is set. C-13 (Y)
(3) Turn the ignition switch to the "LOOK" (OFF) Harness side
position. connector
(rear view)
YES : Go to Step 2. 21 22 23 24 SRS-ECU
NO : Go to Step 3. 2526 27 282930 313233
3435 3637 38394041 42
AC101951AL
STEP 2. Connector lock check: SRS-ECU Connector: D-16

<LHD>
connector C-13 (M.U.T.-II/III diagnosis code) Harness side
(1) Disconnect the negative battery terminal. connector
(front view)
Connector: C-13
C-13 (Y)
Harness side
D-16 (B)
connector
AC310465 AN
(rear view)
21 22 23 24 SRS-ECU Connector: D-03

2526 27 282930 313233
<RHD>
3435 3637 38394041 42
AC101951AL D-03 (B)
(2) Disconnect the connectors C-13 and then
Harness side
reconnect them. connector
(3) Connector the negative battery terminal. (front view)
diagnosis code.
YES : Go to Step 4. AC310471 Ai
NO : The procedure is complete. It is assumed D-16 <LHD>,

that diagnosis code 26 set as connector D-03 <RHD>
C-13 was engaged improperly. Driver's seat
belt pre-tensioner
Flat-tipped connector
screwdriver
Locking button
D-16 <LHD>, D-03 <RHD>

Harness side connector AC300147AW
(2) Disconnect connectors C-13, D-16 <LHD>, or

D-03 <RHD>, and then reconnect them. For
connector D-16 <LHD> or D-03 <RHD>, use a
flat-tipped screwdriver to pull out the locking
button at the harness side connector, and then
TROUBLESHOOTING
(3) Connector the negative battery terminal. connector D-16 <LHD> or D-03 <RHD>. Use a
(4) Erase the diagnosis code memory, and check the flat-tipped screwdriver to pull out the locking
diagnosis code. button at the harness side connector, and then
YES : Go to Step 4. MB991884
MB991865 MB991885
NO : The procedure is complete. It is assumed (Dummy resistor : 3 )
C-13, D-16 <LHD>, or D-03 <RHD> was
engaged improperly.
MB991884
STEP 4. Check the diagnosis code by connecting (Resistor
a dummy resistor. (M.U.T.-II/III diagnosis code) harness)
(1) Disconnect the negative battery terminal. D-16 <LHD>, D-03 <RHD>
Harness side connectors AC300975 AI
Connector: D-16
<LHD> (3) Connect special tool dummy resistor (MB991865)
Harness side to special tool resistor harness (MB991884).
connector
(front view)
(4) Connect special tool (MB991884) to the
D-16<LHD> or D-03 <RHD> harness side
connector.
(6) Erase diagnosis code memory, and then check
the diagnosis code.
D-16 (B)
AC310465 AN Q: Is diagnosis code 26 set?
YES : Go to Step 5.
Connector: D-03 NO : Replace the driver's seat belt with
<RHD>
pre-tensioner (Refer to P.52B-117).
D-03 (B)
Harness side
connector
(front view)
AC310471 Ai
D-16 <LHD>,
D-03 <RHD>
Driver's seat
belt pre-tensioner
screwdriver
Locking button
D-16 <LHD>, D-03 <RHD>

(2) Disconnect driver's seat belt pre-tensioner
TROUBLESHOOTING
52B-33
STEP 5. Resistance measurement at the connector D-16 <LHD> or D-03 <RHD>. Use a
SRS-ECU connector C-13. flat-tipped screwdriver to pull out the locking
Connector: C-13 disconnect the connector.
CAUTION
D-16 <LHD>, D-03 <RHD>
C-13 (Y) Harness side connector
Harness side (front view)
connector Terminal
(rear view) Section
A-A Cable tie
21 22 23 24 SRS-ECU A
2526 27 282930 313233
3435 3637 38394041 42
AC101951AL A

Short spring
DANGER 4 mm or more
AC200988 AM
Connector: D-16
<LHD> Insert an insulator such as a cable tie to a depth
Harness side
of 4mm or more, otherwise the short spring will
connector
(front view) not be released.
CAUTION
D-16 (B) Do not insert a test probe into the terminal from
AC310465 AN its front side directly as the connector contact
Connector: D-03
<RHD>
D-03 (B) C-13
Harness side (rear view)
connector
(front view) 21 22 23 24
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
AC310471 Ai
AC006244 AS
To prevents the air bag from deploying unin-
tentionally, disconnect the driver’s seat belt (4) Resistance measurement between C-13 harness
pre-tensioner connector D-16 <LHD> or D-03
<RHD> to short the squib circuit. OK: Open circuit
D-16 <LHD>, Q: Is the check result normal?
D-03 <RHD> YES : Go to Step 6.
Driver's seat NO : Repair the harness wires between
belt pre-tensioner
Flat-tipped connector SRS-ECU connector C-13 (terminal No.29
screwdriver and 30) and driver’s seat belt pre-tensioner
connector D-16 <LHD>, D-03 <RHD>
Locking button (terminal No.2 and 1).
D-16 <LHD>, D-03 <RHD>


TROUBLESHOOTING

reset.
P.52B-109).
P.00-5).
Code No.27: Driver's seat belt pre-tensioner (squib) system (open-circuited in the squib circuit)
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(LH) SWITCH
Wire colour code

TROUBLESHOOTING
52B-35
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(RH) SWITCH
Wire colour code


The SRS-ECU judges how severe a collision is by This diagnosis code is set if driver's seat belt pre-ten-
detecting signals from the front impact sensors and sioner squib wire(s) are open-circuited. However, if
the front air bag analogue G-sensor. If the impact is no diagnosis code resets, the SRS warning lamp will
over a predetermined level, the SRS-ECU outputs an be switched off (diagnosis code will be retained).
ignition signal. At this time, if the front air bag safing
G-sensor is on, the seat belt pre-tensioner will PROBABLE CAUSES
deploy. • Improper connector contact
• Open circuit in the driver's seat belt pre-tensioner
(squib) circuit
TROUBLESHOOTING
DIAGNOSIS PROCEDURE connector D-16 <LHD> or D-03 <RHD>. Use a

STEP 1. Check the diagnosis code by connecting disconnect the connector.
MB991884
(1) Disconnect the negative battery terminal. MB991865 MB991885
(Dummy resistor : 3 )
Connector: D-16
<LHD>
Harness side
connector
(front view)
MB991884
(Resistor
harness)
D-16 <LHD>, D-03 <RHD>
D-16 (B)
AC310465 AN
to special tool resistor harness (MB991884).
Connector: D-03 (4) Connect special tool (MB991884) to the D-16
<RHD>
<LHD> or D-03 <RHD> harness side connector.
D-03 (B) (5) Connect the negative battery terminal.
Harness side
the diagnosis code.
connector
(front view) Q: Is diagnosis code 27 set?
YES : Go to Step 2.
NO : Replace the driver's seat belt with
AC310471 Ai
D-16 <LHD>,
D-03 <RHD>
Driver's seat
belt pre-tensioner
screwdriver
Locking button
D-16 <LHD>, D-03 <RHD>


TROUBLESHOOTING
52B-37
STEP 2. Resistance measurement between <LHD> or D-03 <RHD>, and measure at the
SRS-ECU connector C-13 (terminal No.29 and 30) wiring harness side. For connector D-16 <LHD>
and the driver's seat belt pre-tensioner D-16 or D-03 <RHD>, use a flat-tipped screwdriver to
<LHD> or D-03 <RHD> (terminal No.2 and 1). pull out the locking button at the harness side
connector, and then disconnect the connector.
Connector: C-13
MB991884
C-13 (Y)
Harness side
connector
(rear view)
D-16 <LHD>,
21 22 23 24 SRS-ECU D-03 <RHD>
2526 27 282930 313233 Harness side
3435 3637 38394041 42
AC101951AL connectors
AC201287AZ
Connector: D-16
<LHD> (2) Connect D-16 <LHD> or D-03 <RHD> harness
Harness side side connector to special tool resistor harness
connector (MB991884).
(front view)
C-13 Harness side

connector Special tool
(rear view) MB991884
1
21 22 23 24
D-16 (B) 2
25 26 27 28 29 30 31 32 33
AC310465 AN 34 35 36 37 38 39 40 41 42
Connector: D-03
<RHD>
D-03 (B) AC203780 AE
Harness side CAUTION

connector Do not insert a test probe into the terminal from
(front view) its front side directly as the connector contact
(3) Resistance measurement between the following
terminals.
AC310471 Ai
D-16 <LHD>, special tool terminal No.1
D-03 <RHD> • SRS-ECU connector C-13 terminal No.30 and
Driver's seat
belt pre-tensioner special tool terminal No.2
Flat-tipped connector OK: Less than 2 Ω
screwdriver
Locking button YES : Go to Step 3.
D-16 <LHD>, D-03 <RHD> and 30) and driver’s seat belt pre-tensioner
Harness side connector AC300147AW connector D-16 <LHD> or D-03 <RHD>
(1) Disconnect SRS-ECU connector C-13 and (terminal No.2 and 1).
driver's seat belt pre-tensioner connector D-16
TROUBLESHOOTING

reset.
Q: Is diagnosis code No.27 set?
YES : Replace the SRS-ECU (Refer
toP.52B-109).
P.00-5).
Code No.28: Passenger's (front) seat belt pre-tensioner (squib) system (short-circuit between
terminals of the squib circuit)
Passenger's (Front) Seat Belt Pre-tensioner (Squib) (LHD)
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(RH) SWITCH
Wire colour code

TROUBLESHOOTING
52B-39
Passenger's (Front) Seat Belt Pre-tensioner (Squib) (RHD)
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(LH) SWITCH
Wire colour code

OPERATION • Malfunction of the SRS-ECU

The SRS-ECU judges how severe a collision is by NOTE: *: The squib circuit connectors integrate a
detecting signals from the front impact sensors and "short" spring (which prevents the air bag from
the front air bag analogue G-sensor. If the impact is deploying unintentionally due to static electricity by
over a predetermined level, the SRS-ECU outputs an shorting the positive wire to the earth wire in the
ignition signal. At this time, if the front air bag safing squib circuit when the connectors are disconnected).
G-sensor is on, the seat belt pre-tensioner will Therefore, if connector C-13, D-03 <LHD> or
deploy. D-16<RHD> is damaged or improperly engaged, the
short spring may not be released when the connector
DIAGNOSIS CODE SET CONDITIONS is connected.
This diagnosis code is set if one passenger’s (front)
seat belt pre-tensioner squib wire shorted to the DIAGNOSIS PROCEDURE
other. However, if no diagnosis code resets, the SRS
warning lamp will be switched off (diagnosis code will STEP 1. M.U.T.-II/III diagnosis code
be retained).
CAUTION
PROBABLE CAUSES To prevent damage to M.U.T.-II/III, always turn the
• Improper engaged connector or defective short ignition switch to the "LOCK" (OFF) position
spring* before connecting or disconnecting M.U.T.-II/III.
• Short circuit between the passenger's (front) seat (1) Turn the ignition switch to the "ON" position.
belt pre-tensioner (squib) circuit terminals (2) Check if the diagnosis code is set.
• Damaged connector(s) (3) Turn the ignition switch to the "LOOK" (OFF)
position.
TROUBLESHOOTING

STEP 3. Connector lock check: SRS-ECU
YES : Go to Step 2.
NO : Go to Step 3.
connector C-13 and passenger’s (front) seat belt
pre-tensioner connector D-03 <LHD> or D-16
<RHD> (M.U.T.-II/III diagnosis code)
STEP 2. Connector lock check: SRS-ECU (1) Disconnect the negative battery terminal.
connector C-13. (M.U.T.-II/III diagnosis code)
Connector: C-13
Connector: C-13
C-13 (Y)
Harness side
C-13 (Y) connector
Harness side (rear view)
connector
21 22 23 24 SRS-ECU
(rear view) 2526 27 282930 313233
3435 3637 38394041 42
23 24 SRS-ECU AC101951AL
21 22
2526 27 282930 313233
3435 3637 38394041 42
AC101951AL
Connector: D-03
<LHD>
(2) Disconnect the connectors C-13 and then Harness side
reconnect them. connector
(3) Connector the negative battery terminal. (front view)
diagnosis code.
YES : Go to Step 4.
D-03 (B)
AC310465 AO
C-13, D-03 <LHD> or D-16 <RHD> was Connector: D-16
engaged improperly. <RHD>
D-16 (B)
Harness side
connector
(front view)
AC310471 AJ
D-03 <LHD>,
D-16 <RHD>
Passenger's (front)
seat belt
pre-tensioner
screwdriver
Locking button
D-03 <LHD>, D-16 <RHD>

Harness side connector AC300147AX
(2) Disconnect connectors C-13 and D-03 <LHD> or

D-16 <RHD>, and then reconnect them. For
connector D-03 <LHD> or D-16 <RHD>, use a
TROUBLESHOOTING
52B-41
(3) Connector the negative battery terminal. pre-tensioner connector D-03 <LHD> or D-16
(4) Erase the diagnosis code memory, and check the <RHD>. Use a flat-tipped screwdriver to pull out
diagnosis code. the locking button at the harness side connector,
and then disconnect the connector.
YES : Go to Step 4. MB991884
MB991865 MB991885
NO : The procedure is complete. It is assumed (Dummy Resistor : 3 )
C-13, D-03 <LHD> or D-16 <RHD> was
engaged improperly.
MB991884
STEP 4. Check the diagnosis code by connecting (Resistor
a dummy resistor. (M.U.T.-II/III diagnosis code) Harness)
(1) Disconnect the negative battery terminal. D-03 <LHD>, D-16 <RHD>
Harness side connector AC103283AY
Connector: D-03
<LHD> (3) Connect special tool dummy resistor (MB991865)
Harness side to special tool resistor harness (MB991884).
connector
(front view)
(4) Connect special tool (MB991884) to the D-03
the diagnosis code.
D-03 (B) Q: Is diagnosis code 28 set?
AC310465 AO YES : Go to Step 5.
NO : Replace the passenger's (front) seat belt
Connector: D-16 with pre-tensioner (Refer to P.52B-117).
<RHD>
D-16 (B)
Harness side
connector
(front view)
AC310471 AJ
D-03 <LHD>,
D-16 <RHD>
Passenger's (front)
seat belt
pre-tensioner
screwdriver
Locking button
D-03 <LHD>, D-16 <RHD>

(2) Disconnect passenger's (front) seat belt

TROUBLESHOOTING
STEP 5. Resistance measurement at the pre-tensioner connector D-03 <LHD> or D-16

SRS-ECU connector C-13 <RHD>. Use a flat-tipped screwdriver to pull out
the locking button at the harness side connector,
Connector: C-13 and then disconnect the connector.
CAUTION
D-03 <LHD>, D-16 <RHD>
C-13 (Y) Harness side connector
connector
(rear view) Cable tie
Terminal
21 22 23 24 SRS-ECU Section
2526 27 282930 313233 A A-A
3435 3637 38394041 42
AC101951AL
A
DANGER Short spring 4 mm or more
AC100393 AQ
AB
Connector: D-03
<LHD> Insert an insulator such as a cable tie to a depth
Harness side
of 4 mm or more, otherwise the short spring will
connector
(front view) not be released.
CAUTION
D-03 (B)
AC310465 AO C-13 Harness side
connector
Connector: D-16 (rear view)
<RHD>
D-16 (B) 21 22 23 24
25 26 27 28 29 30 31 32 33
Harness side 34 35 36 37 38 39 40 41 42
connector
(front view)
AC100326AQ

AC310471 AJ its front side directly as the connector contact
To prevents the air bag from deploying unin- pressure may be weakened.
tentionally, disconnect the passenger’s (4) Resistance measurement between C-13 harness
(front) seat belt pre-tensioner connector D-03
<LHD> or D-16 <RHD> to short the squib cir- OK: Open circuit.
cuit. Q: Is the check result normal?
D-03 <LHD>,
YES : Go to Step 6.
D-16 <RHD> NO : Repair the harness wires between
Passenger's (front)
seat belt SRS-ECU connector C-13 (terminal No.7
Flat-tipped
pre-tensioner and 8) and passenger’s (front) seat belt
connector
screwdriver pre-tensioner connector D-03 <LHD> or
D-16 <RHD> (terminal No.1 and 2).
Locking button
D-03 <LHD>, D-16 <RHD>


TROUBLESHOOTING
52B-43
reset.
P.52B-109).
P.00-5).
Code No.29: Passenger's (front) seat belt pre-tensioner (squib) system (open-circuited in the squib
circuit)
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(RH) SWITCH
Wire colour code

TROUBLESHOOTING
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(LH) SWITCH
Wire colour code


The SRS-ECU judges how severe a collision is by This diagnosis code is set if the passenger's (front)
detecting signals from the front impact sensors and seat belt pre-tensioner squib wire(s) are
the front air bag analogue G-sensor. If the impact is open-circuited. However, if no diagnosis code resets,
over a predetermined level, the SRS-ECU outputs an the SRS warning lamp will be switched off (diagnosis
ignition signal. At this time, if the front air bag safing code will be retained).
G-sensor is on, the seat belt pre-tensioner will
deploy. PROBABLE CAUSES
• Open circuit in the passenger's (front) seat belt
pre-tensioner (squib) circuit
• Improper connector contact
TROUBLESHOOTING
52B-45
DIAGNOSIS PROCEDURE pre-tensioner connector D-03 <LHD> or D-16
<RHD>. Use a flat-tipped screwdriver to pull out
STEP 1. Check the diagnosis code by connecting and then disconnect the connector.
MB991884
(Dummy Resistor : 3 )
Connector: D-03
<LHD>
Harness side
connector
(front view)
MB991884
(Resistor
Harness)
D-03 <LHD>, D-16 <RHD>
D-03 (B)
AC310465 AO
<RHD>
Harness side
the diagnosis code.
connector
YES : Go to Step 2.
with pre-tensioner (Refer to P.52B-117).
AC310471 AJ
D-03 <LHD>,
D-16 <RHD>
Passenger's (front)
seat belt
pre-tensioner
screwdriver
Locking button
D-03 <LHD>, D-16 <RHD>


TROUBLESHOOTING
STEP 2. Resistance measurement between passenger's (front) seat belt pre-tensioner

SRS-ECU connector C-13 (terminal No.27 and 28) connector D-03 <LHD> or D-16 <RHD>. For
and the passenger's (front) seat belt connector D-03 <LHD> or D-16 <RHD>, use a
pre-tensioner connector D-03 <LHD> or D-16 flat-tipped screwdriver to pull out the locking
<RHD> (terminal No.1 and 2) button at the harness side connector, and then
Connector: C-13
MB991884
C-13 (Y)
Harness side
connector
(rear view)
D-03 <LHD>,
21 22 23 24 SRS-ECU D-16 <RHD>
2526 27 282930 313233 Harness side
3435 3637 38394041 42
AC101951AL connectors
AC201287BB
Connector: D-03
<LHD> (2) Connect D-03 <LHD> or D-16 <RHD> harness
Harness side side connector to special tool resistor harness
connector (MB991884).
(front view)
CAUTION
D-03 (B)
AC310465 AO
C-13 Harness side Resister harness
Connector: D-16 connector (rear view) connector
<RHD>
1
21 22 23 24
D-16 (B) 2
25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42
Harness side
connector
(front view)
AC210076 AG

terminals.
AC310471 AJ
D-03 <LHD>, the special tool terminal No.2
D-16 <RHD>
Passenger's (front) • SRS-ECU connector C-13 terminal No.28 and
seat belt the special tool terminal No.1
pre-tensioner
Flat-tipped connector OK: Less than 2 Ω
screwdriver
Locking button YES : Go to Step 3.
D-03 <LHD>, D-16 <RHD> and 28) passenger’s (front) seat belt
Harness side connector AC300147AX pre-tensioner connector D-03 <LHD> or
(1) Disconnect SRS-ECU connector C-13 and D-16 <RHD> (terminal No.1 and 2).
TROUBLESHOOTING
52B-47
STEP 3.Check whether the diagnosis code is
reset.
P.52B-109).
P.00-5).
Code No.34: SRS-ECU connector lock out of order
DIAGNOSIS CODE SET CONDITIONS PROBABLE CAUSES

This diagnosis code is set if a poor connection at the • Damaged connectors
SRS-ECU is detected. However, if the vehicle condi- • Malfunction of the SRS-ECU
tion returns to normal, diagnosis code number 34 will
be automatically erased, and the SRS warning lamp
will go out.
TROUBLESHOOTING

connector C-12 and C-13
STEP 1. Connector lock check: SRS-ECU CONNECTORS: C-12, C-13
connector C-12 and C-13 (M.U.T.-II/III diagnosis
code)
(1) Disconnect the negative battery terminal. C-12 (Y)
C-13 (Y)
CONNECTORS: C-12, C-13
C-12 (Y)
C-13 (Y) SRS-ECU
SRS-ECU Harness side

(front view)
C-12 C-13
Harness side 21 22 23 24
(front view) 2526 27 282930 313233
3435 3637 38394041 42
C-12 C-13
AC309146 AC
21 22 23 24
2526 27 282930 313233
3435 3637 38394041 42
SRS-ECU Harness side connector

AC309146 AC (front view) Connector lock
switch terminal
SRS-ECU Harness side connector

(front view) Connector lock
switch terminal
AC006249 AM
(1) Disconnect SRS-ECU connectors C-12 and

C-13.
(2) Check the connector lock switch terminal inside
AC006249 AM the harness side connector for improper contact
(2) Disconnect SRS-ECU connectors C-12 and or deformation.
C-13, and then reconnect them. Q: Are the SRS-ECU connector C-12 and C-13 in good
(3) Connect the negative battery terminal. condition?
(4) Erase diagnosis code memory, and then check YES : Go to Step 3.
the diagnosis code. NO : Repair the SRS-ECU connector C-12 or
C-13.
YES : Go to Step 2.
C-12 or C-13 was engaged improperly.
TROUBLESHOOTING
52B-49
reset.
YES : Replace the SRS-ECU (Refer
toP.52B-109).
P.00-5).
Code No.35: Ignition of the air bag completed
DIAGNOSIS CODE SET CONDITIONS PROBABLE CAUSE

This diagnosis code is set after the air bag has Malfunction of the SRS-ECU
deployed. If this diagnosis code is set before the air
bag has deployed, the cause is probably a malfunc- DIAGNOSIS
tion inside the SRS-ECU. Replace the SRS-ECU. (Refer to P.52B-109).
Code No. 39 Air bags Deployed Simultaneously
DIAGNOSIS CODE SET CONDITIONS PROBABLE CAUSE

This code is set when the air bags have deployed Malfunction of the SRS-ECU
simultaneously. If this code is set before the air bags
have deployed, an internal failure may have occurred DIAGNOSIS PROCEDURE
in the SRS-ECU. Replace the SRS-ECU. (Refer to P.52B-109).
TROUBLESHOOTING
Code No.41: Power supply voltage (IG1 (A) voltage) drops abnormally.
IG1 Power Supply Circuit System

IGNITION
SWITCH (IG1)
SRS-ECU
POWER SOURCE D.C.-D.C. BACK-UP
CIRCUIT CONVERTER CAPACITOR
MICROCOMPUTER
WARNING LAMP
DRIVE CIRCUIT
COMBINATION
METER
Wire colour code NOTE

: LH drive
B : Black LG : Light green vehicles
G : Green L : Blue : RH drive
W : White Y : Yellow vehicles

OPERATION This diagnosis code is set if the voltage between the
• The SRS-ECU is powered from the ignition IG1 terminals (fuse No.2 circuit) and earth is lower
switch (IG1). than a predetermined value for a continuous period
• The SRS-ECU power is supplied from two cir- of 5 second or more. However, if the system returns
cuits. Even if one circuit is shut off, the air bag to normal condition, code number 41 will be erased
can inflate. automatically and the SRS warning lamp will go out.
PROBABLE CAUSES
• Damaged wiring harnesses or connectors
TROUBLESHOOTING
52B-51
DIAGNOSIS PROCEDURE (3) Connect the negative battery terminal.
STEP 1. Check junction block fuse number 2. CAUTION
C-12
Harness connector
(rear view)
Fuse No.2 1 2 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
Junction
block
AC203279 AF
AC301761 AC
Q: Is the fuse burned out? its front side directly as the connector contact
YES : Go to Step 4. pressure may be weakened.
NO : Go to Step 2.
(5) Voltage measurement between C-12 harness
side connector terminal 16 and body earth.
STEP 2. Voltage measurement at the SRS-ECU OK: 9 V or more.
connector C-12
(1) Disconnect the negative battery terminal. Q: Is the check result normal?
YES : Go to Step 8.
Connector: C-12 NO : Go to Step 3.
C-12 (Y)
Harness side
connector
(rear view)
SRS-ECU
AC101950AJ

TROUBLESHOOTING
STEP 3. Check the connectors between SRS-ECU Connectors: C-211, C-214

connector C-12 and ignition switch connector <RHD>
C-208. Junction block (front view)
Connector: C-12
C-211
C-12 (Y)
Harness side
connector
(rear view) C-214
SRS-ECU
Harness side
AC101950AJ
(front view)
Connector: C-208 C-214 C-211

<LHD>
Clock spring
Harness side
connector
(front view)
AC303823 AV

AC303806 AI <LHD>
Connector: C-208
<RHD> Clock spring C-211
C-214
Harness side
connector
(front view)
AC303820 AE
Harness side
(front view)
C-214 C-211
AC303809 AY

YES : Check the harness wires for open circuit
between SRS-ECU connector C-12
(terminal No.16) and ignition switch
TROUBLESHOOTING
52B-53
STEP 4. Check a burned-out fuse.
YES : Go to Step 6.
(1) Replace the fuse. NO : Go to Step 7.
(2) Turn the ignition switch to the "ON" position, wait
for at least one minute and then turn the ignition
switch to the "LOCK" (OFF) position. STEP 6. Resistance measurement at junction
(3) Check the fuse. block connector C-214
Q: Is the fuse in good condition? Connector: C-214
YES : This diagnosis is complete. <LHD>
NO : Go to Step 5. Junction block (front view)
STEP 5. Resistance measurement at the junction

block connector C-214 Harness side (front view)
Connector: C-214
<LHD>
AC303808AN
Connector: C-214
<RHD>
Harness side (front view) Junction block (front view)
AC303808AN
Connector: C-214
<RHD>
Junction block (front view) AC303822AO
(1) Disconnect junction block connector C-214, and

measure at the wiring harness side.
Harness side (front view) CAUTION
C-214 Harness side connector (rear view)
Y1729AU
AC303822AO
1 2 3 4 5 6 7 8 9 10 11 12 13 14
(1) Disconnect junction block connector C-214, and 15 16 17 18 19 20 21 22 23 24 25 26 27 28
CAUTION
1 2 3 4 5 6 7 8 9 10 11121314 AC106854 AM
1516 171819 20 212223242526 2728
(2) Resistance measurement between terminal 25
and body earth.
AC106855 AN OK: Open circuit
and body earth.
OK: Open circuit
TROUBLESHOOTING

YES : Check the other circuit, which flows through YES : Go to Step 8.
fuse number 2. NO : Check the harness wire for short circuit
NO : Check the harness wire for short circuit between SRS-ECU connector C-12
between junction block connector C-214 (terminal No.16) and junction block
(terminal No.25) and combination meter connector C-214 (terminal No.24), and
connector C-01 (terminal No.9), and repair if repair if necessary.
necessary.
STEP 7. Resistance measurement at the reset.
SRS-ECU connector C-12 Q: Is diagnosis code 41 set?
Connector: C-12 YES : Replace the SRS-ECU (Refer to
P.52B-109).
C-12 (Y)
Harness side Troubleshooting/Inspection Service Points
connector P.00-5).
(rear view)
SRS-ECU
AC101950AJ
(1) Disconnect SRS-ECU connector C-12, and

CAUTION
1 2 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
C-12 Harness connector

(rear view)
AC201665 AI

and body earth.
OK: Open circuit
TROUBLESHOOTING
52B-55
Code No.42: Power supply voltage (IG1 (B) voltage) drops abnormally.
IG1 Power Supply Circuit System

IGNITION
SWITCH (IG1)
SRS-ECU
MICROCOMPUTER
WARNING LAMP
DRIVE CIRCUIT
COMBINATION
METER
Wire colour code NOTE

: LH drive
B : Black LG : Light green vehicles
G : Green L : Blue : RH drive
W : White Y : Yellow vehicles

• The SRS-ECU is powered from the ignition This diagnosis code is set if the voltage between the
switch (IG1). IG1 terminals (fuse No.3 circuit) and earth is lower
• The SRS-ECU power is supplied from two cir- than a predetermined value for a continuous period
cuits. Even if one circuit is shut off, the air bag of 5 second or more. However, if the system returns
can inflate. to normal condition, code number 42 will be erased
automatically and the SRS warning lamp will go out.
PROBABLE CAUSES
• Damaged wiring harnesses or connectors
TROUBLESHOOTING
DIAGNOSIS PROCEDURE (3) Connect the negative battery terminal.

STEP 1. Check junction block fuse number 3. CAUTION
C-12 Harness side

Fuse No.3
1 2 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
Junction
block
AC203280 AH
AC301761 AD
Q: Is the fuse burned out? Do not insert a test probe into the terminal from
YES : Go to Step 4. its front side directly as the connector contact
NO : Go to Step 2. pressure may be weakened.
STEP 2. Voltage measurement at SRS-ECU side connector terminal 13 and body earth.
connector C-12 OK: 9 V or more
NO : Go to Step 3.
C-12 (Y)
Harness side
connector
(rear view)
SRS-ECU
AC101950AJ

TROUBLESHOOTING
52B-57
STEP 3. Check the connectors between SRS-ECU Connectors: C-211, C-214
connector C-12 and ignition switch connector <RHD>
C-208. Junction block (front view)
Connector: C-12
C-211
C-12 (Y)
Harness side
connector
(rear view) C-214
SRS-ECU
Harness side
AC101950AJ
(front view)
Connector: C-208 C-214 C-211

<LHD>
Clock spring
Harness side
connector
(front view)
AC303823 AV

AC303806 AI <LHD>
Connector: C-208
<RHD> Clock spring C-211
C-214
Harness side
connector
(front view)
AC303820 AE
Harness side
(front view)
C-214 C-211
AC303809 AY

YES : Check the harness wires for open or short
circuit between SRS-ECU connector C-12
(terminal No.13) and ignition switch
TROUBLESHOOTING

STEP 4. Check a burned-out fuse.
YES : Check the other circuit, which flows through
(1) Replace the fuse.
fuse number 3.
(2) Turn the ignition switch to the "ON" position, wait NO : Go to Step 6.
for at least one minute and then turn the ignition
switch to the "LOCK" (OFF) position.
(3) Check the fuse. STEP 6. Resistance measurement at the
SRS-ECU connector C-12
Q: Is the fuse in good condition?
YES : Go to Step 7. Connector: C-12
NO : Go to Step 5.
STEP 5. Resistance measurement at the junction

block connector C-214 C-12 (Y)
Harness side
Connector: C-214 connector
<LHD> (rear view)
SRS-ECU
AC101950AJ
Harness side (front view) (1) Disconnect SRS-ECU connector C-12, and
CAUTION
AC303808AN C-12 Harness connector (rear view)
Connector: C-214 1 2 3 4
5 6 7 8 9 10 11 12
<RHD>
13 14 15 16 17 18 19 20
AC202026 AL
AC303822AO
(1) Disconnect junction block connector C-214, and its front side directly as the connector contact
measure at the wiring harness side. pressure may be weakened.
CAUTION (2) Resistance measurement between terminal 13
and body earth.
OK: Open circuit
1 2 3 4 5 6 7 8 9 1011121314
1516171819202122232425262728
YES : Go to Step 7.
NO : Check the harness wire for short circuit
(terminal No.13) and junction block
connector C-214 (terminal No.7), and repair
if necessary.
AC100339 AI

and body earth.
OK: Open circuit
TROUBLESHOOTING
52B-59
reset.
P.52B-109).
P.00-5).
TROUBLESHOOTING
Code No.43: SRS warning lamp circuit open-circuited (Lamp does not Illuminate).
SRS Warning Lamp Drive Circuit
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONNECTOR
LOCK SWITCH
SRS-ECU
WARNING LAMP
DRIVE CIRCUIT
NOTE
: CONNECTOR
COUPLED: ON
UNCOUPLED: OFF
: LH drive vehicles
: RH drive vehicles
Wire colour code

TROUBLESHOOTING
52B-61
• Power for the SRS warning lamp is supplied from
the ignition switch (IG1) circuit. STEP 1. Check the SRS warning lamp.
• The SRS warning lamp illuminates when the igni- (1) Disconnect the negative battery terminal.
tion switch is turned to the "ON" position and
goes out after approximately 7 seconds if there is Connector: C-12
not a malfunction in the SRS system.
DIAGNOSIS CODE SET CONDITIONS C-12 (Y)

• This diagnosis code is set when an open circuit is Harness side
detected for a continuous period of 5 seconds connector
while the SRS-ECU is monitoring the SRS warn- (rear view)
ing lamp and the lamp is OFF. (transistor OFF). SRS-ECU
However, if the vehicle condition returns to nor-
mal, diagnosis code 43 will be automatically AC101950AJ
erased, and the SRS warning lamp will go out. (2) Disconnected the SRS-ECU connector C-12.
PROBABLE CAUSES (4) Turn the ignition switch to the "ON" position.
• Damaged wiring harnesses of connectors
Q: Does the warning lamp illuminate?
• Blown bulb
YES : Go to Step 4.
NO : Go to Step 2.
• Malfunction of the combination meter
STEP 2. Check the SRS warning lamp bulb.
SRS warning lamp AC311044 AB
Q: Has the SRS warning lamp bulb blown?

YES : Replace the SRS warning lamp bulb.
NO : Go to Step 3.
TROUBLESHOOTING
STEP 3. Check the harness for open circuit Connectors: C-01, C-02
between ignition switch connector C-208 <RHD>
(terminal No.2) and combination meter C-01
(terminal No.9) and between combination meter C-01 C-02(L)
C-02 (terminal No.36) and SRS-ECU connector
C-12 (terminal No.8).
Connector: C-208
<LHD>
Clock spring
Harness side
connector
(front view)
C-01
Harness side
AC303806 AI
C-02
Harness side
Connector: C-208
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
<RHD> Clock spring
AC303815 AR
Harness side
Connector: C-12
connector
(front view)
C-12 (Y)
AC303820 AE Harness side
connector
Connectors: C-01, C-02, C-23 (rear view)
<LHD>
SRS-ECU
C-01
C-02 (L)
C-23 (B) AC101950AJ
NOTE: After inspecting intermediate connectors

C-01, C-02, C-23 <LHD> or C-01, C-02 <RHD>
inspect the wiring harness. If intermediate connec-
tors C-01, C-02, C-23 <LHD> or C-01, C-02 <RHD>.
are damaged, repair or replace them.
C-23 YES : Replace the combination meter (Refer to
1 2 3 4 5 6 7 8 9 10 11 GROUP 54A − Combination Meters
12 13 14 15 16 17 18 19 20 21 22
Assembly P.54A-56). Then go to Step 4.
C-01 Harness side SRS-ECU connector C-12 (terminal No.8)
and the ignition switch connector C-208
(terminal No.2).
C-02 Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC303799 AQ
TROUBLESHOOTING
52B-63
reset.
P.52B-109).
P.00-5).
TROUBLESHOOTING
Code No.43: SRS warning lamp circuit open-circuited (Lamp does not Switch Off).
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONNECTOR
LOCK SWITCH
SRS-ECU
WARNING LAMP
DRIVE CIRCUIT
NOTE
: CONNECTOR
COUPLED: ON
UNCOUPLED: OFF
: LH drive vehicles
: RH drive vehicles
Wire colour code

TROUBLESHOOTING
52B-65
• Power for the SRS warning lamp is supplied from
the ignition switch (IG1) circuit. STEP 1. Check the SRS warning lamp.
• The SRS warning lamp illuminates when the igni- (1) Disconnect the negative battery cable.
tion switch is turned to the "ON" position and
goes out after approximately 7 seconds if there is Connector: C-02
C-02 (L)
not a malfunction in the SRS system. <LHD>

• This diagnosis code is set when a short to earth
occurs in the harness between the SRS warning
lamp and SRS-ECU while SRS-ECU is monitor-
ing the lamp and the lamp is ON. However, if the Harness side
vehicle condition returns to normal, diagnosis
code 43 will be automatically erased, and the
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC303798 AZ
SRS warning lamp will go out.

Connector: C-02 C-02 (L)
TROUBLESHOOTING HINTS <RHD>

• Malfunction of the combination meter
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC303814 AV
(2) Disconnect the combination meter connector

C-02.
(3) Connect the negative battery cable.
Q: Does the SRS warning lamp go out?

YES : Go to Step 2.
GROUP 54A − Combination Meters
Assembly P.54A-56).
TROUBLESHOOTING
STEP 2. Check the harness for short circuit to STEP 3. Check whether the diagnosis code is
earth between SRS-ECU connector C-12 reset.
(terminal No.8) and combination meter connector Q: Is diagnosis code 43 set?
C-02 (terminal No.36). YES : Replace the SRS-ECU (Refer to
Connector: C-12 P.52B-109).
C-12 (Y)
Harness side P.00-5).
connector
(rear view)
SRS-ECU
AC101950AJ
Connector: C-02
<LHD> C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC303798 AZ
Connector: C-02 C-02 (L)

<RHD>
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC303814 AV

YES : Go to Step 3.
NO : Repair the harness wire between SRS-ECU
connector C-12 (terminal No.8) and
combination meter connector C-02 (terminal
No.36).
TROUBLESHOOTING
52B-67
Code No.44: SRS warning lamp circuit malfunction
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONNECTOR
LOCK SWITCH
SRS-ECU
WARNING LAMP
DRIVE CIRCUIT
NOTE
: CONNECTOR
COUPLED: ON
UNCOUPLED: OFF
: LH drive vehicles
: RH drive vehicles
Wire colour code

TROUBLESHOOTING
OPERATION • When a malfunction is detected in the output

• Power for the SRS warning lamp is supplied from transistor inside the SRS-ECU.
the ignition switch (IG1). • However, if the vehicle condition returns to nor-
• The SRS warning lamp illuminates when the igni- mal, diagnosis code 44 will be automatically
tion switch is turned to the "ON" position and erased, and the SRS warning lamp will go out.
goes out after approximately 7 seconds if there is
not a malfunction in the SRS system. PROBABLE CAUSES
DIAGNOSIS CODE SET CONDITIONS • Malfunction of the SRS-ECU
• This diagnosis code is set under one of the fol-
lowing cases while the SRS-ECU is monitoring DIAGNOSIS PROCEDURE
the warning lamp drive circuit: Check the SRS warning lamp drive circuit system.
• When a short circuit occurs in the warning Refer to P.52B-60, P.52B-64.
lamp drive circuit.
Code No. 46 Improper installation of SRS-ECU
DIAGNOSIS CODE SET CONDITIONS PROBABLE CAUSES

This diagnosis code is set when an SRS-ECU Incorrect SRS-ECU
designed only for the driver's air bag, is installed on
vehicle, which has both driver's and passenger's DIAGNOSIS PROCEDURE
(front) air bags. However, if the system returns to Replace the SRS-ECU to a proper one for equipment
normal condition, code number 46 will be erased (Refer to P.52B-109).
automatically and the SRS warning lamp will go out.
TROUBLESHOOTING
52B-69
Code No.61: Driver's air bag module (squib) system (short-circuited to the power supply)
SRS-ECU
MICROCOMPUTER
AIR BAG
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
CLOCK CONNECTOR
SPRING LOCK
SWITCH
NOTE
: CONNECTOR
COUPLED: ON
: RH drive vehicles
Wire colour code


• The SRS-ECU judges how severe a collision is This diagnosis code is set if the driver’s air bag squib
by detecting signals from the front impact sensors wire(s) are short-circuited to the power supply.
and the front air bag analogue G-sensor. If the
impact is over a predetermined level, the PROBABLE CAUSES
SRS-ECU sends an ignition signal. At this time, if • Malfunction of the clock spring
the front air bag safing G-sensor is on, the SRS • Damaged harness wires and connectors
air bag will inflate. • Short to the power supply in the driver's air bag
• The ignition signal is input to the air bag module module (squib) harness
TROUBLESHOOTING
DIAGNOSIS PROCEDURE Q: Is diagnosis code 61 out put?

YES : Go to Step 2.
NO : Replace the driver’s air bag module (Refer
Steering
Harness side
connector
(rear view)
C-205 (Y)
AC304700
AC310479 AG
C-201 Air bag
Harness side
connector
(rear view)
A
C-205 (Y)
AC105823
AC305145AE

module connector C-201 in arrow direction, AC310481AG
MB991865 MB991866 MB991865 (Dummy
resistor : 3 )
(Resistor harness)
C-201 Air bag

module
AC300945AE AC300949AC
CAUTION CAUTION
TROUBLESHOOTING
52B-71
Q: Is diagnosis code 61 set? (3) Turn the ignition switch to the "ON" position.
YES : Go to Step 3.
CAUTION
P.52B-110).
C-12 Harness side
STEP 3. Voltage measurement at the SRS-ECU
connector C-12 1 2 3 4
5 6 7 8 9 10 11 12
Connector: C-12 13 14 15 16 17 18 19 20
C-12 (Y) AC006255 AT

Harness side
(rear view)
SRS-ECU pressure may be weakened.
AC101950AJ side connector terminals 11, 12 and body earth.
(1) Disconnect SRS-ECU connector C-12. OK: 0 V
DANGER Q: Is the check result normal?
Connector: C-205 <LHD> YES : Go to Step 4.
Harness side
connector and 12) and clock spring connector C-205
(rear view) (terminal No.3 and 4).

C-205 (Y) reset.
AC310479 AG
Connector: C-205 <RHD> P.52B-109).
Harness side NO : An intermittent malfunction is suspected
connector (Refer to GROUP 00 − How to Use
(rear view) Troubleshooting/Inspection Service Points
C-205 (Y)
P.00-5).
AC310481AG

TROUBLESHOOTING
Code No.62: Driver's air bag module (squib) system (short-circuited to the earth)
SRS-ECU
MICROCOMPUTER
AIR BAG
DRIVE CIRCUIT
CONNECTOR
LOCK
SWITCH
CLOCK CONNECTOR
SPRING LOCK
SWITCH
NOTE
: CONNECTOR
COUPLED: ON
: RH drive vehicles
Wire colour code


• The SRS-ECU judges how severe a collision is This diagnosis code is set if the driver's air bag squib
by detecting signals from the front impact sensors wire(s) are short-circuited to the earth.
SRS-ECU outputs an ignition signal. At this time, • Malfunction of the clock spring
if the front air bag safing G-sensor is on, the SRS • Damaged harness wires and connectors
air bag will inflate. • Short to the earth in the driver's air bag module
• The ignition signal is input to the air bag module (squib) harness
TROUBLESHOOTING
52B-73
DIAGNOSIS PROCEDURE Q: Is diagnosis code 62 out put?
YES : Go to Step 2.
NO : Replace the driver’s air bag module (Refer
Steering
Harness side
connector
(rear view)
C-205 (Y)
AC304700
AC310479 AG
C-201 Air bag
Harness side
connector
(rear view)
A
C-205 (Y)
AC105823
AC305145AE

module connector C-201 in arrow direction, AC310481AG
MB991865 MB991866 MB991865 (Dummy
resistor : 3 )
(Resistor harness)
C-201 Air bag

module
AC300945AE AC300949AC
CAUTION CAUTION
TROUBLESHOOTING

YES : Go to Step 3.
P.52B-110). 1 2 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
STEP 3. Resistance measurement at the
Connector: C-12
C-12 Harness side
AC006256 AS
C-12 (Y)
connector its front side directly as the connector contact
(rear view) pressure may be weakened.
SRS-ECU (3) Check for continuity between C-12 harness side
connector terminals 11, 12 and body earth.
AC101950AJ
OK: Open circuit
DANGER YES : Go to Step 4.
Connector: C-205 <LHD> NO : Repair the harness wires between
and 12) and clock spring connector C-205
Harness side
connector
(terminal No.3 and 4).
(rear view)
reset.
C-205 (Y)
AC310479 AG
P.52B-109).
Connector: C-205 <RHD> NO : An intermittent malfunction is suspected
Harness side (Refer to GROUP 00 − How to Use
connector Troubleshooting/Inspection Service Points
(rear view) P.00-5).
C-205 (Y)
AC310481AG

TROUBLESHOOTING
52B-75
Code No.64: Passenger's (front) air bag module (squib) system (short-circuited to the power supply)
SRS-ECU NOTE
: CONNECTOR
COUPLED: ON
UNCOUPLED: OFF
: LH drive vehicles
: RH drive vehicles
AIR BAG DRIVE
CIRCUIT
CONNECTOR
LOCK
SWITCH
Wire colour code


• The SRS-ECU judges how severe a collision is This diagnosis code is set if the passenger's (front)
by detecting signals from the front impact sensors air bag squib wire(s) are short-circuited to the power
and the front air bag analogue G-sensor. If the supply.
impact is over a predetermined level, the
SRS-ECU outputs an ignition signal. At this time, PROBABLE CAUSES
if the front air bag safing G-sensor is on, the SRS • Damaged harness wires and connectors
air bag will inflate. • Short to the power supply in the passenger's
• The ignition signal is input to the air bag module (front) air bag module (squib) harness
to inflate the air bag. • Malfunction of the SRS-ECU
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Voltage measurement at the SRS-ECU

connector C-12
STEP1. Check the diagnosis code by connecting Connector: C-12
Connector: C-106 Glove box striker C-12 (Y)
Harness side
connector
(rear view)
C-106 (R) SRS-ECU
Harness side AC101950AJ

1 2 CAUTION
AC100985 AQ
Connector: C-106
(2) Disconnect passenger’s (front) air bag module Glove box striker
connector C-106.
MB991865
C-106 (R)
C-106 Harness side
MB991866 1 2
(Resistor harness) AC100985 AQ
To prevents the air bag from deploying uninten-

C-106 Passenger's (front) tionally, disconnect the passenger’s (front) air
air bag module connector AC300956AL
bag module connector C-106 to short the squib
(3) Connect special tool dummy resistor (MB991865) circuit.
to special tool resistor harness (MB991866). (2) Disconnect the passenger's (front) air bag
CAUTION module connector C-106.
Do not insert a test probe into the terminal from (3) Turn the ignition switch to the "ON" position.
its front side directly as the connector contact CAUTION
(4) Disconnect the passenger's (front) air bag C-12 Harness side
module connector C-106, and insert special tool connector (rear view)
backprobing. 1 2 3 4
5 6 7 8 9 10 11 12
(5) Connect the negative battery terminal. 13 14 15 16 17 18 19 20
diagnosis code.
YES : Go to Step 2. AC006257AR
side connector terminals 9, 10 and body earth.
OK: 0 V
TROUBLESHOOTING
52B-77
YES : Go to Step 3.
reset.
SRS-ECU connector C-12 (terminal No.9 Q: Is diagnosis code 64 set?
and 10) and passenger's (front) air bag YES : Replace the SRS-ECU (Refer to
module connector C-106 (terminal No.1 and P.52B-109).
2). NO : An intermittent malfunction is suspected
P.00-5).
Code No.65: Passenger's (front) air bag module (squib) system (short-circuited to the earth)
SRS-ECU NOTE
: CONNECTOR
COUPLED: ON
UNCOUPLED: OFF
: LH drive vehicles
: RH drive vehicles
AIR BAG DRIVE
CIRCUIT
CONNECTOR
LOCK
SWITCH
Wire colour code


• The SRS-ECU judges how severe a collision is This diagnosis code is set if the passenger's (front)
by detecting signals from the front impact sensors air bag squib wire(s) are short-circuited to the earth.
SRS-ECU outputs an ignition signal. At this time, • Damaged harness wires and connectors
if the front air bag safing G-sensor is on, the SRs • Short to the earth in the passenger's (front) air
(front) air bag will inflate. bag module (squib) harness
• The ignition signal is input to the air bag module • Malfunction of the SRS-ECU
spring to inflate the air bag.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Resistance measurement at the

STEP 1. Check the diagnosis code by connecting Connector: C-12
Connector: C-106 Glove box striker C-12 (Y)
Harness side
connector
(rear view)
C-106 (R) SRS-ECU
Harness side AC101950AJ

1 2 CAUTION
AC100985 AQ
Connector: C-106
(2) Disconnect passenger’s (front) air bag module Glove box striker
connector C-106.
MB991865
C-106 (R)
C-106 Harness side
MB991866 1 2
(Resistor harness) AC100985 AQ
To prevents the air bag from deploying uninten-

C-106 Passenger's (front) tionally, disconnect the passenger’s (front) air
air bag module connector AC300956AL
bag module connector C-106 to short the squib
(3) Connect special tool dummy resistor (MB991865) circuit.
to special tool resistor harness (MB991866). (2) Disconnect passenger’s (front) air bag module
CAUTION connector C-106.
Do not insert a test probe into the terminal from CAUTION
(4) Disconnect the passenger's (front) air bag 1 2 3 4
5 6 7 8 9 10 11 12
module connector C-106, and insert special tool 13 14 15 16 17 18 19 20
backprobing.
(6) Erase the diagnosis code memory, and check the C-12 Harness side connector
diagnosis code. (rear view)
Q: Is diagnosis code 65 set? AC006258 AR

YES : Go to Step 2.
TROUBLESHOOTING
52B-79
(3) Resistance measurement between C-12 harness STEP 3. Check whether the diagnosis code is
side connector terminals 9, 10 and body earth. reset.
OK: Open circuit
Q: Is the check result normal? YES : Replace the SRS-ECU (Refer to
YES : Go to Step 3. P.52B-109).
NO : Repair the harness wires between NO : An intermittent malfunction is suspected
SRS-ECU connector C-12 (terminal No.9 (Refer to GROUP 00 − How to Use
and 10) and passenger's (front) air bag Troubleshooting/Inspection Service Points
module connector C-106 (terminal No.1 and P.00-5).
2).
Code No.66: Driver's seat belt pre-tensioner (squib) system (short-circuited to the power supply)
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(LH) SWITCH
Wire colour code

TROUBLESHOOTING
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(RH) SWITCH
Wire colour code


The SRS-ECU judges how severe a collision is by This diagnosis code is set if the driver's seat belt
detecting signals from the front impact sensors and pre-tensioner wire(s) are short-circuited to the power
the front air bag analogue G-sensor. If the impact is supply.
over a predetermined level, the SRS-ECU outputs an
ignition signal. At this time, if the front air bag safing PROBABLE CAUSES
G-sensor is on, the seat belt pre-tensioner will • Damaged wiring harnesses or connectors
deploy. • Short to the power supply in the driver's seat belt
pre-tensioner (squib) harness
TROUBLESHOOTING
52B-81
MB991884
Connector: D-16
<LHD>
Harness side
connector
(front view)
MB991884
(Resistor
harness)
D-16 <LHD>, D-03 <RHD>
D-16 (B)
AC310465 AN
<RHD>
(6) Erase diagnosis code memory, and check the
Harness side
diagnosis code.
connector
YES : Go to Step 2.
AC310471 Ai
D-16 <LHD>,
D-03 <RHD>
Driver's seat
belt pre-tensioner
screwdriver
Locking button
D-16 <LHD>, D-03 <RHD>


TROUBLESHOOTING
STEP 2. Voltage measurement at the SRS-ECU connector D-16 <LHD> or D-03 <RHD>. Use a
connector C-13 flat-tipped screwdriver to pull out the locking
CAUTION
C-13 (Y)
Harness side C-13 Harness side
connector connector (rear view)
(rear view)
21 22 23 24 SRS-ECU 21 22 23 24
2526 27 282930 313233 25 26 27 28 29 30 31 32 33
3435 3637 38394041 42 34 35 36 37 38 39 40 41 42
AC101951AL

Connector: D-16
<LHD>
AC006259 AS
Harness side
(front view)
OK: 0 V
D-16 (B)
AC310465 AN Q: Is the measured voltage within the specified
range?
Connector: D-03 YES : Go to Step 3.
<RHD>
NO : Repair the harness wire between SRS-ECU
D-03 (B) connector C-13 (terminal No.29 and 30) and
Harness side
driver’s seat belt pre-tensioner connector
connector D-16 <LHD> or D-03 <RHD> (terminal No.1
(front view) and 2).

reset.
AC310471 Ai
D-16 <LHD>,
D-03 <RHD>
Driver's seat P.52B-109).
belt pre-tensioner NO : An intermittent malfunction is suspected
screwdriver
Locking button P.00-5).
D-16 <LHD>, D-03 <RHD>


TROUBLESHOOTING
52B-83
Code No.67: Driver's seat belt pre-tensioner (squib) system (short-circuited to the earth)
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(LH) SWITCH
Wire colour code

TROUBLESHOOTING
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(RH) SWITCH
Wire colour code


The SRS-ECU judges how severe a collision is by This diagnosis code is set if the driver's seat belt
detecting signals from the front impact sensors and pre-tensioner wire(s) are short-circuited to the earth.
the front air bag analogue G-sensor. If the impact is
over a predetermined level, the SRS-ECU outputs an PROBABLE CAUSES
ignition signal. At this time, if the front air bag safing • Damaged wiring harnesses or connectors
G-sensor is on, the seat belt pre-tensioner will • Short to the earth in the driver's seat belt pre-ten-
deploy. sioner (squib) harness
TROUBLESHOOTING
52B-85
MB991884
Connector: D-16
<LHD>
Harness side
connector
(front view)
MB991884
(Resistor
harness)
D-16 <LHD>, D-03 <RHD>
D-16 (B)
AC310465 AN
<RHD>
(6) Erase diagnosis code memory, and check the
Harness side
diagnosis code.
connector
YES : Go to Step 2.
AC310471 Ai
D-16 <LHD>,
D-03 <RHD>
Driver's seat
belt pre-tensioner
screwdriver
Locking button
D-16 <LHD>, D-03 <RHD>


TROUBLESHOOTING
STEP 2. Resistance measurement at the connector D-16 <LHD> or D-03 <RHD>. Use a
SRS-ECU connector C-13 flat-tipped screwdriver to pull out the locking
CAUTION
C-13 Harness side
C-13 (Y) connector (rear view)
Harness side
2122 23 24
connector
25 26 27 28 29 30 31 32 33
(rear view) 34 35 36 37 38 39 40 41 42
21 22 23 24 SRS-ECU
2526 27 282930 313233
3435 3637 38394041 42
AC101951AL

Connector: D-16 AC201666 AM
<LHD>
(front view)
(3) Resistance measurement between C-13 harness
OK: Open circuit
D-16 (B) Q: Is the check result normal?
AC310465 AN YES : Go to Step 3.
NO : Repair the harnss wire between SRS-ECU
Connector: D-03 connector C-13 (terminal No.29 and 30) and
<RHD>
driver’s seat belt pre-tensioner connector
D-03 (B) D-16 <LHD> or D-03 <RHD> (terminal No.1
Harness side and 2).
connector
(front view)
reset.
AC310471 Ai YES : Replace the SRS-ECU (Refer
toP.52B-109).
D-16 <LHD>,
D-03 <RHD>
Driver's seat (Refer to GROUP 00 − How to Use
belt pre-tensioner Troubleshooting/Inspection Service Points
screwdriver
P.00-5).
Locking button
D-16 <LHD>, D-03 <RHD>


TROUBLESHOOTING
52B-87
Code No.68: Passenger's (front) seat belt pre-tensioner (squib) system (short-circuited to the power
supply)
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(RH) SWITCH
Wire colour code

TROUBLESHOOTING
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(LH) SWITCH
Wire colour code


The SRS-ECU judges how severe a collision is by This diagnosis code is set if passenger's (front) seat
detecting signals from the front impact sensors and belt pre-tensioner wire(s) are short-circuited to the
the front air bag analogue G-sensor. If the impact is power supply.
deploy. • Short to the power supply in the passenger's
(front) seat belt pre-tensioner (squib) harness
TROUBLESHOOTING
52B-89
MB991884
Connector: D-03
<LHD>
Harness side
connector
(front view)
MB991884
(Resistor
Harness)
D-03 <LHD>, D-16 <RHD>
D-03 (B)
AC310465 AO
<RHD>
Harness side
the diagnosis code.
connector
YES : Go to Step 2.
AC310471 AJ
D-03 <LHD>,
D-16 <RHD>
Passenger's (front)
seat belt
pre-tensioner
screwdriver
Locking button
D-03 <LHD>, D-16 <RHD>


TROUBLESHOOTING
STEP 2. Voltage measurement at the SRS-ECU pre-tensioner connector D-03 <LHD> or D-16
connector C-13 <RHD>. Use a flat-tipped screwdriver to pull out
(3) Turn the ignition switch to the "ON" position,
CAUTION
C-13 (Y)
Harness side C-13 Harness side
connector connector (rear view)
(rear view)
21 22 23 24 SRS-ECU 21 22 23 24
2526 27 282930 313233 25 26 27 28 29 30 31 32 33
3435 3637 38394041 42 34 35 36 37 38 39 40 41 42
AC101951AL

Connector: D-03
<LHD>
AC100341AS
Harness side
(front view)
OK: 0 V
D-03 (B)
AC310465 AO Q: Is the check result normal?
YES : Go to Step 3.
Connector: D-16 NO : Repair the harness wires between
<RHD>
D-16 (B) and 28) and passenger's (front) seat belt
Harness side pre-tensioner connector D-03 <LHD> or
connector D-16 <RHD> (terminal No.1 and 2).
(front view)

reset.
AC310471 AJ Q: Is diagnosis code 68 set?
D-03 <LHD>,
D-16 <RHD> P.52B-109).
Passenger's (front)
seat belt
Flat-tipped
pre-tensioner (Refer to GROUP 00 − How to Use
connector
screwdriver Troubleshooting/Inspection Service Points
P.00-5).
Locking button
D-03 <LHD>, D-16 <RHD>


TROUBLESHOOTING
52B-91
Code No.69: Passenger's (front) seat belt pre-tensioner (squib) system (short-circuited to the earth)
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(RH) SWITCH
Wire colour code

TROUBLESHOOTING
SRS-ECU
MICROCOMPUTER
NOTE
COUPLED: ON
LOCK CONNECTOR
SEAT BELT CONNECTOR

PRE-TENSIONER LOCK
(LH) SWITCH
Wire colour code


The SRS-ECU judges how severe a collision is by This diagnosis code is set if passenger's (front) seat
detecting signals from the front impact sensors and belt pre-tensioner wire(s) are short-circuited to the
the front air bag analogue G-sensor. If the impact is earth.
deploy. • Short to the earth in the passenger's (front) seat
belt pre-tensioner (squib) harness
TROUBLESHOOTING
52B-93
MB991884
Connector: D-03
<LHD>
Harness side
connector
(front view)
MB991884
(Resistor
Harness)
D-03 <LHD>, D-16 <RHD>
D-03 (B)
AC310465 AO
<RHD>
Harness side
the diagnosis code.
connector
YES : Go to Step 2.
AC310471 AJ
D-03 <LHD>,
D-16 <RHD>
Passenger's (front)
seat belt
pre-tensioner
screwdriver
Locking button
D-03 <LHD>, D-16 <RHD>


TROUBLESHOOTING
STEP 2. Resistance measurement at the pre-tensioner connector D-03 <LHD> or D-16

SRS-ECU connector C-13 <RHD>. Use a flat-tipped screwdriver to pull out
CAUTION
C-13 (Y)
Harness side
2122 23 24
connector
25 26 27 28 29 30 31 32 33
(rear view) 34 35 36 37 38 39 40 41 42
21 22 23 24 SRS-ECU
2526 27 282930 313233
3435 3637 38394041 42
AC101951AL
C-13 Harness side
(1) Disconnect SRS-ECU connector C-13. connector (rear view)
Connector: D-03 AC201663 AK
<LHD>
(front view)
(3) Resistance measurement between C-13 harness
OK: Open circuit
D-03 (B) Q: Is the check result normal?
AC310465 AO YES : Go to Step 3.
Connector: D-16 SRS-ECU connector C-13 (terminal No.27
<RHD>
and 28) and passenger's (front) seat belt
D-16 (B) pre-tensioner connector D-03 <LHD> or
Harness side D-16 <RHD> (terminal No.1 and 2).
connector
(front view)
reset.
AC310471 AJ YES : Replace the SRS-ECU (Refer to
P.52B-109).
D-03 <LHD>,
D-16 <RHD> NO : An intermittent malfunction is suspected
Passenger's (front)
seat belt
Flat-tipped
pre-tensioner Troubleshooting/Inspection Service Points
connector
screwdriver P.00-5).
Locking button
D-03 <LHD>, D-16 <RHD>


TROUBLESHOOTING
52B-95
CHECK CHART FOR TROUBLE
SYMPTOMS
M1524003400611
Trouble Inspection procedure No. Reference page

Communication with M.U.T.-II MB991502 or − GROUP 13A −
M.U.T.-III MB991955 is not possible Troubleshooting
(Communication with all systems is not P.13A-237
possible).
Communication with M.U.T.-II MB991502 or 1 P.52B-96
M.U.T.-III MB991955 is not possible
(Communication is not possible with SRS).
When the ignition switch is turned to the "ON" Refer to diagnosis code No.43. P.52B-60
position (engine stopped), the SRS warning
lamp does not illuminate.
After the ignition switch is turned to the "ON" Refer to diagnosis code No.43. P.52B-64
position, the SRS warning lamp does not go off
within approximately 7 seconds.
TROUBLESHOOTING
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Communication with M.U.T.-II MB991502 or M.U.T.-III MB991955 is not

possible (Communication is not possible with SRS).
SRS-ECU Power Supply Circuit

IGNITION
SWITCH (IG1)
SRS-ECU
MICROCOMPUTER
MUT INTERFACE
CIRCUIT
DIAGNOSIS
CONNECTOR
FRONT SIDE
NOTE
: LH drive vehicles
: RH drive vehicles
Wire colour code

OPERATION • The SRS-ECU power is supplied from two cir-

• The SRS-ECU is powered from the ignition cuits. Even if one circuit is shut off, the air bag
switch (IG1). can inflate.
• The SRS system diagnosis can be done by con-
necting M.U.T.-II MB991502 or M.U.T.-III
MB991955 to the diagnosis connector.
TROUBLESHOOTING
52B-97
COMMENTS ON TROUBLE SYMPTOM STEP 2. Resistance measurement between
If communication is not possible with the SRS only, SRS-ECU connector C-12 (terminal No.20) and
the cause is probably an open circuit in the on-board diagnosis connector C-14 (terminal No.7)
diagnostic output circuit of the SRS or in the power
Connector: C-12
circuit (including earth circuit).
PROBABLE CAUSES
• Damaged wiring harnesses or connectors C-12 (Y)
• Malfunction of the SRS-ECU Harness side
• Incorrect M.U.T.-II ROM pack connector
(rear view)
DIAGNOSIS PROCEDURE
SRS-ECU
STEP 1. Check that the M.U.T.-II/III can AC101950AJ
communicate with the other systems.

Connector: C-14
Q: Can the M.U.T.-II/III communicate with the other <LHD>
systems?
YES : Go to Step 2.
NO : Refer to GROUP 13A − Troubleshooting Front side
P.13A-237.
C-14 (B)
AC303800 AJ
Connector: C-14
<RHD>
Front side
C-14(B)
AC303812AE
(1) Disconnect SRS-ECU connector C-12 and

diagnosis connector C-14, and measure at the
TROUBLESHOOTING
CAUTION STEP 3. Resistance measurement the earth

C-12 Harness side circuit to the SRS-ECU connector C-12
connector Connector: C-12
(rear view)
C-14 Diagnosis
connector 1 2 3 4
1 2 3 4 5 6 7 8 5 6 7 8 9 10 1112
9 10 111213141516 131415 1617 181920
C-12 (Y)
Harness side
connector
(rear view)
SRS-ECU
AC201667AN
Do not insert a test probe into the terminal from AC101950AJ
of the SRS-ECU connector C-12 its front side (1) Disconnect SRS-ECU connector C-12 and
directly as the connector contact pressure may measure at the wiring harness side.
be weakened. CAUTION
terminals. C-12 Harness side
• SRS-ECU connector C-12 (terminal No.20) connector (rear view)
and diagnosis connector C-14 (terminal No.7) 1 2 3 4
5 6 7 8 9 10 11 12
OK: Less than 2 Ω 13 14 15 16 17 18 19 20
Q: Is the check results normal?
YES : Go to Step 3.
NO : Go to Step 5.
AC006264 AM

(2) Check for continuity between terminal 7 and body
earth.
OK: Less than 2 Ω
YES : Go to Step 4.
NO : Check the harness wire for open circuit
(terminal No.7) and earth, and repair if
necessary.
TROUBLESHOOTING
52B-99
STEP 4. Voltage measurement the power supply STEP 5. Check the harness wires between
circuit to the SRS-ECU connector C-12 SRS-ECU connector C-12 and diagnosis
Connector: C-12
connector C-14.
Connector: C-12
C-12 (Y)
Harness side C-12 (Y)
(rear view) connector
(rear view)
SRS-ECU
SRS-ECU
AC101950AJ
(1) Disconnect SRS-ECU connector C-12 and AC101950AJ

Connector: C-14
<LHD>
CAUTION
Front side
C-12 Harness side
C-14 (B)
1 2 3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
AC303800 AJ
Connector: C-14
<RHD>
AC006265 AR

its front side directly as the connector contact Front side
(4) Voltage measurement between terminals 13, 16 C-14(B)
and body earth.
OK: 9 V or more AC303812AE

YES : Go to Step 7.
NO : Go to Step 6.
TROUBLESHOOTING
NOTE: STEP 6. Check the harness wires between

Connector: C-101
<LHD>
SRS-ECU connector C-12 and ignition switch
connector C-208.
Connector: C-12
C-101 (L)
C-12 (Y)
Harness side
1 2 3 4 5 6 7 8 9 10 11
connector
12 13 14 15 16 17 18 19 20 21 22
AC303798 BA (rear view)
SRS-ECU
Connector: C-23
<RHD>
C-23 (B) AC101950AJ
Connector: C-208
<LHD>
Clock spring
Harness side
connector
(front view)
AC303814AW

block connector C-101 <LHD> or C-23 <RHD>, and
AC303806 AI
YES : An intermittent malfunction is suspected <RHD> Clock spring
P.00-5). Harness side
NO : Repair the harness wires. connector
(front view)
AC303820 AE
TROUBLESHOOTING
52B-101
Connectors: C-211, C-214 YES : An intermittent malfunction is suspected
<RHD> (Refer to GROUP 00 − How to Use
Junction block (front view) Troubleshooting/Inspection Service Points
P.00-5).
C-211 NO : Repair the harness wires.

Q: Does the M.U.T.-II/III communicate normally with
the SRS system?
C-214
YES : An intermittent malfunction is suspected
Harness side Troubleshooting/Inspection Service Points
(front view) P.00-5).
C-211
NO : Replace the SRS-ECU (Refer to
C-214
P.52B-109).
AC303823 AV

<LHD>
C-211
C-214
Harness side
(front view)
C-214 C-211
AC303809 AY

block connectors C-211 and C-214, and repair if nec-
essary.
POST-COLLISION DIAGNOSIS
M1524001100692
Whether or not the air bags have deployed, check 2. Read (and write down) all displayed diagnosis
and service the vehicle after collision as follows: codes (Refer to P.52B-9).
NOTE: If battery power supply has been shut
SRS-ECU MEMORY CHECK down by the collision, the M.U.T.-II/III cannot com-
CAUTION municate with the SRS-ECU. Check and, repair if
necessary, the instrument panel wiring harness
Steering shaft
before the next job.
3. Use the M.U.T.-II/III to read the data list (how long
trouble(s) have continued and how often memory
have been erased).
MB991502
AC304777AB
16-PIN
MB991911
MB991824
MB991827 AC211686 AE
Refer to that the ignition switch is "LOCK" (OFF)

when connecting or disconnecting M.U.T.-II/III.
1. Connect the M.U.T.-II/III to the diagnosis
connector (Refer to GROUP 00 − How to Use
P.00-5).
52B-103
Data list
No Data List Item Applicability
92 Number indicating how often the memory is Maximum time to be stored: 250 times
cleared
93 How long a problem has lasted (How long it Maximum time to be stored: 9,999 minutes
takes from the occurrence of the problem till (approximately 7 days)
the first air bag squib igniting signal)
94 How long a problem has lasted (How long it
takes from the first air bag squib igniting
signal till now).
4. Erase the diagnosis codes and after waiting 5 WHEN AIR BAGS DO NOT DEPLOY IN
seconds or more read (and write down) all LOW-SPEED COLLISION
displayed diagnosis codes. Check the SRS components. If visible damage such
as dents, cracks, or deformation are found on the
REPAIR PROCEDURE SRS components, replace them with new ones. Con-
WHEN FRONT AIR BAGS DEPLOY IN A cerning parts removed for inspection, replacement
COLLISION with new parts and cautions in working refer to
1. Replace the following parts with new ones. P.52B-105.
• Front impact sensor (Refer to P.52B-107).
• SRS-ECU (Refer to P.52B-109). FRONT IMPACT SENSOR
• Driver’s and passenger’s (front) air bag modules
Battery
• Seat belt with pre-tensioner (Refer to P.52B-117).
• Instrument panel (Refer to GROUP 52A − Instru-
ment Panel Assembly P.52A-2).
2. Check the following parts and replace if there are Front impact
any malfunctions. sensor
• Clock spring (Refer to P.52B-110).
• Steering wheel, steering column and shaft
assembly AC208855 AF
(1) Check the wiring harness (built into the
steering wheel) and connectors for damage, 1. Check the radiator support panel for distortion and
and terminals for deformation. rust.
(2) Install the air bag module to check fit or 2. Check the front impact sensor for dents, cracks,
alignment with the steering wheel. deformation or rust.
(3) Check the steering wheel for noise, binds or 3. Check the front impact sensor wiring harness for
difficult operation and excessive free play. binding, check the connector for damage, and
(4) Check the steering column shaft shock check the terminals for deformation.
absorbing mechanism (Refer to GROUP 37 −
On-vehicle Service P.37-12). SRS-ECU
3. Check the harness for binding, connectors for
damage, poor connections, and terminals for SRS-ECU
deformation (Refer to P.52B-2).
AC300582AB
1. Check the SRS-ECU case and brackets for dents, CLOCK SPRING
cracks or deformation.
2. Check the connector for damage, and the
Case
terminals for deformation.
3. Check the SRS-ECU and bracket for installation
condition.
AIR BAG MODULES

<Driver's side> Connector Protective tubes
AC300585AB
Steering
wheel
1. Check the clock spring connectors and protective
tube for damage, and the terminals for
deformation.
2. Visually check the case for damage.
AC304700 STEERING WHEEL, STEERING COLUMN

<Front passenger's side>
AND SHAFT ASSEMBLY
1. Check the wiring harness (built into the steering
wheel) and the connectors for damage, and the
terminals for deformation.
2. Install the air bag module to check fit or alignment
with the steering wheel.
3. Check the steering wheel for noise, binding or
difficult operation and excessive free play.
Inflator case Connector
AC006205 4. Check the steering column shaft shock absorbing
mechanism (Refer to GROUP 37 − On-vehicle
AC311067 AC Service P.37-12).
1. Check the pad cover for dents, cracks or
deformation. SEAT BELT WITH PRE-TENSIONER
2. Check the connector for damage, terminals 1. Check the seat belt for damage or deformation.
deformities, and the harness for binding. 2. Check the seat belt with pre-tensioner for cracks
3. Check the air bag inflator case for dents, cracks or or deformation.
deformities. 3. Check that the unit is installed correctly to the
4. Check the air bag modules for proper installation. vehicle body.
HARNESS CONNECTOR (INSTRUMENT

PANEL WIRING HARNESS AND FLOOR
WIRING HARNESS, ROOF WIRING
HARNESS)
Check harnesses for binding, connectors for damage
and terminals for deformation (Refer to P.52B-2).
INDIVIDUAL COMPONENT SERVICE
52B-105
INDIVIDUAL COMPONENT SERVICE
M1524002900431
WARNING
• If heat damage may occur during paint work, remove the SRS-ECU, the driver’s and pas-
senger’s (front) air bag modules, the clock spring, front impact sensors and the seat belt
with pre-tensioner.
• SRS-ECU, driver’s and passenger’s (front) air bag modules, clock spring and front
impact sensors: 93° C or more
• Seat belt with pre-tensioner: 90°C or more
• If the SRS components are removed for the purpose of check, sheet metal repair, painting,
etc., they should be stored in a clean, dry place until they are reinstalled.
If the SRS components are to be removed or replaced as a result of maintenance, troubleshooting etc., follow
the service procedures that follow. (Front impact sensor; refer to P.52B-107, SRS-ECU; refer to P.52B-109,
Driver’s and passenger’s (front) air bag modules and clock spring; refer to P.52B-110, Seat belt with pre-ten-
sioner; refer to P.52B-117).
WARNING/CAUTION LABELS
WARNING/CAUTION LABELS
M1524003000431
Caution labels on the SRS are attached in the vehicle as shown. Follow label instructions when servicing the
SRS. If the label(s) are dirty or damaged, replace with new one(s).
Steering wheel Front impact sensor
Instrument panel Clock spring Passenger's (front)

air bag module
SRS-ECU Sun visor
Seat belt with pre-tensioner

(driver's and passenger's seat) HOOD
NOTE
: Indicates RHD vehicles. For LHD vehicles, the specified application position of label is reversed left to right. AC504533 AC
FRONT IMPACT SENSORS
52B-107
M1524001500407
WARNING
• Disconnect the negative battery terminal and wait for 60 seconds or more before starting
work. Furthermore, the disconnected battery terminal should be covered with tape to
insulate it.
• Never attempt to disassemble or repair the front impact sensor. If faulty, replace it.
• Do not drop or subject the front impact sensor to impact or vibration. If denting, cracking,
deformation, or rust are discovered in the front impact sensor, replace it with a new front
impact sensor. Discard the old one.
• After deployment of an air bag, replace the front impact sensor with a new one.
• Turn the ignition switch to the "LOCK" (OFF)
position.
• Disconnect the Negative Battery Terminal.
Radiator
5.0 ± 1.0 N·m
AC311090 AB
Removal step NOTE: The figure on the left indicates the left front
1. Front impact sensor impact sensor.
Installation steps
>>A<< • Pre-installation inspection
>>B<< 1. Front impact sensor
• Negative battery cable connection
>>C<< • Post-installation inspection
INSTALLATION SERVICE POINTS WARNING

>>A<<PRE-INSTALLATION INSPECTION Always replace the sensor with a new one if
When the new front impact sensor refer to the previ- the resistance shows a short or open circuit.
ous item "INSPECTION."
>>B<<FRONT IMPACT SENSOR

INSTALLATION
WARNING
The SRS may not activate properly if a front
impact sensor is not installed properly.
1. Securely connect the connector.
2. Position the front impact sensor facing toward the ACX00597AC
front of the vehicle as shown by the arrow on the
label, and install it securely. 2. Check short or open circuit between the terminals
of the front impact sensor.
>>C<<POST-INSTALLATION INSPECTION Short circuit: 2 Ω or less
1. Connect the negative battery cable. Open circuit: 2 MΩ or more
2. Turn the ignition switch to "ON" position.
ACX00598 AC
3. Check the continuity between the terminal and
3. Does the SRS warning lamp illuminate for about 7 bracket. If there is a continuity, the insulation is
seconds and then goes out? malfunctioned, and replace the sensor with a new
4. If no, refer to troubleshooting (Refer toP.52B-9). one.
4. Check the head lamp support pane for
INSPECTION deformation and rust.
M1524001600374
WARNING
If a dent, crack, deformation or rust is
detected, replace with a new sensor.
1. Check the front impact sensor for dents, cracks,
deformation or rust.
SRS CONTROL UNIT (SRS-ECU)
52B-109
SRS CONTROL UNIT (SRS-ECU)
M1524002100491
WARNING
insulate it.
• Never attempt to disassemble or repair the SRS-ECU. If faulty, replace it.
• Do not drop or subject the SRS-ECU to impact or vibration. If denting, cracking, deforma-
tion, or rust are discovered in the SRS-ECU, replace it with a new SRS-ECU. Discard the
old one.
• After deployment of an air bag, replace the SRS-ECU with a new one.
• Never use an ohmmeter on or near the SRS-ECU, and use only the special test equipment
described on P.52B-8.
• Turn the ignition switch to the "LOCK" (OFF) position.
5.0 ± 1.0 N·m
2
1
5.0 ± 1.0 N·m 3
5.0 ± 1.0 N·m
AC311091 AB
Removal steps Installation steps

• Front floor console (Refer to 3. SRS-ECU bracket
GROUP 52A − Front floor console >>A<< 2. SRS-ECU
assembly P.52A-7). 1. SRS-ECU and SRS-ECU bracket
1. SRS-ECU and SRS-ECU bracket • Front floor console (Refer to
2. SRS-ECU GROUP 52A − Front floor console
3. SRS-ECU bracket assembly P.52A-7).
>>B<< • Post-installation inspection
DRIVER'S AND PASSENGER'S (FRONT) AIR BAG MODULES AND CLOCK SPRING
INSTALLATION SERVICE POINTS 3. Does the SRS warning lamp illuminate for about 7
>>A<< SRS-ECU INSTALLATION seconds and then goes out?
4. If no, refer to troubleshooting (Refer toP.52B-9).
WARNING
The SRS may not activate if SRS-ECU is not INSPECTION
installed properly. M1524002200324
WARNING
>>B<< POST-INSTALLATION If any problems are found, replace the
INSPECTION SRS-ECU.
• Check the SRS-ECU and brackets for dents,
1. Connect the negative battery cable. cracks or deformation.
2. Turn the ignition switch to "ON" position. • Check the SRS-ECU connector for damage, and
the terminals for deformation.
NOTE: For the checks other than the items above,
refer to "Troubleshooting" (Refer to P.52B-9).
DRIVER'S AND PASSENGER'S (FRONT) AIR BAG

MODULES AND CLOCK SPRING
M1524014500269
WARNING
insulate it.
• Never attempt to disassemble or repair the air bag modules or clock spring. If faulty,
replace it.
• Do not drop the air bag modules or clock spring or allow contact with water, grease or oil.
Replace it if a dent, crack, deformation or rust is detected.
• The air bag modules should be stored on a flat surface is facing upward. Do not place
anything on top of it.
• Do not expose the air bag modules to temperatures over 93°C.
• After deployment of an air bag, replace the clock spring with a new one.
• Wear gloves and safety glasses when handling air bags that have already deployed.
• An undeployed air bag module should only be disposed of in accordance with the proce-
dures (Refer to P.52B-120).
52B-111
<DRIVER’S AIR BAG MODULE AND CLOCK SPRING>
2
0.69 ± 0.15 N·m A A Column switch
3
B
5 B
1 Section A - A Section B - B
AC211864
Claw Claw
NOTE
: Claw positions
50 ± 5 N·m
AC504607AB
Driver’s air bag module removal Driver’s air bag module installation
steps steps (Continued)
<<A>> 1. Cover 1. Cover
<> 2. Steering wheel and driver’s air bag • Negative battery cable connection
module assembly >>D<< • Post-installation inspection
Clock spring removal steps Clock spring installation steps
<<A>> 1. Cover >>A<< • Pre-installation inspection
<> 2. Steering wheel and driver’s air bag >>B<< 3. Clock spring
module assembly • Lower column cover (Refer to
• Lower column cover (Refer to GROUP 37 − Steering shaft P.37-15).
GROUP 37 − Steering shaft P.37-15). >>C<< 2. Steering wheel and driver’s air bag
<<C>> 3. Clock spring module assembly
Driver’s air bag module installation 1. Cover
steps • Negative battery cable connection
>>A<< • Pre-installation inspection >>D<< • Post-installation inspection
>>C<< 2. Steering wheel and driver’s air bag
module assembly
<PASSENGER'S (FRONT) AIR BAG MODULE>
AC304946AB
Passenger’s (front) removal steps Passenger’s (front) installation

• Instrument panel (Refer to GROUP steps
52A − Instrument panel P.52A-2). >>A<< • Pre-installation inspection
<<D>> 1. Passenger’s (front) air bag module 1. Passenger’s (front) air bag module
• Instrument panel (Refer to GROUP
52A − Instrument panel P.52A-2).
>>D<< • Post-installation inspection

<<A>> COVER REMOVAL Insert the special tool ornament remover
(MB990784) as shown in the illustration to remove
the cover.
MB990784
AC211761AB
52B-113
<> STEERING WHEEL AND DRIVER’S NOTE: Use a hexagonal bit socket or a hexagonal
AIR BAG MODULE ASSEMBLY REMOVAL wrench having an effective length of 75 mm or
more in the hexagonal section and the diameter of
WARNING 8 mm or more.
• The air bag module must not be measured
with such equipment as an ohmmeter, nor <C>> CLOCK SPRING REMOVAL
disassembled.
• The removed air bag module should be WARNING
stored in a clean, dry place with the The removed clock spring should be stored
deployment surface facing up. in a clean, dry place.
<<D>> PASSENGER’S (FRONT) AIR BAG

Steering
MODULE REMOVAL
wheel WARNING •
AC304700
Air bag module AC100443

connector
When the air bag module is removed, do not
damage the engagement of the pawls.
A • The removed air bag module should be
stored in a clean, dry place with facing the
AC105823 deployment surface facing up.
AC305145AB Insert the screwdriver (−) into the position specified
in the figure and lift the screwdriver upward to
1. By sliding the A section (in the figure) of the air release the pawls engaged, and then remove the air
bag module connector in the arrow direction, bag module.
Hexagonal bit
socket
>>A<< PRE-INSTALLATION INSPECTION
WARNING
Dispose of air bag modules only according
to the specified procedure (Refer to
P.52B-120).
1. When installing the new air bag modules and
clock spring, refer to “INSPECTION” (P.52B-115).
AC211762 AC
2. Connect the negative battery cable.
2. Insert the hexagonal bit socket into the arrow
section in the figure. Completely loosen the bolt,
and then remove the steering wheel air bag
module assembly.
CAUTION >>B<< CLOCK SPRING INSTALLATION

<Using the M.U.T.-II> WARNING
Steering shaft Ensure that the clock spring’s mating marks
are properly aligned. If not, the steering
wheel may not rotate completely during a
turn, or the flat cable in the clock spring
could be damaged, This would prevent nor-
mal SRS operation and possibly cause seri-
ous injury to the driver.
MB991502
AC304777AB
Mating marks
AC300168 AB
16-PIN 1. Align the mating marks of the clock spring.

MB991911 <Mating Mark Alignment>
Turn the clock spring clockwise fully. Then turn it
MB991824 back approximately 3 3/4 turns counterclockwise
to align the mating marks.
2. Turn the front wheels to the straight-ahead
position. Then install the clock spring to the
column switch.
>>C<< STEERING WHEEL AND DRIVER’S

MB991827 AC211686 AE
AIR BAG MODULE ASSEMBLY
To prevent damage to M.U.T.-II/III, always turn the INSTALLATION
ignition, switch to the “LOCK” (OFF) position
before connecting or disconnecting M.U.T.-II/III. CAUTION
When installing the steering wheel, and driver’s
3. Connect M.U.T.-II/III to the diagnosis connector. air bag module ensure that the harness of the
4. Turn the ignition switch to the “ON” position. clock spring does not become caught or tangled.
5. Check diagnosis codes using M.U.T.-II/III ensure 1. Before installing the steering wheel, and driver’s
that the SRS operates properly. air bag module turn the vehicle’s front wheels to
Confirm that the diagnosis codes other than 21 the straight-ahead position and align the mating
and 24 are not set. marks of the clock spring.
DANGER 2. After securing the steering wheel, turn the
Wait at least 60 seconds after disconnecting steering wheel all the way in both directions to
the battery cable before doing any further confirm that the steering wheel rotation is normal.
work (Refer to P.52B-3).
>>D<< POST-INSTALLATION
position. Disconnect the negative battery cable INSPECTION
and tape the terminal to prevent accidental 1. Reconnect the negative battery cable.
connection and air bags deployment. 2. Turn the ignition switch to “ON” position.
52B-115
INSPECTION
M1524014600039
AIR BAG MODULE CHECK

WARNING
• If any component damage is found during
the following inspection, replace the air
bag module(s) with a new one. Dispose of
the old one according to the specified
procedure (Refer to P.52B-120).
• Never attempt to measure the circuit
3. Does the SRS warning lamp illuminate for about 7 resistance of he air bag module (squib)
seconds and then goes out? even if you are using the specified tester.
4. If yes, the SRS system is functioning properly. If If the circuit resistance is measured with a
no, refer to P.52B-8. tester, accidental air bag module(s)
deployment will result in serious personal
injury.
<Driver's side> Connector
Steering
wheel
AC304700
<Front passenger's side>
Inflator case Connector

AC006205
AC311067 AC
1. Check the pad cover for dents, cracks or

deformation.
2. Check the connectors for damage, the terminals
for deformation, and the harness for binds.
3. Check the air bag inflator case for dents, cracks or
deformation.
4. Install the air bag module (driver’s side) to the
steering wheel and check fit and alignment with
the wheel.
5. Install the air bag module (front passenger’s side)
to the instrument panel and front deck
crossmember and check fit and alignment.
CLOCK SPRING CHECK CAUTION

Case C-204 Clock spring
connector
1 2 3 4 5 6
Protective tube
C-205 Air bag C-205 Air bag
module connector module connector
C-203 Horn switch

AC300312AD
Extra fine probe
(MB992006)
If any malfunction is found in the following inspec-
tions, replace the clock spring with a new one.
1. Check the connectors and protective tube for Clock spring
damage, and the terminals for deformation. Digital
2. Visually check the case for damage. C-205 Air bag
multi-meter
3. Check to see that there is a charge (continuity) module connector

between the C-204 clock spring connector (driver's side)
terminal 1 and C-203 horn switch. AC300374AE
Do not directly insert a probe, etc. into the termi-

nal from the front of the connector.
4. Insert the special tool extra fine probe
(MB992006) from behind the C-205 air bag
module connector (driver’s side).
5. As shown in the Figure, connect the circuit tester
to the special tool extra fine probe (MB992006)
and check to see that there is a charge between
the terminals.
SEAT BELTS WITH PRE-TENSIONER
52B-117
M1524004100390
WARNING
• Never attempt to disassemble or repair the seat belt pre-tensioner. If faulty, replace it.
• Be extremely careful when handling the seat with pre-tensioner. Do not subject it to
shocks, drop it, bring it close to strong magnets or allow contact with water, grease or oil.
Always replace it with a new part if any dents, cracks or deformation is found.
• Do not place anything on top of the seat belt pre-tensioner.
• Do not expose the seat belt with pre-tensioner to temperatures over 90°C.
• After operating the seat belt pre-tensioner, replace the seat belt with pre-tensioner with a
new part.
• Gloves and protective goggles should be worn when handling a seat belt pre-tensioner
once it has been used.
• If disposing of a seat belt with pre-tensioner which has not yet been operated, its seat belt
pre-tensioner should be operated first before disposal (Refer to P.52B-120).
• Turn the ignition switch to the "LOCK" (OFF) position.
2 44 ± 10 N·m
5
6
4
44 ± 10 N·m
3
AC101710 AC
Removal steps Installation steps

1. Sash guide cover >>A<< • Pre-installation inspection
2. Seat belt shoulder anchor bolt 6. Seat belt with pre-tensioner
3. Seat belt lower anchor bolt 5. Bracket
• Centre pillar trim, lower (Refer to >>B<< 4. Pre-tensioner connector connection
GROUP 52A − Trims P.52A-10). • Centre pillar trim, lower (Refer to
<<A>> 4. Pre-tensioner connector connection GROUP 52A − Trims P.52A-10).
5. Bracket 3. Seat belt lower anchor bolt
6. Seat belt with pre-tensioner 2. Seat belt shoulder anchor bolt
1. Sash guide cover
>>C<< • Post-installation inspection
NOTE: The figure shows the seat belt with pre-ten-
sioner (RH).

<<A>>PRE-TENSIONER CONNECTOR CAUTION
DISCONNECTION <Using the M.U.T.-II>
Steering shaft
Pre-tensioner
connector
Flat-tipped
screwdriver
Locking button
MB991502
Harness side connector AC304777AB
AC300147 AS
1. Use a flat-tipped screwdriver to pull out forward
and unlock the locking button of the harness-side
connector.
2. Disconnect the pre-tensioner connector.

>>A<< PRE-INSTALLATION INSPECTION
WARNING 16-PIN
When discarding the seat belt with pre-ten- MB991911
sioner, operate the pre-tensioner as speci-
fied in the service procedure (Refer to MB991824
P.52B-120).
1. Even new seat belt with pre-tensioner require
inspection before installation.
2. Connect the negative battery cable.
MB991827 AC211686 AE

ignition, switch to the “LOCK” (OFF) position
3. Connect M.U.T.-II/III to the diagnosis connector.
52B-119
4. Turn the ignition switch to the ON position.
5. Check diagnosis codes using M.U.T.-II/III to
ensure that the SRS operates properly.
Confirm that the diagnosis codes other than 26
and 28 are not set.
6. Turn the ignition switch to "LOCK" (OFF) position.
DANGER
Wait at least 60 seconds after the disconnec-
tion of the battery cable before any further SRS warning lamp AC311044 AB
job (Refer to P.52B-3).
3. Does the SRS warning lamp illuminate for about 7
7. Disconnect the negative battery cable and seconds and then goes out?
insulate with tape.
4. If no, refer to troubleshooting (Refer toP.52B-9).
>>B<< PRE-TENSIONER CONNECTOR
INSPECTION
CONNECTION M1524004200245
Connect the pretensioner connector then securely WARNING

lock the locking button of the harness-side connec- • If any component damage is found during
tor. the following inspection, replace the seat
belt with pre-tensioner with a new one.
>> C<< POST-INSTALLATION
Dispose of the old one according to the
INSPECTION specified procedure (Refer to P.52B-120).
1. Connect the negative battery cable. • Never attempt to measure the circuit
2. Turn the ignition switch to "ON" position. resistance of the seat belt pre-tensioner
even if you are using the specified tester.
If the circuit resistance is measured with a
tester, accidental seat belt pre-tensioner
operation will result in serious personal
injury.
1. Check the seat belt pre-tensioner deployment
section for dents and deformation.
2. Check the harness and connector for damage and
the terminals for deformation.
AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES
AIR BAG MODULE AND SEAT BELT PRE-TENSIONER

DISPOSAL PROCEDURES
M1524001200989
Before disposing of an air bag or a vehicle equipped
with an air bag, follow the procedures below to
deploy the air bag.
UNDEPLOYED AIR BAG MODULE DIS- C-205 Clock spring
POSAL connector (4-pin)
WARNING
• If the vehicle is to be scrapped or other-
C-205 Harness side
wise disposed of, deploy the air bags and connector
operate the seat belt pre-tensioner inside (4-pin, yellow)
AC300379 AD
the vehicle. If the vehicle will continue to
be used and only the air bag modules and 4. Remove the connection between the C-205 clock
seat belt pre-tensioner are to be disposed spring connector (4-pin) and the harness side
of, deploy the air bags and operate the connector (4-pin, yellow).
seat belt pre-tensioner outside the vehi- NOTE: Once disconnected from the instrument
cle. panel wiring harness, both electrodes of the clock
• Since a large amount of smoke is pro- spring connector short automatically. This pre-
vents the driver's air bag from accidental deploy-
duced when the air bag is deployed and
ment caused by static, etc.
the seat belt pre-tensioner is operated,
avoid residential areas whenever possi-
Deployment wires
ble.
Connection
• Since there is loud noise when the air
bags are deployed and when the seat belt
pre-tensioner are operated, avoid residen-
tial areas whenever possible. If anyone is
nearby, give warning of the impending
noise. 6 m or longer
• Suitable ear protection should be worn by AC300381AD
personnel performing these procedures
or by people in the immediate area. 5. Obtain two suitable wires, which are 6 meters or
longer, as deployment wires. Then connect the
DEPLOYMENT INSIDE THE VEHICLE wires at one end to short.
(WHEN DISPOSING OF A VEHICLE) 6. Touch the vehicle's body with bare hands to
<DRIVER'S AIR BAG MODULE> discharge static in you.
1. Move the vehicle to an isolated spot.
DANGER C-205 Clock spring C-205 Harness side
connector (4-pin)
Wait at least 60 seconds after the disconnec- connector
(4-pin, yellow)
tion of the battery cable before any further
Deployment wire
2. Disconnect the negative and positive battery
cables from the battery terminals, and then
remove the battery from the vehicle. Connection
Insulator tape
3. Remove the column cover lower (Refer to AC300384 AC
GROUP 37 − Steering shaft P.37-15).
52B-121
7. Cut with a pliers, etc. the instrument panel wiring WARNING
harness shown in the figure of the instructions, • Before deploying the air bag in this man-
while the C-205 clock spring connector is ner, first check to be sure that there is no
disconnected. one in or near the vehicle. Wear safety
NOTE: The disconnection location should be suf- glasses.
ficiently away from the C-205 harness side con- • The inflator will be quite hot immediately
nector with consideration to the expansion following the deployment, so wait at least
harness connection location upon disconnections.
30 minutes to allow it to cool before
8. Connect the deployment wires on the two attempting to handle it. Although not poi-
instrument panel wiring harnesses disconnected,
sonous, do not inhale gas from the air bag
cover the connection areas with insulator tape
deployment. See Deployed Air Bag Mod-
and then pull out the deployment wires outside the
vehicle. ule and Operated Seat Belt Pre-tensioner
Disposal (Refer to P.52B-128) for
9. Connect the C-205 harness side connector
connected with an expansion harness to the
post-deployment handling instructions.
C-205 clock spring connector. • If the air bag module fails to deploy, do
not go near the module. Contact your dis-
WARNING
tributor.
Cover
11.At a location as far away from the vehicle as
possible, disconnect the two connected wires
from each other, and connect them to the two
terminals of the battery (which has been removed
from the vehicle) to deploy the air bag.
Deployment wire 12.After deployment, dispose of the air bag module
6 m or longer according to the Deployed Air Bag Module and
Operated Seat Belt Pre-tensioner Disposal (Refer
to P.52B-128).
AC300388AD
If the glass is scratched, air bag deployment DEPLOYMENT INSIDE THE VEHICLE
could cause it to crack and fly out of the
(WHEN DISPOSING OF A VEHICLE)
vehicle, so always put a cover over the vehi-
cle. <PASSENGER'S (FRONT) AIR BAG
10.To suppress the operation sound as much as MODULE>
possible completely close all door windows, close 1. Move the vehicle to an isolated spot.
the doors and put the cover on the vehicle. DANGER
Wait at least 60 seconds after the disconnec-
tion of the battery cable before any further
remove the battery from the vehicle.
3. Remove the glove box (Refer to GROUP 52A −
Connector: C-106
6. Connect the C-106 passenger's (front) air bag
Glove box striker module connector (2-pin, red) to special tool SRS
air bag adapter harness (MB686560) and move
the deployment wires out of the vehicle.
C-106 Passenger's (front) WARNING
air bag module connector
(2-pin, red)
Cover
AC100985 AT
4. Remove the connection between the C-106 Deployment wire

passenger's (front) air bag module connector 6 m or longer
(2-pin, red) and the harness side connector (2-pin,
red).
AC300388AD
NOTE: Once disconnected from the instrument
panel wiring harness, both electrodes of the pas- If the glass is scratched, air bag deployment
senger's (front) air bag module short automati- could cause it to crack and fly out of the
cally. This prevents the passenger's (front) air bag vehicle, so always put a cover over the vehi-
from accidental deployment caused by static, etc. cle.
7. To suppress the operation sound as much as
Connection
possible completely close all door windows, close
the doors and put the cover on the vehicle.
Deployment wires
WARNING
• Before deploying the air bag in this man-
6 m or longer
MB686560 ner, first check to be sure that there is no
one in or near the vehicle. Wear safety
Insulator tape glasses.
AC300419AC
• The inflator will be quite hot immediately
following the deployment, so wait at least
5. Connect deployment wires longer than 6 m to 30 minutes to allow it to cool before
each SRS air bag adapter harness (MB686560) attempting to handle it. Although not poi-
and insulate the connections with insulator tape. sonous, do not inhale gas from the air bag
Also, connect the deployment wires in the other
deployment. See Deployed Air Bag Mod-
ends to short, thereby preventing the passenger's
ule and Operated Seat Belt Pre-tensioner
(front) air bag from accidental deployment caused
by static etc. Disposal (Refer to P.52B-128) for
post-deployment handling instructions.
• If the air bag module fails to deploy, do
not go near the module. Contact your dis-
MB686560 tributor.
8. At a location as far away from the vehicle as
from each other, and connect them to the two
air bag module connector
Deployment wires (2-pin, red) from the vehicle) to deploy the air bag.
AC300420AK
9. After deployment, dispose of the air bag module
according to the Deployed Air Bag Module and
Operated Seat Belt Pre-tensioner Disposal (Refer
to P.52B-128).
52B-123
DEPLOYMENT INSIDE THE VEHICLE 5. Connect deployment wires longer than 6 m to
(WHEN DISPOSING OF A VEHICLE) each special tool SRS air bag adapter harness
(MB991885) and insulate the connections with
<SEAT BELT PRE-TENSIONER>
insulator tape. Also, connect the deployment
1. Move the vehicle to an isolated spot. wires in the other ends to short, thereby
DANGER preventing the seat belt pre-tensioner from
Wait at least 60 seconds after disconnecting accidental deployment caused by static etc.
the battery cables before doing any further
remove the battery from the vehicle. MB991885
D-03 or D-16
3. Remove the centre pillar lower trim (Refer to
Seat belt
GROUP 52A − Trim P.52A-10). pre-tensioner
D-03 or D-16 2-pin connector Deployment
Seat belt wires
AC300448AD
pre-tensioner
connector (2-pin)
Flat-tipped 6. Connect the D-03 or D-16 seat belt pre-tensioner
screwdriver 2-pin connector (black) to special tool SRS air bag
Locking button adapter harness (MB991885) and move the
D-03 or D-16
deployment harness out of the vehicle.
Harness side WARNING
connector
• Before operating the seat belt pre-ten-
(2-pin, black)
AC300446 AL sioner in this manner, first check to be
4. Execute the following steps to disconnect the sure that there is no one in or near the
connection between D-03 or D-16 seat belt vehicle. Wear safety glasses.
pre-tensioner connector (2-pin) and harness side • The inflator will be quite hot immediately
connector (2-pin, black). following the operation, so wait at least 30
NOTE: Once disconnected from the floor wiring minutes to allow it to cool before attempt-
harness, both electrode of the seat belt pre-ten- ing to handle it. Although no poisonous,
sioner connector short automatically. This pre- do not inhale gas from the seat belt
vents the seat belt pre-tensioner from accidental pre-tensioner operation. See Deployed Air
deployment caused by static etc. Bag and Operated Seat Belt pre-tensioner
(1) Use a flat-tipped screwdriver to pull out Disposal (Refer to P.52B-128) for
forward and unlock the locking button of the post-operation handling instructions.
harness-side connector (2-pin, black). • If the seat belt pre-tensioner fails to oper-
(2) Disconnect the D-03 or D-16 harness side ate, do not go near the seat belt pre-ten-
connector. sioner. Contact your distributor.
Connection 7. At a location as far away from the vehicle as
Deployment wires
from each the, and connect them to the two
MB991885
from the vehicle) to operating the seat belt
6 m or longer
pre-tensioner.
8. After operation, dispose of the seat belt
Insulator tape
pre-tensioner according to the Deployed Air Bag
Module operated seat belt pre-tensioner Disposal
AC300447 AC
DEPLOYMENT OUTSIDE THE VEHICLE Steering wheel-driver's Deployment

<DRIVER’S AIR BAG MODULE> air bag module
assembly
harness
WARNING
• This should be carried out in a wide, flat
area at least 6 m away from obstacles and
other people.
• Do not deploy outside if wind is high.
Even in a soft wind, ignite to windward of Insulator tape
the air bag modules. Connection AC211892 AE
DANGER
5. Release the secured connector of the steering
Wait at least 60 seconds after disconnecting
wheel-driver's air bag module assembly to cut off
the battery cables before doing any further the connector from the harness with a nipper and
work (Refer to P.52B-3). etc. Connect deployment harnesses to each of
1. Disconnect the negative and positive battery two separated harnesses and cover the area with
cables from the battery terminals, and then insulator tape.
Steering wheel-driver's air bag
WARNING module assembly
Once disconnected, both electrodes of the
driver’s air bag module connector short
automatically to prevent accidental deploy- Deployment
ment caused by static etc. Still, in considera- harness
tion of the accidental deployment, store the
air bag module on flat place with deployment
surface facing up. Also, do not put anything
AC211893 AC
on it.
2. Remove the driver’s air bag module from the 6. Use a rope to tie the steering wheel-driver's air
vehicle (Refer to P.52B-110). bag module assembly to secure old tyres with
wheels.
Deployment wires 7. Route the deployment harness connected to
driver's air bag module beneath old tyres with
Connection
wheels. Then, secure the steering wheel-driver's
air bag module assembly with the deployment
surface facing up.
Tyre without wheels

6 m or longer
AC300381AD
3. Obtain two suitable wires, which are 6 meters or

longer, as deployment wires. Then connect the
wires at one end to short.
4. Touch the vehicle’s body with bare hands to Deployment wires
discharge static in you. AC300478 AE
8. Place three old tyres without wheels on the tyre

secured with the driver’s air bag module.
52B-125
WARNING DEPLOYMENT OUTSIDE THE VEHICLE
• Before deployment, check carefully to be <PASSENGER'S (FRONT) AIR BAG
sure that no one is nearby. MODULE>
WARNING
following the deployment, so wait at least • This should be carried out in a wide, flat
30 minutes to allow it to cool before area at least 6 m away from obstacles and
attempting to handle it. Although not poi- other people.
sonous, do not inhale gas from air bag • Do not deploy outside if wind is high.
deployment. See Deployed Air Bag Mod- Even in a soft wind, ignite to windward of
ule and Operated Seat Belt Pre-tensioner the air bag modules.
Disposal (Refer to P.52B-128) for
post-deployment handling instructions. DANGER
Wait at least 60 seconds after disconnecting
• If the air bag fails to deploy, do not go
near the module. Contact your distributor.
WARNING
Once disconnected, both electrodes of the
passenger’s (front) air bag module connec-
tor short automatically to prevent accidental
Deployment
wires deployment caused by static etc. Still, in
Vehicle battery
AC300493AB consideration of the accidental deployment,
9. At a location as far away from the driver’s air bag store the air bag module on flat place with
module as possible, and from a shielded position, deployment surface facing up. Also, do not
disconnect the two connected wires from each put anything on it.
other, and connect them, to the two terminals of 2. Remove the passenger’s (front) air bag module
the battery (which has been removed from the from the vehicle (Refer to P.52B-110).
vehicle) to deploy the air bag.
10.Discard the deployed driver’s air bag module as Connection
specified in Deployed Air Bag Module and
Operated Seat Belt Pre-tensioner Disposal (Refer Deployment wires
to P.52B-128).
MB686560 6 m or longer
Insulator tape
AC300419AC
3. Connect deployment wires longer than 6 m to

each SRS air bag adapter harness (MB686560)
and insulate the connections with insulator tape.
Also, connect the deployment wires in the other
ends to short, thereby preventing the passenger's
(front) air bag from accidental deployment caused
by static etc.
6. Place three old tyres without wheels on top of the

Passenger's (front) air bag module tyre secured to the passenger's (front) air bag
module, and secure all tyres together with ropes
(four locations).
WARNING
• Before deployment, check carefully to be
sure that no one is nearby.
Deployment wires following the deployment, so wait at least
AC300520 AE
30 minutes to allow it to cool before
4. Connect the deployment wires to SRS air bag attempting to handle it. Although not poi-
adapter harness (MB686560), pass it beneath the sonous, do not inhale gas from air bag
tyre and wheel assembly, and connect it to the deployment. See Deployed Air Bag Mod-
passenger's (front) air bag module. ule and Operated Seat Belt Pre-tensioner
CAUTION Disposal (Refer to P.52B-128) for
• The adapter harness below the wheel should post-deployment handling instructions.
be loose. If it is too tight, the reaction when • If the air bag fails to deploy, do not go
the air bag deploys could damage the adapter near the module. Contact your distributor.
harness.
• During deployment, the connector of SRS air
bag adapter harness (MB686560) must not be
between the tyres.
5. Pass the thick wire through the passenger's (front)
air bag module mounting hole, and then secure
the passenger's (front) air bag module to an old
tyre with a wheel in it so that the pad on the
module is facing upwards. Deployment wires
AC300522 AB
7. At a location as far away from the passenger's

Tyres without wheels (front) air bag module as possible, and from a
shielded position, disconnect the two connected
wires from each other, and connect them, to the
two terminals of the battery (which has been
removed from the vehicle) to deploy the air bag.
8. Discard the deployed air bag module as specified
Deployment wires in Deployed Air Bag Module and Operated Seat
AC300521AB Belt Pre-tensioner Disposal (Refer to P.52B-128).
52B-127
DEPLOYMENT OUTSIDE THE VEHICLE 4. Disconnect the D-03 or D-16 harness side
<SEAT BELT PRE-TENSIONER> connector.
WARNING Connection
• This should be carried out in a wide, flat
Deployment wires
area at least 6 m away from obstacles and
other people.
MB991885
• Do not deploy outside if wind is high. 6 m or longer
Even in a soft wind, ignite to windward of
the air bag modules. Insulator tape
DANGER
Wait at least 60 seconds after disconnecting AC300447 AC
5. Connect deployment wires longer than 6 m to
each special tool SRS air bag adapter harness
1. Disconnect the negative and positive battery (MB991885) and insulate the connections with
cables from the battery terminals, and then insulator tape. Also, connect the deployment
remove the battery from the vehicle. wires in the other ends to short, thereby
WARNING preventing the passenger's (front) air bag from
Once disconnected, both electrodes of the accidental deployment caused by static etc.
seat belt pre-tensioner connector short auto- 6. Connect the special tool SRS air bag adapter
matically to prevent accidental operate harness (MB991885), which the deployment wires
caused by static etc. Still, in consideration of is attached to, to the seat belt pre-tensioner
the accidental deployment, store the oper- connector.
ated seat belt pre-tensioner the correct way CAUTION
up with its operation surface upper most on The adapter harness below the wheel should be
a flat surface. Do not place anything on top loose. If it is too tight, the reaction when the seat
of them. belt pre-tensioner operates could damage the
adapter harness.
2. Remove the seat belt pre-tensioner from the
vehicle (Refer to P.52B-117). 7. Pass the thick wires through the hole on the seat
belt pre-tensioner bracket and secure them to the
D-03 or D-16 front (raised part) of the wheel on two place.
Seat belt
pre-tensioner
Flat-tipped connector (2-pin)
Tyres
screwdriver without
wheels
Locking button
D-03 or D-16
Harness side
connector
(2-pin, black) Seat belt
AC300446 AL
Deployment
3. Use a flat-tipped screwdriver to unlock the locking wires AC300552AB
button of the harness-side connector (2-pin,
black) by with drawing it toward you in two stages. 8. Pull the seat belt out the outside of the tyre, and
then place one tyre without a wheel inside on top
of the existing tyre.
WARNING DEPLOYED AIR BAG MODULE AND

OPERATED SEAT BELT PRE-TEN-
•
<Seat belt pre-tensioner>

SIONER DISPOSAL
After deployment and operation, the air bag module
and seat belt pre-tensioner should be disposed of in
the same manner as any other scrap parts, adhering
to local laws and/or legislation. Observe the following
precautions during air bag or seat belt pre-tensioner
Deployment wires
disposal:
Vehicle battery
1. The inflator will be quite hot immediately following
AC300555 AB deployment, so wait at least 30 minutes to allow it
Before operation, check carefully to be sure cool before attempting to handle it.
that no one is nearby. 2. Do not put water or oil on the air bag after
• The inflator will be quite hot immediately deployment or on the seat belt pre-tensioner after
following the operation, so wait at least 30 operation.
minutes to allow it to cool before attempt- WARNING
ing to handle it. Although not poisonous, If after following these precautions, any
do not inhale gas from seat belt pre-ten- material does get into the eyes or on the
sioner operation. See Deployed Air Bag skin, immediately rinse the affected area with
Module and Operated Seat Belt pre-ten- a large amount of clean water. If any irritation
sioner Disposal (Refer to P.52B-128) for develops, seek medical attention.
post-operation handling instructions. 3. There may be material on the deployed air bag
• If the seat belt pre-tensioner fails to oper- module or the operated seat belt pre-tensioner,
ate, do not go near the seat belt pre-ten- that could irritate the eye and/or skin. Wear gloves
sioner. Contact your distributor. and safety glasses when handling a deployed air
bag module or the operated seat belt
9. At a location as far away from the seat belt
pre-tensioner.
pre-tensioner as possible, and from a shielded
position, disconnect the two connected wires from
each other, and connect them to the two terminals
of the battery (which has been removed from the Strong plastic bag
vehicle) to operated seat belt pre-tensioner. Air bag module
10.Discard the operated seat belt pre-tensioner as
specified in Deployed Air Bag Module and Seat
Belt pre-tensioner Disposal (Refer to P.52B-128).
AC300562 AB
4. Tightly seal the air bag module and seat belt

pre-tensioner in a strong plastic bag for disposal.
5. Be sure to always wash your hands after
completing this operation.
14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . . 14-2 FAN CONTROLLER CHECK . . . . . . . . . . . 14-16

FAN CONTROL RELAY CONTINUITY
SERVICE SPECIFICATIONS. . . . . . . 14-2 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
COOLING FAN MOTOR CHECK . . . . . . . . 14-17
LUBRICANT. . . . . . . . . . . . . . . . . . . . 14-2
THERMOSTAT . . . . . . . . . . . . . . . . . . 14-18
SEALANT. . . . . . . . . . . . . . . . . . . . . . 14-2 REMOVAL AND INSTALLATION . . . . . . . . 14-18
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-19
SPECIAL TOOLS. . . . . . . . . . . . . . . . 14-3
WATER PUMP . . . . . . . . . . . . . . . . . . 14-20
TROUBLESHOOTING . . . . . . . . . . . . 14-3 REMOVAL AND INSTALLATION . . . . . . . . 14-20
ON-VEHICLE SERVICE. . . . . . . . . . . 14-15 WATER HOSE AND WATER PIPE . . 14-22

ENGINE COOLANT LEAK CHECK . . . . . . 14-15 REMOVAL AND INSTALLATION . . . . . . . . 14-22
RADIATOR CAP PRESSURE CHECK. . . . 14-15 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-23
ENGINE COOLANT REPLACEMENT . . . . 14-15
CONCENTRATION MEASUREMENT . . . . 14-16 RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-24
14-2 ENGINE COOLING
GENERAL INFORMATION
GENERAL INFORMATION
M1141000100456
The cooling system is designed to keep every part of coolant through the radiator as well so that the heat
the engine at appropriate temperature in whatever absorbed by the coolant may be radiated into the air.
condition the engine may be operated. The cooling The water pump is of the centrifugal type and is
method is of the water-cooled, pressure forced circu- driven by the drive belt from the crankshaft. The radi-
lation type in which the water pump pressurizes cool- ator is the corrugated fin, down flow type. The cool-
ant and circulates it throughout the engine. If the ing fan is controlled by the fan controller and
engine coolant temperature exceeds the prescribed engine-ECU depend on driving conditions.
temperature, the thermostat opens to circulate the
Item Specification
Radiator Performance kJ/h 216,700
M1141000300483

Radiator cap pressure kPa 93 − 123 Minimum 83
Range of coolant antifreeze concentration of radiator % 30 − 60 -
Fan controller input voltage V Ignition switch: "ON" Battery positive voltage -
Fan controller output voltage V A/C switch: "OFF" 1 or less -
A/C switch: "ON" Repeat steps 1) and 2). -
1) 8.2 ± 2.6
2) Battery positive voltage
± 2.6
Thermostat Valve opening temperature of thermostat °C 80 ± 1.5 -
Full-opening temperature of thermostat °C 93 -
Valve lift mm 9.5 or more -
LUBRICANT
M1141000400424
Item Specified lubricant Quantity L

Engine coolant (including DIA QUEEN SUPER LONG LIFE COOLANT or equivalent 6.0
reserve tank)
SEALANT
M1141000500658
Item Specified sealant Remark

Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent Drying sealant
ENGINE COOLING
SPECIAL TOOLS
14-3
SPECIAL TOOLS
M1141000600592

MB991223 Harness set Making voltage and
A
A: MB991219 A: Check harness resistance measurement
B: MB991220 B: LED harness during troubleshooting
C: MB991221 C: LED harness A: Connector pin contact
D: MB991222 adapter pressure inspection
B D: Probe B: Power circuit inspection
C: Power circuit inspection
connection
C
D DO NOT USE
MB991223 AZ
MB992006 Extra fine probe Making voltage and

resistance measurement
during troubleshooting
MB992006
MB991871 LLC changer Coolant refilling
MB991871
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE
SYMPTOMS
M1141005600434

procedure No.
Cooling fan does not operate 1 P.14-4
Cooling fan does not change speed or does not stop 2 P.14-10
14-4 ENGINE COOLING
TROUBLESHOOTING

TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1: Cooling fan does not operate
Cooling fan drive circuit <L.H. drive vehicles>
INPUT SIGNAL
ENGINE
· A/C SWITCH · VEHICLE SPEED FUSIBLE CONTROL
· ENGINE SENSOR LINK 2 RELAY
COOLANT
TEMPERATURE
SENSOR
ENGINE
ENGINE- CONTROL
ECU SYSTEM
FAN
CONTROL
RELAY
SMOOTHING
CIRCUIT
RADIATOR
INPUT SIGNAL FIELD EFFECT FAN
TRANSISTOR
PROCESSING CIRCUIT MOTOR
DRIVE
CIRCUIT
TEMPERATURE CURRENT
DETECTION DETECTION
FAN CONTROLLER
Wire colour code

AC505138AB
ENGINE COOLING
TROUBLESHOOTING
14-5
Cooling fan drive circuit <R.H. drive vehicles>
INPUT SIGNAL
ENGINE
· A/C SWITCH · VEHICLE SPEED FUSIBLE CONTROL
· ENGINE SENSOR LINK 2 RELAY
COOLANT
TEMPERATURE
SENSOR
ENGINE
ENGINE- CONTROL
ECU SYSTEM
FAN
CONTROL
RELAY
SMOOTHING
CIRCUIT
RADIATOR
FIELD EFFECT FAN
INPUT SIGNAL
TRANSISTOR
PROCESSING CIRCUIT MOTOR
DRIVE
CIRCUIT
TEMPERATURE CURRENT
DETECTION DETECTION
FAN CONTROLLER
Wire colour code

AC505139AB
CIRCUIT OPERATION • The engine-ECU judges the required revolution

• The fan controller is powered from fusible link speed of cooling fan motor using the input signals
No.2. transmitted from A/C switch, vehicle speed sen-
sor and engine coolant temperature sensor. The
engine-ECU activates the fan controller to drive
the cooling fan motor.
14-6 ENGINE COOLING
TROUBLESHOOTING
TECHNICAL DESCRIPTION STEP 3. Check for harness damage between

• The cause could be a malfunction of the fan con- fusible link No.2 and fan control relay connector
troller power supply or earth circuit. A-09X terminal 4.
• The cause could also be a malfunction of the fan
Fusible link (2) And
controller or the engine-ECU. Connector: A-09X
TROUBLESHOOTING HINTS A-09X

• Malfunction of fusible link 4
3
2
• Malfunction of fan control relay 1
• Malfunction of cooling fan motor Relay box

side
• Malfunction of fan controller
• Malfunction of engine-ECU
• Damaged wiring harness or connector Fusible link (2) AC310900AC
DIAGNOSIS Q: Are the harness wires between fusible link No.2

and fan control relay connector A-09X damaged?
YES : Repair or replace them, then go to Step 13.
STEP 1. Check the circuit at fan controller NO : Go to Step 4.
connector A-17 terminal 3.
Connector: A-17 STEP 4. Check for harness damage between fan
control relay connector A-09X terminal 2 and fan
Fan controller
controller connector A-17 terminal 3.
Connector: A-09X
A-09X
A-17 (GR) 3
4 2
1
Component side Relay box
AC210859 AD
side
(1) Disconnect fan controller connector A-17, and
measure at the harness side connector.
(2) Measure the voltage between terminal No.3 and AC310900AB
earth.
• When the ignition switch is turned to the "ON" Connector: A-17
position, voltage should measure battery pos-
itive voltage. Fan controller
Q: Is the voltage battery positive voltage when the

ignition switch is turned to the "ON" position?
YES : Go to Step 7.
NO : Go to Step 2.
A-17 (GR)
STEP 2. Check the fan control relay. Component side

AC210859 AD
Refer to P.14-17.
Q: Is the fan control relay in good condition? Q: Are the harness wires between fan control relay
YES : Go to Step 3. connector A-09X terminal 2 and fan controller
NO : Replace it, then go to Step 1. connector A-17 terminal 3 damaged?
NO : Go to Step 5.
ENGINE COOLING
TROUBLESHOOTING
14-7
STEP 5. Check for harness damage between J/C Connector: A-09X
(6) C-105 and fan control relay connector A-09X.
NOTE: A-09X
Connector: A-13 <LHD> 3
4 2
1
Relay box
side
A-13 (B)
AC310900AB
AC210877AC

C-105
AC310901AB
C-31
AC310903AB
C-105
C-105
AC310902AB
Q: Are the harness wires between J/C (6) C-105

terminal 28 and fan control relay connector A-09X
AC310901AB
terminal 1 damaged?
NO : Go to Step 6.
STEP 6. Check for harness damage between fan

control relay connector A-09X terminal 3 and
earth.
Connector: A-09X
C-105
AC310902AB
A-09X
3
After inspecting intermediate connector A-13 <LHD> 4

1
2
terminal 3, intermediate connector C-31 <RHD> ter- Relay box

minal 12 and J/C (6) C-105 terminal 28, 33 inspect side
the wires. If intermediate connector A-13 <LHD>,
C-31<RHD> and J/C (6) C-105 are damaged, repair
or replace them. Refer to GROUP 00, How to Use AC310900AB
Troubleshooting/Inspection Service Points P.00-5.
14-8 ENGINE COOLING
TROUBLESHOOTING
Q: Are the harness wires between fan control relay

STEP 10. Measure the output circuit voltage at
connector A-09X terminal 3 and earth damaged?
YES : Repair or replace them, then go to Step 13. engine-ECU connector C-121 terminal 18 by
NO : Go to Step 7. backprobing.
STEP 7. Check the cooling fan motor.
Refer to P.14-17. Engine-ECU
Q: Is the cooling fan motor in good condition?
YES : Go to Step 8.
NO : Replace it, then go to Step 13.
STEP 8. Check the circuit at fan controller

connector A-17 terminal 1.
Connector: A-17 C-121 (GR)
Fan controller 1 2 3 4 JAE 5 6 7 8

9 10 11 12 13 1415 16 1718 19 20 21 22 23
24 25 26 27 2829 3031 32 33 34 35
Harness side
AC505254 AB
A-17 (GR)
Component side
AC210859 AD
Engine-ECU
(1) Disconnect fan controller connector A-17, and
measure at the harness side connector.
(2) Measure the resistance between terminal No.1
and earth.
• The resistance should measure less than 2
ohms.
C-121 (GR)
Q: Is the resistance less than 2 ohms?
NO : Go to Step 9.
1 2 3 4 JAE 5 6 7 8
9 10 11 12 13 1415 16 1718 19 20 21 22 23
STEP 9. Check the harness wire between fan 24 25 26 27 2829 3031 32 33 34 35
controller connector A-17 and earth. Harness side

AC505255 AB
Connector: A-17
(1) Do not disconnect engine-ECU connector C-121.
Fan controller (2) Start the engine and allow it to idle.
(3) Turn the A/C switch to the "ON" position.
(4) Measure the voltage between terminal No.18 and
earth by backprobing.
• The voltage should measure 0.7 volt or more
A-17 (GR) when the cooling fan is operating.
Component side Q: Is the voltage 0.7 volt or more when the cooling fan
AC210859 AD is operating?
Q: Are the harness wires between fan controller
NO : Go to Step 11.
connector A-17 and earth damaged?
NO : Go to Step 10.
ENGINE COOLING
TROUBLESHOOTING
14-9
STEP 11. Check the harness wire between Connector: C-121 <LHD>
engine-ECU connector C-121 and fan controller
connector A-17. Engine-ECU
NOTE:
A-13 (B)
C-121 (GR)
8 7 6 5 JAE 4 3 2 1
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
AC210877AC 3534 33 32 31 30 29 2827 26 25 24
Component side
AC505254 AC
Engine-ECU
C-31
AC310903AB
If intermediate connector A-13 <LHD> terminal 2 and

intermediate connector C-31 <RHD> terminal 14 is C-121 (GR)
damaged, repair or replace it. Refer to GROUP 00,
Points P.00-5.
8 7 6 5 JAE 4 3 2 1
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
3534 33 32 31 30 29 2827 26 25 24
Component side
AC505255 AC
Connector: A-17
Fan controller
A-17 (GR)
Component side
AC210859 AD
Q: Are the harness wires between engine-ECU

connector C-121 terminal 18 and fan controller
connector A-17 terminal 2 damaged?
NO : Go to Step 12.
14-10 ENGINE COOLING
TROUBLESHOOTING
STEP 12. Check the fan controller at engine-ECU (2) Pull out terminal No.18.
connector C-121. (3) Turn the ignition switch to the "ON" position.
Q: Does the cooling fan motor operate?
YES : Replace the engine-ECU. Then go to Step
13.
Engine-ECU NO : Replace the fan controller. Then go to Step
13.
STEP 13. Check the symptoms.

Q: Does the cooling fan operate correctly?
C-121 (GR)
1 2 3 4 JAE 5 6 7 8
9 10 11 12 13 1415 16 1718 19 20 21 22 23
24 25 26 27 2829 3031 32 33 34 35
Harness side
AC505254 AB
Engine-ECU
C-121 (GR)
1 2 3 4 JAE 5 6 7 8
9 10 11 12 13 1415 16 1718 19 20 21 22 23
24 25 26 27 2829 3031 32 33 34 35
Harness side
AC505255 AB
INSPECTION PROCEDURE 2: Cooling fan does not change speed or does not stop
NOTE: If the engine coolant temperature reaches 110°C or higher, the cooling fan control runs the cooling fan
for up to 5 minutes even after the ignition switch is turned to the "LOCK" (OFF) position (the fan stops its rota-
tion when the engine coolant temperature decreases to 110°C or lower).
COOLING FAN DRIVE CIRCUIT • The engine-ECU judges the required revolution
Refer to P.14-4. speed of cooling fan motor using the input signals
transmitted from A/C switch, vehicle speed sen-
CIRCUIT OPERATION sor and engine coolant temperature sensor. The
• The fan controller is powered from fusible link engine-ECU activates the fan controller to drive
No.2. the cooling fan motor.
ENGINE COOLING
TROUBLESHOOTING
14-11
TECHNICAL DESCRIPTION STEP 3. Measure the output circuit voltage at
• The fan controller has variable control of the cool- engine-ECU connector C-121 terminal 18 by
ing fan motor speed using signals transmitted backprobing.
from the engine-ECU.
TROUBLESHOOTING HINTS
• Malfunction of fan control relay Engine-ECU
• Malfunction of fan controller
• Malfunction of engine-ECU
DIAGNOSIS
STEP 1. Check the fan control relay.

Refer to P.14-17. C-121 (GR)
Q: Is the fan control relay in good condition?
YES : Go to Step 2.
1 2 3 4 JAE 5 6 7 8
9 10 11 12 13 1415 16 1718 19 20 21 22 23
NO : Replace the part, then go to Step 8. 24 25 26 27 2829 3031 32 33 34 35
Harness side
STEP 2. Check the harness wire between fan AC505254 AB
control relay connector A-09X terminal 2 and fan

controller connector A-17 terminal 3. Connector: C-121 <RHD>
Connector: A-09X
Engine-ECU
A-09X
3
4 2
1
Relay box
side
C-121 (GR)
AC310900AB
Connector: A-17
1 2 3 4 JAE 5 6 7 8
9 10 11 12 13 1415 16 1718 19 20 21 22 23
24 25 26 27 2829 3031 32 33 34 35
Fan controller
Harness side
AC505255 AB

(2) Start the engine and allow it to idle.
A-17 (GR) (3) Measure the voltage between terminal No.18 and
Component side
AC210859 AD • The voltage should measure less than 0.3 volt
when the cooling fan is not operating.
Q: Are the harness wire between fan control relay
Q: Is the voltage less than 0.3 volt when the cooling
connector A-09X and fan controller connector A-17
fan is not operating?
damaged?
YES : Go to Step 6.
YES : Repair or replace the part, then go to Step
NO : Go to Step 4.
6.
NO : Go to Step 3.
TROUBLESHOOTING
STEP 4. Measure the output circuit voltage at (2) Start the engine and allow it to idle.
engine-ECU connector C-121 terminal 18 by (3) Turn the A/C switch to the "ON" position.
backprobing. (4) Measure the voltage between terminal No.18 and
Connector: C-121 <LHD> • The voltage should measure 0.7 volt or more
when the cooling fan is operating.
Engine-ECU Q: Is the voltage 0.7 volt or more when the cooling fan
is operating?
YES : Go to Step 6.
NO : Go to Step 5.
C-121 (GR)
1 2 3 4 JAE 5 6 7 8
9 10 11 12 13 1415 16 1718 19 20 21 22 23
24 25 26 27 2829 3031 32 33 34 35
Harness side
AC505254 AB
Engine-ECU
C-121 (GR)
1 2 3 4 JAE 5 6 7 8
9 10 11 12 13 1415 16 1718 19 20 21 22 23
24 25 26 27 2829 3031 32 33 34 35
Harness side
AC505255 AB

ENGINE COOLING
TROUBLESHOOTING
14-13
STEP 5. Check the harness wire between Connector: C-121 <LHD>
engine-ECU connector C-121 and fan controller
connector A-17. Engine-ECU
NOTE:
A-13 (B)
C-121 (GR)
8 7 6 5 JAE 4 3 2 1
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
AC210877AC 3534 33 32 31 30 29 2827 26 25 24
Component side
AC505254 AC
Engine-ECU
C-31
AC310903AB
If intermediate connector A-13 <LHD> terminal 2 and

intermediate connector C-31 <RHD> terminal 14 is C-121 (GR)
damaged, repair or replace it. Refer to GROUP 00,
Points P.00-5.
8 7 6 5 JAE 4 3 2 1
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
3534 33 32 31 30 29 2827 26 25 24
Component side
AC505255 AC
Connector: A-17
Fan controller
A-17 (GR)
Component side
AC210859 AD
Q: Are the harness wires between engine-ECU

connector C-121 terminal 18 and fan controller
connector A-17 terminal 2 damaged?
NO : Go to Step 6.
TROUBLESHOOTING
STEP 6. Check the fan controller at engine-ECU STEP 7. Check the fan controller at engine-ECU
Engine-ECU Engine-ECU
C-121 (GR) C-121 (GR)
1 2 3 4 JAE 5 6 7 8 1 2 3 4 JAE 5 6 7 8
9 10 11 12 13 1415 16 1718 19 20 21 22 23 9 10 11 12 13 1415 16 1718 19 20 21 22 23
24 25 26 27 2829 3031 32 33 34 35 24 25 26 27 2829 3031 32 33 34 35
AC505254 AB AC505254 AB
Engine-ECU Engine-ECU
C-121 (GR) C-121 (GR)
1 2 3 4 JAE 5 6 7 8 1 2 3 4 JAE 5 6 7 8
9 10 11 12 13 1415 16 1718 19 20 21 22 23 9 10 11 12 13 1415 16 1718 19 20 21 22 23
24 25 26 27 2829 3031 32 33 34 35 24 25 26 27 2829 3031 32 33 34 35

AC505255 AB AC505255 AB
(1) Do not disconnect engine-ECU connector C-121. (1) Disconnect engine-ECU connector C-121.
(2) Pull out terminal No.18. (2) Pull out terminal No.18.
(3) Turn the ignition switch to the "ON" position. (3) Connect terminal No.18 to the body earth.
Q: Does the cooling fan motor operate?
YES : Replace the engine-ECU. Then go to Step Q: Does the cooling fan motor stop running?
8. YES : Replace the engine-ECU. Then go to Step
NO : Go to Step 7. 8.
NO : Replace the fan controller. Then go to Step
8.
STEP 8. Check the symptoms.

Q: Does the cooling fan operate correctly?
ENGINE COOLING
ON-VEHICLE SERVICE
14-15
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK Minimum limit: 83 kPa
M1141001000388 Standard value: 93 − 123 kPa
WARNING 3. Replace the radiator cap if the reading does not
When pressure testing the cooling system, remain at or above the minimum limit.
slowly release cooling system pressure to
avoid getting burned by hot coolant. ENGINE COOLANT REPLACEMENT
M1141001200553
CAUTION
1. Remove the under cover (Refer to GROUP 51,
• Be sure to completely clean away any mois- Front Bumper P.51-2).
ture from the places checked.
• When the tester is taken out, be careful not to WARNING
spill any coolant. When removing the radiator cap, use care to
• Be careful when installing and removing the avoid contact with hot coolant or steam.
tester and when testing not to deform the Place a shop towel over the cap and turn the
filler neck of the radiator. cap anti-clockwise a little to let the pressure
escape through the vinyl tube. After relieving
the steam pressure, remove the cap by
Cap adapter
slowly turning it anti-clockwise.
2. Drain the water from the radiator, heater core and
Adapter engine after unplugging the radiator drain plug
and removing the radiator cap.
ACX01844 AB
1. Check that the coolant level is up to the filler neck.

Install a radiator tester and apply 160 kPa
Water inlet pipe
pressure, and then check for leakage from the
radiator hose or connections.
2. If there is leakage, repair or replace the
appropriate part.
RADIATOR CAP PRESSURE CHECK 44 ± 5 N·m

M1141001300453
NOTE: Be sure that the cap is clean before testing.
Rust or other foreign material on the cap seal will
cause an improper reading.
Cap adapter
AC210639AB
3. Drain the water in the water jacket by unplugging

the drain plug of the cylinder block.
4. Remove the reserve tank and drain the coolant.
5. Drain the cooling water then clean the path of the
AC211643 AB
cooling water by injecting water into the radiator
1. Use a cap adapter to attach the cap to the tester. from the radiator cap area.
2. Increase the pressure until the indicator of the
gauge stops moving.
ON-VEHICLE SERVICE
6. Apply the designated sealant to the screw area of CAUTION

the cylinder block drain plug, and then tighten to Do not overfill the reserve tank.
the standard torque.
14.Add coolant to the reserve tank between the
Specified sealant: 3M Nut Locking Part "FULL" and "LOW" mark if necessary.
No.4171 or equivalent
15.Install the under cover (Refer to GROUP 51,
Front Bumper P.51-2).
7. Securely tighten the drain plug of the radiator.
8. Assemble the reserve tank. CONCENTRATION MEASUREMENT
M1141001100448
CAUTION Measure the temperature and specific gravity of the
Do not use alcohol or methanol anti-freeze or any engine coolant to check the antifreeze concentration.
engine coolants mixed with alcohol or methanol Standard value: 30 − 60 % (allowable concen-
anti-freeze. The use of an improper anti-freeze tration range)
can cause corrosion of the aluminium compo- Recommended antifreeze: DIA QUEEN SUPER
nents. LONG LIFE COOLANT or equivalent
CAUTION
MB991871 If the concentration of the anti-freeze is below 30
%, the anti-corrosion property will be adversely
affected. In addition, if the concentration is
Air hose
above 60 %, both the anti-freezing and engine
cooling properties will decrease, affecting the
engine adversely. For these reasons, be sure to
maintain the concentration level within the speci-
fied range.
AC210658AB
9. By referring to the section on coolant, select an FAN CONTROLLER CHECK

M1141006100238
appropriate concentration for safe operating 1. Remove the centre under cover (Refer to GROUP
temperature within the range of 30 to 60 %. Use 51, Front Bumper P.51-2).
special tool LLC changer (MB991871) to refill the
coolant. A convenient mixture is a 50 % water and Fan controller
50 % antifreeze solution (freezing point: −31°C).
Recommended antifreeze: DIA QUEEN SUPER Fan controller
connector:
LONG LIFE COOLANT or equivalent
Component
Quantity: 6.0 L side
NOTE: For how to use the special tool, refer to its 3 2 1
manufacturer’s instructions.
10.Reinstall the radiator cap.
11.Start the engine and let it warm up until the AC210945AB
thermostat opens.
2. Disconnect the fan controller connector.
12.Repeatedly revving the engine up to 3,000 r/min
several times, then stop the engine. 3. Turn the ignition switch to the "ON" position, and
measure the voltage between the harness-side
13.Remove the radiator cap after the engine has
connector terminals.
become cold, and pour in coolant up to the brim.
Reinstall the cap. Standard value: Battery positive voltage
position, and connect the fan controller connector.
ENGINE COOLING
ON-VEHICLE SERVICE
14-17
FAN CONTROL RELAY CONTINUITY
Fan controller CHECK
M1141006200354
MB991222
Circuit tester
Cooling fan motor

connector:
Harness side Battery
2 4
2
1 3
4 3 1
AC210667 AB
5. Insert special tool probe (MB991222) at the back

of the cooling fan motor connector. AC210672 AB
6. Connect the special tool to the circuit tester.
7. Ensure that the A/C switch is off, and start the Battery Terminal No.to Continuity test
engine and run it at idle. voltage be connected to results
tester
8. Measure the voltage between the cooling fan
motor connector terminals. Not applied 4−2 Open circuit
Standard value: 1V or less • Connect 4 − 2 Less than 2 ohms
terminal
9. Turn the A/C switch to the "ON" position.
No.1 and
WARNING battery
Stay clear of the fan when the fan starts run- (+)
ning. terminal.
10. Measure the voltage between the cooling fan • Connect
motor connector terminals while the fan is terminal
running. The voltage should repeat the values 1) No.3 and
and 2) below. battery
(−)
Standard value:
terminal.
1) 8.2 ± 2.6 V
2) Battery positive voltage ± 2.6 V
COOLING FAN MOTOR CHECK
11.If the voltage does not repeatedly change as M1141007100134
indicated, replace the fan controller. 1. Remove the centre under cover (Refer to GROUP
12.Install the centre under cover (Refer to GROUP 51, Front Bumper P.51-2).
51, Front Bumper P.51-2).
THERMOSTAT
Cooling fan Cooling fan motor WARNING

motor Stay clear of the fan when the fan starts run-
connector: ning.
Component side
3. Check to see that the fan motor of the radiator
turns when applying battery power between the
connector terminals of the cooling fan motor. Also
check to see that there is no abnormal sound
coming from the cooling fan motor at this time.
4. If the cooling fan motor is defective, replace it.
AC210668 AB
5. Install the centre under cover (Refer to GROUP
2. Remove the cooling fan motor connector. 51, Front Bumper P.51-2).
THERMOSTAT
M1141002400884

• Under Cover Removal (Refer to GROUP 51, Front • Air Hose E, Air Pipe C and Air Hose D Installation (Refer
Bumper P.51-2). to GROUP 15, Intercooler P.15-6).
• Engine Coolant Draining (Refer to P.14-15). • Intake Air Duct Installation (Refer to GROUP 15, Air
• Intake Air Duct Removal (Refer to GROUP 15, Air Cleaner P.15-5).
Cleaner P.15-5). • Engine Coolant Refilling (Refer to P.14-15).
• Air Hose E, Air Pipe C and Air Hose D Removal (Refer to • Under Cover Installation (Refer to GROUP 51, Front
GROUP 15, Intercooler P.15-6). Bumper P.51-2).
10 ± 1 N·m
6 4
7 5.0 ± 1.0 N·m
8 11 ± 1 N·m
1 11 ± 1 N·m
AC504958 AB

1. Accelerator cable connection <LH 3. Vacuum hose and pipe assembly
drive vehicles> <<A>> >>B<< 4. Radiator upper hose connection
2. Control wiring harness connection 5. Wiring harness clamp
ENGINE COOLING
THERMOSTAT
14-19
Removal steps (Continued) 1. Insert each hose as far as the projection of the
6. Harness bracket water outlet fitting.
7. Water outlet fitting
2. Align the mating marks on the radiator hose and
>>A<< 8. Thermostat
hose clamp, and then connect the radiator hose.
<<A>> RADIATOR UPPER HOSE DISCON- M1141002500494
THERMOSTAT CHECK
NECTION
Mating marks
ACX00400
AC200641AB
Make mating marks on the radiator hose and the 1. Immerse the thermostat in water, and heat the
hose clamp. Disconnect the radiator hose. water while stirring. Check the thermostat valve
opening temperature.
INSTALLATION SERVICE POINTS Standard value:
>>A<< THERMOSTAT INSTALLATION Valve opening temperature: 80 ± 1.5°C
CAUTION
Make absolutely sure that no oil is adhering to
the rubber ring of the thermostat. In addition, be
careful not to fold over or scratch the rubber ring
when inserting. If the rubber ring is damaged,
replace the thermostat.
Install the thermostat being careful not to fold over or
Valve lift
scratch the rubber ring.
>>B<< RADIATOR UPPER HOSE

ACX00401AB
CONNECTION 2. Check that the amount of valve lift is at the

standard value when the water is at the
full-opening temperature.
Projection NOTE: Measure the valve height when the ther-
mostat is fully closed, and use this measurement
to compare the valve height when the thermostat
is fully open.
Standard value:
Water outlet fitting
Mating marks Full-opening temperature: 93°C
Amount of valve lift: 9.5 mm or more
AC200642 AB
WATER PUMP
WATER PUMP
M1141002701004
CAUTION
the caliper with tools or parts, because the caliper paint will be scratched.
• Under Cover Removal (Refer to GROUP 51, Front • Timing Tensioner Adjuster Belt Installation (Refer to
Bumper P.51-2). GROUP 11A, Timing Belt P.11A-36).
• Engine Coolant Draining (Refer to P.14-15). • Engine Coolant Refilling (Refer to P.14-15).
• Timing Belt Tensioner Adjuster Removal (Refer to • Under Cover Installation (Refer to GROUP 51, Front
GROUP 11A, Timing Belt P.11A-36). Bumper P.51-2).
20 ± 2 N·m 22 ± 4 N·m
24 ± 4 N·m N4
2
23 ± 3 N·m Bolt specifications
8 × 22
8 × 60
3N
8 × 14
14 ± 1 N·m
2
8 × 55
8 × 22
Nominal diameter × Nominal length mm
AC406755
AC504976 AB

1. Alternator brace 3. Water pump gasket
2. Water pump >>A<< 4. O-ring
ENGINE COOLING
WATER PUMP
14-21
INSTALLATION SERVICE POINT Fit an O-ring into the O-ring groove located at the
end of the water inlet pipe and apply water to the
>>A<< O-RING INSTALLATION
O-ring or the inside of the mounting surface of the
CAUTION water pump for insertion.
Do not let the O-ring get contaminated with
grease or engine oil.
Water pump
O-ring
Water inlet pipe
AC103005AC
WATER HOSE AND WATER PIPE

M1141003301076

• Under Cover Removal (Refer to GROUP 51, Front • Thermostat Installation (Refer to P.14-18).
Bumper P.51-2). • Turbocharger Bypass Valve Assembly, Air By-pass Hose,
• Engine Coolant Draining (Refer to P.14-15). Air Hose E, Air Pipe C and Air Hose D Installation (Refer
• Battery and Battery Tray Removal to GROUP 15, Intercooler P.15-6).
• Air Cleaner Assembly Removal (Refer to GROUP 15, Air • Air Cleaner Assembly Installation (Refer to GROUP 15,
Cleaner P.15-5). Air Cleaner P.15-5).
• Turbocharger Bypass Valve Assembly, Air By-pass Hose, • Battery and Battery Tray Installation
Air Hose E, Air Pipe C and Air Hose D Removal (Refer to • Engine Coolant Refilling (Refer to P.14-15).
GROUP 15, Intercooler P.15-6). • Under Cover Installation (Refer to GROUP 51, Front
• Thermostat Removal (Refer to P.14-18). Bumper P.51-2).
12
13 11 ± 1 N·m
10 N
13 ± 2 N·m 5.0 ± 1.0 N·m 2
11
1
8 4 23 ± 4 N·m
9 6
N 16
3
15
42 ± 7 N·m 5
7N
20 N
10 ± 1 N·m
14
17
42 ± 7 N·m
10 ± 1 N·m 19
18 N
AC504959 AB

1. Wiring harness clamp 12. Water return hose
2. Harness bracket 13. Heater hose connection
3. Engine coolant temperature gauge 14. Water return hose
unit connector >>B<< 15. Water inlet pipe
4. Engine coolant temperature >>A<< 16. O-ring
sensor connector 17. Turbocharger water feed pipe
5. Water feed hose 18. Gaskets
6. Thermostat case assembly • Turbocharger and exhaust fitting
7. Thermostat case gasket assembly (Refer to GROUP 15,
<<A>> >>C<< 8. Radiator lower hose connection Exhaust Manifold and
9. Detonation sensor connection Turbocharger P.15-10).
>>A<< 10. O-ring 19. Turbocharger water return pipe
11. Water feed hose 20. Gaskets
ENGINE COOLING
14-23
REMOVAL SERVICE POINT >>B<< WATER INLET PIPE
<<A>> RADIATOR LOWER HOSE DIS- INSTALLATION
CONNECTION Temporarily install the water inlet pipe. After installing
the water outlet fitting and thermostat case assembly,
tighten the mounting bolt of the water inlet pipe to the
specified torque.
Tightening torque
M6 bolt: 5.0 ± 1.0 N⋅m
M8 bolt: 13 ± 2 N⋅m
Mating marks >>C<< RADIATOR LOWER

HOSE/RADIATOR UPPER HOSE
AC200641AB
CONNECTION
Make mating marks on the radiator hose and the
hose clamp. Disconnect the radiator hose.
Projection

>>A<< O-RING INSTALLATION
CAUTION
Do not let the O-ring get contaminated with
grease or engine oil. Water inlet pipe or Mating
water outlet fitting marks
Water pump AC200642 AD
1. Insert each hose as far as the projection of the

O-ring
water inlet pipe or water outlet fitting.
Water inlet pipe

INSPECTION
M1141003400360
AC103005AC WATER PIPE AND HOSE CHECK
Fit an O-ring into the O-ring groove located at the Check the water pipe and hose for cracks, damage
end of the water inlet pipe and apply water to the and clogs. Replace them if necessary.
O-ring or the inside of the mounting surface of the
water pump for insertion.
RADIATOR
RADIATOR
M1141001501193

• Under Cover Removal (Refer to GROUP 51, Front • Air Hose E, Air Pipe C and Air Hose D Installation (Refer
Bumper P.51-2). to GROUP 15, Intercooler P.15-6).
• Engine Coolant Draining (Refer to P.14-15). • Air Cleaner Assembly Installation (Refer to GROUP 15,
• Battery and Battery Tray Removal Air Cleaner P.15-5).
• Air Cleaner Assembly Removal (Refer to GROUP 15, Air • Battery and Battery Tray Installation
Cleaner P.15-5). • Engine Coolant Refilling (Refer to P.14-15).
• Air Hose E, Air Pipe C and Air Hose D Removal (Refer to • Under Cover Installation (Refer to GROUP 51, Front
GROUP 15, Intercooler P.15-6). Bumper P.51-2).
5.0 ± 1.0 N·m

12 ± 2 N·m
12 ± 2 N·m
11 6 7
4
3
11
13
9
5
5.0 ± 1.0 N·m
5.0 ± 1.0 N·m
2N
1 8
14
3.5 ± 0.4 N·m 5.4 ± 0.5 N·m
4.5 ± 0.4 N·m
14
20
22
21
10 19
12 ± 2 N·m
17
12 18
16 15
AC210706 AC
Radiator removal steps Radiator removal steps

1. Radiator drain plug 15. Fan controller connector
2. O-ring 16. Fan controller, cooling fan motor,
3. Radiator cap fan and shroud assembly
4. Reserve tank hose Fan controller and cooling fan
5. Reserve tank motor removal steps
6. Reserve tank cap <> 12. Air pipe B mounting bolt
7. Reserve tank hose 15. Fan controller connector
8. Reserve tank bracket 17. Cooling fan motor connector
<<A>> >>A<< 9. Radiator upper hose 18. Fan controller
<<A>> >>A<< 10. Radiator lower hose 19. Cooling fan motor, fan and shroud
11. Upper insulator assembly
<> 12. Air pipe B mounting bolt 20. Cooling fan
13. Radiator assembly 21. Cooling fan motor
14. Lower insulator 22. Cooling fan shroud
ENGINE COOLING
RADIATOR
14-25
REMOVAL SERVICE POINTS After removing the bolt, position air pipe B out of the
way so that the pipe does not interfere with the radia-
<<A>> RADIATOR UPPER HOSE/RADIA-
tor assembly or the cooling fan motor, the fan and
TOR LOWER HOSE DISCONNECTION shroud assembly.

>>A<< RADIATOR LOWER HOSE/RADIA-
TOR UPPER HOSE CONNECTION
Projection
Mating marks
AC200641AB
Make mating marks on the radiator hose and the

hose clamp. Disconnect the radiator hose.
Water inlet pipe, Mating marks
water outlet fitting
<> AIR PIPE B MOUNTING BOLT or radiator AC200642 AC
REMOVAL
1. Insert each hose as far as the projection of the
water inlet pipe, water outlet fitting or radiator.
AC210705
NOTES
32-1
GROUP 32
POWER PLANT
MOUNT
CONTENTS
GENERAL INFORMATION . . . . . . . . 32-2 ENGINE ROLL STOPPER,

CENTREMEMBER . . . . . . . . . . . . . . . 32-7
SPECIAL TOOL . . . . . . . . . . . . . . . . . 32-4 REMOVAL AND INSTALLATION . . . . . . . . 32-7
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 32-9
ENGINE MOUNTING . . . . . . . . . . . . . 32-4
REMOVAL AND INSTALLATION . . . . . . . . 32-4 CROSSMEMBER* . . . . . . . . . . . . . . . 32-10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 32-5 REMOVAL AND INSTALLATION . . . . . . . . 32-10
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 32-14
TRANSMISSION MOUNTING . . . . . . 32-5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 32-6
WARNING
NOTE
32-2 POWER PLANT MOUNT
GENERAL INFORMATION
GENERAL INFORMATION
M1321000100544
Inertia principal axes system is incorporated into the • Installation of roll stopper in the upper area has
engine mount system. reduced engine rolling. Furthermore, enlarge-
• The liquid-filled mount system has been adopted ment of insulator diameter has reduced idle vibra-
for engine mounting insulator and transmission tion.
mounting insulator to improve ride feeling by opti-
mising the insulator.
Engine mounting insulator
Transmission mounting
insulator
AC310393 AC
POWER PLANT MOUNT
GENERAL INFORMATION
32-3
Transmission case rear

roll stopper bracket
Engine rear
roll stopper rod
Engine rear
roll stopper rod
Transmission case bracket
front roll stopper bracket
Engine front
roll stopper
bracket
Front axle No.1

crossmember
Front axle
crossmember bar
10012AU
Front suspension
centremember
Transmission case rear

roll stopper bracket
Engine rear
roll stopper
Transmission case bracket
front roll stopper bracket
Engine front
roll stopper
bracket
Front axle No.1

crossmember
Front axle
crossmember bar
10011AU
Front suspension
centremember
AC310460 AB
SPECIAL TOOL
SPECIAL TOOL
M1321000600442

MB991897 Ball joint remover Knuckle and tie rod end ball joint
disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113) is also
available to disconnect knuckle and
AC106827
tie rod end ball joint.
ENGINE MOUNTING
M1321001100752
CAUTION
*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.
• Under Cover Removal (Refer to GROUP 51, Front • Under Cover Installation (Refer to GROUP 51, Front
Bumper P.51-2). Bumper P.51-2).
• Raise the engine and transmission assembly until its
weight is not applied to the insulator, and support it
securely.
12 ± 2 N·m
2
1
67 ± 7 N·m*
98 ± 10 N·m*
3
4
AC210425 AB

1. Power steering oil pressure hose 3. Engine mounting insulator
2. Engine mounting bolt >>A<< 4. Engine mounting cushion stoppers
POWER PLANT MOUNT
TRANSMISSION MOUNTING
32-5
INSTALLATION SERVICE POINT Arrow marks on the engine mounting cushion stop-
per should face the shown direction.
>>A<< ENGINE MOUNTING CUSHION
NOTE: Disregard F and R stamped as a shared part.
STOPPER INSTALLATION
Engine side Engine side INSPECTION
M1321001200232
• Check the engine mounting insulator for cracks,
separation or deformation.
R F
• Check the engine mounting cushion stoppers for
deformation.
R
F
Engine mounting
cushion stopper
<Vehicle <Vehicle
rear view> front view>
AC210426 AC
M1321001400968
CAUTION
• Under Cover Removal (Refer to GROUP 51, Front • Rear Roll Stopper Installation (Refer to P.32-7).
Bumper P.51-2). • Air Pipe C, Air By-pass Hose, Air Hose D Installation
• Raise the engine and transmission assembly until its (Refer to GROUP 15, Intercooler P.15-6).
weight is not applied to the insulator, and support it • Radiator Assembly Installation (Refer to GROUP 14,
securely. Radiator P.14-24).
• Battery and Battery Tray Removal • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner P.15-5).
P.15-5). • Battery and Battery Tray Installation
• Radiator Assembly Removal (Refer to GROUP 14, Radia- • Under Cover Installation (Refer to GROUP 51, Front
tor P.14-24). Bumper P.51-2).
• Air Pipe C, Air By-pass Hose, Air Hose D Removal (Refer
to GROUP 15, Intercooler P.15-6).
• Rear Roll Stopper Removal (Refer to P.32-7).
3
2
47 ± 7 N·m*
82 ± 7 N·m* AC505022AB

1. Transmission mounting bolt 2. Transmission mounting insulator
>>A<< 3. Transmission mounting stopper
INSTALLATION SERVICE POINT Install the transmission mounting stopper so that its
arrow points upward.
>>A<< TRANSMISSION MOUNTING
STOPPER INSTALLATION INSPECTION
M1321001500200
Engine side Transmission • Check the transmission mounting insulator for
mounting cracks, separation or deformation.
stopper
• Check the transmission mounting stoppers for
Transmission deformation.
mounting
insulator
AC200645 AI
POWER PLANT MOUNT
ENGINE ROLL STOPPER, CENTREMEMBER
32-7
M1321002300362
<LH DRIVE VEHICLES>

CAUTION
10
70 ± 10 N·m
52 ± 7 N·m*
6 45 ± 5 N·m*
7 9
8
70 ± 10 N·m 52 ± 7 N·m*
52 ± 7 N·m*
5
45 ± 5 N·m*
2
69 ± 10 N·m
1
69 ± 10 N·m
49 ± 10 N·m
49 ± 10 N·m 1
49 ± 10 N·m
AC210447AB
Front roll stopper bracket and Rear roll stopper rod removal
centremember removal steps steps
1. Front axle crossmember bars 6. Engine rear roll stopper rod bolt
2. Engine front roll stopper bracket 7. Transmission case rear roll
bolt stopper bracket
3. Front suspension centremember 8. Engine rear roll stopper rod bolt
>>A<< 4. Engine front roll stopper bracket 9. Engine rear roll stopper rod
5. Transmission case front roll bracket
stopper bracket 10. Engine rear roll stopper rod
<RH DRIVE VEHICLES>

CAUTION
70 ± 10 N·m
8
6 45 ± 5 N·m*
70 ± 10 N·m 52 ± 7 N·m*
52 ± 7 N·m* 5
45 ± 5 N·m* 2
69 ± 10 N·m
1
69 ± 10 N·m
49 ± 10 N·m
49 ± 10 N·m 1
49 ± 10 N·m
AC310765 AB
Front roll stopper bracket and Rear roll stopper rod removal
centremember removal steps steps
1. Front axle crossmember bars 6. Engine rear roll stopper bolt
2. Engine front roll stopper bracket 7. Transmission case rear roll
bolt stopper bracket
3. Front suspension centremember 8. Engine rear roll stopper bracket
>>A<< 4. Engine front roll stopper bracket
5. Transmission case front roll
stopper bracket
POWER PLANT MOUNT
32-9
M1321002400080
>>A<< ENGINE FRONT ROLL STOPPER • Check the engine roll stopper insulators for
BRACKET INSTALLATION cracks, separation or deformation.
Hole
Front of vehicle
AC210448 AB
Install the front roll stopper so that its hole points

towards the front side of the vehicle.
CROSSMEMBER
CROSSMEMBER
M1321003200443
<LH drive vehicles>

CAUTION
• Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B -
Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so that they are
facing straight forward, and remove the ignition key. If you fail to do this, the SRS clock spring will
be damaged, causing the SRS air bag to be inoperative and serious injury.
• *1: Indicates parts which should be initially tightened, and then fully tightened after placing the
• *2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in the unladen condition.
• If the vehicle is equipped with the Brembo™ disc brake, during maintenance, take care not to con-
tact the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal and Post-installation Operation Pre-removal and Post-installation Operation
• Under Cover Removal (Refer to GROUP 51, Front • Front Exhaust Pipe Installation (Refer to GROUP 15,
Bumper P.51-2). Exhaust Pipe and Main Muffler P.15-13).
• Front Axle Crossmember Bar, Front Suspension Center- • Front Axle Crossmember Bar, Front Suspension Center-
member Removal (Refer to P.32-7). member Installation (Refer to P.32-7).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Steering Wheel Air Bag Module Assembly Installation
Exhaust Pipe and Main Muffler P.15-13). (Refer to GROUP 37, Steering Wheel P.37-13).
• Steering Wheel Air Bag Module Assembly Removal • Power Steering Fluid Supplying (Refer to GROUP 37,
(Refer to GROUP 37, Steering Wheel P.37-13). On-vehicle Service − Fluid Replacement P.37-10).
• Power Steering Fluid Draining (Refer to GROUP 37, • Power Steering Fluid Line Bleeding (Refer to GROUP 37,
On-vehicle Service − Fluid Replacement P.37-10). On-vehicle Service − Power Steering System Air Bleeding
P.37-10).
• Press the dust cover with a finger to check whether the
dust cover cracked or damaged.
Ahead.
GROUP 37, On-vehicle Service − Steering Angle Check
P.37-8).
Bumper P.51-2).
POWER PLANT MOUNT
CROSSMEMBER
32-11
18 ± 2 N·m
4
9
12 ± 2 N·m
10 N
70 ± 10 N·m 57 ± 7 N·m
13 8N 15 ± 3 N·m
16 14 15
12 ± 2 N·m
5
45 ± 5 N·m*¹ 25 ± 4 N·m
N 11
21 ± 4 N·m 7
12
21 ± 4 N·m
52 ± 7 N·m*¹
108 ± 10 N·m
6
2
39 ± 5 N·m
3
1
186 ± 10 N·m*²
39 ± 5 N·m
167 ± 9 N·m
49 ± 10 N·m
AC210547 AB

1. Lower arm and knuckle 9. Pressure hose connection
connection 10. Gaskets
2. Stabilizer link 11. Self-locking nut
<<A>> 3. Lower arm assembly <> 12. Tie rod end and knuckle
4. Steering shaft assembly and gear connection
box connecting bolt <<C>> 13. Front axle No.1 crossmember
5. Engine rear roll stopper rod bolt assembly
6. Engine rear roll stopper rod and >>A<< 14. Stabilizer bar
bracket assembly 15. Steering gear and linkage
7. Return hose and return pipe 16. Front axle No.1 crossmember
8. O-ring
CROSSMEMBER
<RH drive vehicles>

CAUTION
• Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B -
Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so that they are
facing straight forward, and remove the ignition key. If you fail to do this, the SRS clock spring will
be damaged, causing the SRS air bag to be inoperative and serious injury.
• *1: Indicates parts which should be initially tightened, and then fully tightened after placing the
• *2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in the unladen condition.
• If the vehicle is equipped with the Brembo™ disc brake, during maintenance, take care not to con-
tact the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal and Post-installation Operation Pre-removal and Post-installation Operation
• Under Cover Removal (Refer to GROUP 51, Front • Front Exhaust Pipe Installation (Refer to GROUP 15,
Bumper P.51-2). Exhaust Pipe and Main Muffler P.15-13).
• Front Axle Crossmember Bar, Front Suspension Center- • Front Axle Crossmember Bar, Front Suspension Center-
member Removal (Refer to P.32-7). member Installation (Refer to P.32-7).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Steering Wheel Air Bag Module Assembly Installation
Exhaust Pipe and Main Muffler P.15-13). (Refer to GROUP 37, Steering Wheel P.37-13).
• Steering Wheel Air Bag Module Assembly Removal • Power Steering Fluid Supplying (Refer to GROUP 37,
(Refer to GROUP 37, Steering Wheel P.37-13). On-vehicle Service − Fluid Replacement P.37-10).
• Power Steering Fluid Draining (Refer to GROUP 37, • Power Steering Fluid Line Bleeding (Refer to GROUP 37,
On-vehicle Service − Fluid Replacement P.37-10). On-vehicle Service − Power Steering System Air Bleeding
P.37-10).
• Press the dust cover with a finger to check whether the
dust cover cracked or damaged.
Ahead.
GROUP 37, On-vehicle Service − Steering Angle Check
P.37-8).
Bumper P.51-2).
POWER PLANT MOUNT
CROSSMEMBER
32-13
6 15 ± 3 N·m
18 ± 2 N·m
4 7N 8
N 5 70 ± 10 N·m
12
16 14 15
57 ± 7 N·m
45 ± 5 N·m*¹ 25 ± 4 N·m
11 13 N 9
21 ± 4 N·m
10
21 ± 4 N·m
52 ± 7 N·m*¹
108 ± 10 N·m
2
39 ± 5 N·m
3
1
186 ± 10 N·m*²
39 ± 5 N·m
167 ± 9 N·m
49 ± 10 N·m
AC310965AB

1. Lower arm and knuckle <> 10. Tie rod end and knuckle
connection connection
2. Stabilizer link 11. Engine rear roll stopper bolt
<<A>> 3. Lower arm assembly <<C>> 12. Front axle No.1 crossmember
4. Pressure hose connection assembly
5. Gaskets 13. Engine rear roll stopper bracket
6. Return hose and return pipe >>A<< 14. Stabilizer bar
7. O-ring 15. Steering gear and linkage
8. Steering shaft assembly and gear 16. Front axle No.1 crossmember
box connecting bolt
9. Self-locking nut
CROSSMEMBER
REMOVAL SERVICE POINTS 2. Turn the bolt and knob as necessary to make the
<<A>> LOWER ARM ASSEMBLY jaws of the special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel.
REMOVAL
Transmission jack Wooden sure the knob is in the position shown in the fig-
block ure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.
<<C>> FRONT AXLE NO.1

CROSSMEMBER ASSEMBLY REMOVAL
Mounting
bolt
AC210537AB
Lift the transmission with a transmission jack, and

then withdraw the front mounting bolt on the left
lower arm assembly.
Wooden
<> TIE ROD END AND KNUCKLE block
DISCONNECTION
Transmission
CAUTION jack AC210538AB
Retain the crossmember with a transmission jack,
and then remove the crossmember mounting bolt.
(MB991897) to avoid possible damage to ball
joint threads.
• Hang the special tool with cord to prevent it
from falling. >>A<< STABILIZER BAR INSTALLATION
Outside of
Cord vehicle Identification
colour
Self-locking
nut MB991897
Bushing
Fixture
Bolt
Ball joint AC208247AD AC006141AF
Align the identification colour on the left side of the

1. Install the special tool as shown in the figure.
stabilizer bar with the right end of the bushing.
Bolt
INSPECTION
M1321003300246
• Check the front axle No.1 crossmember for
Parallel cracks or damage.
Knob Correct
Wrong AC106821AC
13B-1
GROUP 13B
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION . . . . . . . . 13B-2 FUEL GAUGE UNIT REPLACEMENT . . . . 13B-3
ON-VEHICLE SERVICE. . . . . . . . . . . 13B-2 FUEL TANK . . . . . . . . . . . . . . . . . . . . 13B-5

FUEL PUMP OPERATION CHECK . . . . . . 13B-2 REMOVAL AND INSTALLATION . . . . . . . . 13B-5
FUEL PUMP MODULE REPLACEMENT . . 13B-2 FUEL PUMP MODULE DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 13B-9
FUEL GAUGE UNIT CHECK . . . . . . . . . . . 13B-3
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 13B-11
13B-2 FUEL SUPPLY
GENERAL INFORMATION
GENERAL INFORMATION
M1135000100480
• The fuel tank is located under the floor of the rear • A fuel pump module, including fuel pump, fuel fil-
seats to provide increased protection and more ter assembly and fuel gauge unit (main), is uti-
luggage space. lized to reduce weight and improve serviceability.
• A fuel tank safety valve is used to prevent fuel
from leaking out in case of a collision.
ON-VEHICLE SERVICE
FUEL PUMP OPERATION CHECK CAUTION
M1135001000204
Refer to GROUP 13A, On-vehicle Service
P.13A-399.
FUEL PUMP MODULE REPLACEMENT Float

M1135004900369
1. Remove the rear seat cushion assembly. (Refer to
GROUP 52A, Rear Seat Assembly P.52A-20).
Fuel pump
2. Remove the service hole cover. module
Harness Fuel high-

connector pressure hose AC211368 AB
When withdrawing the fuel pump module from

the fuel tank, be careful not damage the module
unit and the float.
5. Unscrew the mounting nuts to remove the fuel
pump module.
Fuel return 6. Replace the fuel pump (Refer to P.13B-9).
Suction hose
hose AC210801AB CAUTION

NOTE: Check the fuel pump (Refer to GROUP
13A, On-vehicle Service P.13A-399). If defective,
replace the fuel pump, which is incorporated in Float
the fuel pump module.
4. Disconnect fuel high-pressure hose, suction hose Fuel pump
and fuel return hose. module
AC211368 AB
When installing the fuel pump module into the

fuel tank, be careful not damage the module unit
and the float.
7. Install the fuel pump module. Tighten the
mounting nuts to the specified torque.
FUEL SUPPLY
ON-VEHICLE SERVICE
13B-3
CAUTION <Fuel gauge unit (Main)>
Corresponding Fuel Harness Fuel high-
side high-pressure connector pressure hose
hose Fuel pump
module
3.0 mm
Fuel return
hose
Suction Y2014AU
AC100963 AC hose
<Fuel gauge unit (Sub)>
Snap the fuel high-pressure hose one-touch joint
into place, then pull back slightly on the hose to
assure it is secure. However, the connection Harness Suction
connector hose
should have a play of approximately 3.0 mm.
8. Connect the harness connector, fuel
high-pressure hose, suction hose and fuel return
hose.
9. Replace the service hole cover.
10.Install the rear seat cushion assembly (Refer to Fuel pipe and AC310596
gauge assembly AC310872AB
3. Disconnect the harness connector, fuel
FUEL GAUGE UNIT CHECK high-pressure hose, suction hose and fuel return
M1135003100401
Refer to GROUP 54A, Combination Meter Assembly hose.
and Vehicle Speed Sensor − On-vehicle Service CAUTION
P.54A-54.
FUEL GAUGE UNIT REPLACEMENT

M1135001400428
1. Remove the rear seat cushion assembly. (Refer to
Float
2. Remove the service hole cover.
Fuel pump
module
Float
Fuel pipe
and gauge
assembly
AC310597 AB
When withdrawing the fuel pump module or fuel

pipe and gauge assembly from the fuel tank, be
careful not damage the sensor unit and the float.
13B-4 FUEL SUPPLY
ON-VEHICLE SERVICE
4. Unscrew the mounting nuts to remove the fuel CAUTION

pump module or fuel pipe and gauge assembly.
Corresponding Fuel
NOTE: Check the fuel gauge unit (Refer to side high-pressure
GROUP 54A, Combination Meter Assembly and hose
Vehicle Speed Sensor − On-vehicle Service
P.54A-54). If defective, replace it. (Refer to
P.13B-9).
CAUTION 3.0 mm
AC100963 AC
Snap the fuel high-pressure hose one-touch joint

Float into place, then pull back slightly on the hose to
assure it is secure. However, the connection
Fuel pump should have a play of approximately 3.0 mm.
module
6. Connect the harness connector, fuel
high-pressure hose, suction hose and fuel return
hose.
7. Replace the service hole cover.
8. Install the rear seat cushion assembly. (Refer to
Float
Fuel pipe
and gauge
assembly
AC310597 AB
When inserting the fuel pump module or fuel pipe

and gauge assembly into the fuel tank, be careful
not damage the sensor unit and the float.
5. Install the fuel pump module or fuel pipe and
gauge assembly. Tighten the mounting nuts to the
specified torque.
FUEL SUPPLY
FUEL TANK
13B-5
FUEL TANK
M1135001901095
Pre-removal Operation Pre-installation Operation

• Draining Fuel • Propeller Shaft Installation (Refer to GROUP 25, Propeller
• Fuel Pump Connector Disconnection (How to Reduce Shaft P.25-3).
Fuel Pressure). (Refer to GROUP 13A, On-vehicle Serv- • Centre Exhaust Pipe Installation (Refer to GROUP 15,
ice P.13A-398). Exhaust Pipe and Main Muffler P.15-13).
• Centre Exhaust Pipe Removal (Refer to GROUP 15, • Refilling Fuel
Exhaust Pipe and Main Muffler P.15-13). • Checking for Fuel Leaks
• Propeller Shaft Removal (Refer to GROUP 25, Propeller
Shaft P.25-3).
<Fuel tank assembly> 2.5 ± 0.5 N·m
2.5 ± 0.5 N·m

23 20
11
21 26
N 27 19
N 22 10 18
24
3
N 25
17 2
7
16
1
6
2.5 ± 0.5 N·m
6
12
9
14
26 ± 4 N·m 8 6 5 15
13
4 AC311018 AC
Fuel tank assembly removal Fuel tank assembly removal

1. Fuel filler neck hose connection >>B<< 5. Fuel high-pressure hose connection
2. Fuel filler neck breather hose 6. Fuel wiring harness connector
connection • Parking brake cable clamp
3. Fuel vapour hose connection connection (Refer to GROUP 36,
4. Fuel return hose connection Parking Brake Cable P.36-5).
13B-6 FUEL SUPPLY
FUEL TANK
Fuel tank assembly removal Fuel tank assembly removal

steps (Continued) steps (Continued)
• Rear ABS sensor connector and 15. Fuel pipe assembly
harness clamp connection (Refer to 16. Fuel filler neck hose
GROUP 35B, ABS Sensor 17. Fuel filler neck breather hose
P.35B-146). 18. Fuel vapour hose
<<A>> 7. Fuel tank assembly 19. Fuel tank check valve
8. Fuel tank lower protector 20. Fuel vapour hose
9. Fuel wiring harness <> >>A<< 21. Fuel pipe and gauge assembly
>>B<< 10. Suction hose 22. Packing
>>B<< 11. Fuel high-pressure hose 23. Plate
12. Fuel return hose <> >>A<< 24. Fuel pump module
13. Fuel return hose 25. Packing
>>B<< 14. Fuel high-pressure hose 26. Fuel tank safety valve
27. Packing
<Fuel filler neck assembly>
31
34 N
30
32
24 ± 4 N·m
28
29 33
AC310598AB
Fuel filler neck assembly removal Fuel filler neck assembly removal
28. Fuel tank protector 32. Fuel filler neck assembly
29. Fuel filler neck hose connection 33. Fuel filler neck valve
30. Fuel filler neck breather hose 34. Packing
connection
31. Fuel tank filler cap
FUEL SUPPLY
FUEL TANK
13B-7
REMOVAL SERVICE POINTS <> FUEL PIPE AND GAUGE
<<A>> FUEL TANK ASSEMBLY ASSEMBLY/FUEL PUMP MODULE
REMOVAL REMOVAL
CAUTION
Floor
Float
Tilt Fuel pump

Removal
direction Differential module
Fuel tank carrier
assembly AC210871AB
1. Remove the differential support member and tilt

the differential carrier. (Refer to GROUP 27,
Differential Carrier P.27-43).
2. Hold the fuel tank assembly with a transmission
jack and remove the nuts connected to the fuel
tank assembly. Float
3. Remove the fuel tank assembly in the tilting
Fuel pipe
direction to avoid contact with the differential and gauge
carrier. assembly
AC310597 AB
When withdrawing the fuel pipe and gauge

assembly and fuel pump module from the fuel
tank, be careful not damage the sensor unit and
the float.
13B-8 FUEL SUPPLY
FUEL TANK

>>A<< FUEL PUMP MODULE/FUEL PIPE >>B<< FUEL HIGH-PRESSURE
AND GAUGE ASSEMBLY INSTALLATION HOSE/SUCTION HOSE INSTALLATION
CAUTION CAUTION
Corresponding Fuel high-pressure
side hose or suction hose
Float
Fuel pump 3.0 mm

module
AC100963 AD
After connecting the quickrelease joint of the fuel

high-pressure hose or suction hose, pull the joint
lightly away from the quickrelease joint to con-
firm that it is secure. In addition, confirm that
there is a play of approximately 3.0 mm at the
Float joint.
Fuel pipe
and gauge
assembly
AC310597 AB
When inserting the fuel pump module and fuel

pipe and gauge assembly into the fuel tank, be
careful not damage the sensor unit and the float.
FUEL SUPPLY
FUEL TANK
13B-9
FUEL PUMP MODULE DISASSEMBLY
AND REASSEMBLY
M1135004600410
<FUEL PUMP MODULE>
12
11 N
10
9 2
7N
6
3
AC210872AB

1. Fuel gauge unit (Main) >>A<< 7. Grommet
2. Fuel pump harness 8. Fuel feed assist pump
3. Fuel pump bracket 9. Fuel hose
4. Fuel pump cushion 10. Cap
5. Fuel pump >>A<< 11. O-ring
6. Spacer 12. Fuel filter assembly
13B-10 FUEL SUPPLY
FUEL TANK
<FUEL PIPE AND GAUGE ASSEMBLY>
16
N 17
18
1.2 ± 0.2 N·m
15
N 13
14
AC310599 AB

13. Packing 16. Connector
14. Fuel filter 17. O-ring
15. Fuel gauge unit (Sub) 18. Fuel pipe assembly
FUEL SUPPLY
FUEL TANK
13B-11
REASSEMBLY SERVICE POINT 2. Obtain a container, which is full of water.
>>A<< O-RING/GROMMET INSTALLA- 3. Invert the fuel tank safety valve, and submerge it
TION slowly in the water while placing your fingers over
the nozzle.
Apply gasoline on the O-ring and the grommet before
mounting them to prevent damage or twisting. 4. Check that no more air bubbles appears from the
fuel tank safety valve, and withdraw it slowly.
INSPECTION
M1135002000274 <Normal>
FUEL TANK SAFETY VALVE CHECK
<Defective>
ACX00760AB
1. Shake the fuel tank safety valve up and down to

check the float inside the fuel tank safety valve is
not seized.
AC102263 AB
5. Open the fuel tank safety valve nozzle. If no water

flows out from the nozzle aperture, the valve is
normal. If water flows out, the float or spring inside
the fuel tank safety valve is defective. Replace the
fuel tank safety valve.
Nozzle AC102262 AB
NOTES
GROUP INDEX
General . . . . . . . . . . . . . . . . . . . . . . . . 00
LANCER Engine . . . . . . . . . . . . . . . . . . . . . . . . 11
EVOLUTION IX Engine Lubrication . . . . . . . . . . . . . . 12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WORKSHOP MANUAL Engine Cooling . . . . . . . . . . . . . . . . . 14
Intake and Exhaust . . . . . . . . . . . . . . 15
Engine Electrical . . . . . . . . . . . . . . . . 16
Engine and Emission Control . . . . . 17
FOREWORD Clutch . . . . . . . . . . . . . . . . . . . . . . . . . 21
This Workshop manual contains procedures for
service mechanics, including removal, disassembly, Manual Transmission . . . . . . . . . . . . 22
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
Propeller Shaft. . . . . . . . . . . . . . . . . . 25
manual as required. Front Axle. . . . . . . . . . . . . . . . . . . . . . 26
Rear Axle . . . . . . . . . . . . . . . . . . . . . . 27
Wheel and Tyre . . . . . . . . . . . . . . . . . 31
TECHNICAL INFORMATION MANUAL
IEVE04E1CD
Power Plant Mount . . . . . . . . . . . . . . 32
IEVE04E1CD Front Suspension . . . . . . . . . . . . . . . 33
IEVE04E1CD
Rear Suspension . . . . . . . . . . . . . . . . 34
WORKSHOP MANUAL
CHASSIS GROUP Service Brakes. . . . . . . . . . . . . . . . . . 35
BODY REPAIR MANUAL
CEVX04E1CD
Parking Brakes . . . . . . . . . . . . . . . . . 36
CEVX05E1CD Power Steering . . . . . . . . . . . . . . . . . 37
PARTS CATALOGUE B606K006A Body . . . . . . . . . . . . . . . . . . . . . . . . . . 42
All information, illustrations and product descriptions Exterior. . . . . . . . . . . . . . . . . . . . . . . . 51
contained in this manual are current as at the time of Interior and Supplemental
publication. We, however, reserve the right to make Restraint System (SRS) ............ 52
changes at any time without prior notice or obligation. Chassis Electrical . . . . . . . . . . . . . . . 54
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . . 55
Component Locations . . . . . . . . . . . 70
Configuration Diagrams . . . . . . . . . . 80
Circuit Diagrams . . . . . . . . . . . . . . . . 90
©0LWVXELVKL0RWRUV(XURSH%9 2FW
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
(1) Improper service or maintenance of any component of the SRS or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative).
(2) The SRS components and seat belt with pretensioner should not be subjected to heat, so
remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag
modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.
• SRS-ECU, air bag module and clock spring 93°C or more
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this Manual, and especially its GROUP
52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of
any component of the SRS or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
70-1
GROUP 70
COMPONENT
LOCATIONS
CONTENTS
SENSOR. . . . . . . . . . . . . . . . . . . . . . . 70-2 SOLENOID AND SOLENOID VALVE 70-12
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . 70-6 EARTH CABLE. . . . . . . . . . . . . . . . . . 70-13
INSPECTION CONNECTOR AND FUSIBLE LINK AND FUSE . . . . . . . . 70-14

SPARE CONNECTOR . . . . . . . . . . . . 70-9
EARTH . . . . . . . . . . . . . . . . . . . . . . . . 70-15
RELAY . . . . . . . . . . . . . . . . . . . . . . . . 70-10
70-2 COMPONENT LOCATIONS
SENSOR
SENSOR
M1701000600846

Air flow sensor J Interior temperature sensor N
Air thermo sensor P Outside thermo sensor H
Crank angle sensor A Oxygen sensor (front) G
Detonation sensor C Oxygen sensor (rear) S
Engine coolant temperature sensor I Photo sensor L
Engine oil level sensor B Pressure sensor U
Exhaust camshaft position sensor E Steering wheel sensor M
Front impact sensor K Throttle position sensor D
G-sensor (lateral) O Transmission oil temperature sensor Q
G-sensor (longitudinal) O Vehicle speed sensor F
Heter water temperature sensor P Wheel speed sensor (front) R
Intake camshaft position sensor E Wheel speed sensor (rear) T
A B C D E F L
G H I J K * M N O P
Q R * S T *
U
AC501366AB
NOTE: The * symbols indicate also equipped at the right side.

COMPONENT LOCATIONS
SENSOR
70-3
Crank angle Crank angle

sensor connector sensor
Crankshaft
sprocket
AC208835 AC
B
Engine
oil filter
Engine oil
level sensor
AC310230AB
C
Intake
manifold
Detonation
sensor
connector
Detonation
sensor
AC208837AG
D F
Vehicle speed
sensor
Throttle
position
sensor
Transmission
AC208857 AC assembly AC209488AF
E
Intake camshaft
position sensor
Exhaust camshaft
position sensor
AC406674AD
SENSOR
Oxygen
sensor (front)
connector Oxygen
sensor (front)
AC208841AE
H L
Outoside
thermo
sensor Photo sensor
AC212287AE AC500112AB
I M
Engine coolant
temperature
sensor
Steering
wheel
sensor
AC504759 AC AC500111AB
J N
Air flow
sensor
Interior
temperature
sensor
AC500113AB
AC208832 AH
K O
Air cleaner
Parking brake
lever
Front impact
sensor
G-sensor
(lateral) G-sensor
(longitudinal)
AC208855AI AC208854AL
COMPONENT LOCATIONS
SENSOR
70-5
P Heater water Q
temperature
sensor Centremember Transmission oil
assembly temperature sensor
Air thermo
sensor
AC504978AB AC504979AB
Wheel speed
sensor (front)
connector Wheel speed
sensor (front)
AC208845AI
Oxygen sensor Oxygen sensor

(rear) connector (rear)
Glove box
Catalytic
converter
AC310231AD
T
Wheel speed
sensor (rear)
Wheel speed
sensor (rear)
connector
Trailing arm
AC208851AK
U
Pressure
sensor
Hydraulic unit
assemmbly
AC212291AG
ECU
ECU
M1701000500281

A/C-ECU H Front-ECU C
ABS-ECU LHD A Headlamp assembly E
RHD B (incorporating ECU)
Blower linear controller M Immobilizer-ECU G
Column switch F Power window main switch O
(incorporating Column-ECU) (incorporating ECU)
Engine-ECU L Power window sub switch N
(incorporating ECU)
ETACS-ECU I SRS-ECU J
Fan controller D 4WD-ECU K
A B C F G H
*²
D E *¹ I J K L M
N *²
O
AC501370AB
NOTE: .
1. *1: also equipped at the right side.
2. *2: also equipped at the rear doors.
COMPONENT LOCATIONS
ECU
70-7
A <LHD> F
ABS-ECU
Column switch
(incorporating
Column-ECU)
Hydraulic unit
AC100209AD AC500116AB
B <RHD> G
ABS-ECU Immobilizer-
ECU
AC311142AB AC310233 AB
C Battery Front-ECU H
A/C-ECU
AC310360 AB AC500703 AB
D I
ETACS-ECU
Fan controller
Radiator fan
Junction
block
AC100211AI AC310361AB
E J
SRS-ECU
Headlamp assembly
(incorporating ECU)
Center
reinforcement
Horn (HI)
AC208848 AD AC504981AC
ECU
K N
Power window
sub switch
4WD-ECU (incorporating
Centre ECU)
reinforcement
AC310234AC AC301749AD
L O
Power window
Engine-ECU main switch
(incorporating
ECU)
AC100229AM AC301748AE
M
Blower unit
Blower linear
controller
AC504982AB
COMPONENT LOCATIONS
INSPECTION CONNECTOR AND SPARE CONNECTOR
70-9
INSPECTION CONNECTOR AND SPARE CONNECTOR
M1701000200622

Diagnosis connector B Spare connector (for audio) C
Engine speed detection connector A
B C
AC501369AC
A C
Battery
Spare connector
Engine speed (for audio)
detection
connector
AC310329 AB AC500118AB
Diagnosis connector
AC100188AM
RELAY
RELAY
M1701000400723

A/C compressor relay C Fan control relay C
Blower relay D Fuel pump relay (1) D
Condenser fan relay (HI) C Fuel pump relay (2) D
Condenser fan relay (LO) C Fuel pump relay (3) LHD A
Defogger relay D RHD B
Electric pump relay LHD A Horn relay C
RHD B Ignition coil relay <RHD> C
Engine control relay C Power window relay D
Engine oil revel relay E
A B C
D E
AC501369AB
A <LHD> B <RHD>
Fuel pump relay (3)
Fuel pump relay (3)
Electric pump relay

Electric pump relay
AC310180 AB AC211639AD
COMPONENT LOCATIONS
RELAY
70-11
C A/C compressor relay Condenser fan relay (HI)
Condenser fan relay (LO)

Horn relay
Ignition coil relay

<RHD>
Fan control relay
AC310225 AB
D
Fuel pump relay (1) Power window relay
Fuel pump relay (2) Defogger relay
Rear fog lamp relay Blower relay
AC500114 AB
AC504985
E
Engine oil
level relay
AC504980 AC
SOLENOID AND SOLENOID VALVE
SOLENOID AND SOLENOID VALVE

M1701000800721

EGR control solenoid valve D Hydraulic unit <for ABS LHD B
Fuel pressure control solenoid valve C (incorporating solenoid RHD E
valve)>
Hydraulic unit assembly <for ACD and G Purge control solenoid valve C
AYC (incorporating solenoid valve)> Wastegate solenoid valve F
Oil feeder control valve A
A B C D E
F G
AC501371AB
A C Fuel pressure
control solenoid
valve
Oil feeder control

valve Purge control
solenoid valve
AC406813 AC AC209008AE
B <LHD> D
Hydraulic unit
<for ABS
(incorporating
solenoid valve)>
EGR control
solenoid valve
Intake
Intake manifold manifold
AC100230AJ stay AC209007AE
COMPONENT LOCATIONS
EARTH CABLE
70-13
E <RHD> G Hydraulic unit assembly

<for ACD and AYC>
Hydraulic unit Proportioning valve
<for ABS (for ACD control)
(incorporating
solenoid valve)>
Direction
valve
(LH, RH)
AC212305
Proportioning valve
AC212303AE (for AYC control) AC212305 AE
Wastegate
solenoid valve
Battery
AC209011AE
EARTH CABLE
M1701001000579
AC501372AB
FUSIBLE LINK AND FUSE

M1701000100711

Fuses No.1 to 23 C Fusible links No.1 to 5 B
(Passenger compartment) (Engine compartment)
Fuses No.6 to 25 B Fusible links No.26, 27 A
(Engine compartment) (Battery positive terminal)
A B
C
AC501369AD
A Fusible link B Battery

(No.26, 27)
Fuses
(No.6 to 25)
Battery
AC212324 AC
AC310326AB
B Battery Fusible links C

(No.4, 5) Fuses
(No.1 to 20)
Fuses
(No.21, 23)
Fusible link
(No.1) Fusible links
(No.2, 3) Junction
AC310325 AB block AC310327 AB
COMPONENT LOCATIONS
EARTH
70-15
EARTH
M1701000300704
<LH drive vehicles>

1 2 3 4 5 6 7 8 9
10 11 12 13 14 15
AC310178AB
<RH drive vehicles>

1 2 7 4 6 5 8 9
10 11 12 13 14 15 3
AC310179 AB
NOTE: Same earth numbers are used in the circuit diagram.

EARTH
1 5
Centre
reinforcement
AC208862 AD AC504983AB
2 6
Door check
AC100190AC AC504985AB
3 <LHD> Front deck

7 <LHD>
crossmember
Windshield
wiper arm
AC100191AD AC100195AH
3 <RHD> 7 <RHD>
Front deck
crossmember
Windshield
wiper arm
AC212332AC AC212321AC
4 BATTERY 8
Rear shelf
panel
AC208863 AC AC100196AD
COMPONENT LOCATIONS
EARTH
70-17
9 Rear shelf 13
panel
AC100197AD AC504984AB
10 14
SRS-ECU
Exhaust
manifold
cover AC208867AD AC208540 AE
11 15 Junction block
Rocker
cover
AC208868 AC AC208871AD
12 Relay box
AC208869AD
NOTES
90-1
GROUP 90
CIRCUIT DIAGRAMS
CONTENTS
J/B . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4 HEADLAMP

HEADLAMP <LH drive vehicles> . . . . . . . . 90-62
J/C HEADLAMP <RH drive vehicles> . . . . . . . . 90-66
J/C <LH drive vehicles> . . . . . . . . . . . . . . . 90-6
J/C <RH drive vehicles> . . . . . . . . . . . . . . . 90-12 TAIL LAMP, POSITION LAMP, LICENCE
PLATE LAMP AND LIGHTING MONITOR
CENTRALIZED JUNCTION . . . . . . . . 90-18 BUZZER
TAIL LAMP, POSITION LAMP, LICENCE PLATE
POWER DISTRIBUTION SYSTEM LAMP AND LIGHTING MONITOR BUZZER
<LH drive vehicles> . . . . . . . . . . . . . . . . . . . 90-70
POWER DISTRIBUTION SYSTEM
<LH drive vehicles>. . . . . . . . . . . . . . . . . . . 90-24 TAIL LAMP, POSITION LAMP, LICENCE PLATE
LAMP AND LIGHTING MONITOR BUZZER
<RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-74
REAR FOG LAMP

STARTING SYSTEM . . . . . . . . . . . . . 90-36
REAR FOG LAMP <LH drive vehicles> . . . 90-78
IGNITION SYSTEM REAR FOG LAMP <RH drive vehicles> . . . 90-82
IGNITION SYSTEM <LH drive vehicles> . . 90-37

ROOM LAMP, LUGGAGE COMPARTMENT
IGNITION SYSTEM <RH drive vehicles> . . 90-38
LAMP, IGNITION KEY CYLINDER
ILLUMINATION LAMP AND DOOR AJAR
CHARGING SYSTEM
WARNING LAMP
CHARGING SYSTEM <LH drive vehicles> 90-40
ROOM LAMP, LUGGAGE COMPARTMENT LAMP,
CHARGING SYSTEM <RH drive vehicles> 90-41 IGNITION KEY CYLINDER ILLUMINATION LAMP
AND DOOR AJAR WARNING LAMP
ENGINE CONTROL SYSTEM <LH drive vehicles> . . . . . . . . . . . . . . . . . . . 90-86
ENGINE CONTROL SYSTEM ROOM LAMP, LUGGAGE COMPARTMENT LAMP,
<LH drive vehicles>. . . . . . . . . . . . . . . . . . . 90-42 IGNITION KEY CYLINDER ILLUMINATION LAMP
ENGINE CONTROL SYSTEM AND DOOR AJAR WARNING LAMP
<RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-50 <RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-90
COOLING SYSTEM Continued on next page

COOLING SYSTEM <LH drive vehicles> . . 90-58
COOLING SYSTEM <RH drive vehicles>. . 90-60
90-2
HEADLAMP LEVELLING SYSTEM TRANSMISSION OIL TEMPERATURE

HEADLAMP LEVELLING SYSTEM WARNING LAMP
<LH drive vehicles>. . . . . . . . . . . . . . . . . . . 90-94 TRANSMISSION OIL TEMPERATURE
HEADLAMP LEVELLING SYSTEM WARNING LAMP <LH drive vehicles> . . . . 90-126
<RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-96 TRANSMISSION OIL TEMPERATURE
WARNING LAMP <RH drive vehicles> . . . . 90-127
TURN-SIGNAL LAMP AND HAZARD
WARNING LAMP POWER WINDOWS
TURN-SIGNAL LAMP AND HAZARD WARNING POWER WINDOWS <LH drive vehicles> . . 90-128
LAMP <LH drive vehicles> . . . . . . . . . . . . . 90-98 POWER WINDOWS <RH drive vehicles>. . 90-134
TURN-SIGNAL LAMP AND HAZARD WARNING
LAMP <RH drive vehicles> . . . . . . . . . . . . . 90-102 CENTRAL DOOR LOCKING SYSTEM
BACK-UP LAMP <LH drive vehicles> . . . . . . . . . . . . . . . . . . . 90-140
BACK-UP LAMP <LH drive vehicles>. . . . . 90-106 CENTRAL DOOR LOCKING SYSTEM
BACK-UP LAMP <RH drive vehicles> . . . . 90-107 <RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-146
STOP LAMP AUTOMATIC AIR CONDITIONER

STOP LAMP <LH drive vehicles> . . . . . . . . 90-108 AUTOMATIC AIR CONDITIONER
STOP LAMP <RH drive vehicles> . . . . . . . 90-109 <LH drive vehicles> . . . . . . . . . . . . . . . . . . . 90-152
AUTOMATIC AIR CONDITIONER
HORN <RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-160
HORN <LH drive vehicles> . . . . . . . . . . . . . 90-110

HORN <RH drive vehicles> . . . . . . . . . . . . 90-111
<LH drive vehicles> . . . . . . . . . . . . . . . . . . . 90-168
METER AND GAUGE
METER AND GAUGE <LH drive vehicles> 90-112 <RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-172
METER AND GAUGE <RH drive vehicles> 90-116
REMOTE CONTROLLED MIRROR
BRAKE WARNING LAMP, OIL PRESSURE REMOTE CONTROLLED MIRROR
WARNING LAMP AND FUEL WARNING <LH drive vehicles> . . . . . . . . . . . . . . . . . . . 90-176
LAMP REMOTE CONTROLLED MIRROR
BRAKE WARNING LAMP, OIL PRESSURE <RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-177
WARNING LAMP AND FUEL WARNING LAMP
<LH drive vehicles>. . . . . . . . . . . . . . . . . . . 90-120 REAR WINDOW DEFOGGER AND
BRAKE WARNING LAMP, OIL PRESSURE DOOR MIRROR HEATER
WARNING LAMP AND FUEL WARNING LAMP
REAR WINDOW DEFOGGER AND DOOR
MIRROR HEATER <LH drive vehicles> . . . 90-178
REAR WINDOW DEFOGGER AND DOOR
ENGINE OIL LEVEL WARNING MIRROR HEATER <RH drive vehicles> . . . 90-180
LAMP
ENGINE OIL LEVEL WARNING LAMP Continued on next page
<LH drive vehicles>. . . . . . . . . . . . . . . . . . . 90-124
ENGINE OIL LEVEL WARNING LAMP
90-3
AUDIO SYSTEM SPARE CONNECTOR ANTI-SKID BRAKING SYSTEM (ABS)

AUDIO SYSTEM SPARE CONNECTOR <RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-198
AUDIO SYSTEM SPARE CONNECTOR SUPPLEMENTAL RESTRAINT
<RH drive vehicles> . . . . . . . . . . . . . . . . . . 90-184 SYSTEM (SRS)
CIGARETTE LIGHTER <LH drive vehicles> . . . . . . . . . . . . . . . . . . . 90-206
CIGARETTE LIGHTER <LH drive vehicles> 90-186 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
CIGARETTE LIGHTER <RH drive vehicles> 90-187
ACD AND AYC

CLOCK
ACD AND AYC <LH drive vehicles> . . . . . . 90-214
CLOCK <LH drive vehicles> . . . . . . . . . . . . 90-188
ACD AND AYC <RH drive vehicles> . . . . . . 90-224
CLOCK <RH drive vehicles>. . . . . . . . . . . . 90-189
IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM <LH drive vehicles> 90-234
<LH drive vehicles>. . . . . . . . . . . . . . . . . . . 90-190 IMMOBILIZER SYSTEM <RH drive vehicles> 90-236
90-4 CIRCUIT DIAGRAMS
J/B
J/B
M1901000201447
POWER
WINDOW
RELAY
FUSE
FUEL
PUMP
RELAY (2)
FUEL
PUMP
RELAY (1)
DEFOG- BLOW-
GER ER
RELAY RELAY
REAR
FOG
NO LAMP
CONNECTION RELAY
NO
CONNECTION
NOTE:
CONNECTOR NUMBERS ARE KEYED TO THE CONFIGURATION
DIAGRAM (DASH PANEL) AND EACH CIRCUIT DIAGRAM.
J/B SIDE
CIRCUIT DIAGRAMS
J/B
90-5
Front side Rear side
To instrument panel To instrument panel

wiring harness wiring harness
To instrument C-209 C-211

panel wiring
harness
C-210 ETACS-ECU
Power C-225 C-212
window C-226
relay
C-214
Fuel pump
relay (1)
1 3 Blower
relay
C-223 2 4
No connection
1 3
Defogger
C-222 2 4 C-224 C-216 C-215 relay
1 3
Fuel pump C-221
2 4 Fuses
relay (2)
(No.1 to 20)
C-220
No connection
1 3
C-219
2 4
Rear fog C-217
lamp relay C-218
To roof wiring To floor wiring

harness harness (LH)
AC208362AL
J/C
J/C
J/C <LH drive vehicles>
M1901014201718
NOTE: IN ACTUAL VEHICLES, ANY OF THE TERMINALS CONNECTED IN J/C

ARE USED. THE TERMINAL ARRANGEMENT DESCRIBED IN THE CIRCUIT
DIAGRAM MAY NOT BE IDENTICAL TO THOSE OF THE VEHICLES.
·HEADLAMP
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
·BRAKE WARNING AND LIGHTING
LAMP, OIL PRESSURE MONITOR BUZZER
WARNING LAMP ·TURN-SIGNAL LAMP AND
AND FUEL HAZARD WARNING LAMP
WARNING LAMP ·WINDSHIELD WIPER
·METER AND GAUGE AND WASHER
AOTOMATIC AUDIO SYSTEM

AIR ACD AND SPARE
CONDITIONER AYC CONNECTOR CLOCK
ETACS- RELAY BOX

ECU (FUSE 22 )
AUDIO ACD REAR

TURN-SIGNAL LAMP SYSTEM AND FOG LAMP
AND HAZARD SPARE AYC RELAY BOX
WARNING LAMP CONNECTOR (FUSE 20 )
HEADLAMP CIGARETTE CLOCK ·AUTOMATIC TAIL LAMP,

LEVELLING LIGHTER AIR POSITION LAMP,
SYSTEM CONDITIONER LICENCE PLATE LAMP
·REARWINDOW AND LIGHTING
DEFOGGER MONITOR BUZZER
AND DOOR
MIRROR HEATER
CIRCUIT DIAGRAMS
J/C
90-7
·CENTRAL DOOR
LOCKING SYSTEM
·ROOM LAMP, LUGGAGE
COMPARTMENT LAMP,
IGNITION KEYCYLINDER
ILLUMINATION LAMP HEADLAMP
AND DOOR AJAR LEVELING DIAGNOSIS
WARNING LAMP SYSTEM CONNECTOR
SUPPLEMENTAL
REMOTE RESTRAINT
REAR FOG CONTROLLED SYSTEM (SRS)
LAMP MIRROR
J/C (6)
J/B
AUTOMATIC AIR (FUSE 5 )
CONDITIONER ETACS-ECU
POWER
WINDOWS ·HEADLAMP
·AUTOMATIC AIR ·REAR FOG LAMP
·ACD AND AYC ·TAIL LAMP,
·ANTI-SKID CONDITIONER
·COOLING SYSTEM POSITION LAMP,
BRAKING LICENCE PLATE LAMP
SYSTEM (ABS) ·HEADLAMP
·HEADLAMP AND LIGHTING
LEVELLING SYSTEM MONITOR BUZZER
·REAR FOG LAMP ·TURN-SIGNAL LAMP
·TAIL LAMP, POSITION AND HAZARD
LAMP, LICENCE PLATE WARNING LAMP
LAMP AND LIGHTING ·WINDSHIELD WIPER
MONITOR BUZZER AND WASHER
·TURN-SIGNAL
LAMP AND HAZARD
WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
J/C
J/C <LH drive vehicles> (CONTINUED)
·HEADLAMP
·REAR FOG LAMP
·TAIL LAMP, POSITION
LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD WARNING
TURN-SIGNAL LAMP
ENGINE OIL LAMP AND HAZARD ·WINDSHIELD WIPER AND
·ACD AND AYC LEVEL WARNING
·ANTI-SKID WARNING LAMP WASHER
LAMP
BRAKING
ETACS-ECU SYSTEM (ABS)
IMMOBILIZER AUTOMATIC AIR

SYSTEM CLOCK CONDITIONER
TURN-SIGNAL HEADLAMP
LAMP AND LEVELLING REAR FOG
HAZARD SYSTEM LAMP
WARNING
LAMP
·AUTOMATIC AIR
CONDITIONER
·REAR WINDOW
CIGARETTE METER AND ACD AND AYC DEFOGGER AND
LIGHTER GAUGE DOOR MIROR HEATER
CIRCUIT DIAGRAMS
J/C
90-9
AUTOMATIC AIR DIAGNOSIS

CONDITIONER CONNECTOR
·ACD AND AYC
·ANTI-SKID
·ACD AND BRAKING SYSTEM(ABS)
AYC ·BRAKE WARNING
·ANTI-SKID LAMP, OIL PRESSURE
BRAKING WARNING LAMP AND
ROOM LAMP,LUGGAGE SYSTEM(ABS) FUEL WARNING LAMP
COMPARTMENT LAMP, ETACS-ECU
IGNITION KEY CYLINDER
ILLUMINATION LAMP AND BRAKE WARNING
DOOR AJAR WARNING LAMP LAMP, OIL
PRESSURE WARNING
LAMP AND
FUEL WARNING LAMP
ETACS-ECU J/C (6)
J/B
(FUSE 2 )
BACK-UP
LAMP
ENGINE OIL
LEVEL ACD AND
WARNING LAMP ·HEADLAMP
AYC ·ACD AND AYC ·ENGINE OIL LEVEL ·REAR FOG LAMP
·ANTI-SKID WARNING LAMP ·TAIL LAMP,
BRAKING ·METER AND GAUGE POSITION LAMP,
SYSTEM (ABS) ·SUPPLEMENTAL LICENCE PLATE LAMP
·BRAKE WARNING RESTRAINT AND LIGHTING
LAMP, OIL SYSTEM (SRS) MONITOR BUZZER
PRESSURE ·TORANSMISSION ·TURN-SIGNAL LAMP
WARNING LAMP OIL TEMPERATURE AND HAZARD
AND FUEL WARNING LAMP WARNING LAMP
WARNING LAMP ·WINDSHIELD WIPER
·CHARGING SYSTEM AND WASHER
·ENGINE CONTROL
SYSTEM
J/C
J/C <LH drive vehicles> (CONTINUED)
·METER AND GAUGE

·WINDSHIELD WIPER
AND WASHER
HORN METER AND

GAUGE
IMMOBILIZER ·METER AND GAUGE

SYSTEM ·WINDSHIELD WIPER
AND WASHER
J/C (6) WINDSHIELD WIPER

AND WASHER
CIRCUIT DIAGRAMS
J/C
90-11
·ACD AND
AYC
·ANTI-SKID BRAKING
SYSTEM (ABS)
ACD AND ·ENGINE CONTROL

AYC SYSTEM ·ENGINE CONTROL
·IGNITION SYSTEM SYSTEM
ANTI-SKID ·METER AND GAUGE ·IGNITION SYSTEM
BRAKING ·METER AND GAUGE
SYSTEM (ABS)
METER AND
ACD AND AYC GAUGE
ANTI ENGINE CONTROL

-SKID SYSTEM
J/C (2) BRAKING
SYSTEM ·ENGINE
(ABS) CONTROL ·AUTOMATIC AIR
·ENGINE CONTROL SYSTEM CONDITIONER
SYSTEM ANTI ·IMMOBILIZER ·COOLING SYSTEM
·IMMOBILIZER -SKID SYSTEM
SYSTEM BRAKING
SYSTEM
(ABS) ACD AND J/C (5)
AYC ENGINE
CONTROL
SYSTEM
ACD AND J/C (4)
AYC
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM
·ENGINE CONTROL
SYSTEM
·IMMOBILIZER SYSTEM
J/C
J/C <RH drive vehicles>

M1901014201729
NOTE: IN ACTUAL VEHICLES, ANY OF THE TERMINALS CONNECTED IN J/C

ARE USED. THE TERMINAL ARRANGEMENT DESCRIBED IN THE CIRCUIT
DIAGRAM MAY NOT BE IDENTICAL TO THOSE OF THE VEHICLES.
·HEADLAMP
·REAR FOG LAMP
·BRAKE WARNING ·TAIL LAMP, POSITION
LAMP, OIL PRESSURE LAMP, LICENCE PLATE
WARNING LAMP AND LAMP AND LIGHTING
FUEL WARNING LAMP MONITOR BUZZER
·METER AND GAUGE ·TURN-SIGNAL LAMP AND
HAZARD WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
ACD AND RELAY BOX

CLOCK (FUSE 22 ) ETACS-ECU
AYC
AUDIO
AUTOMATIC AIR SYSTEM
CONDITIONR SPARE
CONNECTOR
AUDIO CIGARETTE ACD AND TURN-SIGNAL RELAY BOX

SYSTEM LIGHTER AYC LAMP AND (FUSE 20 )
SPARE HAZARD
CONNECTOR WARNING
LAMP
REAR ·AUTOMATIC AIR CLOCK HEADLAMP ·METER AND GAUGE

FOG LAMP CONDITIONER LEVELLING ·TAIL LAMP, POSITION
·REAR WINDOW SYSTEM LAMP, LICENCE PLATE
DEFOGGER AND LAMP AND LIGHTING
DOOR MIRROR MONITOR BUZZER
HEATER
CIRCUIT DIAGRAMS
J/C
90-13
·AUTOMATIC AIR ·TAIL LAMP,

CONDITIONER POSITION LAMP,
·COOLING SYSTEM LICENCE PLATE LAMP
·HEADLAMP AND LIGHTING
·HEADLAMP MONITOR BUZZER
LEVELLING ·TURN-SIGNAL LAMP
·METER AND SYSTEM AND HAZARD
GAUGE ·ACD AND AYC ·REAR FOG LAMP WARNING LAMP
·WINDSHIELD ·ANTI-SKID ·WINDSHIELD WIPER
WIPER AND BRAKING AND WASHER
DIAGNOSIS
WASHER CONNECTOR SYSTEM (ABS)
AUTOMATIC AIR
CONDITIONER
METER AND J/B
ETACS-ECU GAUGE (FUSE 5 )
BACK-UP BACK-UP
POWER LAMP
WINDOWS LAMP
ETACS-ECU
·HEADLAMP
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
J/C
J/C <RH drive vehicles> (CONTINUED)
·CENTRAL DOOR LOCKING SYSTEM

COMPARTMENT LAMP, IGNITION
KEY CYLINDER ILLUMINATION LAMP
AND DOOR AJAR WARNING LAMP
REMOTE
CONTROLLED
MIRROR
AUTOMATIC AIR REAR

CONDITIONER FOG LAMP ETACS-ECU ·ACD AND AYC
·ANTI-SKID BRAKING
SYSTEM (ABS)
ENGINE OIL LEVEL
WARNING LAMP
·CLOCK
ENGINE HEADLAMP ·TURN-SIGNAL LAMP
CONTROL REAR LEVELLING AND HAZARD
SYSTEM FOG LAMP SYSTEM WARNING LAMP
METER AND
REAR GAUGE
FOG LAMP
CIGARETTE ACD AND AYC TURN-SIGNAL LAMP
HEADLAMP LIGHTER AND HAZARD WARNING
LEVELLING LAMP
SYSTEM
·AUTOMATIC AIR
CONDITIONER
·REAR WINDOW
DEFOGGER AND
DOOR MIRROR
HEATER
CIRCUIT DIAGRAMS
J/C
90-15
AUDIO SYSTEM
SPARE CONNECTOR
REMOTE
CONTROLLED RELAY BOX
MIRROR (FUSE 23 ) ETACS-ECU
J/B
(FUSE 11 ) CLOCK
J/C (6) DIAGNOSIS

CONNECTOR
ROOM LAMP, LUGGAGE ·BRAKE WARNING

COMPARTMENT LAMP, LAMP, OIL PRESSURE
SUPPLEMENTAL ·ENGINE IGNITION KEY CYLINDER WARNING LAMP AND
RESTRAINT CONTROL SYSTEM ILLUMINATION LAMP AND FUEL WARNING LAMP
SYSTEM (SRS) ·IMMOBILIZER DOOR AJAR WARNING LAMP ·METER AND GAUGE
SYSTEM
J/C
J/C <RH drive vehicles> (CONTINUED)
J/B REAR
(FUSE 16 ) FOG LAMP
REAR DIAGNOSIS
FOG LAMP CONNECTOR HORN
J/C (6) HORN
AUTOMATIC AIR ETACS-ECU

CONDITIONER
CIRCUIT DIAGRAMS
J/C
90-17
·ENGINE CONTROL
SYSTEM
ACD AND AYC ·ENGINE CONTROL SYSTEM ·IGNITION SYSTEM
·IGNITION SYSTEM ·METER AND GAUGE
METER AND GAUGE

ANTI-SKID
BRAKING
SYSTEM
J/C (5) (ABS)
J/C (4)
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM
ANTI-SKID ANTI ·ENGINE CONTROL
BRAKING -SKID SYSTEM
SYSTEM BRAKING ENGINE
(ABS SYSTEM CONTROL
(ABS) SYSTEM
·AUTOMATIC AIR IMMOBILIZER

CONDITIONER SYSTEM
·COOLING SYSTEM
·ENGINE CONTROL
SYSTEM ·ENGINE
ACD AND ·ACD AND ACD ·IMMOBILIZER CONTROL
AYC AYC AND SYSTEM SYSTEM
·ANTI-SKID AYC ·IMMOBILIZER
BRAKING SYSTEM
SYSTEM
(ABS)
CENTRALIZED JUNCTION
M1901000301392

ENGINE COMPARTMENT
No. Power supply circuit Name Rated Housing Load circuit
capacity (A) colour
1 Battery Fusible 60 Yellow Fuse No.15, 16, 19, 20 (in junction
link block) circuit
2 50 Red Fan controller and fan control relay
3 60 Yellow ABS-ECU
4 40 Green Ignition switch circuit
5 40 Green Fuse No.21 (in junction block) circuit,
power window main switch and power
window sub switch
6 Fuse − − −
7 10 Red Horn and horn relay
8 20 Yellow Engine control relay, engine-ECU,
ignition coil <RH drive vehicles>,
ignition coil relay <RH drive vehicles>
and immobilizer-ECU
9 10 Red A/C compressor and A/C compressor
relay
10 15 Blue ABS-ECU, high-mounted stop lamp,
rear combination lamp, stop lamp
switch and 4WD-ECU
11 30 Green Condenser fan motor and condenser
fan relay
12 7.5 Brown Alternator
13 10 Red ETACS-ECU
14 − − −
15 20 Yellow Fuel pump relay, fuel pump and
gauge unit and fuel pump resistor
16 Front-ECU 10 Red Headlamp
17 (Headlamp relay: HI) 10 Red Combination meter and headlamp
18 Front-ECU 10 Red Headlamp assembly
19 (Headlamp relay: LO) 10 Red Headlamp assembly and headlamp
levelling switch
20 Front-ECU (Tail lamp 7.5 Brown A/C-ECU, ACD mode changeover
relay) switch, ashtray illumination lamp,
cigarette lighter illumination lamp,
clock, combination meter <RH drive
vehicles>, fog lamp switch, hazard
warning switch, headlamp assembly,
headlamp levelling switch, rear
combination lamp and audio system
spare connector
CIRCUIT DIAGRAMS
90-19
capacity (A) colour
21 Front-ECU (Tail lamp Fuse 7.5 Brown Combination meter <LH drive
relay) vehicles>, headlamp assembly,
licence plate lamp and rear
combination lamp
22 Battery 10 Red A/C-ECU, clock, column switch,
combination meter, ETACS-ECU,
front-ECU, spare connector (for
audio) and 4WD-ECU
23 Ignition switch (ACC) 10 Red Clock, ETACS-ECU and spare
connector (for audio)
24 − − − −
25 Battery 30 Green Condenser fan motor and condenser
fan relay
26 Battery Fusible 100 − Alternator
27 link 60 Electric pump
−
(Relay box in engine compartment)
1 24
6 25 7 8 9 10 11 12 13 14 15 4
Front of vehicle
16 18 20
23 22 5
2 3 17 19 21
(Connected directly to battery positive terminal)
27
Front of vehicle 26
AC310556AB
CIRCUIT DIAGRAMS
90-21
PASSENGER COMPARTMENT
capacity (A) colour
1 Ignition switch (IG1) Fuse 10 Red Ignition coil <LH drive vehicles> and
ignition coil relay <RH drive vehicles>
2 7.5 Brown ACD mode changeover switch,
column switch, combination meter,
engine oil level relay, ETACS-ECU,
SRS-ECU, vehicle speed sensor and
4WD-ECU
3 7.5 Brown Back-up lamp switch, rear
combination lamp and SRS-ECU
4 7.5 Brown −
5 Ignition switch (IG2) 7.5 Brown A/C compressor relay, A/C-ECU,
blower relay, condenser fan relay,
defogger relay, front-ECU,
outside/inside air selection damper
control motor, steering wheel sensor
and 4WD-ECU <RH drive vehicles>
6 Defogger relay 7.5 Brown Remote controlled mirror
7 Ignition switch (ACC) 20 Yellow Front-ECU and windshield wiper
motor
8 Ignition switch (IG1) 7.5 Brown Engine-ECU, fuel pump relay (1) and
fuel pump relay (2)
9 Ignition switch (ACC) 15 Blue Cigarette lighter
10 − − −
11 7.5 Brown Remote controlled mirror switch
12 Ignition switch (IG2) 7.5 Brown ABS-ECU, G-sensor and 4WD-ECU
<LH drive vehicles>
13 Ignition switch (ACC) − − −
14 15 Blue ETACS-ECU
15 Fusible link No.1 15 Blue Diagnosis connector
16 10 Red Combination meter, rear combination
lamp and rear fog lamp relay
17 − − −
18 − − −
19 30 Green Blower linear controller and blower
relay
20 30 Green Defogger and defogger relay
21 Fusible link No.5 20 Yellow −
22 − − − −
23 Ignition switch (IG2) 10 Red −
24 − − − −
(In junction block)
<LH drive vehicles> 1 2 3 4 5 6

19
7 8 9 10 11 12
21 22
13 14 15 16 17 18 20
23 24
<RH drive vehicles>

1 2 3 4 5 6
19
7 8 9 10 11 12
21 22
13 14 15 16 17 18 20
23 24
AC310557AB
CIRCUIT DIAGRAMS
90-23
CENTRALIZED RELAY
Connector No. Name Connector No. Name
A-04X − B-06X Engine speed detection
connector
A-05X Horn relay B-07X −
A-06X Condenser fan relay (LO) B-08X −
A-07X Condenser fan relay (HI) B-09X −
A-08X − B-10X Ignition coil relay <RH drive
vehicles>
A-09X Fan control relay B-11X −
A-10X Front-ECU B-12X Engine control relay
A-11X Front-ECU B-13X A/C compressor relay
(Relay box in engine compartment)
A-04X A-05X A-06X A-07X A-08X
2 1 2 1 2 1
4 3 4 3 4 3
Front of vehicle
A-10X
A-11X
A-09X
AC208462 AU
B-08X B-09X B-10X B-11X B-12X B-13X

B-07X
B-06X 2 1 2 1 2 1
Front of vehicle
4 3 4 3 4 3
AC208464 AO
NOTE: .
• The triangle mark on the relay housing should face that on the J/B and the relay box.

<LH drive vehicles>
M1901000401753
BATTERY
STARTING SYSTEM
FUSIBLE LINK
FUSIBLE
LINK
CHARGING ACD AND ·AUTOMATIC AIR

SYSTEM AYC CONDITIONER
·COOLING
SYSTEM
ANTI-SKID
BRAKING
SYSTEM
RELAY BOX (ABS)
·ENGINE CONTROL ·ACD AND AYC CHARGING SYSTEM ENGINE CONTROL

SYSTEM ·ANTI-SKID BRAKING SYSTEM
·IMMOBILIZER SYSTEM (ABS)
SYSTEM ·STOP LAMP
HORN AUTOMATIC AIR ·AUTOMATIC AIR ·CENTRAL DOOR LOCKING

CONDITIONER CONDITIONER SYSTEM
·COOLING SYSTEM ·TURN-SIGNAL LAMP AND
HAZARD WARNING LAMP
CIRCUIT DIAGRAMS
90-25
FRONT-ECU
HEADLAMP HEADLAMP TAIL LAMP

RELAY : LO RELAY : HI RELAY
·AUTOMATIC AIR ·HEADLAMP

CONDITIONER ·METER AND GAUGE
·HEADLAMP HEADLAMP ·TAIL LAMP, POSITION
·COOLING SYSTEM LEVELLING LAMP, LICENCE PLATE
SYSTEM LAMP AND LIGHTING
HEADLAMP MONITOR BUZZER
·ACD AND AYC ·REAR FOG LAMP ·ACD AND AYC ·REAR WINDOW
·AUDIO SYSTEM ·ROOM LAMP, LUGGAGE ·AUDIO SYSTEM DEFOGGER AND
SPARE CONNECTOR COMPARTMENT LAMP, SPARE CONNECTOR DOOR MIRROR HEATER
·AUTOMATIC AIR IGNITION KEY ·AUTOMATIC AIR ·TAIL LAMP, POSITION
CONDITIONER CYLINDER CONDITIONER LAMP, LICENCE PLATE
·BRAKE WARNING LAMP, ILLUMINATION LAMP ·CIGARETTE LIGHTER LAMP AND LIGHTING
OIL PRESSURE AND DOOR AJAR ·CLOCK MONITOR BUZZER
WARNING LAMP AND WARNING LAMP ·HEADLAMP LEVELLING ·TURN-SIGNAL LAMP
FUEL WARNING LAMP ·TAIL LAMP, POSITION SYSTEM AND HAZARD
·CENTRAL DOOR LAMP, LICENCE PLATE ·REAR FOG LAMP WARNING LAMP
LOCKING SYSTEM LAMP AND LIGHTING
·CLOCK MONITOR BUZZER
·HEADLAMP ·TURN-SIGNAL LAMP
·HEADLAMP LEVELLING AND HAZARD WARNING
SYSTEM LAMP
·METER AND GAUGE ·WINDSHIELD WIPER
·POWER WINDOWS AND WASHER
Wire colour code

POWER DISTRIBUTION SYSTEM <LH drive vehicles> (CONTINUED)
FUSIBLE LINK 4
RELAY
BOX
IGNITION
SWITCH
·AUDIO SYSTEM
SPARE CONNECTOR
·CLOCK
COMPARTMENTLAMP,
ILLUMINATION LAMP AND
DOOR AJAR WARNING LAMP
STARTING SYSTEM
IGNITION SYSTEM ·BACK-UP LAMP ENGINE CONTROL

·SUPPLEMENTAL SYSTEM
RESTRAINT
SYSTEM (SRS)
·ACD AND AYC ·ROOM LAMP, LUGGAGE
·ANTI-SKID BRAKING COMPARTMENT LAMP,
SYSTEM (ABS) IGNITION KEY CYLINDER
·BRAKE WARNING LAMP, ILLUMINATION LAMP AND
OIL PRESSURE DOOR AJAR WARNING
WARNING LAMP AND LAMP
FUEL WARNING LAMP ·SUPPLEMENTAL
·CENTRAL DOOR RESTRAINT SYSTEM (SRS)
LOCKING SYSTEM ·TAIL LAMP, POSITION LAMP,
·CHARGING SYSTEM LICENCE PLATE LAMP AND
·ENGINE CONTROL LIGHTING MONITOR BUZZER
SYSTEM ·TRANSMISSION OIL
·ENGINE OIL LEVEL TEMPERATURE
WARNING LAMP WARNING LAMP
·HEADLAMP ·TURN-SIGNAL LAMP AND
·METER AND GAUGE HAZARD WARNING LAMP
·POWER WINDOWS ·WINDSHIELD WIPER
·REAR FOG LAMP AND WASHER
CIRCUIT DIAGRAMS
90-27
·ACD AND AYC

·ANTI-SKID
BRAKING WINDSHIELD REMOTE ·ROOM LAMP,
SYSTEM (ABS) WIPER AND CONTROLLED LUGGAGE
WASHER MIRROR COMPARTMENT
LAMP, IGNITION
KEY CYLINDER
·ACD AND AYC CIGARETTE ILLUMINATION
·ANTI-SKID BRAKING LIGHTER LAMP AND DOOR
SYSTEM (ABS) AJAR WARNING
·AUTOMATIC AIR LAMP
CONDITIONER ·WINDSHIELD
·COOLING SYSTEM WIPER AND
·HEADLAMP WASHER
·HEADLAMP LEVELLING
SYSTEM
·REAR FOG LAMP
·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING MONITOR
BUZZER
·TURN-SIGNAL LAMP AND
HAZARD WARNING LAMP
·WINDSHIELD WIPER AND
WASHER
Wire colour code

POWER DISTRIBUTION SYSTEM <LH drive vehicles> (CONTINUED)
FUSIBLE LINK 1 FUSIBLE LINK 5
NO
CONNECTION
·ACD AND AYC REAR AUTOMATIC AIR POWER

·ANTI-SKID BRAKING FOG LAMP CONDITIONER WINDOWS
SYSTEM (ABS)
·CENTRAL DOOR
LOCKING SYSTEM
·ENGINE CONTROL
SYSTEM
·HEADLAMP
·METER AND GAUGE
·POWER WINDOWS
·REAR FOG LAMP
·ROOM LAMP, J/B
LUGGAGE COMPARTMENT
LAMP, IGNITION KEY (FUSE 5 )
CYLINDER ILLUMINATION
LAMP AND DOOR AJAR
WARNING LAMP
·SUPPLEMENTAL RESTRAINT
SYSTEM (SRS)
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
HAZARD WARNING LAMP DEFOGGER
·WINDSHIELD WIPER AND RELAY
WASHER
REAR WINDOW REAR WINDOW REAR WINDOW

DEFOGGER DEFOGGER DEFOGGER
AND DOOR AND DOOR AND DOOR
MIRROR HEATER MIRROR HEATER MIRROR HEATER
Wire colour code

CIRCUIT DIAGRAMS
90-29
NOTES

<RH drive vehicles>
M1901000401764
BATTERY
STARTING SYSTEM
FUSIBLE LINK
FUSIBLE
LINK
CHARGING ACD AND ·AUTOMATIC AIR

SYSTEM AYC CONDITIONER
·COOLING
SYSTEM
ANTI-SKID
BRAKING
SYSTEM
RELAY BOX (ABS)
·ENGINE CONTROL ·ACD AND AYC CHARGING SYSTEM ENGINE CONTROL

SYSTEM ·ANTI-SKID BRAKING SYSTEM
·IGNITION SYSTEM SYSTEM (ABS)
·IMMOBILIZER ·STOP LAMP
SYSTEM
HORN AUTOMATIC AIR ·AUTOMATIC AIR ·CENTRAL DOOR LOCKING

CONDITIONER CONDITIONER SYSTEM
·COOLING SYSTEM ·TURN-SIGNAL LAMP AND
HAZARD WARNING LAMP
CIRCUIT DIAGRAMS
90-31
FRONT-ECU
HEADLAMP HEADLAMP TAIL LAMP

RELAY : LO RELAY : HI RELAY
·AUTOMATIC AIR ·HEADLAMP TAIL LAMP, POSITION

CONDITIONER ·HEADLAMP HEADLAMP LAMP, LICENCE PLATE
·COOLING SYSTEM LEVELLING LAMP AND LIGHTING
SYSTEM MONITOR BUZZER
HEADLAMP
·ACD AND AYC ·REAR FOG LAMP ·ACD AND AYC ·REAR WINDOW
·AUDIO SYSTEM ·ROOM LAMP, LUGGAGE ·AUDIO SYSTEM DEFOGGER AND
SPARE CONNECTOR COMPARTMENT LAMP, SPARE CONNECTOR DOOR MIRROR HEATER
·AUTOMATIC AIR IGNITION KEY ·AUTOMATIC AIR ·TAIL LAMP, POSITION
CINDITIONER CYLINDER CONDITIONER LAMP, LICENCE PLATE
·BRAKE WARNING LAMP, ILLUMINATION LAMP ·CIGARETTE LIGHTER LAMP AND LIGHTING
OIL PRESSURE AND DOOR AJAR ·CLOCK MONITOR BUZZER
WARNING LAMP WARNING LAMP ·HEADLAMP LEVELLING ·TURN-SIGNAL LAMP
AND FUEL WARNING ·TAIL LAMP, POSITION SYSTEM AND HAZARD
LAMP LAMP, LICENCE PLATE ·METER AND GAUGE WARNING LAMP
·CENTRAL DOOR LAMP AND LIGHTING ·REAR FOG LAMP
LOCKING SYSTEM MONITOR BUZZER
·CLOCK ·TURN-SIGNAL LAMP
·HEADLAMP AND HAZARD WARNING
·HEADLAMP LEVELLING LAMP
SYSTEM ·WINDSHIELD WIPER
·METER AND GAUGE AND WASHER
·POWER WINDOWS
Wire colour code

POWER DISTRIBUTION SYSTEM <RH drive vehicles> (CONTINUED)
FUSIBLE LINK 4
RELAY
BOX
IGNITION
SWITCH
·AUDIO SYSTEM SPARE
CONNECTOR
·CLOCK
COMPARTMENT LAMP,
STARTING SYSTEM
IGNITION SYSTEM ·BACK-UP LAMP ENGINE CONTROL

·SUPPLEMENTAL SYSTEM
RESTRAINT
SYSTEM (SRS)
·ACD AND AYC ·ROOM LAMP, LUGGAGE
·ANTI-SKID BRAKING COMPARTMENT LAMP,
SYSTEM (ABS) IGNITION KEY CYLINDER
·BRAKE WARNING LAMP, ILLUMINATION LAMP AND
OIL PRESSURE DOOR AJAR WARNING LAMP
WARNING LAMP AND ·SUPPLEMENTAL RESTRAINT
FUEL WARNING LAMP SYSTEM (SRS)
·CENTRAL DOOR ·TAIL LAMP, POSITION LAMP,
LOCKING SYSTEM LICENCE PLATE LAMP AND
·CHARGING SYSTEM LIGHTING MONITOR BUZZER
·ENGINE CONTROL ·TRANSMISSION OIL
SYSTEM TEMPERATURE WARNING
·ENGINE OIL LEVEL LAMP
WARNING LAMP ·TURN-SIGNAL LAMP AND
·HEADLAMP HAZARD WARNING LAMP
·METER AND GAUGE ·WINDSHIELD WIPER AND
·POWER WINDOWS WASHER
·REAR FOG LAMP
CIRCUIT DIAGRAMS
90-33
·ACD AND AYC

·ANTI-SKID
BRAKING WINDSHIELD REMOTE ·ROOM LAMP,
SYSTEM (ABS) WIPER AND CONTROLLED LUGGAGE
WASHER MIRROR COMPARTMENT
LAMP, IGNITION
KEY CYLINDER
·ACD AND AYC CIGARETTE ILLUMINATION
·ANTI-SKID BRAKING LIGHTER LAMP AND DOOR
SYSTEM (ABS) AJAR WARNING
·AUTOMATIC AIR LAMP
CONDITIONER ·WINDSHIELD
·COOLING SYSTEM WIPER AND
·HEADLAMP WASHER
SYSTEM
·REAR FOG LAMP
LICENCE PLATE LAMP
BUZZER
HAZARD WARNING LAMP
WASHER
Wire colour code

POWER DISTRIBUTION SYSTEM <RH drive vehicles> (CONTINUED)
FUSIBLE LINK 1 FUSIBLE LINK 5
NO
CONNECTION
·ACD AND AYC REAR AUTOMATIC POWER

·ANTI-SKID BRAKING FOG LAMP AIR WINDOWS
SYSTEM (ABS) CONDITIONER
·AUTOMATIC AIR
CONDITIONER
·CENTRAL DOOR
LOCKING SYSTEM
·ENGINE CONTROL
SYSTEM
·HEADLAMP
·METER AND GAUGE
·POWER WINDOWS
·REAR FOG LAMP J/B
·ROOM LAMP, (FUSE 5 )
LUGGAGE COMPARTMENT
LAMP, IGNITION KEY
LAMP AND DOOR AJAR
WARNING LAMP
SYSTEM (SRS)
LICENCE PLATE LAMP
AND LIGHTING DEFOGGER
MONITOR BUZZER RELAY
HAZARD WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
REAR WINDOW REAR WINDOW REAR WINDOW

DEFOGGER DEFOGGER DEFOGGER
AND DOOR AND DOOR AND DOOR
MIRROR HEATER MIRROR HEATER MIRROR HEATER
Wire colour code

CIRCUIT DIAGRAMS
90-35
NOTES
STARTING SYSTEM
STARTING SYSTEM
M1901000501976
IGNITION
BATTERY SWITCH (ST)
ENGINECONTROL
SYSTEM
STARTER
Wire colour code

BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU: Purple
CIRCUIT DIAGRAMS
IGNITION SYSTEM
90-37
IGNITION SYSTEM
IGNITION SYSTEM <LH drive vehicles>
M1901000602716
IGNITION
SWITCH (IG1)
IGNITION IGNITION
COIL (1) COIL (2)
SPARK PLUG SPARK PLUG
ENGINE-
ECU
INPUT SIGNAL
·BAROMETRIC ·EXHAUST ·INTAKE
PRESSURE CAMSHAFT CAMSHAFT
SENSOR POSITION POSITION
·CRANK ANGLE SENSOR SENSOR
SENSOR ·IGNITION ·OXYGEN
·DETONATION SWITCH (ST) SENSOR
SENSOR ·INTAKE AIR ·THROTTLE
·ENGINE TEMPERATURE POSITION
COOLANT SENSOR SENSOR
TEMPERATURE ·VEHICLE SPEED
SENSOR SENSOR ENGINE SPEED
DETECTION
CONNECTOR
IGNITION SYSTEM
IGNITION SYSTEM <RH drive vehicles>

M1901000602727
IGNITION
RELAY
BOX
·ENGINE CONTROL
SYSTEM
IGNITION
COIL RELAY
CIRCUIT DIAGRAMS
IGNITION SYSTEM
90-39
IGNITION COIL RELAY
IGNITION IGNITION
COIL (1) COIL (2)
INPUT SIGNAL
·BAROMETRIC PRESSURE
SENSOR
·CRANK ANGLE SENSOR
·DETONATION SENSOR
·ENGINE COOLANT
TEMPERATURE SENSOR
·EXHAUST CAMSHAFT
POSITION SENSOR
·IGNITION SWITCH (ST)
·INTAKE AIR TEMPERATURE
SENSOR
·INTAKE CAMSHAFT
POSITION SENSOR
·OXYGEN SENSOR
·THROTTLE POSITION
SENSOR
·VEHICLE SPEED SENSOR
SPARK PLUG
ENGINE-
ECU
ENGINE SPEED
DETECTION CONNECTOR
Wire colour code

CHARGING SYSTEM
CHARGING SYSTEM
CHARGING SYSTEM <LH drive vehicles>
M1901000701914
FUSIBLE IGNITION
LINK 26 BATTERY SWITCH (IG1)
RELAY
BOX
ENGINE-ECU
COMBI-
NATION
METER
BRAKE WARNING
LAMP, OIL PRESSURE
WARNING LAMP ENGINE
AND FUEL OIL LEVEL
WARNING LAMP WARNING
LAMP
ALTERNATOR
FIELD
COIL
STATOR
COIL
IC VOLTAGE REGULATOR
CIRCUIT DIAGRAMS
CHARGING SYSTEM
90-41
CHARGING SYSTEM <RH drive vehicles>
M1901000701925
FUSIBLE IGNITION
RELAY
BOX
·ENGINE CONTROL SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
·HEADLAMP
·METER AND GAUGE
·REAR FOG LAMP
LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
HAZARD WARNING LAMP
ENGINE-ECU WASHER
COMBI-
NATION
METER
BRAKE WARNING
LAMP, OIL PRESSURE
WARNING LAMP ENGINE
AND FUEL OIL LEVEL
WARNING LAMP WARNING
LAMP
ALTERNATOR
FIELD
COIL
STATOR
COIL
IC VOLTAGE REGULATOR
ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM <LH drive vehicles>
M1901000803649
FUSIBLE IGNITION
LINK 1 SWITCH (IG1)
FUEL FUEL
PUMP PUMP
RELAY (1) RELAY (2)
COMBINATION
METER
ENGINE-
ECU
CIRCUIT DIAGRAMS
90-43
BATTERY
RELAY
BOX
ENGINE
CONTROL
RELAY
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM
POWER BATTERY
SOURCE BACK-UP
ENGINE CONTROL SYSTEM <LH drive vehicles> (CONTINUED)
ENGINE ENGINE
CONTROL CONTROL
RELAY RELAY J/C(6)
CRANK EXHAUST INTAKE

ANGLE CAMSHAFT CAMSHAFT
SENSOR SENSOR
ENGINE-
ECU
ENGINE
CONTROL
RELAY
TRANSMISSION
DETONATION OIL TEMPERATURE
SENSOR WARNING LAMP
OXYGEN SENSOR (FRONT)

CIRCUIT DIAGRAMS
90-45
ENGINE
CONTROL
RELAY
AIR
FLOW
SENSOR
BAROMETRIC
PRESSURE INTAKE AIR
SENSOR TEMPERATURE
SENSOR
ACD
AND
AYC
J/C (6)
ENGINE THROTTLE
COOLANT POSITION
TEMPERATURE SENSOR
SENSOR
OXYGEN SENSOR (REAR)
Wire colour code

ENGINE CONTROL RELAY
STARTING
SYSTEM
FUEL WASTEGATE PURGE EGR
PRESSURE SOLENOID CONTROL CONTROL
CONTROL VALVE SOLENOID SOLENOID
SOLENOID VALVE VALVE
VALVE
CHARGING IGNITION
SYSTEM SYSTEM
ENGINE SPEED
DETECTION
CONNECTOR
POWER
STEERING FLUID
PRESSURE
SWITCH
CIRCUIT DIAGRAMS
90-47

J/C(6)
IDLE OIL FEEDER

SPEED CONTROL
CONTROL IMMOBILIZER VALVE
SERVO ACD AND AYC SYSTEM
ENGINE-
ECU
·AUTOMATIC AIR AUTOMATIC AIR ·AUTOMATIC AIR CLUTCH

CONDITIONER CONDITIONER
CONDITIONER
·COOLING SWITCH
·COOLING SYSTEM
SYSTEM
Wire colour code

J/B
FUEL PUMP
RELAY (2)
FUEL
PUMP
RELAY (3)
J/C (6)
INJECTOR RESISTOR
INJECTOR INJECTOR INJECTOR INJECTOR FUEL PUMP

AND GAUGE
UNIT (MAIN)
ENGINE-ECU
FRONT
FRONT SIDE SIDE
CIRCUIT DIAGRAMS
90-49
ENGINE-
ECU
J/B ·METER AND

(FUSE 2 ) GAUGE
·WINDSHIELD
WIPER
AND WASHER
FUEL PUMP
RESISTOR
J/B
(FUSE 15 )
VEHICLE
SPEED
SENSOR
DIAGNOSIS
CONNECTOR
DIAGNOSIS
CONNECTOR
Wire colour code


<RH drive vehicles>
M1901000803650
NOTE
FUSIBLE : ·ENGINE OIL LEVEL WARNING LAMP
IGNITION ·HEADLAMP
LINK 1 SWITCH (IG1) ·REAR FOG LAMP
LICENCE PLATE LAMP
AND LIGHTING MONITOR BUZZER
HAZARD WARNING LAMP
·WINDSHIELD WIPER AND WASHER
FUEL FUEL
PUMP PUMP
RELAY (1) RELAY (2)
COMBINATION
METER
ENGINE-
ECU
CIRCUIT DIAGRAMS
90-51
BATTERY
RELAY
BOX
IGNITION
SYSTEM
ENGINE
CONTROL
RELAY
·AUTOMATIC
AIR CONDITIONER
·COOLING
SYSTEM
POWER BATTERY
SOURCE BACK-UP
ENGINE CONTROL SYSTEM <RH drive vehicles> (CONTINUED)
ENGINE ENGINE
CONTROL CONTROL
RELAY RELAY J/C(6)
CRANK EXHAUST INTAKE

ANGLE CAMSHAFT CAMSHAFT
SENSOR SENSOR
ENGINE-
ECU
ENGINE
CONTROL
RELAY
TRANSMISSION
DETONATION OIL TEMPERATURE
WARNING LAMP
SENSOR
OXYGEN SENSOR (FRONT)

CIRCUIT DIAGRAMS
90-53
ENGINE
CONTROL
RELAY
AIR
FLOW
SENSOR
BAROMETRIC
PRESSURE INTAKE AIR
SENSOR TEMPERATURE
SENSOR
ACD
AND
AYC
J/C (6)
ENGINE THROTTLE
COOLANT POSITION
TEMP- SENSOR
ERATURE
SENSOR
OXYGEN SENSOR(REAR)
Wire colour code

STARTING
SYSTEM
FUEL WASTEGATE PURGE EGR
PRESSURE SOLENOID CONTROL CONTROL
CONTROL VALVE SOLENOID SOLENOID
SOLENOID VALVE VALVE
VALVE
CHARGING IGNITION
SYSTEM SYSTEM
ENGINE SPEED
DETECTION
CONNECTOR
POWER
STEERING FLUID
PRESSURE
SWITCH
CIRCUIT DIAGRAMS
90-55

J/C(6)
IDLE OIL FEEDER

SPEED CONTROL
CONTROL IMMOBILIZER VALVE
SERVO ACD AND AYC SYSTEM
ENGINE-
ECU
CLUTCH
·AUTOMATIC AIR SWITCH
·AUTOMATIC AIR AUTOMATIC AIR CONDITIONER
CONDITIONER CONDITIONER ·COOLING
·COOLING SYSTEM SYSTEM
Wire colour code

J/B
FUEL PUMP
RELAY (2)
FUEL
PUMP
RELAY (3)
J/C (6)
INJECTOR RESISTOR
INJECTOR INJECTOR INJECTOR INJECTOR FUEL PUMP

AND GAUGE
UNIT (MAIN)
ENGINE-ECU
FRONT SIDE FRONT

SIDE
CIRCUIT DIAGRAMS
90-57
ENGINE-
ECU
J/B ·METER AND

(FUSE 2 ) GAUGE
·WINDSHIELD
WIPER
AND WASHER
FUEL PUMP
RESISTOR
J/B
(FUSE 15 )
VEHICLE
SPEED
SENSOR
DIAGNOSIS
CONNECTOR
DIAGNOSIS
CONNECTOR
Wire colour code

COOLING SYSTEM
COOLING SYSTEM
COOLING SYSTEM <LH drive vehicles>
M1901001001509
ENGINE
INPUT SIGNAL FUSIBLE CONTROL
· A/C SWITCH · VEHICLE SPEED LINK 2 RELAY
· ENGINE SENSOR
COOLANT
TEMPERATURE
SENSOR
ENGINE- ENGINE
CONTROL
ECU SYSTEM
FAN
CONTROL
RELAY
SMOOTHING
CIRCUIT
FIELD EFFECT RADIATOR

INPUT SIGNAL TRANSISTOR
PROCESSING CIRCUIT FAN MOTOR
DRIVE
CIRCUIT
TEMPERATURE CURRENT
DETECTION DETECTION
FAN CONTROLLER
CIRCUIT DIAGRAMS
COOLING SYSTEM
90-59
IGNITION
RELAY
BOX
·HEADLAMP
CONDENSER CONDENS- SYSTEM
FAN RELAY ER ·REAR FOG LAMP
(HI) FAN RELAY LICENCE PLATE LAMP AND
(LO) LIGHTING MONITOR
BUZZER
HAZARD WARNING LAMP
WASHER
CONDENSER
FAN MOTOR
ENGINE-
ECU
Wire colour code

COOLING SYSTEM
COOLING SYSTEM <RH drive vehicles>

M1901001001510
ENGINE
· A/C SWITCH · VEHICLE SPEED
LINK 2 RELAY
· ENGINE SENSOR
COOLANT
TEMPERATURE
SENSOR
ENGINE- ENGINE
CONTROL
ECU SYSTEM
FAN
CONTROL
RELAY
SMOOTHING
CIRCUIT
FIELD EFFECT
INPUT SIGNAL TRANSISTOR RADIATOR
PROCESSING CIRCUIT FAN MOTOR
DRIVE
CIRCUIT
TEMPERATURE CURRENT
DETECTION DETECTION
FAN CONTROLLER
CIRCUIT DIAGRAMS
COOLING SYSTEM
90-61
IGNITION
RELAY
BOX
AUTOMATIC AIR
CONDITIONER
·HEADLAMP
CONDENSER CONDENS- SYSTEM
·REAR FOG LAMP
FAN RELAY ER ·TAIL LAMP, POSITION LAMP,
(HI) FAN RELAY LICENCE PLATE LAMP AND
(LO) LIGHTING MONITOR
BUZZER
HAZARD WARNING LAMP
WASHER
CONDENSER
FAN MOTOR
ENGINE-
ECU
Wire colour code

HEADLAMP
HEADLAMP
HEADLAMP <LH drive vehicles>
M1901001501991
BATTERY
RELAY
BOX
FRONT-ECU
HEADLAMP HEADLAMP
RELAY : LO RELAY : HI
RELAY
BOX
HEADLAMP
LEVELLING
SYSTEM
HEADLAMP HEADLAMP HEADLAMP HEADLAMP COMBINATION

ASSEMBLY ASSEMBLY (HI : RH) (HI : LH) METER
(LO : RH) (LO : LH)
CIRCUIT DIAGRAMS
HEADLAMP
90-63
IGNITION IGNITION
SWITCH (IG2) SWITCH (IG1)
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM
POWER
SOURCE
COLUMN-ECU
DIMMER · LIGHTING
PASSING SWITCH
SWITCH
COLUMN SWITCH
Wire colour code

HEADLAMP
HEADLAMP <LH drive vehicles> (CONTINUED)

CIRCUIT DIAGRAMS
HEADLAMP
90-65
NOTES
HEADLAMP
HEADLAMP <RH drive vehicles>

M1901001502002
BATTERY
RELAY
BOX
FRONT-ECU
HEADLAMP HEADLAMP
RELAY : LO RELAY : HI
RELAY
BOX
HEADLAMP
LEVELLING
SYSTEM
HEADLAMP HEADLAMP COMBINATION

ASSEMBLY ASSEMBLY HEADLAMP HEADLAMP
(HI : RH) (HI : LH) METER
(LO : RH) (LO : LH)
CIRCUIT DIAGRAMS
HEADLAMP
90-67
IGNITION IGNITION
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM AUTOMATIC AIR
CONDITIONER
·ACD AND AYC

·ANTI-SKID
BRAKING SYSTEM (ABS)
·BRAKE WARNING LAMP,
OIL PRESSURE
WARNING LAMP
AND FUEL WARNING LAMP
·CHARGING SYSTEM
POWER ·ENGINE OIL LEVEL
SOURCE WARNING LAMP
·METER AND GAUGE
SYSTEM (SRS)
·WINDSHIELD WIPER
AND WASHER
COLUMN-ECU
DIMMER · LIGHTING
PASSING SWITCH
SWITCH
COLUMN SWITCH
Wire colour code

HEADLAMP
HEADLAMP <RH drive vehicles> (CONTINUED)
COLUMN
SWITCH FUSIBLE
J/C (1) FRONT-ECU LINK 1
J/B
(FUSE 2 )
ETACS-ECU
POWER
SOURCE
COLUMN
SWITCH
FRONT
DOOR
SWITCH (RH)
DIAGNOSIS
CONNECTOR
NO
CONNECTION
FRONT
SIDE
J/B SIDE
CIRCUIT DIAGRAMS
HEADLAMP
90-69
NOTES
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND

TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR
BUZZER <LH drive vehicles> M1901001700798
BATTERY
FRONT-ECU
TAIL LAMP
RELAY
RELAY
BOX
REAR HEADLAMP HEADLAMP

COMBINATION ASSEMBLY ASSEMBLY
LAMP (POSITION : RH) (POSITION : LH)
(TAIL : RH)
CIRCUIT DIAGRAMS
90-71
IGNITION
J/C(1) SWITCH (IG2)
RELAY
BOX
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM
POWER
SOURCE
COMBINATION
METER LICENCE
REAR PLATE
COMBINATION LAMP
LAMP (LH) (RH)
(TAIL : LH)
Wire colour code

<LH drive vehicles> (CONTINUED)
IGNITION
SWITCH (IG1)
FRONT-ECU
COLUMN
SWITCH
COLUMN-ECU
LIGHTING
SWITCH
FRONT
SIDE
J/B/ SIDE
CIRCUIT DIAGRAMS
90-73
COLUMN FUSIBLE
J/C(1) SWITCH FRONT-ECU LINK 1
ETACS-
ECU
BUZZER
POWER
SOURCE
DIAGNOSIS
CONNECTOR
FRONT
DOOR SWITCH
(LH)
Wire colour code

TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR
BUZZER <RH drive vehicles>
M1901001700806
BATTERY
FRONT-ECU
TAIL LAMP
RELAY
RELAY
BOX
COMBINATION
METER
REAR HEADLAMP HEADLAMP
COMBINATION ASSEMBLY ASSEMBLY
LAMP (POSITION (POSITION : LH)
(TAIL : RH) : RH)
CIRCUIT DIAGRAMS
90-75
IGNITION
J/C (1) SWITCH (IG2)
RELAY
BOX
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM
AUTOMATIC AIR
CONDITIONER
POWER
SOURCE
LICENCE
REAR PLATE
COMBINATION LAMP
LAMP (LH) (RH)
(TAIL : LH)
Wire colour code

<RH drive vehicles> (CONTINUED)
IGNITION
SWITCH (IG1)
FRONT-ECU
·ACD AND AYC

·ANTI-SKID
BRAKING
SYSTEM (ABS)
·BRAKE WARNING
LAMP, OIL
PRESSURE
WARNING LAMP
AND FUEL
WARNING LAMP
·CHARGING SYSTEM
·ENGINE CONTROL
SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
·METER AND GAUGE
·SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
·WINDSHIELD WIPER
AND WASHER
COLUMN
SWITCH
COLUMN-ECU
LIGHTING
SWITCH
FRONT
SIDE
J/B/ SIDE
CIRCUIT DIAGRAMS
90-77
COLUMN FUSIBLE
J/C (1) SWITCH FRONT-ECU LINK 1
ETACS-
ECU
BUZZER
POWER
SOURCE
DIAGNOSIS
CONNECTOR
FRONT
DOOR SWITCH
(RH)
Wire colour code

REAR FOG LAMP
REAR FOG LAMP

REAR FOG LAMP <LH drive vehicles>
M1901012000469
FUSIBLE
LINK 1 BATTERY
RELAY
BOX
FRONT-ECU
TAIL LAMP
RELAY
REAR
FOG
LAMP
RELAY RELAY ETACS-
BOX ECU
TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
COMBI- REAR FOG

NATION COMBINATION LAMP
METER LAMP SWITCH
(REAR FOG
: LH)
ETACS-
ECU
CIRCUIT DIAGRAMS
REAR FOG LAMP
90-79
IGNITION IGNITION
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM
POWER
SOURCE
ETACS-ECU ETACS-ECU
COLUMN
SWITCH
COLUMN-ECU
LIGHTING
SWITCH
REAR FOG LAMP
REAR FOG LAMP <LH drive vehicles> (CONTINUED)
FUSIBLE
J/C (1) LINK 1
J/B
(FUSE 2 )
ETACS-ECU
POWER
SOURCE
COLUMN
SWITCH
DIAGNOSIS
CONNECTOR
FRONT SIDE
J/B SIDE
CIRCUIT DIAGRAMS
REAR FOG LAMP
90-81
NOTES
REAR FOG LAMP
REAR FOG LAMP <RH drive vehicles>

M1901012000470
FUSIBLE
LINK 1 BATTERY
RELAY
BOX
FRONT-ECU
TAIL LAMP
RELAY
REAR
FOG
LAMP
RELAY RELAY ETACS-
BOX ECU
·METER AND GAUGE
LICENCE PLATE LAMP
AND LIGHTING MONITOR BUZZER
TAIL LAMP,
POSITION LAMP,
LICENCE
PLATE LAMP
AND LIGHTING
MONITOR BUZZER
COMBI- REAR FOG

NATION COMBINATION LAMP
METER LAMP SWITCH
(REAR FOG
: RH)
ETACS-
ECU
CIRCUIT DIAGRAMS
REAR FOG LAMP
90-83
IGNITION IGNITION
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM
·AUTOMATIC AIR
CONDITIONER
POWER ·ACD AND AYC
SOURCE ·ANTI-SKID BRAKING
SYSTEM (ABS)
·BRAKE WARNING
LAMP, OIL PRESSURE
WARNING LAMP
AND FUEL
WARNING LAMP
·CHARGING SYSTEM
·ENGINE CONTROL
ETACS-ECU ETACS-ECU SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
·METER AND GAUGE
·SUPPLEMENTAL
RESTRAINT SYSTEM
(SRS)
·WINDSHIELD WIPER
AND WASHER
COLUMN
SWITCH
COLUMN-ECU
LIGHTING
SWITCH
REAR FOG LAMP
REAR FOG LAMP <RH drive vehicles> (CONTINUED)
FUSIBLE
J/C (1) LINK 1
J/B
(FUSE 2 )
ETACS-ECU
POWER
SOURCE
DIAGNOSIS
CONNECTOR
FRONT SIDE
J/B SIDE
CIRCUIT DIAGRAMS
REAR FOG LAMP
90-85
NOTES
ROOM LAMP, LUGGAGE COMPARTMENT LAMP, IGNITION KEY CYLINDER ILLUMINATION LAMP AND DOOR AJAR WARNING LAMP
ROOM LAMP, LUGGAGE COMPARTMENT LAMP, IGNITION KEY

CYLINDER ILLUMINATION LAMP AND DOOR AJAR WARNING LAMP
ROOM LAMP, LUGGAGE COMPARTMENT LAMP, IGNITION KEY CYLINDER ILLUMINATION LAMP
AND DOOR AJAR WARNING LAMP <LH drive vehicles> M1901024000013
IGNITION
SWITCH (ACC)
RELAY
BOX
·AUDIO SYSTEM
SPARE CONNECTOR
·CLOCK
ETACS-ECU
INTERIOR LAMP AUTOMATIC

SHUTDOWN BACK-UP CIRCUIT
REAR
ROOM
LAMP
COMBINATION KEY REMINDER
METER SWITCH
IGNITION KEY
CYLINDER
ILLUMINATION
LAMP
J/B SIDE
CIRCUIT DIAGRAMS
90-87
IGNITION
RELAY ·HEADLAMP
BOX ·HEADLAMP LEVELLING SYSTEM
·REAR FOG LAMP
HAZARD WARNING LAMP
WASHER
KEEP RELAY
POWER
SOURCE
LOAD
DETERMINATION
CIRCUIT
LUGGAGE
FRONT COMPARTMENT
ROOM LAMP
LAMP
LUGGAGE
COMPARTMENT
LAMP SWITCH
Wire colour code

AND DOOR AJAR WARNING LAMP <LH drive vehicles> (CONTINUED)
COMBINATION
METER
ETACS-ECU
FRONT REAR REAR FRONT

DOOR DOOR DOOR DOOR
SWITCH (RH) SWITCH (RH) SWITCH (LH) SWITCH (LH)
FRONT
SIDE
J/B SIDE
CIRCUIT DIAGRAMS
90-89
FUSIBLE
LINK 1
KEY
REMINDER
SWITCH
(WHEN
KEY IS
REMOVED)
DIAGNOSIS
CONNECTOR
ROOM LAMP, LUGGAGE COMPARTMENT LAMP, IGNITION KEY CYLINDER

ILLUMINATION LAMP AND DOOR AJAR WARNING LAMP <RH drive vehicles>
M1901024000035
IGNITION
RELAY SWITCH (ACC)
BOX
ETACS-ECU
INTERIOR LAMP AUTOMATIC

SHUTDOWN BACK-UP CIRCUIT
REAR
ROOM
COMBINATION LAMP
KEY REMINDER
METER SWITCH
IGNITION KEY
CYLINDER
ILLUMINATION
LAMP
J/B SIDE
CIRCUIT DIAGRAMS
90-91
IGNITION
SWITCH (IG1) ·HEADLAMP
BATTERY
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP RELAY
AND HAZARD ·HEADLAMP
WARNING LAMP BOX ·HEADLAMP LEVELLING SYSTEM
·WINDSHIELD ·REAR FOG LAMP
WIPER AND ·TAIL LAMP, POSITION LAMP,
WASHER LICENCE PLATE LAMP AND
HAZARD WARNING LAMP
WASHER
KEEP RELAY
POWER
SOURCE
LOAD
DETERMINATION
CIRCUIT
LUGGAGE
FRONT COMPARTMENT
ROOM LAMP
LAMP
LUGGAGE
COMPARTMENT
LAMP SWITCH
Wire colour code

AND DOOR AJAR WARNING LAMP <RH drive vehicles>
COMBINATION
METER
ETACS-ECU
FRONT REAR REAR FRONT

DOOR DOOR DOOR DOOR
SWITCH (LH) SWITCH (LH) SWITCH (RH) SWITCH (RH)
FRONT
SIDE
CIRCUIT DIAGRAMS
90-93
FUSIBLE
LINK 1
KEY
REMINDER
SWITCH
(WHEN
KEY IS
REMOVED)
DIAGNOSIS
CONNECTOR
J/B SIDE
Wire colour code

HEADLAMP LEVELLING SYSTEM

<LH drive vehicles>
M1901012500635
BATTERY
FRONT-ECU
HEADLAMP
RELAY : LO
RELAY
BOX
HEADLAMP
HEADLAMP ASSEMBLY HEADLAMP ASSEMBLY

(LEVELLING : LH) (LEVELLING : RH)
MOTOR VOLTAGE MOTOR VOLTAGE

DRIVE COMPARISON DRIVE COMPARISON
CIRCUIT CIRCUIT CIRCUIT CIRCUIT
CIRCUIT DIAGRAMS
90-95
IGNITION
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM RELAY
BOX
TAIL LAMP
RELAY
POWER
SOURCE
RELAY
BOX
TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING ·ACD AND AYC
MONITOR BUZZER ·AUDIO SYSTEM SPARE CONNECTOR
·AUTOMATIC AIR CONDITIONER
OIL PRESSURE WARNING LAMP
·CLOCK
·HEADLAMP
·METER AND GAUGE
·POWER WINDOWS
HEADLAMP ·REAR FOG LAMP
LEVELLING ·ROOM LAMP, LUGGAGE
COMPARTMENT LAMP, IGNITION KEY
SWITCH CYLINDERILLUMINATION LAMP AND
HAZARD WARNING LAMP
Wire colour code


<RH drive vehicles>
M1901012500646
BATTERY
FRONT-ECU
HEADLAMP
RELAY : LO
RELAY
BOX
HEADLAMP
HEADLAMP ASSEMBLY HEADLAMP ASSEMBLY

(LEVELLING : LH) (LEVELLING : RH)
MOTOR VOLTAGE MOTOR VOLTAGE

DRIVE COMPARISON DRIVE COMPARISON
CIRCUIT CIRCUIT CIRCUIT CIRCUIT
CIRCUIT DIAGRAMS
90-97
IGNITION
NOTE ·AUTOMATIC AIR

: ·AUTOMATIC AIR CONDITIONER CONDITIONER
·COOLING SYSTEM RELAY
BOX
TAIL LAMP
RELAY
POWER
SOURCE
RELAY
BOX
TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·METER AND GAUGE
LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·ACD AND AYC

·AUDIO SYSTEM SPARE CONNECTOR
·AUTOMATIC AIR CONDITIONER
OIL PRESSURE WARNING LAMP
·CLOCK
HEADLAMP ·HEADLAMP
LEVELLING ·METER AND GAUGE
·POWER WINDOWS
SWITCH ·REAR FOG LAMP
COMPARTMENT LAMP, IGNITION KEY
CYLINDERILLUMINATION LAMP AND
HAZARD WARNING LAMP
Wire colour code

TURN-SIGNAL LAMP AND HAZARD WARNING LAMP

TURN-SIGNAL LAMP AND HAZARD WARNING LAMP <LH drive vehicles>
M1901002901646
BATTERY
RELAY
BOX
ETACS-ECU
TURN-SIGNAL TURN-SIGNAL
LAMP RELAY : LH LAMP RELAY : RH
SIDE HEADLAMP REAR REAR

TURN-SIGNAL ASSEMBLY COMBI- COMBINATION
LAMP (LH) (TURN : LH) NATION LAMP
LAMP (TURN : RH)
(TURN
: LH)
J/B SIDE
CIRCUIT DIAGRAMS
90-99
COMBINATION
METER
SIDE HEADLAMP
TURN-SIGNAL ASSEMBLY
LAMP (RH) (TURN : RH)
Wire colour code

TURN-SIGNAL LAMP AND HAZARD WARNING LAMP <LH drive vehicles> (CONTINUED)
IGNITION
RELAY
BOX
·AUTOMATIC AIR
CONDITIONER
·COOLING
SYSTEM
FRONT-
ECU
TAIL LAMP
RELAY POWER
SOURCE
RELAY
BOX
TAIL LAMP, POSITION

LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER
HAZARD
WARNING
SWITCH
FRONT SIDE
CIRCUIT DIAGRAMS
90-101
IGNITION COLUMN FRONT- FUSIBLE

SWITCH (IG1) SWITCH ECU LINK 1
ETACS-ECU
POWER SOURCE
RELAY BOX
(FUSE 22 )
COLUMN-ECU
TURN-SIGNAL DIAGNOSIS
LAMP CONNECTOR
SWITCH
COLUMN SWITCH
J/B SIDE
TURN-SIGNAL LAMP AND HAZARD WARNING LAMP <RH drive vehicles>

M1901002901657
BATTERY
RELAY
BOX
ETACS-ECU
SIDE HEADLAMP REAR SIDE

TURN-SIGNAL ASSEMBLY COMBI- TURN-SIGNAL
LAMP (LH) (TURN : LH) NATION LAMP (RH)
LAMP
(TURN
: LH)
J/B SIDE
CIRCUIT DIAGRAMS
90-103
COMBINATION
HEADLAMP METER REAR
ASSEMBLY COMBINATION
(TURN : RH) LAMP
(TURN : RH)
Wire colour code

TURN-SIGNAL LAMP AND HAZARD WARNING LAMP <RH drive vehicles> (CONTINUED)
IGNITION
RELAY
BOX
·AUTOMATIC AIR
CONDITIONER
·AUTOMATIC AIR
CONDITIONER
·COOLING
SYSTEM
FRONT-
ECU
TAIL LAMP
RELAY POWER
SOURCE
RELAY
BOX
TAIL LAMP, POSITION

LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER
HAZARD
WARNING
SWITCH
·METER AND
GAUGE
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND
LIGHTING MONITOR
BUZZER
FRONT SIDE
CIRCUIT DIAGRAMS
90-105
IGNITION COLUMN FRONT- FUSIBLE

SWITCH (IG1) SWITCH ECU LINK 1
ETACS-ECU
POWER SOURCE
·ACD AND AYC ·ENGINE CONTROL

·ANTI-SKID SYSTEM RELAY
BRAKING ·ENGINE OIL
SYSTEM (ABS) LEVEL WARNING BOX
·BRAKE WARNING LAMP (FUSE 22 )
LAMP, OIL ·METER AND
PRESSURE GAUGE
WARNING LAMP ·SUPPLEMENTAL
AND FUEL RESTRAINT
WARNING LAMP SYSTEM (SRS)
·CHARGING ·WINDSHIELD
SYSTEM WIPER AND
WASHER
COLUMN-ECU
TURN-SIGNAL DIAGNOSIS
LAMP CONNECTOR
SWITCH
COLUMN SWITCH
J/B SIDE
BACK-UP LAMP
BACK-UP LAMP
BACK-UP LAMP <LH drive vehicles>
M1901011700120
IGNITION
SWITCH (IG1)
BACK-UP
LAMP SWITCH
REAR
COMBINATION
LAMP
(BACK : RH)
Wire colour code

CIRCUIT DIAGRAMS
BACK-UP LAMP
90-107
BACK-UP LAMP <RH drive vehicles>
M1901011700131
IGNITION
SWITCH (IG1)
BACK-UP
LAMP SWITCH
REAR
COMBINATION
LAMP
(BACK : LH)
Wire colour code

STOP LAMP
STOP LAMP
STOP LAMP <LH drive vehicles>
M1901003001710
BATTERY
RELAY
BOX
STOP LAMP
SWITCH
·ACD AND AYC

·ANTI-SKID BRAKING
SYSTEM (ABS)
REAR HIGH-
COMBINATION HIGH- MOUNTED
LAMP (STOP) MOUNTED STOP LAMP
(RH) (LH) STOP LAMP <REAR
<REAR SPOILER>
SHELF>
Wire colour code

CIRCUIT DIAGRAMS
STOP LAMP
90-109
STOP LAMP <RH drive vehicles>
M1901003001721
BATTERY
RELAY
BOX
STOP LAMP
SWITCH
·ACD AND AYC

·ANTI-SKID BRAKING
SYSTEM (ABS)
REAR HIGH-
COMBINATION HIGH- MOUNTED
LAMP (STOP) MOUNTED STOP LAMP
(LH) (RH) STOP LAMP <REAR
<REAR SPOILER>
SHELF>
Wire colour code

HORN
HORN
HORN <LH drive vehicles>
M1901003301302
BATTERY
RELAY
BOX
HORN
RELAY
CLOCK
SPRING
HORN
HORN HORN SWITCH
(LO) (HI)
Wire colour code

CIRCUIT DIAGRAMS
HORN
90-111
HORN <RH drive vehicles>
M1901003301313
BATTERY
RELAY
BOX
HORN
RELAY
CLOCK
SPRING
HORN
HORN HORN SWITCH
(LO) (HI)
Wire colour code

METER AND GAUGE
METER AND GAUGE

METER AND GAUGE <LH drive vehicles>
M1901003501908
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONTROL CIRCUIT
FUEL PUMP
AND GAUGE
UNIT (MAIN)
FUEL
ENGINE GAUGE
COOLANT UNIT (SUB)
TEMPERATURE
GAUGE UNIT
CIRCUIT DIAGRAMS
METER AND GAUGE
90-113
FRONT-ECU
TAIL LAMP
BATTERY RELAY
RELAY
BOX
·HEADLAMP
SYSTEM
·REAR FOG LAMP
LAMP, LICENCE PLATE TAIL LAMP,
LAMP AND LIGHTING POSITION
MONITOR BUZZER LAMP, LICENCE
·TURN-SIGNAL LAMP PLATE LAMP
AND HAZARD AND LIGHTING
WARNING LAMP MONITOR
·WINDSHIELD WIPER BUZZER
AND WASHER
LCD ODO/ TRIP
ENGINE-
ENGINE ECU
SPEED
DETECTION
CONNECTOR
METER AND GAUGE
METER AND GAUGE <LH drive vehicles> (CONTINUED)
FUSIBLE
J/B LINK 1
(FUSE 2 )
J/C (5)
ENGINE
CONTROL
SYSTEM
VEHICLE DIAGNOSIS
SPEED CONNECTOR
SENSOR
FRONT SIDE
Wire colour code

CIRCUIT DIAGRAMS
METER AND GAUGE
90-115
NOTES
METER AND GAUGE
METER AND GAUGE <RH drive vehicles>

M1901003501919
IGNITION
SWITCH (IG1)
·ENGINE CONTROL
SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
·HEADLAMP
·REAR FOG LAMP
LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
COMBINATION
METER
CONTROL CIRCUIT
FUEL PUMP
AND GAUGE
UNIT (MAIN)
ENGINE
COOLANT FUEL
TEMPERATURE GAUGE
GAUGE UNIT UNIT (SUB)
CIRCUIT DIAGRAMS
METER AND GAUGE
90-117
FRONT-ECU
TAIL LAMP
BATTERY RELAY
RELAY
BOX
RELAY
BOX
·HEADLAMP
SYSTEM
·REAR FOG LAMP
LAMP, LICENCE PLATE
LAMP AND LIGHTING ·HEADLAMP
MONITOR BUZZER ·REAR FOG LAMP TAIL LAMP,
·TURN-SIGNAL LAMP ·TAIL LAMP, POSITION POSITION
AND HAZARD LAMP, LICENCE PLATE LAMP, LICENCE
WARNING LAMP LAMP AND LIGHTING PLATE LAMP
·WINDSHIELD WIPER MONITOR BUZZER AND LIGHTING
AND WASHER ·TURN-SIGNAL LAMP MONITOR
AND HAZARD BUZZER
WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
LCD ODO/ TRIP
ENGINE-
ENGINE ECU
SPEED
DETECTION
CONNECTOR
METER AND GAUGE
METER AND GAUGE <RH drive vehicles> (CONTINUED)
FUSIBLE
J/B LINK 1
(FUSE 2 )
J/C (2)
ENGINE
CONTROL
SYSTEM
VEHICLE DIAGNOSIS
SPEED CONNECTOR
SENSOR
FRONT SIDE
Wire colour code

CIRCUIT DIAGRAMS
METER AND GAUGE
90-119
NOTES
BRAKE WARNING LAMP, OIL PRESSURE WARNING LAMP AND FUEL WARNING LAMP
BRAKE WARNING LAMP, OIL PRESSURE WARNING LAMP

BRAKE WARNING LAMP, OIL PRESSURE WARNING LAMP AND FUEL WARNING
LAMP <LH drive vehicles> M1901011801164
IGNITION
SWITCH (IG1)
COMBINATION METER
·CHARGING SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
BRAKE FLUID
LEVEL
SWITCH
PARKING
BRAKE
SWITCH
CIRCUIT DIAGRAMS
90-121
BATTERY
RELAY
BOX
·HEADLAMP
SYSTEM
·REAR FOG LAMP
LICENCE PLATE LAMP
BUZZER
HAZARD WARNING LAMP
WASHER
FUEL
CONTROL CIRCUIT GAUGE
UNIT (SUB)
FUEL PUMP
AND GAUGE
UNIT (MAIN)
OIL
PRESSURE
SWITCH
Wire colour code

BRAKE WARNING LAMP, OIL PRESSURE WARNING LAMP AND FUEL WARNING
LAMP <RH drive vehicles>
M1901011801175
IGNITION
SWITCH (IG1)
·ENGINE CONTROL
SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
·HEADLAMP
·METER AND GAUGE
·REAR FOG LAMP
LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
COMBINATION METER
·CHARGING SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
BRAKE FLUID
LEVEL
SWITCH ·ACD AND AYC
·ANTI-SKID BRAKING
SYSTEM (ABS)
PARKING
BRAKE
SWITCH
CIRCUIT DIAGRAMS
90-123
BATTERY
RELAY
BOX
·HEADLAMP
SYSTEM
·REAR FOG LAMP
LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·HEADLAMP ·TURN-SIGNAL LAMP
·REAR FOG LAMP AND HAZARD
·TAIL LAMP, POSITION WARNING LAMP
LAMP, LICENCE PLATE ·WINDSHIELD
LAMP AND LIGHTING WIPER AND WASHER
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
FUEL
GAUGE
CONTROL CIRCUIT UNIT (SUB)
FUEL PUMP
AND GAUGE
UNIT (MAIN)
OIL
PRESSURE
SWITCH
Wire colour code


<LH drive vehicles>
M1901023500082
IGNITION
SWITCH (IG1)
COMBINATION
METER ACD AND AYC
CHARGING
SYSTEM
ENGINE
OIL LEVEL
RELAY
DELAY CIRCUIT
ENGINE
OIL
LEVEL
SENSOR
CIRCUIT DIAGRAMS
90-125
<RH drive vehicles>
M1901023500093
IGNITION
SWITCH (IG1)
COMBINATION ·ENGINE CONTROL

METER SYSTEM
·HEADLAMP
·METER AND GAUGE
·REAR FOG LAMP
LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER
·TURN-SIGNAL LAMP
AND HAZARD WARNING
LAMP
·WINDSHIELD WIPER
CHARGING AND WASHER
SYSTEM
ENGINE
OIL LEVEL
RELAY
DELAY CIRCUIT
ENGINE
OIL
LEVEL
SENSOR
TRANSMISSION OIL TEMPERATURE WARNING LAMP

TRANSMISSION OIL TEMPERATURE WARNING LAMP <LH drive vehicles>
M1901023900024
IGNITION
SWITCH (IG1)
TRANSMISSION OIL
TEMPERATURE
SENSOR
COMBINATION
METER
ENGINE CONTROL
SYSTEM
ENGINE-ECU
CIRCUIT DIAGRAMS
90-127
TRANSMISSION OIL TEMPERATURE WARNING LAMP <RH drive vehicles>
M1901023900046
IGNITION
AWITCH (IG1)
TRANSMISSION OIL
TEMPERATURE
SENSOR
·ENGINE CONTROL
SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
·HEADLAMP
·METER AND GAUGE
·REAR FOG LAMP
LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD WARNING
LAMP
·WINDSHIELD WIPER
AND WASHER
COMBINATION
METER
ENGINE CONTROL
SYSTEM
ENGINE-ECU
POWER WINDOWS
POWER WINDOWS
POWER WINDOWS <LH drive vehicles>
M1901004601856
FUSIBLE IGNITION
NOTE
: ·HEADLAMP
RELAY ·HEADLAMP LEVELLING SYSTEM
BOX ·REAR FOG LAMP
HAZARD WARNING LAMP
POWER
WINDOW
RELAY
ETACS-ECU
POWER
SOURCE
DIAGNOSIS
CONNECTOR
FRONT
DOOR
SWITCH (LH)
FRONT SIDE
J/B SIDE
CIRCUIT DIAGRAMS
POWER WINDOWS
90-129
FUSIBLE
LINK 5
POWER
WINDOW
SUB SWITCH
(FRONT)
CPU
HALL IC HALL IC
POWER WINDOW
MOTOR (FRONT : RH)
POWER WINDOWS
POWER WINDOWS <LH drive vehicles> (CONTINUED)
J/B
POWER
WINDOW
J/C (2) RELAY
POWER WINDOW
MAIN SWITCH
LOCK
SWITCH FRONT
(RH)
CPU
FRONT
(LH)
POWER
WINDOW
MOTOR
(FRONT : LH)
HALL IC HALL IC
CIRCUIT DIAGRAMS
POWER WINDOWS
90-131
POWER WINDOWS
POWER WINDOWS <LH drive vehicles> (CONTINUED)
J/B
POWER POWER
WINDOW WINDOW
MAIN SWITCH RELAY
POWER
WINDOW
SUB
SWITCH
(REAR : RH)
CPU
POWER
WINDOW
MOTOR
(REAR : RH)
HALL IC HALL IC
Wire colour code

CIRCUIT DIAGRAMS
POWER WINDOWS
90-133
NOTES
POWER WINDOWS
POWER WINDOWS <RH drive vehicles>

M1901004601867
FUSIBLE IGNITION
NOTE
RELAY :·HEADLAMP
·HEADLAMP LEVELLING SYSTEM
BOX ·REAR FOG LAMP
HAZARD WARNING LAMP
POWER
WINDOW
RELAY
ETACS-ECU
POWER
SOURCE
DIAGNOSIS
CONNECTOR
FRONT
DOOR
SWITCH (RH)
FRONT SIDE
J/B SIDE
CIRCUIT DIAGRAMS
POWER WINDOWS
90-135
FUSIBLE
LINK 5
: ·HEADLAMP
·REAR FOG
LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD POWER
WARNING LAMP
·WINDSHIELD WINDOW
WIPER AND SUB SWITCH
WASHER (FRONT)
CPU
HALL IC HALL IC
POWER WINDOW
MOTOR (FRONT : LH)
POWER WINDOWS
POWER WINDOWS <RH drive vehicles> (CONTINUED)
J/B
POWER
WINDOW
J/C (2) RELAY
POWER WINDOW
MAIN SWITCH
LOCK
SWITCH FRONT
(RH)
CPU
FRONT
(LH)
POWER
WINDOW
MOTOR
(FRONT : RH)
HALL IC HALL IC
CIRCUIT DIAGRAMS
POWER WINDOWS
90-137
POWER WINDOWS
POWER WINDOWS <RH drive vehicles> (CONTINUED)
J/B
POWER POWER
WINDOW WINDOW
MAIN SWITCH RELAY
POWER
WINDOW
SUB
SWITCH
(REAR : RH)
CPU
POWER
WINDOW
MOTOR
(REAR : RH)
HALL IC HALL IC
Wire colour code

CIRCUIT DIAGRAMS
POWER WINDOWS
90-139
NOTES

<LH drive vehicles>
M1901004702867
FUSIBLE IGNITION
LINK 1 ·HEADLAMP
BATTERY ·HEADLAMP SWITCH
(IG1)
LEVELLING SYSTEM
·REAR FOG LAMP
LICENCE PLATE LAMP
AND LIGHTING
RELAY MONITOR BUZZER
BOX ·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
POWER
SOURCE
DIAGNOSIS
CONNECTOR
DOOR LOCK
ACTUATOR
(FRONT : LH)
FRONT SIDE
J/B SIDE
CIRCUIT DIAGRAMS
90-141
KEYLESS ENTRY TRANSMITTER
CONTROL
CIRCUIT
ETACS-
ECU
KEYLESS
ENTRY
RECEIVER
DOOR LOCK DOOR LOCK DOOR LOCK

ACTUATOR ACTUATOR ACTUATOR
(REAR : RH) (FRONT : RH) (REAR : LH)
CENTRAL DOOR LOCKING SYSTEM <LH drive vehicles> (CONTINUED)
BATTERY
RELAY
BOX
ETACS-ECU

TURN-SIGNAL ASSEMBLY COMBI- COMBINATION
LAMP (LH) (TURN : LH) NATION LAMP
LAMP (TURN : RH)
(TURN
: LH)
J/B SIDE
CIRCUIT DIAGRAMS
90-143
COMBINATION
METER
SIDE HEADLAMP
TURN-SIGNAL ASSEMBLY
LAMP (RH) (TURN : RH)
Wire colour code

CENTRAL DOOR LOCKING SYSTEM <LH drive vehicles> (CONTINUED)
FRONT REAR
ROOM ROOM
LAMP LAMP
ETACS-
ECU
KEY
REMINDER
SWITCH
WHEN KEY
IS REMOVED
FRONT REAR
DOOR DOOR
SWITCH SWITCH
(LH) (LH)
CIRCUIT DIAGRAMS
90-145
SRS-
ECU
CRASH DETECTION
DOOR UNLOCK
SIGNAL PROCESS
CIRCUIT
DOOR
LOCK KEY
CYLINDER
SWITCH
(RH)
FRONT REAR
DOOR DOOR
SWITCH SWITCH
(RH) (RH)
J/B SIDE
Wire colour code


<RH drive vehicles>
M1901004702878
FUSIBLE IGNITION
·HEADLAMP
LINK 1 BATTERY ·HEADLAMP SWITCH (IG1)
LEVELLING SYSTEM
·REAR FOG LAMP
LICENCE PLATE LAMP
AND LIGHTING
RELAY MONITOR BUZZER
BOX ·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
POWER
SOURCE
DIAGNOSIS
CONNECTOR
DOOR LOCK
ACTUATOR
(FRONT : RH)
FRONT SIDE
J/B SIDE
CIRCUIT DIAGRAMS
90-147
KEYLESS ENTRY TRANSMITTER
NOTE
: ·HEADLAMP
·REAR FOG LAMP
LICENCE PLATE LAMP CONTROL
AND LIGHTING
MONITOR BUZZER CIRCUIT
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
ETACS-
ECU
KEYLESS
ENTRY
RECEIVER

(REAR : LH) (FRONT : LH) (REAR : RH)
CENTRAL DOOR LOCKING SYSTEM <RH drive vehicles> (CONTINUED)
BATTERY
RELAY
BOX
ETACS-ECU
SIDE HEADLAMP REAR SIDE

TURN-SIGNAL ASSEMBLY COMBI- TURN-SIGNAL
LAMP (LH) (TURN : LH) NATION LAMP (RH)
LAMP
(TURN
: LH)
J/B SIDE
CIRCUIT DIAGRAMS
90-149
COMBINATION
METER
HEADLAMP REAR
ASSEMBLY COMBINATION
(TURN : RH) LAMP
(TURN : RH)
Wire colour code

CENTRAL DOOR LOCKING SYSTEM <RH drive vehicles> (CONTINUED)
FRONT REAR
ROOM ROOM
LAMP LAMP
ETACS-
ECU
KEY
REMINDER
SWITCH
WHEN KEY
IS REMOVED
FRONT REAR
DOOR DOOR
SWITCH SWITCH
(RH) (RH)
CIRCUIT DIAGRAMS
90-151
SRS-
ECU
CRASH DETECTION
DOOR UNLOCK
SIGNAL PROCESS
CIRCUIT
DOOR
LOCK KEY
CYLINDER
SWITCH
(LH)
FRONT REAR
DOOR DOOR
SWITCH SWITCH
(LH) (LH)
J/B SIDE
Wire colour code


<LH drive vehicles>
M1901005600737
FUSIBLE IGNITION
LINK 1 SWITCH (IG2) BATTERY
NOTE
: ·HEADLAMP
·REAR FOR LAMP
LICENCE PLATE LAMP, AND
·TURN-SIGNAL LAMP AND HAZARD
WARNING LAMP
RELAY
BOX
BLOWER
RELAY
BLOWER LINER
CONTROLLER
A/C-ECU
BATTERY
BACK-UP
CIRCUIT DIAGRAMS
90-153
FRONT-ECU
TAIL LAMP
RELAY
RELAY
BOX
OUTSIDE
THERMO
SENSOR
TAIL LAMP,
POSITION LAMP,
LICENCE PLATE REAR WINDOW
LAMP AND LIGHTING DEFOGGER AND
MONITOR BUZZER DOOR MIRROR
HEATER
AIR THERMO
SENSOR
A/C-ECU
ILL
INTERIOR
TEMPERATURE
SENSOR
Wire colour code

G : Green L : Blue
O : Orange GR : Grey
R : Red P : Pink
V : Violet PU : Purple
AUTOMATIC AIR CONDITIONER <LH drive vehicles> (CONTINUED)
ENGINE
· ENGINE SENSOR
COOLANT
TEMPERATURE
SENSOR
ENGINE
ENGINE- CONTROL
ECU SYSTEM
FAN
CONTROL
RELAY
SMOOTHING
CIRCUIT
RADIATOR
FIELD EFFECT
INPUT SIGNAL TRANSISTOR FAN MOTOR
PROCESSING CIRCUIT
DRIVE
CIRCUIT
TEMPERATURE CURRENT
DETECTION DETECTION
FAN CONTROLLER
CIRCUIT DIAGRAMS
90-155
BATTERY J/C (2)
RELAY
BOX
·HEADLAMP
CONDENSER SYSTEM
CONDENSER ·REAR FOG LAMP
FAN RELAY FAN RELAY ·TAIL LAMP, POSITION LAMP,
(HI) (LO) LICENCE PLATE LAMP AND
LIGHTING MONITOR
BUZZER
HAZARD WARNING LAMP
WASHER
CONDENSER
FAN MOTOR
ENGINE-
ECU
Wire colour code

HEATER WATER
AIR MIXING DAMPER TEMPERATURE AIR THERMO
SENSOR SENSOR
CONTROL MOTOR AND
POTENTIOMETER
A/C-ECU
MOTOR DRIVE
CIRCUIT
MOTOR DRIVE
CIRCUIT
J/C(2)
OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL
MOTOR
FRONT SIDE
CIRCUIT DIAGRAMS
90-157
MODE SELECTION DAMPER

CONTROL MOTOR AND
POTENTIOMETER FUSIBLE
LINK 1
MOTOR DRIVE
CIRSUIT
DIAGNOSIS
CONNECTOR
PHOTO SENSOR
Wire colour code

G : Green L : Blue
R : Red P : Pink
A/C-ECU
BATTERY J/C (2)
RELAY
BOX
A/C LOW- DUAL

COMPRESSOR PRESSURE PRESSURE
SIDE
RELAY SWITCH
HIGH-
PRESSURE
SIDE
A/C
COMPRESSOR
A/C
REFRIGERANT
TEMPERATURE
SWITCH
MAGNETIC ENGINE-
CLUTCH
ECU
CIRCUIT DIAGRAMS
90-159
NOTES

<RH drive vehicles>
M1901005600759
FUSIBLE IGNITION
LINK 1 SWITCH (IG2) BATTERY
NOTE
: ·HEADLAMP
·REAR FOG LAMP
LICENCE PLATE LAMP, AND
·TURN-SIGNAL LAMP AND HAZARD
WARNING LAMP
RELAY
BOX
BLOWER
RELAY
BLOWER LINEAR
CONTROLLER
A/C-ECU
BATTERY
BACK-UP
CIRCUIT DIAGRAMS
90-161
FRONT-ECU
TAIL LAMP
RELAY
RELAY
BOX
OUTSIDE
THERMO
SENSOR
TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER REAR WINDOW
DEFOGGER AND
DOOR MIRROR
AIR THERMO HEATER
SENSOR
A/C-ECU
ILL
INTERIOR
TEMPERATURE
SENSOR
Wire colour code

G : Green L : Blue
R : Red P : Pink
AUTOMATIC AIR CONDITIONER <RH drive vehicles> (CONTINUED)
ENGINE
· ENGINE SENSOR
COOLANT
TEMPERATURE
SENSOR
ENGINE- ENGINE
ECU CONTROL
SYSTEM
FAN
CONTROL
RELAY
SMOOTHING
CIRCUIT
RADIATOR
FIELD EFFECT
INPUT SIGNAL TRANSISTOR FAN MOTOR
PROCESSING CIRCUIT
DRIVE
CIRCUIT
TEMPERATURE CURRENT
DETECTION DETECTION
FAN CONTROLLER
CIRCUIT DIAGRAMS
90-163
BATTERY J/C (2)
RELAY
BOX
·HEADLAMP
CONDENSER CONDENSER SYSTEM
·REAR FOG LAMP
FAN RELAY FAN RELAY ·TAIL LAMP, POSITION LAMP,
(HI) (LO) LICENCE PLATE LAMP AND
LIGHTING MONITOR
BUZZER
HAZARD WARNING LAMP
WASHER
CONDENSER
FAN MOTOR
ENGINE-
ECU
Wire colour code

HEATER WATER
AIR MIXING DAMPER TEMPERATURE AIR THERMO
CONTROL MOTOR AND SENSOR SENSOR
POTENTIOMETER
A/C-ECU
MOTOR DRIVE
CIRCUIT
MOTOR DRIVE
CIRCUIT
J/C(2)
OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL
MOTOR
FRONT SIDE
CIRCUIT DIAGRAMS
90-165
MODE SELECTION DAMPER

CONTROL MOTOR AND
POTENTIOMETER FUSIBLE
LINK 1
MOTOR DRIVE
CIRSUIT
DIAGNOSIS
CONNECTOR
PHOT SENSOR
Wire colour code

A/C-ECU
BATTERY J/C (2)
RELAY
BOX
A/C LOW- DUAL

COMPRESSOR PRESSURE PRESSURE
RELAY SIDE
SWITCH
HIGH-
PRESSURE
SIDE
A/C
COMPRESSOR
A/C
REFRIGERANT
TEMPERATURE
SWITCH
MAGNETIC ENGINE-
CLUTCH
ECU
CIRCUIT DIAGRAMS
90-167
NOTES

<LH drive vehicles>
M1901006101761
IGNITION
SWITCH (ACC)
FRONT-ECU
WIPER SPEED WIPER

WINDSHIELD SWITCHING AUTOMATIC
WASHER RELAY RELAY STOP RELAY
J/B
(FUSE 7 )
WINDSHIELD
WIPER MOTOR
CIRCUIT
WINDSHIELD BREAKER
WASHER MOTOR
CIRCUIT DIAGRAMS
90-169
IGNITION IGNITION
BATTERY SWITCH (IG2) SWITCH (IG1)
RELAY
BOX
·AUTOMATIC AIR
CONDITIONER
·COOLING SYSTEM
POWER
SOURCE
ETACS-
ETACS-ECU J/C(2) ECU
ETACS-
ECU
COLUMN-ECU
WINDSHIELD WINDSHIELD
WASHER SWITCH INTERMITTENT
WINDSHIELD WIPER WIPER INTERVAL
SWITCH ADJUSTING KNOB
COLUMN SWITCH
WINDSHIELD WIPER AND WASHER <LH drive vehicles> (CONTINUED)
FRONT- IGNITION FUSIBLE

J/C (5) ECU J/C (1) SWITCH (ACC) LINK 1
ENGINE
CONTROL
SYSTEM
J/B
(FUSE 2 )
ETACS-ECU
POWER
SOURCE
VEHICLE
SPEED
SENSOR
DIAGNOSIS
CONNECTOR
FRONT SIDE
J/B SIDE
CIRCUIT DIAGRAMS
90-171
NOTES

<RH drive vehicles>
M1901006101772
IGNITION
SWITCH(ACC)
FRONT-ECU
WINDSHIELD WIPER SPEED WIPER

WASHER RELAY SWITCHING AUTOMATIC
RELAY STOP RELAY
J/B
(FUSE 7 )
WINDSHIELD
WIPER MOTOR
CIRCUIT
BREAKER
WINDSHIELD
WASHER MOTOR
UPPER UPPER
SIDE SIDE
CIRCUIT DIAGRAMS
90-173
IGNITION IGNITION
BATTERY SWITCH (IG2) SWITCH (IG1)
RELAY
BOX
·ACD AND AYC

·AUTOMATIC AIR ·ANTI-SKID BRAKING
CONDITIONER SYSTEM (ABS)
AUTOMATIC AIR ·BRAKE WARNING LAMP,
·COOLING SYSTEM CONDITIONER OIL PRESSURE
WARNING LAMP AND
FUEL WARNING LAMP
·CHARGING SYSTEM
·ENGINE CONTROL
SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
·METER AND GAUGE
·SUPPLEMENTAL
RESTRAINT SYSTEM (SRS)
POWER
SOURCE
ETACS-
ETACS-ECU J/C(2) ECU
ETACS-
ECU
COLUMN-ECU
WINDSHIELD WINDSHIELD
WASHER SWITCH INTERMITTENT
WINDSHIELD WIPER WIPER INTERVAL
SWITCH ADJUSTING KNOB
COLUMN SWITCH
WINDSHIELD WIPER AND WASHER <RH drive vehicles> (CONTINUED)
J/B FRONT- IGNITION FUSIBLE

J/C (2) (FUSE 2 ) ECU J/C (1) SWITCH (ACC) LINK 1
ENGINE
CONTROL
SYSTEM
J/B
(FUSE 2 )
ETACS-ECU
POWER
SOURCE
VEHICLE
SPEED
SENSOR
DIAGNOSIS
CONNECTOR
FRONT SIDE
J/B SIDE
CIRCUIT DIAGRAMS
90-175
NOTES

<LH drive vehicles>
M1901006501480
IGNITION
SWITCH (ACC)
REMOTE
CONTROLLED
MIRROR
SWITCH
REMOTE REMOTE
MIRROR (LH) MIRROR (RH)
CIRCUIT DIAGRAMS
90-177
<RH drive vehicles>
M1901006501491
IGNITION
SWITCH (ACC)
REMOTE
CONTROLLED
MIRROR
SWITCH
REMOTE REMOTE
MIRROR (LH) MIRROR (RH)
REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER

REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER <LH drive vehicles>
M1901013500984
FRONT-ECU
TAIL LAMP IGNITION FUSIBLE
RELAY SWITCH (IG2) LINK 1
RELAY
BOX
DEFOGGER
RELAY
TAIL LAMP, POSITION

LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
A/C-ECU
DEFOGGER
SWITCH, ILL
DEFOGGER
CIRCUIT DIAGRAMS
90-179
REMOTE REMOTE
MIRROR
MIRROR MIRROR
MIRROR
HEATER (LH) HEATER (RH)
REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER <RH drive vehicles>
M1901013500995
FRONT-ECU
TAIL LAMP IGNITION FUSIBLE
RELAY SWITCH (IG2) LINK 1
RELAY
BOX
TAIL LAMP, POSITION

LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
DEFOGGER
RELAY
·METER AND GAUGE

LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
A/C-ECU
DEFOGGER
SWITCH, ILL
DEFOGGER
CIRCUIT DIAGRAMS
90-181
REMOTE REMOTE
MIRROR
MIRROR MIRROR MIRROR
HEATER (LH) HEATER (RH)
AUDIO SYSTEM SPARE CONNECTOR

<LH drive vehicles>
M1901007600090
FRONT-ECU
TAIL LAMP
RELAY
RELAY
BOX
ROOF ANTENNA
ANTENNA
AMPLIFIRE

ANTENNA LIGHTING MONITOR BUZZER
FEEDER
CABLE
(LH) (RH) (LH) (RH)
TWEETER FRONT DOOR SPEAKER

CIRCUIT DIAGRAMS
90-183
IGNITION
SWITCH (ACC) BATTERY
RELAY
BOX
·HEADLAMP
·HEADLAMP
LEVELLING SYSTEM
·REAR FOG LAMP
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD WIPER
·CLOCK AND WASHER
COMPARTMENT LAMP,
SPARE CONNECTOR
(FOR AUDIO) SPARE CONNECTOR
(FOR AUDIO)
(LH) (RH)
REAR DOOR SPEAKER
Wire colour code


<RH drive vehicles>
M1901007600108
FRONT-ECU
TAIL LAMP
RELAY
RELAY
BOX
ROOF ANTENNA

ANTENNA
AMPLIFIRE
·METER AND GAUGE

ANTENNA LICENCE PLATE LAMP AND
FEEDER LIGHTING MONITOR BUZZER
CABLE
(LH) (RH) (LH) (RH)
TWEETER FRONT DOOR SPEAKER

CIRCUIT DIAGRAMS
90-185
IGNITION
SWITCH (ACC) BATTERY
RELAY
BOX
·HEADLAMP
·REAR FOG LAMP
HAZARD WARNING LAMP
·HEADLAMP
·REAR FOG LAMP
HAZARD WARNING LAMP
SPARE CONNECTOR
(FOR AUDIO) SPARE CONNECTOR
(FOR AUDIO)
(LH) (RH)
REAR DOOR SPEAKER
Wire colour code

CIGARETTE LIGHTER
CIGARETTE LIGHTER
CIGARETTE LIGHTER
<LH drive vehicles>
M1901007801075
FRONT-ECU
IGNITION TAIL LAMP
SWITCH (ACC) RELAY
RELAY
BOX

CIGARETTE LICENCE PLATE LAMP
LIGHTER AND LIGHTING MONITOR
BUZZER
ASHTRAY CIGARETTE LIGHTER

ILLUMINATION ILLUMINATION LAMP
LAMP
CIRCUIT DIAGRAMS
CIGARETTE LIGHTER
90-187
CIGARETTE LIGHTER
<RH drive vehicles>
M1901007801086
FRONT-ECU
IGNITION TAIL LAMP
SWITCH (ACC) RELAY
RELAY
BOX

LICENCE PLATE LAMP
BUZZER
CIGARETTE
LIGHTER ·METER AND GAUGE
LICENCE PLATE LAMP
BUZZER
ASHTRAY CIGARETTE LIGHTER

ILLUMINATION ILLUMINATION LAMP
LAMP
CLOCK
CLOCK
CLOCK <LH drive vehicles>
M1901007701056
FRONT-ECU
IGNITION TAIL LAMP
SWITCH (ACC) BATTERY RELAY
RELAY
BOX
·HEADLAMP
·HEADLAMP
LEVELLING SYSTEM
·REAR FOG LAMP
LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
HAZARD WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
·AUDIO SYSTEM SPARE

CONNECTOR
COMPARTMENT LAMP,
DOOR AJAR WARNING TAIL LAMP, POSITION LAMP,
LAMP LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
CLOCK
Wire colour code

CIRCUIT DIAGRAMS
CLOCK
90-189
CLOCK <RH drive vehicles>
M1901007701067
FRONT-ECU
IGNITION TAIL LAMP
SWITCH (ACC) BATTERY RELAY
RELAY
BOX
·HEADLAMP
·HEADLAMP
LEVELLING SYSTEM
·REAR FOG LAMP
·TAIL LAMP, POSITION TAIL LAMP, POSITION LAMP,
LAMP, LICENCE PLATE LICENCE PLATE LAMP
LAMP AND LIGHTING AND LIGHTING
MONITOR BUZZER MONITOR BUZZER
HAZARD WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
·METER AND GAUGE

·HEADLAMP ·TAIL LAMP,
·REAR FOG LAMP POSITION LAMP,
·TAIL LAMP, POSITION LICENCE PLATE LAMP
LAMP, LICENCE PLATE AND LIGHTING
LAMP AND LIGHTING MONITOR BUZZER
MONITOR BUZZER
HAZARD WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
CLOCK
Wire colour code


<LH drive vehicles>
M1901008401304
FUSIBLE IGNITION IGNITION

LINK 3 SWITCH (IG2) SWITCH (IG1)
ACD AND AYC
COMBINATION
METER
ABS-ECU
SOLENOID MOTOR POWER
VALVE POWER SOURCE
POWER SOURCE
SOURCE
CIRCUIT DIAGRAMS
90-191
BATTERY
RELAY
BOX
STOP LAMP
SWITCH
STOP LAMP
HYDRAULIC UNIT
Wire colour code

ANTI-SKID BRAKING SYSTEM (ABS) <LH drive vehicles> (CONTINUED)
IGNITION
SWITCH (IG2)
ABS-ECU
ACD AND AYC
STEERING
WHEEL
SENSOR
CIRCUIT DIAGRAMS
90-193
WHEEL SPEED SENSOR
Wire colour code

IGNITION
SWITCH (IG2)
G-SENSOR G-SENSOR
(LONGITUDINAL) (LATERAL)
ACD AND AYC ACD AND AYC
ABS-ECU
CIRCUIT DIAGRAMS
90-195
4WD-ECU
Wire colour code

G : Green L : Blue
R : Red P : Pink
FUSIBLE
LINK 1
ABS-ECU
ACD AND AYC
DIAGNOSIS
CONNECTOR
PARKING
BRAKE
SWITCH
FRONT SIDE
CIRCUIT DIAGRAMS
90-197
NOTES

<RH drive vehicles>
M1901008401315
FUSIBLE IGNITION IGNITION

LINK 3 SWITCH (IG2) SWITCH (IG1)
·ENGINE CONTROL
SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
·HEADLAMP
·METER AND GAUGE
·REAR FOG LAMP
LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP COMBI-
AND HAZARD NATION
WARNING LAMP METER
·WINDSHIELD WIPER
AND WASHER
ABS-ECU
SOLENOID MOTOR POWER
VALVE POWER POWER SOURCE
SOURCE SOURCE
CIRCUIT DIAGRAMS
90-199
BATTERY
RELAY
BOX
STOP LAMP
SWITCH
STOP LAMP
HYDRAULIC UNIT
Wire colour code

ANTI-SKID BRAKING SYSTEM (ABS) <RH drive vehicles> (CONTINUED)
IGNITION
SWITCH (IG2)
ABS-ECU
ACD AND AYC
·AUTOMATIC AIR
CONDITIONER
STEERING
WHEEL
SENSOR
CIRCUIT DIAGRAMS
90-201
WHEEL SPEED SENSOR
Wire colour code

IGNITION
SWITCH (IG2)
G-SENSOR G-SENSOR
ACD AND AYC ACD AND AYC
ABS-ECU
CIRCUIT DIAGRAMS
90-203
FUSIBLE
LINK 1
ABS-ECU
ACD AND AYC
BRAKE WARNING
LAMP, OIL PRESSURE
WARNING LAMP AND
FUEL WARNING LAMP
DIAGNOSIS
CONNECTOR
PARKING
BRAKE
SWITCH
FRONT SIDE
CIRCUIT DIAGRAMS
90-205
NOTES

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <LH drive vehicles>
M1901009701803
IGNITION
SWITCH (IG1)
COMBINATION
METER
POWER
BACK-UP D.C.-D.C. SOURCE FRONT AIR BAG
CAPACITOR CONVERTER CIRCUIT ANALOG G-SENSOR
MICROCOMPUTER
FRONT AIR BAG AIR BAG AIR BAG

SAFING G-SENSOR DRIVE CIRCUIT DRIVE CIRCUIT
CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH
CLOCK CONNECTOR
SPRING LOCK SWITCH
CONNECTOR
LOCK SWITCH
AIR BAG CONNECTOR

MODULE LOCK SWITCH
(SQUIB)
(DRIVER'S
SIDE) AIR BAG MODULE (SQUIB)
(PASSENGER'S SIDE)
CIRCUIT DIAGRAMS
90-207
NOTE
COUPLED
LOCK SWITCH : ON
CONNECTOR
UNCOUPLED
: OFF
CONNECTOR LOCK SWITCH
SRS-ECU
WARNING LAMP CONNECTOR LOCK

DRIVE CIRCUIT DETECTION CIRCUIT
AIR BAG AIR BAG

DRIVE CIRCUIT DRIVE CIRCUIT
CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH
CONNECTOR CONNECTOR
LOCK SWITCH LOCK SWITCH
SEAT BELT SEAT BELT

PRE-TENSIONER (LH) PRE-TENSIONER (RH)
Wire colour code

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <LH drive vehicles> (CONTINUED)
FUSIBLE
LINK 1
CENTRAL DOOR
LOCKING SYSTEM
SRS-ECU
CRASH DETECTION DOOR UNLOCK

SIGNAL PROCESS CIRCUIT
MICROCOMPUTER
M.U.T.-II/III
INTERFACE CIRCUIT INTERFACE
CIRCUIT
DIAGNOSIS
CONNECTOR

FRONT SIDE
CIRCUIT DIAGRAMS
90-209
NOTES
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <RH drive vehicles>

M1901009701814
IGNITION
SWITCH (IG1) ·ENGINE OIL LEVEL WARNING
LAMP
·HEADLAMP
·METER AND GAUGE
·REAR FOG LAMP COMBINATION
·TAIL LAMP, POSITION LAMP, METER
LICENCE PLATE LAMP
BUZZER
HAZARD WARNING LAMP
WASHER
BACK-UP D.C.-D.C. POWER FRONT AIR BAG

CAPACITOR CONVERTER SOURCE ANALOG G-SENSOR
CIRCUIT
MICROCOMPUTER
FRONT AIR BAG AIR BAG AIR BAG

SAFING G-SENSOR DRIVE CIRCUIT DRIVE CIRCUIT
CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH
CLOCK CONNECTOR
SPRING LOCK SWITCH
CONNECTOR
LOCK SWITCH
AIR BAG CONNECTOR

MODULE LOCK SWITCH
(SQUIB)
(DRIVER'S
SIDE) AIR BAG MODULE (SQUIB)
(PASSENGER'S SIDE)
CIRCUIT DIAGRAMS
90-211
NOTE
: CONNECTOR
COUPLED
CONNECTOR : ON
LOCK SWITCH CONNECTOR
UNCOUPLED
: OFF
CONNECTOR LOCK SWITCH
SRS-ECU
WARNING LAMP CONNECTOR LOCK

DRIVE CIRCUIT DETECTION CIRCUIT
AIR BAG AIR BAG

DRIVE CIRCUIT DRIVE CIRCUIT
CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH
CONNECTOR CONNECTOR
LOCK SWITCH LOCK SWITCH
SEAT BELT SEAT BELT

PRE-TENSIONER (RH) PRE-TENSIONER (LH)
Wire colour code

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <RH drive vehicles> (CONTINUED)
FUSIBLE
LINK 1
CENTRAL DOOR
LOCKING SYSTEM
SRS-ECU
CRASH DETECTION DOOR UNLOCK

SIGNAL PROCESS CIRCUIT
MICROCOMPUTER
M.U.T.-II/III
INTERFACE CIRCUIT INTERFACE
CIRCUIT
DIAGNOSIS
CONNECTOR

FRONT SIDE
CIRCUIT DIAGRAMS
90-213
NOTES
ACD AND AYC
ACD AND AYC

ACD AND AYC <LH drive vehicles>
M1901023600089
IGNITION
BATTERY SWITCH (IG2) BATTERY
RELAY RELAY
BOX BOX
·HEADLAMP
·HEADLAMP
LEVELLING SYSTEM
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD WARNING
LAMP
·WINDSHIELD WIPER
AND WASHER STOP
LAMP
SWITCH
STOP LAMP
ANTI-SKID BRAKING
SYSTEM (ABS)
4WD-
ECU
BATTERY POWER
BACK-UP SOURCE
CIRCUIT DIAGRAMS
ACD AND AYC
90-215
IGNITION
SWITCH (IG2)
G-SENSOR G-SENSOR
ABS-ECU
ACD AND AYC
ACD AND AYC <LH drive vehicles> (CONTINUED)
FRONT-ECU
TAIL LAMP IGNITION
RELAY SWITCH (IG1)
RELAY
BOX
TAIL LAMP, POSITION

LAMP, LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
ENGINE OIL LEVEL

WARNING LAMP
COMBINA-
TION
DRIVE CIRCUIT METER
ACD MODE
CHANGEOVER
SWITCH
4WD-ECU
CIRCUIT DIAGRAMS
ACD AND AYC
90-217
ENGINE-
ECU
ENGINE CONTROL
SYSTEM
·ENGINE CONTROL
SYSTEM
·TRANSMISSION
OIL TEMPERATURE
WARNING LAMP
Wire colour code

ACD AND AYC
ABS-ECU
PARKING
BRAKE
SWITCH
4WD-ECU
CIRCUIT DIAGRAMS
ACD AND AYC
90-219
(FRONT : LH) (FRONT : RH) (REAR : LH) (REAR : RH)
WHEEL SPEED SENSOR
Wire colour code

ACD AND AYC
FUSIBLE
LINK 27
ELECTRIC
PUMP
RELAY
ELECTRIC
PUMP
PRESSURE
SENSOR
PRESSURE
UNIT
ASSEMBLY
PRESSURE UNIT ASSEMBLY

CIRCUIT DIAGRAMS
ACD AND AYC
90-221
4WD-ECU
PRESSURE
UNIT
PROPOR- PROPOR- DIRECTION DIRECTION ASSEMBLY
TIONING TIONING VALVE (LH) VALVE (RH)
VALVE VALVE
FOR ACD FOR AYC
CONTROL CONTROL
Wire colour code

ACD AND AYC
IGNITION
SWITCH (IG2)
4WD-ECU
ANTI-SKID BRAKING
SYSTEM (ABS)
STEERING
WHEEL
SENSOR
FRONT SIDE
CIRCUIT DIAGRAMS
ACD AND AYC
90-223
FUSIBLE
LINK 1
DIAGNOSIS
CONNECTOR
Wire colour code

ACD AND AYC
ACD AND AYC <RH drive vehicles>

M1901023600090
IGNITION
BATTERY SWITCH (IG2) BATTERY
RELAY RELAY
BOX BOX
·HEADLAMP
·HEADLAMP
LEVELLING SYSTEM
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
HAZARD WARNING LAMP
·WINDSHIELD WIPER STOP
AND WASHER LAMP
SWITCH
·HEADLAMP
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
HAZARD WARNING LAMP STOP LAMP
·WINDSHIELD WIPER
AND WASHER
4WD-ECU
BATTERY POWER
BACK-UP SOURCE
CIRCUIT DIAGRAMS
ACD AND AYC
90-225
IGNITION
SWITCH (IG2)
G-SENSOR G-SENSOR
ABS-ECU
ACD AND AYC
ACD AND AYC <RH drive vehicles> (CONTINUED)
FRONT-ECU
TAIL LAMP IGNITION
RELAY SWITCH (IG1)
RELAY
BOX
·ENGINE CONTROL
SYSTEM
·ENGINE OIL LEVEL
WARNING LAMP
·HEADLAMP
TAIL LAMP, ·METER AND GAUGE
POSITION LAMP, ·REAR FOG LAMP
LICENCE PLATE ·TAIL LAMP,
LAMP AND POSITION LAMP,
LIGHTING LICENCE PLATE LAMP
MONITOR BUZZER AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD
·METER AND GAUGE WIPER AND WASHER
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND
LIGHTING
MONITOR BUZZER
COMBINA-
TION
DRIVE CIRCUIT METER
ACD MODE
CHANGEOVER
SWITCH
4WD-ECU
CIRCUIT DIAGRAMS
ACD AND AYC
90-227
ENGINE-
ECU
ENGINE
CONTROL
SYSTEM
Wire colour code

ACD AND AYC
ABS-ECU
BRAKE
WARNING LAMP,
OIL PRESSURE
WARNING LAMP
AND FUEL
WARNING LAMP
PARKING
BRAKE
SWITCH
4WD-ECU
CIRCUIT DIAGRAMS
ACD AND AYC
90-229
(FRONT : LH) (FRONT : RH) (REAR : LH) (REAR : RH)
WHEEL SPEED SENSOR
Wire colour code

ACD AND AYC

CIRCUIT DIAGRAMS
ACD AND AYC
90-231
ACD AND AYC
IGNITION
SWITCH (IG2)
4WD-ECU
ANTI-SKID BRAKING
SYSTEM (ABS)
·AUTOMATIC AIR
CONDITIONER
STEERING
WHEEL
SENSOR
FRONT SIDE
CIRCUIT DIAGRAMS
ACD AND AYC
90-233
FUSIBLE
LINK 1
DIAGNOSIS
CONNECTOR
Wire colour code

IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM
<LH drive vehicles>
M1901013601995
BATTERY
RELAY
BOX
ENGINE CONTROL
SYSTEM
ENGINE CONTROL
RELAY
ENGINE
CONTROL
SYSTEM
POWER
SOURCE
ENGINE-
ECU
FRONT
SIDE
CIRCUIT DIAGRAMS
IMMOBILIZER SYSTEM
90-235
FUSIBLE
LINK 1
ENGINE-
ECU
DIAGNOSIS
IMMOBILIZER- CONNECTOR
ECU
HIGH-FREQUENCY
CIRCUIT
IGNITION KEY
TRANSPONDER
ID
CODE
IGNITION KEY
RING ANTENNA
Wire colour code

IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM
<RH drive vehicles>
M1901013602006
BATTERY
RELAY
BOX
·ENGINE CONTROL
SYSTEM
·IGNITION SYSTEM
ENGINE CONTROL
RELAY
ENGINE
CONTROL
SYSTEM
POWER
SOURCE
ENGINE-
ECU
FRONT SIDE
CIRCUIT DIAGRAMS
IMMOBILIZER SYSTEM
90-237
FUSIBLE
LINK 1
ENGINE-
ECU
DIAGNOSIS
IMMOBILIZER- CONNECTOR
ECU
HIGH-FREQUENCY
CIRCUIT
IGNITION KEY
TRANSPONDER
ID
CODE
IGNITION KEY
RING ANTENNA
Wire colour code

NOTES
80-1
GROUP 80
CONFIGURATION
DIAGRAMS
CONTENTS
OVERALL CONFIGURATION DASH PANEL . . . . . . . . . . . . . . . . . . . 80-16

DIAGRAM. . . . . . . . . . . . . . . . . . . . . . 80-2 DASH PANEL <LH drive vehicles> . . . . . . . 80-16
OVERALL WIRING DIAGRAM DASH PANEL <RH drive vehicles>. . . . . . . 80-22
OVERALL WIRING DIAGRAM FLOOR AND ROOF . . . . . . . . . . . . . . 80-28
FLOOR AND ROOF <LH drive vehicles> . . 80-28
FLOOR AND ROOF <RH drive vehicles> . . 80-30
ENGINE COMPARTMENT. . . . . . . . . 80-4
ENGINE COMPARTMENT
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 80-32
DOOR <LH drive vehicles> . . . . . . . . . . . . . 80-32
ENGINE COMPARTMENT
<RH drive vehicles> . . . . . . . . . . . . . . . . . . 80-6 DOOR <RH drive vehicles>. . . . . . . . . . . . . 80-34
ENGINE AND TRANSMISSION. . . . . 80-8 TRUNK (LUGGAGE COMPARTMENT) 80-36

ENGINE AND TRANSMISSION TRUNK <LH drive vehicles> . . . . . . . . . . . . 80-36
<LH drive vehicles>. . . . . . . . . . . . . . . . . . . 80-8 TRUNK <RH drive vehicles> . . . . . . . . . . . . 80-37
ENGINE AND TRANSMISSION
80-2 CONFIGURATION DIAGRAMS
OVERALL CONFIGURATION DIAGRAM

OVERALL WIRING DIAGRAM <LH drive vehicles>
M1801000101175
Control wiring Instrument panel Roof wiring Floor wiring

harness wiring harness harness harness (RH)
Front wiring
harness (RH)
Rear door
wiring harness*
Battery wiring Front wiring Front door Floor wiring Fuel wiring
harness harness (LH) wiring harness* harness (LH) harness
AC208864 AE
NOTE: .
1. This illustration shows only major wiring harnesses.
2. *: also equipped at the right side.
CONFIGURATION DIAGRAMS
80-3
OVERALL WIRING DIAGRAM <RH drive vehicles>
M1801000101186
AC212063
Control wiring Instrument panel Roof wiring Floor wiring
harness wiring harness harness harness (RH)
Front wiring
harness (RH)
Rear door
wiring harness*
Battery wiring Front wiring Front door Floor wiring Fuel wiring
harness harness (LH) wiring harness* harness (LH) harness
AC310155AB
NOTE: .
1. This illustration shows only major wiring harnesses.
2. *: also equipped at the right side.
ENGINE COMPARTMENT
ENGINE COMPARTMENT
ENGINE COMPARTMENT <LH drive vehicles>
M1801000302213
Connector
symbol
A-01
A
A-27
A-25
Front wiring
harness (RH)
A-40
A-21
A-39
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue
None : Milk white
O : Orange
R : Red
A-37 A-36 A-35 A-34
V : Violet
Y : Yellow
AC500087AB
A-01 (2-GR) Side turn signal lamp (RH) A-12 (2-B) Front wiring harness (LH) and control
A-02 (2-GR) Side turn signal lamp (LH) wiring harness combination
A-03 (2-B) Wheel speed sensor (Front: LH) A-13 (8-B) Front wiring harness (LH) and control
A-05X (4) Horn relay wiring harness combination
A-06X (4) Condenser fan relay (LO) A-15 (2-B) Headlamp (HI: LH)
A-07X (4) Condenser fan relay (HI) A-17 (3-GR) Fan controller
A-09X (4) Fan control relay A-18 (1-B) Horn (HI)
A-10X (11) Front-ECU A-19 (1-B) Horn (LO)
A-11X (11) Front-ECU
ENGINE COMPARTMENT
80-5
A-02
A-03
A-05X
A-06X
A-07X
A-09X
A-10X
A-11X
Front wiring
harness (LH)
A-12
12
A-13
A-29
A-15
A-31
A-19 A-44 A-17 A-33 A-18
AC500088AB
A-21 (2-B) Headlamp (HI: RH) A-34 (2-B) Condenser fan motor
A-25 (2-BR) Dual pressure switch A-35 (2-GR) Condenser fan motor
A-27 (2-B) Wheel speed sensor (Front: RH) A-36 (1-B) A/C compressor
A-29 (8-B) Front wiring harness (LH) and control A-37 (2-Y) Front impact sensor (RH)
wiring harness combination A-39 (8-B) Headlamp assembly (RH)
A-31 (8-B) Headlamp assembly (LH) A-40 (1-B) Power steering fluid pressure switch
A-33 (2-Y) Front impact sensor (LH) A-44 (2-BR) Outside thermo sensor
ENGINE COMPARTMENT
ENGINE COMPARTMENT <RH drive vehicles>

M1801000302224
Connector
symbol
A-01 A-43
A A-27
A-25
A-42
Front wiring
harness (RH)
Connector colour
code A-39
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue A-21
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow A-36 A-40 A-37 A-35 A-34
AC500090AB
A-01 (2-GR) Side turn signal lamp (RH) A-11X (11) Front-ECU
A-02 (2-GR) Side turn signal lamp (LH) A-12 (2-B) Front wiring harness (LH) and control
A-03 (2-B) Wheel speed sensor (Front: LH) wiring harness combination
A-05X (4) Horn relay A-15 (2-B) Headlamp (HI: LH)
A-06X (4) Condenser fan relay (LO) A-17 (3-GR) Fan controller
A-07X (4) Condenser fan relay (HI) A-18 (1-B) Horn (HI)
A-09X (4) Fan control relay A-19 (1-B) Horn (LO)
A-10X (11) Front-ECU
ENGINE COMPARTMENT
80-7
A-02
Front wiring
harness (LH)
A-03
A-05X
A-06X
A-07X
A-09X
A-10X
A-11X
A-12
12
A-31
A-15
A-19 A-44 A-17 A-33 A-18

AC500091AB
A-21 (2-B) Headlamp (HI: RH) A-36 (1-B) A/C compressor

A-25 (2-BR) Dual pressure switch A-37 (2-Y) Front impact sensor (RH)
A-27 (2-B) Wheel speed sensor (Front: RH) A-39 (8-B) Headlamp assembly (RH)
A-31 (8-B) Headlamp assembly (LH) A-40 (1-B) Power steering fluid pressure switch
A-33 (2-Y) Front impact sensor (LH) A-42 (2) No connection
A-34 (2-B) Condenser fan motor A-43 (2-GR) Brake fluid level switch
A-35 (2-GR) Condenser fan motor A-44 (2-BR) Outside thermo sensor

ENGINE AND TRANSMISSION <LH drive vehicles>
M1801000401693
Connector
symbol
B -01
thru
-30
B-01 B-02
B-28
B-24
Connector colour
code
B : Black B-29
BR : Brown
G : Green
GR : Grey B-23 B-25 B-22 B-20
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
AC500093AB
B-01 (5-GR) Windshield wiper motor B-12X (4) Engine control relay
B-02 (2-B) Purge control solenoid valve B-13X (4) A/C compressor relay
B-03 (4-B) Throttle position sensor B-14 (10-B) Control wiring harness and battery
B-04 (3-B) Vehicle speed sensor wiring harness combination
B-05 (2-GR) Brake fluid level switch B-17 (2-B) Injector (4)
B-06X (1) Engine speed detection connector
80-9
AC208204
Earth cable
B-18 B-17 B-03 B-05
Control wiring
harness
B-04
4 B-06X
B-12X
B-13X
B-14
11
Transmission
wiring harness
10
B-26
B-19 B-21 B-30 B-27
Battery wiring
harness
AC500094AB
B-18 (2-B) Injector (3) B-26 (2-GR) Wastegate solenoid valve

B-19 (1) Starter B-27 (8-B) Control wiring harness and
B-20 (2-B) Injector (2) transmission wiring harness
B-21 (1-B) Starter combination
B-22 (2-B) Injector (1) B-28 (2-B) Fuel pressure control solenoid valve
B-23 (1-B) Oil pressure switch B-29 (2-B) Engine oil level sensor
B-24 (1) Alternator B-30 (2-B) Transmission oil temperature sensor
B-25 (4-GR) Alternator
ENGINE AND TRANSMISSION <LH drive vehicles> (CONTINUED)
Connector
symbol
B -101
thru
-124
B-118 B-119 B-122 B-120 B-121
B-117
B-123
B-114
B-113
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Grey B-108 B-101
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
AC500093AC
B-101 (2-BR) EGR control solenoid valve B-106 (3-B) Exhaust camshaft position sensor
B-103 (3-GR) Ignition coil (1) B-107 (2-B) Engine coolant temperature sensor
B-104 (6-B) Idle speed control servo B-108 (2-GR) Detonation sensor
B-105 (7-B) Air flow sensor
80-11
AC208204
B-103 B-104 B-124

Control wiring
Earth cable harness
B-107
Transmission
11 wiring harness
B-111
10
B-106 B-112 B-105
Battery wiring
harness
AC500094AC
B-111 (2-B) Back-up lamp switch B-119 (6-B) Injector resistor

B-112 (1-B) Engine coolant temperature gauge B-120 (4) Fuel pump relay (3)
unit B-121 (2-B) Fuel pump resistor
B-113 (4-B) Oxygen sensor (Front) B-122 (4) Electric pump relay
B-114 (3-GR) Ignition coil (2) B-123 (2-B) Oil feeder control valve
B-117 (3-B) Crank angle sensor B-124 (3-B) Intake camshaft position sensor
B-118 (34-B) ABS-ECU
ENGINE AND TRANSMISSION <RH drive vehicles>

M1801000401701
Connector
symbol
B -01
thru
-29
B-28 B-22 B-20
Control wiring
harness
B-02
B-24
Connector colour
code
B : Black
Battery wiring
BR : Brown harness
B-29
G : Green
GR : Grey
L : Blue B-23 B-25
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
AC500096AB
B-01 (5-GR) Windshield wiper motor B-12X (4) Engine control relay
B-02 (2-B) Purge control solenoid valve B-13X (4) A/C compressor relay
B-03 (4-B) Throttle position sensor B-14 (10-B) Control wiring harness and battery
B-04 (3-B) Vehicle speed sensor wiring harness combination
B-06X (1) Engine speed detection connector B-17 (2-B) Injector (4)
B-10X (4) Ignition coil relay
80-13
B-18 B-17 B-03 B-01
Earth cable
B-04
B-06X
4 B-10X
B-12X
B-13X
11
B-14
Transmission
wiring harness
10 B-26
B-19 B-21 B-30 B-27
AC500097AB
B-18 (2-B) Injector (3) B-26 (2-GR) Wastegate solenoid valve

B-19 (1) Starter B-27 (8-B) Control wiring harness and
B-20 (2-B) Injector (2) transmission wiring harness
B-21 (1-B) Starter combination
B-22 (2-B) Injector (1) B-28 (2-B) Fuel pressure control solenoid valve
B-23 (1-B) Oil pressure switch B-29 (2-B) Engine oil level sensor
B-24 (1) Alternator B-30 (2-B) Transmission oil temperature sensor
B-25 (4-GR) Alternator
ENGINE AND TRANSMISSION <RH drive vehicles> (CONTINUED)
Connector
symbol
B -101
thru
-124
B-123 B-117
Earth cable
Control wiring
harness
B-114
B-113
Connector colour
code
B : Black
BR : Brown Battery wiring
G : Green harness
GR : Grey
L : Blue B-108 B-101
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
AC500096AC
B-101 (2-BR) EGR control solenoid valve B-106 (3-B) Exhaust camshaft position sensor
B-103 (3-GR) Ignition coil (1) B-107 (2-B) Engine coolant temperature sensor
B-104 (6-B) Idle speed control servo B-108 (2-GR) Detonation sensor
B-105 (7-B) Air flow sensor
80-15
B-103 B-124 B-104 B-122 B-120 B-119 B-121
B-118
Transmission
wiring harness
11
B-111
10
B-106 B-112 B-105 B-107
AC500097AC
B-111 (2-B) Back-up lamp switch B-119 (6-B) Injector resistor

B-112 (1-B) Engine coolant temperature gauge B-120 (4) Fuel pump relay (3)
unit B-121 (2-B) Fuel pump resistor
B-113 (4-B) Oxygen sensor (Front) B-122 (4) Electric pump relay
B-114 (3-GR) Ignition coil (2) B-123 (2-B) Oil feeder control valve
B-117 (3-B) Crank angle sensor B-124 (3-B) Intake camshaft position sensor
B-118 (34-B) ABS-ECU
DASH PANEL
DASH PANEL
DASH PANEL <LH drive vehicles>
M1801000601545
Connector
Instrument
symbol panel wiring
C-01 C-02 harness C-03 C-04 C-05 C-29
C -01
thru
-37
C-21
C-24
C-20
7
15 6
C-23 J/B 5
C-18 Y
C-17
Connector colour
code
B : Black C-28
14
BR : Brown
G : Green
GR : Grey C-37
L : Blue
None : Milk white
O : Orange
R : Red C-36 C-27 C-15 C-14 C-13 C-12
V : Violet
Y : Yellow
AC500099AB
C-01 (21) Combination meter C-07 (7) Outside/inside air selection damper
C-02 (21-L) Combination meter control motor
C-03 (4) Hazard warning switch C-10 (13) Instrument panel wiring harness and
C-04 (4) Clock A/C wiring harness combination
C-05 (22-GR) J/C (1) C-12 (20-Y) SRS-ECU
C-06 (22-GR) J/C (3) C-13 (22-Y) SRS-ECU
DASH PANEL
80-17
C-32 C-06 C-07 C-34
3
C-33
13
Control
wiring
harness
C-26 C-25 C-10 C-35
AC500100AB
C-14 (16-B) Diagnosis connector C-26 (22-Y) 4WD-ECU

C-15 (12) Diagnosis connector C-27 (6) Engine oil level relay
C-17 (20) Instrument panel wiring harness and C-28 (1) Instrument panel wiring harness and
front door wiring harness (LH) floor wiring harness (LH) combination
combination C-29 (1-B) Spare connector (for audio)
C-18 (6) Instrument panel wiring harness and C-32 (2) Heater water temperature sensor
roof wiring harness combination C-33 (2) No connection
C-20 (6) Fog lamp switch C-34 (6) Blower linear controller
C-21 (13) J/C (5) C-35 (2) Air thermo sensor
C-23 (22-B) J/C (4) C-36 (20-B) A/C-ECU
C-24 (6-GR) Headlamp levelling switch C-37 (16-B) A/C-ECU
C-25 (26-Y) 4WD-ECU
DASH PANEL
DASH PANEL <LH drive vehicles> (CONTINUED)
Connector
symbol
C-101 C-102 C-141 C-142 C-103 C-104 C-105
C -101
thru
-145 C-132
C-135
C-130
15
C-145 7
J/B 6
C-129
5
C-134 Instrument
panel wiring
harness
Y
Connector colour
code
B : Black 14
C-127
BR : Brown
G : Green
GR : Grey
L : Blue
None : Milk white C-126
O : Orange
R : Red
V : Violet C-124 C-123 C-122 C-138 C-137
Y : Yellow
AC500099AC
C-101 (22-L) J/C (2) C-111 (13) Front wiring harness (RH) and
C-102 (4) Stop lamp switch instrument panel wiring harness
C-103 (14) Spare connector (for audio) combination
C-104 (1) Roof antenna C-112 (9-GR) Instrument panel wiring harness and
C-105 (33) J/C (6) floor wiring harness (RH) combination
C-106 (2-R) Air bag module (squib) <Passenger’s C-113 (25) Instrument panel wiring harness and
side> floor wiring harness (RH) combination
C-109 (2) Instrument panel wiring harness and C-117 (30-GR) Engine-ECU
tweeter wiring harness combination C-119 (28-GR) Engine-ECU
front door wiring harness (RH) C-122 (22-L) Instrument panel wiring harness and
combination control wiring harness combination
DASH PANEL
80-19
C-143 C-144 C-106
C-136
C-109
C-110
13
C-113
Control
wiring
harness C-112
C-117 C-119 C-121 C-111
AC500100AC
C-123 (10-GR) Instrument panel wiring harness and C-135 (6) ACD mode changeover switch
control wiring harness combination C-136 (11-L) Instrument panel wiring harness and
C-124 (25) Instrument panel wiring harness and control wiring harness combination
control wiring harness combination C-137 (4) Oxygen sensor (Rear)
C-126 (3) Front wiring harness (LH) and C-138 (1) Instrument panel wiring harness and
instrument panel wiring harness control wiring harness combination
combination C-141 (5) Photo sensor
C-127 (13) Instrument panel wiring harness and C-142 (2-B) Interior temperature sensor
floor wiring harness (LH) combination C-143 (6) Mode selection damper control motor
C-129 (25) Front wiring harness (LH) and and potentiometer
instrument panel wiring harness C-144 (6) Air mixing damper control motor and
combination potentiometer
C-130 (2) Clutch switch C-145 (2) Instrument panel wiring harness and
C-132 (11-B) Remote controlled mirror switch front wiring harness (LH) combination
C-134 (11-B) Floor wiring harness (LH) and
instrument panel wiring harness
combination
DASH PANEL
DASH PANEL <LH drive vehicles> (CONTINUED)
Connector
symbol
C -201
thru
-230
Steering column
Instrument panel
wiring harness
Clock spring
C-201
C-203
C-205 C-204 C-230 C-206 C-207 C-208
AC208208AC
C-201 (2) Air bag module (squib) <Driver’s side> C-210 (14) Instrument panel wiring harness and
C-203 (1) Horn switch J/B combination
C-204 (6) Clock spring C-211 (6) Instrument panel wiring harness and
C-205 (4-Y) Clock spring J/B combination
C-206 (10) Column switch C-212 (1-B) Instrument panel wiring harness and
C-207 (7) Key reminder switch J/B combination
C-208 (6) Ignition switch C-214 (28) Instrument panel wiring harness and
C-209 (13) Instrument panel wiring harness and J/B combination
J/B combination
DASH PANEL
80-21
J/B
(Front view) (Rear view)
C-209 C-211 C-226
C-225
C-212
C-224
C-210
C-223
C-222 C-214
C-215
C-221
C-216
C-220 C-219 C-218 C-217 C-228 C-227
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
AC500713AB
C-215 (5) Defogger relay C-222 (4) No connection

C-216 (5) Blower relay C-223 (4) Fuel pump relay (1)
C-217 (15) Floor wiring harness (LH) and J/B C-224 (5) Power window relay
combination C-225 (2) Instrument panel wiring harness and
C-218 (3) Roof wiring harness and J/B J/B combination
combination C-226 (20) ETACS-ECU
C-219 (4) Rear fog lamp relay C-227 (24) ETACS-ECU
C-220 (4) No connection C-228 (24-GR) ETACS-ECU
C-221 (4) Fuel pump relay (2) C-230 (5) Steering wheel sensor
DASH PANEL
DASH PANEL <RH drive vehicles>

M1801000601556
Connector
symbol
C-07 C-10 C-21 C-32 C-05 C-27 C-03 C-04 C-37 C-29 C-36
C -01
thru
-37
Instrument panel
wiring harness
6
C-33
Y
13
15
Connector colour Control 5 Y

code C-31 wiring
B : Black harness
BR : Brown
G : Green C-30
GR : Grey 14
L : Blue
None : Milk white C-17
O : Orange
R : Red
C-34 C-35 C-25 C-26 C-12 C-13
V : Violet
Y : Yellow
AC500103AB
C-01 (21) Combination meter C-07 (7) Outside/inside air selection damper
C-02 (21-L) Combination meter control motor
C-03 (4) Hazard warning switch C-10 (13) Instrument panel wiring harness and
C-04 (4) Clock A/C wiring harness combination
C-05 (22-GR) J/C (1) C-12 (20-Y) SRS-ECU
C-06 (22-GR) J/C (3) C-13 (22-Y) SRS-ECU
DASH PANEL
80-23
C-01 C-06 C-02 C-23
7
C-20
2 C-24
J/B
C-18
C-14 C-15
AC500104AB
C-14 (16-B) Diagnosis connector C-27 (6) Engine oil level relay
C-15 (12) Diagnosis connector C-29 (1-B) Spare connector (for audio)
C-17 (16) Instrument panel wiring harness and C-30 (1-GR) Control wiring harness and floor wiring
front door wiring harness (LH) harness (LH) combination
combination C-31 (16) Control wiring harness and front wiring
C-18 (6) Instrument panel wiring harness and harness (LH) combination
roof wiring harness combination C-32 (2) Heater water temperature sensor
C-20 (6) Fog lamp switch C-33 (2) No connection
C-21 (13) J/C (5) C-34 (6) Blower linear controller
C-23 (22-B) J/C (4) C-35 (2) Air thermo sensor
C-24 (6-GR) Headlamp levelling switch C-36 (20-B) A/C-ECU
C-25 (26-Y) 4WD-ECU C-37 (16-B) A/C-ECU
C-26 (22-Y) 4WD-ECU
DASH PANEL
DASH PANEL <RH drive vehicles> (CONTINUED)
Connector
symbol
C-106 C-144 C-143 C-104 C-103
C -101
thru
-144 Instrument panel
wiring harness
C-121
C-119
C-117
Y
3
13
15
Connector colour Control Y

code C-109 wiring 5
B : Black harness
BR : Brown
G : Green C-129
GR : Grey 14
L : Blue
C-134
None : Milk white
O : Orange
R : Red C-127 C-126 C-105 C-137 C-124 C-123 C-122 C-138
V : Violet
Y : Yellow
AC500103AC
C-101 (22-L) J/C (2) C-111 (25) Front wiring harness (RH) and
C-102 (4) Stop lamp switch instrument panel wiring harness
C-103 (14) Spare connector (for audio) combination
C-104 (1) Roof antenna C-112 (9-GR) Instrument panel wiring harness and
C-105 (33) J/C (6) floor wiring harness (RH) combination
C-106 (2-R) Air bag module (squib) <Passenger’s C-113 (13) Instrument panel wiring harness and
side> floor wiring harness (RH) combination
tweeter wiring harness combination C-119 (28-GR) Engine-ECU
front door wiring harness (RH) C-122 (22-L) Instrument panel wiring harness and
DASH PANEL
80-25
C-141 C-101 C-102
C-132
7 C-135
J/B
C-110
C-111
C-112
C-113
C-142 C-130 C-140
AC500104 AC
C-123 (10-GR) Instrument panel wiring harness and C-134 (11-B) Floor wiring harness (LH) and
control wiring harness combination instrument panel wiring harness
C-124 (25) Instrument panel wiring harness and combination
control wiring harness combination C-135 (6) ACD mode changeover switch
C-126 (3) Front wiring harness (LH) and C-137 (4) Oxygen sensor (Rear)
instrument panel wiring harness C-138 (11) Instrument panel wiring harness and
C-127 (13) Instrument panel wiring harness and C-140 (2) No connection
floor wiring harness (LH) combination C-141 (5) Photo sensor
C-129 (25) Front wiring harness (LH) and C-142 (2-B) Interior temperature sensor
instrument panel wiring harness C-143 (6) Mode selection damper control motor
combination and potentiometer
C-130 (2) Clutch switch C-144 (6) Air mixing damper control motor and
C-132 (11-B) Remote controlled mirror switch potentiometer
DASH PANEL
DASH PANEL <RH drive vehicles> (CONTINUED)
Connector
symbol
C -201
thru
-230
Steering column
Clock spring
Instrument panel C-201
wiring harness
Y C-203
C-205
C-208 C-207 C-206 C-230 C-204

AC212076AC
C-201 (2) Air bag module (squib) <Driver’s side> C-210 (14) Instrument panel wiring harness and
C-203 (1) Horn switch J/B combination
C-204 (6) Clock spring C-211 (6) Instrument panel wiring harness and
C-205 (4-Y) Clock spring J/B combination
C-206 (10) Column switch C-212 (1-B) Instrument panel wiring harness and
C-207 (7) Key reminder switch J/B combination
C-208 (6) Ignition switch C-214 (28) Instrument panel wiring harness and
C-209 (13) Instrument panel wiring harness and J/B combination
J/B combination
DASH PANEL
80-27
J/B
(Front view) (Rear view)
C-209 C-210 C-211 C-226
C-225 C-212
C-224
C-223 C-214
C-222 C-215
C-216
C-221
C-220
C-219 C-218 C-217

C-227 C-228
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
AC500714AB
C-215 (5) Defogger relay C-222 (4) No connection

C-216 (5) Blower relay C-223 (4) Fuel pump relay (1)
C-217 (15) Floor wiring harness (RH) and J/B C-224 (5) Power window relay
combination C-225 (2) Instrument panel wiring harness and
C-218 (3) Roof wiring harness and J/B J/B combination
combination C-226 (20) ETACS-ECU
C-219 (4) Rear fog lamp relay C-227 (24) ETACS-ECU
C-220 (4) No connection C-228 (24-GR) ETACS-ECU
C-221 (4) Fuel pump relay (2) C-230 (5) Steering wheel sensor
FLOOR AND ROOF
FLOOR AND ROOF

FLOOR AND ROOF <LH drive vehicles>
M1801000901386
AC208213
Connector
symbol Roof wiring
harness
D D-03 D-01 D-04 D-34 D-05 D-06 D-07 D-08
D-30
D-29
D-28
Floor wiring Y
harness (RH)
Instrument panel
wiring harness
D-26
D-25
Console wiring
harness
D-24 D-23 D-21 D-39 D-21 D-38 D-37 D-33
AC310169AB
D-01 (3) Front door switch (RH) D-11 (3) Rear door switch (LH)
D-03 (2-B) Seat belt pre-tensioner (RH) D-12 (5-GR) Fuel pump and gauge unit (main)
D-04 (8) Floor wiring harness (RH) and rear D-13 (2-B) Wheel speed sensor (Rear: LH)
door wiring harness (RH) combination D-15 (8) Floor wiring harness (LH) and rear
D-05 (2) Front room lamp door wiring harness (LH) combination
D-06 (2-B) Wheel speed sensor (Rear: RH) D-16 (2-B) Seat belt pre-tensioner (LH)
D-07 (2-GR) Rear room lamp D-18 (3) Front door switch (LH)
D-08 (3) Rear door switch (RH) D-21 (4) Instrument panel wiring harness and
D-10 (2) Fuel gauge unit (sub) console wiring harness combination
FLOOR AND ROOF
80-29
AC208216
D-10
D-11
D-12
Y
D-13
Floor wiring
harness (LH)
Connector colour
code
B : Black
Fuel wiring BR : Brown
harness G : Green
GR : Grey
L : Blue
None : Milk white
D-16 D-18 D-15 O : Orange
R : Red
V : Violet
Y : Yellow AC310170AE
D-23 (1) Cigarette lighter D-33 (1) Floor wiring harness (RH) and fuel
D-24 (1-B) Cigarette lighter wiring harness combination
D-25 (2-B) Ashtray illumination lamp D-34 (8) Floor wiring harness (RH) and fuel
D-26 (2-B) Cigarette lighter illumination lamp wiring harness combination
D-28 (1-B) Parking brake switch D-37 (3-B) G-sensor (lateral)
D-29 (2) Tweeter (LH) D-38 (3-B) G-sensor (longitudinal)
D-30 (2) Tweeter (RH) D-39 (6) No connection
FLOOR AND ROOF
FLOOR AND ROOF <RH drive vehicles>

M1801000901397
AC211087
Connector
symbol
D-01 D-03 D-04 D-34 D-05 D-33 D-07
D
D-30
D-29
Y
Roof wiring Floor wiring
harness harness (RH)
D-28
Instrument panel
wiring harness
D-26
D-25
D-24
Console wiring
harness
D-23
D-39 D-21 D-38 D-37

AC310176AC
D-01 (3) Front door switch (RH) D-11 (3) Rear door switch (LH)
D-03 (2-B) Seat belt pre-tensioner (RH) D-12 (5-GR) Fuel pump and gauge unit (main)
D-04 (8) Floor wiring harness (RH) and rear D-13 (2-B) Wheel speed sensor (Rear: LH)
door wiring harness (RH) combination D-15 (8) Floor wiring harness (LH) and rear
D-05 (2) Front room lamp door wiring harness (LH) combination
D-06 (2-B) Wheel speed sensor (Rear: RH) D-16 (2-B) Seat belt pre-tensioner (LH)
D-07 (2-GR) Rear room lamp D-18 (3) Front door switch (LH)
D-08 (3) Rear door switch (RH) D-21 (4) Instrument panel wiring harness and
D-10 (2) Fuel gauge unit (sub) console wiring harness combination
FLOOR AND ROOF
80-31
AC211088
D-08 D-06 D-10
D-11
D-12
Y
D-13
Connector colour
Floor wiring code
harness (LH) B : Black
BR : Brown
G : Green
Fuel wiring GR : Grey
harness L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
D-16 D-18 D-15 Y : Yellow
AC310177AD
D-23 (1) Cigarette lighter D-33 (1) Floor wiring harness (RH) and fuel
D-24 (1-B) Cigarette lighter wiring harness combination
D-25 (2-B) Ashtray illumination lamp D-34 (8) Floor wiring harness (RH) and fuel
D-26 (2-B) Cigarette lighter illumination lamp wiring harness combination
D-28 (1-B) Parking brake switch D-37 (3-B) G-sensor (lateral)
D-29 (2) Tweeter (LH) D-38 (3-B) G-sensor (longitudinal)
D-30 (2) Tweeter (RH) D-39 (6) No connection
DOOR
DOOR
DOOR <LH drive vehicles>
M1801001401276
Connector Driver's side

symbol
E-02 E-03
Front
E-04 E-05 E-06

Front door
wiring harness (LH)
Rear
Rear door
wiring harness (LH)
E-07 E-08 E-09

AC310171AB
E-02 (6-GR) Power window motor (Front: LH) E-07 (6-B) Door lock actuator (Rear: LH)
E-03 (7) Remote controlled mirror (LH) E-08 (8) Power window sub switch (Rear: LH)
E-04 (6-B) Door lock actuator (Front: LH) E-09 (6-GR) Power window motor (Rear: LH)
E-05 (14) Power window main switch E-10 (7) Remote controlled mirror (RH)
E-06 (2) Door speaker (LH)
DOOR
80-33
Passenger's side
E-10 E-11 E-12
Front
E-13 E-14 E-15

Front door
wiring harness (RH)
Connector colour
Rear code
B : Black
BR : Brown
G : Green
GR : Grey
Rear door L : Blue
wiring harness (RH) None : Milk white
O : Orange
R : Red
V : Violet
E-16 E-17 E-18 Y : Yellow
AC208224AC
E-11 (6-GR) Power window motor (Front: RH) E-15 (6-B) Door lock actuator (Front: RH)
E-12 (3-B) Door lock key cylinder switch E-16 (6-GR) Power window motor (Rear: RH)
E-13 (2) Door speaker (RH) E-17 (8) Power window sub switch (Rear: RH)
E-14 (8) Power window sub switch (Front) E-18 (6-B) Door lock actuator (Rear: RH)
DOOR
DOOR <RH drive vehicles>

M1801001401287
Connector Driver's side

symbol
E-10 E-11
Front
E-13 E-05 E-15

Front door
wiring harness (RH)
Rear
Rear door
wiring harness (RH)
E-16 E-17 E-18

AC310172AB
E-02 (6-GR) Power window motor (Front: LH) E-07 (6-B) Door lock actuator (Rear: LH)
E-03 (7) Remote controlled mirror (LH) E-08 (8) Power window sub switch (Rear: LH)
E-04 (6-B) Door lock actuator (Front: LH) E-09 (6-GR) Power window motor (Rear: LH)
E-05 (14) Power window main switch E-10 (7) Remote controlled mirror (RH)
E-06 (2) Door speaker (LH)
DOOR
80-35
Passenger's side
E-12 E-02 E-03
Front
E-04 E-14 E-06

Front door
wiring harness (LH)
Connector colour
Rear code
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue
Rear door None : Milk white
wiring harness (LH) O : Orange
R : Red
V : Violet
E-07 E-08 E-09 Y : Yellow
AC310173 AD
E-11 (6-GR) Power window motor (Front: RH) E-15 (6-B) Door lock actuator (Front: RH)
E-12 (3-B) Door lock key cylinder switch E-16 (6-GR) Power window motor (Rear: RH)
E-13 (2) Door speaker (RH) E-17 (8) Power window sub switch (Rear: RH)
E-14 (8) Power window sub switch (Front) E-18 (6-B) Door lock actuator (Rear: RH)
TRUNK (LUGGAGE COMPARTMENT)

TRUNK <LH drive vehicles>
M1801001500560
AC208225
Connector
symbol F-04
F-01 F-02 F-05 F-06 F-07
F Defogger
earth
Floor wiring F-15

harness (RH)
F-18
F-16
F-17
Floor wiring
harness (LH)
Connector colour F-08

code
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue
None : Milk white F-09
O : Orange
R : Red
V : Violet
Y : Yellow
F-14 F-10
Bumper
F-26 4WD wiring wiring
harness harness
F-11
F-25 F-24 F-23 F-22 F-21 F-20 F-12
AC310174 AB
F-01 (2) Rear speaker (LH) F-15 (2) High mounted stop lamp <rear
F-02 (2) Luggage compartment lamp spoiler>
F-04 (2-B) High mounted stop lamp <rear shelf> F-16 (1) Defogger (+)
F-05 (4) No connection F-17 (2-G) No connection
F-06 (1-B) Defogger (−) F-18 (2) Windshield washer motor
F-07 (2) Rear speaker (RH) F-20 (2-B) Electric pump
F-08 (6-B) Rear combination lamp (RH) F-21 (8-B) Floor wiring harness (LH) and 4WD
F-09 (1-B) Luggage compartment lamp switch wiring harness combination
F-10 (2-GR) Licence plate lamp (RH) F-22 (2-B) Direction valve (LH)
F-11 (2-GR) Licence plate lamp (LH) F-23 (2-B) Direction valve (RH)
F-12 (2-GR) Floor wiring harness (LH) and bumper F-24 (3-B) Proportioning valve (for ACD control)
wiring harness combination F-25 (3-B) Proportioning valve (for AYC control)
F-14 (6-B) Rear combination lamp (LH) F-26 (3-B) Pressure sensor
80-37
TRUNK <RH drive vehicles>
M1801001500571
AC211091
Connector
symbol
F-02 F-04 F-05
F
F-07 F-16
Defogger Floor wiring F-15

earth harness (RH)
F-06 F-18
F-01
F-17
Floor wiring
harness (LH)
Connector colour F-08

code
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue
None : Milk white F-09
O : Orange
R : Red
V : Violet
Y : Yellow
F-14 F-10
Bumper
F-26 4WD wiring wiring
harness harness
F-11
F-25 F-24 F-23 F-22 F-21 F-20 F-12

AC310175 AB
F-01 (2) Rear speaker (LH) F-15 (2) High mounted stop lamp <rear
F-02 (2) Luggage compartment lamp spoiler>
F-04 (2-B) High mounted stop lamp <rear shelf> F-16 (1) Defogger (+)
F-05 (4) No connection F-17 (2-G) No connection
F-06 (1-B) Defogger (−) F-18 (2) Windshield washer motor
F-07 (2) Rear speaker (RH) F-20 (2-B) Electric pump
F-08 (6-B) Rear combination lamp (RH) F-21 (8-B) Floor wiring harness (LH) and 4WD
F-09 (1) Luggage compartment lamp switch wiring harness combination
F-10 (2-GR) Licence plate lamp (RH) F-22 (2-B) Direction valve (LH)
F-11 (2-GR) Licence plate lamp (LH) F-23 (2-B) Direction valve (RH)
F-12 (2-GR) Floor wiring harness (LH) and bumper F-24 (3-B) Proportioning valve (for ACD control)
wiring harness combination F-25 (3-B) Proportioning valve (for AYC control)
F-14 (6-B) Rear combination lamp (LH) F-26 (3-B) Pressure sensor
NOTES
00E-1
GROUP 00E
GENERAL
<ELECTRICAL>
CONTENTS
HOW TO READ WIRING DIAGRAMS 00E-2 HOW TO READ CIRCUIT DIAGRAMS . . . . 00E-4
COMPOSITION AND CONTENTS OF WIRING MARKINGS FOR CONNECTOR AND
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 00E-2 EARTHING . . . . . . . . . . . . . . . . . . . . . . . . . 00E-6
HOW TO READ CONFIGURATION WIRE COLOUR CODE . . . . . . . . . . . . . . . . 00E-9
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 00E-3 ABBREVIATION SYMBOLS . . . . . . . . . . . . 00E-9
00E-2 GENERAL <ELECTRICAL>
HOW TO READ WIRING DIAGRAMS

COMPOSITION AND CONTENTS OF
WIRING DIAGRAMS
M1001012800150
In each section, all specifications are listed, including optional specifications. Accordingly, some specifica-
tions may not be applicable for individual vehicles.
Section Basic contents

Component Locations are shown for each point of relays, ECUs, sensors, solenoid valves,
locations inspection connectors, fusible links, fuses, etc. In the part’s lists, parts are listed in
alphabetical order.
Configuration Connector locations and harness wiring configurations on actual vehicles are
diagrams illustrated.
Circuit diagrams Circuits from power source to earth are shown completely, classified according to
system. There is a main division into power source circuits and circuits classified by
system.
• Junction block
The entire circuit for the junction block is described, because only the part of the
junction block needed is normally shown in each circuit diagram.
• Joint connectors
The internal circuits for all joint connectors are described, because only the part
needed is shown in each circuit diagram.
• Power source circuits
Circuits from the battery to fusible link, fuse, ignition switch, etc are shown.
• Circuits classified by system
For each system, the circuits are shown from fuse to earth, excluding the power
source sections.
GENERAL <ELECTRICAL>
00E-3
HOW TO READ CONFIGURATION
DIAGRAMS
M1001006400238
The wiring harness diagrams clearly show the connector locations and harness routings at each site on
actual vehicles.
Denotes connector No.

The same connector No. is used throughout the circuit diagrams to facilitate connector location search.
The first alphabetical symbol indicates the location site of the connector and a number that follows is the unique number.
Numbers are usually assigned to part in clockwise order on the diagram.
Example: A-19
Number specific to connector (serial number)
Connector location site symbol

A: Engine compartment
B: Engine and transmission
C: Dash panel
D: Floor and roof
E: Door
F: Trunk
A-19
Denotes earth point.
Same earth number is used throughout circuit
diagrams to facilitate search of earth point.
Refer to GROUP 70 COMPONENT LOCATIONS
- EARTH MOUNTING LOCATIONS 1
for details of earth points.
Front
wiring
harness
(RH)
Denotes harness name.
A-18
Denotes a section covered by a

corrugated tube. A-17
The mark shows the

standard mounting position
of wiring harness.
Denotes the colour of the tube A-16

(If not specified, it is black).
R: Red
Y: Yellow Y
The number of connector pins and the connector colour

(except milk white)* are shown for ease of retrieval. A-15
Example: (2-B)
Connector colour
(milk white if no colour is indicated) A-15 (2) Fog lamp (RH)
A-16 (2-GR) Horn (LO)
Number of connector pins A-17 (2-B) Headlamp (RH)
A-18 (2-B) Windshield washer motor
*: Typical connector colours A-19 (2-GR) Dual pressure switch
B: Black BR: Brown
Y: Yellow V: Violet
L: Blue O: Orange
G: Green GR: Grey Indicates the device to which the
R: Red None: Milk white connector is connected.
AC208446AQ
HOW TO READ CIRCUIT DIAGRAMS

M1001006500183
The circuit of each system from the fuse (or fusible link) to earth is shown. The power source is shown at the
top and the earth at the bottom to facilitate understanding of how the current flows. The circuit diagrams show
the state when switches are not operated.
Indicates power source. Indicates connector number.

The same number as used in the
wiring harness diagram.
Connector and connector numbers
Indicates that terminal is conne- are shown at the lower part of the
cted via a plate in the relay box. page.
Connector numbers not enclosed
by frame indicate the device incor-
porated into wiring harness.
Each circuit diagram consists of

block(s).
FUSIBLE FUSIBLE
LINK 1 LINK 2
Indicates harness junction point
numbers for another system.
The number corresponds to the RELAY
BOX
junction point number indicated
on another circuit diagram.
DIODE
Indicates the circuit name to be

connected. The arrow indicates HEATER
the current flow direction. STARTING

SYSTEM
MOTOR
ECU
Indicates the power supply in
the control unit. If no voltage is
displayed, this indicates battery
positive voltage.
RELAY
An "X" at the end of a connector

number indicates that the conn-
ector is connected to a central- SWITCH
ized junction that is shown in the
section "Centralized Junction."
RESISTOR
Indicates that the diagram contin- SENSOR

ues at which belongs to the
block in the same circuit.
Indicates the connector symbol.

Connectors in the circuit diagram
are indicated in numerical order.
Indicates the operating conditions Indicates shield wire. One-directional arrow indicates
of the engine coolant switch, etc. that current flows upwards.
AC502478 AB
00E-5
Indicates input/output Indicates a wiring connector which is inside

to/from control unit the equipment and which is not shown in
(current flow direction). the wiring harness configuration diagram.
Input Output Input/ Example C-15-2 Indicates a connector
output
which is inside the
equipment, numbered Indicates that the diagram comes
in order starting from 1. from which belongs to the
block in the same circuit.
Indicates the connector number shown in
the wiring harness configuration diagram.
Indicates that these connectors

IGNITION are the same intermediate
SWITCH (IG1) RESISTOR connectors.
SOLENOID
VALVE
ASSEMBLY
Indicates terminal number.
SOLENOID SOLENOID
VALVE 1 VALVE 2
In case two or more connectors
are connected to the same de-
vice, the same connector are
shown by a broken line.
Bi-directional arrow indicates

that current flows in both
directions due to control by an
ECU.
Indicates harness junction where

wire diameter or colour changes.
SENSOR
MOTOR Indicates intersections at
which the lead wires are
not connected.
Indicates intersections at
which the lead wires are
connected.
Indicates representative vehicle

body earth point. (Same number
as that of earth point in
EARTHING LOCATION).
Indicates that the terminal is a

spare one if the device (sensor
in this case) is not provided.
AC209124 AC
MARKINGS FOR CONNECTOR AND

EARTHING
M1001007900162
IGNITION FUSIBLE
SWITCH (IG1) LINK 1
SOLENOID
VALVE 5
1
8 ECU
4
SENSOR
MOTOR
INSPECTION
CONNECTOR
AC208460 AB
7
2
00E-7
Item No. Connector/Earthing Symbol Contents
Connector 1 Male terminal The male and female terminals
and terminal Male connector are indicated as shown. The
marking connector with male terminal(s)
is called as male connector and
indicated by two connector
ACX01252AD
contour lines, while the
Male connector
connector with female
terminal(s) is called as female
connector and indicated by
Male terminal single connector contour line.
ACX01253 AI
ACX01251AE
Female terminal
Female connector
ACX01255AD
Female connector
Female terminal
ACX01256 AH
ACX01254 AD
Connector 2 Device The symbol indicates the

symbol connector is viewed as shown.
marking At a device connection, the
connector symbol on the device
side is shown. For an
ACX01253 intermediate connector, the
ACX01257AD male connector symbol is
shown. For spare connectors
Intermediate connector
and check connectors, no
device is connected, and so the
harness-side connector symbol
is shown for these connectors.
However, a diagnosis connector
ACX01258AD is exceptional.
Spare connector, check connector
ACX01256
ACX01816 AD
Item No. Connector/Earthing Symbol Contents

Connector 3 Direct connection type Connection between a device
connection and the harness is either by
marking direct insertion in the device
(direct connection type) or by
connection with a harness
connector furnished on the
ACX01261
ACX01260 AD device side (harness
connection type). The two types
4 Harness connection type are indicated as illustrated.
ACX01263
ACX01262 AD
5 Intermediate connector
ACX01265
ACX01264AD
Earth 6 Body earth Earthing is either by body earth,

marking device earth or control unit
interior earth. These are
indicated as illustrated.
AC208448AB ACX01274
7 Device earth
AC208449AB ACX01276
8 Earth in control unit
ACX01278
AC208450AB
00E-9
WIRE COLOUR CODE
M1001008000195
Wire colours are identified by the following colour
codes.
Code Wire colour Code Wire colour Code Wire colour Code Wire colour
B Black L Blue PU Purple V Violet
BR Brown LG Light green R Red W White
G Green O Orange SB Sky blue Y Yellow
GR Grey P Pink SI Silver − −
If a cable has two colours, the first of the two colour
code characters indicates the basic colour (colour of
Example: <F> 1.25 G B
the cable coating) and the second indicates the
1 2 3 4 marking colour.
ACX01279 AE
No. Meaning
1 <F>: Flexible wire
<T>: Twisted wire
2 Wire size (mm2)*
3 Basic colour (colour of the cable coating)
4 Marking colour
NOTE:
*: No code indicates 0.5 mm2. Cable colour code in
parentheses indicates 0.3 mm2.
ABBREVIATION SYMBOLS
M1001008100255
The abbreviation symbols used in wiring diagrams are defined below.
1. For system name
Abbreviation Meaning Abbreviation Meaning
symbol symbol
ABS Anti-skid braking system J/C Joint connector
ACD Active centre differential M/T Manual transmission
AYC Active yaw control MPI Multi-point injection
DOHC Double overhead camshaft engine SRS Supplemental restraint system
J/B Junction block
2. For combination meter

symbol symbol
ABS Anti-skid braking system warning POSITION Position lamp indicator lamp
lamp
BEAM High beam indicator lamp REAR FOG Rear fog lamp indicator lamp
BRAKE Brake warning lamp SPEED Speedometer
CHECK Check engine warning lamp SRS Supplemental restraint system
ENGINE warning lamp
CHG Charging warning lamp T/GA Engine coolant temperature gauge
DOOR Door-ajar warning lamp TACHO Tachometer
F/GA Fuel gauge TRIP Tripmeter
FUEL Low fuel warning lamp TARMAC Active centre differential mode
LCD Liquid crystal display GRAVEL indicator lamp
ODO Odometer SNOW
OIL Oil pressure warning lamp TURN (LH) Turn signal indicator lamp, hazard
OIL LEVEL Engine oil level warning lamp TURN (RH) indicator lamp
3. For switches and relays

Name of switches Abbreviation Operation
and relays symbols
Blower switch LO Blower operates at low speed
ML Blower operates at medium low speed
MH Blower operates at medium high speed
HI Blower operates at high speed
Dimmer passing switch LO Low beams ON
HI High beams ON
PASS High beams ON
Door lock actuator LOCK Door lock
UNLOCK Door unlock
Front room lamp, rear DOOR Room lamp ON when a door is open
room lamp
Headlamp leveling 1 Lower the low-beam in one step
switch 2 Lower the low-beam in two steps
3 Lower the low-beam in three steps
4 Lower the low-beam in four steps
00E-11
Name of switches Abbreviation Operation
and relays symbols
Ignition switch LOCK When turned to the LOCK position, no circuits will start
ACC When turned to the ACC (ACCESSORY) or ON position, the
power circuit will start
IG2 When at the ST (START) position, the power circuit will not start
functioning
IG1 Even when at the ST (START) position, the power circuit will start
ST Only when turned to the ST (START) position, the power circuit
will start
Lighting switch TAIL Position, tail, licence plate and illumination lamps ON
HEAD Headlamps ON
Power window switch UP Windows close
DOWN Windows open
LOCK Prevents all switches other than the main switch from operating
the power windows
UNLOCK Every switch can open or close the respective window
Remote controlled LH LH mirror operates
mirror switch RH RH mirror operates
Switch and relay OFF Switched OFF
ON Switched ON
Turn signal switch LH LH turn signal lamps ON
RH RH turn signal lamps ON
Variable intermittent SLOW Lengthens pause time for intermittent operation
wiper control switch FAST Shortens pause time for intermittent operation
Windshield wiper MIST Wiper operates once
switch INT Wiper operates intermittently
LO Wiper operates at low speed
HI Wiper operates at high speed
4. For others
symbol symbol
4WD 4 wheel-drive vehicles HI High
A/C Air conditioner IC Integrated circuit
CPU Central processing unit ILL Illumination lamp
ECU Electronic control unit LH Left hand
EGR Exhaust gas recirculation LHD LH drive vehicles
ETACS Electronic time and alarm control LO Low
system RH Right hand
GND Earth RHD RH drive vehicles
NOTES
11B-1
GROUP 11B
ENGINE OVERHAUL
CONTENTS
GENERAL INFORMATION . . . . . . . . 11B-2 INLET MANIFOLD . . . . . . . . . . . . . . . 11B-31

GENERAL SPECIFICATIONS . . . . . . 11B-2
EXHAUST MANIFOLD . . . . . . . . . . . . 11B-32
SERVICE SPECIFICATIONS. . . . . . . 11B-3 REMOVAL AND INSTALLATION . . . . . . . . 11B-32
REWORK DIMENSIONS . . . . . . . . . . 11B-5 WATER PUMP AND WATER HOSE . 11B-34

TORQUE SPECIFICATIONS . . . . . . . 11B-5
ROCKER ARMS AND CAMSHAFT . . 11B-36
SEALANTS . . . . . . . . . . . . . . . . . . . . 11B-8 REMOVAL AND INSTALLATION . . . . . . . . 11B-36
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-39
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-10
CYLINDER HEAD AND VALVES. . . . 11B-42
ALTERNATOR AND IGNITION REMOVAL AND INSTALLATION . . . . . . . . 11B-42
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11B-14 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-46
OIL PAN AND OIL PUMP. . . . . . . . . . 11B-49
SOLENOID AND VACUUM HOSE . . 11B-16 REMOVAL AND INSTALLATION . . . . . . . . 11B-49
REMOVAL AND INSTALLATION . . . . . . . . 11B-16 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-56
TIMING BELT. . . . . . . . . . . . . . . . . . . 11B-17 PISTON AND CONNECTING ROD . . 11B-57

REMOVAL AND INSTALLATION . . . . . . . . 11B-17 REMOVAL AND INSTALLATION . . . . . . . . 11B-57
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11B-27 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-62
FUEL AND EMISSION PARTS . . . . . 11B-29 CRANKSHAFT AND CYLINDER

REMOVAL AND INSTALLATION . . . . . . . . 11B-29 BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11B-64
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-67
11B-2 ENGINE OVERHAUL
GENERAL INFORMATION
GENERAL INFORMATION
M1113000100329
VEHICLE AND ENGINE MODELS

Vehicle name Vehicle Engine model Displacement Specification
model mL
LANCER CT9A 4G63-7 1,997 Double overhead camshaft, 16-valve
EVOLUTION
GENERAL SPECIFICATIONS
M1113000200597
Item Specification
Bore × stroke mm 85 × 88
Displacement mL 1,997
Combustion chamber Pentroof type
Number of cylinders 4
Valve mechanism Type Double overhead camshaft
Number of intake valves 2
Number of exhaust 2
valves
Lash adjusters Hydraulic
Rocker arms Roller cam followers
Compression ratio 8.8
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
ENGINE OVERHAUL
11B-3
M1113000301199

TIMING BELT
Auto-tensioner rod extension length 3.8 − 4.5 −
(with timing belt installed) mm
Auto-tensioner rod extension length (when free) mm 12.0 −
Auto-tensioner rod retraction length Less than 1 −
(when pressed with force of 98 to 196 N) mm
ROCKER ARMS AND CAMSHAFTS
Cam height mm Intake 35.96 35.46
Exhaust 35.49 34.99
CYLINDER HEAD AND VALVES
Cylinder head gasket surface warp mm Less than 0.05 0.2
Cylinder head gasket surface grinding limit − 0.2
(including cylinder block grinding amount) mm
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 43.5° − 44° −
Valve stem-to-guide clearance mm Intake valves 0.02 − 0.05 0.10
Exhaust valves 0.05 − 0.09 0.15
Valve height mm Intake valves 109.5 109.0
Valve stem projection mm Intake valves 49.2 49.7
Valve spring free height mm 50.4 49.4
Valve spring load/height N/mm 279/40 −
Valve spring squareness 1.5° or smaller 4°
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 −

OIL PAN AND OIL PUMP
Oil pump gear side clearance mm Drive gear 0.08 − 0.14 −
Driven gear 0.06 − 0.12 −
Oil cooler by-pass valve mm Dimension (Normal 34.5 −
temperature)
By-pass hole closing 40.0 −
temperature 97 to
103°C
Oil pressure at curb idle speed kPa 78 or more −
[oil temperature is 75 to 90°]
PISTONS AND CONNECTING RODS
Piston outside diameter mm 85.0 −
Piston ring side clearance in ring No. 1 0.03 − 0.07 0.1
groove mm 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 − 0.50 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 0.02 − 0.04 0.1
Connecting rod big end thrust clearance mm 0.10 − 0.25 0.4
CRANKSHAFT AND CYLINDER BLOCK
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
Cylinder block gasket surface grinding limit − 0.2
(including cylinder head grinding amount) mm
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
ENGINE OVERHAUL
REWORK DIMENSIONS
11B-5
REWORK DIMENSIONS
M1113024300264
Item Standard value

Diameter of oversize valve seat ring hole in cylinder head Intake 0.3 oversize 35.30 − 35.33
mm 0.6 oversize 35.60 − 35.63
Exhaust 0.3 oversize 33.30 − 33.33
0.6 oversize 33.60 − 33.63
Diameter of oversize valve guide hole in cylinder head mm 0.05 oversize 12.05 − 12.07
0.25 oversize 12.25 − 12.27
0.50 oversize 12.50 − 12.52
TORQUE SPECIFICATIONS
M1113023401421
Item N⋅m
ALTERNATOR AND IGNITION COIL
Oil level gauge guide bolt 13 ± 1
Auto-tensioner assembly bolt (M8) 22 ± 4
Auto-tensioner assembly bolt (M10) 44 ± 10
Water pump pulley bolts 8.8 ± 1.0
Alternator bracket bolt (flange bolt) 24 ± 4
Alternator bracket bolts (M8 × 22 washer assembled bolt) 22 ± 4
Alternator bracket bolts (M8 × 32 washer assembled bolt) 20 ± 2
Alternator nuts 44 ± 10
Crankshaft pulley bolts 25 ± 4
Centre cover bolts 3.0 ± 0.5
Ignition coil bolts 10 ± 2
Spark plugs 25 ± 5
SOLENOID AND VACUUM HOSE
Vacuum pipe and hose assembly bolts 11 ± 1
Solenoid valve assembly bolts 9.0 ± 1.0
TIMING BELT
Timing belt cover bolts (flange bolt) 11 ± 1
Timing belt cover bolt (washer-assembled bolt) 9.0 ± 1.0
Plug cap 32 ± 2
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
Crankshaft angle sensor bolts 8.8 ± 1.0
Item N⋅m
Oil pump sprocket nut 54 ± 5
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
V.V.T. sprocket bolt 65 ± 5
Camshaft sprocket bolt 88 ± 10
FUEL AND EMISSION SYSTEM
Throttle body bolts 19 ± 3
EGR valve bolts 20 ± 2
Fuel pressure regulator bolts 8.8 ± 2.0
Delivery pipe and injector assembly bolts 12 ± 1
INLET MANIFOLD
Engine hanger bolt 19 ± 3
Inlet manifold stay bolts 31 ± 3
Inlet manifold bolts (M8) 20 ± 2
Inlet manifold bolts and nuts (M10) 36 ± 6
EXHAUST MANIFOLD
Engine hanger bolt 19 ± 3
Turbocharger heat protector bolts 23 ± 3
Oxygen sensor 44 ± 5
Exhaust fitting bracket bolts 35 ± 6
Exhaust fitting bolts 59 ± 5
Air outlet fitting bolts 19 ± 1
Oil return pipe bolts (oil pan side) 14 ± 1
Oil return pipe bolts (turbocharger side) 9.0 ± 1.0
Exhaust manifold heat protector bolts 23 ± 3
Turbocharger assembly and pipe assembly bolts, nuts 64 ± 5
Oil pipe bolt (flange bolt) 11 ± 1
Oil pipe bolt (eye bolt M10) 17 ± 2
Oil pipe bolt (eye bolt M12) 31 ± 2
Water pipe bolt (eye bolt M12) 42 ± 7
Water pipe bolt (flange bolt) 10 ± 1
Exhaust manifold nuts (M8) 33 ± 6
Exhaust manifold nuts (M10) 55 ± 5
ENGINE OVERHAUL
11B-7
Item N⋅m
WATER PUMP AND WATER HOSE
Engine coolant temperature sensor 29 ± 10
Engine coolant temperature gauge unit 11 ± 1
Water outlet fitting bolts 10 ± 1
Thermostat housing bolts 23 ± 4
Water inlet pipe bolt (M6) 10 ± 1
Water inlet pipe bolt (M8) 13 ± 2
Water pump bolts 14 ± 1
Detonation sensor 23 ± 2
ROCKER ARMS AND CAMSHAFT
Camshaft position sensor bolt 11 ± 1
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
Oil feeder control valve bolt 11 ± 1
Check valve 30 ± 3
Eye bolt 42 ± 2
Oil pipe bolt 11 ± 1
Oil pipe joint 30 ± 3
Cylinder head bolts 78 ± 2 → 0 → 20 ± 2 → +90° → +90°
Drain plug 39 ± 5
Oil level sensor bolts 9.0 ± 1.0
Oil filter 14 ± 2
Oil pan bolts 9.0 ± 3.0
Oil screen bolts 19 ± 3
Baffle plate bolts 22 ± 4
Oil pressure switch 19 ± 3
Oil cooler by-pass valve 54 ± 5
Relief plug 44 ± 5
Oil filter bracket bolts 19 ± 3
Plug cap 23 ± 3
Flange bolt 36 ± 3
Oil pump case bolts 23 ± 3
Oil pump cover bolts 17 ± 1
Oil pump cover screw 10 ± 2
SEALANTS
Item N⋅m
PISTON AND CONNECTING ROD
Connecting rod cap nuts 20 ± 2 → +90° to 94°
Flywheel bolts 132 ± 5
Rear plate bolt 11 ± 1
Bell housing cover bolts 9.0 ± 1.0
Rear oil seal case bolts 11 ± 1
Beam bearing cap bolts 25 ± 2 → +90°
Check valve 32 ± 2
SEALANTS
M1113000501007
Item Specified sealant

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 e gauge unit 3M Nut Locking Part No.4171 or
equivalent
Engine coolant temperature sensor 3M ATD No.8660 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
Rear oil seal case* or equivalent
NOTE: *: Part to be sealed with a form-in-place gasket (FIPG)

ENGINE OVERHAUL
SEALANTS
11B-9
FORM-IN-PLACE GASKET (FIPG) CLEANING FIPG APPLICATION
This engine has several areas where the SURFACE
form-in-place gasket (FIPG) is used for sealing. To Thoroughly remove all substances deposited on the
ensure that the FIPG fully serves its purpose, it is FIPG application surface, using a gasket scraper or
necessary to observe some precautions when apply- wire brush. Make sure that the FIPG application sur-
ing it. face is flat and smooth. Also make sure that the sur-
Bead size, continuity and location are of paramount face is free from oils, greases and foreign
importance. Too thin a bead could cause leaks. Too substances. Do not fail to remove old FIPG that may
thick a bead, on the other hand, could be squeezed remain in the fastener fitting holes.
out of location, causing blocking or narrowing of fluid
passages. To prevent leaks or blocking of passages, APPLICATION OF FIPG
therefore, it is absolutely necessary to apply the Applied FIPG bead should be of the specified size
FIPG evenly without a break, while observing the and free of any break. FIPG can be wiped away
correct bead size. unless it has completely hardened. Install the mating
FIPG hardens as it reacts with the moisture in the parts in position while the FIPG is still wet (in less
atmospheric air, and it is usually used for sealing than 15 minutes after application). Do not allow FIPG
metallic flange areas. to spread beyond the sealing areas during installa-
tion. Avoid operating the engine or letting oils or
REMOVAL OF FIPG SEALED PARTS water come in contact with the sealed area before a
Parts sealed with a FIPG can be easily removed time sufficient for FIPG to harden (approximately one
without need for the use of a special method. In hour) has passed. FIPG application method may
some cases, however, the FIPG in joints may have to vary from location to location. Follow the instruction
be broken by tapping parts with a mallet or similar for each particular case described later in this man-
tool. You can also tap a flat, thin gasket scraper into ual.
the joint to break the FIPG, taking extreme care not
to damage the mating surfaces. The oil pan cutter
(MD998727) is available as a special tool for remov-
ing the oil pan. The tool, however, must not be.
SPECIAL TOOLS
SPECIAL TOOLS
M1113000601394

MD998781 Flywheel stopper Retention of flywheel
D998781
MD998778 Crankshaft sprocket Removal of crankshaft sprocket

puller 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
D998767
MD998738 Set screw Retention of tensioner arm and

auto-tensioner during timing belt
installation
D998738
MD998713 Camshaft oil seal Installation of camshaft oil seal

installer
D998713
MD998442 Air bleed wire Air bleeding of lash adjuster
MB991654 Cylinder head bolt Removal and installation of

wrench cylinder head bolts
B991654
ENGINE OVERHAUL
SPECIAL TOOLS
11B-11
MD998772 Valve spring Compression of valve spring
compressor
MD998735 Valve spring Compression of valve spring

compressor
MD998737 Valve stem seal Installation of valve stem seal

installer
MD998012 Oil pressure socket Removal and installation of oil

wrench pressure switch
MD998727 Oil pan cutter Removal of oil pan
D998727
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 Removal of counterbalancer shaft

puller front bearing
SPECIAL TOOLS

MD998372 Silent shaft bearing Removal of counterbalancer shaft
puller front and rear bearings
MB991603 Silent shaft bearing Guide and stopper for removal

installer stopper and press-fitting of
counterbalancer shaft rear
bearing
MD998705 Silent shaft bearing Press-fitting of counterbalancer

installer shaft front and rear bearings
MD998375 Crankshaft front oil Installation of crankshaft front oil

seal installer seal
MD998285 Crankshaft front oil Guide for installation of

seal guide crankshaft front oil seal
D998285
MD998780 Piston pin setting tool Removal and press-fitting of

piston pin
ENGINE OVERHAUL
SPECIAL TOOLS
11B-13
MB992010 Bolt guide Removal and installation of piston
and connecting rod assembly
MD998776 Crankshaft rear oil Installation of crankshaft rear oil

seal installer seal
D998776
MB990938 Handle Installation of crankshaft rear oil

seal
(Use with MD998776)
ALTERNATOR AND IGNITION SYSTEM

M1113001000983
CAUTION
Do not remove the ignition coil boot from the ignition coil except the replacement. When removing
the ignition coil boot, always replace it with the new one.
1 10 3.0 ± 0.5 N·m
2 10 ± 2 N·m
12
3 11
13 ± 1 N·m
13
12
13 14
25 ± 5 N·m
20 ± 2 N·m 4
24 ± 4 N·m
22 ± 4 N·m
8 7
44 ± 10 N·m
5
6 8.8 ± 1.0 N·m
44 ± 10 N·m
9
24 ± 4 N·m
25 ± 4 N·m AK501687AB

1. Oil level gauge 8. Alternator
2. O-ring 9. Crankshaft pulley
3. Oil level gauge guide 10. Centre cover
4. O-ring 11. Spark plug cable
5. Water pump pulley 12. Ignition coil
6. Auto-tensioner assembly >>A<< 13. Ignition coil boot
7. Alternator bracket 14. Spark plug
ENGINE OVERHAUL
11B-15
INSTALLATION SERVICE POINTS CAUTION
>>A<< IGNITION COIL BOOT INSTALLA- • When the ignition coil boot is not installed as
TION indicated, realize that it would be possibly the
causes of the malfunctions which lead to an
inappropriate ignition coil operation, a dam-
Air-bleeding hole aged ignition coil, a high voltage leakage
Fitting part toward the outside and water immersion into
the hole.
• White powders are applied to the fitting area
Air-bleeding Top view of the spark plug on the ignition coil boot in
hole order to prevent the fitting area from baking
onto the spark plug. Do not touch or clean
Do not touch the white powders them.
applied to the inside AK404096 AC
1. Confirm the spring is attached to the new ignition
coil boot inside.
2. Push and install the new ignition coil boot into the
ignition coil without a clearance, turning the fitting
area twice or three times.
3. After the installation, turn the ignition coil boot so
that the air bleeding hole can be in position
indicated in the illustration.

M1113025300115
11 ± 1 N·m
7
11 ± 1 N·m
9.0 ± 1.0 N·m 4

6
9.0 ± 1.0 N·m

5
3
8
9.0 ± 1.0 N·m
AK501688AB

1. Vacuum pipe and hose assembly 5. Vacuum hose
2. Solenoid valve 6. Solenoid valve
3. Solenoid valve 7. Vacuum pipe and hose assembly
4. Vacuum hose 8. Vacuum hose assembly
ENGINE OVERHAUL
TIMING BELT
11B-17
TIMING BELT
M1113001901138
CAUTION
Never overhaul the V.V.T. sprocket.
9 3.5 ± 0.5 N·m

11 ± 1 N·m
8 13
11 ± 1 N·m
6 10
1 5
16 4
17 7
48 ± 5 N·m
11
2 21 ± 4 N·m
18 12
23 ± 3 N·m
11 ± 1 N·m
11 ± 1 N·m
36
23 37
22
31
167 N·m
11 ± 1 N·m
49 ± 5 N·m
9.0 ± 1.0 N·m
15
33 45 ± 3 N·m
65 ± 5 N·m 27 28
35
19 ± 3 N·m
32 3
32 ± 2 N·m 25
14
38
34 30
20 49 ± 9 N·m
88 ± 10 N·m 29
26 8.8 ± 1.0 N·m
24
19 21
35 ± 6 N·m 54 ± 5 N·m AK501689 AB

1. Timing belt front upper cover 7. PCV valve gasket
2. Timing belt front lower cover 8. Oil filler cap
3. Power steering pump bracket 9. Connentor bracket
4. Breather hose >>O<< 10. Rocker cover
5. PCV hose >>O<< 11. Rocker cover gasket "A"
6. PCV valve 12. Rocker cover gasket "B"
TIMING BELT
Removal steps (Continued) Removal steps (Continued)

>>N<< 13. Semicircular packing <<F>> >>G<< 26. Timing belt "B"
<<A>> >>M<< 14. Plug cap <<G>> >>F<< 27. Counterbalancer shaft sprocket
<> >>L<< 15. Timing belt >>E<< 28. Spacer
>>K<< 16. Tensioner pulley <<H>> >>D<< 29. Crankshaft sprocket "B"
17. Tensioner arm 30. Crankshaft key
>>J<< 18. Auto-tensioner >>C<< 31. Engine support bracket
19. Idler pulley <> >>B<< 32 V.V.T. sprocket bolt
20. Crankshaft angle sensor >>B<< 33 V.V.T. sprocket
<<C>> >>I<< 21. Oil pump sprocket <<J>> >>A<< 34 Camshaft sprocket bolt
<<D>> >>H<< 22. Crankshaft bolt 35 Camshaft sprocket
<<E>> >>H<< 23. Crankshaft sprocket 36. Timing belt rear cover, right
>>H<< 24. Crankshaft sensing blade 37 Timing belt rear upper cover, left
25. Tensioner "B" 38 Timing belt rear lower cover, left

<<A>> PLUG CAP REMOVAL
Timing marks
AK304440AB
AK403832
CAUTION
Loosen the plug cap, holding the hexagonal portion Never remove the timing belt with any piston at
of the camshaft with a wrench. the top dead centre (TDC). If a piston is at TDC,
the exhaust valves of the cylinder are pushed by
<> TIMING BELT REMOVAL the exhaust cams, compressing the valve
springs. If the belt is removed under this condi-
tion, 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
AK501768
remove the timing belt.
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.
ENGINE OVERHAUL
TIMING BELT
11B-19
<<C>> OIL PUMP SPROCKET REMOVAL Use the special tool Crankshaft sprocket puller
1. Remove the plug on the left side of cylinder block. (MD998778) if the sprocket is stuck and hard to
remove.
<<F>> TIMING BELT "B" REMOVAL
Crosspoint
screwdriver
AK202825 AD
2. Insert a crosspoint screwdriver (shank diameter 8

mm) to prevent the counterbalancer shaft from AK202758AB
rotating.
3. Remove the flange bolt. CAUTION
Water or oil on the belt shortens its life drasti-
4. Remove the oil pump sprocket.
cally, so the removed timing belt, sprocket, and
tensioner must be free from oil and water. These
<<D>> CRANKSHAFT BOLT REMOVAL parts should not be washed or immersed in sol-
vent. Replace parts if contaminated. If there is oil
or water on each part, check the front case oil
seals, camshaft oil seal and water pump for
leaks.
1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner "B" bolt, and then remove
the timing belt "B."
MD998781
AK202738 AC
<<G>> COUNTERBALANCER SHAFT
SPROCKET REMOVAL
1. Hold the drive plate with the special tool Flywheel
stopper (MD998781).
2. Remove the crankshaft bolt.
<<E>> CRANKSHAFT SPROCKET MD998785

REMOVAL
MD998778
AK202739AC
1. Use the special tool Sprocket stopper

(MD998785) to prevent the counterbalancer shaft
sprocket from rotating.
2. Remove the counterbalancer shaft mounting bolt.
AK304176AB
TIMING BELT
<<H>> CRANKSHAFT SPROCKET "B" INSTALLATION SERVICE POINTS

REMOVAL >>A<< CAMSHAFT SPROCKET BOLT
INSTALLATION
MD998778
AK202740AC
Use the special tool Crankshaft sprocket puller AK202858AB

(MD998778) if the sprocket is stuck and hard to
remove.
<> V.V.T. SPROCKET BOLT REMOVAL
AK304435
Tighten the camshaft sprocket bolt to 88 ± 10 N⋅m

while preventing the camshaft from rotation using a
wrench fitted on the hexagonal portion of the cam-
AK403833
shaft.
Loosen the V.V.T. sprocket bolt, holding the hexago-
nal portion of the camshaft with a wrench. >>B<< V.V.T. SPROCKET / V.V.T.
SPROCKET BOLT INSTALLATION
<<J>> CAMSHAFT SPROCKET BOLT
REMOVAL V.V.T. sprocket
V.V.T. sprocket Camshaft

bolt
AK403834AC
AK202858AB 1. Apply minimum amount of engine oils adequately

to the following portions.
Remove the camshaft sprocket bolt while preventing
• All directions of camshaft top
the camshaft from rotation using a wrench fitted on
• Inner and outer surfaces of place in which V.V.T.
the hexagonal portion of the camshaft.
sprocket is inserted
• Threads and top seat of V.V.T. sprocket bolt
• V.V.T. sprocket bolt seat
2. Install the V.V.T. sprocket.
ENGINE OVERHAUL
TIMING BELT
11B-21
3. Firmly and deeply insert the V.V.T. sprocket, and >>D<< CRANKSHAFT SPROCKET "B"
then confirm the V.V.T. sprocket is not rotated, INSTALLATION
holding the hexagonal portion of the camshaft
with a wrench. Sprocket "B"
Crankshaft
Degrease
Front case AK301828AD
Clean and then degrease the crankshaft sprocket "B"

AK403835
and the sprocket fitting surface of the crankshaft.
4. Holding the hexagonal portion of the camshaft NOTE: Degreasing is necessary to prevent lack of
with a wrench, tighten the V.V.T. sprocket bolt to frictional coefficient between the mating surfaces.
the specified torque of 65 ± 5 N⋅m.
5. Holding the hexagonal portion of the camshaft >>E<< SPACER INSTALLATION
with a wrench, confirm the V.V.T. sprocket is not
rotated. Counter
Oil seal balance
NOTE: This shows the V.V.T. sprocket being shaft
locked at the most retarded angle with the inside Spacer
pin.
>>C<< ENGINE SUPPORT BRACKET

INSTALLATION
Chamfered
AK301298AD
CAUTION
If the spacer is opposite in direction to that
shown in the drawing when installed, it will dam-
age the oil seal lip.
1. Smear slightly oil on the outer surface of the
spacer that comes into contact with the oil seal.
AK202743AB
2. Install the spacer with the chamfered end toward
the oil seal.
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
TIMING BELT
>>F<< COUNTERBALANCER SHAFT

SPROCKET INSTALLATION
MD998785
AK304436AB
4. Lift the tensioner "B" with fingers to move it in the

AK202739AC direction of the arrow until the tension section of
the timing belt becomes taut. While keeping the
1. Use the special tool Sprocket stopper
tensioner "B" in this position, tighten its bolt.
(MD998785) as shown in the drawing to prevent
the counterbalancer shaft sprocket from rotating. NOTE: When the bolt is tightened, prevent the
2. Tighten the sprocket mounting bolt to 45 ± 3 N⋅m. tensioner "B" shaft from turning. If the shaft turns,
the belt will be overtightened.
5. Make sure that the timing marks on the oil pump
>>G<< TIMING BELT "B" INSTALLATION
case and those of the sprockets are all aligned
with each other.
Timing 5 – 7 mm
marks
Timing
marks
AK202920 AB
1. Align the timing marks on the crankshaft sprocket AK202919 AB
"B" and counterbalancer shaft sprocket with the

6. Push a central point of the timing belt "B" tension
corresponding timing marks on the oil pump case.
section lightly with an index to see if it deflects 5 −
2. Install the timing belt "B" on the crankshaft 7 mm.
sprocket "B" and counterbalancer shaft sprocket.
There should be no slack in the tension section of
the belt.
>>H<< CRANKSHAFT
BOLT/CRANKSHAFT
Tension section of belt
Tensioner "B"
Timing
SPROCKET/CRANKSHAFT SENSING
belt "B" BLADE INSTALLATION
Crankshaft sensing blade
Crankshaft bolt
Crankshaft
Clean
Tensioner "B"
centre
Mounting bolt centre AK202921 AC
3. Make sure that the tensioner "B" centre is Washer

Chamfer Degrease
positioned as shown in the drawing relative to the Crankshaft sprocket AK202838 AC
mounting bolt centre.
ENGINE OVERHAUL
TIMING BELT
11B-23
1. Clean and then degrease the crankshaft sprocket, >>J<< AUTO-TENSIONER INSTALLATION
sprocket fitting surface of the crankshaft, and
crankshaft sensing blade. Install the crankshaft
sprocket and crankshaft sensing blade on the A
crankshaft. B
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.
AK301074AD
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.
MD998781 (2) Push in the rod little by little with the vise until
the set hole A in the rod is aligned with the set
AK202738 AC
hole "B" in the cylinder.
4. Hold the drive plate using the special tool (3) Insert a piece of wire (1.4 mm diameter) into
Flywheel stopper (MD998781). the set holes.
5. Tighten the crankshaft bolt to a torque of 167 N⋅m. (4) Remove the auto-tensioner from the vise.
>>I<< OIL PUMP SPROCKET

INSTALLATION
AK300154
2. Install the auto-tensioner in position. Leave the

wire installed until the auto-tensioner is
AK300172 completely installed.
1. Prevent the counterbalancer shaft from rotating in
the same method as in the removal procedure. >>K<< TENSIONER PULLEY
2. Install the oil pump sprocket. INSTALLATION
3. Apply a thin coat of engine oil to the seating
surface of the nut.
4. Tighten the flange nut to 54 ± 5 N⋅m.
Tensioner
pulley hole AK300147 AE
Install the tensioner pulley with its holes aligned as

shown in the drawing.
TIMING BELT
>>L<< TIMING BELT INSTALLATION
Timing marks
Plug Crosspoint
screwdriver
AK202752 AD
AK304440AB
4. Align the timing mark on the oil pump sprocket
1. Bring the timing mark on the exhaust camshaft with that on the cylinder block.
sprocket to a point one sprocket tooth away from (1) Remove the plug from the cylinder block.
the timing mark on the rocker cover in the (2) Insert a crosspoint screwdriver with a shank
anti-clockwise direction. diameter of 8 mm through the plug hole. If it
NOTE: If the timing marks were aligned, the can be inserted 60 mm or more, the sprocket
exhaust camshaft would be turned anti-clockwise is in the correct phase. If the insertion depth is
by one sprocket tooth and stay there by the force up to 20 − 25 mm, the screwdriver is blocked
of the valve springs. by the counterbalancer shaft. Then turn the oil
pump sprocket one turn and realign the timing
Timing marks
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
AK501745 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 AK202761 AD
aligned by the force of the valve springs and stay (3) Turn the oil pump sprocket anti-clockwise by
there. one sprocket tooth.
Timing marks
AK304563AB AK202771
3. Bring the timing mark on the crankshaft sprocket 5. Install the timing belt on the exhaust camshaft
to a point one sprocket tooth away from the sprocket, and hold it in place with a paper clip at
mating timing mark in the anti-clockwise direction the point indicated in the drawing.
like in the operation with the exhaust camshaft
sprocket.
ENGINE OVERHAUL
TIMING BELT
11B-25
V.V.T.
sprocket
Tensioner
pulley
AK501746 AK501748AB
6. Turn the intake camshaft sprocket anti-clockwise 9. Install the timing belt on the tensioner pulley.
to bring the timing mark on it one sprocket tooth NOTE: Turning slightly the intake camshaft
away from the mating timing mark in the sprocket anti-clockwise will facilitate installation of
anti-clockwise direction. Then install the timing the belt on the tensioner pulley.
belt on the sprocket and hold it in place with a
paper clip. Crankshaft
sprocket
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.
Timing marks
AK202763AB
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
AK501747 AB
crankshaft, oil pump, and exhaust camshaft
sprockets is one sprocket tooth away from its
7. Turn the exhaust camshaft sprocket clockwise to mating timing mark in the anti-clockwise direction.
align the timing marks, and make sure that the
intake camshaft sprocket timing marks are also
aligned.
MD998767
Crankshaft
sprocket
AK202764 AD
Oil pump
sprocket 12.Turn the tensioner pulley anti-clockwise using the
AK202762AE special tool Tension pulley socket wrench
(MD998767) to give tension to the belt and hold
8. Install the timing belt on the idler pulley, oil pump the tensioner in position by temporarily tightening
sprocket, and crankshaft sprocket, in this order. the tensioner lock bolt.
NOTE: There should be no slack in the installed NOTE: Take up the slack in the belt portion
portion of the belt. between the intake and exhaust camshaft sprock-
ets.
TIMING BELT
13.Turn the crankshaft clockwise to make the timing

mark align with the No.1 cylinder top dead centre
mark.
Extension
amount
MD998738
AK202829 AB
20.Check that the wire (inserted in the auto-tensioner

when it was installed) can be moved freely. If the
AK202774 AD
wire can be pulled freely, the belt tensioner is
14.Install the special tool Set screw (MD998738) and adjusted properly. Remove the wire. At that time,
turn down the tool until the wire (inserted in the check that the auto-tensioner rod extends by the
auto-tensioner when it was installed) can be specified amount.
moved freely. Standard value: 3.8 − 4.5 mm
15.Loosen the tensioner pulley lock bolt. CAUTION
Be sure to check the tightening torque of the
crankshaft bolt anytime the crankshaft has been
turned anti-clockwise. 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.
MD998767 AK202775 AD >>M<< PLUG CAP INSTALLATION

CAUTION
Prevent the timing belt from slipping as it
becomes loose following rotation of the intake
and exhaust camshafts.
16.Turn the torque wrench attached to the special
tool Tension pulley socket wrench (MD998767)
anti-clockwise 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 AK403836
becomes 3.5 N⋅m, then tighten the tensioner

CAUTION
pulley lock bolt.
Do not reuse the washer.
18.Remove the special tool Set screw (MD998738)
that was installed in step 14. 1. Install the washer to the plug cap.
19.Turn the crankshaft clockwise two turns, then let it 2. Holding the hexagonal portion of the camshaft
alone for approx. 15 minutes. with a wrench, tighten the plug cap to the
specified torque of 32 ± 2 N⋅m.
ENGINE OVERHAUL
TIMING BELT
11B-27
>>N<< SEMICIRCULAR PACKING 1. Apply beads of FIPG on the surfaces of the rocker
INSTALLATION cover indicated in the drawing.
1. Remove thoroughly the old sealant and FIPG Specified sealant:
remaining on the semicircular packing, cylinder Mitsubishi Genuine Part No.MD970389 or
head, and rocker cover. equivalent
2. Install the rocker cover gasket "A" on the rocker
cover before the FIPG hardens.
Timing belt side
AK202860AB
2. Apply sealant to the surface indicated in the

AK304204AB
drawing of the semicircular packing.
Specified sealant: 3. Apply beads of FIPG to the surfaces of the rocker
3M ATD No.8660 or equivalent cover indicated in the drawing.
3. Install the semicircular packing on the cylinder Specified sealant:
head. Mitsubishi Genuine Part No.MD970389 or
equivalent
10 mm 4. Install the rocker cover on the cylinder head
before the FIPG hardens.
INSPECTION
M1113002000500
TIMING BELT
10 mm
Check closely the entire timing belt.
Semicircular Replace it if any of the following conditions is found.
packing Cylinder head AK304411AB
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
>>O<< ROCKER COVER/ROCKER

COVER GASKET "A" INSTALLATION AK202794
Timing belt side 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.
AK304203AB
TIMING BELT
AUTO-TENSIONER
Cracks Cracks
12 mm
Peeling of canvas
Cracks in sides
Cracks in tooth roots AK202793 AB
AK301307AD
2. Cracks in back rubber surface.
3. Cracks in canvas. 1. Check the auto-tensioner for leaks from the
4. Cracks in tooth roots. sealed sections.
5. Cracks in belt sides. Replace it if leaky.
2. Check the rod end for wear and other damage.
Rounded edge
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
Abnormal wear
(Fluffy strand) 98 to 196 N
AK202795 AB
6. Abnormally worn belt sides;

Movement
NOTE: belt sides are normal if they have
“knife-cut” surfaces.
Canvas lost and

rubber exposed
AK301308AE
Missing
Tooth 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.
AK202796 AB Standard value: 1 mm maximum
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.
ENGINE OVERHAUL
FUEL AND EMISSION PARTS
11B-29
M1113002200485
12 ± 1 N·m 8
15
19 ± 3 N·m
5 10 1
13
14 2
12 3
11
7
8.8 ± 2.0 N·m 9
6 20 ± 2 N·m
AK203808 AE

1. Throttle body 9. Insulator
>>C<< 2. Throttle body gasket 10. Fuel return pipe
3. EGR valve 11. Insulator
4. EGR valve gasket >>A<< 12. Injector
5. Fuel hose 13. O-ring
>>B<< 6. Fuel pressure regulator 14. Grommet
7. O-ring 15. Delivery pipe
8. Injector and delivery pipe
INSTALLATION SERVICE POINTS 3. Check that the fuel pressure regulator turns
>>A<< INJECTOR INSTALLATION smoothly. If it does not, the O-ring may be
jamming, so remove the fuel pressure regulator
1. Apply a thin coat of engine oil to a new O-ring. and check the O-ring for damage. If the O-ring is
CAUTION intact, insert it into the delivery pipe and check it
Prevent engine oil from getting into the delivery for smooth rotation again.
pipe.
2. Insert the injector into the delivery pipe while >>C<< THROTTLE BODY GASKET
turning it in both directions carefully not to INSTALLATION
damage the O-ring.
3. Check that the injector turns smoothly. If it does
Tab
not, the O-ring may be jamming, so remove the
injector and check the O-ring for damage. If the
O-ring 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. AK203932AG
CAUTION Install the throttle body gasket with its tab located as
Prevent engine oil from getting into the delivery shown in the drawing.
pipe.
2. Insert the fuel pressure regulator into the delivery
pipe while turning it in both directions carefully not
to damage the O-ring.
ENGINE OVERHAUL
INLET MANIFOLD
11B-31
INLET MANIFOLD
M1113026100211
19 ± 3 N·m
36 ± 6 N·m
1
3
20 ± 2 N·m 36 ± 6 N·m
36 ± 6 N·m
31 ± 3 N·m
AK501690AB
Removal steps INSTALLATION SERVICE POINTS

1. Engine hanger >>A<< INLET MANIFOLD STAY INSTAL-
>>A<< 2. Inlet manifold stay
3. Inlet manifold LATION
4. Inlet manifold gasket
Inlet manifold
stay
AK202865 AD
Tighten the bolts to the specified torque 31 ± 3 N⋅m

on both ends after making sure that the stay is in
close contact with the bosses on the inlet manifold
and cylinder block.
EXHAUST MANIFOLD
EXHAUST MANIFOLD
M1113004901007
23 ± 3 N·m
12
17 ± 2 N·m
1 64 ± 5 N·m
20
19 ± 3 N·m
19
11 ± 1 N·m
31 ± 2 N·m
33 ± 6 N·m 15
16
55 ± 10 N·m 14 10 ± 1 N·m
42 ± 7 N·m
13
17
10 ± 1 N·m
3
6
44 ± 5 N·m
18
23 ± 3 N·m 42 ± 7 N·m
10
8
59 ± 5 N·m 9 19 ± 1 N·m
2 11
4 9.0 ± 1.0 N·m 7
35 ± 6 N·m AK501691AB
14 ± 1 N·m

1. Engine hanger 12. Exhaust manifold heat protector
2. Turbocharge heat protector 13. Turbocharge assembly and pipe
3. Oxygen sensor assembly
4. Exhaust fitting bracket 14. Turbocharge gasket
5. Exhaust fitting 15. Oil pipe
6. Exhaust fitting gasket 16. Water pipe "B"
7. Air outlet fitting 17. Water pipe "A"
>>C<< 8. Air outlet fitting gasket 18. Turbocharge assembly
9. Oil return pipe >>A<< 19. Exhaust manifold
10. Oil return pipe gasket 20. Exhaust manifold gasket
>>B<< 11. Oil return pipe gasket
ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-33
INSTALLATION SERVICE POINT >>B<< OIL RETURN PIPE GASKET
>>A<< EXHAUST MANIFOLD INSTALLA- INSTALLATION
TION
Tab
1. Hand tighten all the exhaust manifold mounting
nuts.
2. Tighten the M8 nuts to 29 ± 3 N⋅m in the indicated
sequence.
3. Tighten the M10 nuts to 49 ± 5 N⋅m in the
indicated sequence.
4. Tighten the M8 nuts again to 29 ± 3 N⋅m in the
indicated sequence. AK304540AB
Install the oil return pipe gasket with its tab located
as shown in the drawing.
NOTE: The gasket on the turbocharger end of the
3 4 5 6
pipe does not require special alignment for installa-
tion.
1 7 9 8 2
>>C<< OUTLET FITTING GASKET
INSTALLATION
AK202866 AB
5. Finally tighten the M10 nuts and the M8 nuts to Tab

the specified torque, both in the indicated
sequence.
Tightening torque:
33 ± 6 N⋅m <M8>
55 ± 10 N⋅m <M10>
A
A AK202868 AB
Install the air outlet fitting gasket with its tab located
as shown in the drawing.

M1113017900491
11 ± 1 N·m
4 10 ± 1 N·m
1
13
13 ± 2 N·m 7
23 ± 4 N·m
11 ± 1 N·m
29 ± 10 N·m 8
11 5
10 ± 1 N·m
2 23 ± 4 N·m
6 11 ± 1 N·m
12 9 3
10
16
23 ± 2 N·m
15
14
14 ± 1 N·m AK501692AB
Removal sequence Removal sequence (Continued)

1. Water hose 9. Thermostat housing
2. Water hose 10. Gasket
3. Water hose >>A<< 11. Water inlet pipe
4. Water hose >>A<< 12. O-ring
>>C<< 5. Engine coolant temperature sensor >>A<< 13. O-ring
>>B<< 6. Engine coolant temperature gauge 14. Water pump
unit 15. Water pump gasket
7. Water outlet fitting 16. Detonation sensor
8. Thermostat
ENGINE OVERHAUL
11B-35
INSTALLATION SERVICE POINTS NOTE: A new engine coolant temperature gauge
unit is coated with sealant. It does not require
>>A<< O-RING/WATER INLET PIPE
coating with sealant before installation.
INSTALLATION 2. Apply sealant to the indicated threads of the
CAUTION engine coolant temperature gauge unit.
• Never allow any oil or grease to touch the Specified sealant:
O-rings. 3M Nut Locking Part No.4171 or equivalent
• Clamp the water inlet pipe only after installa-
tion of the thermostat case.
Replace the O-rings at both ends of the water inlet >>C<< ENGINE COOLANT
pipe with new ones. Insert the O-rings into the water TEMPERATURE SENSOR INSTALLATION
pump and thermostat housing after wetting their
peripheries with water.
>>B<< ENGINE COOLANT

TEMPERATURE GAUGE UNIT
INSTALLATION
AK202799AB
CAUTION
When using a tool, avoid letting it touch the con-
nector portion which is made of plastic.
1. Remove all old sealant remaining on the threads
of the engine coolant temperature sensor and in
AK202800AB the threaded hole in the thermostat housing.
1. Remove all old sealant remaining on the threaded 2. Apply sealant to the engine coolant temperature
hole in the engine coolant temperature gauge unit sensor's threads indicated in the drawing.
and the thermostat housing. Specified sealant:
3M ATD Part No.8660 or equivalent

M1113005401179
11 ± 1 N·m
10 9
12
8
11 10 ± 2 N·m
7
14 ± 1 N·m
22 ± 4 N·m
14 3 10 ± 2 N·m
17 4
20 6
19 15
20 ± 1 N·m 18 14 ± 1 N·m
2
16 1
11 ± 1 N·m 22 ± 4 N·m
42 ± 2 N·m 30 ± 3 N·m 21 5
11 ± 1 N·m
28 29 27 11 ± 1 N·m
13 24
22
30 23
31
32
Apply engine oil to
30 ± 3 N·m all moving parts
25 before installation.
11 ± 1 N·m 26
AK403842AC

>>J<< 1. Camshaft position sensor >>E<<
17. Bearing cap No.5
2. O-ring >>E<<
>>I<< 3. Cover >>E<<
>>I<< 4. Gasket >>E<<
>>H<< 5. Camshaft position sensing cylinder >>D<<
21. Camshaft
>>G<< 6. Camshaft position sensor support 22. Rocker arm
>>J<< 7. Camshaft position sensor <<A>> >>C<< 23. Lash adjuster
8. O-ring 24. Oil delivery body
>>I<< 9. Cover 25. Oil feeder control valve
>>I<< 10. Gasket 26. O-ring
>>H<< 11. Camshaft position sensing cylinder 27. Check valve
>>G<< 12. Camshaft position sensor support >>B<< 28. Eye bolt
>>F<< 13. Camshaft oil seal 29. Oil pipe
>>E<< 14. Bearing cap, rear right >>A<< 30. Oil feeder control valve filter
>>E<< 15. Bearing cap, rear left 31. Oil pipe joint
>>E<< 16. Bearing cap, front 32. Gasket
ENGINE OVERHAUL
11B-37
SERVICE POINTS FOR REMOVAL >>D<< CAMSHAFT INSTALLATION
<<A>> LASH ADJUSTER REMOVAL Timing belt side
CAUTION Intake camshaft
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
P.11B-39, the instruction under LASH ADJUSTER
in the INSPECTION section.)

>>A<< OIL FEEFER CONTROL VALVE Exhaust camshaft
AK501789AB
FILTER INSTALLATION
CAUTION
CAUTION • Do not confuse the intake camshaft with the
Install the OCV filter on which no foreign materi- exhaust camshaft.
als, no defects and no deformation are con- • As shown in the illustration, the shapes of the
firmed. intake camshaft and the exhaust camshaft are
different.
>>B<< EYE BOLT INSTALLATION
>>E<< BEARING CAP INSTALLATION
Dowel pin
Eye bolt
Spanner
Oil pipe joint
AK403894AC
NOTE: When the oil pipe joint is rotated together with AK203979 AC
the eye bolt at the installation, the oil pump would be 1. Set each camshaft with its dowel pin at the top.
possibly damaged.
Holding the oil pipe joint with a spanner, tighten the
eye bolt to the specified torque of 42 ± 2 N⋅m.
>>C<< LASH ADJUSTER INSTALLATION Cap number

CAUTION Intake/exhaust
When reusing a lash adjuster, it must be washed identification
letter
and inspected before installation. (Refer to
P.11B-39, the instruction under LASH ADJUSTER
in the INSPECTION section.) AK202870 AB
Install the lash adjuster into the rocker arm, being
careful not to spill the diesel fuel it contains. 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.
1. Remove completely the FIPG remaining on the

camshaft position sensor support and cylinder
head.
2. Apply a 3 ± 1 mm diameter bead of FIPG to the
indicated surface of the camshaft position sensor
support.
Specified sealant:
equivalent
AK202871AB
4. Apply sealant to the surfaces indicated in the >>H<< CAMSHAFT POSITION SENSING
drawing. CYLINDER INSTALLATION
Specified sealant:
3M ATD No.8660 or equivalent Exhaust side Intake side
5. Install each bearing cap and tighten its bolts in two Paint
Vane (small)
or three passes.
6. Finally tighten the bolts to 20 ± 1 N⋅m.
7. Check that the rocker arms are correctly installed.
NOTE: Wipe off any squeezed out sealant com-
pletely.
Vane (big)
>>F<< CAMSHAFT OIL SEAL AK501669AB
INSTALLATION 1. Turn the exhaust camshaft to the No.1 cylinder

top dead centre position.
MD998713 NOTE: The camshaft will slightly turn counter-
clockwise by the force of the exhaust valve spring.
2. Install the camshaft position sensing cylinder with
the vanes and paint located as shown in the
drawing.
>>I<< COVER / GASKET INSTALLATION

AK304515AB Exhaust side Intake side
Use the special tool Camshaft oil seal installer Paint
(MD998713) to drive each oil seal into position in the Vane (small)
cylinder head.
>>G<< CAMSHAFT POSITION SENSOR

SUPPORT INSTALLATION
Vane (big)
AK501669AB
1. Before the cover and the gasket installations,

confirm the vanes and paint of the every sensing
cylinder are in position indicated in the illustration
with the camshaft on No.1 top dead center of
compression stroke.
Exhaust side Intake side

AK403895AC
ENGINE OVERHAUL
11B-39
Measure the cam height (nose-to-heel diameter).
Exhaust side Intake side If any cam is worn beyond the limit, replace the cam-
shaft.
Standard value:
Projection Intake: 35.96 mm
Exhaust: 35.49 mm
Limit:
Intake: 35.46 mm
Notch Projection Exhaust: 34.99 mm
Notch AK403948AC
2. At the intake side, install the cover notch and the LASH ADJUSTERS
gasket projection in position indicated in the CAUTION
illustration, and then tighten them to the specified • The lash adjuster is a precision-engineered
torque of 14 ± 1 N⋅m. component. Do not allow dust or other for-
At the exhaust side, the cover and the gasket do eign matter to enter it.
not have the specified direction or angle of the • Do not disassemble lash adjusters.
installation. • Use only non-contaminated diesel fuel to
NOTE: The cover and the gasket have no differ- clean the lash adjuster.
ence between the front and the reverse sides.
For rough For finish For diesel
>>J<< CAMSHAFT POSITION SENSOR cleaning cleaning fuel filling
INSTALLATION
Paint
A B C
AK202836 AB
1. Prepare three containers and approximately five

litres of diesel fuel. Pour into each container the
diesel fuel in an amount enough for a lash
AK501790AB adjuster placed in the container in its upright
position to completely submerge.
Install the camshaft position sensor with paying
attention to the installation direction because an
identification paint is not applied to the camshaft
position sensor at the intake side.
INSPECTION
M1113005500979
CAMSHAFT
Diesel fuel
AK300587AB
2. Place the lash adjuster in container A and wash

its outside surface.
NOTE: Use a nylon brush if there are
hard-to-remove deposits.
AK202797AB
Diesel fuel Diesel fuel

MD998442 MD998442
AK202839 AB AK202839 AB
CAUTION CAUTION
The steel ball spring of the lash adjuster is The steel ball spring of the lash adjuster is
extremely weak. The lash adjuster's functionality extremely weak. The lash adjuster's functionality
may be badly affected if the special tool is may be badly affected if the special tool is
inserted too strongly. inserted too strongly.
3. While gently pushing the internal steel ball using 5. Soak the lash adjuster in the diesel fuel in
the special tool Air bleed wire (MD998442), move container B. Move the plunger in and out 5 − 10
the plunger in and out 5 − 10 times to eliminate times by gently pushing the internal steel ball
stiffness in the plunger and expel contaminated using the special tool Air bleed wire (MD998442)
oil. until the plunger moves smoothly to wash the lash
NOTE: The plunger must be free from jamming adjuster’s pressure chamber.
and any other abnormalities. If a defect is found in
plunger operation, replace the lash adjuster.
MD998442
MD998442 Diesel fuel

AK202840 AC
Diesel fuel CAUTION

AK202840 AC
The hole in the side of the lash adjuster must be
CAUTION directed toward the inside of container B. Never
The hole in the side of the lash adjuster must be direct it against any person.
directed toward the inside of container A. Never 6. Take the lash adjuster out of the container, then
direct it against any person. move the plunger by pushing the steel ball gently
4. Take the lash adjuster out of the container, then to discharge the diesel fuel from the pressure
move the plunger by pushing the steel ball gently chamber.
to discharge the diesel fuel from the pressure
chamber.
Diesel fuel
MD998442
AK202841 AB
ENGINE OVERHAUL
11B-41
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).
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
MD998442 Diesel fuel adjuster if it still contracts even after the pressure
chamber has completely been filled with diesel
AK202842 AB fuel (air has been bled).
8. Place the lash adjuster upright with the plunger at 10.Keep the serviced lash adjusters in their upright
the top. Push the plunger firmly until it makes a positions to prevent diesel fuel from spilling out.
full stroke, then return the plunger slowly and Protect them from dust or other foreign matter.
release the hold of the steel ball to allow the Install the lash adjusters onto the engine as soon
pressure chamber to be filled with diesel fuel. as possible.

M1113006900583
78 ± 2 N·m 0 N·m
20 ± 2 N·m +90˚ +90˚
1
2
8
9
4
5 10
20 14
6
15
12
17
13
16
19
18 11
Apply engine oil to

all moving parts
before installation.
AK203813 AC

<<A>> >>D<< 1. Cylinder head bolt <<D>> 11. Exhaust valve
2. Cylinder head assembly <<C>> >>A<< 12. Valve stem seal
3. Cylinder head gasket 13. Valve spring seat
<> >>C<< 4. Retainer lock <<C>> >>A<< 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
>>B<< 6. Valve spring 16. Intake valve guide
7. Intake valve 17. Exhaust valve guide
<> >>C<< 8. Retainer lock 18. Intake valve seat
9. Valve spring retainer 19. Exhaust valve seat
>>B<< 10. Valve spring 20. Cylinder head
ENGINE OVERHAUL
11B-43
REMOVAL SERVICE POINTS <<C>> VALVE STEM SEAL REMOVAL
<<A>> CYLINDER HEAD BOLT REMOVAL
MB991654
AK304633
AK202723 AE Do not reuse removed valve stem seal.

Use the special tool Cylinder head bolt wrench
(MB991654) to loosen the cylinder head bolts. <<D>> VALVE HANDLING PRECAUTIONS
WARNING
<> RETAINER LOCK REMOVAL Sodium reacts violently with water or mois-
ture generation heat and liberating hydro-
MD998735 gen. It must be handled with utmost care
because otherwise the following dangerous
conditions may result:
• Loss of eyesight if sodium gets in eyes.
• Burns if sodium contacts skin.
• Fire hazard.
1. Handling of Sodium-filled Exhaust Valves
AK202873 AD
(1) Sodium-filled exhaust valves are not
dangerous and may be handled in the same
MD998772 way as ordinary valves unless they are
broken.
(2) Never try to break the valves and expose
sodium to the air.
(3) When worn exhaust valves are to be
discarded, have them disposed of by a
salvage company equipped with special
disposal system, notifying them that the valves
contain sodium.
AK202742 AD
(4) Should the exhaust valves be broken,
Compress the valve spring using the special tool neutralize sodium using the method described
Valve spring compressor (MD998735 or MD998772), below, and discard the valves in the same way
then remove the retainer lock. as ordinary valves.
NOTE: Store removed valves, springs and other CAUTION
parts, after putting to each of them a tag that identi- • Do not let the solution contact the eyes or the
fies its cylinder No. or installation location. skin.
• Should it get in the eyes, immediately flush
them with clean water thoroughly, and receive
medical attention. When it contacts he skin,
wash with ample amounts of clean water.
2. How to Neutralize Sodium

(1) Place a container filled with more than 10 litres
of water in a well ventilated large space.
(2) Wear rubber gloves and goggles, and carefully
take out broken valves from the cylinder head. MD998737
CAUTION
• Valves must be neutralized one at a time.
• Put a valve in the container only after sodium
in the preceding one has completely reacted
with water. AK304485 AC
(3) Put a broken valves in the water-filled 4. Use the special tool Valve stem seal installer
container and quickly get away from the (MD998737) to install the stem seal on the valve
container at least 2 or 3 m. guide. Use the stem of the valve to guide the stem
(4) Keep fire away from the container during the seal.
neutralization. The resulting hydrogen gas is
highly explosive. Intake valve stem seal Exhaust valve stem seal
Colour: Gray Colour: Grayish green
NOTE: The reaction occurs when water enters
the cavity in he valve. Hydrogen gas may be
trapped inside the valve, temporarily blocking
the water passage. In such a case, wait until
hydrogen gas in released and remaining
sodium reacts with water.
(5) After the neutralization of sodium, water in the
container contains sodium hydroxide and is AK304538AB
highly alkaline. The water solution should be
disposed of according to local regulations. NOTE: Do not confuse the stem seals for intake
valves with those for exhaust valves.
>>A<< VALVE STEM SEAL INSTALLA- >>B<< VALVE SPRING INSTALLATION
TION
Small diameter
CAUTION
The special tool must always be used when
installing the valve stem seal. Improper installa-
tion 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. AK305040AB
Install the valve spring whose small diameter is

shown from the rocker arm side.
ENGINE OVERHAUL
11B-45
>>C<< RETAINER LOCK INSTALLATION
MD998735
MB991654
AK202723 AE
AK202873 AD
MD998772 Timing belt side
8 6 1 3 9
10 4 2 5 7
AK202806 AB
3. Tighten the bolts to 78 ± 2 N⋅m in the indicated

AK202742 AD
Compress the valve spring using the special tool sequence.

Valve spring compressor (MD998735 or MD998772), NOTE: Use the special tool Cylinder head bolt
then install the retainer lock. wrench (MB991654) to tighten the bolts.
4. Loosen all the bolts completely.
>>D<< CYLINDER HEAD BOLT 5. Tighten the bolts again to a torque of 20 ± 2 N⋅m
INSTALLATION in the indicated sequence.
90˚
Shank length
90˚
Paint marks
AK300591AB AK202720 AB
1. When reusing a cylinder head bolt, check that its CAUTION

nominal length (shank length) is not greater than • If the tightening angle is smaller than 90°,
the limit. If the limit is exceeded, replace the bolt. proper fastening performance could not be
Limit: 99.4 mm assured. Be sure to respect that angle.
2. Apply engine oil to the threads and washer of the • If the bolt is tightened to an angle greater than
bolt. the specified angle, loosen the bolt com-
pletely and then retighten it beginning with
the first step.
6. Make paint marks on each bolt’s 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
Contact
same line. (Should be at
centre of face)
INSPECTION Margin
M1113007000981
CYLINDER HEAD
1. Before cleaning the cylinder head, check it for
traces of water and gas leakage and for cracks AK300593AB
and any other damage.
2. Thoroughly remove oils, scale, sealants, carbon 2. Measure the margin.
and other contamination. Clean the oil passages, Replace the valve if its margin is smaller than the
then check using compressed air that they are not limit.
blocked.
Standard values:
Intake 1.0 mm
Exhaust 1.5 mm
Limits:
Intake 0.5 mm
Exhaust 1.0 mm
AK202724
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 length
total. AK202876 AB
3. Check the cylinder head gasket surface for warp
using a straightedge and thickness gauge. 3. Measure the total length of the valve.
If the surface is warped beyond the limit, grind the Replace the valve if the length is less than the
surface for rectification. limit.
Gasket surface warp Standard values:
Standard value: Less than 0.05 mm Intake 109.5 mm
Limit: 0.2 mm Exhaust 109.7 mm
Grinding limit: 0.2 mm Limits:
Cylinder head height (standard value for new Intake 109.0 mm
part): 131.9 − 132.1 mm Exhaust 109.2 mm
VALVES
1. Check the valve face for correct contact with the
seat. Reface the valve if the contact is partial or
one sided.
ENGINE OVERHAUL
11B-47
VALVE SPRINGS VALVE SEATS
Valve stem
end
Out of square
Valve stem
projection
Free height Spring

seating
surface
AK300594 AB AK202814 AB
1. Measure the free height of the spring. With the valve installed in position and its face
pressed against the valve seat, measure the valve
Replace the spring if its height is smaller than the stem projection (distance between the valve stem
limit. end and spring seating surface). If the measurement
Standard value: 50.4 mm exceeds the limit, replace the valve seat.
Limit: 49.4 mm Standard values:
2. Measure the squareness of the spring. Intake 49.2 mm
Exhaust 48.4 mm
Replace the spring if it is out of square beyond the
limit. Limits:
Standard value: 1.5° or smaller Intake 49.7 mm
Limit: 4° Exhaust 48.9 mm
VALVE SEAT RECONDITIONING

VALVE GUIDE
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 – 1.3mm 0.9 – 1.3 mm

Valve
guide 65˚ 65˚
Stem diameter
15˚ 25˚
Guide inside diameter AK300168 AE
Measure the valve guide inside diameter and valve 43.5˚ – 44˚
stem diameter to calculate the clearance between AK202850 AC
the valve guide and valve stem.
If the limit is exceeded, replace the valve guide or 2. Resurface the valve seat to the indicated width
valve, or both. and angles.
Standard values: 3. After resurfacing, lap the valve and valve seat
Intake 0.02 − 0.05 mm using lapping compound.
Exhaust 0.05 − 0.09 mm
Limits:
Intake 0.10 mm
Exhaust 0.15 mm
VALVE SEAT REPLACEMENT VALVE GUIDE REPLACEMENT

1. Force out the valve guide toward the cylinder
0.5 – 1 mm block using a press.
CAUTION
Do not use a replacement valve guide of the
same size as the removed one.
Cut
2. Machine the valve guide hole in the cylinder head
to the size matched to the selected oversize valve
0.5 – 1 mm guide.
Valve guide hole diameters
AK300719AB
0.05 oversize: 12.05 − 12.07 mm
1. Cut inside of the valve seat to be replaced until its 0.25 oversize: 12.25 − 12.27 mm
wall becomes thin enough for removal, then 0.50 oversize: 12.50 − 12.52 mm
remove the valve seat.
Valve seat
height
19.2 – 19.8 mm
Oversize hole diameter AK202877 AC
AK300720AB
3. Press-fit the valve guide until it remains protruded
2. Rebore the valve seat hole in the cylinder head to above the cylinder head by the amount indicated
a diameter matched to the diameter of the in the drawing.
selected oversize valve seat. Standard value: 19.2 − 19.8 mm
Intake valve seat hole diameters: NOTE: Press the valve guide from above the cyl-
0.3 oversize: 35.30 − 35.33 mm inder head.
0.6 oversize: 35.60 − 35.63 mm NOTE: The valve guides for the intake valves are
Exhaust valve seat hole diameters: different in length from those for the exhaust
0.3 oversize: 33.30 − 33.33 mm valves (45.5 mm for intake valves; 50.5 mm for
0.6 oversize: 33.60 − 33.63 mm exhaust valves)
3. Before fitting the valve seat, cool it in liquid 4. After installing the valve guide, insert a new valve
nitrogen to prevent damage to its hole in the in it to check for smooth movement.
cylinder head due to interference.
4. Resurface the valve seat. See the VALVE SEAT
RECONDITIONING section.
ENGINE OVERHAUL
11B-49
M1113008100464
19 ± 3 N·m
30 31
Apply engine oil to

9
all moving parts
before installation. 28
32
21
23 ± 3 N·m
22
26 20 29
54 ± 5 N·m
23 8
16 24
10 10 ± 2 N·m
25 17 ± 1 N·m 7
15
6
22 ± 4 N·m
19 5
27 19 ± 3 N·m
14 18 23 ± 3 N·m
13 17 36 ± 3 N·m
19 ± 3 N·m 12 23 ± 3 N·m 2
39 ± 5 N·m
11 9.0 ± 3.0 N·m
1
44 ± 5 N·m
9.0 ± 1.0 N·m
4 3
14 ± 2 N·m AK304531AB

1. Drain plug 18.O-ring
>>N<< 2. Drain plug gasket <<D>> >>I<< 19.Flange bolt
3. Oil level sensor >>H<< 20.Front case
>>M<< 4. Oil filter 21.Gasket
<<A>> >>L<< 5. Oil pan 22.Oil pump cover
6. Oil screen >>G<< 23.Oil pump driven gear
7. Gasket >>G<< 24.Oil pump drive gear
8. Baffle plate >>F<< 25.Crankshaft front oil seal
<> >>K<< 9. Oil pressure switch >>E<< 26.Counterbalancer shaft oil seal
10.Oil cooler by-pass valve >>D<< 27.Oil pump oil seal
11. Relief plug 28.Counterbalancer shaft, right
12.Gasket 29.Counterbalancer shaft, left
13.Relief spring <<E>> >>C<< 30.Counterbalancer shaft front bearing
14.Relief plunger <<F>> >>B<< 31.Counterbalancer shaft rear bearing,
15.Oil filter bracket right
16.Gasket <<F>> >>A<< 32.Counterbalancer shaft rear bearing,
<<C>> >>J<< 17.Plug left
REMOVAL SERVICE POINTS Fit the teeth of the special tool in notches of the plug
as shown in the drawing and support the tool with the
<<A>> OIL PAN REMOVAL
special tool to loosen the plug.
1. Remove the oil pan bolts. • Plug wrench (MD998162)
• Plug wrench retainer (MD998783)
MD998727
<<D>> FLANGE BOLT REMOVAL
AK202574 AD
2. Insert the special tool Oil pen remover Plug Crosspoint

(MD998727) into the joint between the cylinder screwdriver
block and oil pan by tapping the tool with a AK202752 AD
hammer.
1. Remove the plug on the left side of the cylinder
3. Remove the oil pan by tapping an edge of the block. Insert a cross point screwdriver (shank
special tool with a hammer to move it sideways. diameter 8 mm) into the plug hole more than 60
mm to prevent the left counterbalancer shaft from
<> OIL PRESSURE SWITCH rotating.
REMOVAL
MD998012
AK304384
AK300617AC
2. Loosen and remove the flange bolt.
Using the special tool Oil pressure switch socket
wrench (MD998012) to removal the oil pressure <<E>> COUNTERBALANCER SHAFT
switch
FRONT BEARING REMOVAL
<<C>> PLUG REMOVAL
MD998162
Front
bearing
MD998371
AK202633 AE
MD998783 AK202585 AC
ENGINE OVERHAUL
11B-51
CAUTION
Remove the front bearing first. Otherwise, the MB991603 MD998705
special tool cannot be used. (Stopper)
Use the special tool Silent shaft bearing puller
(MD998371) to remove the counterbalancer shaft
front bearing from the cylinder block.
<<F>> COUNTERBALANCER SHAFT

Rear bearing
REAR BEARING REMOVAL
AK300619AF
1. Use the special tool Silent shaft bearing puller
(MD998372) to remove the counterbalancer shaft 2. Set the rear bearing on the special tool Silent
rear bearings from the cylinder block. shaft bearing installer (MD998705).
NOTE: The left counterbalancer shaft rear bearing
MB991603
has no oil hole.
3. Force the rear bearing into the cylinder block by
sticking the special tool.
>>B<< COUNTERBALANCER SHAFT

REAR BEARING, RIGHT INSTALLATION
MD998372
AK202634 AC
2. When removing the rear bearing of the left

MD998705
counterbalancer shaft, install the special tool (Guide pin)
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.
AK304433AB
>>A<< COUNTERBALANCER SHAFT 1. Install the guide pin of the special tool Silent shaft
bearing installer (MD998705) on the cylinder
REAR BEARING, LEFT INSTALLATION
block.
MB991603 Front bearing right
Ratchet ball Oil hole
MD998705
(Stopper)
AK202548 AC
AK300620AE
1. Install the special tool Silent shaft bearing installer
stopper (MB991603) on the cylinder block. 2. Set the bearing on the special tool with its oil hole
on the ratchet ball.
MD998705
(Stopper)
MD998705
(Guide pin)
MD998705
(Guide pin) AK304434AC AK304433AB
2. Install the guide pin of the special tool on the

MD998705
(Stopper) cylinder block.
Rear bearing right
Ratchet ball
Oil hole
AK300622AF
3. Insert the special tool while passing the guide pin

through its hole and force the bearing into position AK300621AE
by striking the tool.

3. Set the bearing on the special tool with its oil hole
on the ratchet ball.
>>C<< COUNTERBALANCER SHAFT
FRONT BEARING INSTALLATION
MD998705
MD998705 (Stopper) (Stopper)
MD998705
Rear bearing (Guide pin) AK304434AC
installing portion
AK300623AD
1. Detach from the special tool Silent shaft bearing

installer (MD998705) its element for rear bearing
installation.
AK300624
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.
ENGINE OVERHAUL
11B-53
>>D<< OIL PUMP OIL SEAL >>G<< OIL PUMP DRIVEN GEAR/OIL
INSTALLATION PUMP DRIVE GEAR INSTALLATION
Socket wrench
Oil seal Alignment

marks
Front case
AK301070AE AK202660 AB
Use an appropriate socket wrench to install the oil Apply engine oil generously to the gears and line up
pump oil seal. the alignment marks.
>>E<< COUNTERBALANCER SHAFT OIL >>H<< FRONT CASE INSTALLATION

SEAL INSTALLATION Counterbalancer
shaft, left
Socket wrench
Counterbalancer
Oil seal Front case MD998285 shaft, right
AK202577 AC
AK301071AE
1. Install the special tool crankshaft front oil seal
Use an appropriate socket wrench to install the coun- guide (MD998285) on the front end of crankshaft
terbalancer shaft oil seal. and apply a thin coat of engine oil to the outer
surface of the special tool. Be sure to use the
>>F<< CRANKSHAFT OIL SEAL special tool when the front case is fitted with an oil
INSTALLATION seal.
2. Install the front case on the cylinder block with a
MD998375 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
Oil seal
temporarily tighten the washer-assembled bolts.
Front case
AK301072AE
Use the special tool Crankshaft front oil seal installer

(MD998375) to install the crankshaft oil seal.
MD998285
AK202656 AC
4. Tighten all the bolts to the specified torques.

>>I<< FLANGE BOLT INSTALLATION >>K<< OIL PRESSURE SWITCH

INSTALLATION
Crosspoint
screwdriver
AK202641 AC
AK300616AB
1. Insert a correspond screwdriver (shank diameter
8 mm) into the hole in the left side of the cylinder CAUTION
block to prevent the counterbalancer shaft from Be careful not to block the oil passage with seal-
rotating. ant.
1. Apply sealant to the threaded portion.
Specified Sealant:
3M ATD Part No.8660 or equivalent
MD998012
AK304385
2. Tighten the flange bolts.
>>J<< PLUG INSTALLATION AK300617AC
1. Install a new O-ring on the front case.

2. Tighten the oil pressure switch together with the
cylinder block by the specified torque using of the
MD998162
special tool Oil pressure switch socket wrench
(MD998012).
>>L<< OIL PAN INSTALLATION

CAUTION
Do not apply FIPG over remaining old FIPG.
MD998783 AK202585 AC
Doing so could result in oil leakage.
2. Use the special tool to tighten the plug to the 1. Thoroughly remove old FIPG from the gasket
specified torque. surfaces of the cylinder block and oil pan.
• Plug wrench (MD998162)
• Plug wrench retainer (MD998783)
ENGINE OVERHAUL
11B-55
1. Clean the installation surface of the filter bracket.
Timing belt side
2. Apply engine oil to the o-ring of the oil filter.
3. Install the oil filter to the bracket and tighten it to
Bolt hole
area the specified torque.
4. If no torque wrench can be used for tightening,
use the following procedure:
Grooved (1) Screw in the oil filter until its o-ring contacts
area
AK202694 AB the oil filter bracket.
(2) Tighten the oil filter 3/4 turn.
CAUTION
Too much FIPG will squeeze out, blocking cool-
ant or oil passages, while too thin a bead could
>>N<< DRAIN PLUG GASKET
result in leakage. INSTALLATION
2. Apply a 4 mm diameter bead of FIPG to the flange
surface all around the oil pan. Drain plug
Specified sealant:
equivalent
NOTE: In the grooved areas on the oil pan flange,
apply FIPG bead along the centre of the groove.
Timing belt side

Oil pan
M6 × 8
Oil pan
side
AK202693 AC
3. Install the shorter bolts in the locations indicated

in the drawing. Gasket
AK300601AE
>>M<< OIL FILTER INSTALLATION CAUTION

Installing the gasket with the wrong side facing
the oil pan will result in oil leakage.
Bracket side Replace the drain plug gasket with a new one. Install
it with the side indicated in the drawing toward the oil
pan.
Engine oil
AK202556 AB
INSPECTION OIL COOLER BY-PASS VALVE

M1113008200308
COUNTERBALANCE SHAFTS
L
1. Check that the oil holes are not blocked.
Clean if necessary.
Valve AK000032 AC
1. Make sure that valve moves smoothly.

2. Ensure that the dimension L measures the
AK202835AB
standard value under normal temperature and
humidity.
2. Check the journals for seizure, damage and Standard value: 34.5 mm
defective contact with bearings.
3. The dimension must be the standard value when
If any of these faults is found, replace the measured after the valve has been dipped in 97 to
counterbalance shaft, bearings and/or oil pump 103°C oil.
case assembly.
OIL PUMP
OIL LEVEL SENSOR
AK202831
AK304606AB
1. Install the drive and driven gears in the oil pump
case. Put the oil level sensor in oil, then move the float
2. Measure the gear side clearance using a straight up and down with the oil at a temperature either
edge and thickness gauge. lower than 40°C or higher than 80°C, and check
for continuity.
Standard values:
Drive gear 0.08 − 0.14 mm 40°C
Driven gear 0.06 − 0.12 mm Float position Switch ON/OFF
Condition when down ON (continuity)
Condition when up ON (continuity)
80°C
Float position Switch ON/OFF
Condition when down OFF (no continuity)
Condition when up ON (continuity)
ENGINE OVERHAUL
11B-57
M1113008401338
6
7
Apply engine oil to
all moving parts 8
10
9 4
12
11
2
20 ± 2 N·m +90˚ to 94˚
1 AK501781AB

>>G<< 1. Connecting rod cap nut >>C<< 7. Piston ring No. 2
<<A>> >>F<< 2. Connecting rod cap >>B<< 8. Oil ring
>>E<< 3. Connecting rod bearing <<C>> >>A<< 9. Piston pin
<> >>D<< 4. Piston and connecting rod assembly 10. Piston
5. Connecting rod bearing 11. Connecting rod
>>C<< 6. Piston ring No. 1 12. Bolt
REMOVAL SERVICE POINTS <<C>> PISTON PIN REMOVAL

<<A>> CONNECTING ROD CAP Guide A: 18.9 mm
REMOVAL Guide B
Push rod
Cylinder Guide A: 17.9 mm

number
Guide C
Guide A: 20.9 mm
AK202812 AB
Base
Mark the cylinder number on the side of the connect-
ing rod big end as a guide for reassembly.
Guide A: 21.9 mm
<> PISTON AND CONNECTING ROD
ASSEMBLY REMOVAL
MB992010
AK301431AD
The special tool Piston pin setting tool (MD998780),

consists of the elements shown in the drawing.
P Push rod
Crank pin
AK402310 AC
Front mark
1. Not to damage the crank pin, attach a special tool
Bolt guide (MB992010), to the connecting rod Front mark
bolt.
2. Remove the piston and connecting rod assembly P
from the cylinder block.
Guide C
Base
AK501782AB
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.
ENGINE OVERHAUL
11B-59
NOTE: Keep the disassembled pistons, piston
pins and connecting rods cylinder by cylinder.
Push rod
INSTALLATION SERVICE POINTS P
>>A<< PISTON PIN INSTALLATION

Front mark
Timing belt side Crankshaft
bore size mark Front mark
P
No.4
No.3 Guide A
No.2
No.1
Base
AK202923 AB
Guide B
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 AK501783AB
I A 7. Install the piston and connecting rod assembly

II No mark with the tools onto the special tool Piston Setting
Base, ensuring that the piston front mark faces
III C
upwards.
NOTE: The piston size mark is located on the pis- 8. Using a press, press fit the piston pin. If the force
ton top surface. required to press fit the piston pin is less than the
2. Insert the special tool Push Rod into the piston standard value, replace the piston pin (piston
pin, and install Guide A. assembly) or the connecting rod, or both.
3. Assemble the piston and the connecting rod Standard value: 7,350 − 17,100 N
together, ensuring that their front marks are
aligned with each other.
>>B<< OIL RING INSTALLATION
4. Apply engine oil onto the periphery of the piston
pin. Coil expander
5. Insert the piston pin assembled in Step 1 above end gap
into the piston pin boss. Guide A end of the piston

pin should be inserted first into the front mark end
of the boss.
L
Oil ring
end gap
AK502373 AB
1. Fit the oil ring coil expander and oil ring into the
piston ring groove.
NOTE: Locate the oil ring and coil expander end
Guide B Guide A gaps as shown in the drawing.
AK304522AC
NOTE: New coil expander and oil ring are an
6. Insert Guide B into Guide A with having 1.25 mm identified by colour marks as follows:
of the clearance "L" between Guide A and B.
Size Colour mark Using a piston ring expander, install the piston rings
with their identification marks facing up (toward the
Standard No mark piston crown).
0.50 mm oversize Red Identification marks:
1.00 mm oversize Yellow No.1 ring: 1R
No.2 ring: 2R
CAUTION
Use of ring expander to expand the oil ring end NOTE: Each of the available piston rings has a size
gap can break the oil ring, unlike other piston mark as follows:
rings. Size Size mark
Oil ring end Standard No. 1 ring No mark (white paint on
periphery)
No. 2 ring No mark
0.50 mm oversize 50
1.00 mm oversize 100
>>D<< PISTON AND CONNECTING ROD

ASSEMBLY INSTALLATION
AK202785 AD
1. Apply engine oil generously to the piston's outside
2. To install each coil expander, first fit one end of surface, piston rings, and oil ring.
the oil ring into the piston groove, then press the
remaining portion progressively into position by
Coil expander No. 1
finger as shown in the drawing.
3. Make sure that the installed oil ring move
smoothly in either direction.
Piston pin
>>C<< PISTON RING NO. 2 / PISTON

RING NO. 1 INSTALLATION
No. 2 Oil ring
AK202730 AE
2. Align the end gaps of the piston rings and oil ring
(oil ring and coil expander) as shown in the
drawing.
Piston ring 3. Insert the piston and connecting rod assembly
expander
from the top of cylinder with the front mark on the
crown toward the camshaft sprocket.
AK202786 AC Bolt
Identification mark
Size marks
MB992010
No. 1
Connecting rod
No. 2
AK402300AC
AK202807 AB 4. Not to damage the crank pin, attach a special tool

Bolt guide (MB992010), to the connecting rod
bolt.
ENGINE OVERHAUL
11B-61
3. Connecting rod bearing identification mark is
stamped in the indicated location on each
bearing.
Crankshaft pin Connecting rod
bearing
Identification Diameter mm Identification
mark mark
I 44.995 − 45.000 0
AK202798 II 44.985 − 44.995 1
CAUTION III 44.980 − 44.985 2
• Do not strike the assembly with a large force. <Bearing selection example>
Doing so could break the piston rings. If the crankshaft pin diameter mark is “I,” select a
• When striking the assembly into cylinder, do bearing marked “1.”
not allow it to interfere with the oil jet.
If the crankshaft pin diameter mark is illegible,
5. Use a piston ring band to hold the piston rings measure the pin diameter and select a bearing
compressed when inserting the piston and with the mark corresponding to the measurement.
connecting rod assembly into the cylinder.
4. Install the upper and lower halves of the selected
bearing on the connecting rod big end and cap,
>>E<< CONNECTING ROD BEARING respectively.
INSTALLATION
1. When replacing the connecting rod bearing, >>F<< CONNECTING ROD CAP
select a bearing of the size appropriate for the INSTALLATION
crankshaft pin diameter in accordance with the
crankshaft pin and connecting rod bearing
matching table shown below.
Locations of crankshaft pin diameter Cylinder
marks number
Bearing
locating
No. 2 notches
No. 1 No. 3 AK202813 AB
1. Install the bearing cap on the connecting rod while

No. 4 AK202909 AB aligning the marks made during disassembly. If
the connecting rod is new and has no alignment
2. Crankshaft pin diameter marks are stamped in the
mark, assemble it with the cap such that the both
indicated locations.
bearing locating notches are on the same side as
shown in the drawing.
Identification mark
AK203964AC
AK202821
2. Make sure that the thrust clearance of the INSPECTION

connecting rod big end is proper. M1113008500990
Standard value: 0.10 − 0.25 mm PISTON RING

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.
AK202787
Whether or not the bolt has been elongated can
be determined by running a nut with fingers 1. Measure the clearance between each piston ring
through all the threads of the bolt. If the nut does and its groove. If the limit is exceeded, replace the
not turn smoothly over all the threads, the bolt has ring or piston, or both.
been elongated and must be replaced.
Standard values:
2. Apply engine oil to the threads and bearing No. 1 ring: 0.03 − 0.07 mm
surface of each nut before installation. No. 2 ring: 0.02 − 0.06 mm
3. Finger-tighten the nuts on the bolts, then tighten Limits: 0.1 mm
the nuts alternately and repeatedly to install the
cap properly.
Force ring down
4. Tighten the nuts to a torque of 20 ± 2 N⋅m. with piston
Paint marks
90˚ to 94˚
Paint marks
Piston ring End gap AK202788 AB

Nut Bolt
2. Install a piston ring or oil ring side rail into the
AK300612AC cylinder bore and force it down with the head of a
piston until the ring is at right angles to the
5. Make a paint mark on the head of each nut. cylinder wall. Measure the end gap with a
CAUTION thickness gauge.
• If the tightening angle is less than 90°, ade- NOTE: If the end gap is excessive, replace the
quate tightness could not be assured. piston ring.
• If the tightening angle exceeds 94°, loosen the Standard values:
nut completely and then perform the tighten- No. 1 ring: 0.20 − 0.30 mm
ing procedure again beginning with the first No. 2 ring: 0.30 − 0.50 mm
step. Oil ring: 0.10 − 0.40 mm
6. Make a paint mark on the bolt at a point 90° to 94° Limits:
away from the paint mark made on the nut in the No. 1 ring: 0.8 mm
tightening direction. No. 2 ring: 0.8 mm
7. Turn the nut 90° to 94° to bring the mark on the Oil ring: 1.0 mm
nut into alignment with that on the bolt.
ENGINE OVERHAUL
11B-63
CRANKSHAFT PIN OIL CLEARANCE
(PLASTIGAGE METHOD)
1. Wipe off oil from the crankshaft pin and
connecting rod bearing.
2. Cut a piece of plastigage 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 torque 20 ± 2 N⋅m + 90°
AK202848
to 94°.
4. Remove the nuts, then remove the connecting rod 5. Measure the largest width of the crushed
cap carefully. plastigage using the ruler printed on the bag of the
plastigage.
Standard value: 0.02 − 0.04 mm
Limit: 0.1 mm

M1113008700693
11 ± 1 N·m
3
1
6
15 132 ± 5 N·m
4
5 9.0 ± 1.0 N·m
11 ± 1 N·m
12 11
14
13
32 ± 2 N·m
10
8 Apply engine oil to

all moving parts
25 ± 2 N·m +90˚
7
AK203816 AC

1. Flywheel bolt >>B<< 9. Crankshaft bearing, lower
2. Flywheel 10. Crankshaft
3. Rear plate >>B<< 11. Crankshaft bearing, upper
4. Bell housing cover >>A<< 12. Thrust bearing
>>E<< 5. Oil seal case 13. Check valve
>>D<< 6. Oil seal 14. Oil jet
>>C<< 7. Bearing cap bolt 15. Cylinder block
>>C<< 8. Beam bearing cap
ENGINE OVERHAUL
11B-65
INSTALLATION SERVICE POINTS <Bearing selection example>
>>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
Groove
measurement.
AK202769 AB Timing belt side
Install the two thrust bearings in the No. 3 bearing Diameter identification marks of
bore in the cylinder block. Each thrust bearing must bearing bores in cylinder block
be installed with the grooved end toward the crank-
No. 4
shaft web. No. 3
No. 1 No. 2 No. 5
NOTE: Applying engine oil to the bearings will help
facilitate holding them in position.
>>B<< CRANKSHAFT BEARING

INSTALLATION
Cylinder
Location of crankshaft journal bore size
diameter marks mark
No. 2
No. 1 No. 3
AK304518AB
No. 4 No. 5 AK202908 AB
2. The diameter identification marks of the bearing
1. Location of crankshaft journal diameter marks bores in the cylinder block are stamped in the
location shown in the drawing.
Crankshaft journal diameter Cylinder block bearing Crankshaft bearing
bore
Identification mark Journal diameter Identification mark Identification mark
measurement mm
0 56.994 − 57.000 0 0
1 1
2 2
1 56.988 − 56.994 0 1
1 2
2 3
2 56.982 − 56.988 0 2
1 3
2 4
Crankshaft bearing identification mark location
8 4 1 5 9
7 3 2 6 10
Identification mark
AK304464AC Arrow AK202737 AB
3. The size mark of each crankshaft bearing is 4. Tighten the bolts to 25 ± 2 N⋅m in the indicated
indicated by ink in the location shown in the sequence.
drawing. 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.
Groove
Paint mark Paint mark
For upper
For lower
AK301466AD
90˚ to 100˚
4. Install bearing halves with oil grooves in the AK202722 AB

cylinder block bearing bores.
CAUTION
5. Install bearing halves with no oil grooves in the
• If the tightening angle is less than 90°, ade-
beam bearing cap. quate tightness could not be assured.
• If the tightening angle exceeds 100°, loosen
>>C<< BEAM BEARING CAP/BEARING the bolt completely and then perform the
tightening again beginning with the first step.
CAP BOLT INSTALLATION
7. Turn clockwise the bolts 90° to 100° in the
1. Install the beam bearing cap on the cylinder block
indicated tightening sequence to bring the mark
with the arrow pointing to the timing belt.
on each bolt head into alignment with that on the
bearing cap.
Shank length
AK301471AD
2. Measure the shank length of each bearing cap AK202823
bolt before installation. If the measurement 8. After installing the beam bearing cap, measure
exceeds the limit, replace the bolt. the end play of the crankshaft. If the end play
Limit: 71.1 mm exceeds the limit, replace the crankshaft bearings.
3. Apply engine oil to the threads and bearing Standard value: 0.05 − 0.25 mm
surface of the bolt. Limit: 0.4 mm
ENGINE OVERHAUL
11B-67
>>D<< REAR OIL SEAL INSTALLATION Measure the crankshaft oil clearance using a plasti-
gage as follows:
MB990938 1. Wipe off oil from the crankshaft journal surface
and the crankshaft bearing inner surface.
2. Install the crankshaft.
MD998776 Plastigage
AK202827 AC
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) AK202826 AB
3. Cut a piece of plastigage whose length is

>>E<< REAR OIL SEAL CASE equivalent to the width of the bearing and place it
INSTALLATION on the crankshaft journal in parallel with its axis.
1. Remove completely old FIPG remaining on the 4. Install the crankshaft bearing cap carefully and
rear oil seal case and cylinder block. tighten the bolts to the specified torque of 25 ± 2
N⋅m + 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

Plastigage
seal case as shown in the drawing.
AK202822 AB
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or 6. Measure the largest width of the crushed
equivalent plastigage using the ruler printed on the bag of the
plastigage.
3. Install the oil seal into the cylinder block after
applying an appropriate amount of engine oil to Standard value: 0.03 − 0.04 mm
the entire circumference of its lip portion. Limit: 0.1 mm
4. Install the rear oil seal case by tightening its bolts
to 11 ± 1 N⋅m. CYLINDER BLOCK
INSPECTION 1. Visually check the cylinder block for scratches,
M1113008800485 rust, and any other corrosion. Also check it for
CRANKSHAFT OIL CLEARANCE cracks using a flaw detecting penetrant.
(PLASTIGAGE METHOD) If any defect is evident, replace the cylinder block.
This plastigage method is recommended as a sim-
plest way of measuring the crankshaft oil clearance.
BORING CYLINDERS
1. Select an oversize of the pistons to be used
based on the largest of the cylinder bores.
AK401851
2. Use a straightedge and thickness gauge to check 12.5 mm

the cylinder block top surface for warp. Piston diameter
AK203804 AC
Make sure that the surface is free from remaining
gasket material and other foreign matter. 2. Oversize pistons are available in two oversizes:
Standard value: 0.05 mm 0.50 mm and 1.00 mm. Bore each cylinder to a
Limit: 0.1 mm size that provides the standard clearance when
combined with the selected piston. The reference
3. If the distortion is excessive, correct within the position for piston diameter measurement is as
allowable limit or replace. shown in the drawing.
Grinding limit: 0.2 mm 3. Based on the piston diameter measurement,
*Includes/combined with cylinder head calculate the boring finish dimension.
grinding • Boring finish dimension = [Piston diameter] +
Cylinder block height (when new): 284 mm [0.02 − 0.04 mm (clearance between piston and
4. Check cylinder walls for scratches and seizure. cylinder)] − [0.02 mm (honing margin)]
If defects are evident, rebore to oversize or CAUTION
replace the cylinder block. 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.
12 mm
5. Hone the bored cylinders to the final finish
dimension (piston diameter + clearance between
Center piston and cylinder).
Bottom 6. Check the clearance between the piston and
AK202731 AB cylinder.
5. Use a cylinder gauge to measure the cylinder Standard value: 0.02 − 0.04 mm
bore diameter and taper.
If the cylinder is worn badly, rebore it to an
oversize and replace the piston and piston rings
with ones matched with the new bore size.
Taper: 0.01 mm
11-1
GROUP 11
ENGINE
CONTENTS
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

NOTES
52-1
GROUP 52
INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM(SRS)
CONTENTS
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . 52B

NOTES
52A-1
GROUP 52A
INTERIOR
CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . 52A-2 HEADLINING . . . . . . . . . . . . . . . . . . . 52A-17

INSTRUMENT PANEL ASSEMBLY*. 52A-2
REMOVAL AND INSTALLATION . . . . . . . . 52A-2 INSIDE REAR VIEW MIRROR . . . . . . 52A-18
DISASSEMBLY AND REASSEMBLY. . . . . 52A-6
FRONT SEAT ASSEMBLY. . . . . . . . . 52A-18
FRONT FLOOR CONSOLE REMOVAL AND INSTALLATION . . . . . . . . 52A-18
ASSEMBLY . . . . . . . . . . . . . . . . . . . . 52A-7 DISASSEMBLY AND REASSEMBLY . . . . . 52A-19
REAR SEAT ASSEMBLY. . . . . . . . . . 52A-20
REAR FLOOR CONSOLE ASSEMBLY 52A-8 REMOVAL AND INSTALLATION . . . . . . . . 52A-20
REMOVAL AND INSTALLATION . . . . . . . . 52A-8 DISASSEMBLY AND REASSEMBLY . . . . . 52A-21
DISASSEMBLY AND REASSEMBLY. . . . . 52A-8
FRONT SEAT BELT . . . . . . . . . . . . . . 52A-22
TRIMS. . . . . . . . . . . . . . . . . . . . . . . . . 52A-10 REMOVAL AND INSTALLATION . . . . . . . . 52A-22
REAR SEAT BELT . . . . . . . . . . . . . . . 52A-23
DOOR TRIM . . . . . . . . . . . . . . . . . . . . 52A-12 REMOVAL AND INSTALLATION . . . . . . . . 52A-23
WARNING
NOTE
52A-2 INTERIOR
SPECIAL TOOL
SPECIAL TOOL
M1521000600349

MB990784 Ornament remover Removal of switch, trim,
etc.
MB990784
INSTRUMENT PANEL ASSEMBLY

M1521001701018
The following bolts and screws are used for installing
the instrument panel. Bolts and screws are indicated
as marks shown in the illustration in the sections of
"Removal and Installation" and "Disassembly and
Reassembly."
Name Symbol Size (D × L) mm Colour Shape
Tapping screw a 5 × 16 Black
b 5 × 16 -
c 5 × 16 Green ACX01282
d 5 × 12 -
ACX01283
Bolt with washer e 6 × 12 -
ACX02229
f 5 × 20 -
AC005505
D: Thread diameter L: Effective thread length

INTERIOR
52A-3
CAUTION
• Refer to GROUP 52B, SRS Service Precautions P.52B-3 and Driver’s, Passenger’s (front) Air Bag
Module and Clock Spring P.52B-110 before removing the passenger’s (front) air bag module.
• Do not subject the SRS-ECU to any shocks when removing or installing the instrument panel.
• Removal and Installation of Front Pillar Trim (Refer to
P.52A-10).
• Hood Opener Lever (Refer to GROUP 42, Hood P.42-4).
2 3
20 21
b a
18
1 e
e e
e 19
4 e
8 e 18
c
c e
e
13 e 16
5 a
a 15
b
10 11
12
a 14 17
6
7 9
c
AC309832 AC

1. Column cover 14. Centre lower case
2. Meter bezel 15. Stopper
3. Combination meter 16. Glove box
4. Instrument panel ornament 17. Harness cover
5. Under cover 18. Instrument panel side cover
6. Switch panel 19. SRS passenger’s (front) air bag
7. Side box module mounting bolt
8. Lower frame • Steering column shaft mounting bolt
9. Heater control knob (Refer to GROUP 37, Steering
10. Centre panel Column Shaft P.37-15).
11. Heater control assembly mounting 20. Instrument panel assembly
screw <<A>> 21. SRS passenger’s (front) air bag
12. Heater control assembly module
13. Centre air outlet panel
52A-4 INTERIOR
CLIP AND CLAW POSITION
C B
D
B A
A
D
G
H G
H
F F
I I
Note
(1) : Clip positions
(2) : Claw positions
Clip Column cover
Instrument panel
Claw assembly Claw
Instrument panel
assembly
Section D – D Section E – E Section F – F
Clip Clip
Claw
Claw Instrument panel Instrument panel

assembly assembly
Instrument panel
assembly
Section G – G Section H – H Section I – I
Clip Clip Instrument panel
Instrument panel assembly Clip
assembly
Claw
Instrument panel
assembly
AC504401 AB
INTERIOR
52A-5
REMOVAL SERVICE POINT Insert the flat-tipped screwdriver into the position
shown in the illustration and pull up the screwdriver
<<A>> SRS PASSENGER’S (FRONT) AIR
to disengage the claws for removal of the passen-
BAG MODULE REMOVAL ger’s (front) air bag module.
CAUTION
• Do not damage the claws of the hinge when
removing the passenger’s (front) air bag mod-
ule.
• Store the removed passenger’s (front) air bag
module with the deployed side facing upward,
in a clean and dry place.
AC005174
52A-6 INTERIOR

M1521001900622
13 12 14
d
2
d
d
2
d
4 3 13
d d d d
5
d
7 6 d d
d d
d 7
f
d f
10
d
16 d
d
15 9 8
d d
1 d
15
d
11
AC005175 AG

1. Instrument panel upper support 9. Centre lower reinforcement
2. Side defroster duct 10. Glove box striker
3. Centre defroster duct 11. Glove box cover
4. Distribution duct 12. Instrument panel pad
5. Driver side upper bracket 13. Side demister
6. Centre upper reinforcement 14. Defroster garnish
7. Instrument panel centre 15. Side air outlet assembly
reinforcement 16. Instrument panel
8. Bridge reinforcement
INTERIOR
FRONT FLOOR CONSOLE ASSEMBLY
52A-7
FRONT FLOOR CONSOLE ASSEMBLY
M1521005200164

• Removal and Installation of Rear Floor Console (Refer to
P.52A-8).
5
9
8 10 6 4
3
13
A
A
1
7
2
Note 12
: Clip positions
Section A – A
6
11
10
Clip
AC504404 AB

1. Console side cover (LH) 7. Shift lever cover
2. Console side cover bracket <R.H. 8. Cigarette lighter
drive vehicles> 9. Ashtray
3. Console side cover (RH) <L.H. 10. Front floor console
drive vehicles> 11. Front floor console bracket
4. Shift lever knob 12. Harness
5. Front floor console assembly 13. Console side cover bracket <L.H.
6. Front floor console panel drive vehicles>
52A-8 INTERIOR
REAR FLOOR CONSOLE ASSEMBLY

M1521005700084
AC211586 AB

1. Rear console assembly • Lower centre pillar trim (refer to
• Rear seat cushion assembly (refer P.52A-10).
to P.52A-20). • Floor carpet
• Front scuff plate (refer to 2. Rear console bracket
P.52A-10).
• Rear scuff plate (refer to P.52A-10).

M1521005900118
5
4 6
7
3 8
10
1
2
9 AC211588 AB

1. Ashtray 6. Upper lid lock
2. Cup holder 7. Lower lid striker
3. Hole lock 8. Hinge bracket
<<A>> 4. Console lid assembly 9. Box
5. Console lid 10. Rear floor console
INTERIOR
52A-9
DISASSEMBLY SERVICE POINT Insert the special tool ornament remover
(MB990784) into the hinges of the console lid
<<A>> CONSOLE LID ASSEMBLY
assembly and the rear floor console through the ash-
REMOVAL tray mounting hole to pry for removal.
Console lid assembly
Rear floor
console Ashtray mounting
hole
A
View A
Hinges
MB990784
AC005508 AD
52A-10 INTERIOR
TRIMS
TRIMS
M1521001100499
22 ± 4 N·m
14
10 15
16
9 5 13
17 12
4
6 18 12
44 ± 10 N·m
11
8
20
21
2 3
1 7
19
22
AC309857AB
1. Front scuff plate 12. Speaker garnish

2. Cowl side trim 13. Retractor cover
3. Rear scuff plate 14. Child restraint fitting
4. Front door opening trim 15. Cover
5. Rear door opening trim 16. Spacer
<<A>> 6. Front pillar trim 17. Plain washer
7. Lower centre pillar trim 18. Fiber washer
8. Front seat belt connection 19. Rear end trim
9. Upper centre pillar trim 20. Trunk room side trim lid
10. Rear pillar trim 21. Trunk room side trim
11. Rear shelf trim 22. Trunk room front trim
INTERIOR
TRIMS
52A-11
CLIP POSITION
B B D
D GG H
E
E
B B B H
B
F
A F
A
I
C
I
C C
Note
: Clip positions
: Claw positions

Front scuff plate,
Clip rear scuff plate
Headlining
Front pillar trim Front pillar trim, Clip

upper centre pillar trim,
Clip rear pillar trim
Section D – D Section E – E Section F – F
Rear shelf trim

Clip Speaker garnish
Clip
Clip
Rear pillar trim
Section G – G Section H – H Section I – I
Rear end trim
Rear shelf trim Rear shelf trim
Retractor
cover
Claw Clip
AC504405AB
52A-12 INTERIOR
DOOR TRIM
REMOVAL SERVICE POINT Release the clip by pulling in the direction shown in
the illustration and remove the front pillar trim.
<<A>> FRONT PILLAR TRIM REMOVAL
Section A - A
Front pillar
trim Front pillar
trim
A
A Instrument
panel
AC005511AB
DOOR TRIM
M1521006400213
<Front door trim>
2
3
AC210022 AB

1. Cap <<A>> 4. Door inside handle cover
2. Pull handle box 5. Front door trim
3. Power window switch panel assembly 6. Front door pull handle bracket
INTERIOR
DOOR TRIM
52A-13
AC208724
<Rear door trim>
6
1
2
5
AC210019 AB

1. Cap <<A>> 4. Door inside handle cover
2. Pull handle box 5. Rear door trim
3. Power window switch panel 6. Rear door pull handle bracket
assembly
52A-14 INTERIOR
DOOR TRIM
CLIP AND CLAW POSITIONS
<Front door trim>
C
B
View A View B Power window switch View C

Front door trim
panel assembly
Cap
F F F F
E E G G
D E E
F F F F
D
Section D – D Section E – E
Power window switch
panel assembly
Clip Front door trim
Front door trim

Door panel Clip
Section F – F Section G – G
Power window switch Cap
panel assembly Pull handle box
Front door trim
Note Claw
(1) : Clip positions Claw
AC210245 AE
INTERIOR
DOOR TRIM
52A-15
<Rear door trim>
View A View B Power window switch View C

Rear door trim
panel assembly
Cap
F F F
F G G
E E
F E E
D F F F
Section D – D Section E – E Power window switch

panel assembly
Clip
Rear door trim
Rear door trim

Door panel Clip
Section F – F Section G – G
Power window switch
panel assembly Cap Pull handle box
Rear door trim
Note Claw
(1) : Clip positions Claw
AC211593 AF
52A-16 INTERIOR
DOOR TRIM
REMOVAL SERVICE POINT Door inside Special tool

<<A>> DOOR INSIDE HANDLE COVER handle cover insertion
position
REMOVAL A
A
Tapping screw cap
MB990784
Section A – A
Door inside
handle cover
AC100003AB
1. Insert a flat-tipped screwdriver into the rear end of

Door trim
the tapping screw cap on the door inside handle
cover, and pry out the cap in the direction shown.
Then remove the tapping screw. Claw
AC504658AB
2. Insert special tool ornament remover (MB990784)

into the clearance between the door inside handle
cover and the door inside handle, and disengage
the claws of the door inside handle.
3. Insert special tool ornament remover (MB990784)
into the rear end of the inside handle cover, and
pry out the cover in the direction shown. Then
remove the door inside handle cover.
INTERIOR
HEADLINING
52A-17
HEADLINING
M1521001400393

Front Pillar Trim, Centre Pillar Trim Upper, Rear pillar Trim
Removal and Installation (Refer to P.52A-10).
4 2
3
1
4 5 AC304633 AB

1. Assist grip <<A>> 4. Sunvisor holder
2. Room lamp assembly 5. Sunvisor assembly
3. Front room lamp • Front floor console assembly (Refer
to P.52A-7).
<> 6. Headlining

<<A>> SUNVISOR HOLDER REMOVAL Insert the special tool ornament remover
(MB990784) into the claws of the sunvisor holder to
remove the hinges.
MB990784
<> HEADLINING REMOVAL
Bend the headlining to removal from the front pas-
senger’s door.
MB990784
Sunvisor holder
AC304786 AB
52A-18 INTERIOR
INSIDE REAR VIEW MIRROR
INSIDE REAR VIEW MIRROR

M1521002600260
REMOVAL SERVICE POINT 1. Disengage claw A and lower the cover in the
arrow 1 direction.
3
Claw A 2. Push claw B in the arrow 2 direction to unlock,
2
and pull out the mirror in the arrow 3 direction.
Cover
Claw B
AC209066 AC
FRONT SEAT ASSEMBLY

M1522001300429
45 ± 10 N·m
30 ± 5 N·m
45 ± 10 N·m
1 AC310714 AB
Removal steps
1. Front seat anchor cover
>>A<< 2. Front seat assembly
INTERIOR
FRONT SEAT ASSEMBLY
52A-19
INSTALLATION SERVICE POINT Temporarily tighten the nuts and bolts in all mounting
locations shown in the illustration with no load
>>A<< FRONT SEAT ASSEMBLY INSTAL-
applied to the front seat cushion, and check the
LATION operation of the seat slide.
1.
2. Tighten the nuts and bolts in all mounting loca-

tions to the specified torque.
AC310736 AB

M1522001500519
22 ± 3 N·m
6
1
5
44 ± 10 N·m
22 ± 3 N·m
9 7
2
4 22 ± 3 N·m
11
10 3
AC310735 AB
22 ± 3 N·m
52A-20 INTERIOR
REAR SEAT ASSEMBLY

1. Cap 7. Cushion shield outer
2. Reclining adjuster knob 8. Seatback assembly
3. Slide adjuster outer 9. Seat cushion assembly
4. Slide adjuster inner 10. Snap ring
5. Inner seat belt 11. Slide adjuster lever
6. Cushion shield inner
REAR SEAT ASSEMBLY

M1522001800338
1
5
1
22 ± 4 N·m
3
2
6 AC310031AB
1. Headrestraint Removal steps (Continued)

Removal steps 4. Armrest
>>B<< 2. Rear seat cushion assembly >>A<< 5. Rear seatback assembly
3. Armrest spacer 6. Rear seat hook
INTERIOR
REAR SEAT ASSEMBLY
52A-21
>>A<< INSTALLATION OF REAR SEAT- >>B<< INSTALLATION OF REAR SEAT
BACK ASSEMBLY CUSHION ASSEMBLY
Rear seat cushion

Rear seatback assembly
assembly
Attachment wire
Rear seat hook
Hook
AC005521AB
AC005519AB
Press the rear seatback assembly in the direction Fit the rear seat cushion into the rear seat hook
shown in the illustration and fit the attachment wire securely.
into the hook securely to install the rear seatback
assembly.

M1522002000380
4
7
4
6
5N
N 1 AC310045 AB

1. Hog ring 5. Hog ring
2. Rear seat cushion cover 6. Rear seatback cover
3. Rear seat cushion pad 7. Rear seatback pad
4. Headrestraint guide
52A-22 INTERIOR
FRONT SEAT BELT
FRONT SEAT BELT

M1523001300400
CAUTION
SRS: Before removing and installing the seat belts with pre-tensioner, refer to GROUP 52B, Seat Belts
with Pre-tensioner P.52B-120.
• Turn the ignition key to the LOOK (OFF) position.
• Disconnect the negative battery terminal.
5
4
44 ± 10 N·m
1 44 ± 10 N·m
2
3
44 ± 10 N·m 44 ± 10 N·m
AC310727 AB
Outer seat belt removal steps Outer seat belt removal steps
1. Sash guide cover 4. Upper centre pillar trim (Refer to
• Lower centre pillar trim (refer to P.52A-10).
P.52A-10). 5. Adjustable seat belt anchor
2. Bracket Inner seat belt removal steps
3. Outer seat belt (refer to GROUP 52B, • Shield cover (refer to P.52A-19).
Seat Belts with Pre-tensioner 6. Inner seat belt
P.52B-120).
INTERIOR
REAR SEAT BELT
52A-23
REAR SEAT BELT
M1523001600401
44 ± 10 N·m
4
44 ± 10 N·m
44 ± 10 N·m 3
2 AC211443 AB

• Rear seat cushion assembly (refer to • Rear shelf trim (refer to P.52A-10).
P.52A-20). 1. Centre seat belt, inner
• Rear seatback assembly (refer to 2. Inner seat belt
P.52A-20). 3. Centre seat belt, outer
4. Outer seat belt
NOTES
00-1
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

NOTES
00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 00-2 SUPPLEMENTAL RESTRAINT

SYSTEM (SRS) . . . . . . . . . . . . . . . . . . 00-22
HOW TO USE
TROUBLESHOOTING/INSPECTION SRS SERVICE PRECAUTIONS . . . . . 00-23
SERVICE POINTS . . . . . . . . . . . . . . . 00-5
SUPPORT LOCATIONS FOR LIFTING
VEHICLE IDENTIFICATION . . . . . . . 00-14 AND JACKING . . . . . . . . . . . . . . . . . . 00-25
GENERAL DATA AND STANDARD PART/TIGHTENING-

SPECIFICATIONS . . . . . . . . . . . . . . . 00-17 TORQUE TABLE . . . . . . . . . . . . . . . . 00-27
PRECAUTIONS BEFORE SERVICE. 00-18

00-2 GENERAL
HOW TO USE THIS MANUAL

M1001000101083
SCOPE OF MAINTENANCE, REPAIR AND LIMIT

SERVICING EXPLANATIONS Shows the standard for judging the quality of a part
This manual provides explanations, etc. concerning or assembly on inspection and means the maximum
procedures for the inspection, maintenance, repair or minimum value within which the part or assembly
and servicing of the subject model. Note, however, must be kept functionally or in strength. It is a value
that for engine and transmission-related component established outside the range of standard value.
parts, this manual covers only on-vehicle inspec-
tions, adjustments, and the removal and installation REFERENCE VALUE
procedures for major components. For detailed infor- Indicates the adjustment value prior to starting the
mation concerning the inspection, checking, adjust- work (presented in order to facilitate assembly and
ment, disassembly and reassembly of the engine, adjustment procedures, and so they can be com-
transmission and major components after they have pleted in a shorter time).
been removed from the vehicle, please refer to sepa-
rate manuals covering the engine and the transmis- DANGER, WARNING, AND CAUTION
sion. DANGER, WARNING, and CAUTION call special
attention to a necessary action or to an action that
ON-VEHICLE SERVICE
must be avoided. The differences among DANGER,
"On-vehicle Service" is the procedure for performing WARNING, and CAUTION are as follows:
inspections and adjustments of particularly important • If a DANGER is not followed, the result is severe
locations with regard to the construction and for bodily harm or even death.
maintenance and servicing, but other inspection (for • If a WARNING is not followed, the result could be
looseness, play, cracking, damage, etc.) must also bodily injury.
be performed. • If a CAUTION is not followed, the result could be
damage to the vehicle, vehicle components or
INSPECTION
service equipment.
Under this title are presented inspection and check-
ing procedures to be performed by using special INDICATION OF TIGHTENING TORQUE
tools and measuring instruments and by feeling, but,
Tightening torques (units: N⋅m) are set to take into
for actual maintenance and servicing procedures,
account the central value and the allowable toler-
visual inspections should always be performed as
ance. The central value is the target value, and the
well.
allowable tolerance provides the checking range for
tightening torques. If bolts and nuts are not provided
DEFINITION OF TERMS
with tightening torques, refer to P.00-27.
STANDARD VALUE
Indicates the value used as the standard for judging MODEL INDICATIONS
the quality of a part or assembly on inspection or the The following abbreviations are used in this manual
value to which the part or assembly is corrected and for identification of model types.
adjusted. It is given by tolerance. MPI: Indicates the multipoint injection.
DOHC: Indicates an engine with the double over-
head camshaft.
MIVEC: Indicates an engine with the Mitsubishi Inno-
vative Valve timing Electronic Control system.
M/T: Indicates the manual transmission.
A/C: Indicates the air conditioner.
GENERAL
00-3
EXPLANATION OF MANUAL CONTENTS
Indicates the
Denotes tightening torque. section title.
For bolts and nuts which do
not have a tightening torque
listed, refer to the "Standard Indicates the Indicates the
Parts Tightening-torque Table" group title. group number.
Indicates the page number.
Indicates procedures to be performed be-

fore the work in that section is started, and
procedures to be performed after the work
in that section is finished.
Component diagram
A diagram of the component parts is pro-
vided near the front of each section in order
to give the reader a better understanding of
the installed condition of component parts.
Mark N denotes nonreusable part.
Repair kit or parts sets are shown.

(Only very frequently used parts are shown.)
Maintenance and servicing procedures

The numbers provided within the diagram indicate the Installation steps :
sequence for maintenance and servicing procedures. Specified in case installation is impossible in
Removal steps : reverse order of removal steps. Omitted if
The part designation number corresponds to installation is possible in reverse order of
the number in the illustration to indicate remov- removal steps.
al steps. Reassembly steps :
Disassembly steps : Specified in case reassembly is impossible in
The part designation number corresponds to reverse order of removal steps. Omitted if
the number in the illustration to indicate disas- reassembly is possible in reverse order of
sembly steps. disassembly steps.
AC311238 AD
00-4 GENERAL
Classifications of major maintenance / service points

When there are major points relative to maintenance and servicing procedures (such as essential maintenance
and service points, maintenance and service standard values, information regarding the use of special tools, etc.),
these are arranged together as major maintenance and service points and explained in detail.
<<A>> : Indicates that there are essential points for removal or disassembly.
>>A<< : Indicates that there are essential points for installation or reassembly.
35A-21 Operating procedures,

cautions, etc. on removal,
installation, disassembly and
reassembly are described.
The title of the page

(following the page on which
the diagram of component
parts is presented) indicating
the locations of lubrication and
sealing procedures.
Indicates (by symbols) where

lubrication is necessary.
Symbols for lubrication, sealants and adhesives

Symbols are used to show the locations for lubrication Grease
and for application of sealants and adhesives. (Multi-purpose grease unless there is a
These symbols are included in the diagram of compo- brand or type specified)
nent parts or on the page following the component Sealant or adhesive
parts page. The symbols do not always have accomp- Brake fluid or automatic transmission fluid
anying text to support that symbol. Engine oil, gear oil or air conditioning com-
pressor oil
Adhesive tape or butyl rubber tape
AC311239 AD
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-5
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS
M1001000201143
CONTENTS OF TROUBLESHOOTING
Troubleshooting of electronic control systems for which the M.U.T.-II/III can be used follows the basic outline
described below. Even in systems for which the M.U.T.-II/III cannot be used, some of these systems still fol-
low this outline.
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 Does not reoccur
Read the diagnosis code. Read the diagnosis code.

Diagnosis code Diagnosis code
displayed. displayed.
After taking note of the

malfunction code, erase the
diagnosis code memory. No diagnosis
No diagnosis code
or communication code.
with M.U.T.-II/III
not possible Recheck trouble symptom.
Read the diagnosis codes.

No diagnosis
Diagnosis code code.
displayed.
Refer to the TROUBLE Refer to the DIAGNOSIS CODE INTERMITTENT MALFUNCTIONS
SYMPTOM CHART (Refer to CHART (Refer to applicable
applicable group.) group.)
AC300864AE
SYSTEM OPERATION AND SYMPTOM DIAGNOSIS CODE CHART

VERIFICATION TESTS Diagnosis codes and diagnostic items are shown.
If verification of the symptom(s) is difficult, proce-
dures for checking operation and verifying symptoms DIAGNOSIS CODE PROCEDURES
are shown. Indicates the inspection procedures corresponding to
each diagnosis code (Refer to How to read inspec-
DIAGNOSIS FUNCTION tion procedure P.00-10).
Details which are different from those in the "Diagno-
sis function " section are described.
00-6 GENERAL
TROUBLE SYMPTOM CHART <Using the M.U.T.-III>

If there are trouble symptoms even though the <Using the M.U.T.-III>
M.U.T.-II/III does not find any diagnosis codes,
Inspection procedures for each trouble symptom will
be found by means of this chart.
SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptom classified in the Symptom Chart
(Refer to How to read inspection procedure P.00-10).
16-PIN
SERVICE DATA REFERENCE TABLE MB991911
Inspection items and normal judgment values have
been provided in this chart as reference information.
MB991824
CHECK AT ECU TERMINALS

Terminal numbers for the ECU connectors, inspec-
tion items, and judgment values have been provided
in this chart as reference information.
INSPECTION PROCEDURE BY USING AN

OSCILLOSCOPE MB991827 AC211686 AE
When there are inspection procedures using an Connect the M.U.T.-III to the 16-pin diagnosis con-
oscilloscope, these are described here. nector, and read the diagnosis code.
NOTE: For details on how to use the M.U.T.-III, refer
DIAGNOSIS FUNCTION to the "M.U.T.-III operation manual."
HOW TO READ DIAGNOSIS CODE 1. Ensure that the ignition switch is at the
CAUTION "LOCK" (OFF).
Before connecting or disconnecting the 2. Start up the personal computer.
M.U.T.-II/III, turn the ignition switch to the "LOCK" 3. Connect M.U.T.-III USB cable MB991827 to
(OFF) position. special tool Vehicle Communication Interface
(V.C.I.) MB991824 and the personal compu-
<Using the M.U.T.-II> ter.
<Using the M.U.T.-II> 4. Connect M.U.T.-III main wiring harness B
Steering shaft MB991911 to the V.C.I.
5. Connect M.U.T.-III main wiring harness B to
the diagnosis connector.
6. Turn the V.C.I. power switch to the "ON" posi-
tion.
NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green
MB991502
AC304777AB
colour.
7. Start the M.U.T.-III system on the PC and turn
Connect the M.U.T.-II to the diagnosis connector, the ignition switch to the "ON" position.
and read the diagnosis code.
8. Read the diagnosis code.
9. Disconnecting the M.U.T.-III is the reverse of
the connecting sequence, making sure that
the ignition switch is at the "LOCK" (OFF).
GENERAL
00-7
NOTE: The ABS warning lamp may flash when the ERASING DIAGNOSIS CODE (BY USING
ignition switch is turned ON with the M.U.T.-II/III con- NO M.U.T.-II/III)
nected. This is because the diagnosis display func-
tion of the ABS warning lamp is activated by earthing CAUTION
the diagnosis connector terminal No.1, and is not Some diagnosis codes can not be erased accord-
detrimental in any way. ing to the procedure below. If you attempt to
erase a diagnosis code, refer to an applicable
GROUP.
ERASING DIAGNOSIS CODE (BY USING
THE M.U.T.-II/III) position.
CAUTION 2. Disconnect the negative battery cable, wait for at
Before connecting or disconnecting the least 10 minutes, and then reconnect it.
M.U.T.-II/III, turn the ignition switch to the "LOCK" 3. Start the engine and let it run at idle for 10
(OFF) position. minutes.
Steering shaft INPUT SIGNAL CHECK (WHEN USING
THE M.U.T.-II/III) <SWS>
CAUTION
Before connecting or disconnecting the
M.U.T.-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
MB991502 <Using the M.U.T.-II>
AC304777AB Steering shaft
MB991502
AC304777AB

16-PIN
MB991911
MB991824
16-PIN
MB991911
MB991827 AC211686 AE
MB991824
Connect the M.U.T.-II/III to the diagnosis connector,
and erase the diagnosis code. The procedure is the
same as "HOW TO READ DIAGNOSIS CODE ".
MB991827 AC211686 AE
00-8 GENERAL
1. Connect the M.U.T.-II/III to the diagnosis 1. Use the special tool diagnosis code check
connector, and erase the diagnosis code. harness (MB991529) to connect the ETACS
2. If the M.U.T.-II/III buzzer sounds once when each terminal (terminal 9) and the earth terminals
switch is operated (ON/OFF), the input signal for (terminals 4 and 5) of the diagnosis connector to
that switch circuit system is normal. the voltage meter.
2. If the needle of the voltage meter flickers once
INPUT SIGNAL CHECK (WHEN USING A when each switch is operated (ON/OFF), the input
VOLTMETER) <SWS> signal for that switch circuit system is normal.
Steering
shaft
MB991529 AC304779AB
GENERAL
00-9
HOW TO USE THE INSPECTION PROCE-
DURES
The causes of many of the problems occurring in
electric circuitry are generally the connectors, com-
ponents, the ECU, the wiring harnesses between
connectors, in that order. These inspection proce-
dures follow this order. They first try to discover a
problem with a connector or a defective component.
Relevant circuit(s) of the component which

the Code No. indicates are described.
AC301964AB
00-10 GENERAL
Explains about the basic Start of diagnosis Describes

operation of the components. procedure inspection
procedure.
PROCEDURE
M.U.T.-ll/lll data list
Explains about
technical details.
Describes the
conditions for that
diagnosis code being
set.
Describes possible
causes(s) for that
diagnosis code.
AC305342AD
HARNESS CHECK MEASURES TO TAKE AFTER

Check for an open or short circuit in the harness REPLACING THE ECU
between the terminals which were faulty according to If the trouble symptoms have not disappeared even
the connector measurements. Carry out this inspec- after replacing the ECU, repeat the inspection proce-
tion while referring to the Electrical Wiring Manual. dure from the beginning.
Here, "Check the wiring harness between the power
supply and terminal xx" also includes checking for CONNECTOR MEASUREMENT SERVICE
blown fuse. For inspection service points when there
POINTS
is a blown fuse, refer to "Inspection Service Points
for a Blown Fuse." 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.
GENERAL
00-11
IF INSPECTING WITH THE CONNECTOR IF INSPECTING WITH THE CONNECTOR
CONNECTED DISCONNECTED
<Waterproof Connectors> <When Inspecting a Female Pin>
MD998459
MB991219
AC300881AD ACX00865AB
Be sure to use special tool harness connector Use the special tool inspection harness (MB991219)
(MD998459). Never insert a test probe from the har- (inspection harness for connector pin contact pres-
ness side, as this will reduce the waterproof perform- sure in the harness set for inspection). The inspec-
ance and result in corrosion. tion harness for connector pin contact pressure
should be used. The test bar should never be forcibly
inserted, as it may cause a defective contact.
<Ordinary (non-waterproof) Connectors>
<When Inspecting a Male Pin>

CAUTION
MB992006
AC105598AH
Inspect by inserting a test probe from the harness

side. If the connector is too small to insert a test
probe (e.g. control unit connector), do not insert it AC300890
forcibly. Use special tool extra fine probe At this time, be careful not to short the connector
(MB992006). pins with the test bars. To do so may damage the
circuits inside the ECU.
Touch the pin directly with the test bar.
00-12 GENERAL
CONNECTOR INSPECTION SERVICE CONNECTOR PIN INSPECTION

POINTS
VISUAL INSPECTION
•
Connector disconnected or
improperly connected
AC300898
If the connector pin stopper is damaged, the terminal

connections (male and female pins) will not be per-
fect even if the connector body is connected, and the
Stretched or broken wires pins may pull out of the reverse side of the connec-
tor. Therefore, gently pull the harnesses one by one
to make sure that no pins pull out of the connector.
CONNECTOR ENGAGEMENT
INSPECTION
MB991219
Harness wire breakage

at terminal section
Low contact
pressure
Good
Bad
AC300899AB
Use the special tool inspection harness (MB991219)

(connector pin connection pressure inspection har-
ness of the inspection harness set) to inspect the
AC300896AB
engagement of the male pins and female pins. (Pin
drawing force: 1 N or more)
Connector is disconnected or improperly connected
• Connector pins are pulled out
• Due to harness tension at terminal section
• Low contact pressure between male and female
terminals
• Low connection pressure due to rusted terminals
or foreign matter lodged in terminals
GENERAL
00-13
INSPECTION SERVICE POINTS FOR A
BLOWN FUSE
Battery
Fuse
Short-circuit
Load occurrence
switch 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
ohm at this time, there is a short somewhere
between these switches and the load. If the resist-
ance is not 0 ohm, there is no short at the present
time, but a momentary short has probably caused AC300901
the fuse to blow.
Intermittent malfunctions often occur under certain
The main causes of a short circuit are the following.
conditions, and if these conditions can be ascer-
• Harness being clamped by the vehicle body
tained, determining the cause becomes simple. In
• Damage to the outer casing of the harness due to
order to ascertain the conditions under which an
wear or heat
intermittent malfunction occurs, first ask the cus-
• Water getting into the connector or circuitry
tomer for details about the driving conditions,
• Human error (mistakenly shorting a circuit, etc).
weather conditions, frequency of occurrence and
trouble symptoms, and then try to recreate the trou-
HOW TO COPE WITH INTERMITTENT
ble symptoms. Next, ascertain whether the reason
MALFUNCTIONS why the trouble symptom occurred under these con-
NOTE: If determining the cause is difficult, the flight ditions is due to vibration, temperature or some other
recorder function of the M.U.T.-II/III can also be factor. If vibration is thought to be the cause, carry
used. 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 gen-
erates diagnosis codes or trouble symptoms).
00-14 GENERAL
VEHICLE IDENTIFICATION
• Gently shake the connector up, down and to the • Gently rock each sensor and relay, etc. by hand.
left and right. • Gently shake the wiring harness at suspensions
• Gently shake the wiring harness up, down and to and other moving parts.
the left and right.
M1001000401329
VEHICLE IDENTIFICATION CODE PLATE The vehicle information code plate is riveted to the
back of the engine hood.
Code plate The plate shows model code, engine model, trans-
1
mission model and body colour code.
No. Item Content
3
2 1 MODEL CT9ASJG CT9A: Vehicle model
FZL6 SJGFZL6: Model
series
2 ENGINE 4G63 Engine model
3 EXT A02A Exterior code
5 4 6 7
4 TRANS W6MAA Transmission model
Engine hood AXLE
5 COLOUR A02 Body colour code
6 INT 90J Interior code
7 OPT ZP3 Equipment code
For monotone colour vehicles, the body colour code
shall be indicated.
AC504461AD
GENERAL
00-15
MODELS
Model code Engine model Price class Transmission Fuel supply
model system
CT9A SJGFZL6 4G63-DOHC-intercoo GSR W6MAA MPI
SJGFZR6 ler turbocharger <4WD, 6M/T>
(1,997 mL)
MODEL CODE No. Item Content

4 Body style S: 4-door sedan
5 Transmission J: 6-speed manual
CT 9 A S J G F Z L 6 type transmission
6 Trim level G: GSR
7 Specification F: MPI-DOHC-MIVEC,
engine feature intercooler turbocharger
1 2 3 4 5 6 7 8 9 10 8 Special feature Z: 4WD
9 Steering wheel L: Left hand
AC504314
location R: Right hand
No. Item Content 10 Destination 6: For Europe
1 Development CT: MITSUBISHI
LANCER EVOLUTION
2 Engine type 9: 1,997mL
3 Sort A: Passenger car
00-16 GENERAL
CHASSIS NUMBER The chassis number is stamped on the toeboard

inside the engine compartment.
AC310384
J M B S J CT 9 A 6 U 000001
1 2 3 4 5 6 7 8 9 10 11
AC504317
No. Item Content

1 Fixed figure J Asia
2 Distribution channel M Japan channel
3 Destination A For Europe, right hand drive
B For Europe, left hand drive
4 Body style S 4-door sedan
5 Transmission type J 6-speed manual transmission
6 Development order CT LANCER EVOLUTION
7 Engine 9 1,997 mL petrol engine
8 Soft A Passenger car
9 Model year 6 2006
10 Plant U Mizushima
11 Serial number − −
ENGINE MODEL STAMPING The engine model is stamped on the cylinder block.
This engine model numbers is as shown as follow.
Engine model Engine displacement
4G63 1,997 mL
The engine serial number is stamped near the
engine model number.
AC310394
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-17
GENERAL DATA AND SPECIFICATIONS
M1001000901045
7
1 3 4 5 9
2 6
AC505135AB
Items CT9A
SJGFZL6/R6
Vehicle Front track 1 1,515
dimensions mm Overall width 2 1,770
Front overhang 3 930
Wheel base 4 2,625
Rear overhang 5 935
Overall length 6 4,490
Ground clearance 7 140
(unladen)
Overall height (unladen) 8 1,450
Rear track 9 1,515
Vehicle weight kg Kerb weight 1,465
Max. gross vehicle weight 1,885
Max. axle weight rating-front 1,015
Max. axle weight rating-rear 900
Seating capacity 5
Engine Model code 4G63 DOHC-MIVEC with intercooler turbocharger
Total displacement mL 1,997
Maximum output kW/r/min 206/6,500
Maximum torque N⋅m/r/min 355/3,500
Transmission Model code W6MAA
Type 6-speed manual
Fuel system Fuel supply system MPI
Maximum speed km/h 250
Minimum turning radius m 5.9
00-18 GENERAL
PRECAUTIONS BEFORE SERVICE

M1001000501058
SUPPLEMENTAL RESTRAINT SYSTEM 8. Be sure to deploy the air bag before disposing
(SRS) of the air bag module or disposing of a vehicle
equipped with an air bag (Refer to GROUP
1. Items to review when servicing SRS:
52B − Air Bag Module Disposal Procedures
1. Be sure to read GROUP 52B − Supplemental
P.52B-120).
Restraint System (SRS). For safe operation,
please follow the directions and heed all 2. Observe the following when carrying out opera-
warnings. tions on places where SRS components are
installed, including operations not directly related
2. Wait at least 60 seconds after disconnecting
to the SRS air bag.
the battery cable before doing any further
work. The SRS system is designed to retain 1. When removing or installing parts, do not
enough voltage to deploy the air bag even allow any impact or shock to the SRS compo-
after the battery has been disconnected. Seri- nents.
ous injury may result from unintended air bag 2. If heat damage may occur during paint work,
deployment if work is done on the SRS sys- remove the SRS-ECU, the air bag module,
tem immediately after the battery cable is dis- clock spring, the front impact sensor, the side
connected. impact sensor, and the seat belt pre-ten-
3. Warning labels must be heeded when servic- sioner.
ing or handling SRS components. Warning • SRS-ECU, air bag module, clock spring,
labels can be found in the following locations. front impact sensor, the side impact sen-
• Front impact sensor sor: 93 °C or more
• Hood • Seat belt pre-tensioner: 90 °C or more
• Sun visor
• SRS-ECU LEARNING PROCEDURE FOR IDLING IN
• Steering wheel MPI ENGINE
• Clock spring PURPOSE
• Steering joint cover When the engine-ECU is replaced, or when the
• Air bag module (Driver's and front passen- learning value is initialized, the idling is not stabilized
ger's) because the learning value in MPI engine is not com-
• Side-airbag module (Driver's side and pleted. In this case, carry out the learning method for
front passenger's side) the idling through the following procedures.
• Curtain air bag module (Driver's side and
front passenger's side) LEARNING PROCEDURE
• Side impact sensor
1. Start the engine and carry out the warm-up for the
• Seat belt pre-tensioner
engine coolant temperature to reach 80°C or
• Instrument panel
more.
4. Always use the designated special tools and
test equipment. 2. When the engine coolant temperature is 80°C or
more, the warm-up is not needed if the ignition
5. Store components removed from the SRS in a
switch is in "ON" position once.
clean and dry place. The air bag module
should be stored on a flat surface and placed 3. Place the ignition switch in "LOCK" (OFF) position
so that the pad surface is facing upward. Do and stop the engine.
not place anything on top of it. 4. After 10 seconds or more, start the engine again.
6. Never attempt to disassemble or repair the 5. For 10 minutes, carry out the idling under the
SRS components (SRS-ECU, air bag module condition shown below and then confirm the
and clock spring). engine has the normal idling.
7. Whenever you finish servicing the SRS, • Transmission: Neutral
check the SRS warning lamp operation to • Operation in ignition-related, fan and attach-
make sure that the system functions properly. ments: Not to be operated
• Engine coolant temperature: 80°C or more
GENERAL
00-19
NOTE: When the engine stalls during the idling, PRE-INSPECTION CONDITION
check the dirtiness (on the throttle valve) of the "Pre-inspection condition" refers to the condition that
throttle body and then perform the service from the vehicle must be in before proper engine inspec-
Procedure 1 again. tion can be carried out. If you see the words "Set the
vehicle to the pre-inspection condition". In this man-
SERVICING ELECTRICAL SYSTEM ual, it means to set the vehicle to the following condi-
CAUTION tion.
Before connecting or disconnecting the negative • Engine coolant temperature 80 to 90°C
(−) cable, be sure to turn off the ignition switch • Lamps, electric cooling fan and all accessories:
and the lighting switch (If this is not done, there OFF
is the possibility of semiconductor parts being • M/T: Neutral
damaged).
VEHICLE WASHING
Approximately 40 cm
AC300693
Before replacing a component related to the electri- AC300832AB
cal system and before undertaking any repair proce- If high-pressure car-washing equipment or steam
dures involving the electrical system, be sure to first car-washing equipment is used to wash the vehicle,
disconnect the negative (−) cable from the battery in be sure to note the following information in order to
order to avoid damage caused by short-circuiting. avoid damage to plastic components, etc.
• Spray nozzle distance: Approx. 40 cm or more
APPLICATION OF ANTI-CORROSION • Spray pressure: 3,900 kPa or less
AGENTS AND UNDERCOATS • Spray temperature: 82°C or less
• Time of concentrated spray to one point: within
If oil or grease gets onto the oxygen sensor, it will
30 sec.
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats.
00-20 GENERAL
MULTI USE TESTER (M.U.T.-II/III) SUB

ASSEMBLY
M.U.T.-II sub assembly
Rom pack
AC300834AC
M.U.T.-III sub assembly
Vehicle communication interface (V.C.I.) M.U.T.-III USB cable M.U.T.-III main harness A
Do not used
MB991824 MB991827 MB991910
M.U.T.-III main harness B M.U.T.-III measurement adapter M.U.T.-III trigger harness
MB991911 MB991825 MB991826
AC502279AC
Refer to the "M.U.T.-II REFERENCE MANUAL",

"M.U.T.-II OPERATING INSTRUCTIONS" or
"M.U.T.-III OPERATING INSTRUCTIONS" for
instructions on handling the M.U.T.-II/III.
GENERAL
00-21
CAUTION ENGINE OILS
<Using the M.U.T.-II> HEALTH WARNING
Steering shaft 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 addi-
tion, used engine oil contains potentially harmful con-
taminants which may cause skin cancer. Adequate
means of skin protection and washing facilities must
be provided.
MB991502
AC304777AB RECOMMENDED PRECAUTIONS
The most effective precaution is to adapt working
<Using the M.U.T.-III> 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
16-PIN gloves where practicable.
MB991911 • Avoid contaminating clothes, particularly under-
pants, with oil.
MB991824 • 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 per-
sonal clothing.
• Where there is a risk of eye contact, eye protec-
tion should be worn, for example, chemical gog-
MB991827 AC211686 AE
gles or face shields; in addition an eye wash
Turn the ignition switch to the "LOCK" (OFF) facility should be provided.
position before connecting or disconnecting the • Obtain First Aid treatment immediately for open
M.U.T.-II/III. cuts and wounds.
Connect the M.U.T.-II/III to the diagnosis connector • Wash regularly with soap and water to ensure all
as shown in the illustration. oil is removed, especially before meals (skin
cleansers and nail brushes will help). After clean-
IN ORDER TO PREVENT VEHICLES ing, the application of preparations containing
FROM FIRE lanolin to replace the natural skin oils is advised.
"Improper installation of electrical or fuel related parts • Do not use petrol, kerosene, diesel fuel, gas oil,
could cause a fire. In order to retain the high quality thinners or solvents for cleaning skin.
and safety of the vehicle, it is important that any • Use barrier creams, applying them before each
accessories that may be fitted or modifica- work period, to help the removal of oil from the
tions/repairs that may be carried out which involve skin after work.
the electrical or fuel systems, MUST be carried out in • If skin disorders develop, obtain medical advice
accordance with MMC's information/Instructions". without delay.
00-22 GENERAL

M1001009800075
The Supplemental Restraint System (SRS) and seat monitors the system and has a safing G-sensor and
belt with pre-tensioner is designed to supplement the analogue G-sensor. The warning lamp on the instru-
driver's and front passenger's seat belts to help ment panel indicates the operational status of the
reduce the risk or severity of injury to the driver and SRS. The clock spring is installed in the steering col-
front passenger by activating and deploying both umn. The seat belt pre-tensioner is built into the
front air bags in certain frontal collisions. driver's and passenger's front seat belt retractor. The
The SRS consist of two air bag modules, SRS air front impact sensor is assembled on the headlamp
bag control unit (SRS-ECU), two front impact sen- support panel to monitor collision upon frontal
sors, SRS warning lamp, clock spring and seat belt impact.
pre-tensioner. Front air bags are located in the centre Only authorized service personnel should do work on
of the steering wheel and above the glove box. Each or around the SRS components. Those service per-
air bag is made up of a folded air bag and an inflator sonnel should read this manual carefully before start-
unit. The SRS-ECU under the front floor console ing any such work.
Seat belt with

pre-tensioner
SRS warning lamp

AC310070
Diagnosis connector
Driver's air bag Passenger's (front)
module air bag module
Clock spring
SRS-ECU AC208855
AC304668
Front impact sensor
AC310783 AB
GENERAL
SRS SERVICE PRECAUTIONS
00-23
M1001006000229
DANGER CAUTION
In order to avoid injury to yourself or others
from accidental deployment of the air bag
SRS-ECU connector
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION
Do not use any electrical test equipment on or
near SRS components, except those specified on
P.52B-8.
AC300634 AB
CAUTION
Never Attempt to Repair the Following Compo- Do not attempt to repair the wiring harness con-
nents: nectors of the SRS. If a defective wiring harness
is found, repair or replace it by referring to the
1. SRS air bag control unit (SRS-ECU)
table below.
2. Clock spring
3. Driver's and passenger's (front) air bag mod-
ules
4. Front impact sensor
5. 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 pro-
cedures in this manual, starting at page P.52B-105.
Front wiring harness (RH) → Front harness.
impact sensor (RH)
Front wiring harness (LH) → Front harness.
impact sensor (LH)
7 Instrument panel wiring harness→ Correct or replace the instrument
Earth panel wiring harness.
SRS warning lamp panel wiring harness.
9, 10 Instrument panel wiring harness → Correct or replace the instrument
Passenger's (front) air bag module panel wiring harness.
11, 12 Instrument panel wiring harness → Correct or replace instrument panel
Clock spring → Driver's air bag wiring harness. Replace the clock
module spring.
00-24 GENERAL

Diagnosis connector panel wiring harness.
27, 28 Floor wiring harness (RH) → Connect or replace the floor wiring
Passenger's (front) seat belt harness.
pre-tensioner <LH drive vehicles>
Floor wiring harness (LH) →
Passenger's (front) seat belt
pre-tensioner <RH drive vehicles>
29, 30 Floor wiring harness (LH) → Driver's Connect or replace the floor wiring
seat belt pre-tensioner <LH drive harness.
vehicles> Floor wiring harness (RH)
→ Driver's seat belt pre-tensioner
<RH drive vehicles>
DANGER CAUTION
Insulating tape SRS-harness connector

Battery
MB992006
Battery cable
AC300580AB
After disconnecting the battery cable, wait 60

seconds or more before proceeding with the SRS-ECU harness connector
following work. In addition, insulate the neg- (rear side)
ative battery terminal with a tape. The con-
denser 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. AC006195 AH
CAUTION
The SRS components and seat belt with pre-ten- If checks are carried out by using the SRS-ECU
sioner should not be subjected to heat, so harness connector, observe the following proce-
remove the SRS-ECU, driver’s and passenger’s dures: Insert the special tool extra fine probe
(front) air bag modules, clock spring, and seat (MB992006) into connector from harness side
belt pre-tensioner before drying or baking the (rear side), and connect the tester to this probe. If
vehicle after painting. any tool than special tool is used, damage to the
• SRS-ECU, air bag modules, clock spring, harness and other components will result. Never
impact sensors: 93°C or more 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
CAUTION touched directly by the probe, the plating may
Whenever you finish servicing the SRS, always break, which will cause drops in reliability.
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.
GENERAL
SUPPORT LOCATIONS FOR LIFTING AND JACKING
00-25
M1001000700305
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.
AC310387
00-26 GENERAL
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 attach-
ments.
AXLE STANDS
Notch Notch
Rubber
Rubber
SINGLE-POST LIFT
OR DOUBLE-POST LIFT
Notch Notch
Rubber
Rubber
AC310389AC
GENERAL
STANDARD PART/TIGHTENING-TORQUE TABLE
00-27
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

M1001001100674
Each torque value in the table is a standard value for 1. If toothed washers are inserted.
tightening under the following conditions. 2. If plastic parts are fastened.
1. Bolts, nuts and washers are all made of steel and 3. If bolts are tightened to plastic or die-cast
plated with zinc. inserted nuts.
2. The threads and bearing surface of bolts and 4. If self-tapping screws or self-locking nuts are
nuts are all in dry condition. used.
The values in the table are not applicable:
STANDARD BOLT AND NUT TIGHTENING TORQUE

Thread size Torque N⋅m
Bolt nominal Pitch Head mark "4" Head mark "7" Head mark "8"
diameter (mm) (mm)
M5 0.8 2.5 ± 0.5 5.0 ± 1.0 6.0 ± 1.0
M6 1.0 5.0 ± 1.0 8.5 ± 1.5 10 ± 2
M8 1.25 11 ± 2 20 ± 4 24 ± 4
M10 1.25 23 ± 4 42 ± 8 53 ± 7
M12 1.25 42± 8 80 ± 10 93 ± 12
M14 1.5 70 ± 10 130 ± 20 150 ± 20
M16 1.5 105 ± 15 195 ± 25 230 ± 30
M18 1.5 150 ± 20 290 ± 40 335 ± 45
M20 1.5 210 ± 30 400 ± 60 465 ± 65
M22 1.5 290 ± 40 540 ± 80 630 ± 90
M24 1.5 375 ± 55 705 ± 105 820 ± 120
FLANGE BOLT AND NUT TIGHTENING TORQUE
Thread size Torque N⋅m
Bolt nominal Pitch Head mark "4" Head mark "7" Head mark "8"
diameter (mm) (mm)
M6 1.0 5.0 ± 1.0 10 ± 2 12 ± 2
M8 1.25 13 ± 2 24 ± 4 28 ± 5
M10 1.25 26 ± 5 50 ± 5 58 ± 7
M10 1.5 25 ± 4 46 ± 8 55 ± 5
M12 1.25 47 ± 9 93 ± 12 105 ± 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
54-1
GROUP 54
CHASSIS
ELECTRICAL
CONTENTS
CHASSIS ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54A
SMART WIRING SYSTEM (SWS) NOT USING SWS

MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54B
SMART WIRING SYSTEM (SWS) USING SWS MONITOR . . . . 54C

NOTES
54B-1
GROUP 54B
SMART WIRING
SYSTEM (SWS) NOT
USING SWS
MONITOR
CONTENTS
GENERAL INFORMATION . . . . . . . . 54B-2 SYMPTOM PROCEDURES . . . . . . . . 54B-38

BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . 54B-46
SPECIAL TOOLS. . . . . . . . . . . . . . . . 54B-11 CENTRAL DOOR LOCKING SYSTEM . . . . 54B-48
POWER WINDOW . . . . . . . . . . . . . . . . . . . 54B-72
TROUBLESHOOTING . . . . . . . . . . . . 54B-13 KEYLESS ENTRY SYSTEM . . . . . . . . . . . . 54B-125
PRIOR TO TROUBLESHOOTING . . . . . . . 54B-13 WINDSHIELD WIPER AND WASHER . . . . 54B-130
STANDARD FLOW OF DIAGNOSTIC IGNITION KEY CYLINDER ILLUMINATION
TROUBLESHOOTING . . . . . . . . . . . . . . . . 54B-13 LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54B-156
DIAGNOSTIC FUNCTION . . . . . . . . . . . . . 54B-13 HEADLAMP AND TAIL LAMP . . . . . . . . . . . 54B-160
FLASHER TIMER . . . . . . . . . . . . . . . . . . . . 54B-191
DIAGNOSIS CODE CHART. . . . . . . . 54B-14 FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 54B-212
INTERIOR LAMP. . . . . . . . . . . . . . . . . . . . . 54B-225
PROCEDURES . . . . . . . . . . . . . . . . . 54B-15 INPUT SIGNAL PROCEDURES. . . . . 54B-239
TROUBLE SYMPTOM CHART . . . . . 54B-33 CHECK AT ECU TERMINAL . . . . . . . 54B-296
CHECK TROUBLE BY USING THE INPUT ON-VEHICLE SERVICE . . . . . . . . . . . 54B-302
SIGNAL CHECK . . . . . . . . . . . . . . . . 54B-36
CONFIGURATION FUNCTION <VEHICLES
WITH KEYLESS ENTRY SYSTEM> . . . . . . 54B-302
OPERATION AND FUNCTION
QUICK-REFERENCE TABLE FOR
INPUT SIGNAL INSPECTION
PROCEDURES . . . . . . . . . . . . . . . . . 54B-37
54B-2 SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR
GENERAL INFORMATION
GENERAL INFORMATION
M1549000100544
The exclusive signal lines for transmitting the
multi-distribution data are connected as follows
between the ETACS-ECU, column switch (incorpo-
rated inside the column-ECU), front-ECU, power win-
dow main switch (incorporated inside the power
window-ECU), and power window sub switches
(incorporated inside the power window-ECU) for
internal communication.
Power window
sub switch
ETACS-ECU
(Rear RH)
Power window
Column switch
main switch
Power window Power window

sub switch sub switch
(Front) (Rear LH)
Front-ECU
: Bidirectional communication
: Unidirectional communication AC212517AG
BUZZER CENTRAL DOOR LOCKING

LAMP REMINDER FUNCTION CENTRAL DOOR LOCKING CONTROL
FUNCTION
Tail lamp or ON
headlamp t: 0.25 seconds
OFF
Key ON ON
reminder (Key removed) Lock switch
switch OFF OFF
(Key inserted)
Driver's
ON
ON (Open) Unlock switch
door OFF
switch OFF (Closed)
Lock relay ON
ON (Tone alarm output
Buzzer sounds) OFF t
output OFF (Tone alarm
does not sound) Unlock relay ON
AC101512 output OFF t
When the ignition key is removed and then the AC101496 AD
driver's door is opened with turning ON the tail lamp When the front doors is locked (when the lock switch
or the headlamp, the buzzer sounds continuously to turns ON after turning OFF the unlock switch in the
alert the driver that the lamp is still ON. driver's door lock actuator or front passenger’s door
However, if the tail lamp or the headlamp is turned off lock key cylinder switch), ETACS-ECU turns ON the
by the headlamp automatic-shutdown function, the lock relay output for 0.25 second, and locks all doors.
buzzer does not sound. When the front doors is unlocked (when the unlock
switch turns ON after turning OFF the lock switch on
the driver's door lock actuator or front passenger’s
door lock key cylinder switch), ETACS-ECU turns ON
the unlock relay output for 0.25 second, and unlocks
all doors.
SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR
GENERAL INFORMATION
54B-3
Key reminder function
Key reminder (Key inserted) ON

switch (Key removed) OFF
Driver's door (Open) ON

switch
(Closed) OFF
Driver's door actuator LOCK

switch
UNLOCK
t t t t t
ON
Lock relay
OFF T2 T2 T2 T2
ON
Unlock relay
OFF
T1 T1 T1 T1 T1 T1 T1 T1
t: 0.3 seconds AC101499 AB

T1: 0.25 seconds
T2: 1 second
When the driver's door is opened with the ignition NOTE: The fail safe disables the operation under the
key inserted to the ignition cylinder and the door is following conditions (Diagnosis code No.31 or 32 is
locked (when the lock switch turns ON after turning set). Turn ON the ignition switch again after turning
OFF the unlock switch in the driver's door lock actua- the ignition switch to LOCK (OFF) to return from the
tor), after approximately 0.3 second, ETACS-ECU fail safe state.
turns ON the unlock relay output for 0.25 second to .
discourage the door lock operation so that the igni- • No.31: When the ignition switch is ON, and the
tion key left in the ignition cylinder is prevented. sensor shows under the short circuit voltage for
If the discouraging the door lock operation fails, the 2.5 second
current supply will be retried (The unlock relay output • No.32: When the ignition switch is ON, and the
is turned ON for 0.25 second up to five times with sensor shows over the closed circuit voltage for
one second interval). 0.4 second
NOTE: The broken line in the graph indicates the
current supply retry state if the discouraging door KEYLESS ENTRY SYSTEM
lock operation fails. KEYLESS ENTRY HAZARD LAMP
DOOR UNLOCK FUNCTION WITH THE ANSWERBACK FUNCTION (THE INITIAL
IMPACT DETECTION CONDITION: WITH FUNCTION OF
If the vehicle crashed with the ignition switch ON or LOCK/UNLOCK)
30 seconds after turning the ignition switch to LOCK
(OFF), and the impact sensor detects an impact LOCK
greater than the predetermined value, the impact Keyless entry
OFF
transmitter
sensor sends the signal to ETACS-ECU. Then, UNLOCK
within the 0.1 second, ETACS-ECU energizes the Lock relay output
ON
unlock relay for one second for releasing the door OFF
lock to prevent passengers to be kept inside the Unlock relay output

ON
OFF
vehicle after the crash. Hazard Illuminate
warning light Extinguish
AC101500AB
GENERAL INFORMATION
The hazard answerback function that allows check- KEYLESS ENTRY INTERIOR LAMP
ing the lock/unlock state of the door easily even in ANSWERBACK FUNCTION
the daytime is adopted. When the lock signal from
the keyless entry transmitter is received into LOCK
ETACS-ECU, all doors are locked, and the hazard Lock/unlock
signal by OFF
warning lamps blink twice. When the unlock signal is keyless entry
UNLOCK
received, all doors are unlocked, and the hazard
warning lamps blink once.
100 %
NOTE: The answerback blink time can be adjusted
Interior lamp 65 %
by the adjusting function. brightness
0%
15 seconds
AC304773 AB
The interior lamp blinks two times while locking the

door for easy checking the keyless entry function.
When the door is unlocked, the lamp lamps on for 15
seconds (100%), and turns off.
TIMED LOCKING MECHANISM

After unlocking the doors with the keyless entry
transmitter, if no doors are opened, if the ignition key
is not inserted or if the locking function is not oper-
ated, the ETACS-ECU automatically locks the doors
in 30 seconds.

Intermittent control (the initial condition: with function)
18 18 Intermittent wiper volume

"FAST" position
Intermittent time: Intermittent time:

TI (sec.) TI (sec.) Intermittent wiper volume
"SLOW" position
0
FAST SLOW 0 100
Intermittent wiper volume position Vehicle speed (km/h)
AC304771AB
ETACS-ECU calculates the intermittent time TI from NOTE: The vehicle speed-dependent wiper function
the windshield intermittent wiper volume of the col- can be invalidated by the adjusting function.
umn switch and the vehicle speed calculated from
the vehicle speed signals (vehicle speed sensor),
and sends it to the front ECU as SWS data.
GENERAL INFORMATION
54B-5
ON
Windshield wiper
auto stop signal
OFF
ON
Windshield wiper
drive signal OFF TI TI TI
TI: Intermittent time

AC304772 AB
The front ECU determines the intermittent time TI When the intermittent time TI is elapsed after being
from the input SWS data, and turns ON the wind- turned ON the windshield wiper drive signal, the
shield wiper drive signal. When the wiper comes to windshield wiper drive signal is turned ON again, and
the stop position, the windshield wiper auto-stop sig- the above-mentioned operation is repeated.
nal is turned OFF, and the windshield wiper drive sig-
nal turns OFF.
Mist wiper control
Windshield wiper ON
"MIST" switch OFF
Windshield wiper ON
auto stop signal OFF
Windshield wiper ON
drive signal OFF
TI TI
Windshield wiper (HI) ON
speed switching relay (LO) OFF
Windshield wiper switch Windshield wiper intermittent operation

TI: Intermittent time "OFF" position
AC300283 AD
When the windshield wiper mist switch of the column

switch is turned ON while the ignition switch is ACC
or ON, the column switch turns ON the windshield
wiper drive signal. At the same time, the wiper speed
switching relay turns to ON (HI). When the wind-
shield mist wiper switch is ON, the windshield wipers
operate at the high speed.
GENERAL INFORMATION
Low speed wiper and high speed wiper control
ON
Windshield wiper "LO" switch
OFF
ON
Windshield wiper "HI" switch
OFF
Windshield wiper ON
Windshield wiper ON
drive signal OFF
Windshield wiper speed (HI) ON

switching relay (LO) OFF
Windshield wiper low speed operation Windshield wiper high speed operation
AC300284AC
When the windshield low speed wiper switch of the When the windshield high speed wiper switch is
column switch is turned ON while the ignition switch turned ON, the windshield wiper drive signal turns
is ACC or ON, the column switch turns ON the wind- ON. Also, the wiper speed switching relay turns ON
shield wiper drive signal. Also, the wiper speed (HI), and the windshield wipers operate at the high
switching relay turns to OFF (LO), and the windshield speed.
wipers operate at the low speed.
Windshield wiper linked with washer function (initial condition: function available)
ON
Windshield washer switch
OFF
t t
ON
Windshield washer relay
OFF
Windshield wiper ON
ON
Windshield wiper relay
OFF
T T1 T T1
t: 0.3 seconds Wiper switch in Wiper switch in intermittent

operation position AC207005AD
T: 3 seconds off position
T1: Intermittent wiper
intermittent time
Wiper OFF position Intermittent operation position Low-speed or

switch high-speed
operation
position
Washer 0.3 0.3 to 0.5 to 0.7 0.2 0.2 to 0.5 to 0.7 -
switch ON seconds 0.5 0.7 seconds seconds 0.5 0.7 seconds
time or less seconds seconds or more or less seconds seconds or more
T1 0 1 2 3 0 1 2 3 3 seconds
second second seconds seconds second second seconds seconds
GENERAL INFORMATION
54B-7
• When the front-ECU receives a windshield windshield wiper at high speed. Turning off the
washer switch signal from the column switch with windshield washer switch causes the front-ECU
the ignition switch in the ACC or the ON position, to turn off the windshield wiper relay "T" seconds
the ECU turns on the windshield washer relay. later, thus operating the wiper to the auto stop
When the windshield washer relay becomes ON, position at low speed.
the windshield washer motor starts to run to • When the windshield washer switch is turned ON
spray the washer fluid in the washer tank onto the during the intermittent operation of the windshield
windshield through the washer nozzles. When wiper, the windshield wiper switches to continu-
the windshield washer switch signal remains on ous operation and then resumes intermittent
for 0.3 seconds or more, the signal turns on the operation.
windshield wiper relay (The wiper interval NOTE: The function to interlock the washer with
depends. For details, see the list) to operate the windshield wiper operation can be enabled or disa-
bled with its adjustment function.
HEADLAMP
Headlamp automatic-shutdown function (the initial condition: function available)
Ignition switch (IG) ON

OFF
Driver's seat (Opened) ON

door switch (Closed) OFF
Headlamp
Lighting switch Tail lamp
OFF
ON
Tail lamp output
OFF
ON
Headlamp output
OFF
3 minutes 1 second
AC300449 AB
Even when the lighting switch (tail lamp switch or When the lighting switch is turned off and then on, or
headlamp) is ON, the headlamp (including the tail the ignition switch is turned ON while the headlamp
lamps) turns off automatically with any of the follow- automatic shutdown function is active, the head-
ing conditions to prevent the battery discharge lamps illuminate again.
caused by unattended operation. NOTE: For vehicles with the keyless entry system,
• If the ignition switch is turned OFF with the light- this function can be invalidated by the adjusting func-
ing switch ON, the lamp turns off automatically tion.
after 3 minutes. If the driver's door is opened dur-
ing the 3 minutes, the lamp turns off after one
second (One second before turning off, the lamp
reminder buzzer sounds).
GENERAL INFORMATION
FLASHER TIMER FUNCTION HAZARD WARNING LAMP

TURN SIGNAL LAMP
Ignition ON Hazard lamp ON

switch (IG) OFF switch
OFF
Turn-signal lamp ON Turn signal ON
switch RH OFF lamp output
OFF
RH
Turn-signal lamp ON ON
Turn signal
switch LH OFF lamp output OFF
Turn-signal lamp ON LH
output RH OFF
Turn-signal lamp ON AC101509AC
output LH OFF
AC101508AC When the hazard lamp switch input signal turning
When the turn signal lamp switch is ON (LH or RH) from OFF to ON is detected, the flashing states turns
with the ignition switch ON, the turn signal lamp out- over by the signal (When the hazard lamp is not
put (flash signal) is turned ON. blinking, it blinks. If it is blinking, it turns off).
If the lamp bulb of the front or rear turn signal lamp NOTE: .
has burned out, the flashing speed becomes faster to 1. The push-return switch is adopted for the hazard
alert the driver that the lamp bulb has burned out. lamp switch.
2. Even if the lamp bulb has burned out, the flashing
speed of the hazard lamp is not changed.
FOG LAMP
Rear Fog Lamp Control Function
Headlamp
Lighting switch
Tail lamp
OFF
Illuminated
Front fog lamps
Extinguished
ON
Rear fog lamp switch
OFF
ON
Rear fog lamps
OFF
AC212279 AB
If the rear fog lamp switch is turned ON when the If the headlamp and the front fog lamp are turned
headlamp or the front fog lamp is turned ON, the rear OFF, the rear fog lamp is turned OFF at the same
fog lamp is switched ON and OFF alternatively. time.
GENERAL INFORMATION
54B-9
Interior lamp
Dimmer interior lamp control function (the initial condition: function available)
ON
Ignition switch ACC
OFF
Key removed
(Any one open) ON

Door switch
(All closed) OFF
Driver's door (Any one open) ON

lock actuator switch
(lock switch) (All closed) OFF
100 %
65 %
Interior lamp brightness
0%
15 seconds 15 seconds
AC310770 AB
When the interior lamp switch is on the door position, 3. When all doors are closed, and the ignition key is
ETACS-ECU controls the interior lamp illuminates as removed:
follows. By removing the ignition key with all doors closed,
1. When the ignition switch is OFF: the lamp turns ON (100%), and turns off after 15
By opening any door, the lamp turns ON (100%), and seconds.
dims (65%) when the door is closed, then and By inserting the ignition key again or operating the
turns off after 15 seconds. door lock with the lamp lit, the lamps turns off.
However, when the ignition switch is turned ON or NOTE: For the vehicles with the keyless entry sys-
the door lock is operated, the lamps turn off at tem, the delayed interior lamp turning off duration
that time. can be changed by the adjusting function.
2. When the ignition switch is ON:
By opening any door, the lamp (100%) turns ON and
OFF when the door is closed.
GENERAL INFORMATION
Interior lamp automatic-shutdown off function (the initial condition: function

available)
ON
Ignition switch ACC
OFF
(Any one open) ON

Door switch
(All closed) OFF
(Illuminated) ON
Interior lamp
(Extinguished) OFF
T T t t t
T: 30 minutes
AC212552AB
t: Within 30 minutes
When the interior lamp such as the interior lamp [all After automatic-shutdown function, the interior lamp
interior lamps connecting to the interior lamp fuse turns ON when any of the following condition is met.
(the front interior lamp, the map lamp, the rear inte- • Open and close doors.
rior lamp)] is lit, but either one of the conditions is • Operate the keyless entry transmitter.
met, the interior lamp is turned off automatically for • Turn the ignition switch to ACC or ON.
preventing the battery discharge caused by the unat- NOTE: .
tended operation or the door-ajar. 1. The interior lamp automatic-shutdown function
• After 30 minutes with the interior lamp lit while the can be disabled or enabled by the adjusting func-
ignition switch is OFF, the lamp turns off automat- tion.
ically.
2. After illuminating again, the lamp turns off after 30
• After 30 minutes with any door opened while the
minutes, when the interior lamp automatic-shut-
ignition switch is OFF, the lamp turns off automat-
down function is met.
ically.
SPECIAL TOOLS
54B-11
SPECIAL TOOLS
M1549000300775

MB991502 M.U.T.-II sub Check the SWS (The M.U.T.-II
assembly displays diagnosis codes and
input signals)
B991502
MB991955 M.U.T.-III Check the SWS (The M.U.T.-III

A A: MB991824 sub-assembly displays diagnosis codes and
B: MB991827 A: Vehicle input signals)
C: MB991910 Communication CAUTION
D: MB991911 Interface (V. C. I.) M.U.T.-III main harness B
MB991824
E: MB991825 B: M.U.T.-III USB (MB991911) should be used.
B F: MB991826 cable M.U.T.-III main harness A
C: M.U.T.-III main should not be used for this
harness A vehicle.
(Vehicles with CAN
system)
C
D: M.U.T.-III main
(Vehicles without
MB991910
CAN
communication
D system)
E: M.U.T.-III
measurement
adapter
MB991911
harness
E
MB991825
MB991826
MB991955
SPECIAL TOOLS

MB991529 Diagnosis code check Input signal check by using a
harness voltmeter
MB991529

a
a. MB991219 a. Check harness measurement at harness wire or
b. MB991220 b. LED harness connector
c. MB991221 c. LED harness a. For checking connector pin
d. MB991222 adapter contact pressure
b
d. Probe b. For checking power supply
circuit
circuit
c
d. For connecting a locally
sourced tester
d
DO NOT USE
MB991223BA

connector
MB992006
TROUBLESHOOTING
54B-13
TROUBLESHOOTING
PRIOR TO TROUBLESHOOTING NOTE: Connect the M.U.T.-II/III to the 16-pin diagno-
M1549014700497 sis connector (black).
Before carrying out troubleshooting, check the fol-
NOTE: A diagnosis code can not be read when the
lowing two items.
ETACS-ECU is defective or the power supply voltage
• Make sure that the ETACS-ECU, the junction
has risen. In this case, refer to inspection procedure
block (J/B), the front-ECU and the engine com-
A-1 "Communication with the M.U.T.-II/III is not pos-
partment relay box are connected securely.
sible P.54B-38."
• Check that the system fuses and fusible links are
not burned out.
HOW TO CHECK INPUT SIGNALS
STANDARD FLOW OF DIAGNOSTIC 1. Use the M.U.T.-II/III or a voltmeter to check input
TROUBLESHOOTING signals (Refer to GROUP 00 − How to Use Trou-
M1549000500683 bleshooting/Inspection Service Points P.00-5).
2. The input signals below can be checked by con-
necting the M.U.T.-II/III or a voltmeter to the diag-
DIAGNOSTIC FUNCTION nosis connector.
M1549028900148 NOTE: If a fault is found at the input signal check,
HOW TO READ DIAGNOSIS CODE refer to trouble symptom chart P.54B-36.
Use the M.U.T.-II/III to read diagnosis code (Refer to
GROUP 00 − How to Use Troubleshooting/Inspec-
tion Service Points P.00-5).
SWITCHES WHICH ARE APPLICABLE TO INPUT SIGNAL CHECK, AND THEIR CHECK
CONDITIONS
Input signal Requirements for sounding buzzer
Ignition switch (ACC) When turned from the LOCK (OFF) position to the
ACC position
Ignition switch (IG1) When turned from ACC to ON
Key reminder switch When the inserted ignition key is pulled out
Hazard warning lamp switch When the switch is turned from off to on
Rear fog lamp switch
Driver's door switch When the driver's door is opened
All of the door switches A door is opened when all the doors are closed
Driver's door lock actuator When the driver's key cylinder or inside lock knob is
unlocked or locked
Door lock key cylinder switch Turn the key to the lock or unlock position
Vehicle speed signal When the vehicle speed has reached 10 km/h or
more
Input signal Requirements for sounding buzzer

Column switch Tail lamp switch When the lighting switch is moved from the
headlamp position to the tail lamp position.
Headlamp switch When the lighting switch is moved from the tail lamp
position to the headlamp position.
Dimmer switch When the switch is turned from off to on
Passing lamp switch
Turn-signal lamp switch (LH)
Turn-signal lamp switch (RH)
Wind shield mist wiper switch
Windshield intermittent wiper
switch
Windshield low-speed wiper
switch
Windshield high-speed wiper
switch
Windshield intermittent wiper When the windshield intermittent wiper volume is
volume rotated from "FAST" to "SLOW" (a pulse is sent
around the volume middle position)
Windshield washer switch When the switch is turned from off to on
Keyless entry Switches When the switch is turned from off to on
transmitter
Interior lamp loaded signal When a load is applied through multi-purpose fuse
No.18

M1549000700331
Code No. Diagnosis Details Reference

page
11 Trouble related to the ETACS-ECU P.54B-15
12 Trouble related to the column switch or improper connection to the P.54B-16
ETACS-ECU
13 Trouble related to the front-ECU or improper connection to the P.54B-22
ETACS-ECU
21 Short circuit in SWS communication line P.54B-26
31 Open circuit in the signal line between the SRS-ECU and the P.54B-30
ETACS-ECU (impact detection signal)
32 Short circuit in the signal line between the SRS-ECU and the
ETACS-ECU (impact detection signal)
DIAGNOSTIC TROUBLE CODE PROCEDURES
54B-15
Diagnosis code 11: Trouble related to the ETACS-ECU
DIAGNOSIS CODE SET CONDITIONS DIAGNOSTIC PROCEDURE

The ETACS-ECU monitors the data, which the ECU
itself sends. If errors occur consecutively 15 times Check whether the diagnosis code is reset.
(for 0.6 seconds), a diagnosis code will be set. Then, (1) Erase the diagnosis code.
if the data does not contain any errors consecutively (2) Again check that diagnosis code No.11 is set.
15 times (for 0.6 seconds), the ECU will stop sending
the diagnosis code. Q: Is diagnosis code No.11 set?
YES : Replace the ETACS-ECU.
POSSIBLE CAUSES NO : The trouble can be an intermittent
• Malfunction of the ETACS-ECU malfunction (Refer to GROUP 00 − How to
Diagnosis code 12: Trouble related to the column switch or improper connection to the ETACS-ECU
CAUTION
Whenever the ECU is replaced, ensure that the
power supply circuit, the earthing circuit and the
communication circuit are normal.
Column Switch Power Supply and SWS Communication Circuit
IGNITION
RELAY
BOX
LHD RHD LHD RHD

NOTE
: LHD
: RHD
COLUMN
COLUMN-ECU SWITCH
Wire colour code

B : Black
LG : Light green
G : Green
L: Blue
W : White
Y: Yellow
SB : Sky blue
ETACS-ECU BR : Brown
O : Orange
GR : Gray
R : Red
P : Pink
V : Violet
54B-17
DIAGNOSIS CODE SET CONDITIONS Step 3. Voltage measurement at C-206 column
If the column switch ignores the data request signal switch connector
sent by the ETACS-ECU (three times or more for one
second), this diagnosis code will be set. Then, when
the column switch observes the request signal for
one second, the ECU will stop sending the diagnosis
code. Harness side
POSSIBLE CAUSES
• Malfunction of the column switch
• Malfunction of the ETACS-ECU
AC310479AD
DIAGNOSTIC PROCEDURE Connector: C-206 <RHD>
Step 1. M.U.T.-II/III diagnosis code.

(1) Ignition switch: ON
(2) On completion, check that diagnosis code No.12
is not reset. Harness side

YES : Go to Step 5.
NO : Go to Step 2.
AC310481AD
(1) Disconnect the column switch connector, and

Step 2. Connector check: C-206 column switch measure at the wiring harness side.
connector
Connector C-206
(Harness side)
Harness side
5 4 3 2 1
10 9 8 7 6
AC301541HQ
AC310479AD
(2) Voltage between C-206 column switch connector
Connector: C-206 <RHD> terminal No.1 and body earth
OK: System voltage
YES : Replace the column switch.
Harness side NO : Go to Step 4.
AC310481AD

YES : Go to Step 3.
Step 4. Check the wiring harness between C-206 NOTE:

column switch connector terminal No.1 and the
battery.
Connector: C-206 <LHD> C-05 (GR)
Harness side C-129
C-05
AC310479AD
C-129
Harness side
AC310447AC

AC310481AD
C-05 (GR)
C-129
C-05
C-129
AC310455AB

diate connector C-129 and joint connector C-05, and
malfunction (Refer to GROUP 00 − How to
54B-19
Step 5. Resistance measurement at the C-206 Step 6. Check the wiring harness between C-206
column switch connector column switch connector terminal No.4 and the
body earth.
Harness side
Harness side
AC310479AD
AC310479AD
Harness side
Harness side
AC310481AD
(1) Disconnect the column switch connector, and AC310481AD
measure at the wiring harness side. NOTE:

Connector C-206 C-06 (GR)

(Harness side)
5 4 3 2 1
10 9 8 7 6
AC310452 AB
AC310506AK
(2) Resistance between C-206 column switch Connector: C-06 <RHD>

C-06 (GR)
OK: 2 Ω or less
YES : Go to Step 7.
NO : Go to Step 6.
AC310456 AB


Step 8. Check the wiring harness from C-228
ETACS-ECU connector terminal Nos.59 and 68 to
C-206 column switch connector terminal Nos.3
and 2.
Step 7. Connector check: C-228 ETACS-ECU

connector
Connector: C-228 <LHD> Harness side
Junction block (rear view)
Harness side AC310479AD
59 58 57 56 55 54 53 52 51 Connector: C-206 <RHD>

C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC

Junction block (rear view) Harness side
AC310481AD
Harness side
59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60
C-228 (GR)
74 73 72 71 70 69
AC310461AC

59 58 57 56 55 54 53 52 51
C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC

Harness side
59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60 C-228 (GR)
74 73 72 71 70 69
AC310461AC
54B-21
NOTE: Step 9. Check whether the diagnosis code is
reset.
C-101 (L) Replace the column switch, and then check that the
diagnosis code is not reset.
(1) Replace the column switch.
(3) On completion, check that diagnosis code No.12
is not reset.
AC310446AW YES : Replace the ETACS-ECU.
C-101 (L)
AC310456 AQ

• Check the communication lines for open circuit.
YES : Go to Step 9.
Diagnosis code 13: Trouble related to the front-ECU or improper connection to the ETACS-ECU
CAUTION
Front-ECU Power Supply and SWS Communication Circuit
IGNITION
RELAY
BOX
FRONT-ECU
POWER NOTE
SOURCE : LHD
: RHD
ETACS-ECU
Wire colour code

54B-23
DIAGNOSIS CODE SET CONDITIONS Step 3. Voltage measurement at A-10X front-ECU
If the front-ECU has sent abnormal signal to the connector
ETACS-ECU for consecutively 15 communication
Connector: A-10X
cycles (0.6 second), the diagnosis code will be set. If
the front-ECU has sent normal signal to the
ETACS-ECU for consecutively 15 communication
Battery
cycles (0.6 second), the ETACS-ECU will stop send-
ing the diagnosis code.
POSSIBLE CAUSES Relay box side

• Malfunction of the front-ECU
11 10 9 8 7 6 5 4 3 2 1
• Damaged harness wires and connectors AC310572AB
(1) Remove the front-ECU, and measure at the relay

DIAGNOSTIC PROCEDURE box side.

Connector A-10X
(2) On completion, check that diagnosis code No.13 (Relay box side)
is not reset.
11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 5.
NO : Go to Step 2.
AC301541CT
Step 2. Connector check: A-10X front-ECU
connector (2) Voltage between A-10X front-ECU connector
terminal No.7 and body earth
Connector: A-10X
OK: System voltage
Battery YES : Replace the front-ECU.
NO : Go to Step 4.
Step 4. Check the wiring harness between A-10X

Relay box side front-ECU connector terminal No.7 and the
11 10 9 8 7 6 5 4 3 2 1
battery.
AC310572AB Connector: A-10X
YES : Go to Step 3.
NO : Repair the defective connector. Battery
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB

Step 5. Connector check: A-11X front-ECU Step 7. Check the wiring harness between A-11X
connector front-ECU connector terminal No.31 and the body
Connector: A-11X earth.
Connector: A-11X
Battery
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21 Relay box side
31 30 29 28 27 26 25 24 23 22 21
AC310572AC
AC310572AC
YES : Go to Step 6. • Check the earth wires for open circuit.
Step 6. Resistance measurement at A-11X malfunction (Refer to GROUP 00 − How to
front-ECU connector Cope with Intermittent Malfunction P.00-5).
Connector: A-11X

Battery connector
Relay box side

31 30 29 28 27 26 25 24 23 22 21

(1) Remove the front-ECU, and measure at the relay 59 58 57 56 55 54 53 52 51
box side. C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC

Connector A-11X Junction block (rear view)
(Relay box side)
31 30 29 2827 26 25 24 2322 21
Harness side
AC301541CU 59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60 C-228 (GR)
(2) Resistance between A-11X front-ECU connector 74 73 72 71 70 69
AC310461AC
OK: 2 Ω or less Q: Is the check result normal?
YES : Go to Step 9.
YES : Go to Step 8.
NO : Go to Step 7.
54B-25
ETACS-ECU connector terminal No.59 and A-11X
front-ECU connector terminal No.22. C-101 (L)
Connector: A-11X
Battery
AC310446AW
Relay box side
31 30 29 28 27 26 25 24 23 22 21 Connector: C-101 <RHD>
AC310572AC

C-101 (L)
Harness side
AC310456 AQ
59 58 57 56 55 54 53 52 51
C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC

Harness side AC310446 AS

59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60 Connector: C-129 <RHD>
C-228 (GR)
74 73 72 71 70 69
AC310461AC
AC310454 AV

connector C-101 and intermediate connector C-129,
Step 10. Check whether the diagnosis code is (3) On completion, check that diagnosis code No.13
reset. is not reset.
Replace the column switch, and then check that the Q: Is diagnosis code No.13 set?
diagnosis code is not reset. YES : Replace the ETACS-ECU.
(1) Replace the column switch. NO : The procedure is complete.
Diagnosis code 21: Short circuit in SWS communication line
CAUTION
communication circuit is normal.
SWS Communication Line
FRONT-ECU ETACS-ECU
COLUMN POWER
COLUMN-ECU SWITCH CPU WINDOW
MAIN SWITCH
NOTE
: LHD
: RHD
Wire colour code

DIAGNOSIS CODE SET CONDITIONS POSSIBLE CAUSES

If the SWS communication line voltage is kept at low • Malfunction of the column switch
level for 0.3 second, the diagnosis code will be set. If • Malfunction of the front-ECU
the ETACS-ECU data line voltage is kept at high • Malfunction of the power window main switch
level for 0.3 second, or the ETACS-ECU has • Malfunction of the ETACS-ECU
received normal signal from the other ECUs or • Damaged harness wires and connectors
switches, the ETACS-ECU will stop sending the
diagnosis code. While this code is set, the other
codes will not be set.
54B-27
DIAGNOSTIC PROCEDURE Connector: C-228 <RHD>
Step 1. Connector check: A-11X front-ECU Junction block (rear view)
connector, C-206 column switch connector,
C-228 ETACS-ECU connector and E-05 power
window main switch connector
Connector: A-11X
Harness side
59 58 57 56 55 54 53 52 51
Battery 68 67 66 65 64 63 62 61 60 C-228 (GR)
74 73 72 71 70 69
AC310461AC
Connector: E-05 <LHD>

Relay box side Front door (LH)
31 30 29 28 27 26 25 24 23 22 21
AC310572AC
Connector: C-206 <LHD> Harness side

6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side AC310484 AD
Connector: E-05 <RHD>

Front door (RH)
AC310479AD
Connector: C-206 <RHD> Harness side

6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310493 AG
Harness side
YES : Go to Step 2.
AC310481AD

Harness side
59 58 57 56 55 54 53 52 51
C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC
Step 2. Check the wiring harness from each of Connector: C-228 <RHD>
A-11X front-ECU connector terminal No.22, C-206 Junction block (rear view)
column switch connector terminal No.3 and E-05
power window main switch connector terminal
No.4 to C-228 ETACS-ECU connector terminal
No.59.
Harness side
Connector: A-11X
59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60 C-228 (GR)
74 73 72 71 70 69
Battery AC310461AC

Front door (LH)
Relay box side
31 30 29 28 27 26 25 24 23 22 21
AC310572AC
Harness side
Connector: C-206 <LHD> 6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310484 AD
Harness side
Front door (RH)
AC310479AD
Harness side
Connector: C-206 <RHD> 6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310493 AG
Harness side
AC310481AD

Harness side
59 58 57 56 55 54 53 52 51
C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC
54B-29
NOTE: Step 3. Check the wiring harness between C-206
column switch connector terminal No.2 and
C-101 (L) C-228 ETACS-ECU connector terminal No.68.
C-17
Harness side
AC310479AD
C-17
C-101
Harness side
AC310447AF

AC310481AD

C-101 (L)
Harness side
AC310456 AQ 59 58 57 56 55 54 53 52 51
C-228 (GR) 68 67 66 65 64 63 62 61 60
Connector: C-110 <RHD> 74 73 72 71 70 69
AC310450AC

Harness side
AC310456 AH
59 58 57 56 55 54 53 52 51
Prior to the wiring harness inspection, check joint 68 67 66 65 64 63 62 61 60 C-228 (GR)
connector C-101 and intermediate connector C-17 74 73 72 71 70 69
AC310461AC
<LH drive vehicles> or C-110 <RH drive vehicles>,
• Check the communication lines for open circuit. Q: Is the check result normal?
YES : Go to Step 4.
Q: Is the check result normal? NO : Repair the wiring harness.
YES : Go to Step 3.
Step 4. Check whether the diagnosis code is Step 6. Check that the hazard warning lamps
reset. illuminate.
When A-11X front-ECU connector is disconnected, When the ignition switch is turned to the LOCK
check that diagnosis code No.21 is not reset. How- (OFF) position, check if the hazard warning lamps
ever, diagnosis code No.13 will be set at this time. illuminate.
Q: Is diagnosis code No.21 set? Q: Is the check result normal?
YES : Replace the front-ECU. YES : Refer to diagnosis code No.12 "Trouble
NO : Go to Step 5. related to the column switch or improper
connection to the ETACS-ECU P.54B-16."
NO : Refer to inspection procedure A-2 "Check
Step 5. Check whether the diagnosis code is
reset. the battery power supply circuit to the
When E-05 power window main switch connector is ETACS-ECU P.54B-42."
disconnected, check that diagnosis code No.21 is
not reset.
YES : Replace the power window main switch.
NO : Go to Step 6.
Diagnosis code 31: Open circuit in the signal line between the SRS-ECU and the ETACS-ECU (impact
detection signal)
Diagnosis code 32: Short circuit in the signal line between the SRS-ECU and the ETACS-ECU (impact
detection signal)
CAUTION
input signal circuit is normal.
ETACS-ECU
SRS-ECU Wire colour code

CRASH DETECTION G : Green L : Blue
DOOR UNLOCK W : White Y : Yellow
SIGNAL PROCESS CIRCUIT SB : Sky blue BR : Brown
54B-31
DIAGNOSIS CODE SET CONDITIONS Step 2. Connector check: C-12 SRS-ECU
If the voltage in the signal line between the connector and C-227 ETACS-ECU connector
SRS-ECU and the ETACS-ECU has exceeded 4.6 V
Connector: C-12
for 40 milliseconds or more, the ETACS-ECU will set <LHD>
diagnosis code No.31 as an open circuit. If the signal
line voltage has reached 1.5 V or less for at least 2.5
seconds, the ETACS-ECU will set diagnosis code
No.32 as a short circuit. If the ignition switch is turned Harness side
off, the ETACS-ECU will stop sending the diagnosis
code.
C-12 (Y)
POSSIBLE CAUSES
• Malfunction of the SRS-ECU AC310446AX
• Malfunction of the ETACS-ECU Connector: C-12

• Damaged harness wires and connectors <RHD>
DIAGNOSTIC PROCEDURE
Harness side
Check that the SRS-ECU sets a diagnosis code.
Q: Is the check result normal? C-12 (Y)
YES : Go to Step 2.
NO : Refer to GROUP 52B − Troubleshooting
AC310454BB
P.52B-9. Connector: C-227

<LHD> Junction block
(rear view)
Harness side
29 28 27 26 25 24 23 22 21
38 37 36 35 34 33 32 31 30
44 43 42 41 40 39
AC310450AG
Connector: C-227 Junction block (rear view)

<RHD>
Harness side
29 28 27 26 25 24 23 22 21
38 37 36 35 34 33 32 31 30
44 43 42 41 40 39
AC310461AF

YES : Go to Step 3.
Step 3. Check the wiring harness between C-227 Step 4. Check whether the diagnosis code is
ETACS-ECU connector terminal No.29 and C-12 reset.
SRS-ECU connector terminal No.14. Replace the SRS-ECU, and then check that the diag-
Connector: C-227 nosis code is not reset.
<LHD> Junction block (1) Replace the SRS-ECU.
(rear view) (2) Ignition switch: ON
(3) Check that diagnosis code No.31 or 32 is not
reset.
Harness side Q: Is diagnosis code No.31 or 32 set?
YES : Replace the ETACS-ECU.
29 28 27 26 25 24 23 22 21
38 37 36 35 34 33 32 31 30 NO : The procedure is complete.
44 43 42 41 40 39
AC310450AG

<RHD>
Harness side
29 28 27 26 25 24 23 22 21
38 37 36 35 34 33 32 31 30
44 43 42 41 40 39
AC310461AF
Connector: C-12
<LHD>
Harness side
C-12 (Y)
AC310446AX
Connector: C-12
<RHD>
Harness side
C-12 (Y)
AC310454BB

YES : Go to Step 4.
54B-33
M1549000800866

procedure page
number
Communication with the M.U.T.-II/III is not possible. A-1 P.54B-38
When the ignition switch is at the LOCK (OFF) position, the functions do A-2 P.54B-42
not work normally.
Check the battery power supply circuit to the ETACS-ECU.
<FUNCTION SYSTEM>
procedure page
number
Buzzer Lamp reminder buzzer function does not B-1 P.54B-46
work normally.
Central door locking Central door locking system does not work. C-1 P.54B-48
system <LH drive vehicles>
Central door locking system does not work. P.54B-51
<RH drive vehicles>
A door or a tailgate can not be locked or C-2 P.54B-54
unlocked by the central door locking
system. <LH drive vehicles>
A door or a tailgate can not be locked or P.54B-61
unlocked by the central door locking
system. <RH drive vehicles>
The central door locking system can not be C-3 P.54B-68
operated by means of the front
passenger's door lock key cylinder.
The ignition key reminder function does not C-4 P.54B-69
work normally.
The impact detection door unlock function C-5 P.54B-71
does not function.

procedure page
number
Power windows Power windows do not work at all. D-1 P.54B-72
Driver's power window does not work by D-2 P.54B-81
means of the power window main switch.
<LH drive vehicles>
Driver's power window does not work by P.54B-83
<RH drive vehicles>
Relevant power window(s) do not work by D-3 P.54B-85
means of the front and rear passenger's
power window sub switches.
Front and/or rear passenger's power D-4 P.54B-103
window(s) do not work by means of the
power window main switch.
The window glass lowers automatically D-5 P.54B-112
while it is rising.
Power window anti-trap function does not D-6 P.54B-113
work normally.
Keyless entry system Keyless entry system does not work. E-1 P.54B-125
Keyless entry hazard warning lamp E-2 P.54B-127
answerback function or the room lamp
answerback function does not work
normally.
Encrypted code cannot be registered. E-3 P.54B-128
The timer lock function does not work after E-4 P.54B-129
the doors have been unlocked by the
keyless entry system.
Windshield wiper and The windshield wipers do not work at all. F-1 P.54B-130
washer The windshield wipers do not work when F-2 P.54B-137
the wiper switch is at "INT", "Washer" or
"Mist" position. However, the wipers work
at low speed when the switch is at "Lo" and
"Hi" position.
The windshield wipers do not stop at the F-3 P.54B-139
specified park position.
The windshield wipers does not work F-4 P.54B-144
normally.
The intermittent wiper interval can not be F-5 P.54B-149
adjusted by operating the windshield
intermittent wiper volume control.
The intermittent wiper interval is not F-6 P.54B-150
changed according to the vehicle speed.
The windshield washer does not work. F-7 P.54B-152
Ignition key cylinder The ignition key cylinder illumination lamp G-1 P.54B-156
illumination lamp does not illuminate/extinguish normally.
54B-35
procedure page
number
Headlamp and tail lamp The tail lamps do not illuminate normally. H-1 P.54B-160
The low-beam headlamps do not illuminate H-2 P.54B-162
normally.
The high-beam headlamps do not H-3 P.54B-164
illuminate normally.
The high-beam and low-beam headlamps H-4 P.54B-165
do not illuminate when the passing switch
is operated.
The headlamp automatic shutdown H-5 P.54B-166
function does not work normally.
Any of tail lamps, position lamps or licence H-6 P.54B-168
plate lamps does not illuminate. <LH drive
vehicles>
Any of tail lamps, position lamps or licence P.54B-175
plate lamps does not illuminate. <RH drive
vehicles>
The headlamp(s) do not illuminate. H-7 P.54B-182
<including high-beam indicator>
Flasher timer The turn-signal lamps do not illuminate. I-1 P.54B-191
The hazard warning lamps do not I-2 P.54B-196
illuminate.
Any of the turn-signal lamps does not I-3 P.54B-198
illuminate. <LH drive vehicles>
Any of the turn-signal lamps does not P.54B-205
illuminate. <RH drive vehicles>
Fog lamp The rear fog lamp do not illuminate J-1 P.54B-212
normally.
The rear fog lamp or the rear fog lamp J-2 P.54B-218
indicator does not illuminate normally.
Room lamp The front, rear room lamp and/or luggage K-1 P.54B-225
compartment lamp do not illuminate or
extinguish normally.
Interior lamp automatic shutdown function K-2 P.54B-233
does not work normally.
The door-ajar warning lamp does not K-3 P.54B-235
illuminate/extinguish normally.
CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK
CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK

M1549024200318
<PULSE CHECK>
If a problem is found in the Service Data inspection, observe the table below.
procedure page
number
The ignition switch (ACC) signal is not received. L-1 P.54B-239
The ignition switch (IG1) signal is not received. L-2 P.54B-242
The door switch (front: LH) signal is not received. <LH drive vehicles> L-3 P.54B-244
The door switch (front: RH) signal is not received. <RH drive vehicles> P.54B-246
Column switch (lighting and The tail lamp switch signal is not L-4 P.54B-248
turn-signal lamp switch) received.
The headlamp switch signal is not
received.
The dimmer switch signal is not
received.
The passing switch signal is not
received.
The turn-signal lamp switch (LH)
signal is not received.
The turn-signal lamp switch (RH)
signal is not received.
Column switch (windshield The windshield mist wiper switch L-5 P.54B-249
wiper/washer switch) signal is not received.
The windshield intermittent wiper
switch signal is not received.
The windshield low-speed wiper
The windshield high-speed wiper
The windshield washer switch signal
is not received.
The windshield intermittent wiper L-6 P.54B-250
volume signal is not received.
Power window main switch When the power window main switch L-7 P.54B-254
is operated, the switch signals are
not received.
The key reminder switch signal is not received. L-8 P.54B-257
The hazard warning lamp switch signal is not received. L-9 P.54B-261
All the door switch signals are not LH drive vehicles L-10 P.54B-265
received. RH drive vehicles P.54B-268
OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION PROCEDURES
54B-37
procedure page
number
The front door lock actuator (LH) switch signal is not received. <LH drive L-11 P.54B-272
vehicles>
The front door lock actuator (RH) switch signal is not received. <RH drive P.54B-275
vehicles>
The vehicle speed sensor signal is not received. L-12 P.54B-278
Each switch signal of the keyless entry transmitter is not received. L-13 P.54B-282
The rear fog lamp switch signal is not received. L-14 P.54B-283
The interior lamp loaded signal is not received. L-15 P.54B-287
The door lock key cylinder switch signal is not received. L-16 P.54B-292
OPERATION AND FUNCTION QUICK-REFERENCE TABLE

FOR INPUT SIGNAL INSPECTION PROCEDURES
M1549020300313
If troubles have occurred in the functions which use the SWS simultaneously, observe the table below to
check input signals.
(This table shows only the input signals which will cause troubles in at least two functions simultaneously).
Function L-1 L-2 L-3 L-4 L-8 L-10 L-11 L-15

Lamp reminder function − × × × − − − −
Control of central door − − − − − − × −
locking
Key reminder function − − × − × − × −
Door locking released due to − − − − − − − −
impact detection
Keyless entry system − − × − × × × −
Keyless entry hazard − − − − − − − −
warning lamp answerback
Power window control − × − − − − − −
Control of windshield × − − − − − − −
wiper/washer
Ignition key cylinder − × × − × − − ×
illumination lamp function
Headlamp control − × − × − − − −
Tail lamp control − × − × − − − −
Headlamp automatic − × × × − − − −
shutdown function
Fog lamp control − − − × − − − −
Turn-signal lamp control − × − × − − − −
SYMPTOM PROCEDURES
Function L-1 L-2 L-3 L-4 L-8 L-10 L-11 L-15

Room lamp control − × × − × × × ×
Interior lamp automatic × − − − − − − ×
shutdown function
Door-ajar indicator lamp − − × − − × − −
SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-1: Communication with the M.U.T.-II/III is not possible.
CAUTION
MUT-II/III Communication Circuit and ETACS-ECU Ground Circuit
ETACS-
ECU
J/B SIDE
LHD RHD
DIAGNOSIS
CONNECTOR
Wire colour code FRONT SIDE
COMMENTS ON TROUBLE SYMPTOM NOTE: If the wiring harness between the

It is suspected that the power supply circuit to the ETACS-ECU and body earth is defective, also check
ETACS-ECU is defective, or the wiring harness C-225 ETACS-ECU connector terminal No.3, and
between the diagnosis connector and the repair if necessary.
ETACS-ECU or their connector(s) is damaged.
SYMPTOM PROCEDURES
54B-39
POSSIBLE CAUSES Step 4. Resistance measurement at the C-228
• Malfunction of the ETACS-ECU ETACS-ECU connector
Step 1. Check that the M.U.T.-II/III communicates

with the other systems. Harness side
Use the M.U.T.-II/III to confirm that it communicates
with the engine-ECU. C-228 (GR)
59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60
Q: Is the check result normal? 74 73 72 71 70 69
YES : Go to Step 2. AC310450AC
NO : Diagnose the engine control system by

referring to P.13A-237. Junction block (rear view)
Step 2. Check that the M.U.T.-II/III can

communicate with the system.
When the ignition switch is turned ON, check if the
M.U.T.-II/III can communicate with the system. Harness side
Q: Is the check result normal? 59 58 57 56 55 54 53 52 51
YES : Refer to inspection procedure A-2 "Check 68 67 66 65 64 63 62 61 60 C-228 (GR)

74 73 72 71 70 69
the battery power supply circuit to the AC310461AC
ETACS-ECU P.54B-42." (1) Disconnect the connector, and measure at the

NO : Go to Step 3. junction block side.

connector
59 58 57 5655 54 53 52 51
68 67 66 6564 63 62 61 60
74 73 72 71 70 69
Connector C-228
Harness side (Harness side)
AC310506AB
59 58 57 56 55 54 53 52 51
C-228 (GR) 68 67 66 65 64 63 62 61 60 (2) Resistance between C-228 ETACS-ECU
74 73 72 71 70 69 connector terminal No.56 and body earth
AC310450AC
OK: 2 Ω or less
Connector: C-228 <RHD> Q: Is the check result normal?
Junction block (rear view) YES : Go to Step 6.
NO : Go to Step 5.
Harness side
59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60 C-228 (GR)
74 73 72 71 70 69
AC310461AC

YES : Go to Step 4.
SYMPTOM PROCEDURES

Step 5. Check the wiring harness between C-228
ETACS-ECU connector terminal No.56 and body
earth.
Connector: C-228 <LHD> NO : Repair the wiring harness.
Step 6. Connector check: C-14 diagnosis

connector
Harness side
59 58 57 56 55 54 53 52 51
C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC
Connector: C-228 <RHD> Front side

Junction block (rear view) C-14 (B)
AC310446 AB

Harness side
59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60 C-228 (GR)
74 73 72 71 70 69
AC310461AC
Front side
NOTE:
Connector: C-06 <LHD> C-14 (B)
C-06 (GR)
AC310456 AC

YES : Go to Step 7.
AC310452 AB
C-06 (GR)
AC310456 AB

SYMPTOM PROCEDURES
54B-41
Step 7. Check the wiring harness from C-228 Connector: C-228 <RHD>
ETACS-ECU connector terminal Nos.51 and 67 to Junction block (rear view)
C-14 diagnosis connector terminal Nos.9 and 1.
Harness side
59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60 C-228 (GR)
C-23 (B) 74 73 72 71 70 69
AC310461AC

C-14 (B)
C-23
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Front side AC310454AB

C-14
joint connector C-23 <LH driver vehicles> or C-21
<RH drive vehicles>, and repair if necessary.
AC310447AB
YES : Go to Step 8.
Step 8. Retest the system.

Front side
Check whether the communication with the
C-14 (B) M.U.T.-II/III is possible.
AC310456 AC YES : The trouble can be an intermittent
Connector: C-228 <LHD> Cope with Intermittent Malfunction P.00-5).
NO : Replace the ETACS-ECU.
Harness side
59 58 57 56 55 54 53 52 51
C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC
SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-2: When the ignition switch is at the LOCK (OFF) position, the functions
do not work normally. Check the battery power supply circuit to the ETACS-ECU.
CAUTION
power supply circuit and the earthing circuit are
normal.
BATTERY
RELAY
BOX
NOTE
: LHD
: RHD
ETACS-ECU
J/B SIDE
Wire colour code

G : Green L : Blue
COMMENTS ON TROUBLE SYMPTOM • Reading diagnosis code and checking input sig-
If this circuit is defective and the ignition switch is at nal by M.U.T.-II/III.
the LOCK (OFF) position, the ETACS-ECU does not • Central door locking
work. In this case, the functions below will be sus- • Headlamp and tail lamp
pended. • Hazard warning lamp
• Lamp reminder function • Room lamps
• Keyless entry system
• Headlamp automatic shutdown function POSSIBLE CAUSES
However, when the ignition switch is at the ON posi- • Malfunction of the ETACS-ECU
tion, the functions below will work. • Damaged harness wires and connectors
SYMPTOM PROCEDURES
54B-43
DIAGNOSTIC PROCEDURE Step 2. Voltage measurement at the C-226
ETACS-ECU connector
Step 1. Connector check: C-226 ETACS-ECU Connector: C-226 <LHD>
connector Junction block (rear view)
Junction block side
Junction block side AC310450 AB

AC310450 AB
Junction block
(rear view)
Junction block
(rear view)
Junction block side
AC310461AE
Junction block side
(1) Remove the ETACS-ECU, and measure at the
AC310461AE junction block side.
YES : Go to Step 2.
Connector C-226
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC310507AB
(2) Voltage between C-226 ETACS-ECU connector

terminal No.20 and body earth.
OK: System voltage
YES : Go to Step 4.
NO : Go to Step 3.
SYMPTOM PROCEDURES
Step 3. Check the wiring harness between C-226 Connectors: C-05, C-129 <RHD>
ETACS-ECU connector terminal No.20 and
battery. C-05 (GR)

C-129
Junction block side
C-05
AC310450 AB

Junction block
(rear view)
C-129
AC310455AB
Junction block side Connector: C-210 <LHD>

AC310461AE
NOTE:
Harness side
C-05 (GR) 6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310448AD
C-129
C-05
Harness side
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310458 AD
C-129
connector C-05, intermediate connector C-129 and
AC310447AC sary.
SYMPTOM PROCEDURES
54B-45
Step 4. Resistance measurement at the C-226 Step 5. Check the wiring harness between C-226
ETACS-ECU connector ETACS-ECU connector terminal No.3 and body
earth.
Junction block (rear view) Connector: C-226 <LHD>
Junction block side

Junction block side
AC310450 AB
AC310450 AB
Junction block Connector: C-226 <RHD>
(rear view) Junction block
(rear view)
Junction block side

Junction block side
AC310461AE
(1) Remove the ETACS-ECU, and measure at the AC310461AE
junction block side. NOTE:

Connector C-226
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310448AE
AC310506AC
(2) Continuity between C-226 ETACS-ECU Connector: C-214 <RHD>

connector terminal No.3 and body earth. Junction block (front view)
OK: 2Ω or less
YES : Go to Step 6.
NO : Go to Step 5.
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310458 AE

block connector C-214, and repair if necessary.
SYMPTOM PROCEDURES

Check that the battery power supply circuit to the
ETACS-ECU is normal.
NO : Repair the wiring harness. Q: Is the check result normal?
BUZZER
INSPECTION PROCEDURE B-1: Lamp reminder buzzer function does not work normally.
CAUTION
input and output signal circuits are normal.
Lamp Reminder Tone Alarm Function
ETACS-ECU
INPUT SIGNAL
· FRONT DOOR SWITCH (RH) <RHD>
· FRONT DOOR SWITCH (LH) <LHD>
· HEADLAMP SWITCH
· IGNITION SWITCH (IG1)
· TAIL LAMP SWITCH
COMMENTS ON TROUBLE SYMPTOM • Damaged harness wires and connectors

The ETACS-ECU operates this function in accord-
ance with the input signals below. DIAGNOSTIC PROCEDURE
• Ignition switch (IG1)
• Driver's door switch Step 1. Check the power supply circuit.
• Tail lamp switch When the ignition switch is turned to the LOCK
• Headlamp switch (OFF) position, check if the hazard warning lamps
If this function does not work normally, these input illuminate.
signal circuit(s) or the ETACS-ECU may be defec-
tive. Q: Is the check result normal?
YES : Go to Step 2.
POSSIBLE CAUSES NO : Refer to inspection procedure A-2 "Check
• Malfunction of the driver's door switch the battery power supply circuit to the
• Malfunction of the column switch ETACS-ECU P.54B-42."
SYMPTOM PROCEDURES
54B-47
Step 2. Pulse check
All the signals are received normally. : Go to Step
Check the input signals below, which are related to
3.
the lamp reminder buzzer function. The ignition switch (IG1) signal is not received. :
System switch Check condition Refer to inspection procedure L-2 "The
Ignition switch (IG1) When turned from ACC ignition switch (IG1) signal is not received
to ON P.54B-242."
The driver's door switch signal is not received. :
Driver's door switch When the driver's door is Refer to inspection procedure L-3 "The door
opened switch (front: LH) signal is not received <LH
Tail lamp switch When the lighting switch drive vehicles>P.54B-244 ." Refer to
is turned to the TAIL inspection procedure L-3 "The door switch
position (front: RH) signal is not received <RH drive
Headlamp switch When the lighting switch vehicles>P.54B-246 ."
is turned to the The tail lamp switch signal is not received. : Refer
HEADLAMP position to inspection procedure L-4 "The column
switch (lighting and turn-signal lamp switch)
OK: The M.U.T.-II/III sounds or the voltmeter signal is not received P.54B-248."
needle fluctuates. The headlamp switch signal is not received. :
Refer to inspection procedure L-4 "The
column switch (lighting and turn-signal lamp
switch) signal is not received P.54B-248."

The lamp reminder buzzer function should work nor-
mally.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-1: Central door locking system does not work. <LH drive vehicles>
CAUTION
Central Door Lock Power Supply Circuit <LHD>
FUSIBLE
LINK 1
J/B SIDE
ETACS-ECU
DOOR DOOR
UNLOCK LOCK
RELAY RELAY
DOOR LOCK
ACTUATOR
(FRONT: LH)
Wire colour code

SYMPTOM PROCEDURES
54B-49
COMMENT ON TROUBLE SYMPTOM Step 3. Connector check: E-04 front door lock
If the central door locking system does not work at actuator (LH) connector
all, the front door lock actuator (LH) or the
ETACS-ECU may be defective.
Front door (LH)
POSSIBLE CAUSES
• Malfunction of the front door lock actuator (LH)
Harness side
• Damaged harness wires and connectors E-04(B)
DIAGNOSIS PROCEDURE
AC310484 AB
Step 1. Check the power supply circuit.
When the ignition switch is turned to the LOCK Q: Is the check result normal?
(OFF) position, check if the hazard warning lamps YES : Go to Step 4.
illuminate. NO : Repair the defective connector.

YES : Go to Step 2. Step 4. Check the front door lock actuator (LH)
NO : Refer to inspection procedure A-2 "Check Check that the front door lock actuator (LH) works
the ETACS-ECU battery power supply normally. Refer to GROUP 42 − Door P.42-31.
circuit P.54B-42." Q: Is the check result normal?
YES : Go to Step 5.
Step 2. Pulse check NO : Replace the front door lock actuator (LH).
Check the input signal from the driver's door lock
actuator switch. Step 5. Connector check: C-226 ETACS-ECU
System switch Check condition connector
Driver's door lock When the driver's key Connector: C-226 <LHD>
actuator switch cylinder or inside lock Junction block (rear view)
knob is unlocked or
locked
OK: The M.U.T.-II/III sound or the voltmeter
needle fluctuate.
Junction block side
YES : Go to Step 3.
NO : Refer to inspection procedure L-11 "The AC310450 AB
front door lock actuator (LH) switch signal is
not received <LH drive vehicles>P.54B-272 Q: Is the check result normal?
." YES : Go to Step 6.
SYMPTOM PROCEDURES

YES : Go to Step 7.
ETACS-ECU connector terminal No.2 and fusible NO : Repair the wiring harness.
link (1).
Check that the central door locking system works
normally.
Junction block side Cope with Intermittent Malfunction P.00-5).
AC310450 AB
Fusible link: No.1
AC310523AB
NOTE:
AC310446 AD

C-212 (B)
Harness side
AC310448 AF

diate connector C-126 and junction block connector
• Check the power supply line for open or short cir-
cuit.
SYMPTOM PROCEDURES
54B-51
INSPECTION PROCEDURE C-1: Central door locking system does not work. <RH drive vehicles>
CAUTION
Central Door Lock Power Supply Circuit <RHD>
FUSIBLE
LINK 1
J/B SIDE
ETACS-ECU
DOOR DOOR
UNLOCK LOCK
RELAY RELAY
DOOR LOCK
ACTUATOR
(FRONT: RH)
Wire colour code

SYMPTOM PROCEDURES
COMMENT ON TROUBLE SYMPTOM Step 3. Connector check: E-15 front door lock
If the central door locking system does not work at actuator (RH) connector
all, the front door lock actuator (RH) or the
ETACS-ECU may be defective.
POSSIBLE CAUSES
• Malfunction of the front door lock actuator (RH)
• Damaged harness wires and connectors Harness side E-15 (B)
DIAGNOSIS PROCEDURE
AC310493 AF
When the ignition switch is turned to the LOCK Q: Is the check result normal?
(OFF) position, check if the hazard warning lamps YES : Go to Step 4.
illuminate. NO : Repair the defective connector.

YES : Go to Step 2. Step 4. Check the front door lock actuator (RH)
NO : Refer to inspection procedure A-2 "Check Check that the front door lock actuator (RH) works
the ETACS-ECU battery power supply normally. Refer to GROUP 42 − Door P.42-31.
circuit" P.54B-42. Q: Is the check result normal?
YES : Go to Step 5.
Step 2. Pulse check NO : Replace the front door lock actuator (RH).
Check the input signal from the driver's door lock
actuator switch. Step 5. Connector check: C-226 ETACS-ECU
System switch Check condition connector
Driver's door lock When the driver's key Connector: C-226 <RHD>
actuator switch cylinder or inside lock Junction block
(rear view)
knob is unlocked or
locked
OK: The M.U.T.-II/III sound or the voltmeter
needle fluctuate.
YES : Go to Step 3. Junction block side
NO : Refer to inspection procedure L-11 "The AC310461AE
front door lock actuator (RH) switch signal is
not received <RH drive vehicles>P.54B-275 Q: Is the check result normal?
." YES : Go to Step 6.
SYMPTOM PROCEDURES
54B-53
YES : Go to Step 7.
ETACS-ECU connector terminal No.2 and fusible NO : Repair the wiring harness.
link (1).
Junction block
Check that the central door locking system works
(rear view)
normally.
Junction block side NO : Replace the ETACS-ECU.
AC310461AE
Fusible link: No.1
AC310523AB
NOTE:
AC310454 AF

C-212 (B)
Harness side
AC310458 AF

• Check the power supply line for open or short cir-
cuit.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-2: A Door or a tailgate can not be locked or unlocked by the central door
locking system. <LH drive vehicles>
Central Door Lock Circuit <LHD>
J/B SIDE
ETACS-ECU
DOOR DOOR
UNLOCK LOCK
RELAY RELAY
DOOR LOCK
ACTUATOR
(FRONT:RH)

(FRONT: LH) (REAR: RH) (REAR: LH)
Wire colour code

SYMPTOM PROCEDURES
54B-55
COMMENT ON TROUBLE SYMPTOM Step 3. Check the front door lock actuator (LH)
If a door can not be locked or unlocked by the central Check that the front door lock actuator (LH) works
door locking system, the door lock actuator may be normally. Refer to GROUP 42 − Door P.42-31.
defective.
POSSIBLE CAUSES YES : Go to Step 4.
NO : Replace the front door lock actuator (LH).
• Malfunction of the door lock actuator
Step 4. Connector check: C-226, C-227
DIAGNOSIS PROCEDURE ETACS-ECU connector
Step 1. Confirm which door lock actuator is Junction block (rear view)
defective.
Q: Which door fails to lock correctly?
Driver's door : Go to Step 2.
C-226
Front passenger's door : Go to Step 6.
Rear right door : Go to Step 10.
Rear left door : Go to Step 14.
C-227
Step 2. Connector check: E-04 front door lock
actuator (LH) connector
Junction block side
Connector: E-04 <LHD> C-226
Front door (LH)
Harness side
Harness side C-227
E-04(B) 29 28 27 26 25 24 23 22 21
38 37 36 35 34 33 32 31 30
44 43 42 41 40 39
AC310451AB
AC310484 AB
YES : Go to Step 3. NO : Repair the defective connector.
SYMPTOM PROCEDURES
Step 5. Check the wiring harness from C-226 NOTE:

ETACS-ECU connector terminal No.12 and C-227
ETACS-ECU connector terminal No.22 to E-04
front door lock actuator (LH) connector terminal
Nos.4 and 6.
AC310446 AE
C-226
C-227
Harness side
Junction block side
C-226 14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310448AE
Harness side
C-227 Prior to the wiring harness inspection, check interme-
29 28 27 26 25 24 23 22 21
38 37 36 35 34 33 32 31 30 • Check the input and output lines for open circuit.
44 43 42 41 40 39
AC310451AB Q: Is the check result normal?
Front door (LH) Cope with Intermittent Malfunction P.00-5).
Harness side
E-04(B) actuator (RH) connector
Connector: E-15 <LHD> Front door (RH)
AC310484 AB
Harness side E-15(B)
AC310488AB

YES : Go to Step 7.
SYMPTOM PROCEDURES
54B-57
Step 7. Check the front door lock actuator (RH). Step 9. Check the wiring harness from C-226
Check that the front door lock actuator (RH) works ETACS-ECU connector terminal Nos.12 and 13 to
normally. Refer to GROUP 42 − Door P.42-31. E-15 front door lock actuator (RH) connector
terminal Nos.4 and 6.
YES : Go to Step 8. Connector: C-226 <LHD>
NO : Replace the front door lock actuator (RH). Junction block (rear view)

connector
Junction block (rear view) Junction block side
AC310450 AB
Junction block side
AC310450 AB
Q: Is the check result normal? E-15(B)

Harness side
YES : Go to Step 9.
AC310488AB
NOTE:
AC310452 AC

Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310448AE

• Check the input and output lines for open circuit.
SYMPTOM PROCEDURES

connector
Cope with Intermittent Malfunction P.00-5). Connector: C-226 <LHD>
NO : Repair the wiring harness. Junction block (rear view)
Step 10. Connector check: E-18 rear door lock

actuator (RH) connector
Connector: E-18 Rear door (RH)
Junction block side
AC310450 AB

E-18 (B)
AC310491AB Step 13. Check the wiring harness from C-226

E-18 rear door lock actuator (RH) connector
Step 11. Check the rear door lock actuator (RH).
Check that the rear door lock actuator (RH) is in
good condition. Refer to GROUP 42 − Door P.42-31.
NO : Replace the rear door lock actuator (RH). Junction block side
AC310450 AB
Harness side E-18 (B)
AC310491AB
SYMPTOM PROCEDURES
54B-59
NOTE: Step 14. Connector check: E-07 rear door lock
actuator (LH) connector
Connector: E-07
Rear door (LH)
Harness side
C-112 (GR)
AC310452AD
E-07 (B)
Connector: C-214 <LHD> AC310486AC
Harness side
Step 15. Check the rear door lock actuator (LH).
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Check that the rear door lock actuator (LH) is in good
condition. Refer to GROUP 42 − Door P.42-31.
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310448AE
Connector: D-04 <LHD> YES : Go to Step 16.
NO : Replace the rear door lock actuator (LH).

connector
AC310463AB
Prior to the wiring harness inspection, check C-112,

D-04 intermediate connectors and C-214 junction
block connector, and repair if necessary. Junction block side
Q: Is the check result normal? AC310450 AB
malfunction (Refer to GROUP 00 − How to Q: Is the check result normal?
SYMPTOM PROCEDURES

E-07 rear door lock actuator (LH) connector
terminal Nos.4 and 6. NO : Repair the wiring harness.
Junction block side
AC310450 AB
Connector: E-07
Rear door (LH)
Harness side
E-07 (B)
AC310486AC
NOTE:
Harness side
AC310448 AG
Connector: D-15 <LHD>
AC310465AC
Prior to the wiring harness inspection, check D-15

intermediate connectors and C-217 junction block
connector, and repair if necessary.
SYMPTOM PROCEDURES
54B-61
INSPECTION PROCEDURE C-2: A door or a tailgate can not be locked or unlocked by the central door
locking system. <RH drive vehicles>
Central Door Lock Circuit <RHD>
J/B SIDE
ETACS-ECU
DOOR DOOR
UNLOCK LOCK
RELAY RELAY
DOOR LOCK
ACTUATOR
(FRONT:RH)

(FRONT: LH) (REAR: RH) (REAR: LH)
Wire colour code

SYMPTOM PROCEDURES
COMMENT ON TROUBLE SYMPTOM Step 3. Check the front door lock actuator (RH)
If a door can not be locked or unlocked by the central Check that the front door lock actuator (RH) works
door locking system, the door lock actuator may be normally. Refer to GROUP 42 − Door P.42-31.
defective.
POSSIBLE CAUSES YES : Go to Step 4.
NO : Replace the front door lock actuator (RH).
• Malfunction of the door lock actuator
Step 4. Connector check: C-226, C-227
DIAGNOSIS PROCEDURE ETACS-ECU connector
Step 1. Confirm which door lock actuator is
defective.
C-226
Q: Which door fails to lock correctly?
Driver's door : Go to Step 2.
Front passenger's door : Go to Step 6.
Rear right door : Go to Step 10.
C-227
Step 2. Connector check: E-15 front door lock Junction block side
actuator (RH) connector C-226
Harness side
C-227
29 28 27 26 25 24 23 22 21
Harness side E-15 (B) 38 37 36 35 34 33 32 31 30
44 43 42 41 40 39
AC310462AB
AC310493 AF
SYMPTOM PROCEDURES
54B-63
Step 5. Check the wiring harness from C-226 NOTE:
ETACS-ECU connector terminal No.22 to E-15
front door lock actuator (RH) connector terminal
Nos.4 and 6.
C-226
AC310456 AH

C-227
Junction block side
C-226
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side 28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310458 AE
C-227
29 28 27 26 25 24 23 22 21 diate connector C-110 and junction block connector
38 37 36 35 34 33 32 31 30 C-214, and repair if necessary.
44 43 42 41 40 39

Harness side E-15 (B) actuator (LH) connector
AC310493 AF
Harness side
E-04 (B) AC310498AF

YES : Go to Step 7.
SYMPTOM PROCEDURES
Step 7. Check the front door lock actuator (LH). Step 9. Check the wiring harness from C-226
Check that the front door lock actuator (RH) works ETACS-ECU connector terminal Nos.12 and 13 to
normally. Refer to GROUP 42 − Door P.42-31. E-04 front door lock actuator (LH) connector
YES : Go to Step 8. Connector: C-226 <RHD>
NO : Replace the front door lock actuator (LH). Junction block
(rear view)

connector
Junction block
(rear view) Junction block side
AC310461AE
Junction block side
AC310461AE Harness side

YES : Go to Step 9.
E-04 (B) AC310498AF
NOTE:
AC310454 AH

Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310458 AE

SYMPTOM PROCEDURES
54B-65
E-18 rear door lock actuator (RH) connector
Junction block
Step 10. Connector check: E-18 rear door lock
(rear view)
actuator (RH) connector
Connector: E-18
Junction block side

Harness side AC310461AE
Connector: E-18
E-18 (B)
AC310495AE

Step 11. Check the rear door lock actuator (RH). E-18 (B)
Check that the rear door lock actuator (RH) is in AC310495AE
good condition. Refer to GROUP 42 − Door P.42-31.
NOTE:
Q: Is the check result normal? Connector: D-04 <RHD>
NO : Replace the rear door lock actuator (RH).

connector
Junction block
(rear view)
AC310471AC

diate connector D-04, and repair if necessary.
Junction block side YES : The trouble can be an intermittent
AC310461AE malfunction (Refer to GROUP 00 − How to
SYMPTOM PROCEDURES
Step 14. Connector check: E-07 rear door lock Step 17. Check the wiring harness from C-226
actuator (LH) connector ETACS-ECU connector terminal Nos.12 and 13 to
Connector: E-07
E-07 rear door lock actuator (LH) connector
Junction block
(rear view)
Harness side
E-07 (B)
AC310500AB
Junction block side
Q: Is the check result normal? AC310461AE
NO : Repair the defective connector. Connector: E-07
Step 15. Check the rear door lock actuator (LH).

Check that the rear door lock actuator (LH) is in good
condition. Refer to GROUP 42 − Door P.42-31. Harness side
NO : Replace the rear door lock actuator (LH).
E-07 (B)
AC310500AB
connector
Junction block
(rear view)
Junction block side
AC310461AE

SYMPTOM PROCEDURES
54B-67
Connector: C-127 <RHD> YES : The trouble can be an intermittent
AC310454AI

Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310458 AE
Connector: D-15 <RHD>
AC310473AC

diate connectors C-127, D-15 and junction block
SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-3: The central door locking system can not be operated by means of the
front passenger's door lock key cylinder.
CAUTION
Central Door Lock (Front Passenger's Door Lock Key Cyilinder Switch) Circuit
FUSIBLE
LINK 1
ETACS-ECU
DOOR DOOR
UNLOCK LOCK INPUT SIGNAL
RELAY RELAY FRONT
PASSENGER'S
DOOR LOCK KEY
CYLINDER SWITCH
J/B SIDE
· DOOR LOCK ACTUATOR (FRONT: LH)

· DOOR LOCK ACTUATOR (FRONT: RH)
· DOOR LOCK ACTUATOR (REAR: LH)
· DOOR LOCK ACTUATOR (REAR: RH)
COMMENTS ON TROUBLE SYMPTOM DIAGNOSTIC PROCEDURE

If the central door locking system does not work by
means of the front passenger's door lock key cylin- Step 1. Check the operation of the central door
der, the front passenger's door lock key cylinder or locking system.
the ETACS-ECU may be defective. Check that the central door locking system works
normally by means of the driver's door lock key cylin-
POSSIBLE CAUSES
der and inside lock knob.
• Malfunction of the front passenger's door lock key
cylinder Q: Is the check result normal?
• Malfunction of the ETACS-ECU YES : Go to Step 2.
• Damaged harness wires and connectors NO : Refer to inspection procedure C-1 "Central
door locking system does not work
P.54B-48. <LH drive vehicles>" Refer to
inspection procedure C-1 "Central door
locking system does not work P.54B-51.
<RH drive vehicles>"
SYMPTOM PROCEDURES
54B-69
Step 2. Pulse check
YES : Go to Step 3.
Check the input signal from the front passenger’s NO : Refer to inspection procedure L-16 "The
door lock key cylinder switch. door lock key cylinder switch signal is not
System switch Check condition received P.54B-292."
Front passenger’s door Turn the key to the lock
lock key cylinder switch or unlock position Step 3. Retest the system.
OK: The M.U.T.-II/III sounds or the voltmeter Check that the central door locking system works
needle fluctuates. normally by means of the front passenger's door lock
key cylinder.
INSPECTION PROCEDURE C-4: The ignition key reminder function does not work normally.
CAUTION
Ignition Key Reminder Function Circuit
FUSIBLE
LINK 1
ETACS-ECU
INPUT SIGNAL
DOOR DOOR · DRIVER'S DOOR
UNLOCK LOCK LOCK ACTUCTOR
RELAY RELAY SWITCH
· DRIVER'S DOOR
SWITCH
· KEY REMINDER
SWITCH
J/B SIDE
· DOOR LOCK ACTUATOR (FRONT: LH)

· DOOR LOCK ACTUATOR (FRONT: RH)
· DOOR LOCK ACTUATOR (REAR: LH)
· DOOR LOCK ACTUATOR (REAR: RH)
SYMPTOM PROCEDURES

If the key reminder function does not work normally, All the signals are received normally. : Go to Step
the input signal circuits below or the ETACS-ECU 3.
may be defective.
Refer to inspection procedure L-3 "The door
• Key reminder switch
switch (front: LH) signal is not received <LH
• Driver's door switch
drive vehicles>P.54B-244 ." Refer to
• Driver's door lock actuator
inspection procedure L-3 "The door switch
POSSIBLE CAUSES (front: RH) signal is not received <RH drive
vehicles>P.54B-246 ."
• Malfunction of the key reminder switch
The key reminder switch signal is not received. :
• Malfunction of the driver's door switch
Refer to inspection procedure L-8 "The key
• Malfunction of the driver's door lock actuator
reminder switch signal is not received
• Damaged harness wires and connectors P.54B-257."
The driver's door lock actuator switch signal is not
received. : Refer to inspection procedure L-11
DIAGNOSIS PROCEDURE "The front door lock actuator (LH) switch
signal is not received <LH drive
Step 1. Check the power supply circuit. vehicles>P.54B-272 . " Refer to inspection
When the ignition switch is turned to the LOCK procedure L-11 "The front door lock actuator
(OFF) position, check if the hazard warning lamps (RH) switch signal is not received <RH drive
illuminate. vehicles>P.54B-275 ."
YES : Go to Step 2. Step 3. Retest the system.
Q: Does the ignition key reminder function work
the ETACS-ECU battery power supply normally?
circuit" P.54B-42. YES : The trouble can be an intermittent
Step 2. Pulse check Cope with Intermittent Malfunction P.00-5).
Check the input signals below which are related to NO : Replace the ETACS-ECU.
the key reminder function.
System switch Check condition
Driver's door switch When the driver's door is
opened
Key reminder switch When the inserted
ignition key is pulled out
Driver's door lock When the driver's key
actuator switch cylinder or inside lock
knob is unlocked or
locked
OK: The M.U.T.-II/III sounds or the voltmeter
needle fluctuates.
SYMPTOM PROCEDURES
54B-71
INSPECTION PROCEDURE C-5: The impact detection door unlock function does not function.
CAUTION • Malfunction of the ETACS-ECU

Whenever the ECU is replaced, ensure that the • Damaged harness wires and connectors
If the impact detection door unlock function does not
work normally, the input signal circuit from the impact Use the M.U.T.-II/III to confirm a diagnosis code.
detection sensor, the SRS-ECU or the ETACS-ECU Check whether the ETACS-ECU sets diagnosis code
may be defective. No.31 or 32.
POSSIBLE CAUSES YES : Refer to P.54B-30.
• Malfunction of the SRS-ECU NO : Replace the ETACS-ECU.
SYMPTOM PROCEDURES
POWER WINDOW
INSPECTION PROCEDURE D-1: Power windows do not work at all.
CAUTION
Power Window Relay Circuit <LHD>
FUSIBLE
LINK 5
J/B SIDE
ETACS-ECU POWER WINDOW

RELAY
FRONT REAR REAR

POWER POWER POWER
WINDOW WINDOW WINDOW
SUB SUB SUB
SWITCH SWITCH SWITCH
(RH) (LH) (RH)
POWER WINDOW
Wire colour code MAIN SWITCH
B : Black CPU
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
SYMPTOM PROCEDURES
54B-73
Power Window Relay Circuit <RHD>
FUSIBLE LINK 5
J/B SIDE
POWER WINDOW
RELAY
FRONT REAR REAR

POWER POWER POWER
WINDOW WINDOW WINDOW
SUB SUB SUB
SWITCH SWITCH SWITCH
(LH) (LH) (RH)
Wire colour code POWER WINDOW

B : Black MAIN SWITCH
LG : Light green CPU
G : Green
L: Blue
W : White
Y: Yellow
SB : Sky blue
BR : Brown
O : Orange
GR : Gray
R : Red
P : Pink
V : Violet

If the power windows do not work at all, the power
window relay, the power window main switch or the Step 1. Pulse check
ETACS-ECU may be defective. Check the input signal from the ignition switch.
POSSIBLE CAUSES System switch Check condition
• Malfunction of the power window relay Ignition switch (IG1) When turned from ACC to
• Malfunction of the power window main switch ON
needle fluctuates.
SYMPTOM PROCEDURES

Step 3. Check the power window relay.
YES : Go to Step 2.
NO : Refer to inspection procedure A-2 "When
Refer to GROUP 42 − Door − On-vehicle Service
the ignition switch is at the LOCK (OFF) P.42-24.
position, the functions do not work normally. Q: Is the check result normal?
Check the battery power supply circuit to YES : Go to Step 4.
the ETACS-ECU P.54B-42." NO : Replace the power window relay.
Step 2. Connector check: C-224 power window Step 4. Connector check: E-05 power window
relay connector main switch connector
Connector: C-224 <LHD> Connector: E-05 <LHD>
Junction block (front view) Front door (LH)
Junction block side Harness side

6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310448AI AC310484 AD
Connector: C-224 <RHD> Connector: E-05 <RHD>

Junction block (front view) Front door (RH)

side 6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310458AG AC310493 AG

NO : Repair the connector. NO : Repair the connector.
SYMPTOM PROCEDURES
54B-75
Step 5. Voltage measurement at the E-05 power Step 6. Voltage measurement at the C-224 power
window main switch connector window relay connector
Connector: E-05 <LHD> Connector: C-224 <LHD>
Front door (LH) Junction block (front view)
Harness side Junction block side

6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310484 AD AC310448AI
Connector: E-05 <RHD> Connector: C-224 <RHD>

Front door (RH) Junction block (front view)
Harness side Junction block

6 5 4 3 2 1 side
14 13 12 11 10 9 8 7
AC310493 AG AC310458AG
(1) Disconnect the connector, and measure at the (1) Disconnect the connector, and measure at the
wiring harness side. wiring junction block side.
Connector C-224
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Connector E-05
(Harness side)
AC303986AB AC310507AG
(2) Voltage between terminal 6 and body earth (2) Voltage between terminal 5 and body earth
OK: System voltage OK: System voltage
NO : Go to Step 6. NO : Go to Step 7.
SYMPTOM PROCEDURES
Step 7. Check the wiring harness between C-224 Connector: C-126 <LHD>
power window relay connector terminal No.5 and
fusible link (5).
Junction block side

AC310446 AD
AC310448AI

Junction block AC310454 AF

side
AC310458AG
Fusible link: No.5
Harness side
AC310448AJ

AC310523AC
Harness side
AC310458AI

intermediate connector C-126 and junction block
SYMPTOM PROCEDURES
54B-77
Step 8. Resistance measurement at C-224 power Step 9. Check the wiring harness between C-224
window relay connector power window relay connector terminal No.3 and
body earth.
Junction block (front view) Connector: C-224 <LHD>
Junction block side

Junction block side
AC310448AI
AC310448AI
Junction block (front view) Connector: C-224 <RHD>
Junction block
side Junction block
side
AC310458AG
(1) Disconnect the connector, and measure at the AC310458AG
junction block side. Connector: C-214 <LHD>

Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
Connector C-223
AC310448AE
AC303984AB
(2) Resistance between terminal 3 and body earth Junction block (front view)
OK: 2Ω or less
NO : Go to Step 9.
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310458 AE

sary.
SYMPTOM PROCEDURES

power window relay connector terminal No.1.
NO : Repair the wiring harness. Connector: C-224 <LHD>

connector
Junction block side
AC310448AI

Junction block side Junction block (front view)
AC310450 AB

Junction block Junction block
side
(rear view)
AC310458AG

Junction block side
AC310461AE

NO : Repair the connector. Junction block side
AC310450 AB

Junction block
(rear view)
Junction block side
AC310461AE

SYMPTOM PROCEDURES
54B-79
Step 12. Check the wiring harness between C-224 Connector: C-17 <LHD>
power window relay connector terminal No.4 and
E-05 power window main switch connector
terminal No.6.
AC310446 AE
Junction block side
AC310448AI

AC310456 AH
Junction block
side Connector: C-211 <RHD>
AC310458AG

Front door (LH)
Harness side
AC310458AI
Harness side
6 5 4 3 2 1 Connector: C-211 <LHD>
14 13 12 11 10 9 8 7 Junction block (front view)
AC310484 AD

Harness side
Front door (RH)
AC310448AJ
Harness side
6 5 4 3 2 1 NOTE: Prior to the wiring harness inspection, check
14 13 12 11 10 9 8 7 intermediate connectors C-17 <LH drive vehicles>,
C-110 <RH drive vehicles> and junction block con-
AC310493 AG nector C-211, and repair if necessary.
NO : Repair the harness wire.
SYMPTOM PROCEDURES
Step 13. Resistance measurement at E-05 power Step 14. Check the wiring harness between E-05
window main switch connector power window main switch connector terminal
Front door (LH) Connector: E-05 <LHD>
Front door (LH)
Harness side
6 5 4 3 2 1 Harness side
14 13 12 11 10 9 8 7
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310484 AD
AC310484 AD
Front door (RH) Connector: E-05 <RHD>
Front door (RH)
Harness side
14 13 12 11 10 9 8 7
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310493 AG
(1) Disconnect the connector, and measure at the AC310493 AG
harness side. Connector: C-17 <LHD>
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Connector E-05
(Harness side) AC310446 AE
AC310506 AD
(2) Resistance between terminal 2 and body earth
OK: 2Ω or less
NO : Go to Step 14.
AC310452 AC

intermediate connector C-17 <LH drive vehicles> or
C-110 <RH drive vehicles>, and repair if necessary.
SYMPTOM PROCEDURES
54B-81
Q: Is the check result normal? (2) Check that the all the power windows work.
After the power window main switch is replaced,
check that all the power windows work.
(1) Replace the power window main switch.
INSPECTION PROCEDURE D-2: Driver's power window does not work by means of the power window
main switch. <LH drive vehicles>
Power Window (front: LH) Circuit <LHD>
POWER WINDOW
RELAY
POWER
WINDOW
MAIN SWITCH
CPU
FRONT
(LH)
POWER WINDOW
MOTOR
(FRONT: LH)
Wire colour code


If the driver's power window does not work by means • Malfunction of the power window main switch
of the power window main switch, the power window • Malfunction of the front power window regulator
main switch or the driver's door power window regu- motor (LH)
lator motor may be defective. • Damaged harness wires and connectors
SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE STEP 3. Check the wiring harness from E-02 front
power window regulator motor (LH) connector
STEP 1. Check the power window main switch. terminal Nos.1 and 4 to E-05 power window main
Check that all of the front passenger's and rear door switch connector terminal Nos.7 and 1.
power windows can operate by means of the power Connectors: E-02, E-05 <LHD>
window main switch.
Front door (LH)
YES : Go to Step 2.
NO : Refer to Inspection Procedure D-1 "Power
E-02 (GR)
windows do not work at all P.54B-72."
STEP 2. Connector check: E-05 power window E-05

main switch connector and E-02 front power
window regulator motor (LH) connector
Harness side
Connectors: E-02, E-05 <LHD>
E-02
Front door (LH)
E-02 (GR)
Harness side
E-05
E-05 6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310485AB
Harness side • Check the input and output lines for open or short
E-02 circuit.
YES : Go to Step 4.
Harness side
E-05 STEP 4. Retest the system.
6 5 4 3 2 1 After the power window main switch is replaced,
14 13 12 11 10 9 8 7
check that the driver's door power window can be
AC310485AB operated by the power window main switch.
Q: Are the check result normal? (2) Check that the driver's power window works by
YES : Go to Step 3.
NO : Replace the front power window regulator
motor assembly (LH).
SYMPTOM PROCEDURES
54B-83
INSPECTION PROCEDURE D-2: Driver's power window does not work by means of the power window
main switch. <RH drive vehicles>
Power Window (front: RH) Circuit <RHD>
POWER WINDOW
RELAY
POWER
FRONT WINDOW
(RH) MAIN SWITCH
CPU
POWER WINDOW
MOTOR
(FRONT: RH)
Wire colour code


If the driver's power window does not work by means
of the power window main switch, the power window STEP 1. Check the power window main switch.
main switch or the driver's door power window regu- Check that all of the front passenger's and rear door
lator motor may be defective. power windows can operate by means of the power
window main switch.
POSSIBLE CAUSES
• Malfunction of the power window main switch Q: Is the check result normal?
• Malfunction of the front power window regulator YES : Go to Step 2.
motor (RH) NO : Refer to Inspection Procedure D-1 "Power
• Damaged harness wires and connectors windows do not work at all P.54B-72."
SYMPTOM PROCEDURES
STEP 2. Connector check: E-05 power window STEP 3. Check the wiring harness from E-11 front
main switch connector and E-11 front power power window regulator motor (RH) connector
window regulator motor (RH) connector terminal Nos.1 and 4 to E-05 power window main
switch connector terminal Nos.7 and 1.
Connectors: E-05, E-11 <RHD>
Front door (RH) Connectors: E-05, E-11 <RHD>
Front door (RH)
E-11 (GR)
E-11 (GR)
E-05
E-05
Harness side
E-05 Harness side
6 5 4 3 2 1 E-05
14 13 12 11 10 9 8 7
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side
E-11 Harness side
E-11
AC310494 AB
AC310494 AB
Q: Are the check result normal?
YES : Go to Step 3. • Check the input and output lines for open or short
NO : Repair the connector. circuit.
YES : Go to Step 4.

check that the driver's door power window can be
operated by the power window main switch.
(2) Check that the driver's power window works by
motor assembly (RH).
SYMPTOM PROCEDURES
54B-85
INSPECTION PROCEDURE D-3: Relevant power window(s) do not work by means of the front and
rear passenger's power window sub switches.
Power Window (front: RH) Circuit <LHD>
FUSIBLE
LINK 5
POWER
WINDOW
RELAY
ETACS-
ECU
POWER
WINDOW SUB SWITCH
(FRONT)
CPU
POWER
WINDOW MOTOR
(FRONT: RH)
Wire colour code

SYMPTOM PROCEDURES
Power Window (front: LH) Circuit <RHD>
FUSIBLE
LINK 5
POWER
WINDOW
RELAY
ETACS-
ECU
POWER
WINDOW SUB SWITCH
(FRONT)
CPU
POWER
WINDOW MOTOR
(FRONT: LH)
Wire colour code

SYMPTOM PROCEDURES
54B-87
Power Window (rear) Circuit
FUSIBLE
LINK 5
POWER
WINDOW
RELAY
ETACS-ECU
POWER POWER
WINDOW WINDOW
SUB SWITCH SUB SWITCH
(REAR: LH) (REAR: RH)
CPU CPU
POWER POWER
WINDOW WINDOW
MOTOR MOTOR
Wire colour code


If the front passenger's or rear power window does
not work by means of the respective power window
sub switch, the power window sub switch or the
power window regulator motor may be defective.
SYMPTOM PROCEDURES
POSSIBLE CAUSES Step 4. Resistance measurement at E-14 front

• Malfunction of the front power window sub power window sub switch connector
switch, rear power window sub switch (RH) or
rear power window sub switch (LH)
• Malfunction of the front power window regulator
motor (RH) <LH drive vehicles>, front power win-
dow regulator motor (LH) <RH drive vehicles>,
rear power window regulator motor (RH) or rear Harness side
power window regulator motor (LH)
DIAGNOSIS PROCEDURE
AC310488AD

Step 1. Check the power window main switch. wiring harness side.
Check that the power window lock switch is turned
off.
YES : Go to Step 2.
NO : Turn off the power window lock switch.
Step 2. Determine a trouble spot.

Q: Which power window does not work? Connector E-14
Front passenger's door <LH drive vehicles> : Go (Harness side)
to Step 3. AC303981AC
Front passenger's door <RH drive vehicles> : Go (2) Resistance between E-14 front power window
to Step 12. sub switch connector terminal No.1 and body
Rear right door : Go to Step 21. earth
OK: 2Ω or less
Step 3. Connector check: E-14 front power YES : Go to Step 6.
window sub switch connector NO : Go to Step 5.
Harness side
AC310488AD

YES : Go to Step 4.
SYMPTOM PROCEDURES
54B-89
Step 5. Check the wiring harness from E-14 front (2) Turn the ignition switch to the ON position.
power window sub switch connector terminal
No.1 to body earth.
Harness side
Connector E-14
(Harness side)
AC303982AC
(3) Voltage between E-14 front power window sub

AC310488AD switch connector terminal No.4 and body earth
NOTE: OK: System voltage
Connector: C-110 <LHD> Q: Is the check result normal?
YES : Go to Step 9.
NO : Go to Step 7.
Step 7. Connector check: C-224 power window

relay connector
AC310452 AC

• Check the earth wires for open circuit. Junction block side

malfunction (Refer to GROUP 00, How to AC310448AI
YES : Go to Step 8.
Step 6. Voltage measurement at E-14 front power
window sub switch connector
Harness side
AC310488AD

SYMPTOM PROCEDURES

Step 8. Check the wiring harness from E-14 front
No.4 to C-224 power window relay connector
terminal No.4. NO : Repair the wiring harness.
Step 9. Connector check: E-11 front power
C-211 window regulator motor (RH) connector
C-224
Harness side E-11 (GR)
Harness side
C-211
AC310488 AE

Junction block side
C-224 NO : Repair the connector.
Step 10. Check the wiring harness from E-11

front power window regulator motor (RH)
AC310449AD
connector terminal Nos.1 and 4 to E-14 front
Connector: E-14 <LHD> Front door (RH) power window sub switch connector terminal
Nos.5 and 7.
Front door (RH)
Harness side
E-11 (GR)
AC310488AD
NOTE: E-14
Harness side
E-11
Harness side
E-14
AC310452 AC

diate connectors C-110 and junction block connector AC310489AB
C-211, and repair if necessary. • Check the input and output lines for open or short
• Check the power supply line for open circuit. circuit.
SYMPTOM PROCEDURES
54B-91
Step 13. Resistance measurement at E-14 front
power window sub switch connector
Step 11. Retest the system. Front door (LH)
After the front power window sub switch is replaced,
check that the front passenger's door power window
Harness side
can be operated by the front power window sub
switch.
(1) Replace the front power window sub switch.
(2) Check that the front passenger's door power
window can be operated by the front power
window sub switch. AC310498AC


Connector: E-14 <RHD> Connector E-14
(Harness side)
Front door (LH) AC310506 AE
(2) Resistance between E-14 front power window

Harness side sub switch connector terminal No.1 and body
earth
OK: 2Ω or less
AC310498AC NO : Go to Step 14.
SYMPTOM PROCEDURES
Step 14. Check the wiring harness from E-14 (2) Turn the ignition switch to the ON position.
front power window sub switch connector
terminal No.1 to body earth.
Front door (LH)
Harness side
Connector E-14
(Harness side) AC310507AD
(3) Voltage between E-14 front power window sub

AC310498AC switch connector terminal No.4 and body earth
NOTE: OK: System voltage
Connector: C-17 <RHD> Q: Is the check result normal?
NO : Go to Step 16.
Step 16. Connector check: C-224 power window

relay connector
AC310454 AH

• Check the earth wires for open circuit. Junction block
side
malfunction (Refer to GROUP 00, How to AC310458AG
Step 15. Voltage measurement at E-14 front
power window sub switch connector
Front door (LH)
Harness side
AC310498AC

SYMPTOM PROCEDURES
54B-93
front power window sub switch connector
terminal No.4 to C-224 power window relay
connector terminal No.4. NO : Repair the wiring harness.
Front door (LH) Step 18. Connector check: E-02 front power
Harness side Connector: E-02 <RHD>
Front door (LH)
E-02 (GR) Harness side

AC310498AC

Junction block (front view) C-211
AC310498 AD

C-224
front power window regulator motor (LH)
Harness side
connector terminal Nos.1 and 4 to E-14 front
C-211
Nos.5 and 7.
Front door (LH)
Junction block side
C-224
E-02 (GR)
AC310459AD
E-14
NOTE:
Harness side
E-02
Harness side
E-14
AC310454 AH

diate connectors C-17 and junction block connector AC310499AB
C-211, and repair if necessary. • Check the input and output lines for open or short
• Check the power supply line for open circuit. circuit.
SYMPTOM PROCEDURES

Step 22. Resistance measurement at E-17 rear
power window sub switch (RH) connector
check that the front passenger's door power window
can be operated by the front power window sub Harness side
switch.
(2) Check that the front passenger's door power
window can be operated by the front power
window sub switch. AC310491AC

Step 21. Connector check: E-17 rear power

window sub switch (RH) connector
Connector: E-17 Rear door (RH) Connector E-17
(Harness side)
AC310506 AF
(2) Resistance between E-17 rear power window sub

switch (RH) connector terminal No.1 and body
Harness side earth
OK: 2Ω or less
AC310491AC NO : Go to Step 23.
SYMPTOM PROCEDURES
54B-95
Step 23. Check the wiring harness from E-17 rear
power window sub switch (RH) connector
Connector: E-17 Rear door (RH) NO : Repair the wiring harness.
Step 24. Voltage measurement at E-17 rear power

Harness side Connector: E-17 Rear door (RH)

NOTE:
AC310491AC

Connector E-17
AC310463AB (Harness side)
AC310507AE
(3) Voltage between E-17 rear power window sub

switch (RH) connector terminal No.4 and body
AC310471AC earth
diate connectors D-04, and repair if necessary. Q: Is the check result normal?
• Check the earth wires for open circuit. YES : Go to Step 27.
NO : Go to Step 25.
SYMPTOM PROCEDURES
Step 25. Connector check: C-224 power window Connectors: C-211, C-224 <LHD>
relay connector Junction block (front view)
Connector: C-224 <LHD> C-211

Harness side
AC310448AI
C-211
Junction block side

C-224
Junction block
side
AC310449AD
AC310458AG Connectors: C-211, C-224 <RHD>


power window sub switch (RH) connector C-224
terminal No.4 to C-224 power window connector
terminal No.4.
Harness side
Connector: E-17 Rear door (RH) C-211
Harness side
Junction block side
C-224
AC310491AC
AC310459AD
SYMPTOM PROCEDURES
54B-97
NOTE: Step 27. Connector check: E-16 rear power
window regulator motor (RH) connector

C-112 (GR)
AC310452AD

AC310491AD


power window regulator motor (RH) connector
terminal Nos.1 and 4 to E-17 rear power window
AC310456 AN sub switch (RH) connector terminal Nos.5 and 7.
Connector: D-04 <LHD> Connectors: E-16, E-17
Rear door (RH)
E-17
E-16 (GR)
AC310463AB
Connector: D-04 <RHD> Harness side

E-16
Harness side
E-17
AC310471AC
AC310492 AB
• Check the input and output lines for open or short
diate connectors C-112 <LH drive vehicles>, C-113
circuit.
<RH drive vehicles>, D-04 and junction block con-
nector C-211, and repair if necessary. Q: Is the check result normal?
• Check the power supply line for open circuit. YES : Go to Step 29.
SYMPTOM PROCEDURES
Step 29. Retest the system. Step 31. Resistance measurement at E-08 rear
After the rear power window sub switch (RH) is power window sub switch (LH) connector
replaced, check that the rear right door power win- Connector: E-08
dow can be operated by the rear power window sub Rear door (LH)
switch (RH).
(1) Replace the rear power window sub switch (RH).
(2) Check that the rear right door power window can
be operated by the rear power window sub switch Harness side
(RH).
malfunction (Refer to GROUP 00 − How to AC310486 AD
Cope with Intermittent Malfunction P.00-5). (1) Disconnect the connector, and measure at the
NO : Replace the rear power window regulator

window sub switch (LH) connector
Connector: E-08 Rear door (LH)
Connector E-08
Harness side (Harness side)
AC303981AB
(2) Resistance between E-08 rear power window sub

switch (LH) connector terminal No.1 and body
earth
AC310486 AD
OK: 2Ω or less
NO : Repair the connector. NO : Go to Step 32.
SYMPTOM PROCEDURES
54B-99
power window sub switch (LH) connector
Connector: E-08 Rear door (LH) NO : Repair the wiring harness.
Step 33. Voltage measurement at E-08 rear power

window sub switch (LH) connector
Harness side Connector: E-08 Rear door (LH)
AC310486 AD
Harness side
NOTE:
AC310486 AD

AC310465AC
Connector E-08
(Harness side)
AC303982AB
(3) Voltage between E-08 rear power window sub

switch (LH) connector terminal No.4 and body
AC310473AD
earth
diate connectors D-15, and repair if necessary. Q: Is the check result normal?
NO : Go to Step 34.
SYMPTOM PROCEDURES
Step 34. Connector check: C-224 power window Connectors: C-211, C-224 <LHD>
relay connector Junction block (front view)
Connector: C-224 <LHD> C-211

Harness side
AC310448AI
C-211
Junction block side

C-224
Junction block
side
AC310449AD
AC310458AG Connectors: C-211, C-224 <RHD>


power window sub switch (LH) connector C-224
terminal No.4 to C-224 power window relay
Harness side
Connector: E-08 Rear door (LH) C-211
Harness side
Junction block side
C-224
AC310486 AD
AC310459AD
SYMPTOM PROCEDURES
54B-101
NOTE: Step 36. Connector check: E-09 rear power
Connector: E-09
Rear door (LH)
Harness side
AC310446AO
Connector: C-127 <RHD> E-09 (GR)

AC310486AB


terminal Nos.1 and 4 to E-08 rear power window
AC310454AI sub switch (LH) connector terminal Nos.5 and 7.
Connector: D-15 <LHD> Connectors: E-08, E-09
Rear door (LH)
E-09 (GR)
E-08
AC310465AC
Connector: D-15 <RHD> Harness side

E-08
Harness side
E-09
AC310473AD
AC310487AB
• Check the input and output lines for open or short
diate connectors C-127, D-15 and junction block
circuit.
• Check the power supply line for open circuit. Q: Is the check result normal?
SYMPTOM PROCEDURES

After the rear power window sub switch (LH) is
replaced, check that the rear left door power window
can be operated by the rear power window sub NO : Replace the rear power window regulator
switch (LH). motor assembly (LH).
(1) Replace the rear power window sub switch (LH).
(2) Check that the rear left door power window can
be operated by the rear power window sub switch
(LH).
SYMPTOM PROCEDURES
54B-103
INSPECTION PROCEDURE D-4: Front and/or rear passenger's power window(s) do not work by
Power Window Circuit <LHD>
LOCK FRONT REAR

SWITCH (RH) (RH)
CPU
REAR
(LH)
POWER WINDOW
MAIN SWITCH
CPU CPU CPU
POWER WINDOW POWER WINDOW POWER WINDOW

SUB SWITCH SUB SWITCH SUB SWITCH
(FRONT) (REAR: LH) (REAR: RH)
Wire colour code

SYMPTOM PROCEDURES
Power Window Circuit <RHD>
LOCK FRONT REAR

SWITCH (LH) (RH)
CPU
REAR
(LH)
POWER WINDOW
MAIN SWITCH
CPU CPU CPU
POWER WINDOW POWER WINDOW POWER WINDOW

SUB SWITCH SUB SWITCH SUB SWITCH
(FRONT) (REAR: LH) (REAR: RH)
Wire colour code


If the passenger's and/or rear power window does • Malfunction of the power window main switch
not work by means of the power window main switch, • Malfunction of the front power window sub
the power window main switch or the respective switch, rear power window sub switch (RH) or
power window sub switch(es) may be defective. rear power window sub switch (LH)
SYMPTOM PROCEDURES
54B-105
DIAGNOSIS PROCEDURE Step 3. Determine a trouble spot.
Q: Which power window does not work when the
Step 1. Check the power window main switch. power window main switch is operated?
Check that the driver's power window works by Front passenger's door <LH drive vehicles> : Go
means of the power window main switch. to Step 4.
Front passenger's door <RH drive vehicles> : Go
YES : Go to Step 2. to Step 7.
NO : Refer to inspection procedure D-2 "Driver's Rear right door : Go to Step 10.
power window does not work by means of
the power window main switch <LH drive
vehicles>P.54B-81 ." Refer to inspection Step 4. Connector check: E-05 power window
procedure D-2 "Driver's power window does main switch connector and E-14 front power
not work by means of the power window window sub switch connector
main switch <RH drive vehicles>P.54B-83 ." Connector: E-05 <LHD>
Front door (LH)
Step 2. Check the power window sub switch.
Check that each power window works by means of
the respective power window sub switch when the
power window lock switch is turned off. Harness side
Q: Is the check result normal? 6 5 4 3 2 1
YES : Go to Step 3. 14 13 12 11 10 9 8 7
NO : Refer to inspection procedure D-3 "Relevant

power window(s) do not work by means of AC310484 AD
the front and rear passenger's power Connector: E-14 <LHD> Front door (RH)
window sub switches P.54B-85."
Harness side
AC310488AD

YES : Go to Step 5.
SYMPTOM PROCEDURES

Step 5. Check the wiring harness between E-05
YES : Go to Step 6.
power window main switch connector terminal NO : Repair the wiring harness.
No.11 and E-14 front power window sub switch
Front door (LH) check that the front passenger's door power window
can be operated by the power window sub switch.
(2) Check that the front passenger's power window
Harness side works by means of the power window main
6 5 4 3 2 1 switch.
14 13 12 11 10 9 8 7
AC310484 AD
Connector: E-14 <LHD> Front door (RH) Cope with Intermittent Malfunction P.00-5).
NO : Replace the power window main switch.
Step 7. Connector check: E-05 power window

Harness side main switch connector and E-14 front power
Front door (RH)
AC310488AD
NOTE:
Harness side
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310493 AG
Front door (LH)
AC310446 AE
Harness side
AC310498AC

YES : Go to Step 8.
AC310452 AC

diate connectors C-17, C-110, and repair if neces-
sary.
SYMPTOM PROCEDURES
54B-107
Step 8. Check the wiring harness between E-05
YES : Go to Step 9.
power window main switch connector terminal NO : Repair the wiring harness.
No.11 and E-14 front power window sub switch
Front door (RH) check that the front passenger's door power window
Harness side works by means of the power window main
6 5 4 3 2 1 switch.
14 13 12 11 10 9 8 7
AC310493 AG
Connector: E-14 <RHD> Cope with Intermittent Malfunction P.00-5).
Front door (LH)
Harness side
AC310498AC
NOTE:
AC310454 AH
AC310456 AH

diate connectors C-17, C-110, and repair if neces-
sary.
SYMPTOM PROCEDURES
Step 10. Connector check: E-05 power window Step 11. Check the wiring harness between E-05
main switch connector and E-17 rear power power window main switch connector terminal
window sub switch (RH) connector No.11 and E-17 rear power window sub switch
(RH) connector terminal No.6.
Front door (LH)
Harness side
14 13 12 11 10 9 8 7
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310484 AD
AC310484 AD
Front door (RH)
Harness side
14 13 12 11 10 9 8 7
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310493 AG
AC310493 AG
Harness side
Harness side
AC310491AC
AC310491AC
SYMPTOM PROCEDURES
54B-109
NOTE: Connector: D-04 <LHD>
AC310463AB
AC310446 AE

AC310471AC
AC310456 AH
Connector: C-113 <LHD> diate connectors C-113, C-17 <LH drive vehicles>,
C-110 <RH drive vehicles>, D-04, and repair if nec-
essary.
AC310452 AO Step 12. Retest the system.

After the rear power window sub switch (RH) is
Connector: C-113 <RHD> replaced, check that the rear right door power win-
dow can be operated by the power window sub
switch.
(2) Check that the rear right power window works by
AC310456 AN
SYMPTOM PROCEDURES
Step 13. Connector check: E-05 power window Step 14. Check the wiring harness between E-05
main switch connector and E-08 rear power power window main switch connector terminal
window sub switch (LH) connector No.11 and E-08 rear power window sub switch
(LH) connector terminal No.6.
Front door (LH)
Harness side
14 13 12 11 10 9 8 7
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310484 AD
AC310484 AD
Front door (RH)
Harness side
14 13 12 11 10 9 8 7
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310493 AG
AC310493 AG
Harness side
Harness side
AC310486 AD
AC310486 AD
SYMPTOM PROCEDURES
54B-111
NOTE: Connector: D-15 <LHD>
AC310465AC
AC310446 AE
AC310473AD
AC310456 AH Prior to the wiring harness inspection, check interme-
diate connectors C-17 <LH drive vehicles>, C-110
<RH drive vehicles>, C-127, D-15, and repair if nec-
essary.

AC310446AO After the rear power window sub switch (LH) is
replaced, check that the rear left door power window
(2) Check that the rear left power window works by
AC310454AI NO : Replace the power window main switch.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE D-5: The window glass lowers automatically while it is rising.

If the sliding resistance is too great when the window YES : Adjust the door window glass (Refer to
is being raised or the window glass encounters an GROUP 42 − Door − On-vehicle service
object, the window glass will lower by approximately P.42-23), and then go to Step 3.
150 mm. NO : Replace the defective power window
regulator motor assembly which operating
POSSIBLE CAUSES current are abnormal.
• Improper adjusted door window glass
• Incorrectly installed or warped glass slider Step 3. Check that the door window glasses are
• Malfunction of the power window regulator motor installed correctly.
• Malfunction of the window regulator Check that the door window glasses are installed
correctly. Refer to GROUP 42 − Door − On-vehicle
DIAGNOSIS PROCEDURE Service P.42-23.
Step 1. Check the power window anti-trap YES : Go to Step 4.
function. NO : Adjust the door window glass (Refer to
Check that the power window anti-trap function GROUP 42 − Door − On-vehicle service
works. Refer to GROUP 42 − Door − On-vehicle P.42-23).
Service P.42-24.
Q: Is the check result normal? Step 4. Retest the system.
YES : Go to Step 2. Check that the power window does not lower auto-
NO : Refer to Inspection Procedure D-6 "Power matically while it is being raised.
window anti-trap function does not work
normally P.54B-113." YES : The trouble can be an intermittent
Step 2. Check the power window operating Cope with Intermittent Malfunction P.00-5).
current. NO : Replace the power window regulator motor
Check that the power window operating current is assembly of the defective window.
normal (Refer to GROUP 42 − Door − On-vehicle
Service P.42-24).
SYMPTOM PROCEDURES
54B-113
INSPECTION PROCEDURE D-6: Power window anti-trap function does not work normally.
Power Window (front) Circuit <LHD>
POWER WINDOW
POWER WINDOW SUB SWITCH
MAIN SWITCH (FRONT)
(FRONT: LH)
CPU CPU
HALL IC HALL IC HALL IC HALL IC
POWER POWER
WINDOW MOTOR WINDOW MOTOR
(FRONT: LH) (FRONT: RH)
Wire colour code

SYMPTOM PROCEDURES
Power Window (front) Circuit <RHD>
POWER POWER WINDOW

WINDOW MAIN SUB SWITCH
SWITCH (FRONT)
(FRONT: RH)
CPU CPU
POWER POWER
(FRONT: RH) (FRONT: LH)
Wire colour code

SYMPTOM PROCEDURES
54B-115
Power Window (rear) Circuit
POWER POWER
WINDOW SUB WINDOW SUB
SWITCH (REAR: LH) SWITCH (REAR: RH)
CPU CPU
POWER POWER
Wire colour code

COMMENTS ON TROUBLE SYMPTOM Step 2. Confirm the power window learning

The revolution detection sensor, which is incorpo- function.
rated in the power window regulator motor, may be Check that the power window switch has learned the
defective. fully closed position of the windows (Refer to
GROUP 42 − Door P.42-29).
POSSIBLE CAUSES
• Malfunction of the power window regulator motor
YES : Go to Step 3.
NO : Make the power window switch learn the
DIAGNOSIS PROCEDURE fully closed position of the windows (Refer
to GROUP 42 − Door P.42-29).
Step 1. Check the power window operating
current. Step 3. Determine a trouble spot.
Check that the power window operating current is Q: Which door does the power window anti-trap
normal (Refer to GROUP 42 − Door − On-vehicle function fail on?
Service P.42-24). Driver's door <LH drive vehicles> : Go to Step 4.
Q: Is the check result normal? Driver's door <RH drive vehicles> : Go to Step 7.
YES : Adjust the door window glass (Refer to Front passenger's door <LH drive vehicles> : Go
GROUP 42 − Door − On-vehicle service to Step 10.
P.42-23), and then go to Step 2. Front passenger's door <RH drive vehicles> : Go
NO : Replace the defective power window to Step 16.
regulator motor assembly which operating Rear right door : Go to Step 22.
current are abnormal.
SYMPTOM PROCEDURES
Step 4. Connector check: E-05 power window Step 5. Check the wiring harness from E-05
main switch connector and E-02 front power power window main switch connector terminal
window regulator motor (LH) connector Nos.8, 9, 10 and 12 to E-02 front power window
regulator motor (RH) connector terminal Nos.5, 2,
3 and 6.
Front door (LH)
Front door (LH)
E-02 (GR)
E-02 (GR)
E-05
E-05
Harness side
E-02
Harness side
E-02
Harness side
E-05
14 13 12 11 10 9 8 7
E-05
AC310485AB 6 5 4 3 2 1
14 13 12 11 10 9 8 7

YES : Go to Step 5.
NO : Repair the defective connector. • Check the input and output lines to the revolution
detection sensor for open or short circuit.
YES : Go to Step 6.

check that the driver's power window anti-trap func-
tion works.
(2) Check that the driver's power window anti-trap
function works.
SYMPTOM PROCEDURES
54B-117
Step 7. Connector check: E-05 power window Step 8. Check the wiring harness from E-05
main switch connector and E-11 front power power window main switch connector terminal
window regulator motor (RH) connector Nos.8, 9, 10 and 12 to E-11 front power window
regulator motor (RH) connector terminal Nos.5, 2,
3 and 6.
Front door (RH)
Front door (RH)
E-11 (GR)
E-11 (GR)
E-05
E-05
Harness side
E-05
14 13 12 11 10 9 8 7 E-05
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side
E-11
Harness side
E-11
AC310494 AB
Q: Is the check result normal? AC310494 AB

YES : Go to Step 8.
NO : Repair the defective connector. • Check the input and output lines to the revolution
YES : Go to Step 9.

check that the driver's power window anti-trap func-
tion works.
(2) Check that the driver's power window anti-trap
function works.
SYMPTOM PROCEDURES
Step 10. Connector check: E-11 front power Step 12. Check the wiring harness from E-11
window regulator motor (RH) connector front power window regulator motor (RH)
connector terminal No.5 to body earth.

AC310488 AE
AC310488 AE
YES : Go to Step 11. NOTE:
NO : Repair the defective connector. Connector: C-110 <LHD>

AC310452 AC
• Check the input and output lines to the revolution
AC310488 AE
(1) Disconnect the connector, and measure at the YES : Go to Step 13.
wiring harness side. NO : Repair the wiring harness.

Connector E-02 Harness side

(Harness side)
AC310506AG
(2) Resistance between E-11 front power window

regulator motor (RH) connector terminal No.5
and body earth. AC310488AD
OK: 2Ω or less
NO : Go to Step 12.
SYMPTOM PROCEDURES
54B-119
Step 14. Check the wiring harness from E-14 Step 16. Connector check: E-02 front power
front power window sub switch connector window regulator motor (LH) connector
terminal Nos.2, 8 and 3 to E-11 front power Connector: E-02 <RHD>
window regulator motor (RH) connector terminal
Nos.2, 3 and 6. Front door (LH)

Front door (RH)
E-11 (GR)
AC310498 AD
E-14 Q: Is the check result normal?

Harness side
E-11
Harness side Front door (LH)

E-14

AC310489AB

AC310498 AD
YES : Go to Step 15. (1) Disconnect the connector, and measure at the
NO : Repair the wiring harness. wiring harness side.

check that the front passenger's anti-trap function
(1) Replace the front power window sub switch (RH).
anti-trap function works.
Connector E-02
Q: Is the check result normal? (Harness side)
YES : The trouble can be an intermittent AC310506AG
malfunction (Refer to GROUP 00 − How to (2) Resistance between E-02 front power window
Cope with Intermittent Malfunction P.00-5). regulator motor (LH) connector terminal No.5 and
NO : Replace the front power window regulator body earth.
motor assembly (RH). OK: 2Ω or less
NO : Go to Step 18.
SYMPTOM PROCEDURES
Step 18. Check the wiring harness from E-02 Step 20. Check the wiring harness from E-14
front power window regulator motor (LH) front power window sub switch connector
connector terminal No.5 to body earth. terminal Nos.2, 8 and 3 to E-02 front power
window regulator motor (LH) connector terminal
Nos.2, 3 and 6.
Front door (LH)
Front door (LH)
E-02 (GR)
AC310498 AD
E-14
NOTE:
Harness side
E-02
Harness side
E-14
AC310454 AH

AC310499AB
• Check the input and output lines to the revolution • Check the input and output lines to the revolution
detection sensor for open or short circuit. detection sensor for open or short circuit.
NO : Repair the wiring harness. NO : Repair the wiring harness.
Step 19. Connector check: E-14 front power Step 21. Retest the system.
window sub switch connector After the front power window sub switch is replaced,
check that the front passenger's anti-trap function
Front door (LH) (1) Replace the front power window sub switch.
anti-trap function works.
Harness side
AC310498AC
SYMPTOM PROCEDURES
54B-121
Step 22. Connector check: E-16 rear power Step 24. Check the wiring harness from E-16 rear
window regulator motor (RH) connector power window regulator motor (RH) connector
Connector: E-16
Rear door (RH)

AC310491AD
AC310491AD
YES : Go to Step 23. NOTE:
NO : Repair the defective connector. Connector: D-04 <LHD>
Step 23. Resistance measurement at E-16 rear

AC310463AB
AC310491AD

AC310471AC

Connector E-16
(Harness side) AC310506 AE
(2) Resistance between E-16 rear power window
regulator motor (RH) connector terminal No.5
and body earth.
OK: 2Ω or less
NO : Go to Step 24.
SYMPTOM PROCEDURES
Step 25. Connector check: E-17 rear power Step 27. Retest the system.
window sub switch (RH) connector After the rear power window sub switch (RH) is
Connector: E-17
replaced, check that the rear right door anti-trap
Rear door (RH)
function can be operated by the power window sub
switch.
(2) Check that the rear right power window anti-trap
Harness side function works.
AC310491AC Cope with Intermittent Malfunction P.00-5).
Q: Is the check result normal? motor assembly (RH).
power window sub switch (RH) connector Connector: E-09
Rear door (LH)
terminal Nos.2, 8 and 3 to E-16 rear power
window regulator motor (RH) connector terminal
Nos.2, 3 and 6.
Connectors: E-16, E-17 Harness side
Rear door (RH)
E-09 (GR)
AC310486AB
E-17
E-16 (GR)
Harness side
E-16
Harness side
E-17
AC310492 AB

SYMPTOM PROCEDURES
54B-123
Step 29. Resistance measurement at E-09 rear Step 30. Check the wiring harness from E-09 rear
power window regulator motor (LH) connector power window regulator motor (LH) connector
Connector: E-09
Rear door (LH)
Connector: E-09
Rear door (LH)
Harness side
Harness side
E-09 (GR)
AC310486AB
E-09 (GR)
(1) Disconnect the connector, and measure at the AC310486AB
wiring harness side. NOTE:

Connector E-09
(Harness side) AC310465AC
AC310506 AI
(2) Resistance between E-09 rear power window Connector: D-15 <RHD>
regulator motor (LH) connector terminal No.5 and
body earth.
OK: 2Ω or less
NO : Go to Step 30.
AC310473AD

SYMPTOM PROCEDURES

window sub switch (LH) connector NO : Repair the wiring harness.
After the rear power window sub switch (LH) is
replaced, check that the rear left door anti-trap func-
Harness side tion can be operated by the power window sub
switch.
(2) Check that the rear left power window anti-trap
function works.
AC310486 AD
Q: Is the check result normal? YES : The trouble can be an intermittent
YES : Go to Step 32. malfunction (Refer to GROUP 00 − How to
NO : Repair the defective connector. Cope with Intermittent Malfunction P.00-5).
Step 32. Check the wiring harness from E-08 rear motor assembly (LH).
power window sub switch (LH) connector
terminal Nos.8, 2 and 3 to E-09 rear power
window regulator motor (LH) connector terminal
Nos.3, 2 and 6.
Connectors: E-08, E-09
Rear door (LH)
E-09 (GR)
E-08
Harness side
E-08
Harness side
E-09
AC310487AB

SYMPTOM PROCEDURES
54B-125
INSPECTION PROCEDURE E-1: Keyless entry system does not work.
CAUTION
Keyless Entry System Function Circuit
ETACS-ECU
KEYLESS ENTRY
RECEIVER
INPUT SIGNAL
· ALL DOOR SWITCHES

· DRIVER'S DOOR LOCK ACTUATOR SWITCH
· KEYLESS ENTRY TRANSMITTER BUTTON
· KEY REMINDER SWITCH
COMMENTS ON TROUBLE SYMPTOM • Malfunction of the driver's door lock actuator

If the keyless entry system does not work normally, • Malfunction of the ETACS-ECU
the input signal circuits to the components below or • Damaged harness wires and connectors
the ETACS-ECU may be defective.
• Key reminder switch DIAGNOSIS PROCEDURE
• All of the door switches
• Keyless entry transmitter Step 1. Check the power supply circuit.
• Driver's door lock actuator When the ignition switch is turned to the LOCK
(OFF) position, check if the hazard warning lamps
POSSIBLE CAUSES illuminate.
• Malfunction of the door switches Q: Is the check result normal?
• Malfunction of the keyless entry transmitter YES : Go to Step 2.
the ETACS-ECU battery power supply
circuit P.54B-42."
SYMPTOM PROCEDURES

Step 2. Pulse check
Check the input signals below which are related to
3.
the keyless entry system. The key reminder switch signal is not received. :
System switch Check condition Refer to inspection procedure L-8 "The key
Key reminder switch When the inserted reminder switch signal is not received
ignition key is pulled out P.54B-257."
All the door switch signals are not received. :
All of the door switches A door is opened when Refer to inspection procedure L-10 "All the
all the doors are closed door switch signals are not received <LH
Driver's door lock When the driver's key drive vehicles>P.54B-265 ." Refer to
actuator switch cylinder or inside lock inspection procedure L-10 "All the door
knob is unlocked or switch signals are not received <RH drive
locked vehicles>P.54B-268 ."
Keyless entry transmitter When the switch is The driver's door lock actuator switch signal is not
switch turned from off to on received. : Refer to inspection procedure L-11
"The front door lock actuator (LH) switch
OK: The M.U.T.-II/III sounds or the voltmeter signal is not received <LH drive
needle fluctuates. vehicles>P.54B-272 ." Refer to inspection
procedure L-11 "The front door lock actuator
(RH) switch signal is not received <RH drive
The keyless entry transmitter switch signal is not
"Each switch signal of the keyless entry
transmitter is not received P.54B-282."

Check the keyless entry system works normally.
SYMPTOM PROCEDURES
54B-127
INSPECTION PROCEDURE E-2: Keyless entry hazard warning lamp answerback function or the room
lamp answerback function does not work normally.
CAUTION Step 2. Check the operation of the hazard

Whenever the ECU is replaced, ensure that the warning lamp.
input and output signal circuits are normal. Check that the hazard warning lamps illuminate nor-
COMMENTS ON TROUBLE SYMPTOM mally.
If the hazard warning lamp and the room lamp work Q: Is the check result normal?
normally, the ETACS-ECU may be defective. YES : Go to Step 3.
Alternatively, it is possible that the keyless entry haz- NO : Refer to inspection procedure I-2 "The
ard warning lamp answerback function was disabled hazard warning lamps do not illuminate
by the adjustment function. P.54B-196".
POSSIBLE CAUSES
Step 3. Check the operation of the room lamps.
• Defective turn-signal lamp
Check that the room lamps illuminate normally.
• Malfunction of the room lamp
• Malfunction of the ETACS-ECU Q: Is the check result normal?
NO : Refer to inspection procedure K-1 "The
DIAGNOSIS PROCEDURE front, rear room lamp and/or luggage
extinguish normally P.54B-225."
Step 1. Check the adjustment function.
Check that the keyless entry hazard warning lamp
answerback function has been enabled by using the Step 4. Retest the system.
adjustment function. Check that the keyless entry hazard warning lamp
answerback function or the room lamp answerback
Q: Is the check result normal? function work normally.
YES : Go to Step 2.
NO : Enable the keyless entry hazard warning Q: Is the check result normal?
lamp answerback function by using the YES : The trouble can be an intermittent
adjustment function (Refer to P.54B-302). malfunction (Refer to GROUP 00 − How to
SYMPTOM PROCEDURES
INSPECTION PROCEDURE E-3: Encrypted code cannot be registered.
CAUTION
Encrypted Transmitter Code Register Mode
ETACS-ECU
INPUT SIGNAL
· HAZARD WARNING LAMP SWITCH

· KEYLESS ENTRY TRANSMITTER BUTTON
· KEY REMINDER SWITCH
COMMENTS ON TROUBLE SYMPTOM Step 2. Pulse check

If the encrypted code registration mode is not Check the input signals below which are related to
entered, the key reminder switch, the hazard warning the encrypted code of the keyless entry transmitter.
lamp switch or the ETACS-ECU may be defective.
If the registration is not possible although the regis-
tration mode is entered, the keyless entry transmitter Key reminder switch When the inserted
or the ETACS-ECU may be defective. ignition key is pulled out
Hazard warning lamp When the switch is
POSSIBLE CAUSES switch turned from off to on
• Malfunction of the keyless entry transmitter
Keyless entry transmitter When the switch is
switch turned from off to on
DIAGNOSIS PROCEDURE needle fluctuates.
Step 1. Check the encrypted code registration

mode.
Check that the encrypted code registration mode is
entered.
YES : Go to Step 3.
NO : Go to Step 2.
SYMPTOM PROCEDURES
54B-129
Check that the encrypted code can be registered.
3.
The key reminder switch signal is not received. : Q: Is the check result normal?
Refer to inspection procedure L-8 "The key YES : The trouble can be an intermittent
reminder switch signal is not received malfunction (Refer to GROUP 00 − How to
P.54B-257." Cope with Intermittent Malfunction P.00-5).
The hazard warning lamp switch signal is not NO : Replace the ETACS-ECU.
received. : Refer to inspection procedure L-9 "The
hazard warning lamp switch signal is not
received P.54B-261."
The keyless entry transmitter switch signal is not
"Each switch signal of the keyless entry
transmitter is not received P.54B-282."
INSPECTION PROCEDURE E-4: The timer lock function does not work after the doors have been
unlocked by the keyless entry system.
CAUTION DIAGNOSIS PROCEDURE

input and output signal circuits are normal. Step 1. Check the operation of the keyless entry
COMMENT ON TROUBLE SYMPTOM system.
If the keyless entry timer lock does not work nor- Check that the keyless entry system works normally.
mally, the input signal circuit(s) to the keyless entry Q: Is the check result normal?
transmitter or the ETACS-ECU may be defective. YES : Go to Step 2.
NO : Refer to inspection procedure E-1 "Keyless
POSSIBLE CAUSES entry system does not work P.54B-125."
• Malfunction of the keyless entry transmitter
• Damaged harness wires and connectors Step 2. Retest the system.
Check that the timer lock works normally.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-1: The windshield wipers does not work at all.
CAUTION
Windshield Wiper Power Supply Circuit
IGNITION
SWITCH (ACC)
FRONT-ECU
WIPER SPEED WIPER

SWITCHING AUTOMATIC
RELAY STOP RELAY
WINDSHIELD COLUMN
WIPER MOTOR SWITCH
CIRCUIT
BREAKER
COLUMN-
ECU
Wire colour code

SYMPTOM PROCEDURES
54B-131
COMMENTS ON TROUBLE SYMPTOM Step 3. Connector check: B-01 windshield wiper
The windshield wiper motor, the column switch or the motor connector
front-ECU may be defective.
Connector: B-01 <LHD>
POSSIBLE CAUSES B-01 (GR)
• Malfunction of the windshield wiper motor
Harness side
AC310437AB
When the ignition switch is turned to the LOCK Connector: B-01 <RHD>
(OFF) position, check that the ETACS-ECU does not B-01 (GR)
set the diagnosis code.
YES : Refer to diagnosis code chart P.54B-14. Harness side
NO : Go to Step 2.
Step 2. Pulse check

Check the input signals below which are related to AC310477AD
the windshield wiper.
System switch Check condition YES : Go to Step 4.
Ignition switch (ACC) When turned from the NO : Repair the connector.
LOCK (OFF) position to
the ACC position. Step 4. Check the windshield wiper motor
Windshield mist wiper When the switch is assembly.
switch turned from off to on. Refer to GROUP 51 − Windshield wiper P.51-21.
OK: The M.U.T.-II/III sounds or the voltmeter Q: Is the check result normal?
needle fluctuates. YES : Go to Step 5
NO : Replace the windshield wiper motor
All the signals are received normally : Go to Step assembly.
3.
The ignition switch (ACC) signal is not received. :
ignition switch (ACC) signal is not received
P.54B-239."
Windshield mist wiper switch signal is not
column switch (windshield wiper washer
and rear wiper washer switch) signal is not
SYMPTOM PROCEDURES
Step 5. Resistance measurement at the B-01 Step 6. Check the wiring harness between B-01
windshield wiper motor connector windshield wiper motor connector terminal No.5
and body earth.
B-01 (GR) Connector: B-01 <LHD>
B-01 (GR)
Harness side
Harness side
AC310437AB
AC310437AB
Connector: B-01 <RHD>
B-01 (GR)
B-01 (GR)
Harness side
Harness side
AC310477AD
(1) Disconnect the connector, and measure at the AC310477AD
wiring harness side. • Check the earth wires for open circuit.
3 2 1 malfunction (Refer to GROUP 00 − How to
5 4 Cope with Intermittent Malfunction P.00-5).

Connector B-01 connector
(Harness side) Connector: A-11X
AC301635 AC
(2) Continuity between B-01 windshield wiper motor

connector terminal No.5 and body earth Battery
OK: 2Ω or less
YES : Go to Step 7.
Relay box side
NO : Go to Step 6.
31 30 29 28 27 26 25 24 23 22 21
AC310572AC

YES : Go to Step 8.
SYMPTOM PROCEDURES
54B-133
Step 8. Voltage measurement at the A-11X Step 9. Check the wiring harness between A-11X
front-ECU connector front-ECU connector terminal No.24 and the
Connector: A-11X ignition switch (ACC).
Connector: A-11X
Battery
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21 Relay box side
31 30 29 28 27 26 25 24 23 22 21
AC310572AC
(1) Remove the front-ECU, and measure at the relay AC310572AC
box side.
(2) Ignition switch: ACC
31 30 29 2827 26 25 24 2322 21
Connector A-11X
(Relay box side)
AC304768 AB
(3) Check the voltage between the A-11X front-ECU

connector terminal No.24 and body earth.
OK: System voltage
NO : Go to Step 9.
SYMPTOM PROCEDURES
NOTE: Connector: C-129

Connectors: C-210, C-211 <LHD> <LHD>
C-211
C-210
AC310446AI
Connector: C-129
Harness side <RHD>
C-210
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side
C-211
2 1
6 5 4 3 AC310454AJ
AC310449AF Prior to the wiring harness inspection, check the
junction block connectors C-210, C-211 and interme-
Junction block (front view) C-211 diate connector C-129 and repair if necessary.
• Check the power supply line to the ignition switch
(ACC) for open circuit.
C-210 YES : The trouble can be an intermittent
Harness side
C-210
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Harness side
C-211
2 1
6 5 4 3
AC310459AF
SYMPTOM PROCEDURES
54B-135
Step 10. Connector check: C-206 column switch Step 11. Check the wiring harness between C-206
connector column switch connector terminal No.8 and
A-11X front-ECU connector terminal No.26.
Connector: A-11X
Harness side Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310479AD
AC310572AC
AC310481AD
AC310479AD
YES : Go to Step 11. Connector: C-206 <RHD>
Harness side
AC310481AD
SYMPTOM PROCEDURES
NOTE: Step 12. Retest the system.

The windshield wiper should now work normally at
all.
NO : Replace the front-ECU.
AC310446 AS
AC310454 AV
Prior to the wiring harness inspection, check the

intermediate connector C-129 and repair if neces-
sary.
• Check the wiper backup circuit.
SYMPTOM PROCEDURES
54B-137
INSPECTION PROCEDURE F-2: The windshield wipers do not work when the wiper switch is at "INT",
"Washer" or "Mist" position. However, the wipers work at low speed when the switch is at "Lo" and
"Hi" position.
CAUTION
Windshield Wiper Motor Drive Circuit
FRONT-ECU INPUT SIGNAL

WIPER SPEED · WINDSHIELD WIPER HI SPEED SWITCH
SWITCHING · WINDSHIELD WIPER INTERMIT SWITCH
RELAY · WINDSHIELD WIPER LO SPEED SWITCH
· WINDSHIELD WIPER MIST SWITCH
WINDSHIELD
WIPER MOTOR
Wire colour code

CIRCUIT W : White Y : Yellow SB : Sky blue BR : Brown
BREAKER O : Orange GR : Gray R : Red P : Pink V : Violet

The system may be at fail-safe mode as the SWS • Malfunction of the column switch
communication line is defective. If the front-ECU • Malfunction of the front-ECU
does not receive the ignition switch (ACC) signal due • Damaged harness wires and connectors
to an open circuit in the SWS communication lines or
other reasons when the ignition switch is at the ACC
position, the system will enter the fail-safe mode.
SYMPTOM PROCEDURES
DIAGNOSTIC PROCEDURE Q: Is the check result normal?

All the signals are received normally : Go to Step
3.
Step 1. M.U.T.-II/III diagnosis code. The ignition switch (ACC) signal is not received. :
When the ignition switch is turned to the LOCK Refer to inspection procedure L-1 "The
(OFF) position, check that the ETACS-ECU does not ignition switch (ACC) signal is not received
set the diagnosis code. P.54B-239."
Q: Is the diagnosis code set? Windshield mist wiper switch signal is not
YES : Refer to diagnosis code chart P.54B-14. received. : Refer to inspection procedure L-5 "The
NO : Go to Step 2. column switch (windshield wiper washer
Step 2. Pulse check
the windshield wiper. Step 3. Retest the system.
The windshield wiper should now work normally.
Ignition switch (ACC) When turned from the
the ACC position.
Windshield mist wiper When the switch is NO : Replace the front-ECU.
switch turned from off to on.
needle fluctuates.
SYMPTOM PROCEDURES
54B-139
INSPECTION PROCEDURE F-3: The windshield wipers do not stop at the specified park position
CAUTION
Windshield Wiper Automatic Stop Relay Circuit
IGNITION
SWITCH (ACC)
FRONT-ECU
WIPER
AUTOMATIC
STOP RELAY
WINDSHIELD
WIPER MOTOR
Wire colour code


The windshield wiper motor or the front-ECU may be • Malfunction of the windshield wiper motor
defective. • Malfunction of the front-ECU
SYMPTOM PROCEDURES
DIAGNOSTIC PROCEDURE Step 3. Voltage measurement at the B-01

windshield wiper motor connector
Step 1. Connector check: B-01 windshield wiper Connector: B-01 <LHD>
motor connector B-01 (GR)
B-01 (GR)
Harness side
Harness side
AC310437AB

AC310437AB
B-01 (GR)
B-01 (GR)
Harness side
Harness side
AC310477AD

AC310477AD wiring harness side.
(2) Ignition switch: ACC
YES : Go to Step 2.
NO : Repair the connector. Connector B-01
(Harness side)
Step 2. Check the windshield wiper motor

3 2 1
assembly.
5 4
Refer to GROUP 51 − Windshield wiper P.51-21.
YES : Go to Step 3
NO : Replace the windshield wiper motor AC304770AB
assembly.
(3) Check the voltage between the B-01 windshield
wiper motor connector terminal No.4 and body
earth.
OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.
SYMPTOM PROCEDURES
54B-141
Step 4. Check the wiring harness between B-01 Connectors: C-210, C-211 <LHD>
windshield wiper motor connector terminal No.4 Junction block (front view)
and ignition switch (ACC). C-211
B-01 (GR)
C-210
Harness side
Harness side
C-210
AC310437AB
6 5 4 3 2 1
Connector: B-01 <RHD> 14 13 12 11 10 9 8 7
B-01 (GR)
Harness side
C-211
Harness side 2 1
6 5 4 3
AC310449AF

AC310477AD
NOTE:
C-210
C-123 (GR)
Harness side
C-210
AC310446AT
6 5 4 3 2 1
Connector: C-123 <RHD> 14 13 12 11 10 9 8 7
Harness side
C-211
2 1
6 5 4 3
AC310459AF
C-123 (GR)
junction connectors C-210, C-211 and the intermedi-
AC310454 AX ate connector C-123 and repair if necessary.
• Check the power supply line to ignition switch
SYMPTOM PROCEDURES
Step 5. Connector check: A-11X front-ECU Step 6. Check the wiring harness between B-01
connector windshield wiper motor connector terminal No.3
Connector: A-11X and A-11X front-ECU connector terminal No.23.
B-01 (GR)
Battery
Harness side
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
AC310437AB
YES : Go to Step 6. Connector: B-01 <RHD>
B-01 (GR)
Harness side
AC310477AD
Connector: A-11X
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
SYMPTOM PROCEDURES
54B-143
Connector: A-13
<LHD>
Check that the windshield wipers stop at the speci-
fied park position.
A-13 (B)
AC303857AB
1 2 3 4 5 6 7
8 9 10111213141516
AC310454 AY

intermediate connector A-13 <LH drive vehicles>,
C-31 <RH drive vehicles> and repair if necessary.
• Check the input signal lines.
YES : Go to Step 7.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-4: The windshield wipers does not work normally.
CAUTION
Windshield Wiper Motor Drive Circuit

WIPER SPEED · WINDSHIELD WIPER HI SPEED SWITCH
SWITCHING · WINDSHIELD WIPER INTERMIT SWITCH
RELAY · WINDSHIELD WIPER LO SPEED SWITCH
· WINDSHIELD WIPER MIST SWITCH
WINDSHIELD
WIPER MOTOR
Wire colour code

CIRCUIT W : White Y : Yellow SB : Sky blue BR : Brown
BREAKER O : Orange GR : Gray R : Red P : Pink V : Violet

The windshield wiper motor, the column switch or the • Malfunction of the windshield wiper motor
front-ECU may be defective. • Malfunction of the column switch
SYMPTOM PROCEDURES
54B-145
DIAGNOSTIC PROCEDURE Step 2. Check the operation of the windshield
wipers.
Step 1. Pulse check Check that the windshield wipers work at high speed
Check the input signals below which are related to and the mist mode.
the windshield wiper. Q: Is the check result normal?
System switch Check condition YES : Go to Step 3.
NO : Go to Step 8.
the ACC position. Step 3. Connector check: B-01 windshield wiper
motor connector
Windshield mist wiper When the switch is
switch turned from off to on. Connector: B-01 <LHD>
B-01 (GR)
Windshield intermittent When the switch is
wiper switch turned from off to on.
Windshield low-speed When the switch is Harness side
Windshield high-speed When the switch is
needle fluctuates. AC310437AB
Q: Is the check result normal? Connector: B-01 <RHD>

All the signals are received normally : Go to Step
B-01 (GR)
2.
Refer to inspection procedure L-1 "The Harness side
P.54B-239."
Windshield mist wiper switch signal is not
column switch (windshield wiper washer AC310477AD
received P.54B-249." Q: Is the check result normal?
Windshield intermittent wiper switch signal is not YES : Go to Step 4.
received. : Refer to inspection procedure L-5 "The NO : Repair the defective connector.
and rear wiper washer switch) signal is not Step 4. Check the windshield wiper motor
received P.54B-249." assembly.
Windshield low-speed wiper switch signal is not Refer to GROUP 51 − Windshield wiper P.51-21.
column switch (windshield wiper washer Q: Is the check result normal?
and rear wiper washer switch) signal is not YES : Go to Step 5
NO : Replace the windshield wiper motor
Windshield high-speed wiper switch signal is not assembly.
SYMPTOM PROCEDURES
Step 5. Connector check: A-11X front-ECU Step 6. Check the wiring harness between A-11X
connector front-ECU connector terminal No.27 and B-01
Connector: A-11X windshield wiper motor connector terminal No.1.
Connector: A-11X
Battery
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21 Relay box side
31 30 29 28 27 26 25 24 23 22 21
AC310572AC
AC310572AC
YES : Go to Step 6. Connector: B-01 <LHD>
NO : Repair the defective connector. B-01 (GR)
Harness side
AC310437AB
B-01 (GR)
Harness side
AC310477AD
SYMPTOM PROCEDURES
54B-147
NOTE: Step 8. Connector check: B-01 windshield wiper
motor connector
B-01 (GR)
A-13 (B)
Harness side
AC310542 AC
Connector: C-31 <RHD> AC310437AB
B-01 (GR)
Harness side
1 2 3 4 5 6 7
8 9 10111213141516
AC310454 AY

intermediate connector A-13 <LH drive vehicles>, AC310477AD
C-31 <RH drive vehicles>, and repair if necessary. Q: Is the check result normal?
• Check the power supply line to front-ECU for YES : Go to Step 9.
open circuit. NO : Repair the defective connector.
YES : Go to Step 7. Step 9. Check the windshield wiper motor
NO : Repair the wiring harness. assembly.
Refer to GROUP 51 − Windshield wiper P.51-21.
Step 7. Retest the system. Q: Is the check result normal?
Check that the windshield wipers work normally by YES : Go to Step 10
moving the switch to each position. NO : Replace the windshield wiper motor
Q: Is the check result normal? assembly.
malfunction (Refer to GROUP 00 − How to Step 10. Connector check: A-11X front-ECU
Cope with Intermittent Malfunction P.00-5). connector
Connector: A-11X
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC

SYMPTOM PROCEDURES
Step 11. Check the wiring harness between A-11X NOTE:

front-ECU connector terminal No.28 and B-01
windshield wiper motor connector terminal No.2.
Connector: A-11X
A-13 (B)
Battery
AC310542 AC
Relay box side
31 30 29 28 27 26 25 24 23 22 21 Connector: C-31 <RHD>
AC310572AC

B-01 (GR)
Harness side
1 2 3 4 5 6 7
8 9 10111213141516
AC310454 AY

intermediate connector A-13 <LH drive vehicles>,
AC310437AB C-31 <RH drive vehicles>, and repair if necessary.
• Check the power supply line to front-ECU for
open circuit.
B-01 (GR)
Harness side

Check that the windshield wipers work normally by
moving the switch to each position.
AC310477AD
SYMPTOM PROCEDURES
54B-149
INSPECTION PROCEDURE F-5: The intermittent wiper interval can not be adjusted by operating the
windshield intermittent wiper volume control.
CAUTION
Windshield Wiper Intermittent Volume Input Signal
ETACS-ECU
INPUT SIGNAL
WINDSHIELD WIPER
INTERMITTENT VOLUME

The column switch or the front-ECU may be defec- All the signals are received normally. : Go to Step
tive. 2.
The ignition switch (IG1) signal is not received. :
POSSIBLE CAUSES Refer to inspection procedure L-1 "The
• Malfunction of the front-ECU P.54B-239."
• Damaged harness wires and connectors The windshield wiper volume signal is not
windshield intermittent wiper volume signal
DIAGNOSIS PROCEDURE
is not received P.54B-250."
Step 1. Pulse check Step 2. Retest the system.

Check the input signals below which are related to Check that the windshield intermittent wiper interval
the windshield intermittent wiper function. can be adjusted by operating the windshield intermit-
System switch Check condition tent wiper volume control.
Ignition switch (ACC) When turned from LOCK OK: The intermittent wiper interval is
(OFF) position to the changed as the intermittent wiper volume is
ACC position rotated.
Windshield intermittent When the windshield Q: Is the check result normal?
wiper volume intermittent wiper volume YES : The trouble can be an intermittent
is rotated from "FAST" to malfunction (Refer to GROUP 00 − How to
"SLOW" (a pulse is sent Cope with Intermittent Malfunction P.00-5).
around the volume NO : Replace the front-ECU
middle position)
needle fluctuates.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-6: The intermittent wiper interval is not changed according to the
vehicle speed.
CAUTION
Vehicles Speed Input Signal
ETACS-ECU
INPUT SIGNAL
VEHICLE SPEED
COMMENTS ON TROUBLE SYMPTOM Step 2. Retest the system.

The ETACS-ECU calculates the intermittent wiper Check that the windshield intermittent wiper interval
interval according to the vehicle speed signal which can be adjusted by operating the windshield intermit-
is sent by the vehicle speed sensor. tent wiper volume control.
If the intermittent wiper interval does not depend on
the vehicle speed, the input circuit of the vehicle
YES : Go to Step 3.
speed signal and the ETACS-ECU may be defective.
NO : Refer to Inspection Procedure F-5 "The
POSSIBLE CAUSES intermittent wiper interval can not be
adjusted by operating the windshield
• Malfunction of the vehicle speed signal (vehicle
intermittent wiper volume control
speed sensor)
P.54B-149."
Step 3. Pulse check
DIAGNOSIS PROCEDURE Check the input signals below which are related to
the vehicle speed-dependent intermittent wiper.
Step 1. Check the adjustment function. System switch Check condition
Check that the vehicles speed sensing function has Ignition switch (ACC) When turned from LOCK
been enabled by using the adjustment function. (OFF) position to the
Q: Is the check result normal? ACC position
YES : Go to Step 2. Vehicle speed signal When the vehicle speed
NO : Enable the vehicles speed sensing function (engine-ECU) has reached 10 km/h or
by using the adjustment function (Refer to more
P.54B-302). OK: The M.U.T.-II/III sounds or the voltmeter
needle fluctuates.
SYMPTOM PROCEDURES
54B-151
Check that the intermittent wiper interval depends on
4.
the vehicle speed.
Refer to inspection procedure L-1 "The Q: Is the check result normal?
ignition switch (ACC) signal is not received YES : The trouble can be an intermittent
P.54B-239." malfunction (Refer to GROUP 00 − How to
The vehicle speed signal (engine-ECU) is not Cope with Intermittent Malfunction P.00-5).
received. : Refer to inspection procedure L-12 NO : Replace the ETACS-ECU.
"The vehicle speed sensor signal is not
SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-7: The windshield washer does not work.
CAUTION
Windshield Washer Motor Circuit
IGNITION
SWITCH (ACC)
FRONT-ECU
WINDSHIELD INPUT SIGNAL
WASHER
RELAY WINDSHIELD WASHER
WINDSHIELD
WASHER MOTOR
Wire colour code

SYMPTOM PROCEDURES
54B-153
The windshield washer motor, the column switch or All the signals are received normally : Go to Step
the front-ECU may be defective. 3.
POSSIBLE CAUSES Refer to inspection procedure L-1 "The
• Malfunction of the windshield washer motor
• Malfunction of the column switch P.54B-239."
• Malfunction of the front-ECU Windshield washer switch signal is not received. :
• Damaged harness wires and connectors Refer to inspection procedure L-5 "The
DIAGNOSIS PROCEDURE
Step 1. Check the operation of the windshield

Step 3. Connector check: F-18 windshield washer
wipers.
motor connector
Check that the windshield wipers work normally.
YES : Go to Step 2.
NO : Refer to Inspection Procedure F-1 "The
windshield wipers do not work at all
P.54B-130." Harness side
Step 2. Pulse check

the windshield wiper. AC310467AF
System switch Check condition Connector: F-18 <RHD>

the ACC position.
Windshield washer When the switch is
Harness side
switch turned from off to on.
needle fluctuates.
AC310469AF

YES : Go to Step 4.
Step 4. Check the windshield washer motor

assembly.
Refer to GROUP 51 − Windshield washer P.51-24.
YES : Go to Step 5
NO : Replace the windshield washer motor.
SYMPTOM PROCEDURES
Step 5. Resistance measurement at the F-18 Step 6. Check the wiring harness between F-18
windshield washer motor connector windshield washer motor connector terminal
Connector: F-18 <LHD> No.1 and body earth.
Harness side
Harness side
AC310467AF
AC310467AF
Harness side
Harness side
AC310469AF
(1) Disconnect the connector, and measure at the AC310469AF
wiring harness side. • Check the earth wires for open circuit.
1
2 Step 7. Connector check: A-11X front-ECU
connector
Connector F-18
(Harness side) Connector: A-11X
AC310506 AJ
(2) Continuity between F-18 windshield washer

motor connector terminal No.1 and body earth Battery
OK: 2Ω or less
YES : Go to Step 7. Relay box side
NO : Go to Step 6. 31 30 29 28 27 26 25 24 23 22 21
AC310572AC

YES : Go to Step 8.
SYMPTOM PROCEDURES
54B-155
Step 8. Check the wiring harness between F-18 NOTE:
windshield washer motor connector terminal
No.2 and A-11X front-ECU connector terminal
No.21.
Connector: A-11X
Battery
AC310452 AO
Relay box side Connector: C-113 <RHD>

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
Harness side AC310456 AN
AC310467AF
Harness side
AC310446 AS
AC310469AF
AC310454 AV

intermediate connector C-129, C-113 and repair if
necessary.
• Check the power supply line to the ignition switch
YES : Go to Step 9.
SYMPTOM PROCEDURES

The windshield washer should now work normally.
Q: Is the check result normal? NO : Replace the front-ECU.
IGNITION KEY CYLINDER ILLUMINATION LAMP
INSPECTION PROCEDURE G-1: The ignition key cylinder illumination lamp does not
illuminate/extinguish normally.
CAUTION
Ignition Key Cylinder Illumination Lamp Circuit
ETACS-ECU
KEY
REMINDER SWITCH
IGNITION KEY
LAMP
Wire colour code


The ETACS-ECU operates this function in accord- • Malfunction of the key reminder switch
ance with the input signals below. • Malfunction of the driver's door switch
• Ignition switch (IG1) • Malfunction of the ignition key cylinder illumina-
• Key reminder switch tion lamp
• Driver's door switch • Malfunction of the ETACS-ECU
• Interior lamp loaded signal • Damaged harness wires and connectors
If this function does not work normally, these input
signal circuit(s), the ignition key cylinder illumination
lamp or the ETACS-ECU may be defective.
SYMPTOM PROCEDURES
54B-157
DIAGNOSTIC PROCEDURE Step 3. Connector check: C-207 key reminder
switch connector
Step 1. Check the operation of the room lamp. Connector: C-207 <LHD>
Check that the room lamps illuminate and extinguish
normally.
YES : Go to Step 2. 2 1
NO : Refer to inspection procedure K-1 "The 7 6 5 4 3
front, rear room lamp and/or luggage

AC310479AE
Step 2. Pulse check Connector: C-207 <RHD>

the ignition key cylinder illumination lamp.
Harness side
Ignition switch (IG1) When turned from ACC 2 1
to ON 7 6 5 4 3
Key reminder switch When the inserted

ignition key is pulled out
Driver's door switch When the driver's door is AC310481AE
opened
OK: The M.U.T.-II/III sounds or the voltmeter YES : Go to Step 4.
needle fluctuates. NO : Repair the defective connector.
All the signals are received normally. : Go to Step Step 4. Check the bulb of the ignition key
3. cylinder illumination lamp.
The ignition switch (IG1) signal is not received. : Check the bulb of the ignition key cylinder illumina-
Refer to inspection procedure L-2 "The tion lamp.
ignition switch (IG1) signal is not received
P.54B-242."
YES : Go to Step 5.
The key reminder switch signal is not received. :
NO : Replace the bulb of the ignition key cylinder
Refer to inspection procedure L-8 "The key
illumination lamp.
reminder switch signal is not received
P.54B-257."
Refer to inspection procedure L-3 "The door
switch (front: LH) signal is not received <LH
drive vehicles>P.54B-244 ." Or refer to
(front: RH) signal is not received <RH drive
SYMPTOM PROCEDURES
Step 5. Connector check: C-228 ETACS-ECU Step 6. Check the wiring harness from C-228
connector ETACS-ECU connector terminal Nos.69 and 71 to
C-207 ignition key cylinder illumination lamp
Junction block (rear view) connector terminal Nos.1 and 2.

2 1
59 58 57 56 55 54 53 52 51 7 6 5 4 3
C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC

AC310479AE

2 1
59 58 57 56 55 54 53 52 51 7 6 5 4 3
68 67 66 65 64 63 62 61 60 C-228 (GR)
74 73 72 71 70 69
AC310461AC
Q: Is the check result normal? AC310481AE

YES : Go to Step 6.
NO : Repair the defective connector. Connector: C-228 <LHD>
Harness side
59 58 57 56 55 54 53 52 51
C-228 (GR) 68 67 66 65 64 63 62 61 60
74 73 72 71 70 69
AC310450AC

Harness side
59 58 57 56 55 54 53 52 51
68 67 66 65 64 63 62 61 60 C-228 (GR)
74 73 72 71 70 69
AC310461AC
SYMPTOM PROCEDURES
54B-159
Connector: C-23 <LHD> YES : Go to Step 7.

C-23 (B) Check that the ignition key cylinder illumination lamp
illuminates/extinguishes normally.
AC310446AY
Connector: C-23 NO : Replace the ETACS-ECU.
<RHD>
C-23 (B)
Harness side
AC310456AJ

SYMPTOM PROCEDURES
HEADLAMP AND TAIL LAMP
INSPECTION PROCEDURE H-1: The tail lamps do not illuminate normally.
CAUTION
Taillamp Relay Circuit
BATTERY
TAIL LAMP · HEADLAMP AUTOMATIC

RELAY SHUTDOWN
· TAIL LAMP SWITCH
RELAY
BOX
Wire colour code

<LHD> <LHD> B : Black LG : Light green G : Green L : Blue
· HEADLAMP · HEADLAMP
ASSEMBLY (LH) ASSEMBLY (RH) W : White Y : Yellow SB : Sky blue BR : Brown
· REAR COMBINATION · REAR COMBINATION O : Orange GR : Gray R : Red P : Pink V : Violet
LAMP (LH) LAMP (RH)
· COMBINATION METER
· LICENCE PLATE LAMP <RHD>
· HEADLAMP
<RHD> ASSEMBLY (RH)
· HEADLAMP · REAR COMBINATION
ASSEMBLY (LH) LAMP (RH)
· REAR COMBINATION · COMBINATION METER
LAMP (LH)
· LICENCE PLATE LAMP

If all the tail lamps do not illuminate, the tail lamp
switch input circuit or the front-ECU may be defec- Step 1. M.U.T.-II/III diagnosis code.
tive. When the ignition switch is turned to the LOCK
(OFF) position, check that the ETACS-ECU does not
POSSIBLE CAUSES
• Malfunction of the front-ECU Q: Is the diagnosis code set?
• Damaged harness wires and connectors YES : Refer to diagnosis code chart P.54B-14.
NO : Go to Step 2.
SYMPTOM PROCEDURES
54B-161
Step 2. Pulse check Step 4. Voltage measurement at A-10X front-ECU
Check the input signal from the tail lamp switch. connector
System switch Check condition Connector: A-10X
Ignition switch (IG1) When turned from ACC

to ON
Battery
Tail lamp switch When the lighting switch
is turned to the TAIL
position
OK: The M.U.T.-II/III sounds or the voltmeter Relay box side
needle fluctuates. 11 10 9 8 7 6 5 4 3 2 1
All the signals are received normally. : Go to Step (1) Remove the front-ECU, and measure at the relay
3. box side.
P.54B-242." Connector A-10X
The tail lamp switch signal is not received. : Refer (Relay box side)
to inspection procedure L-4 "The column
11 10 9 8 7 6 5 4 3 2 1
signal is not received P.54B-248."
Step 3. Connector check: A-10X front-ECU AC301541 DB

connector
(2) Voltage between A-10X front-ECU connector
Connector: A-10X terminal No.5 and body earth
OK: System voltage
Battery Q: Is the check result normal?
YES : Go to Step 6.
NO : Go to Step 5.
Relay box side Step 5. Check the wiring harness between A-10X
11 10 9 8 7 6 5 4 3 2 1 front-ECU connector terminal No.5 and the
AC310572AB battery.
Connector: A-10X
YES : Go to Step 4.
Battery
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB

SYMPTOM PROCEDURES

Check that the tail lamps illuminate normally.
Q: Is the check result normal? NO : Replace the front-ECU.
INSPECTION PROCEDURE H-2: The low-beam headlamps do not illuminate normally.
CAUTION
Headlamp Relay (Low-Beam) Circuit
BATTERY
HEADLAMP
RELAY: LO · HEADLAMP AUTOMATIC
SHUTDOWN
· TAIL LAMP SWITCH
RELAY
BOX
Wire colour code

HEADLAMP HEADLAMP W : White Y : Yellow SB : Sky blue BR : Brown
ASSEMBLY (LH) ASSEMBLY (RH) O : Orange GR : Gray R : Red P : Pink V : Violet

If the low-beam headlamps do not illuminate, the
headlamp switch input circuit or the front-ECU may Step 1. M.U.T.-II/III diagnosis code.
be defective. When the ignition switch is turned to the LOCK
(OFF) position, check that the ETACS-ECU does not
POSSIBLE CAUSES
• Malfunction of the front-ECU Q: Is the diagnosis code set?
• Damaged harness wires and connectors YES : Refer to diagnosis code chart P.54B-14.
NO : Go to Step 2.
SYMPTOM PROCEDURES
54B-163
Step 2. Pulse check Step 4. Voltage measurement at A-10X front-ECU
Check the input signal from the headlamp switch. connector
System switch Check condition Connector: A-10X
Ignition switch (IG1) When turned from ACC

to ON
Battery
Headlamp switch When the lighting switch
is turned to the
HEADLAMP position
OK: The M.U.T.-II/III sounds or the voltmeter Relay box side
needle fluctuates. 11 10 9 8 7 6 5 4 3 2 1
All the signals are received normally. : Go to Step (1) Remove the front-ECU, and measure at the relay
3. box side.
P.54B-242." Connector A-10X
The headlamp switch signal is not received. : (Relay box side)
11 10 9 8 7 6 5 4 3 2 1
Step 3. Connector check: A-10X front-ECU AC301541 DC

connector
(2) Voltage between A-10X front-ECU connector
Connector: A-10X terminal Nos.3, 4 and body earth
OK: System voltage
Battery Q: Is the check result normal?
YES : Go to Step 6.
NO : Go to Step 5.
Relay box side Step 5. Check the wiring harness between A-10X
11 10 9 8 7 6 5 4 3 2 1
front-ECU connector terminal Nos.3, 4 and the
AC310572AB battery.
Connector: A-10X
YES : Go to Step 4.
Battery
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB

SYMPTOM PROCEDURES

Check that the low-beam headlamps illuminate nor-
mally.
INSPECTION PROCEDURE H-3: The high-beam headlamps do not illuminate normally.
CAUTION
Headlamp Relay (High-Beam) Circuit
BATTERY
TAIL LAMP
RELAY: HI · HEADLAMP AUTOMATIC
SHUTDOWN
· TAIL LAMP SWITCH
RELAY
BOX
Wire colour code

· COMBINATION METER HEADLAMP (RH) W : White Y : Yellow SB : Sky blue BR : Brown
· HEADLAMP (LH) O : Orange GR : Gray R : Red P : Pink V : Violet

If the high-beam headlamps do not illuminate, the
dimmer switch input circuit or the front-ECU may be Step 1. Check that the headlamps operate.
defective. Check that the low-beam headlamps illuminate and
extinguish normally.
POSSIBLE CAUSES
• Malfunction of the column switch Q: Is the check result normal?
• Malfunction of the front-ECU YES : Go to Step 2.
• Damaged harness wires and connectors NO : Refer to inspection procedure H-2 "The
low-beam headlamps do not illuminate
normally P.54B-162."
SYMPTOM PROCEDURES
54B-165
Step 2. Pulse check
YES : Go to Step 3.
Check the input signal from the dimmer switch. NO : Refer to inspection procedure L-4 "The
System switch Check condition column switch (lighting and turn-signal lamp
Dimmer switch When the dimmer switch switch) signal is not received P.54B-248."
is turned from off to on
OK: The M.U.T.-II/III sounds or the voltmeter Step 3. Retest the system.
needle fluctuates. Check that the high-beam headlamps illuminate nor-
mally.
INSPECTION PROCEDURE H-4: The high-beam and low-beam headlamps do not illuminate when the
passing switch is operated.
CAUTION Step 2. Pulse check

Whenever the ECU is replaced, ensure that the Check the input signal from the passing switch.
Passing lamp switch When the passing switch
If the low-beam and high-beam headlamps are nor- is turned from off to on
mal, the passing switch input signal circuit or the
front-ECU may be defective. OK: The M.U.T.-II/III sounds or the voltmeter
needle fluctuates.
POSSIBLE CAUSES Q: Is the check result normal?
• Malfunction of the column switch YES : Go to Step 3.
• Malfunction of the front-ECU NO : Refer to inspection procedure L-4 "The
• Damaged harness wires and connectors column switch (lighting and turn-signal lamp
Step 1. Check that the headlamps operate. When the passing switch is turned on, check if the
Check that the low-beam and high-beam headlamps headlamps illuminate normally.
work normally. Q: Is the check result normal?
Q: Is the check result normal? YES : The trouble can be an intermittent
YES : Go to Step 2. malfunction (Refer to GROUP 00 − How to
NO : Repair the headlamps. Refer to trouble Cope with Intermittent Malfunction P.00-5).
symptom chart P.54B-33. NO : Replace the front-ECU.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE H-5: The headlamp automatic shutdown function does not work normally.
CAUTION
Headlamp Automatic Shutdown Function
ETACS-ECU
INPUT SIGNAL
· DRIVER'S DOOR SWITCH
· HEADLAMP SWITCH
· IGNITION SWITCH (IG1)
· TAIL LAMP SWITCH

The ETACS-ECU operates this function in accord-
ance with the input signals below. Step 1. Check the adjustment function.
• Ignition switch (IG1) Check that the headlamp automatic shutdown func-
• Driver's door switch tion has been enabled by using the adjustment func-
• Tail lamp switch tion.
• Headlamp switch
If this function does not work normally, these input Q: Is the check result normal?
signal circuit(s), the front-ECU or the ETACS-ECU YES : Go to Step 2.
may be defective. Note that this function can be disa- NO : Enable the headlamp automatic shutdown
bled/enabled by the adjustment function (default set- function by using the adjustment function.
ting; enabled). Refer to P.54B-302.
POSSIBLE CAUSES Step 2. Check that the headlamps operate.

• Malfunction of the driver's door switch Check that the low-beam and high-beam headlamps
• Malfunction of the front-ECU work normally.
YES : Go to Step 3.
• Damaged harness wires and connectors NO : Repair the headlamps. Refer to trouble
symptom chart P.54B-33.
SYMPTOM PROCEDURES
54B-167
Step 3. Pulse check
4.
the headlamp automatic shutdown function. The ignition switch (IG1) signal is not received. :
System switch Check condition Refer to inspection procedure L-2 "The
Ignition switch (IG1) When turned from ACC ignition switch (IG1) signal is not received
to ON P.54B-242."
Driver's door switch When the driver's door is Refer to inspection procedure L-3 "The door
opened switch (front: LH) signal is not received <LH
Tail lamp switch When the lighting switch drive vehicles>P.54B-244 ." Refer to
is turned to the TAIL inspection procedure L-3 "The door switch
position (front: RH) signal is not received <RH drive
OK: The M.U.T.-II/III sounds or the voltmeter vehicles>P.54B-246 ."
needle fluctuates. The tail lamp switch signal is not received. : Refer
signal is not received P.54B-248."

Replace the ETACS-ECU, and then check that the
headlamp automatic shutdown function works nor-
mally.
(1) Replace the ETACS-ECU.
(2) Check that the headlamp automatic shutdown
function works normally.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE H-6: Any of tail lamps, position lamps or licence plate lamps does not
illuminate. <LH drive vehicles>
CAUTION
Whenever the ECU is replaced, ensure that the input
and output signal circuits are normal.
Taillamps, Position Lamps and License Plate Lamps Circuit <LHD>
FRONT-ECU
TAIL LAMP
RELAY
HEADLAMP
ASSEMBLY
(POSITION)
(RH) (LH)
COMBINATION METER
LICENCE
PLATE
LAMP
(LH) (RH)
REAR
REAR COMBINATION
COMBINATION LAMP
LAMP (TAIL: LH)
(TAIL: RH)
Wire colour code

SYMPTOM PROCEDURES
54B-169
COMMENTS ON TROUBLE SYMPTOM Connectors: A-39
If the tail lamps, the position lamps or the licence <LHD>
plate lamps do not illuminate, the wiring harness con-
nector(s), the bulb or the fuse may be defective or
A-39
burned out. Harness side
POSSIBLE CAUSES
• Burned-out bulb
• Damaged harness wires and connectors A-39(B)
AC310431AE
Connector: C-02
<LHD> C-02 (L)
Step 1. Connector check: F-14 <tail lamp LH> or
F-08 <tail lamp RH> rear combination lamp
connector, A-31 <position lamp LH> or A-39
<position lamp RH> headlamp assembly
connector, F-11 <licence plate lamp LH> or F-10
<licence plate lamp RH> licence plate lamp
Harness side
connector, C-02 <tail lamp indicator>
combination meter connector
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Connectors: F-08, F-10, F-11, F-14

<LHD> Q: Is the check result normal?
YES : Go to Step 2.
Step 2. Check the bulbs of the tail lamps, the

position lamp, the licence plate lamp or tail lamp
F-08(B) indicator.
F-14(B)
Check the bulb of the lamp which does not illumi-
F-10(GR) nate.
F-11(GR)
YES : Go to Step 3.
NO : Replace the bulb of the lamp which does not
F-08 F-10 illuminate.
F-11 F-14
AC310468AD
Connectors: A-31
<LHD>
A-31
Harness side
A-31(B)
AC310542AD
SYMPTOM PROCEDURES
Step 3. Resistance measurement at the F-14 <tail Connector: C-02

lamp LH> or F-08 <tail lamp RH> rear <LHD> C-02 (L)
combination lamp connector, the A-31 <position
lamp LH> or A-39 <position lamp RH> headlamp
assembly connector, the F-11 <licence plate lamp
LH> or F-10 <licence plate lamp RH> licence
plate lamp connector or C-02 <tail lamp
indicator> combination meter connector Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
<LHD>
(2) Check the resistance between the lamp
•
F-14(B) F-08(B)
Connector A-31, A-39
F-10(GR) (Harness side)
F-11(GR)
F-08 F-10
AC301541HP
F-11 F-14 Resistance between A-31 <position lamp LH>

Harness side Harness side headlamp assembly connector terminal No.7
and body earth
• Resistance between A-39 <position lamp
AC310468AD
RH> headlamp assembly connector terminal
Connectors: A-31 No.7 and body earth
•
<LHD>
Connector F-08, F-14

A-31
(Harness side)
Harness side
A-31(B)
AC310542AD
Connectors: A-39 AC301541HN
<LHD> Resistance between F-14 <tail lamp LH> rear

combination lamp connector terminal No.5
A-39 and body earth
Harness side • Resistance between F-08 <tail lamp RH> rear
and body earth
A-39(B)
AC310431AE
SYMPTOM PROCEDURES
54B-171
•
Step 4. Check the wiring harness from F-14 <tail

lamp LH> or F-08 <tail lamp RH> rear
combination lamp connector terminal No.5, A-31
Connector F-10, F-11 <position lamp LH> or A-39 <position lamp RH>
(Harness side) headlamp assembly connector terminal No.7,
F-11 <licence plate lamp LH> or F-10 <licence
2 1
plate lamp RH> licence plate lamp connector
terminal No.1 or C-02 <tail lamp indicator>
combination meter connector terminal No.48 to
body earth.
AC301541HO Connectors: F-08, F-10, F-11, F-14
<LHD>
Resistance between F-11 <licence plate lamp
LH> licence plate lamp connector terminal
No.1 and body earth
• Resistance between F-10 <licence plate lamp
RH> licence plate lamp connector terminal
No.1 and body earth
•
F-14(B) F-08(B)
Connector C-02 F-10(GR)

(Harness side) F-11(GR)
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
F-08 F-10
F-11 F-14
AC301541HE
Resistance between C-02 <tail lamp indicator>
combination meter connector terminal No.48
and body earth AC310468AD
OK: 2 Ω or less Connectors: A-31

<LHD>
YES : Go to Step 5.
NO : Go to Step 4. A-31
Harness side
A-31(B)
AC310542AD
Connectors: A-39
<LHD>
A-39
Harness side
A-39(B)
AC310431AE
SYMPTOM PROCEDURES
Connector: C-02
<LHD> YES : The trouble can be an intermittent
C-02 (L)

51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 Connector: A-10X
AC310446AK
NOTE:
Connector: F-12 <LHD> Battery
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB

F-12 (GR) YES : Go to Step 6.
AC310467AG
diate connector F-12 <licence plate lamp> and repair
if necessary.
SYMPTOM PROCEDURES
54B-173
Step 6. Check the wiring harness from F-14 <tail Connector: C-02
lamp LH> or F-08 <tail lamp RH> rear <LHD> C-02 (L)
<position lamp LH> or A-39 <position lamp RH>
headlamp assembly connector terminal No.3,
terminal No.2, C-02 <tail lamp indicator>
combination meter connector terminal No.38 to Harness side
A-10X front-ECU connector terminal No.8.
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
Connectors: F-08, F-10, F-11, F-14 AC310446AK

<LHD>
Connector: A-10X
Battery
F-14(B) F-08(B)
F-10(GR) Relay box side

F-11(GR) 11 10 9 8 7 6 5 4 3 2 1
AC310572AB
NOTE:
F-08 F-10 Connectors: C-129
Harness side Harness side <LHD>
F-11 F-14
C-129
AC310468AD
Connectors: A-31
AC310446AP
<LHD>
Connector: C-113
A-31 <LHD>
Harness side
A-31(B)
AC310542AD
Connectors: A-39
AC310452AF
<LHD>
A-39
Harness side
A-39(B)
AC310431AE
SYMPTOM PROCEDURES

YES : Go to Step 7.

Check that the tail lamps, the position lamps and the
licence plate lamps illuminate normally.
The all lamps illuminate normally : The trouble can
F-12 (GR)
AC310467AG be an intermittent malfunction (Refer to
GROUP 00 − How to Cope with Intermittent
Connectors: C-05
<LHD>
When the tail lamps do not illuminate : Replace
C-05
the rear combination lamp socket assembly.
C-05 When the position lamps do not illuminate :
Replace the position lamp socket.
When the licence plate lamps do not illuminate :
Replace the licence plate lamp socket.
When the tail lamp indicator do not illuminate :
Replace the combination meter assembly.
AC310446AV
Connectors: C-210, C-214, C-217

<LHD>
C-210 C-214
C-217
C-210 C-214
6 5 4 3 2 1
14 13 12 11 10 9 8 7 14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-217
Harness side
AC310449AE

diate connector C-129 <tail lamp LH, licence plate
lamp or tail lamp indicator>, C-113 <tail lamp RH> or
F-12 <licence plate lamp>, joint connector C-05 <tail
lamp RH>, junction block connector C-210 <tail lamp
LH, licence plate lamp or tail lamp indicator>, C-214
<tail lamp indicator> or C-217 <tail lamp LH or
licence plate lamp> and repair if necessary.
• Check the output lines for open circuit.
SYMPTOM PROCEDURES
54B-175
INSPECTION PROCEDURE H-6: Any of tail lamps, position lamps or licence plate lamps does not
illuminate. <RH drive vehicles>
CAUTION
Whenever the ECU is replaced, ensure that the input
and output signal circuits are normal.
Taillamps, Position Lamps and License Plate Lamps Circuit <RHD>
FRONT-ECU
TAIL LAMP
RELAY
RELAY
BOX
HEADLAMP
ASSEMBLY
(RH) (LH)
REAR REAR
COMBINATION COMBINATION
LAMP (RH) LAMP (LH)
COMBINATION
METER LICENCE
PLATE
LAMP
(LH) (RH)
Wire colour code

SYMPTOM PROCEDURES
COMMENTS ON TROUBLE SYMPTOM Connectors: A-39

If the tail lamps, the position lamps or the licence <RHD>
plate lamps do not illuminate, the wiring harness con-
nector(s), the bulb or the fuse may be defective or A-39
burned out. Harness side
POSSIBLE CAUSES
• Burned-out bulb
A-39(B)
AC310433AD
Connector: C-02
Step 1. Connector check: F-14 <tail lamp LH> or <RHD>
C-02 (L)
F-08 <tail lamp RH> rear combination lamp
connector, A-31 <position lamp LH> or A-39
<position lamp RH> headlamp assembly
connector, F-11 <licence plate lamp LH> or F-10
<licence plate lamp RH> licence plate lamp
connector, C-02 <tail lamp indicator>
combination meter connector Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
<RHD> AC310456AK

YES : Go to Step 2.
F-08(B) Step 2. Check the bulbs of the tail lamps, the

F-14(B)
position lamp, the licence plate lamp or tail lamp
F-10(GR)
indicator.
F-11(GR)
Check the bulb of the lamp which does not illumi-
nate.
F-08 F-10 YES : Go to Step 3.
NO : Replace the bulb of the lamp which does not
illuminate.
F-11 F-14
AC310470AD
Connectors: A-31
<RHD>
A-31
Harness side
A-31(B)
AC310475AB
SYMPTOM PROCEDURES
54B-177
Step 3. Resistance measurement at the F-14 <tail Connector: C-02
lamp LH> or F-08 <tail lamp RH> rear <RHD>
C-02 (L)
combination lamp connector, the A-31 <position
lamp LH> or A-39 <position lamp RH> headlamp
assembly connector, the F-11 <licence plate lamp
LH> or F-10 <licence plate lamp RH> licence
plate lamp connector or C-02 <tail lamp
Harness side
indicator> combination meter connector
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

AC310456AK
<RHD>
•
F-14(B) F-08(B) Connector A-31, A-39

F-10(GR) (Harness side)
F-11(GR)
F-08 F-10
AC301541HP
F-11 F-14 Resistance between A-31 <position lamp LH>

Harness side Harness side headlamp assembly connector terminal No.7
and body earth
• Resistance between A-39 <position lamp
AC310470AD
RH> headlamp assembly connector terminal
Connectors: A-31 No.7 and body earth
<RHD> •
A-31 Connector F-08, F-14

(Harness side)
Harness side
A-31(B)
AC310475AB
Connectors: A-39 AC301541HN

<RHD> Resistance between F-14 <tail lamp LH> rear
A-39 and body earth
Harness side • Resistance between F-08 <tail lamp RH> rear
and body earth
A-39(B)
AC310433AD
SYMPTOM PROCEDURES
•

<RHD>
(Harness side)
2 1
F-14(B) F-08(B)
F-10(GR)
AC301541HO
F-11(GR)
Resistance between F-11 <licence plate lamp
LH> licence plate lamp connector terminal
No.1 and body earth
• Resistance between F-10 <licence plate lamp F-08 F-10
RH> licence plate lamp connector terminal
No.1 and body earth
•
F-11 F-14
Connector C-02 Harness side Harness side
(Harness side)
AC310470AD
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
Connectors: A-31
<RHD>
A-31
Harness side
AC301541HE
A-31(B)
Resistance between C-02 <tail lamp indicator>
combination meter connector terminal No.48
and body earth
OK: 2 Ω or less AC310475AB

Connectors: A-39
YES : Go to Step 5.
<RHD>
NO : Go to Step 4.
A-39
Step 4. Check the wiring harness from F-14 <tail Harness side
lamp LH> or F-08 <tail lamp RH> rear
A-39(B)
F-11 <licence plate lamp LH> or F-10 <licence AC310433AD
terminal No.1 or C-02 <tail lamp indicator> Connector: C-02
combination meter connector terminal No.48 to <RHD>
C-02 (L)
body earth.
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK
SYMPTOM PROCEDURES
54B-179
NOTE: Step 5. Connector check: A-10X front-ECU
connector
Connector: A-10X
Battery
F-12 (GR) Relay box side

AC310469AG
11 10 9 8 7 6 5 4 3 2 1
diate connector F-12 <licence plate lamp> and repair AC310572AB
if necessary. Q: Is the check result normal?

Q: Is the check result normal? NO : Repair the defective connector.
SYMPTOM PROCEDURES
Step 6. Check the wiring harness from F-14 <tail Connector: C-02
lamp LH> or F-08 <tail lamp RH> rear <RHD>
C-02 (L)
terminal No.2, C-02 <tail lamp indicator>
combination meter connector terminal No.38 to Harness side
A-10X front-ECU connector terminal No.8. 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
Connectors: F-08, F-10, F-11, F-14 AC310456AK

<RHD>
Connector: A-10X
Battery
F-14(B) F-08(B)
F-10(GR) Relay box side

F-11(GR) 11 10 9 8 7 6 5 4 3 2 1
AC310572AB
Connector: A-10X
F-08 F-10
Battery
F-11 F-14
Relay box side

AC310470AD 11 10 9 8 7 6 5 4 3 2 1
Connectors: A-31 AC310572AB

<RHD>
A-31
Harness side
A-31(B)
AC310475AB
Connectors: A-39
<RHD>
A-39
Harness side
A-39(B)
AC310433AD
SYMPTOM PROCEDURES
54B-181
NOTE: Connectors: C-210, C-214, C-217
Connectors: C-127, C-129 <RHD> Junction block (front view)
<RHD>
C-210
C-214
C-210
Harness side C-217
C-129 C-127 6 5 4 3 2 1
14 13 12 11 10 9 8 7
C-127
C-214
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-129 28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-217
Harness side
AC310459AE
AC310455AE
Connector: F-12 <RHD> diate connector C-129 <tail lamp, licence plate lamp
or tail lamp indicator>, C-127 <tail lamp LH or licence
plate lamp> or F-12 <licence plate lamp>, joint con-
nector C-05 <tail lamp RH, or tail lamp indicator>,
junction block connector C-210 <tail lamp RH, or tail
lamp indicator>, C-214 <tail lamp indicator> or C-217
<tail lamp RH> and repair if necessary.
F-12 (GR) Q: Is the check result normal?
AC310469AG
YES : Go to Step 7.
Connectors: C-05 NO : Repair the wiring harness.
<RHD>
C-05
Check that the tail lamps, the position lamps and the
C-05 licence plate lamps illuminate normally.
The all lamps illuminate normally : The trouble can
be an intermittent malfunction (Refer to
GROUP 00 − How to Cope with Intermittent
AC310454AZ
When the tail lamps do not illuminate : Replace
the rear combination lamp socket assembly.
When the position lamps do not illuminate :
Replace the position lamp socket.
When the licence plate lamps do not illuminate :
Replace the licence plate lamp socket.
When the tail lamp indicator do not illuminate :
Replace the combination meter assembly.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE H-7: The headlamp(s) do not illuminate. <including high-beam indicator>
CAUTION
Headlamps Circuit
HEADLAMP HEADLAMP FRONT-ECU

RELAY: LO RELAY: HI
RELAY
BOX
HEADLAMP HEADLAMP
ASSEMBLY ASSEMBLY
(LH) (LO) (RH) (LO) HEADLAMP HEADLAMP
(HI: RH) (HI: LH)
COMBINATION
METER
Wire colour code


If any of the headlamps or the high-beam indicator • Malfunction of the headlamp bulbs
does not illuminate, the wiring harness connector(s), • Malfunction of the high-beam indicator bulb
the bulb or the fuse may be defective or burned out. • Damaged harness wires and connectors
SYMPTOM PROCEDURES
54B-183
DIAGNOSTIC PROCEDURE Connectors: A-21, A-39
<LHD>
Step 1. Connector check: A-31 <headlamp (LO)
RH>, A-39 <headlamp (LO) LH>, A-21 <headlamp
(HI) RH>, A-15 <headlamp (HI) LH> headlamp
assembly connector or C-01 <high-beam
indicator> combination meter connector
Connectors: A-15, A-31
<LHD> A-21
A-39
A-21
Harness side
A-15
A-31
A-39
Harness side
A-15

A-31 <RHD>
Harness side
AC310543AC

<RHD> A-21
A-39
A-21
Harness side
A-31
A-15
A-39
Harness side
A-15
A-31
Harness side
AC310476AC
SYMPTOM PROCEDURES
Connector: C-01 Step 2. Check the bulb(s) of the headlamps or the

<LHD> high-beam indicator lamp.
Check the bulb(s) of the defective lamp.
YES : Go to Step 3.
NO : Replace the bulb(s) of the defective lamp.
Harness side
AC310446AM
Connector: C-01
<RHD>
Harness side
AC310456AL

YES : Go to Step 2.
SYMPTOM PROCEDURES
54B-185
Step 3. Resistance measurement at A-31 Connectors: A-21, A-39
<headlamp (LO) RH>, A-39 <headlamp (LO) LH>, <LHD>
A-21 <headlamp (HI) RH>, A-15 <headlamp (HI)
LH> headlamp assembly connector or C-01
<high-beam indicator> combination meter
connector
<LHD>
A-21
A-39
A-21
Harness side
A-15
A-31
A-39
Harness side
A-15
Harness side
AC310432AC
A-31 Connectors: A-21, A-39

Harness side <RHD>
AC310543AC

<RHD>
A-21
A-39
A-21
A-31 Harness side
A-15
A-39
Harness side
A-15
Harness side
AC310434AC
A-31
Harness side
AC310476AC
SYMPTOM PROCEDURES
•
Connector: C-01
<LHD>

(Harness side)
Harness side
AC310446AM AC301541HK
Connector: C-01 Resistance between A-21 <headlamp (HI) RH>

<RHD> headlamp assembly connector terminal No.2
and body earth
• Resistance between A-15 <headlamp (HI)
LH> headlamp assembly connector terminal
No.2 and body earth
•
Harness side
Connector C-01
(Harness side)
AC310456AL

•
AC301541HL

Resistance between C-01 <high-beam indicator>
(Harness side) combination meter connector terminal No.5
and body earth
OK: 2 Ω or less
YES : Go to Step 5.
NO : Go to Step 4.
AC301541HJ
Resistance between A-31 <headlamp (LO) RH>

headlamp assembly connector terminal No.8
and body earth
• Resistance between A-39 <headlamp (LO)
LH> headlamp assembly connector terminal
No.8 and body earth
SYMPTOM PROCEDURES
54B-187
Step 4. Check the wiring harness from A-31 Connectors: A-21, A-39
<headlamp (LO) RH> or A-39 <headlamp (LO) <LHD>
LH> headlamp connector terminal No.8, or A-21
<headlamp (HI) RH> or A-15 <headlamp (HI) LH>
headlamp connector terminal No.2, or C-01
<LHD> A-21
A-39
A-21
Harness side
A-15
A-31 A-39
Harness side
A-15
AC310432AC
Harness side
A-31 <RHD>
Harness side
AC310543AC
Connectors: A-15, A-31 A-21

<RHD>
A-39
A-21
Harness side
A-31
A-15 A-39
Harness side
A-15 AC310434AC
Harness side
A-31
Harness side
AC310476AC
SYMPTOM PROCEDURES
Connector: C-01 Step 5. Connector check: A-10X front-ECU

<LHD> connector
Connector: A-10X
Battery
Harness side
AC310446AM Relay box side

11 10 9 8 7 6 5 4 3 2 1
Connector: C-01
<RHD> AC310572AB

YES : Go to Step 6.
Harness side
AC310456AL

YES : Go to Step 7.
SYMPTOM PROCEDURES
54B-189
Step 6. Check the wiring harness from A-31 Connectors: A-21, A-39
<headlamp (LO) RH> or A-39 <headlamp (LO) <LHD>
LH> headlamp connector terminal No.4, or A-21
<headlamp (HI) RH> or A-15 <headlamp (HI) LH>
headlamp connector terminal No.1, or C-01
connector terminal No.5 to A-10X front-ECU
connector terminal No.6 <low-beam> or No.2
<high-beam>.
Connectors: A-15, A-31 A-21
<LHD> A-39
A-21
Harness side
A-15 A-39
A-31 Harness side
A-15 AC310432AC
Harness side
<RHD>
A-31
Harness side
AC310543AC
A-21
<RHD> A-39
A-21
Harness side
A-31
A-39
A-15 Harness side
AC310434AC
A-15
Harness side
A-31
Harness side
AC310476AC
SYMPTOM PROCEDURES
Connector: C-01
<LHD> diate connector C-129 <high-beam indicator>, and
YES : Go to Step 7.
Harness side

AC310446AM Check that the headlamps and the high-beam indica-
Connector: C-01
tor lamp illuminate/extinguish normally.
<RHD> Q: Is the check result normal?
The lamps illuminate normally at both high and low
beams. : The trouble can be an intermittent
Harness side When the headlamps do not illuminate : Replace
the headlamp socket.
When the high-beam indicator lamp does not
illuminate : Replace the combination meter.
AC310456AL
Connector: A-10X
Battery
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB
NOTE:
Connector: C-129
<LHD>
AC310446AI
Connector: C-129
<RHD>
AC310454AJ
SYMPTOM PROCEDURES
54B-191
FLASHER TIMER
INSPECTION PROCEDURE I-1: The turn-signal lamps do not illuminate.
CAUTION
Turn-Signal Lamp Power Supply Circuit <LHD>
BATTERY
RELAY
BOX
J/B SIDE
ETACS-ECU
LAMP RELAY: LH LAMP RELAY: RH
· HEADLAMP REAR · SIDE TURN SIGNAL COMBINATION · COMBINATION

ASSEMBLY (LH) COMBINATION LAMP (RH) METER METER
· SIDE TURN SIGNAL LAMP (LH) · REAR COMBINATION · HEADLAMP
LAMP (LH) LAMP (RH) ASSEMBLY (RH)
Wire colour code

SYMPTOM PROCEDURES
Turn-Signal Lamp Power Supply Circuit <RHD>
BATTERY
RELAY
BOX
J/B SIDE
ETACS-ECU
· HEADLAMP REAR · HEADLAMP

ASSEMBLY (LH) COMBINATION ASSEMBLY (RH) COMBINATION
· SIDE TURN SIGNAL LAMP (RH) · SIDE TURN SIGNAL METER
LAMP (LH) LAMP (RH)
· REAR COMBINATION
LAMP (LH)
Wire colour code


If all the turn-signal lamps do not illuminate, the igni-
tion switch (IG1), the turn-signal lamp switch input Step 1. Check that the hazard warning lamps
circuit or the ETACS-ECU may be defective. operate.
Check that the hazard warning lamps illuminate nor-
POSSIBLE CAUSES
mally.
• Malfunction of the ETACS-ECU Q: Is the check result normal?
NO : Go to Step 2.
SYMPTOM PROCEDURES
54B-193
Step 2. Connector check: C-226 ETACS-ECU Step 3. Voltage measurement at the C-226
connector ETACS-ECU connector
<LHD> <LHD>
Junction block (rear view) Junction block (rear view)
AC310450AB AC310450AB
Connector: C-226 Junction block (rear view) Connector: C-226 Junction block (rear view)
<RHD> <RHD>
AC310461AB AC310461AB

YES : Go to Step 3. junction block side.
Connector C-226
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC301541HF

OK: System voltage
YES : Go to Step 5.
NO : Go to Step 4.
SYMPTOM PROCEDURES

Connector: C-129
ETACS-ECU connector terminal No.11 and the <LHD>
battery.
Connector: C-226
<LHD>
AC310446AI
Junction block side
Connector: C-129
<RHD>
AC310450AB

<RHD>
AC310454AJ
Junction block side
Connector: C-210
<LHD>
AC310461AB
Harness side
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310448AK
Connector: C-210
<RHD>
Harness side
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310458AH

SYMPTOM PROCEDURES
54B-195
Check that the turn-signal lamps illuminate normally.
7.
Q: Is the check result normal? The turn-signal lamp switch (RH) signal is not
YES : The trouble can be an intermittent received. : Refer to inspection procedure L-4 "The
malfunction (Refer to GROUP 00 − How to column switch (lighting and turn-signal lamp
Cope with Intermittent Malfunction P.00-5). switch) signal is not received P.54B-248."
NO : Replace the ETACS-ECU. The turn-signal lamp switch (LH) signal is not
Step 6. Pulse check
the turn-signal lamp illumination.
Check that the turn-signal lamps illuminate.
Turn-signal lamp switch When the turn-signal
(RH) lamp switch (RH) is Q: Is the check result normal?
turned from off to on
Turn-signal lamp switch When the turn-signal Cope with Intermittent Malfunction P.00-5).
(LH) lamp switch (LH) is NO : Replace the ETACS-ECU.
needle fluctuates.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE I-2: The hazard warning lamps do not illuminate.
CAUTION
Hazard Warning Lamp Circuit
BATTERY
RELAY
BOX
J/B SIDE
ETACS-ECU
INPUT SIGNAL
LAMP RELAY: LH LAMP RELAY: RH HAZARD
WARNING
LAMP SWITCH
· COMBINATION METER · COMBINATION METER

· HEADLAMP · HEADLAMP
ASSEMBLY (LH) ASSEMBLY (RH)
· REAR COMBINATION · REAR COMBINATION
LAMP (LH) LAMP (RH)
· SIDE TURN SIGNAL · SIDE TURN SIGNAL
LAMP (LH) LAMP (RH)
Wire colour code


If the hazard warning lamps do not illuminate, the
hazard warning lamp input signal circuit or the Step 1. Check that the turn-signal lamps operate.
ETACS-ECU may be defective. Check that the turn-signal lamps illuminate normally.
• Malfunction of the hazard warning lamp switch YES : Go to Step 2.
• Malfunction of the ETACS-ECU NO : Refer to inspection procedure I-1 "The
• Damaged harness wires and connectors turn-signal lamps do not illuminate
P.54B-191."
SYMPTOM PROCEDURES
54B-197
Step 2. Check the power supply circuit. Step 3. Pulse check
When the ignition switch is at the LOCK (OFF) posi- Check the input signal from the hazard warning lamp
tion, check that the functions below work normally. switch.
• Lamp reminder function System switch Check condition
• Central door locking system
• Dome lamp (excluding interior lamp automatic Hazard warning lamp When the hazard
shutdown function) switch warning lamp switch is
YES : Go to Step 3. OK: The M.U.T.-II/III sounds or the voltmeter
NO : Refer to inspection procedure A-2 "Check needle fluctuates.
the battery power supply circuit to the Q: Is the check result normal?
ETACS-ECU P.54B-42." The signal is received normally. : Go to Step 4.
The hazard warning lamp switch signal is not
hazard warning lamp switch signal is not

Check that the hazard warning lamps illuminate.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE I-3: Any of the turn-signal lamps does not illuminate. <LH drive vehicles>
CAUTION
Turn-Signal Lamps Circuit <LHD>
J/B SIDE
ETACS-ECU
SIDE HEADLAMP REAR REAR HEADLAMP

TURN ASSEMBLY COMBINATION COMBINATION ASSEMBLY
SIGNAL (LH) LAMP (LH) LAMP (RH) (RH)
LAMP
(LH)
SIDE TURN COMBINATION

SIGNAL LAMP METER
(RH)
Wire colour code


If any of the turn-signal lamp does not illuminate nor- • Defective turn-signal lamp bulb
mally, wiring harness connector(s) or the bulb may • Damaged harness wires and connectors
be defective.
SYMPTOM PROCEDURES
54B-199
DIAGNOSTIC PROCEDURE Connectors: A-02, A-31
<LHD>
Step 1. Connector check: A-39 <front RH> or
A-31 <front LH> headlamp assembly connector, A-02 (GR)
A-01 <side RH> or A-02 <side LH> side
turn-signal lamp connector, F-08 <rear RH> or
F-14 <rear LH> rear combination lamp connector,
C-02 <turn-signal indicator lamp> and C-01
<turn-signal indicator lamp (LH)> combination
meter connector
Connectors: C-01, C-02 A-31
<LHD>
C-02(L)
C-01
A-02 A-31
AC310543AB
C-01
Harness side Connectors: F-08, F-14
<LHD>
C-02
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310447AE F-08
Connectors: A-01, A-39 F-14

<LHD>
A-01 (GR)
F-08 F-14
A-39
AC310468AC

A-01 A-39 YES : Go to Step 2.
Harness side Harness side NO : Repair the defective connector.
Step 2. Check the bulb(s) of the turn-signal lamps

or the turn-signal indicator lamps.
YES : Go to Step 3.
SYMPTOM PROCEDURES
Step 3. Resistance measurement at the A-39 Connectors: F-08, F-14

<front RH> or A-31 <front LH> headlamp <LHD>
assembly connector, the A-01 <side RH> or A-02
<side LH> side turn-signal lamp connector, the
F-08 <rear RH> or F-14 <rear LH> rear
combination lamp connector, the C-02
<turn-signal indicator lamp> combination meter
connector
<LHD>
F-14
A-01 (GR)
F-08 F-14
A-39
AC310468AC
A-01 A-39 Connector: C-02

Harness side Harness side <LHD> C-02 (L)
AC310432AB
Connectors: A-02, A-31 Harness side

<LHD> 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
A-02 (GR) AC310446AK

A-31
A-02 A-31
AC310543AB
SYMPTOM PROCEDURES
54B-201
(2) Measure the resistance between the defective
•
lamp connector terminal and body earth. Connector C-02

•
(Harness side)
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
(Harness side)
AC301541HE
Resistance between C-02 <turn-signal indicator

AC301541HG
lamp> combination meter terminal No.48 and
Resistance between A-39 <front RH> headlamp body earth
assembly connector terminal No.7 and body OK: 2 Ω or less
earth
• Resistance between A-31 <front LH> head- Q: Is the check result normal?
YES : Go to Step 5.
lamp assembly connector terminal No.7 and
NO : Go to Step 4.
body earth
•

(Harness side)
AC301541HH
Resistance between A-01 <side RH> side

turn-signal lamp connector terminal No.1 and
body earth
• Resistance between A-02 <side LH> side
body earth
•

(Harness side)
AC301541HI
Resistance between F-08 <rear RH> rear combi-

nation lamp connector terminal No.5 and
body earth
• Resistance between F-14 <rear LH> rear
and body earth
SYMPTOM PROCEDURES
Step 4. Check the wiring harness from A-39 Connectors: F-08, F-14
assembly connector terminal No.7, A-01 <side
RH> or A-02 <side LH> side turn-signal lamp
connector terminal No.1, F-08 <rear RH> or F-14
<rear LH> rear combination lamp connector
terminal No.5, or C-02 <turn-signal indicator
lamp> combination meter connector terminal
No.48 to body earth.
<LHD>
F-14
A-01 (GR)
F-08 F-14
A-39
AC310468AC

Harness side Harness side <LHD> C-02 (L)
AC310432AB
Connectors: A-02, A-31 Harness side

<LHD> 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
A-02 (GR) AC310446AK

A-31 Step 5. Connector check: C-226 ETACS-ECU
connector
Connector: C-226
<LHD>
A-02 A-31
Junction block side
AC310543AB AC310450AB

YES : Go to Step 6.
SYMPTOM PROCEDURES
54B-203
Step 6. Check the wiring harness from the A-39 Connectors: F-08, F-14
assembly connector terminal No.2, the A-01
<side RH> or A-02 <side LH> side turn-signal
lamp connector terminal No.2, the F-08 <rear RH>
or F-14 <rear LH> rear combination lamp
connector terminal No.1, the C-02 <turn-signal
indicator lamp> combination meter connector
terminal No.49 or C-01 <turn-signal indicator
lamp (LH)> combination lamp connector terminal F-08
No.9 <RH> or 14 <LH>. F-14
<LHD>
A-01 (GR)
F-08 F-14
A-39
AC310468AC

<LHD>
A-01 A-39 C-02(L)
Harness side Harness side C-01
AC310432AB

<LHD>
A-02 (GR)
C-01
Harness side
C-02
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
A-31
AC310447AE
A-02 A-31
AC310543AB
SYMPTOM PROCEDURES
Connector: C-226 Connectors: C-210, C-214, C-217

<LHD> <LHD>
Junction block (rear view) Junction block (front view)
C-210 C-214
Junction block side
C-217
AC310450AB
NOTE:
C-210 C-214
<LHD>
6 5 4 3 2 1
14 13 12 11 10 9 8 7 14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-217
Harness side
C-111 C-113 AC310449AE

Harness side diate connector C-129 <front or side LH>, C-113
<rear RH> or C-111 <side RH> and junction block
connector C-210 <front LH, side or rear RH>, C-217
<rear LH> or C-214 <front RH or turn-signal indicator
C-113 lamp>, and repair if necessary.
Harness side
YES : Go to Step 7.
AC310453AB
Connectors: C-129 Step 7. Retest the system.

<LHD> Check that the turn-signal lamps and the indicator
lamps illuminate normally.
C-129
The front turn-signal lamps do not illuminate. :
AC310446AP Replace the socket.
The side turn-signal lamps do not illuminate. :
Replace the socket.
The rear turn-signal lamps do not illuminate. :
Replace the socket assembly.
The turn-signal indicator lamps do not illuminate. :
Replace the combination meter.
SYMPTOM PROCEDURES
54B-205
INSPECTION PROCEDURE I-3: Any of the turn-signal lamps does not illuminate. <RH drive vehicles>
CAUTION
Turn-Signal Lamps Circuit <RHD>
J/B SIDE
ETACS-ECU
( TURN-SIGNAL
LAMP RELAY: LH ) (TURN-SIGNAL
LAMP RELAY: RH)

TURN ASSEMBLY COMBINATION COMBINATION
SIGNAL (LH) LAMP (LH) LAMP (RH)
LAMP
(LH)
HEADLAMP SIDE TURN COMBINATION

ASSEMBLY SIGNAL LAMP METER
(RH) (RH)
Wire colour code


If any of the turn-signal lamp does not illuminate nor- • Defective turn-signal lamp bulb
mally, wiring harness connector(s) or the bulb may • Damaged harness wires and connectors
be defective.
SYMPTOM PROCEDURES
DIAGNOSTIC PROCEDURE Connectors: F-08, F-14

<RHD>
Step 1. Connector check: A-39 <front RH> or
A-31 <front LH> headlamp assembly connector,
A-01 <side RH> or A-02 <side LH> side
turn-signal lamp connector, F-08 <rear RH> or
F-14 <rear LH> rear combination lamp connector,
C-02 <turn-signal indicator lamp> and C-01
<turn-signal indicator lamp (LH)> combination
meter connector
F-08
<RHD> F-14
A-01 (GR)
F-08 F-14
A-39
AC310470 AC

A-01 A-39
<RHD>
C-02(L)
C-01
AC310434AB

<RHD>
A-02 (GR)
C-01
Harness side
C-02
A-31
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310457AB

A-02 A-31 YES : Go to Step 2.
Harness side Harness side NO : Repair the defective connector.
Step 2. Check the bulb(s) of the turn-signal lamps

or the turn-signal indicator lamps.
AC310476AB
YES : Go to Step 3.
SYMPTOM PROCEDURES
54B-207
Step 3. Resistance measurement at the A-39 Connectors: F-08, F-14
<front RH> or A-31 <front LH> headlamp <RHD>
assembly connector, the A-01 <side RH> or A-02
<side LH> side turn-signal lamp connector, the
F-08 <rear RH> or F-14 <rear LH> rear
combination lamp connector, the C-02
<turn-signal indicator lamp> combination meter
connector F-08
F-14
<RHD>
A-01 (GR)
F-08 F-14
A-39
AC310470 AC
Connector: C-02
A-01 A-39 <RHD>
C-02 (L)
Harness side
AC310434AB
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

<RHD> AC310456AK
A-02 (GR) (1) Disconnect the connector, and measure at the

A-31
A-02 A-31
AC310476AB
SYMPTOM PROCEDURES
(2) Measure the resistance between the defective

•
lamp connector terminal and body earth. Connector C-02

•
(Harness side)
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
(Harness side)
AC301541HE
Resistance between C-02 <turn-signal indicator

AC301541HG
lamp> combination meter terminal No.48 and
Resistance between A-39 <front RH> headlamp body earth
assembly connector terminal No.7 and body OK: 2 Ω or less
earth
• Resistance between A-31 <front LH> head- Q: Is the check result normal?
YES : Go to Step 5.
lamp assembly connector terminal No.7 and
NO : Go to Step 4.
body earth
•

(Harness side)
AC301541HH
Resistance between A-01 <side RH> side

body earth
• Resistance between A-02 <side LH> side
body earth
•

(Harness side)
AC301541HI
Resistance between F-08 <rear RH> rear combi-

nation lamp connector terminal No.5 and
body earth
• Resistance between F-14 <rear LH> rear
and body earth
SYMPTOM PROCEDURES
54B-209
Step 4. Check the wiring harness from A-39 Connectors: F-08, F-14
assembly connector terminal No.7, A-01 <side
RH> or A-02 <side LH> side turn-signal lamp
connector terminal No.1, F-08 <rear RH> or F-14
<rear LH> rear combination lamp connector
terminal No.5, or C-02 <turn-signal indicator
lamp> combination meter connector terminal
No.48 to body earth.
<RHD>
F-14
A-01 (GR)
F-08 F-14
A-39 Harness side Harness side
AC310470 AC

Harness side Harness side <RHD>
C-02 (L)
AC310434AB
Harness side
Connectors: A-02, A-31 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
<RHD>
A-02 (GR) AC310456AK
A-31
connector
<RHD>
A-02 A-31
Junction block side
AC310476AB AC310461AB

YES : Go to Step 6.
SYMPTOM PROCEDURES
Step 6. Check the wiring harness from the A-39 Connectors: F-08, F-14
assembly connector terminal No.2, the A-01
<side RH> or A-02 <side LH> side turn-signal
lamp connector terminal No.2, the F-08 <rear RH>
or F-14 <rear LH> rear combination lamp
connector terminal No.1, the C-02 <turn-signal
indicator lamp RH> combination meter connector
terminal No.49 or C-01 <turn-signal indicator
lamp LH> combination lamp connector terminal F-08
No.9 <RH> or 14 <LH>. F-14
<RHD>
A-01 (GR)
F-08 F-14
A-39
AC310470 AC

<RHD>
C-02(L)
A-01 A-39
C-01
AC310434AB

<RHD>
A-02 (GR)
C-01
Harness side
C-02
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
A-31
AC310457AB
A-02 A-31
AC310476AB
SYMPTOM PROCEDURES
54B-211
Connector: C-226 Junction block (rear view) Connectors: C-210, C-214, C-217
<RHD> <RHD> Junction block (front view)
C-210
C-214
Junction block side

C-210
AC310461AB Harness side C-217
6 5 4 3 2 1
NOTE: 14 13 12 11 10 9 8 7
Connectors: C-127, C-129 C-214

<RHD> Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-217
Harness side
AC310459AE
C-129 C-127
diate connector C-129 <front or side LH>, C-127
<rear LH> or C-111 <side RH> and junction block
connector C-210 <front, side or rear LH>, C-217
<rear RH> or C-214 <turn-signal indicator lamp>,
C-129
YES : Go to Step 7.
AC310455AE
Connectors: C-111 Step 7. Retest the system.

<RHD> Check that the turn-signal lamps and the indicator
lamps illuminate normally.
The front turn-signal lamps do not illuminate. :
AC310456AP Replace the socket.
The side turn-signal lamps do not illuminate. :
Replace the socket.
The rear turn-signal lamps do not illuminate. :
Replace the socket assembly.
The turn-signal indicator lamps do not illuminate. :
Replace the combination meter.
SYMPTOM PROCEDURES
FOG LAMP
INSPECTION PROCEDURE J-1: The rear fog lamps do not illuminate normally.
CAUTION
Rear Fog Lamp Circuit <LHD>
FUSIBLE
LINK 1
REAR
FOG
LAMP
RELAY
ETACS-ECU
COMBINATION REAR
METER COMBINATION
LAMP
(REAR FOG)
Wire colour code

SYMPTOM PROCEDURES
54B-213
Rear Fog Lamp Circuit <RHD>
FUSIBLE
LINK 1
REAR FOG
LAMP RELAY
ETACS- REAR
ECU COMBINATION
LAMP COMBINATION
(REAR FOG) METER
Wire colour code

OPERATION • Rear fog lamp switch

The ETACS-ECU operates this function in accord- If the rear fog lamps do not illuminate normally, these
ance with the input signals below. input signal circuit(s) or the ETACS-ECU may be
• Tail lamp switch defective.
• Headlamp switch
SYMPTOM PROCEDURES

• Malfunction of the column switch All the signals are received normally. : Go to Step
• Malfunction of the fog lamp switch 3.
DIAGNOSTIC PROCEDURE P.54B-242."
The tail lamp switch signal is not received. : Refer
Step 1. Check that the tail lamps and headlamps switch (lighting and turn-signal lamp switch)
operate. signal is not received P.54B-248."
Check that the tail lamps and headlamps illuminate The headlamp switch signal is not received. :
normally. Refer to inspection procedure L-4 "The
YES : Go to Step 2. switch) signal is not received P.54B-248."
NO : Check the tail lamps and the headlamps The rear fog lamp switch signal is not received. :
(Refer to trouble symptom chart P.54B-33). Refer to inspection procedure L-14 "The
rear fog lamp switch signal is not received
P.54B-283."
Step 2. Pulse check
the rear fog lamps. Step 3. Connector check: C-219 rear fog lamp
relay connector
Connector: C-219
Ignition switch (IG1) When turned from ACC <LHD>
to ON Junction block (front view)
Tail lamp switch When the lighting switch
is turned to the TAIL
position
Junction block side
Headlamp switch When the lighting switch 2 1
is turned to the 4 3
HEADLAMP position
AC310448AN
Rear fog lamp switch When the rear fog lamp
switch is turned from off Connector: C-219 Junction block (front view)
to on <RHD>
needle fluctuates.
Junction block side

2 1
4 3
AC310458AK

YES : Go to Step 4.
Step 4. Check the rear fog lamp relay.

Refer to GROUP 54A − Rear fog lamp P.54A-64.
YES : Go to Step 5.
NO : Replace the rear fog lamp relay.
SYMPTOM PROCEDURES
54B-215
Step 5. Voltage measurement at the C-219 rear Step 6. Check the wiring harness between C-219
fog lamp relay connector rear fog lamp relay connector (terminal Nos.3
Connector: C-219
and 4) and the battery.
<LHD> Connectors: C-209, C-212, C-214, C-219
Junction block (front view) <LHD>
C-209 C-212(B)
Junction block side

2 1 C-214
4 3
AC310448AN
C-209
Harness side
<RHD> C-219
C-212 C-219
Harness side Junction block side
2 1
C-214 4 3
Junction block side
Harness side
2 1
4 3
14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC310458AK
28 27 26 25 24 23 22 21 20 19 18 17 16 15
(1) Remove the rear fog lamp relay, and measure at AC310449AC
the junction block side.
Connectors: C-209, C-212, C-214, C-219
<RHD> Junction block (front view)
C-212(B)
Connector C-219 C-209
2 1
4 3 C-214
C-209
AC301541HC
Harness side C-219
(2) Check the voltage between the rear fog lamp

relay connector and body earth.
C-219
• Voltage between C-219 rear fog lamp relay C-212
Junction block side
Harness side
2 1
• Voltage between C-219 rear fog lamp relay
4 3
connector terminal No.4 and body earth C-214
Harness side
OK: System voltage
Q: Is the check result normal? 14 13 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 7. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
NO : Go to Step 6. AC310459AC
SYMPTOM PROCEDURES

Connector: C-126 YES : The trouble can be an intermittent
<LHD> malfunction (Refer to GROUP 00 − How to

connector
Connector: C-228
AC310446AJ (rear view)
<RHD>
C-21 Harness side
59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69
AC310450AH

<RHD>
C-126
Harness side
59 58 57 56 55 54 53 52 51
C-21
58 5756 555453 52 51 60
Junction block side C-126 74 7372 71 70 69
AC310461AG

YES : Go to Step 8.
AC310455 AD NO : Repair the defective connector.
diate connector C-126, joint connector C-21 <RH
drive vehicles> and junction block connectors C-209,
C-212 and C-214, and repair if necessary.
SYMPTOM PROCEDURES
54B-217
Connector: C-209
rear fog lamp relay connector terminal No.2 and <LHD>
C-228 ETACS-ECU connector terminal No.74. Junction block (front view)
Connector: C-219
<LHD>
Harness side
Junction block side

AC310448 AO
2 1
4 3 Connector: C-209 Junction block (front view)
<RHD>
AC310448AN

<RHD>
Harness side
Junction block side AC310458AL
2 1 Prior to the wiring harness inspection, check junction

4 3 block connector C-209, and repair if necessary.
AC310458AK
Connector: C-228 Q: Is the check result normal?
<LHD> Junction block YES : Go to Step 9.
(rear view)

Harness side Check that the rear fog lamps illuminate normally.
59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69 YES : The trouble can be an intermittent
AC310450AH
Connector: C-228 Junction block (rear view) NO : Replace the ETACS-ECU.
<RHD>
Harness side
59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69
AC310461AG
SYMPTOM PROCEDURES
INSPECTION PROCEDURE J-2: The rear fog lamp or the rear fog lamp indicator does not illuminate
normally.
CAUTION
Rear Fog Lamp Circuit <LHD>
FUSIBLE
LINK 1
REAR
FOG
LAMP
RELAY
ETACS-ECU
COMBINATION REAR
METER COMBINATION
LAMP
(REAR FOG)
Wire colour code

SYMPTOM PROCEDURES
54B-219
Rear Fog Lamp Circuit <RHD>
FUSIBLE
LINK 1
REAR FOG
LAMP RELAY
ETACS- REAR
ECU COMBINATION
LAMP COMBINATION
(REAR FOG) METER
Wire colour code


If any of the rear fog lamps do not illuminate, the wir- • Burned-out rear fog lamp bulb
ing harness connector(s), the bulb or the fuse may • Damaged harness wires and connectors
be defective or burned out.
SYMPTOM PROCEDURES
DIAGNOSTIC PROCEDURE Step 2. Check the bulbs of the rear fog lamps or
the rear fog lamp indicator lamp.
Step 1. Connector check: F-14 <LH drive Check the bulb(s) of the defective lamp.
vehicles>, F-08 <RH drive vehicles> rear fog lamp Q: Is the check result normal?
connector or C-02 <rear fog lamp indicator lamp> YES : Go to Step 3.
combination meter connector NO : Replace the bulb(s) of the defective lamp.
Connector: F-14
<LHD>
Harness side
AC310467AC
Connector: F-08
<RHD>
Harness side
AC310469AC
Connector: C-02
<LHD> C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Connector: C-02
<RHD>
C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK

YES : Go to Step 2.
SYMPTOM PROCEDURES
54B-221
Step 3. Resistance measurement at the F-14 <LH (2) Check the resistance between the lamp
drive vehicles>, F-08 <RH drive vehicles> rear connector and body earth.
•
fog lamp connector or C-02 <fog lamp indicator

lamp> combination meter connector
Connector: F-14 Connector F-08, F-14
<LHD> (Harness side)
Harness side
AC301541HD
Resistance between F-14 <LH drive vehicles>,

AC310467AC F-08 <RH drive vehicles> rear fog lamp relay
Connector: F-08 •
<RHD>
Connector C-02
(Harness side)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310469AC
AC301541HE
Connector: C-02
<LHD> C-02 (L)
Resistance between C-02 <rear fog lamp indica-
tor lamp> combination meter connector termi-
nal No.48 and body earth
OK: 2 Ω or less
YES : Go to Step 5.
Harness side NO : Go to Step 4.
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Connector: C-02
<RHD>
C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK

SYMPTOM PROCEDURES

Step 4. Check the wiring harness from F-14 <LH
drive vehicles>, F-08 <RH drive vehicles> rear
fog lamp connector terminal No.5, C-02 <rear fog
lamp indicator lamp> combination meter NO : Repair the wiring harness.
Connector: F-14
Step 5. Connector check: C-219 rear fog lamp
<LHD> relay connector, C-01 <rear fog lamp indicator
lamp> combination meter connector
Connector: C-219
Harness side <LHD>
Junction block side

AC310467AC
2 1
4 3
Connector: F-08
<RHD>
AC310448AN

Harness side <RHD>
AC310469AC Junction block side

2 1
Connector: C-02
4 3
<LHD> C-02 (L) AC310458AK
Connector: C-01
<LHD>
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Harness side
Connector: C-02
<RHD>
C-02 (L) AC310446AM
Connector: C-01
<RHD>
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
Harness side
AC310456AK

AC310456AL

YES : Go to Step 6.
SYMPTOM PROCEDURES
54B-223
Step 6. Check the wiring harness from F-14 <LH Connector: C-219
drive vehicles>, F-08 <RH drive vehicles> rear <LHD>
fog lamp connector terminal No.4, C-01 <rear fog Junction block (front view)
lamp indicator lamp> combination meter
connector terminal No.21 to C-219 rear fog lamp
relay connector terminal No.1.
Junction block side
Connector: F-14 2 1
<LHD> 4 3
AC310448AN
Harness side
<RHD>
AC310467AC
Connector: F-08 Junction block side

<RHD> 2 1
4 3
AC310458AK
Harness side
AC310469AC
Connector: C-02
<LHD> C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Connector: C-02
<RHD>
C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK
SYMPTOM PROCEDURES

Connector: C-127
<LHD> Check that the rear fog lamp and the rear fog lamp
indicator lamp illuminate normally.
C-112(GR) Cope with Intermittent Malfunction P.00-5).
The rear fog lamps do not illuminate. : Replace the
AC310446AN
rear fog lamp(s).
The rear fog lamp indicator lamp does not
Connector: C-112 illuminate. : Replace the combination meter.
<RHD>
C-112(GR)
AC310456AM
Connector: C-209
<LHD>
Harness side
AC310448 AO

<RHD>
Harness side
AC310458AL

diate connector C-127 <LH drive vehicles - rear fog
lamp>, C-112 <RH drive vehicles - rear fog lamp>
and junction block connector C-209, and repair if
necessary.
YES : Go to Step 7.
SYMPTOM PROCEDURES
54B-225
INTERIOR LAMP
INSPECTION PROCEDURE K-1: The front, rear room lamp and/or luggage compartment lamp do not
illuminate or extinguish normally.
CAUTION
Room Lamp Circuit
J/B SIDE
ETACS-ECU
LUGGAGE
COMPARTMENT
LAMP
REAR FRONT
ROOM ROOM
LAMP LAMP
LUGGAGE
COMPARTMENT
LAMP SWITCH
Wire colour code

COMMENTS ON TROUBLE SYMPTOM If this function does not work normally, these input
The ETACS-ECU operates this function in accord- signal circuit(s), the interior lamp automatic shut-
ance with the input signals below. down function or the ETACS-ECU may be defective.
• Ignition switch (IG1) The delay-off setting of this function can be changed
• Key reminder switch by the adjustment function (default setting; 15 sec-
• All of the door switches onds).
• Driver's door lock actuator
• Interior lamp loaded signal POSSIBLE CAUSES
• Malfunction of the door switches
• Malfunction of the driver's door lock actuator
SYMPTOM PROCEDURES

4.
Step 1. Check the adjustment function. The ignition switch (IG1) signal is not received. :
Check that the room lamp delay-off time has been Refer to inspection procedure L-2 "The
set to other than "0 second" by the adjustment func- ignition switch (IG1) signal is not received
tion. P.54B-242."
Q: Is the check result normal? All the door switch signals are not received. :
YES : Go to Step 2. Refer to inspection procedure L-10 "All the
NO : Use the adjustment function to set the room door switch signals are not received <LH
lamp delay-off time to other than "0 second." drive vehicles>P.54B-265 ." Refer to
Refer to P.54B-302. inspection procedure L-10 "All the door
switch signals are not received <RH drive
The driver's door lock actuator switch signal is not
When the ignition switch is turned to the LOCK received. : Refer to inspection procedure L-11
(OFF) position, check if the hazard warning lamps "The front door lock actuator (LH) switch
illuminate. signal is not received <LH drive
Q: Is the check result normal? vehicles>P.54B-272 ." Refer to inspection
YES : Go to Step 3. procedure L-11 "The front door lock actuator
NO : Refer to inspection procedure A-2 "Check (RH) switch signal is not received <RH drive
the battery power supply circuit to the vehicles>P.54B-275 ."
ETACS-ECU P.54B-42." Interior lamp loaded signal is not detected. : Refer
to inspection procedure L-15 "Interior lamp
Step 3. Pulse check loaded signal is not detected P.54B-287."
the front and rear room lamps. Step 4. Determine a trouble spot.
System switch Check condition Q: Which lamp does not illuminate?
Ignition switch (IG1) When turned from ACC No lamp illuminates. : Replace the ETACS-ECU.
to ON The front room lamp or the rear room lamp does
not illuminate. : Go to Step 5.
All of the door switches A door is opened when The luggage compartment lamp does not
all the doors are closed illuminate. : Go to Step 10.
Driver's door lock When the driver's door is
actuator switch unlocked or locked
Interior lamp loaded When a load is applied
signal through multi-purpose
fuse No.18
needle fluctuates.
SYMPTOM PROCEDURES
54B-227
Step 5. Connector check: D-05 front room lamp Step 6. Check the bulbs of the front or rear room
connector, D-07 rear room lamp connector lamps.
Check that the front or rear room lamp bulbs are not
<LHD> burned out.
D-05
D-07 YES : Go to Step 7.
(GR) NO : Replace the front or rear room lamp bulb.

connector
Connector: C-226
<LHD>
D-05
Harness side
Junction block side
D-07

AC310464AB <RHD>

<RHD> D-05
D-07
(GR)
Junction block side
AC310461AB

YES : Go to Step 8.
D-05
Harness side
D-07
Harness side
AC310472 AB

YES : Go to Step 6.
SYMPTOM PROCEDURES
Step 8. Check the wiring harness from C-226 Connectors: D-05, D-07
ETACS-ECU connector terminal Nos.5 and 6 to <RHD> D-05
D-05 front room lamp connector terminal Nos.2
and 1 or D-07 rear room lamp connector terminal D-07
Nos.2 and 1. (GR)
Connector: C-226
<LHD>
Junction block side D-05

Harness side
AC310450AB
Connector: C-226 Junction block (rear view) D-07

<RHD> Harness side
AC310472 AB
NOTE:
Connector: C-218
Junction block side <LHD>
AC310461AB

<LHD> D-05
Harness side
D-07
(GR)
AC310448AL

<RHD>
D-05
AC310458AJ
D-07 Prior to the wiring harness inspection, check junction

Harness side block connector C-218, and repair if necessary.
• Check the input or output lines for open circuit.
YES : Go to Step 9.
SYMPTOM PROCEDURES
54B-229
Step 9. Retest the system. Step 10. Connector check: F-02 luggage
Check that the front or rear room lamp illuminates compartment lamp connector, F-09 luggage
and extinguishes normally. compartment lamp switch connector
Q: Is the check result normal? Connectors: F-02, F-09
YES : The trouble can be an intermittent <LHD>
F-02
F-09 (B)
F-02
Harness side
F-09
Harness side
AC310468AB
Connectors: F-02, F-09

<RHD>
F-02
F-09 (B)
F-02
Harness side
F-09
Harness side
AC310470AB

SYMPTOM PROCEDURES
Step 11. Check the bulbs of the luggage Step 13. Check the wiring harness from F-02
compartment lamp. luggage compartment lamp connector terminal
Check that the luggage compartment lamp bulb are No.2 to F-09 luggage compartment lamp switch
not burned out. connector terminal No.1.
Q: Is the check result normal? Connectors: F-02, F-09
YES : Go to Step 12. <LHD>
NO : Replace the luggage compartment lamp
bulb.
Step 12. Check the luggage compartment lamp F-02

switch.
Check the luggage compartment lamp switch.Refer
F-09 (B)
to GROUP 42 − Trunk lid P.42-39.
NO : Replace the luggage compartment lamp
switch. F-02
Harness side
F-09
Harness side
AC310468AB
Connectors: F-02, F-09

<RHD>
F-02
F-09 (B)
F-02
Harness side
F-09
Harness side
AC310470AB

SYMPTOM PROCEDURES
54B-231
Step 14. Connector check: C-226 ETACS-ECU Step 15. Check the wiring harness from C-226
connector ETACS-ECU connector terminal No.6 to F-02
Connector: C-226 luggage compartment lamp connector terminal
<LHD> No.1.
Junction block (rear view) Connector: C-226
<LHD>
Junction block side
Junction block side

AC310450AB
Connector: C-226 Junction block (rear view) AC310450AB

<RHD>
<RHD>
Junction block side
AC310461AB Junction block side

NO : Repair the defective connector. Connector: F-02
<LHD>
Harness side
AC310467AB
Connector: F-02
<RHD>
Harness side
AC310469AB
SYMPTOM PROCEDURES

Connector: C-217
<LHD> Check that the luggage compartment lamp illumi-
Junction block (front view) nates and extinguishes normally.
Harness side
AC310448AC

<RHD>
Harness side
AC310458AC

SYMPTOM PROCEDURES
54B-233
INSPECTION PROCEDURE K-2: Interior lamp automatic shutdown function does not work normally.
CAUTION
Interior Lamp Automatic Shutdown Function Circuit
RELAY BOX
(FUSE 22 )
J/B SIDE
ETACS-ECU
INPUT SIGNAL
· ALL DOOR
SWITCH KEEP RELAY
· DRIVER'S DOOR
SWITCH
· IGNITION
SWITCH (ACC)
LOAD
· IGNITION DETERMINATION LOAD
SWITCH (IG1) CIRCUIT DETERMINATION
CIRCUIT
· INTERIOR LAMP
LOADED SIGNAL
COMBINATION · FRONT ROOM LAMP

METER · REAR ROOM LAMP
· LUGGAGE COMPARTMENT LAMP
COMMENTS ON TROUBLE SYMPTOM • Malfunction of the room lamp

The ETACS-ECU operates the interior lamp auto- • Malfunction of the ETACS-ECU
matic shutdown function in accordance with the input • Damaged harness wires and connectors
signals below.
• Ignition switch (ACC) DIAGNOSTIC PROCEDURE
• Ignition switch (IG1)
• Driver's door switch Step 1. Check the adjustment function.
• All of the door switches Check that the interior lamp automatic shutdown
• Interior lamp loaded signal function has been enabled by using the adjustment
If this function does not work normally, these input function.
signal circuit(s) or the ETACS-ECU may be defec-
tive. Note that this function can be disabled/enabled Q: Is the check result normal?
by the adjustment function (default setting; enabled). YES : Go to Step 2.
NO : Enable the interior lamp automatic
POSSIBLE CAUSES shutdown function by using the adjustment
• Malfunction of the door switches function. Refer to P.54B-302.
SYMPTOM PROCEDURES

When the ignition switch is turned to the LOCK
4.
(OFF) position, check if the hazard warning lamps The ignition switch (ACC) signal is not received. :
illuminate. Refer to inspection procedure L-1 "The
Q: Is the check result normal? ignition switch (ACC) signal is not received
YES : Go to Step 3. P.54B-239."
NO : Refer to inspection procedure A-2 "Check The ignition switch (IG1) signal is not received. :
the battery power supply circuit to the Refer to inspection procedure L-2 "The
ETACS-ECU P.54B-42." ignition switch (IG1) signal is not received
P.54B-242."
Step 3. Pulse check The driver's door switch signal is not received. :
Check the input signals below, which are related to Refer to inspection procedure L-3 "The door
the front and rear dome lamps. switch (front: LH) signal is not received <LH
System switch Check condition inspection procedure L-3 "The door switch
Ignition switch (ACC) When turned from the (front: RH) signal is not received <RH drive
LOCK (OFF) position to vehicles>P.54B-246 ."
the ACC position All the door switch signals are not received. :
Ignition switch (IG1) When turned from ACC Refer to inspection procedure L-10 "All the
to ON door switch signals are not received <LH
Driver's door switch Driver's door is opened inspection procedure L-10 "All the door
while all the other doors switch signals are not received <RH drive
are closed. vehicles>P.54B-268 ."
All of the door switches A door is opened when Interior lamp loaded signal is not detected : Refer
all the doors are closed to inspection procedure L-15 "Interior lamp
Interior lamp loaded When a load is applied loaded signal is not detected P.54B-287."
signal through multi-purpose
fuse No.18 Step 4. Retest the system.
OK: The M.U.T.-II/III sounds or the voltmeter Check that the interior lamp automatic shutdown
needle fluctuates. function works normally.
SYMPTOM PROCEDURES
54B-235
INSPECTION PROCEDURE K-3: The door-ajar warning lamp does not illuminate/extinguish normally.
CAUTION
Door Ajar Indicator Lamp Circuit
ETACS-ECU
INPUT SIGNAL
COMBINATION
METER · ALL DOOR SWITCH
· DRIVER'S DOOR SWITCH
Wire colour code

COMMENTS ON TROUBLE SYMPTOM Step 2. Pulse check

If the door-ajar warning lamp does not work normally, Check the input signals below, which are related to
the input signal circuits from all the door switches or the door-ajar warning lamp.
the ETACS-ECU may be defective.
POSSIBLE CAUSES Driver's door switch Driver's door is opened
• All the door switches are defective. while all the other doors
• Malfunction of the ETACS-ECU are closed.
• Damaged harness wires and connectors All of the door switches A door is opened when
all the doors are closed
needle fluctuates.
Step 1. Check the operation of the room lamp.
Q: Does the room lamp illuminate/extinguish?
YES : Go to Step 2.
NO : Refer to inspection procedure K-1 "The
front, rear room lamp and/or luggage
SYMPTOM PROCEDURES

Step 3. Connector check: C-01 and C-02
combination meter connector
3.
The driver's door switch signal is not received. : Connectors: C-01, C-02
Refer to inspection procedure L-3 "The door <LHD>
switch (front: LH) signal is not received <LH C-02(L)
drive vehicles>P.54B-244 ." Refer to C-01
(front: RH) signal is not received <RH drive
All the door switch signals are not received. :
Refer to inspection procedure L-10 "All the
door switch signals are not received <LH
inspection procedure L-10 "All the door
switch signals are not received <RH drive
C-01
vehicles>P.54B-268 ." Harness side
C-02
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310447AE

<RHD>
C-02(L)
C-01
C-01
Harness side
C-02
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310457AB

YES : Go to Step 4.
SYMPTOM PROCEDURES
54B-237
Step 4. Check the door-ajar warning lamp bulb. Step 5. Connector check: C-228 ETACS-ECU
Check the door-ajar warning lamp bulb. connector
YES : Go to Step 5. <LHD> Junction block
NO : Replace the door-ajar warning lamp bulb. (rear view)
Harness side
59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69
AC310450AH

<RHD>
Harness side
59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69
AC310461AG

YES : Go to Step 6.
SYMPTOM PROCEDURES
Step 6. Check the wiring harness from C-228 Connectors: C-01, C-02
ETACS-ECU connector terminal Nos.53 and 71 to <RHD>
C-02 combination meter connector terminal C-02(L)
No.34 and C-01 combination meter connector
C-01
terminal No.8.
Connector: C-228
(rear view)
Harness side
59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60 C-01
74 7372 71 70 69 Harness side
AC310450AH
C-02
Harness side
<RHD>
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310457AB
Harness side • Check the input or output lines for open circuit.
59 58 57 56 55 54 53 52 51 Q: Is the check result normal?
58 5756 555453 52 51 60
74 7372 71 70 69
YES : Go to Step 7.
AC310461AG

<LHD>
Replace the ETACS-ECU, and then check that the
C-02(L)
door-ajar warning lamp illuminates/extinguishes nor-
C-01
mally.
(1) Replace the ETACS-ECU.
(2) Check that the door-ajar warning lamp
illuminates/extinguishes normally.
NO : Replace the combination meter.
C-01
Harness side
C-02
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310447AE
INPUT SIGNAL PROCEDURES
54B-239
INSPECTION PROCEDURE L-1: The ignition switch (ACC) signal is not received.
CAUTION
Ignition Switch (ACC) Input Circuit
IGNITION
SWITCH (ACC)
J/B SIDE
ETACS-ECU
Wire colour code


Input signal from the ignition switch (ACC) is used to • Malfunction of the ETACS-ECU
operate the functions below. If the signal is abnormal, • Damaged harness wires and connectors
these functions will not work normally.
• Windshield wiper and washer
• Interior lamp automatic shutdown function
DIAGNOSTIC PROCEDURE Step 2. Voltage measurement at the C-226

ETACS-ECU connector
Step 1. Connector check: C-226 ETACS-ECU Connector: C-226
connector <LHD>
Connector: C-226
<LHD>
Junction block side
Junction block side AC310450AB

AC310450AB <RHD>

<RHD>
Junction block side
Junction block side AC310461AB

AC310461AB junction block side.
(2) Ignition switch: ACC position
YES : Go to Step 2.
Connector C-226
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC301541GT

OK: System voltage
YES : Go to Step 4.
NO : Go to Step 3.
54B-241
ETACS-ECU connector terminal No.18 and the
ignition switch (ACC).
Connector: C-226 NO : Repair the wiring harness.
<LHD>
Check that the ignition switch (ACC) signal is
received normally.
Junction block side YES : The trouble can be an intermittent
AC310450AB
<RHD>
Junction block side
AC310461AB
NOTE:
Connector: C-211
<LHD>
Harness side
2 1
6 5 4 3
AC310448AB

<RHD>
Harness side
AC310458AB

INSPECTION PROCEDURE L-2: The ignition switch (IG1) signal is not received.
CAUTION
Ignition Switch (IG1) Input Circuit

IGNITION
SWITCH (IG1)
J/B SIDE
ETACS-ECU
Wire colour code


Input signal from the ignition switch (IG1) is used to
operate the functions below. If the signal is abnormal, Step 1. Connector check: C-226 ETACS-ECU
these functions will not work normally. connector
• Lamp reminder function
• Ignition key cylinder illumination lamp Connector: C-226
<LHD>
• Headlamp automatic shutdown function
• Turn signal lamp
• Room lamps
POSSIBLE CAUSES
Junction block side
AC310450AB

<RHD>
Junction block side
AC310461AB

YES : Go to Step 2.
54B-243
Step 2. Voltage measurement at the C-226 Step 3. Check the wiring harness between C-226
ETACS-ECU connector ETACS-ECU connector terminal No.8 and the
Connector: C-226 ignition switch (IG1).
<LHD> Connector: C-226
Junction block (rear view) <LHD>
Junction block side

Junction block side
AC310450AB
AC310450AB
<RHD> Connector: C-226 Junction block (rear view)
<RHD>
Junction block side

Junction block side
AC310461AB
(1) Remove the ETACS-ECU, and measure at the AC310461AB
junction block side. NOTE:

(2) Ignition switch: ON position Connector: C-211
<LHD>
Connector C-226
Harness side
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2 1
6 5 4 3
AC310448AB
AC301541GU Connector: C-211 Junction block (front view)

<RHD>
OK: System voltage
NO : Go to Step 3.
AC310458AB


Check that the ignition switch (IG1) signal is received
normally.
INSPECTION PROCEDURE L-3: The door switch (front: LH) signal is not received. <LH drive
vehicles>
CAUTION
Door Switch Input Circuit <LHD>
ETACS-ECU
J/B SIDE
FRONT DOOR
SWITCH (LH)
Wire colour code


Input signal from the door switch (front: LH) is used
to operate the functions below. If the signal is abnor- Step 1. Check the installation condition.
mal, these functions will not work normally. Check that the door switch (front: LH) is installed on
• Lamp reminder function the body correctly.
• Room lamps Q: Is the check result normal?
YES : Go to Step 2.
POSSIBLE CAUSES NO : Correct the installation condition.
• Malfunction of the door switch (front: LH)
54B-245
Step 2. Connector check: D-18 door switch (front: Step 5. Check the wiring harness between D-18
LH) connector door switch (front: LH) connector terminal No.3
Connector: D-18 and C-226 ETACS-ECU connector terminal No.10.
<LHD>
Harness side
Junction block side
AC310465AB
AC310450AB
NO : Repair the defective connector. <LHD>
Step 3. Check the door switch (front: LH).

Refer to GROUP 42 − Door P.42-27.
Harness side
YES : Go to Step 4.
NO : Replace the door switch (front: LH).
AC310465AB
NOTE:
connector Connector: C-217
<LHD> Junction block (front view)
Harness side
Junction block side
AC310448AC
AC310450AB
Q: Is the check result normal? connector C-217, and repair if necessary.
YES : Go to Step 5. • Check the input line for open circuit.
YES : Go to Step 6.

Check that the door switch (front: LH) signal is
received normally.
INSPECTION PROCEDURE L-3: The door switch (front: RH) signal is not received. <RH drive
vehicles>
CAUTION
Door Switch Input Circuit <RHD>
ETACS-ECU
J/B SIDE
DOOR SWITCH
(RH)
Wire colour code

COMMENTS ON TROUBLE SYMPTOM Step 2. Connector check: D-01 door switch (front:
Input signal from the door switch (front: RH) is used RH) connector
to operate the functions below. If the signal is abnor-
Connector: D-01
mal, these functions will not work normally. <RHD>
• Room lamps
Harness side
POSSIBLE CAUSES
• Malfunction of the door switch (front: RH)
AC310471AB

YES : Go to Step 3.
Step 1. Check the installation condition. NO : Repair the defective connector.
Check that the door switch (front: RH) is installed on
the body correctly. Step 3. Check the door switch (front: RH).
Q: Is the check result normal? Refer to GROUP 42 − Door P.42-27.
NO : Correct the installation condition. YES : Go to Step 4.
NO : Replace the door switch (front: RH).
54B-247
Step 4. Connector check: C-226 ETACS-ECU Step 5. Check the wiring harness between D-01
connector door switch (front: RH) connector terminal No.3
Connector: C-226
and C-226 ETACS-ECU connector terminal No.10.
<RHD>
Junction block side

Junction block side
AC310461AB
AC310461AB
NO : Repair the defective connector. <RHD>
Harness side
AC310471AB
NOTE:
<RHD>
Harness side
AC310458AC

• Check the input line for open circuit.
YES : Go to Step 6.

Check that the door switch (front: RH) signal is
received normally.
INSPECTION PROCEDURE L-4: The column switch (lighting and turn-signal lamp switch) signal is not
received.
CAUTION
Lighting Switch Input Circuit
COLUMN SWITCH
COLUMN-ECU
DIMMER· TURN-SIGNAL LIGHTING

PASSING SWITCH LAMP SWITCH SWITCH
COMMENTS ON TROUBLE SYMPTOM Step 2. Check the column switch (lighting switch
Input signal from the column switch (lighting and and switch body).
turn-signal lamp switch) is used to operate the func- Refer to GROUP 54A − Column switch P.54A-74.
tions below. If the signal is abnormal, these functions
will not work normally.
YES : Go to Step 3.
NO : Replace the column switch.
• Headlamp and tail lamp
• Fog lamp
• Turn signal lamp Step 3. M.U.T.-II/III diagnosis code.
Check that the ETACS-ECU sets a diagnosis code.
POSSIBLE CAUSES Q: Is the diagnosis code set?
• Malfunction of the column switch YES : Refer to diagnosis code chart P.54B-14.
• Damaged harness wires and connectors NO : Go to Step 4.
Replace the column switch, and check if the column
Step 1. Check the column switch connector. switch (lighting, turn-signal lamp) sends signal.
Check that the wiper and washer switch connector, (1) Replace the column switch.
the lighting switch connector and the switch body (2) Check if the column switch (lighting and
connector are in good condition. turn-signal switch) sends signal.
YES : Go to Step 2. YES : The procedure is complete.
NO : Repair the defective connector. NO : Replace the ETACS-ECU.
54B-249
INSPECTION PROCEDURE L-5: The column switch (windshield wiper/washer) signal is not received.
CAUTION
Windshield Wiper and Washer Switch Input Circuit
COLUMN SWITCH
COLUMN-ECU
UPPER
SIDE
UPPER
SIDE
WINDSHIELD
WASHER
WINDSHIELD SWITCH
WIPER SWITCH
COMMENTS ON TROUBLE SYMPTOM Step 2. Retest the system.

Input signal from the column switch (wiper switch) is Replace the column switch, and check if the column
used to operate the functions below. If the signal is switch (windshield wiper washer) sends signal.
abnormal, these functions will not work normally. (1) Replace the column switch.
• Windshield wiper and washer (2) Check if the column switch (windshield
wiper/washer) sends signal.
POSSIBLE CAUSES

Check that the ETACS-ECU sets a diagnosis code.
YES : Refer to diagnosis code chart P.54B-14.
NO : Go to Step 2.
INSPECTION PROCEDURE L-6: The windshield intermittent wiper volume signal is not received.
CAUTION
Windshield Intermittent Wiper Interval Adjusting Knob Input Circuit
ETACS-
ECU
COLUMN
SWITCH
UPPER
SIDE
UPPER
WINDSHIELD SIDE
INTERMITTENT
WIPER INTERVAL
ADJUSTING KNOB
Wire colour code


The intermittent wiper interval is calculated in • Malfunction of the column switch
accordance with the input signal from the windshield • Malfunction of the ETACS-ECU
intermittent wiper volume. If this signal is abnormal, • Damaged harness wires and connectors
the wiper interval can not be adjusted.
54B-251
DIAGNOSTIC PROCEDURE Step 2. Resistance measurement at the C-206
column switch connector
Step 1. Connector check: C-206 column switch Connector: C-206
connector <LHD>
Connector: C-206
<LHD>
Harness side
Harness side
AC310479AB
Connector: C-206
AC310479AB <RHD>
Connector: C-206
<RHD>
Harness side
Harness side
AC310481AB

AC310481AB column switch side.
YES : Go to Step 2.
NO : Repair the defective connector. Connector C-206
(Harness side)
AC301541GV
(2) Resistance between C-206 column switch

OK: The resistance should rise from 0 to
1 kΩ when the windshield intermittent
wiper volume is rotated from "Fast" to
"Slow".
YES : Go to Step 3.
NO : Replace the column switch.
Step 3. Connector check: C-228 ETACS-ECU Step 4. Check the wiring harness between C-206
connector column switch connector terminal No.6 and
C-228 ETACS-ECU connector terminal No.66.
Connector: C-228
Junction block (rear view) <LHD>
Harness side
Harness side
C-228(GR)
C-228(GR)
AC310450AE
AC310450AE
<RHD>
C-228(GR)
Harness side C-228(GR)
Harness side
AC310461AD
AC310461AD
YES : Go to Step 4. Connector: C-206
NO : Repair the defective connector. <LHD>
Harness side
AC310479AB
Connector: C-206
<RHD>
Harness side
AC310481AB

YES : Go to Step 5.
54B-253
Check that the windshield intermittent wiper volume
is sending a correct signal.
INSPECTION PROCEDURE L-7: When the power window main switch is operated, the switch signals
are not received.
CAUTION
Power Window Main Switch Circuit
FUSIBLE
LINK 5
J/B SIDE
ETACS-ECU POWER
WINDOW RELAY
POWER WINDOW
MAIN SWITCH CPU
Wire colour code

54B-255
COMMENTS ON TROUBLE SYMPTOM Step 2. Connector check: C-228 ETACS-ECU
Input signal from the power window main switch is connector and E-05 power window main switch
used in order to check the power window main connector
switch and confirm how the system is communicating
Connector: C-228
with the ETACS-ECU. If the communication line is <LHD> Junction block
defective, the power windows will not work normally. (rear view)
POSSIBLE CAUSES
• Malfunction of the power window main switch
• Damaged harness wires and connectors Harness side
59 58 57 56 55 54 53 52 51
DIAGNOSTIC PROCEDURE 58 5756 555453 52 51 60

74 7372 71 70 69
AC310450AH
Step 1. Check the operation by using the power
window main switch.
<RHD>
Check if each window can be operated by means of
the power window main switch.
Q: Can each power window be operated by means of
the power window main switch?
NO : Refer to Inspection Procedure D-1 "Power 59 58 57 56 55 54 53 52 51
windows do not work at all P.54B-72." 58 5756 555453 52 51 60
74 7372 71 70 69
AC310461AG

Front door (LH)
Harness side
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310484AC
Connector: E-05 Front door (RH)

<RHD>
Harness side
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310493AC

YES : Go to Step 3.

Connector: C-17
ETACS-ECU connector terminal No.59 and E-05 <LHD>
power window main switch connector terminal
No.4.
Connector: C-228
(rear view)
Harness side AC310446 AC
59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69
AC310450AH

<RHD>
AC310456 AE
Harness side
59 58 57 56 55 54 53 52 51 Connector: C-101
58 5756 555453 52 51 60 <LHD>
74 7372 71 70 69
AC310461AG
Connector: E-05 <LHD> Harness side

Front door (LH)
Harness side
6 5 4 3 2 1
14 13 12 11 10 9 8 7
AC310446AF
Connector: C-101
<RHD>
AC310484AC
Harness side
Connector: E-05 Front door (RH)
<RHD>
Harness side
6 5 4 3 2 1 AC310456AF
14 13 12 11 10 9 8 7
diate connector C-17 <LH drive vehicles> or C-110
<RH drive vehicles> and joint connector C-101, and
AC310493AC
YES : Go to Step 4.
54B-257
Step 4. Replace the power window main switch, (2) Check that the power window main switch signal
and then retest the system. is received.
Replace the power window main switch, and check Q: Is the check result normal?
that the power window main switch signal is YES : The procedure is complete.
received. NO : Replace the ETACS-ECU.
INSPECTION PROCEDURE L-8: The key reminder switch signal is not received.
CAUTION
Key Reminder Switch Input Circuit
ETACS-
ECU
KEY
REMINDER
SWITCH
WHEN KEY
IS REMOVED
Wire colour code


Input signal from the key reminder switch is used to • Malfunction of the key reminder switch
operate the functions below. If the signal is abnormal, • Malfunction of the ETACS-ECU
these functions will not work normally. • Damaged harness wires and connectors
• Keyless entry system
• Room lamps
DIAGNOSTIC PROCEDURE Step 3. Resistance measurement at the C-207 key

reminder switch connector
Step 1. Connector check: C-207 key reminder Connector: C-207
switch connector <LHD>
Connector: C-207
<LHD>
Harness side
2 1
Harness side 7 6 5 4 3
2 1
7 6 5 4 3
AC310479AC
Connector: C-207
AC310479AC <RHD>
Connector: C-207
<RHD> Harness side
Harness side
AC310481AC

AC310481AC wiring harness side.
YES : Go to Step 2. Connector C-207
NO : Repair the defective connector. (Harness side)
2 1
Step 2. Check the key reminder switch. 7 6 5 4 3
Refer to GROUP 54A − Ignition switch P.54A-30.
YES : Go to Step 3.
NO : Replace the key reminder switch.
AC301541GY
(2) Resistance between C-207 key reminder switch

OK: 2 Ω or less
YES : Go to Step 5.
NO : Go to Step 4.
54B-259
key reminder switch connector terminal No.4 and
the body earth.
<LHD>

2 1 Connector: C-227
7 6 5 4 3
(rear view)
AC310479AC
Harness side
Connector: C-207
29 28 27 26 25 24 23 22 21
<RHD> 38 37 36 35 34 33 32 31 30
44 43 42 41 40 39
Harness side AC310450AG

<RHD>
AC310481AC
NOTE: Harness side

Connector: C-101
29 28 27 26 25 24 23 22 21
<LHD>
38 37 36 35 34 33 32 31 30
44 43 42 41 40 39
AC310461AF

YES : Go to Step 6.
AC310446AF
Connector: C-06
<RHD>
Harness side
AC310456AG

connector C-101 <LH drive vehicles> or C-06 <RH
drive vehicles>, and repair if necessary.
Step 6. Check the wiring harness between C-207 Step 7. Retest the system.
key reminder switch connector terminal No.6 and Check that the key reminder switch signal is received
C-227 ETACS-ECU connector terminal No.30. normally.
<LHD> YES : The trouble can be an intermittent
Harness side
2 1
7 6 5 4 3
AC310479AC
Connector: C-207
<RHD>
Harness side
AC310481AC
Connector: C-227
(rear view)
Harness side
29 28 27 26 25 24 23 22 21
38 37 36 35 34 33 32 31 30
44 43 42 41 40 39
AC310450AG

<RHD>
Harness side
29 28 27 26 25 24 23 22 21
38 37 36 35 34 33 32 31 30
44 43 42 41 40 39
AC310461AF

YES : Go to Step 7.
54B-261
INSPECTION PROCEDURE L-9: The hazard warning lamp switch signal is not received.
CAUTION
Hazard Warning Lamp Switch Input Circuit
ETACS-
ECU
HAZARD
WARNING
LAMP SWITCH
Wire colour code


Input signal from the hazard warning lamp switch is • Malfunction of the hazard warning lamp switch
used to operate the functions below. If the signal is • Malfunction of the ETACS-ECU
abnormal, these functions will not work normally. • Damaged harness wires and connectors
• Keyless entry system (encrypted code registra-
tion)
• Hazard warning lamp
DIAGNOSTIC PROCEDURE Step 3. Resistance measurement at the C-03

hazard warning lamp switch connector
Step 1. Connector check: C-03 hazard warning Connector: C-03
lamp switch connector <LHD>
Connector: C-03
<LHD>
Harness side
Harness side
AC310446AG
Connector: C-03
AC310446AG <RHD>
Connector: C-03
<RHD>
Harness side
Harness side
AC310454AG

AC310454AG wiring harness side.
YES : Go to Step 2.
NO : Repair the defective connector. Connector C-03
(Harness side)
Step 2. Check the hazard warning lamp switch. 4 3 2 1

Refer to GROUP 54A − Hazard warning lamp switch
P.54A-72.
YES : Go to Step 3. AC301541GZ
NO : Replace the hazard warning lamp switch.
(2) Resistance between C-03 hazard warning lamp
switch connector terminal No.2 and body earth
OK: 2 Ω or less
YES : Go to Step 5.
NO : Go to Step 4.
54B-263
hazard warning lamp switch connector terminal
No.2 and the body earth.
<LHD>

Connector: C-228
(rear view)
AC310446AG
Harness side
Connector: C-03
<RHD> 59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69
AC310450AH
Harness side
<RHD>
AC310454AG
NOTE: Harness side

Connector: C-06 <LHD> 59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69
C-06 (GR) AC310461AG

YES : Go to Step 6.
AC310452AE
Connector: C-06
<RHD>
Harness side
AC310456AG

Step 6. Check the wiring harness between C-228 Step 7. Retest the system.
ETACS-ECU connector terminal No.55 and C-03 Check that the hazard warning lamp switch signal is
hazard warning lamp switch connector terminal received normally.
No.1. Q: Is the check result normal?
Connector: C-03 YES : The trouble can be an intermittent
<LHD> malfunction (Refer to GROUP 00 − How to
Harness side
AC310446AG
Connector: C-03
<RHD>
Harness side
AC310454AG
Connector: C-228
(rear view)
Harness side
59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69
AC310450AH

<RHD>
Harness side
59 58 57 56 55 54 53 52 51
58 5756 555453 52 51 60
74 7372 71 70 69
AC310461AG

YES : Go to Step 7.
54B-265
INSPECTION PROCEDURE L-10: All the door switch signals are not received. <LH drive vehicles>
CAUTION
All Door Switches Input Circuit <LHD>
ETACS-ECU
J/B SIDE
DOOR DOOR DOOR DOOR

SWITCH SWITCH SWITCH SWITCH
(FRONT: RH) (REAR: RH) (REAR: LH) (FRONT: LH)
Wire colour code


Input signals from all the door switches are used to
operate the functions below. If the signal(s) are Step 1. Pulse check
abnormal, these functions will not work normally. Check the input signal from the door switch (front:
• Keyless entry system LH).
• Room lamps
POSSIBLE CAUSES door switch (front: LH) When the driver's door is
• Malfunction of the door switches opened
needle fluctuates.

Step 3. Check the installation condition.
YES : Go to Step 2.
NO : Refer to inspection procedure L-3 "The door
Check that the door switch is installed on the body
switch (front: LH) signal is not received correctly.
P.54B-244." Q: Is the check result normal?
YES : Go to Step 4.
NO : Correct the installation condition.
Step 2. Connector check: D-18 <front: LH>, D-01
<front: RH>, D-08 <rear: RH> or D-11 <rear: LH>
door switch connectors, and C-226 ETACS-ECU Step 4. Check the door switch.
connector Refer to GROUP 42 − Door P.42-27.
<LHD> YES : Go to Step 5.
Junction block (rear view) NO : Replace the door switch.
Step 5. Check the wiring harness from terminal

No.2 of the D-18 <front: LH>, D-01 <front: RH>,
D-08 <rear: RH> or D-11 <rear: LH> door switch
Junction block side
connector to terminal No.7 of the C-226
ETACS-ECU connector.
AC310450AB Connector: C-226
<LHD>
<LHD> Junction block (rear view)
D-01 D-08
Harness side D-01
D-08 Junction block side

Harness side
AC310450AB
AC310463AC
<LHD>
<LHD> D-01 D-08
Harness side D-01
D-11
Harness side
D-11 D-08
D-18 Harness side
Harness side
AC310463AC
D-18
AC310465AD Connectors: D-11, D-18
<

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15-1

GENERAL INFORMATION . . . . . . . . 15-2 REMOVAL AND INSTALLATION . . . . . . . . 15-5

SERVICE SPECIFICATIONS. . . . . . . 15-2 INTERCOOLER . . . . . . . . . . . . . . . . . 15-6

SUPERCHARGING PRESSURE CON-

Item Standard value Limit

Tool Number Name Use

1. Connect a hand vacuum pump to the solenoid

2. Using a jumper wire, connect between the

4.0 ± 1.0 N·m

9.0 ± 1.0 N·m

Removal steps Removal steps (Continued)

Pre-removal and Post-installation Operation

6.0 ± 1.0 N·m 6.0 ± 1.0 N·m

6.0 ± 1.0 N·m

11 6.0 ± 1.0 N·m

6.0 ± 1.0 N·m

6.0 ± 1.0 N·m

Removal steps Removal steps (Continued)

Pre-removal Operation Post-installation Operation

2 1 3.0 ± 0.5 N·m

Removal steps Removal steps (Continued)

Removal steps Removal steps (Continued)

EXHAUST MANIFOLD AND TURBOCHARGER

Pre-removal Operation Post-installation Operation

Removal steps Removal steps (Continued)

REMOVAL SERVICE POINTS

Exhaust main muffler removal Front exhaust pipe removal steps

CHARGING SYSTEM . . . . . . . . 16-2 IGNITION SYSTEM . . . . . . . . . 16-26

GENERAL INFORMATION . . . . . . 16-2 GENERAL INFORMATION . . . . . . 16-26

SERVICE SPECIFICATIONS. . . . . 16-3 SERVICE SPECIFICATIONS . . . . . 16-27

SPECIAL TOOL . . . . . . . . . . . . . . . 16-4 SPECIAL TOOL . . . . . . . . . . . . . . . 16-28

ON-VEHICLE SERVICE. . . . . . . . . 16-5 ON-VEHICLE SERVICE . . . . . . . . . 16-28

STARTING SYSTEM . . . . . . . . . 16-18 IGNITION COIL. . . . . . . . . . . . . . . . 16-34

STARTER MOTOR ASSEMBLY . . 16-20 CRANK ANGLE SENSOR . . . . . . . 16-36

STARTER MOTOR ASSEMBLY DETONATION SENSOR . . . . . . . . 16-37

Item Standard value Limit

Tool Number Name Use

MB991955 M.U.T.-III sub assembly • Checking the idle speed

MB991519 Alternator test harness Checking the alternator

ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

OUTPUT CURRENT TEST

REGULATED VOLTAGE TEST

WAVEFORM CHECK USING AN OSCILLOSCOPE

MEASUREMENT METHOD Connect the oscilloscope special patterns pick-up to

"B" terminal AK100002 AC

NOTE: when the voltage waveform reaches an excessively

The voltage waveform of the alternator "B" terminal

Example 2 Short in diode

Example 3 Broken wire in

Example 4 Short in stator

5.0 ± 1.0 N·m

8 9.0 ± 1.0 N·m

Removal steps Removal steps (Continued)

REMOVAL SERVICE POINTS 1. Securely insert the spindle handle or ratchet

<<B>> DRIVE BELT REMOVAL

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

Disassembly steps Disassembly steps (Continued)

DISASSEMBLY SERVICE POINTS CAUTION

Remove the brush holding wire after the rotor has

INSPECTION 1. Check the continuity between coil leads.

1. Check the condition of the (+) heat sink by

3. Check the condition of the diode trio by testing

circuit tester connected to both sides of the diode.

Holding coil Plunger